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RISO
57A01C
&
KZ30
TECHNICAL MANUAL
REVISION 1.2
OCTOBER, 2011
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.
CHAPTER
1:
MAINTENANCE
MAINTENANCE
CONTENTS
PREFACE...........................................................................................................1-3
1. Warning.........................................................................................................1-4
2. Work Precautions.........................................................................................1-5
3. Jigs.................................................................................................................1-7
4. Exterior Cover Removal...............................................................................1-8
1) Print Drum..............................................................................................1-8
[-]
1-1 ]
MAINTENANCE
[-]
1-2 ]
MAINTENANCE
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.
[-]
1-3 ]
MAINTENANCE
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.
FIRST
THEN
Press the center, firmly.
[-4]
1-4 ]
MAINTENANCE
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.
GOOD
BAD
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.
Positioning pin
[-]
1-5 ]
MAINTENANCE
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.
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
Self-tapping screw
Pan-head screw
Binding-head screw
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.
Wiring bundle band
(bar lock ties)
[-6]
1-6 ]
MAINTENANCE
3. Jigs
List of the Jigs needed to maintenance this machine.
1.
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>
2.
OR
PLUS
Rectangular Box
Needed to align the Print drum Rear.
<Refer to the Chapter on the Print Drum>
015-26128-008 Drum Shaft Jig (8mm diameter)
Needed to align the Print drum Front.
<Refer to the Chapter on the Print Drum>
[-7]
1-7 ]
MAINTENANCE
Rear cover
Front cover
(Already removed on the photograph.)
Swing open
[-]
1-8 ]
MAINTENANCE
< Do not lift the Print drum or the Print drum will fall off the machine. >
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.
Hold firmly
ont
e fr out.
h
t
Lift slide
and
Hold firmly
[-9]
1-9 ]
MAINTENANCE
[-]
1-10 ]
MAINTENANCE
[-]
1-11 ]
MAINTENANCE
[-]
1-12 ]
MAINTENANCE
Pressure spiring
Follow the instruction in the opposite order in hooking the Pressure spring back on the machine.
[-]
1-13 ]
MAINTENANCE
MEMO
[-4]
1-14 ]
2:
CHAPTER
MACHINE SUMMARY
MACHINE SUMMARY
CONTENTS
1. Specifications...............................................................................................2-3
RISO 57A01C
......................................................................2-3
RISO KZ30............................................................................................2-4
[-]
2-1 ]
MACHINE SUMMARY
MEMO
[-]
2-2 ]
MACHINE SUMMARY
1. Specifications
RISO 57A01C
[-]
2-3 ]
MACHINE SUMMARY
[-4]
2-4 ]
MACHINE SUMMARY
Image scanner
Master disposal box
Original rack
Write roller
6
Master roll
7
1
10
2
Separator
Pickup roller
Timing roller
Pressure roller
Guide roller
Feeds single sheets of paper to the second paper feed area via Pickup
roller and Stripper pad.
Controls the vertical print position and feeds paper to the print area via
the Timing and Guide rollers.
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.
Separates a printed paper from the Drum, and transports it onto the
paper receiving tray.
5 Drum Area:
Separates used master from the Drum and disposes it into the Master
disposal box.
Carries an original and scans it with the Image scanner and converts
the image information into digital data.
[-]
2-5 ]
MACHINE SUMMARY
3. Machine Operations
Master Disposal
Master Making
Printing
Paper is fed one sheet at a time from
the Paper feed tray, printed, and stored
on the paper receiving tray.
[-6]
2-6 ]
MACHINE SUMMARY
Pickup roller
Drum
Stripper pad
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.
Guide roller
Timing roller
The Guide and Timing rollers in the second paper feed
area are rotated and the paper is fed to the printing
area.
Pressure roller
Separation fan
Separator
Transfer belt
[-7]
2-7 ]
MACHINE SUMMARY
Clamp plate
Vertical
transport roller
Master Removal
The Clamp plate opens and Master release
shaft releases the master from the Clamp
plate.
Master
The Drum and Vertical transport rollers starts
rotating and removes the master from the
Drum and feed it into the Master disposal
box.
Master
disposal box
Master Making
The Image scanner scans the image on the
original and Thermal print head (TPH) makes
the image on the master material.
The Master tension plate drops down and
applies tension on the master material.
Master Loading
The master is transferred onto the Drum and
the leading edge is clamped by the Clamp
plate.
The Drum rotates to wrap the master on the
Drum.
Cutter
[-]
2-8 ]
MACHINE SUMMARY
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.
< Sample Instructions >
Item No. 30: Total Copy Count Display
The total number of pages printed with the machine is
1. Press the CUSTOM key
EXA
MPL
on the Control Panel.
displayed.
E
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.
135
7900
30 -
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.
Turning the machine power OFF and then ON will automatically return the test mode setting back to the
default setting of [1], which allows the counter to activate.
< The setting automatically returns back to the default [1] setting when the machine power
is turned OFF and ON. >
[-9]
2-9 ]
MACHINE SUMMARY
MEMO
[-]
2-10 ]
CHAPTER
3:
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
6. Print Drum Safety Switch.....................................................................3-15
[-]
3-1 ]
MEMO
[-]
3-2 ]
Theory of Operation
1. Main Drive
The main motor drives the following components of the machine.
* Print drum
Print drum
Pressure roller
Suction belt
[-]
3-3 ]
The same four switches act also as Safety switches for the Thermal power.
[-4]
3-4 ]
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 is the position where the light path of the Position-A sensor is cut by the Position-A
plate on the Drum.
Position-A sensor
Drum angle
FRONT
1
View under the Print drum
[-]
3-5 ]
(b)
(a)
Drum angle
(Encoder sensor)
Position-A sensor
Main motor
270
0 (Position-A)
Open
90
180
270
340
End of movement
0 (Position-A)
Blocked
ON
OFF
15 rpm
1.95 rpm
(a) If the light path of the Position-A sensor is cut when the last paper is counted, the Main motor speed
becomes from printing to 15 rpm to stop the drum rotation.
(b) When the Drum rotates to 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].
[-6]
3-6 ]
Screw
FG Sensor disc
Connector
Spacer
Insert thin rod to prevent Main
motor shaft from turning.
[-7]
3-7 ]
Screw
7. Remove the Timing clutch support plate (4 screws), disconnect the connector and remove the Timing
clutch.
[-]
3-8 ]
8. Disconnect wire harness clamps from the Drive gear bracket and remove the bracket. (8 screws)
[-9]
3-9 ]
Turn OFF the machine power and disconnect the power cord from the machine..
Remove the Rear cover.
Remove the Paper receiving tray.
Remove Suction cover.
Remove Suction unit.
Suction cover
Suction unit
[-]
3-10 ]
6. Remove the Drive gear bracket by following the instructions given on pages from 3-7 to 3-9.
7. Remove the mounting screws, disconnect the connector and remove the Main motor out from the
opening in the paper receiving area. (3 screws)
[-]
3-11 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Master removal unit cover.
Open the Master removal unit, disconnect the Connector of the Master removal unit safety switch and
remove the switch assembly. (1 screw)
Open the Master removal unit safety switch assembly and remove the switch. (2 screws)
[-]
3-12 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Master removal unit from the machine. (Refer to the Chapter on Master making unit.)
Disconnect the Connector of the Master making unit safety switch.
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.
[-]
3-13 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Front cover.
Remove the Mechanical control PCB.
Open the Separation unit as shown on the photograph below.
Disconnect the connector, remove the Separation unit switch assembly from the machine (1 screw)
and remove the switch from the bracket.
Separation unit
[-4]
3-14 ]
[-]
3-15 ]
MEMO
[-6]
3-16 ]
CHAPTER
4:
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
1. Paper Feed Clutch ON/OFF Timing . ..................................................4-15
[4-]
4-1 ]
MEMO
[4-]
4-2 ]
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.
[4-]
4-3 ]
Pickup roller
Pickup roller shaft
Main motor
[4-4]
4-4 ]
Drum rotation
2-1 157.8
1-2 76.7
2-2 155.2
1-1 79.3
2-1 157.8
1-2 76.7
2-2 155.2
ON
Main motor
Position-A Sensor
Blocked
Open
ON
Print drum
Guide roller
Pickup roller
Paper
Stripper pad
Timing roller
[4-]
4-5 ]
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
Paper
Stripper pad
Stripper spring
[4-6]
4-6 ]
>
>
>
>
The Paper feed pressure adjust lever is 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.
Pressure spring
[4-7]
4-7 ]
MEMO
[4-]
4-8 ]
Lock pin
[4-9]
4-9 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Lower the Paper feed tray.
Remove the Rear cover.
Remove the Paper feed tray from the machine.
Remove Lock rings on the right end of the Pickup roller shaft and remove the Metal.
Slide the Pickup roller shaft to the rear side of the machine and remove the Pick up roller
assembly.
Lock ring
Metal
[4-]
4-10 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Pickup roller assembly.
Slide the Paper feed support rollers from the Pickup roller shaft.
Remove Lock ring from the Pickup roller shaft.
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.
Pin
Lock ring
Pickup roller
[4-]
4-11 ]
4. Stripper Pad
1.
2.
3.
4.
5.
Turn OFF the machine power and disconnect the power cord from the machine.
Lower the Paper feed tray all the way down.
Remove the Lock ring of the Pickup roller then slide the roller towards the rear of the machine and
remove the Pin.
Remove the Stripper pad base carefully, not to damage the Stripper spring.
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
Stripper spring
[4-]
4-12 ]
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)
[4-]
4-13 ]
MEMO
[4-4]
4-14 ]
3. Adjustment
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-]
4-15 ]
MEMO
[4-6]
4-16 ]
CHAPTER
5:
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
[-]
5-1 ]
MEMO
[-]
5-2 ]
1. Theory of Operation
Drive
Timing clutch makes 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
Load spring
Guide roller
Timing roller
Timing clutch
Main motor
Timing gear
[-]
5-3 ]
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.
0
90
180
270
Drum rotation
79.3 (76.7)
157.8 (155.2)
78.5
160.3 (157.7)
Guide roller
Timing roller
Timing clutch
[-4]
5-4 ]
360
1. Load Spring
1.
2.
3.
4.
6.
Tun OFF the machine power and disconnect the power cord from the machine.
Remove Front cover.
Remove Print drum.
Remove E-ring and Washer from the Timing roller shaft.
Remove the Load spring from the shaft.
Precaution in Assembly
> Install the Load spring in the correct direction.
Load spring
washer
E-ring
[-]
5-5 ]
2. Timing Clutch
1.
2.
3.
4.
Turn OFF the machine power and disconnect power cord from the machine.
Remove Rear cover.
Remove the Timing clutch support plate. (4 screws)
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
[-6]
5-6 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove following parts from the machine.
> Rear cover
> Paper feed tray unit
> Paper feed clutch with the bracket
> Pick up roller assembly
> Print drum
Remove the Paper guide plate upper. (2 screws)
Remove 2 mounting screws from the Paper guide plate lower.
Slide out the Master removal unit and remove the Paper gate. (1 screw)
Take out the Paper guide plate lower from the the Paper feed tray side while raising the Guide roller
by hand.
Paper gate
[-7]
5-7 ]
4. Paper Gate
1.
2.
3.
4.
Turn OFF the machine power and disconnect power cord from the machine.
Remove the Print drum.
Slide out the Master removal unit.
Remove the mounting screw of the Paper gate and remove the Paper gate.
Mounting screw
Paper gate
[-]
5-8 ]
E-ring
Bushing (short)
Load spring
Bushing (long)
E-ring
Bushing (short)
Bushing (long)
One-way gear
Timing roller
Guide roller
[-9]
5-9 ]
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.
[-]
5-10 ]
CHAPTER
6:
PRESS SECTION
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
1. Pressure Lever Assembly Position........................................................6-9
[6-]
6-1 ]
PRESS SECTION
MEMO
[6-]
6-2 ]
PRESS SECTION
1. Theory of Operation
1. Press Mechanism
1.
>
>
>
>
>
>
>
Pressure roller
Pressure cam
Paper gate
Cam follower
Pressure assembly
Pressure spring
Main motor
Pressure lever assembly
Pressure hook
[6-]
6-3 ]
PRESS SECTION
Print drum
Pressure shaft
Pressure cam
Pressure roller
Pressure spring
[6-4]
6-4 ]
PRESS SECTION
Turn OFF the machine power and disconnect power cord from the machine.
Remove the Rear cover.
Remove the Print drum.
Remove the Suction unit.
Remove the Pressure spring.
Remove mounting screw of the Pressure roller from the Pressure shaft assembly through a hole on
the drive side of the machine frame.
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
Pressure roller
[6-]
6-5 ]
PRESS SECTION
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Rear cover.
Remove the Print drum from the machine.
Remove the Pressure spring.
Remove two set screws from the Pressure lever assembly.
Turn the Pressure lever in clockwise direction (Pressure lever shows up behind the gear) then
remove the Pressure lever assembly from the Pressure shaft.
Set screws
[6-6]
6-6 ]
PRESS SECTION
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Print drum from the machine.
Remove both the Front and Rear covers.
Remove the Pressure spring.
Remove the Pressure lever assembly. (Refer to the previous page)
Remove E-rings from both ends of the Pressure shaft assembly and remove the Bushings.
Remove the Suction unit.
Remove the Pressure spring.
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.
E-ring
Bushing
Pressure shaft assembly
Bushing
E-ring
Pressure spring
[6-7]
6-7 ]
PRESS SECTION
MEMO
[6-]
6-8 ]
PRESS SECTION
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.
Hook lever
Pressure cam
2.0
m
mt
o2
.5 m
m
Pressure assembly
Cam follower
Pressure lever assembly
B-position
[6-9]
6-9 ]
PRESS SECTION
MEMO
[6-]
6-10 ]
CHAPTER
7:
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-]
7-1 ]
MEMO
[7-]
7-2 ]
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.
Separation fan
Separator
Transfer belts
Suction fan
[7-]
7-3 ]
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
Separator shaft
[7-4]
7-4 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove Rear cover.
Remove the Paper receiving tray.
Remove the Suction unit cover.
Disconnect the Connector of the Suction unit.
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.
Base plate
Suction unit
[7-]
7-5 ]
2. Transfer Belt
1.
2.
3.
4.
5.
6.
7.
8.
9.
Turn OFF the machine power and disconnect the power cord from the machine.
Remove Rear cover.
Remove Suction unit.
Remove two mounting screws of the De-electricity brush and remove the brush.
Remove the Jump wings.
Remove four mounting screws of the Suction face cover.
Lift the face cover and remove the Belt driven shaft by unhooking the Transfer belts.
Remove E-ring of the Belt pulley shaft and remove the Bushing.
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
E-ring
Bushing
De-electricity brush
[7-6]
7-6 ]
3. Suction Fan
1.
2.
3.
4.
5.
Turn OFF the machine power and disconnect the power cord from the machine.
Remove Rear cover.
Remove Suction unit.
Turn over the Suction unit and disconnect the Connector of the Suction fan.
Remove two mounting screws of the Suction fan and remove the fan.
Suction unit
Suction fan
[7-7]
7-7 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove Rear cover.
Disconnect the Connector of the Separation fan unit.
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.
[7-]
7-8 ]
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.
Separation fan
[7-9]
7-9 ]
7. Separator
1.
2.
3.
4.
5.
6.
7.
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Back cover and Front cover.
Remove the Paper receiving tray.
Remove the Separation fan unit.
Remove the Separation spring.
Remove E-ring from the drive side of the Separator shaft.
Slide the Separation shaft towards the rear (machine drive side) and remove the Separation shaft.
E-ring
Separation shaft
Separator spring
[7-]
7-10 ]
3. Adjustment
1. Separator Position
1.
2.
3.
4.
5.
6.
7.
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.
Print drum
Print drum
Separator
Separator
Separator lever
Print drum
Slid
e pl
ate
Mounting screw
e th
Separator plate
UP
N
OW
or D
[7-]
7-11 ]
MEMO
[7-]
7-12 ]
CHAPTER
8:
PRINT DRUM
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
3. Ink blocking plate position adjustment...................................................8-19
[-]
8-1 ]
Imagetec Solutions Australia
PRINT DRUM
MEMO
[-]
8-2 ]
Imagetec Solutions Australia
PRINT DRUM
MECHANISM
[-]
8-3 ]
Imagetec Solutions Australia
PRINT DRUM
Overflow sensor
Ink sensor
Inking motor
Driving shaft
Squeegee roller
[-4]
8-4 ]
Imagetec Solutions Australia
PRINT DRUM
DISASSEMBLY
[-]
8-5 ]
Imagetec Solutions Australia
PRINT DRUM
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
[-6]
8-6 ]
Imagetec Solutions Australia
PRINT DRUM
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.
[-7]
8-7 ]
Imagetec Solutions Australia
PRINT DRUM
Grip handle
15
5
o2
mm
Inking motor
[-]
8-8 ]
Imagetec Solutions Australia
PRINT DRUM
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.
Screen hanger
Screen JIG
Hook
Hook
[-9]
8-9 ]
Imagetec Solutions Australia
PRINT DRUM
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.
Drum body
Imprinted marking
Imprinted marking
Screen JIG
Hook
Hook
[-]
8-10 ]
Imagetec Solutions Australia
PRINT DRUM
Precaution in Assembly
1) The Ink sensor and Overflow sensor needles must be straight. Do not deform or bend the sensor
needles.
2) If the needles are bent, straighten then out by hand before installing the Ink sensor PCB back on
the Drum.
3) The Clamp plate base assembly should be pushed towards the rear of the Drum, as there is a
small play in mounting the assembly.
Checks after Assembly
1) Make sure that the Ink sensor is not touching the Doctor roller or Driving shaft, as that would
cause the Ink sensor to make false detection.
2) In normal condition, the tip of the Ink sensor should be 5mm plus/minus 0.5mm from the outer
surface of the Driven shaft. The tip of the Overflow sensor should be 10mm plus/minus 1mm
from the outer surface of the Driving shaft.
* As shown on the photograph, the Ink sensor and Overflow sensor should be 90 degrees against the
Ink sensor PCB.
Overflow sensor
[-]
8-11 ]
Imagetec Solutions Australia
Ink sensor
PRINT DRUM
[ Refer to the photographs on the next page for the instructions given above.]
[ Also refer to the Precautions, which follow after the photographs.]
[-]
8-12 ]
Imagetec Solutions Australia
PRINT DRUM
Rear frame
Drum support R
Side channel
Rear frame
IB lock
Set screw
Cap screw
Drum support F
Front frame
[-]
8-13 ]
Imagetec Solutions Australia
PRINT DRUM
Precaution in Assembly
1) Use the Drum Shaft JIG when mounting the screws back onto the Drum shaft clamper.
( Dram shaft Jig = 015-75008-006 Drum Shaft JIG )
2) With the Drum at position-B, insert the Drum Shaft JIG through the Front support plate, Drum
flange-F, Front frame, Rear frame, Drum flange-R and Rear support plate. Then tighten the
screws on the front and rear Drum shaft clamper.
3) The Clamp plate base assembly should be pushed towards the rear of the Drum, as there is a
small play in mounting the assembly.
4) Using three wire harness lock bands of each about 100mm long, fix the position of the Ink sensor
relay wire harness to the Support frame and Rear support plate.
5) Make sure that the Ink sensor relay wire harness does not have any slack in the area indicated by
the dotted line on the photograph, and that the wire harness lock band tie area does not protrude
outside the bracket. This is to protect the wire harness.
Adjustments after Assembly
1) Squeegee gap adjustment
2) Ink blocking plate position adjustment
3) Squeegee pressure balance adjustment
Drum support F
Drum support R
Rear frame
Support frame
Rear frame
[-4]
8-14 ]
Imagetec Solutions Australia
PRINT DRUM
If older version Drum Shaft Jig 015-26128-008, it works only for the Drum support F (front).
It will not work for the Drum support R (rear).
[-]
8-15 ]
Imagetec Solutions Australia
PRINT DRUM
Mounting screw
Front frame
[-6]
8-16 ]
Imagetec Solutions Australia
PRINT DRUM
Shaft joint
Center shaft
Squeegee roller
Driving shaft
Front frame
Squeegee roller
Rear frame
[-7]
8-17 ]
Imagetec Solutions Australia
PRINT DRUM
ADJUSTMENT
Filter
Mounting screw of the Intake nozzle
Inking motor
[-]
8-18 ]
Imagetec Solutions Australia
PRINT DRUM
[-9]
8-19 ]
Imagetec Solutions Australia
PRINT DRUM
MEMO
[-]
8-20 ]
Imagetec Solutions Australia
CHAPTER
9:
CLAMP UNIT
CLAMP UNIT
CONTENTS
MECHANISM......................................................................................................9-2
1. Clamp Unit Home Position Movement.....................................................9-2
2. Clamp Plate Master Release Movement.................................................9-2
3. Clamp Plate Master Clamp Mechanism...................................................9-3
DISASSEMBLY...................................................................................................9-4
1. Clamp Unit...............................................................................................9-4
2. Clamp Motor............................................................................................9-5
3. Clamp Sensor..........................................................................................9-6
[9-]
9-1 ]
Imagetec Solutions Australia
CLAMP UNIT
MECHANISM
Clamp cam
Clamp motor
Print drum
Position-A
[9-]
9-2 ]
Imagetec Solutions Australia
CLAMP UNIT
Position-B
[9-]
9-3 ]
Imagetec Solutions Australia
CLAMP UNIT
DISASSEMBLY
1. Clamp Unit
REMOVAL
1) Turn OFF the machine power, disconnect the power cord from the machine and remove the Rear
cover.
2) Unplug the wire harness connectors of the Clamp motor and Clamp sensor.
3) Remove the mounting screws of the Clamp unit and remove the unit. (M3x6 screws; 3 pcs)
Precaution in Assembly
1) Match the positioning hole against the positioning pin in attaching the Clamp unit back on the
machine.
Mounting screw
Clamp motor
Mounting screw
Clamp sensor
Mounting screw
Apply grease.
10
8
6
16
15
1
5
4
3
2
Print drum
14
A
14
13
11
12
[9-4]
9-4 ]
Imagetec Solutions Australia
CLAMP UNIT
2. Clamp Motor
REMOVAL
1) Turn OFF the machine power, disconnect the power cord from the machineand remove following
parts.
Rear cover
Clamp unit (M3x6 screws; 3 pcs)
2) Remove E-ring from the Clamp gear and detach the gear.
3) Detach the Clamp motor.
Precaution in Assembly
1) When mounting the Clamp gear back on the Clamp unit, make sure that both the Clamp open
arm and Master release arm are in fully raised position.
Clamp motor
Mounting screw
[9-]
9-5 ]
Imagetec Solutions Australia
CLAMP UNIT
3. Clamp Sensor
REMOVAL
1) Turn OFF the machine power, disconnect the power cord from the machinand remove following
parts.
Rear cover
Clamp unit (M3x6 screws; 3 pcs)
2) Remove E-ring from the Clamp gear and detach the gear.
3) Rotate the Clamp cam and move the actuator plate out from the Clamp sensor.
4) Detach the Clamp sensor.
Precaution in Assembly
1) When mounting the Clamp gear back on the Clamp unit, make sure that both the Clamp open
arm and Master release arm are in fully raised position.
Clamp cam
Clamp sensor
[9-6]
9-6 ]
Imagetec Solutions Australia
CHAPTER
10:
CONTENTS
1. Theory of Operation...................................................................................10-3
1. Master Removal Unit Mechanism........................................................10-3
2. Master on the Drum (before master removal) Check Mechanism....... 10-4
3. Master Removal Mechanism...............................................................10-5
4. Master Disposal Box Set Mechanism..................................................10-6
2. Removal and Assembly.............................................................................10-7
1. Master Removal Unit...........................................................................10-7
2. Master Removal Motor Assembly........................................................10-8
3. Master Removal Sensor......................................................................10-9
4. Disposal Box Set Sensor ..................................................................10-10
5. Master Removal Hook.......................................................................10-11
6. Vertical Transport Roller (Upper).......................................................10-12
7. Vertical Transport Roller (Lower).......................................................10-12
[-]
10-1 ]
MEMO
[-]
10-2 ]
1. Theory of Operation
1. Master Removal Unit Mechanism
>
>
>
The Master removal unit removes the master on the drum each time the master making operation is
made.
The Master removal hooks guide the removed master towards the Master disposal box.
The Transportation roller upper and lower are engaged via gears. And rotation of the transportation
roller upper and lower is made by the Mater removal motor.
[-]
10-3 ]
Master Sensor
Master sensor checks the presence of the Master on the drum when the Start button is pressed for
confidential master making or normal master making.
The sensor looks for the presence of the Master on the drum when the drum angle is at 107 degrees
from the A-position, where the black colored Light absorber strip is on the drum.
If the machine already knows the presence of the Master on the drum from the earlier machine
operations, this Master checking movement is skipped.
Master sensor
Master
Print drum
[-4]
10-4 ]
[-]
10-5 ]
Metal leg
[-6]
10-6 ]
Connector
Screw
Screw
Screw
Screw
[-7]
10-7 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Rear cover.
Disconnect the Connector of the Master removal motor.
Remove two mounting screws of the Master removal motor assembly and remove the motor
assembly from the machine.
Precaution in Assembly
> Match the half-pierced section when mounting the motor assembly back on the machine.
[-]
10-8 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Master removal unit cover and Master disposal box.
Slide the Master removal unit from the machine.
Disconnect the Connector of the Master removal sensor.
Remove the mounting screw of the Master removal sensor bracket and remove the bracket.
Remove the sensor from the bracket.
Precaution in Assembly
> Match the half-pierced section of the Master removal sensor bracket with its counter part.
Screw
Connector
Sensor bracket
[-9]
10-9 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Master removal unit cover.
Remove the Master removal guide lower (3 screws).
Disconnect the Connector of the Disposal box set sensor.
Remove the two mounting screws of the Disposal box set sensor bracket and remove the bracket.
Remove the sensor from the bracket.
Precaution in Assembly
> Match the half-pierced section of the Disposal box set sensor bracket with its counter part.
Connector
[-]
10-10 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove Master removal unit.
Remove the Master removal guide lower.
Gently disengage the Master removal hooks from the Master removal guide lower.
Precaution in Assembly
> Do not apply unnecessary force to the Master removal hooks to avoid any damage on the hooks.
[-]
10-11 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Master disposal box.
Remove the Master removal unit.
Remove the Master removal sensor.
Remove the Master removal guide lower.
Remove the Master removal guide upper.
Remove E-rings from both ends of the Vertical transport roller (Upper) and remove the Bushing.
Remove the Vertical transport roller (Upper).
[-]
10-12 ]
CHAPTER
11:
CONTENTS
1. Theory of Operation...................................................................................11-3
1. Original Loading Mechanism...............................................................11-3
2. Original Scanning Mechanism.............................................................11-4
2. Removal and Assembly.............................................................................11-5
1. Image Scanner Unit.............................................................................11-5
2. Original IN Sensor................................................................................11-6
3. Pickup Roller........................................................................................11-7
4. Eject Roller Upper................................................................................11-7
5. Document Feeder Hook.......................................................................11-7
6. Load Roller...........................................................................................11-8
7. Eject Roller Lower................................................................................11-8
8. Read Pulse Motor..................................................................................11-9
[-]
11-1 ]
MEMO
[-]
11-2 ]
1. Theory of Operation
1. Original Loading Mechanism
An original placed on the Original rack Is automatically fed when the master making process is started.
1. Shading Compensation
> When the Original IN sensor detects the original, the LED of the Image scanner turns ON and the
shading compensation takes place.
2.
>
>
>
Original Loading
After the shading compensation is done, the Read pulse motor Activates to start feeding the original
by rotating the Pickup roller and Load roller.
The original put on the Original rack is fed into between the Image scanner and the white Shading
sheet. Then the original is fed towards the Eject roller upper and lower.
The Eject roller upper and lower ejects the original out.
Load roller
Originl feed tray
Eject roller lower
Original IN sensor
[-]
11-3 ]
2.
>
>
Original IN sensor
After the tailing edge of the Original clears out from the Original IN sensor, the Read/Write start signal
and the Image scanner LED are turned OFF to stop the image scanning.
The Read pulse motor stops after the original scanning movement ends.
Image scanner
Original IN sensor
[-4]
11-4 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Master making unit from the machine. (Refer to the next chapter.)
From the front of the Master making unit, remove two gears. (See the photograph below.)
Remove one mounting screw from the front and two mounting screws from the back of the unit.
Caution:
The Image scanner is to be taken off with the brackets attached. Do not remove the brackets, as they
are factory adjusted in position at the Factory.
Disconnect the Connector and remove the Image scanner unit.
Master making unit
Two gears to remove
Connector
[-]
11-5 ]
2. Original IN Sensor
1.
2.
3.
4.
Turn OFF the machine power and disconnect the poer cord from the machine.
Remove the Master making unit cover.
Remove the mounting screw of the Original IN sensor.
Disconnect the connector of the Original IN sensor and remove the sensor.
Connector
Original IN sensor
Screw
[-6]
11-6 ]
3. Pickup Roller
1. Remove the Document feeder from the Master making unit.
2. Remove the Document feeder top cover.
3. Remove the Pick up roller spring plate and then remove the Pick up roller.
Pickup roller
Ejection roller
Hook spring
[-7]
11-7 ]
6. Load Roller
1.
2.
3.
4.
5.
6.
7.
Turn OFF the machine power and disconnect power cord from the machine.
Remove the document feeder.
Remove the Master making unit from the machine. (Refer to the next Chapter.)
Remove two gears from the front of the Master making unit. (E-rings)
Remove the Gear from the Load roller shaft in the front of the Master making unit. (E-ring)
Remove Bushing from the Load roller shaft in the rear of the Master making unit. (E-ring)
Remove the Load roller.
Eject roller
Watch out for the Pin
Load roller
< FRONT OF THE MASTER MAKING UNIT >
Bushings to remove on the Load roller and Eject roller.
Load roller
Eject roller
[-]
11-8 ]
Turn OFF the machine power and disconnect power cord from the machine.
Remove the document feeder.
Remove the Master making unit from the machine. (Refer to the next Chapter.)
Disconnect the connector of the Read pulse motor.
Remove two mounting screws of the Read pulse motor and remove the motor.
Precaution in Assembly
> Connector of the Read pulse motor should face to the Image scanner side when install the motor.
Connector
Screws
[-9]
11-9 ]
MEMO
[-]
11-10 ]
CHAPTER
12:
CUTTER SECTION
CUTTER SECTION
CONTENTS
1. Theory of Operation...................................................................................12-3
1. Cutter Home Positioning Mechanism...................................................12-3
2. Cutting Mechanism..............................................................................12-4
2. Removal and Assembly.............................................................................12-5
1. Cutter Unit............................................................................................12-5
[-]
12-1 ]
CUTTER SECTION
MEMO
[-]
12-2 ]
CUTTER SECTION
1. Theory of Operation
1. Cutter Home Positioning Mechanism
1.
>
>
2.
>
>
Home Position
The Home position of the Cutter is where the Home position switch is detected.
If the Home positioning switch is not detected, the Cutter motor activates and rotates the Cutter gear
until the Home position switch becomes detected.
Cutter unit
Cutter
Cutter gear
Cutter motor
[-]
12-3 ]
CUTTER SECTION
2. Cutting Mechanism
1. Master Cutting
> Cutter motor activates and cuts the master each time the master loading is made on the Drum.
2.
>
>
>
Cutter Motor
As the Cutter motor activates, it rotates the Cutter gear and the housing of the Cutter presses against
the actuator of the End position switch.
Then the Cutter motor activates again and return to the Home position switch.
The Cutter motor then stops at the Home position switch and the cutting motion ends.
Cutter unit
Cutter
[-4]
12-4 ]
Cutter gear
Cutter motor
CUTTER SECTION
Turn OFF the machine power and disconnect power cord from the machine.
Remove the Front cover.
remove the Print drum from the machine.
Open the Master making unit.
Disconnect the Connector of the Cutter unit.
Remove the mounting screws of the Cutter unit and remove the unit.
Precaution in Assembly
> Match the half-pierced sections of the Cutter unit with its counter part.
Connector
Cutter unit
Screw
[-]
12-5 ]
CUTTER SECTION
MEMO
[-6]
12-6 ]
CHAPTER
13:
CONTENTS
1. Theory of Operation...................................................................................13-3
1. Master Making.....................................................................................13-3
2. TPH Positioning...................................................................................13-4
3. Thermal Power Safety Switches..........................................................13-5
2. Removal and Assembly.............................................................................13-7
1. Write Roller..........................................................................................13-7
2. Thermal Print Head (TPH)...................................................................13-8
3. TPH Position Sensor............................................................................13-9
3. Adjustment................................................................................................13-11
1. Thermal Power of Thermal Print Head..............................................13-11
[-]
13-1 ]
MEMO
[-]
13-2 ]
1. Theory of Operation
1. Master Making
When the START key is pressed for master making, the Drum rotates to remove the master on the Drum.
At the same time the TPH-Control signal is turned ON to supply heating power to the Thermal print head.
1.
>
>
>
2.
>
>
>
>
Write roller
Master roll
[-]
13-3 ]
2. TPH Positioning
The TPH moves down and up when master feeding is necessary or the master making process is ended.
When the TPH unit is at the home position, the TPH unit is away from the Write roller.
When the Master making starts, the TPH unit [C] is lowered by the Write pulse motor.
Rotation of the Write pulse motor is transferred to the TPH position cam via gears on the Master making
unit.
1. TPH position sensor
> The TPH position sensor [A] checks whether if the TPH stays upper or not.
> If the light path of the TPH position sensor is changed from "unblocked" to "blocked", the machine
assumes that the TPH is at upper position. (The TPH is away from the Write roller)
> If the light path of the TPH position sensor is changed from "blocked" to "unblocked", the machine
assumes that the TPH is at lower position. (The TPH is touching the Write roller)
TPH positioning sensor
Spring force
Sensor blocked
Sensor opened
Space
TPH unit
Write roller
[-4]
13-4 ]
Touching
Safety Switches
The actuators of all four safety switches must be pressed in order to feed electrical power to the TPH
unit.
These four switches also acts as Main motor safety switches.
[-]
13-5 ]
MEMO
[-6]
13-6 ]
Turn OFF the machine power and disconnect the power cord from the machine..
Open the Master making unit and remove the Master roll.
On the front side, remove the plastic Lock ring from the Whit roller shaft and remove the collar and
the metal from the shaft.
Remove the Write roller assembly by lifting the assembly from the machine.
Precaution in Assembly
> Match the flat part of the Bushing on the rear side of the roller shaft to keep clear of the flat-cut
surface on the Bushing. (Refer to the photographs below)
Write roller
Lock ring
Bushing
Flat-cut area on the Bushing
REAR
Collar
Collar
Bushing
FRONT
[-7]
13-7 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Open the Master making unit.
Disconnect two TPH connectors from the TPH assembly.
Remove the screw of the Ground wire.
Remove the two TPH assembly mounting screws.
Slide the TPH assembly up to release from the Master making unit.
Remove two mounting screws from the TPH mounting plate from the TPH .
TPH assembly
TPH connector
Ground wire
TPH connector
TPH mounting plate
TPH assembly
[-]
13-8 ]
TPH
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Master making unit cover.
Remove the connector of the TPH position sensor.
Remove the TPH position sensor from the Master making unit by gently unhooking the sensor legs
from the Master making unit.
Connector
[-9]
13-9 ]
MEMO
[-]
13-10 ]
3. Adjustment
1. Thermal Power of Thermal Print Head
Thermal power must be adjusted each time the Thermal print head is replaced.
1.
2.
3.
4.
[-]
13-11 ]
MEMO
[-]
13-12 ]
CHAPTER
14:
CONTENTS
1. Theory of Operation...................................................................................14-3
1. Master Making Unit Set Mechanism....................................................14-3
2. Master Positioning Mechanism............................................................14-4
3. Master Feeding Mechanism.................................................................14-5
4. Master Loading on the Drum Mechanism............................................14-6
5. Master Advance after Master Cutting..................................................14-7
2. Removal and Assembly.............................................................................14-9
1. Master Making Unit..............................................................................14-9
2. Master Making Unit Safety Switch.....................................................14-12
3. Write Pulse Motor..............................................................................14-13
4. Master Positioning Sensor.................................................................14-14
5. Master Loading Solenoid...................................................................14-15
6. Master End Sensor............................................................................14-16
[4-]
14-1 ]
MEMO
[4-]
14-2 ]
1. Theory of Operation
1. Master Making Unit Set Mechanism
1.
>
[4-]
14-3 ]
Master Positioning
The leading edge of the master material rests against the Master tension plate just after the master
loading.
As the START button is pressed for normal master making or confidential master making, the Master
loading solenoid activates to release the Mater tension plate from master and the Write pulse motor
activates and rotates the Write roller to feed the master material.
When the Master positioning sensor detects the leading edge of the master, the Master loading
solenoid and the Write pulse motor turn OFF and completes the master positioning movement.
[4-4]
14-4 ]
1.
>
>
Clamp plate
Master material
[4-]
14-5 ]
2.
>
>
Master cutting
The Cutter unit cuts the master when maximum master length is made.
The Main motor keeps rotating and loads the remaining length of master on the Drum while making
one proof print.
Clamp plate
TPH
Master Loading Movement
Print drum
Position-A
Write roller
Master sensor
107 degrees
1.
2.
[4-6]
14-6 ]
TPH
Write roller
Master roll
[4-7]
14-7 ]
MEMO
[4-]
14-8 ]
[4-9]
14-9 ]
[4-]
14-10 ]
Cutter unit
[4-]
14-11 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Master making unit.
Disconnect the Connector of the Master making unit safety switch.
Remove two mounting screws of the Master making unit safety switch and remove the switch.
[4-]
14-12 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove Master making unit.
Disconnect the Connector of the Write pulse motor.
Remove two mounting screws of the Write pulse motor and remove the motor.
Precaution in Assembly
> Keep little backlash between the motor gear and the drive gear when installing the motor on the
Master making unit.
Drive gear
Motor gear
[4-]
14-13 ]
Connector
Mounting screw
[4-4]
14-14 ]
Turn OFF the machine power and disconnect the power cord from the machine.
Remove the Master making unit.
Disconnect the Connector of the Master loading solenoid.
Remove two mounting screws of the Master loading solenoid and remove the solenoid from the
Master making unit.
[4-]
14-15 ]
Precaution in Assembly
> Do not damage the hooks of the Master end sensor when installing the sensor on the sensor
bracket on the machine.
Master making unit
Hooks
[4-6]
14-16 ]
Hooks
[4-7]
14-17 ]
MEMO
[4-]
14-18 ]
CHAPTER
15:
PANEL MESSAGE
PANEL MESSAGE
CONTENTS
[-]
15-1 ]
PANEL MESSAGE
[-]
15-2 ]
PANEL MESSAGE
Error Point
P01-520
[-]
15-3 ]
PANEL MESSAGE
6
5
2
7
LED
Area
1
2
3
4
5
6
7
8
9
Scanning Area
Master Removal
Master Making
Job Separator
Paper Feed
Paper Ejection
6
5
7
1
: Solid Light
: Blinking Light
[-4]
15-4 ]
PANEL MESSAGE
3. Error Type
[ERROR TYPE]
The panel messages starts with Error Type
INFORMATION
TYPE SYMBOL
DESCRIPTION
P-xx
A-xx
Jam Error
Jam errors which occurs during the machine usage, and these can
be corrected by the operator by following the troubleshooting steps
given on the Users Guide.
b-xx
Option Error
Error created from the optional units connected to the main unit,
such as jam errors and connection errors.
Checking the connections, turning the power ON again or pressing
the RESET key may correct the problem.
Consumable Error
Master roll is empty.
c-xx
Consumable Error
Master disposal box is full.
Consumable Error
Ink bottle is empty.
Consumable Error
No paper on paper feed tray.
d-xx
Set Error
One or more of the set switch or sensor is in OFF state.
E-xx
Warning
Another type of serviceman call error, in which if the machine is kept
used in this state may cause a problem.
F-xx
Warning
The machine is not in a fit state to operate the job requested.
Hxxx
Jxx
Jam Error
The A-07, A-08, A-09 and A-10 jam error displays are replaced by
Jxx display. When Jxx display is made, it could be only one of these
four A-xx error or mixture of these four errors.
[-]
15-5 ]
PANEL MESSAGE
4. Error Point
[ERROR POINT]
The error type is followed by Error Point
ERROR
POINT
UNIT
0 xx
1xx
2xx
Master Making
3xx
Master Removal
4xx
5xx
Print Drum
6xx
7xx
[-6]
15-6 ]
PANEL MESSAGE
Error Description
Bit
3
2
1
0
Corresponding
Value
8
4
2
1
For above four jam errors, even though only one error occurs, the error type code of Axx is
substited by Jxx error code.
Example:
When A09 (Paper ejection jam) occurs, the error type code displayed is J02.
When A07 (Paper feed jam) occurs, the error type code displayed is J08.
The LED lamp to indicate the place of the problem is determined by the error type number.
Example:
When A09 (Paper ejection) jam occurs, the LED lamp lit is number 9 on the operation panel.
The error type code displayed is J02 (Paper ejection error).
6
5
7
1
: Solid Light
: Blinking Light
When paper feed jam (A07) and paper jam on the drum (A08) errors occur simultaneously,
No.2 and No.8 LEDs light in solid and LED in front of the Jam symbol mark blinks.
On the panel display, J12 is displayed.
6
5
7
1
: Solid Light
: Blinking Light
[-7]
15-7 ]
PANEL MESSAGE
Error Type
Description
To reset
display
Error Point
520
Main encoder sensor does not go ON/OFF within 10 milliseconds after the main motor activates.
521
Position-A sensor status does not change even after main motor activates for 1 drum rotation.
536
537
582
Print drum angle cannot be detected even though the Position-A sensor detected the Print drum 3
times.
Error Type
501
Clamp sensor does not go OFF within 1 second from the time the clamp motor operates.
502
Clamp sensor does not go ON within 2.5 seconds from the time the clamp motor operates.
504
At the start of Clamp plate open action, the detection of clamp sensors is OFF.
506
At the start of print drum Position-A compensation movement, the detection of clampsensor is
OFF.
At the start of Clamp unit Home-positioning movement, the detection of clamp sensor is ON.
507
508
505
[-]
15-8 ]
PANEL MESSAGE
Error Type
513
Error Type
Description
The overflow sensor is ON for a set number of times in succession during the 10-millisecond
interval overflow-sensor check.
To reset
display
Error Point
300
Error Type
Error Conditions
221
The cutter HP switch and cutter stop position switch are both ON at the same time.
231
Cutter HP switch does not go OFF within 500 milliseconds after the cutter operation started from
the HP position.
232
Cutter stop position switch does not go ON even after 2 seconds after the cutting movement
started.
233
Cutter stop position switch does not go OFF even after 500 milliseconds after the cutter HP
movement started.
234
Cutter HP switch does not go ON even after 2 seconds from the cutter HP movement started.
[-9]
15-9 ]
PANEL MESSAGE
Error Type
125
126
Error Type
Error Type
Description
To reset
display
Error Point
539
Error Type
Description
To reset
Error Conditions
[-]
15-10 ]
PANEL MESSAGE
Error Type
Error Conditions
939
940
941
942
943
944
PC card ID error.
945
946
990
991
992
993
994
Error Type
[-]
15-11 ]
PANEL MESSAGE
Error Type
Error Conditions
Communication error between neoROSA and MCTL PCB (04) - on MCTL PCB side.
Communication error between neoROSA and MCTL PCB (05) - on MCTL PCB side.
Communication error between neoROSA and MCTL PCB (06) - on MCTL PCB side.
Communication error between neoROSA and MCTL PCB (07) - on MCTL PCB side.
Communication error between neoROSA and MCTL PCB (08) - on MCTL PCB side.
Communication error between neoROSA and MCTL PCB (09) - on MCTL PCB side.
Communication error between neoROSA and MCTL PCB (10) - on neoROSA side.
Communication error between neoROSA and MCTL PCB (11) - on neoROSA side.
Communication error between neoROSA and MCTL PCB (12) - on neoROSA side.
Communication error between neoROSA and MCTL PCB (13) - on neoROSA side.
Communication error between neoROSA and MCTL PCB (14) - on neoROSA side.
Communication error between neoROSA and MCTL PCB (15) - on neoROSA side.
Communication error between neoROSA and MCTL PCB (16) - on neoROSA side.
Communication error between neoROSA and MCTL PCB (17) - on neoROSA side.
Communication error between neoROSA and MCTL PCB (18) - on neoROSA side.
Communication error between neoROSA and MCTL PCB (19) - on neoROSA side.
Communication error between neoROSA and MCTL PCB (20) - on neoROSA side.
Machine serial number information does not match between the backup data and EEPROM.
Defective image PCB (memory check error on the image processing IC).
Scanner adjustment error (IFLG does not change within set time).
Scanner adjustment error (IMFLGdoes not change within set time).
Timeout error on master transfer during master-making (related to Write pulse motor).
USB controller chip does not reply. May need to replace neoROSA.
Communication error between MCTL PCB and RF PCB. (on RF PCB side)
Communication error between MCTL PCB and RF PCB. (on MCTL PCB side)
Serial number not set.
EEPROM version down.
24V-A does not go ON. (possibility of 24v fuse broken on A-series)
24V-B does not go ON. (possibility of 24v fuse broken on B-series)
42V-A does not go OFF.
42V-B does not go OFF.
Check-sum error on neoROSA PCB flash memory.
Write error on the neoROSA PCB flash memory.
Read error on the neoROSA PCB flash memory.
Flash memory on neoROSA PCB not used.
Error Type
[-]
15-12 ]
PANEL MESSAGE
Error Type
258
Master-positioning sensor does not go ON even after the write pulse motor is activated during the
master-positioning, master-cut, or master-loading operation.
Master end tape detected twice in a row.
Error Type
Error Type
Error Type
[-]
15-13 ]
PANEL MESSAGE
Error Conditions
Paper-ejection sensor was OFF when the paper should have arrived. (Paper misfeed).
Error Conditions
Paper-ejection sensor was ON when the paper should have left the paper-ejection sensor.
Error Conditions
103
107
Error Type
Pull out the print cylinder (drum), remove the master around it and insert it back.
display
Error Point
Error Conditions
525
Waiting for the master to be removed from the print cylinder (drum).
Error Type
Open the Master making unit, remove the master and close the master making unit.
Error Conditions
205
Master positioning sensor is ON after master cutting and Print drum returns back to Position-A.
(Master cut error)
209
Cutter HP switch is OFF when master making started or when the master material was set.
Error Type
206
218
Open the Master making unit, re-insert the master material into the master making unit.
Error Conditions
When the Master making unit safety switch turned from OFF to ON, the Master position sensor was
ON. (Master setting error)
Requesting for the leading edge of the master material to be set in the master making unit.
[-4]
15-14 ]
PANEL MESSAGE
Error Type
Error Type
Error Type
Remove master disposal box from the machine, throw away the disposed master from the disposal
display
box and return the disposal box in the machine after an interval of over 5 seconds.
Error Point
311
Error Conditions
The master disposal software counter counted maximum. (Master disposal box full by the software
count.)
[-]
15-15 ]
PANEL MESSAGE
Error Type
Error Type
Error Conditions
Error Type
Error Type
Error Conditions
Error Type
[-6]
15-16 ]
PANEL MESSAGE
Error Type
Error Type
Error Type
Description
To reset
Error Type
Description
To reset
display
Error Point
Error Conditions
529
Print drum set sensor stays OFF even after the print drum set signal and print drum safety switch
went ON.
530
Either the print drum set signal or print drum safety switch is OFF while the other is ON.
(Print drum not fully inserted in position.)
Error Type
238
239
241
256
[-7]
15-17 ]
PANEL MESSAGE
Error Type
Description
To reset
display
Error Point
046
Error Type
Error Type
[-]
15-18 ]
PANEL MESSAGE
Message
Description
To reset
display
Message
Description
To reset
display
Following three (3) Error Types are backed up in memory and these error messages cannot be reset by turning
OFF the power.
The cause for the message must be solved to reset the error display.
Error Type
Error Description
C01
C02
C03
[-9]
15-19 ]
PANEL MESSAGE
MEMO
[-]
15-20 ]
CHAPTER
16:
TEST MODE
TEST MODE
CONTENTS
1. Operating Method......................................................................................................16-3
[ 16-1 ]
Imagetec Solutions Australia
TEST MODE
MEMO
KZ (Revision 1.2)
[ 16-2 ]
Imagetec Solutions Australia
TEST MODE
1. Operating Method
1) Launching the Normal Test Mode
To start Test Mode, switch ON the machine power while simultaneously pressing the left and right keys of
the vertical print positioning.
The firmware version number is displayed when the Test Mode is launched.
Press the Stop Key or Cancel Key to go into standby mode.
From the standby mode, enter the required test mode number and press Start Key to activate.
Press the Stop Key or Cancel Key to return back to the standby mode.
Enter next desired test mode number to continue using the test mode, or press the Reset Key for one
second to escape out from the Test Mode.
The Reset Key must be pressed (for 1 second) to escape out from the Test Mode only when the machine
is in the standby mode of the test mode.
[ 16-3 ]
Imagetec Solutions Australia
KZ (Revision 1.2)
TEST MODE
0094
0095
KZ (Revision 1.2)
[ 16-4 ]
Imagetec Solutions Australia
TEST MODE
No.
Data clear
Clearing Jam Status Data
Details
This test mode can be used to temporary clear error display. For acutal cor-
0110
rection of the problem, the cause for the display should be corrected.
Consumable error displays cannot be cleared.
clear for test modes on the ma- The initializing is effective after rebooting the machine.
The protected area test modes stay unchanged.
chine.
No.
0120
Data check
The Test Mode No. and the setting are displayed alterately. This does not
confirmation
0130
display
0131 System program version display Displays ROSA program version. Example: Displays "0101" for Ver.1.01
The digits from ten thousand and digits thousand and under will display
alternately.
Beep sound will be heard when digits ten thousand and over are displayed.
[ 16-5 ]
Imagetec Solutions Australia
KZ (Revision 1.2)
TEST MODE
No.
Data setting
Print Quantity Selection (ref: Test Mode No.0090)
Selects the print quantity for the continuous master-making & printing
Description
0147
operation by Test Mode No. 0090.
Selectable range : 1 to 100 (1 to 100 prints)
Setting
Default : 3 (3 prints)
Master-Making Type Selection (ref: Test Mode No.0090)
Selects the type of image for the continuous master-making & printing
Description
operation by Test Mode No. 0090.
Selectable range : 0 to 6
0 : Image by Test Mode No.0080.
1 : Image by Test Mode No.0081.
0148
0151
0155
and turned back ON, the setting automatically changes back to the default
setting of Counter Active [1].
Setting
Master Making Action Standby
Description
0162
Setting
KZ (Revision 1.2)
After selecting the Master-making mode, the machine resets itself from
the master-making mode after the selected time frame has passed.
Range :
0 to 180 seconds (0 = no standby)
Unit :
1 = 1 second
Default :
[ 16-6 ]
Imagetec Solutions Australia
TEST MODE
Detection status
Detecting (original present)
Remarks
Switches ON/OFF scanner lamp
No.
Data setting
Line-Copy Slice Level Adjustment
Description
Sets the slice level for line mode.
Range :
- 8 to + 8 (Larger valudes for lighter print.)
0340
Setting
Unit :
1
Default :
0
Auto Base Control (ABC) Slice Level Adjustment
Description Sets the slice level for ABC.
Range :
- 8 to + 8 (Larger valudes for lighter print.)
0341
Setting
Unit :
1
Default :
0
Shading Compensation Averaging
Range :
0 to +16 (0 = One type shading compensation only)
0342
Description Unit :
Default :
8 (Averages out values from 9 times shading compensation).
Auto Base Control (ABC) Slice Level Adjustment for Reduction Size Master-Making.
This test mode setting becomes effective for master-making in Line Mode, Auto Scanning
Description
Density and Reduced Reproduction Size.
The purpose of this test mode is to prevent thin lines from disappearing when the
0343
Range :
- 8 to + 8
Unit :
Default :
-5
[ 16-7 ]
Imagetec Solutions Australia
KZ (Revision 1.2)
TEST MODE
Edge Emphasis Threshold Offset for Line-Mode printing (for master-making density setting 1 to 2)
0364
Unit :
Default :
Edge Emphasis Threshold Offset for Line-Mode printing (for master-making density setting 3 to 5)
0365
Unit :
Default :
Edge Emphasis Threshold Offset for Line-Mode printing (for master-making in Duo mode)
Description Selects the matrix forming the halftone-curve base
0366
Setting
Range :
0 to 7
Unit :
Default :
Edge Emphasis Threshold Offset for Line-Mode printing (for master-making in Pencil original mode)
0367
Unit :
Default :
2
ABC Edge Emphasis Filter when ABC is activated.
Selects the matrix forming the halftone-curve filter when ABC is activated (Line Mode, Density
Description
at auto).
0369
Setting
Range :
0 to 255
Unit :
Default :
205
ABC Edge Emphasis Filter when ABC is activated (under the border-line)
Description
0370
Setting
Selects the matrix forming the halftone-curve filter when ABC is activated (Line Mode, Density
at auto) for when the border-line is under the setting made by Test Mode No.0369.
Range :
0 to 7
Unit :
Default :
3
ABC Edge Emphasis Filter when ABC is activated (over the border-line)
Description
0371
Setting
Selects the matrix forming the halftone-curve filter when ABC is activated (Line Mode, Density
at auto) for when the border-line is over the setting made by Test Mode No.0369.
Range :
0 to 7
Unit :
Default :
5
ABC Slice Level (super-black)
Description Sets the slice level when super-black histogram is produced in prescanning.
0372
Range :
Setting
KZ (Revision 1.2)
-16 to +16
Unit :
Default :
[ 16-8 ]
Imagetec Solutions Australia
TEST MODE
0380
Setting
Unit :
5 (0.5mm)
Default :
0 (0mm)
0381
Setting
Unit :
1 (0.1mm)
Default:
0 (0mm)
Adjusts the original scanning speed on the AF unit (Adjust the speed of AF Read Pulse
Motor)
Range :
Setting
Unit :
1 (0.1%)
Default :
0 (0%)
Description
(The dotted line is added only when the original is scanned on the AF unit.)
The setting returns back automatically to the default setting when the machine power is
turned OFF.
Setting
0387
Setting
0:
Active
1: Inactive (default)
[ 16-9 ]
Imagetec Solutions Australia
KZ (Revision 1.2)
TEST MODE
Detection status
0424 Master-disposal box set sensor ON (master-disposal box is set) / OFF (master-dispoasal box not set)
No.
0462
0463
0470
Motor, solenoid
Write pulse motor in feed
direction
Write pulse motor in return
direction
Master removal motor in feed
direction
No.
0480
0481
0482
0487
Remarks
Rotates in master feeding direction (clockwise direction)
Rotates in master returning direction (counter-clockwise)
Rotates in the direction to feed the removed master towards the master
disposal box (clockwise direction)
Unit check
0494
[This test mode is for checking the motor as one independent part. Disconnect the motor from the cutter unit
before activation.]
Rotates the cutter motor in the cut direction (maximum 10 seconds)
Master disposal software count clear
0510
Resets the master-disposal software count to 0.
KZ (Revision 1.2)
[ 16-10 ]
Imagetec Solutions Australia
TEST MODE
No.
Data check
Details
0521 TPH thermistor temperature data Displays the temperature of the TPH thermistor in [degrees Celsius]
Displays the voltage applied to the TPH when the power to the TPH is
switched ON. (The display is voltage x 100. Example: 10V=1000.)
0528 Master disposal software count Displays the master disposal software count.
0529 Master remaining amout display
No.
Data setting
Master Leading-Edge Position Adjust
0540
Adjusts return amount of the master material from the Master positioning sensor after the master
Description is set or master cutting operation is made. The pulse is counted from the time the Master
positioning sensor no longer detect the master leading edge.
Range :
Setting
Unit :
Default :
Adjusts the master-clamp amount under the clamp plate during master loading onto the drum.
(This adjustment affects the master-write-start-position)
Range :
0543
Setting
Unit :
Default :
Range :
Unit :
Default :
[ 16-11 ]
Imagetec Solutions Australia
KZ (Revision 1.2)
TEST MODE
TPH temperature to be above this parameter, the machine displays a message and stops the
master-making job.
Turning the machine power OFF and then ON will reset the error message.
0552
Range :
Setting
Unit :
1 (1 degrees Celcius)
Default :
Thermal Print Head (TPH) over-heat temperature detection Enable or Disable selection.
Description Selection of enabling or disabling the TPH over-heat detection by Test Mode No.0552.
0553
Range :
0 or 1
0 = Disable
Setting
Default :
1=Enable
1 (Enable)
Range :
-50 to 0
Unit :
Default :
1 (1 degrees)
0 (0 degrees)Msterdsfsfssdfsfsfsssfsf
KZ (Revision 1.2)
Range :
10 to 30
Unit :
Default :
[ 16-12 ]
Imagetec Solutions Australia
TEST MODE
Sensors, switches
Paper-ejection sensor
Paper feed Safety Switch
Master removal Safty Switch
Motor solenoid system
Suction fan
Separation fan
Detection status
Sensor light blocked (paper detected)
ON (switch activated) / OFF (switch deactivated).
ON (switch activated) / OFF (switch deactivated).
Remarks
Activates the fan.
Activates the fan.
Unit check
Paper feed path area Fan ON action.
0680
Pressing the START key runs the Separtation Fan and Suction Fan. Press STOP key to deactivate.
First Paper-feed clutch ON/OFF action
0688
Presses START key to turn ON the clutch. The clutch automatically switches off after 10 seconds.
Second Paper-feed clutch ON/OFF action
0691
Presses START key to turn ON the clutch. The clutch automatically switches off after 10 seconds.
No.
Data setting
First Paper-feed-clutch ON angle (speed 1)
Description
Adjusts the drum angle timing for activating the paper-feed clutch.
Range :
0741
Setting
Unit :
Default :
First Paper-feed-clutch OFF angle (speed 1)
Description
Adjusts the drum angle timing for deactivating the paper-feed clutch.
Range :
0742
Setting
Unit :
Default :
First Paper-feed-clutch ON angle (speed 2)
Description
Adjusts the drum angle timing for activating the paper-feed clutch.
Range :
0744
Setting
Unit :
Default :
Adjusts the drum angle timing for deactivating the paper-feed clutch.
Range :
0745
Setting
Unit :
Default :
Adjusts the drum angle timing for activating the paper-feed clutch.
Range :
Setting
Unit :
Default :
Paper feed IN jam detection angle. (Paper feed jam at Paper sensor)
0751
Description
Setting
Adjusts the drum angle timing for detecting the paper feed jam by paper
sensor. (Paper IN)
Range :
Unit :
Default :
[ 16-13 ]
Imagetec Solutions Australia
KZ (Revision 1.2)
TEST MODE
0752
Paper feed OUT jam detection angle. (Paper feed jam at Paper sensor)
Adjusts the drum angle timing for detecting the paper feed jam by paper
Description
sensor. (Paper OUT)
Setting
Range :
Unit :
Default :
0753
Setting
0754
0783
0784
0789
0790
0791
Range :
Unit :
Default :
0778
Adjusts the drum angle timing for detecting the paper feed jam by paper
ejection sensor. (Paper IN)
Range :
Unit :
Default :
0792
Range :
Setting
KZ (Revision 1.2)
Adjusts the drum angle timing for deactivating the paper-feed clutch.
Unit :
Default :
[ 16-14 ]
Imagetec Solutions Australia
TEST MODE
Sensors, switches
Position-A sensor
Main motor FG sensor
Clamp sensor A
Master loading sensor
Ink sensor
Overflow sensor
Ink bottle set switch
Inking motor FG sensor
Drum free rotation SW
Print-drum connection signal
Detection status
Blocked (detection plate detected) Drum is at position-B.
Blocked (detection plate detected)
Blocked (disc detected)
Light reflected (master on the drum)
In contact with ink (ink present )
In contact with ink (ink present )
Switch pressed.
Blocked (encoder disc detected)
Pressed
Connected
Switch ON (drum installed).
Other safety switches must be ON for this check.
Blocked (Drum installed)
Remarks
Print drum rotation at speed of 30rpm.
0884
Make sure to bring the print drum to Position-A by test mode No. 0881 before activating this test mode to
prevent machine damage.
Press START key each time to perform the operations specified below.
Step 1: From clamp plate closed position to clamp open.
Step 2: From Clamp open position to Position-A compensation action.
Step 3: From Position-A compensation action to clamp closed position.
Print drum inking action
0887
Performs the inking operations in following sequence by one press of the START key:
1. Pumps in the ink into print drum while rotating the drum until the Ink Sensor detects Ink,
without pressure roller touching the print drum.
2. Makes a confidential master on the print drum.
3. From the time the ink sensor detects the ink again, the print drum makes 10 rotations
with the Pressure Roller pressing against the print drum.
4. The print drum stops at Position-B.
Print drum ink-drainage action.
0888
Performs the ink drainage from the print drum in following sequence by one press of the START key:
1. Makes TPH test mode image on the master and wraps around the print drum.
2. Printing is started with no inking motion and with the ink sensor deactivated.
3. The printing is continued until the STOP key is pressed.
4. The print drum stops at Position-B.
[ 16-15 ]
Imagetec Solutions Australia
KZ (Revision 1.2)
TEST MODE
Machine Position-B stop. (The position in which the print drum can be removed from the machine.)
0892
0896
0909
Stops the print drum at machine Position-B. (The test mode can be activated with or without print drum
in the machine.)
Rotates and stops the Print drum at a timing 1000ms from the Clamp sensor OFF position.
Data check
Details
Displays the amount of ink left in the ink bottle in percentage (%) [Ink TAG
information]
Displays the inking motor FG count value read from the ink bottle tag. (1
count = 0.1 ml)
Example: For the 12,648 FG count, [ 1 ] is displayed.
Displays the inking motor FG count value read from the ink bottle tag. (1
count = 0.1 ml)
Example: For the 12,648 FG count, [ 2648 ] is displayed.
No.
Data setting
Master loading sensor detection timing adjustment
Description
Adjusts the angle to detect master on the print drum by master loading sensor.
Range :
0940
Setting
Unit :
Default :
0941
Setting
Unit :
Default :
0942
Setting
KZ (Revision 1.2)
Unit :
Default :
[ 16-16 ]
Imagetec Solutions Australia
TEST MODE
Sets the timer for the Replace Ink Bottle message to come out after the Ink sensor stops
Description detecting the ink bead in the Drum.
<When the ink left in the Ink bottle is in large amount , which is set by Test Mode No. 0948>
0943
Setting
Range :
5 to 60
(1 second to 60 seconds)
Unit :
1 (1 second)
Default :
15 (15 seconds)
0944
Setting
Range :
5 to 60
(5 seconds to 60 seconds)
Unit :
1 (1 second)
Default :
50 (50 seconds)
Sets the number of detection times for the overflow sensor to determine that an ink overflow
has occurred in the print drum.
Range :
1 to 200
Unit :
1 (1 time)
Default :
50 (50 times)
Inking time adjustment (In normal printing) - When the ink in the ink bottle is in small amount.
Sets the timer for the Replace Ink Bottle message to come out after the Ink sensor stops
Description detecting the ink bead in the Drum.
<When the ink left in the Ink bottle is in small amount , which is set by Test Mode No. 0948>
0946
Setting
Range :
5 to 60
(1 second to 60 seconds)
Unit :
1 (1 second)
Default :
55 (55 seconds)
Print drum rotation quantity after Ink bottle is removed and inserted back.
Description
0947
Setting
Sets the number of Print drum free rotation after the Ink bottle is removed and inserted
back in the Priint drum.
Range :
0 to 10
(0 rotation to 10 rotations)
Unit :
1 (1 rotation)
Default :
0 (0 rotation)
0948
Setting
Range :
1 to 100
Unit :
1 (1%)
Default :
25 (25%)
(1% to 100%)
< In this default setting, ink remaining under 25% is determined as ink in the Ink bottle as
small amount. Over 25% will be determined as ink in large amount is left in the ink bottle. >
[ 16-17 ]
Imagetec Solutions Australia
KZ (Revision 1.2)
TEST MODE
No.
Data setting
Memory Initialization
1198
1201
Description
Setting
Selecting whether the machine is for Millimeter paper size machine or Inch paper size
machine.
Range :
0 or 1
Default :
1233
Setting
-23 to +23
(-2.3mm to +2.3mm)
1 (0.1mm)
Default :
0 (0mm)
KZ (Revision 1.2)
Range :
1200 to 2200
Unit :
1 (1 ohm)
Default :
[ 16-18 ]
Imagetec Solutions Australia
CHAPTER
17:
ELECTRICAL COMPONENTS
ELECTRICAL COMPONENTS
CONTENTS
1. Sensors................................................................................................17-3
2. Switches...............................................................................................17-4
3. Clutches & Solenoids...........................................................................17-5
4. Motors & Fan.......................................................................................17-6
[7-]
17-1 ]
ELECTRICAL COMPONENTS
MEMO
[7-]
17-2 ]
ELECTRICAL COMPONENTS
1. Sensors
Original IN sensor
Clamp sensor
Master sensor
Position-A sensor
Ink sensor
[7-]
17-3 ]
ELECTRICAL COMPONENTS
2. Switches
[7-4]
17-4 ]
ELECTRICAL COMPONENTS
Timing clutch
[7-]
17-5 ]
ELECTRICAL COMPONENTS
Separation fan
Clamp motor
Suction fan
Main motor
Ink motor
[7-6]
17-6 ]
CHAPTER
18:
WIRING DIAGRAM
WIRING DIAGRAM
CONTENTS
1. Overall Diagram...................................................................................18-3
2. Power Supply.......................................................................................18-4
3. Paper Feed & Paper Ejection..............................................................18-5
4. Print Drum Area...................................................................................18-6
5. Master Making Area.............................................................................18-7
6. Options.................................................................................................18-8
[-]
18-1 ]
WIRING DIAGRAM
MEMO
[-]
18-2 ]
WIRING DIAGRAM
1. Overall Diagram
Paper Feed
&
Ejection
Interlock
Area
Rear I/F
Print Drum
Diagram
Area
Panel
Front/
Master Making
Mechanical
Control
Motor
PCB
Master Making
Area
Drum I/F
Scanner
(CIS)
Options
TPH
NeoROSA
[-]
18-3 ]
WIRING DIAGRAM
2. Power Supply
neoROSA power
RIP power
(not used)
Main motor
Mechanical
Control PCB
Power switch wire harness
Power switch
Not used
Power
Supply
Unit
[-4]
18-4 ]
Print drum
safety switch
Separation unit
safety switch
CT-4P
Interlock wire
harness
CT-3P
CT-3P
CT-4P
CT-4P
CT-4P
Mini CT28P
14P double
CN1-A miniCT-14P GRAY
CN1-B miniCT-14P BLUE
Mechanical
Control
PCB
CT-3P
CT-2P
CT-2P
CT-2P
CT-2P
CT-2P
CT-2P
Master removal
motor
Clamp motor
Paper feed
clutch
Timing clutch
Clamp
sensor
Position-A
sensor
Encoder
sensor
Paper receiving
sensor
Separation
fan
Suction
fan
[-]
18-5 ]
WIRING DIAGRAM
WIRING DIAGRAM
Ink motor FG
Ink motor
Bottle set switch wire harness
Bottle set
switch
Ink sensor wire harness
GND
Overflow SNR
Ink sensor
Thermister
VCC
Ink sensor
Drum set
sensor
Rear wire harness L
RF Tag
Mechanical
Control
PCB
Drum jumper
wire harness
[-6]
18-6 ]
WIRING DIAGRAM
Panel PCB
Cutter Motor
CT-6P
Cutter SW
Scanner
(CIS)
Cutter HP SW
Master Positioning
Sensor
Master End
sensor
Master Making
Solenoid
TPH
Positioning
Sensor
CT-3P
To power supply
wiring diagram
Original IN
Sensor
Master
Sensor
Mechanical
Control
PCB
Master removal
wire harness
Maser Removal
Box Set
Sensor
CT-6P
Maser Removal
Jam
Sensor
Master removal jam sensor wire harness
RF-Tag
TPH
[-7]
18-7 ]
WIRING DIAGRAM
6. Options
Not Used
(15P double)
(15P double)
Not Used
Not Used
Mechanical
Control
PCB
Option power wire harness
To power supply
wiring diagram
[-]
18-8 ]
CHAPTER
19:
OTHER PRECAUTIONS
OTHER PRECAUTIONS
CONTENTS
1. Replacement of PCBs................................................................................19-3
1. Mechanical Control PCB......................................................................19-3
2. NeoROSA PCB (option).......................................................................19-4
2. Firmware Installation..................................................................................19-6
1. Mechanical Control PCB......................................................................19-6
2. NeoROSA PCB (option).......................................................................19-7
(1) Firmware Installation Procedure for the
CHINA destination machine.......................................................19-7
(2) Firmware Installation Procedure for the
machine destinations other than CHINA....................................19-8
[
19-1 ]
OTHER PRECAUTIONS
MEMO
[
19-2 ]
OTHER PRECAUTIONS
1. Replacement of PCBs
1. Mechanical Control PCB
1. Replacement Procedure
CAUTION: Do not turn ON the machine power in normal operation mode until Step-14 given below.
1) Turn OFF the machine power.
2) Remove static electricity from the body before touching the PCB.
3) Remove the Front Cover and Print Drum from the machine.
4) Detach the Mechanical Control PCB from the machine and remove both the EEPROM and
EPROM from the existing PCB.
5) Mount the previously removed EEPROM and EPROM on the new Mechanical Control PCB.
6) Attach the new Mechanical Control PCB on the machine.
7) Turn ON the machine power by going into Test Mode.
8) Activate Test Mode No. 9874 to go into the protected area test mode.
9) Then activate Test Mode No. 1198 [Memory Initialization] to initialize the memory on the
Mechanical Control PCB.
10) Turn OFF the machine power and then turn the machine power back ON by going into Test Mode.
11) Insert the Print Drum back in the machine and activate Test Mode No. 0883 [Clamp Home
Position Action] to reset the clamp unit to the home position.
12) Turn OFF the machine power.
13) Mount the Front Cover and Print Drum Lock Mechanism back on the machine.
14) Turn ON the machine power in normal operation mode and if the machine boots up in normal
condition, the Mechanical Control PCB replacement procedure is completed.
EEPROM
< View with the Front Cover and Print Drum removed.>
[
19-3 ]
OTHER PRECAUTIONS
Screw
Screw
Screw
Screw
< View with the Front Cover and Print Drum removed.>
[
19-4 ]
SCREW
SCREW
SCREW
SCREW
OTHER PRECAUTIONS
Mechanical Control
PCB
SCREW
NeoROSA PCB
Refer to the page on the Firmware Installation, in this Chapter, for the information on
the CF Card Adapter JIG and on the Firmware installation procedure.
[
19-5 ]
OTHER PRECAUTIONS
2. Firmware Installation
1. Mechanical Control PCB
Note: The machine firmware program is contained in the EPROM, which is mounted on the Mechanical
Control PCB.
1. Replacement Procedure
1) Turn OFF the machine power.
2) Remove static electricity from the body before touching the PCB.
3) Remove the existing EPROM from the PCB.
4) Mount the new EPROM containing the new machine firmware.
5) Turn ON the machine power in normal operation mode, and confirm that the machine boots up in
normal condition to complete the procedure.
EPROM
[
19-6 ]
OTHER PRECAUTIONS
CF Card
CF Card Adapter
JIG for CF Card
without adapter.
+
NeoROSA PCB
< CHINA Type >
CF Card
CF Card
Adapter
CF Card Adapter
JIG for CF Card
with adapter.
=
< View of the JIG for CF Card with the adopter.>
[
19-7 ]
OTHER PRECAUTIONS
CF Card Adapter
CF Card
< Use only the CF Card. CF Card Adapter is not necessary >
[
19-8 ]
RISO 57A01C