KIP 2000 Printer Service Manual Ver D.2 - US

DIGITAL PRINTER

KIP2000

Series

(K-66)

SERVICE MANUAL

K66sm0e2-1.doc (Ver. D.2) (1)

PREFACE

This service manual contains information required to preform field service to maintain the image quality and printer functions on the KIP 2000 Series printers.

Chapter 1 Introduction : Features, specifications and operational Chapter 2 Installation : Installation location, procedure / Unpacking Chapter 3 Print Process : Explanation of print processes

Chapter 4 Electrical Systems : Basic principles of electrical system and operation

Chapter 5 Mechanical Systems : Mechanical structure, disassembly, assembly, and adjustments

Chapter 6 Maintenance/Checking : Replacement parts, Preventative Maintenance Chapter 7 Troubleshooting : Procedures to repair malfunctions and image quality Chapter 8 Service Modes

Appendices : timing charts, circuit diagrams

Some of the information contained in this manual may be changed by product upgrades etc. Such information will be communicated as Technical Bulletins as required. Please read this service manual and any technical bulletins carefully.

Table of Contents

Chapter 1 Introduction

Page

1.1 Features 1- 1

1.2 Specifications 1- 2

1.3 Name of Each Part 1- 3

1.3.1 Front view 1- 3 1.3.2 Rear view 1- 3

Chapter 2 Installation

2.3 Packing Tape Removal 2- 3

2.4 Installation of Floor Plates 2- 5

2.5 Contents of Accessory Box 2- 6

2.6 Installation of the Process Unit 2- 7

2.6.1 Remove the Process Unit from the printer 2- 7

2.6.2 Release the LED Head 2-10

2.6.3 Setting up the Process Unit 2-11

2.6.4 Installing the Process Unit to the machine 2-18

2.7 Install the Toner Cartridge 2-21

2.8 Installing the Print Tray 2-25

Chapter 3 Print Process

Page

3.1 Outline of Process 3- 1

3.2 Theory / Construction of Contact Toner System ( HDP ) 3- 2 3.2.1 General information of the development and print process 3- 2

3.2.2 Print Process 3- 3

Step 1. Erasing process 3- 3

Step 2. Charging process 3- 3

Step 3. Exposure process 3- 3

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Chapter 4 Electrical Systems

Page

4.1 Basic Operations 4- 1

4.2 Summary 4- 3

4.3 DC Controller and Roll Feeder Board 4- 4

4.3.1 DC Controller (PW6620) 4- 4

4.3.2 Roll Feeder Board (PW6623) 4- 4

4.4 Schematic Explanation 4- 5

4.4.1 Image Charging Unit Current Controller 4- 5

4.4.2 Transfer Charging Unit Current Controller 4- 6

4.4.3 Separation Charging Unit Current Controller 4- 7

4.4.4 Developer Bias Control Circuit 4- 8

4.4.5 Image Charging Wire Cleaning Controller 4-10

4.4.6 Power Supply 4-11

4.5 Electric Assembly Location/Function 4-13 4.5.1 Sensor / Switch / Toner Sensor / Thermistor / Thermostat 4-13

Front View 4-13

Rear View 4-14

4.5.2 Motor / Clutch / Fan / CNT / RY / CB / LF / SSR / Dehumidify Heater / SL 4-15

Front View 4-15

Rear View 4-16

Air Flow 4-17

4.5.3 Printed Circuit Board / DCP / HVP 4-18

Front View 4-18

Rear View 4-19

4.6 Down Sequence 4-20

4.6.1 Down Sequence caused by Fuser Temperature 4-20

Chapter 5 Mechanical Systems

Page

5.1 External covers 5- 2

5.1.1 Upper cover 1 (Toner cover) 5- 3

5.1.2 Upper cover 2 (Operation cover) 5- 4

5.1.3 Upper cover 3 5- 4

5.1.4 Right/Left side upper covers 5- 5

5.1.5 Right/Left side lower covers 5- 5

5.1.6 Right/Left side covers 5- 6

5.1.7 Rear upper cover 5- 6

5.1.8 Rear lower cover 5- 6

5.2 Upper Frame 5- 7

5.2.1 Opening of Movable unit 5- 7

5.2.2 Main motor (M1) 5- 9

5.2.3 LED head 5-10

5.2.4 Eraser lamp 5-10

5.2.5 LED head cooling fans (Fan7, Fan8) 5-11

5.2.6 Timing belts (two) 5-12

A. Timing belt for main motor 5-12

B. Timing belt for pulley/P161 5-12

5.3 Lower Frame 5-13

5.3.1 Clutches (two) 5-13

A. Flapper clutch (MC3) 5-13

B. Paper gate clutch (MC4) 5-13

5.3.2 Timing belt 5-14

A. Timing belt for Inside feed assembly 5-14

5.3.3 Ozone filters 5-14

5.3.4 Fans 5-15

A. Fuser cooling fan left (Fan 3) 5-15

B. Fuser cooling fan right (Fan 4) 5-15

C. Fuser cooling fan S-left (Fan 5) 5-16

D. Fuser cooling fan S-right (Fan 6) 5-16

5.3.5 Counter (CNT1) 5-17

5.3.6 Main switch (S1) 5-17

5.3.7 Fuser shutter solenoid (SL1) 5-18

5.4 Process Unit 5-19

5.4.1 Disassembling Process unit 5-19

5.4.2 Photoconductive drum 5-23

5.5 Main Frame 5-25

5.5.1 Cutter assembly 5-25

A. Paper sensor below cutter (PH3) 5-27

5.5.2 Gas spring 5-28

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5.8 Fuser Assembly 5-37

5.8.1 Disassembling Heater assembly 5-37

A. Thermistors (TH1, TH2) 5-39

B. Fin Heater – oven type (100V, 120V and 230V) 5-39

5.8.2 Thermostat (TS1) 5-41

5.8.3 Paper Transportation Sensor (TP9) 5-41

5.8.4 Fuser Lower assembly 5-42

A. Paper exit sensor (PH8) 5-43

B. Thermistor (TH3) 5-43

C. Exit Roller 5-43

5.8.5 Agitating motor 5-45

5.8.6 Agitator fan (Fan 2) 5-46

5.8.7 Agitator fan (Fan 2) – R2 Modified Assembly 5-50

5.9 Development Assembly 5-52

5.9.1 Disassembling Toner hopper assembly 5-52

5.9.2 Development roller 5-54

5.9.3 Regulation roller 5-56

5.9.4 Supply roller and side seals 5-58

5.9.5 Sender screw 5-59 5.9.6 Scraper 5-61 5.9.7 Toner motor (M5) 5-63 5.9.8 Toner sensors (TLS1, TLS2) 5-63 5.9.9 Spacing roller 5-64 A. Left side 5-64 B. Right side 5-64 5.9.10 Gears 5-65

5.10 Inner Feed Assembly 5-66

5.10.1 Disassembling Inside feed assembly 5-66

5.10.2 Paper separation sensor (PH7) 5-66

5.10.3 Feed belt 5-67

5.10.4 Feed roller 5-67

5.10.5 Separation fan (Fan 1) 5-68

5.11 Paper Feeder Assembly 5-69

5.11.1 Roll decks 5-69

5.11.2 Roll feed motor (M2) 5-70

5.11.3 Roll paper clutch (MC1, MC2A, MC2B, MC2C) 5-70

5.11.4 Pick up roller 5-71

5.11.5 Sensors 5-71

A. Paper clock end sensors (PH2A, PH2B, PH2C) 5-71 B. Paper set sensors (PH1A, PH1B, PH1C) 5-72

5.11.6 Size switch 5-73

5.11.7 Fitting Paper feeder assembly (Option) 5-74

Chapter 6 Maintenance

Page

Chapter 7 Troubleshooting

Page

7.1 Error Code List 7- 1

7.1.1 Call Operator Errors 7- 1

7.1.2 Call Service Errors 7- 3

7.2 Error Troubleshooting 7- 4

7.2.1 Call Operator Errors 7- 4

(1) “J-01” 1st Roll Deck Jam 7- 4

(2) “J-02” 2nd Roll Deck Jam 7- 5

(3) “J-03” 3rd Roll Deck Jam 7- 6

(4) “J-04” 4th Roll Deck Jam 7- 7

(5) “J-05” Cut Sheet Paper Feeding Jam 7- 7

(6) “J-10” Flapper Area Jam 7- 8

(7) “J-11” Gate Roller Section Jam 7- 9

(8) “J-12” Separation Area Jam 7-10

(9) “J-13” Exit Area Jam (Delay) 7-11

(10) “J-14” Exit Area Jam (Stay) 7-12

(11) “U-01” 1st Roll Deck Open Error 7-13

(12) “U-02” 2nd Roll Deck Open Error 7-13

(13) “U-03” 3rd Roll Deck Open Error 7-14

(14) “U-04” 4th Roll Deck Open Error 7-14

(15) “U-05” Upper Frame / Upper Cover 1 Open Error 7-15

(16) “U-06” Heater Unit Open Error 7-15

(17) Toner Low 7-16

(18) Roll Empty 7-17

7.2.2 Call Service Errors 7-18

(1) “E-01” Fuser Temperature Rising Error 7-18 (2) “E-02” Fuser Over Temperature Error 7-20

(3) “E-04” Developer Error 7-22

(4) “E-06” Counter Error 7-22

(5) “E-07” Cutter Error 7-23

(6) “E-16” Wire Cleaning Error 7-24

(7) “E-21” Fuser Thermostat Error 7-25

(8) “E-28” Fuser Agitator Fan Error 7-25

(9) “E-40” Folder Error 7-26

(10) “E-41” Key Card Error 7-26

7.3 Image Quality Troubleshooting 7-27

7.3.1 Basic Image Adjustments 7-27

7.3.2 Image Issues 7-28

(1) Too light (Only the halftone image) 7-28

(2) Too light (Halftone and solid black) 7-29

(3) Extremely light image (whole image) 7-30

(4) Different copy density 7-31

(5) Totally appeared foggy image 7-32

(6) Vertically blur or foggy black wide line 7-32

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Chapter 8 Service Modes

Page

8.1 General Operation 8- 1

8.1.1 Entering the Service Mode 8- 1

8.1.2 Selecting the Service Modes 8- 3

8.1.3 Exit Service Modes 8- 6

8.2 Device Status Mode 8- 7

8.2.1 Function 8- 7

8.2.2 Operation Panel Display 8- 7

8.2.3 Operation (Example of use) 8- 8

8.2.4 Device Signal List 8-11

8.3 Display / View Mode 8-15

8.3.1 Function 8-15

8.3.2 Operation Panel Display 8-15

8.3.3 Operation (Example of use) 8-16

8.4 Device Operation Mode 8-18

8.4.1 Function 8-18

8.4.2 Operation Panel Display 8-18

8.4.3 Operation (Example of use) 8-19

8.5 Adjustment Mode 8-23

8.5.1 Function 8-23

8.5.2 Operation Panel Display 8-25

8.5.3 Operation (Example of use) 8-26

8.5.4 Explanation for each Sub Mode 8-29

(1) Metric or inch (Sub Mode No.00) 8-29

(2) Maximum cut length (Sub Mode No.01) 8-30 (3) Cut sheet size signal(Sub Mode No.02) 8-31 (4) LED Head strobe time (Overall) (Sub Mode No.03) 8-32 (5) LED Head strobe time compensation (Left block) (Sub Mode No.04) 8-34 (6) LED Head strobe time compensation (Right block) (Sub Mode No.05) 8-36 (7) Image delay (Left block) (Sub Mode No.06) 8-38 (8) Image delay (Right block) (Sub Mode No.07) 8-40 (9) Fusing temperature (Plain paper) (Sub Mode No.08) 8-42 (10) Fusing temperature (Tracing paper) (Sub Mode No.09) 8-43 (11) Fusing temperature (Film) (Sub Mode No.0A) 8-44 (12) Fusing temperature cycle (Sub Mode No.0b) 8-45 (13) Warm Sleep Temperature (Sub Mode No.0C) 8-47 (14) Developer Bias Voltage (Plain Paper) (Sub Mode No.0d) 8-49 (15) Fusing temperature overshoot (Sub Mode No.0E) 8-50 (16) Transfer Corona ON timing (Sub Mode No.0F) 8-52 (17) Transfer Corona OFF timing (Sub Mode No.10) 8-54 (18) Leading Edge ( Position of Image ) - Roll Media

(Sub Mode No.11) 8-56 (19) Leading Edge ( Position of Image ) - Cut Sheets

(Sub Mode No.12) 8-59 (20) Cut length (Copies buffered from Scanner, Standard Cut or Prints from Controller) (Sub Mode No.13) 8-62 (21) Cut length (Copies using Synchro Cut, first copy out) (Sub Mode No.14) 8-65

(22) Image Void - Trailing Edge (Copies buffered from Scanner,

Standard Cut or Prints from Controller) (Sub Mode No.15) 8-68 (23) Image Void - Trailing Edge (Copies using Synchro Cut, first copy out)

(Sub Mode No.16) 8-70

(24) Side Image Void (Sub Mode No.17) 8-72

(25) Irregular Roll paper size setting (Sub Mode No.18) 8-74 (26) Dehumidify Heater setting (Sub Mode No.19) 8-76

(27) Counter Setting (Sub Mode No.1A) 8-77

(28) Key Card setting (Sub Mode No.1b) 8-79

(29) Print Stacker / Folder setting (Sub Mode No.1C) 8-80 (30) Transfer Corona voltage (Plain paper) (Sub Mode No.1d) 8-81 (31) Transfer Corona voltage (Tracing paper) (Sub Mode No.1E) 8-82 (32) Transfer Corona voltage (Film) (Sub Mode No.1F) 8-83 (33) Number of Roll Decks (Sub Mode No.20) 8-84

(34) Power OFF Timer (Sub Mode No.21) 8-86

(35) Main Motor Speed (Sub Mode No.22) 8-87

(36) Paper Feeding Motor speed (Plain paper) (Sub Mode No.23) 8-89 (37) Paper Feeding Motor speed (Tracing paper) (Sub Mode No.24) 8-90 (38) Paper Feeding Motor speed (Film) (Sub Mode No.25) 8-91 (39) AC Corona OFF Timing (Plain paper) (Sub Mode No.26) 8-92 (40) AC Corona OFF Timing (Tracing paper) (Sub Mode No.27) 8-93 (41) AC Corona OFF Timing (Film) (Sub Mode No.28) 8-94 (42) Fuser Agitator Fan speed(Sub Mode No.29) 8-95 (43) Developer Bias voltage (Tracing Paper) (Sub Mode No.2A) 8-96 (44) Developer Bias voltage (Film) (Sub Mode No.2b) 8-97 (45) Down Sequence Temperature adjustment (Sub Mode No.2C) 8-98

(46) Tracing Paper mode (Sub Mode No.2d) 8-99

(47) User Mode Function (Sub Mode No.2E) 8-100

(48) Fan Cool mode ( Sub Mode No.2F ) 8-100

(49) E0-1 Reset Method ( Sub Mode No. 30 )

(50) Toner Down Sequence Function ( Sub Mode No. 31 )

8.6 Factory Mode (DO NOT USE) 8-101

8.6.1 Function 8-101

8.6.2 Operation Panel Display 8-101

8.6.3 Operation 8-102

8.7 Error Mask / Error Reset Mode 8-105

8.7.1 Function 8-105

8.7.2 Operation Panel Display 8-106

8.7.3 Operation (Example of usage) 8-107

8.8 Test Print Mode 8-110

8.8.1 Function 8-110

8.8.2 Operation Panel Display 8-110

8.8.3 Operation 8-111

8.9 Factory Adjustment Mode 8-126

8.9.1 Function 8-126

8.9.2 Operation Panel Display 8-126

8.9.3 Operation (Example of usage) 8-127

8.10 Ram Clear Mode 8-130

8.10.1 Function 8-130

K66sm1e1.doc (Ver. D.2)

Chapter 1

Introduction

1.3 Name of Each Part 1- 3

1.3.1 Front view 1- 3

1.1 Features

(1) KIP2000 Series Printer prints 4 “D” size per minute. ( 51 mm / sec )

The maximum print size is 36 inches wide, and the minimum is 8.5” (210mm).

(2) The print quality is exceptional due to nonmagnetic, mono-component development KIP HDP Print process.

(3) The new KIP Pressure Free Fusing System is used (4) There are no drum cleaning blades or waste toner.

K66sm1e1.doc (Ver. D.2) 1-2

1.2 Specifications

Subject Specification

Model KIP2000 Series Printer

2001 (1 Roll Model) 2002 (2 Roll Model) 2003 (3 Roll Model) Configuration Console Printing method Electro-photography

Photoconductor Organic Photoconductive Drum

Print speed 51mm per second (2 sheets of A0 in one minute, 4 “D” per Minute)

Print head LED

Resolution 400dpi

Print width Maximum width 914mm (36 inches) Minimum width 210mm ( 8.5” ) Print length Maximum length 6m ( approx 19.6 Ft )

16m ( approx 50 ft ) or unlimited Minimum length 279mm ( 11 “ )

NOTE : If the print is longer than 6m, we do not guarantee the image quality or the reliability of the paper feeding.

Warm up time 120V = less than12 minutes, 100V/230V = less than 10 minutes First print time 47 seconds ( “E” print from 1st Roll Deck)

Fusing method KIP Pressure Free Fusing

Development method Dry type with non-magnetic mono-component toner Input power 120V plus or minus 10%, 12A and 50/60Hz in U.S.A.

220-240V plus 6%, minus 10%, 10A and 50/60Hz in Europe 100V plus or minus 10%, 15A and 50/60Hz in Japan

Maximum power consumption

120V, 60Hz and Dehumidify Heater is ON Stand by 0.604 Kwh

Printing 1.205 Kwh

230V, 50Hz and Dehumidify Heater is ON Stand by 0.633 Kwh

Printing 1.225 Kwh

100V, 50Hz and Dehumidify Heater is ON Stand by 0.608 Kwh

Printing 1.196 Kwh

Acoustic noise Less than 60db (Printing) Less than 55db (Stand by)

Ozone Smaller than 0.1ppm (Average)

Dimensions 1300mm (Width) x 725.5mm (Depth) x 1046mm (Height)

Weight 190kg (In case of 2001)

Environmental condition for usage (Temperature) 10 to 32 degrees centigrade (Humidity) 15 to 85% RH Storage of consumables (Toner cartridge)

Store the cartridge within the temperature range from 0 to 35 degrees centigrade and within the humidity range from 10 to 85% RH.

1.3 Name of Each Part

1.3.1 Front view

Upper Cover 2 Operation Panel Upper Cover

Upper Cover 1 Right Side Cover 2

Front Cover 2 Right Side Cover 1

Cutter Cover Front Cover 1

Cover 2 Right Side Cover

1.3.2 Rear view

Rear Upper Cover Left Side Cover 1

Exit Cover Left Side Cover 2

K66sm2e1-1.doc (Ver. D.2)

Chapter 2

Installation

2.3 Packing Tape Removal 2- 3

2.4 Installation of Floor Plates 2- 5

2.5 The Contents of Accessory Box 2- 6

2.6 Installation of the Process Unit 2- 7

2.6.1 Remove the Process Unit from the printer 2- 7

2.6.2 Release the LED Head 2-10

2.6.3 Setting up the Process Unit 2-11

2.6.4 Installing the Process Unit to the machine 2-18

2.7 Install the Toner Cartridge 2-21

2.8 Installing the Print Tray 2-25 This machine is packaged and shipped after careful adjustment in the factory. All printers pass a strict inspection.

The Installation is important to ensure the quality and reliability of the machine

A service technician must understand this machine’s function well, install this machine in a good environment and in the correct procedure, to ensure the clients satisfaction with the system.

2.1 Installation Requirements

The following conditions are required for the installation of the equipment.

Please confirm that the requirements are met before installation commences and before delivery.

(1) Electrical power source must be:.

North America 120V plus or minus 10%, 12A and 50/60Hz

Europe 220-240V plus 6% or minus10%, 10A and 50/60Hz Japan 100V plus or minus 10%, 15A and 50/60Hz

(2) The equipment must be connected to a dedicated wall outlet ( circuit ).

To disconnect the equipment from the power source, remove the power plug from the outlet. The wall outlet must be easily accessible near the equipment.

(3) Make sure to connect this equipment to the outlet with a proper ground.

(4) The temperature must be from 10 to 32 degrees centigrade, and the humidity must be from 15% to 85% RH.

Do not install the equipment near water sources, boilers, humidifiers or refrigerators. Ensure that no air vents / air conditioning vents blow directly onto the printer.

(5) Do not install near sources of heat, fire, dust and ammonia gas.

(6) The equipment should not be exposed to direct sunlight. Please draw curtains to block any sunlight.

When you remove the Process Unit from the equipment, be careful not to expose the Drum to any sunlight.

(7) Ozone will be generated while this equipment is in use, although the quantity generated is within a safe level.

If you print large volumes for a long time in a small room, ventilate the room as required ( an order can be detected.)

(8) Level Adjusters on the bottom of equipment must touch the floor correctly.

The equipment must be levelled with the floor strength to support the weight of equipment. (9) Keep enough space around the equipment for comfortable operation.

Required space is shown as follows.

60cm or wider Rear side

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2.2 Unpacking

If the printer is installed in winter, or if the machine was kept in a cold warehouse then moved to a warm room and then is unpacked, you may experience condensation.

In these cases, leave the machine in the warm room for more than 6 hours before it is installed.

1. Cut four packing bands (1) and remove Top board (2). 2. Open plastic sheet (3) to open the top of outer carton box (4).

3. Remove Upper board (5) to take out Accessories box (6) (Photoconductive drum (7), Sub Plate (8), Tray (9), User’s Manual, Setup Procedure and Power Cord.)

4. Lift the outer carton box upward and remove it. 5. Peel off plastic bag (10) fully to the floor.

6. Unload the machine from the pallet to the floor by forklift (11).

7. Remove wrapping film (12) from the machine and move it to the proper installation place selected in advance. 1 2 3 4 5 6 7 8 9 10 11 12

2.3 Packing Tape Removal

1) There is Tape (1) on the left of machine to protect the lever.

Remove it.

2) Open the Toner Cover (2).

You will find 4 Pads (3) that protect the Process Unit. Remove them.

3) There are 2 Pads (4) on both sides protecting the Fuser Shutter. Remove them. 1 2 3 3 4

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4) Open the Upper Frame Assembly (5).

You will find Tapes (6) on both sides protecting the Flapper. Remove them.

5) There are Pads (7) on the Exit Cover protecting Levers.

Remove them.

6) Open each Roll Deck (8).

The Roll Spool is fixed with Tape (9). Remove them. 5 6 5 6 7 8 9 9

2.4 Installation of Floor Plates

1. Insert Sub Plate A(2) between floor and Adjusters(1) located bottom of the machine. For fitting direction, see illustration.

2. Loosen Adjusters to lower until it touches Sub Plate.

3. Slide Sub Plate in the arrow direction until it hits Positioning plate(3), respectively. 4. Fully lower all of four adjusters.

5. Fit four Brackets(4). (8 screws attached) 6. Lower four nuts(5) to fix these Brackets. 7. Fit four Covers (6). (8 screws attached) 8. Fit two Brackets C(7). (4 screws attached)

1 2 3 6 1 6 2 5 M4x6 1 1 4 4 4 7 6 6

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2.5 Contents of Accessory Box

KIP2000 Series Printer requires the following parts. 1. Photoconductive Drum 2. Sub Plate 3. Tray 4. Power Cord 5. Setup Procedure 6. User’s Manual

2.6 Installation of the Process Unit

2.6.1 Remove the Process Unit from the machine

1) Pull up the Lever (1) on the left to unlock and open the Upper Frame Assembly (2).

2) Loosen the screw (3) on the right.

Move the Process Unit Fixing Lever (4) to the arrow direction to unlock the Process Unit.

3) Close the Upper Frame Assembly. Then, open the Upper Cover 1 (5).

1

2

4

3

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4) Loosen screws (6), and then move Shaft Brackets (7) on both sides toward the arrow direction. Also, loosen 2 screws (8) on either side (ex. Left).

5) Slide the Shaft Bracket (7) inward to remove the Upper Cover 1 (5).

6) There are Stopper Levers (9) on both sides being fixed with the screw (10).

Move both Stopper Levers (9) toward the rear side, and then fix them tightening screws (10).

If you do so, the LED Unit is unlocked and it becomes possible to open it.

(Movable Unit is locked.) (Movable Unit is unlocked.) 6 8 7 7 6 5 7 10 9

7) Stand the LED Unit (11) vertically.

8) Disconnect the connector (12) of Imaging Charger. Also, disconnect the connector (13) of Developer Unit.

9) Catching Developer Side Plates (14) on both sides, slide the whole Process Unit (15) rightward and then take it out from the machine.

12 13 15 11 14 15

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2.6.2 Release the LED Head

1) Set the LED Unit vertically.

2) Remove 4 red screws (1) to release the LED Head (2).

In case it is difficult to access screws “1”, loosen screws “A”, temporarily.

1 LED head.doc A 1 A LED head.doc

2.6.3 Setting up the Process Unit

1) Remove a screw (1) to remove the Imaging Charger (2) from the Process Unit.

2) Remove 4 screws (3) on both sides, and then move the Frame (4) upward and remove it.

3) Remove Pressure Springs (5) on both sides so as not to lose them, which exist between Frame and Developer Unit.

1 2 2 3 4 3 4 5 5

K66sm2e4.doc (Ver. D.2) 2-12

4) Remove 3 screws (6) to remove the Electrode Plate (7) on the left.

5) Catching Developer Side Plates on both sides, remove the Developer Unit (8) from the Process Unit by lifting up your side first.

6 7

8

6) Remove “screws with tag” (9) from both sides to make “Regulation Roller Brackets” (10) free. Press both Pressure Plates (11) fully to the arrow direction, and then fix them tightening screws (12).

The Regulation Roller in the Developer Unit is pressed to the Developer Roller by this treatment.

Note

In order to make a print, it is necessary to press the Regulation Roller to the Developer Roller as the following figure.

Therefore, make sure to move both Pressure Plates as shown on the former page when you install the machine.

In case you move the printer to another place, it is necessary to release the Regulation Roller. So, move both Pressure Plates to the opposite direction before moving the machine.

Regulation Roller Developer Roller Regulation Roller Developer Roller 11 12 9 10 12 11 9 10

K66sm2e4.doc (Ver. D.2) 2-14

7) Disconnect a connector (13) on the right, and remove 2 screws (14) on both sides.

8) Remove the Toner Hopper (15) from the Developer Unit by bringing up.

9) Remove a screw (16) to remove the Bracket (17), and then remove the Partition Plate (18). 15 13 14 14 16 17 18

10) Supply the Developer Unit with 500 grams of Starting Toner.

Then, rotate the Developer Roller (19) clockwise with the Jig (20) so that the Developer Roller should be covered with the toner.

At this time, it is better to make Developer Roller side lower.

Jig No.: 6608520010

11) Put back both Partition Plate (18) and the Bracket (17).

Note

It is enough if the surface of Developer Roller is covered with the toner some degree. Since the Developing Bias is not supplied at this time, you will not be able to cover it completely with the toner.

When you input the Starting Toner, shake the bottle well.

However, if you open the cap right after shaking, toner will be spread out. Wait 10 to 20 seconds before opening.

20

19

17 18

K66sm2e4.doc (Ver. D.2) 2-16

12) Put back the Toner Hopper (15).

13) Remove 2 screws (21) to remove the Drum Shaft (22) on the right side of Process Unit.

14) Remove 3 screws (23) to remove both Drum Fixing Plate (24) and Bearing (25) on the left side of Process Unit. 15 21 22 23 24 25

15) Take out the Photoconductive Drum (26) from the packaging box.

16) Install the Photoconductive Drum (26) to the Process Unit. (Set the left side first.)

Then, fix the Photoconductive Drum with Drum Shaft, Drum Fixing Plate and Bearing that you have

removed at the former steps 13) and 14).

17) Put Back the Developer Unit to the Process Unit. Then, re-assemble the Process Unit in the reversed order.

26

K66sm2e5.doc (Ver. D.2) 2-18

2.6.4 Installing the Process Unit to the machine

1) Open the Upper Frame Assembly, and then confirm that the Process Unit Fixing Lever (1) is moved to the arrow direction.

Then, close the Upper Frame Assembly.

2) Put the Process Unit (2) into the machine, and then slide it to the right first.

3) Open the Upper Frame Assembly.

Rotate the Gear (3) so that the Drum Drive Shaft (4) should match with the cross-shaped groove of Shaft (5). 2 3 4 5 1

4) Slide the Process Unit fully to the left.

Be sure that the cross-shaped groove of Shaft (5) is firmly jointed with the Drum Drive Shaft (4).

5) Connect 2 connectors (6).

6) Move the Process Unit Fixing Lever (1) toward the arrow mark, and then tighten the screw (7) to fix the Process Unit firmly.

Close the Upper Frame Assembly after that. 4

5

6 ₆

1

K66sm2e5.doc (Ver. D.2) 2-20

7) Moving the Stopper (8) toward the front side, close the Movable Unit (9).

8) Loosen screws (10), slide Stopper Levers (11) on both sides toward the front side, and then fix them tightening screws (10).

The Movable Unit is locked by this treatment.

(Movable Unit is unlocked.) (Movable Unit is locked.)

9) Put back the Upper Cover 1 (12) as it was. 8

11

10

12 9

2.7 Install the Toner Cartridge

1) Open the Upper Cover 1 (1).

2) Shake the Toner Cartridge (2) several times left and right to make the toner smooth.

(2)

K66sm2e5.doc (Ver. D.2) 2-22

3) Film (3) is taped on one side of the Toner Cartridge. Insert the end of this side under black plates on the right.

4) Press down another side until the cartridge is firmly locked by the Lever (4).

(3)

5) Strip off the tape, and then insert the Spool (5) into the hole (6) on the right while putting the film (3) between both pins of Spool.

6) Rotate the Spool (5) clockwise to wind up the film (3).

(6)

(3)

(5)

(5) (3)

K66sm2e5.doc (Ver. D.2) 2-24

7) After winding up the film, rotate the Spool counterclockwise to unfasten the film, and then pull out the Spool from the film.

Dispose the film, but keep the Spool for the next use.

1

2

3

2.8 Installing the Print Tray

1) Open the packaging box and take out Trays (1).

2) Install Trays to the machine as shown in the right figure.

K66sm3e1.doc (Ver. D.2)

Chapter 3

Print Process

Page

3.1 Outline of Process 3- 1

3.2 Theory / Construction of Contact Toner System ( HDP ) 3- 2 3.2.1 General information of the development and print process 3- 2

3.2.2 Print Process 3- 3

Step 1. Erasing process 3- 3

Step 2. Charging process 3- 3

Step 3. Exposure process 3- 3

Step 4. Simultaneous Development and Cleaning process 3- 4

Step 5. Transfer process 3- 4

Step 6. Separation process 3- 4

Step 7. Fusing process 3- 4

3.3 Supplementary 3- 5

3.1 Outline of Process

The image formation steps are shown in the following figure.

The image formation follows the processes in sequence to form the image:

All of the high-voltage loads are controlled by high-voltage circuits on the high-voltage power supply PCB These are controlled from signals from the DC controller PCB.

The image formation process comprises of seven steps.

1. Erasing(Pre-exposure) 5. Transfer 2. 1st charging 6. Separation 3. Image exposure 7. Fusing 4. Simultaneously development & cleaning

3. Exposure 2. Charging 1. Erasing 5. Transfer 6. Separation 7. Fusing Ejection Register Electrostatic latent image fomation block

Roll paper 4. Simultaneously development & cleaning

Roll paper Roll paper

K66sm3e1.doc (Ver. D.2) 3-2

3.2

Theory / Construction of Contact Toner

System ( KIP HDP )

3.2.1

General information on the process

In the KIP2000 series printer a reverse development method is used, both development and cleaning process can be done at the same time.

Fig. 1 shows “the configuration of no drum cleaner blade printing process”.

The drum cleaner and the wasted toner bottle are not required, because the residual toner on drum surface after transfer process is returned to the Development unit during the development process.

Fig. 2 shows “Simultaneous development and cleaning by the contact-type monocomponent non-magnetic development system”.

Residual toner Toner layer Shaft Development roller Development bias Photoconductor

Fig. 2: Simultaneous development and cleaning by the contact-type monocomponent non-magnetic development system.

Regulation roller

Fig. 1: Configuration of cleanerless printing process. Development unit light Image charger Transfer charger Separation charger Erase lamp media LED Head

3.2.2 Print Process

Step 1. Erasing process

Drum surface charge is exposed by Eraser Lamp prior to 1st charging.

Any residual charged potential on the drum surface is removed by this step.

Any residual toner grains, not transferred on the previous drum rotation, are still on the surface of drum. The charge polarity of these toner grains

can be both negative and positive toner

particles. They are discharged to near 0 Volts under this process.

(the small round spheres represent unused toner on the drum surface.)

Step 2. Charging process

Drum surface is evenly charged by the negative 1st Charger (Primary). The residual toner is also charged by the 1st charger at this time, and

all grains are the same negative polarity as the drum surface.

Surface potential of Drum is determined by the potential of grid screen which is connected to ground through a zener diode in order to get a constant voltage. This voltage cannot be adjusted in the KIP 2000

Step 3. Exposure process

With respects to the image’s data,

infrared light from the LED head is exposed to the drum’s surface.

The negative electrostatic charge on the drum is neutralized by this light, and surface potential decreases. As a result, electrostatic Latent Image is formed onto the drum’s surface.

At this time, if there is any residual toner grains which may exist on the drum’s surface from the

Residual potential Development bias Dark potential Vd Vb Vr 0 Residual toner (1) Erasing process Vd Vb 0 (2) Charging process Vb Vl 0 (3) Exposure process

K66sm3e1.doc (Ver. D.2) 3-4

Step 4. Simultaneous Development and Cleaning process

Toner is always attracted to a more positive Voltage. The negative charged toner in the Contact Development Unit (see Vb, the Development

Roller potential) are attracted to the higher potential, of an exposed area of the drum. (see figure 4, “Development” arrows) This will cause the toner to remain on these areas on the drum.

Simultaneously, on unexposed areas ( no LED light ) the lower Potential, (see Vd) the residual toner is attracted to the development roller and therefore removed from the drum surface (removing

unwanted toner from the drum or cleaning the drum)

Step 5. Transfer process

A positive corona is applied onto the media (from the back) and intern the media s charged positive. As a result, the more negative toner on the drum’s surface is transferred to the media.

To prevent inefficient transfer and unwanted toner on the back of the media, the Media Guide Plate is grounded through a varistor.

(NOTE)

If the Guide Plate is grounded directly (shorted), the back side of paper is not charged and causes defective transfer.

If the Guide Plate is floating (not shorted or not held at the varistor voltage), the Guide Plate may attract toner, thus causing unwanted toner (dirt) on the rear of media.

Step 6. Separation process

The media is charged positive by the transfer corona and is attracted to the drum’s surface by static electricity.

An AC corona discharger removes the static electricity between drum and the media (paper). As a result the media is separated from drum.

Step 7. Fusing process

The media with the toner image is fed through the Pressure Free Fuser (Convection Heat Process) and the toner is fused to the media.

Guide plate Separation charger media ～ 12.8KVp-p +250Vdc Vd Vb Vl 0 (4) Simultaneous development and cleaning process

Development Cleaning Vd Vb Vl 0 (5) Transfer process Paper

Primary Charge Current

1.3 ma

LED Strobe time = 35 microseconds ( average ) for image

Approx -700 Vdc Grid

Regulation roller ( Blade Roller ) = -300Vdc

Development Roller = -280Vdc

Supply Roller = -500Vdc

Transfer Current = 1.0 ma

Separation = -250 Vdc & 12.8 KVac

Freq = 500 Hz

Development Unit Theory

The Toner Supply Roller ( 1 ) applies toner onto Development Roller ( 3 )The toner is attracted to more positive voltage of the Dev

KIP 2000 Series Current / Voltages

KIP 2000 Series Current / Voltages

During Print Process

During Print Process

1

2

3

4

area with solid black image = approx -50Vdc

area with no image and

unused toner from previous rotation = -700Vdc

t

s

Primary Charge Current

1.3 ma

Approx -700 Vdc Grid

Regulation roller ( Blade Roller ) = +250Vdc

Development Roller = +350Vdc

Supply Roller = +130Vdc

After Final Print exits Printer

- one drum revolution cleans drum and development roll of excess toner with bias values stated

KIP 2000 Series Current / Voltages

KIP 2000 Series Current / Voltages

After Print Processed

After Print Processed

1

2

3

4

area with no image and

unused toner from previous rotation = -700Vdc

t

s

Regulation Roller "Isolated End" Theory

Regulation Roller "Isolated End" Theory

Top View

No bias supplied to this region of Regulation Roller ( it is grounded ).

This is required so the the toner is attracted NO BIAS on this section

Diameter of Regulation Roller = 25 mm

Diameter of Development Roller = 50 mm

Diameter of Supply Roller = 30 mm

KIP 2000 Series Roller Diameters

KIP 2000 Series Roller Diameters

Diameter of edges = 78 mm

Diameter of Coated Organic Surface = 80 mm

1

2

3

Side View

Top View

Drum

Development Roller

78mm

51.2mm

Not to scale

Spacing Discs

Drum

point of contact = 5mm at end

2 mm in center in engaged position

No contact when power off or after

55 Minutes in

standby-3.3 Supplementary

3.3.1 Ozone Filter

To prevent unwanted ozone emissions caused by the print process, catalytic filters remove the ozone which are placed on all exhaust blower vents.

K66sm4e1.doc (Ver. D.2)

Chapter 4

Electrical Systems

4.3 DC Controller and Roll Feeder Board 4- 4

4.3.1 DC Controller (PW6620) 4- 4

4.3.2 Roll Feeder Board (PW6623) 4- 4

4.4 Schematic Explanation 4- 5

4.4.1 Image Charging Unit Current Controller 4- 5

4.4.2 Transfer Charging Unit Current Controller 4- 6

4.4.3 Separation Charging Unit Current Controller 4- 7

4.4.4 Developer Bias Control Circuit 4- 8

4.4.5 Image Charging Wire Cleaning Controller 4-10

4.4.6 Power Supply 4-11

4.5 Electric Assembly Location/Function 4-13 4.5.1 Sensor / Switch / Toner Sensor / Thermistor / Thermostat 4-13

Front View 4-13

Rear View 4-14

4.5.2 Motor / Clutch / Fan / CNT / RY / CB / LF / SSR / Dehumidify Heater / SL 4-15

Front View 4-15

Rear View 4-16

Air Flow 4-17

4.5.3 Printed Circuit Board / DCP / HVP 4-18

Front View 4-18

Rear View 4-19

4.6 Down Sequence 4-20

4.6.1 Down Sequence caused by Fuser Temperature 4-20

4.1 Basic Operations

This machine can be separated into 4 major blocks, Paper Feed and Transport System, Optic System, Image Process System and Control System.

Fig.4-1-1 Interface Optic system Optical path system Image process system Electrostatic latent image forming system Developer Fuser

Transport Separation Transfer Paper feed control system

Roll paper Control system

Control circuit

Paper feed and transport system External

instrument

Option Option

K66sm4e1.doc (Ver. D.2) 4-2

Following figure is a side view of the machine.

Fig.4-1-2 PH9 PH8 PH7 PH6 PH5 PH10 PH4 PH2B PH2C PH1A PH1B PH1C PH2A PH3 Option Option TLS1

4.2 Summary

This machine is controlled by two microcomputers, which are located on DC Controller and Roll Feeder Board.

These microcomputers read input signals from sensors, and on programmed timing control loads such as motors, SSRs, solenoid, clutches and blowers.

Fig.4-2-1

Fig. 4-2-1 shows a rough block diagram of basic signal flow.

Followings are main PCBs and their functions.

1) DC Controller PW6620 Overall Sequence Control w/Interface 2) Driver Board PW6650 Output driving, Fans, Solenoid

3) Eraser lamp PW6631

4) DC terminal PCB PW6690 LED Head

5) Roll Feeder Board PW6623 Roll Feeder Controller

6) Driver Board PW6652 Main Motor & Wire Cleaning Motor

Flapper Clutch & Paper Gate Clutch

7) Driver Board PW6654 Cartridge M / Toner M / Eraser Lamp

8) Operation Pcb PW6672 Error & Jam Code Indication / Density

9) AC Terminal Board PW6610

10) Zener diode Pcb PW6693 Grid Plate

11) Signal Relay Pcb PW4690 for Paper Decks

12) Paper Selector Pcb PW5722 Size & Media selection

13) Transmitter Pcb (Option) PW5490 LED for optional Auto Stacker or Folder 14) Receiver Pcb (Option) PW5491 Photo sensor for optional Stacker or

Folder

15) DC Power Supply DCP1 +24V dc, always live

16) DC Power Supply DCP2 +5V dc for LED Head Power Supply

17) DC Power Supply DCP3 +24V dc

18) High Voltage Power Supply HVP Imaging, Transfer, Separation & Dev.Bias

Sensor Micro Computer

(CPU&ROM)

K66sm4e1.doc (Ver. D.2) 4-4

4.3 DC Controller and Roll Feeder Board

4.3.1 DC Controller (PW6620)

DC Controller is controlling all inputs and all outputs, which belong Upper Unit, such as

Process Unit

Operation PCB

Inner Transportation Area

Fuser Unit

LED Head

All Coronas

DC Controller is communicating with Roll Feeder Board, which is controlling Roll Feeder Section, via “J204”.

4.3.2 Roll Feeder Board (PW6623)

Roll Feeder Board is controlling all inputs and all outputs, which belong Lower Unit, such as Deck1

Deck2 Deck3 Cutter

4.4 Schematic Explanation

4.4.1 Image Charging Unit Current Controller

Image Corona HV_1ST(sig-in)

1ST_LD(sig-out)

Fig.4-4-1 1. Summary

Image Charger (negative charge) is controlling a constant-current system, so that the corona charging is not affected by environmental variations.

Corona output is controlled ON or OFF by the signal HV_1ST from DC Controller. Then signal 1ST_LD is fed back from HVP.

2. Operation of HV1

If corona current flows more than adjusted value because of environmental variation, for example,

Out3 Out2 Out1 HV3 HV2 HV1 CN301 CN302 CN303 HV3Vp-p HV3f Out1 Out3 Out2 HV1

HV1 status Voltage of connector Service mode

CN302-1 CN302-6 HV_1ST(1-51) 1ST_LD(1-44)

ON 0V 0V H L

K66sm4e1.doc (Ver. D.2) 4-6

4.4.2 Transfer Charging Unit Current Controller

Transfer Corona HV_TR(sig-in) TR_LD(sig-out) Fig.4-4-2 1. Summary

Transfer Charger (positive charge) is controlled constant-current control system, so as corona charging effect is not affected by the environmental variation.

Corona output is controlled ON/OFF by the signal HV_TR from DC Controller. Then signal TR_LD is fed back from HVP.

2. Operation

If corona current flows more than adjusted value because of environmental variation, for example, feedback current level of current control circuit becomes higher.

In this case, current control circuit works to transfer charger drive circuit in order to decrease secondary current of high voltage transformer.

Since primary voltage of high voltage power source is kept constantly at this time, primary feedback voltage is referred by voltage control circuit.

Transfer charger drive circuit is controlled constantly like this way.

The value of TR_ANLOG is controlling the output current of Transfer Corona.

It is adjustable using Service mode 4-1d(Plain paper), 4-1E(Tracing Paper) and 4-1F(Film) respectively.

Out3 Out2 Out1 HV3 HV2 HV1 CN301 CN302 CN303 HV3Vp-p HV3f Out1 Out3 Out2 HV1

HV2 status Voltage of connector Service mode

CN302-2 CN302-7 HV_TR(1-52) TR_LD(1-45)

ON 0V 0V H L

4.4.3 Separation Charging Unit Current Controller

Separation Charger (AC + DC positive) is controlled constant-current control system, so as corona charging effect is not affected by the environmental variation.

Corona output is controlled ON/OFF by the signal HV_SEP from DC Controller. AC + DC(positive)

Then signal AC_LD is fed back from HVP. 2. Operation

Out3 Out2 Out1 HV3 HV2 HV1 CN301 CN302 CN303 HV3Vp-p HV3f Out1 Out3 Out2 HV1

HV3 status Voltage of connector Service mode

CN302-3 CN302-8 HV_SEP(1-53) AC_LD(1-46)

ON 0V 0V H L

K66sm4e1.doc (Ver. D.2) 4-8

4.4.4 Developer Bias Control Circuit

Fig.4-4-4

Regulation

Roller

Developer

Roller

Toner Supply

Roller

Out3 Out2 Out1

HV3 HV2 HV1 CN301 CN302 CN303 HV3Vp-p HV3f Out1 Out3 Out2 HV1

1. Summary

DC Bias is applied on Developer Roller while copying. DC Bias is set at -280V normally.

Even if image density setting is changed by copy density adjustment key, Developer Bias does not change. LED ON time is changed.

2. Developer Bias Control Circuit

Developer Unit has three rollers, as follows. Out1: Toner Supply Roller -500V

Out2: Developer Roller -280V

Out3: Regulation Roller -300V (For Japan and Europe) -320V (For North America) 3. Operation

Since Out1, Out2 and Out3 are linked each other in HVP, once Out2 is adjusted, Out1 and Out3 are shifted automatically.

While DBIAS is applied, signal BIAS_LD is fed back from HVP.

DBIAS status Voltage of connector Service mode

CN302-4 CN302-9 DBIAS_TRG(1-54) BIAS_LD(1-47)

K66sm4e1.doc (Ver. D.2) 4-10

4.4.5 Charge Wire Cleaning Controller

1. Summary

This machine auto-cleans the Charge wire. A cleaning pad moves one round trip along the charge wire via the Charger Wire Cleaning Motor(M4). 2. Operation

Charger Wire Cleaning Motor works under the following condition ( when power is applied ). 1) When the Fuser temperature is 50degrees centigrade or less.

When TH1 detected 50degrees centigrade or less, Charger Wire Cleaning Operation is done one round trip. Signals change as WCMTR=L, WCMTR_DIR=L, motor starts and Cleaning pad is send forward. When the Cleaning pad reaches to end of pass, WCMTR_OC (overload signal) is output. After WCMTR_OC is output for approx. 0.5 sec., WCMTR turns H and motor stops. For the next, signals change as WCMTR=L, WCMTR_DIR=H, motor starts reversibly. When the Cleaning pad reaches to end, WCMTR_OC is output for 0.5 sec., WCMTR turns H and motor stops.

2) In case the Fuser temperature exceeds 50degrees centigrade.

When TH1 detected it exceeds 50degrees centigrade, Charge Wire Cleaning Operation is not done. However, in order to avoid Cleaning pad stays other end of pass, signals change as WCMTR=L, WCMTR_DIR=H, and motor starts reversibly. In case the Fuser temperature exceeds 50degrees centigrade, WCMTR_OC is output soon commonly and motor stops.

4.4.6 Power Supply

1. Electric Power Supply

AC Power is supplied to DCP1 all the time via CB1 regardless position of main switch. AC Power is supplied to DCP2 and DCP3 by turning ON the main switch.

Meaning of 5VB, 24VA, 24VB and 24VC are explained as follows.

Fig.4-4-5 DCP1 DCP2 DCP3 Circuit Breaker Main Switch 24VA 5VB 24VB TS1(Fuser Unit) MS3A(Fuser L) MS3B(Fuser R) MS1A(Dev Roll L) MS1B(Dev Roll R) 24VC 24VC RY1 AC in Unit Door

K66sm4e1.doc (Ver. D.2) 4-12

2. Door Switch

When each door is opened in case of jam treatment or etc., 24VDC for motors and High Voltage Power Sources are shut down by relay (RY1), and ceases the output for driving parts and High Voltage Power Sources.

[U-xx] is also indicated on display.

U-05: Upper unit / Toner supply door open U-06: Paper exit door open

3. Paper Deck

When Paper Deck is opened, 24VDC for paper feed motor and paper feed clutches (MC1, MC2A, MC2B, MC2C) are shut down, and paper feeding is ceased.

[U-01], [U-02], [U-03] or [U-04] is indicated on display. 4. Cartridge Motor (M6)

Cartridge Motor is prepared in order to get better contact between Developer Roller and Drum. When Main Switch is turned ON, Developer Unit is pressed toward Drum by the rotation of Cartridge Motor.

When Main Switch is turned OFF, or if the machine is left more than 55 min. without any job; charged electric power in the Capacitors of Driver Board(PW6654) allows Cartridge Motor ON in order to release the pressure from the Drum.

4.5 Electric Assembly Location/Function

4.5.1 Sensor / Switch / Toner Sensor / Thermistor / Thermostat

Front View

Fig.4-5-1

Symbol Code Name Part # ( can change without notice)

1) PH1A RPSET1 Paper set sensor, 1st 9000100667

2) PH1B RPSET2 Paper set sensor, 2nd 9000100667

3) PH1C RPSET3 Paper set sensor, 3rd 9000100667

4) PH2A RPCLK1 Paper end clock, 1st 9000100811

5) PH2B RPCLK2 Paper end clock, 2nd 9000100811

6) PH2C RPCLK3 Paper end clock, 3rd 9000100811

7) PH3 RP_IN Paper sensor below cutter 9000100667 8) PH4 P_FLAP Flapper position sensor 9000100667 9) PH5 P_ENT Paper entry sensor 9000100667 10) PH6 P_GATE Paper gate sensor 9000100667 11) PH7 P_SEP Paper separation sensor 9000100811 12) PH8 P_EXIT Paper exit sensor 9000100667 13) PH9 Paper transportation sensor 9000100811

14) PH10 CG_HP Cartridge set sensor 9000100811

15) MS1A INTLK3 Toner supply door, left 9000310068 16) MS1B INTLK3 Toner supply door, right 9000310068

17) MS2 INTLK3 Upper Unit 9000310068

18) MS4A DECKSW1 Roll deck 1, left 9000310068

19) MS5A DECKSW2 Roll deck 2, left 9000310068

MS9 MS4A S5 S4 S3 S1 MS5A MS6A MS8B MS2 MS1B MS1A MS8A PH5 PH6 PH1A PH1B PH1C PH8 PH7 PH10 PH3 PH4 TLS1 PH2A PH2B PH2C PH9 TLS2

K66sm4e2-1.doc (Ver. D.2) 4-14

Rear View

Fig.4-5-2

Symbol Code Name Part # ( can change without notice) 1) MS3A INTLK2 Interlock switch, exit door 9000310068

2) MS3B INTLK2 Interlock switch, exit door 9000310068 3) MS4B DECKSW1 Micro switch deck 1, right 9000310068

4) MS5B DECKSW2 Micro switch deck 2, right 9000310068

5) MS6B DECKSW3 Micro switch deck 3, right 9000310068

6) S2 Dehumidify Switch

7) TH1 F_TEMP1 Thermistor Fuser temp, outside 6606160010 8) TH2 F_TEMP2 Thermistor Fuser temp, inside 6606160010

9) TH3 Thermistor Fuser temp, bottom 6606160030

10) TS1 INTLK1 Thermostat Fuser 49517

11) TS2A Thermostat Dehumidify 1st

12) TS2B Thermostat Dehumidify 2nd 13) TS2C Thermostat Dehumidify 3rd TS1 MS3B MS4B MS5B MS6B MS3A S2 TS2A TS2B TS2C TH2 TH1 TH3

4.5.2

Motor / Clutch / Fan / CNT / RY / CB / LF / SSR / Dehumidify Heater

/ SL

Front View

Fig.4-5-3

Symbol Code Name Part # ( can change without notice)

1) M2 RFMTR Roll feed motor 9000380074

2) M3 CUTMTR Cutter motor see cutter assy 3) M4 WCMTR Wire cleaning motor 9000380075

4) M5 TNMTR Toner motor 9000380069

5) M6 CGMTR Cartridge motor 9000380072

6) MC1 RPFD_0 Roll paper clutch 0 6606700010

7) MC2A RPFD_1 Roll paper clutch 1 1116300020

8) MC2B RPFD_2 Roll paper clutch 2 1116300020

9) MC2C RPFD_3 Roll paper clutch 3 1116300020

10) Fan2 AGFAN Agitator fan 3106700010

11) Fan4 FUFAN Fuser cooling fan, right 9000470116 12) Fan6 FUFAN_S Fuser cooling fan, S-right 9000470103 13) Fan7 LEDFAN LED Head cooling fan, left 6601120300 14) Fan8 LEDFAN LED Head cooling fan, right 6601120300

Fan7 Fan8 CNT1 Fan4 Fan6 M6 M5 CB1 LF1 MC1 MC2A MC2B MC2C M2 M3 M4 RY1 Fan2 H2A H2B H2C

K66sm4e2-1.doc (Ver. D.2) 4-16

Rear View

Fig.4-5-4

Symbol Code Name Part # ( can change without notice)

1) M1 MAMTR Main motor 9000380073

2) MC3 P_SHUT Flapper clutch

3) MC4 RF_FD Paper gate clutch 3006700040

4) Fan1 FAN1H,L Separation fan 6601120290

5) Fan3 FUFAN Fuser cooling fan, left 9000470080

6) Fan5 FUFAN_S Fuser cooling fan, S-left 9000470103

7) Fan9 Inner feeder fan 9000470103

8) SSR1 F_HEAT Fuser Heater Relay 9000400017

9) SSR2 DEHUM Dehumidify Heater 9000400017

10) SSR3 EUROPE Fuser Control Sig. of Trans na 11) SSR4 EUROPE Fuser Control Sig. of Trans na

10) SL1 FSHUT Fuser Shutter Solenoid 9000390019

11) RY2 SFRY Fuser Heater Relay 9000370075

Fan3 MC4 Fan5 M1 MC3 Fan1 SL1 (SSR4) RY2 SSR1 Fan9 SSR2 (SSR3) K66sm4e1.jtd

Air Flow

K66sm4e2-1.doc (Ver. D.2) 4-18

4.5.3 Printed Circuit Board / DCP / HVP

Front View

Fig.4-5-6

Symbol Code Name Part # ( can change without notice)

1) PW6620 Main controller(w/interface) 6606270011

Note : DO NOT remove the battery loaded in the Main Controller. This battery is supposed to be collected by the service technician with the Main Controller.

CAUTION

Danger of explosion if battery is incorrectly replaced.

Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions.

Waste disposal method of battery:

As for the waste disposal of battery, dispose in accordance with local state and federal relations.

2) PW6650 Driver Board 6606260030

3) PW6631 E_LAMP Eraser lamp 6606260050

4) PW6690 DC terminal PCB 6606260061 7) PW6654 Driver Board 6606260150 8) PW6672 Operation PCB 6606260190 9) PW6610 AC Terminal Board 6606260210 10) PW6693 Zener diode PCB 6606260200 12) PW5722 Paper Selector PCB 57062600030 15) DCP1 DC Power Supply 24V dc 9000500210 16) DCP2 DC Power Supply 5V dc 9000500209 17) DCP3 DC Power Supply 24V dc 9000500211 19) TP0455 Motor Driver 6606600020

20) PW4215 Filter PCB (EUR only) na

1 2 3 4 7 12 10 9 8 DCP3 DCP1 DCP2 19 20 (EUR only) K66sm4e1.jtd

Rear View

Fig.4-5-7

Symbol Code Name Part # ( can change without notice)

5) PW6623 Roll Feeder Board 6606270030

6) PW6652 Driver Board 6606260140

11) PW4690 Signal Relay PCB 6606260230

13) PW5490 Receiver PCB (Option) 5406260020

14) PW5491 Transmitter PCB (Option) 5406260060

18) HVP High Voltage Power Supply 6606600010

Imaging, Transfer, Separation

& Dev. Bias

21) KCT021D Transformer (EUR only) na

6 5 14 13 11 HVP Transformer (EUR only) K66sm4e1.jtd

K66sm4e2-1.doc (Ver. D.2) 4-20

4.6 Down Sequence

4.6.1 Down Sequence caused by Low Fuser Temperature

[℃] 210

200 TH2(Center)

Controlled temperature It is switched is switched to 210 ℃ here. to 200 ℃ again. 180 TH3 150 130 110 Printing Printing stops here. restarts here.

TH2 (Center) is controlling the temperature, while TH1 (Side) and TH3 (Bottom) are just confirming the temperature during normal opertaions.

While TH2 is controlling the temperature at around 200 degrees, the temperature around TH3 is around 180 degrees.

While continuous printing, temperature around TH3 decreases gradually.( lower plate ) When TH3 decreases less than 130 degrees, TH2 starts to control the temperature at 210 Degrees rather than 200.

Down Sequence 1

If temperature around TH3 goes down and reaches 110 degrees, printing Is paused until it reaches up to 150 degrees.

(It is approx. 90 secs, dependent on the wall voltage)

Printing is paused during that period in order to help recover the temperature; it is called “Down Sequence”.

Down Sequence 2

If TH2 detects 5 degrees less (adjustable with 4-2C) compare with 200 degrees during TH3 detects less than 130 degrees, this machine also enters to “Down Sequence”.

Once “Down Sequence” is taken, Ready indication of Operation Panel starts blinking green, and it keeps blinking until the temperature of fuser is recovered.

4.6.2 Down Sequence caused by Toner Consumption

Toner circulates as shown arrows.

TLS1 TLS2

When TLS1 detects “L” status ( no toner ) for 15 seconds ( continuously ) toner is normally supplied for 2 minutes from Toner Hopper

If TLS2 detects “L” ( no toner ) for 21 seconds continuously, the printing is paused for a few minutes after current printing is finished, in order to help supplying toner much more.

However, if TLS2 detects “H” for 3 seconds, “Down Sequence” is cancelled at that moment.

If Toner “Down Sequence” occurs, the Toner indication of Operation Panel starts blinking green, and it keeps blinking until the “Down Sequence” is complete.

K66sm5e1.doc (Ver. D.2) (1)

Chapter 5

Mechanical Systems

5.1.1 Upper cover 1 (Toner cover) 5- 3

5.1.2 Upper cover 2 (Operation cover) 5- 4

5.1.3 Upper cover 3 5- 4

5.1.4 Right/Left side upper covers 5- 5

5.1.5 Right/Left side lower covers 5- 5

5.1.6 Right/Left side covers 5- 6

5.1.7 Rear upper cover 5- 6

5.1.8 Rear lower cover 5- 6

5.2 Upper frame assembly of main body 5- 7

5.2.1 Opening of Movable unit 5- 7

5.2.2 Main motor (M1) 5- 9

5.2.3 LED head 5-10

5.2.4 Eraser lamp 5-10

5.2.5 LED head cooling fans (Fan7, Fan8) 5-11

5.2.6 Timing belts (two) 5-12

A. Timing belt for main motor 5-12

B. Timing belt for pulley/P161 5-12

5.3 Lower frame assembly of main body 5-13

5.3.1 Clutches (two) 5-13

A. Flapper clutch (MC3) 5-13

B. Paper gate clutch (MC4) 5-13

5.3.2 Timing belt 5-14

A. Timing belt for Inside feed assembly 5-14

5.3.3 Ozone filters 5-14

5.3.4 Fans 5-15

A. Fuser cooling fan left (Fan 3) 5-15

B. Fuser cooling fan right (Fan 4) 5-15

C. Fuser cooling fan S-left (Fan 5) 5-16

D. Fuser cooling fan S-right (Fan 6) 5-16

5.3.5 Counter (CNT1) 5-17

5.3.6 Main switch (S1) 5-17

5.3.7 Fuser shutter solenoid (SL1) 5-18

5.4 Process unit 5-19

5.4.1 Disassembling Process unit 5-19

5.4.2 Photoconductive drum 5-23

5.5 Main frame 5-25

5.5.1 Cutter assembly 5-25

A. Paper sensor below cutter (PH3) 5-27

5.6 Primary charger assembly 5-29

5.6.1 Primary charger assembly 5-29

5.6.2 Corona charging wire 5-30

5.6.3 Height adjustment of corona charging wire 5-31

5.6.4 Grid plate 5-31

5.6.5 Wire cleaning motor (M4) 5-32

5.6.6 Wire cleaning pad 5-33

5.7 Transfer/Separation charger assembly 5-34

5.7.1 Transfer/Separation charger assembly 5-34

5.7.2 Transfer/Separation corona charging wire 5-35

5.7.3 Corona Guard 5-35

5.7.4 Height adjustment of corona charging wire 5-36

5.8 Fuser assembly 5-37

5.8.1 Disassembling Heater assembly 5-37

A. Thermistors (TH1, TH2) 5-39

B. Fin Heater – oven type (100V, 120V and 230V) 5-39

5.8.2 Thermostat (TS1) 5-41

5.8.3 Paper Transportation Sensor (TP9) 5-41

5.8.4 Fuser Lower assembly 5-42

A. Paper exit sensor (PH8) 5-43

B. Thermistor (TH3) 5-43

C. Exit Roller 5-43

5.8.5 Agitating motor 5-45

5.8.6 Agitator fan (Fan 2) 5-46

5.8.7 Agitator fan (Fan 2) - Modified Assembly 5-50

5.9 Development assembly 5-52

5.9.1 Disassembling Toner hopper assembly 5-52

5.9.2 Development roller 5-54

5.9.3 Regulation roller 5-56

5.9.4 Supply roller and side seals 5-58

5.9.5 Sender screw 5-59 5.9.6 Scraper 5-61 5.9.7 Toner motor (M5) 5-63 5.9.8 Toner sensors (TLS1, TLS2) 5-63 5.9.9 Spacing roller 5-64 A. Left side 5-64 B. Right side 5-64 5.9.10 Gears 5-65

5.10 Inside feed assembly 5-66

5.10.1 Disassembling Inside feed assembly 5-66

5.10.2 Paper separation sensor (PH7) 5-66

5.10.3 Feed belt 5-67

5.10.4 Feed roller 5-67