KS800 Series Version 3.1

VERSION 3.1February, 2004

TECHNICAL MANUAL

SERIES

RISO INTERNATIONAL GROUP

RISO KAGAKU CORPORATION (JAPAN) RISO DEUTSCHLAND GMBH (GERMANY)RISO, INC. (U.S.A.) RISO FRANCE (FRANCE)RISO EUROPE LIMITED (U.K.) RISO IBERICA (SPAIN)RISO HONG KONG (HONG KONG) RISO CANADA (CANADA)RISO UK (U.K.) ZHUHAI RISO TECHNOLOGY (CHINA)RISO THAILAND LIMITED (THAILAND) RISO AFRICA (SOUTH AFRICA)RISO KOREA LIMITED (KOREA) RISOGRAPH ITALIA (ITALY)

Copyright : 2004 Riso Kagaku CorporationAll Rights Reserved. This Technical Manual was prepared andwritten for the exclusive use of RISO International Group CertifiedDealers. Reproduction and/or transmittal of this material in anyform or by any means, including photocopying or recording of theinformation is strictly prohibited without the consent of a memberof RISO International Group.

( KS500 / KS600 / KS800 )

KS Series (Version 3.1)- 1 -

CONTENTS

CHAPTER 1: MAINTENANCE1. Preface ..................................................................................................................... 1

CAUTION .................................................................................................................. 2WARNING ................................................................................................................ 3

2. WORK PRECAUTIONS ............................................................................................ 43. Exterior Cover Removal

> Front cover ............................................................................................................. 6> Back cover ............................................................................................................. 6> Master removal cover ............................................................................................. 6

CHAPTER 2: MACHINE SUMMARY1. Specifications .......................................................................................................... 12. Cross Sectional Diagram ........................................................................................ 43. Machine Operations ................................................................................................ 54. Paper Feed and Receiving ...................................................................................... 65. Master Removal and Feed ...................................................................................... 76. Counter Indication .................................................................................................. 8

CHAPTER 3: MAIN DRIVE SECTION1. Theory of Operation

1. Main Drive ............................................................................................................. 12. Main Motor Safety Switches .................................................................................. 23. Drum Position ........................................................................................................ 34. Drum Rotation Lever ............................................................................................. 5

2. Removal and Assembly1. Main Motor Unit ..................................................................................................... 72. Master Removal Unit Safety Switch ...................................................................... 93. Master Making Unit Safety Switch ....................................................................... 104. Sparation Unit Safety Switch ............................................................................... 115. Paper Guide Plate Safety Switch ......................................................................... 126. Drum Rotation Lever ........................................................................................... 13

CHAPTER 4: FIRST PAPER FEED SECTION1. Theory of Operation

1. Paper Feed Tray Position ...................................................................................... 12. First Paper Feed Drive Mechanism ....................................................................... 23. Paper Pickup System ............................................................................................ 44. Paper Feed Pressure Select System..................................................................... 5

2. Removal and Assembly1. Paper Feed Tray Unit ............................................................................................ 62. Pickup Roller Assembly ......................................................................................... 73. Pickup Roller and PF Support Roller ..................................................................... 84. Stripper Pad .......................................................................................................... 95. Paper Feed Clutch .............................................................................................. 10

3. Adjustment1. Paper Feed Tray Pressure .................................................................................. 112. Paper Feed Tray Position Adjustment ................................................................. 133. Paper Feed Clutch ON Timing ............................................................................ 154. Paper Feed Clutch OFFTiming ........................................................................... 15


CHAPTER 5: SECOND PAPER FEED SECTION1. Theory of Operation

1. Second Paper Feed Drive Mechanism .................................................................. 12. Vertical Print Position ............................................................................................ 2

2. Removal and Assembly1. Load Spring ........................................................................................................... 32. Timing Clutch ........................................................................................................ 43. Paper Guide Plate ................................................................................................. 54. Paper Gate ............................................................................................................ 65. Timing Roller / Guide Roller .................................................................................. 7

3. Adjustment1. Print Position(Timing Clutch ON Timing) ............................................................... 8

CHAPTER 6: PRESS SECTION1. Theory of Operation

1. Press Mechanism.................................................................................................. 12. Removal and Assembly

1. Pressure Roller ..................................................................................................... 32. Pressure Lever Ass'y ............................................................................................ 43. Pressure Shaft Ass'y ............................................................................................. 5

3. Adjustment1. Pressure Lever Ass'y Position ............................................................................... 7

CHAPTER 7: PAPER EJECTION SECTION1. Theory of Operation

1. Paper Ejection Mechanism.................................................................................... 12. Paper Separation Mechanism ............................................................................... 3

2. Removal and Assembly1. Suction Unit ........................................................................................................... 52. Transfer Belt ......................................................................................................... 63. Suction Fan ........................................................................................................... 74. Separation Fan Unit .............................................................................................. 85. Separation Fan ...................................................................................................... 96. Paper Receiving Sensor ........................................................................................ 97. Separator ............................................................................................................ 108. Paper Receiving Tray .......................................................................................... 11

3. Adjustment1. Separator Position ............................................................................................... 13

CHAPTER 8: DRUM SECTION1. Theory of Operation

1. Master on Drum (in printing) Check Mechanism ................................................... 12. Ink Bottle Set Check Mechanism .......................................................................... 23. Ink Supply Mechanism .......................................................................................... 34. Squeegee Roller Rotation Mechanism .................................................................. 5

2. Removal and Assembly1. Drum Unit .............................................................................................................. 72. Screen ................................................................................................................... 83. Drum Body ............................................................................................................ 94. Ink sensor PCB ................................................................................................... 115. Ink Bottle Guide ................................................................................................... 12


6. Ink bottle set Sensor ............................................................................................ 127. Drum Support F & Drum Support R ..................................................................... 138. Squeegee Roller .................................................................................................. 149. Ink Pump Unit ...................................................................................................... 1710. Inking Motor ...................................................................................................... 18

3. Adjustment1. Squeegee Gap .................................................................................................... 19

CHAPTER 9: PAPER JAM1. Theory of Operation

1. Paper Jam at First Paper Feed Area ..................................................................... 12. Paper Jam at Paper Receiving Area ..................................................................... 23. Print Start Timing Chart ......................................................................................... 34. During the Printing Timing Chart ........................................................................... 45. Print Stop Timing Chart ......................................................................................... 5

CHAPTER 10: MASTER CLAMP SECTION1. Theory of Operation

1. Clamp Unit Positioning Mechanism ....................................................................... 12. Clamp Plate Master Release Mechanism ............................................................. 23. Clamp Plate Master Clamp Mechanism ................................................................ 4

2. Removal and Assembly1. Clamp Unit ............................................................................................................ 72. Clamp Motor .......................................................................................................... 83. Clamp Sensor C .................................................................................................... 84. Clamp Sensor L .................................................................................................... 8

CHAPTER 11: MASTER REMOVAL SECTION1. Theory of Operation

1. Master Removal Unit Mechanism.......................................................................... 12. Master on the Drum (before master removal) Check Mechanism ......................... 23. Clamp Plate Master Release Mechanism ............................................................. 44. Master Removal Mechanism ................................................................................. 65. Master Disposal Box Set Mechanism .................................................................... 8

2. Removal and Assembly1. Master Removal Unit ............................................................................................. 92. Master Removal Clutch ....................................................................................... 103. Master Removal Sensor ...................................................................................... 114. Disposal Box Set Sensor ..................................................................................... 115. Master Removal Hook ......................................................................................... 126. Vertical Transport Roller (Upper) ......................................................................... 137. Vertical Transport Roller (Lower) ......................................................................... 138. Master Removal Guide (Lower) ........................................................................... 13

CHAPTER 12: IMAGE SCANNING SECTION1. Theory of Operation

1. Original Loading Mechanism ................................................................................. 12. Original Scanning Mechanism ............................................................................... 33. Image Scanner ...................................................................................................... 5

2. Removal and Assembly1. White Roller .......................................................................................................... 72. Image Scanner Unit .............................................................................................. 8


3. Original IN Sensor ................................................................................................. 94. Pickup Roller ....................................................................................................... 105. Eject Roller Upper ............................................................................................... 106. Document Feeder Hook ...................................................................................... 107. Load Roller .......................................................................................................... 118. Eject Roller Lower ............................................................................................... 119. Read Pulse Motor ................................................................................................ 11

3. Adjustment1. Image scanner gain adjustment .......................................................................... 13

CHAPTER 13: CUTTER SECTION1. Theory of Operation

1. Cutter Home Positioning Mechanism .................................................................... 12. Cutting Mechanism ............................................................................................... 3

2. Removal and Assembly1. Cutter Unit ............................................................................................................. 5

CHAPTER 14: MASTER MAKING SECTION1. Theory of Operation

1. Master Making ....................................................................................................... 12. TPH Positioning .................................................................................................... 33. Thermal Power Safety Switches ............................................................................ 5

2. Removal and Assembly1. Write Roller ........................................................................................................... 72. Thermal Print Head (TPH)..................................................................................... 83. TPH Position Sensor ............................................................................................. 9

3. Adjustment1. Thermal Power of Thermal Print Head ................................................................ 11

CHAPTER 15: MASTER CLAMPING / LOADING SECTION1. Theory of Operation

1. Master Making Unit Set Mechanism ...................................................................... 12. Master Positioning Mechanism.............................................................................. 23. Master Feeding Mechanism .................................................................................. 44. Clamp Plate Master Clamp Mechanism ................................................................ 65. Master Loading on the Drum Mechanism .............................................................. 86. Master Advance after Master Cutting .................................................................. 10

2. Removal and Assembly1. Master Making Unit ............................................................................................. 132. Master Making Unit Safety Switch ....................................................................... 153. Write Pulse Motor ................................................................................................ 164. Master Positioning Sensor ................................................................................... 175. Master Loading Solenoid ..................................................................................... 186. Master End Sensor ............................................................................................. 19

APPENDIXElectrical Components ................................................................................... APX(0)-1Test Mode ........................................................................................................ APX(1)-1Users Mode ...................................................................................................... APX(2)-1Advice Displays (Call Service Messages) ..................................................... APX(3)-1Wiring Diagram................................................................................................ APX(4)-1

KS Series (Version 3.1)

CONTENTS

1. Preface ..................................................................................................................... 1CAUTION .................................................................................................................. 2WARNING ................................................................................................................ 3

2. WORK PRECAUTIONS ............................................................................................ 43. Exterior Cover Removal

> Front cover ............................................................................................................. 6> Back cover ............................................................................................................. 6> Master removal cover ............................................................................................. 6

CHAPTER 1: MAINTENANCE


MEMO


PREFACE

This manual provides Technical Service Information for RISO KS duplicators.This manual is published as a reference guide for use by certified field servicemen trainedunder RISO International Group technical trainers.

This manual includes procedures for removal, installation and adjustments of major componentsfound on the machine. Following these procedures will prevent injuries and malfunctions onthe machine, as well as to achieve end-user satisfaction.

If assistance is required, please contact one of the Riso International Group companiesor the Riso Distributors to whom you have the direct communication.

1 - 1

MAINTENANCEPREFACE


[Handling of Lithium Battery]

- Never fail to follow the following instructions when you discard the used lithiumbattery.

1. Never let the battery short-circuited.If the (+) and (-) terminals contact each other or metal materials, the battery will beshort-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 intofire.

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 throator the negative lithium may heat up into fire.If the battery is pressed into deformation, the liquid inside may leak out of the sealedpart 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 servicetechnician.

2. The battery must be replaced only with the same or equivalent type recom-mended by the manufacturer.

3. Discard used batteries according to the manufacturer's instructions.

CAUTION

1 - 2

MAINTENANCECAUTION


!! WARNING !!

Important Safety Precautions

1. Always disconnect electrical supply before placing hands in themachine.

I. To avoid injuries:Be sure to disconnect the electrical power before disassembling, assembling,or when making adjustments on the machine.

II. Protection of the machine:Make sure to turn OFF the power to the machine before plugging or unpluggingthe 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.

II. Protection of the electrical components:The electrical components may be damaged due to short circuits caused by a loose connector.

Wire harness connector

FIRST

THEN

Press the ends.

Press the center, firmly.

1 - 3

MAINTENANCEWARNING


Half-pierced section

2. Work PrecautionsInspection

If inspection finds a defective or problem part, correct it.Replace parts as necessary.

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 installationUnless otherwise specified, assembly and installation followthe reverse order of removal. When there is a protrudingsection and a hole for positioning a part, align them correctlybefore fastening.(Part positioning protruding section and hole is referred as"half-pierced section" in the manual.)

MAINTENANCEWORK PRECAUTIONS

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 andinstalled frequently. Therefore it is recommended that screws, of which are expected to be removedand installed frequently should be replaced from the self-tapping screws with normal screws such aspan-head screws or binding screws.Below figure is the difference between Self-tipping screw and Pan-head screw.

Self-tapping screw Pan-head screwor Binding-head screw

1 - 4


Wiring bundle band(bar lock ties)

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.

MAINTENANCEWORK PRECAUTIONS

1 - 5


MAINTENANCEEXTERIOR COVER REMOVAL

3. Exterior Cover RemovalDisconnect the power supply from the machine and remove the cover.

> Front cover> Back cover> Master removal cover: ......Remove the Master disposal first.

A: Front coverB: Back coverC: Master removal cover

A

B

C

1 - 6


1. Specifications .......................................................................................................... 12. Cross Sectional Diagram ........................................................................................ 43. Machine Operations ................................................................................................ 54. Paper Feed and Receiving ...................................................................................... 65. Master Removal and Feed ...................................................................................... 76. Counter Indication .................................................................................................. 8

CHAPTER 2: MACHINE SUMMARY

CONTENTS


MEMO


MACHINE SUMMARYSPECIFICATIONS

1. Specifications

Processing Automatic digital scanningFully 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 257mm or B5KS500C Max. 273 x 394mm Min. 182 x 257mm or B5KS500AL Max. 210 x 297mm or A4 Min. 182 x 257mm or B5

Paper Size KS500 Max. 257 x 364mm or B4 Min. 182 x 257mm or B5KS500C Max. 273 x 394mm Min. 182 x 257mm or B5KS500AL Max. 210 x 297mm or A4 Min. 182 x 256mm or B5

Original Weight Max. 107 g/m2Min. 50 g/m2

Paper Weight KS500 / KS500AL Max. 80 g/m2 Min. 50 g/m2KS500C Max. 70 g/m2 Min. 35 g/m2

Image Area 249 x 352mm

Paper Capacity KS500 / KS500AL Feed tray - 250 sheets (64 g/m2 ) Receiving tray - 250 sheets (64 g/m2 )

KS500C Feed tray - 280 sheets (50 g/m2 ) Receiving tray - 280 sheets (50 g/m2 )

Machine Weight Approx. 45 kg

Dimensions In use / 1200 x 650 x 470mm[ W x D x H ]

In storage / 635 x 645 x 479mm

Power Source KS500 / KS500AL220 to 240 VAC, 50/60 Hz <1.5A-2.0A><Requirements>

KS500C220 VAC, 50 Hz <1.5A-2.0A><Requirements>

KS500(120)110 to 127 VAC, 50/60 Hz <1.9A-2.5A><Requirements>

Features Print speed control, Confidential mode, Photo processing mode,Scanning contrast adjustment, Print position adjustment,Newspaper mode, Print/Master count display

2 - 1

KS500 / KS500C / KS500AL



1. Specifications





Original Type Sheet

Original Size KS600 Max. 257 x 364mm or B4 Min. 182 x 257mm or B5KS600C Max. 273 x 394mm Min. 182 x 257mm or B5KS600AL Max. 210 x 297mm or A4 Min. 182 x 257mm or B5

Paper Size KS600 Max. 257 x 364mm or B4 Min. 182 x 257mm or B5KS600C Max. 273 x 394mm Min. 182 x 257mm or B5KS600AL Max. 210 x 297mm or A4 Min. 182 x 257mm or B5


Paper Weight KS600 / KS600AL Max. 80 g/m2 Min. 50 g/m2KS600C Max. 70 g/m2 Min. 35 g/m2

Image Area 249 x 352mm

Paper Capacity KS600 / KS600AL Feed tray - 250 sheets (64 g/m2 ) Receiving tray - 250 sheets (64 g/m2 )

KS600C Feed tray - 280 sheets (50 g/m2 ) Receiving tray - 280 sheets (50 g/m2 )



Power Source KS600 / KS600AL220 to 240 VAC, 50/60 Hz <1.5A-2.0A><Requirements>


KS600 (120)110 to 127 VAC, 50/60 Hz <1.9A-2.5A><Requirements>


2 - 2

KS600 / KS600C / KS600AL


1. Specifications





Original Type Sheet

Original Size KS800 Max. 257 x 394mm or B4 Min. 182 x 257mm or B5KS800C Max. 273 x 394mm Min. 182 x 257mm or B5KS800(AL) Max. 257 x 394mm or B4 Min. 182 x 257mm or B5

Paper Size KS800 Max. 297 x 420mm or A3 Min. 182 x 257mm or B5KS800C Max. 297 x 420mm or A3 Min. 182 x 257mm or B5KS800(AL) Max. 210 x 297mm or A4 Min. 182 x 257mm or B5


Paper Weight KS800 / KS800(AL) Max. 128 g/m2 Min. 50 g/m2KS800C Max. 128 g/m2 Min. 35 g/m2

Image Area KS800 249 x 352mmKS800C 249 x 352mmKS800(AL) 210 x 280mm

Enlargement Parameters 141%, 122%, 116%

Reduction Parameters 71%, 82%, 87%, 94%

Paper Capacity KS800 / KS800(AL) Feed tray: 250 sheets (64 g/m2 )Receiving tray: 250 sheets (64 g/m2 )

KS800C Feed tray: 280 sheets (50 g/m2 )Receiving tray: 280 sheets (50 g/m2 )



Power Source KS800 / KS800(AL)220 to 240 VAC, 50/60 Hz <1.5A-2.0A><Requirements>


KS800(120)110 to 127 VAC, 50/60 Hz <1.9A-2.5A><Requirements>


KS800 / KS800C / KS800AL


2 - 3


2. Cross Sectional Diagram

MACHINE SUMMARYCROSS SECTIONAL DIAGRAM

2 - 4

5

6

2

Timing roller

Paper receiving tray

Separator4

7

Guide roller

Pressure roller

Master roll

Write roller

10 9

8Master disposal box

Image scanner

Documentfeeder

Thermal print headOriginal rack

Cutter unit

Paper feed tray

Pickup roller

3

Suction unit

1

1 First Paper Feed Area: Feeds single sheets of paper to the second paper feed area viathe Pickup roller and Stripper pad.

2 Second Paper Feed Area: Controls the vertical print position and feeds paper to the printarea via the Timing and Guide rollers.

3 Press (Printing) Area: Uses the Pressure roller to press paper against the master on theDrum.The Drum rotates with the Pressure roller and prints an image onpaper.

4 Paper Ejection Area: Separates a printed paper from the Drum, and transports it ontothe 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 theMaster disposal box.

8 Image Scanning Area: Carries an original and scans it with the Image scanner andconverts 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 anappropriate length.

KS Series (Version 3.1)2 - 5

3. Machine Operations

Master Disposal

The used master is removed fromthe drum and stored in the

disposal box.

Printing

Paper is fed one sheet at a time fromthe Paper feed tray, printed, and

stored on the paper receiving tray.

Master Making

The original is scanned by the imagescanner and the image is made on the

master with the thermal print head.

Master Carrier and Loading

The made master is wrapped onto thedrum and cut.

Also, a proof print is printed.

Set the original and press the Start key.

MACHINE SUMMARYMACHINE OPERATIONS


MACHINE SUMMARYPAPER FEED AND RECEIVING

4. Paper Feed and Receiving

DrumPickup roller

Guide roller

Timing roller

Pressure roller

Separation fan

Separator

Transfer belt

The paper feed to the second paper feed area isstopped by the Guide and Timing rollers to form abuckle. The paper then waits until the rotation ofthe Guide roller starts.

While the paper is being fed from the secondpaper feed area, the Pressure roller rises andprinting starts.(The Pressure roller contacts the Drum and startsrotating.)

After the Pressure roller contacts the Drum to startprinting, the Separator approaches the Drum andthe Separation fan starts to blow.The Guide roller goes up to release the paper.(The paper is then transferred by the rotation ofthe Drum.)

The Timing roller contacts with the Guide roller tofeed the next sheet of paper.

The printed paper is separated from the Drum bythe Separator and with a help of the air blow fromthe Separation fan.It is then transported onto the Paper receiving trayby the Transfer belts using Suction fan.

The Drum is rotated and a sheet of paper is fedfrom the first paper feed area to the second paperfeed area by Pickup rollers, and Stripper pad.

The Guide and Timing rollers in the second paperfeed area are rotated and the paper is fed to theprinting area.

Stripper pad


MACHINE SUMMARYMASTER REMOVAL AND FEED

2 - 7

5. Master Removal and Feed

Master Making

Master Loading

Master Removal

The Clamp plate opens and Masterrelease shaft releases the master from theClamp plate.

The Drum and Vertical transport rollersstarts rotating and removes the masterfrom the Drum and feed it into the Masterdisposal box.

The Master compressing plate startscompressing the removed master withinthe Master removal box.

The Image scanner scans the image onthe original and Thermal print head (TPH)makes the image on the master material.The Master tension plate drops down andapplies tension on the master material.

The master is transferred onto the Drumand the leading edge is clamped by theClamp plate.

The Drum rotates to wrap the master onthe Drum.

The Cutter cuts the master.

Master

Master rollClamp plate

Verticaltransport roller

Cutter

Masterprojection shaft

Masterdisposal box

TPH


MACHINE SUMMARYCOUNTER FOR MAINTENANCE

2 - 8

6. Counter Indication

1. Indicate Copy and Master Counter:No mechanical counters are installed on KS therefore the alternatives are available as softwarecounter.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 displaysthe Copy counter. The three digits of seven segments change every 2 seconds then displays ninedigits 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.

Copy Count1. Press [*] key then [1] key.2. [ - - - ] will be indicated at first.3. After 2 seconds, the indication will be changed to [ 1 2 3 ].4. After 2 seconds, the indication will be changed to [ 4 5 6 ].

Master Count1. Press [*] key then [2] key.2. [ - - 1 ] will be indicated at first.3. After 2 seconds, the indication will be changed to [ 2 3 4 ].

2. Clear of Copy and Master Counter:The counter indication can be cleared and set back to default zero by using TEST MODE No.97.

By pressing the print position adjustment key or on the control panel then Power On.Three digits of seven segments indication on the control panel displays version of the System ROMinitially. 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 counter 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, input test mode No.97 then press [Start] key

while test mode is available. If the indication is [0], counter cannot be cleared. If the indicationis [1], the counter can be cleared.

*2. It is recommended that the prohibit clear mode should be done before the machine is installedat customer site. Once the prohibit clear mode is activated, the counters will no longer be ableto be cleared permanently.


1. Theory of Operation1. Main Drive ............................................................................................................. 12. Main Motor Safety Switches .................................................................................. 23. Drum Position ........................................................................................................ 34. Drum Rotation Lever ............................................................................................. 5

2. Removal and Assembly1. Main Motor Unit ..................................................................................................... 72. Master Removal Unit Safety Switch ...................................................................... 93. Master Making Unit Safety Switch ....................................................................... 104. Sparation Unit Safety Switch ............................................................................... 115. Paper Guide Plate Safety Switch ......................................................................... 126. Drum Rotation Lever ........................................................................................... 13

CHAPTER 3: MAIN DRIVE SECTION

CONTENTS


MEMO


MAIN DRIVE SECTIONTHEORY OF OPERATION

1. Theory of Operation1. 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.

3 - 1

A : DrumB : Drum Main gearC : Intermediate gearD : Main gearE : Step-down gear AF : Step-down gear BG : Main motor gearH : Main motorI : Encoder sensorJ : Encorder

B

A

C

D

E

JI

G

H

F



2. Main Motor Safety Switch1. 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: Master removal unit safety switchB: Master making unit safety switchC: Separation unit safety switchD: Paper guide plate safety swich

A

B

C

D



3. Drum Positions1. Sensors for the Drum positioning

> The position of the Drum is determined by the Position-A sensor [A] and Encoder sensor onthe 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.

3 - 3

Drum position-A

A : Position-A plateB : Position-A sensor

Drum angle0

A

B



3 - 4

Drum angle(Encoder sensor)

Position-A sensor

Main motor

OpenBlocked

0 (Position-A)

15 rpm

End of movement0 (Position-A)

(a) If the light path of the Position-A sensor is cut when the last paper is counted, the Main motor speedbecomes 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 theDrum- 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 machineassumes 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 signalfor 0.1 seconds, the machine assumes that the Main motor has locked and displays error message[E 01].

Drum A-Positioning Movement Timing Chart

270 270 315 90 180(a) (b)

1.95 rpm

ON

OFF



3 - 5

A:DrumB:Drum gearC:Drum rotation levarD:Drum rotation gear

A

B

C

4. Drum Rotation Lever1. 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


MEMO

3 - 6


MAIN DRIVE SECTIONREMOVAL AND ASSEMBLY

3 - 7

2. Removal and Assembly1. Main Motor Unit

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

(continues on page 3-8)

A : Paper receiving trayB : Suction coverC : Suction unit

B

A

C

NOTE:The paper receiving tray and thesuction unit on KS800 looks a littledifferent.


A

F

E

D

B

C

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.


3 - 8

Precautions in Assembly> Match the half-pierced sections of brackets against those on the machine frame.

A: Main motor unitB: P.-F. clatch bracketC: Timing clatch support plateD: Clutch support plateE: EncoderF: Drive gear bracket


MECHANICAL OVERVIEWREMOVAL AND ASSEMBLY

2. Master Removal Unit Safety Switch1. Disconnect the power supply from the machine.2. Remove the Front cover.(See page 1-6)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.

Precautions in Assembly> 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.

3 - 9

A: Master removal unitB: Master removal unit safety switch

B

B

A



3 - 10

3. Master Making Unit Safety Switch1. Disconnect the power supply from the machine.2. Remove the Master making unit [B](See page 15-13).3. Disconnect the Connector of the Master making unit safety switch [A].4. Remove two mounting screws of the Master making unit safety switch [A] and remove the

switch.

Precautions in Assembly> Install the switch [B] in the correct direction.

A: Master making unitB: Master making unit safety switch

B

A



3 - 11

4. Separation Unit Safety Switch1. Disconnect the power supply from the machine.2. Remove the Front cover.(See page 1-6)3. Remove the Main PCB. (See page 8-7)4. Open the Separation unit [B] as the below photo shows.5. Remove the Separation unit switch [A] from the bracket.

Precautions in Assembly> 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 switchB:Separation Unit

A

B



3 - 12

5. Paper Guide Plate Safety Switch1. Disconnect the power supply from the machine.2. Remove Back & Front cover (See page 1-6)3. Remove the Power supply unit (See page 8-7)4. Remove the PF tray [C] & the Pickup roller ass'y [B] (See page 4-6, 4-7)5. Remove the PF clutch bracket & the PF clutch (See page 4-10)6. Remove the PF guide plate upper plate (See page 5-5)7.Remove the Master loading senser bracket (See page 5-5)8.Remove the Paper gate (See page 5-6)9.Remove the PF guide plate lower plate (See page 5-5)10.Remove the PF plate safety SW [A]

Precautions in Assembly> 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.

A:Guide Plate Safety SwitchB:Pickup roller ass'yC:Paper feed (PF) tray

A

B

C



6. Drum Rotation Lever

6-1. Old Type: For KS500 Serial Number 81530001- 81530500For KS500C Serial Number 81510001- 81510500

A

B

C

D

1. Dosconnect the power supply from the machine.2. Remove the Back cover (See page 1-6)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: Drum rotation gearB: Drum rotation lever bracketC: Drum rotation leverD: Drum rotation lever ass'y

Refer to the next pagefor the New Type.


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] isindicated on the machine.

A: Gear;m1*26*11B: Gear plate;Drum rotation leverC: Gear Shaft;rotation leverD: Link shaft;Drum rotation leverE: Link plate;Drum rotation leverF: Drum rotation leverG: Cover;Drum rotation lever

3 - 14


1. Disconnect the power supply from the machine.2. Remove the Back cover (See page 1-6)3. Remove the Cover;Drum rotation Lever [G].4. Remove the Gear plate;Drum rotation lever [B].5. Seperate the Gear plate Drum rotation lever [B] and the Gear;m1*26*11 [A].

D

DB

C

E

F

A

G

6-2. New type : For KS500 Serial No. 81530501 -For KS500C Serial No. 81510501 -

Also for all KS600 & KS800


1. Theory of Operation1. Paper Feed Tray Position ...................................................................................... 12. First Paper Feed Drive Mechanism ....................................................................... 23. Paper Pickup System ............................................................................................ 44. Paper Feed Pressure Select System..................................................................... 5

2. Removal and Assembly1. Paper Feed Tray Unit ............................................................................................ 62. Pickup Roller Assembly ......................................................................................... 73. Pickup Roller and PF Support Roller ..................................................................... 84. Stripper Pad .......................................................................................................... 95. Paper Feed Clutch .............................................................................................. 10

3. Adjustment1. Paper Feed Tray Pressure .................................................................................. 112. Paper Feed Tray Position Adjustment ................................................................. 133. Paper Feed Clutch ON Timing ............................................................................ 154. Paper Feed Clutch OFFTiming ........................................................................... 15

CHAPTER 4: FIRST PAPER FEED SECTION

CONTENTS


MEMO


FIRST PAPER FEED SECTIONTHEORY OF OPERATION

1. Theory of Operation1. Paper Feed Tray Positions (Upper / Lower)

1. Paper Feed Tray Set Lever

4 - 1

A: Paper feed tray set leverB: Paper feed trayC: PF tray springD: PF lever plate ass'yE: PFT leverF: PFT lever shaftG: Pick up roller

> 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.

A

E

D

C

F

G

B



2. First Paper Feed Drive Mechanism1. Paper Feed Clutch

> When the Main motor [C] activates, the Drum rotates in the clockwise direction via the Drivegear 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 Drumposition A.

> The Paper feed tray clutch [B] activate timing and release timing is changed by the drumrotation 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.

A:Pickup rollerB:Paper feed clutchC:Main motorD - I: Drive gears

C

D

A

BE

F

G

H

I



4 - 3

First Paper Feed Timing Chart

1-1 The Paper feed clutch activates each time the Drum rotates 66.3 ±c from the A position.The angle "c" 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 ±c from the A position.The angle "c" can be adjusted by Test Mode No. 81, which adjusts the paper buckle amount.

A:DrumB:Pickup rollerC:PaperD:Paper gateE:Guide rollerF:Stripper padG:Timing rollerH:Pressure roller

B

E AD

C

F

G

H

[In case the drum rotation speed is 60 r.p.m.]

Drum rotation starts from Drum Position-A

01-1 66.3 ±χ1-2 63.7 ±χ

2-1 144.8 ±χ2-2 142.2 ±χ 0 0

Open

ON

ON

Drum rotation

Main motor

Position-Asensor

Paper feedclutch

Blocked

Press "START" key

[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 ±c from the A position.The angle "c" 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 ±c from the A position.The angle "c" can be adjusted by Test Mode No. 83, which adjusts the paper buckle amount.

2-1 144.8 ±χ2-2 142.2 ±χ

1-1 66.3 ±χ1-2 63.7 ±χ



4 - 4

3. Paper Pickup System1. Feeding

> The papers on the Paper feed tray are fed by the Pick roller [A], in several layers, in betweenthe 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 paperstack.

A:Pickup rollerB:Stripper springC:Stripper padD:Paper

C

A

B

D



4. Paper Feed Pressure Select System1. Paper Feed Pressure Adjust Lever

> The Paper feed pressure adjust lever [A] is located on the front side of the machine, and itchanges the pressure of the Paper feed tray applied against the Pick up roller, as a result thepressure 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 againstthe 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 Paperfeed tray. Thus the paper feed pressure is increased. Therefore this position is for "NORMAL"papers.

A:Paper feed pressure adjust leverB:Pressure adjust lever springC:Pressure arm

A

BC

For THIN Paper

For NORMAL Paper


FIRST PAPER FEED SECTIONREMOVAL AND ASSEMBLY

2. Removal and Assembly1. Paper Feed Tray Unit

1. Disconnect the power supply from the machine.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

A:Paper feed tray unitB:Lock pin

B

KS Series (Version 3.1)4 -7

2. Pickup Roller Assembly1. Disconnect the power supply from the machine.2. Lower the Paper feed tray [D].3. Remove Back cover. (See Page 1-6)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.


A:Pickup roller shaftB:MetalC:Lock ringD:Paper feed tray

B

A

C

D


3. Pickup Roller and PF Support Roller1. Disconnect the power supply from the machine.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.

Precautions in Assembly> 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 rollershaft.


A:Pickup rollerB:Lock ringC: PF support rollerD: Pin

A

C

C

BD


4. Stripper Pad1. Disconnect the power supply from the machine.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].

Precaution in Assembly> 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 baseB:Stripper springC:Stripper pad

A

B

C


5. Paper Feed Clutch1. Disconnect the power supply from the machine.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.

Precautions in Assembly> 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 theclutch from rotating. (Refer to fig.b)


A:Paper feed clutchB:PF Clutch support plateC:MetalD:Drive gear bracket

A

B

C

fig.b

D

A

D


FIRST PAPER FEED SECTIONADJUSTMENT

3. Adjustment1. Paper Feed Tray Pressure

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)

*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] willbe damaged.

WeakStrong

fig.a

B

fig.c

7mm

A

B

fig.b

1mm

A:Paper feed tray set leverB:PF adj. screw

For KS500C Serial Number 81510001- 81510500

Weak(CCW)+1mm

Strong(CW)-7mm

1-1. Old Type of the Paper feed Tray set Lever

For KS500 Serial Number 81530001- 81530500 Refer to the next pagefor the New Type.


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

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 edgeof

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)

*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.

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] willbe damaged.

>Adjust set position of the PF adj. dial [C] against the PF adj.screw [B].C

A:Paper feed tray set leverB:PF adj. screwC:PF adj. dial

B

A

fig.a

fig.b

Weak(CCW)+12mm

Strong(CW)

+7mm

For KS500 Serial Number 81530501- For KS500C Serial Number 81510501- For KS500AL Serial Number 81540001- For KS500(120) Serial Number 81550001-


Also for all KS600 & KS800


2. Paper Feed Tray Position Adjustment1. Separate Base plate;PFT[A] from Plate;PFT[B].2. [For KS500C] Measure 42mm from the bottom of inside of the Plate; PFT [A]then mark the 42mm point on the Plate;PTF[B]. [For other KS models] Measure 43mm 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: Base plate;PFTB: Plate;PFTC: PF press-adj. LeverD: PF Adj. screwE: PF Adj. dialF: Paper feed tray set lever

DE D

New TypeOld Type

F

A

B

42mm or 43mm

C

B

B

6. 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.7. Paper feed adjustment for each paper will be required after this adjustment is done.



[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 feedpressure 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 atonce. Then fed by Pick up roller.

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.

*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.

Multiple PaperFeeding

NO PaperFeeding

Paper

Paper fed on to the centerof the stripper pad.

Paper

Standardrange

A: Stripper padB: paper guide plate lower A

B

A

Top view

4 -14



3. Paper Feed Clutch ON TimingIf the paper jams or does not feed smoothly due to incorrect timing of the paper feed clutch activatetiming, 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 90r.p.m..

4 - 15

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 TimingIf the paper jams or does not feed smoothly due to incorrect amount of the paper buckle at thefinish of the first paper feed timing, use Test mode No.81 or No.83 to adjust the timing of thePaper 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 90r.p.m..

Note:>The Paper feed clutch adjustment is affected by the Timing clutch timing adjustment as same as the Paper feed clutch ON timing adjustment.

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.

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.

Adjustment Procedure1. 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 [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 orkey.

Adjustment Procedure1. 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 orkey.

Indication / Amount(mm) -4 -3 -2 -1 0 1 2 3 4

INCREASEDECREASEAdjustment Table

Indication / Amount(mm) -4 -3 -2 -1 0 1 2 3 4

DECREASE INCREASE

Adjustment Table


MEMO

4 - 16


1. Theory of Operation1. Second Paper Feed Drive Mechanism .................................................................. 12. Vertical Print Position ............................................................................................ 2

2. Removal and Assembly1. Load Spring ........................................................................................................... 32. Timing Clutch ........................................................................................................ 43. Paper Guide Plate ................................................................................................. 54. Paper Gate ............................................................................................................ 65. Timing Roller / Guide Roller .................................................................................. 7

3. Adjustment1. Print Position(Timing Clutch ON Timing) ............................................................... 8

CHAPTER 5: SECOND PAPER FEED SECTION

CONTENTS


MEMO


SECOND PAPER FEED SECTIONTHEORY OF OPERATION

5 - 1

1. Theory of Operation1. 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.

A:Paper gateB:Guide rollerC:Timing rollerD:Load springE:Timing clutchF:Timing gearG:main motor

B

C

A

E

D

F

G


2. Vertical Printing Position1. 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.

SECOND PAPER FEED SECTIONTHEORY OF OPERATION

A:Guide rollerB:Timing rollerC:Timing clutchD:Timing clutch gear

B

A

C

D

Drum rotation

Paper feed clutch 1st

Paper feed clutch 2nd

Paper gate

0 90 180 270 360

66.3 144.8

61.3

160.3

(157.7)

(144.2)(63.7)

(58.7)

78.5


SECOND PAPER FEED SECTIONREMOVAL AND ASSEMBLY

2. Removal and Assembly1. Load Spring

1. Disconnect the power supply from the machine.2. Remove Front cover.3. Remove power supply PCB. (See page 8-7)4. Remove E-ring [C] and Collar [B] from the Timing roller shaft.6. Remove the Load spring [A] from the shaft.

Precaution before Assembly> Install the Load spring in the correct direction.

A:Load springB:CollarC:E-ring

C

B

A



2. Timing Clutch1. Disconnect the power supply from the machine.2. Remove Back cover.3. Remove the PF-Clutch support plate [H].4. Remove the Clutch support plate [A] then remove the encoder [B] and the Encoder sensor [C].5. Remove the BKT; Drive gears [D].6. 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.

A:Timing clutch support plateB:PF/M-Rmv clutch

A

B


3. Paper Guide Plate1. Disconnect the power supply from the machine.2. Remove following parts from the machine.

> Back cover (See page 1-6)> 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 5-6)6. Take out the Paper guide plate lower [D] from the the Paper feed tray side.


A:Paper feed trayB:Pickup roller assyC:Paper guide plate upperD:Paper guide plate lowerE:Master loading sensorbracketF:Paper feed clutchG:Paper gateAdjustment after Assembly

> Make sure the position of the Paper guide plate upper at the correct position as below picturesshow.

B

A

D

C

E

F

G

Drive side

Front side

C

C



5 - 6

4. Paper Gate1. Disconnect the power supply from the machine.2. Remove the Paper guide plate upper. (See page 5-5)3. Slide out the Master removal unit.4. 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

A


5. Timing Roller / Guide Roller1. Disconnect the power supply from the machine.2. Remove the Paper guide plate (See page 5-5)3. Remove the Paper gate (See page 5-6)4. Remove the Power supply unit (See page 8-7)5. 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 ofthe Guide roller shaft [B].

8. Remove the Guide roller ass'y[B] (Complete the Guide roller ass'y removal)


Precaution before Assembly> 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.

5 - 7

A:Timing rollerB:Guide rollerC:Metal(Long)D:Metal(Short)E:One-way gearF:E-ringG:Load spring

A

B

F

F

E

G

C

C

D

D


SECOND PAPER FEED SECTIONADJUSTMENT

5 - 8

3. Adjustment1. 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 runsat 90 r.p.m..

Adjustment Procedure1. Turn off the power of the machine.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] andselect the number by pressing or key.

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 drumsurface.

[Exsample] : In case the line is positioned 7mm 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.

Adjustment Table of TEST MODE No.84 / No. 86

10mm

Printed paper

-7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7

Image upImage downAmount(mm)/ Indication


1. Theory of Operation1. Press Mechanism.................................................................................................. 1

2. Removal and Assembly1. Pressure Roller ..................................................................................................... 32. Pressure Lever Ass'y ............................................................................................ 43. Pressure Shaft Ass'y ............................................................................................. 5

3. Adjustment1. Pressure Lever Ass'y Position ............................................................................... 7

CHAPTER 6: PRESS SECTION

CONTENTS


MEMO


PRESS SECTIONTHEORY OF OPERATION

1. Theory of Operation1. 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'ystays lower.

> When paper comes in and pushes the Paper gate [J] up, the Pressure hook [I] is risen. So thePressure 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 Drumwhen Drum rotation is at 218.2 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

Pressur 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 118.5 degreesfrom the A-position where the Clamp plate on the Drum comes near the Pressure roller [A].

> The Pressure lever [D] becomes risen again by Pressure cam [E] at Drum rotation 218.2degrees.

A:Pressure rollerB:Pressure springC:Main moterD:Pressure lever ass'yE:Pressure camF:Pressure shaft ass'yG:Pressure shaftH:Pressure hook I :Cam followerJ :Paper gateK:Pressure ass'y

6 - 1

A

E

D

C

B

F

G

H

I

J

Paper gate is pushedup by paper.And Pressure hook israised.Then Pressure leverrises by Pressure camat Drum 218.2.

H

Pressure hookbecomes lower whenthe paper throughsout. Then Pressurelever is risen byPressure cam at Drum118.5.

K


PRESS SECTIONTHEORY OF OPERATION

6 - 2

A:Pressure rollerB:Pressure lever ass'yC:DrumD:Pressure springE:Pressure shaft

Lifting the Pressure RollerThe Paper gate is pushed up by paper throughoutthe printing. So the Pressure lever [B] becomes free.The Pressure spring [D] pulls back the Pressurelever [B] and rotates the Pressure shaft [E] which isacting as a pivot.The rotation of the Pressure shaft [E] lifts thePressure roller [A] up against the Drum [C].

Lowering the Pressure RollerThe Pressure roller [A] is lowered by force, away fromthe Drum[C], by the high part of the Pressure cam[F].During the Drum rotation, when the Clamp plate ofthe Drum comes close to the Pressure roller (drumrotation at 218.2 degrees), the high part of thePressure cam [F] pushes the Pressure lever [B] down,rotating the Pressure shaft [E] counter-clockwise tobring the Pressure roller down, away from the Drum.Then Pressure lever [B] is lowered by Pressurecam [F] at Drum 118.5 degrees.

A

B

C

E

D

Pressure hook becomes lower when the paper throughs out.

F

E


PRESS SECTIONREMOVAL AND ASSEMBLY

2. Removal and Assembly1. Pressure Roller

1. Disconnect the power supply from the machine.2. Remove the Back cover from the machine.(See page 1-6)3. Remove the Suction unit from the machine. (See page 7-5)4. Remove mounting screw of the Pressure roller [C] from the Pressure shaft 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:ScrewB:Pressure roller

A

B



6 - 4

2. Pressure Lever Ass'y1. Disconnect the power supply from the machine.2. Remove Back cover.(See page 1-6)3. Remove the Drum unit from the machine. (See page 8-7)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

A



3. Pressure Shaft Ass'y1. Disconnect the power supply from the machine.2. Remove the Drum from the machine. (See page 8-7)3. Remove the Back cover and Front cover.(See 1-6)4. Remove the Pressure lever ass'y [E]. (page 6-4)5. Remove E-rings [C] from both ends of the Pressure shaft ass'y and remove the Metals [D].6. Remove the Suction unit. (See page 7-5)7. Remove the Pressure spring [B].8. 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:Pressure shaft ass'yB:Pressure springC:E-ringD:MetalE:Pressure lever ass'y

A

B

C D

E

C

D


MEMO


PRESS SECTIONADJUSTMENT

3. Adjustment1. Pressure Lever Ass'y Position

1. Make confidential master on the Drum.2. Bring the Drum to the Position-A.3. Disconnect the power supply from the machine.4. Remove Back cover. (See page 1-6)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 tighteningthe two set screws.

Results of Incorrect Adjustment> 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.

6 - 7

A:Pressure lever ass'yB:Pressure camC:Cam followerD:Hook lever

Turn the Pressure shaft to lift thePressure roller against the Drum.

2-2.5mm

Adjust the gap between the Pressure cam and Cam follower to2mm - 2.5 mm by inserting 2 mmAllen wrench between the Cam andCam follower.

AC

BD


MEMO

6 - 8


1. Theory of Operation1. Paper Ejection Mechanism.................................................................................... 12. Paper Separation Mechanism ............................................................................... 3

2. Removal and Assembly1. Suction Unit ........................................................................................................... 52. Transfer Belt ......................................................................................................... 63. Suction Fan ........................................................................................................... 74. Separation Fan Unit .............................................................................................. 85. Separation Fan ...................................................................................................... 96. Paper Receiving Sensor ........................................................................................ 97. Separator ............................................................................................................ 108. Paper Receiving Tray .......................................................................................... 11

3. Adjustment1. Separator Position ............................................................................................... 13

CHAPTER 7: PAPER EJECTION SECTION

CONTENTS


MEMO


PAPER EJECTION SECTIONTHEORY OF OPERATION

1. Theory of Operation1. 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.

7 - 1

A: Separation fanB: Transfer beltsC: Suction fanD: SeparatorE: Paper receiving sensor

A

C

E

D

B



Paper Ejection Timing Chart - From Start to in printing -

Position-Asensor

Paper receivingsensor

Press START button

Open

No detection Detecting paperON

Separation fanSuction fan

Main motor

Detecting paper

Paper Ejection Timing Chart - From in printing to Stop -

ON

ON

OFF

Position-Asensor

Main motor



Detecting paper No detection

Blocked Blocked Blocked

Blocked Blocked

Press STOP button

ON

1 The Paper receiving sensor is checked to see whether no paper is detected at every Drum angle 257degrees 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 334degrees and 104 degrees.If paper is not detected, the machine assums that paper jam occurs in the paper feed area and indicates[J 2].

334 104

280257334

257 280

OFF

0

334

0

0 0 0

104

257 280

1 1

2 2 21 1

1 The Paper receiving sensor is checked to see whether no paper is detected at Drum angle 257 degreesand 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 334degrees and 104 degrees.If paper is not detected, the machine assums that paper jam occurs in the paper feed area and indicates[J 2].



7 - 3

2. Paper Separation Mechanism1. 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.

A:Separator shaftB:SeparatorC:Separator lever ass'yD:Paper receiving trayE: Drum support left

AC

D

CE


MEMO

7 - 4


PAPER EJECTION SECTIONREMOVAL AND ASSEMBLY

2. Removal and Assembly1. Suction Unit

1. Disconnect the power supply from the machine.2. Remove Back cover.(See page 1-6)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.

Precaution in Assembly> 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].

A:Suction unitB:Suction unit CoverC:Feet (of Suction cover)D:Base plate

A

B

C

D



2. Transfer Belt1. Disconnect the power supply from the machine.2. Remove Back cover. (See page 1-6)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:Transfer beltsB:Suction face coverC:Belt pulley shaftD:Belt driven shaftE:De-electricity brushF:Bearing

Precautions in Assembly> 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.

Remove the beltsfrom this side.

A

B

C

D

E

F

KS500 & KS600 KS800



3. Suction Fan1. Disconnect the power supply from the machine.2. Remove Back cover.(See page 1-6)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 unitB:Suction fan

B

A



4. Separation Fan Unit1. Disconnect the power supply from the machine.2. Remove Back cover.(See page 1-6)3. Disconnect the Connector of the Separation fan unit [A].4. Remove two mounting screws of the Separation fan unit [A] and remove the unit.

Precaution in Assembly> Match the half-pierced section on hinge of the Separation fan unit [B] with its counter part.

A:Separation fan unitB:Hing (of Separation unit)

A

B



5. Separation Fan1. 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.

6. Paper Receiving Sensor1. Remove the Separation fan unit [C]. (See page 7-9)2. Disconnect two mounting screws of the Separation fan [A].3. Lift the fan and disconnect the Connector of the Paper receiving sensor [B].4. Press the center hook of the Paper receiving sensor socket and lift the sensor out.

A:Separation fanB:Paper receiving sensorC:Separation fan unit

A

B

C



7. Separator1. Disconnect the power supply from the machine.2. Remove the Back cover and Front cover.(See page 1-6)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].

A:E-RingB:Separation shaftC:Separator spring

B

C

A


8. Paper Receiving Tray Unit1. Disconnect the power supply from the machine.2. Remove Back cover and Front cover. (See page 1-6)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].

Precaution in Assembly> Match the half-pierced sections on the Lock plates F and R with their counter parts.


7 - 11

A:Paper ejection guide RB:Paper ejection guide FC:Paper back stopD:Paper receiving tray

KS500 & KS600 KS800

Remove the Paperreceiving tray by slidingit out.

A B

C

DFig.a


MEMO

7 - 12


PAPER EJECTION SECTIONADJUSTMENT

3. Adjustment1. 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 1-6) and the Power supply PCB. (See page 8-7)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.

Precaution in Adjustment> 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.

Results of Incorrect Adjustment> 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 andmay 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

A:Separator leverB:SeparatorC:DrumD:Mounting screwE:Separator plate

A

B

[1] direction :Increases the gap[2]direction :Decreases the gap

[1] [2]

A

1.0 - 1.4mm

C

C

D

E

B


MEMO


1. Theory of Operation1. Master on Drum (in printing) Check Mechanism ................................................... 12. Ink Bottle Set Check Mechanism .......................................................................... 23. Ink Supply Mechanism .......................................................................................... 34. Squeegee Roller Rotation Mechanism .................................................................. 5

2. Removal and Assembly1. Drum Unit .............................................................................................................. 72. Screen ................................................................................................................... 83. Drum Body ............................................................................................................ 94. Ink sensor PCB ................................................................................................... 115. Ink Bottle Guide ................................................................................................... 126. Ink bottle set Sensor ............................................................................................ 127. Drum Support F & Drum Support R ..................................................................... 138. Squeegee Roller .................................................................................................. 149. Ink Pump Unit ...................................................................................................... 1710. Inking Motor ...................................................................................................... 18

3. Adjustment1. Squeegee Gap .................................................................................................... 19

CHAPTER 8: DRUM SECTION

CONTENTS


MEMO


1. Theory of Operation1. Master on Drum (in printing) Check Mechanism

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, [J1] is indicated on the Operation panel and stops the

printing operation.

DRUM SECTIONTHEORY OF OPERATION

8 - 1

(From Position-A)

A: MasterB: Master sensor

(From position-A)

Drum angle = 134

AAaaa

A

B

Drum angle = 134



2. Ink Bottle Set Check Mechanism1. 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 'C5'.

A: Ink bottle set sensorB: Ink bottle guideC: Ink bottleD: Actuator plate

A BIn case No bottle is installed

In case bottle is installed

C

Ink bottle set sensor detects the actuatorplate

The actuator plate is released by inkbottle thus Ink bottle set sensor does notdetect the actuator plate

D



B

3. Ink Supply Mechanism1. 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 ischecked 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)

8 - 3

A: Squeegee rollerB: Doctor rollerC: Inking motorD: Driven shaftE: Ink distributorF: Long roll of ink tubeG: Ink sensorH: Overflow sensorI: Ink sensor PCBJ: Ink bottle

A

D

EG

H

C

J

I

F


Inking Timing Chart

1 The Inking motor does not activate at the start of Main motor even though the Ink sensor is notdetecting 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 machineassumes 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 pointwhen the machine is turned ON again.

> If Overflow sensor detects ink for more than 0.5 seconds, the machine assumes that the ink has overflown 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 machineassumes that the Inking motor has locked and indicates error message [E 16].

8 - 4

Ink is pushed out

Ink is sucked in

A: Inner rotorB: Outer rotorC: Ink "IN"D: Ink "OUT"

The ink sucked in is carried between the Outer and Innerrotors of the Ink pump and as the gap between the rotorsbecomes small, the ink is pushed out.

Main motor


Blocked Blocked

ON

Open

Drum stops

Blocked

OFFON

No detection

Ink detected

Position-Asensor

Ink sensor

Inking motor

Drum rotation starts

1 2 3 4

A

B

D

C

5



4. Squeegee Roller Rotation Mechanism1. 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] fromrotating when the Drum is accidentally rotated in the opposite way by hand.

2. Rotation of the Driven ShaftWith 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.

A: Squeegee rollerB: Doctor rollerC: Squeegee roller gear R [with one way clutch]D: Squeegee roller gear FE: Drum main gearF: Intermediate gear AG: Intermediate gear BH: Intermediate gear C I: Intermediate gear DJ: Main motor gearK: Main motorL: Driven shaft

A

D

G

L

B

C

E

F

H

IJ

K


MEMO


2. Removal and Assembly

DRUM SECTIONREMOVAL AND ASSEMBLY

8 - 7

1.1. Drum Unit1. Disconnect the power supply from the machine.2. Remove the Back cover and the Front cover (See page 1-6)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)

A: Load spring plateB:Power supply coverC:Power supply PCBD: Main PCB coverE: Main PCB

F: Main PCB brackettG: Inking motorH: Drum unit

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.

A

B

C

E

D

F

G

H



2. Screen1. Make a confidential master on the Drum.2. Remove the Drum from the machine (See page 8-7)3. Remove the two Screen springs [B].4. 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].

Precaution in Assembly> Do not bend, wrinkle or damage the Screen [B].

A: ScreenB: Screen springsC: Clamp plate baseD: Special screw

B

AC

D



3. Drum Body1. Make a confidential master on the Drum.2. Remove the Drum from the machine.(See page 8-7)3. Remove the Screen from the Drum. (page 8-8)4. Remove two Special screws [E] from the Clamp plate base [A] and remove the base.5. 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")

A: Clamp plate baseB: Drum bodyC: Drum support FD: Drum Support RE: Special screw

A

D

E

C

B

E



Precaution in Assembly> 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.

> 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.

> 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.

B:Screen spring

A: Special screwsA

B



8 - 11

4. Ink Sensor PCB1. 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.

Precaution in Assembly> 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

A



5. Ink Bottle Guide1. Remove the Front cover. (See page 1-6)2. Remove two mounting screws of the Ink bottle guide [A] and remove the Ink bottlt guide [A].

A: Ink bottle guide

6. Ink Bottle Set Sensor1. Remove the Front cover (See page 1-6), 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

AAA

B



8 - 13

7. Drum Support F & Drum Support R1. Make a confidential master on the Drum.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 harnessfrom 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 supportBKTs.

6. Loosen the Mounting screws [H1 & 2:set screw] of Drum Shaft Clampers [F] to the Drum centershaft [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].

A:Drum U Support BKT RB:Drum Support R Ass'yC:Drum Support F Ass'yD:Drum U Support BKT FE:Intermediate wire harnessF:Drum Shaft ClampersG1-4: Mounting screws (cap screw)H1-2: Mounting screws (set screw) I :Drum center shaft

A

B

C

F

E

D

G1

G 3

G2

G 4

I

H1

H2


8. Squeegee Roller1. Make a confidential master on the Drum.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 8-12)4. Remove Drum support F & Drum support R (See page 8-13)5. Remove following parts from the Drum unit.

> Ink pump unit (See page 8-17)> Screen (See page 8-8)> Drum body (See page 8-9)

6. Remove Ink sensor PCB[K] (page 8-11)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].


A: Center shaftB: Drive shaftC: Drum shaft jointD: Squeegee drive gearE: Squeegee idlerF: Ink blocking plate FG: Ink bolcking plate RH: Transfer gearI: Squeegee frame FJ:Squeegee frame RK: Ink sensor PCBL: Drive shaft gearM: Squeegee Roller

I

J

C

H

A

B

C

D

E

GF

K

L

M

(Continue to page 8-15)


B A

C

D

C

EFRONT


8 - 15

14. Remove four screws each from the Drum main frames [C].15. Remove the Squeegee frame R [A] and the Squeegee frame F [E].16. Slowly take out the Squeegee roller [B].17. 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].

Precaution in Assembly> Do not forget to return the two O-rings [H] in their original positions.

Adjustments after Assembly> Squeegee gap adjustment is required. (See page 8-19)

A: Squeegee frame RB: Squeegee rollerC: Drum Main FrameD: Doctor rollerE: Squeegee frame FF: Squeegee block FG:Squeegee block RH:O-ring

REAR

F

G

H

H

(Continue to page 8-16)



8 - 16

Precaution in Assembly> 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 theJIG[C] through the holes on the Drum U support BKT R [D], Drum support R ass'y [G], Drumsupport F ass'y [F] and the Drum U support BKT F [E].

A:Drum shaft clamperB:Center shaftC:Drum grip shaft (JIG)D:Drum U support BKT RE:Drum U support BKT FF:Drum support F ass'yG:Drum support R ass'y

B

C

AREAR

B

FRONTA

B

D

E

F

G



8 - 17

9. Ink Pump Unit1. Remove the Front cover (See page 1-6)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.

Precautions in Assembly> Match the half-pierced section of the Ink pump unit with its counter part.

A: Ink pump unitB: Ink bottle guide

B

A


10. Inking Motor1. Remove the Front cover.(See page 1-6)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 unitB:Inking motor

A

B


DRUM SECTIONADJUSTMENT

8 - 19

3. Adjustment1. Squeegee Gap

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. 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 endsof 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.

Results of Incorrect Adjustment> If the gap is too big:

Too much gap will allow excess amount of ink to get on the inner surface of the Drum andresults 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 withuneven print density.

A: Doctor roller adjust plateB: Securing screwC: Adj. holeD: 2.5mm Allen wrench

(FRONT)

NARROWER

(REAR)

NARROWER

WIDER

WIDER

ABC

D

C

C

0.08 mm ± 0.02mm

0.08 mm ± 0.02mm


MEMO


1. Theory of Operation1. Paper Jam at First Paper Feed Area ..................................................................... 12. Paper Jam at Paper Receiving Area ..................................................................... 23. Print Start Timing Chart ......................................................................................... 34. During the Printing Timing Chart ........................................................................... 45. Print Stop Timing Chart ......................................................................................... 5

CONTENTS

CHAPTER 9: PAPER JAM


MEMO


PAPER JAMTHEORY OF OPERATION

1. Theory of Operation1. 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].

A:If the Paper recieving sensor does not detect any paper at Drum angle from 334 to 104, the machineassumes paper jam occurred and displays [J 2].

PAPER JAM AT PAPER FEED AREA

A: Pickup rollerB: PaperC: Pressure rollerD: Paper receiving sensorE: Drum

9 - 1

ON

Blocked Blocked

ONMain motor

Position-A sensor

Paper recieving sensor

NORMAL PAPER FEED

A

E

D

C

A A

Drum at 104

Drum 104 Drum 334 Drum 104

Drum at 334

Drum 334

Drum at 334

Drum at 104



2. Paper Jam at Paper Receiving Area1. Paper Receiving Sensor

> 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 areaand displays message [J 3].

PAPER JAM AT PAPER RECEIVING AREA

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

NORMAL PAPER DISCHARGE

Position-A sensor

Open

Main motor ON

Looks at the paper


Drum at 280

Drum at 280

A: Paper recieving sensorB: PaperC: The previous paperD: Drum

Drum at 257

AB

C

D

Paper Detected

257 2800 0180

A

A: Paper recieving sensor does not detect the paper at the drum angle from 257 to 280.

Drum at 257



3. Printing Start Timing Chart


Press START button

Drum angle

Paper feed clutch


Position-A sensor

Main motor

Blocked

Detection

No detection

Timing clutch

ON

Blocked Blocked

1 2

43

ON

ON

ON

0 0 090 180 270 66.3 160.3 334

60 rpm90 rpm

1stpaper

2ndpaper1st paper

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.

1. 60 rpm: 66.3 / 90 rpm: 63.72. 60 rpm: 144.8 / 90 rpm: 142.23. 60 rpm: 160.3 / 90 rpm: 157.74. 60 rpm: 61.3 / 90 rpm: 58.7

30rpm



Drum angle

Total countercount

Position-A sensor



Timing clutch

Paper feed clutch

Main motor Detection

Blocked

ON

Detection

4. During the Printing Timing Chart

Detection

ON ON

ON

ON

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 assumesthat 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 assumesthat the paper jam has occurred in the paper receiving area and indicates the message [J 3].

0 0334 257 280104 104 280

2. J 31. J 2

0


5. Print Stop Timing Chart


ON

Blocked Blocked

No detection

ON OFF

Detection(Last paper)

Print quantity onthe Display panelbecomes "0"orPress "STOP Key"

The TIMING CHART below is identical for both whenthe printing movement stops automatically by theprint quantity count on the Operation panel becomes"0" (Printing finished) and when the STOP button ispressed manually.

(Count of the last paper)

Drum angle

Main motor

Position-A sensor



Total countercount

1 When the Paper receiving sensor changes from "detecting ( the drum at 334 and 104 ) " to "notdetecting" (the drum angle at 257 and 280 ), the count signal is activated and the print quantity displayon the Panelis 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, theprint 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 forthe 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.

0104 257 104 315 0

OFF

15 rpm 1.95 rpm

0

Blocked

60 or 90 rpm

1

334

2 3 4

280

9 - 5


MEMO


1. Theory of Operation1. Clamp Unit Positioning Mechanism ....................................................................... 12. Clamp Plate Master Release Mechanism ............................................................. 23. Clamp Plate Master Clamp Mechanism ................................................................ 4

2. Removal and Assembly1. Clamp Unit ............................................................................................................ 72. Clamp Motor .......................................................................................................... 83. Clamp Sensor C .................................................................................................... 84. Clamp Sensor L .................................................................................................... 8

CHAPTER 10: MASTER CLAMP SECTION

CONTENTS


MEMO


MASTER CLAMP SECTIONTHEORY OF OPERATION

1. Theory of Operation1. 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 STARTbutton 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 Clampsensor 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, themachine indicates [E 3] immediately.

10 - 1

A:Clamp plate armB:Clamp motorC:Clamp sensor CD:Clamp encoder discE:Master projection plate armF:Clamp sensor LG:Clamp cam assembly

A

BD

C

F

E

G

*Light paths of the Clamp sensors C and L are both opened at Home position.

C

F



2. Clamp Plate Master Release Mechanism1. Check presence of the Clamp Sensor L

> When the START 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 Masterrelease 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.

A: Clamp sensor LB: Clamp sensor CC: Master release barD: Clamp cam ass'yE: Master projection plate armF: Clamp plate armG: Clamp plate

A

B

F

G

E

D

C


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 lightpath of the Clamp sensor L and C became opened, the machine assumes that the Clamp motor haslocked 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 notbecome open within 10 seconds after the light path of the Clamp sensor L and C became blocked, themachine assumes that the Clamp motor has locked and displays error message [E 3].

4 When START button is pressed, the machine confirms whether the light path of Clamp sensors L and Care opened or not. If the light paths of Clamp sensors L and C are not both open, the machine willdisplay [E 3] immediately.

Clamp Plate Master Release Timing Chart

4

Blocked

Max. 10sec

Clamp sensor C

Clamp sensor L

Open

Start buttonis pressed


0 180 270 0 180 270 0

1

2

3

Max. 10sec

Clamp encoder




3. Clamp Plate Master Clamp Mechanism1. Master removal

> The master clamp movement is made after the master is removed from the Drum.

2. Master clamping> With 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.

Sends master

A: Clamp plateB: Clamp encoder discC: Clamp cam ass'yD: Clamp open armE: Clamp sensor LF: Clamp sensor C

A

E

D

F CB

E

F



10 - 5

Master Clamping Timing Chart

1 If the light path of the Clamp sensor L is not blocked within 10 seconds after the Clamp motor isactivated, 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 isactivated, the machine assumes that the Clamp motor is locked and displays error message [E 03].

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 isactivated, the machine assumes that the Clamp motor is locked and displays error message [E 03].

5 The Clamp motor activates to clamp the master with the Clamp plate when the master loading to thedrum is completed.

Motion ends

Motion starts

Clamp sensor C

Clamp sensor L

Position-A sensor

Blocked

Clamp motor

Open

Blocked

Blocked

Open

ON OFFON

10 sec.10 sec.

1

2

3

4

5


MEMO


MASTER CLAMP SECTIONREMOVAL AND ASSEMBLY

2. Removal and Assembly1. Clamp Unit

1. Disconnect the power supply from the machine.2. Remove Back cover. (See page 1-6)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.

Precaution in Assembly> Match the half-pierced section on the Clamp unit [A] with its counter part.

A: Clamp unitB: Clamp motorC: Clamp sensor CD: Clamp sensor L

A

C

B

D

NOTE:The Clamp Unit used on KS800 may look a little different.


MASTER CLAMP SECTIONREMOVAL AND ASSEMBLY

2. Clamp Motor1. Disconnect the power supply from the machine.2. Remove Back cover. (See page 1-6)3. Remove Clamp unit. (See page 10-7)4. Remove two mounting screws of the Clamp motor [A] and remove the motor.

A: Clamp motorB: Clamp sensor CC: Clamp sensor L

4. Clamp Sensor L1. Disconnect the power supply from the machine.2. Remove the Back cover. (See page 1-6)3. Remove Clamp unit. (See page 10-7)4. Remove the mounting screw of the Clamp sensor L [B] and remove the sensor.

Precaution in Assembly> Match the half-pierced section of the sensor with its counter part.

3. Clamp Sensor C1. Disconnect the power supply from the machine.2. Remove Back cover.(See page 1-6)3. Remove Clamp unit. (See page 10-7)4. Remove the mounting screw of the Clamp sensor C [C] bracket with the sensor attached.5. Remove the sensor from the bracket.

Precaution in Assembly> Match the half-pierced section of the Clamp sensor bracket with its counter part.

A

B

C

NOTE:The Clamp Unit used on KS800 may look a little different.


1. Theory of Operation1. Master Removal Unit Mechanism.......................................................................... 12. Master on the Drum (before master removal) Check Mechanism ......................... 23. Clamp Plate Master Release Mechanism ............................................................. 44. Master Removal Mechanism ................................................................................. 65. Master Disposal Box Set Mechanism .................................................................... 8

2. Removal and Assembly1. Master Removal Unit ............................................................................................. 92. Master Removal Clutch ....................................................................................... 103. Master Removal Sensor ...................................................................................... 114. Disposal Box Set Sensor ..................................................................................... 115. Master Removal Hook ......................................................................................... 126. Vertical Transport Roller (Upper) ......................................................................... 137. Vertical Transport Roller (Lower) ......................................................................... 138. Master Removal Guide (Lower) ........................................................................... 13

CHAPTER 11: MASTER REMOVAL SECTION

CONTENTS


MEMO


MASTER REMOVAL SECTIONTHEORY OF OPERATION

1. Theory of Operation1. Master Removal Unit Mechanism

> The Master removal unit [A] removes the master on the drum each time the master makingoperation 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 Materremoval clutch [B].

11 - 1

B

A

E

F

D

DC

A

B

A:Master removal unitB:Master removal clutchC:Master disposal boxD:Master removal hookE:Transpotation roller upperF:Transpotation roller lower

(for KS500)C

(for KS600)One for KS800 looks alittle different.

(KS800 uses master removal motorinstead of a clutch.)

(for KS500 & KS600)



2. Master on the Drum (before master removal) Check Mechanism1. Master Sensor

> Master sensor [B] checks the presence of the Master [D] on the drum when the Start button ispressed 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 thePosition-A.

> If the machine already knows the presence of the Master [D] on the drum from the earliermachine 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.

11 - 2

A:Light absorber stripB:Master sensorC:DrumD:Master Drum angle = 134

(From Position-A)

D

B

B

A

C



Master on the Drum Check Timing Chart (before master removal)

Main motor

Master sensor

Position-A sensor

Press START button

BlockedBlocked

ONOFF

2

Detectingmaster

Drum at 134

~~

1

1 The Drum is at Position-A when the START button is pressed.

2 If the light of the Master sensor is reflected back (detecting master) at Drum 134 , the Master removalsensor 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 removalmovement will be skipped.

* If the machine knows the presence of master on the Drum from earlier machine movements, this masteron the Drum check movement is skipped.

Open


3. Clamp Plate Master Release Mechanism1. Master on the Drum check

> When the START button is pressed for confidential or regular master making, the Drum rotatesand 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 returnsto 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 releasebar [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:Clamp cam ass'yB:Clamp open armC:Clamp plateD:Master release armE:Master release barF:Clamp sensor CG:Clamp sensor L

11 - 4


A

F

D

B

C

E

G



Clamp Plate Master Release Timing Chart

4

Blocked

Max. 10sec

Clamp sensor C

Clamp sensor L

Open



0 180 270 0 180 270 0

1

2

3

Max. 10sec

Max. 10sec

Clamp encoder

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 lightpath of the Clamp sensor L and C became opened, the machine assumes that the Clamp motor haslocked 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 notbecome open within 10 seconds after the light path of the Clamp sensor L and C became blocked, themachine assumes that the Clamp motor has locked and displays error message [E 3].

4 When START button is pressed, the machine confirms whether the light path of Clamp sensors L and Care opened or not. If the light paths of Clamp sensors L and C are not both open, the machine willdisplay [E 3] immediately.

123456789012345678901234123123

123123

1234567890123456123 1231234123123



4. Master Removal Mechanism1. Master Removal Clutch

> The Main motor rotatates the Vertical transport roller upper [B] and lower [A] via the Materremoval clutch [E].

> By the rotation of the Drum, the leading edge of the master comes in between the VerticalTransport 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.

A:Vertical transport roller (lower)B:Vertical transport roller (upper)C:Master removal sensorD:Master removal hookE:Master removal clutch

A

B

C

D

E

Sketch of master disposal box for KS500.(That for KS600 & KS800 looks different.)



Master Removal Timing Chart

Master removalsensor

Main motor

Position-A sensor

1 During the initializing of the drum towards the position A in the master removal operation, if removedmaster is detected by Master sensor at Drum angle 134 , the Master removal sensor looks for theremoved master.If removed master is not detected by the Master removal sensor at Drum 134, the machine assumesmaster 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 hascleared through the sensor.If the Master removal sensor still detects removed master, the machine assumes removed master hasjammed at master removal area and displays message [J10].

* If Master removal sensor detects removed master when the Start button is pressed, the machineassumes that the removed master is jammed and the message [J10] is displayed.

ON

Master removalclutch

ON

OpenBlocked

OFF

OFF

Detecting removed master

15rpm 15rpm

1.95rpm

1 2

315134 00

123456789011234567890112345678901123456789011234567890112345678901123456789011234567890112345678901

1234567123123

12121234567890123456789012345678901212123123

123123123456789012

123123

11111111111111111111111111111111111111111111111111111111

121212

1111111111111111111111111111111111111111111111111111111111



5. Master Disposal Box Set Mechanism1. Disposal Box Set Sensor

> Disposal box set sensor checks the presence of the Master disposal box and whether theMaster disposal box is opened or closed.

> When the Master disposal box is set in the machine, its tip blocks light path of the Disposalbox set sensor.

A:Disposal box set sensorB:Master disposal boxC:TipD:Master removal unit (closed)

B

D

A

C

Sketch of masterdisposal box for KS500.

Sketch of master disposalbox for KS600.

(That for KS500 and KS800 looks different.)


MASTER REMOVAL SECTIONREMOVAL AND ASSEMBLY

2. Removal and Assembly1. Master Removal Unit

1. Disconnect the power supply from the machine.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].

A:Master removal unitB:Master Disposal BoxC:Master removal unit leverD:Connector

B

C

D

A

Sketch of master disposalbox for KS600.

(That for KS500 andKS800 looks different.)



11 - 10

2. Master Removal Clutch1. Disconnect the power supply from the machine.2. Remove the Back cover. (See page 1-6)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].

Precaution in Assembly> Mount the slit on the Master removal clutch [C] over the Clutch B bracket [A].

A:Clutch B BKTB:MetalC:Master Removal ClutchD:MetalE:M-R GearF:E-ring

B

C

E

A

D

F

KS800 uses Master removalmotor instead of a clutch.KS500 & KS600 only

(KS800 uses master removal motorinstead of a clutch.)

(for KS500 & KS600)



3. Master Removal Sensor1. Disconnect the power supply from the machine, and remove Master removal cover.(See page 1-

6)2. Slide the Master removal unit out.3. Disconnect the Connector of the Master removal sensor [C].4. Remove the mounting screw of the Master removal sensor bracket and remove the bracket.5. Remove the sensor from the bracket.

Precaution in Assembly> Match the half-pierced section of the Master removal sensor bracket with its counter part.

4. Disposal Box Set Sensor1. Disconnect the power supply from the machine, and remove Master removal cover.(See page 1-

6)2. Disconnect the Connector of the Disposal box set sensor [A].3. Remove the mounting screw of the Disposal box set sensor bracket and remove the bracket.4. Remove the sensor [A] from the bracket.

A

A:Disposal box set sensorB:Master removal UnitC:Master removal sensor

11 - 11

B

C



5. Master Removal Hook1. 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.

Precaution in Assembly> 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.

11 - 12

A:Master removal unitB:Master removal hooks

A

B



6. Vertical Transport Roller (Upper)1. Disconnect the power supply from the machine.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)1. Disconnect the power supply from the machine.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 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.

11 - 13

A:Master removal guide (Upper)B:Vertical transport roller (Upper)C:Vertical transport roller (Lower)D:Master removal unitE:Master removal guide (Lower)F:Master disposal boxG:Transport roller gearH:Master removal sensor

8. Master Removal Guide (Lower)1. Disconnect the power supply from the machine.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 the Vertical transport roller (Upper) [B] and (Lower) [C].7. Remove three mounting screws then remove the Master removal guide(Lower) [E].

A

B

C

D

E

F

G

H

Sketch of master disposal box for KS500.(That for KS600 & KS800 looks different.)


MEMO


1. Theory of Operation1. Original Loading Mechanism ................................................................................. 12. Original Scanning Mechanism ............................................................................... 33. Image Scanner ...................................................................................................... 5

2. Removal and Assembly1. White Roller .......................................................................................................... 72. Image Scanner Unit .............................................................................................. 83. Original IN Sensor ................................................................................................. 94. Pickup Roller ....................................................................................................... 105. Eject Roller Upper ............................................................................................... 106. Document Feeder Hook ...................................................................................... 107. Load Roller .......................................................................................................... 118. Eject Roller Lower ............................................................................................... 119. Read Pulse Motor ................................................................................................ 11

3. Adjustment1. Image scanner gain adjustment .......................................................................... 13

CHAPTER 12: IMAGE SCANNING SECTION

CONTENTS


MEMO


IMAGE SCANNING SECTIONTHEORY OF OPERATION

1. Theory of Operation1. Original Loading Mechanism

An original placed on the Original rack [G] is automatically fed when the master making process isstarted.

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] byrotation of the White roller [C].

> The Eject roller upper [E] and lower [J] feeds the original then ejects it from the documentfeeder.

12 - 1

A: Read pulse motorB: Pickup rollerC: White rollerD: Original detection sensorE: Eject roller upperF: Load rollerG: Original feed trayH: Image scanner I :Original IN sensorJ :Eject roller lower

A

C

D

F

E B

H

I

J G


Original Loading Timing Chart


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 offthe 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.

Original set

Original IN sensor

Scanner LED

Read pulse motor

No detection Original detected

OFFON

OFF

ON

293pulses

Max.5sec.

150 ms 150 ms

ONOFF

1

2Motion ends

A: Read pulse motorB: Pickup rollerC: White rollerD: Original detection sensorE: Eject rollerF: Load rollerG: Original IN sensorH: Image scanner I : Eject roller lower

A

CD FE B

H G

I

150 ms



2. Original Scanning MechanismWhen the master removal is completed, the Read pulse motor [F] turns ON to feed the original ontothe Image scanner [H].And after completing the master removal, the Drum rotates to place the master onto the Drum untilthe Original scanning ends. Then original loading movement is completed.

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 turnsON 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 scannerLED are turned OFF to stop the image scanning.

> The Read pulse motor [E] stops after 539 pulses from the original scanning movement ends.

A:Image scannerB:Eject rollerC:White rollerD:Original IN sensorE:Read pulse motorF:Eject roller (Lower)

A

C

D

E

B

F



Original Scanning Timing Chart

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 outfrom the Original IN sensor, the Read/Write start signal and the Image scanner LED are turned OFF tostop the image scanning.

3 After the pulse of the Read pulse motor is counted 539 pulses from the Read/Write start signal and theImage scanner LED are turned OFF or, the pulse of the Read pulse motor is counted 5082 pulses fromthe Read pulse motor starts activating.

Motion ends

Scanner LED

Read pulse motor

Main motor

180 ms

Original IN sensor

Clamp motor

Detecting original

OFF

ON

ON

ON

128 p

539 pMAX 5082 pulses

1 2

3



3. Image ScannerThe image scanning is done by an optical type Image scanner [A] which emits greenish-yellow lightfrom 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. Thosereceiving 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).

A

A:Image scanner unitB:LED arrayC:Photo transistor array

BC

Top view


MEMO


2. Removal and Assembly1. White Roller

1. Disconnect the power supply from the machine.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.

Precaution before Assembly> Insert the Pin [C] in the White roller shaft and match the Pin [C] to slit of the White roller gear

[D].

IMAGE SCANNING SECTIONREMOVAL AND ASSEMBLY

12 - 7

A:Document feederB:White rollerC:PinD:White roller gearE:White roller holder

D

E

B

C

A



2. Image Scanner Unit1. Disconnect the power supply from the machine.2. Remove the Document feeder [D]. (See page 12-7)3. Remove the Document feeder cover.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.

A:Image scanner unitB:Scanner holder LC:Scanner holder RD:Document feeder

A

B

C

D



3. Original IN Sensor1. Disconnect the power supply from the machine.2. Remove the Document feeder. (See page 12-7)3. Remove the Document feeder cover.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 sensorB:Original guide base plate

A

B


4. Pickup Roller1. Disconnect the power supply from the machine.2. Remove the White roller cover upper [E] from the document feeder. (See page 12-7)3. Remove the Pick up roller spring [C] then remove the Pick up roller [D].


5. Eject Roller Upper1. Disconnect the power supply from the machine.2. Remove the White roller cover upper [E] from the document feeder. (See page 12-7)3. Remove the Eject roller spring [A] then remove the Eject roller upper [B].

A:Eject roller springB:Eject roller upperC:Pick up roller springD:Pick up rollerE:White roller cover upperF:Document feeder hookG:Hook springH:White roller cover lower

B

A

C

D

E

H

FG

G

6. Document Feeder Hook1. Disconnect the power supply from the machine.2. Remove the White roller cover upper [E] from the document feeder. (See page 12-7)3. Remove the Hook springs [G].4. Remove Document feeder hook[F].


7. Load Roller1. Disconnect the power supply from the machine.2. Remove the Document feeder (See page 12-7) and the Document feeder cover.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.


A:Eject rollerB:Load rollerC:Read pulse motorD:Pin

9. Read Pulse Motor1. Disconnect the power supply from the machine.2. Remove the Document feeder (See page 12-7) and the Document feeder cover.3. Remove two mounting screw of the Read pulse motor [C] and remove the motor.

Precaution before Assembly> Connector of the Read pulse motor [C] should face to the Image scanner side when install the

motor[C].

B

C

8. Eject Roller Lower1. Disconnect the power supply from the machine.2. Remove the Document feeder (See page 12-7) and the Document feeder cover.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.

Precaution before Assembly> Insert the Pin [D] in the Eject roller lower shaft and match the Pin [D] to slit of the counter gear

[E].

DA


MEMO


IMAGE SCANNING SECTIONADJUSTMENT

3. Adjustment1. Image scanner gain adjustmentAfter replacing the Image scanner unit, the gain adjustment of the scanner is required.The adjustment procedure is as follows.

1. Disconnect the power supply from the machine.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

after pressing the Stop key.5. If the voltage is not in the range, turn the VR1 [A] on the Main PCB [C] to adjust the voltage.

A: VR 1B: CN111C:Main PCBD:Digital multi meter

A

B DC

Precaution before Assembly> Do not short circuit the 1 pin with the 2 pin when connecting the Digital multi meter with the

CN 111.


MEMO

12 - 14


1. Theory of Operation1. Cutter Home Positioning Mechanism .................................................................... 12. Cutting Mechanism ............................................................................................... 3

2. Removal and Assembly1. Cutter Unit ............................................................................................................. 5

CHAPTER 13: CUTTER SECTION

CONTENTS


MEMO


CUTTER SECTIONTHEORY OF OPERATION

1. Theory of Operation1. 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.

13 - 1

A:Cutter UnitB:CutterC:Cutter motorD:Home position switchE:Cutter gearF:End position switch

F

C D

E

DA

B



13 - 2

Home PositionSwitch

Cutter motor

Movementcompleted

Cutter Home Positioning Timing Chart

Movement starts

1 If the Home position switch is detected (the Cutter does not move from the Home position) even though500 ms has passed after the Cutter motor activated, the machine assumes the Cutter motor has lockedand 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 though500 ms has passed after the Cutter motor activated, the machine assumes the Cutter motor has lockedand indicates error message [E 13].

4 If the Home position switch is not detected within 2000 ms after the Cutter motor activates (cutter notat End position), the machine assumes the Cutter motor has locked and indicates error message [E 13].

End positionSwitch

CCW

CW ON

ON

2000ms 2000ms

500ms

500ms

breakes

2 3 4

breakes

1



13 - 3

2. Cutting Mechanism1. Master Cutting

> Cutter motor [C] activates and cuts the master each time the master loading is made on theDrum.

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.

A:Cutter UnitB:CutterC:Cutter motorD:Home position switchE:Cutter gearF:End position switch

B

A

CE

F

D


MEMO


CUTTER SECTIONREMOVAL AND ASSEMBLY

2. Removal and Assembly1. Cutter Unit

1. Disconnect the power supply from the machine.2. Remove the Front cover. (See page 1-6)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.

Precaution in Assembly> Match the half-pierced sections of the Cutter unit with its counter part.

A:Cutter unit

A

FRONT


1. Theory of Operation1. Master Making ....................................................................................................... 12. TPH Positioning .................................................................................................... 33. Thermal Power Safety Switches ............................................................................ 5

2. Removal and Assembly1. Write Roller ........................................................................................................... 72. Thermal Print Head (TPH)..................................................................................... 83. TPH Position Sensor ............................................................................................. 9

3. Adjustment1. Thermal Power of Thermal Print Head ................................................................ 11

CHAPTER 14: MASTER MAKING SECTION

CONTENTS


MEMO


MASTER MAKING SECTIONTHEORY OF OPERATION

1. Theory of Operation1. Master Making

When the START key is pressed for master making, the Drum rotates to remove the master on theDrum.At the same time the TPH-CTL signal is turned ON to supply heating power to the Thermal printhead [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 Drumrotates 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.

14 - 1

A:Thermal print head (TPH)B:Write rollerC:Master rollD:Write pulse motor

A

B

C

D


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 andmaster making starts. The original scanning starts at the same time.

3 After the Scanning is completed or Write pulse motor has rotated maximum master making length, boththe 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 (4769pulses) of master material is moved forward.The Write pulse motor then turns OFF and the Cutter unit cuts the master material.


14 - 2

1. Master Making Timing Chart

Cutter unitactivates

Scanning is completed, orWrite pulse motor has rotatedmaximum master makinglength.

Clamp motor

Write pulsemotor

TPH-CTL signal

Read pulse motor

Original IN sensor Detecting original

4769 pulses

14pluse

180ms

MAX 4141pulses *1

10.87mm

ON OFF

ON

ON

1

2

3

4

*1



2. TPH Positioning

The TPH [C] moves down and up when master feeding is necessary or the master making process isended.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 Mastermaking 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)

A

C

B

A:TPH positioning sensorB:Write rollerC:TPH unitD:Write pulse motorE:TPH position cam

TPHdetouching

A Sensor blocked

D

TPHTouching

Sensor opened

D

B C

Spring force

E



2. TPH Positioning Timing Chart

1. From Original set to Preparation of Scanning

2. From Master making to Master cutting

Read pulse motor

White pulsemotor

TPH positionsensor

ON

ON CCW

OFF ON

ON CW

ON CCWON CW

Blocked

Blocked

Blocked

ON CW

OFF

OFFTPH positionsensor

White pulsemotor

Read pulse motor

Master making ended Master cutting



14 - 5

3. Thermal Power Safety Switches1. Safety Switches

> The actuators of all four safety switches must be pressed in order to feed electrical power tothe TPH unit.

> These four switches also acts as Main motor safety switches.

A:Master removal unit safety switchB:Guide plate safety switchC:Master making unit safety switchD:Separation unit safety switch

B

D

C

A


MEMO

14 - 6


MASTER MAKING SECTIONREMOVAL AND ASSEMBLY

2. Removal and Assembly1. Write Roller

1. Disconnect the power supply from the machine.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.

Precaution in Assembly> 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)

A:Lock ringB:Write roller ass'yC:MetalD:Collar

a. Corrct position

b. Incorrct position

B

A

REAR

FRONT

Flat part

C

C

D

D



2. Thermal Print Head (TPH)1. Disconnect the power supply from the machine.2. Open the Master making unit.3. Disconnect the TPH connectors [A] out from the TPH ass'y [D].4. Remove the screw of the Grand wire [B].5. Remove the TPH ass'y screws [C].6. Slide the TPH ass'y [D] up to release from the Master making unit.7. Remove two mounting screws of the TPH position plate [E] from the TPH ass'y [D].

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.

Adjustment after Assembly> Thermal power adjustment of the TPH must be done when replacing the TPH ass'y.

A:TPH connectorB:Ground wireC:TPH ass'y screwD:TPH ass'yE:TPH position plate

BA C A

D

A AB E



3. TPH Position Sensor1. Disconnect the power supply from the machine.2. Open the Master making unit [D].3. Remove the Springs [A] from the Master making unit [D].4. Remove the the Master making upper unit cover [B].5. Remove the Position sensor plate [C].6. Remove the connector of the TPH position sensor [E].7. Remove the TPH position sensor [E] from the Master making unit [D].

BE

D

C

A

A: SpringB: Master making upper unit coverC: Position sensor plateD: Master making unitE: TPH position sensor

A


MEMO


MASTER MAKING SECTIONADJUSTMENT

3. Adjustment1. 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)2. Remove the Front cover. (See page 1-6)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(ΩΩΩΩΩ) setting.The resistance (ΩΩΩΩΩ) of the new TPH is found printed on a seal attached on the TPH itself.

8. If the voltage on the Voltmeter does not match with the voltage on the chart in the next page, turnthe Volume adjust knob, of which can be seen throgh the protection cover of the Power supllyPCB 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 byFINE Adj. VR.

10. After the adjustment is done, exit from the Test mode.

No.1 pin No.3 pin

Power supply PCB

* TPH Adjustment Table is the next page

FINE Adj. VR

NORMAL Adj. VR

CN008


MEMO


MASTER MAKING SECTIONADJUSTMENT

Resistance (ΩΩΩΩΩ) Voltage (V)1360 ~ 1373 16.11374 ~ 1390 16.21391 ~ 1407 16.31408 ~ 1424 16.41425 ~ 1442 16.51443 ~ 1459 16.61460 ~ 1477 16.71478 ~ 1494 16.81495 ~ 1512 16.91513 ~ 1530 17.01531 ~ 1548 17.11549 ~ 1566 17.21567 ~ 1584 17.31585 ~ 1603 17.41604 ~ 1621 17.51622 ~ 1640 17.61641 ~ 1658 17.71659 ~ 1677 17.81678 ~ 1696 17.9

All KS Models

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.

Results of Incorrect Adjustment> If the voltage is too High:

The solid print image will be deformed and the heating elements of the Thermal print head willbe damaged from overheat.

> If the voltage is too Low:The heat from the Thermal print head becomes too weak and the thin lines cannot bereproduced clearly.

TPH Adjustment Table

Resistance (ΩΩΩΩΩ) Voltage (V)1697 ~ 1715 18.01716 ~ 1734 18.11735 ~ 1753 18.21754 ~ 1772 18.31773 ~ 1792 18.41793 ~ 1811 18.51812 ~ 1831 18.61832 ~ 1840 18.7

All KS Models


1. Theory of Operation1. Master Making Unit Set Mechanism ...................................................................... 12. Master Positioning Mechanism.............................................................................. 23. Master Feeding Mechanism .................................................................................. 44. Clamp Plate Master Clamp Mechanism ................................................................ 65. Master Loading on the Drum Mechanism .............................................................. 86. Master Advance after Master Cutting .................................................................. 10

2. Removal and Assembly1. Master Making Unit ............................................................................................. 132. Master Making Unit Safety Switch ....................................................................... 153. Write Pulse Motor ................................................................................................ 164. Master Positioning Sensor ................................................................................... 175. Master Loading Solenoid ..................................................................................... 186. Master End Sensor ............................................................................................. 19

CHAPTER 15: MASTER CLAMP/LOADING SECTION

CONTENTS


MEMO


MASTER CLAMP & LOADING SECTIONTHEORY OF OPERATION

1. Theory of Operation1. Master Making Unit Set Mechanism

1. Master Making Unit Safety Switch> 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 motorand 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].

15 - 1

A:Master making unit safety switchB:Master making unit upper frameC:Master end sensor

B

A

C



2. Master Positioning Mechanism1. Master Positioning

> The leading edge of the master material [A] rests against the Master tension plate [C] just afterthe master loading.

> As the START button is pressed for normal master making or confidential master making, theMaster loading solenoid [F] activates to release the Mater tension plate [C] from master andthe 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 Masterloading solenoid [F] and the Write pulse motor [E] turn OFF and completes the masterpositioning movement.

15 - 2

A:Lead edge of the masterB:Write rollerC:Master tension plateD:Master positioning sensorE:Write pulse motorF:Master loading solenoid

B

CA

E

D

F



15 - 3

Master Positioning Timing Chart

End of movement

Master positioningsensor

Write pulse motor

Press START button

Master LoadingSolenoid

Detecting master

1 The Master loading solenoid activates to release the Master tension plate from the master. At the sametime, 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 secondsafter the activation of the Write pulse motor, the machine assumes master mis-feed has occurred andindicates the message [J 4].

max. 5 seconds 188pulse

A:Master rollB:Thermal print headC:CutterD:Write rollerE:Master positioning sensor

A

CB

E

D

1

2



15 - 4

3. Master Feeding Mechanism1. Start of Master Feeding

> At the Drum position-A, the Write pulse motor activate to rotates the Write roller to feed themaster material [A].

> The Master loading solenoid activates when the lead edge of the master [A] is fed onto theMater 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 materialB:Clamp plate

A

B



15 - 5

Master Feeding Timing Chart

Clamp motor

Write pulse motor

Main motor

Position-A sensor

Clamp platestarts to open

1 If the light path of the Clamp sensor L does not becomes blocked and the Clamp sensor C does notbecomes open, the machine assumes that the Clamp motor did not activate or Clamp sensor L or C hasbeen 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 masteris under the Clamp plate.

3 If the light path of the Clamp sensor L does not becomes open, the machine assumes that the Clampmotor did not activate or Clamp sensor L has been damaged and [E 3] is indicated.

DRUMPosition-A

B

FG

A

CD

E

A:Master rollB:Thermal print headC:Cutter unitD:Master positioning sensorE:Clamp plateF:Write rollerG:Master material

OFF

ON ON

ON

Clamp plateclose

1

10 sec.

10 sec.

Blocked

Clamp sensor L

Clamp sensor C

2

3

Blocked

Blocked

Open

Open

389 pulses(32.4mm)



4. Clamp Plate Master Clamp Mechanism1. Master removal

> During the master removal movement, when the Drum comes back to position-A, the leadingedge of the new master comes towards the Drum, ready to be clamped.

2. Master clamping> With 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 movedby following the Clamp cam [B].

> The Clamp motor stops when the light path of Clamp sensor C [D] becomes open and keepsthe Clamp plate [C] raised open.

> When the Write pulse motor sends certain set amount of master [H] onto the Drum, the Clampmotor 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.The Clamp unit is back at the Home position.

A:Clamp encoder discB:Clamp cam ass'yC:Clamp plateD:Clamp sensor CE:M-Projection plate armF:Clamp sensor LG:Clamp plate armH:Master

A

B

C

D

F

E

G

Sends master

H


Clamp motor

Clamp sensor L

Clamp sensor C

Blocked

Blocked

15 - 7

Master Clamping Timing Chart

1 If the light path of the Clamp sensor C is not opened within 10 seconds after the Clamp motor isactivated, the machine assumes that the Clamp motor is locked and displays error message [E 3].

2 If the light path of the Clamp sensor L is not blocked within 10 seconds after the Clamp motor isactivated, the machine assumes that the Clamp motor is locked and displays error message [E 3].

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 thedrum is completed.

5 If the light path of the Clamp sensorL is not opened within 10 seconds after the Clamp motor isactivated, the machine assumes that the Clamp motor is locked and displays error message [E 03].

Motion starts


10 sec. 10 sec.

1

2

Open

Open

ON ON3 4

5

Motion ends



5. Master Loading on the Drum MechanismAs 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 anymaster loading error.> The Write pulse motor keeps feeding the master, and if no master loading is detected, the

Main motor stops at position-A.and [J 5] is displayed.

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.

A:Clamp plateB:DrumC:TPHD:Write rollerE:Master rollF:Cutter unitG:Master sensor

Master Loading Movement

1. After the master is clamped on theDrum and Write pulse motor rotatesfor a set amount, the Drum rotates tostart the master loading.

2. The Drum position at 134 , the Mastersensor [G] checks for any masterloading error while the Write pulsemotor keeps feeding the master.

292

PositionA

3. Cutter motor activates to cut themaster at the Drum posiotion 292 .

C

F

E

B

A

134D

G



Master Loading Timing Chart

Position-A sensor

Main motor

Write pulse motor

Master countercount signal

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.

Clamp motor 180ms

Drum angle

134 292

5mm

Cutter motor

1

3

4

Master sensorDetecting masterNot detecting master

Detecting Not Detecting

ON

ON

OFF

OFF

OFF

OFF

ON

ON

1.95 rpm

4854 pulses2


6. Master Advance after Master CuttingIf the master cutting is confirmed by the Master positioning sensor [E] after the master cutting, themaster material from the master roll is moved forward until the leading edge is under the Masterpositioning 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].


15 - 10

A:Master rollB:Themal Print headC:Write pulse motorD:Write rollerE:Master positioning sensor

A

BD

C

E


Master Advance after Master Cutting Timing Chart

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 occcurredand [J 6] is indicated.

2. If the Master poitioning sensor [E] does not detecte the master within 5 seconds, the machine assumsthat 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 proceedthe 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].


Master advancemovement starts

Cutter motor

Master positioningsensor

Write pulse motor

Master loadingsolenoid

A

C

BE

D

A:Master rollB:Thermal print headC:Cutter UnitD:Write rollerE:Master positioning sensor

ON

OFF

Not detecting master

Detecting master

ON

ON

OFF

OFF

max 5 sec.

Position A

1

2

3

4 188pulses


MEMO


2. Removal and Assembly1. Master Making Unit

1. Disconnect the power supply from the machine.2. Slide the Master removal unit.3. Remove the Back cover, Front cover. (See page 1-6)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 8-7) 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)

15 - 13

MASTER CLAMP & LOADING SECTIONREMOVAL AND ASSEMBLY

A:Mounting screwB:HookC:Powe supply PCBD:Main PCBE:Master making unitF:Cutter unit

A B

C ED



15 - 14

Precaution in Assembly> 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

E

F



2. Master Making Unit Safety Switch1. Disconnect the power supply from the machine.2. Remove the Master making unit [B](See page 15-13).3. Disconnect the Connector of the Master making unit safety switch [A].4. Remove two mounting screws of the Master making unit safety switch [A] and remove the

switch.

A:Master making unit safety switchB:Master making unit

B

A



3. Write Pulse Motor1. Disconnect the power supply from the machine.2. Remove Master making unit. (See page 15-13)3. Disconnect the Connector of the Write pulse motor [A].4. Remove two mounting screws of the Write pulse motor [A] and remove the motor.

Precaution in Assembly> 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 motorB:Motor gearC:Drive gear

A

B

C


A

15 - 17


4. Master Positioning Sensor1. Disconnect the power supply from the machine.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].

A:Master positioning sensorB:Master tension shaftC:Cutter guide plateD:Master feed sheetE:Wire clampper

C

Precaution in Assembly> 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].

C

A

BC E

D

B



A:Master loading solenoidB:Master making unit

5. Master Loading Solenoid1. Disconnect the power supply from the machine.2. Remove the Master making unit.[B] (See page 15-13)3. Disconnect the Connector of the Master loading solenoid [A].4. Remove two mounting screws of the Master loading solenoid [A] and remove the solenoid from

the Master making unit [B].

A

B



6. Master End Sensor1. Disconnect the power supply from the machine.2. Remove the Master making unit [B]. (See page 15-13)3. Open the Master making unit and remove the master roll.4. Disconnect the Connector of the Master end sensor and remove the sensor from the sensor

bracket on the machine.

Precaution in Assembly> Do not damage the hooks of the Master end sensor when install the sensor to the sensor

bracket on the machine.

A:Master end sensorB:Master making unit

A

B

Hooks


MEMO


Electrical Components1. Sensors .................................................................................................... APX(0)-12. Switches ................................................................................................... APX(0)-23. Clutches & Solenoids ............................................................................... APX(0)-34. Motors & Fan............................................................................................ APX(0)-4

Test Mode1. Operation Procedures .............................................................................. APX(1)-12. Test Items and Operations ....................................................................... APX(1)-3

Users Mode1. Operation Procedures & Items ................................................................. APX(2)-1

Advice Displays (Call Service Messages)1. Display Messages .................................................................................... APX(3)-1

Wiring Diagram1. Wiring Diagram ........................................................................................ APX(4)-1

CONTENTS

APPENDIX


MEMO


APPENDIX (0)ELECTRICAL COMPONENTS

APX(0) - 1

Electrical Components1. Sensors

A:Master positioning sensorB:Original IN sensorC:TPH position sensorD:Paper receiving sensorE:Master end sensorF:Main motor encoderG:Clamp sensor LH:Clamp sensor CI:Master removal sensorJ:Master sensorK:Overflow sensorL:Ink sensorM:Ink bottle Set sensorN:Position-A sensorO:Master disposal box set sensor

K

A

B

C

F

G

D

E

H

I

J

L

M

N

O


A:Master removal unit safety switchB:Guide plate safety switchC:Main power switchD:Master making unit safety switchE:Separation base safety switch


APX(0) - 2

2. Switches

B

E

D

A

C



APX(0) - 3

3. Clutches & Solenoids

A:Master loading solenoidB:Master removal clutchC:Paper feed clutchD:Timing clutch

A B

C

D



APX(0) - 4

4. Motors & Fan

A:Cutter motorB:Read pulse motorC:Separation fanD:Suction fanE:Write pulse motorF:Clamp motorG:Main motorH:Ink motor

B

C

D

A

G

F

H

E


Test Mode1. Operation Procedures

The Test mode program enables a service technician to check the operation of each electricalcomponent in the machine.

1. [Starting Up Test Mode]Turn ON the power while pressing the PRINT POSITION buttons and on the machineoperation 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:

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).

APPENDIX (1)TEST MODE

APX(1) - 1

System ROMVersion No.(Ver. 1.01)

Press the "START" button to start the test.

Press the "START" button again to stop the test.

• 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.

Test No.

Test Mode status 0 for OFF status 1 for ON status

3. [Selecting Another Test Number]To select another Test No., clear the set Test No. by pressing the "C" or "STOP" button andselect another Test No.

The previous Test No. is erased.

Select a new Test No. (Example: No.35)

1 10

1 20

1 21

1 20

0 00

3 50


[Example] - In selecting Test mode No.80. Select 80 and then press "START".

APX(1) - 2

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 thenpress the "ALL RESET" button for 1 second.

The Test No. is cleared by "C" or "STOP".


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.

Test mode No.

The selectable settings are:-3-2,-1,0, 1, 2, 3

flashes

Use the PRINT POSITION button or to make the setting selection.

[Example] - In selecting "3" for the setting, press the button until "3" flashes in the first display window.

Press "ALL RESET" button for 1 second.

Press the "START" button to input the newly selected setting.

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.

0 00

0

8 00

Test Mode status 0 for OFF status 1 for ON status

3

0 00

0


1 Original IN sensor Reflected light is detected (Original is set)

2 Master sensor Reflected light is detected (Master is detected)

3 Master positioning sensor Reflected light is detected (Master is detected)

4 Master end sensor Light path is blocked (Master end detected)

5 TPH position sensor Light path is blocked (TPH is raised)

6 Cutter home position switch Actuator is pressed (Cutter at home position)

7 Cutter end position switch Actuator is pressed (Cutter at end position)

8 Clamp sensor L Light path is blocked (Disc is detected)

9 Clamp sensor C Light path is blocked (Disc is detected)

10 Master removal sensor Actuator is pressed (Master is jammed)

11 Position-A sensor Light path is blocked (Drum is at position-A)

12 Paper receiving sensor Reflected light is detected (Paper is detected)

13 Ink sensor Ink is detected

14 Overflow sensor Ink is detected

Paper Guide Plate safety SW Actuator is pressed (Unit is set)

Separation unit safety SW Actuator is pressed (Unit is set)

16 Master making unit safety SW Actuator is pressed (Unit is set)

17 Master removal unit safety SW Actuator is pressed (Unit is set)

18 Ink Bottle set sensor Light path is open (Ink bottle is set)

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 Light path is blocked (Disposal box is set)

29 Not available

2. Test Items and Operations


APX(1) - 3

No. Test Component Detection status

1) Sensor/SW Test

A beep sounds in two ways to tell the current condition. (except No.28)Detection: 0.1 second interval beepNo detection: 0.5 second interval beep

15 Serialconnection

28 TPH thermister readingThe temperature is shown on the print quantity

display window in degrees Celsius.


30 Main motor (1.95 rpm)

31 Main motor (10 rpm)



34 Main motor (60rpm)


36 Not available

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

44 Master removal motor

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

2) Motor/Solenoid Test

Use "START" button for ON/OFF control.

No. Test Component

All the Safety switches mustbe pressed and the Drummust be set in the machine.

(For KS500 & KS600)

(For KS800)


53 TPH Heating power selectionTPH heating time can be changed to suit the amount of ink from the drum to thepaper color. The selection range is from 0 to 2.For the adjustment, use the Print position button or to make thesetting.

0: Chinese papers / Thin papers (default setting)1: Chinese papers / Thick papers2: White color paper

54 Not available

55 Life counter displayCopy counter (from machine set up) is displayed on the panel.

56 Model selectionThe model setting must be chosen to suit each model. The selection range is from0 to 2.For the adjustment, use the Print position button or to make thesetting.

0: KS500C 0: KS600C 0: KS800C1: KS500AL 1: KS600AL 1: KS800AL2: KS500 / KS500(120V) 2: KS600 / KS600 (120V) 2: KS800 / KS800 (120V)

3: Max. 500 prints (B4)

*1. In case of selecting [0] for KS500 and KS600, the print quantity per printjob is limited to maximum 500 copies.

*2. In case of selecting [1] for all of the models, the master cut length is setto A4 length.

*3. For KS800, maximum 500 copy limit setting is removed from selection [0].Instead, selection [3] is added for KS800 to limit the per print jobmaximum print quantity to 500 for B4 models (excludes KS800AL).

57 Not available

58 Not available

59 Not available


APX(1) - 5

No. Check Items & Setting Selections

3) TPH Heating power/ Life counter display etc.

Press "START" button to enable the functions.

KS500 KS600 KS800

Non-erasable.



APX(1) - 6

4) Unit check mode etc.

Use "START" button for ON/OFF control.

60 TPH move downActivate the TPH pressure motor until the light path of the TPH position sensorfrom "blocked" to "unblocked".

61 TPH move upActivate the TPH pressure motor until the light path of the TPH position sensorfrom "unblocked" to "blocked".

62 Cutter Home PositioningCutter motor activates to move the cutter until the Cutter home sensor detects the Cutter ifthe 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 clamphome position. (both light path of the Clamp sensor L & C "Opened")

65 Clamp plate Open/Close operationOpen and close the clamp plate ( master clamp action ).

66 Clamp plate Open/Close operationOpen 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.

69 Drum position A

Drum rotation to the position-A.

70 Master making operation test

Master making operation is available.

71 Master removal operation test

Master removal operation is available.

72 Confidential operation test

Confidential operation is available.

73 Paper feed & Printing operation (30 rpm)

Printing with the drum speed 30 rpm is available.

74 Paper feed & Printing operation (90 rpm)

Printing with the drum speed 90 rpm is available.

75 Thermal print head check operation 1

Makes a master of test pattern #1 memorized in the main PCB.(within the spec. area)

76 Thermal print head check operation 2

Makes a master of test pattern #1 memorized in the main PCB.(full range of the master)

77 Drum angle is displayed on the panel. Drum angle is displaied as drum rotates at 5 rpm while the Start button is kept pressing.

No. Test Item


80 Paper feed clutch 60 rpmPaper feed clutch ON timing setting.

81 Paper feed clutch 60 rpmPaper feed clutch OFF timing setting.

82 Paper feed clutch 90 rpmPaper feed clutch ON timing setting.

83 Paper feed clutch 90 rpmPaper feed clutch OFF timing setting.

APX(1) - 7


No. Test Item

Use the Print position button or to make the setting.

5) Adjustment mode etc.The following items can be reprogrammed to make fine adjustments in Image scanning andMaster making.

84 Second Paper feed clutch ON timing (60 rpm)

85 Second Paper feed clutch OFF timing (60 rpm)

SW setting -4 -3 -2 -1 0 1 2 3

Amount (mm) -4 -3 -2 -1 0 1 2 3

SW setting -4 -3 -2 -1 0 1 2 3

Amount (mm) -4 -3 -2 -1 0 1 2 3

SW setting -4 -3 -2 -1 0 1 2 3

Amount (mm) -4 -3 -2 -1 0 1 2 3

SW setting -4 -3 -2 -1 0 1 2 3

Amount (mm) -4 -3 -2 -1 0 1 2 3

SW setting -7 -6 -5 -4 -3 -2 -1 0

Amount (mm) -7 -6 -5 -4 -3 -2 -1 0

SW setting 1 2 3 4 5 6 7

Amount (mm) 1 2 3 4 5 6 7

SW setting -7 -6 -5 -4 -3 -2 -1 0

Amount (mm) -7 -6 -5 -4 -3 -2 -1 0

SW setting 1 2 3 4 5 6 7

Amount (mm) 1 2 3 4 5 6 7

KS Series (Version 3.1)APX(1) - 8


No. Test Item

86 Timing clutch ON timing (90 rpm)

87 Timing clutch OFF timing (90 rpm)

89 Image elongation and shrikage in master making

88 Not available

89 Image elongation and shrikage in master making

SW setting -7 -6 -5 -4 -3 -2 -1 0

Amount (mm) -7 -6 -5 -4 -3 -2 -1 0

SW setting 1 2 3 4 5 6 7

Amount (mm) 1 2 3 4 5 6 7

SW setting -7 -6 -5 -4 -3 -2 -1 0

Amount (mm) -7 -6 -5 -4 -3 -2 -1 0

SW setting 1 2 3 4 5 6 7

Amount (mm) 1 2 3 4 5 6 7

SW setting -2 -1 0 1 2 3 4 5

Amount (mm) -1 -0.5 0 0.5 1 1.5 2 2.5

SW setting 6 7 8 9 10 11 12 13

Amount (mm) 3 3.5 4 4.5 5 5.5 6 6.5

NOTE:KS800, KS800(120), KS800C Check the elongation/shrinkage between the

original and the print at the distance of 280 mmfrom the top of the original, and make aboveadjustment.

KS800(AL) Use the area 250 mm from the top of the original to check theelongation/shrinkage and make above adjustment.

SW setting -15 -14 -13 -12 -11 -10 -9 -8

Amount (mm) -7.5 -7 -6.5 -6 -5.5 -5 -4.5 -4

SW setting -7 -6 -5 -4 -3 -2 -1 0

Amount (mm) -3.5 -3 -2.5 -2 -1.5 -1 -0.5 0

SW setting 1 2 3 4 5 6 7 8

Amount (mm) 0.5 1 1.5 2 2.5 3 3.5 4

SW setting 9 10 11 12 13 14 15

Amount (mm) 4.5 5 5.5 6 6.5 7 7.5


KS500&

KS600

KS800ONLY



91 Shading compensation (White side only)This adjustment is for the factory use only and the result of the adjustment is not effectto the image processing.

91 Position-A adjustment [ 1unit = 1 degree in angle ]

92 Slice level adjustment (Line mode only) The defult number is 3

93 Image horizontal center position adjustment [ 1unit = 0.125 mm ]Adjustment range: -16 to +15 (-) moves image to the left. (+) to the right.Default setting = 0.

94 Vertical print position & Image shrinkage/elongation checkMakes 2mm wide line at print position 2mm from the top and another 2mm wide line at250mm from the top for (AL) machines and 280mm from the top for other models.Using these two lines on the prints, the vertical print position and image shrinkage/elongation can be checked.

95 Master slack adjustmentAdjusts the amount of master slack between the master-making area and the print drum.Too much slack on the master between the master-making area and print drum willcause image shrinkage. Too less slack will cause the print durm to pull the mastermaterial before master-making starts.[ Default = 0 ] With each increase in the setting, the slack lessens by 0.5mm.

96 Master removal countMaster removal count is displayed on the panel.

97 Clearing the count of the Main counter in the memoryThe master count and copy count in the memory will be cleared by pressing [C] key afterthe 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 indicationfrom [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.

90 Shading compensation

Shading compensation ON 1

Shading compensation OFF 0


-4 -3 -2 -1 0 1 2 3

-4 -3 -2 -1 0 1 2 3

SW setting

Amount (degrees)

0 1 2 3 4 5 6 7Image light Image dark

DEFAULT

KS800ONLY

0 1 2 3 4 5 6 7

0 -0.5 -1 -1.5 -2.0 -2.5 -3.0 -3.5

SW setting

Amount (mm)

APX(1) - 9

KS800ONLY

KS500&

KS600


99 Initiarizing EEP ROMInkless timer, Master count, Copy count, Master removal count will not be initiarized.

98 Clearing EEP ROMAll memory will be cleared except the Master count, Copy count and the Main counterclear prohibit mode in Test No.97

No. Test Item



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 ifrequired

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 itemappears on the display as shown below.

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.

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.

APX(2) - 1

APPENDIX (2)USERS MODE

Users Mode1. Operation Procedures

U - 1

U - 2

Item No. Contents

1 Copy counter Displaying the Copy counter on the print quantity display.

2 Master counter Displaying the Master counter on the print quantity display.

3 Avarage copy counter Displaying the avarage copy count per master.

4 Confidential mode Remove the master on the drum then put the new master onthe drum.

5 Newspaper mode Removing unwanted background of the original such asnewspaper to obtain the clear image of the printouts.


MEMO

APX(2) - 2


Advice Displays (Call Service Messages)

APPENDIX (3)ADVICE DISPLAYS

No. Display Condition

E 1 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.

Turn Power SW OFF & ON.

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

seconds after the Clamp motor is activated.[When the Clamp Plate opens during Master Clamping]• 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

seconds after the Clamp motor is activated.[When the Clamp Plate closes during Master Clamping]• If the light path of the Clamp sensor L is not opened within 10

seconds after the Clamp motor is activated.

E 3

E 4 Ink Overflow• If the Overflow sensor detects excessive ink in the Squeegee unit.

Remove excess inkfrom the Drum.

E 6 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 outputafter the Main motor is activated.


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.


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.

[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.


Use test mode.

E12 Master removal motor lock• Excessive current to the motor is detected three time consecutively

during the current check made every 100 ms.




Master making unitsafety SW OFF &ON.

Press ALL RESETbutton.

• Remove thejammed paper.


• Remove thejammed paper.


Master removalsensor OFF

• Remove thejammed master.


No. Display Condition Resetting Method

Note: The Advice Display number with "( )" will be displayed while " " key is pressed.

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 theposition-A.

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.

J 1

J 4 Master Loading Error• If the Master sensor does not detect the master (light not reflected)

within 5 seconds.

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 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.

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.

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 duringthe master removal even though a master was detected on theDrum 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-Aafter the master removal process.

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.

Original IN sensorOFF & ON.

• Remove thejammed master.



APX(3) - 3

No. Display Condition Resetting Method

Note: The Advice Display number with "( )" will be displayed while " " key is pressed.

C 3 Close Master Removal Unit• If the actuator of the Master removal unit safety switch is not

depressed.

Close the Masterremoval unit.

C 2 Close Master Making Unit• If the actuator of the Master making unit safety switch is not

depressed.

Close the Mastermaking unit.

C 1 Close Separation fan unit• If the actuator of the Separation base unit safety switch is not

depressed.

Close theseparationfan unit.

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 isinstalled just after replacing empty ink bottle.

Ink bottle set sensorOFF & 5 secondslater ON.

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 orconfidential operation.


• Replace thedepleted Masterroll with a newone.

C 7 Empty Disposal Box• If the Master removal 5 times.

Master disposalboxl set sensor OFF&5 seconds later ON.

• Empty thedisposal box.

C 4 Set master disposal box.• If the master disposal box set sensor does not detect.

Set the Masterdisposal box.

C 5 Set Ink bottle in Place• If the Ink bottle set sensor does not detect the Ink bottle.

Set the Ink bottle inthe Drum.


APPENDIX (4)WIRING DIAGRAM

RISO KS800

PARTS LIST

Version: March,2004

Page No

* Fig.1 Main Body -------------------------------------- I-1* Fig.2 Drive Machanism -------------------------------------- I-3* Fig.3 Pressure Area -------------------------------------- I-5* Fig.4 Paper Feed Area -------------------------------------- I-7* Fig.5 PF Set Lever -------------------------------------- I-9* Fig.6 Paper Feed Tray -------------------------------------- I-11* Fig.7 Paper Receiving Area -------------------------------------- I-13* Fig.8 Paper Receiving Tray -------------------------------------- I-15* Fig.9 Separation Fan Unit -------------------------------------- I-17* Fig.10 Suction Unit -------------------------------------- I-19* Fig.11 Squeegee Unit -------------------------------------- I-21* Fig.12 Drum Area -------------------------------------- I-23* Fig.13 Master Removal Area -------------------------------------- I-25* Fig.14 Master Disposal Box -------------------------------------- I-27* Fig.15 Master Removal Unit -------------------------------------- I-29* Fig.16 Clamp Unit -------------------------------------- I-31* Fig.17 Scanner Area -------------------------------------- I-33* Fig.18 Cutter Area -------------------------------------- I-35* Fig.19 Master Making Area -------------------------------------- I-37* Fig.20 Exterior Covers -------------------------------------- I-39* Fig.21 Lavel -------------------------------------- I-41* Fig.22 Electrical Components -------------------------------------- I-43* Fig.23 Wire Harnesses -------------------------------------- I-45

* Index -------------------------------------- 1

Parts List

Version: March,2004

KS800

I - 1

Fig.1 Main Body

11

11

12

1212

12

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KS800

Fig.1 Main BodyNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 Main Frame; Front 1

2 Main Frame; R Ass'y 80 1

3 Base Plate 1

4 035-11005-107 Stay; Vertical 1

5 035-11006-006 Stay; Lower 2

6 035-11007-100 Stay; Middle 2

7 035-11008-106 Stay; Upper 1

8 035-11022-001 Cover; Wire Harness 1

9 035-19045-000 BKT; M-Feed Sheet 5

10 035-19046-309 M-Feed Sheet 2

11 035-19079-002 M-Feed Sheet 80 2

12 660-01002-105 Rubber Foot TK-3215 4

I - 2

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Fig.2 Drive Mechanism

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KS800

Fig.2 Drive MechanismNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 035-11009-005 Plate; M-Shaft Catch 1 30 612-82701-005 Gear; m1*70+m1*60 1

2 035-12001-008 Gear; m1*51L+m1*20L 1 31 634-04030-002 Collar; dia.4*3 1

3 035-12003-000 Gear; m1*66R+m2*28 1 32 035-12108-309 Drum Rotation Lever 1

4 035-12005-100 Gear; m2*49*14 1 33 035-12112-101 Gear plate; Drum rotation lever 1

5 035-12103-005 Clutch Support Plate 1 34 035-92002-050 Main Motor Ass'y 1

6 035-12107-000 Encoder 1 35 035-12121-003 Cover;Rotation Lever 1

7 490-20002-106 Main Motor 1 36 612-80014-000 Gear;m1*57+m1*49 1

8 035-12110-001 Shaft; Rotation Lever 1 37 612-80015-007 Gear;m1*41+m1*35 1

9 035-12111-202 Cover; Drum Rotation Lever 1 38 023-74001-046 Motor ; Clamp / M-Rmv 1

10 035-12113-000 Link plate; Drum rotation lever 1 39 612-11303-009 Gear ; m0.8*34*7 1

11 035-12114-007 Link shaft; Drum rotation lever 2 40 612-81303-006 Gear ; m0.8*35+m0.8*15 1

12 035-12115-100 Gear; m1*26*11 1 41 612-11307-004 Gear ; m0.8*24*7 1

13 035-14311-004 PF-Clutch Support Plate 1 42 035-12125-009 BKT;M-Rmv Motor 1

14 035-14312-000 Shaft ; PF-Clatch 1 43 612-12319-006 Gear ; m1*36*7 1

15 035-19027-100 Collar; M-Rmv 1 44 612-12309-000 Gear ; m1*37*9 1

16 444-41001-107 Encoder Sensor 1 45 035-12127-109 Spring ; M-Rmv 1

17 035-12109-100 Gear Shaft; Rotation Lever 1 46 035-12124-100 Shaft ; M-Rmv 1

18 490-51001-000 PF/M-Rmv Clutch 2 47 035-19037-008 Shaft B; M-Rmv Gear 1

19 607-13000-003 Metal;F6*10/9*4;12*1.5 4

20 607-15000-000 MetalF8*13/12*5;16*2 2

21 607-16001-000 Metal;F10*15/14*6;18*2 1

22 607-70815-005 Washer;R-WAS8399H 2

23 612-10012-000 Gear; m1*31*8 1

24 035-12101-100 Shaft; Timing Clutch 1

25 035-12102-106 BKT; Drive Gears 1

26 612-16300-008 Gear; m2*32*13 1

27 612-32100-000 Gear; m1*16R*16 1

28 035-12123-006 Timing Clutch Support Plate 1

29 612-82600-004 Gear; m1*65+m2*29 1

I - 4

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Fig.3 Pressure Area

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KS800

Fig.3 Pressure AreaNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 035-13011-104 Pressure Roller 1

2 035-11010-003 Hook; Press-Spring 1

3 035-12104-001 BKT; Pressure Hook 1

4 035-13001-001 Press-Roller Shaft 1

5 035-13002-008 Press-Balance Shaft 1

6 035-13003-306 Press-Roller Support 2

7 035-13004-000 Center Support Block 1

8 035-13005-007 Center Support Plate 1

9 035-13101-502 Pressure Lever Ass'y 1

10 035-13107-004 Pressure Spring 1

11 035-13111-303 Press-Hook Plate Ass'y 1

12 035-13115-007 Spring; Hook 1

13 600-20061-009 Bearing;608ZZ 2

14 607-16001-000 Metal;F10*15/14*6;18*2 2

15 635-09308-103 Pan-head Tap Tight P Screw 3*8 1

I - 6

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Fig.4 Paper Feed Area

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KS800

Fig.4 Paper Feed AreaNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 000-06123-007 Stopper;Paper Guide Roller 2 27 035-14412-005 Guide Roller Shaft 1

2 019-11812-106 Lock Ring 2 28 035-14413-001 G-Roller S-Shaft 1

3 019-25533-005 Actuator Plate;Micro-SW 1 29 035-14414-105 Paper Gate 1

4 020-11309-006 Load Spring 1 30 035-14415-101 Paper Gate Shaft 1

5 020-11707-109 Housing; Stripper 1 31 035-14445-000 P-Guide Lower Ass'y 80 1

6 020-11708-008 Spring;Stripper 1 32 035-14440-009 P-Guide Upper Ass'y 80 1

7 020-11711-009 Stripper Pad 1 33 035-14431-000 PF Safety SW Plate 1

7 011-11822-006 Stripper Pad;SR-29 1 34 035-14432-006 Safety SW Protection 1

7 035-14452-007 Stripper Pad;50 1 35 035-51023-108 Safety SW Ass'y 1

7 035-14453-003 Stripper Pad;60 1 36 035-94302-000 Pickup Roller Ass'y 1

7 020-11721-004 Stripper Pad;Black 1 37 607-13000-003 Metal;F6*10/9*4;12*1.5 4

8 035-12007-103 Gear; m1*20*8 1 38 607-15000-000 MetalF8*13/12*5;16*2 1

9 035-14115-000 Lock Pin 4 39 607-16001-000 Metal;F10*15/14*6;18*2 4

10 035-14201-101 Shaft; PFT Lever 1 40 607-16002-007 Metal;F10*16/12.8*12:18*2 2

11 035-14202-108 PFT Lever 1 41 638-90000-128 Washer;18*10.4*0.4 1

12 035-14256-003 PF Lever ; BKT ASS'Y 1 42 035-14446-104 Sheet ; P-Guide 2

13 035-14218-004 Set Lever BKT Ass'y 1 43 035-14254-000 Plate ; PF Press-Adj. 1

14 035-14222-001 Lock Plate 1 44 035-14250-005 Cam ; PF Press-Adj. 1

15 035-14231-000 Shaft; Support Lever 1 45 035-14247-004 Lever ; PF Press Adj. 1

16 035-14240-000 Roller; PFT Press-Adj. Lever 1 46 035-14249-007 Shaft ; PF Press Adj. Lever 2

17 035-14305-004 PF-Support Roller 2 47 035-14251-109 BKT ; PF Press-Adj. 1

18 035-14313-007 Shaft; Pichup Roller 1 48 035-14241-006 BKT ; PFT Lever 80 1

19 035-14402-000 Timing Roller 1 49 035-14255-007 Shaft ; PFT 1

20 035-14230-004 Support Spring 2 50 035-14246-008 Support Spring 1

21 035-14406-005 Guide Roller Spring 1 51 035-14248-000 Spring ; PF-Press Adj. 1

22 035-14407-001 Plate; Load Spring 1 52 035-14244-005 Spring ; PF Press 80 1

23 035-14408-008 Guide Roller 1

24 035-14409-004 Guide Roller BKT 1

25 035-14410-002 Support BKT F; G-Roller 1

26 035-14411-009 Support BKT R; G-Roller 1

I - 8

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Fig.5 PF Set Lever

Version: March,2004

KS800

Fig.5 PF Set LeverNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 035-14207-207 PF Set Lever Ass'y 1

2 035-14214-106 PF Adj. Screw 1

3 035-14215-200 Cover; Set Lever 1

4 035-14217-008 Sheet; Adj. Screw 1

5 035-14220-009 PF Adj. Dial 1

6 035-14221-005 PF Adj. Collar 1

I - 10

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Fig.6 Paper Feed Tray

Version: March,2004

KS800

Fig.6 Paper Feed TrayNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 020-11513-002 Lever;P.-F.-T. 2

2 035-14117-003 Base Plate ; PFT 80 1

3 035-14118-000 Plate ; PFT 80 1

4 035-14103-304 Frame F ; PFT 80 1

5 035-14104-300 Frame R ; PFT 80 16 035-14119-103 Side Guide F ; PFT 80 1

7 035-14121-108 Side Guide R ; PFT 80 1

8 035-14123-003 Guide ; Fence 80 2

9 035-14124-000 Lock Plate ; PFT Side Guide 80 2

10 035-14116-104 L. O. Sheet 1

11 488-90028-007 RS3-150-RS3 1I - 12

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Fig.7 Paper Receiving Area

Version: March,2004

KS800

Fig.7 Paper Receiving AreaNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 002-17017-203 Cover Catch B; Front 1

2 019-25533-005 Actuator Plate;Micro-SW 1

3 035-11021-102 Cover; Suction 1

4 035-15051-103 Separator 1

5 035-15052-002 Shaft ; Separator 1

6 035-15055-001 Separator Lever Ass'y 1

7 035-15057-004 Spring ; Separator 1

8 035-15058-000 Fan Set SW Plate 1

9 035-15080-006 Set Switch BKT 1

10 035-15090-001 Shaft; Belt Drive Gear 1

11 035-51023-108 Safety SW Ass'y 1

12 607-15000-000 MetalF8*13/12*5;16*2 3

13 612-12312-001 Gear; m1*39*8 1

14 612-16100-009 Gear; m2*18*8 1

I - 14

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I - 15

Fig.8 Paper Receiving Tray

Version: March,2004

KS800

Fig.8 Paper Receiving TrayNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 035-15203-000 Paper Receiving Tray 80 1

2 035-15204-007 Paper Base Stop 80 1

3 035-15138-209 P-Rcv-T BKT F 1

4 035-15139-205 P-Rcv-T BKT R 1

5 035-15205-003 P-Rcv-T BKT 80 1

6 035-15206-000 P-Ejection Guide 2

7 035-15207-006 Side Base ; P-Rcv-T 2

I - 16

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Fig.9 Separation Fan Unit

Version: March,2004

KS800

Fig.9 Separation Fan UnitNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 035-04006-009 Label;P-Rcv. Cover 1

2 035-15058-000 Fan Set SW Plate 1

3 035-15153-003 Fan Base; Separation 1

4 035-15156-002 Nozzle-Up; Separation 1

5 035-15157-106 Nozzle-Low; Separation 1

6 035-15161-006 Fan Base Support BKT 1

7 035-15162-002 Fan Base Shaft 1

8 035-51013-102 Wire; P-Rcv Sensor 1

9 444-33000-002 GP2A200LCS 1

10 490-41002-106 Fan 1

I - 18

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Fig.10 Suction Unit

Version: March,2004

KS800

Fig.10 Suction UnitNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 035-15018-009 De-electricity Brush ; Suction 80 1

2 020-13108-105 Belt Pulley;Suction 2

3 020-13110-100 Idle Shaft;Suction 1

4 020-13116-205 P.-E. Pulley; Suction 2

5 035-15002-102 Suction Base 1

6 035-15200-001 Suction Face Cover 80 1

7 035-15004-008 Suction Duct 1

8 035-15016-006 Suction Gear Shaft 2

9 035-15017-002 Drive Shaft; Suc-Belt 1

10 490-41002-106 Fan 1

11 607-15000-000 MetalF8*13/12*5;16*2 2

12 612-12207-003 Gear; m1*20*10 1

13 612-12313-008 Gear; m1*33*6 1

14 612-82308-001 Gear; m1*36+m1*15 1

15 629-93810-202 Transfer Belt;14*0.65*381 2

16 035-15201-008 Suction Wing F 80 1

17 035-15202-004 Suction Wing R 80 1

18 635-00410-002 Stepped Screw ; m4*10 2

I - 20

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Fig.11 Squeegee Unit

Version: March,2004

KS800

Fig.11 Squeegee UnitNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 020-12502-306 Shaft Joint;Drum 2

2 020-12508-002 Stopper;Ink Distributor 1

3 020-12512-000 Metal Fix Plate 2

4 020-12513-006 Metal F;Drive Shaft 1

5 020-12514-100 Metal R;Drive Shaft 1

6 020-12521-602 Squeegee Roller 1

7 020-12522-102 Doctor Roller 1

8 020-12531-306 Drive Shaft; Squeegee 1

9 020-12534-100 Block F; Squeegee 1

10 020-12535-107 Block R; Squeegee 1

11 020-12536-200 Ink Blocking Plate(Front) 1

12 020-12537-207 Ink Blocking Plate(Rear) 1

13 020-12538-009 Adj.Plate;Doctor 1

14 020-12549-000 Adj.Plate(Rear);Doctor 1

15 020-60004-202 Drum PCB 1

16 035-16501-005 Center Shaft 1

17 035-16502-001 Main Frame; Drum 2

18 035-16503-202 Sqg. F Plate Ass'y 1

19 035-16506-201 Sqg. R Plate Ass'y 1

20 612-11102-003 Gear;m0.8*18*5 1

21 612-11401-000 Gear;m0.8*45*5 1

22 612-12303-002 Gear;m1*30*5 1

23 612-12304-009 Gear;OWC;m1*30*5 1

24 640-60030-004 O Ring ; P3-1.9 2

25 640-60100-100 O Ring ; P10-2.4 1

26 640-60180-006 O Ring ; P18-2.4 2

I - 22

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Fig.12 Drum Area

32

33

Version: March,2004

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Fig.12 Drum AreaNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 020-12101-204 Drum Body 1 27 035-96321-002 Ink Pump Unit 1

1 035-16111-002 Drum Body;AL 1 28 444-30000-001 GP1A73A 1

2 020-12104-505 Ink Blocking Sheet;B4 1 29 640-60100-100 O Ring ; P10-2.4 1

3 020-12113-008 Bearing Cap 1 30 640-61550-001 O Ring ; P115-2.4 2

4 020-12119-006 Main Gear;Squeegee 1 31 665-02903-005 Power Band T14 2

5 020-12125-308 Screen Hanger Plate 1 32 020-12132-002 Seal tape0.5 1

6 020-12126-002 Screw;Screw Hanger 4 33 035-16202-008 Friction Sheet 1

7 020-12127-203 Spring ;Screen 2

8 020-12201-209 Clamp Plate Base 1

9 020-12205-204 Clamp Magnet 1

10 020-12213-100 Clamp Base C 1

11 020-12220-106 Clamp Plate 2 1

12 020-12344-000 Set Plate;Center Nozzle 1

13 020-12441-200 Drum Shaft Clamp 2

14 020-12449-006 Sleeve 32 1

15 035-16101-007 Drum Support F Ass'y 1

16 035-16103-107 Drum Support R Ass'y 1

16 035-16110-006 Drum Support R Ass'y;AL 1

17 035-16105-002 Drum Main Gear 1

18 035-16106-009 Compensator 1

19 035-16107-005 Pressure Cam 1

19 035-16108-001 Pressure Cam;A4 1

20 035-16109-008 Screen Ass'y 1

21 035-16201-001 M-Projection Plate 1

22 035-16304-005 Inking Hose dia.10 1

23 035-16305-001 Center Nozzle 1

24 035-16401-205 Drum U Support BKT F 1

25 035-16402-007 Drum U Support BKT R 1

26 035-51007-102 Wire; Ink Sensor 1

I - 24

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Fig.13 Master Removal Area

Version: March,2004

KS800

Fig.13 Master Removal AreaNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 019-25533-005 Actuator Plate;Micro-SW 2

2 035-11103-303 M-Rmv Upper Cover 1

3 035-11109-000 Original Receive Tray 1

4 035-19077-000 BKT A;M-Rmv SW 80 1

5 035-19078-006 BKT B;M-Rmv SW 80 1

6 035-51025-003 M-Rmv Safety SW Ass'y 1

I - 26

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Fig.14 Master Disposal Box Area

Version: March,2004

KS800

Fig.14 Master Disposal Box AreaNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

035-99060-005 M-Disposal Box Ass'y 1

1 035-19071-001 *M-Disposal ; Guide 1

2 035-19073-101 *M-Disposal ; Link 2

3 035-19072-008 *M-Disposal ; Lever 1

4 035-19075-007 *M-Disposal ; Spring 2

5 035-19069-007 *M-Disposal ; Main Box Ass'y 1

6 035-19070-005 *M-Disposal Box ; Cover 1

I - 28

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Fig.15 Mater Removal Unit

Version: March,2004

KS800

Fig.15 Master Removal UnitNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 035-11725-002 Sensor BKT L 80 1 30 612-82400-005 Gear; m1*41+m1*36 1

2 035-19059-109 Frame ; M-Rmv U 80 1 31 035-19062-002 M-Rmv Guide ; Upper2 80 1

3 035-19076-003 Stay ; M-Rmv U Frame 1

4 035-19060-000 M-Rmv Guide ; Lower 80 1

5 035-19061-006 M-Rmv Guide ; Upper 80 1

6 035-19008-105 M-Rmv Hook 2

7 035-19063-009 BKT F ; Trans-Roller 80 1

8 035-19064-005 BKT R ; Trans-Roller 80 1

9 035-19065-001 Spring Trans-Roller 80 2

10 035-19066-008 Trans-Roller ; Lower 1

11 035-19067-004 Trans-Roller ; Upper 1

12 035-19025-000 Wire; M-Rmv Link 1

13 035-19026-006 M-Rmv Link 2

14 035-19027-100 Collar; M-Rmv 10

15 035-19029-005 Hinge; M-Rmv 2

16 035-19033-100 Lever; M-Rmv 1

17 035-19034-009 Spring; M-Rmv Lever 1

18 035-19035-005 BKT; M-Rmv Lever 2

19 035-19036-001 Shaft A; M-Rmv Gear 1

20 035-19037-008 Shaft B; M-Rmv Gear 1

21 035-19038-004 Shaft; M-Rmv Lever 1

22 035-19047-208 BKT; M-Rmv Sensor 1

23 035-19058-005 Cover;M-Rmv Lever 1

24 444-30000-001 GP1A73A 1

25 444-31001-001 M-Rmv Sensor 1

26 607-13000-003 Metal;F6*10/9*4;12*1.5 4

27 612-03104-005 Gear; m1.25*14*6 2

28 612-12102-007 Gear; m1*17*6.5 1

29 612-12309-000 Gear; m1*37*9 1

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Version: March,2004

KS800

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Fig.16 Clamp Unit

Version: March,2004

KS800

Fig.16 Clamp UnitNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 035-11701-103 Housing; Cam 1

2 035-11723-000 Shaft Clutch Plate Ass'y 1

3 035-11706-008 Arm; Clamp Plate 1

4 035-11707-101 Arm; M-Projection Plate 1

5 035-11708-000 Shaft; Arms 1

6 035-11709-007 Spring; Clamp Lever 2

7 035-11711-001 Shaft; Cam/Gear 1

8 035-11712-008 Clamp Cam 1

9 035-11713-004 Encoder; Clamp Motor 1

10 035-11721-104 Sensor BKT C 1

11 035-11722-003 Sensor BKT L 1

12 444-30000-001 GP1A73A 2

13 490-21005-001 Clamp Motor 1

14 607-15000-000 MetalF8*13/12*5;16*2 2

15 612-12311-005 Gear; m1*36*7 1

16 612-82307-005 Gear;m0.5*40+m1*16 1

17 612-82310-006 Gear; m1*36+m1*14 2

18 035-11962-004 Shaft ; 6*9.5*18 1

19 612-82313-005 Gear ; m1*21+m1*14 1

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Version: March,2004

KS800

I - 33

Fig.17 Scanner AreaA

AB

B

D

C

D

C E

E

28

11

17

34

12

19

14

7

13

6

8

1

9

1

10

215

16

18

25

9

26

28

26

26

5

24

4

23

31

32

22

3

11

20

5

27

29

26

18

21

30

33

22

Fig.17 Scanner Area

Version: March,2004

KS800

Fig.17 Scanner AreaNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 020-15702-101 Slide Rack ;Original Holder 2 30 612-12206-007 Gear; m1*24*4 1

2 035-17001-006 OF F Frame Ass'y 1 31 035-17012-008 Org-Ejc-Roller 1

3 035-17003-009 OF R Frame Ass'y 1 32 035-17009-007 Org-Load Roller 1

4 035-17004-005 BKT; O-Det. Sensor 1 33 635-09308-103 Pan-head Tap Tight P Screw 3*8 1

5 035-17005-001 Spring; Scanner 2 34 035-17022-100 Cover Up; Wh-Roller 1

6 035-17006-008 Spring; Load Roller 1

7 035-17007-004 Spring; Ejc-Roller 1

8 035-17021-309 DFeeder Cover 1

9 035-17024-006 Original Guide 2

10 035-11108-003 Original Feed Tray 1

11 035-17015-007 Wh-Roller Holder 2

12 035-17016-003 White Roller 1

13 035-17019-002 Roller; L40 1

14 035-17020-000 Roller; L74 1

15 612-80800-006 Gear;m0.5*86+m0.5*49 1

16 612-11501-005 Gear; m0.8*52*7 1

17 035-17023-000 Cover Low; Wh-Roller 1

18 612-11205-007 Gear; m0.8*28*4 2

19 035-17025-002 Hook; DFeeder 1

20 035-17026-009 Scanner Holder L 1

21 035-17027-005 Scanner Holder R 1

22 035-17028-001 Spring; Hook 2

23 443-32005-003 GP2A25 1

24 444-60000-103 Image Scanner 1

25 490-33006-003 DFeed Motor 1

26 607-13000-003 Metal;F6*10/9*4;12*1.5 4

27 612-80801-002 Gear; m0.5*85+0.8*19 1

28 612-11402-007 Gear; m0.8*40*3 2

29 612-80900-000 Gear;m0.5*94+m0.5*48 1

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Version: March,2004

KS800

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Fig.18 Cutter Area

Version: March,2004

KS800

Fig.18 Cutter AreaNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 035-18301-003 Shaft; M-Guide 1

2 035-18302-000 M-Guide Plate; Lower 1

3 035-18303-200 M-Guide Plate; Upper 1

4 035-98004-101 Cutter Unit 1

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Version: March,2004

KS800

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49

Fig.19 Master Making Area

54

55

Version: March,2004

KS800

Fig.19 Master Making AreaNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 019-25533-005 Actuator Plate;Micro-SW 1 30 035-18411-208 Base; M-M Upper U 1

2 020-15252-009 De-electricity Brush;L 1 31 035-18412-000 Cover; M-M Upper U 1

3 035-04007-102 Label;M-Set Guide 1 32 035-18413-103 Locking Plate Ass'y 1

4 035-18101-101 Master Flange 1 33 035-18415-009 Shaft; M-Holder 1

5 035-18102-000 M-Flange Holder 2 34 035-18501-002 Spring ; TPH Pressure 2

6 035-18103-007 M-Flange Guide 1 35 035-18502-009 Spring R; M-M Upper U 1

7 035-18104-100 Tension Plate 2 36 035-18503-005 Spring F; M-M Upper U 1

8 035-18105-204 Tension Plate Ass'y 1 37 035-18504-001 Tension Spring 1

9 035-18107-100 Plate; Plunger 1 38 035-18505-008 Spring ; Rev-gear Plate 1

10 035-18108-203 Rubber; Tension 1 39 035-51023-108 Safety SW Ass'y 1

11 035-18109-102 Master Flange R 1 40 443-32005-003 GP2A25 1

12 035-18110-100 De-electricity Brush;KS 2 41 444-30000-001 GP1A73A 2

13 035-18111-107 Master Tension Sheet 2 42 444-80300-308 TPH 1

14 035-18201-009 Write Roller 1 43 490-33006-003 DFeed Motor 1

15 035-18204-008 TPH Press-Plate 1 44 490-50001-104 M-Loading Solenoid 1

16 035-18205-306 TPH Position-Plate 1 45 550-20118-104 TPH Seal 1

17 035-18206-108 TPH Press-Shaft 1 45 550-21519-005 TPH Seal;CH 1

18 035-18207-007 Press-sensor Plate 1 46 607-07004-005 Metal; S8*10*15 2

19 035-18208-003 TPH Press-Cam 1 47 607-13000-003 Metal;F6*10/9*4;12*1.5 2

20 035-18209-000 TPH Support Shaft 1 48 612-00401-009 Gear; m0.5*48*4 1

21 035-18210-008 Shaft Stopper 1 49 612-11205-007 Gear; m0.8*28*4 2

22 035-18304-207 Cutter Guide Plate 1 50 612-80800-006 Gear;m0.5*86+m0.5*49 1

23 035-18305-009 Rev-gear Plate Ass'y 1 51 612-80801-002 Gear; m0.5*85+0.8*19 2

24 035-18401-202 Frame R Ass'y; M-M U 1 52 612-80900-000 Gear;m0.5*94+m0.5*48 2

25 035-18404-104 Frame F Ass'y; M-M U 1 53 635-17523-005 Stepped Screw;dia.5*2;M3*3 4

26 035-18406-000 Base; M-M U 1 54 035-18416-005 Shaft; M-M U 2

27 035-18407-103 Cover; M-M U 1 55 035-18417-001 Washer;3.5*14*1.2 2

28 035-18408-002 M-Tension Shaft 1

29 035-18410-007 Release Lever 1

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Version: March,2004

KS800

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Fig.20 Exterior Covers

Version: March,2004

KS800

Fig.20 Exterior CoversNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 035-11013-002 BKT; C-Panel 2

2 035-11102-005 Rear Cover 1

3 035-11110-008 Front Cover ; KS800C 1

3 Front Cover ; KS800 1

4 035-90002-002 Control Panel Unit KS800C 1

4 Control Panel Unit KS800 1

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Version: March,2004

KS800

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Fig.21 Label

Version: March,2004

KS800

Fig.21 LabelNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 035-04016-004 Label ; Caution 80 1

1-a 035-04018-007 Label ; P-Rcv 80 1

1-b Label; M-Replace 1

1-c 035-04017-000 Label ; M-Disposal 80 1

1-d Label; Ink Replace 1

2 035-04019-003 Label ; PF-Press Adj. 80 1

I - 42

Version: March,2004

KS800

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Fig.22 Electrical Components

Version: March,2004

KS800

Fig.22 Electrical ComponentsNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 035-11011-000 Drum Rail; R 1

2 035-11012-006 Drum Rail; L 1

3 035-11014-009 BKT; P-Supply PCB 2

4 035-11015-005 BKT; Main PCB 1

5 035-11016-001 Cover; Main PCB 1

6 035-11025-000 BKT ; M-L Sensor 1

7 035-11023-008 Cover;P-Supply PCB 1

8 035-16301-006 BKT; Ink Bottle Guide 1

9 035-16302-002 Ink Bottle Guide 1

10 035-16303-009 Bottle Hook-Spring 3

11 035-16306-008 BKT; Ink Bottle Sensor 1

12 035-16307-004 Ink Bottle Sensor Plate 1

13 035-50506-105 Main-PCB-KS800 1

14 035-50505-001 P-Supply PCB XIII-N200 II 1

14 035-50504-102 P-Supply PCB XIII-N100 1

15 035-52001- System ROM ; KS 1

16 444-30000-001 GP1A73A 1

17 444-43000-302 KH0726 1

18 488-00033-104 Power Code; CH 1

19 035-14443-008 Clip ; ;BKT M-L Sensor 2

20 035-14444-004 Spring ; BKT M-L Sensor 2

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Version: March,2004

KS800

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Fig.23 Wire Harnesses

Version: March,2004

KS800

Fig.23 Wire HarnessesNo. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark

1 035-51001-104 Wire; M-M Unit 1

2 035-51010-103 Wire; F 1

3 035-51011-100 Wire; R 1

4 035-51018-104 Wire; Main-Scanner 1

5 035-51024-201 Wire;M-Rmv Unit 1

6 435-00025-000 Noise Filter;SFC-6 1

7 035-51025-003 M-Rmv Safety SW Ass'y 1

I - 46

Version: March,2004

Index KS800

No. Part No. Part Name(English) Part Name(Chinese) Q'ty1 000-06123-007 Stopper;Paper Guide Roller 2 Fig.4 12 002-17017-203 Cover Catch B; Front 1 Fig.7 13 011-11822-006 Stripper Pad;SR-29 1 Fig.4 74 019-11812-106 Lock Ring 2 Fig.4 25 019-25533-005 Actuator Plate;Micro-SW 1 Fig.4 36 019-25533-005 Actuator Plate;Micro-SW 1 Fig.7 27 019-25533-005 Actuator Plate;Micro-SW 2 Fig.13 18 019-25533-005 Actuator Plate;Micro-SW 1 Fig.19 19 020-11309-006 Load Spring 1 Fig.4 4

10 020-11513-002 Lever;P.-F.-T. 2 Fig.6 111 020-11707-109 Housing; Stripper 1 Fig.4 512 020-11708-008 Spring;Stripper 1 Fig.4 613 020-11711-009 Stripper Pad 1 Fig.4 714 020-11721-004 Stripper Pad;Black 1 Fig.4 715 020-12101-204 Drum Body 1 Fig.12 116 020-12104-505 Ink Blocking Sheet;B4 1 Fig.12 217 020-12113-008 Bearing Cap 1 Fig.12 318 020-12119-006 Main Gear;Squeegee 1 Fig.12 419 020-12125-308 Screen Hanger Plate 1 Fig.12 520 020-12126-002 Screw;Screw Hanger 4 Fig.12 621 020-12127-203 Spring ;Screen 2 Fig.12 722 020-12132-002 Seal tape0.5 1 Fig.12 3223 020-12201-209 Clamp Plate Base 1 Fig.12 824 020-12205-204 Clamp Magnet 1 Fig.12 925 020-12213-100 Clamp Base C 1 Fig.12 1026 020-12220-106 Clamp Plate 2 1 Fig.12 1127 020-12344-000 Set Plate;Center Nozzle 1 Fig.12 1228 020-12441-200 Drum Shaft Clamp 2 Fig.12 1329 020-12449-006 Sleeve 32 1 Fig.12 1430 020-12502-306 Shaft Joint;Drum 2 Fig.11 131 020-12508-002 Stopper;Ink Distributor 1 Fig.11 232 020-12512-000 Metal Fix Plate 2 Fig.11 333 020-12513-006 Metal F;Drive Shaft 1 Fig.11 434 020-12514-100 Metal R;Drive Shaft 1 Fig.11 535 020-12521-602 Squeegee Roller 1 Fig.11 636 020-12522-102 Doctor Roller 1 Fig.11 737 020-12531-306 Drive Shaft; Squeegee 1 Fig.11 838 020-12534-100 Block F; Squeegee 1 Fig.11 939 020-12535-107 Block R; Squeegee 1 Fig.11 1040 020-12536-200 Ink Blocking Plate(Front) 1 Fig.11 1141 020-12537-207 Ink Blocking Plate(Rear) 1 Fig.11 1242 020-12538-009 Adj.Plate;Doctor 1 Fig.11 1343 020-12549-000 Adj.Plate(Rear);Doctor 1 Fig.11 1444 020-13108-105 Belt Pulley;Suction 2 Fig.10 245 020-13110-100 Idle Shaft;Suction 1 Fig.10 346 020-13116-205 P.-E. Pulley; Suction 2 Fig.10 447 020-15252-009 De-electricity Brush;L 1 Fig.19 248 020-15702-101 Slide Rack ;Original Holder 2 Fig.17 149 020-60004-202 Drum PCB 1 Fig.11 1550 023-74001-046 Motor ; Clump / M-Rmv 1 Fig.2 3851 035-04006-009 Label;P-Rcv. Cover 1 Fig.9 152 035-04007-102 Label;M-Set Guide 1 Fig.19 353 035-04016-004 Label ; Caution 80 1 Fig.21 154 035-04019-003 Label ; PF-Press Adj. 80 1 Fig.21 2

Remark

1 Version :March,2004

Index KS800

No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark55 035-11005-107 Stay; Vertical 1 Fig.1 456 035-11006-006 Stay; Lower 2 Fig.1 557 035-11007-100 Stay; Middle 2 Fig.1 658 035-11008-106 Stay; Upper 1 Fig.1 759 035-11009-005 Plate; M-Shaft Catch 1 Fig.2 160 035-11010-003 Hook; Press-Spring 1 Fig.3 261 035-11011-000 Drum Rail; R 1 Fig.22 162 035-11012-006 Drum Rail; L 1 Fig.22 263 035-11013-002 BKT; C-Panel 2 Fig.20 164 035-11014-009 BKT; P-Supply PCB 2 Fig.22 365 035-11015-005 BKT; Main PCB 1 Fig.22 466 035-11016-001 Cover; Main PCB 1 Fig.22 567 035-11021-102 Cover; Suction 1 Fig.7 368 035-11022-001 Cover; Wire Harness 1 Fig.1 869 035-11023-008 Cover;P-Supply PCB 1 Fig.22 770 035-11025-000 BKT ; M-L Sensor 1 Fig.22 671 035-11102-005 Rear Cover 1 Fig.20 272 035-11103-303 M-Rmv Upper Cover 1 Fig.13 273 035-11108-003 Original Feed Tray 1 Fig.17 1074 035-11109-000 Original Receive Tray 1 Fig.13 375 035-11110-008 Front Cover ; KS800C 1 Fig.20 376 035-11701-103 Housing; Cam 1 Fig.16 177 035-11706-008 Arm; Clamp Plate 1 Fig.16 378 035-11707-101 Arm; M-Projection Plate 1 Fig.16 479 035-11708-000 Shaft; Arms 1 Fig.16 580 035-11709-007 Spring; Clamp Lever 2 Fig.16 681 035-11711-001 Shaft; Cam/Gear 1 Fig.16 782 035-11712-008 Clamp Cam 1 Fig.16 883 035-11713-004 Encoder; Clamp Motor 1 Fig.16 984 035-11721-104 Sensor BKT C 1 Fig.16 1085 035-11722-003 Sensor BKT L 1 Fig.16 1186 035-11723-000 Shaft Clutch Plate Ass'y 1 Fig.16 287 035-11725-002 Sensor BKT L 80 1 Fig.15 188 035-11962-004 Shaft ; 6*9.5*18 1 Fig.16 1889 035-12001-008 Gear; m1*51L+m1*20L 1 Fig.2 290 035-12003-000 Gear; m1*66R+m2*28 1 Fig.2 391 035-12005-100 Gear; m2*49*14 1 Fig.2 492 035-12007-103 Gear; m1*20*8 1 Fig.4 893 035-12101-100 Shaft; Timing Clutch 1 Fig.2 2494 035-12102-106 BKT; Drive Gears 1 Fig.2 2595 035-12103-005 Clutch Support Plate 1 Fig.2 596 035-12104-001 BKT; Pressure Hook 1 Fig.3 397 035-12107-000 Encoder 1 Fig.2 698 035-12108-309 Drum Rotation Lever 1 Fig.2 3299 035-12109-100 Gear Shaft; Rotation Lever 1 Fig.2 17100 035-12110-001 Shaft; Rotation Lever 1 Fig.2 8101 035-12111-202 Cover; Drum Rotation Lever 1 Fig.2 9102 035-12112-101 Gear plate; Drum rotation lever 1 Fig.2 33103 035-12113-000 Link plate; Drum rotation lever 1 Fig.2 10104 035-12114-007 Link shaft; Drum rotation lever 2 Fig.2 11105 035-12115-100 Gear; m1*26*11 1 Fig.2 12106 035-12121-003 Cover;Rotation Lever 1 Fig.2 35107 035-12123-006 Timing Clutch Support Plate 1 Fig.2 28108 035-12124-100 Shaft ; M-Rmv 1 Fig.2 46


Index KS800

No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark109 035-12125-009 BKT;M-Rmv Motor 1 Fig.2 42110 035-12127-109 Spring ; M-Rmv 1 Fig.2 45111 035-13001-001 Press-Roller Shaft 1 Fig.3 4112 035-13002-008 Press-Balance Shaft 1 Fig.3 5113 035-13003-306 Press-Roller Support 2 Fig.3 6114 035-13004-000 Center Support Block 1 Fig.3 7115 035-13005-007 Center Support Plate 1 Fig.3 8116 035-13011-104 Pressure Roller 1 Fig.3 1117 035-13101-502 Pressure Lever Ass'y 1 Fig.3 9118 035-13107-004 Pressure Spring 1 Fig.3 10119 035-13111-303 Press-Hook Plate Ass'y 1 Fig.3 11120 035-13115-007 Spring; Hook 1 Fig.3 12121 035-14103-304 Frame F ; PFT 80 1 Fig.6 4122 035-14104-300 Frame R ; PFT 80 1 Fig.6 5123 035-14115-000 Lock Pin 4 Fig.4 9124 035-14116-104 L. O. Sheet 1 Fig.6 10125 035-14117-003 Base Plate ; PFT 80 1 Fig.6 2126 035-14118-000 Plate ; PFT 80 1 Fig.6 3127 035-14119-103 Side Guide F ; PFT 80 1 Fig.6 6128 035-14121-108 Side Guide R ; PFT 80 1 Fig.6 7129 035-14123-003 Guide ; Fence 80 2 Fig.6 8130 035-14124-000 Lock Plate ; PFT Side Guide 80 2 Fig.6 9131 035-14201-101 Shaft; PFT Lever 1 Fig.4 10132 035-14202-108 PFT Lever 1 Fig.4 11133 035-14207-207 PF Set Lever Ass'y 1 Fig.5 1134 035-14214-106 PF Adj. Screw 1 Fig.5 2135 035-14215-200 Cover; Set Lever 1 Fig.5 3136 035-14217-008 Sheet; Adj. Screw 1 Fig.5 4137 035-14218-004 Set Lever BKT Ass'y 1 Fig.4 13138 035-14220-009 PF Adj. Dial 1 Fig.5 5139 035-14221-005 PF Adj. Collar 1 Fig.5 6140 035-14222-001 Lock Plate 1 Fig.4 14141 035-14230-004 Support Spring 2 Fig.4 20142 035-14231-000 Shaft; Support Lever 1 Fig.4 15143 035-14240-000 Roller; PFT Press-Adj. Lever 1 Fig.4 16144 035-14241-006 BKT ; PFT Lever 80 1 Fig.4 48145 035-14244-005 Spring ; PF Press 80 1 Fig.4 52146 035-14246-008 Support Spring 1 Fig.4 50147 035-14247-004 Lever ; PF Press Adj. 1 Fig.4 45148 035-14248-000 Spring ; PF-Press Adj. 1 Fig.4 51149 035-14249-007 Shaft ; PF Press Adj. Lever 2 Fig.4 46150 035-14250-005 Cam ; PF Press-Adj. 1 Fig.4 44151 035-14251-109 BKT ; PF Press-Adj. 1 Fig.4 47152 035-14254-000 Plate ; PF Press-Adj. 1 Fig.4 43153 035-14255-007 Shaft ; PFT 1 Fig.4 49154 035-14256-003 PF Lever ; BKT ASS'Y 1 Fig.4 12155 035-14305-004 PF-Support Roller 2 Fig.4 17156 035-14311-004 PF-Clutch Support Plate 1 Fig.2 13157 035-14312-000 Shaft ; PF-Clatch 1 Fig.2 14158 035-14313-007 Shaft; Pichup Roller 1 Fig.4 18159 035-14402-000 Timing Roller 1 Fig.4 19160 035-14406-005 Guide Roller Spring 1 Fig.4 21161 035-14407-001 Plate; Load Spring 1 Fig.4 22162 035-14408-008 Guide Roller 1 Fig.4 23


Index KS800

No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark163 035-14409-004 Guide Roller BKT 1 Fig.4 24164 035-14410-002 Support BKT F; G-Roller 1 Fig.4 25165 035-14411-009 Support BKT R; G-Roller 1 Fig.4 26166 035-14412-005 Guide Roller Shaft 1 Fig.4 27167 035-14413-001 G-Roller S-Shaft 1 Fig.4 28168 035-14414-105 Paper Gate 1 Fig.4 29169 035-14415-101 Paper Gate Shaft 1 Fig.4 30170 035-14431-000 PF Safety SW Plate 1 Fig.4 33171 035-14432-006 Safety SW Protection 1 Fig.4 34172 035-14440-009 P-Guide Upper Ass'y 80 1 Fig.4 32173 035-14443-008 Clip ; ;BKT M-L Sensor 2 Fig.22 19174 035-14444-004 Spring ; BKT M-L Sensor 2 Fig.22 20175 035-14445-000 P-Guide Lower Ass'y 80 1 Fig.4 31176 035-14446-104 Sheet ; P-Guide 2 Fig.4 42177 035-14452-007 Stripper Pad;50 1 Fig.4/white 7178 035-14453-003 Stripper Pad;60 1 Fig.4/red 7179 035-15002-102 Suction Base 1 Fig.10 5180 035-15004-008 Suction Duct 1 Fig.10 7181 035-15016-006 Suction Gear Shaft 2 Fig.10 8182 035-15017-002 Drive Shaft; Suc-Belt 1 Fig.10 9183 035-15018-009 De-electricity Brush ; Suction 80 1 Fig.10 1184 035-15051-103 Separator 1 Fig.7 4185 035-15052-002 Shaft ; Separator 1 Fig.7 5186 035-15055-001 Separator Lever Ass'y 1 Fig.7 6187 035-15057-004 Spring ; Separator 1 Fig.7 7188 035-15058-000 Fan Set SW Plate 1 Fig.7 8189 035-15058-000 Fan Set SW Plate 1 Fig.9 2190 035-15080-006 Set Switch BKT 1 Fig.7 9191 035-15090-001 Shaft; Belt Drive Gear 1 Fig.7 10192 035-15138-209 P-Rcv-T BKT F 1 Fig.8 3193 035-15139-205 P-Rcv-T BKT R 1 Fig.8 4194 035-15153-003 Fan Base; Separation 1 Fig.9 3195 035-15156-002 Nozzle-Up; Separation 1 Fig.9 4196 035-15157-106 Nozzle-Low; Separation 1 Fig.9 5197 035-15161-006 Fan Base Support BKT 1 Fig.9 6198 035-15162-002 Fan Base Shaft 1 Fig.9 7199 035-15200-001 Suction Face Cover 80 1 Fig.10 6200 035-15201-008 Suction Wing F 80 1 Fig.10 16201 035-15202-004 Suction Wing R 80 1 Fig.10 17202 035-15203-000 Paper Receiving Tray 80 1 Fig.8 1203 035-15204-007 Paper Base Stop 80 1 Fig.8 2204 035-15205-003 P-Rcv-T BKT 80 1 Fig.8 5205 035-15206-000 P-Ejection Guide 2 Fig.8 6206 035-15207-006 Side Base ; P-Rcv-T 2 Fig.8 7207 035-16101-007 Drum Support F Ass'y 1 Fig.12 15208 035-16103-107 Drum Support R Ass'y 1 Fig.12 16209 035-16105-002 Drum Main Gear 1 Fig.12 17210 035-16106-009 Compensator 1 Fig.12 18211 035-16107-005 Pressure Cam 1 Fig.12 19212 035-16108-001 Pressure Cam;A4 1 Fig.12 19213 035-16109-008 Screen Ass'y 1 Fig.12 20214 035-16110-006 Drum Support R Ass'y;AL 1 Fig.12 16215 035-16111-002 Drum Body;AL 1 Fig.12 1216 035-16201-001 M-Projection Plate 1 Fig.12 21


Index KS800

No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark217 035-16202-008 Friction Sheet 1 Fig.12 33218 035-16301-006 BKT; Ink Bottle Guide 1 Fig.22 8219 035-16302-002 Ink Bottle Guide 1 Fig.22 9220 035-16303-009 Bottle Hook-Spring 3 Fig.22 10221 035-16304-005 Inking Hose dia.10 1 Fig.12 22222 035-16305-001 Center Nozzle 1 Fig.12 23223 035-16306-008 BKT; Ink Bottle Sensor 1 Fig.22 11224 035-16307-004 Ink Bottle Sensor Plate 1 Fig.22 12225 035-16401-205 Drum U Support BKT F 1 Fig.12 24226 035-16402-007 Drum U Support BKT R 1 Fig.12 25227 035-16501-005 Center Shaft 1 Fig.11 16228 035-16502-001 Main Frame; Drum 2 Fig.11 17229 035-16503-202 Sqg. F Plate Ass'y 1 Fig.11 18230 035-16506-201 Sqg. R Plate Ass'y 1 Fig.11 19231 035-17001-006 OF F Frame Ass'y 1 Fig.17 2232 035-17003-009 OF R Frame Ass'y 1 Fig.17 3233 035-17004-005 BKT; O-Det. Sensor 1 Fig.17 4234 035-17005-001 Spring; Scanner 2 Fig.17 5235 035-17006-008 Spring; Load Roller 1 Fig.17 6236 035-17007-004 Spring; Ejc-Roller 1 Fig.17 7237 035-17009-007 Org-Load Roller 1 Fig.17 32238 035-17012-008 Org-Ejc-Roller 1 Fig.17 31239 035-17015-007 Wh-Roller Holder 2 Fig.17 11240 035-17016-003 White Roller 1 Fig.17 12241 035-17019-002 Roller; L40 1 Fig.17 13242 035-17020-000 Roller; L74 1 Fig.17 14243 035-17021-309 DFeeder Cover 1 Fig.17 8244 035-17022-100 Cover Up; Wh-Roller 1 Fig.17 34245 035-17023-000 Cover Low; Wh-Roller 1 Fig.17 17246 035-17024-006 Original Guide 2 Fig.17 9247 035-17025-002 Hook; DFeeder 1 Fig.17 19248 035-17026-009 Scanner Holder L 1 Fig.17 20249 035-17027-005 Scanner Holder R 1 Fig.17 21250 035-17028-001 Spring; Hook 2 Fig.17 22251 035-18101-101 Master Flange 1 Fig.19 4252 035-18102-000 M-Flange Holder 2 Fig.19 5253 035-18103-007 M-Flange Guide 1 Fig.19 6254 035-18104-100 Tension Plate 2 Fig.19 7255 035-18105-204 Tension Plate Ass'y 1 Fig.19 8256 035-18107-100 Plate; Plunger 1 Fig.19 9257 035-18108-203 Rubber; Tension 1 Fig.19 10258 035-18109-102 Master Flange R 1 Fig.19 11259 035-18110-100 De-electricity Brush;KS 2 Fig.19 12260 035-18111-107 Master Tension Sheet 2 Fig.19 13261 035-18201-009 Write Roller 1 Fig.19 14262 035-18204-008 TPH Press-Plate 1 Fig.19 15263 035-18205-306 TPH Position-Plate 1 Fig.19 16264 035-18206-108 TPH Press-Shaft 1 Fig.19 17265 035-18207-007 Press-sensor Plate 1 Fig.19 18266 035-18208-003 TPH Press-Cam 1 Fig.19 19267 035-18209-000 TPH Support Shaft 1 Fig.19 20268 035-18210-008 Shaft Stopper 1 Fig.19 21269 035-18301-003 Shaft; M-Guide 1 Fig.18 1270 035-18302-000 M-Guide Plate; Lower 1 Fig.18 2


Index KS800

No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark271 035-18303-200 M-Guide Plate; Upper 1 Fig.18 3272 035-18304-207 Cutter Guide Plate 1 Fig.19 22273 035-18305-009 Rev-gear Plate Ass'y 1 Fig.19 23274 035-18401-202 Frame R Ass'y; M-M U 1 Fig.19 24275 035-18404-104 Frame F Ass'y; M-M U 1 Fig.19 25276 035-18406-000 Base; M-M U 1 Fig.19 26277 035-18407-103 Cover; M-M U 1 Fig.19 27278 035-18408-002 M-Tension Shaft 1 Fig.19 28279 035-18410-007 Release Lever 1 Fig.19 29280 035-18411-208 Base; M-M Upper U 1 Fig.19 30281 035-18412-000 Cover; M-M Upper U 1 Fig.19 31282 035-18413-103 Locking Plate Ass'y 1 Fig.19 32283 035-18415-009 Shaft; M-Holder 1 Fig.19 33284 035-18416-005 Shaft; M-M U 2 Fig.19 54285 035-18417-001 Washer;3.5*14*1.2 2 Fig.19 55286 035-18501-002 Spring ; TPH Pressure 2 Fig.19 34287 035-18502-009 Spring R; M-M Upper U 1 Fig.19 35288 035-18503-005 Spring F; M-M Upper U 1 Fig.19 36289 035-18504-001 Tension Spring 1 Fig.19 37290 035-18505-008 Spring ; Rev-gear Plate 1 Fig.19 38291 035-19008-105 M-Rmv Hook 2 Fig.15 6292 035-19025-000 Wire; M-Rmv Link 1 Fig.15 12293 035-19026-006 M-Rmv Link 2 Fig.15 13294 035-19027-100 Collar; M-Rmv 1 Fig.2 15295 035-19027-100 Collar; M-Rmv 10 Fig.15 14296 035-19029-005 Hinge; M-Rmv 2 Fig.15 15297 035-19033-100 Lever; M-Rmv 1 Fig.15 16298 035-19034-009 Spring; M-Rmv Lever 1 Fig.15 17299 035-19035-005 BKT; M-Rmv Lever 2 Fig.15 18300 035-19036-001 Shaft A; M-Rmv Gear 1 Fig.15 19301 035-19037-008 Shaft B; M-Rmv Gear 1 Fig.2 47302 035-19037-008 Shaft B; M-Rmv Gear 1 Fig.15 20303 035-19038-004 Shaft; M-Rmv Lever 1 Fig.15 21304 035-19045-000 BKT; M-Feed Sheet 5 Fig.1 9305 035-19046-309 M-Feed Sheet 2 Fig.1 10306 035-19047-208 BKT; M-Rmv Sensor 1 Fig.15 22307 035-19058-005 Cover;M-Rmv Lever 1 Fig.15 23308 035-19059-109 Frame ; M-Rmv U 80 1 Fig.15 2309 035-19060-000 M-Rmv Guide ; Lower 80 1 Fig.15 4310 035-19061-006 M-Rmv Guide ; Upper 80 1 Fig.15 5311 035-19062-002 M-Rmv Guide ; Upper2 80 1 Fig.15 31312 035-19063-009 BKT F ; Trans-Roller 80 1 Fig.15 7313 035-19064-005 BKT R ; Trans-Roller 80 1 Fig.15 8314 035-19065-001 Spring Trans-Roller 80 2 Fig.15 9315 035-19066-008 Trans-Roller ; Lower 1 Fig.15 10316 035-19067-004 Trans-Roller ; Upper 1 Fig.15 11317 035-19069-007 *M-Disposal ; Main Box Ass'y 1 Fig.14 5318 035-19070-005 *M-Disposal Box ; Cover 1 Fig.14 6319 035-19071-001 *M-Disposal ; Guide 1 Fig.14 1320 035-19072-008 *M-Disposal ; Lever 1 Fig.14 3321 035-19073-101 *M-Disposal ; Link 2 Fig.14 2322 035-19075-007 *M-Disposal ; Spring 2 Fig.14 4323 035-19076-003 Stay ; M-Rmv U Frame 1 Fig.15 3324 035-19077-000 BKT A;M-Rmv SW 80 1 Fig.13 4


Index KS800

No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark325 035-19078-006 BKT B;M-Rmv SW 80 1 Fig.13 5326 035-19079-002 M-Feed Sheet 80 2 Fig.1 11327 035-50504-102 P-Supply PCB XIII-N100 1 Fig.22 14328 035-50505-001 P-Supply PCB XIII-N200 II 1 Fig.22 14329 035-50506-105 Main-PCB-KS800 1 Fig.22 13330 035-51001-104 Wire; M-M Unit 1 Fig.23 1331 035-51007-102 Wire; Ink Sensor 1 Fig.12 26332 035-51010-103 Wire; F 1 Fig.23 2333 035-51011-100 Wire; R 1 Fig.23 3334 035-51013-102 Wire; P-Rcv Sensor 1 Fig.9 8335 035-51018-104 Wire; Main-Scanner 1 Fig.23 4336 035-51023-108 Safety SW Ass'y 1 Fig.4 35337 035-51023-108 Safety SW Ass'y 1 Fig.7 11338 035-51023-108 Safety SW Ass'y 1 Fig.19 39339 035-51024-201 Wire;M-Rmv Unit 1 Fig.23 5340 035-51025-003 M-Rmv Safety SW Ass'y 1 Fig.23 7341 035-51025-003 M-Rmv Safety SW Ass'y 1 Fig.13 6342 035-52001- System ROM ; KS 1 Fig.22 15343 035-90002-002 Control Panel Unit KS800C 1 Fig.20 4344 035-92002-050 Main Motor Ass'y 1 Fig.2 34345 035-94302-000 Pickup Roller Ass'y 1 Fig.4 36346 035-96321-002 Ink Pump Unit 1 Fig.12 27347 035-98004-101 Cutter Unit 1 Fig.18 4348 035-99060-005 M-Disposal Box Ass'y 1 Fig.14349 435-00025-000 Noise Filter;SFC-6 1 Fig.23 6350 443-32005-003 GP2A25 1 Fig.17 23351 443-32005-003 GP2A25 1 Fig.19 40352 444-30000-001 GP1A73A 1 Fig.12 28353 444-30000-001 GP1A73A 1 Fig.15 24354 444-30000-001 GP1A73A 2 Fig.16 12355 444-30000-001 GP1A73A 2 Fig.19 41356 444-30000-001 GP1A73A 1 Fig.22 16357 444-31001-001 M-Rmv Sensor 1 Fig.15 25358 444-33000-002 GP2A200LCS 1 Fig.9 9359 444-41001-107 Encoder Sensor 1 Fig.2 16360 444-43000-302 KH0726 1 Fig.22 17361 444-60000-103 Image Scanner 1 Fig.17 24362 444-80300-308 TPH 1 Fig.19 42363 488-00033-104 Power Code; CH 1 Fig.22 18364 488-90028-007 RS3-150-RS3 1 Fig.6 11365 490-20002-106 Main Motor 1 Fig.2 7366 490-21005-001 Clamp Motor 1 Fig.16 13367 490-33006-003 DFeed Motor 1 Fig.17 25368 490-33006-003 DFeed Motor 1 Fig.19 43369 490-41002-106 Fan 1 Fig.9 10370 490-41002-106 Fan 1 Fig.10 10371 490-50001-104 M-Loading Solenoid 1 Fig.19 44372 490-51001-000 PF/M-Rmv Clutch 2 Fig.2 18373 550-20118-104 TPH Seal 1 Fig.19 45374 550-21519-005 TPH Seal;CH 1 Fig.19 45375 600-20061-009 Bearing;608ZZ 2 Fig.3 13376 607-07004-005 Metal; S8*10*15 2 Fig.19 46377 607-13000-003 Metal;F6*10/9*4;12*1.5 4 Fig.2 19378 607-13000-003 Metal;F6*10/9*4;12*1.5 4 Fig.4 37


Index KS800

No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark379 607-13000-003 Metal;F6*10/9*4;12*1.5 4 Fig.15 26380 607-13000-003 Metal;F6*10/9*4;12*1.5 4 Fig.17 26381 607-13000-003 Metal;F6*10/9*4;12*1.5 2 Fig.19 47382 607-15000-000 MetalF8*13/12*5;16*2 2 Fig.2 20383 607-15000-000 MetalF8*13/12*5;16*2 1 Fig.4 38384 607-15000-000 MetalF8*13/12*5;16*2 3 Fig.7 12385 607-15000-000 MetalF8*13/12*5;16*2 2 Fig.10 11386 607-15000-000 MetalF8*13/12*5;16*2 2 Fig.16 14387 607-16001-000 Metal;F10*15/14*6;18*2 1 Fig.2 21388 607-16001-000 Metal;F10*15/14*6;18*2 2 Fig.3 14389 607-16001-000 Metal;F10*15/14*6;18*2 4 Fig.4 39390 607-16002-007 Metal;F10*16/12.8*12:18*2 2 Fig.4 40391 607-70815-005 Washer;R-WAS8399H 2 Fig.2 22392 612-00401-009 Gear; m0.5*48*4 1 Fig.19 48393 612-03104-005 Gear; m1.25*14*6 2 Fig.15 27394 612-10012-000 Gear; m1*31*8 1 Fig.2 23395 612-11102-003 Gear;m0.8*18*5 1 Fig.11 20396 612-11205-007 Gear; m0.8*28*4 2 Fig.17 18397 612-11205-007 Gear; m0.8*28*4 2 Fig.19 49398 612-11303-009 Gear ; m0.8*34*7 1 Fig.2 39399 612-11307-004 Gear ; m0.8*24*7 1 Fig.2 41400 612-11401-000 Gear;m0.8*45*5 1 Fig.11 21401 612-11402-007 Gear; m0.8*40*3 2 Fig.17 28402 612-11501-005 Gear; m0.8*52*7 1 Fig.17 16403 612-12102-007 Gear; m1*17*6.5 1 Fig.15 28404 612-12206-007 Gear; m1*24*4 1 Fig.17 30405 612-12207-003 Gear; m1*20*10 1 Fig.10 12406 612-12303-002 Gear;m1*30*5 1 Fig.11 22407 612-12304-009 Gear;OWC;m1*30*5 1 Fig.11 23408 612-12309-000 Gear ; m1*37*9 1 Fig.2 44409 612-12309-000 Gear; m1*37*9 1 Fig.15 29410 612-12311-005 Gear; m1*36*7 1 Fig.16 15411 612-12312-001 Gear; m1*39*8 1 Fig.7 13412 612-12313-008 Gear; m1*33*6 1 Fig.10 13413 612-12319-006 Gear ; m1*36*7 1 Fig.2 43414 612-16100-009 Gear; m2*18*8 1 Fig.7 14415 612-16300-008 Gear; m2*32*13 1 Fig.2 26416 612-32100-000 Gear; m1*16R*16 1 Fig.2 27417 612-80014-000 Gear;m1*57+m1*49 1 Fig.2 36418 612-80015-007 Gear;m1*41+m1*35 1 Fig.2 37419 612-80800-006 Gear;m0.5*86+m0.5*49 1 Fig.17 15420 612-80800-006 Gear;m0.5*86+m0.5*49 1 Fig.19 50421 612-80801-002 Gear; m0.5*85+0.8*19 1 Fig.17 27422 612-80801-002 Gear; m0.5*85+0.8*19 2 Fig.19 51423 612-80900-000 Gear;m0.5*94+m0.5*48 1 Fig.17 29424 612-80900-000 Gear;m0.5*94+m0.5*48 2 Fig.19 52425 612-81303-006 Gear ; m0.8*35+m0.8*15 1 Fig.2 40426 612-82307-005 Gear;m0.5*40+m1*16 1 Fig.16 16427 612-82308-001 Gear; m1*36+m1*15 1 Fig.10 14428 612-82310-006 Gear; m1*36+m1*14 2 Fig.16 17429 612-82313-005 Gear ; m1*21+m1*14 1 Fig.16 19430 612-82400-005 Gear; m1*41+m1*36 1 Fig.15 30431 612-82600-004 Gear; m1*65+m2*29 1 Fig.2 29432 612-82701-005 Gear; m1*70+m1*60 1 Fig.2 30


Index KS800

No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark433 629-93810-202 Transfer Belt;14*0.65*381 2 Fig.10 15434 634-04030-002 Collar; dia.4*3 1 Fig.2 31435 635-00410-002 Stepped Screw ; m4*10 2 Fig.10 18436 635-09308-103 Pan-head Tap Tight P Screw 3*8 1 Fig.3 15437 635-09308-103 Pan-head Tap Tight P Screw 3*8 1 Fig.17 33438 635-17523-005 Stepped Screw;dia.5*2;M3*3 4 Fig.19 53439 638-90000-128 Washer;18*10.4*0.4 1 Fig.4 41440 640-60030-004 O Ring ; P3-1.9 2 Fig.11 24441 640-60100-100 O Ring ; P10-2.4 1 Fig.11 25442 640-60100-100 O Ring ; P10-2.4 1 Fig.12 29443 640-60180-006 O Ring ; P18-2.4 2 Fig.11 26444 640-61550-001 O Ring ; P115-2.4 2 Fig.12 30445 660-01002-105 Rubber Foot TK-3215 4 Fig.1 12446 665-02903-005 Power Band T14 2 Fig.12 31447 Main Frame; Front 1 Fig.1 1448 Main Frame; R Ass'y 80 1 Fig.1 2449 Base Plate 1 Fig.1 3450 Front Cover ; KS800 1 Fig.20 3451 Control Panel Unit KS800 1 Fig.20 4452 Label ; P-Rcv 80 1 Fig.21 1-a453 Label; M-Replace 1 Fig.21 1-b454 Label ; M-Disposal 80 1 Fig.21 1-c455 Label; Ink Replace 1 Fig.21 1-d

New Part for KS800


KS800 Series Version 3.1

Documents

master removal cover

exterior cover removal

main motor unit

main drive section1

main motor safety switches

machine summary1

drum position

machine operations