Riso KS 500 Service Manual

7/23/2019 Riso KS 500 Service Manual

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RISO KAGAKU CORPORATION (JAPAN)

RISO, INC. (U.S.A.)

RISO EUROPE LIMITED (U.K.)

RISO HONG KONG (HONG KONG)

RISO UK (U. K.)RISO THAILAND LIMITED (THAILAND)

RISO DEUTSCHLAND GmBH (GERMANY)

RISO FRANCE (FRANCE)

RISO IBERICA (SPAIN)

RISO CANADA (CANADA)

RISO CHINA (HONG KONG)

RISO AFRICA (SOUTH AFRICA)RISO THECHNOLOGY ZHUHAI (CHINA)

RISO INTERNATIONAL GROUP

Copyright : 2000 RISO Kagaku Corporation

All Rights Reserved. This Technical Manual was prepared and

written for the exclusive use of RISO International Group

Certified Dealers. Reproduction and/or transmittal of this

material in any form or by any means, including photocopying

or recording of the information is strictly prohibited without theconsent of a member of RISO International Group.

VERSION 1.2December, 2000

TECHNICAL MANUAL

SERIES


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KS Series (Version 1.2)- 1 -

CHAPTER 1: MAINTENANCE

1. PREFACE ......................................................................................................... 1-1

CAUTION ........................................................................................................... 1-2

WARNING ......................................................................................................... 1-3

2. Work Precautions .............................................................................................. 1-4

3. Exterior Cover Removal

> Front cover ..................................................................................................... 1-6

> Back cover ..................................................................................................... 1-6

> Master removal cover ...................................................................................... 1-6

CHAPTER 2: MACHINE SUMMARY1. Specifications

1. KS500 / 500C ............................................................................................... 2-1

2. Cross Sectional Diagram ................................................................................... 2-2

3. Machine Operations........................................................................................... 2-3

4. Paper Feed and Receiving ................................................................................. 2-4

5. Master Removal and Feed ................................................................................. 2-5

6. Counter indication .............................................................................................. 2-6

CHAPTER 3: MAIN DRIVE SECTION

1. Theory of Operation

1. Main Drive...................................................................................................... 3-1

2. Main Motor Safety Switches ..........................................................................3-2

3. Drum Positions .............................................................................................. 3-3

4. Drum Rotation Lever ...................................................................................... 3-5

2. Removal and Assembly

1. Main Motor Unit ............................................................................................. 3-7

2. Master Removal Unit Safety Switch ...............................................................3-9

3. Master Making Unit Safety Switch .................................................................3-10

4. Separation Fan Safety Switch........................................................................ 3-11

5. Paper Guide Plate Safety Switch ...................................................................3-12

6. Drum Rotation Lever ...................................................................................... 3-13

CHAPTER 4: FIRST PAPER FEED SECTION


1. Paper Feed Tray Position .............................................................................. 4-12. First Paper Feed Drive Mechanism ................................................................4-2

3. Paper Pickup System.................................................................................... 4-4

4. Paper Feed Pressure Select System............................................................. 4-5


1. Paper Feed Tray Unit..................................................................................... 4-6

2. Pickup Roller Assembly ................................................................................4-7

3. Pickup Roller .................................................................................................4-8

4. Stripper Pad .................................................................................................. 4-9

5. Paper Feed Clutch......................................................................................... 4-10

CONTENTS


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3. Adjustment

1. Paper Feed Tray Pressure............................................................................. 4-11

2. Paper Feed Tray Position Adjustment ........................................................... 4-13

3. Paper Feed Clutch ON Timing .......................................................................4-14

4. Paper Feed Clutch OFF Timing .....................................................................4-15

CHAPTER 5: SECOND PAPER FEED SECTION


1. Second Paper Feed Drive Mechanism ........................................................... 5-1

2. Vertical Print Position ................................................................................... 5-2


1. Load Spring ................................................................................................... 5-3

2. Timing Clutch ................................................................................................5-4

3. Paper Guide Plate ......................................................................................... 5-5

4. Paper Gate .................................................................................................... 5-6

5. Timing Roller / Guide Roller ........................................................................... 5-73. Adjustment

1. Print Position (Timing Clutch ON timing) ....................................................... 5-8

CHAPTER 6: PRESS SECTION


1. Press Mechanism ......................................................................................... 6-1


1. Pressure Roller.............................................................................................. 6-3

2. Pressure Lever Ass'y ..................................................................................... 6-4

3. Pressure Shaft Ass'y ..................................................................................... 6-5

3. Adjustment

1. Pressure Lever Ass'y Position ....................................................................... 6-7

CHAPTER 7: PAPER EJECTION SECTION


1. Paper Ejection Mechanism ........................................................................... 7-1

2. Paper Separation Mechanism ....................................................................... 7-3


1. Suction Unit .................................................................................................. 7-5

2. Transfer Belt .................................................................................................. 7-6

3. Suction Fan................................................................................................... 7-7

4. Separation Fan Unit....................................................................................... 7-8

5. Separation Fan .............................................................................................. 7-9

6. Paper Receiving Sensor ................................................................................7-9

7. Separator....................................................................................................... 7-10

8. Paper Receiving Tray ..................................................................................... 7-113. Adjustment

1. Separator Position .........................................................................................7-13


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CHAPTER 8: DRUM SECTION1. Theory of Operation

1. Master on Drum (in printing) Check Mechanism ............................................ 8-1

2. Ink Bottle Set Check Mechanism .................................................................. 8-2

3. Ink Supply Mechanism .................................................................................. 8-3

4. Squeegee Roller Rotation Mechanism ........................................................... 8-5


1. Drum Unit ...................................................................................................... 8-7

2. Screen........................................................................................................... 8-8

3. Drum Body .................................................................................................... 8-9

4. Ink Sensor PCB............................................................................................. 8-11

5. INk Bottle Guide ............................................................................................8-12

6. INk Bottle Set Sensor.................................................................................... 8-127. Drum Support F & Drum Support R ............................................................... 8-13

8. Squeegee Roller ............................................................................................ 8-14

9. Ink Pump Unit................................................................................................8-17

10. Inking Motor................................................................................................. 8-18

3. Adjustment

1. Squeegee Gap .............................................................................................. 8-19

CHAPTER 9: PAPER JAM


1. Paper Jam at First Paper Feed Area ............................................................. 9-1

2. Paper Jam at Paper Receiving Area ..............................................................9-2

5. Print Start Timing Chart ................................................................................. 9-3

6. During the Printing Timing Chart ....................................................................9-47. Print Stop Timing Chart ................................................................................. 9-5

CHAPTER 10: MASTER CLAMP SECTION


1. Clamp Unit Home Positioning Mechanism .................................................... 10-1

2. Clamp Plate Master Release Mechanism...................................................... 10-2

3. Clamp Plate Master Clamp Mechanism ........................................................ 10-4


1. Clamp Unit .................................................................................................... 10-7

2. Clamp Motor.................................................................................................. 10-8

3. Clamp Sensor C ............................................................................................ 10-8

4. Clamp Sensor L............................................................................................. 10-8


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CHAPTER 11: MASTER REMOVAL SECTION


1. Master Removal Unit Home Positioning Mechanism ..................................... 11-12. Master on the Drum (before master removal) Check Mechanism................... 11-2

3. Clamp Plate Master Release Mechanism...................................................... 11-4

4. Master Removal Mechanism .........................................................................11-6

5. Master Disposal Box Set Mechanism ........................................................... 11-8


1. Master Removal Unit ..................................................................................... 11-9

2. Master Removal Clutch.................................................................................. 11-10

3. Master Removal Sensor................................................................................. 11-11

4. Disposal Box Set Sensor .............................................................................. 11-11

5. Master Removal Hook ................................................................................... 11-12

6. Vertical Transport Roller (Upper)....................................................................11-13

7. Vertical Transport Roller (Lower)....................................................................11-138. Master Removal Guide .................................................................................. 11-13

CHAPTER 12: IMAGE SCANNING SECTION


1. Original Loading Mechanism .........................................................................12-1

2. Original Scanning Mechanism .......................................................................12-3

3. Image Scanner .............................................................................................. 12-5


1. White Roller .................................................................................................. 12-7

2. Image Scanner Unit ....................................................................................... 12-8

3. Original IN Sensor ......................................................................................... 12-9

4. Pickup Roller ................................................................................................. 12-10

5. Eject Roller Upper ......................................................................................... 12-106. Document Feeder Hook ................................................................................. 12-10

7. Load Roller .................................................................................................... 12-11

8. Eject Roller Lower ......................................................................................... 12-11

8. Read Pulse Motor.......................................................................................... 12-11

3. Adjustment

1. Image Scanner .............................................................................................. 12-13

CHAPTER 13: CUTTER SECTION


1. Cutter Home Positioning Mechanism ............................................................ 13-1

2. Cutting Mechanism........................................................................................ 13-3

2. Removal and Assembly1. Cutter Unit ..................................................................................................... 13-5


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CHAPTER 14: MASTER MAKING SECTION


1. Master Making .............................................................................................. 14-12. TPH Positioning............................................................................................. 14-3

3. Thermal Power Safety Switches .................................................................... 14-5


1. Write Roller ...................................................................................................14-7

2. Thermal Print Head (TPH)..............................................................................14-8

3. TPH Position Sensor ..................................................................................... 14-9

3. Adjustment

1. Thermal Power of Thermal Print Head............................................................ 14-11

CHAPTER 15: MASTER CLAMPING / LOADING SECTION


1. Master Making Unit Set Mechanism.............................................................. 15-1

2. Master Positioning Mechanism .....................................................................15-2

3. Master Feeding Mechanism ..........................................................................15-4

4. Clamp Plate Master Clamp Mechanism ........................................................ 15-6

5. Master Loading on the Drum Mechanism ...................................................... 15-8

6. Master Advancement after Master Cutting..................................................... 15-10


1. Master Making Unit ....................................................................................... 15-13

2. Master Making Unit Set Switch .....................................................................15-15

3. Write Pulse Motor ......................................................................................... 15-16

4. Master Positioning Sensor ............................................................................ 15-17

5. Master Loading Solenoid ............................................................................... 15-18

6. Master End Sensor........................................................................................ 15-19

APPENDIX

Electrical Components ........................................................................................... APX(0)-1

Test Mode .............................................................................................................. APX(1)-1

Users Mode ............................................................................................................ APX(2)-1

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

Description of PCBs ............................................................................................... APX(4)-1


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KS Series (Version 1.2)

CONTENTS

1. Preface..................................................................................................................... 1

CAUTION .................................................................................................................. 2

WARNING ................................................................................................................. 3

2. WORK PRECAUTIONS ............................................................................................. 4

3. Exterior Cover Removal> Front cover ............................................................................................................. 6

> Back cover ............................................................................................................. 6

> Master removal cover .............................................................................................. 6

CHAPTER1: MAINTENANCE


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PREFACE

This manual provides Technical Service Information for the RISOKS duplicators.

This manual is published as a reference guide for use by RISO Group (RISO Kagaku Corp./RISO China Ltd./RISO Technology Zhuhai Co., Ltd./RISO(Thailand) Ltd.) Certified Technical

Representatives experienced in duplicator repair and service.

This manual also provides procedures for removing and installing major components.

Following these procedures will minimize machine malfunctions. This information and

format will also increase technical representatives' awareness and experience regarding

repairs necessary to insure end-user satisfaction.

If assistance is required, please contact one of the following:

[ RISO Kagaku Corp.]

Overseas Technical Section, Overseas Technical Department

2-5-1, Akanehama, Narashino-shi, Chiba 275, JAPAN

TEL: (0474)52-4111 FAX: (0474)52-3106

[ RISO China Ltd.]

Technical Department

Unit A&C, 4/F., Gee Hing Chang Industrial Building, Cheung Yue St., Cheung sha wan,

Kowloon, Hong Kong , China

TEL: (852)2786-3911 FAX: (852)2310-8381

[ RISO Technology Zhuhai Co. Ltd.]


Jida Haibin Nan Lu, Guangda Guoji Maoyi Zhongxin 29 Ceng, Zhuhai shi, P.R. China,

519015

TEL: (0756)332-3300 FAX: (0756)332-3301

[ RISO (Thailand) Ltd.]


400 Phairojkijjia Tower, 10/F, Bangna-Trad Road, Km.4, Bangkok 10260, Thailand

TEL: (662)3614643 FAX: (662)3614652

1 - 1


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KS Series (Version 1.2)1 - 2

[Handling of Lithium Battery]

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

lithium battery.

1. Never let the battery short-circuited.

If the (+) and (-) terminals contact each other or metal materials, the battery will be

short-circuited. If the batteries are collected and stored inorderly or one upon

another, the above-mentioned case will occur.

- DANGER -If the battery is short-circuited, it will heat up and may in some cases explode into

fire.

2. Never heat up the battery.

- DANGER -

If you heat the battery up to more than 100 degrees centigrade or put it into the fire, it

may burn dangerously or explode.

3. Never disassemble the battery or press it into deformation.

- DANGER -

If you disassemble the battery, the gas pouring out of the inside may hurt your

throat or the negative lithium may heat up into fire.

If the battery is pressed into deformation, the liquid inside may leak out of the

sealed part or the battery may be short-circuited inside an explode.

4. Never fail to keep the battery out of reach of children.

If you put the battery within reach of children, they may swallow it down.

Should they swallow the battery, immediately consult the doctor.

[Replacement of the Lithium Battery]

1. The lithium battery must be replaced by a trained and authorized service

technician.

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

3. Discard used batteries according to the manufacturers instructions.

CAUTION


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!! 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 bya loose connector.

Wire harness connector

FIRST

THEN

Press the ends.

Press the center, firmly.

1 - 3


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Half-pierced section

2. Work Precautions

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 the like, use the specified

size.

Assembly and installation

Unless otherwise specified, assembly and installation follow

the reverse order of removal. When there is a protruding

section and a hole for positioning a part, align them correctly

before fastening.

(Part positioning protruding section and hole is referred as

"half-pierced section" in the manual.)

MAINTENANCE

WORK 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 and

installed frequently. Therefore it is recommended that screws, of which are expected to be removed and

installed frequently should be replaced from the self-tapping screws with normal screws such as pan-

head screws or binding screws.

Below figure is the difference between Self-tipping screw and Pan-head screw.

Self-tapping screw Pan-head screw

or Binding-head screw


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1 - 5

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.

MAINTENANCE

WORK PRECAUTIONS


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MAINTENANCE

EXTERIOR COVER REMOVAL

3. Exterior Cover Removal

Disconnect the power supply from the machine and remove the cover.> Front cover

> Back cover

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

1 - 6

A: Front cover

B: Back cover

C: Master removal cover

A

B

C


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1. Specifications....................................................................................................1

2. Cross Sectional Diagram ........................................................................................ 2

3. Machine Operations................................................................................................ 3

4. Paper Feed and Receiving..................................................................................... 4

5. Master Removal and Feed ..................................................................................... 56. Counter Indication .................................................................................................. 6

CHAPTER2: MACHINE SUMMARY

CONTENTS


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MACHINE SUMMARY

SPECIFICATIONS

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 KS500C Max. 273 x 394mm Min. 182 x 256mm or B5 Min. 182 x 256mm or B5

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

Original Weight Max. 107 g/m2

Min. 50 g/m2

Paper Weight KS500 Max. 80 g/m2 KS500C Max. 70 g/m2

Min. 50 g/m2 Min. 35 g/m2

Image Area 249 x 352mm

Paper Capacity KS500 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 220 to 240 VAC, 50/60 Hz

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


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2. Cross Sectional Diagram

MACHINE SUMMARY

CROSS SECTIONAL DIAGRAM

2 - 2

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 print

area via the Timing and Guide rollers.

3 Press (Printing) Area: Uses the Pressure roller to press paper against the master on the

Drum.

The Drum rotates with the Pressure roller and prints an image on

paper.

4 Paper Ejection Area: Separates a printed paper from the Drum, and transports it onto

the paper receiving tray.

5 Drum Area: Supplies the Drum surface with ink from an Ink cartridge.

6 Master Clamp Area: Clamps the leading edge of the master.

7 Master Disposal Area: Separates used master from the Drum and disposes it into the

Master disposal box.

8 Image Scanning Area: Carries an original and scans it with the Image scanner and

converts the image information into digital data.

9 Master Making Area: Makes a master with the Thermal print head.

10 Master Loading Area: Feeds the prepared master material to the Drum and cuts it to an

appropriate length.

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

Document

feederThermal print head

Original rack

Cutter unit

Paper feed tray

Pickup roller

3

Suction unit

1


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KS Series (Version 1.2)2 -3

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.

MACHINE SUMMARY

MACHINE OPERATIONS


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MACHINE SUMMARY

PAPER 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 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 printingstarts.

(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 the Guide roller to feed

the next sheet of paper.

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.

Stripper pad


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MACHINE SUMMARY

MASTER REMOVAL AND FEED

2 - 5

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 rollClamp plate

Verticaltransport roller

Cutter

Master projectionshaft

Master

disposal box

TPH


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MACHINE SUMMARY

COUNTER FOR MAINTENANCE

6. Counter Indication

1. Indicate Copy and Master Counter:

No mechanical counters are installed on KS therefore the alternatives are available as software

counter.

The counter indication can be shown by using USER MODE.

By pressing [*] and then [1], three digits of seven segments indication on the control panel displays

the Copy counter. The threee digits of seven segments change every 2 seconds then displays nine

digites of numbers finally.

By pressing [*] and then [2], the Master counter can be shown as same method as the above.

[Example] In case the Copy count is 123,456 and the Master count is 1,234.1. Press [*] key then [1] key.

2. [ - - - ] will be indicated at first.

3. After 2 seconds, the indication will be changed to [ 1 2 3 ].


5. Press [*] key then [2] key.

6. [ - - 1 ] will be indicated at first.


2 - 6

2. Clear of Copy and Master Counter:

There is "Counter clear mode" instead of Counter stop mode, of which has been programmed as Testmode No.92 on existing RISOGRAPHs.

The counter indication can be clear 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 ROM

initially. Then press [C] button so that the Test numbers can be input.

Clear Copy and Master counter:

1. Press [9] and [7] key then press [Start] key while test mode is available.

2. [1] will be indicated. In case the indication is [0], counter cannot be clear.

3. Press [C] to clear the memorised copy and master counter.

4. Press [Reset] key or power off to be back to normal operation.

Prohibit clear of Copy and Master counter:

1. Press [9] key and [7] key then press [Start] key while test mode is available.

2. [1] will be indicated. In case the indication is [0], counter cannot be clear.

3. Press [C] to clear the memorised copy and master counter.

4. Press the print position adjustment key or to the indication change from [1] to [0].

5. Press [Start] key so that conter clear mode becomes no longer available.

6. Press [Reset] key or power off to be back to normal operation.

Note:

*1. To confirm the status of the counter clear mode, imput test mode No.97 then press [Start] key

while test mode is available. If the indication is [0], counter cannot be clear. If not, the counter can

be clear.

*2. It is reccommended that the prohibit clear mode should be done before the machine is installed at

customer site.


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1. Main Drive.............................................................................................................. 1

2. Main Motor Safety Switches .................................................................................. 2

3. Drum Position ........................................................................................................ 3

4. Drum Rotation Lever .............................................................................................. 52. Removal and Assembly

1. Main Motor Unit ..................................................................................................... 7

2. Master Removal Unit Safety Switch ....................................................................... 9

3. Master Making Unit Safety Switch ....................................................................... 10

4. Sparation Unit Safety Switch ............................................................................... 11

5. Paper Guide Plate Safety Switch ......................................................................... 12

6. Drum Rotation Lever ............................................................................................ 13

CHAPTER3: MAIN DRIVE SECTION

CONTENTS


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MAIN DRIVE SECTION

THEORY OF OPERATION


1. Main Drive1. 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 : Drum

B : Drum Main gear

C : Intermediate gear

D : Main gear

E : Step-down gear A

F : Step-down gear BG : Main motor gear

H : Main motor

I : Encoder sensor

J : Encorder

B

A

C

D

E

JI

G

H

F


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MAIN DRIVE SECTION

THEORY OF OPERATION

2. Main Motor Safety Switch

1. Following all three Safety switches must be activated to run the Main motor.

> Master removal unit safety switch [A]

> Master making unit safety switch [B]

> Separation unit safety switch [C]

> Paper guide plate safety switch [D]

The same three switches act also as Safety switches for the Thermal power.

A: Master removal unit safety switch

B: Master making unit safety switch

C: Separation unit safety switch

D: Paper guide plate safety swich

A

B

C

D


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MAIN DRIVE SECTION

THEORY OF OPERATION

3. Drum Positions

1. Sensors for the Drum positioning

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

Main motor.

2. Position-A

> This is the position where the Clamp plate is at the top of the Drum.

> This position is also referred as the 0 position.

> The Clamp plate opens and closes at this position.

> This is the position where the light path of the Position-A sensor [A] is cut by the Position-A

plate [B] on the Drum.

3 - 3

Drum position-A

A : Position-A plate

B : Position-A sensor

Drum angle

0

A

B


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MAIN DRIVE SECTION

THEORY OF OPERATION

3 - 4

Drum angle

(Encoder sensor)

Position-A sensor

Main motor

Open

Blocked

0 (Position-A)

15 rpm

End of movement

0 (Position-A)

(a) If the light path of the Position-A sensor is cut when the last paper is counted, the Main motor speed

becomes from printing to 15 rpm to stop the drum rotation.

(b) When the Drum rotates to 315, the drum rotation speed becomes 1.95 rpm to stop the drum at the

Drum- A position (at Drum 0 ) exactlly. Then Main motor turns off.

> If the Encoder sensor does not output the Main motor rotation signal within 1.2 seconds, the machine

assumes that the Main motor has locked and displays error message [E 01].

> If over load current is detected and the Encoder sensor does not output th Main motor rotation signal for

0.1 seconds, the machine assumes that the Main motor has locked and displays error message [E 01].

Drum A-Positioning Movement Timing Chart

270 270 31590 180

(a) (b)

1.95 rpm

O N

OFF


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MAIN DRIVE SECTION

THEORY OF OPERATION

3 - 5

A:Drum

B:Drum gear

C:Drum rotation levar

D:Drum rotation gear

A

B

C

4. Drum Rotation Lever

1. Drum rotation lever

> The Drum [A] is rotated by pusing down the Drum rotation lever [C].

> The Drum rotation gear [B] is moved up and down by the Drum rotation lever [C].> The Drum rotation gear [B] rotates drive gears, thus the drum is rotated forward.

D


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M E M O


31/221


MAIN DRIVE SECTION

REMOVAL AND ASSEMBLY

3 - 7


1. Main Motor Unit

1. Disconnect the power supply from the machine.2. Remove Back cover.(See page 1-5)

3. Remove Paper receiving tray [A].

4. Remove Suction cover [B].(See page 7-6)

5. Remove Suction unit [C]. (See page 7-6)

(continues on page 3-8)

A : Paper receiving tray

B : Suctioncover

C : Suction unit

B

A

C


32/221


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.

MAIN DRIVE SECTION


3 - 8

Precautions in Assembly

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

A: Main motor unit

B: P.-F. clatch bracket

C: Timing clatch braket A

D: Timing clatch braket B

E: Encoder

F: Drive gear bracket

A

B

C

E

F D


33/221


MECHANICAL OVERVIEW


2. Master Removal Unit Safety Switch

1. Disconnect the power supply from the machine.

2. Remove the Front cover.(See page 1-5)

3. Open the Master removal unit [A] and disconnect the Connector of the Master removal unit safety

switch [B].

4. Remove three mounting screws of the Switch bracket and remove the bracket with the switch

attached.

5. Remove the switch [B] from the bracket.


> The mounting section of the bracket should be positioned behind the stay of the Master

removal unit [A].

> Match the half-pierced section on the Switch bracket with that on the machine.

3 - 9

A: Master removal unit

B: Master removal unit safety switch

A

B

B


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MAIN DRIVE SECTION


3 - 10

3. Master Making Unit Safety Switch


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.


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

A: Master making unit

B: Master making unit safety switch

AB


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MAIN DRIVE SECTION


3 - 11

4. Separation Unit Safety Switch


2. Remove the Front cover.(See page 1-5)

3. Remove the Main PCB. (See page 8-6)

4. Open the Separation unit [B] as the below photo shows.

5. Remove the Separation unit switch [A] from the bracket.


> Do not bend the Switch bracket, as it acts as a spring plate to press against the actuator of the

Separetion unit switch [A] when the Drum is inserted in the machine.

A:Separation Unit Safety Switch switch

B:Separation Unit

A

B


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MAIN DRIVE SECTION


3 - 12

5. Paper Guide Plate Safety Switch


2. Remove Back & Front cover (See page 1-5)

3. Remove the Power supply unit (See page 8-6)

4. Remove the PF tray [C] & the Pickup roller ass'y [B] (See page 4-6, 4-8)

5. Remove the PF clutch bracket & the PF clutch (See page 4-10)

6. Remove the PF guide plate upper plate (See page 5-7)

7.Remove the Master senser bracket (See page 5-5)

8.Remove the Paper gate (See page 5-12)

9.Remove the PF guide plate lower plate (See page 5-7)

10.Remove the PF plate safety SW [A]


> Do not bend the Switch bracket, as it acts as a spring plate to press against the actuator of the

switch when the Drum is inserted in the machine.

A:Guide Plate Safety Switch

B:Pickup roller ass'yC:Paper feed (PF) tray

A

B

C


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MAIN DRIVE SECTION


6. Drum Rotation Lever

6-1. Original Type: For KS500 Serial Number 81530001- 81530500

For KS500C Serial Number 81510001- 81510500

A

B

C

D

1. Dosconnect the power supply from the machine.

2. Remove the Back cover (See page 1-5)

3. Remove the Drum rotation lever bracket [B]

4. Remove the Drum rotation lever ass'y [D].

5. Separate the Drum rotation lever [C] and the Drum rotation gear [A].

Important caution of the Assembly

> Blue color of the One-way clutch in the Drum rotation gear [A] must face to the Drum rotation lever

bracket [B].

If the Drum rotation gear [A] is installed in the opposite direction, the Drum will be locked and [E 1] will be indicated on the machine.

A: Drum rotation gear

B: Drum rotation lever bracket

C: Drum rotation lever

D: Drum rotation lever ass'y


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Important caution of the Assembly

> Blue color of the One-way clutch in the Gear,m1*26*11 [A] must be face to the Gear plate;Drum

rotation lever [B].

If the Gear,m1*26*11 [A] is installed in the opposite direction, the Drum is locked and [E 1] is

indicated on the machine.

A: Gear;m1*26*11

B: Gear plate;Drum rotation lever

C: Gear Shaft;rotation lever

D: Link shaft;Drum rotation leverE: Link plate;Drum rotation lever

F: Drum rotation lever

G: Cover;Drum rotation lever

3 - 14

MAIN DRIVE SECTION



2. Remove the Back cover (See page 1-5)

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 -


39/221


1. Theory of Operation1. Paper Feed Tray Position ...................................................................................... 12. First Paper Feed Drive Mechanism ....................................................................... 23. Paper Pickup System ............................................................................................ 4

4. Paper Feed Pressure Select System .................................................................... 52. Removal and Assembly1. Paper Feed Tray Unit ............................................................................................ 62. Pickup Roller Assembly ......................................................................................... 73. Pickup 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 ............................................................................ 144. Paper Feed Clutch OFFTiming ............................................................................ 14

CHAPTER4: FIRST PAPER FEED SECTION

CONTENTS


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41/221


FIRST PAPER FEED SECTION

THEORY OF OPERATION


1. 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


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THEORY OF OPERATION

2. First Paper Feed Drive Mechanism

1. Paper Feed Clutch> When the Main motor[C] activates, the Drum rotates in the clockwise direction via the Drive

gear D-E-F-G-H-I. (looking from back of the machine).> The Paper feed clutch [B] activates at a certain Drum angle from the Position-A.

This Drum angle is determined by the count signal from the motor encoder sensor.> The Paper feed clutch is released as the Drum rotates for a certain set degrees from the Drum

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

rotation speed.

2. End of First Paper Feed> The First paper feed ends when the Paper feed clutch [B] is released.> The leading edge of the paper rests against the Guide roller and Timing roller.

> The Pickup roller [A] rotates free in the direction of paper feed by one-way clutch to avoidapplying 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


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THEORY OF OPERATION

4 - 3

First Paper Feed Timing Chart

1-1 The Paper feed clutchactivates each time the Drum rotates 66.3 from the A position.The angle "" can be adjusted by Test Mode No. 80, which adjusts the ON timing of the Paper feed clutch.

2-1 The Paper feed clutch is deactivated when the Drum rotates 144.8 from the A position.The angle "" can be adjusted by Test Mode No. 81, which adjusts the paper buckle amount.

A:DrumB:Pickup rollerC:PaperD:Paper gateE:Guide rollerF:Stripper pad

G: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

0

1-1 66.3

1-2 63.7

2-1 144.8

2-2 142.2 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 from the A position.

The angle "" can be adjusted by Test Mode No. 82, which adjusts the ON timing of the Paper feed clutch.

2-1 The Paper feed clutch is deactivated when the Drum rotates 142.2 from the A position.The angle "" can be adjusted by Test Mode No. 83, which adjusts the paper buckle amount.

2-1 144.8

2-2 142.2

1-1 66.3

1-2 63.7


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THEORY OF OPERATION

4 - 4

3. Paper Pickup System

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

the Pickup roller [A] and Stripper pad [C].

2. Pick-up> The top sheet is separated from the rest by the Pickup roller [A] and Stripper pad [C].> The Stripper pad [C] is pushed against the Pickup roller [A] by the Stripper spring [B] to provide

resistance against paper feed, by which only a single sheet of paper [D] is fed from the paperstack.

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

C

A

B

D


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THEORY OF OPERATION

4. Paper Feed Pressure Select System

1. Paper Feed Pressure Adjust Lever> The Paper feed pressure adjust lever[A] is located on the front side of the machine, and it

changes the pressure of the Paper feed tray applied against the Pick up roller, as a result 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 against thePaer feed tray. Thus the paper feed pressure is not increased at the lower position. Therefore thisposition 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


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1. Paper Feed Tray Unit1. 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


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2. Pick up Roller Assembly

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

ass'y.



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

B

A

C

D


48/221


3. Pickup Roller and PF Support Roller

1. 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.


> 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


49/221


4. Stripper Pad

1. 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


50/221


5. Paper Feed Clutch

1. 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.


> Match the position of the flat cut portion of the Metals [C] with that of the Main frame or PFclutch 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


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ADJUSTMENT

3. Adjustment

1. 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 + 1mmto - 7mmfrom 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 isthe sign of the limit position of the adjustment.) Otherwise the steps of the PF adj. screw [B] willbe damaged.

WeakStorong

fig.a

B

fig.c

7 m m

A

B

fig.b

1 m m

A:Paper feed tray set lever

B:PF adj. screw

For KS500C Serial Number 81510001- 81510500

W eak(CCW)+1mm

Strong(CW)

-7mm

1-1.Original Type of the Paper feed Tray set LeverFor KS500 Serial Number 81530001- 81530500


52/221


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 edge of

the PF adj. screw [B] to the edge of the Paper feed tray set lever [A].4. The adjustable range is + 7mmto +12mmfrom 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 todecrease 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 isthe 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 lever

B:PF adj. screw

C:PF adj. dial

B

A

fig.a

fig.b

W eak(CCW)

+12mm

Strong(CW)

+7mm

For KS500C Serial Number 81510001- 81510500For KS500 Serial Number 81530001- 81530500


ADJUSTMENT


53/221


2. Paper Feed Tray Position Adjustment

1. 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 KS500] 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)

8. Turn the PF Adj. screw[D] as left figures show.

In case of the New type of the Paper feed tray set lever[F].

*Trun it towards CCW if the Base plate;PFT[A] is higher than the line. *Trun it towards CW if the Base plate;PFT[A] is lower than the line.9. Paper feed adjustment for each paper will be required after this adjustment is done.


ADJUSTMENT

A

B

A: Base plate;PFT

B: Plate;PFT

C: PF press-adj. Lever

D: PF Adj. screw

E: PF Adj. dial

F: Paper feed tray set lever

42mm or 43mm

C

D

E D

New TypeOld Type

F

B

B


54/221



ADJUSTMENT

[Checking of Paper Feeding]

1.Select PF press-adj lever position depending on the paper weight.

*Less than 50g/m2:Upper position(THIN), More than 50g/m2: Lower position(NORMAL)2. In case of occuring maltiple paper feeding or No paper feeding frequently, adjust paper feed

pressure by Adj. screw.

*Remove Adj. Dial for the adjustment if Adj. Dial is installed.

*Normally truning the adj. screw a half trun for each direction is enough for the adjustment.

*Trun CCWif multiple paper feeding occurs.

*Trun CWif No paper feeding occurs.

3.During normal paper feeding, paper is fed onto the center of the stripper pad then stop at

once. Then fed by Pick up roller.

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 center

of the stripper pad.

Paper

Standardrange

A: Stripper padB: paper guide plate lower A

B

A

Top view


55/221



ADJUSTMENT

3. Paper Feed Clutch ON Timing

If the paper jams or does not feed smoothly due to incorrect timing of the paper feed clutch activatetiming, use Test mode No.80 or No.82to adjust the timing of the Paper feed clutch activation.Test No.80 for when the machine runs at 60 r.p.m.. Test No.82 for when the machine runs at 90

r.p.m..

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 the Paperfeed 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 theSecond 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 theSecond paper feed section and may result in paper jamming.

Adjustment Procedure

1. Turn off the power of the machine.2. Keep pressing and key on the control panel then turn on the power.3. Check whether the paper buckle is normal or not.4. In case the paper buckle is not enoght, start up the Test Mode and enter [8] and [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


56/221



1. Second Paper Feed Drive Mechanism ................................................................... 1

2. Vertical Print Position ............................................................................................ 2


1. Load Spring ........................................................................................................... 32. Timing Clutch......................................................................................................... 4

3. Paper Guide Plate ................................................................................................. 5

4. Paper Gate ............................................................................................................ 6

5. Timing Roller.......................................................................................................... 7

3. Adjustment

1. Print Position(Timing Clutch ON Timing) ................................................................ 8

CHAPTER5: SECOND PAPER FEED SECTION

CONTENTS


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58/221


SECOND PAPER FEED SECTION

THEORY OF OPERATION

5 - 1


1. Second Paper Feed Drive Mechanism

1. Drive> Timing clutch[F]makes clockwise rotation (looking from the rear) with the turn of the main

motor [G].

> The Timing gear [F] rotation is transfered to the Timing gear [F] via the Timing clutch [E].

> The Timing roller [C] rotates Guide roller [B].

2. Timing Clutch

> After certain time from paper got in the Timing clutch [E] activates then the Timing clutch gear

rotation is transfered to Timing roller [C].

3. Timing Roller

> The Timing roller [C] contains Load spring which applies brake on the roller at all times.

It stops the rotation of the roller as soon as the Timing clutch [E] goes off.

4. Guide Roller

> The Guide roller [B] always contacts with the Timing roller [C].

> It rotates when the Timing roller [C] starts rotating.

> The Guide roller [B] rotation stops when the Timing clutch [E] goes off.

A:Paper gate

B:Guide roller

C:Timing roller

D:Load spring

E:Timing clutchF:Timing gear

G:main motor

B

C

A

E

D

F

G


59/221


2. Vertical Printing Position

1. Timing Clutch

> The print position is depending on when the Timing clutch [C] goes on.

> Normally the Timing clutch [C] goes on when the drum angle becomes 160.3 degrees and goes

off when the drum angle becomes 61.3 degrees in case the drum speed is 60r.p.m.

> When the drum rotation speed is 90 r.p.m., the Timinig clutch [C] goes on at the drum angle

157.7 degrees and goes off at the drum angle 58.7 degrees.

2.Print Position

> Print position can be changed by pressing the print position adjustment key or on the

control panel.

> When the key is pressed, the Timing clutch [C] on timing becomes earlier and the print

position moves down.

> When the key is pressed, the Timing clutch[C] on timing becomes late and the print

position moves up.


THEORY OF OPERATION

A:Guide roller

B:Timing rollerC:Timing clutch

D: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


60/221





1. Load Spring1. Disconnect the power supply from the machine.

2. Remove Front cover.

3. Remove power supply PCB. (See page 8-6)

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 spring

B:Collar

C:E-ring

C

B

A


61/221




2. Timing Clutch


2. Remove Back cover.

3. Remove thePF-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:Clutch support plate

B:Encoder

C:Encoder sensor

D:BKT; Drive gears

E:Metal

F:Timing clutchG:Timing gear

H:PF-Clutch support plate

CB

F

G

A

D

E

H


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3. Paper Guide Plate


2. Remove following parts from the machine.

> Back cover (See page 1-5)> Paper feed tray unit [A] (See page 4-6)

> Paper feed clutch [F] with the bracket. (See page 4-10)

> Pick up roller ass'y [B] (page 4-7)

3. Remove the Paper guide plate upper [C].

4. Remove the Master loading sensor bracket [E].

5. Slide the Master removal unit then remove mounting

screw of the Paper gate [G]. (See page 5-12)

6. Take out the Paper guide plate lower [D] from the the Paper feed tray side.



A:Paper feed tray

B:Pickup roller assy

C:Paper guide plate upper

D:Paper guide plate lower

E:Master loading sensor bracket

F:Paper feed clutchG:Paper gate

Adjustment after Assembly

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

show.

B

A

D

C

E

F

G

Drive side

Front side

C

C


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5 - 6

4. Paper Gate


2. Remove the Paper guide plate upper. (See page 5-7)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


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5. Timing Roller/ Guide Roller


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 8-6)

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 of

the 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 roller

B:Guide roller

C:Metal(Long)

D:Metal(Short)

E:One-way gearF:E-ring

G:Load spring

A

B

F

F

E

G

C

C

D

D


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ADJUSTMENT

5 - 8

3. Adjustment

1. Print Position (Timing Clutch ON timing)

Vertical print position can be changed by changing the Timing clutch activate timing.The Timing Clutch activate timing can be cahnged by using TEST MODE No.84 or No.86.

Test No.84 is for when the machine runs at 60 r.p.m. and Test No.86 is for when the machine runs at

90 r.p.m..

Adjustment Procedure

1. Turn off the power of the machine.

2. Keep pressing and key on the control panel then turn on the power.

3. Enter [9] and [4] with the ten key to put a master that has horizontal line on the top of the master.

The line is for checking the print position.

4. Press [Reset] key to the machine operation be back to normal then get 5 sheets printouts with

60 r.p.m. and get another 5 sheets printouts with 90r.p.m..

5. Measure the position of the horizontal line from the top edge of the paper.

6. Check the printouts whether the horizontal line on the paper is 10mm from the edge or not.(refer

to the figure below)

7. In case the horizontal line is not at 10mm when the printing speed is 60 r.p.m., start up the

TEST MODE and enter [8] and [4] and select the number by pressing or key.

In case the horizontal line is not at 10mm when the print speed is 90 r.p.m., enter [8] and [6] and

select the number by pressing or key.

Result of Incorrect Adjustment

> If adjusted as [7], the paper could not reached the drum before the pressure roller rises.

As a result, paper jam could occur and the pressure roller could be dirty with ink from the drum

surface.

[Exsample] : In case the line is positioned 7 m m from edge of the paper with the printing speed at 60 r.p.m..

1. Go into Test mode and enter [8] and [4].

2. Change the indication from [0] to [-3] by pressing key.

3. Press [Reset] key to the machine operation to be back to normal and try to print 5 sheets.

4. Measure the distance between edge of the paper and the horizontal line. If the distance is not 10mm,

back to the procedure 1.

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


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1. Press Mechanism.................................................................................................. 1


1. Pressure Roller ...................................................................................................... 3

2. Pressure Lever Ass'y ............................................................................................. 43. Pressure Shaft Ass'y ............................................................................................. 5

3. Adjustment

1. Pressure Lever Ass'y Position ............................................................................... 7

CHAPTER6: PRESS SECTION

CONTENTS


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PRESS SECTION

THEORY OF OPERATION


1. Press Mechanism

1. Pressure Lever and Pressure Roller> The Pressure lever [D] is fixed with the Pressure shaft [G] at certain position. And the Pressure

roller [A] stays on the Pressure ass'y [K], of which is fixed the Pressure shaft [G].

> While the Main motor [C] is making the Drum rotation without paper (not prininting process), the

Pressure hook [H] engages with the Pressure lever [D] so that the Pressure shaft ass'y stays

lower.

> When paper comes in and pushes the Paper gate [J] up, the Pressure hook [I] is risen. So the

Pressure lever [D] is released then the Cam follower [I] of the Pressure lever ass'y gets contact

with the Pressure cam [E]. Thus the Pressure roller [A] is risen and contacted to the Drum when

Drum rotation is at 118 degrees.

> Pressure of the Pressure roller [A] is given to the Drum [F] by the Pressure spring [B].

> Once the Pressure lever [D] is released from the Pressure hook [H], movement of the Pressure

lever [D] is controled by the Pressure cam [E].> The Pressure hook becomes lower when the paper throughs out from the Paper gate [J]. Then

the Pressure roller [A] is lowered by the Pressure cam [E] at the Drum rotation 118 degrees

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

> The Pressure lever [D] becomes lowered again by Pressure cam [E] at Drum rotation 218

degrees.

A:Pressure roller

B:Pressure spring

C:Main moter

D:Pressure lever ass'y

E:Pressure cam

F:Pressure shaft ass'y

G:Pressure shaft

H:Pressure hookI :Cam follower

J :Paper gate

K:Pressure ass'y

6 - 1

A

E

D

C

B

F

G

H

I

J

Paper gate is pushed

up by paper.And Pressure hook is

raised.

Then Pressure lever

rises by Pressure cam

at Drum 118.

H

Pressure hook

becomes lower when

the paper throughs

out. Then Pressure

lever is lowered by

Pressure cam at Drum

218.

K


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PRESS SECTION

THEORY OF OPERATION

6 - 2

A:Pressure roller

B:Pressure lever ass'y

C:Drum

D:Pressure spring

E:Pressure shaft

Lifting the Pressure Roller

The Paper gate is pushed up by paper throughout

the printing. So the Pressure lever [B] becomes free.The Pressure spring [D] pulls back the Pressure lever

[B] and rotates the Pressure shaft [E] which is acting

as a pivot.

The rotation of the Pressure shaft [E] lifts the Pressure

roller [A] up against the Drum [C].

Lowering the Pressure Roller

The 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 of the

Drum comes close to the Pressure roller (drum rotation

at 118 degrees), the high part of the Pressure cam [F]

pushes the Pressure lever [B] down, rotating the

Pressure shaft [E] clockwise to bring the Pressure

roller down, away from the Drum.

Then Pressure lever [B] is lowered by Pressure cam

[F] at Drum 218 degrees.

A

B

C

E

D

Pressure hook becomes lower when the paper throughs out.

F

E


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PRESSURE SECTION



1. Pressure Roller1. Disconnect the power supply from the machine.

2. Remove the Back cover from the machine.(See page 1-5)

3. Remove the Suction unit from the machine. (See page 7-5)

4. Remove mounting screw of the Pressure roller [C] from the Pressure ass'y (refer to 6-5) through a

hole on the drive

Riso KS 500 Service Manual

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Transcript of Riso KS 500 Service Manual