Riso KS 500 Service Manual

SERIES
TECHNICAL MANUAL
VERSION 1.2
December, 2000
Copyright : 2000 RISO Kagaku Corporation
All Rights Reserved. This Technical Manual was prepared and
written for the exclusive use of RISO International Group
Certified Dealers. Reproduction and/or transmittal of this
material in any form or by any means, including photocopying
or recording of the information is strictly prohibited without the
consent of a member of RISO International Group.
RISO INTERNATIONAL GROUP

RISO KAGAKU CORPORATION (JAPAN)
RISO, INC. (U.S.A.)
RISO EUROPE LIMITED (U.K.)
RISO HONG KONG (HONG KONG)
RISO UK (U. K.)
RISO THAILAND LIMITED (THAILAND)
RISO DEUTSCHLAND GmBH (GERMANY)
RISO FRANCE (FRANCE)

RISO IBERICA (SPAIN)
RISO CANADA (CANADA)
RISO CHINA (HONG KONG)
RISO AFRICA (SOUTH AFRICA)
RISO THECHNOLOGY ZHUHAI (CHINA)
CONTENTS
CHAPTER 1: MAINTENANCE
1. PREFACE ......................................................................................................... 1-1
CAUTION ........................................................................................................... 1-2
WARNING ......................................................................................................... 1-3
2. Work Precautions .............................................................................................. 1-4
3. Exterior Cover Removal
> Front cover ..................................................................................................... 1-6
> Back cover ..................................................................................................... 1-6
> Master removal cover ...................................................................................... 1-6
CHAPTER 2: MACHINE SUMMARY
1. Specifications
1. KS500 / 500C ............................................................................................... 2-1
2. Cross Sectional Diagram ................................................................................... 2-2
3. Machine Operations ........................................................................................... 2-3
4. Paper Feed and Receiving ................................................................................. 2-4
5. Master Removal and Feed ................................................................................. 2-5
6. Counter indication .............................................................................................. 2-6
CHAPTER 3: MAIN DRIVE SECTION
1. Theory of Operation
1. Main Drive ...................................................................................................... 3-1
2. Main Motor Safety Switches .......................................................................... 3-2
3. Drum Positions .............................................................................................. 3-3
4. Drum Rotation Lever ...................................................................................... 3-5
2. Removal and Assembly
1. Main Motor Unit ............................................................................................. 3-7
2. Master Removal Unit Safety Switch ............................................................... 3-9
3. Master Making Unit Safety Switch ................................................................. 3-10
4. Separation Fan Safety Switch ........................................................................ 3-11
5. Paper Guide Plate Safety Switch ................................................................... 3-12
6. Drum Rotation Lever ...................................................................................... 3-13
CHAPTER 4: FIRST PAPER FEED SECTION
1. Paper Feed Tray Position .............................................................................. 4-1
2. First Paper Feed Drive Mechanism ................................................................ 4-2
3. Paper Pickup System .................................................................................... 4-4
4. Paper Feed Pressure Select System ............................................................. 4-5
1. Paper Feed Tray Unit ..................................................................................... 4-6
2. Pickup Roller Assembly ................................................................................ 4-7
3. Pickup Roller ................................................................................................. 4-8
4. Stripper Pad .................................................................................................. 4-9
5. Paper Feed Clutch ......................................................................................... 4-10
-1-
KS Series (Version 1.2)
3. Adjustment
1. Paper Feed Tray Pressure ............................................................................. 4-11
2. Paper Feed Tray Position Adjustment ........................................................... 4-13
3. Paper Feed Clutch ON Timing ....................................................................... 4-14
4. Paper Feed Clutch OFF Timing ..................................................................... 4-15
CHAPTER 5: SECOND PAPER FEED SECTION
1. Second Paper Feed Drive Mechanism ........................................................... 5-1
2. Vertical Print Position ................................................................................... 5-2
1. Load Spring ................................................................................................... 5-3
2. Timing Clutch ................................................................................................ 5-4
3. Paper Guide Plate ......................................................................................... 5-5
4. Paper Gate .................................................................................................... 5-6
5. Timing Roller / Guide Roller ........................................................................... 5-7
3. Adjustment
1. Print Position (Timing Clutch ON timing) ....................................................... 5-8
CHAPTER 6: PRESS SECTION
1. Press Mechanism ......................................................................................... 6-1
1. Pressure Roller .............................................................................................. 6-3
2. Pressure Lever Ass'y ..................................................................................... 6-4
3. Pressure Shaft Ass'y ..................................................................................... 6-5
3. Adjustment
1. Pressure Lever Ass'y Position ....................................................................... 6-7
CHAPTER 7: PAPER EJECTION SECTION
1. Paper Ejection Mechanism ........................................................................... 7-1
2. Paper Separation Mechanism ....................................................................... 7-3
1. Suction Unit .................................................................................................. 7-5
2. Transfer Belt .................................................................................................. 7-6
3. Suction Fan ................................................................................................... 7-7
4. Separation Fan Unit ....................................................................................... 7-8
5. Separation Fan .............................................................................................. 7-9
6. Paper Receiving Sensor ................................................................................ 7-9
7. Separator ....................................................................................................... 7-10
8. Paper Receiving Tray ..................................................................................... 7-11
3. Adjustment
1. Separator Position ......................................................................................... 7-13
-2-
CHAPTER 8: DRUM SECTION

1. Master on Drum (in printing) Check Mechanism ............................................ 8-1
2. Ink Bottle Set Check Mechanism .................................................................. 8-2
3. Ink Supply Mechanism .................................................................................. 8-3
4. Squeegee Roller Rotation Mechanism ........................................................... 8-5
1. Drum Unit ...................................................................................................... 8-7
2. Screen ........................................................................................................... 8-8
3. Drum Body .................................................................................................... 8-9
4. Ink Sensor PCB ............................................................................................. 8-11
5. INk Bottle Guide ............................................................................................ 8-12
6. INk Bottle Set Sensor .................................................................................... 8-12
7. Drum Support F & Drum Support R ............................................................... 8-13
8. Squeegee Roller ............................................................................................ 8-14
9. Ink Pump Unit ................................................................................................ 8-17
10. Inking Motor ................................................................................................. 8-18
3. Adjustment
1. Squeegee Gap .............................................................................................. 8-19
CHAPTER 9: PAPER JAM
1. Paper Jam at First Paper Feed Area ............................................................. 9-1
2. Paper Jam at Paper Receiving Area .............................................................. 9-2
5. Print Start Timing Chart ................................................................................. 9-3
6. During the Printing Timing Chart .................................................................... 9-4
7. Print Stop Timing Chart ................................................................................. 9-5
CHAPTER 10: MASTER CLAMP SECTION
1. Clamp Unit Home Positioning Mechanism .................................................... 10-1
2. Clamp Plate Master Release Mechanism ...................................................... 10-2
3. Clamp Plate Master Clamp Mechanism ........................................................ 10-4
1. Clamp Unit .................................................................................................... 10-7
2. Clamp Motor .................................................................................................. 10-8
3. Clamp Sensor C ............................................................................................ 10-8
4. Clamp Sensor L ............................................................................................. 10-8
-3-
CHAPTER 11: MASTER REMOVAL SECTION

1. Master Removal Unit Home Positioning Mechanism ..................................... 11-1
2. Master on the Drum (before master removal) Check Mechanism ................... 11-2
3. Clamp Plate Master Release Mechanism ...................................................... 11-4
4. Master Removal Mechanism ......................................................................... 11-6
5. Master Disposal Box Set Mechanism ........................................................... 11-8
1. Master Removal Unit ..................................................................................... 11-9
2. Master Removal Clutch .................................................................................. 11-10
3. Master Removal Sensor ................................................................................. 11-11
4. Disposal Box Set Sensor .............................................................................. 11-11
5. Master Removal Hook ................................................................................... 11-12
6. Vertical Transport Roller (Upper) .................................................................... 11-13
7. Vertical Transport Roller (Lower) .................................................................... 11-13
8. Master Removal Guide .................................................................................. 11-13
CHAPTER 12: IMAGE SCANNING SECTION
1. Original Loading Mechanism ......................................................................... 12-1
2. Original Scanning Mechanism ....................................................................... 12-3
3. Image Scanner .............................................................................................. 12-5
1. White Roller .................................................................................................. 12-7
2. Image Scanner Unit ....................................................................................... 12-8
3. Original IN Sensor ......................................................................................... 12-9
4. Pickup Roller ................................................................................................. 12-10
5. Eject Roller Upper ......................................................................................... 12-10
6. Document Feeder Hook ................................................................................. 12-10
7. Load Roller .................................................................................................... 12-11
8. Eject Roller Lower ......................................................................................... 12-11
8. Read Pulse Motor .......................................................................................... 12-11
3. Adjustment
1. Image Scanner .............................................................................................. 12-13
CHAPTER 13: CUTTER SECTION
1. Cutter Home Positioning Mechanism ............................................................ 13-1
2. Cutting Mechanism ........................................................................................ 13-3
1. Cutter Unit ..................................................................................................... 13-5
-4-
CHAPTER 14: MASTER MAKING SECTION

1. Master Making .............................................................................................. 14-1
2. TPH Positioning ............................................................................................. 14-3
3. Thermal Power Safety Switches .................................................................... 14-5
1. Write Roller ................................................................................................... 14-7
2. Thermal Print Head (TPH) .............................................................................. 14-8
3. TPH Position Sensor ..................................................................................... 14-9
3. Adjustment
1. Thermal Power of Thermal Print Head ............................................................ 14-11
CHAPTER 15: MASTER CLAMPING / LOADING SECTION
1. Master Making Unit Set Mechanism .............................................................. 15-1
2. Master Positioning Mechanism ..................................................................... 15-2
3. Master Feeding Mechanism .......................................................................... 15-4
4. Clamp Plate Master Clamp Mechanism ........................................................ 15-6
5. Master Loading on the Drum Mechanism ...................................................... 15-8
6. Master Advancement after Master Cutting ..................................................... 15-10
1. Master Making Unit ....................................................................................... 15-13
2. Master Making Unit Set Switch ..................................................................... 15-15
3. Write Pulse Motor ......................................................................................... 15-16
4. Master Positioning Sensor ............................................................................ 15-17
5. Master Loading Solenoid ............................................................................... 15-18
6. Master End Sensor ........................................................................................ 15-19
APPENDIX
Electrical Components ........................................................................................... APX(0)-1
Test Mode .............................................................................................................. APX(1)-1
Users Mode ............................................................................................................ APX(2)-1
Advice Displays (Call Service Messages) ............................................................... APX(3)-1
Description of PCBs ............................................................................................... APX(4)-1
-5-
CHAPTER
1:
MAINTENANCE
CONTENTS
1. Preface .....................................................................................................................
CAUTION ..................................................................................................................
WARNING .................................................................................................................
2. WORK PRECAUTIONS .............................................................................................
> Front cover .............................................................................................................
> Back cover .............................................................................................................
> Master removal cover ..............................................................................................
1
2
3
4
6
6
6
PREFA C E
This manual provides Technical Service Information for the RISO K S duplicators.
This manual is published as a reference guide for use by RISO Group (RISO Kagaku Corp./
RISO China Ltd./RISO Technology Zhuhai Co., Ltd./RISO(Thailand) Ltd.) Certified Technical
Representatives experienced in duplicator repair and service.
This manual also provides procedures for removing and installing major components.
Following these procedures will minimize machine malfunctions. This information and
format will also increase technical representatives' awareness and experience regarding
repairs necessary to insure end-user satisfaction.
If assistance is required, please contact one of the following:
[ RISO Kagaku Corp.]

Overseas Technical Section, Overseas Technical Department
2-5-1, Akanehama, Narashino-shi, Chiba 275, JAPAN
TEL: (0474)52-4111 FAX: (0474)52-3106
[ RISO China Ltd.]
Technical Department
Unit A&C, 4/F., Gee Hing Chang Industrial Building, Cheung Yue St., Cheung sha wan,
Kowloon, Hong Kong , China
TEL: (852)2786-3911 FAX: (852)2310-8381
[ RISO Technology Zhuhai Co. Ltd.]
Jida Haibin Nan Lu, Guangda Guoji Maoyi Zhongxin 29 Ceng, Zhuhai shi, P.R. China,
519015
TEL: (0756)332-3300 FAX: (0756)332-3301
[ RISO (Thailand) Ltd.]
400 Phairojkijjia Tower, 10/F, Bangna-Trad Road, Km.4, Bangkok 10260, Thailand
TEL: (662)3614643 FAX: (662)3614652
1-1
CAUTION
[Handling of Lithium Battery]
- Never fail to follow the following instructions when you discard the used
lithium battery.
1. Never let the battery short-circuited.
If the (+) and (-) terminals contact each other or metal materials, the battery will be
short-circuited. If the batteries are collected and stored inorderly or one upon
another, the above-mentioned case will occur.
- DANGER If the battery is short-circuited, it will heat up and may in some cases explode into
fire.
2. Never heat up the battery.
- DANGER If you heat the battery up to more than 100 degrees centigrade or put it into the fire, it
may burn dangerously or explode.
3. Never disassemble the battery or press it into deformation.
- DANGER If you disassemble the battery, the gas pouring out of the inside may hurt your
throat or the negative lithium may heat up into fire.
If the battery is pressed into deformation, the liquid inside may leak out of the
sealed part or the battery may be short-circuited inside an explode.
4. Never fail to keep the battery out of reach of children.
If you put the battery within reach of children, they may swallow it down.
Should they swallow the battery, immediately consult the doctor.
[Replacement of the Lithium Battery]

1. The lithium battery must be replaced by a trained and authorized service
technician.
2. The battery must be replaced only with the same or equivalent type recommended by the manufacturer.
3. Discard used batteries according to the manufacturers instructions.
1-2
!! WARNING !!
Important Safety Precautions
1. Always disconnect electrical supply before placing hands in the
machine.
I.
To avoid injuries:
Be sure to disconnect the electrical power before disassembling, assembling,
or when making adjustments on the machine.
I. Protection of the machine:

Make sure to turn OFF the power to the machine before plugging or unplugging
the electrical connectors, or when connecting a Meter.
2. Always connect electrical connectors firmly.

I.
To avoid electrical failure:

The connectors must be connected firmly together and onto the PCBs.
Press on the ends of the connectors and then the center to ensure a firm fit.
I. Protection of the electrical components:

The electrical components may be damaged due to short circuits caused by
a loose connector.
Wire harness connector
FIRST
Press the ends.
THEN
Press the center, firmly.
1-3
MAINTENANCE
WORK PRECAUTIONS
2. Work Precautions
Inspection
If inspection finds a defective or problem part, correct it.
Replace parts as necessary.
Half-pierced section
Removal
(1)Carry out work according to the procedures in the
technical manual.
(2)Arrange the removed parts carefully and in order.
(3)Distinguish parts to be replaced and those to be reused.
(4)When replacing screws and the like, use the specified
size.
Assembly and installation

Unless otherwise specified, assembly and installation follow
the reverse order of removal. When there is a protruding
section and a hole for positioning a part, align them correctly
before fastening.
(Part positioning protruding section and hole is referred as
"half-pierced section" in the manual.)
Replace mount screws

Self-tapping screws have been used on KS machines to reduce its production cost.
The ability of the self-tapping screw is same as normal screws used on the previous Riso products.
However the self-tapping screws will make damage of the screw hole if the screw is removed and
installed frequently. Therefore it is recommended that screws, of which are expected to be removed and
installed frequently should be replaced from the self-tapping screws with normal screws such as panhead screws or binding screws.
Below figure is the difference between Self-tipping screw and Pan-head screw.
Pan-head screw
or Binding-head screw
Self-tapping screw
1-4
MAINTENANCE
WORK PRECAUTIONS
Electrical system work

>
>
>
>
>
After removing wiring bundles, fasten them with bands (bar lock ties) so that they do not sag.
When installing parts, be careful to avoid pinching and damaging wiring bundles.
If a fuse blows, always replace it with one of the specified capacity.
Using a larger fuse can not only damage parts, but also cause fires.
Image scanner, thermal heads, and sensors are extremely vulnerable to shock, so do not drop
them.
> Always disconnect the power before plugging or unplugging sensor connectors.
Wiring bundle band

(bar lock ties)
1- 5
MAINTENANCE
EXTERIOR COVER REMOVAL

Disconnect the power supply from the machine and remove the cover.
> Front cover
> Back cover
> Master removal cover: ...... Remove the Master disposal first.
B
A
A: Front cover
B: Back cover
C: Master removal cover
1-6
CHAPTER
2:
MACHINE SUMMARY
CONTENTS
1.
2.
3.
4.
5.
6.
Specifications....................................................................................................1
Cross Sectional Diagram ........................................................................................ 2
Machine Operations ................................................................................................ 3
Paper Feed and Receiving ..................................................................................... 4
Master Removal and Feed ..................................................................................... 5
Counter Indication .................................................................................................. 6
MACHINE SUMMARY
SPECIFICATIONS
1. Specifications
KS500 / KS500C
Processing
Automatic digital scanning

Fully automatic, thermal screening duplicating system
Time to First Copy
60 seconds (A4 or B4 original)
Print Speed
2 selectable print speeds (60, 90 sheets/min.)
Scanning Resolution
200 x 300 dpi
Original Type
Sheet
Original Size
KS500 Max. 257 x 394mm or B4

Min. 182 x 256mm or B5
Paper Size
Max. 273 x 394mm

Original Weight
Max. 107 g/m2

Min. 50 g/m2
Paper Weight
KS500 Max. 80 g/m2

Min. 50 g/m2
Image Area
KS500C
Max. 273 x 394mm

KS500C Max. 70 g/m2

Min. 35 g/m2
249 x 352mm
Feed tray 250 sheets (64 g/m2 )
Receiving tray - 250 sheets (64 g/m 2 )
KS500C Feed tray 280 sheets (50 g/m2 )
Receiving tray - 280 sheets (50 g/m 2 )
Paper Capacity
KS500
Machine Weight
Approx. 45 kg
Dimensions
[WxDxH]
In use / 1200 x 650 x 470mm

In storage / 635 x 645 x 479mm
Power Source
220 to 240 VAC, 50/60 Hz <1.5A-2.0A>

<Requirements>
Features
Print speed control, Confidential mode, Photo processing mode,

Scanning contrast adjustment, Print position adjustment,
Newspaper mode, Print/Master count display
2-1
MACHINE SUMMARY
CROSS SECTIONAL DIAGRAM
2. Cross Sectional Diagram

Document
feeder
Cutter unit
Image scanner
Thermal print head

Original rack
Master disposal box
8
Write roller
6
Master roll
7
1
10
2
5
Separator
3
Paper feed tray
Paper receiving tray
Suction unit
Pickup roller
Pressure roller
Timing roller
Guide roller
1 First Paper Feed Area:
Feeds single sheets of paper to the second paper feed area via
the Pickup roller and Stripper pad.
2 Second Paper Feed Area:

Controls the vertical print position and feeds paper to the print
area via the Timing and Guide rollers.
3 Press (Printing) Area:
Uses the Pressure roller to press paper against the master on the
Drum.
The Drum rotates with the Pressure roller and prints an image on
paper.
4 Paper Ejection Area:
Separates a printed paper from the Drum, and transports it onto

the paper receiving tray.
5 Drum Area:
Supplies the Drum surface with ink from an Ink cartridge.
6 Master Clamp Area:
Clamps the leading edge of the master.
7 Master Disposal Area:
Separates used master from the Drum and disposes it into the
Master disposal box.
8 Image Scanning Area:
Carries an original and scans it with the Image scanner and

converts the image information into digital data.
9 Master Making Area:
Makes a master with the Thermal print head.
10 Master Loading Area:
Feeds the prepared master material to the Drum and cuts it to an

appropriate length.
2- 2
MACHINE SUMMARY
MACHINE OPERATIONS
3. Machine Operations
Set the original and press the Start key.
Master Disposal
Master Making
The used master is removed from

the drum and stored in the disposal
box.
The original is scanned by the image

scanner and the image is made on the
master with the thermal print head.
Master Carrier and Loading

The made master is wrapped onto the drum
and cut.
Also, a proof print is printed.
Printing
Paper is fed one sheet at a time from
the Paper feed tray, printed, and stored
on the paper receiving tray.
2- 3
MACHINE SUMMARY
PAPER FEED AND RECEIVING
4. Paper Feed and Receiving

Pickup roller
Drum
The Drum is rotated and a sheet of paper is fed
from the first paper feed area to the second paper
feed area by Pickup rollers, and Stripper pad.
Stripper pad
Guide roller
The paper feed to the second paper feed area is
stopped by the Guide and Timing rollers to form a
buckle. The paper then waits until the rotation of the
Guide roller starts.
Timing roller
The Guide and Timing rollers in the second paper

feed area are rotated and the paper is fed to the
printing area.
Pressure roller
Separation fan
While the paper is being fed from the second paper

feed area, the Pressure roller rises and printing
starts.
(The Pressure roller contacts the Drum and starts
rotating.)
Separator
After the Pressure roller contacts the Drum to start
printing, the Separator approaches the Drum and
the Separation fan starts to blow.
The Guide roller goes up to release the paper.
(The paper is then transferred by the rotation of the
Drum.)
Transfer belt
The printed paper is separated from the Drum by

the Separator and with a help of the air blow from
the Separation fan.
It is then transported onto the Paper receiving tray
by the Transfer belts using Suction fan.
The Timing roller contacts the Guide roller to feed

the next sheet of paper.
2- 4
MACHINE SUMMARY
MASTER REMOVAL AND FEED
5. Master Removal and Feed

Clamp plate
Master projection
shaft
Master roll
Master Removal
The Clamp plate opens and Master release
shaft releases the master from the Clamp
plate.
Vertical
transport roller
Master
The Drum and Vertical transport rollers

starts rotating and removes the master
from the Drum and feed it into the Master
disposal box.
Master
disposal box
The Master compressing plate starts

compressing the removed master within the
Master removal box.
TPH
Master Making
The Image scanner scans the image on the
original and Thermal print head (TPH)
makes the image on the master material.
The Master tension plate drops down and
applies tension on the master material.
Master Loading
The master is transferred onto the Drum
and the leading edge is clamped by the
Clamp plate.
The Drum rotates to wrap the master on
the Drum.
Cutter
The Cutter cuts the master.
2-5
MACHINE SUMMARY
COUNTER FOR MAINTENANCE
6. Counter Indication
1. Indicate Copy and Master Counter:
No mechanical counters are installed on KS therefore the alternatives are available as software
counter.
The counter indication can be shown by using USER MODE.
By pressing [*] and then [1], three digits of seven segments indication on the control panel displays
the Copy counter. The threee digits of seven segments change every 2 seconds then displays nine
digites of numbers finally.
By pressing [*] and then [2], the Master counter can be shown as same method as the above.
[Example] In case the Copy count is 123,456 and the Master count is 1,234.
1. Press [*] key then [1] key.
2. [ - - - ] will be indicated at first.
3. After 2 seconds, the indication will be changed to [ 1 2 3 ].
5. Press [*] key then [2] key.
6. [ - - 1 ] will be indicated at first.
2. Clear of Copy and Master Counter:

There is "Counter clear mode" instead of Counter stop mode, of which has been programmed as Test
mode No.92 on existing RISOGRAPHs.
The counter indication can be clear by using TEST MODE No.97.
or
on the control panel then Power On.
By pressing the print position adjustment key
Three digits of seven segments indication on the control panel displays version of the System ROM
initially. Then press [C] button so that the Test numbers can be input.
Clear Copy and Master counter:
1. Press [9] and [7] key then press [Start] key while test mode is available.
2. [1] will be indicated. In case the indication is [0], counter cannot be clear.
3. Press [C] to clear the memorised copy and master counter.
4. Press [Reset] key or power off to be back to normal operation.
Prohibit clear of Copy and Master counter:
1. Press [9] key and [7] key then press [Start] key while test mode is available.
2. [1] will be indicated. In case the indication is [0], counter cannot be clear.
3. Press [C] to clear the memorised copy and master counter.
4. Press the print position adjustment key
or
to the indication change from [1] to [0].
5. Press [Start] key so that conter clear mode becomes no longer available.
6. Press [Reset] key or power off to be back to normal operation.
Note:
*1. To confirm the status of the counter clear mode, imput test mode No.97 then press [Start] key
while test mode is available. If the indication is [0], counter cannot be clear. If not, the counter can
be clear.
*2. It is reccommended that the prohibit clear mode should be done before the machine is installed at
customer site.
2-6
CHAPTER
3:
MAIN DRIVE SECTION
CONTENTS
1. Main Drive .............................................................................................................. 1
2. Main Motor Safety Switches .................................................................................. 2
3. Drum Position ........................................................................................................ 3
4. Drum Rotation Lever .............................................................................................. 5
1. Main Motor Unit ..................................................................................................... 7
2. Master Removal Unit Safety Switch ....................................................................... 9
3. Master Making Unit Safety Switch ....................................................................... 10
4. Sparation Unit Safety Switch ............................................................................... 11
5. Paper Guide Plate Safety Switch ......................................................................... 12
6. Drum Rotation Lever ............................................................................................ 13
MAIN DRIVE SECTION

T H E O RY OF OPERATION
1. Main Drive
1. Drum rotation
> The Main motor gear [A] on the Main motor [H] rotates the Main gear [G]via
the Step-down gaer A [F] and B [G].
> The Main gear [G] rotates the Intermediate gear [C].
> The Drum [A] is rotated by the Drum main gear [B] via the Intermadiate gear [C].
2. First paper feed area drive
> When the Paper feed clutch is activated, the main drive is transferred to the First paper feed
drive via clutch.
3. Main motor encoder sensor
> The Encoder sensor [I] on the Main motor [H] keeps check on the Main motor rotation speed
and Drum position.
A
F
H
A : Drum
B : Drum Main gear
C : Intermediate gear
D : Main gear
E : Step-down gear A
F : Step-down gear B
G : Main motor gear
H : Main motor
I : Encoder sensor
J : Encorder
G
I
3-1
MAIN DRIVE SECTION

2. Main Motor Safety Switch

1. Following all three Safety switches must be activated to run the Main motor.
> Master removal unit safety switch [A]
> Master making unit safety switch [B]
> Separation unit safety switch [C]
> Paper guide plate safety switch [D]
The same three switches act also as Safety switches for the Thermal power.
A
D
A: Master removal unit safety switch

B: Master making unit safety switch
C: Separation unit safety switch
D: Paper guide plate safety swich
3-2
MAIN DRIVE SECTION

3. Drum Positions
1. Sensors for the Drum positioning
> The position of the Drum is determined by the Position-A sensor [A] and Encoder sensor on the
Main motor.
2. Position-A
> This is the position where the Clamp plate is at the top of the Drum.
> This position is also referred as the 0 position.
> The Clamp plate opens and closes at this position.
> This is the position where the light path of the Position-A sensor [A] is cut by the Position-A
plate [B] on the Drum.
Drum position-A
A
B
Drum angle
0
A : Position-A plate
B : Position-A sensor
3-3
MAIN DRIVE SECTION

Drum A-Positioning Movement Timing Chart

270
(a)
0 (Position-A)
(b)
90
180
270
315
End of movement
0 (Position-A)
Drum angle
(Encoder sensor)
Blocked
Open
Position-A sensor
ON
Main motor
OFF
15 rpm
1.95 rpm
(a) If the light path of the Position-A sensor is cut when the last paper is counted, the Main motor speed
becomes from printing to 15 rpm to stop the drum rotation.
(b) When the Drum rotates to 315, the drum rotation speed becomes 1.95 rpm to stop the drum at the
Drum- A position (at Drum 0 ) exactlly. Then Main motor turns off
.
> If the Encoder sensor does not output the Main motor rotation signal within 1.2 seconds, the machine
assumes that the Main motor has locked and displays error message [E 01].
> If over load current is detected and the Encoder sensor does not output th Main motor rotation signal for
0.1 seconds, the machine assumes that the Main motor has locked and displays error message [E 01].
3-4
MAIN DRIVE SECTION

4. Drum Rotation Lever

1. Drum rotation lever
> The Drum [A] is rotated by pusing down the Drum rotation lever [C].
> The Drum rotation gear [B] is moved up and down by the Drum rotation lever [C].
> The Drum rotation gear [B] rotates drive gears, thus the drum is rotated forward.
D
C
A:Drum
B:Drum gear
C:Drum rotation levar
D:Drum rotation gear
3-5
MEMO
MAIN DRIVE SECTION

R E M O VAL AND ASSEMBLY

1. Main Motor Unit
1. Disconnect the power supply from the machine.
2. Remove Back cover.(See page 1-5)
3. Remove Paper receiving tray [A].
4. Remove Suction cover [B].(See page 7-6)
5. Remove Suction unit [C]. (See page 7-6)
(continues on page 3-8)
C
B
A : Paper receiving tray

B : Suction cover
C : Suction unit
3-7
MAIN DRIVE SECTION

6.Remove three mounting screws of the P.-F. clatch bracket [B].

7.Remove each two mounting screws of the Timing clatch bracket A [C] and B [D].
8. Remove mounting screw of the Encoder [E].
9. Remove mounting screws of the Drive gear bracket [F] then remove the bracket.
10. Disconnect a connector of the Main motor unit [A] from the System PCB.
11. Remove three mounting screws of the Main motor unit [A] and remove the unit from the machine.
E
D
A: Main motor unit

B: P.-F. clatch bracket
C: Timing clatch braket A
D: Timing clatch braket B
E: Encoder
F: Drive gear bracket
Precautions in Assembly
> Match the half-pierced sections of brackets against those on the machine frame.
3-8
MECHANICAL OVERVIEW
2. Master Removal Unit Safety Switch

2. Remove the Front cover.(See page 1-5)
3. Open the Master removal unit [A] and disconnect the Connector of the Master removal unit safety
switch [B].
4. Remove three mounting screws of the Switch bracket and remove the bracket with the switch
attached.
5. Remove the switch [B] from the bracket.
> The mounting section of the bracket should be positioned behind the stay of the Master
removal unit [A].
> Match the half-pierced section on the Switch bracket with that on the machine.
A: Master removal unit

B: Master removal unit safety switch
3-9
MAIN DRIVE SECTION

3. Master Making Unit Safety Switch

1.
2.
3.
4.
Disconnect the power supply from the machine.

Remove the Master making unit [B](See page 15-13).
Disconnect the Connector of the Master making unit safety switch [A].
Remove two mounting screws of the Master making unit safety switch [A] and remove the switch.
> Install the switch [B] in the correct direction.
A: Master making unit

B: Master making unit safety switch
3 - 10
MAIN DRIVE SECTION

4. Separation Unit Safety Switch

3. Remove the Main PCB. (See page 8-6)
4. Open the Separation unit [B] as the below photo shows.
5. Remove the Separation unit switch [A] from the bracket.
> Do not bend the Switch bracket, as it acts as a spring plate to press against the actuator of the
Separetion unit switch [A] when the Drum is inserted in the machine.
A:Separation Unit Safety Switch switch

B:Separation Unit
3 - 11
MAIN DRIVE SECTION

5. Paper Guide Plate Safety Switch

2. Remove Back & Front cover (See page 1-5)
3. Remove the Power supply unit (See page 8-6)
4. Remove the PF tray [C] & the Pickup roller ass'y [B] (See page 4-6, 4-8)
5. Remove the PF clutch bracket & the PF clutch (See page 4-10)
6. Remove the PF guide plate upper plate (See page 5-7)
7.Remove the Master senser bracket (See page 5-5)
8.Remove the Paper gate (See page 5-12)
9.Remove the PF guide plate lower plate (See page 5-7)
10.Remove the PF plate safety SW [A]
> Do not bend the Switch bracket, as it acts as a spring plate to press against the actuator of the
switch when the Drum is inserted in the machine.
B
C
A:Guide Plate Safety Switch

B:Pickup roller ass'y
C:Paper feed (PF) tray
3 - 12
MAIN DRIVE SECTION

6. Drum Rotation Lever

6-1. Original Type: For KS500 Serial Number
For KS500C Serial Number
81530001- 81530500
81510001- 81510500
1. Dosconnect the power supply from the machine.

2. Remove the Back cover (See page 1-5)
3. Remove the Drum rotation lever bracket [B]
4. Remove the Drum rotation lever ass'y [D].
5. Separate the Drum rotation lever [C] and the Drum rotation gear [A].
Important caution of the Assembly

> Blue color of the One-way clutch in the Drum rotation gear [A] must face to the Drum rotation lever
bracket [B].
If the Drum rotation gear [A] is installed in the opposite direction, the Drum will be locked and [E 1]will
be indicated on the machine.
A
B
A: Drum rotation gear

B: Drum rotation lever bracket
C: Drum rotation lever
D: Drum rotation lever ass'y
3 - 13
MAIN DRIVE SECTION

Serial No. 81530501 -
6-2. New type : For KS500

For KS500C
1.
2.
3.
4.
5.
Serial No. 81510501 -

Remove the Back cover (See page 1-5)
Remove the Cover;Drum rotation Lever [G].
Remove the Gear plate;Drum rotation lever [B].
Seperate the Gear plate Drum rotation lever [B] and the Gear;m1*26*11 [A].
Important caution of the Assembly

> Blue color of the One-way clutch in the Gear,m1*26*11 [A] must be face to the Gear plate;Drum
rotation lever [B].
If the Gear,m1*26*11 [A] is installed in the opposite direction, the Drum is locked and [E 1]is
indicated on the machine.
G
D
C
A: Gear;m1*26*11
B: Gear plate;Drum rotation lever
C: Gear Shaft;rotation lever
D: Link shaft;Drum rotation lever
E: Link plate;Drum rotation lever
F: Drum rotation lever
G: Cover;Drum rotation lever
F
3 - 14
CHAPTER
4:
FIRST PAPER FEED SECTION
CONTENTS
1. Paper Feed Tray Position ...................................................................................... 1
2. First Paper Feed Drive Mechanism ....................................................................... 2
3. Paper Pickup System ............................................................................................ 4
4. Paper Feed Pressure Select System .................................................................... 5
1. Paper Feed Tray Unit ............................................................................................ 6
2. Pickup Roller Assembly ......................................................................................... 7
3. Pickup Roller ......................................................................................................... 8
4. Stripper Pad .......................................................................................................... 9
5. Paper Feed Clutch .............................................................................................. 10
3. Adjustment
1. Paper Feed Tray Pressure .................................................................................. 11
2. Paper Feed Tray Position Adjustment ................................................................. 13
3. Paper Feed Clutch ON Timing ............................................................................ 14
4. Paper Feed Clutch OFFTiming ............................................................................ 14

THEORY OF OPERATION
1. Paper Feed Tray Positions (Upper / Lower)
1. Paper Feed Tray Set Lever
> The Paper feed tray set lever [A] is linked with the PF lever plate ass'y [D] by the PF tray spring [C].
And the PF lever plate ass'y [D] is fixed with PFT lever shaft [F].
> When the paper feed tray set lever [A] is set lower position, the PFT lever [E] rises and push the
Paper feed tray [B] up. Thus papers on the Paper feed tray [B] touch the Pick up roller [G].
> When the paper feed tray set lever [A] is set upper position, the PFT lever [E] moves down and
Paper feed tray [B] goes down too. Thus papers on the Paper feed tray [B] is released from the Pick
up roller [G].
> Pressure between paper on the Paper feed tray and the Pick up roller can be adjusted.
F
G
E
A
D
A: Paper feed tray set lever

B: Paper feed tray
C: PF tray spring
D: PF lever plate ass'y
E: PFT lever
F: PFT lever shaft
G: Pick up roller
4-1

THEORY OF OPERATION
2. First Paper Feed Drive Mechanism

1. Paper Feed Clutch
> When the Main motor [C] activates, the Drum rotates in the clockwise direction via the Drive
gear D-E-F-G-H-I. (looking from back of the machine).
> The Paper feed clutch [B] activates at a certain Drum angle from the Position-A.
This Drum angle is determined by the count signal from the motor encoder sensor.
> The Paper feed clutch is released as the Drum rotates for a certain set degrees from the Drum
position A.
> The Paper feed tray clutch [B] activate timing and release timing is changed by the drum
rotation speed.
2. End of First Paper Feed
> The First paper feed ends when the Paper feed clutch [B] is released.
> The leading edge of the paper rests against the Guide roller and Timing roller.
> The Pickup roller [A] rotates free in the direction of paper feed by one-way clutch to avoid
applying brake on the paper when the Second paper feed takes over the paper feed.
H
F
C
E
B
G
I
A:Pickup roller
B:Paper feed clutch
C:Main motor
D - I: Drive gears
4-2

THEORY OF OPERATION
First Paper Feed Timing Chart
Press "START" key
Drum rotation starts from Drum Position-A
1-1 66.3
2-1 144.8
1-1 66.3
2-2 142.2 0 1-2 63.7
0 1-2 63.7
Drum rotation
2-1 144.8
2-2 142.2
ON
Main motor
Blocked
Open
Position-A
sensor
ON
Paper feed
clutch
[In case the drum rotation speed is 60 r.p.m.]

1-1 The Paper feed clutch activates each time the Drum rotates 66.3 from the A position.
The angle "" can be adjusted by Test Mode No. 80, which adjusts the ON timing of the Paper feed clutch.
2-1 The Paper feed clutch is deactivated when the Drum rotates 144.8 from the A position.
The angle "" can be adjusted by Test Mode No. 81, which adjusts the paper buckle amount.
[In case the drum rotation speed is 90 r.p.m.]
1-2 The Paper feed clutch activates each time the Drum rotates 63.7 from the A position.
The angle "" can be adjusted by Test Mode No. 82, which adjusts the ON timing of the Paper feed clutch.
2-1 The Paper feed clutch is deactivated when the Drum rotates 142.2 from the A position.
The angle "" can be adjusted by Test Mode No. 83, which adjusts the paper buckle amount.
A:Drum
B:Pickup roller
C:Paper
D:Paper gate
E:Guide roller
F:Stripper pad
G:Timing roller
H:Pressure roller
B
C
H
G
F
4-3

THEORY OF OPERATION
3. Paper Pickup System

1. Feeding
> The papers on the Paper feed tray are fed by the Pick roller [A], in several layers, in between
the Pickup roller [A] and Stripper pad [C].
2. Pick-up
> The top sheet is separated from the rest by the Pickup roller [A] and Stripper pad [C].
> The Stripper pad [C] is pushed against the Pickup roller [A] by the Stripper spring [B] to provide
resistance against paper feed, by which only a single sheet of paper [D] is fed from the paper
stack.
A:Pickup roller
B:Stripper spring
C:Stripper pad
D:Paper
4-4

THEORY OF OPERATION
4. Paper Feed Pressure Select System

1. Paper Feed Pressure Adjust Lever
> The Paper feed pressure adjust lever [A] is located on the front side of the machine, and it
changes the pressure of the Paper feed tray applied against the Pick up roller, as a result the
pressure against the papers on the Paper feed tray is changed.
> When the Paper feed pressure adj. lever [A] is positioned at upper position, the Pressure arm
[C] is lowered and the pressure of the Pressure adj. lever spring [B] does not applied against the
Paer feed tray. Thus the paper feed pressure is not increased at the lower position. Therefore this
position is for "THIN" papers.
> When the Paper feed pressure adj. lever is positioned at lower position, the Pressure arm [C]
becomes free and the pressure of the Pressure adj. lever spring [B] applies against the Paper
feed tray. Thus the paper feed pressure is increased. Therefore this position is for "NORMAL"
papers.
For NORMAL Paper
For THIN Paper
A:Paper feed pressure adjust lever

B:Pressure adjust lever spring
C:Pressure arm
A
C
4-5
B

REMOVAL AND ASSEMBLY

1. Paper Feed Tray Unit
2. Lower the Paper feed tray.
3. Remove the Paper feed tray unit [A] from the both side of the Lock pins [B].
Precaution in Assembly
> Make sure to hook the the Paper feed tray unit [A] to the both side of the Lock pins [B] firmly in
position.
A
B
A:Paper feed tray unit

B:Lock pin
4-6

2. Pick up Roller Assembly

2. Lower the Paper feed tray [D].
3. Remove Back cover. (See Page 1-5)
4. Remove the Paper feed tray [D] from the machine. (See page 4-6)
5. Remove Lock rings [C] on the right end of the Pickup roller shaft [A] and remove the Metal [B].
6. Slide the Pickup roller shaft [A] to the front side of the machine and remove the Pick up roller
ass'y.
C
B
A:Pickup roller shaft

B:Metal
C:Lock ring
D:Paper feed tray
4 -7

3. Pickup Roller and PF Support Roller

2. Remove the Pick up ass'y.(See page 4-7)
3. Slide the PF support rollers [C] from the Pickup roller shaft.
4. Remove Lock ring [B] from the Pickup roller shaft.
5. Slide the Pickup roller [A] out from the shafts.
> Core of the Pick up roller has the slit for the Pin [D] on the drive side when the roller is installed.
If the rollers are put back on the shaft the opposite side (turned around), the Pick up roller [A]
cannot be positioned correctly so the the Lock ring [B] cannot be installed.
Placed correctly on the shafts, the roller should be fixed by the Pin [D] of the Pick up roller
shaft.
C
A:Pickup roller
B:Lock ring
C: PF support roller
D: Pin
4-8

4. Stripper Pad
2. Lower the Paper feed tray all the way down.
3. Remove the Lock ring of the Pickup roller them slide the roller towards front side.
4. Remove the Stripper pad [C] base carefully, not to damage the Stripper spring [B].
5. Remove the Stripper Pad [B] from the Stripper pad base [A].
> Set the Stripper spring [B] correctly in the machine before setting the Stripper pad base [A]
back
in place.
> Make sure to fif the Pickup roller in correct position then insert the Lock ring.
A:Stripper pad base

B:Stripper spring
C:Stripper pad
4-9

5. Paper Feed Clutch

2. Remove Back cover.
3. Remove the PF Clutch support plate [B].
4. Disconnect the Connector of the Paper feed clutch [A].
5. Remove the Paper feed clutch [A] from the shaft.
> Match the position of the flat cut portion of the Metals [C] with that of the Main frame or PF
clutch support plate [B].
> Mount the slit on the clutch over the Drive gears bracket [D] on the machine to prevent the
clutch
from rotating. (Refer to fig.b)
C
A
B
A:Paper feed clutch

B:PF Clutch support plate
C:Metal
D:Drive gear bracket
fig.b
4 - 10

ADJUSTMENT
3. Adjustment
1. Paper Feed Tray Pressure
1-1.Original Type of the Paper feed Tray set Lever
For KS500
Serial Number 81530001- 81530500
For KS500C Serial Number 81510001- 81510500
1. Lower the Paper feed tray set lever [A] .(Upper the Paper feed tray)
2. Insert ruler to the slit of the Paper feed tray set lever [A] to measure the distance from top edge
of the PF adj. screw [B] to the edge of the Paper feed tray set lever [A].
3. The adjustable range is + 1mm to - 7mm from the edge of the Paper feed tray set lever [A].(refer
to fig.a)
Strong(CW)
W eak(CCW)
-7mm
+1mm
*1. If the distance is already positioned at +1mm, it cannot be adjusted weaker.(fig.b)
*2. If the distance is already positioned at -7mm, it cannot be adjusted stronger.(fig.c)
*3. The standard position can be adjusted by the PF tray position adjustment.(See page 4-13)
4. In case of no paper feeding occurs, trun the PF adj. screw [B] towareds CW direction to increase
the the pressure.
5.In case of multiple paper feeding occurs, turn the PF adj. screw [B] towards CCW direction to
decrease the pressure.
Precaution in Adjustment
> Do not turn the PF adj. screw [B] any more if the PF adj. screw [B] rotation becomes tight. (It is
the sign of the limit position of the adjustment.) Otherwise the steps of the PF adj. screw [B] will
be damaged.
Storong
A:Paper feed tray set lever

B:PF adj. screw
Weak
fig.a
B
7mm
1mm
fig.c
fig.b
4 -11

ADJUSTMENT
1-2. New Type of the Paper Feed Tray set Lever

For KS500
Serial Number 81530001- 81530500
For KS500C Serial Number 81510001- 81510500
1. Lower the Paper feed tray set lever [A] .(Upper the Paper feed tray)
2. Pull out the PF adj. dial [C] from the PF adj. screw [B].
3. Insert lular to the slit of the Paper feed tray set lever [A] to measure the distance from top edge of
the PF adj. screw [B] to the edge of the Paper feed tray set lever [A].
4. The adjustable range is + 7mm to +12mm from the edge of the Paper feed tray set lever
[A].(refer to fig.a)
Strong(CW)
W eak(CCW)
+12mm
+7mm
*1. If the distance is already positioned at +7mm, it cannot be adjusted stronger.(refer to fig.b)
*2. If the distance is already positioned at +12mm, it cannot be adjusted weaker.(refer to fig.b)
*3. The standard position can be adjusted by the PF tray position adjustment.(See page 4-13)
5. In case of no paper feeding occurs, trun the PF adj. screw [B] towareds CW direction to increase
the the pressure.
6.In case of multiple paper feeding occurs, turn the PF adj. screw [B] towards CCW direction to
decrease the pressure.
> Do not turn the PF adj. screw [B] any more if the PF adj. screw [B] rotation becomes tight. (It is
the sign of the limit position of the adjustment.) Otherwise the steps of the PF adj. screw [B] will
be damaged.
>Adjust set position of the PF adj. dial [C] against the PF adj.screw [B].
fig.a
A
A:Paper feed tray set lever

B:PF adj. screw
C:PF adj. dial
fig.b
4 -12

ADJUSTMENT
2. Paper Feed Tray Position Adjustment

1. Separate Base plate;PFT[A] from Plate;PFT[B].
2. [For KS500C] Measure 4 2 m m from the bottom of inside of the Plate; PFT [A]then mark the 42mm
point on the Plate;PTF[B].
[For KS500] Measure 4 3 m m from the bottom of inside of the Plate; PFT [B] then mark the 43mm
point on the Plate;PTF[B].
3. Putting together the Base plate;PFT[A] and the Plate;PFT[B].
4. PF press-adj. Lever[C] must be at "THIN" position.
5. Adjust the base of the Base plate;PFT[A] with the line to be the same level while PF set lever [C] is
released. (not in setting position)
A
42mm or 43mm
8. Turn the PF Adj. screw[D] as left figures show.

In case of the New type of the Paper feed tray set lever[F].
*Trun it towards CCW if the Base plate;PFT[A] is higher than the line.
*Trun it towards CW if the Base plate;PFT[A] is lower than the line.
9. Paper feed adjustment for each paper will be required after this adjustment is done.
D
A: Base plate;PFT
B: Plate;PFT
C: PF press-adj. Lever
D: PF Adj. screw
E: PF Adj. dial
F: Paper feed tray set lever
Old Type
4 -13
New Type

ADJUSTMENT
[Checking of Paper Feeding]

1.Select PF press-adj lever position depending on the paper weight.
*Less than 50g/m2:Upper position(THIN), More than 50g/m2: Lower position(NORMAL)
2. In case of occuring maltiple paper feeding or No paper feeding frequently, adjust paper feed
pressure by Adj. screw.
*Remove Adj. Dial for the adjustment if Adj. Dial is installed.
*Normally truning the adj. screw a half trun for each direction is enough for the adjustment.
*Trun CCW if multiple paper feeding occurs.
*Trun CW if No paper feeding occurs.
3.During normal paper feeding, paper is fed onto the center of the stripper pad then stop at
once. Then fed by Pick up roller.
B
Paper fed on to the center
of the stripper pad.
A: Stripper pad
B: paper guide plate lower
A
Paper
4.See the stoping position of the paper during the printing and if it is not the same as the
above, adjust paper feed pressure.
*Certain count of paper feeding is needed for the checking. If checking with just few sheets
of papers, the stopping position would not be stable.
Top view
A
Multiple Paper
Feeding
Standard
range
NO Paper
Feeding
Paper
*In case Paper got into more than the standard range, turn Adj. Screw CCW to decrease the
pressure.
*In case Paper didi not get into the standard range, turn Adj. Screw CW to increase pressure.
4 -14

ADJUSTMENT
3. Paper Feed Clutch ON Timing

If the paper jams or does not feed smoothly due to incorrect timing of the paper feed clutch activate
timing, use Test mode No.80 or No.82 to adjust the timing of the Paper feed clutch activation.
Test No.80 for when the machine runs at 60 r.p.m.. Test No.82 for when the machine runs at 90
r.p.m..
Adjustment Procedure
1. Turn off the power of the machine.
2. Keep pressing
and key on the control panel then turn on the power.
3. Check whether the paper buckle is normal or not.
4. In case the paper buckle is not enoght, start up the Test Mode and enter [8] and [0] and select
the number by pressing
or key.
In case the print speed is 90 r.p.m., enter [8] and [2] and select the number by pressing
or
key.
Adjustment Table
DECREASE
INCREASE
Indication / Amount(mm)
-4
-3
-2
-1
Results of Incorrect Adjustment

> If too much or too little paper buckle is made, the paper does not transfer correctly into the
Second paper feed section and may result in paper jamming.
Note:
>The Paper feed clutch adjustment is affected by the Timing clutch timing adjustment. For instance,
the Timing clutch timing is adjusted as the print position shifts for +2mm, the Paper feed clutch ON
timing also shifts +2mm. That means the timing of the movement between the Timing clutch and the
Paper feed clutch is unchanged.
4. Paper Feed Clutch OFF Timing

If the paper jams or does not feed smoothly due to incorrect amount of the paper buckle at the
finish of the first paper feed timing, use Test mode No.81 or No.83 to adjust the timing of the Paper
feed clutch deactivation.
Test No. 81 for when the machine runs at 60 r.p.m.. Test No. 83 for when the machine runs at 90
r.p.m..
2. Keep pressing
and key on the control panel then turn on the power.
3. Check whether the paper buckle is normal or not.
4. In case the paper buckle is not enoght, start up the Test Mode and enter [8] and [1] and select
the number by pressing
or key.
In case the print speed is 90 r.p.m., enter [8] and [3] and select the number by pressing
or
key.
Adjustment Table
INCREASE
DECREASE
Indication / Amount(mm)
-4
-3
-2
-1

> If too much or too little paper buckle is made, the paper does not transfer correctly into the
Second paper feed section and may result in paper jamming.
Note:
>The Paper feed clutch adjustment is affected by the Timing clutch timing adjustment as same as the
Paper feed clutch ON timing adjustment.
4 - 15
CHAPTER
5:
SECOND PAPER FEED SECTION
CONTENTS
1. Second Paper Feed Drive Mechanism ...................................................................
2. Vertical Print Position ............................................................................................
1. Load Spring ...........................................................................................................
2. Timing Clutch .........................................................................................................
3. Paper Guide Plate .................................................................................................
4. Paper Gate ............................................................................................................
5. Timing Roller ..........................................................................................................
3. Adjustment
1. Print Position(Timing Clutch ON Timing) ................................................................
1
2
3
4
5
6
7
8

1. Second Paper Feed Drive Mechanism
1. Drive
> Timing clutch [F] makes clockwise rotation (looking from the rear) with the turn of the main
motor [G].
> The Timing gear [F] rotation is transfered to the Timing gear [F] via the Timing clutch [E].
> The Timing roller [C] rotates Guide roller [B].
2. Timing Clutch
> After certain time from paper got in the Timing clutch [E] activates then the Timing clutch gear
rotation is transfered to Timing roller [C].
3. Timing Roller
> The Timing roller [C] contains Load spring which applies brake on the roller at all times.
It stops the rotation of the roller as soon as the Timing clutch [E] goes off.
4. Guide Roller
> The Guide roller [B] always contacts with the Timing roller [C].
> It rotates when the Timing roller [C] starts rotating.
> The Guide roller [B] rotation stops when the Timing clutch [E] goes off.
B
A
A:Paper gate
B:Guide roller
C:Timing roller
D:Load spring
E:Timing clutch
F:Timing gear
G:main motor
E
F
5-1

2. Vertical Printing Position

1. Timing Clutch
> The print position is depending on when the Timing clutch [C] goes on.
> Normally the Timing clutch [C] goes on when the drum angle becomes 160.3 degrees and goes
off when the drum angle becomes 61.3 degrees in case the drum speed is 60r.p.m.
> When the drum rotation speed is 90 r.p.m., the Timinig clutch [C] goes on at the drum angle
157.7 degrees and goes off at the drum angle 58.7 degrees.
2.Print Position
> Print position can be changed by pressing the print position adjustment key
or
on the
control panel.
> When the
key is pressed, the Timing clutch [C] on timing becomes earlier and the print
position moves down.
> When the
key is pressed, the Timing clutch [C] on timing becomes late and the print
position moves up.
90
0
180
360
270
Drum rotation
66.3
144.8
(144.2)
(63.7)
78.5
Paper feed clutch 1st
160.3
Paper feed clutch 2nd
(157.7)
61.3
(58.7)
Paper gate
B
D
A:Guide roller
B:Timing roller
C:Timing clutch
D:Timing clutch gear
5-2


1. Load Spring
1.
2.
3.
4.
6.

Remove Front cover.
Remove power supply PCB. (See page 8-6)
Remove E-ring [C] and Collar [B] from the Timing roller shaft.
Remove the Load spring [A] from the shaft.
A
Precaution before Assembly

> Install the Load spring in the correct direction.
A:Load spring
B:Collar
C:E-ring
5-3

2. Timing Clutch
1.
2.
3.
4.
5.
6.

Remove Back cover.
Remove the PF-Clutch support plate [H].
Remove the Clutch support plate [A] then remove the encoder [B] and the Encoder sensor [C].
Remove the BKT; Drive gears [D].
Remove the Metal [E] and the Timing clutch [F]
Adjustment after Assembly

> Adjust the position of the Timing clutch at the correct position as below photograph shows.
> Adjust the position of the Paper feed clutch at the correct position as page 4-10 explains.
F
C
B
A
E
H
5- 4
A:Clutch support plate

B:Encoder
C:Encoder sensor
D:BKT; Drive gears
E:Metal
F:Timing clutch
G:Timing gear
H:PF-Clutch support plate

3. Paper Guide Plate

2. Remove following parts from the machine.
> Back cover (See page 1-5)
> Paper feed tray unit [A] (See page 4-6)
> Paper feed clutch [F] with the bracket. (See page 4-10)
> Pick up roller ass'y [B] (page 4-7)
3. Remove the Paper guide plate upper [C].
4. Remove the Master loading sensor bracket [E].
5. Slide the Master removal unit then remove mounting
screw of the Paper gate [G]. (See page 5-12)
6. Take out the Paper guide plate lower [D] from the the Paper feed tray side.
E
D
C
B
A
A:Paper feed tray

B:Pickup roller assy
C:Paper guide plate upper
D:Paper guide plate lower
E:Master loading sensor bracket
F:Paper feed clutch
G:Paper gate

> Make sure the position of the Paper guide plate upper at the correct position as below pictures
show.
Drive side
Front side
5-5

4. Paper Gate
1.
2.
3.
4.

Remove the Paper guide plate upper. (See page 5-7)
Slide out the Master removal unit.
Remove the mounting screw of the Paper gate, and remove the Paper gate [A].
Precautions before Assembly

>Do not secure the mounting screw too much to prevent the Paper gate [A] from breakage.
A:Paper gate
5- 6

5. Timing Roller / Guide Roller

1.
2.
3.
4.
5.

Remove the Paper guide plate (See page 5-5)
Remove the Paper gate (See page 5-6)
Remove the Power supply unit (See page 8-6)
Remove following parts from the Timing roller shaft.
> Load spring [G] (See page 5-3)
> One-way gear [E] and Metal [C]
6. Remove the Timing roller [A] (Complete the Timing roller removal)
7. After removing the Timing roller [A], remove the E-rings [F] and the Metals [D] from both side of
the Guide roller shaft [B].
8. Remove the Guide roller ass'y[B] (Complete the Guide roller ass'y removal)

> Install the Load spring [G] in the correct direction.
> Assemble procedure is just the reversing the disassemble procedure.
> Check if paper is fed correctly or not after assembled all parts. If not disassemble all parts
then assemble those parts once again.
D
C
F
C
E
A:Timing roller
B:Guide roller
C:Metal(Long)
D:Metal(Short)
E:One-way gear
F:E-ring
G:Load spring
A
B
5-7

ADJUSTMENT
3. Adjustment
1. Print Position (Timing Clutch ON timing)
Vertical print position can be changed by changing the Timing clutch activate timing.
The Timing Clutch activate timing can be cahnged by using TEST MODE No.84 or No.86.
Test No.84 is for when the machine runs at 60 r.p.m. and Test No.86 is for when the machine runs at
90 r.p.m..
2. Keep pressing
and
key on the control panel then turn on the power.
3. Enter [9] and [4] with the ten key to put a master that has horizontal line on the top of the master.
The line is for checking the print position.
4. Press [Reset] key to the machine operation be back to normal then get 5 sheets printouts with
60 r.p.m. and get another 5 sheets printouts with 90r.p.m..
5. Measure the position of the horizontal line from the top edge of the paper.
6. Check the printouts whether the horizontal line on the paper is 10mm from the edge or not.(refer
to the figure below)
7. In case the horizontal line is not at 10mm when the printing speed is 60 r.p.m., start up the
TEST MODE and enter [8] and [4] and select the number by pressing
or
key.
In case the horizontal line is not at 10mm when the print speed is 90 r.p.m., enter [8] and [6] and
select the number by pressing
or
key.
10mm
Printed paper
Adjustment Table of TEST MODE No.84 / No. 86

Amount(mm)
/ Indication
Image up
Image down
-7
-6
-5
-4
-3
-2
-1
[Exsample] : In case the line is positioned 7 m m from edge of the paper with the printing speed at 60 r.p.m..
1. Go into Test mode and enter [8] and [4].
2. Change the indication from [0] to [-3] by pressing
key.
3. Press [Reset] key to the machine operation to be back to normal and try to print 5 sheets.
4. Measure the distance between edge of the paper and the horizontal line. If the distance is not 10mm,
back to the procedure 1.
Result of Incorrect Adjustment

> If adjusted as [7], the paper could not reached the drum before the pressure roller rises.
As a result, paper jam could occur and the pressure roller could be dirty with ink from the drum
surface.
5 -8
CHAPTER
6:
PRESS SECTION
CONTENTS
1. Press Mechanism ..................................................................................................
1. Pressure Roller ......................................................................................................
2. Pressure Lever Ass'y .............................................................................................
3. Pressure Shaft Ass'y .............................................................................................
3. Adjustment
1. Pressure Lever Ass'y Position ...............................................................................
1
3
4
5
7
PRESS SECTION
1. Press Mechanism
1. Pressure Lever and Pressure Roller
> The Pressure lever [D] is fixed with the Pressure shaft [G] at certain position. And the Pressure
roller [A] stays on the Pressure ass'y [K], of which is fixed the Pressure shaft [G].
> While the Main motor [C] is making the Drum rotation without paper (not prininting process), the
Pressure hook [H] engages with the Pressure lever [D] so that the Pressure shaft ass'y stays
lower.
> When paper comes in and pushes the Paper gate [J] up, the Pressure hook [I] is risen. So the
Pressure lever [D] is released then the Cam follower [I] of the Pressure lever ass'y gets contact
with the Pressure cam [E]. Thus the Pressure roller [A] is risen and contacted to the Drum when
Drum rotation is at 118 degrees.
> Pressure of the Pressure roller [A] is given to the Drum [F] by the Pressure spring [B].
> Once the Pressure lever [D] is released from the Pressure hook [H], movement of the Pressure
lever [D] is controled by the Pressure cam [E].
> The Pressure hook becomes lower when the paper throughs out from the Paper gate [J]. Then
the Pressure roller [A] is lowered by the Pressure cam [E] at the Drum rotation 118 degrees
from the A-position where the Clamp plate on the Drum comes near the Pressure roller [A].
> The Pressure lever [D] becomes lowered again by Pressure cam [E] at Drum rotation 218
degrees.
F
E
J
A
G
I
K
D
HH
Paper gate is pushed
up by paper.
And Pressure hook is
raised.
Then Pressure lever
rises by Pressure cam
at Drum 118.
C
A:Pressure roller
B:Pressure spring
C:Main moter
D:Pressure lever ass'y
E:Pressure cam
F:Pressure shaft ass'y
G:Pressure shaft
H:Pressure hook
I :Cam follower
J :Paper gate
K:Pressure ass'y
Pressure hook
becomes lower when
the paper throughs
out. Then Pressure
lever is lowered by
Pressure cam at Drum
218.
6-1
PRESS SECTION
Lifting the Pressure Roller

The Paper gate is pushed up by paper throughout
the printing. So the Pressure lever [B] becomes free.
The Pressure spring [D] pulls back the Pressure lever
[B] and rotates the Pressure shaft [E] which is acting
as a pivot.
The rotation of the Pressure shaft [E] lifts the Pressure
roller [A] up against the Drum [C].
C
E
F
B
E
Pressure hook becomes lower when the paper throughs out.
Lowering the Pressure Roller

The Pressure roller [A] is lowered by force, away from
the Drum[C], by the high part of the Pressure cam [F].
During the Drum rotation, when the Clamp plate of the
Drum comes close to the Pressure roller (drum rotation
at 118 degrees), the high part of the Pressure cam [F]
pushes the Pressure lever [B] down, rotating the
Pressure shaft [E] clockwise to bring the Pressure
roller down, away from the Drum.
Then Pressure lever [B] is lowered by Pressure cam
[F] at Drum 218 degrees.
A:Pressure roller
B:Pressure lever ass'y
C:Drum
D:Pressure spring
E:Pressure shaft
6-2
PRESSURE SECTION

1. Pressure Roller
1.
2.
3.
4.

Remove the Back cover from the machine.(See page 1-5)
Remove the Suction unit from the machine. (See page 7-5)
Remove mounting screw of the Pressure roller [C] from the Pressure ass'y (refer to 6-5) through a
hole on the drive side of the machin frame.
5. Take out the Pressure roller [B] from the Paper receiving side of the machine.
A
B
A:Screw
B:Pressure roller
6-3
PRESSURE SECTION
2. Pressure Lever Ass'y

3. Remove the Drum unit from the machine. (See page 8-6)
4. Remove set screws from the Pressure lever [A] ass'y.
5. Trun the Pressure lever [A] towards clockwise (Pressure lever shows up behined the gear) then
remove the Pressure lever ass'y from the Pressure shaft.
Adjustment after the Assembly

> Adjust the position of the Pressure lever ass'y. (See page 6-7)
A:Pressure lever ass'y
6-4
PRESSURE SECTION
3. Pressure Shaft Ass'y

1.
2.
3.
4.
5.
6.
7.
8.

Remove the Drum from the machine. (See page 8-6)
Remove the Back cover and Front cover.(See 1-5)
Remove the Pressure lever ass'y [E]. (page 6-4)
Remove E-rings [C] from both ends of the Pressure shaft ass'y and remove the Metals [D].
Remove the Suction unit. (See page 7-5)
Remove the Pressure spring [B].
Slide the Pressure shaft ass'y towards the rear (drive side) of the machine once, and then remove
it out from the Paper receiving side of the machine.
Adjustment after the Assembly

> Adjust the position of the Pressure lever ass'y. (page 6-7)
A
C
A:Pressure shaft ass'y

B:Pressure spring
C:E-ring
D:Metal
E:Pressure lever ass'y
6-5
MEMO
6-6
PRESSURE SECTION
ADJUSTMENT
3. Adjustment
1. Pressure Lever Ass'y Position
1. Make confidential master on the Drum.
2. Bring the Drum to the Position-A.
4. Remove Back cover. (See page 1-5)
5. By using the Drum rotation lever, place high position of the Pressure cam [B] to the Cam follower
[C] of the Pressure lever [A].
6. Using fingure, disengage the Pressure lever [A] from the Hook lever [D]by pushing up the Hook
lever [D] then rotate the Drum by using Drum rotation lever until the Pressure lever [A] disengages
from the Hook lever [D] without any support. (At A-position is reccommended)
7. Confirm that the gap between the Pressure cam [B] and Cam follower [C]on the Pressure lever [A]
is 2 mm -2.5 mm.
8. If the gap is too small or big, loosen the two set screws on the Pressure lever ass'y [A].
9. Place 2 mm Allen key or 2 mm thick plate between the Pressure cam [B] and Cam follower [C]
and rotate the Pressure lever towards clockwise.
10. While rotating the Pressure lever towards clockwise, tighten the two set screws on the Pressure
lever ass'y. The Pressure lever ass'y should be pushed all the way in when tightening the two
set screws.

> If the gap is smaller than 2 mm, the Pressure roller leaves from the Drum earlier. As a result,
printing area may become smaller.
> If the gap is too big, the Pressure roller may hit the Clamp plate of the Drum during printing and
damage the Clamp plate.
B
D
Turn the Pressure shaft to lift the
Pressure roller against the Drum.
2-2.5m m
Adjust the gap between the

Pressure cam and Cam follower to
2mm - 2.5 mm by inserting 2 mm
Allen wrench between the Cam and
Cam follower.
A:Pressure lever ass'y

B:Pressure cam
C:Cam follower
D:Hook lever
C
6-7
CHAPTER
7:
PAPER EJECTION SECTION
CONTENTS
1. Paper Ejection Mechanism .................................................................................... 1
2. Paper Separation Mechanism ................................................................................ 3
1. Suction Unit ........................................................................................................... 5
2. Transfer Belt .......................................................................................................... 6
3. Suction Fan ........................................................................................................... 7
4. Separation Fan Unit ............................................................................................... 8
5. Separation Fan ...................................................................................................... 9
6. Paper Receiving Sensor ......................................................................................... 9
7. Separator ............................................................................................................. 10
8. Paper Receiving Tray ........................................................................................... 11
3. Adjustment
1. Separator Position ............................................................................................... 13
KS Series(Version 1.2)

1. Paper Ejection Mechanism
1. Paper Separation from the Drum
> The paper is separated from the Drum by the Paper separation fan [A] and Separator [D].
2. Paper Ejection
> Suction fan [C] pulls the paper, separated from the Drum, on to the Suction unit.
> The Transfer belts [B] on the Suction unit, driven by the Main motor, ejects the paper onto
the Paper receiving tray.
> Drive speed of the Transfer belt is 1.6 times as the Drum rotation speed.
3. Paper Receiving Sensor
> Paper receiving sensor [E] checks whether the paper is separated from the Drum and ejected
correctly or jammed.
A
D
E
A: Separation fan
B: Transfer belts
C: Suction fan
D: Separator
E: Paper receiving sensor
7-1

Paper Ejection Timing Chart - From Start to in printing Press STA RT button
Blocked
Blocked
Position-A
sensor
Blocked
ON
Main motor
Open
Paper receiving
sensor
1
257 280
No detection
ON
2
104
2
334
1
1
257 280
2
334
Detecting paper
Detecting paper
Separation fan
Suction fan
1 The Paper receiving sensor is checked to see whether no paper is detected at every Drum angle 257
degrees and 280 degrees.
If paper is detected, the machine assums that paper jam occurs in the paper ejection area and indicates
[J 3]
.
2 The Paper receiving sensor is checked to see whether paper is detected at every Drum angle 334
If paper is not detected, the machine assums that paper jam occurs in the paper feed area and indicates
[J 2]
.
Paper Ejection Timing Chart - From in printing to Stop Press STOP button
Blocked
Blocked
Position-A
sensor
Main motor
ON
334
Paper receiving
sensor
Separation fan
Suction fan
OFF
104
257 280
Detecting paper
No detection
ON
OFF
1 The Paper receiving sensor is checked to see whether no paper is detected at Drum angle 257 degrees
and 280 degrees after paper feed is stopped.
If paper is detected, the machine assums that paper jam occurs in the paper ejection area and indicates
[J 3]
.
2 The Paper receiving sensor is checked to see whether paper is detected at Drum angle 334
If paper is not detected, the machine assums that paper jam occurs in the paper feed area and indicates
[J 2]
.
7-2

2. Paper Separation Mechanism

1. Separator
> The tip of the Separator [B] is close to the Drum when it separates a paper from the Drum.
> When the Clamp plate on the Drum comes close to the Separator [B], the Drum support left [E]
which is attached on the Drum pushes the Separator [B] away from the Drum.
C
E
B
A
C
A:Separator shaft
B:Separator
C:Separator lever ass'y
D:Paper receiving tray
E: Drum support left
7-3
MEMO
7-4


1. Suction Unit
3. Remove the Paper receiving tray.
4. Remove the Suction unit cover [B].
5. Disconnect the Connector of the Suction unit [A].
6. Remove two mounting screws of the Suction unit [A] and remove the unit by sliding it out.
> Hook the Suction unit [A] on both side of the plates on the machine frame.
> Insert theFeet of the Suction unit cover [C] to holes of the Base plate [D].
C
B
A:Suction unit
B:Suction unit Cover
C:Feet (of Suction cover)
D:Base plate
7-5

2. Transfer Belt
3. Remove Suction unit. (See page 7-5)
4. Remove two mounting screws of the De-electricity brush and remove the brush.
5. Remove four mounting screws of the Suction face cover [B].
6. Lift the face cover and remove the Belt driven shaft [D] by unhooking the Transfer belts [A].
7. Remove E-ring of the Belt pulley shaft [C] and remove the Bearing [F].
8. Slide the Belt pulley shaft [C] and remove the Transfer belts [A] from the Suction face cover [B].
A
Remove the belts

from this side.
C
F
D
E
A:Transfer belts
B:Suction face cover
C:Belt pulley shaft
D:Belt driven shaft
E:De-electricity brush
F:Bearing
> Match the half-pierced section on the Suction face cover [B] with its counter part.
> Match the half-pierced section on the De-electricity brush [E] with its counter part.
7-6

3. Suction Fan
3. Remove Suction unit [B]. (See page 7-5)
4.Turn over the Suction unit [B] and disconnect the Connector of the Suction fan [A].
5. Remove two mounting screws of the Suction fan [A] and remove the fan.
A:Suction unit
B:Suction fan
7-7

4. Separation Fan Unit

1.
2.
3.
4.

Remove Back cover.(See page 1-5)
Disconnect the Connector of the Separation fan unit [A].
Remove two mounting screws of the Separation fan unit [A] and remove the unit.
> Match the half-pierced section on hinge of the Separation fan unit [B] with its counter part.
A
A:Separation fan unit
B:Hing (of Separation unit)
7-8

5. Separation Fan
1. Remove the Separation fan unit [C]. (See page 7-8)
2. Disconnect the Connector of the Separation fan [C].
3. Remove two mounting screws of the Separation fan [A] and remove the fan.

1.
2.
3.
4.
Remove the Separation fan unit [C]. (See page 7-9)

Disconnect two mounting screws of the Separation fan [A].
Lift the fan and disconnect the Connector of the Paper receiving sensor [B].
Press the center hook of the Paper receiving sensor socket and lift the sensor out.
A:Separation fan
B:Paper receiving sensor
C:Separation fan unit
7-9

7. Separator
2. Remove the Back cover and Front cover.(See page 1-5)
3. Remove the Paper receiving tray.
4.Remove the Separation fan unit.(See page 7-8)
5. Remove the Separation spring [C].
6. Remove E-ring [A] from the drive side of the Separator shaft [B].
7. Slide the Separation shaft [B] towards the rear (machine drive side) and remove the Separation
shaft [B].
B
C
A:E-Ring
B:Separation shaft
C:Separator spring
7 - 10

8. Paper Receiving Tray Unit

2. Remove Back cover and Front cover. (See page 1-5)
3. Remove two mounting screws of the Paper receiving tray [D] with referring the Fig. a below then
the Paper receiving tray [D].
4. Remove the Paper ejection guide F [B] and the Paper ejection guide R [A].
5. Remove the Paper back stop [C].
> Match the half-pierced sections on the Lock plates F and R with their counter parts.
A
B
Remove the Paper receiving

tray by sliding it out.
D
Fig.a
A:Paper ejection guide R

B:Paper ejection guide F
C:Paper back stop
D:Paper receiving tray
7 - 11
MEMO
7 - 12

ADJUSTMENT
3. Adjustment
1. Separator Position
1. Using Test Chart No.8 or No.14, make a master and prints.
2. Adjust the printing position by the Print position button on the Operation panel, so that there is
10 mm white margin on the top of the prints.
3. Confirm that the paper separates from the Drum [C] and there is no black line on the center of the
prints.
4. If the paper does not separate from the Drum, or there is a black line on the center of the prints,
an adjustment on the Separator position is necessary.
5. For the adjustment, disconnect the power cable from the machine and remove the Front cover.
(See page 1-5) and the Power supply PCB. (See page 8-6)
6. Loosen the mounting screw [D] of the Separator plate [E] and slide the plate.
7. Tighten the mounting screw [D] of the plate when the space between the tip of the Separator [B] is
between 1.0mm and 1.4mm from the Drum surface and not touching it.
8. Make sure if the space is between 1mm and 1.4mm anywhere on the Drum surface by using the
Drum rotation lever.
> Printed papers using Test Chart No.8 / No.14 original should separate from the Drum [C] when
the top white margin on the prints are adjusted to 10 mm by the Print position button.

> If the tip of the Separator [B] is in contact with the Drum [C] , the Separator [B] will scratch the
surface of the master on the Drum, creating a black line in the center of the printed copies and
may damage the screens.
> If the tip of the Separator [B is placed too far off the Drum [C], printed copies will not separate
from the Drum [C], causing paper jams.
1.0 - 1.4mm
B
C
1.0 - 1.4mm
B
A
D
[1]
[2]
A
E
[1] direction :Increases the gap
[2]direction :Decreases the gap
A:Separator lever
B:Separator
C:Drum
D:Mounting screw
E:Separator plate
7 - 13
CHAPTER
8:
DRUM SECTION
CONTENTS
1. Master on Drum (in printing) Check Mechanism ..................................................... 1
2. Ink Bottle Set Check Mechanism ........................................................................... 2
3. Ink Supply Mechanism .......................................................................................... 3
4. Squeegee Roller Rotation Mechanism ................................................................... 5
1. Drum Unit .............................................................................................................. 7
2. Screen ................................................................................................................... 8
3. Drum Body ............................................................................................................ 9
4. Ink sensor PCB ................................................................................................... 11
5. Ink Bottle Guide ................................................................................................... 12
6. Ink bottle set Sensor ............................................................................................ 12
7. Drum Support F & Drum Support R ...................................................................... 13
8. Squeegee Roller .................................................................................................. 14
9. Ink Pump Unit ...................................................................................................... 17
10. Inking Motor ....................................................................................................... 18
3. Adjustment
1. Squeegee Gap ..................................................................................................... 19
DRUM SECTION
1. Master on Drum (in printing) Check Mechanism
AAaaa
1. Master Sensor
> Master Sensor [B] checks the presence of master on the Drum before the start of printing.
> 134 Drum rotation after the first Position-A, the Master Sensor [B] looks for the master [A] on
the Drum.
> The result (whether the master [A] is found or not) is memorized until the Drum is pulled out of
the machine or the power is turned off.
> If no master is detected on the Drum, [C27] is indicated on the Operation panel and stops the
printing operation.
A
Drum angle = 134

(From position-A)
A: Master
B: Master sensor
Drum angle = 134
(From Position-A)
8-1
DRUM SECTION
2. Ink Bottle Set Check Mechanism

1. Ink bottle Set Sensor
> Ink bottle set sensor[A] checks the presence of the Ink bottle[C] in the Ink bottle guide[B].
> There is an actuator plate[D] on the bottle set sensor ass'y as shown on below figure.
> The machine will judge by the sensor staus, whether Ink bottle [C]is installed or not.
If the Ink bottle [C] is not installed, the machine will indecate 'C7'.
In case No bottle is installed
Ink bottle set sensor detects the actuator

plate
In case bottle is installed
The actuator plate is released by ink

bottle thus Ink bottle set sensor does not
detect the actuator plate
C
A: Ink bottle set sensor

B: Ink bottle guide
C: Ink bottle
D: Actuator plate
8-2
DRUM SECTION
3. Ink Supply Mechanism

1. Ink Sensor PCB
> Ink sensor on the Ink sensor PCB [I] checks the presence of ink in the Drum.
> Overflow sensor [H] checks the ink overflow in the Drum.
2. Inking Motor
> Inking motor [C] activates the Ink pump to supply the ink into the Drum when ink is not
detected by the Ink sensor [G].
> Ink from the Ink bottle is pumped through the Ink hose [F] into the Drum, on top
of the Squeegee roller [A], through Ink distributor [E].
> The Inking motor [C] stops when the Ink sensor [C] detects ink.
3. Ink Supply to the Inner Surface of the Drum
> The ink supplied on the Squeegee roller [A] is transferred onto the Drum inner surface by the
rotation of both the Squeegee roller [A] and Drum.
> Excess ink is then made into a long roll of ink tube around a thin Driven shaft [D] located
between the Squeegee roller [A] and Doctor roller, [A] and this excess roll of ink tube is
checked by the Ink sensor [G] and Overflow sensor [H].
4. Ink Overflow
> If an excess amount of ink is supplied in the Drum and Overflow sensor [H] detects the ink,
the machine stops with [E 4] indication on the Operation panel.
(refer to the Timing Chart on page 8-4)
H
C
J
G E
A: Squeegee roller
B: Doctor roller
C: Inking motor
D: Driven shaft
E: Ink distributor
F: Long roll of ink tube
G: Ink sensor
H: Overflow sensor
I: Ink sensor PCB
J: Ink bottle
8-3
DRUM SECTION
Inking Timing Chart
Drum rotation starts
Drum stops
ON
Main motor
Blocked
Blocked
Position-A
sensor
Open
Ink sensor
No detection
Blocked
Ink detected
1
Inking motor
ON
OFF
1 The Inking motor does not activate at the start of Main motor even though the Ink sensor is not
detecting the ink.
2 The Inking motor activates when the light path of the Position-A sensor changes from "blocked" to
"open" with the rotation of the Drum if the Ink sensor is not detecting the ink.
3 The inking motor stops when the Ink senser becomes detecting the ink.
4 The Inking motor activates when the Ink sensor no longer detects the ink during printing.
5 The Inking motor turns off when the Main motor is turned off.
> If Ink sensor does not detect ink within 20 seconds after the Inking motor is activated, the machine
assumes that the Ink Cartridge is empty and [C 8] is indicated.
If the machine power is turned OFF before the 20 second count, the counting continues from that point
when the machine is turned ON again.
> If Overflow sensor detects ink for more than 0.5 seconds, the machine assumes that the ink has over
flown within the Drum and displays error message [E 4].
> If excess current is detected for more than 2.5 seconds after the Inking motor is activated, the machine
assumes that the Inking motor has locked and indicates error message [E 16].
Ink is sucked in
A
A: Inner rotor
B: Outer rotor
C: Ink "IN"
D: Ink "OUT"
Ink is pushed out
The ink sucked in is carried between the Outer and Inner

rotors of the Ink pump and as the gap between the rotors
becomes small, the ink is pushed out.
8-4
DRUM SECTION
4. Squeegee Roller Rotation Mechanism

1. Rotation of the Squeegee Roller
Through the gears, the drive of the Main motor [K] is transferred to the Squeegee roller gear [C]
via the Intermediate gear A [F], gear B [G], gear C [H], gear D [I] and rotates the Squeegee roller
[A].
The Squeegee roller gear R [C] has one way clutch which prevents the Squeegee roller [A]
from rotating when the Drum is accidentally rotated in the opposite way by hand.
2. Rotation of the Driven Shaft
With the rotation of the Squeegee roller [A], the Squeegee roller gear F [D] transfers the rotation
to the gear on the Driven shaft [L] and rotates the shaft.
L
D
B
F
C
G
H
A: Squeegee roller
B: Doctor roller
C: Squeegee roller gear R [with one way clutch]
D: Squeegee roller gear F
E: Drum main gear
F: Intermediate gear A
G: Intermediate gear B
H: Intermediate gear C
I: Intermediate gear D
J: Main motor gear
K: Main motor
L: Driven shaft
K
J
8-5
MEMO
8-6
DRUM SECTION

1.1. Drum Unit
2. Remove the Back cover and the Front cover (See page 1-5)
3. Slide out the Master removal unit to prevent the Master
removal hooks from being damage by the Drum unit.
4. Remove the Separeter spring to keep away the Sparater
from the Drum. (Refer to page 7-3)
5. Remove the following items from the machine;
>Power supply PCB [C]
>Main PCB cover [D], the Main PCB [E]
with Main PCB bracket [F]
>Load spring plate [A]
>Ink bottle guide (See page 8-11)
C
A: Load spring plate
B:Power supply cover
C:Power supply PCB
D: Main PCB cover
E: Main PCB
F
E
6. Disconnect connector of A detection sensor

and connector of Inking motor[G].
7. Remove four mounting screws of the Drum
unit [H] then pull out the drum unit from the
machine.
F: Main PCB brackett

G: Inking motor
H: Drum unit
G
8-7
DRUM SECTION
2. Screen
1.
2.
3.
4.
Make a confidential master on the Drum.

Remove the Drum from the machine (See page 8-6)
Remove the two Screen springs [B].
Remove two mounting screws (regular screws) of the Clamp plate base [C] which are also
holding down the Screen [A] to the Drum.
If neccessary loosen two Special screws [D] which are also on the Clamp plate base [C].
5. Pull out the Screen [B] from under the Clamp plate base [C], and remove the Screen [B].
> Do not bend, wrinkle or damage the Screen [B].
B
A
C
A: Screen
B: Screen springs
C: Clamp plate base
D: Special screw
8- 8
DRUM SECTION
3. Drum Body
1.
2.
3.
4.
5.
Make a confidential master on the Drum.

Remove the Drum from the machine.(See page 8-6)
Remove the Screen from the Drum. (page 8-7)
Remove two Special screws [E] from the Clamp plate base [A] and remove the base.
Remove remaining ten regular mounting screws and two more Special screws [E] holding the
Drum body [B] to the Drum support F [C] and R [D].
6. Separate the Drum body from the Drum supports [C][D], carefully to avoid damaging the Drum
body [B].
(Refer to page 8-9 for the "Precaution in Assembly")
B
A: Clamp plate base
B: Drum body
C: Drum support F
D: Drum Support R
E: Special screw
8- 9
DRUM SECTION
> Do not bend or damage the Drum body.
> The Drum body has
and
marks with F engraved next to one of the two arrow marks.
The F mark indicates the "front" (Operation panel side).
> Mount the screws on the two holes marked
and
first.
Then mount the two Special screws [A] next to the first two screws.
A: Special screws
A
> After the first and second set of the screws are in, temporary hook the Screen springs [B]
in the manner shown by the illustration below.
This is to pull and fit the Screen evenly on the Drum supports F and R.
B:Screen spring
B
> Mount the remaining screws and remove the two temporary mounted Screen springs.
> Mount the last two remaining screws and hook the Screen springs to complete the assembly.
If necessary, refer to page 8-8 to check how the springs were hooked on the Drum.
8- 10
DRUM SECTION
4. Ink Sensor PCB

1. Make a confidential master on the Drum.
2. Remove the Drum from the machine. (See page 8-7)
3. Remove the Screen. (See page 8-8)
4. Remove the Drum body. (See page 8-9)
5. Disconnect the Connector of the Ink sensor PCB [A].
6. Remove two mounting screws of the Ink sensor cover and remove the cover with the PCB in it.
7. Remove Ink sensor PCB [A] from the Ink sensor cover.
CAUTION:
Use special caution not to break or bend the two sensor antennas.
If they are bent, straighten them out with fingers.
> The Ink sensor and Overflow sensor antennas should both be standing at a right angle to the
PCB.
> The two antennas must not be touching the Doctor roller or Driven shaft.
A: Ink sensor PCB
8- 11
DRUM SECTION
5. Ink Bottle Guide

1. Remove the Front cover. (See page 1-5)
2. Remove two mounting screws of the Ink bottle guide [A] and remove the Ink bottlt guide [A].
AA
A: Ink bottle guide
6. Ink Bottle Set Sensor

1. Remove the Front cover (See page 1-5), Ink bottle guide. (See page 8-12)
2. Disconnect the connector of Ink bottle set sensor.
3. Remove a mounting screw of the Ink bottle set sensor ass'y [B].
4. Remove the Ink bottle set sensor from the ass'y.
B:Ink bottle set sensor ass'y
8- 12
DRUM SECTION
7. Drum Support F & Drum Support R

2. Remove the Drum from the machine (See page 8-7)
3. Remove following parts fron Drum unit;
>Screen ass'y (See page 8-8)
>Drum body (See page 8-9)
>Ink sensor PCB (See page 8-11)
4. Disconnect the Connector of the Ink sensor PCB and pull out the Intermediate wire harness
from the Drum U support BKT R [A].
5. Loosen the Mounting screws [G1,2,3,4: cap screw]of Drum Shaft Clampers [F] to Drum support
BKTs.
6. Loosen the Mounting screws [H1 & 2:set screw] of Drum Shaft Clampers [F] to the Drum center
shaft [I].
7. Remove Drum Support BKT R [A] and F [D] from the Drum center shaft [I].
8. Remove Drum Support R [A] Ass'y [B] and Drum Support F Ass'y [C] from the Drum center
shaft [I].
B
E
H2
G3
G4
C
H1
G1
G2
D
A:Drum U Support BKT R
B:Drum Support R Ass'y
C:Drum Support F Ass'y
D:Drum U Support BKT F
E:Intermediate wire harness
F:Drum Shaft Clampers
G1-4: Mounting screws (cap screw)
H1-2: Mounting screws (set screw)
I :Drum center shaft
8- 13
DRUM SECTION
8. Squeegee Roller
2. Remove the Drum from the machine (See page 8-7), and remove Ink bottle from the Drum.
3. Remove Ink bottle guide (See page 8-11)
4. Remove Drum support F & Drum support R (See page 8-12)
5. Remove following parts from the Drum unit.
> Ink pump unit (See page 8-16)
> Screen (See page 8-7)
> Drum body (See page 8-8)
6. Remove Ink sensor PCB[K] (page 8-10)
7. Remove Ink blocking plates [F/G].
8. Loosen securing screw on both side of Drum shaft joint then remove two mounting screws each
from the Squeegee frames [I/J] on both ends.
9. Remove Center shaft ass'y [A].
10. Remove both side of mounting screws and pull out Drive shaft gear [L] then remove Drive
shaft [B] from the Squeegee unit.
11.Remove Squeegee drive gear [D] and Squeegee idler [E] from rear side of Squeegee roller
shaft [M].
12. Remove Transfer gear [H] from front side of Squeegee roller shaft [M].
(Continue to page 8-15)

A: Center shaft
B: Drive shaft
C: Drum shaft joint
D: Squeegee drive gear
E: Squeegee idler
F: Ink blocking plate F
G: Ink bolcking plate R
H: Transfer gear
I: Squeegee frame F
J:Squeegee frame R
K: Ink sensor PCB
L: Drive shaft gear
M: Squeegee Roller
C
K
B
D
E
L
M
H
I
8- 14
DRUM SECTION
14.
15.
16.
17.
Remove four screws each from the Drum main frames [C].
Remove the Squeegee frame R [A] and the Squeegee frame F [E].
Slowly take out the Squeegee roller [B].
The Doctor roller [D] will also come apart from the Squeegee unit.
CAUTION:
Two O-rings [H] may fall off from the Squeegee block F [F] and R [G] when the Doctor roller [D]
is removed.
Do not lose these O-rings [H].
REAR
H
D
F
C
FRONT
A: Squeegee frame R
B: Squeegee roller
C: Drum Main Frame
D: Doctor roller
E: Squeegee frame F
F: Squeegee block F
G:Squeegee block R
H:O-ring
> Do not forget to return the two O-rings [H] in their original positions.
Adjustments after Assembly

> Squeegee gap adjustment is required. (See page 8-20)
(Continue to page 8-16)
8- 15
DRUM SECTION
> When tightening the Drum shaft clampers [A], use the Adj. shaft [C] as a JIG to set the
position.
> Bring the Drum to the Position-A.
Tighten both side of the Drum shaft clamper[A] of the Drum with four screws after placing the
JIG[C] through the holes on the Drum U support BKT R [D], Drum support R ass'y [G], Drum
support F ass'y [F] and the Drum U support BKT F [E].
REAR
FRONT
B
B
A:Drum shaft clamper

B:Center shaft
C:Drum grip shaft (JIG)
D:Drum U support BKT R
E:Drum U support BKT F
F:Drum support F ass'y
G:Drum support R ass'y
F
E
D
8- 16
DRUM SECTION
9. Ink Pump Unit

1. Remove the Front cover (See page 1-5)
2. Remove the Ink bottle and remove the Ink bottle guide [B].(See page 8-12)
3. Disconnect the Connector of the Inking motor.
4. Remove two mounting screws of the Ink pump unit [A] and remove the pump unit.
> Match the half-pierced section of the Ink pump unit with its counter part.
A: Ink pump unit

B: Ink bottle guide
8- 17
DRUM SECTION
10. Inking Motor

2. Remove the Ink bottle and remove the Ink bottle guide.(See page 8-12)
3. Remove the Ink pump unit [A]. (See page 8-17)
4. Remove two mounting screws of the Inking motor [B] and remove the motor.
A:Ink pump unit

B:Inking motor
8- 18
DRUM SECTION
ADJUSTMENT
3. Adjustment
1. Squeegee Gap
2. Remove the Drum from the machine.(See page 8-7)
3. Remove the Screen. (See page 8-8)
4. Remove the Drum body. (See page 8-9)
5. Clean out the ink from the Squeegee unit.
6. Using thickness gauge, measure the gap between the Squeegee roller and Doctor roller.
The gap should be 0.08 mm 0.02 mm.
If not, the gap should be adjusted.
7. To adjust, loosen the securing screw [B] of the Doctor roller adjust plate [A] located at both ends
of the Squeegee unit by 3.0 mm Allen wrench.
8. Move the adjust plate [A] by inserting a rod, such as 2.5mm Allen wrench [D], in the Adj. hole [C]
on the plate to change the Squeegee gap.
9. Tighten the securing screw of the two Doctor roller adjust plates after the adjustment is done.
Caution in Adjustment
> The Squeegee gap between the Squeegee roller and Doctor roller should be equal throughout
the length of the two rollers.

> If the gap is too big:
Too much gap will allow excess amount of ink to get on the inner surface of the Drum and
results in ink leakage from the Drum.
> If the gap is too small:
Not enough ink transfers on the inner surface of the Drum and the prints may come out with
uneven print density.
A: Doctor roller adjust plate

B: Securing screw
C: Adj. hole
D: 2.5mm Allen wrench
NARROWER
C
0.08 mm 0.02mm
WIDER
(REAR)
D
C
NARROWER
0.08 mm 0.02mm
(FRONT)
WIDER
8 - 19
MEMO
8- 20
CHAPTER
9:
PAPER JAM
CONTENTS
1. Paper Jam at First Paper Feed Area ......................................................................
2. Paper Jam at Paper Receiving Area .......................................................................
3. Print Start Timing Chart .........................................................................................
4. During the Printing Timing Chart ............................................................................
5. Print Stop Timing Chart ..........................................................................................
1
2
3
4
5
PAPER JAM
1. Paper Jam at Paper Feed Area
1. Paper recieving sensor
> Paper recieving sensor[D] checks for paper every time the Drum angle at 334 and 104 turn from
the Position-A during printing.
> If the Paper recieving sensor does not detect paper either angle at Drum 334 nor 104,
the machine assumes paper has jammed at the paper feed area and displays message [J 2].
Drum 334
Drum 104
Drum 104
Drum 334
ON
Main motor
ON
Position-A sensor
Blocked
Blocked
Paper recieving sensor

A :If the Paper recieving sensor does not detect any paper at Drum angle from 334 to 104, the machine
assumes paper jam occurred and displays [J 2].
E
NORMAL PAPER FEED
C
Drum at 334
Drum at 104
A: Pickup roller
B: Paper
C: Pressure roller
D: Paper receiving sensor
E: Drum
PAPER JAM AT PAPER FEED AREA
Drum at 104
Drum at 334
9-1
PAPER JAM
2. Paper Jam at Paper Receiving Area

> Paper receiving sensor checks for paper during the printing operation.
> If paper is detected by Paper receiving sensor within one rotation of the Drum from drum position
at 257 to 280 , the machine assumes paper has jammed at the Paper receiving area and
displays message [J 3].
0
0
180
257 280
Main motor
ON
Position-A sensor
Looks at the paper
Paper receiving
sensor
Open
Paper Detected
A : Paper recieving sensor does not detect the paper at the drum angle from 257 to 280.
NORMAL PAPER DISCHARGE
Drum at 257
Drum at 280
D
A
A: Paper recieving sensor

B: Paper
C: The previous paper
D: Drum
PAPER JAM AT PAPER RECEIVING AREA
Drum at 257
Drum at 280
Paper stays under the Paper receiving sensor from Drum position at 257 to 280.
The paper has stuck on the suction unit or stuck with the separator.
9-2
PAPER JAM
3. Printing Start Timing Chart

Press STA RT button
90
180
270
66.3
160.3
334 0
Drum angle
Blocked
Position-A sensor
Main motor
30
rpm
Blocked
60 rpm
90 rpm
ON
Paper receiving
sensor
Blocked
Detection
1st
paper
No detection
1ON 2
Paper feed clutch
2nd
paper
1st paper
Timing clutch
Separation fan
Suction fan
ON
ON
1.
2.
3.
4.
60 rpm: 66.3 / 90 rpm: 63.7

60 rpm: 144.8 / 90 rpm: 142.2
60 rpm: 160.3 / 90 rpm: 157.7
60 rpm: 61.3 / 90 rpm: 58.7
1. When the drum angle becomes 66.3 or 63.7 degrees, the Paper feed clutch is turned ON.
2. When the drum angle becomes 144.8 or 142.2 degrees, the Paper feed clutch is turned OFF.
3. When the drum angle becomes 160.3 or 157.7 degrees, the Timing clutch is turned ON.
4. When the drum angle becomes 61.3 or 58.7 degrees, the Timing clutch is OFF.
9-3
PAPER JAM
4. During the Printing Timing Chart
334
104
257 280
104
280
Drum angle
Blocked
Position-A sensor
Main motor
1. J 2
Paper receiving
sensor
Detection
Detection
ON
Detection
ON
Paper feed clutch
Timing clutch
2. J 3
ON
ON
ON
Separation fan
Suction fan
Total counter
count
Count of A
Count of B
1. The Paper receving sensor checks whether the paper feeding is correct or not.
If the Paper receiving sensor does not detect paper at Drum angle 334 and 104 , the machine assumes
that the paper jam has occurred in the paper feeding area and indicates the message [J 2].
2. The Paper receving sensor checks whether the paper feeding is correct or not.
If the Paper receiving sensor detects paper at Drum angle 257 and 280 , the machine assumes
that the paper jam has occurred in the paper receiving area and indicates the message [J 3].
9-4
PAPER JAM
5. Print Stop Timing Chart

Print quantity on
the Display panel
becomes "0"
or
Press "STOP Key"
334
104
The TIMING CHART below is identical for both when

the printing movement stops automatically by the print
quantity count on the Operation panel becomes "0"
(Printing finished) and when the STOP button is
pressed manually.
257 280
104
315
Drum angle
1
Blocked
Blocked
Blocked
Position-A sensor
2
Main motor
Paper receiving
sensor
Separation fan
Suction fan
ON
60 or 90 rpm
15 rpm
4
1.95 rpm
OFF
No detection
Detection
(Last paper)
OFF
ON
Total counter
count
(Count of the last paper)
1 When the Paper receiving sensor changes from "detecting ( the drum at 334 and 104 ) " to "not detecting"
(the drum angle at 257 and 280 ), the count signal is activated and the print quantity display on the Panel
is decreased by one count and the Copy counter count goes up one count.
If at this time the print quantity display on the Panel becomes zero "0" or the STOP key is pressed, the
print stop movement starts from the next Drum position-A.
2 When the next Drum position-A is detected, the Drum rotation speed becomes 15 rpm to be ready for the
stopping the Drum rotation.
3 The Drum rotation speed becomes 1.95 rpm at Drum angle 315 .
4. Then the Main motor completely stops at the Drum position-A.
9-5
CHAPTER
10:
MASTER CLAMP SECTION
CONTENTS
1. Clamp Unit Positioning Mechanism .......................................................................
2. Clamp Plate Master Release Mechanism ..............................................................
3. Clamp Plate Master Clamp Mechanism .................................................................
1. Clamp Unit .............................................................................................................
2. Clamp Motor ..........................................................................................................
3. Clamp Sensor C ....................................................................................................
4. Clamp Sensor L .....................................................................................................
1
2
4
7
8
8
8

1. Clamp Unit Positioning Mechanism
1. Clamp Sensors C and L
> The Clamp plate arm [A] and the Master projection plate arm [E] of the Clamp unit are checked
by the Clamp sensors C [C] and L [F] to see if they are in home position every time the STA RT
button is pressed for the machine operation with the drum rotation.
> The Clamp unit is at its home position when the light paths of Clamp sensor C [A] and Clamp
sensor L [F] are both opened.
> If the light path of Clamp L [F] and C [C] sensor is cut when the start button is pressed, the
machine indicates [E 3] immediately.
F
C
D
B
A:Clamp plate arm

B:Clamp motor
C:Clamp sensor C
D:Clamp encoder disc
E:Master projection plate arm
F:Clamp sensor L
G:Clamp cam assembly
*Light paths of the Clamp sensors C

and L are both opened at Home position.
10 - 1

2. Clamp Plate Master Release Mechanism

1. Check presence of the Clamp Sensor L
> When the STA RT button s pressed for confidential or regular master making, the machine
checks presence of the Clamp sensor L [A].
> If the Clamp sensor L [A]is blocked, the machine operation is cancelled then [E 3] is indicated.
Otherwise the Clamp plate master release operation is proceeding.
2. Clamp open arm & Master release arm
> The Clamp plate arm [F] comes down first and opens the Clamp plate [G] to free the leading
edge of the master.
> Next, the Master projection plate arm [E] comes down and raises the Master release bar [C] to
push the leading edge of the master out of the Clamp plate.
> The Clamp motor continues to rotate the Clamp cam ass'y until both the Clamp plate arm [F]
and Master projection plate arm [E] are lifted to closes the Clamp plate [G] and the Master
release bar [C].
> The master release movement is completed when the light path of the Clamp sensor L [F]
becomes open and the Clamp motor stops.
D
E
F
B
A
A: Clamp sensor L
B: Clamp sensor C
C: Master release bar
D: Clamp cam ass'y
E: Master projection plate arm
F: Clamp plate arm
G: Clamp plate
10 - 2
DRUM SECTION
Clamp Plate Master Release Timing Chart

Start button
is pressed
Start button
is pressed
180
270
180
270
Clamp encoder
Open
Clamp sensor L
Clamp sensor C 4
Blocked
1
Max. 10sec
Max. 10sec
1 If the Start button is pressed when the light path of the Clamp sensor L is not blocked and the Clamp
sensor C is blocked, the Clamp motor is activated to make the light path of the Calmp sensor L and C
unblocked within 10 seconds. If the both could not be opened within 10 seconds, the machine assumes
that the Clamp motor has locked and displays error message [E 3].
2 If the light path of Clamp sensor L and C does not become blocked within 10 seconds after the light path
of the Clamp sensor L and C became opened, the machine assumes that the Clamp motor has locked
and displays error message [E 3].
3 If the light path of Clamp sensor C does not become blocked and that of Clamp sensor L does not
become open within 10 seconds after the light path of the Clamp sensor L and C became blocked, the
machine assumes that the Clamp motor has locked and displays error message [E 3].
4 When STA RT button is pressed, the machine confirms whether the light path of Clamp sensors L and C
are opened or not. If the light paths of Clamp sensors L and C are not both open, the machine will display
[E 3] immediately.
10 - 3

3. Clamp Plate Master Clamp Mechanism

1. Master removal
> The master clamp movement is made after the master is removed from the Drum.
2. Master clamping
> W ith the activation of the Clamp motor, the Clamp plate arm [D] is pushed down to open the
Clamp plate [A].
> The Clamp motor stops when the light path of Clamp sensor L [F] becomes open and keeps the
Clamp plate [A] raised open.
> When the Write pulse motor sends certain set amount of master onto the Drum, the Clamp
motor activates to raise the Clamp plate arm [D] and close the Clamp plate [A].
> The Clamp motor turns off when the light paths of both the Clamp sensors C [E] and
L [F] becomes open.
The Clamp plate [A] is closed and the Clamp unit is returned to the Home position.
F
E
A: Clamp plate
B: Clamp encoder disc
C: Clamp cam ass'y
D: Clamp open arm
E: Clamp sensor L
F: Clamp sensor C
Sends master
10 - 4

Master Clamping Timing Chart

Motion starts
Blocked
Motion ends
Position-A sensor
Clamp sensor C
Blocked
2
Open
3
10 sec.
10 sec.
4
Open
Blocked
1
Clamp sensor L
Clamp motor
ON
OFF
ON
5
1 If the light path of the Clamp sensor L is not blocked within 10 seconds after the Clamp motor is
activated, the machine assumes that the Clamp motor is locked and displays error message [E 03].
2 If the light path of the Clamp sensor C is not opened within 10 seconds after the Clamp motor is
3 The Drum waits for the master with the Clamp plate opened.
4 If the light path of the Clamp sensor L is not opened within 10 seconds after the Clamp motor is
5 The Clamp motor activates to clamp the master with the Clamp plate when the master loading to the
drum is completed.
10 - 5
MEMO
10 - 6


1. Clamp Unit
3. Disconnect the Connectors of the following three electrical parts.
> Clamp motor [A]
> Clamp sensor C [C]
> Clamp sensor L [D]
4. Remove three mounting screws of the Clamp unit [A] and remove the unit.
> Match the half-pierced section on the Clamp unit [A] with its counter part.
A: Clamp unit
B: Clamp motor
C: Clamp sensor C
D: Clamp sensor L
B
C
D
10 - 7

2. Clamp Motor
3. Remove Clamp unit. (See page 10-7)
4. Remove two mounting screws of the Clamp motor [A] and remove the motor.
3. Clamp Sensor C
1.
2.
3.
4.
5.

Remove Back cover.(See page 1-5)
Remove Clamp unit. (See page 10-7)
Remove the mounting screw of the Clamp sensor C [C] bracket with the sensor attached.
Remove the sensor from the bracket.
> Match the half-pierced section of the Clamp sensor bracket with its counter part.
4. Clamp Sensor L
1.
2.
3.
4.

Remove the Back cover. (See page 1-5)
Remove Clamp unit. (See page 10-8)
Remove the mounting screw of the Clamp sensor L [B] and remove the sensor.
> Match the half-pierced section of the sensor with its counter part.
A: Clamp motor
B: Clamp sensor C
C: Clamp sensor L
10 - 8
CHAPTER
11:
MASTER REMOVAL SECTION
CONTENTS
1. Master Removal Unit Mechanism ........................................................................... 1
2. Master on the Drum (before master removal) Check Mechanism ............................ 2
3. Clamp Plate Master Release Mechanism .............................................................. 4
4. Master Removal Mechanism .................................................................................. 6
5. Master Disposal Box Set Mechanism .................................................................... 8
1. Master Removal Unit .............................................................................................. 9
2. Master Removal Clutch ........................................................................................ 10
3. Master Removal Sensor ....................................................................................... 11
4. Disposal Box Set Sensor ..................................................................................... 11
5. Master Removal Hook .......................................................................................... 12
6. Vertical Transport Roller (Upper) .......................................................................... 13
7. Vertical Transport Roller (Lower) .......................................................................... 13
8. Master Removal Guide (Lower) ............................................................................ 13

1. Master Removal Unit Mechanism
> The Master removal unit [A] removes the master on the drum each time the master making
operation is made.
> The Master removal hooks [D] guide the removed master towards the Master disposal box [C].
> The Transpotation roller upper [E] and lower [F] are engaged via gears. And rotation of the
transpotation roller upper and lower is made by the rotation of the Main motor via the Mater
removal clutch [B].
A
F
E
A
D
B
D
A:Master removal unit

B:Master removal clutch
C:Master disposal box
D:Master removal hook
E:Transpotation roller upper
F:Transpotation roller lower
11 - 1

2. Master on the Drum (before master removal) Check Mechanism

1. Master Sensor
> Master sensor [B] checks the presence of the Master [D] on the drum when the Start button is
pressed for confidential master making or normal master making.
> The sensor [B] looks for the Master [D] on the drum when the Drum rotates 134 from the
Position-A.
> If the machine already knows the presence of the Master [D] on the drum from the earlier
machine operations, this Master checking movement is skipped.
2. When master is detected on the Drum
> The machine goes into master removal and Master removal sensor becomes active.
3. When master is not detected on the Drum
> The machine skips the master removal movement and goes directly into master making.
C
B
D
A:Light absorber strip

B:Master sensor
C:Drum
D:Master
Drum angle = 134

(From Position-A)
11 - 2

Master on the Drum Check Timing Chart (before master removal)
Press STA RT button

1 Blocked
Blocked
Open
Position-A sensor
Master sensor
Drum at 134
Detecting
master
Main motor
OFF
ON
1 The Drum is at Position-A when the STA RT button is pressed.

2 If the light of the Master sensor is reflected back (detecting master) at Drum 134 , the Master removal
sensor becomes active and checks the master during the master removal.
If the light of the Master sensor is not reflected back (master not detected) at Drum 134 , master removal
movement will be skipped.
the machine knows the presence of master on the Drum from earlier machine movements, this master
* If
on the Drum check movement is skipped.
11 - 3

3. Clamp Plate Master Release Mechanism

1. Master on the Drum check
> When the STA RT button is pressed for confidential or regular master making, the Drum rotates
and presence of the master on the Drum is checked.
> If a master is found on the Drum, the master release movement is made after the Drum returns
to Position-A.
2. Clamp open arm & Master release arm
> The Clamp open arm [B] comes down first and opens the Clamp plate [C] to free the leading
edge of the master.
> Next, the Master release arm [D] comes down and raises the Master release bar [E] to push the
leading edge of the master out of the Clamp plate [C].
> The Clamp motor continues to rotate the Clamp cam ass'y [A] until both the Clamp open arm [B]
and Master release arm [D] are lifted to closes the Clamp plate [C] and the Master release bar
[E].
> The master release movement is completed when the light path of the Clamp sensor L [G]
becomes open and the Clamp motor stops.
A
D
B
E
C
A:Clamp cam ass'y

B:Clamp open arm
C:Clamp plate
D:Master release arm
E:Master release bar
F:Clamp sensor C
G:Clamp sensor L
11 - 4

Clamp Plate Master Release Timing Chart

Start button
is pressed
Start button
is pressed
180
270
180
270
Clamp encoder
Open
Clamp sensor L
Clamp sensor C 4
Blocked
1
2
Max. 10sec
Max. 10sec
Max. 10sec
If the Start button is pressed when the light path of the Clamp sensor L is not blocked and the Clamp
sensor C is blocked, the Clamp motor is activated to make the light path of the Calmp sensor L and C
unblocked within 10 seconds. If the both could not be opened within 10 seconds, the machine assumes
that the Clamp motor has locked and displays error message [E 3].
2 If the light path of Clamp sensor L and C does not become blocked within 10 seconds after the light path
of the Clamp sensor L and C became opened, the machine assumes that the Clamp motor has locked
and displays error message [E 3].
3 If the light path of Clamp sensor C does not become blocked and that of Clamp sensor L does not
become open within 10 seconds after the light path of the Clamp sensor L and C became blocked, the
machine assumes that the Clamp motor has locked and displays error message [E 3].
4 When STA RT button is pressed, the machine confirms whether the light path of Clamp sensors L and C
are opened or not. If the light paths of Clamp sensors L and C are not both open, the machine will display
[E 3] immediately.
11 -5

4. Master Removal Mechanism

1. Master Removal Clutch
> The Main motor rotatates the Vertical transport roller upper [B] and lower [A] via the Mater
removal clutch [E].
> By the rotation of the Drum, the leading edge of the master comes in between the Vertical
Transport roller upper [B] and lower [A] and the separation of the master from the Drum starts.
> The Main motor stops to complete the master removal movement when the Drum comes back to
the Position-A after making one rotation to remove the master.
2. Master Removal Hooks
> The master removed from the Drum is guided in between the Vertical transport roller upper [B]
and lower [A] by the Master removal hooks [D].
3. Master Removal Sensor
> Master removal sensor [C] checks the presence of the removed master in front of the Master
disposal box to check for master removal jams.
> The Master removal sensor [C] looks for presence of removed master at134 Drum rotation from
Position-A.
D
C
A:Vertical transport roller (lower)

B:Vertical transport roller (upper)
C:Master removal sensor
D:Master removal hook
E:Master removal clutch
11 - 6

Master Removal Timing Chart
315
134
Open
Position-A sensor
ON
Main motor
1.95rpm
OFF
15rpm
15rpm
Blocked
ON
Master removal
clutch
OFF
Detecting removed master
Master removal
sensor
1 During the initializing of the drum towards the position A in the master removal operation, if removed
master is detected by Master sensor at Drum angle 134 , the Master removal sensor looks for the
removed master.
If removed master is not detected by the Master removal sensor at Drum 134, the machine assumes
master removal error has occurred and displays the message [J 9].
2 When the Drum returns to Position-A and the Master removal sensor confirms the removed master has
cleared through the sensor.
If the Master removal sensor still detects removed master, the machine assumes removed master has
jammed at master removal area and displays message [J10].
Master removal sensor detects removed master when the Start button is pressed, the machine assumes
* If
that the removed master is jammed and the message [J10] is displayed.
11 - 7

5. Master Disposal Box Set Mechanism

1. Disposal Box Set Sensor
> Disposal box set sensor checks the presence of the Master disposal box and whether the
Master disposal box is opened or closed.
> When the Master disposal box is set in the machine, its tip blocks light path of the Disposal box
set sensor.
A:Disposal box set sensor

B:Master disposal box
C:Tip
D:Master removal unit (closed)
11 - 8


1. Master Removal Unit
2. Pull up the Master removal unit lever [C] then slide the Master removal unit [A] out.
3. Remove Master removal cover (See page 1-6)
4. Disconnect the Connector [D] of the Master removal unit.
5. Remove the four mounting screws[E] of the Master removal unit.
6. Remove the Master removal unit [A].
B
C
D

B:Master Disposal Box
C:Master removal unit lever
D:Connector
E:Mounting screw
11 - 9

2. Master Removal Clutch

2. Remove the Back cover. (See page 1-5)
3. Remove the Master removal unit.( See page 11-9)
4. Remove the E-ring [F] and remove M-R gear [E].
5. Remove two mounting screws of the Clutch B bracket [A] and remove the bracket.
6. Disconnect the Connector of the Master removal clutch [C].
7. Remove the Master removal clutch [C].
> Mount the slit on the Master removal clutch [C] over the Clutch B bracket [A].
E
C
A:Clutch B BKT
B:Metal
C:Master Removal Clutch
D:Metal
E:M-R Gear
F:E-ring
11 - 10

3. Master Removal Sensor

1.
2.
3.
4.
5.
Disconnect the power supply from the machine, and remove Master removal cover.(See page 1-5)
Slide the Master removal unit out.
Disconnect the Connector of the Master removal sensor [C].
Remove the mounting screw of the Master removal sensor bracket and remove the bracket.
Remove the sensor from the bracket.
> Match the half-pierced section of the Master removal sensor bracket with its counter part.
4. Disposal Box Set Sensor

1.
2.
3.
4.
Disconnect the power supply from the machine, and remove Master removal cover.(See page 1-5)
Disconnect the Connector of the Disposal box set sensor [A].
Remove the mounting screw of the Disposal box set sensor bracket and remove the bracket.
Remove the sensor [A] from the bracket.
A:Disposal box set sensor

B:Master removal Unit
C:Master removal sensor
11 - 11

5. Master Removal Hook

1. Remove Master removal unit [A]. (See page 11-9)
2. Disengage the Master removal hooks [B] from the Master removal unit [A] and remove the hooks.
> Engage the tips of the Master removal hooks with the counter parts correctly.
> Do not apply unnecessary force to the Master removal hooks to avoid any damage of the hooks.

B:Master removal hooks
11 - 12

6. Vertical Transport Roller (Upper)

2. Remove the Master disposal box. [F].
3. Remove the Master removal unit.(See page 11-9)
4. Remove the Master removal sensor. (See page 11-11)
5. Remove the Master removal guide (Upper). [A]
6. Remove E-rings from both ends of the Vertical transport roller (Upper) [B] and remove the Metals.
7. Vertical Transport Roller (Lower)

2. Remove the Master disposal box. [F].
5. Remove the Master removal guide (Upper) [A].
6. Remove the Vertical transport roller (Upper) [B].
7. Remove E-ring then remove the Transpot roller gear [G].
8. Remove E-ring of the Vertical transport roller (Lower) [C] and remove the Metals.
8. Master Removal Guide (Lower)

2. Remove the Master disposal box [F].
5. Remove the Master removal guide (Upper)[A].
6. Remove the Vertical transport roller (Upper) [B] and (Lower) [C].
7. Remove three mounting screws then remove the Master removal guide(Lower) [E].
H
E
B
C
G
A:Master removal guide (Upper)

B:Vertical transport roller (Upper)
C:Vertical transport roller (Lower)
D:Master removal unit
E:Master removal guide (Lower)
F:Master disposal box
G:Transport roller gear
H:Master removal sensor
11 - 13
CHAPTER
12:
IMAGE SCANNING SECTION
CONTENTS
1. Original Loading Mechanism .................................................................................. 1
2. Original Scanning Mechanism ............................................................................... 3
3. Image Scanner ...................................................................................................... 5
1. White Roller ........................................................................................................... 7
2. Image Scanner Unit ............................................................................................... 8
3. Original IN Sensor .................................................................................................. 9
4. Pickup Roller ....................................................................................................... 10
5. Eject Roller Upper ................................................................................................ 10
6. Document Feeder Hook ....................................................................................... 10
7. Load Roller .......................................................................................................... 11
8. Eject Roller Lower ................................................................................................ 11
9. Read Pulse Motor ................................................................................................ 11
3. Adjustment
1. Image scanner ..................................................................................................... 13

1. Original Loading Mechanism
An original placed on the Original rack [G] is automatically fed when the master making process is
started.
1. Shading Compensation
> When the Original IN sensor [I] detects the original, the LED of the Image scanner [H]
turns ON and the shading compensation takes place.
2. Original Loading
> After the shading compensation is done, the Read pulse motor [A] activates to start feeding the
original by rotating the Pickup roller [B] and Load roller [F].
> The original put on the Original rack [G] is fed into between the Image scanner [H] and the White
roller [C]. Then the original is fed towards the Eject roller upper [E] and lower [J] by rotation of
the White roller [C].
> The Eject roller upper [E] and lower [J] feeds the original then ejects it from the document feeder.
B
H
F
G
A: Read pulse motor

B: Pickup roller
C: White roller
D: Original detection sensor
E: Eject roller upper
F: Load roller
G: Original rack
H: Image scanner
I :Original IN sensor
J :Eject roller lower
12 - 1

Original Loading Timing Chart
Motion ends
Original set
2
Original IN sensor
No detection
Original detected
1
ON
Scanner LED
OFF
ON
OFF
150 ms 150 ms 150 ms

ON
Read pulse motor
OFF
293
pulses
Max.
5sec.
1 The Image scanner [H] LED activates for shading compensation.

2 If the original IN sensor[D] does not detect an Original within 5 seconds after the Read pulse motor[A]
activates, the machine assumes the original has jammed and indicates the message [J 7], and turns off
the Read pulse motor[A].
3 The original loading ends when the Read pulse motor[A] rotates 293 pulses after the Original IN senor[D]
detects the Original and the Read pulse motor[A] turns OFF.
E
B
H
F
G
12 - 2
A: Read pulse motor

B: Pickup roller
C: White roller
D: Original IN sensor
E: Eject roller
F: Load roller
G: Original rack
H: Image scanner
I : Eject roller lower

2. Original Scanning Mechanism

When the master removal is completed, the Read pulse motor [F] turns ON to feed the original onto
the Image scanner [H].
And after the Original loading movement is completed, the Drum rotates to remove the master from
the Drum.
1. Read pulse motor

> The Drum comes back to the position-A after the master removal is completed, the Read pulse
motor[E] activates to rotate the White roller [C] , Eject roller [B] and the Eject roller (Lower)[F] to
feed the Original in and out.
> 180 ms after the Main motor is activated (Clamp motor stops), the Read/Write start signal turns
ON and the image scanning is started by the Image scanner [A].
2. Original IN sensor
>Pulse of the Read pulse motor [E] is counted 128 pulses after the tailing edge of the Original
clears out from the Original IN sensor [D], the Read/Write start signal and the Image scanner
LED are turned OFF to stop the image scanning.
> The Read pulse motor [E] stops after 539 pulses from the original scanning movement ends.
C
D
B
A:Image scanner
B:Eject roller
C:White roller
D:Original IN sensor
E:Read pulse motor
F:Eject roller (Lower)
12 - 3

Original Scanning Timing Chart
Motion ends
Clamp motor
OFF
ON
Main motor
Detecting original
Original IN sensor
ON
180 ms
Scanner LED
1
128 p
ON
Read pulse motor

539 p
MAX 5082 pulses
1 180 ms after the Main motor is activated (Clamp motor stops), the Read/Write start signal turns ON and
the image scanning is started (Scanner LED lights ON) by the Image scanner.
2 Pulse of the Read pulse motor is counted 128 pulses after the tailing edge of the Original clears out from
the Original IN sensor, the Read/Write start signal and the Image scanner LED are turned OFF to stop the
image scanning.
3 After the pulse of the Read pulse motor is counted 539 pulses from the Read/Write start signal and the
Image scanner LED are turned OFF or, the pulse of the Read pulse motor is counted 5082 pulses from
the Read pulse motor starts activating.
12 - 4

3. Image Scanner
The image scanning is done by an optical type Image scanner [A] which emits greenish-yellow light
from LED array [B] against an original and catches the image after it is reflected.
2048 pieces of photo transistors are installed as the receiving elements of the scanner. Those
receiving elements are combined as the Photo transistor array [C].
And the Image scanner covers around 260mm width which is about the size of B4 width.
Therefore the scanner is called Contact Image Scanner (CIS).
Top view
A:Image scanner unit

B:LED array
C:Photo transistor array
12 - 5
MEMO
12 - 6


1. White Roller
2. Remove the Document feeder [A] from the machine.
3.Remove mounting screws then remove the White roller holders [E].
4. Remove the E-ring and remove the White roller gear [D]from the White roller shaft.

> Insert the Pin [C] in the White roller shaft and match the Pin [C] to slit of the White roller gear
[D].
A:Document feeder
B:White roller
C:Pin
D:White roller gear
E:White roller holder
12 - 7

2. Image Scanner Unit

2. Remove the Document feeder [D]. (See page 12-7)
3. The Document feeder cover. (See page 3-10)
4. Disconnect the connector of the Image scanner [A].
5. Take out the scanner [A] from the machine.
>If needed, remove the mounting screws of the Scanner holder R [C] and L [B] from the Scanner unit.
B
D
A:Image scanner unit

B:Scanner holder L
C:Scanner holder R
D:Document feeder
12 - 8

3. Original IN Sensor
2. Remove the Document feeder. (See page 12-7)
3. The Document feeder cover. (See page 3-10)
4. Disconnect connector of the Original IN sensor [A] and remove the mounting screw of the sensor
then remove the Original IN sensor [A].
A:Original IN sensor
B:Original guide base plate
12 - 9

4. Pickup Roller
2. Remove the White roller cover upper [E] from the document feeder. (See page 12-8)
3. Remove the Pick up roller spring [C] then remove the Pick up roller [D].
5. Eject Roller Upper

2. Remove the White roller cover upper [E] from the document feeder. (See page 12-8)
3. Remove the Eject roller spring [A] then remove the Eject roller upper [B].
6. Document Feeder Hook

1.
2.
3.
4.

Remove the White roller cover upper [E] from the document feeder. (See page 12-8)
Remove the Hook springs [G].
Remove Document feeder hook[F].
A
G
B
H
C
D
12 - 10
A:Eject roller spring

B:Eject roller upper
C:Pick up roller spring
D:Pick up roller
E:White roller cover upper
F:Document feeder hook
G:Hook spring
H:White roller cover lower

7. Load Roller
2. Remove the Document feeder (See page 12-7) and the Document feeder cover. (See page 3-10)
3. Remove both side of E-rings then remove metals and gears from shaft of the Load roller [B].
4. Remove the Laod roller [B] from the unit.
8. Eject Roller Lower

3. Remove both side of E-rings then remove metals and gears from shaft of the Eject roller lower [A].
4. Remove the Pin [D] from the shaft.
5. Remove the Eject roller lower [A] from the unit.

> Insert the Pin [D] in the Eject roller lower shaft and match the Pin [D] to slit of the counter gear
[E].
9. Read Pulse Motor

3. Remove two mounting screw of the Read pulse motor [C] and remove the motor.

> Connector of the Read pulse motor [C] should face to the Image scanner side when install the
motor[C].
D
E
12 - 11
A:Eject roller
B:Load roller
C:Read pulse motor
D:Pin
E:Gear

MEMO
12 - 12

ADJUSTMENT
3. Adjustment
1. Image scanner gain adjustment
After replacing the Image scanner unit, the gain adjustment of the scanner is required.
The adjustment procedure is as follows.
2. Connect the probes of a Digital multi meter (Valtage tester) [D] with 1 pin and 2 pin (in case there is
any difficulties to connect the 2 pin, it is acceptable to connect the main body instead) of the CN111
[B] on the Main PCB [C].
3. Set up Test mode and enter "9" and "0" (No.90) then press the Start key.
4. Check the indication of the multi meter whether it is between the range of 1.85 V and 1.95 V.
5. If the voltage is not in the range, turn the VR1 [A] on the Main PCB [C] to adjust the voltage.
B

> Do not short circuit the 1 pin with the 2 pin when connecting the Digital multi meter with the
CN 111.
A: VR 1
B: CN111
C:Main PCB
D:Digital multi meter
12 - 13
CHAPTER
13:
CUTTER SECTION
CONTENTS
1. Cutter Home Positioning Mechanism ..................................................................... 1
2. Cutting Mechanism ................................................................................................ 3
1. Cutter Unit ............................................................................................................. 5
CUTTER SECTION
1. Cutter Home Positioning Mechanism
1. Home Position Switch
> Each time the machine power is turned ON or All Reset Button is pressed, the Home
position switch [D] checks the position of the Cutter [B].
> The Cutter position is checked by the Home position switch [B] and the End position switch
[D], of which is located the opposit end of the Cutter rail.
2. Home Position
> The Home position of the Cutter [B] is where the Home position switch [D] is detected.
> If the Home positioning switch [D] is not detected, the Cutter motor [C] activates and rotates the
Cutter gear [E] until the Home position switch [B] becomes detecting.
F
D
A
C
A:Cutter Unit
B :Cutter
C:Cutter motor
D:Home position switch
E:Cutter gear
F:End position switch
13 - 1
CUTTER SECTION
Cutter Home Positioning Timing Chart

Movement
completed
Movement starts
Home Position
Switch
End position
Switch
C W
Cutter motor
1
ON
2000ms
2
500ms
3
CCW
2000ms
4
ON
500ms
breakes
breakes
1 If the Home position switch is detected (the Cutter does not move from the Home position) even though
500 ms has passed after the Cutter motor activated, the machine assumes the Cutter motor has locked
and indicates error message [E 13].
2 If the End position switch is not detected within 2000 ms after the Cutter motor activates (cutter not at
home position), the machine assumes the Cutter motor has locked and indicates error message [E 13].
3 If the Home position switch is detected (the Cutter does not move from the End position) even though
500 ms has passed after the Cutter motor activated, the machine assumes the Cutter motor has locked
and indicates error message [E 13].
4 If the Home position switch is not detected within 2000 ms after the Cutter motor activates (cutter not
at End position), the machine assumes the Cutter motor has locked and indicates error message [E 13].
13 - 2
CUTTER SECTION
2. Cutting Mechanism
1. Master Cutting
> Cutter motor [C] activates and cuts the master each time the master loading is made on the
Drum.
2. Cutter Motor
> As the Cutter motor [C] activates, it rotates the Cutter gear [E], and the housing of the Cutter [B]
presses against the actuator of the End position switch [F].
> Then the Cutter moter [C] activates again and return to the Home position switch [D].
> The Cutter motor [C] then stops at the Home position switch [D] and the cutting motion ends.
B
D
A:Cutter Unit
B :Cutter
C:Cutter motor
D:Home position switch
E:Cutter gear
F:End position switch
13 - 3
MEMO
13 - 4
CUTTER SECTION

1. Cutter Unit
3. Open the Master making unit.
4. Disconnect the Connector of the Cutter unit [A].
5. Remove the mounting screws of the Cutter unit [A] and remove the unit.
> Match the half-pierced sections of the Cutter unit with its counter part.
FRONT
A:Cutter unit
13 - 5
CHAPTER
14:
MASTER MAKING SECTION
CONTENTS
1. Master Making ....................................................................................................... 1
2. TPH Positioning ..................................................................................................... 3
3. Thermal Power Safety Switches ............................................................................ 5
1. Write Roller ............................................................................................................ 7
2. Thermal Print Head (TPH) ...................................................................................... 8
3. TPH Position Sensor ............................................................................................. 9
3. Adjustment
1. Thermal Power of Thermal Print Head .................................................................. 11

1. Master Making
When the STA RT key is pressed for master making, the Drum rotates to remove the master on the
Drum.
At the same time the TPH-CTL signal is turned ON to supply heating power to the Thermal print head
[A].
1. Start of the Master Making
> While the Drum is rotates to remove the master on the Drum, the Write pulse motor [D]
activates and starts feeding the master material from the master roll 50 ms after the Drum
rotates 100 from the first Drum Position-A.
> At the same time the original starts feeding through the ADF unit for scanning.
> As the Write pulse motor activates and feeds the master for 5mm, the Read & Write start
signal is turned ON and the Thermal print head begins making image on the master material.
2. End of the Master Making
> After a certain set time, the Master tension plate solenoid activates and swings down the
Master tension plate.
> The master runs through the Master tension plate and as the Master tension plate swings
down, it gives tension on the master while the master is loaded on the Drum.
> Either the original scanning ends or if the Write pulse motor activates for the maximum master
making length, both the TPH-CTL signal and Read & Write start signal turn OFF.
> The Write pulse motor is still activated until full length of master material is transferred.
The Write pulse motor then stops and completes the master making process.
C
D
A:Thermal print head(TPH)

B:Write roller
C:Master roll
D:Write pulse motor
14 - 1

1. Master Making Timing Chart

Scanning is completed, or
Write pulse motor has rotated
maximum master making
length.
Cutter unit
3
activates
Original IN sensor
Clamp motor
Detecting original
OFF
ON
Read pulse motor
ON
1
Write pulse
motor
180ms
ON
2
TPH-CTL signal
*1
4769 pulses
10.87mm
14pluse
MAX 4141pulses
*1
1 The Write pluse motor and the Main motor activate after 180 ms the Clamp motor goes off.
2
After the Write pulse motor activates 14 pulses (1.2 mm), the TPH-CTL start signal turns ON and master
making starts. The original scanning starts at the same time.
After the Scanning is completed or Write pulse motor has rotated maximum master making length, both
the Read/Write start signal and TPH-CTL signal are turned OFF to end the master making.
*1:The maximum master making length of the Write pulse motor is 4141 pluses or 10.87mm plus the
pluses until the original throughing out the Original In sensor.
4 After the TPH CTL signal off, the Write pulse motor keeps turning until one full size master length
(4769 pulses) of master material is moved forward.
The Write pulse motor then turns OFF and the Cutter unit cuts the master material.
14 - 2

2. TPH Positioning
The TPH [C] moves down and up when master feeding is necessary or the master making process is
ended.
When the TPH unit [C] is at the home position, the TPH unit detouch the Write roller [B].
When the Master making starts, the TPH unit [C] is lowered by the Write pulse motor [D].
Rotation of the Write pulse motor is transferred to the TPH position cam [E] via geras on the Master
making unit.
1. TPH position sensor
>The TPH position sensor [A] checks whether if the TPH stays upper or not.
>If the light path of the TPH position sensor is changed from "unblocked" to "blocked", the machine
assums that the TPH stays at upper position.(The TPH detouchs the Write roller)
>If the light path of the TPH position sensor is changed from "blocked" to "unblocked", the machine
assums that the TPH stays at lower position.(The TPH touchs the Write roller)
Spring force
C
B
TPH
detouching
A Sensor blocked
Sensor opened
TPH
Touching
A:TPH positioning sensor

B:Write roller
C:TPH unit
D:Write pulse motor
E:TPH position cam
14 - 3

2. TPH Positioning Timing Chart

1. From Original set to Preparation of Scanning
Read pulse motor
OFF
ON
ON
ON
ON
White pulse motor
TPH position
sensor
CCW
ON
CW
CW
Blocked
2. From Master making to Master cutting

Master making ended
Master cutting
Read pulse motor
White pulse motor

OFF
ON
CW
ON
TPH position
sensor
CCW
OFF
Blocked
Blocked
14 - 4

3. Thermal Power Safety Switches

1. Safety Switches
> The actuators of all four safety switches must be pressed in order to feed electrical power to
the TPH unit.
> These four switches also acts as Main motor safety switches.
A:Master removal unit safety switch

B:Guide plate safety switch
C:Master making unit safety switch
D:Separation unit safety switch
14 - 5
MEMO
14 - 6


1. Write Roller
2. Open the Master making unit and remove the Master roll.
3. Remove front side of Lock ring fitting on the Whit roller shaft and remove the collar and the metal
from the shaft.
4.Remove the Write roller ass'y by lifting the ass'y from the machine.
> Match the flat part of the Metal [C] on the rear side to the E-ring fitting to the Write roller ass'y
[B] shaft.(refer to below photos a and b)
C
A
FRONT
Flat part
B
a. Corrct position
b. Incorrct position
A:Lock ring
B:Write roller ass'y
C:Metal
D:Collar
REAR
14 - 7

2. Thermal Print Head (TPH)

1.
2.
3.
4.
5.
6.
7.

Open the Master making unit.
Disconnect the TPH connectors [A] out from the TPH ass'y [D].
Remove the screw of the Grand wire [B].
Remove the TPH ass'y screws [C].
Slide the TPH ass'y [D] up to release from the Master making unit.
Remove two mounting screws of the TPH position plate [E] from the TPH ass'y [D].
A:TPH connector
B:Ground wire
C:TPH ass'y screw
D:TPH ass'y
E:TPH position plate
Precautions in Removal
> Do not touch the Connector pins [A] on the TPH ass'y [D], as static electricity may damage the
TPH ass'y [D].
> Do not contact the heat emitting portion of the TPH ass'y [D] against hard surfaces.

> Thermal power adjustment of the TPH must be done when replacing the TPH ass'y.
14 - 8

3. TPH Position Sensor

1.
2.
3.
4.
5.
6.
7.

Open the Master making unit [D].
Remove the Springs [A] from the Master making unit [D].
Remove the the Master making upper unit cover [B].
Remove the Position sensor plate [C].
Remove the connector of the TPH position sensor [E].
Remove the TPH position sensor [E] from the Master making unit [D].
A: Spring
B: Master making upper unit cover
C: Position sensor plate
D: Master making unit
E: TPH position sensor
14 - 9
MEMO
14 - 10

ADJUSTMENT
3. Adjustment
1. Thermal Power of Thermal Print Head
Thermal power must be adjusted each time the Thermal print head is replaced.
1. Disconnect the power supply from the machine.(unpluge the power cable)
3. Connect a Voltmeter to No.1 and No.3 pins of the connector CN008 of the Power supply PCB.
4. Connect the power cable back to the machine.
5. Set up Test mode No.51. (refer to page APX(2)-1)
6. Press "Start" button to enable the TPH power supply.
7. Check to see that the Voltage reading on the Voltmeter equals to the voltage setting on the chart
)
shown in the next page for the new Thermal print head on the machine with the new resistance (
setting.
) of the new TPH is found printed on a seal attached on the TPH itself.
The resistance (
8. If the voltage on the Voltmeter does not match with the voltage on the chart in the next page, turn
the Volume adjust knob, of which can be seen throgh the protection cover of the Power suplly
PCB until the corect voltage reading is obtained on the Voltmeter.
9. TPH voltage can be adjusted by the VR named "NORMAL Adj." (lower position) & "FINE Adj."
(upper position).
Firstly adjust the TPH voltage by the NORMAL Adj. VR and precise adjustment can be done by
FINE Adj. VR.
10. After the adjustment is done, exit from the Test mode.
Power supply PCB

No.1 pin
No.3 pin
CN008
FINE Adj. VR
NORMAL Adj. VR
* TPH Adjustment Table is the next page
14 - 11

ADJUSTMENT
TPH Adjustment Table

KS 500 / 500C
)
Resistance (
1360 ~ 1373
1374 ~ 1390
1391 ~ 1407
1408 ~ 1424
1425 ~ 1442
1443 ~ 1459
1460 ~ 1477
1478 ~ 1494
1495 ~ 1512
1513 ~ 1530
1531 ~ 1548
1549 ~ 1566
1567 ~ 1584
1585 ~ 1603
1604 ~ 1621
1622 ~ 1640
1641 ~ 1658
1659 ~ 1677
1678 ~ 1696
All KS Models
)
Resistance (
1697 ~ 1715
1716 ~ 1734
1735 ~ 1753
1754 ~ 1772
1773 ~ 1792
1793 ~ 1811
1812 ~ 1831
1832 ~ 1840
Voltage (V)
16.1
16.2
16.3
16.4
16.5
16.6
16.7
16.8
16.9
17.0
17.1
17.2
17.3
17.4
17.5
17.6
17.7
17.8
17.9
Voltage (V)
18.0
18.1
18.2
18.3
18.4
18.5
18.6
18.7
Caution in Adjustment
> The new Thermal print head must be installed before making above adjustment.
> All four Thermal power safety switches (page 14-5) must be pressed to get the correct
voltage reading on the Voltmeter.

> If the voltage is too High:
The solid print image will be deformed and the heating elements of the Thermal print head will
be damaged from overheat.
> If the voltage is too Low:
The heat from the Thermal print head becomes too weak and the thin lines cannot be
reproduced clearly.
14 - 12
CHAPTER
15:
MASTER CLAMP/LOADING SECTION
CONTENTS
1. Master Making Unit Set Mechanism ...................................................................... 1
2. Master Positioning Mechanism .............................................................................. 2
3. Master Feeding Mechanism ................................................................................... 4
4. Clamp Plate Master Clamp Mechanism ................................................................. 6
5. Master Loading on the Drum Mechanism ............................................................... 8
6. Master Advance after Master Cutting ................................................................... 10
1. Master Making Unit .............................................................................................. 13
2. Master Making Unit Set Switch ............................................................................ 15
3. Write Pulse Motor ................................................................................................ 16
4. Master Positioning Sensor ................................................................................... 17
5. Master Loading Solenoid ..................................................................................... 18
6. Master End Sensor .............................................................................................. 19
MASTER CLAMP & LOADING SECTION

1. Master Making Unit Set Mechanism
> When the Master making unit is closed, the Master making unit safety switch [A] is also
pressed by the Master making unit upper frame [B].
When the Master making unit safety switch [B] is not pressed, the power to the Main motor
and TPH is terminated.
2. Master End Sensor
> The Master end sensor [C] detects the black strip on the master material at the very end of the
master roll and indicates the "Replace master roll" message, [C 6].
A:Master making unit safety switch

B:Master making unit upper frame
C:Master end sensor
15 - 1

2. Master Positioning Mechanism

1. Master Positioning
> The leading edge of the master material [A] rests against the Master tension plate [C] just after
the master loading.
> As the STA RT button is pressed for normal master making or confidential master making, the
Master loading solenoid [F] activates to release the Mater tension plate [C] from master and the
Write pulse motor [E] activates and rotates the Write roller [B] to feed the master material [A].
> When the Master positioning sensor [D] detects the leading edge of the master [A], the
Master loading solenoid [F] and the Write pulse motor [E] turn OFF and completes the master
positioning movement.
A:Lead edge of the master

B:Write roller
C:Master tension plate
D:Master positioning sensor
E:Write pulse motor
F:Master loading solenoid
15 - 2

Master Positioning Timing Chart

End of movement
Press STA RT button

Master positioning
sensor
Detecting master
2
Write pulse motor
max. 5 seconds
Master Loading
Solenoid
188
pulse
1 The Master loading solenoid activates to release the Master tension plate from the master. At the same
time, the White pulse motor activates to feed the lead edge of the master.
2 If the light of Master positioning sensor is not reflected back (no master detection) within 5 seconds
after the activation of the Write pulse motor, the machine assumes master mis-feed has occurred and
indicates the message [J 4].
C
B
A
E
D
A:Master roll
B:Thermal print head
C:Cutter
D:Write roller
E:Master positioning sensor
15 - 3

3. Master Feeding Mechanism

1. Start of Master Feeding
> At the Drum position-A, the Write pulse motor activate to rotates the Write roller to feed the
master material [A].
> The Master loading solenoid activates when the lead edge of the master [A] is fed onto the Mater
positioning sensor or the Clamp plate.
2. End of Master Feeding
> The Write pulse motor turns OFF when the rotation of the Write pulse motor becomes 389
pulses and completes the master feeding operation.
The leading edge of the master [A] rests under the Clamp plate [B].
A:Master material
B:Clamp plate
15 - 4

Master Feeding Timing Chart
ON
Main motor
Clamp plate
close
Clamp plate
starts to open
OFF
Blocked
Position-A sensor
ON
ON
Clamp motor
2
389 pulses
(32.4mm)
Write pulse motor
Clamp sensor C
Blocked
Open
1
10 sec.
Clamp sensor L
Blocked
Open
10 sec.
1 If the light path of the Clamp sensor L does not becomes blocked and the Clamp sensor C does not
becomes open, the machine assumes that the Clamp motor did not activate or Clamp sensor L or C has
been damaged and [E 3] is indicated.
2 The Write pulse motor is activated when the Clamp plate opens and the Clamp motor stops.
The master is then carried 389 pulses (32.4 mm) towards the Drum, until the leading edge of the master
is under the Clamp plate.
3 If the light path of the Clamp sensor L does not becomes open, the machine assumes that the Clamp
motor did not activate or Clamp sensor L has been damaged and [E 3] is indicated.
DRUM
Position-A
F
A:Master roll
C:Cutter unit
D:Master positioning sensor
E:Clamp plate
F:Write roller
G:Master material
15 - 5

4. Clamp Plate Master Clamp Mechanism

1. Master removal
> During the master removal movement, when the Drum comes back to position-A, the leading
edge of the new master comes towards the Drum, ready to be clamped.
2. Master clamping
> W ith the activation of the Clamp motor, the Clamp plate arm [G] is pushed down to open the
Clamp plate [C]. The Clamp plate arm [G] and the Master projection plate arm [E] are moved by
following the Clamp cam [B].
> The Clamp motor stops when the light path of Clamp sensor C [D] becomes open and keeps
the Clamp plate [C] raised open.
> When the Write pulse motor sends certain set amount of master [H] onto the Drum, the Clamp
motor activates to raise the Clamp plate arm [G] and close the Clamp plate [C].
> The Clamp motor turns off when the light paths of both the Clamp sensors L [F] and C [D]
becomes open.
F
The Clamp unit is back at the Home position.
B
G
Sends master
D
A
E
A:Clamp encoder disc

B:Clamp cam ass'y
C:Clamp plate
D:Clamp sensor C
E:M-Projection plate arm
F:Clamp sensor L
G:Clamp plate arm
H:Master
15 - 6

Master Clamping Timing Chart

Motion ends
Motion starts
Clamp sensor C
Blocked
1
Open
10 sec.
10 sec.
Blocked
Clamp sensor L
Open
2
ON
ON
3
Clamp motor
1 If the light path of the Clamp sensor C is not opened within 10 seconds after the Clamp motor is
2 If the light path of the Clamp sensor L is not blocked within 10 seconds after the Clamp motor is
3 The Drum waits for the master with the Clamp plate opened.
4 The Clamp motor activates to clamp the master with the Clamp plate when the master loading to the
drum is completed.
5 If the light path of the Clamp sensorL is not opened within 10 seconds after the Clamp motor is
15 - 7

5. Master Loading on the Drum Mechanism

As the Write pulse motor activates for a certain set time after the Clamp plate clamps the master,
the Main motor activates to load the master on the Drum.
1. Drum angle 134
> During the master loading, when the Drum comes to 134 , the Master sensor checks for any
master loading error.
> The Write pulse motor keeps feeding the master, and if no master loading is detected, the
Main motor starts to rotate again.
2. Master cutting
> The Cutter unit cuts the master when the Drum comes to at 292 .
> The Main motor keeps rotating and loads the remaining length of master on the Drum while
making one proof print.
Master Loading Movement

B
1. After the master is clamped on the

Drum and Write pulse motor rotates
for a set amount, the Drum rotates to
start the master loading.
Position
A
134
2. The Drum position at 134 , the Master

sensor [G] checks for any master
loading error while the Write pulse
motor keeps feeding the master.
D
E
3. Cutter motor activates to cut the

master at the Drum posiotion 292 .
292
F
A:Clamp plate
B:Drum
C:TPH
D:Write roller
E:Master roll
F:Cutter unit
G:Master sensor
15 - 8

Master Loading Timing Chart
134
292
Drum angle
Position-A sensor
Detecting
OFF
Not Detecting
ON
1.95 rpm
Main motor
Clamp motor
ON
180ms
OFF
5mm
OFF
4854 pulses
Write pulse motor

ON
3
Master counter
count signal
ON
OFF
Cutter motor
Master sensor
Not detecting master
Detecting master
1. The Write pulse motor activates after 180ms when the Clamp motor goes off.
2. The Whrite pulse motor keeps going the activation to feed the master until 4854 pulses is counted.
3. The Master sensor checks the master on the Drum at the drum position 134 degrees.
If the Master sensor detects the master, the Master counter adds the one count.
If not, the machine assums that master loading miss occurred and [J 5] is displays.
4. The Drum stops at the durm position 292 degrees to cut the master.
The Drum restarts the rotating to complete the master feeding on the drum.
15 - 11

6. Master Advance after Master Cutting

If the master cutting is confirmed by the Master positioning sensor [E] after the master cutting, the
master material from the master roll is moved forward until the leading edge is under the Master
positioning sensor [E].
1. Write Pulse Motor
> After the master is cut, the Write pulse motor [C] rotates to move the master material forward.
> The Write pulse motor [C] activates for 5 seconds as its maximam time, by which time the
leading edge of the master material is under the Master positioning sensor [E].
E
B
D
A:Master roll
B:Themal Print head
C:Write pulse motor
D:Write roller
15 - 10

Master Advance after Master Cutting Timing Chart
ON
Cutter motor
Master advance
movement starts
OFF
Position A
Master positioning
sensor
188
pulses
Not detecting master
2
Write pulse motor
OFF
Detecting master
ON
max 5 sec.
ON
3
Master loading
solenoid
OFF
1. The Drum comes back to the position -A after the master cutting is done if the Master positioning sensor
[E] detects the master material (master is not cut), the machine assums that master cut miss occcurred
and [J 6] is indicated.
2. If the Master poitioning sensor [E] does not detecte the master within 5 seconds, the machine assums
that Master mis-feed occurred and indicates error message [J 4].
3. The Write pulse motor and the Master loading solenoid strat their activation at the same time to proceed
the master advance operation.
4. The master advance movement ends when the Write pulse motor rotates 188 pulses.(16mm)
Then the leading edge of the master material stops under the Master positioning sensor [E].
B
E
A
A:Master roll
C:Cutter Unit
D:Write roller
15 - 11
MEMO
15 - 12


1. Master Making Unit
2. Slide the Master removal unit.
3. Remove the Back cover, Front cover. (See page 1-5)
4. Remove the Cutter unit [F]. (See page 13-5)
5. Disconnect following wire harnesses on the Main PCB [D] (See page 8-6) and the Power supply
PCB [C] (See page 8-6) from the Master making unit;
>CN108, CN107, CN106, CN101 on Main PCB [D]
>CN003, CN004, CN005 on Power supply PCB [C]
6. Disconnect conenctor of the Master making unit safety switch.
7. Remove the mounting screws [A] from the Mater making unit.
8. Disengage the hook of the Mater making unit [B] from the shaft then remove the Master making
unit [E] from the machine.
(continues on page 15-14)
A
C
A:Mounting screw
B:Hook
C:Powe supply PCB
D:Main PCB
E:Master making unit
F:Cutter unit
15 - 13

> Hook the Master making unit on under the catch on the machine frame.
> Match the half-pierced section of the Cutter unit [F] with its counter part.
Cutter unit removal

F
15 - 14


1.
2.
3.
4.

Remove the Master making unit [B](See page 15-13).
Disconnect the Connector of the Master making unit safety switch [A].
Remove two mounting screws of the Master making unit safety switch [A] and remove the switch.
A:Master making unit safety switch

B:Master making unit
15 - 15

3. Write Pulse Motor

1.
2.
3.
4.

Remove Master making unit. (See page 15-13)
Disconnect the Connector of the Write pulse motor [A].
Remove two mounting screws of the Write pulse motor [A] and remove the motor.
> Keep the certain backlash between the moter gear [B] and the drive gear [C] when install the
motor [A] in the Master making unit.
A:Write pulse motor

B:Motor gear
C:Drive gear
15 - 16

4. Master Positioning Sensor

2. Remove the Master making unit. (See page 15-13)
3. Cut off the Wire clamppers [D] of the Master positioning sensor wire.
4. Disconnect the connecter of the Master positioning sensor [A].
5. Remove both side of E-rings from the Master tension shaft [B] then remove the shaft.
6. Remove the Cutter guide plate [C].
7. Remove the mounting screw of the Master positioning sensor [A] and remove the sensor from the
Cutter guide plate [C].
C
B
C
A:Master positioning sensor

B:Master tension shaft
C:Cutter guide plate
D:Master feed sheet
E:Wire clampper
A
>Do not apply any damages to the Master feed sheets [D] to prevent master jam.
> Place the Master feed sheets [D] under the Cutter guide plate [C].
15 - 17

5. Master Loading Solenoid

1.
2.
3.
4.

Remove the Master making unit.[B] (See page 15-13)
Disconnect the Connector of the Master loading solenoid [A].
Remove two mounting screws of the Master loading solenoid [A] and remove the solenoid from the
Master making unit [B].
A:Master loading solenoid

A
15 - 18

6. Master End Sensor

1.
2.
3.
4.

Remove the Master making unit [B]. (See page 15-13)
Open the Master making unit and remove the master roll.
Disconnect the Connector of the Master end sensor and remove the sensor from the sensor
bracket on the machine.
> Do not damage the hooks of the Master end sensor when install the sensor to the sensor
bracket on the machine.
Hooks
A:Master end sensor

B
15 - 19
APPENDIX
CONTENTS
Electrical Components
1. Sensors .....................................................................................................
2. Switches ....................................................................................................
3. Clutches & Solenoids ................................................................................
4. Motors & Fan .............................................................................................
Test Mode
1. Operation Procedures ................................................................................
2. Test Items and Operations .........................................................................
Users Mode
1. Operation Procedures & Items ...................................................................
Advice Displays (Call Service Messages)
1. Display Messages .....................................................................................
Description of PCBs
1. Block Chart ................................................................................................
2. Location of PCBs .......................................................................................
3. Main PCB ..................................................................................................
4. Power Supply PCB ....................................................................................
5. Ink sensor PCB .........................................................................................
APX(0)-1
APX(0)-2
APX(0)-3
APX(0)-4
APX(1)-1
APX(1)-3
APX(2)-1
APX(3)-1
APX(4)-1
APX(4)-2
APX(4)-3
APX(4)-4
APX(4)-5
APPENDIX (0)
ELECTRICAL COMPONENTS
Electrical Components
1. Sensors
A
H
B
E
I
J
A:Master positioning sensor
B:Original IN sensor
C:TPH position sensor
D:Paper receiving sensor
E:Master end sensor
F:Main motor encoder
G:Clamp sensor L
H:Clamp sensor C
I:Master removal sensor
J:Master sensor
K:Overflow sensor
L:Ink sensor
M:Ink bottle Set sensor
N:Position-A sensor
O:Master disposal box set sensor
M
K
APX(0) - 1
APPENDIX (0)
2. Switches
A
A:Master removal unit safety switch

B:Guide plate safety switch
C:Main power switch
D:Master making unit safety switch
E:Separation base safety switch
APX(0) - 2
APPENDIX (0)
3. Clutches & Solenoids
A:Master loading solenoid

B:Master removal clutch
C:Paper feed clutch
D:Timing clutch
APX(0) - 3
APPENDIX (0)
4. Motors & Fan
B
F
C
G
D
A:Cutter motor
B:Read pulse motor
C:Separation fan
D:Suction fan
E:Write pulse motor
F:Clamp motor
G:Main motor
H:Ink motor
APX(0) - 4
APPENDIX (1)
TEST MODE
Test Mode
1. Operation Procedures
The Test mode program enables a service technician to check the operation of each electrical
component in the machine.
1. [Starting Up Test Mode]
Turn ON the power while pressing the PRINT POSITION buttons
and
on the machine
operation panel.
If the Test mode is activated, the following indication will be displayed in the print quantity display.
The display shows the version number of the System ROM.
- This is a sample of the initial condition of Test mode:
10 1
System ROM
Version No.
(Ver. 1.01)
2. [Checking the Operation of a Component]

To check the operation of a component, select a test No. using panel keys.
[Example] - In selecting Test No.12 (Paper receiving sensor).
12
Test No.
Test Mode status
0 for OFF status
1 for ON status
Press the "START" button to start the test.
12
Press the "START" button again to stop the test.
12
If the test is a one-cycle operation test, it will automatically stop after one check.
If the test is a non-cycle operation test, pressing the "START" button will stop the test.
3. [Selecting Another Test Number]

To select another Test No., clear the set Test No. by pressing the "C" or "STOP" button and
select another Test No.
The previous Test No. is erased.
00
35
Select a new Test No. (Example: No.35)
APX(1) - 1
APPENDIX (1)
TEST MODE
4. [Exiting from the Test Mode]

To exit from a Test mode, clear the set Test No. by pressing the "C" or "STOP" button and then
press the "ALL RESET" button for 1 second.
The Test No. is cleared by "C" or "STOP".
00
0
Press "ALL RESET" button for 1 second.
5. [Operating the Adjustment mode] (Test Mode No. 80 ~ 87)

Start up the Test mode and select the Test mode No. and press "START" button.
flashes
[Example] - In selecting Test mode No.80.
Select 80 and then press "START".
80
Test mode No.
Test Mode status
0 for OFF status
1 for ON status
Use the PRINT POSITION button
or
to make the setting selection.
[Example] - In selecting "3" for the setting, press the

display window.
button until "3" flashes in the first
The selectable settings are:

-3-2,-1,0, 1, 2, 3
Press the "START" button to input the newly selected setting.
Press "ALL RESET" button for 1 second.
00
0
CAUTION:
>Test Mode No.98 resets all the Adjustment selections made on the machine back to "0".
>Test Mode No.99 resets all the Adjustment selections made on the machine back to "0".
Refer to page APX(1)-7 for detail on the above.
APX(1) - 2
APPENDIX (1)
TEST MODE
2. Test Items and Operations

1) Sensor/SW Test
A beep sounds in two ways to tell the current condition. (except No.28)
Detection:
0.1 second interval beep
No detection:
0.5 second interval beep
No.
Test Component
Detection status
Original IN sensor
Reflected light is detected
Master sensor
Master positioning sensor
Master end sensor
TPH position sensor
Light path is blocked
Cutter home position switch
Actuator is pressed
Cutter end position switch
Actuator is pressed
Clamp sensor L
Clamp sensor C
10
Master removal sensor
Actuator is pressed
11
Position-A sensor
12
Paper receiving sensor
13
Ink sensor
Ink is detected
14
Overflow sensor
Ink is detected
15
Separation unit safety SW
Actuator is pressed
16
Master making unit safety SW
Actuator is pressed
17
Master removal unit safety SW
Actuator is pressed
18
Ink Bottle set sensor
Light path is detected
19
Not available
20
Not available
21
Not available
22
Not available
23
Not available
24
Not available
25
Not available
26
Not available
27
Master disposal box set sensor
28
TPH thermister reading
The numbers are displaied on

the print quantity display as
centigrade scale.
29
Not available
APX(1) - 3
APPENDIX (1)
TEST MODE
2) Motor/Solenoid Test
Use "START" button for ON/OFF control.
No.
Test Component
30
Main motor (1.95 rpm)
31
Main motor (10 rpm)
32
Main motor (30 rpm)
33
Main motor (45 rpm)
34
Main motor (60rpm)
35
Main motor (90 rpm)
36
Not available
All the Safety switches must

be pressed and the Drum
must be set in the machine.
37
Read pulse motor ( forward )
38
Read pulse motor ( reverse )
39
Write pulse motor (forward)
40
Write pulse motor (reverse)
41
Master loading solenoid
42
Clamp motor
43
Not available
44
Master removal clutch
45
Paper feed clutch
46
Timing clutch
47
Ink motor
48
Suction fan
49
Separation fan
50
Image scanner LED
51
TPH control signal
52
Not available
APX(1) - 4
APPENDIX (1)
TEST MODE
3) TPH Heating power/ Life counter display etc.

Press "START" button to enable the functions.
No.
Clear Items
53
TPH Heating power selection

TPH heating time can be changed to suit the amount of ink from the drum to the
paper color. The selection range is from 0 to 2.
For the adjustment, use the Print position button
or
to make the
setting.
0: Chinese papers / Thin papers
1: Chinese papers / Thick papers
2: White color paper
54
55
Not available
Life counter display
Total counter (from machine set up) is displayed on the panel.
56
Not available
57
Not available
58
Not available
59
Not available
APX(1) - 5
APPENDIX (1)
TEST MODE
4) Unit check mode etc.

Use "START" button for ON/OFF control.
No.
Test Item
60
TPH move down

Activate the TPH pressure motor until the light path of the TPH position sensor
from "blocked" to "unblocked".
61
TPH move up
Activate the TPH pressure motor until the light path of the TPH position sensor
from "unblocked" to "blocked".
62
Cutter Home Positioning

Cutter motor activates to move the cutter until the Cutter home sensor detects the Cutter if
the Cutter home sensor does not detect the Cutter.
63
Cutter motor ON (One-cut operation)

Cutter motor ON Cutter end sensor ON
Cutter HP sensor ON
64
Clamp arms Home potisioning ( Clamp motor operation)

If the Clamp sensor L,C is not opened, the Clamp motor activates till the clamp
home position. (both light path of the Clamp sensor L & C "Opened")
65
Clamp plate Open/Close operation

Open and close the clamp plate ( master clamp action ).
66
Clamp plate Open/Close operation

Open and close the clamp plate ( master release action ).
67
Inking operation
If ink sensor is not detect ink inside the Squeegee roller, confidential master is made on
the drum. Then starting inking and printing.
68
Panel LED check

All panel LED light ON.
Drum position A
Drum rotation to the position-A.
Master making operation test
Master making operation is available.
Master removal operation test
Master removal operation is available.
Confidential operation test
Confidential operation is available.
Paper feed & Printing operation (30 rpm)
Printing with the drum speed 30 rpm is available.
Paper feed & Printing operation (90 rpm)
Printing with the drum speed 90 rpm is available.
Thermal print head check operation 1
Makes a master of test pattern #1 memorized in the main PCB.(within the spec. area)
Thermal print head check operation 2
Makes a master of test pattern #1 memorized in the main PCB.(full range of the master)
Drum angle is displayed on the panel.
Drum angle is displaied each drum angle while keep pressing the Start button.
69
70
71
72
73
74
75
76
77
APX(1) - 6
APPENDIX (1)
TEST MODE
5) Adjustment mode etc.
The following items can be reprogrammed to make fine adjustments in Image scanning and
Master making.
Use the Print position button
or
to make the setting.
Amount in (+) indicates shift to the LEFT, and (-) indicates shift to the RIGHT.
No.
Test Item
80
Paper feed clutch 60 rpm

Paper feed clutch ON timing setting.
81
82
83
84
SW setting
-4
-3
-2
-1
Amount (mm)
-4
-3
-2
-1

Paper feed clutch OFF timing setting.
SW setting
-4
-3
-2
-1
Amount (mm)
-4
-3
-2
-1

Paper feed clutch ON timing setting.
SW setting
-4
-3
-2
-1
Amount (mm)
-4
-3
-2
-1

Paper feed clutch OFF timing setting.
SW setting
-4
-3
-2
-1
Amount (mm)
-4
-3
-2
-1
Second Paper feed clutch ON timing (60 rpm)

SW setting
Amount (mm)
-7
-7
-6
-6
-5
-5
-4
-4
-3
-3
-2
-2
-1
-1
SW setting
1
1
2
2
3
3
4
4
5
5
6
6
7
7
Amount (mm)
85
0
0
Second Paper feed clutch OFF timing (60 rpm)

SW setting
Amount (mm)
-7
-7
-6
-6
-5
-5
-4
-4
-3
-3
-2
-2
-1
-1
SW setting
1
1
2
2
3
3
4
4
5
5
6
6
7
7
Amount (mm)
APX(1) - 7
0
0
APPENDIX (1)
TEST MODE
Use the PRINT POSITION button

or
to make the setting selection.
Amount in (+) indicates shift to the LEFT, and (-) indicates shift to the RIGHT.
No.
86
Test Item
Timing clutch ON timing (90 rpm)
SW setting
Amount (mm)
-7
-7
-6
-6
-5
-5
-4
-4
-3
-3
-2
-2
-1
-1
SW setting
1
1
2
2
3
3
4
4
5
5
6
6
7
7
Amount (mm)
87
Timing clutch OFF timing (90 rpm)

SW setting
Amount (mm)
-7
-7
-6
-6
-5
-5
-4
-4
-3
-3
-2
-2
-1
-1
SW setting
1
1
2
2
3
3
4
4
5
5
6
6
7
7
Amount (mm)
88
89
90
0
0
0
0
Not available
Image elongation and shurikage in image scanning
SW setting
Amount (mm)
-2
-1
-1
-0.5
0
0
1
0
2
1
3
1.5
4
2
5
2.5
SW setting
Amount (mm)
6
3
7
3.5
8
4
9
4.5
10
5
11
5.5
12
6
13
6.5
Shading compensation
ON
OFF
1
0
91
Shading compensation (White side only)

This adjustment is for the factory use only and the result of the adjustment is not effect
to the image processing.
92
Slice lebel adjustment (Line mode only) The defult number is 3

Image light
0
1
Image dark
6
7
93
Not available
94
Print position & Image shrinkagage / elongation checking

Making horizental line at 10mm from the master making position and at 280mm from the
first horizental line.
95
Not available
APX(1) - 8
APPENDIX (1)
TEST MODE
Press the Start key to enable the Test mode and make the setting selection by pressing the Print
position key
or .
No.
96
Test Item
Master removal count
Master removal count is displayed on the panel.
97
Clearing the count of the Main counter in the memory

The master count and copy count in the memory will be cleared by pressing [C] key
after the Test mode is enabled.
[Prohibit of the Main counter clear]
After input the No.97, press Start key. If the panel indication is [1], chage the indication
from [1] to [0] by press the Print position button then press the Start key.
Thus the Main counter clear function is prohibited.
Press the Stop key instead of the Start key to escape from the clear prohibit mode.
98
Clearing EEP ROM

All memory will be cleared except the Master count, Copy count and the Main counter
clear prohibit mode in Test No.97
99
Initiarizing EEP ROM

Inkless timer, Master count, Copy count, Master removal count will not be initiarized.
APX(1) - 9
MEMO
APX(1) - 10
APPENDIX (2)
USERS MODE
Users Mode
1. Operation Procedures
The users mode program enables a machine operator to get some special functions of the machine.
This mode is explained in "User's Guide" and is intended for customers to make a selection if
required
1. [Starting Up Users Mode]
Turn ON the power.
Press " " key on the Control Panel.
This makes access to the User mode.
2. [Making Selections]
After the access is made, select the item(s). If pressing [1] and then [Start] key, the first item
appears on the display as shown below.
U - 1
If another item is desired, select it using the print quantity keys.
In case of selecting item No.02, press "*" and then "2". The display changes as shown below.
U - 2
Now choose either of the two initial settings for the selected item.
The selection is made by pressing the "START" button.
Repeat this procedure until all required changes are made.
To exit from this mode, press the "ALL RESET" button for 1 second.
All new initial settings are memorized and the display returns to normal operation.
Item No.
Contents
Copy counter
Displaying the Copy counter on the print quantity display.
Master counter
Displaying the Master counter on the print quantity display.
Avarage copy counter Displaying the avarage copy count per master.
Confidential mode
Remove the master on the drum then put the new master on
the drum.
Newspaper mode
Removing unwanted background of the original such as

newspaper to obtain the clear image of the printouts.
APX(2) - 1
MEMO
APX(2) - 2
APPENDIX (3)
ADVICE DISPLAYS
Advice Displays (Call Service Messages)

No.
Display Condition
E1
Main Motor Lock

If excessive current is detected 0.3 seconds consecutively after
the Main motor is activated.
If no Encoder sensor output after Main motor is activated.
E3
Resetting Method
Clamp Motor Lock

[During Clamp Motor Initial Positioning]
If the light path of the Clamp senors both C and L are not opened
within 10 seconds after after the Clamp motor is activated.
[During Master Release from the Clamp Plate]
If the light path of the Clamp sensor L is not blocked within 10
seconds after the Clamp motor is activated.
If the light path of the Clamp sensor C is not opened within 10
[When the Clamp Plate opens during Master Clamping]
If the light path of the Clamp sensor L is not blocked within 10
If the light path of the Clamp sensor C is not opened within 10
[When the Clamp Plate closes during Master Clamping]
If the light path of the Clamp sensor L is not opened within 10
Turn Power SW
OFF & ON.
Use test mode.
E4
Ink Overflow
If the Overflow sensor detects excessive ink in the Squeegee unit.
Remove excess ink

from the Drum.
E6
Position-A Sensor Malfunction

If Position-A sensor cannot be detected (or keeps detecting) even
though the Main motor encoder sensor signal is making the output
after the Main motor is activated.
Turn Power SW
OFF & ON.
E13
Cutter motor Lock

If the Cutter home position switch is not turned OFF within 500 ms
after the Cutter motor is activated.
If the Cutter end position switch is not pressed within 2000 ms after
the Cutter motor is activated.
Use test mode.
E16
Inking Motor Lock

If excessive current is detected 2.5 seconds consecutively after the
Inking motor is activated.
Turn Power SW
OFF & ON.
E19
TPH pressure error

[During TPH Up Positioning]
If the light path of the TPH pressure sensor is not opened within 10
seconds after the Write pulse motor is activated.
Turn Power SW
OFF & ON.
[During TPH Down Positioning]

If the light path of the TPH pressure sensor is not blocked within 10
seconds after the Write pulse motor is activated.
APX(3) - 1
APPENDIX (3)
ADVICE DISPLAYS
Note: The Advice Display number with "( )" will be displayed while " " key is pressed.
No.
Display Condition
Resetting Method
J 1
No Master on the Drum

If the Master sensor does not find master on the Drum when the
Drum is at 134 during the printing movement.
Press ALL RESET

button.
J 2
Paper Jam in the Second Paper Feed Area

If the Paper receiving sensor does not find paper when the Drum is
at Position-334 and 104 the printing operation.
Press ALL RESET

button.
Remove the
jammed paper.
J 3
Paper Jam in the Paper Receiving Area

If the status of the Paper receiving sensor does not change from
detecting paper to not detecting from Drum angle 357 to 280 the
printing operation.
Press ALL RESET

button.
Remove the
jammed paper.
J 4
Master Loading Error

If the Master sensor does not detect the master (light not reflected)
within 5 seconds.
J 5
Master Loading Error (onto the Drum)

If the Master sensor does not detect the master (light not reflected)
during the master loading when the Drum is at 134 from the
position-A.
J 6
Master Cut Malfunction

If the Master positioning sensor is still detecting the master (light
reflected back) when the Drum is at position-A after the cutting.
J 7
Original Jam at Entrance

During the Original scanning, if the Original IN sensor does not
detecting within 5 second after the Read pulse motor activates.
J 8
Original Jam
During the Original set movement, if the Original IN sensor still
detecting Original (sensor light reflected) the master making
movement.
J 9
Master Removal Error

In case the Master removal sensor does not detect the removed
master (light path opened) at Drum 134 from the Position -A during
the master removal even though a master was detected on the Drum
before the master removal operation.
J 10
Removed Master Jammed at the Master removal area

If the Master removal sensor is detecting the removed master (light
path blocked) even though the Drum has returned to the position-A
after the master removal process.
APX(3) - 2
Master making unit

safety SW OFF &
ON.
Master making unit
safety SW OFF &
ON.
Original IN sensor
OFF & ON.
Remove the
jammed master.
Master removal
sensor OFF
Remove the
jammed master.
APPENDIX (3)
ADVICE DISPLAYS
Note: The Advice Display number with "( )" will be displayed while " " key is pressed.
No.
Display Condition
Resetting Method
C 1
Close Separation fan unit

If the actuator of the Separation base unit safety switch is not
depressed.
Close the separation

fan unit.
C 2
Close Master Making Unit

If the actuator of the Master making unit safety switch is not
depressed.
Close the Master

making unit.
C 3
Close Master Removal Unit

If the actuator of the Master removal unit safety switch is not
depressed.
Close the Master

removal unit.
C 4
Set master disposal box.

If the master disposal box set sensor does not detect.
Set the Master

disposal box.
C 5
Set Ink bottle in Place

If the Ink bottle set sensor does not detect the Ink bottle.
Set the Ink bottle in

the Drum.
C 6
Replace Master Roll

If the black tape attached at the end of the Master roll has been
detected by the Master end sensor during master making or
confidential operation.
Master making unit

safety SW OFF &
ON.
Replace the
depleted Master
roll with a new
one.
C 7
Empty Disposal Box

If the Master removal 5 times.
Master disposal boxl

set sensor OFF &
5 seconds later ON.
Empty the
disposal box.
C 8
Replace Ink bottle

If the Ink sensor does not detect ink in the Squeegee unit within 20
seconds after the Inking motor was activated.
If the Ink sensor does not detect ink in the Squeegee unit within 40
seconds after the Inking motor was activated when the Ink bottle is
installed just after replacing empty ink bottle.
Ink bottle set sensor

OFF & 5 seconds
later ON.
APX(3) - 3

Riso KS 500 Service Manual

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Riso KS 500 Service Manual

Caricato da

Copyright:

Formati disponibili

SERIES

RISO INTERNATIONAL GROUP

RISO FRANCE (FRANCE)

KS Series (Version 1.2)

KS Series (Version 1.2)

CHAPTER 8: DRUM SECTION

KS Series (Version 1.2)

CHAPTER 11: MASTER REMOVAL SECTION

KS Series (Version 1.2)

CHAPTER 14: MASTER MAKING SECTION

KS Series (Version 1.2)

KS Series (Version 1.2)

KS Series (Version 1.2)

[ RISO Kagaku Corp.]

KS Series (Version 1.2)

[Replacement of the Lithium Battery]

KS Series (Version 1.2)

I. Protection of the machine:

2. Always connect electrical connectors firmly.

To avoid electrical failure:

I. Protection of the electrical components:

Press the ends.

Press the center, firmly.

KS Series (Version 1.2)

Assembly and installation

Replace mount screws

KS Series (Version 1.2)

Electrical system work

Wiring bundle band

3. Exterior Cover Removal

KS Series (Version 1.2)

KS Series (Version 1.2)

KS Series (Version 1.2)

Automatic digital scanning

Time to First Copy

60 seconds (A4 or B4 original)

2 selectable print speeds (60, 90 sheets/min.)

200 x 300 dpi

KS500 Max. 257 x 394mm or B4

Max. 273 x 394mm

Max. 107 g/m2

KS500 Max. 80 g/m2

Max. 273 x 394mm

KS500C Max. 70 g/m2

In use / 1200 x 650 x 470mm

220 to 240 VAC, 50/60 Hz <1.5A-2.0A>

Print speed control, Confidential mode, Photo processing mode,

KS Series (Version 1.2)

2. Cross Sectional Diagram

Thermal print head

Master disposal box

1 First Paper Feed Area:

2 Second Paper Feed Area:

4 Paper Ejection Area:

Separates a printed paper from the Drum, and transports it onto

Supplies the Drum surface with ink from an Ink cartridge.

6 Master Clamp Area:

Clamps the leading edge of the master.

7 Master Disposal Area:

8 Image Scanning Area:

Carries an original and scans it with the Image scanner and

9 Master Making Area:

Makes a master with the Thermal print head.

10 Master Loading Area: