REVISION 1.2
OCTOBER, 2011
TECHNICAL MANUAL
Copyright : 2011 Riso Kagaku Corporation
All Rights Reserved. This Technical Manual was prepared
and written for the exclusive use of RISO International
Group Certified Dealers. Reproduction and/or transmittal
of this material in any form or by any means, including
photocopying or recording of the information is strictly
prohibited without the consent of a member of RISO
International Group.
57A01C
RISO
KZ30 (Rev. 1.2)
CHAPTER
1
: MAINTENANCE
CONTENTS
PREFACE ...1-3 1. Warning ...1-4 2. Work Precautions ...1-5 3. Jigs ...1-7 4. Exterior Cover Removal ...1-81) Print Drum ...1-8
2) Front Cover ... 1-10
3) Rear Cover ... 1-10
4) Master Removal Unit Cover
... 1-11
5) Master Making Unit Cover ... 1-11
6) Operation Panel Assembly
... 1-12
5. Pressure Spring Removal ...1-13[ 1-2 ] 1-2 ] KZ30 (Rev. 1.2)
PREFACE
This manual provides Technical Service Information for RISO
57A01C and KZ30 digital
duplicator.
This manual is published as a reference guide for use by certified field servicemen trained under
RISO International Group technical trainers.
This manual includes procedures for removal, installation and adjustments of major components
found on the machine. Following these procedures will prevent injuries and malfunctions on the
machine, as well as to achieve end-user satisfaction.
[ 1-4 ] 1-4 ] KZ30 (Rev. 1.2)
1. Warning
Important Safety Precautions
1. Always disconnect electrical supply before placing hands in the
machine.
I.
To avoid injuries:
Be sure to disconnect the electrical power before disassembling, assembling,
or when making adjustments on the machine.
II. Protection of the machine:
Make sure to turn OFF the power to the machine before plugging or unplugging
the electrical connectors, or when connecting a Meter.
2. Always connect electrical connectors firmly.
I.
To avoid electrical failure:
The connectors must be connected firmly together and onto the PCBs.
Press on the ends of the connectors and then the center to ensure a firm fit.
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.
2. Work Precautions
Lifting the machine
The machine should be lifted by two persons, one person on the paper-feed side and the other person on
the paper-receive side.
There is a beam running across on the paper-feed side and also on the paper-receive side. These metal beams should be grabbed firmly by both hands by each person.
Grab the metal beams as shown on the photograph on the LEFT. Do not grab the metal beams as shown on the photograph on the RIGHT. If grabbed as shown on the RIGHT, hands and fingers may be cut and injured by the sharp edges of the metal beam.
Inspection
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 E-rings, use the specified size.
Assembly and installation
Unless otherwise specified, assembly and installation follow the reverse order of removal. When there is a protruding section
Positioning pin
[ 1-6 ] 1-6 ] KZ30 (Rev. 1.2)
Wiring bundle band (bar lock ties)
Electrical system work
> After replacing electrical wires, fasten them with bands (bar lock ties) so that they do not sag. > When installing parts, be careful to avoid pinching and damaging the electrical wires.
> If a fuse blows, always replace it with one of the specified capacity.
> Using a larger fuse will not only damage the machine components, but may also cause fires. > Image scanner, thermal heads, and sensors are extremely vulnerable to shock, so do not handle
them roughly or drop them.
> Always turn OFF the machine power before working on the machine and when plugging or unplugging
sensor connectors.
Self-tapping screws
Self-tapping screw Pan-head screw
Binding-head screw
< These are not self-tapping screws.>
< Caution is needed in mounting the
self-tapping screws.>
Self-tapping screws are used in many places on the machine.
The self-tapping screws, if incorrectly handled, will damage the screw hole on the machine frame.
When mounting the self-tapping screws, first rotate the screw in the counter-clockwise direction to find the
thread on the screw hole. Then start rotating the screw in the clockwise direction to tighten. This is to
prevent the tapping screw from making new screw thread on the screw hole and damaging the original screw
thread on the screw hole
3. Jigs
List of the Jigs needed to maintenance this machine.
021-16007-005 Spring; Screen (2 pieces required) Cut the ring end to make into hook, as shown on the photograph, and attach wire tie bar on the other end.
<Refer to the Chapter on the Print Drum>
051-75008-006 Drum Shaft Jig (8mm diameter) Needed to align the Print drum (Front & Rear).
<Refer to the Chapter on the Print Drum>
OR
PLUS
1.
[ 1-8 ] 1-8 ] KZ30 (Rev. 1.2)
4. Exterior Cover Removal
Disconnect the power supply from the machine and remove the cover. 1) Print drum
2) Front cover 3) Rear cover
4) Master removal unit cover 5) Master making unit cover
6) Operation panel
Master removal unit cover
Operation panel
Front cover
(Already removed on the photograph.)
Rear cover
1) Print Drum (1 screw)
1. Swing open the Separation fan unit.
2. Look into the machine from the paper ejection opening of the machine to find the Print drum lock mechanism. (Refer to the next page for the view of the Lock mechanism.)
3. Loosen the screw of the Print drum lock and remove the lock.
Separation fan unit
Swing open
< Paper Ejection Side of the Machine >
Look into the machine
Master making unit cover
4. Slowly pull out the Print drum, straight, all the way out until it stops. Grab the tail end of the Drum.
< Do not lift the Print drum or the Print drum will fall off the machine. >
Hold onto the Lock mechanism
and loosen the screw.
The Lock can be removed. < View of the Lock >
5. Firmly holding the front and tail end of the Print drum, lift the front end of the Print drum a little and disengage the Print drum from the guide rail to remove it out of the machine.
Pull out the Drum straight
and keep holding the front grip.
Grab the tail end of the Drum. The grip on the rear of the
Print drum.
Hold firmly
[ 1-10 ] 1-10 ] KZ30 (Rev. 1.2)
3) Rear Cover (6 screws)
< Front View > < Rear View >
The rear cover can be
separated into two pieces.
2) Front Cover (8 screws)
< Front View > < Rear View >
The front cover can be
separated into three pieces.
< Front View >
Remove the Print Drum from the machine first.
< Front View >
4) Master Removal Unit Cover (4 screws)
5) Master Making Unit Cover (5 screws)
2 screws on the back. 1 screw from the top.
[ 1-12 ] 1-12 ] KZ30 (Rev. 1.2)
6) Operation Panel Assembly (2 screws)
1. Disconnect one connector from the bottom of the Operation Panel.
2. Remove two screws on the operation panel bracket to detach the Operation panel assembly from the machine.
< Operation Panel - left view >
< Operation Panel - front view >
Operation panel bracket
Connector to the Operation panel.
(View from underneath the panel)
5. Pressure Spring Removal
To avoid injury in removing the Pressure spring from the machine, never use bare hands to unhook the
spring.
One recommendation is to use a piece of strong rope. (refer to the photograph below.)
Long nosed pliers can also be used, but the spring may slip out from the pliers and may not work as well
as a strong rope.
Strong piece of Rope.
Pressure spiring
Remove the Paper receiving tray and Suction unit from the machine prior to the Pressure spring removal
for easier access to the sprint access and safety.
[ 1-14 ] 1-14 ] KZ30 (Rev. 1.2)
MEMO
CHAPTER
2
: MACHINE SUMMARY
CONTENTS
1. Specifications ...2-3 RISO 57A01C ...2-3 RISO KZ30 ...2-4 2. Cross Sectional Diagram ...2-5 3. Machine Operations ...2-6 4. Paper Feed and Receiving ...2-7 5. Master Removal and Feed ...2-8 6. Counter Indication ...2-9 1. Indicate Copy and Master Counter: ... 2-9 2. Stopping of the Copy and Master Software Counter
[ 2-2 ] 2-2 ] KZ30 (Rev. 1.2)
MEMO
1. Specifications
RISO 57A01C
[ 2-4 ] 2-4 ] KZ30 (Rev. 1.2)
2. Cross Sectional Diagram
5 6
2
Timing roller
Paper receiving tray Separator 4 7 Guide roller Pressure roller Master roll Write roller 10 9 8
Master disposal box
Image scanner
Document feeder
Thermal print head
Original 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 via Pickup
roller and Stripper pad.
2 Second Paper Feed Area: Controls the vertical print position and feeds paper to the print area via
the Timing and Guide rollers.
3 Press (Printing) Area: Uses the Pressure roller to press paper against the master on the Drum. The Drum rotates with the Pressure roller and prints an image
on paper.
4 Paper Ejection Area: Separates a printed paper from the Drum, and transports it onto the
paper receiving tray.
5 Drum Area: Supplies the Drum surface with ink from an Ink cartridge. 6 Master Clamp Area: Clamps the leading edge of the master.
[ 2-6 ] 2-6 ] KZ30 (Rev. 1.2)
3. Machine Operations
Master Disposal
The used master is removed from the drum and stored in the disposal box.
Printing
Paper is fed one sheet at a time from
the Paper feed tray, printed, and stored on the paper receiving tray.
Master Making
The original is scanned by the image scanner and the image is made on the
master with the thermal print head.
Master Carrier and Loading
The made master is wrapped onto the drum and cut.
Also, a proof print is printed. Set the original and press the Start key.
4. Paper Feed and Receiving
Drum Pickup roller Guide roller Timing roller Pressure roller Separation fan Separator Transfer beltThe paper feed to the second paper feed area is
stopped by the Guide and Timing rollers to form a buckle. The paper then waits until the rotation of the
Guide roller starts.
While the paper is being fed from the second paper
feed area, the Pressure roller rises and printing starts.
(The Pressure roller contacts the Drum and starts
rotating.)
After the Pressure roller contacts the Drum to start printing, the Separator approaches the Drum and the Separation fan starts to blow.
The Guide roller goes up to release the paper.
(The paper is then transferred by the rotation of the Drum.)
The Timing roller contacts with the Guide roller to feed The printed paper is separated from the Drum by the Separator and with a help of the air blow from the
Separation fan.
It is then transported onto the Paper receiving tray by the Transfer belts using Suction fan.
The Drum is rotated and a sheet of paper is fed from the first paper feed area to the second paper feed area by Pickup rollers, and Stripper pad.
The Guide and Timing rollers in the second paper feed
area are rotated and the paper is fed to the printing area.
[ 2-8 ] 2-8 ] KZ30 (Rev. 1.2)
5. Master Removal and Feed
Master Making
Master Loading Master Removal
The Clamp plate opens and Master release shaft releases the master from the Clamp
plate.
The Drum and Vertical transport rollers starts rotating and removes the master from the Drum and feed it into the Master disposal box.
The Master compressing plate starts compressing the removed master within the Master removal box.
The Image scanner scans the image on the original and Thermal print head (TPH) makes the image on the master material.
The Master tension plate drops down and
applies tension on the master material.
The master is transferred onto the Drum and the leading edge is clamped by the Clamp
plate.
The Drum rotates to wrap the master on the Drum.
The Cutter cuts the master.
Master Master roll Clamp plate Vertical transport roller Cutter
Master projection shaft
Master
disposal box
TPH
6. Counter Indication
1. Indicate Copy and Master Counter:
The Copy and Master Counter on the machine is displayed on the LED panel of the machine by the Custom Setting of the user mode.
2. Stopping of the Copy and Master Software Counter during the machine repair:
During the machine servicing, if the Copy Counter and Master Counter on the customer's machine needs to be stopped in order that the serviceman can make the master and prints to check the machine condition and not wishing to increase the counter reading for those confirmation prints, the software counter can be stopped tentatively by Test Mode No. 155 [Counter Action Control].
Selecting [0] on the Test Mode No. 155 will stop the counter action while the machine power is kept ON.
Item No. 30: Total Copy Count Display
The total number of pages printed with the machine is
displayed.
The total number of counter is shown on the Display. This number is displayed on two screens, consisting of an under bar + 3-digit number and 4-digit number. Example:
If 1,357,900 pages: _135 ---> 7900.
Item No. 31: Total Master Count Display
The total number of masters generated with the machine is displayed.
same description as the Total Counter
-Item No. 32: Average Display Function
Displays the average number of pages printed for each master made on the machine.
same description as the Total Counter
-Refer to the operation steps described on the right.
30
-135
7900
1. Press the CUSTOM key on the Control Panel.
NOTE: To exit the Custom
Setting mode, turn off the indicator by pressing the
CUSTOM key.
2. Enter Item No. 30, 31 or 32 depending on which counter to display.
3. Press the + key to display the first 3 digit numbers.
4. Press again the + key to display the remaining 4 digit numbers.
< Sample Instructions >
[ 2-10 ] 2-10 ] KZ30 (Rev. 1.2)
MEMO
CHAPTER
3
: MAIN DRIVE SECTION
CONTENTS
Theory of Operation ...3-3
1. Main Drive ...3-3 2. Main Motor Safety Switch ...3-4
3. Drum Positions ...3-5
4. Print Drum Locking Mechanism ...3-5 Removal and Assembly ...3-7
1. Main Drive Gears ...3-7 2. Main Motor Unit ...3-10
3. Master Removal Unit Safety Switch ... 3-12 4. Master Making Unit Safety Switch ... 3-13 5. Separation Unit Safety Switch ...3-14
[ 3-2 ] 3-2 ] KZ30 (Rev. 1.2)
MEMO
Theory of Operation
1. Main Drive
The main motor drives the following components of the machine.
* First paper feed unit * Second paper feed unit
* Print drum
* Pressure roller (up & down motion) * Paper ejection suction belt
Print drum Suction belt
[ 3-4 ] 3-4 ] KZ30 (Rev. 1.2)
2. Main Motor Safety Switch
Following all four Safety switches must be activated to run the Main motor.
* Master removal unit safety switch * Master making unit safety switch
* Separation unit safety switch
* Print drum safety switch
The same four switches act also as Safety switches for the Thermal power.
Master removal unit safety switch Master making unit safety switch
Separation unit safety switch
Print drum safety switch
Drum position-A of the Print Drum
3. Drum Positions
1) Sensors for the Drum positioning
The position of the Drum is determined by the Position-A sensor and Encoder sensor on the Main motor.
2) Position-A
* This is the position where the Clamp plate is at the top of the Drum.
* This position is also referred as the 0 .
* The Clamp plate opens and closes at this position.
* This is the position where the light path of the Position-A sensor is cut by the Position-A plate on the Drum.
4. Print Drum Locking Mechanism
1) The Print drum is designed to unlock only when it is at Position-B.
2) At any other Drum positions, the flange around the Drum main gear prevents the Intermediate gear from disengaging from the Drum main gear.
3) Only when the Print drum is at Position-B, the flange on the Drum main gear does not interfere against the Intermediate gear, allowing the Print drum to be pulled out from the machine.
4) When the Print drum is pulled out of the machine, the lock mechanism locks the Print drum at Position-B so that the Print drum does not rotate while it is pulled out of the machine.
Position-A plate Position-A sensor Drum angle 0 FRONT REAR
[ 3-6 ] 3-6 ] KZ30 (Rev. 1.2)
Drum A-Positioning Movement Timing Chart
Drum angle (Encoder sensor) Position-A sensor Main motor 270 90 180 270 340 End of movement 0 (Position-A) ON Open Blocked OFF 15 rpm 1.95 rpm 0 (Position-A) (a) (b)
(a) If the light path of the Position-A sensor is cut when the last paper is counted, the Main motor speed becomes from printing to 15 rpm to stop the drum rotation.
(b) When the Drum rotates to 340, the drum rotation speed becomes 1.95 rpm to stop the drum at the Drum- A position (at Drum 0 ) exactly. Then Main motor turns off.
> If the Encoder sensor does not output the Main motor rotation signal within 1.2 seconds, the machine assumes that the Main motor has locked and displays error message [P 01].
> If over load current is detected and the Encoder sensor does not output th Main motor rotation signal for 0.1 seconds, the machine assumes that the Main motor has locked and displays error message
[P 01].
Removal and Assembly
1. Main Drive Gears
1. Turn OFF the machine power and disconnect the power cord from the machine.. 2. Remove the Rear cover.
3. Remove the Power supply unit. (4 screws and unhook wire harness from the wire saddles.)
Power supply unit
4. Remove the FG Sensor (Encoder sensor)
Remove 2 screws to detach
Encoder cover.
[ 3-8 ] 3-8 ] KZ30 (Rev. 1.2)
5. Remove the Paper feed clutch support plate. (3 screws)
6. Disconnect the connector and remove the Paper feed clutch.
Paper feed clutch support plate
In assembly, make sure to locate the clutch hook in the hook lock to fix the clutch in position. The hook faces down.
Timing clutch support plate
7. Remove the Timing clutch support plate (4 screws), disconnect the connector and remove the Timing
clutch.
In assembly, make sure to locate the clutch
hook in the hook lock to fix the clutch in position. The hook faces up.
8. Disconnect wire harness clamps from the Drive gear bracket and remove the bracket. (8 screws)
9. Remove the E-rings and remove the Gears.
[ 3-10 ] 3-10 ] KZ30 (Rev. 1.2)
2. Main Motor Unit
1. Turn OFF the machine power and disconnect the power cord from the machine.. 2. Remove the Rear cover.
3. Remove the Paper receiving tray. 4. Remove Suction cover.
5. Remove Suction unit.
continues to next page
-Paper receiving tray Suction cover
Suction unit
6. Remove the Drive gear bracket by following the instructions given on pages from 3-7 to 3-9.
Drive gear bracket
7. Remove the mounting screws, disconnect the connector and remove the Main motor out from the
[ 3-12 ] 3-12 ] KZ30 (Rev. 1.2)
3. Master Removal Unit Safety Switch
1. Turn OFF the machine power and disconnect the power cord from the machine. 2. Remove the Master removal unit cover.
3. Open the Master removal unit, disconnect the Connector of the Master removal unit safety switch and remove the switch assembly. (1 screw)
4. Open the Master removal unit safety switch assembly and remove the switch. (2 screws)
Master removal unit Master removal unit safety switch assembly
Master removal unit safety switch assembly Master removal unit safety switch
4. Master Making Unit Safety Switch
1. Turn OFF the machine power and disconnect the power cord from the machine.
2. Remove the Master removal unit from the machine. (Refer to the Chapter on Master making unit.) 3. Disconnect the Connector of the Master making unit safety switch.
4. Remove two mounting screws of the Master making unit safety switch and remove the switch.
Precautions in Assembly
Install the switch in the correct direction.
Master making unit Master making unit safety switch
[ 3-14 ] 3-14 ] KZ30 (Rev. 1.2)
5. Separation Unit Safety Switch
1. Turn OFF the machine power and disconnect the power cord from the machine.
2. Remove the Front cover.
3. Remove the Mechanical control PCB.
4. Open the Separation unit as shown on the photograph below.
5. Disconnect the connector, remove the Separation unit switch assembly from the machine (1 screw) and remove the switch from the bracket.
Master removal unit safety switch assembly
Separation unit
Mechanical control PCB assembly
6. Print Drum Safety Switch
1. Turn OFF the machine power and disconnect the power cord from the machine.
2. Remove the Rear cover.
3. Disconnect the connector and remove the Print drum safety switch. (1 screw)
CAUTION:
Do not deform the sensor bracket, as it acts as metal spring when the Print drum in inserted in the machine.
[ 3-16 ] 3-16 ] KZ30 (Rev. 1.2)
MEMO
CHAPTER
4
: FIRST PAPER FEED SECTION
CONTENTS
1. Theory of Operation ...4-3
1. Paper Feed Tray Positions (Upper / Lower) ... 4-3
2. First Paper Feed Drive Mechanism ... 4-4
3. Paper Pickup System ...4-6
4. Paper Feed Pressure Select System ... 4-7 2. Removal and Assembly ...4-9 1. Paper Feed Tray Unit ...4-9
2. Pickup Roller Assembly ...4-10 3. Pickup Roller and Paper Feed Support Roller ... 4-11 4. Stripper Pad ...4-12 5. Paper Feed Clutch ...4-13 3. Adjustment ...4-15
[ 4-2 ] 4-2 ] KZ30 (Rev. 1.2)
MEMO
1. Theory of Operation
1. Paper Feed Tray Positions (Upper / Lower)
Paper Feed Tray Set Lever> Raising the Paper feed tray set lever raises the Paper feed tray to the upper limit position.
The Paper feed tray (paper) touches the Pickup roller.
> Lowering the Paper feed tray set lever lowers the Paper feed tray to the lower limit position. The Paper feed tray (paper) releases down from the Pickup roller.
Paper feed tray
Paper feed tray set lever
[ 4-4 ] 4-4 ] KZ30 (Rev. 1.2)
2. First Paper Feed Drive Mechanism
Paper Feed Clutch> The drive from the Main motor is transferred to the Pickup roller shaft by the gears.
> The Paper feed clutch activates at a given Print drum angle from drum position-A to rotate the Pickup
roller shaft to feed the papers.
This Drum angle is determined by the count signal from the motor encoder sensor.
> The Paper feed clutch is deactivated as the Print drum rotates for a certain set degrees from the Drum position-A.
> The Paper feed clutch activation and deactivation timings change according to the printing speed.
End of First Paper Feed
> The First paper feed ends when the Paper feed clutch deactivates.
> The leading edge of the paper rests against the Guide roller and Timing roller and makes a buckle. > The Pickup roller rotates freely in the direction of paper feed by the one-way bearing on the roller to
avoid applying brake on the paper when the Second paper feed takes over the paper feed.
Pickup roller
Paper feed clutch
Main motor
Pickup roller shaft
First Paper Feed Timing Chart
Drum rotation starts from Drum Position-A
0 1-1 79.3 1-2 76.7 2-1 157.8 2-2 155.2 0 0 Open ON ON Drum rotation Main motor Position-A Sensor Paper feed clutch
Blocked
Press "START" key
Print drum
Pickup roller
Paper
Guide roller
1-1 The Paper feed clutchactivates each time the Drum rotates 79.3 plus/minus C from the A position.
The angle "C" can be adjusted by Test Mode No. 741, which adjusts the ON timing of the Paper feed
clutch.
2-1 The Paper feed clutch is deactivated when the Drum rotates 157.8 plus/minus C from the A position. The angle "C" can be adjusted by Test Mode No. 742, which adjusts the paper buckle amount. [In case the drum rotation speed is 60 r.p.m.]
[In case the drum rotation speed is 90 r.p.m.]
1-2 The Paper feed clutch activates each time the Drum rotates 76.7 plus/minus C from the A position. The angle "C" can be adjusted by Test Mode No. 744, which adjusts the ON timing of the Paper feed
clutch.
2-2 The Paper feed clutch is deactivated when the Drum rotates 155.2 plus/minus C from the A position. The angle "C" can be adjusted by Test Mode No. 745, which adjusts the paper buckle amount.
1-1 79.3 1-2 76.7
2-1 157.8 2-2 155.2
[ 4-6 ] 4-6 ] KZ30 (Rev. 1.2)
3. Paper Pickup System
Feeding
> The papers on the Paper feed tray are fed by the Pick roller, in several layers, in between the Pickup
roller and Stripper pad.
Pick-up
> The top sheet is separated from the rest by the Pickup roller and Stripper pad.
> The Stripper pad is pushed against the Pickup roller [A] by the Stripper spring to provide resistance against paper feed, by which only a single sheet of paper is fed from the paper
stack.
Pickup roller
Stripper spring Stripper pad
Paper
Paper feed pressure
4. Paper Feed Pressure Select System
Paper Feed Pressure Adjust Lever
> The Paper feed pressure adjust leveris located on the front side of the machine, and it
changes the pressure of the Paper feed tray applied against the Pickup roller, as a result the pressure against the papers on the Paper feed tray is changed.
> When the Paper feed pressure adjust lever is positioned at upper position, the Pressure spring is
loose and applies less pull on the paper feed tray. This is the setting for thin papers.
> As the Paper feed pressure lever is shifted down, the Pressure spring stretches and pulls the Paper feed tray stronger against the Pickup roller.
The lever, at all the way down position is for thick papers.
> The Paper feed pressure adjust lever at in-between-positions are for normal thickness papers.
Paper feed tray set lever
Paper feed pressure adjust lever
[ 4-8 ] 4-8 ] KZ30 (Rev. 1.2)
MEMO
2. Removal and Assembly
1. Paper Feed Tray Unit
1. Turn OFF the machine power and disconnect the power cord from the machine.
2. Lower the Paper feed tray.
3. Remove the Paper feed tray unit from the both side of the Lock pins.
Precaution in Assembly
> Make sure to hook the the Paper feed tray unit to the both side of the Lock pins firmly in position.
Paper feed tray unit
[ 4-10 ] 4-10 ] KZ30 (Rev. 1.2)
2. Pickup Roller Assembly
1. Turn OFF the machine power and disconnect the power cord from the machine.
2. Lower the Paper feed tray.
3. Remove the Rear cover.
4. Remove the Paper feed tray from the machine.
5. Remove Lock rings on the right end of the Pickup roller shaft and remove the Metal. 6. Slide the Pickup roller shaft to the rear side of the machine and remove the Pick up roller
assembly.
Pickup roller shaft
Metal Lock ring
Paper feed tray
3. Pickup Roller and Paper Feed Support Roller
1. Turn OFF the machine power and disconnect the power cord from the machine. 2. Remove the Pickup roller assembly.
3. Slide the Paper feed support rollers from the Pickup roller shaft. 4. Remove Lock ring from the Pickup roller shaft.
5. Slide the Pickup roller out from the shaft.
Precautions in Assembly
> Core of the Pick up roller has a slit for a Pin on the left-hand-side side when the roller is installed.
If the roller is put back on the shaft turned around, the Pick up roller cannot be positioned correctly and the the Lock ring cannot be installed.
When mounted correctly on the shaft, the pin fits in the Pickup roller shaft and the Lock ring can be
installed.
Pickup roller
Lock ring
Paper feed support roller
Pin
[ 4-12 ] 4-12 ] KZ30 (Rev. 1.2)
4. Stripper Pad
1. Turn OFF the machine power and disconnect the power cord from the machine.
2. Lower the Paper feed tray all the way down.
3. Remove the Lock ring of the Pickup roller then slide the roller towards the rear of the machine and remove the Pin.
4. Remove the Stripper pad base carefully, not to damage the Stripper spring. 5. Remove the Stripper Pad from the Stripper pad base.
Precaution in Assembly
> Set the Stripper spring correctly in the machine before setting the Stripper pad base back in place. > Make sure to fit the Pickup roller in correct position then inserting the Lock ring.
Stripper pad base
Stripper pad
Stripper spring
5. Paper Feed Clutch
1. Disconnect the power supply from the machine. 2. Remove Back cover.
3. Remove the Paper feed Clutch support plate. (3 screws) 4. Disconnect the Connector of the Paper feed clutch. 5. Remove the Paper feed clutch from the shaft.
Precautions in Assembly
> Mount the hook on the clutch into the hook lock holes to prevent the clutch from rotating. (Refer to the photograph below)
Paper feed clutch
Paper feed clutch support plate
[ 4-14 ] 4-14 ] KZ30 (Rev. 1.2)
MEMO
3. Adjustment
1. Paper Feed Clutch ON/OFF Timing
Use the Paper feed clutch ON and/or OFF timing adjustment test mode to control the paper buckle amount.
The paper buckle is made on the tip of the paper when the first paper feed action ends. The tip of the paper rests against the Timing roller and Guide roller and makes the buckle.
If not enough buckle is made, the second paper feed will not take the paper, and cause paper jam. If too much buckle is made, the tip of the paper will fold and cause paper jam.
Paper feed clutch ON timing:
For the 60 r.p.m. printing, use test mode No.741. For the 90 r.p.m. printing, use test mode No.744.
The larger parameter numbers for these two test modes make the clutch ON timing earlier, and increase the paper buckle amount.
Paper feed clutch OFF timing:
For the 60 r.p.m. printing, use test mode No.742. For the 90 r.p.m. printing, use test mode No.745.
The smaller parameter numbers for thee two test modes make the clutch OFF timing delayed, and increases the paper buckle amount.
NOTE:
The paper buckle amount is also affected by the Timing clutch ON timing adjustment (next Chapter). The Timing clutch ON timing adjustment will affect the image position on the paper, so do not use that adjustment for the paper buckle amount adjustment.
But keep in mind that if the Timing clutch ON timing adjustment is made to control the image position, the Paper feed clutch ON/OFF timing adjustment may have to be adjusted for proper paper buckle amount.
[ 4-16 ] 4-16 ] KZ30 (Rev. 1.2)
MEMO
CHAPTER
5
: SECOND PAPER FEED SECTION
CONTENTS
1. Theory of Operation ...5-3
1. Second Paper Feed Drive Mechanism ... 5-3 2. Vertical Printing Position ...5-4 2. Removal and Assembly ...5-5 1. Load Spring ...5-5
2. Timing Clutch ...5-6 3. Paper Guide Plate ...5-7 4. Paper Gate ...5-8
5. Timing Roller/ Guide Roller ...5-9 3. Adjustment ...5-10 1. Print Position (Timing Clutch ON timing) ... 5-10
[ 5-2 ] 5-2 ] KZ30 (Rev. 1.2)
MEMO
1. Theory of Operation
1. Second Paper Feed Drive Mechanism
1. Drive> Timing clutchmakes clockwise rotation (looking from the rear of machine) with the turn of the Main motor.
> The Timing gear rotation is transferred to the Timing gear via the Timing clutch. > The Timing roller rotates Guide roller.
2. Timing Clutch
> After given time from the end of the first paper feed, the Timing clutch activates to rotate the Timing
roller.
3. Timing Roller
> The Timing roller 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 goes off.
4. Guide Roller
> The Guide roller is always in contact with the Timing roller. > The rotation of the Guide roller is received from the Timing roller.
> The Guide roller rotation stops when the Timing clutch goes off to stop the Timing roller.
Paper gate
Guide roller
Timing roller
[ 5-4 ] 5-4 ] KZ30 (Rev. 1.2)
2. Vertical Printing Position
1. Timing Clutch> The print position is depending on when the Timing clutch goes on.
> Normally the Timing clutch 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 60 r.p.m.
> When the drum rotation speed is 90 r.p.m., the Timing clutch 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 ON timing becomes earlier and the print position moves down.
> When the key is pressed, the Timing clutch ON timing becomes late and the print position moves
up.
Drum rotation
Paper feed clutch 1st
Paper feed clutch 2nd
Paper gate 0 90 180 270 360 79.3 157.8 61.3 160.3 (157.7) (155.2) (76.7) (58.7) 78.5 Guide roller Timing roller Timing clutch
Timing clutch gear
2. Removal and Assembly
1. Load Spring
1. Tun OFF the machine power and disconnect the power cord from the machine. 2. Remove Front cover.
3. Remove Print drum.
4. Remove E-ring and Washer from the Timing roller shaft. 6. Remove the Load spring from the shaft.
Precaution in Assembly
> Install the Load spring in the correct direction.
[ 5-6 ] 5-6 ] KZ30 (Rev. 1.2)
2. Timing Clutch
1. Turn OFF the machine power and disconnect power cord from the machine. 2. Remove Rear cover.
3. Remove the Timing clutch support plate. (4 screws) 4. Disconnect connector and remove the Timing clutch.
Caution in Assembly
> Make sure to lock the hook on the Timing clutch into the clutch lock hole to prevent clutch body from
rotating.
Timing clutch support plate Timing clutch
Hook on the timing clutch
3. Paper Guide Plate
1. Turn OFF the machine power and disconnect the power cord from the machine. 2. Remove following parts from the machine.
> Rear cover
> Paper feed tray unit
> Paper feed clutch with the bracket > Pick up roller assembly
> Print drum
3. Remove the Paper guide plate upper. (2 screws)
4. Remove 2 mounting screws from the Paper guide plate lower.
5. Slide out the Master removal unit and remove the Paper gate. (1 screw)
6. Take out the Paper guide plate lower from the the Paper feed tray side while raising the Guide roller by hand.
Paper feed tray
Paper guide plate upper Paper guide plate lower
Paper gate
Paper feed clutch
[ 5-8 ] 5-8 ] KZ30 (Rev. 1.2)
4. Paper Gate
1. Turn OFF the machine power and disconnect power cord from the machine. 2. Remove the Print drum.
3. Slide out the Master removal unit.
4. Remove the mounting screw of the Paper gate and remove the Paper gate.
Precautions before Assembly
> Do not secure the mounting screw too much to prevent the plastic Paper gate from breakage.
Mounting screw
Paper gate
5. Timing Roller
/ Guide Roller
1. Disconnect the power supply from the machine. 2. Remove the Print drum.
3. Remove the Paper guide plate (upper & lower). 4. Remove the Paper gate.
5. Remove following parts from the Timing roller shaft.
> Load spring
> One-way gear and Metal
6. Remove the Timing roller
7. After removing the Timing roller, remove the E-rings and Bushings from both sides of the Guide roller
shaft.
8. Remove the Guide roller assembly.
Precaution in Assembly
> Install the Load spring [G] in the correct direction.
> Check if paper is fed correctly or not after assembled all parts. If not, disassemble all parts again and then re-assemble the parts.
Bushing (short) E-ring Load spring Bushing (short) E-ring Bushing (long)
[ 5-10 ] 5-10 ] KZ30 (Rev. 1.2)
3. Adjustment
1
. Print Position (Timing Clutch ON timing)
Vertical print position can be adjusted by changing the Timing clutch activate timing.
The Timing clutch activate timing can be changed by using TEST MODE No.789 or No.791.
Test No.789 is for when the machine runs at 60 r.p.m. and Test No.791 is for when the machine runs at 90 r.p.m..
Adjustment Procedure
1. Turn OFF the machine power.
2. Go into Test Mode by turning the machine power ON by pressing and key on the control panel. 3. With B4 size paper on teh paper feed tray, enter Test Mode No.80 to make a master with checker-
flag image.
4. Press [Reset] key to escape from the Test Mode. Make about 5 prints at speed No.1 (60 r.p.m) and another 5 prints at speed No.2 (90 r.p.m.).
5. For the both set of prints, measure the distance from the top of the paper to where the print image
starts.
6. The image should print 10mm from the top edge of the papers. If not, adjustments using Test Modes No.789 and/or No.791 is necessary.
7. In the case the white margin is less than 10mm, smaller parameter number should be input for those test modes. Smaller parameter numbers make the Timing clutch ON timing faster and increase the white margin.
8. In the case the white margin is more than 10mm, larger parameter number should be input for those test modes. Larger parameter numbers make the Timing clutch ON timing to delay and decrease the white margin.
Result of Incorrect Adjustment
> Incorrect adjustment may cause blurry top image, stained pressure roller caused by image shifting down on the paper, or paper not separated from the Print drum (paper jam) caused by too small white margin on the top of the paper.
CHAPTER
6
: PRESS SECTION
CONTENTS
1. Theory of Operation ...6-3
1. Press Mechanism ...6-3 2. Removal and Assembly ...6-5 1. Pressure Roller ...6-5
2. Pressure Lever Assembly ...6-6
3. Pressure Shaft Assembly ...6-7 3. Adjustment ...6-9
[ 6-2 ] 6-2 ] KZ30 (Rev. 1.2)
MEMO
1. Theory of Operation
1. Press Mechanism
1. Pressure Lever and Pressure Roller
> The Pressure lever is mounted on the Pressure shaft. The Pressure roller is mounted on the Pressure assembly, which is fixed on the Pressure shaft.
> While the Main motor is making the Print drum rotation without paper (not in printing process),
the Pressure hook engages with the Pressure lever so that the Pressure roller stays down.
> When paper comes in and pushes the Paper gate up, the Pressure hook rises. Then the Pressure lever is released and the Cam follower of the Pressure lever assembly touches against the Pressure cam. The Pressure roller is pushed up and hits against the Print drum to make the print.
> The Pressure spring pulls the Pressure roller up against the Print drum.
> Once the Pressure lever is released from the Pressure hook, movement of the Pressure lever is controlled by the Pressure cam.
> The Pressure roller is lowered down by the Pressure cam where the Clamp plate on the Drum comes near the Pressure roller to prevent damaging the Clamp plate.
> The Pressure hook comes down when the printing job is completed and paper is no longer fed from
the Paper feed tray. The Pressure hook engages with the Pressure lever to keep the Pressure roller
away from the Print drum.
Paper gate is pushed up by
paper, and Pressure hook is raised.
Then the Pressure lever is
raised by the Pressure cam
to press the Pressure roller
against the Print drum to make the prints.
Pressure roller Pressure cam
Pressure shaft assembly
Pressure shaft
Cam follower
Paper gate
[ 6-4 ] 6-4 ] KZ30 (Rev. 1.2)
Lifting the Pressure Roller
The Paper gate is pushed up by paper throughout the printing. So the Pressure lever becomes free.
The Pressure spring pulls back the Pressure lever and rotates
the Pressure shaft which is acting as a pivot.
The rotation of the Pressure shaft lifts the Pressure roller up
against the Drum.
Lowering the Pressure Roller
The Pressure roller is lowered by force, away from the Drum[C], by the high part of the Pressure cam.
During the Drum rotation, when the Clamp plate of the Drum comes close to the Pressure roller, the high part of the Pressure cam pushes the Pressure lever down, rotating the Pressure shaft counter-clockwise to bring the Pressure roller down, away from the Drum.
Then Pressure lever is lowered by Pressure cam.
Pressure hook rotates up when the paper comes in.
Pressure hook rotates down when the paper no longer comes.
Pressure roller
Pressure lever assembly Print drum
Pressure spring
Pressure shaft
Pressure cam
2. Removal and Assembly
1. Pressure Roller
1. Turn OFF the machine power and disconnect power cord from the machine. 2. Remove the Rear cover.
3. Remove the Print drum. 4. Remove the Suction unit. 5. Remove the Pressure spring.
6. Remove mounting screw of the Pressure roller from the Pressure shaft assembly through a hole on the drive side of the machine frame.
7. Take out the Pressure roller from the Drum opening side of the machine, or from the top of the machine after sliding the Master removal unit outward to open the top of the machine.
Screw
[ 6-6 ] 6-6 ] KZ30 (Rev. 1.2)
2. Pressure Lever Assembly
1. Turn OFF the machine power and disconnect the power cord from the machine. 2. Remove the Rear cover.
3. Remove the Print drum from the machine. 4. Remove the Pressure spring.
5. Remove two set screws from the Pressure lever assembly.
6. Turn the Pressure lever in clockwise direction (Pressure lever shows up behind the gear) then remove the Pressure lever assembly from the Pressure shaft.
Adjustment after the Assembly
> Adjust the position of the Pressure lever assembly. (Refer to the adjustment section on this Chapter.)
Set screws
Pressure lever assembly
3. Pressure Shaft Assembly
1. Turn OFF the machine power and disconnect the power cord from the machine. 2. Remove the Print drum from the machine.
3. Remove both the Front and Rear covers. 4. Remove the Pressure spring.
5. Remove the Pressure lever assembly. (Refer to the previous page)
6. Remove E-rings from both ends of the Pressure shaft assembly and remove the Bushings. 7. Remove the Suction unit.
8. Remove the Pressure spring.
9. Slide the Pressure shaft assembly 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 assembly. (Refer to the adjustment section on this Chapter.)
Pressure shaft assembly
Pressure spring E-ring
Bushing
Pressure lever assmbly
E-ring Bushing
[ 6-8 ] 6-8 ] KZ30 (Rev. 1.2)
MEMO
3. Adjustment
1. Pressure Lever Assembly Position
1. Make confidential master on the Drum. 2. Bring the Print drum to B-position.
3. Turn OFF the machine power and disconnect power cord from the machine. 4. Remove Rear cover.
5. Remove the Suction unit and disengage the Pressure spring.
6. Using finger, disengage the Pressure lever from the Hook lever by pushing up the Hook lever to
disengage the Pressure lever.
7. Hook the Pressure lever, so that the Pressure roller hits against the Print drum.
8. Confirm that the gap between the Pressure cam and Cam follower on the Pressure lever is between 2 mm to 2.5 mm.
9. If the gap is too small or big, loosen the two set screws on the Pressure lever assembly.
10. Place 2.0 mm or 2.5 mm Allen key (or 2.0 mm to 2.5 mm thick plate) between the Pressure cam and Cam follower and push up the Pressure lever assembly against the Pressure cam.
11. While pushing the Pressure lever assembly tightly against the Pressure came with the Allen key or plate in between (refer to the above), tighten the two set screws on the Pressure lever assembly. 12. Remove the 2.0 mm or 2.5 mm Allen key (or 2.0 mm to 2.5 mm thick plate), which was inserted
between the Pressure cam and Cam follower.
13. Confirm that the gap between the Pressure cam and Cam follower on the Pressure lever is between 2 mm to 2.5 mm.
If not, repeat the above procedures until correct gap is obtained.
Results of Incorrect Adjustment
> If the gap is smaller than 2 mm, the Pressure roller leaves from the Drum too early. As a result, the tailing edge of the paper may not be printed clearly.
> If the gap is too big, the Pressure roller may hit the Clamp plate of the Drum during printing and damage the Clamp plate.
2.0 mm to 2.5 mm gap
Adjust the gap between the Pressure cam and Cam follower to 2.0 mm to 2.5 mm by inserting 2.0 mm or 2.5 mm Allen wrench or plate between the Cam and Cam
follower.
Rotate the Print drum to the B-position before turning the machine power OFF.
(The Print drum in the sketch is
still not in Position-B.)
[ 6-10 ] 6-10 ] KZ30 (Rev. 1.2)
MEMO
CHAPTER
7
: PAPER EJECTION SECTION
CONTENTS
1. Theory of Operation ...7-3
1. Paper Ejection Mechanism ...7-3
2. Paper Separation Mechanism ...7-4 2. Removal and Assembly ...7-5 1. Suction Unit ...7-5 2. Transfer Belt ...7-6 3. Suction Fan ...7-7 4. Separation Fan Unit ...7-8 5. Separation Fan ...7-9 6. Paper Receiving Sensor ...7-9 7. Separator ...7-10 3. Adjustment ...7-11 1. Separator Position ...7-11
[ 7-2 ] 7-2 ] KZ30 (Rev. 1.2)
MEMO
1. Theory of Operation
1. Paper Ejection Mechanism
1. Paper Separation from the Drum
> The paper is separated from the Drum by the Paper separation fan and Separator.
2. Paper Ejection
> Suction fan pulls the paper, separated from the Drum, on to the Suction unit.
> The Transfer belts 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 checks whether the paper is separated from the Drum and ejected correctly or jammed.
Separation fan
Suction fan Separator
Transfer belts
[ 7-4 ] 7-4 ] KZ30 (Rev. 1.2)
2. Paper Separation Mechanism
1. Separator> The tip of the Separator 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, the Drum support left which is attached on the Drum pushes the Separator away from the Drum.
Separator shaft Separator
Separator lever assembly
Paper receiving tray
Drum support left
2. Removal and Assembly
1. Suction Unit
1. Turn OFF the machine power and disconnect the power cord from the machine. 2. Remove Rear cover.
3. Remove the Paper receiving tray. 4. Remove the Suction unit cover.
5. Disconnect the Connector of the Suction unit.
6. Remove two mounting screws of the Suction unit and remove the unit by sliding it out.
Precaution in Assembly
> Hook the Suction unit on both side of the plates on the machine frame.
> Insert the Feet of the Suction unit cover into the slit holes in the machine Base plate.
Suction unit
[ 7-6 ] 7-6 ] KZ30 (Rev. 1.2)
2. Transfer Belt
1. Turn OFF the machine power and disconnect the power cord from the machine. 2. Remove Rear cover.
3. Remove Suction unit.
4. Remove two mounting screws of the De-electricity brush and remove the brush. 5. Remove the Jump wings.
6. Remove four mounting screws of the Suction face cover.
7. Lift the face cover and remove theBelt driven shaft by unhooking the Transfer belts. 8. Remove E-ring of the Belt pulley shaft and remove the Bushing.
9. Slide the Belt pulley shaft and remove the Transfer belts from the Suction face cover.
Precautions in Assembly
> Match the half-pierced section on the Suction face cover with its counter part.
> Match the half-pierced section on the De-electricity brush with its counter part.
Jump wings
Transfer belts
Suction face cover
Belt pulley shaft
Belt driven shaft
De-electricity brush
Bushing E-ring
3. Suction Fan
1. Turn OFF the machine power and disconnect the power cord from the machine. 2. Remove Rear cover.
3. Remove Suction unit.
4. Turn over the Suction unit and disconnect the Connector of the Suction fan.
5. Remove two mounting screws of the Suction fan and remove the fan.
[ 7-8 ] 7-8 ] KZ30 (Rev. 1.2)
4. Separation Fan Unit
1. Turn OFF the machine power and disconnect the power cord from the machine. 2. Remove Rear cover.
3. Disconnect the Connector of the Separation fan unit.
4. Remove two mounting screws of the Separation fan unit and remove the unit.
Precaution in Assembly
> Match the half-pierced section on hinge of the Separation fan unit with its counter part.
Separation fan unit
Hinge of Separation unit
5. Separation Fan
1. Remove the Separation fan unit.
2. Disconnect the Connector of the Separation fan.
3. Remove two mounting screws of the Separation fan and remove the fan.
6. Paper Receiving Sensor
1. Remove the Separation fan unit.
2. Disconnect two mounting screws of the Separation fan.
3. Lift the fan and disconnect the Connector of the Paper receiving sensor.
4. Press the center hook of the Paper receiving sensor socket and lift the sensor out.
Separation fan
Paper receiving sensor
[ 7-10 ] 7-10 ] KZ30 (Rev. 1.2)
7. Separator
1. Turn OFF the machine power and disconnect the power cord from the machine. 2. Remove the Back cover and Front cover.
3. Remove the Paper receiving tray. 4. Remove the Separation fan unit. 5. Remove the Separation spring.
6. Remove E-ring from the drive side of the Separator shaft.
7. Slide the Separation shaft towards the rear (machine drive side) and remove the Separation shaft.
E-ring
Separation shaft
Separator spring
3. Adjustment
1. Separator Position
1. Using Test Chart No.8 or No.14, make a master and prints.
2. Adjust the printing position by the Print position button on the Operation panel, so that there is 10 mm white margin on the top of the prints.
3. Confirm that the paper separates from the Drum 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, turn OFF the machine power and disconnect the power cord from the machine and remove the machine Front cover and Print drum cover.
6. Loosen the mounting screw of the Separator plate and slide the plate.
7. Tighten the mounting screw of the plate when the space between the tip of the Separator is between 1.0 mm and 2.0 mm from the Drum surface and not touching it.
Precaution in Adjustment
> Printed papers using Test Chart No.8 / No.14 original should separate from the Print drum 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 is in contact with the Drum, the Separator will scratch the surface of the master on the Drum, creating a black line in the center of the printed copies and may damage the Drum screen.
> If the tip of the Separator is placed too far off from the Drum, printed copies will not separate from the Drum, causing paper jams.
Separator lever
Separator
Print drum
Print drum
[ 7-12 ] 7-12 ] KZ30 (Rev. 1.2)
MEMO
CHAPTER
8
: PRINT DRUM
CONTENTS
MECHANISM ...8-3
1. Master on Drum (in printing) Check Mechanism ... 8-3
2. Ink Bottle Set Check Mechanism ...8-3
3. Drum Rotation Mechanism ...8-3
4. Ink Supply Mechanism ...8-3 DISASSEMBLY ...8-5 1. Ink Bottle Guide ...8-5 2. Ink Bottle Set Switch ...8-5 3. RF-PCB ...8-6 4. Inking Motor ...8-7
5. Drum Set Sensor ...8-8
6. Drum Screen ...8-9
7. Drum Body ...8-10 8. Ink Sensor PCB ...8-11
9. Drum Flanges F (front) & R (rear) ...8-12 10. Squeegee Roller ...8-16 ADJUSTMENT ...8-18 1. Cleaning the Filter ...8-18
2. Squeegee Gap Adjustment ...8-19
MEMO
[ 8-2 ] 8-2 ]
KZ30 (Rev. 1.2)
MECHANISM
1. Master on Drum (in printing) Check Mechanism
Master Sensor checks the presence of master on the Drum before the start of printing.
The result (whether the master is found or not) is memorized until the Drum is pulled out of the machine or the power is turned off. While the machine knows that there is a master on the Drum, the master on the Drum check procedure is omitted.
If no master is detected on the Drum, an error message is indicated on the panel display and stops
the printing operation.
2. Ink Bottle Set Check Mechanism
The ink bottle is set in position when it is inserted into the Drum and rotated in clockwise direction. When the ink bottle is set in position, one part of the ink bottle pushes the Bottle set switch, and the ink bottle is recognized by the machine.
3. Drum Rotation Mechanism
The Drum is rotated by the Main motor with the gears transferring the drive. As the Drum rotates, the Squeegee roller, inside the Drum, starts it rotation.
As the Squeegee roller rotates, the drive is transferred by a gear to the Driven shaft, which is located above the Squeegee roller.
The Squeegee drive gear R contains a one-way bearing, which prevents the Squeegee roller from rotating when the Drum is rotated manually by hand in the opposite direction.
4. Ink Supply Mechanism
While the Drum is being rotated by the Main motor, if the amount of ink within the Drum reduces and the Ink sensor no longer touches the bead of ink, the Inking motor activates to pump the ink into the Drum. The ink pumped by the Inking pump travels through the hose and goes into the Center shaft of the Drum. The ink then drops onto the Squeegee roller from the distributor holes on the Center
shaft.
The Inking motor stops when the Ink sensor detects the bead of ink.
The ink dropped onto the Squeegee roller is made into an ink bead between the Squeegee roller and Doctor roller. The ink is wrapped around the Driving shaft to be made into an even thickness ink bead. A small gap between the Squeegee roller and Doctor roller allows the ink to cover the inner surface of the Drum.
An Overflow sensor is located within the Drum to detect excess amount of ink to prevent ink-overflow. If an overflow is detected, the machine is stopped with an error code display.
Inking motor Overflow sensor Squeegee roller Driving shaft Ink sensor [ 8-4 ] 8-4 ] KZ30 (Rev. 1.2)
Ink bottle switch cover
Ink bottle guide
DISASSEMBLY
1. Ink Bottle Guide REMOVAL
1) Remove the Drum out from the machine and pull out the ink bottle. 2) Remove the Drum cover. (M3x8 screws; 4 pcs)
3) Remove the Bottle switch cover. (M3x8 screws; 2 pcs) 4) Detach the Ink bottle guide. (M3x8 screws; 3 pcs)
5) Unplug the Bottle set switch wire harness.
2. Ink Bottle Set Switch REMOVAL
1) Remove the Ink bottle guide. (Ref: Above procedure) 2) Remove the upper Bottle guide. (M3x8 screw; 1 pc) 3) Remove the lower Bottle guide. (M3x8 screws; 2 pcs) 4) Remove the Bottle set switch. (M3x8 screws; 2 pcs)
3. RF-PCB REMOVAL
1) Remove the Drum out from the machine and pull out the ink bottle. 2) Remove the Drum cover. (M3x8 screws; 4 pcs)
3) Remove the Bottle switch cover. (M3x8 screws; 2 pcs)
4) Unplug the RF-PCB wire harness.
5) Remove the Antenna holder and Spring. (stepped screws; 2 pcs)
6) Carefully, release the hooks on the Antenna holder and remove the RF-PCBs.
Antenna holder RF-PCB (antenna assembly)
Antenna holder (lower)
Antenna assembly
Antenna holder (upper)
RF-PCB (antenna assembly)
[ 8-6 ] 8-6 ]
KZ30 (Rev. 1.2)
Holder bracket plate 4. Inking Motor
REMOVAL
1) Remove the Drum out from the machine and pull out the ink bottle. 2) Remove the Drum cover. (M3x8 screws; 4 pcs)
3) Remove the Bottle switch cover. (M3x8 screws; 2 pcs)
4) Unplug the RF-PCB wire harness.
5) Remove the upper and lower Ink bottle guides. (M3x8 screws; 3 pcs)
6) Unplug the Bottle set switch wire harness.
7) Remove the Holder bracket. (M3x8 screws; 2 pcs)
8) Remove the Ink intake nozzle bracket. (M3x8 screws; 3 pcs) 9) Remove the Ink bottle base. (M3x8 screws; 4 pcs)
10) Remove the Grip handle. (M4x8 screws; 4 pcs)
11) Unplug the Inking motor wire harness connector and remove the mounting screws of the Inking motor to detach the Inking motor. (M4x10 screws; 2 pcs)
Precaution in Assembly
1) Using a wire harness band of about 100mm in length, fix the RF-wire harness firmly on the Holder bracket. This is to prevent the wire harness from being pinched or cut when mounting the Ink bottle guide.
5. Drum Set Sensor REMOVAL
1) Remove the Inking motor. (Ref: Previous page)
2) Remove the Drum lock spring from the Drum hook right. 3) Remove the Drum hook right. (6mm dia. E-ring; 1 pcs)
4) Carefully, release the hooks on the Drum set sensor and remove the sensor. Precaution in Assembly
1) In mounting back the Inking motor, use a wire harness band of about 100mm in length and fix the RF-wire harness firmly on the Holder bracket. This is to prevent the wire harness from being pinched or cut when mounting the Ink bottle guide. (Ref: Inking motor removal)
Inking motor
Grip handle
Inking motor Drum lock spring Drum set sensor
Drum hook (right) 15 to 25 mm
Wire harness band
[ 8-8 ] 8-8 ]
KZ30 (Rev. 1.2)
Screen JIG Screen hanger Hook Hook 6. Drum Screen REMOVAL
1) Make a confidential master on the Drum and remove the Drum from the machine. 2) Remove the Screen hanger and Screen assembly from the Drum. (M4x8 screws: 4 pcs)
Precaution in Assembly
1) Do not fold the Screen. The Screen is no longer useful if a crease is made. 2) The mounting screws should be matched to those in the front.
3) Use the Screen Jig to keep the Screen wrapped tightly around the Drum when mounting the Screen hanger on the drum.
Drum body
Imprinted marking Imprinted marking 7. Drum Body
REMOVAL
1) Remove the Drum out from the machine, and remove following parts. Clamp plate base unit (M4x8 screws; 4 pcs)
Drum screen (M4x8 screws; 4 pcs)
2) Remove the Drum body from the Drum. (M4x8 screws; 6 pcs)
Precaution in Assembly
1) The Drum body has this arrow marks engraved on the front and rear. The arrow mark on the front has alphabet [F] engraved next to it.
2) The Drum body should be attached onto the Drum with the [F] engrave to the front of the Drum. The arrow marks on the Drum body should meet with the arrow mark on the Drum flange surface. The first two screws to be tightened are those at these arrow marks.
3) Use the Screen Jig to keep the Drum body wrapped tightly around the Flanges when mounting the Drum body with the remaining screws. Make sure that the Drum body fits tightly on the Flanges with no loose fits.
4) The Clamp plate base assembly should be pushed towards the rear of the Drum, as there is a small play in mounting the assembly.
Screen JIG
Hook Hook
[ 8-10 ] 8-10 ]
KZ30 (Rev. 1.2)
