KS800 Series Version 3.1

SERIES
( KS500 / KS600 / KS800 )
TECHNICAL MANUAL
VERSION 3.1 February, 2004
Copyright : 2004 Riso Kagaku Corporation All Rights Reserved. This Technical Manual was prepared and written for the exclusive use of RISO International Group Certified Dealers. Reproduction and/or transmittal of this material in any form or by any means, including photocopying or recording of the information is strictly prohibited without the consent of a member of RISO International Group.
RISO INTERNATIONAL GROUP RISO KAGAKU CORPORATION (JAPAN) RISO, INC. (U.S.A.) RISO EUROPE LIMITED (U.K.) RISO HONG KONG (HONG KONG) RISO UK (U.K.) RISO THAILAND LIMITED (THAILAND) RISO KOREA LIMITED (KOREA) RISO DEUTSCHLAND GMBH (GERMANY) RISO FRANCE (FRANCE) RISO IBERICA (SPAIN) RISO CANADA (CANADA) ZHUHAI RISO TECHNOLOGY (CHINA) RISO AFRICA (SOUTH AFRICA) RISOGRAPH ITALIA (ITALY)
CONTENTS
CHAPTER 1: MAINTENANCE 1. Preface ..................................................................................................................... 1 CAUTION .................................................................................................................. 2 WARNING ................................................................................................................ 3 2. WORK PRECAUTIONS ............................................................................................ 4 3. Exterior Cover Removal > Front cover ............................................................................................................. 6 > Back cover ............................................................................................................. 6 > Master removal cover ............................................................................................. 6 CHAPTER 2: MACHINE SUMMARY 1. Specifications .......................................................................................................... 1 2. Cross Sectional Diagram ........................................................................................ 4 3. Machine Operations ................................................................................................ 5 4. Paper Feed and Receiving ...................................................................................... 6 5. Master Removal and Feed ...................................................................................... 7 6. Counter Indication .................................................................................................. 8 CHAPTER 3: MAIN DRIVE SECTION 1. Theory of Operation 1. Main Drive ............................................................................................................. 1 2. Main Motor Safety Switches .................................................................................. 2 3. Drum Position ........................................................................................................ 3 4. Drum Rotation Lever ............................................................................................. 5 2. Removal and Assembly 1. Main Motor Unit ..................................................................................................... 7 2. Master Removal Unit Safety Switch ...................................................................... 9 3. Master Making Unit Safety Switch ....................................................................... 10 4. Sparation Unit Safety Switch ............................................................................... 11 5. Paper Guide Plate Safety Switch ......................................................................... 12 6. Drum Rotation Lever ........................................................................................... 13 CHAPTER 4: FIRST PAPER FEED SECTION 1. Theory of Operation 1. Paper Feed Tray Position ...................................................................................... 1 2. First Paper Feed Drive Mechanism ....................................................................... 2 3. Paper Pickup System ............................................................................................ 4 4. Paper Feed Pressure Select System ..................................................................... 5 2. Removal and Assembly 1. Paper Feed Tray Unit ............................................................................................ 6 2. Pickup Roller Assembly ......................................................................................... 7 3. Pickup Roller and PF Support Roller ..................................................................... 8 4. Stripper Pad .......................................................................................................... 9 5. Paper Feed Clutch .............................................................................................. 10 3. Adjustment 1. Paper Feed Tray Pressure .................................................................................. 11 2. Paper Feed Tray Position Adjustment ................................................................. 13 3. Paper Feed Clutch ON Timing ............................................................................ 15 4. Paper Feed Clutch OFFTiming ........................................................................... 15
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KS Series (Version 3.1)
CHAPTER 5: SECOND PAPER FEED SECTION 1. Theory of Operation 1. Second Paper Feed Drive Mechanism .................................................................. 1 2. Vertical Print Position ............................................................................................ 2 2. Removal and Assembly 1. Load Spring ........................................................................................................... 3 2. Timing Clutch ........................................................................................................ 4 3. Paper Guide Plate ................................................................................................. 5 4. Paper Gate ............................................................................................................ 6 5. Timing Roller / Guide Roller .................................................................................. 7 3. Adjustment 1. Print Position(Timing Clutch ON Timing) ............................................................... 8 CHAPTER 6: PRESS SECTION 1. Theory of Operation 1. Press Mechanism .................................................................................................. 1 2. Removal and Assembly 1. Pressure Roller ..................................................................................................... 3 2. Pressure Lever Ass'y ............................................................................................ 4 3. Pressure Shaft Ass'y ............................................................................................. 5 3. Adjustment 1. Pressure Lever Ass'y Position ............................................................................... 7 CHAPTER 7: PAPER EJECTION SECTION 1. Theory of Operation 1. Paper Ejection Mechanism .................................................................................... 1 2. Paper Separation Mechanism ............................................................................... 3 2. Removal and Assembly 1. Suction Unit ........................................................................................................... 5 2. Transfer Belt ......................................................................................................... 6 3. Suction Fan ........................................................................................................... 7 4. Separation Fan Unit .............................................................................................. 8 5. Separation Fan ...................................................................................................... 9 6. Paper Receiving Sensor ........................................................................................ 9 7. Separator ............................................................................................................ 10 8. Paper Receiving Tray .......................................................................................... 11 3. Adjustment 1. Separator Position ............................................................................................... 13 CHAPTER 8: DRUM SECTION 1. Theory of Operation 1. Master on Drum (in printing) Check Mechanism ................................................... 1 2. Ink Bottle Set Check Mechanism .......................................................................... 2 3. Ink Supply Mechanism .......................................................................................... 3 4. Squeegee Roller Rotation Mechanism .................................................................. 5 2. Removal and Assembly 1. Drum Unit .............................................................................................................. 7 2. Screen ................................................................................................................... 8 3. Drum Body ............................................................................................................ 9 4. Ink sensor PCB ................................................................................................... 11 5. Ink Bottle Guide ................................................................................................... 12
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6. Ink bottle set Sensor ............................................................................................ 12 7. Drum Support F & Drum Support R ..................................................................... 13 8. Squeegee Roller .................................................................................................. 14 9. Ink Pump Unit ...................................................................................................... 17 10. Inking Motor ...................................................................................................... 18 3. Adjustment 1. Squeegee Gap .................................................................................................... 19 CHAPTER 9: PAPER JAM 1. Theory of Operation 1. Paper Jam at First Paper Feed Area ..................................................................... 1 2. Paper Jam at Paper Receiving Area ..................................................................... 2 3. Print Start Timing Chart ......................................................................................... 3 4. During the Printing Timing Chart ........................................................................... 4 5. Print Stop Timing Chart ......................................................................................... 5 CHAPTER 10: MASTER CLAMP SECTION 1. Theory of Operation 1. Clamp Unit Positioning Mechanism ....................................................................... 1 2. Clamp Plate Master Release Mechanism ............................................................. 2 3. Clamp Plate Master Clamp Mechanism ................................................................ 4 2. Removal and Assembly 1. Clamp Unit ............................................................................................................ 7 2. Clamp Motor .......................................................................................................... 8 3. Clamp Sensor C .................................................................................................... 8 4. Clamp Sensor L .................................................................................................... 8 CHAPTER 11: MASTER REMOVAL SECTION 1. Theory of Operation 1. Master Removal Unit Mechanism .......................................................................... 1 2. Master on the Drum (before master removal) Check Mechanism ......................... 2 3. Clamp Plate Master Release Mechanism ............................................................. 4 4. Master Removal Mechanism ................................................................................. 6 5. Master Disposal Box Set Mechanism .................................................................... 8 2. Removal and Assembly 1. Master Removal Unit ............................................................................................. 9 2. Master Removal Clutch ....................................................................................... 10 3. Master Removal Sensor ...................................................................................... 11 4. Disposal Box Set Sensor ..................................................................................... 11 5. Master Removal Hook ......................................................................................... 12 6. Vertical Transport Roller (Upper) ......................................................................... 13 7. Vertical Transport Roller (Lower) ......................................................................... 13 8. Master Removal Guide (Lower) ........................................................................... 13 CHAPTER 12: IMAGE SCANNING SECTION 1. Theory of Operation 1. Original Loading Mechanism ................................................................................. 1 2. Original Scanning Mechanism ............................................................................... 3 3. Image Scanner ...................................................................................................... 5 2. Removal and Assembly 1. White Roller .......................................................................................................... 7 2. Image Scanner Unit .............................................................................................. 8
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3. Original IN Sensor ................................................................................................. 9 4. Pickup Roller ....................................................................................................... 10 5. Eject Roller Upper ............................................................................................... 10 6. Document Feeder Hook ...................................................................................... 10 7. Load Roller .......................................................................................................... 11 8. Eject Roller Lower ............................................................................................... 11 9. Read Pulse Motor ................................................................................................ 11 3. Adjustment 1. Image scanner gain adjustment .......................................................................... 13 CHAPTER 13: CUTTER SECTION 1. Theory of Operation 1. Cutter Home Positioning Mechanism .................................................................... 1 2. Cutting Mechanism ............................................................................................... 3 2. Removal and Assembly 1. Cutter Unit ............................................................................................................. 5 CHAPTER 14: MASTER MAKING SECTION 1. Theory of Operation 1. Master Making ....................................................................................................... 1 2. TPH Positioning .................................................................................................... 3 3. Thermal Power Safety Switches ............................................................................ 5 2. Removal and Assembly 1. Write Roller ........................................................................................................... 7 2. Thermal Print Head (TPH) ..................................................................................... 8 3. TPH Position Sensor ............................................................................................. 9 3. Adjustment 1. Thermal Power of Thermal Print Head ................................................................ 11 CHAPTER 15: MASTER CLAMPING / LOADING SECTION 1. Theory of Operation 1. Master Making Unit Set Mechanism ...................................................................... 1 2. Master Positioning Mechanism .............................................................................. 2 3. Master Feeding Mechanism .................................................................................. 4 4. Clamp Plate Master Clamp Mechanism ................................................................ 6 5. Master Loading on the Drum Mechanism .............................................................. 8 6. Master Advance after Master Cutting .................................................................. 10 2. Removal and Assembly 1. Master Making Unit ............................................................................................. 13 2. Master Making Unit Safety Switch ....................................................................... 15 3. Write Pulse Motor ................................................................................................ 16 4. Master Positioning Sensor ................................................................................... 17 5. Master Loading Solenoid ..................................................................................... 18 6. Master End Sensor ............................................................................................. 19 APPENDIX Electrical Components ................................................................................... APX(0)-1 Test Mode ........................................................................................................ APX(1)-1 Users Mode ...................................................................................................... APX(2)-1 Advice Displays (Call Service Messages) ..................................................... APX(3)-1 Wiring Diagram ................................................................................................ APX(4)-1
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CHAPTER
1:
MAINTENANCE
CONTENTS
1. Preface ..................................................................................................................... 1 CAUTION .................................................................................................................. 2 WARNING ................................................................................................................ 3 2. WORK PRECAUTIONS ............................................................................................ 4 3. Exterior Cover Removal > Front cover ............................................................................................................. 6 > Back cover ............................................................................................................. 6 > Master removal cover ............................................................................................. 6
MEMO
MAINTENANCE
PREFACE
PREFACE
This manual provides Technical Service Information for RISO KS duplicators. This manual is published as a reference guide for use by certified field servicemen 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.
If assistance is required, please contact one of the Riso International Group companies or the Riso Distributors to whom you have the direct communication.
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MAINTENANCE
CAUTION
CAUTION
[Handling of Lithium Battery]
- Never fail to follow the following instructions when you discard the used lithium battery. 1. Never let the battery short-circuited. If the (+) and (-) terminals contact each other or metal materials, the battery will be short-circuited. If the batteries are collected and stored inorderly or one upon another, the above-mentioned case will occur. - DANGER If the battery is short-circuited, it will heat up and may in some cases explode into fire. 2. Never heat up the battery. - DANGER If you heat the battery up to more than 100 degrees centigrade or put it into the fire, it may burn dangerously or explode. 3. Never disassemble the battery or press it into deformation. - DANGER If you disassemble the battery, the gas pouring out of the inside may hurt your throat or the negative lithium may heat up into fire. If the battery is pressed into deformation, the liquid inside may leak out of the sealed part or the battery may be short-circuited inside an explode. 4. Never fail to keep the battery out of reach of children. If you put the battery within reach of children, they may swallow it down. Should they swallow the battery, immediately consult the doctor.
[Replacement of the Lithium Battery]

1. The lithium battery must be replaced by a trained and authorized service technician. 2. The battery must be replaced only with the same or equivalent type recommended by the manufacturer. 3. Discard used batteries according to the manufacturer's instructions.
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MAINTENANCE
WARNING
!! 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. Protection of the machine: Make sure to turn OFF the power to the machine before plugging or unplugging the electrical connectors, or when connecting a Meter.
II.
2. Always connect electrical connectors firmly.

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

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

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

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

Disconnect the power supply from the machine and remove the cover.
> Front cover > Back cover > Master removal cover: ......Remove the Master disposal first.
B A
A: Front cover B: Back cover C: Master removal cover
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CHAPTER
2:
MACHINE SUMMARY
CONTENTS
1. 2. 3. 4. 5. 6.
Specifications .......................................................................................................... 1 Cross Sectional Diagram ........................................................................................ 4 Machine Operations ................................................................................................ 5 Paper Feed and Receiving ...................................................................................... 6 Master Removal and Feed ...................................................................................... 7 Counter Indication .................................................................................................. 8
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MACHINE SUMMARY
SPECIFICATIONS
1. Specifications
KS500 / KS500C / KS500AL
Processing Time to First Copy Print Speed Scanning Resolution Original Type Original Size Automatic digital scanning Fully automatic, thermal screening duplicating system 60 seconds (A4 or B4 original) 2 selectable print speeds (60, 90 sheets/min.) 200 x 300 dpi Sheet KS500 KS500C KS500AL KS500 KS500C KS500AL Max. 257 x 394mm or B4 Min. 182 x 257mm or B5 Max. 273 x 394mm Min. 182 x 257mm or B5 Max. 210 x 297mm or A4 Min. 182 x 257mm or B5 Max. 257 x 364mm or B4 Min. 182 x 257mm or B5 Max. 273 x 394mm Min. 182 x 257mm or B5 Max. 210 x 297mm or A4 Min. 182 x 256mm or B5
Paper Size
Original Weight Paper Weight Image Area Paper Capacity
Max. 107 g/m2 Min. 50 g/m2 KS500 / KS500AL Max. 80 g/m2 Min. 50 g/m2 KS500C Max. 70 g/m2 Min. 35 g/m2 249 x 352mm KS500 / KS500AL Feed tray - 250 sheets (64 g/m2 ) Receiving tray - 250 sheets (64 g/m2 ) KS500C Feed tray - 280 sheets (50 g/m2 ) Receiving tray - 280 sheets (50 g/m2 ) Approx. 45 kg In use / 1200 x 650 x 470mm In storage / 635 x 645 x 479mm
Machine Weight Dimensions [WxDxH]
Power Source
KS500 / KS500AL 220 to 240 VAC, 50/60 Hz <1.5A-2.0A> <Requirements> KS500C 220 VAC, 50 Hz <1.5A-2.0A> <Requirements> KS500(120) 110 to 127 VAC, 50/60 Hz <1.9A-2.5A> <Requirements>
Features
Print speed control, Confidential mode, Photo processing mode, Scanning contrast adjustment, Print position adjustment, Newspaper mode, Print/Master count display
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MACHINE SUMMARY
SPECIFICATIONS
1. Specifications
KS600 / KS600C / KS600AL
Processing Time to First Copy Print Speed Scanning Resolution Original Type Original Size Automatic digital scanning Fully automatic, thermal screening duplicating system 60 seconds (A4 or B4 original) 2 selectable print speeds (60, 90 sheets/min.) 200 x 300 dpi Sheet KS600 KS600C KS600AL KS600 KS600C KS600AL Max. 257 x 364mm or B4 Min. 182 x 257mm or B5 Max. 273 x 394mm Min. 182 x 257mm or B5 Max. 210 x 297mm or A4 Min. 182 x 257mm or B5 Max. 257 x 364mm or B4 Min. 182 x 257mm or B5 Max. 273 x 394mm Min. 182 x 257mm or B5 Max. 210 x 297mm or A4 Min. 182 x 257mm or B5
Paper Size
Original Weight Paper Weight Image Area Paper Capacity
Max. 107 g/m2 Min. 50 g/m2 KS600 / KS600AL Max. 80 g/m2 Min. 50 g/m2 KS600C Max. 70 g/m2 Min. 35 g/m2 249 x 352mm KS600 / KS600AL Feed tray - 250 sheets (64 g/m2 ) Receiving tray - 250 sheets (64 g/m2 ) KS600C Feed tray - 280 sheets (50 g/m2 ) Receiving tray - 280 sheets (50 g/m2 ) Approx. 46 kg In use / 1200 x 600 x 550mm
Machine Weight Dimensions [WxDxH] Power Source
KS600 / KS600AL 220 to 240 VAC, 50/60 Hz <1.5A-2.0A> <Requirements> KS600C 220 VAC, 50 Hz <1.5A-2.0A> <Requirements> KS600 (120) 110 to 127 VAC, 50/60 Hz <1.9A-2.5A> <Requirements>
Features
2-2
MACHINE SUMMARY
SPECIFICATIONS
1. Specifications
KS800 / KS800C / KS800AL
Processing Time to First Copy Print Speed Scanning Resolution Original Type Original Size Automatic digital scanning Fully automatic, thermal screening duplicating system 60 seconds (A4 or B4 original) 2 selectable print speeds (60, 90 sheets/min.) 200 x 300 dpi Sheet KS800 KS800C KS800(AL) KS800 KS800C KS800(AL) Max. 257 x 394mm or B4 Max. 273 x 394mm Max. 257 x 394mm or B4 Max. 297 x 420mm or A3 Max. 297 x 420mm or A3 Max. 210 x 297mm or A4 Min. 182 x 257mm or B5 Min. 182 x 257mm or B5 Min. 182 x 257mm or B5 Min. 182 x 257mm or B5 Min. 182 x 257mm or B5 Min. 182 x 257mm or B5
Paper Size
Original Weight Paper Weight Image Area
Max. 107 g/m2 Min. 50 g/m2 KS800 / KS800(AL) Max. 128 g/m2 KS800C Max. 128 g/m2 KS800 KS800C KS800(AL) 249 x 352mm 249 x 352mm 210 x 280mm Min. 50 g/m2 Min. 35 g/m2
Enlargement Parameters Reduction Parameters Paper Capacity
141%, 122%, 116% 71%, 82%, 87%, 94%
KS800 / KS800(AL) Feed tray: 250 sheets (64 g/m2 ) Receiving tray: 250 sheets (64 g/m2 ) KS800C Feed tray: 280 sheets (50 g/m2 ) Receiving tray: 280 sheets (50 g/m2 ) Approx. 46 kg In use / 1200 x 600 x 550mm KS800 / KS800(AL) 220 to 240 VAC, 50/60 Hz <1.5A-2.0A> <Requirements> KS800C 220 VAC, 50 Hz <1.5A-2.0A> <Requirements> KS800(120) 110 to 127 VAC, 50/60 Hz <1.9A-2.5A> <Requirements>
Machine Weight Dimensions [WxDxH] Power Source
Features
2-3
MACHINE SUMMARY
CROSS SECTIONAL DIAGRAM
2. Cross Sectional Diagram

Document feeder Image scanner Master disposal box Cutter unit Thermal print head Original rack
8
Write roller
6
Master roll
7 1 2 5
10 4
9
Separator
3
Paper feed tray Paper receiving tray Pickup roller Timing roller Guide roller Suction unit Pressure roller
1 First Paper Feed Area:
Feeds single sheets of paper to the second paper feed area via the 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. Supplies the Drum surface with ink from an Ink cartridge. Clamps the leading edge of the master. 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. Makes a master with the Thermal print head. Feeds the prepared master material to the Drum and cuts it to an appropriate length.
2 Second Paper Feed Area:
3 Press (Printing) Area:
4 Paper Ejection Area:
5 Drum Area: 6 Master Clamp Area: 7 Master Disposal Area:
8 Image Scanning Area:
9 Master Making Area: 10 Master Loading Area:
2-4
MACHINE SUMMARY
MACHINE OPERATIONS
3. Machine Operations
Set the original and press the Start key.
Master Disposal
The used master is removed from the drum and stored in the disposal box.
Master Making
The original is scanned by the image scanner and the image is made on the master with the thermal print head.
Master Carrier and Loading

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

Pickup roller Drum The Drum is rotated and a sheet of paper is fed from the first paper feed area to the second paper feed area by Pickup rollers, and Stripper pad. Stripper pad Guide roller The paper feed to the second paper feed area is stopped by the Guide and Timing rollers to form a buckle. The paper then waits until the rotation of the Guide roller starts.
Timing roller
Pressure roller
The Guide and Timing rollers in the second paper feed area are rotated and the paper is fed to the printing area.
Separation fan Separator
While the paper is being fed from the second paper feed area, the Pressure roller rises and printing starts. (The Pressure roller contacts the Drum and starts rotating.)
After the Pressure roller contacts the Drum to start printing, the Separator approaches the Drum and the Separation fan starts to blow. The Guide roller goes up to release the paper. (The paper is then transferred by the rotation of the Drum.) The printed paper is separated from the Drum by the Separator and with a help of the air blow from the Separation fan. It is then transported onto the Paper receiving tray by the Transfer belts using Suction fan.
Transfer belt
The Timing roller contacts with the Guide roller to feed the next sheet of paper.
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MACHINE SUMMARY
MASTER REMOVAL AND FEED
5. Master Removal and Feed

Clamp plate Master projection shaft Master roll Master Removal The Clamp plate opens and Master release shaft releases the master from the Clamp plate.
Vertical transport roller
Master The Drum and Vertical transport rollers starts rotating and removes the master from the Drum and feed it into the Master disposal box.
Master disposal box
The Master compressing plate starts compressing the removed master within the Master removal box. TPH Master Making The Image scanner scans the image on the original and Thermal print head (TPH) makes the image on the master material. The Master tension plate drops down and applies tension on the master material. Master Loading The master is transferred onto the Drum and the leading edge is clamped by the Clamp plate. The Drum rotates to wrap the master on the Drum. Cutter The Cutter cuts the master.
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MACHINE SUMMARY
COUNTER FOR MAINTENANCE
6. Counter Indication
1. Indicate Copy and Master Counter:
No mechanical counters are installed on KS therefore the alternatives are available as software counter. The counter indication can be shown by using USER MODE. By pressing [*] and then [1], three digits of seven segments indication on the control panel displays the Copy counter. The three digits of seven segments change every 2 seconds then displays nine digits of numbers finally. By pressing [*] and then [2], the Master counter can be shown as same method as the above. [Example] In case the Copy count is 123,456 and the Master count is 1,234. Copy Count 1. Press [*] key then [1] key. 2. [ - - - ] will be indicated at first. 3. After 2 seconds, the indication will be changed to [ 1 2 3 ]. 4. After 2 seconds, the indication will be changed to [ 4 5 6 ]. Master Count 1. Press [*] key then [2] key. 2. [ - - 1 ] will be indicated at first. 3. After 2 seconds, the indication will be changed to [ 2 3 4 ].
2. Clear of Copy and Master Counter:

The counter indication can be cleared and set back to default zero by using TEST MODE No.97. By pressing the print position adjustment key or on the control panel then Power On. Three digits of seven segments indication on the control panel displays version of the System ROM initially. Then press [C] button so that the Test numbers can be input. Clear Copy and Master counter: 1. Press [9] and [7] key then press [Start] key while test mode is available. 2. [1] will be indicated. In case the indication is [0], counter cannot be clear. 3. Press [C] to clear the memorised copy and master counter. 4. Press [Reset] key or power off to be back to normal operation. Prohibit clear of Copy and Master counter: 1. Press [9] key and [7] key then press [Start] key while test mode is available. 2. [1] will be indicated. In case the indication is [0], counter cannot be clear. 3. Press [C] to clear the memorised copy and master counter. 4. Press the print position adjustment key or to the indication change from [1] to [0]. 5. Press [Start] key so that counter clear mode becomes no longer available. 6. Press [Reset] key or power off to be back to normal operation. Note: *1. To confirm the status of the counter clear mode, input test mode No.97 then press [Start] key while test mode is available. If the indication is [0], counter cannot be cleared. If the indication is [1], the counter can be cleared. *2. It is recommended that the prohibit clear mode should be done before the machine is installed at customer site. Once the prohibit clear mode is activated, the counters will no longer be able to be cleared permanently.
2-8
CHAPTER
3:
MAIN DRIVE SECTION
CONTENTS
1. Theory of Operation 1. Main Drive ............................................................................................................. 1 2. Main Motor Safety Switches .................................................................................. 2 3. Drum Position ........................................................................................................ 3 4. Drum Rotation Lever ............................................................................................. 5 2. Removal and Assembly 1. Main Motor Unit ..................................................................................................... 7 2. Master Removal Unit Safety Switch ...................................................................... 9 3. Master Making Unit Safety Switch ....................................................................... 10 4. Sparation Unit Safety Switch ............................................................................... 11 5. Paper Guide Plate Safety Switch ......................................................................... 12 6. Drum Rotation Lever ........................................................................................... 13
MEMO
MAIN DRIVE SECTION

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

THEORY OF OPERATION
2. Main Motor Safety Switch

1. Following all three Safety switches must be activated to run the Main motor. > Master removal unit safety switch [A] > Master making unit safety switch [B] > Separation unit safety switch [C] > Paper guide plate safety switch [D] The same three switches act also as Safety switches for the Thermal power.
A B D
A: Master removal unit safety switch B: Master making unit safety switch C: Separation unit safety switch D: Paper guide plate safety swich
3-2
MAIN DRIVE SECTION

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

THEORY OF OPERATION
Drum A-Positioning Movement Timing Chart

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

THEORY OF OPERATION
4. Drum Rotation Lever

1. Drum rotation lever > The Drum [A] is rotated by pusing down the Drum rotation lever [C]. > The Drum rotation gear [B] is moved up and down by the Drum rotation lever [C]. > The Drum rotation gear [B] rotates drive gears, thus the drum is rotated forward.
D C A:Drum B:Drum gear C:Drum rotation levar D:Drum rotation gear
3-5
MEMO
3-6
MAIN DRIVE SECTION

REMOVAL AND ASSEMBLY
2. Removal and Assembly

1. Main Motor Unit
1. Disconnect the power supply from the machine. 2. Remove Back cover.(See page 1-6) 3. Remove Paper receiving tray [A]. 4. Remove Suction cover [B].(See page 7-5) 5. Remove Suction unit [C]. (See page 7-5) (continues on page 3-8)
C B
A : Paper receiving tray B : Suction cover C : Suction unit
NOTE: The paper receiving tray and the suction unit on KS800 looks a little different.
3-7
MAIN DRIVE SECTION

6.Remove three mounting screws of the P.-F. clatch bracket [B]. 7.Remove each two mounting screws of the Timing clatch bracket A [C] and B [D]. 8. Remove mounting screw of the Encoder [E]. 9. Remove mounting screws of the Drive gear bracket [F] then remove the bracket. 10. Disconnect a connector of the Main motor unit [A] from the System PCB. 11. Remove three mounting screws of the Main motor unit [A] and remove the unit from the machine.
B F
E D A: Main motor unit B: P.-F. clatch bracket C: Timing clatch support plate D: Clutch support plate E: Encoder F: Drive gear bracket
Precautions in Assembly
> Match the half-pierced sections of brackets against those on the machine frame.
3-8
MECHANICAL OVERVIEW
2. Master Removal Unit Safety Switch

1. Disconnect the power supply from the machine. 2. Remove the Front cover.(See page 1-6) 3. Open the Master removal unit [A] and disconnect the Connector of the Master removal unit safety switch [B]. 4. Remove three mounting screws of the Switch bracket and remove the bracket with the switch attached. 5. Remove the switch [B] from the bracket.
> The mounting section of the bracket should be positioned behind the stay of the Master removal unit [A]. > Match the half-pierced section on the Switch bracket with that on the machine.
A: Master removal unit B: Master removal unit safety switch
3-9
MAIN DRIVE SECTION

3. Master Making Unit Safety Switch

1. Disconnect the power supply from the machine. 2. Remove the Master making unit [B](See page 15-13). 3. Disconnect the Connector of the Master making unit safety switch [A]. 4. Remove two mounting screws of the Master making unit safety switch [A] and remove the switch.
> Install the switch [B] in the correct direction.
A: Master making unit B: Master making unit safety switch
3 - 10
MAIN DRIVE SECTION

4. Separation Unit Safety Switch

1. Disconnect the power supply from the machine. 2. Remove the Front cover.(See page 1-6) 3. Remove the Main PCB. (See page 8-7) 4. Open the Separation unit [B] as the below photo shows. 5. Remove the Separation unit switch [A] from the bracket.
> Do not bend the Switch bracket, as it acts as a spring plate to press against the actuator of the Separetion unit switch [A] when the Drum is inserted in the machine.
A:Separation Unit Safety Switch switch B:Separation Unit
3 - 11
MAIN DRIVE SECTION

5. Paper Guide Plate Safety Switch

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

6. Drum Rotation Lever

6-1. Old Type: For KS500 Serial Number 81530001- 81530500 For KS500C Serial Number 81510001- 81510500 Refer to the next page for the New Type.
1. Dosconnect the power supply from the machine. 2. Remove the Back cover (See page 1-6) 3. Remove the Drum rotation lever bracket [B] 4. Remove the Drum rotation lever ass'y [D]. 5. Separate the Drum rotation lever [C] and the Drum rotation gear [A].
Important caution of the Assembly

> Blue color of the One-way clutch in the Drum rotation gear [A] must face to the Drum rotation lever bracket [B]. If the Drum rotation gear [A] is installed in the opposite direction, the Drum will be locked and [ E 1] will be indicated on the machine.
A B
A: Drum rotation gear B: Drum rotation lever bracket C: Drum rotation lever D: Drum rotation lever ass'y
3 - 13
MAIN DRIVE SECTION

6-2. New type : For KS500
Serial No. 81530501 -
For KS500C Serial No. 81510501 -
Also for all KS600 & KS800
1. Disconnect the power supply from the machine. 2. Remove the Back cover (See page 1-6) 3. Remove the Cover;Drum rotation Lever [G]. 4. Remove the Gear plate;Drum rotation lever [B]. 5. Seperate the Gear plate Drum rotation lever [B] and the Gear;m1*26*11 [A].
Important caution of the Assembly

> Blue color of the One-way clutch in the Gear,m1*26*11 [A] must be face to the Gear plate;Drum rotation lever [B]. If the Gear,m1*26*11 [A] is installed in the opposite direction, the Drum is locked and [E 1] is indicated on the machine.
B G C
E D
A: Gear;m1*26*11 B: Gear plate;Drum rotation lever C: Gear Shaft;rotation lever D: Link shaft;Drum rotation lever E: Link plate;Drum rotation lever F: Drum rotation lever G: Cover;Drum rotation lever
3 - 14
CHAPTER
4:
FIRST PAPER FEED SECTION
CONTENTS
1. Theory of Operation 1. Paper Feed Tray Position ...................................................................................... 1 2. First Paper Feed Drive Mechanism ....................................................................... 2 3. Paper Pickup System ............................................................................................ 4 4. Paper Feed Pressure Select System ..................................................................... 5 2. Removal and Assembly 1. Paper Feed Tray Unit ............................................................................................ 6 2. Pickup Roller Assembly ......................................................................................... 7 3. Pickup Roller and PF Support Roller ..................................................................... 8 4. Stripper Pad .......................................................................................................... 9 5. Paper Feed Clutch .............................................................................................. 10 3. Adjustment 1. Paper Feed Tray Pressure .................................................................................. 11 2. Paper Feed Tray Position Adjustment ................................................................. 13 3. Paper Feed Clutch ON Timing ............................................................................ 15 4. Paper Feed Clutch OFFTiming ........................................................................... 15
MEMO

THEORY OF OPERATION
1. Paper Feed Tray Positions (Upper / Lower)
1. Paper Feed Tray Set Lever > The Paper feed tray set lever [A] is linked with the PF lever plate ass'y [D] by the PF tray spring [C]. And the PF lever plate ass'y [D] is fixed with PFT lever shaft [F]. > When the paper feed tray set lever [A] is set lower position, the PFT lever [E] rises and push the Paper feed tray [B] up. Thus papers on the Paper feed tray [B] touch the Pick up roller [G]. > When the paper feed tray set lever [A] is set upper position, the PFT lever [E] moves down and Paper feed tray [B] goes down too. Thus papers on the Paper feed tray [B] is released from the Pick up roller [G]. > Pressure between paper on the Paper feed tray and the Pick up roller can be adjusted.
F G E A D B
A: Paper feed tray set lever B: Paper feed tray C: PF tray spring D: PF lever plate ass'y E: PFT lever F: PFT lever shaft G: Pick up roller
4-1

THEORY OF OPERATION
2. First Paper Feed Drive Mechanism

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

THEORY OF OPERATION First Paper Feed Timing Chart
Press "START" key Drum rotation starts from Drum Position-A 1-1 66.3 2-1 144.8 1-1 66.3 2-2 142.2 0 1-2 63.7 0 1-2 63.7 Drum rotation ON Main motor Position-A sensor Paper feed clutch Open ON Blocked
2-1 144.8 2-2 142.2
[In case the drum rotation speed is 60 r.p.m.] 1-1 The Paper feed clutch activates each time the Drum rotates 66.3 c from the A position. The angle "c" can be adjusted by Test Mode No. 80, which adjusts the ON timing of the Paper feed clutch. 2-1 The Paper feed clutch is deactivated when the Drum rotates 144.8 c from the A position. The angle "c" can be adjusted by Test Mode No. 81, which adjusts the paper buckle amount. [In case the drum rotation speed is 90 r.p.m.] 1-2 The Paper feed clutch activates each time the Drum rotates 63.7 c from the A position. The angle "c" can be adjusted by Test Mode No. 82, which adjusts the ON timing of the Paper feed clutch. 2-1 The Paper feed clutch is deactivated when the Drum rotates 142.2 c from the A position. The angle "c" can be adjusted by Test Mode No. 83, which adjusts the paper buckle amount.
A:Drum B:Pickup roller C:Paper D:Paper gate E:Guide roller F:Stripper pad G:Timing roller H:Pressure roller B C
H G F
4-3

THEORY OF OPERATION
3. Paper Pickup System

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

THEORY OF OPERATION
4. Paper Feed Pressure Select System

1. Paper Feed Pressure Adjust Lever > The Paper feed pressure adjust lever [A] is located on the front side of the machine, and it changes the pressure of the Paper feed tray applied against the Pick up roller, as a result the pressure against the papers on the Paper feed tray is changed. > When the Paper feed pressure adj. lever [A] is positioned at upper position, the Pressure arm [C] is lowered and the pressure of the Pressure adj. lever spring [B] does not applied against the Paer feed tray. Thus the paper feed pressure is not increased at the lower position. Therefore this position is for "THIN" papers. > When the Paper feed pressure adj. lever is positioned at lower position, the Pressure arm [C] becomes free and the pressure of the Pressure adj. lever spring [B] applies against the Paper feed tray. Thus the paper feed pressure is increased. Therefore this position is for "NORMAL" papers.
For NORMAL Paper
For THIN Paper
A:Paper feed pressure adjust lever B:Pressure adjust lever spring C:Pressure arm
A C B
4-5


1. Paper Feed Tray Unit
1. Disconnect the power supply from the machine. 2. Lower the Paper feed tray. 3. Remove the Paper feed tray unit [A] from the both side of the Lock pins [B].
Precaution in Assembly
> Make sure to hook the the Paper feed tray unit [A] to the both side of the Lock pins [B] firmly in position.
A B
A:Paper feed tray unit B:Lock pin
4-6

2. Pickup Roller Assembly

1. Disconnect the power supply from the machine. 2. Lower the Paper feed tray [D]. 3. Remove Back cover. (See Page 1-6) 4. Remove the Paper feed tray [D] from the machine. (See page 4-6) 5. Remove Lock rings [C] on the right end of the Pickup roller shaft [A] and remove the Metal [B]. 6. Slide the Pickup roller shaft [A] to the front side of the machine and remove the Pick up roller ass'y.
C B
A:Pickup roller shaft B:Metal C:Lock ring D:Paper feed tray
4 -7

3. Pickup Roller and PF Support Roller

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

4. Stripper Pad
1. Disconnect the power supply from the machine. 2. Lower the Paper feed tray all the way down. 3. Remove the Lock ring of the Pickup roller them slide the roller towards front side. 4. Remove the Stripper pad [C] base carefully, not to damage the Stripper spring [B]. 5. Remove the Stripper Pad [B] from the Stripper pad base [A].
> Set the Stripper spring [B] correctly in the machine before setting the Stripper pad base [A] back in place. > Make sure to fif the Pickup roller in correct position then insert the Lock ring.
A:Stripper pad base B:Stripper spring C:Stripper pad
4-9

5. Paper Feed Clutch

1. Disconnect the power supply from the machine. 2. Remove Back cover. 3. Remove the PF Clutch support plate [B]. 4. Disconnect the Connector of the Paper feed clutch [A]. 5. Remove the Paper feed clutch [A] from the shaft.
> Match the position of the flat cut portion of the Metals [C] with that of the Main frame or PF clutch support plate [B]. > Mount the slit on the clutch over the Drive gears bracket [D] on the machine to prevent the clutch from rotating. (Refer to fig.b)
C A B
A:Paper feed clutch B:PF Clutch support plate C:Metal D:Drive gear bracket
fig.b
4 - 10

ADJUSTMENT
3. Adjustment
1. Paper Feed Tray Pressure
1-1. Old Type of the Paper feed Tray set Lever For KS500 Serial Number 81530001- 81530500 For KS500C Serial Number 81510001- 81510500 Refer to the next page for the New Type.
1. Lower the Paper feed tray set lever [A] .(Upper the Paper feed tray) 2. Insert ruler to the slit of the Paper feed tray set lever [A] to measure the distance from top edge of the PF adj. screw [B] to the edge of the Paper feed tray set lever [A]. 3. The adjustable range is + 1mm to - 7mm from the edge of the Paper feed tray set lever [A].(refer to fig.a) Strong(CW) Weak(CCW) -7mm +1mm *1. If the distance is already positioned at +1mm, it cannot be adjusted weaker.(fig.b) *2. If the distance is already positioned at -7mm, it cannot be adjusted stronger.(fig.c) *3. The standard position can be adjusted by the PF tray position adjustment.(See page 4-13) 4. In case of no paper feeding occurs, trun the PF adj. screw [B] towareds CW direction to increase the the pressure. 5.In case of multiple paper feeding occurs, turn the PF adj. screw [B] towards CCW direction to decrease the pressure.
Precaution in Adjustment
> Do not turn the PF adj. screw [B] any more if the PF adj. screw [B] rotation becomes tight. (It is the sign of the limit position of the adjustment.) Otherwise the steps of the PF adj. screw [B] will be damaged.
Strong A:Paper feed tray set lever B:PF adj. screw B A B
Weak
fig.a
1mm
7mm
fig.b
fig.c
4 -11

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

For KS500 For KS500C For KS500AL For KS500(120) Serial Number Serial Number Serial Number Serial Number 81530501815105018154000181550001Also for all KS600 & KS800
1. Lower the Paper feed tray set lever [A] .(Upper the Paper feed tray) 2. Pull out the PF adj. dial [C] from the PF adj. screw [B]. 3. Insert lular to the slit of the Paper feed tray set lever [A] to measure the distance from top edge of the PF adj. screw [B] to the edge of the Paper feed tray set lever [A]. 4. The adjustable range is + 7mm to +12mm from the edge of the Paper feed tray set lever [A].(refer to fig.a) Strong(CW) Weak(CCW) +12mm +7mm
*1. If the distance is already positioned at +7mm, it cannot be adjusted stronger.(refer to fig.b) *2. If the distance is already positioned at +12mm, it cannot be adjusted weaker.(refer to fig.b) *3. The standard position can be adjusted by the PF tray position adjustment.(See page 4-13) 5. In case of no paper feeding occurs, trun the PF adj. screw [B] towareds CW direction to increase the the pressure. 6. In case of multiple paper feeding occurs, turn the PF adj. screw [B] towards CCW direction to decrease the pressure.
> Do not turn the PF adj. screw [B] any more if the PF adj. screw [B] rotation becomes tight. (It is the sign of the limit position of the adjustment.) Otherwise the steps of the PF adj. screw [B] will be damaged. >Adjust set position of the PF adj. dial [C] against the PF adj.screw [B]. C
fig.a A
A:Paper feed tray set lever B:PF adj. screw C:PF adj. dial
fig.b
4 -12

ADJUSTMENT
2. Paper Feed Tray Position Adjustment

1. Separate Base plate;PFT[A] from Plate;PFT[B]. 2. [For KS500C] Measure 42mm from the bottom of inside of the Plate; PFT [A]then mark the 42mm point on the Plate;PTF[B]. [For other KS models] Measure 43mm from the bottom of inside of the Plate; PFT [B] then mark the 43mm point on the Plate;PTF[B]. 3. Putting together the Base plate;PFT[A] and the Plate;PFT[B]. 4. PF press-adj. Lever[C] must be at "THIN" position. 5. Adjust the base of the Base plate;PFT[A] with the line to be the same level while PF set lever [C] is released. (not in setting position)
A
42mm or 43mm
C 6. Turn the PF Adj. screw[D] as left figures show. In case of the New type of the Paper feed tray set lever[F]. *Trun it towards CCW if the Base plate;PFT[A] is higher than the line. *Trun it towards CW if the Base plate;PFT[A] is lower than the line. 7. Paper feed adjustment for each paper will be required after this adjustment is done.
E D
A: Base plate;PFT B: Plate;PFT C: PF press-adj. Lever D: PF Adj. screw E: PF Adj. dial F: Paper feed tray set lever
Old Type
New Type
4 -13

ADJUSTMENT
[Checking of Paper Feeding]

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

ADJUSTMENT
3. Paper Feed Clutch ON Timing

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

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

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

> If too much or too little paper buckle is made, the paper does not transfer correctly into the Second paper feed section and may result in paper jamming.
Note:
>The Paper feed clutch adjustment is affected by the Timing clutch timing adjustment as same as the Paper feed clutch ON timing adjustment.
4 - 15
MEMO
4 - 16
CHAPTER
5:
SECOND PAPER FEED SECTION
CONTENTS
1. Theory of Operation 1. Second Paper Feed Drive Mechanism .................................................................. 1 2. Vertical Print Position ............................................................................................ 2 2. Removal and Assembly 1. Load Spring ........................................................................................................... 3 2. Timing Clutch ........................................................................................................ 4 3. Paper Guide Plate ................................................................................................. 5 4. Paper Gate ............................................................................................................ 6 5. Timing Roller / Guide Roller .................................................................................. 7 3. Adjustment 1. Print Position(Timing Clutch ON Timing) ............................................................... 8
MEMO

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

THEORY OF OPERATION
2. Vertical Printing Position

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


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

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

2. Timing Clutch
1. 2. 3. 4. 5. 6. Disconnect the power supply from the machine. Remove Back cover. Remove the PF-Clutch support plate [H]. Remove the Clutch support plate [A] then remove the encoder [B] and the Encoder sensor [C]. Remove the BKT; Drive gears [D]. Remove the Metal [E] and the Timing clutch [F]
Adjustment after Assembly

> Adjust the position of the Timing clutch at the correct position as below photograph shows. > Adjust the position of the Paper feed clutch at the correct position as page 4-10 explains.
A A:Timing clutch support plate B:PF/M-Rmv clutch
5-4

3. Paper Guide Plate

1. Disconnect the power supply from the machine. 2. Remove following parts from the machine. > Back cover (See page 1-6) > Paper feed tray unit [A] (See page 4-6) > Paper feed clutch [F] with the bracket. (See page 4-10) > Pick up roller ass'y [B] (page 4-7) 3. Remove the Paper guide plate upper [C]. 4. Remove the Master loading sensor bracket [E]. 5. Slide the Master removal unit then remove mounting screw of the Paper gate [G]. (See page 5-6) 6. Take out the Paper guide plate lower [D] from the the Paper feed tray side. G
E D C B A
A:Paper feed tray B:Pickup roller assy C:Paper guide plate upper D:Paper guide plate lower E:Master loading sensor bracket F:Paper feed clutch G:Paper gate
> Make sure the position of the Paper guide plate upper at the correct position as below pictures show. Drive side C
Front side
5-5

4. Paper Gate
1. 2. 3. 4. Disconnect the power supply from the machine. Remove the Paper guide plate upper. (See page 5-5) Slide out the Master removal unit. Remove the mounting screw of the Paper gate, and remove the Paper gate [A].
Precautions before Assembly

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

5. Timing Roller / Guide Roller

1. 2. 3. 4. 5. Disconnect the power supply from the machine. Remove the Paper guide plate (See page 5-5) Remove the Paper gate (See page 5-6) Remove the Power supply unit (See page 8-7) Remove following parts from the Timing roller shaft. > Load spring [G] (See page 5-3) > One-way gear [E] and Metal [C] 6. Remove the Timing roller [A] (Complete the Timing roller removal) 7. After removing the Timing roller [A], remove the E-rings [F] and the Metals [D] from both side of the Guide roller shaft [B]. 8. Remove the Guide roller ass'y[B] (Complete the Guide roller ass'y removal)

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

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

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

> If adjusted as [7], the paper could not reached the drum before the pressure roller rises. As a result, paper jam could occur and the pressure roller could be dirty with ink from the drum surface.
5-8
CHAPTER
6:
PRESS SECTION
CONTENTS
1. Theory of Operation 1. Press Mechanism .................................................................................................. 1 2. Removal and Assembly 1. Pressure Roller ..................................................................................................... 3 2. Pressure Lever Ass'y ............................................................................................ 4 3. Pressure Shaft Ass'y ............................................................................................. 5 3. Adjustment 1. Pressure Lever Ass'y Position ............................................................................... 7
MEMO
PRESS SECTION
THEORY OF OPERATION
1. Press Mechanism
1. Pressure Lever and Pressure Roller > The Pressure lever [D] is fixed with the Pressure shaft [G] at certain position. And the Pressure roller [A] stays on the Pressure ass'y [K], of which is fixed the Pressure shaft [G]. > While the Main motor [C] is making the Drum rotation without paper (not prininting process), the Pressure hook [H] engages with the Pressure lever [D] so that the Pressure shaft ass'y stays lower. > When paper comes in and pushes the Paper gate [J] up, the Pressure hook [I] is risen. So the Pressure lever [D] is released then the Cam follower [I] of the Pressure lever ass'y gets contact with the Pressure cam [E]. Thus the Pressure roller [A] is risen and contacted to the Drum when Drum rotation is at 218.2 degrees. > Pressure of the Pressure roller [A] is given to the Drum [F] by the Pressure spring [B]. > Once the Pressure lever [D] is released from the Pressure hook [H], movement of the Pressur lever [D] is controled by the Pressure cam [E]. > The Pressure hook becomes lower when the paper throughs out from the Paper gate [J]. Then the Pressure roller [A] is lowered by the Pressure cam [E] at the Drum rotation 118.5 degrees from the A-position where the Clamp plate on the Drum comes near the Pressure roller [A]. > The Pressure lever [D] becomes risen again by Pressure cam [E] at Drum rotation 218.2 degrees. F
E
1
A G
1
I
1
K B
D
1
HH Paper gate is pushed up by paper. And Pressure hook is raised. Then Pressure lever rises by Pressure cam at Drum 218.2. Pressure hook becomes lower when the paper throughs out. Then Pressure lever is risen by Pressure cam at Drum 118.5.
C A:Pressure roller B:Pressure spring C:Main moter D:Pressure lever ass'y E:Pressure cam F:Pressure shaft ass'y G:Pressure shaft H:Pressure hook I :Cam follower J :Paper gate K:Pressure ass'y
6-1
PRESS SECTION
THEORY OF OPERATION
Lifting the Pressure Roller The Paper gate is pushed up by paper throughout the printing. So the Pressure lever [B] becomes free. The Pressure spring [D] pulls back the Pressure lever [B] and rotates the Pressure shaft [E] which is acting as a pivot. The rotation of the Pressure shaft [E] lifts the Pressure roller [A] up against the Drum [C].
C E F
A
1
B
1
E Pressure hook becomes lower when the paper throughs out. Lowering the Pressure Roller The Pressure roller [A] is lowered by force, away from the Drum[C], by the high part of the Pressure cam [F]. During the Drum rotation, when the Clamp plate of the Drum comes close to the Pressure roller (drum rotation at 218.2 degrees), the high part of the Pressure cam [F] pushes the Pressure lever [B] down, rotating the Pressure shaft [E] counter-clockwise to bring the Pressure roller down, away from the Drum. Then Pressure lever [B] is lowered by Pressure cam [F] at Drum 118.5 degrees.
1
1
1
1
A:Pressure roller B:Pressure lever ass'y C:Drum D:Pressure spring E:Pressure shaft
6-2
PRESS SECTION

1. Pressure Roller
1. Disconnect the power supply from the machine. 2. Remove the Back cover from the machine.(See page 1-6) 3. Remove the Suction unit from the machine. (See page 7-5) 4. Remove mounting screw of the Pressure roller [C] from the Pressure shaft ass'y (refer to 6-5) through a hole on the drive side of the machin frame. 5. Take out the Pressure roller [B] from the Paper receiving side of the machine.
A B
A:Screw B:Pressure roller
6-3
PRESS SECTION
2. Pressure Lever Ass'y

1. Disconnect the power supply from the machine. 2. Remove Back cover.(See page 1-6) 3. Remove the Drum unit from the machine. (See page 8-7) 4. Remove set screws from the Pressure lever [A] ass'y. 5. Trun the Pressure lever [A] towards clockwise (Pressure lever shows up behined the gear) then remove the Pressure lever ass'y from the Pressure shaft.
Adjustment after the Assembly

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

1. Disconnect the power supply from the machine. 2. Remove the Drum from the machine. (See page 8-7) 3. Remove the Back cover and Front cover.(See 1-6) 4. Remove the Pressure lever ass'y [E]. (page 6-4) 5. Remove E-rings [C] from both ends of the Pressure shaft ass'y and remove the Metals [D]. 6. Remove the Suction unit. (See page 7-5) 7. Remove the Pressure spring [B]. 8. Slide the Pressure shaft ass'y towards the rear (drive side) of the machine once, and then remove it out from the Paper receiving side of the machine.
Adjustment after the Assembly

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

> If the gap is smaller than 2 mm, the Pressure roller leaves from the Drum earlier. As a result, printing area may become smaller. > If the gap is too big, the Pressure roller may hit the Clamp plate of the Drum during printing and damage the Clamp plate.
B D
Turn the Pressure shaft to lift the Pressure roller against the Drum.
2-2.5mm
Adjust the gap between the Pressure cam and Cam follower to 2mm - 2.5 mm by inserting 2 mm Allen wrench between the Cam and Cam follower.
1
A:Pressure lever ass'y B:Pressure cam C:Cam follower D:Hook lever C A
6-7
MEMO
6-8
CHAPTER
7:
PAPER EJECTION SECTION
CONTENTS
1. Theory of Operation 1. Paper Ejection Mechanism .................................................................................... 1 2. Paper Separation Mechanism ............................................................................... 3 2. Removal and Assembly 1. Suction Unit ........................................................................................................... 5 2. Transfer Belt ......................................................................................................... 6 3. Suction Fan ........................................................................................................... 7 4. Separation Fan Unit .............................................................................................. 8 5. Separation Fan ...................................................................................................... 9 6. Paper Receiving Sensor ........................................................................................ 9 7. Separator ............................................................................................................ 10 8. Paper Receiving Tray .......................................................................................... 11 3. Adjustment 1. Separator Position ............................................................................................... 13
MEMO

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

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

THEORY OF OPERATION
2. Paper Separation Mechanism

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


1. Suction Unit
1. Disconnect the power supply from the machine. 2. Remove Back cover.(See page 1-6) 3. Remove the Paper receiving tray. 4. Remove the Suction unit cover [B]. 5. Disconnect the Connector of the Suction unit [A]. 6. Remove two mounting screws of the Suction unit [A] and remove the unit by sliding it out.
> Hook the Suction unit [A] on both side of the plates on the machine frame. > Insert theFeet of the Suction unit cover [C] to holes of the Base plate [D].
C B
A:Suction unit B:Suction unit Cover C:Feet (of Suction cover) D:Base plate
7-5

2. Transfer Belt
1. Disconnect the power supply from the machine. 2. Remove Back cover. (See page 1-6) 3. Remove Suction unit. (See page 7-5) 4. Remove two mounting screws of the De-electricity brush and remove the brush. 5. Remove four mounting screws of the Suction face cover [B]. 6. Lift the face cover and remove the Belt driven shaft [D] by unhooking the Transfer belts [A]. 7. Remove E-ring of the Belt pulley shaft [C] and remove the Bearing [F]. 8. Slide the Belt pulley shaft [C] and remove the Transfer belts [A] from the Suction face cover [B].
KS500 & KS600
KS800
Remove the belts from this side.
C D
A:Transfer belts B:Suction face cover C:Belt pulley shaft D:Belt driven shaft E:De-electricity brush F:Bearing
> Match the half-pierced section on the Suction face cover [B] with its counter part. > Match the half-pierced section on the De-electricity brush [E] with its counter part.
7-6

3. Suction Fan
1. Disconnect the power supply from the machine. 2. Remove Back cover.(See page 1-6) 3. Remove Suction unit [B]. (See page 7-5) 4. Turn over the Suction unit [B] and disconnect the Connector of the Suction fan [A]. 5. Remove two mounting screws of the Suction fan [A] and remove the fan.
A:Suction unit B:Suction fan
7-7

4. Separation Fan Unit

1. Disconnect the power supply from the machine. 2. Remove Back cover.(See page 1-6) 3. Disconnect the Connector of the Separation fan unit [A]. 4. Remove two mounting screws of the Separation fan unit [A] and remove the unit.
> Match the half-pierced section on hinge of the Separation fan unit [B] with its counter part.
A A:Separation fan unit B:Hing (of Separation unit)
7-8

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

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

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

8. Paper Receiving Tray Unit

1. Disconnect the power supply from the machine. 2. Remove Back cover and Front cover. (See page 1-6) 3. Remove two mounting screws of the Paper receiving tray [D] with referring the Fig. a below then the Paper receiving tray [D]. 4. Remove the Paper ejection guide F [B] and the Paper ejection guide R [A]. 5. Remove the Paper back stop [C].
> Match the half-pierced sections on the Lock plates F and R with their counter parts.
KS500 & KS600
KS800
A C
Remove the Paper receiving tray by sliding it out.
D Fig.a
A:Paper ejection guide R B:Paper ejection guide F C:Paper back stop D:Paper receiving tray
7 - 11
MEMO
7 - 12

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

> If the tip of the Separator [B] is in contact with the Drum [C] , the Separator [B] will scratch the surface of the master on the Drum, creating a black line in the center of the printed copies and may damage the screens. > If the tip of the Separator [B is placed too far off the Drum [C], printed copies will not separate from the Drum [C], causing paper jams.
1.0 - 1.4mm
C C
1.0 - 1.4mm
B B A D [1] [2] E [1] direction :Increases the gap [2]direction :Decreases the gap
A:Separator lever B:Separator C:Drum D:Mounting screw E:Separator plate
7 - 13
MEMO
7 - 14
CHAPTER
8:
DRUM SECTION
CONTENTS
1. Theory of Operation 1. Master on Drum (in printing) Check Mechanism ................................................... 1 2. Ink Bottle Set Check Mechanism .......................................................................... 2 3. Ink Supply Mechanism .......................................................................................... 3 4. Squeegee Roller Rotation Mechanism .................................................................. 5 2. Removal and Assembly 1. Drum Unit .............................................................................................................. 7 2. Screen ................................................................................................................... 8 3. Drum Body ............................................................................................................ 9 4. Ink sensor PCB ................................................................................................... 11 5. Ink Bottle Guide ................................................................................................... 12 6. Ink bottle set Sensor ............................................................................................ 12 7. Drum Support F & Drum Support R ..................................................................... 13 8. Squeegee Roller .................................................................................................. 14 9. Ink Pump Unit ...................................................................................................... 17 10. Inking Motor ...................................................................................................... 18 3. Adjustment 1. Squeegee Gap .................................................................................................... 19
MEMO
DRUM SECTION
THEORY OF OPERATION
1. Master on Drum (in printing) Check Mechanism
1. Master Sensor > Master Sensor [B] checks the presence of master on the Drum before the start of printing. > 134 Drum rotation after the first Position-A, the Master Sensor [B] looks for the master [A] on the Drum. > The result (whether the master [A] is found or not) is memorized until the Drum is pulled out of the machine or the power is turned off. > If no master is detected on the Drum, [J1] is indicated on the Operation panel and stops the printing operation. A Drum angle = 134 (From position-A)
AAaaa
A: Master B: Master sensor Drum angle = 134 (From Position-A)
8-1
DRUM SECTION
THEORY OF OPERATION
2. Ink Bottle Set Check Mechanism

1. Ink bottle Set Sensor > Ink bottle set sensor[A] checks the presence of the Ink bottle[C] in the Ink bottle guide[B]. > There is an actuator plate[D] on the bottle set sensor ass'y as shown on below figure. > The machine will judge by the sensor staus, whether Ink bottle [C] is installed or not. If the Ink bottle [C] is not installed, the machine will indecate 'C5'. In case No bottle is installed A B
Ink bottle set sensor detects the actuator plate
In case bottle is installed
The actuator plate is released by ink bottle thus Ink bottle set sensor does not detect the actuator plate C A: Ink bottle set sensor B: Ink bottle guide C: Ink bottle D: Actuator plate
8-2
DRUM SECTION
THEORY OF OPERATION
3. Ink Supply Mechanism

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

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

1.1. Drum Unit
1. Disconnect the power supply from the machine. 2. Remove the Back cover and the Front cover (See page 1-6) 3. Slide out the Master removal unit to prevent the Master removal hooks from being damage by the Drum unit. 4. Remove the Separeter spring to keep away the Sparater from the Drum. (Refer to page 7-3) 5. Remove the following items from the machine; >Power supply PCB [C] >Main PCB cover [D], the Main PCB [E] with Main PCB bracket [F] >Load spring plate [A] >Ink bottle guide (See page 8-11)
C A: Load spring plate B:Power supply cover C:Power supply PCB D: Main PCB cover E: Main PCB A
B E
6. Disconnect connector of A detection sensor and connector of Inking motor[G]. 7. Remove four mounting screws of the Drum unit [H] then pull out the drum unit from the machine.
F: Main PCB brackett G: Inking motor H: Drum unit G
8-7
DRUM SECTION
2. Screen
1. Make a confidential master on the Drum. 2. Remove the Drum from the machine (See page 8-7) 3. Remove the two Screen springs [B]. 4. Remove two mounting screws (regular screws) of the Clamp plate base [C] which are also holding down the Screen [A] to the Drum. If neccessary loosen two Special screws [D] which are also on the Clamp plate base [C]. 5. Pull out the Screen [B] from under the Clamp plate base [C], and remove the Screen [B].
> Do not bend, wrinkle or damage the Screen [B]. B A C
A: Screen B: Screen springs C: Clamp plate base D: Special screw
8-8
DRUM SECTION
3. Drum Body
1. Make a confidential master on the Drum. 2. Remove the Drum from the machine.(See page 8-7) 3. Remove the Screen from the Drum. (page 8-8) 4. Remove two Special screws [E] from the Clamp plate base [A] and remove the base. 5. Remove remaining ten regular mounting screws and two more Special screws [E] holding the Drum body [B] to the Drum support F [C] and R [D]. 6. Separate the Drum body from the Drum supports [C][D], carefully to avoid damaging the Drum body [B]. (Refer to page 8-9 for the "Precaution in Assembly")
B A: Clamp plate base B: Drum body C: Drum support F D: Drum Support R E: Special screw
8-9
DRUM SECTION
> Do not bend or damage the Drum body. > The Drum body has and marks with F engraved next to one of the two arrow marks. The F mark indicates the "front" (Operation panel side). > Mount the screws on the two holes marked and first. Then mount the two Special screws [A] next to the first two screws.
A: Special screws A
> After the first and second set of the screws are in, temporary hook the Screen springs [B] in the manner shown by the illustration below. This is to pull and fit the Screen evenly on the Drum supports F and R.
B:Screen spring B
> Mount the remaining screws and remove the two temporary mounted Screen springs. > Mount the last two remaining screws and hook the Screen springs to complete the assembly. If necessary, refer to page 8-8 to check how the springs were hooked on the Drum.
8 - 10
DRUM SECTION
4. Ink Sensor PCB

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

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

1. Remove the Front cover (See page 1-6), Ink bottle guide. (See page 8-12) 2. Disconnect the connector of Ink bottle set sensor. 3. Remove a mounting screw of the Ink bottle set sensor ass'y [B]. 4. Remove the Ink bottle set sensor from the ass'y.
B:Ink bottle set sensor ass'y
8 - 12
DRUM SECTION
7. Drum Support F & Drum Support R

1. Make a confidential master on the Drum. 2. Remove the Drum from the machine (See page 8-7) 3. Remove following parts fron Drum unit; >Screen ass'y (See page 8-8) >Drum body (See page 8-9) >Ink sensor PCB (See page 8-11) 4. Disconnect the Connector of the Ink sensor PCB and pull out the Intermediate wire harness from the Drum U support BKT R [A]. 5. Loosen the Mounting screws [G1,2,3,4: cap screw]of Drum Shaft Clampers [F] to Drum support BKTs. 6. Loosen the Mounting screws [H1 & 2:set screw] of Drum Shaft Clampers [F] to the Drum center shaft [I]. 7. Remove Drum Support BKT R [A] and F [D] from the Drum center shaft [I]. 8. Remove Drum Support R [A] Ass'y [B] and Drum Support F Ass'y [C] from the Drum center shaft [I].
A B E I
H2
1
G3 G4
C H1
1
F
1
G1 G2
1
D A:Drum U Support BKT R B:Drum Support R Ass'y C:Drum Support F Ass'y D:Drum U Support BKT F E:Intermediate wire harness F:Drum Shaft Clampers G1-4: Mounting screws (cap screw) H1-2: Mounting screws (set screw) I :Drum center shaft
8 - 13
DRUM SECTION
8. Squeegee Roller
1. Make a confidential master on the Drum. 2. Remove the Drum from the machine (See page 8-7), and remove Ink bottle from the Drum. 3. Remove Ink bottle guide (See page 8-12) 4. Remove Drum support F & Drum support R (See page 8-13) 5. Remove following parts from the Drum unit. > Ink pump unit (See page 8-17) > Screen (See page 8-8) > Drum body (See page 8-9) 6. Remove Ink sensor PCB[K] (page 8-11) 7. Remove Ink blocking plates [F/G]. 8. Loosen securing screw on both side of Drum shaft joint then remove two mounting screws each from the Squeegee frames [I/J] on both ends. 9. Remove Center shaft ass'y [A]. 10. Remove both side of mounting screws and pull out Drive shaft gear [L] then remove Drive shaft [B] from the Squeegee unit. 11.Remove Squeegee drive gear [D] and Squeegee idler [E] from rear side of Squeegee roller shaft [M]. 12. Remove Transfer gear [H] from front side of Squeegee roller shaft [M]. (Continue to page 8-15) A: Center shaft B: Drive shaft C: Drum shaft joint D: Squeegee drive gear E: Squeegee idler F: Ink blocking plate F G: Ink bolcking plate R H: Transfer gear I: Squeegee frame F J:Squeegee frame R K: Ink sensor PCB L: Drive shaft gear M: Squeegee Roller C
C K B
D E G J M I
F L H
8 - 14
DRUM SECTION
14. 15. 16. 17.
Remove four screws each from the Drum main frames [C]. Remove the Squeegee frame R [A] and the Squeegee frame F [E]. Slowly take out the Squeegee roller [B]. The Doctor roller [D] will also come apart from the Squeegee unit.
CAUTION: Two O-rings [H] may fall off from the Squeegee block F [F] and R [G] when the Doctor roller [D] is removed. Do not lose these O-rings [H].
REAR
H D
F C A: Squeegee frame R B: Squeegee roller C: Drum Main Frame D: Doctor roller E: Squeegee frame F F: Squeegee block F G:Squeegee block R H:O-ring
FRONT
> Do not forget to return the two O-rings [H] in their original positions.
Adjustments after Assembly

> Squeegee gap adjustment is required. (See page 8-19)
(Continue to page 8-16)
8 - 15
DRUM SECTION
> When tightening the Drum shaft clampers [A], use the Adj. shaft [C] as a JIG to set the position. > Bring the Drum to the Position-A. Tighten both side of the Drum shaft clamper[A] of the Drum with four screws after placing the JIG[C] through the holes on the Drum U support BKT R [D], Drum support R ass'y [G], Drum support F ass'y [F] and the Drum U support BKT F [E].
REAR
1
FRONT
A
A:Drum shaft clamper B:Center shaft C:Drum grip shaft (JIG) D:Drum U support BKT R E:Drum U support BKT F F:Drum support F ass'y G:Drum support R ass'y
B B
F G E
D C
8 - 16
DRUM SECTION
9. Ink Pump Unit

1. Remove the Front cover (See page 1-6) 2. Remove the Ink bottle and remove the Ink bottle guide [B].(See page 8-12) 3. Disconnect the Connector of the Inking motor. 4. Remove two mounting screws of the Ink pump unit [A] and remove the pump unit.
> Match the half-pierced section of the Ink pump unit with its counter part.
A: Ink pump unit B: Ink bottle guide
8 - 17
DRUM SECTION
10. Inking Motor

1. Remove the Front cover.(See page 1-6) 2. Remove the Ink bottle and remove the Ink bottle guide.(See page 8-12) 3. Remove the Ink pump unit [A]. (See page 8-17) 4. Remove two mounting screws of the Inking motor [B] and remove the motor.
A B
A:Ink pump unit B:Inking motor
8 - 18
DRUM SECTION
ADJUSTMENT
3. Adjustment
1. Squeegee Gap
1. Make a confidential master on the Drum. 2. Remove the Drum from the machine.(See page 8-7) 3. Remove the Screen. (See page 8-8) 4. Remove the Drum body. (See page 8-9) 5. Clean out the ink from the Squeegee unit. 6. Using thickness gauge, measure the gap between the Squeegee roller and Doctor roller. The gap should be 0.08 mm 0.02 mm. If not, the gap should be adjusted. 7. To adjust, loosen the securing screw [B] of the Doctor roller adjust plate [A] located at both ends of the Squeegee unit by 3.0 mm Allen wrench. 8. Move the adjust plate [A] by inserting a rod, such as 2.5mm Allen wrench [D], in the Adj. hole [C] on the plate to change the Squeegee gap. 9. Tighten the securing screw of the two Doctor roller adjust plates after the adjustment is done.
Caution in Adjustment
> The Squeegee gap between the Squeegee roller and Doctor roller should be equal throughout the length of the two rollers.

> If the gap is too big: Too much gap will allow excess amount of ink to get on the inner surface of the Drum and results in ink leakage from the Drum. > If the gap is too small: Not enough ink transfers on the inner surface of the Drum and the prints may come out with uneven print density. C B A A: Doctor roller adjust plate B: Securing screw C: Adj. hole D: 2.5mm Allen wrench
NARROWER
0.08 mm 0.02mm
(REAR)
WIDER
D C
NARROWER
0.08 mm 0.02mm
(FRONT)
WIDER
8 - 19
MEMO
8 - 20
CHAPTER
9:
PAPER JAM
CONTENTS
1. Theory of Operation 1. Paper Jam at First Paper Feed Area ..................................................................... 1 2. Paper Jam at Paper Receiving Area ..................................................................... 2 3. Print Start Timing Chart ......................................................................................... 3 4. During the Printing Timing Chart ........................................................................... 4 5. Print Stop Timing Chart ......................................................................................... 5
MEMO
PAPER JAM
THEORY OF OPERATION
1. Paper Jam at Paper Feed Area
1. Paper recieving sensor > Paper recieving sensor[D] checks for paper every time the Drum angle at 334 and 104 turn from the Position-A during printing. > If the Paper recieving sensor does not detect paper either angle at Drum 334 nor 104, the machine assumes paper has jammed at the paper feed area and displays message [J 2].
Drum 334 Drum 104 Drum 334 Drum 104
Main motor
ON ON
Position-A sensor
Blocked Blocked
Paper recieving sensor
A:If the Paper recieving sensor does not detect any paper at Drum angle from 334 to 104, the machine assumes paper jam occurred and displays [J 2]. NORMAL PAPER FEED A E
C Drum at 104 A: Pickup roller B: Paper C: Pressure roller D: Paper receiving sensor E: Drum PAPER JAM AT PAPER FEED AREA Drum at 334
Drum at 104
Drum at 334
9-1
PAPER JAM
THEORY OF OPERATION
2. Paper Jam at Paper Receiving Area

1. Paper Receiving Sensor > Paper receiving sensor checks for paper during the printing operation. > If paper is detected by Paper receiving sensor within one rotation of the Drum from drum position at 257 to 280 , the machine assumes paper has jammed at the Paper receiving area and displays message [J 3]. 0 0 180 257 280 Main motor ON
Position-A sensor
Looks at the paper
Paper receiving sensor
Paper Detected
Open
A
A: Paper recieving sensor does not detect the paper at the drum angle from 257 to 280. NORMAL PAPER DISCHARGE Drum at 257 B Drum at 280 D A
A: Paper recieving sensor B: Paper C: The previous paper D: Drum PAPER JAM AT PAPER RECEIVING AREA Drum at 257 Drum at 280
Paper stays under the Paper receiving sensor from Drum position at 257 to 280. The paper has stuck on the suction unit or stuck with the separator.
9-2
PAPER JAM
THEORY OF OPERATION
3. Printing Start Timing Chart

Press START button 0 Drum angle Position-A sensor Main motor Paper receiving sensor Paper feed clutch Timing clutch Separation fan Suction fan ON
1. 2. 3. 4. 60 rpm: 66.3 / 90 rpm: 63.7 60 rpm: 144.8 / 90 rpm: 142.2 60 rpm: 160.3 / 90 rpm: 157.7 60 rpm: 61.3 / 90 rpm: 58.7 30 rpm
Blocked Blocked Blocked
90
180
270
66.3
160.3
334 0
ON No detection
60 rpm 90 rpm
Detection
1st paper
1 ON 2
1st paper
2nd paper
ON
1. When the drum angle becomes 66.3 or 63.7 degrees, the Paper feed clutch is turned ON. 2. When the drum angle becomes 144.8 or 142.2 degrees, the Paper feed clutch is turned OFF. 3. When the drum angle becomes 160.3 or 157.7 degrees, the Timing clutch is turned ON. 4. When the drum angle becomes 61.3 or 58.7 degrees, the Timing clutch is OFF.
9-3
PAPER JAM
THEORY OF OPERATION
4. During the Printing Timing Chart
334 0 Drum angle Position-A sensor Main motor Paper receiving sensor Paper feed clutch
104
257 280
104
280
Blocked
1. J 2 Detection ON
2. J 3
ON Detection
Detection
Timing clutch Separation fan Suction fan Total counter count
ON
ON
ON
Count of A
Count of B
1. The Paper receving sensor checks whether the paper feeding is correct or not. If the Paper receiving sensor does not detect paper at Drum angle 334 and 104 , the machine assumes that the paper jam has occurred in the paper feeding area and indicates the message [J 2]. 2. The Paper receving sensor checks whether the paper feeding is correct or not. If the Paper receiving sensor detects paper at Drum angle 257 and 280 , the machine assumes that the paper jam has occurred in the paper receiving area and indicates the message [J 3].
9-4
PAPER JAM
THEORY OF OPERATION
5. Print Stop Timing Chart

Print quantity on the Display panel becomes "0" or Press "STOP Key" 334 Drum angle 1 Position-A sensor
Blocked
The TIMING CHART below is identical for both when the printing movement stops automatically by the print quantity count on the Operation panel becomes "0" (Printing finished) and when the STOP button is pressed manually.
104 257 280
104
315
Blocked
Blocked
2 Main motor Paper receiving sensor ON 60 or 90 rpm 15 rpm No detection
4
1.95 rpm
OFF
Detection
(Last paper)
Separation fan Suction fan Total counter count
ON
OFF
(Count of the last paper)
1 When the Paper receiving sensor changes from "detecting ( the drum at 334 and 104 ) " to "not detecting" (the drum angle at 257 and 280 ), the count signal is activated and the print quantity display on the Panel is decreased by one count and the Copy counter count goes up one count. If at this time the print quantity display on the Panel becomes zero "0" or the STOP key is pressed, the print stop movement starts from the next Drum position-A. 2 When the next Drum position-A is detected, the Drum rotation speed becomes 15 rpm to be ready for the stopping the Drum rotation. 3 The Drum rotation speed becomes 1.95 rpm at Drum angle 315 . 4. Then the Main motor completely stops at the Drum position-A.
9-5
MEMO
9-6
CHAPTER
10:
MASTER CLAMP SECTION
CONTENTS
1. Theory of Operation 1. Clamp Unit Positioning Mechanism ....................................................................... 1 2. Clamp Plate Master Release Mechanism ............................................................. 2 3. Clamp Plate Master Clamp Mechanism ................................................................ 4 2. Removal and Assembly 1. Clamp Unit ............................................................................................................ 7 2. Clamp Motor .......................................................................................................... 8 3. Clamp Sensor C .................................................................................................... 8 4. Clamp Sensor L .................................................................................................... 8
MEMO

THEORY OF OPERATION
1. Clamp Unit Positioning Mechanism
1. Clamp Sensors C and L > The Clamp plate arm [A] and the Master projection plate arm [E] of the Clamp unit are checked by the Clamp sensors C [C] and L [F] to see if they are in home position every time the START button is pressed for the machine operation with the drum rotation. > The Clamp unit is at its home position when the light paths of Clamp sensor C [A] and Clamp sensor L [F] are both opened. > If the light path of Clamp L [F] and C [C] sensor is cut when the start button is pressed, the machine indicates [E 3] immediately.
F C B A D E
A:Clamp plate arm B:Clamp motor C:Clamp sensor C D:Clamp encoder disc E:Master projection plate arm F:Clamp sensor L G:Clamp cam assembly
C *Light paths of the Clamp sensors C and L are both opened at Home position.
10 - 1

THEORY OF OPERATION
2. Clamp Plate Master Release Mechanism

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

THEORY OF OPERATION
Clamp Plate Master Release Timing Chart

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

THEORY OF OPERATION
3. Clamp Plate Master Clamp Mechanism

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

THEORY OF OPERATION
Master Clamping Timing Chart

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


1. Clamp Unit
1. Disconnect the power supply from the machine. 2. Remove Back cover. (See page 1-6) 3. Disconnect the Connectors of the following three electrical parts. > Clamp motor [A] > Clamp sensor C [C] > Clamp sensor L [D] 4. Remove three mounting screws of the Clamp unit [A] and remove the unit.
> Match the half-pierced section on the Clamp unit [A] with its counter part.
NOTE: The Clamp Unit used on KS800 may look a little different.
A: Clamp unit B: Clamp motor C: Clamp sensor C D: Clamp sensor L
B C D A
10 - 7

2. Clamp Motor
1. Disconnect the power supply from the machine. 2. Remove Back cover. (See page 1-6) 3. Remove Clamp unit. (See page 10-7) 4. Remove two mounting screws of the Clamp motor [A] and remove the motor.
3. Clamp Sensor C
1. Disconnect the power supply from the machine. 2. Remove Back cover.(See page 1-6) 3. Remove Clamp unit. (See page 10-7) 4. Remove the mounting screw of the Clamp sensor C [C] bracket with the sensor attached. 5. Remove the sensor from the bracket.
> Match the half-pierced section of the Clamp sensor bracket with its counter part.
4. Clamp Sensor L
1. Disconnect the power supply from the machine. 2. Remove the Back cover. (See page 1-6) 3. Remove Clamp unit. (See page 10-7) 4. Remove the mounting screw of the Clamp sensor L [B] and remove the sensor.
> Match the half-pierced section of the sensor with its counter part.
NOTE: The Clamp Unit used on KS800 may look a little different.
A: Clamp motor B: Clamp sensor C C: Clamp sensor L C
10 - 8
CHAPTER
11:
MASTER REMOVAL SECTION
CONTENTS
1. Theory of Operation 1. Master Removal Unit Mechanism .......................................................................... 1 2. Master on the Drum (before master removal) Check Mechanism ......................... 2 3. Clamp Plate Master Release Mechanism ............................................................. 4 4. Master Removal Mechanism ................................................................................. 6 5. Master Disposal Box Set Mechanism .................................................................... 8 2. Removal and Assembly 1. Master Removal Unit ............................................................................................. 9 2. Master Removal Clutch ....................................................................................... 10 3. Master Removal Sensor ...................................................................................... 11 4. Disposal Box Set Sensor ..................................................................................... 11 5. Master Removal Hook ......................................................................................... 12 6. Vertical Transport Roller (Upper) ......................................................................... 13 7. Vertical Transport Roller (Lower) ......................................................................... 13 8. Master Removal Guide (Lower) ........................................................................... 13
MEMO

THEORY OF OPERATION
1. Master Removal Unit Mechanism
> The Master removal unit [A] removes the master on the drum each time the master making operation is made. > The Master removal hooks [D] guide the removed master towards the Master disposal box [C]. > The Transpotation roller upper [E] and lower [F] are engaged via gears. And rotation of the transpotation roller upper and lower is made by the rotation of the Main motor via the Mater removal clutch [B].
A C
(for KS500)
E F
A B (for KS600)
One for KS800 looks a little different.
(for KS500 & KS600)
(KS800 uses master removal motor instead of a clutch.)
A:Master removal unit B:Master removal clutch C:Master disposal box D:Master removal hook E:Transpotation roller upper F:Transpotation roller lower
11 - 1

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

1. Master Sensor > Master sensor [B] checks the presence of the Master [D] on the drum when the Start button is pressed for confidential master making or normal master making. > The sensor [B] looks for the Master [D] on the drum when the Drum rotates 134 from the Position-A. > If the machine already knows the presence of the Master [D] on the drum from the earlier machine operations, this Master checking movement is skipped. 2. When master is detected on the Drum > The machine goes into master removal and Master removal sensor becomes active. 3. When master is not detected on the Drum > The machine skips the master removal movement and goes directly into master making. C
B D
A:Light absorber strip B:Master sensor C:Drum D:Master
Drum angle = 134 (From Position-A)
11 - 2

THEORY OF OPERATION
Master on the Drum Check Timing Chart (before master removal)
Press START button 1 Blocked Position-A sensor Open
Blocked
Drum at 134
Detecting master
Master sensor
Main motor
ON
OFF
1 The Drum is at Position-A when the START button is pressed. 2 If the light of the Master sensor is reflected back (detecting master) at Drum 134 , the Master removal sensor becomes active and checks the master during the master removal. If the light of the Master sensor is not reflected back (master not detected) at Drum 134 , master removal movement will be skipped.
If the machine knows the presence of master on the Drum from earlier machine movements, this master on the Drum check movement is skipped.
11 - 3

THEORY OF OPERATION
3. Clamp Plate Master Release Mechanism

1. Master on the Drum check > When the START button is pressed for confidential or regular master making, the Drum rotates and presence of the master on the Drum is checked. > If a master is found on the Drum, the master release movement is made after the Drum returns to Position-A. 2. Clamp open arm & Master release arm > The Clamp open arm [B] comes down first and opens the Clamp plate [C] to free the leading edge of the master. > Next, the Master release arm [D] comes down and raises the Master release bar [E] to push the leading edge of the master out of the Clamp plate [C]. > The Clamp motor continues to rotate the Clamp cam ass'y [A] until both the Clamp open arm [B] and Master release arm [D] are lifted to closes the Clamp plate [C] and the Master release bar [E]. > The master release movement is completed when the light path of the Clamp sensor L [G] becomes open and the Clamp motor stops. A D
1 1
B E C
G
1
A:Clamp cam ass'y B:Clamp open arm C:Clamp plate D:Master release arm E:Master release bar F:Clamp sensor C G:Clamp sensor L
11 - 4

THEORY OF OPERATION
Clamp Plate Master Release Timing Chart

Start button is pressed Start button is pressed
0 Clamp encoder
Open
180
270
180
270
Clamp sensor L
Blocked
Clamp sensor C 4
123 123 123 123 123456789012345678901234
3
123 1234567890123456 123
2 Max. 10sec 1234 123

123
Max. 10sec
Max. 10sec
1 If the Start button is pressed when the light path of the Clamp sensor L is not blocked and the Clamp sensor C is blocked, the Clamp motor is activated to make the light path of the Calmp sensor L and C unblocked within 10 seconds. If the both could not be opened within 10 seconds, the machine assumes that the Clamp motor has locked and displays error message [E 3]. 2 If the light path of Clamp sensor L and C does not become blocked within 10 seconds after the light path of the Clamp sensor L and C became opened, the machine assumes that the Clamp motor has locked and displays error message [E 3]. 3 If the light path of Clamp sensor C does not become blocked and that of Clamp sensor L does not become open within 10 seconds after the light path of the Clamp sensor L and C became blocked, the machine assumes that the Clamp motor has locked and displays error message [E 3]. 4 When START button is pressed, the machine confirms whether the light path of Clamp sensors L and C are opened or not. If the light paths of Clamp sensors L and C are not both open, the machine will display [E 3] immediately.
11 -5

THEORY OF OPERATION
4. Master Removal Mechanism

1. Master Removal Clutch > The Main motor rotatates the Vertical transport roller upper [B] and lower [A] via the Mater removal clutch [E]. > By the rotation of the Drum, the leading edge of the master comes in between the Vertical Transport roller upper [B] and lower [A] and the separation of the master from the Drum starts. > The Main motor stops to complete the master removal movement when the Drum comes back to the Position-A after making one rotation to remove the master. 2. Master Removal Hooks > The master removed from the Drum is guided in between the Vertical transport roller upper [B] and lower [A] by the Master removal hooks [D]. 3. Master Removal Sensor > Master removal sensor [C] checks the presence of the removed master in front of the Master disposal box to check for master removal jams. > The Master removal sensor [C] looks for presence of removed master at134 Drum rotation from Position-A.
Sketch of master disposal box for KS500. (That for KS600 & KS800 looks different.)
D C
A:Vertical transport roller (lower) B:Vertical transport roller (upper) C:Master removal sensor D:Master removal hook E:Master removal clutch
11 - 6

THEORY OF OPERATION
Master Removal Timing Chart
0 Position-A sensor
Main motor
Master removal clutch
Master removal sensor
0 1 1 1 1 1 1 1 1 1 Open 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ON 1 1 1 123 12 123 123 123 1 1.95rpm 1 1 123 1234567 121234567890123456789012345678901212 123 123123456789012 123 1 1 1 1 1 1 1 1 15rpm 15rpm 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ON 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Detecting removed master 1 1 1 1 1 1 1 1 12 1 1 2 1 12 1 1 12 1
1 134 1
315
Blocked
OFF
OFF
12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901 12345678901
1 During the initializing of the drum towards the position A in the master removal operation, if removed master is detected by Master sensor at Drum angle 134 , the Master removal sensor looks for the removed master. If removed master is not detected by the Master removal sensor at Drum 134, the machine assumes master removal error has occurred and displays the message [J 9]. 2 When the Drum returns to Position-A and the Master removal sensor confirms the removed master has cleared through the sensor. If the Master removal sensor still detects removed master, the machine assumes removed master has jammed at master removal area and displays message [J10].
If Master removal sensor detects removed master when the Start button is pressed, the machine assumes that the removed master is jammed and the message [J10] is displayed.
11 - 7

THEORY OF OPERATION
5. Master Disposal Box Set Mechanism

1. Disposal Box Set Sensor > Disposal box set sensor checks the presence of the Master disposal box and whether the Master disposal box is opened or closed. > When the Master disposal box is set in the machine, its tip blocks light path of the Disposal box set sensor.
Sketch of master disposal box for KS500.
B Sketch of master disposal box for KS600. (That for KS500 and KS800 looks different.)
A:Disposal box set sensor B:Master disposal box C:Tip D:Master removal unit (closed)
11 - 8


1. Master Removal Unit
1. Disconnect the power supply from the machine. 2. Pull up the Master removal unit lever [C] then slide the Master removal unit [A] out. 3. Remove Master removal cover (See page 1-6) 4. Disconnect the Connector [D] of the Master removal unit. 5. Remove the four mounting screws[E] of the Master removal unit. 6. Remove the Master removal unit [A].
B Sketch of master disposal box for KS600.

(That for KS500 and KS800 looks different.)
C D
A:Master removal unit B:Master Disposal Box C:Master removal unit lever D:Connector
11 - 9

2. Master Removal Clutch
KS500 & KS600 only
KS800 uses Master removal motor instead of a clutch.
1. Disconnect the power supply from the machine. 2. Remove the Back cover. (See page 1-6) 3. Remove the Master removal unit.( See page 11-9) 4. Remove the E-ring [F] and remove M-R gear [E]. 5. Remove two mounting screws of the Clutch B bracket [A] and remove the bracket. 6. Disconnect the Connector of the Master removal clutch [C]. 7. Remove the Master removal clutch [C].
> Mount the slit on the Master removal clutch [C] over the Clutch B bracket [A].
E C
(for KS500 & KS600)
(KS800 uses master removal motor instead of a clutch.) A:Clutch B BKT B:Metal C:Master Removal Clutch D:Metal E:M-R Gear F:E-ring
11 - 10

3. Master Removal Sensor

1. Disconnect the power supply from the machine, and remove Master removal cover.(See page 16) 2. Slide the Master removal unit out. 3. Disconnect the Connector of the Master removal sensor [C]. 4. Remove the mounting screw of the Master removal sensor bracket and remove the bracket. 5. Remove the sensor from the bracket.
> Match the half-pierced section of the Master removal sensor bracket with its counter part.
4. Disposal Box Set Sensor

1. Disconnect the power supply from the machine, and remove Master removal cover.(See page 16) 2. Disconnect the Connector of the Disposal box set sensor [A]. 3. Remove the mounting screw of the Disposal box set sensor bracket and remove the bracket. 4. Remove the sensor [A] from the bracket.
A:Disposal box set sensor B:Master removal Unit C:Master removal sensor
11 - 11

5. Master Removal Hook

1. Remove Master removal unit [A]. (See page 11-9) 2. Disengage the Master removal hooks [B] from the Master removal unit [A] and remove the hooks.
> Engage the tips of the Master removal hooks with the counter parts correctly. > Do not apply unnecessary force to the Master removal hooks to avoid any damage of the hooks.
A:Master removal unit B:Master removal hooks
11 - 12

6. Vertical Transport Roller (Upper)

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

1. Disconnect the power supply from the machine. 2. Remove the Master disposal box. [F]. 3. Remove the Master removal unit.(See page 11-9) 4. Remove the Master removal sensor. (See page 11-11) 5. Remove the Master removal guide (Upper) [A]. 6. Remove the Vertical transport roller (Upper) [B]. 7. Remove E-ring then remove the Transpot roller gear [G]. 8. Remove E-ring of the Vertical transport roller (Lower) [C] and remove the Metals.
8. Master Removal Guide (Lower)

1. Disconnect the power supply from the machine. 2. Remove the Master disposal box [F]. 3. Remove the Master removal unit.(See page 11-9) 4. Remove the Master removal sensor. (See page 11-11) 5. Remove the Master removal guide (Upper)[A]. 6. Remove the Vertical transport roller (Upper) [B] and (Lower) [C]. 7. Remove three mounting screws then remove the Master removal guide(Lower) [E].
A H
E B
C G
A:Master removal guide (Upper) B:Vertical transport roller (Upper) C:Vertical transport roller (Lower) D:Master removal unit E:Master removal guide (Lower) F:Master disposal box G:Transport roller gear H:Master removal sensor
F
Sketch of master disposal box for KS500. (That for KS600 & KS800 looks different.)
11 - 13
MEMO
11 - 14
CHAPTER
12:
IMAGE SCANNING SECTION
CONTENTS
1. Theory of Operation 1. Original Loading Mechanism ................................................................................. 1 2. Original Scanning Mechanism ............................................................................... 3 3. Image Scanner ...................................................................................................... 5 2. Removal and Assembly 1. White Roller .......................................................................................................... 7 2. Image Scanner Unit .............................................................................................. 8 3. Original IN Sensor ................................................................................................. 9 4. Pickup Roller ....................................................................................................... 10 5. Eject Roller Upper ............................................................................................... 10 6. Document Feeder Hook ...................................................................................... 10 7. Load Roller .......................................................................................................... 11 8. Eject Roller Lower ............................................................................................... 11 9. Read Pulse Motor ................................................................................................ 11 3. Adjustment 1. Image scanner gain adjustment .......................................................................... 13
MEMO

THEORY OF OPERATION
1. Original Loading Mechanism
An original placed on the Original rack [G] is automatically fed when the master making process is started. 1. Shading Compensation > When the Original IN sensor [I] detects the original, the LED of the Image scanner [H] turns ON and the shading compensation takes place. 2. Original Loading > After the shading compensation is done, the Read pulse motor [A] activates to start feeding the original by rotating the Pickup roller [B] and Load roller [F]. > The original put on the Original rack [G] is fed into between the Image scanner [H] and the White roller [C]. Then the original is fed towards the Eject roller upper [E] and lower [J] by rotation of the White roller [C]. > The Eject roller upper [E] and lower [J] feeds the original then ejects it from the document feeder. D C H E B F J I G
A: Read pulse motor B: Pickup roller C: White roller D: Original detection sensor E: Eject roller upper F: Load roller G: Original feed tray H: Image scanner I :Original IN sensor J :Eject roller lower
12 - 1

THEORY OF OPERATION
Original Loading Timing Chart
Original set Original IN sensor No detection
Motion ends 2 Original detected
1 Scanner LED ON OFF ON OFF
150 ms 150 ms 150 ms ON Read pulse motor OFF Max. 5sec. 293 pulses
1 The Image scanner [H] LED activates for shading compensation. 2 If the original IN sensor[D] does not detect an Original within 5 seconds after the Read pulse motor[A] activates, the machine assumes the original has jammed and indicates the message [J 7], and turns off the Read pulse motor[A]. 3 The original loading ends when the Read pulse motor[A] rotates 293 pulses after the Original IN senor[D] detects the Original and the Read pulse motor[A] turns OFF. E D C H G B
A: Read pulse motor B: Pickup roller C: White roller D: Original detection sensor E: Eject roller F: Load roller G: Original IN sensor H: Image scanner I : Eject roller lower
12 - 2

THEORY OF OPERATION
2. Original Scanning Mechanism

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

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

THEORY OF OPERATION
3. Image Scanner
The image scanning is done by an optical type Image scanner [A] which emits greenish-yellow light from LED array [B] against an original and catches the image after it is reflected. 2048 pieces of photo transistors are installed as the receiving elements of the scanner. Those receiving elements are combined as the Photo transistor array [C]. And the Image scanner covers around 260mm width which is about the size of B4 width. Therefore the scanner is called Contact Image Scanner (CIS).
Top view
A:Image scanner unit B:LED array C:Photo transistor array
12 - 5
MEMO
12 - 6


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

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

2. Image Scanner Unit

1. Disconnect the power supply from the machine. 2. Remove the Document feeder [D]. (See page 12-7) 3. Remove the Document feeder cover. 4. Disconnect the connector of the Image scanner [A]. 5. Take out the scanner [A] from the machine. > If needed, remove the mounting screws of the Scanner holder R [C] and L [B] from the Scanner unit. C A
B D
A:Image scanner unit B:Scanner holder L C:Scanner holder R D:Document feeder
12 - 8

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

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

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

1. Disconnect the power supply from the machine. 2. Remove the White roller cover upper [E] from the document feeder. (See page 12-7) 3. Remove the Hook springs [G]. 4. Remove Document feeder hook[F].
A G B
H C D A:Eject roller spring B:Eject roller upper C:Pick up roller spring D:Pick up roller E:White roller cover upper F:Document feeder hook G:Hook spring H:White roller cover lower
12 - 10

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

1. Disconnect the power supply from the machine. 2. Remove the Document feeder (See page 12-7) and the Document feeder cover. 3. Remove both side of E-rings then remove metals and gears from shaft of the Eject roller lower [A]. 4. Remove the Pin [D] from the shaft. 5. Remove the Eject roller lower [A] from the unit.

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

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

> Connector of the Read pulse motor [C] should face to the Image scanner side when install the motor[C].
A:Eject roller B:Load roller C:Read pulse motor D:Pin KS Series (Version 3.1)
12 - 11
MEMO
12 - 12

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

> Do not short circuit the 1 pin with the 2 pin when connecting the Digital multi meter with the CN 111.
A: VR 1 B: CN111 C:Main PCB D:Digital multi meter
12 - 13
MEMO
12 - 14
CHAPTER
13:
CUTTER SECTION
CONTENTS
1. Theory of Operation 1. Cutter Home Positioning Mechanism .................................................................... 1 2. Cutting Mechanism ............................................................................................... 3 2. Removal and Assembly 1. Cutter Unit ............................................................................................................. 5
MEMO
CUTTER SECTION
THEORY OF OPERATION
1. Cutter Home Positioning Mechanism
1. Home Position Switch > Each time the machine power is turned ON or All Reset Button is pressed, the Home position switch [D] checks the position of the Cutter [B]. > The Cutter position is checked by the Home position switch [B] and the End position switch [D], of which is located the opposit end of the Cutter rail. 2. Home Position > The Home position of the Cutter [B] is where the Home position switch [D] is detected. > If the Home positioning switch [D] is not detected, the Cutter motor [C] activates and rotates the Cutter gear [E] until the Home position switch [B] becomes detecting. F A D
A:Cutter Unit B:Cutter C:Cutter motor D:Home position switch E:Cutter gear F:End position switch
13 - 1
CUTTER SECTION
THEORY OF OPERATION
Cutter Home Positioning Timing Chart

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

1. Cutter Unit
1. Disconnect the power supply from the machine. 2. Remove the Front cover. (See page 1-6) 3. Open the Master making unit. 4. Disconnect the Connector of the Cutter unit [A]. 5. Remove the mounting screws of the Cutter unit [A] and remove the unit.
> Match the half-pierced sections of the Cutter unit with its counter part.
FRONT
A:Cutter unit
13 - 5
CHAPTER
14:
MASTER MAKING SECTION
CONTENTS
1. Theory of Operation 1. Master Making ....................................................................................................... 1 2. TPH Positioning .................................................................................................... 3 3. Thermal Power Safety Switches ............................................................................ 5 2. Removal and Assembly 1. Write Roller ........................................................................................................... 7 2. Thermal Print Head (TPH) ..................................................................................... 8 3. TPH Position Sensor ............................................................................................. 9 3. Adjustment 1. Thermal Power of Thermal Print Head ................................................................ 11
MEMO

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-CTL signal is turned ON to supply heating power to the Thermal print head [A]. 1. Start of the Master Making > While the Drum is rotates to remove the master on the Drum, the Write pulse motor [D] activates and starts feeding the master material from the master roll 50 ms after the Drum rotates 100 from the first Drum Position-A. > At the same time the original starts feeding through the ADF unit for scanning. > As the Write pulse motor activates and feeds the master for 5mm, the Read & Write start signal is turned ON and the Thermal print head begins making image on the master material. 2. End of the Master Making > After a certain set time, the Master tension plate solenoid activates and swings down the Master tension plate. > The master runs through the Master tension plate and as the Master tension plate swings down, it gives tension on the master while the master is loaded on the Drum. > Either the original scanning ends or if the Write pulse motor activates for the maximum master making length, both the TPH-CTL signal and Read & Write start signal turn OFF. > The Write pulse motor is still activated until full length of master material is transferred. The Write pulse motor then stops and completes the master making process.
A:Thermal print head (TPH) B:Write roller C:Master roll D:Write pulse motor
14 - 1

THEORY OF OPERATION
1. Master Making Timing Chart

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

THEORY OF OPERATION
2. TPH Positioning
The TPH [C] moves down and up when master feeding is necessary or the master making process is ended. When the TPH unit [C] is at the home position, the TPH unit detouch the Write roller [B]. When the Master making starts, the TPH unit [C] is lowered by the Write pulse motor [D]. Rotation of the Write pulse motor is transferred to the TPH position cam [E] via geras on the Master making unit. 1. TPH position sensor >The TPH position sensor [A] checks whether if the TPH stays upper or not. >If the light path of the TPH position sensor is changed from "unblocked" to "blocked", the machine assums that the TPH stays at upper position.(The TPH detouchs the Write roller) >If the light path of the TPH position sensor is changed from "blocked" to "unblocked", the machine assums that the TPH stays at lower position.(The TPH touchs the Write roller)
Spring force E
C B
A Sensor blocked
TPH detouching
Sensor opened
TPH Touching
D A:TPH positioning sensor B:Write roller C:TPH unit D:Write pulse motor E:TPH position cam
14 - 3

THEORY OF OPERATION
2. TPH Positioning Timing Chart

1. From Original set to Preparation of Scanning
Read pulse motor
ON
OFF
ON ON CW
White pulse motor TPH position sensor
ON CCW
ON CW
Blocked
2. From Master making to Master cutting Master making ended Master cutting Read pulse motor White pulse motor
OFF
ON CW ON CCW
TPH position sensor
OFF Blocked
Blocked
14 - 4

THEORY OF OPERATION
3. Thermal Power Safety Switches

1. Safety Switches > The actuators of all four safety switches must be pressed in order to feed electrical power to the TPH unit. > These four switches also acts as Main motor safety switches.
A:Master removal unit safety switch B:Guide plate safety switch C:Master making unit safety switch D:Separation unit safety switch
14 - 5
MEMO
14 - 6


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

2. Thermal Print Head (TPH)

1. Disconnect the power supply from the machine. 2. Open the Master making unit. 3. Disconnect the TPH connectors [A] out from the TPH ass'y [D]. 4. Remove the screw of the Grand wire [B]. 5. Remove the TPH ass'y screws [C]. 6. Slide the TPH ass'y [D] up to release from the Master making unit. 7. Remove two mounting screws of the TPH position plate [E] from the TPH ass'y [D].
A:TPH connector B:Ground wire C:TPH ass'y screw D:TPH ass'y E:TPH position plate
Precautions in Removal
> Do not touch the Connector pins [A] on the TPH ass'y [D], as static electricity may damage the TPH ass'y [D]. > Do not contact the heat emitting portion of the TPH ass'y [D] against hard surfaces.

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

3. TPH Position Sensor

1. Disconnect the power supply from the machine. 2. Open the Master making unit [D]. 3. Remove the Springs [A] from the Master making unit [D]. 4. Remove the the Master making upper unit cover [B]. 5. Remove the Position sensor plate [C]. 6. Remove the connector of the TPH position sensor [E]. 7. Remove the TPH position sensor [E] from the Master making unit [D].
A: Spring B: Master making upper unit cover C: Position sensor plate D: Master making unit E: TPH position sensor
14 - 9
MEMO
14 - 10

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

No.1 pin No.3 pin
CN008
FINE Adj. VR
NORMAL Adj. VR
* TPH Adjustment Table is the next page
14 - 11
MEMO
13 - 6

ADJUSTMENT
TPH Adjustment Table

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

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

THEORY OF OPERATION
1. Master Making Unit Set Mechanism
1. Master Making Unit Safety Switch > When the Master making unit is closed, the Master making unit safety switch [A] is also pressed by the Master making unit upper frame [B]. When the Master making unit safety switch [B] is not pressed, the power to the Main motor and TPH is terminated. 2. Master End Sensor > The Master end sensor [C] detects the black strip on the master material at the very end of the master roll and indicates the "Replace master roll" message, [C 6].
A:Master making unit safety switch B:Master making unit upper frame C:Master end sensor
15 - 1

THEORY OF OPERATION
2. Master Positioning Mechanism

1. Master Positioning > The leading edge of the master material [A] rests against the Master tension plate [C] just after the master loading. > As the START button is pressed for normal master making or confidential master making, the Master loading solenoid [F] activates to release the Mater tension plate [C] from master and the Write pulse motor [E] activates and rotates the Write roller [B] to feed the master material [A]. > When the Master positioning sensor [D] detects the leading edge of the master [A], the Master loading solenoid [F] and the Write pulse motor [E] turn OFF and completes the master positioning movement.
A
1
A:Lead edge of the master B:Write roller C:Master tension plate D:Master positioning sensor E:Write pulse motor F:Master loading solenoid
15 - 2

THEORY OF OPERATION
Master Positioning Timing Chart

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

THEORY OF OPERATION
3. Master Feeding Mechanism

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

THEORY OF OPERATION
Master Feeding Timing Chart

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

THEORY OF OPERATION
4. Clamp Plate Master Clamp Mechanism

1. Master removal > During the master removal movement, when the Drum comes back to position-A, the leading edge of the new master comes towards the Drum, ready to be clamped. 2. Master clamping > With the activation of the Clamp motor, the Clamp plate arm [G] is pushed down to open the Clamp plate [C]. The Clamp plate arm [G] and the Master projection plate arm [E] are moved by following the Clamp cam [B]. > The Clamp motor stops when the light path of Clamp sensor C [D] becomes open and keeps the Clamp plate [C] raised open. > When the Write pulse motor sends certain set amount of master [H] onto the Drum, the Clamp motor activates to raise the Clamp plate arm [G] and close the Clamp plate [C]. > The Clamp motor turns off when the light paths of both the Clamp sensors L [F] and C [D] becomes open. F The Clamp unit is back at the Home position.
B G
Sends master
D A E
A:Clamp encoder disc B:Clamp cam ass'y C:Clamp plate D:Clamp sensor C E:M-Projection plate arm F:Clamp sensor L G:Clamp plate arm H:Master
15 - 6

THEORY OF OPERATION
Master Clamping Timing Chart

Motion starts Clamp sensor C Blocked 1
Open
Motion ends
10 sec. Blocked Clamp sensor L

Open
10 sec. 5
2 ON Clamp motor 3 4 ON
1 If the light path of the Clamp sensor C is not opened within 10 seconds after the Clamp motor is activated, the machine assumes that the Clamp motor is locked and displays error message [E 3]. 2 If the light path of the Clamp sensor L is not blocked within 10 seconds after the Clamp motor is activated, the machine assumes that the Clamp motor is locked and displays error message [E 3]. 3 The Drum waits for the master with the Clamp plate opened. 4 The Clamp motor activates to clamp the master with the Clamp plate when the master loading to the drum is completed. 5 If the light path of the Clamp sensorL is not opened within 10 seconds after the Clamp motor is activated, the machine assumes that the Clamp motor is locked and displays error message [E 03].
15 - 7

THEORY OF OPERATION
5. Master Loading on the Drum Mechanism

As the Write pulse motor activates for a certain set time after the Clamp plate clamps the master, the Main motor activates to load the master on the Drum. 1. Drum angle 134 > During the master loading, when the Drum comes to 134 , the Master sensor checks for any master loading error. > The Write pulse motor keeps feeding the master, and if no master loading is detected, the Main motor stops at position-A.and [J 5] is displayed. 2. Master cutting > The Cutter unit cuts the master when the Drum comes to at 292 . > The Main motor keeps rotating and loads the remaining length of master on the Drum while making one proof print.
Master Loading Movement

B
Position A
1. After the master is clamped on the Drum and Write pulse motor rotates for a set amount, the Drum rotates to start the master loading.
C
134 G
D E
2. The Drum position at 134 , the Master sensor [G] checks for any master loading error while the Write pulse motor keeps feeding the master.
3. Cutter motor activates to cut the master at the Drum posiotion 292 .
292 F A:Clamp plate B:Drum C:TPH D:Write roller E:Master roll F:Cutter unit G:Master sensor
15 - 8

THEORY OF OPERATION
Master Loading Timing Chart
134 Drum angle Position-A sensor Detecting Not Detecting
292
OFF Main motor Clamp motor ON
ON
1.95 rpm
180ms
OFF
5mm OFF Write pulse motor ON 3 Master counter count signal OFF Cutter motor Not detecting master Detecting master ON 4 1 2 4854 pulses
Master sensor
1. The Write pulse motor activates after 180ms when the Clamp motor goes off. 2. The Whrite pulse motor keeps going the activation to feed the master until 4854 pulses is counted. 3. The Master sensor checks the master on the Drum at the drum position 134 degrees. If the Master sensor detects the master, the Master counter adds the one count. If not, the machine assums that master loading miss occurred and [J 5] is displays. 4. The Drum stops at the durm position 292 degrees to cut the master. The Drum restarts the rotating to complete the master feeding on the drum.
15 - 9

THEORY OF OPERATION
6. Master Advance after Master Cutting

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

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


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

> Hook the Master making unit on under the catch on the machine frame. > Match the half-pierced section of the Cutter unit [F] with its counter part.
Cutter unit removal F
15 - 14

2. Master Making Unit Safety Switch

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

3. Write Pulse Motor

1. Disconnect the power supply from the machine. 2. Remove Master making unit. (See page 15-13) 3. Disconnect the Connector of the Write pulse motor [A]. 4. Remove two mounting screws of the Write pulse motor [A] and remove the motor.
> Keep the certain backlash between the moter gear [B] and the drive gear [C] when install the motor [A] in the Master making unit.
A:Write pulse motor B:Motor gear C:Drive gear
15 - 16

4. Master Positioning Sensor

1. Disconnect the power supply from the machine. 2. Remove the Master making unit. (See page 15-13) 3. Cut off the Wire clamppers [D] of the Master positioning sensor wire. 4. Disconnect the connecter of the Master positioning sensor [A]. 5. Remove both side of E-rings from the Master tension shaft [B] then remove the shaft. 6. Remove the Cutter guide plate [C]. 7. Remove the mounting screw of the Master positioning sensor [A] and remove the sensor from the Cutter guide plate [C]. C B E
B C
A:Master positioning sensor B:Master tension shaft C:Cutter guide plate D:Master feed sheet E:Wire clampper A
> Do not apply any damages to the Master feed sheets [D] to prevent master jam. > Place the Master feed sheets [D] under the Cutter guide plate [C].
15 - 17

5. Master Loading Solenoid

1. Disconnect the power supply from the machine. 2. Remove the Master making unit.[B] (See page 15-13) 3. Disconnect the Connector of the Master loading solenoid [A]. 4. Remove two mounting screws of the Master loading solenoid [A] and remove the solenoid from the Master making unit [B].
A:Master loading solenoid B:Master making unit A
15 - 18

6. Master End Sensor

1. Disconnect the power supply from the machine. 2. Remove the Master making unit [B]. (See page 15-13) 3. Open the Master making unit and remove the master roll. 4. Disconnect the Connector of the Master end sensor and remove the sensor from the sensor bracket on the machine.
> Do not damage the hooks of the Master end sensor when install the sensor to the sensor bracket on the machine.
Hooks
A:Master end sensor B:Master making unit
15 - 19
MEMO
15 - 20
APPENDIX
CONTENTS
Electrical Components 1. Sensors .................................................................................................... 2. Switches ................................................................................................... 3. Clutches & Solenoids ............................................................................... 4. Motors & Fan ............................................................................................ Test Mode 1. Operation Procedures .............................................................................. 2. Test Items and Operations ....................................................................... Users Mode 1. Operation Procedures & Items ................................................................. Advice Displays (Call Service Messages) 1. Display Messages .................................................................................... Wiring Diagram 1. Wiring Diagram ........................................................................................
APX(0)-1 APX(0)-2 APX(0)-3 APX(0)-4 APX(1)-1 APX(1)-3 APX(2)-1 APX(3)-1 APX(4)-1
MEMO
APPENDIX (0)
ELECTRICAL COMPONENTS
Electrical Components
1. Sensors
A H B
E I O
J A:Master positioning sensor B:Original IN sensor C:TPH position sensor D:Paper receiving sensor E:Master end sensor F:Main motor encoder G:Clamp sensor L H:Clamp sensor C I:Master removal sensor J:Master sensor K:Overflow sensor L:Ink sensor M:Ink bottle Set sensor N:Position-A sensor O:Master disposal box set sensor N
M K L
APX(0) - 1
APPENDIX (0)
2. Switches
A
A:Master removal unit safety switch B:Guide plate safety switch C:Main power switch D:Master making unit safety switch E:Separation base safety switch
APX(0) - 2
APPENDIX (0)
3. Clutches & Solenoids
A:Master loading solenoid B:Master removal clutch C:Paper feed clutch D:Timing clutch
APX(0) - 3
APPENDIX (0)
4. Motors & Fan
B F
C G D
A:Cutter motor B:Read pulse motor C:Separation fan D:Suction fan E:Write pulse motor F:Clamp motor G:Main motor H:Ink motor
APX(0) - 4
APPENDIX (1)
TEST MODE
Test Mode
1. Operation Procedures
The Test mode program enables a service technician to check the operation of each electrical component in the machine. 1. [Starting Up Test Mode] Turn ON the power while pressing the PRINT POSITION buttons and on the machine operation panel. If the Test mode is activated, the following indication will be displayed in the print quantity display. The display shows the version number of the System ROM.
- This is a sample of the initial condition of Test mode:
10 1
System ROM Version No. (Ver. 1.01)
2. [Checking the Operation of a Component] To check the operation of a component, select a test No. using panel keys. [Example] - In selecting Test No.12 (Paper receiving sensor).
12
Test No. Test Mode status 0 for OFF status 1 for ON status
Press the "START" button to start the test.
12 12
Press the "START" button again to stop the test.
If the test is a one-cycle operation test, it will automatically stop after one check. If the test is a non-cycle operation test, pressing the "START" button will stop the test.
3. [Selecting Another Test Number] To select another Test No., clear the set Test No. by pressing the "C" or "STOP" button and select another Test No. The previous Test No. is erased.
00 35
Select a new Test No. (Example: No.35)
0
APX(1) - 1
APPENDIX (1)
TEST MODE
4. [Exiting from the Test Mode] To exit from a Test mode, clear the set Test No. by pressing the "C" or "STOP" button and then press the "ALL RESET" button for 1 second. The Test No. is cleared by "C" or "STOP".
00 0
Press "ALL RESET" button for 1 second.
5. [Operating the Adjustment mode] (Test Mode No. 80 ~ 87) Start up the Test mode and select the Test mode No. and press "START" button. flashes [Example] - In selecting Test mode No.80. Select 80 and then press "START".
80
Test mode No. Test Mode status 0 for OFF status 1 for ON status
Use the PRINT POSITION button
or
to make the setting selection.
[Example] - In selecting "3" for the setting, press the display window.
button until "3" flashes in the first
3
Press the "START" button to input the newly selected setting.
The selectable settings are: -3-2,-1,0, 1, 2, 3
00 0
Press "ALL RESET" button for 1 second.
CAUTION: >Test Mode No.98 resets all the Adjustment selections made on the machine back to "0". >Test Mode No.99 resets all the Adjustment selections made on the machine back to "0". Refer to page APX(1)-7 for detail on the above.
APX(1) - 2
APPENDIX (1)
TEST MODE
2. Test Items and Operations

1) Sensor/SW Test A beep sounds in two ways to tell the current condition. (except No.28) Detection: 0.1 second interval beep No detection: 0.5 second interval beep No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Test Component Original IN sensor Master sensor Master positioning sensor Master end sensor TPH position sensor Cutter home position switch Cutter end position switch Clamp sensor L Clamp sensor C Master removal sensor Position-A sensor Paper receiving sensor Ink sensor Overflow sensor Paper Guide Plate safety SW Separation unit safety SW Master making unit safety SW Master removal unit safety SW Ink Bottle set sensor Not available Not available Not available Not available Not available Not available Not available Not available Master disposal box set sensor TPH thermister reading Light path is blocked (Disposal box is set) The temperature is shown on the print quantity display window in degrees Celsius. Detection status Reflected light is detected (Original is set) Reflected light is detected (Master is detected) Reflected light is detected (Master is detected) Light path is blocked (Master end detected) Light path is blocked (TPH is raised) Actuator is pressed (Cutter at home position) Actuator is pressed (Cutter at end position) Light path is blocked (Disc is detected) Light path is blocked (Disc is detected) Actuator is pressed (Master is jammed) Light path is blocked (Drum is at position-A) Reflected light is detected (Paper is detected) Ink is detected Ink is detected Actuator is pressed (Unit is set) Actuator is pressed (Unit is set) Actuator is pressed (Unit is set) Actuator is pressed (Unit is set) Light path is open (Ink bottle is set) Serial connection
29
Not available
APX(1) - 3
APPENDIX (1)
TEST MODE
2) Motor/Solenoid Test Use "START" button for ON/OFF control.
No. 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 44 45 46 47 48 49 50 51 52
Test Component Main motor (1.95 rpm) Main motor (10 rpm) Main motor (30 rpm) Main motor (45 rpm) Main motor (60rpm) Main motor (90 rpm) Not available Read pulse motor ( forward ) Read pulse motor ( reverse ) Write pulse motor (forward) Write pulse motor (reverse) Master loading solenoid Clamp motor Not available Master removal clutch Master removal motor Paper feed clutch Timing clutch Ink motor Suction fan Separation fan Image scanner LED TPH control signal Not available
(For KS500 & KS600) (For KS800)
All the Safety switches must be pressed and the Drum must be set in the machine.
APX(1) - 4
APPENDIX (1)
TEST MODE
3) TPH Heating power/ Life counter display etc. Press "START" button to enable the functions.
No. 53
Check Items & Setting Selections TPH Heating power selection TPH heating time can be changed to suit the amount of ink from the drum to the paper color. The selection range is from 0 to 2. For the adjustment, use the Print position button or to make the setting. 0: Chinese papers / Thin papers (default setting) 1: Chinese papers / Thick papers 2: White color paper
54 55 56
Not available Life counter display Copy counter (from machine set up) is displayed on the panel. Non-erasable.
Model selection The model setting must be chosen to suit each model. The selection range is from 0 to 2. For the adjustment, use the Print position button or to make the setting.
KS500 0: KS500C 1: KS500AL 2: KS500 / KS500(120V) KS600 0: KS600C 1: KS600AL 2: KS600 / KS600 (120V) 0: 1: 2: 3: KS800 KS800C KS800AL KS800 / KS800 (120V) Max. 500 prints (B4)
*1. In case of selecting [0] for KS500 and KS600, the print quantity per print job is limited to maximum 500 copies. *2. In case of selecting [1] for all of the models, the master cut length is set to A4 length. *3. For KS800, maximum 500 copy limit setting is removed from selection [0]. Instead, selection [3] is added for KS800 to limit the per print job maximum print quantity to 500 for B4 models (excludes KS800AL). 57 58 59 Not available Not available Not available
APX(1) - 5
APPENDIX (1)
TEST MODE
4) Unit check mode etc. Use "START" button for ON/OFF control. No. 60 Test Item TPH move down Activate the TPH pressure motor until the light path of the TPH position sensor from "blocked" to "unblocked". TPH move up Activate the TPH pressure motor until the light path of the TPH position sensor from "unblocked" to "blocked". Cutter Home Positioning Cutter motor activates to move the cutter until the Cutter home sensor detects the Cutter if the Cutter home sensor does not detect the Cutter. Cutter motor ON (One-cut operation) Cutter motor ON Cutter end sensor ON Cutter HP sensor ON
61
62
63 64
Clamp arms Home potisioning ( Clamp motor operation) If the Clamp sensor L,C is not opened, the Clamp motor activates till the clamp home position. (both light path of the Clamp sensor L & C "Opened") Clamp plate Open/Close operation Open and close the clamp plate ( master clamp action ). Clamp plate Open/Close operation Open and close the clamp plate ( master release action ). Inking operation If ink sensor is not detect ink inside the Squeegee roller, confidential master is made on the drum. Then starting inking and printing. Panel LED check All panel LED light ON. Drum position A Drum rotation to the position-A. Master making operation test Master making operation is available. Master removal operation test Master removal operation is available. Confidential operation test Confidential operation is available. Paper feed & Printing operation (30 rpm) Printing with the drum speed 30 rpm is available. Paper feed & Printing operation (90 rpm) Printing with the drum speed 90 rpm is available. Thermal print head check operation 1 Makes a master of test pattern #1 memorized in the main PCB.(within the spec. area) Thermal print head check operation 2 Makes a master of test pattern #1 memorized in the main PCB.(full range of the master) Drum angle is displayed on the panel. Drum angle is displaied as drum rotates at 5 rpm while the Start button is kept pressing.
65
66
67
68 69 70 71 72 73 74 75 76 77
APX(1) - 6
APPENDIX (1)
TEST MODE
5) Adjustment mode etc. The following items can be reprogrammed to make fine adjustments in Image scanning and Master making. Use the Print position button No. 80 Test Item Paper feed clutch 60 rpm Paper feed clutch ON timing setting. or to make the setting.
SW setting Amount (mm)
-4 -4
-3 -3
-2 -2
-1 -1
0 0
1 1
2 2
3 3
81
Paper feed clutch 60 rpm Paper feed clutch OFF timing setting. SW setting Amount (mm) -4 -4 -3 -3 -2 -2 -1 -1 0 0 1 1 2 2 3 3
82
Paper feed clutch 90 rpm Paper feed clutch ON timing setting. SW setting Amount (mm) -4 -4 -3 -3 -2 -2 -1 -1 0 0 1 1 2 2 3 3
83
Paper feed clutch 90 rpm Paper feed clutch OFF timing setting. SW setting Amount (mm) -4 -4 -3 -3 -2 -2 -1 -1 0 0 1 1 2 2 3 3
84
Second Paper feed clutch ON timing (60 rpm) SW setting Amount (mm) SW setting Amount (mm) -7 -7 1 1 -6 -6 2 2 -5 -5 3 3 -4 -4 4 4 -3 -3 5 5 -2 -2 6 6 -1 -1 7 7 0 0
85
Second Paper feed clutch OFF timing (60 rpm) SW setting Amount (mm) SW setting Amount (mm) -7 -7 1 1 -6 -6 2 2 -5 -5 3 3 -4 -4 4 4 -3 -3 5 5 -2 -2 6 6 -1 -1 7 7 0 0
APX(1) - 7
APPENDIX (1)
TEST MODE
Use the PRINT POSITION button
or
No. 86
Test Item Timing clutch ON timing (90 rpm) SW setting Amount (mm) SW setting Amount (mm) -7 -7 1 1 -6 -6 2 2 -5 -5 3 3 -4 -4 4 4 -3 -3 5 5 -2 -2 6 6 -1 -1 7 7 0 0
87
Timing clutch OFF timing (90 rpm) SW setting Amount (mm) SW setting
Amount (mm)
-7 -7 1 1
-6 -6 2 2
-5 -5 3 3
-4 -4 4 4
-3 -3 5 5
-2 -2 6 6
-1 -1 7 7
0 0
88 89
Not available Image elongation and shrikage in master making SW setting Amount (mm) SW setting Amount (mm) -2 -1 6 3 -1 -0.5 7 3.5 0 0 8 4 1 0.5 9 4.5 2 1 10 5 3 1.5 11 5.5 4 2 12 6 5 2.5 13 6.5
KS500 & KS600
89
Image elongation and shrikage in master making SW setting Amount (mm) SW setting Amount (mm) SW setting Amount (mm) SW setting Amount (mm) -15 -7.5 -7 -3.5 1 0.5 9 4.5 -14 -7 -6 -3 2 1 10 5 -13 -6.5 -5 -2.5 3 1.5 11 5.5 -12 -6 -4 -2 4 2 12 6 -11 -5.5 -3 -1.5 5 2.5 13 6.5 -10 -5 -2 -1 6 3 14 7 -9 -4.5 -1 -0.5 7 3.5 15 7.5 -8 -4 0 0 8 4
KS800 ONLY
NOTE: KS800, KS800(120), KS800C
Check the elongation/shrinkage between the original and the print at the distance of 280 mm from the top of the original, and make above adjustment.
KS800(AL)
Use the area 250 mm from the top of the original to check the elongation/shrinkage and make above adjustment.
APX(1) - 8
APPENDIX (1)
Use the PRINT POSITION button 90 Shading compensation
Shading compensation Shading compensation ON OFF 1 0
or
TEST MODE
91
KS500 & KS600
Shading compensation (White side only) This adjustment is for the factory use only and the result of the adjustment is not effect to the image processing.
91 KS800 ONLY
Position-A adjustment SW setting

Amount (degrees)
[ 1unit = 1 degree in angle ] -3 -3 -2 -2 -1 -1 0 0 1 1 2 2 3 3
-4 -4
92
Slice level adjustment (Line mode only)

Image light 0 1 2 3
DEFAULT
The defult number is 3
Image dark 6 7
93
Image horizontal center position adjustment [ 1unit = 0.125 mm ] Adjustment range: -16 to +15 (-) moves image to the left. (+) to the right. Default setting = 0. Vertical print position & Image shrinkage/elongation check Makes 2mm wide line at print position 2mm from the top and another 2mm wide line at 250mm from the top for (AL) machines and 280mm from the top for other models. Using these two lines on the prints, the vertical print position and image shrinkage/ elongation can be checked. Master slack adjustment Adjusts the amount of master slack between the master-making area and the print drum. Too much slack on the master between the master-making area and print drum will cause image shrinkage. Too less slack will cause the print durm to pull the master material before master-making starts. [ Default = 0 ] With each increase in the setting, the slack lessens by 0.5mm. SW setting
Amount (mm)
94
95
KS800 ONLY
0 0
1 -0.5
2 -1
3 -1.5
4 -2.0
5 -2.5
6 -3.0
7 -3.5
96
Master removal count Master removal count is displayed on the panel. Clearing the count of the Main counter in the memory The master count and copy count in the memory will be cleared by pressing [C] key after the Test mode is enabled. [Prohibit of the Main counter clear] After input the No.97, press Start key. If the panel indication is [1], chage the indication from [1] to [0] by press the Print position button then press the Start key. Thus the Main counter clear function is prohibited. Press the Stop key instead of the Start key to escape from the clear prohibit mode.
97
APX(1) - 9
APPENDIX (1)
TEST MODE
No. 98
Test Item Clearing EEP ROM All memory will be cleared except the Master count, Copy count and the Main counter clear prohibit mode in Test No.97 Initiarizing EEP ROM Inkless timer, Master count, Copy count, Master removal count will not be initiarized.
99
APX(1) - 10
APPENDIX (2)
USERS MODE
Users Mode
1. Operation Procedures
The users mode program enables a machine operator to get some special functions of the machine. This mode is explained in "User's Guide" and is intended for customers to make a selection if required 1. [Starting Up Users Mode] Turn ON the power. Press " " key on the Control Panel. This makes access to the User mode. 2. [Making Selections] After the access is made, select the item(s). If pressing [1] and then [Start] key, the first item appears on the display as shown below.
U - 1
If another item is desired, select it using the print quantity keys. In case of selecting item No.02, press "*" and then "2". The display changes as shown below.
U - 2
Now choose either of the two initial settings for the selected item. The selection is made by pressing the "START" button. Repeat this procedure until all required changes are made. To exit from this mode, press the "ALL RESET" button for 1 second. All new initial settings are memorized and the display returns to normal operation.
Item No. Contents
1 2 3 4
Copy counter Master counter Avarage copy counter Confidential mode
Displaying the Copy counter on the print quantity display. Displaying the Master counter on the print quantity display. Displaying the avarage copy count per master. Remove the master on the drum then put the new master on the drum. Removing unwanted background of the original such as newspaper to obtain the clear image of the printouts.
Newspaper mode
APX(2) - 1
MEMO
APX(2) - 2
APPENDIX (3)
ADVICE DISPLAYS
Advice Displays (Call Service Messages)

No. E1 Display Condition Main Motor Lock If excessive current is detected 0.3 seconds consecutively after the Main motor is activated. If no Encoder sensor output after Main motor is activated. Clamp Motor Lock [During Clamp Motor Initial Positioning] If the light path of the Clamp senors both C and L are not opened within 10 seconds after after the Clamp motor is activated. [During Master Release from the Clamp Plate] If the light path of the Clamp sensor L is not blocked within 10 seconds after the Clamp motor is activated. If the light path of the Clamp sensor C is not opened within 10 seconds after the Clamp motor is activated. [When the Clamp Plate opens during Master Clamping] If the light path of the Clamp sensor L is not blocked within 10 seconds after the Clamp motor is activated. If the light path of the Clamp sensor C is not opened within 10 seconds after the Clamp motor is activated. [When the Clamp Plate closes during Master Clamping] If the light path of the Clamp sensor L is not opened within 10 seconds after the Clamp motor is activated. Ink Overflow If the Overflow sensor detects excessive ink in the Squeegee unit. Position-A Sensor Malfunction If Position-A sensor cannot be detected (or keeps detecting) even though the Main motor encoder sensor signal is making the output after the Main motor is activated. Master removal motor lock Excessive current to the motor is detected three time consecutively during the current check made every 100 ms. Cutter motor Lock If the Cutter home position switch is not turned OFF within 500 ms after the Cutter motor is activated. If the Cutter end position switch is not pressed within 2000 ms after the Cutter motor is activated. Inking Motor Lock If excessive current is detected 2.5 seconds consecutively after the Inking motor is activated. TPH pressure error [During TPH Up Positioning] If the light path of the TPH pressure sensor is not opened within 10 seconds after the Write pulse motor is activated. [During TPH Down Positioning] If the light path of the TPH pressure sensor is not blocked within 10 seconds after the Write pulse motor is activated. Resetting Method Turn Power SW OFF & ON.
E3
Use test mode.
E4
Remove excess ink from the Drum.
E6
Turn Power SW OFF & ON.
E 12
E 13
Use test mode.
E 16
E 19
APX(3) - 1
APPENDIX (3)
ADVICE DISPLAYS
Note: The Advice Display number with "( )" will be displayed while " " key is pressed. No. J 1 Display Condition No Master on the Drum If the Master sensor does not find master on the Drum when the Drum is at 134 during the printing movement. Resetting Method Press ALL RESET button.
J 2
Press ALL RESET Paper Jam in the Second Paper Feed Area If the Paper receiving sensor does not find paper when the Drum is button. Remove the at Position-334 and 104 the printing operation. jammed paper. Paper Jam in the Paper Receiving Area If the status of the Paper receiving sensor does not change from detecting paper to not detecting from Drum angle 357 to 280 the printing operation. Master Loading Error If the Master sensor does not detect the master (light not reflected) within 5 seconds. Press ALL RESET button. Remove the jammed paper. Master making unit safety SW OFF & ON.
J 3
J 4
J 5
Master Loading Error (onto the Drum) If the Master sensor does not detect the master (light not reflected) Master making unit safety SW OFF & during the master loading when the Drum is at 134 from the ON. position-A. Master Cut Malfunction If the Master positioning sensor is still detecting the master (light reflected back) when the Drum is at position-A after the cutting. Original Jam at Entrance During the Original scanning, if the Original IN sensor does not detecting within 5 second after the Read pulse motor activates. Original Jam During the Original set movement, if the Original IN sensor still detecting Original (sensor light reflected) the master making movement. Master Removal Error In case the Master removal sensor does not detect the removed master (light path opened) at Drum 134 from the Position -A during the master removal even though a master was detected on the Drum before the master removal operation. Removed Master Jammed at the Master removal area If the Master removal sensor is detecting the removed master (light path blocked) even though the Drum has returned to the position-A after the master removal process.
J 6
J 7
J 8
Original IN sensor OFF & ON.
J 9
Remove the jammed master.
J 10
Master removal sensor OFF Remove the jammed master.
APX(3) - 2
APPENDIX (3)
ADVICE DISPLAYS
Note: The Advice Display number with "( )" will be displayed while " " key is pressed. No. Display Condition Resetting Method
C 1
Close Separation fan unit If the actuator of the Separation base unit safety switch is not depressed.
Close the separation fan unit.
C 2
Close Master Making Unit If the actuator of the Master making unit safety switch is not depressed. Close Master Removal Unit If the actuator of the Master removal unit safety switch is not depressed. Set master disposal box. If the master disposal box set sensor does not detect.
Close the Master making unit. Close the Master removal unit.
C 3
C 4
Set the Master disposal box.
C 5
Set Ink bottle in Place If the Ink bottle set sensor does not detect the Ink bottle.
Set the Ink bottle in the Drum.
C 6
Replace Master Roll If the black tape attached at the end of the Master roll has been detected by the Master end sensor during master making or confidential operation.
Master making unit safety SW OFF & ON. Replace the depleted Master roll with a new one. Master disposal boxl set sensor OFF & 5 seconds later ON. Empty the disposal box.
C 7
Empty Disposal Box If the Master removal 5 times.
C 8
Replace Ink bottle If the Ink sensor does not detect ink in the Squeegee unit within 20 seconds after the Inking motor was activated. If the Ink sensor does not detect ink in the Squeegee unit within 40 seconds after the Inking motor was activated when the Ink bottle is installed just after replacing empty ink bottle.
Ink bottle set sensor OFF & 5 seconds later ON.
APX(3) - 3
APPENDIX (4)
WIRING DIAGRAM
APX(4) - 1
RISO KS800
PARTS LIST
Version: March,2004
Parts List
Page No
* Fig.1 * Fig.2 * Fig.3 * Fig.4 * Fig.5 * Fig.6 * Fig.7 * Fig.8 * Fig.9 * Fig.10 * Fig.11 * Fig.12 * Fig.13 * Fig.14 * Fig.15 * Fig.16 * Fig.17 * Fig.18 * Fig.19 * Fig.20 * Fig.21 * Fig.22 * Fig.23 * Index
Main Body Drive Machanism Pressure Area Paper Feed Area PF Set Lever Paper Feed Tray Paper Receiving Area Paper Receiving Tray Separation Fan Unit Suction Unit Squeegee Unit Drum Area Master Removal Area Master Disposal Box Master Removal Unit Clamp Unit Scanner Area Cutter Area Master Making Area Exterior Covers Lavel Electrical Components Wire Harnesses
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
I-1 I-3 I-5 I-7 I-9 I-11 I-13 I-15 I-17 I-19 I-21 I-23 I-25 I-27 I-29 I-31 I-33 I-35 I-37 I-39 I-41 I-43 I-45 1
Version: March,2004
KS800
Fig.1 Main Body
11 11
I-1
12 12 12 12
Version: March,2004
KS800
Fig.1 Main Body

No. 1 2 3 4 5 6 7 8 9 10 11 12
Part No.
Part Name(English)
Main Frame; Front Main Frame; R Ass'y 80 Base Plate
Part Name(Chinese)
Q'ty Remark 1 1 1 1 2 2 1 1 5 2 2 4
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
035-11005-107 Stay; Vertical 035-11006-006 Stay; Lower 035-11007-100 Stay; Middle 035-11008-106 Stay; Upper 035-11022-001 Cover; Wire Harness 035-19045-000 BKT; M-Feed Sheet 035-19046-309 M-Feed Sheet 035-19079-002 M-Feed Sheet 80 660-01002-105 Rubber Foot TK-3215
I-2
Version: March,2004
KS800
Fig.2 Drive Mechanism
I-3 Version: March,2004
KS800
Fig.2 Drive Mechanism

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Part No. Part Name(English) Part Name(Chinese) Q'ty Remark 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 4 2 1 2 1 1 1 1 1 1 1 No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 035-11009-005 Plate; M-Shaft Catch 035-12001-008 Gear; m1*51L+m1*20L 035-12003-000 Gear; m1*66R+m2*28 035-12005-100 Gear; m2*49*14 035-12103-005 Clutch Support Plate 035-12107-000 Encoder 490-20002-106 Main Motor 035-12110-001 Shaft; Rotation Lever 035-12111-202 Cover; Drum Rotation Lever 035-12113-000 Link plate; Drum rotation lever 035-12114-007 Link shaft; Drum rotation lever 035-12115-100 Gear; m1*26*11 035-14311-004 PF-Clutch Support Plate 035-14312-000 Shaft ; PF-Clatch 035-19027-100 Collar; M-Rmv 444-41001-107 Encoder Sensor 035-12109-100 Gear Shaft; Rotation Lever 490-51001-000 PF/M-Rmv Clutch 607-13000-003 Metal;F6*10/9*4;12*1.5 607-15000-000 MetalF8*13/12*5;16*2 607-16001-000 Metal;F10*15/14*6;18*2 607-70815-005 Washer;R-WAS8399H 612-10012-000 Gear; m1*31*8 035-12101-100 Shaft; Timing Clutch 035-12102-106 BKT; Drive Gears 612-16300-008 Gear; m2*32*13 612-32100-000 Gear; m1*16R*16 035-12123-006 Timing Clutch Support Plate 612-82600-004 Gear; m1*65+m2*29
30 612-82701-005 Gear; m1*70+m1*60

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 634-04030-002 Collar; dia.4*3 035-12108-309 Drum Rotation Lever 035-12112-101 Gear plate; Drum rotation lever 035-92002-050 Main Motor Ass'y 035-12121-003 Cover;Rotation Lever 612-80014-000 Gear;m1*57+m1*49 612-80015-007 Gear;m1*41+m1*35 023-74001-046 Motor ; Clamp / M-Rmv 612-11303-009 Gear ; m0.8*34*7 612-81303-006 Gear ; m0.8*35+m0.8*15 612-11307-004 Gear ; m0.8*24*7 035-12125-009 BKT;M-Rmv Motor 612-12319-006 Gear ; m1*36*7 612-12309-000 Gear ; m1*37*9 035-12127-109 Spring ; M-Rmv 035-12124-100 Shaft ; M-Rmv 035-19037-008 Shaft B; M-Rmv Gear
I-4
Version: March,2004
KS800
Fig.3 Pressure Area
KS800
Fig.3 Pressure Area

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 1 2 1 1 1 1 1 1 2 2 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
035-13011-104 Pressure Roller 035-11010-003 Hook; Press-Spring 035-12104-001 BKT; Pressure Hook 035-13001-001 Press-Roller Shaft 035-13002-008 Press-Balance Shaft 035-13003-306 Press-Roller Support 035-13004-000 Center Support Block 035-13005-007 Center Support Plate 035-13101-502 Pressure Lever Ass'y 035-13107-004 Pressure Spring 035-13111-303 Press-Hook Plate Ass'y 035-13115-007 Spring; Hook 600-20061-009 Bearing;608ZZ 607-16001-000 Metal;F10*15/14*6;18*2 635-09308-103 Pan-head Tap Tight P Screw 3*8
I-6
Version: March,2004
KS800
Fig.4 Paper Feed Area
KS800
Fig.4 Paper Feed Area

No. 1 2 3 4 5 6 7 7 7 7 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 2 2 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 1 1 1 1 1 1 4 1 4 2 1 2 1 1 1 2 1 1 1 1 1 1
000-06123-007 Stopper;Paper Guide Roller 019-11812-106 Lock Ring 019-25533-005 Actuator Plate;Micro-SW 020-11309-006 Load Spring 020-11707-109 Housing; Stripper 020-11708-008 Spring;Stripper 020-11711-009 Stripper Pad 011-11822-006 Stripper Pad;SR-29 035-14452-007 Stripper Pad;50 035-14453-003 Stripper Pad;60 020-11721-004 Stripper Pad;Black 035-12007-103 Gear; m1*20*8 035-14115-000 Lock Pin 035-14201-101 Shaft; PFT Lever 035-14202-108 PFT Lever 035-14256-003 PF Lever ; BKT ASS'Y 035-14218-004 Set Lever BKT Ass'y 035-14222-001 Lock Plate 035-14231-000 Shaft; Support Lever 035-14240-000 Roller; PFT Press-Adj. Lever 035-14305-004 PF-Support Roller 035-14313-007 Shaft; Pichup Roller 035-14402-000 Timing Roller 035-14230-004 Support Spring 035-14406-005 Guide Roller Spring 035-14407-001 Plate; Load Spring 035-14408-008 Guide Roller 035-14409-004 Guide Roller BKT 035-14410-002 Support BKT F; G-Roller 035-14411-009 Support BKT R; G-Roller
27 035-14412-005 Guide Roller Shaft 28 035-14413-001 G-Roller S-Shaft 29 035-14414-105 Paper Gate 30 035-14415-101 Paper Gate Shaft 31 035-14445-000 P-Guide Lower Ass'y 80 32 035-14440-009 P-Guide Upper Ass'y 80 33 035-14431-000 PF Safety SW Plate 34 035-14432-006 Safety SW Protection 35 035-51023-108 Safety SW Ass'y 36 035-94302-000 Pickup Roller Ass'y 37 607-13000-003 Metal;F6*10/9*4;12*1.5 38 607-15000-000 MetalF8*13/12*5;16*2 39 607-16001-000 Metal;F10*15/14*6;18*2 40 607-16002-007 Metal;F10*16/12.8*12:18*2 41 638-90000-128 Washer;18*10.4*0.4 42 035-14446-104 Sheet ; P-Guide 43 035-14254-000 Plate ; PF Press-Adj. 44 035-14250-005 Cam ; PF Press-Adj. 45 035-14247-004 Lever ; PF Press Adj. 46 035-14249-007 Shaft ; PF Press Adj. Lever 47 035-14251-109 BKT ; PF Press-Adj. 48 035-14241-006 BKT ; PFT Lever 80 49 035-14255-007 Shaft ; PFT 50 035-14246-008 Support Spring 51 035-14248-000 Spring ; PF-Press Adj. 52 035-14244-005 Spring ; PF Press 80
I-8
Version: March,2004
KS800
Fig.5 PF Set Lever
KS800
Fig.5 PF Set Lever

No. 1 2 3 4 5 6
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
035-14207-207 PF Set Lever Ass'y 035-14214-106 PF Adj. Screw 035-14215-200 Cover; Set Lever 035-14217-008 Sheet; Adj. Screw 035-14220-009 PF Adj. Dial 035-14221-005 PF Adj. Collar
I - 10 Version: March,2004
KS800
Fig.6 Paper Feed Tray
KS800
Fig.6 Paper Feed Tray

No. 1 2 3 4 5 6 7 8 9 10 11
Part No. Part Name(English) Part Name(Chinese) Q'ty Remark 2 1 1 1 No. Part No. Part Name(English) Part Name(Chinese) Q'ty Remark 020-11513-002 Lever;P.-F.-T. 035-14117-003 Base Plate ; PFT 80 035-14118-000 Plate ; PFT 80 035-14103-304 Frame F ; PFT 80 035-14104-300 Frame R ; PFT 80 035-14119-103 Side Guide F ; PFT 80 035-14121-108 Side Guide R ; PFT 80 035-14123-003 Guide ; Fence 80 035-14124-000 Lock Plate ; PFT Side Guide 80 035-14116-104 L. O. Sheet 488-90028-007 RS3-150-RS3
1
1 1 2 2 1 1
I - 12
Version: March,2004
KS800
Fig.7 Paper Receiving Area
KS800
Fig.7 Paper Receiving Area

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 1 1 1 1 1 1 1 3 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
002-17017-203 Cover Catch B; Front 019-25533-005 Actuator Plate;Micro-SW 035-11021-102 Cover; Suction 035-15051-103 Separator 035-15052-002 Shaft ; Separator 035-15055-001 Separator Lever Ass'y 035-15057-004 Spring ; Separator 035-15058-000 Fan Set SW Plate 035-15080-006 Set Switch BKT 035-15090-001 Shaft; Belt Drive Gear 035-51023-108 Safety SW Ass'y 607-15000-000 MetalF8*13/12*5;16*2 612-12312-001 Gear; m1*39*8 612-16100-009 Gear; m2*18*8
I - 14
Version: March,2004
KS800
Fig.8 Paper Receiving Tray
KS800
Fig.8 Paper Receiving Tray

No. 1 2 3 4 5 6 7
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 1 2 2
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
035-15203-000 Paper Receiving Tray 80 035-15204-007 Paper Base Stop 80 035-15138-209 P-Rcv-T BKT F 035-15139-205 P-Rcv-T BKT R 035-15205-003 P-Rcv-T BKT 80 035-15206-000 P-Ejection Guide 035-15207-006 Side Base ; P-Rcv-T
KS800
Fig.9 Separation Fan Unit
KS800
Fig.9 Separation Fan Unit

No. 1 2 3 4 5 6 7 8 9 10
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 1 1 1 1 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
035-04006-009 Label;P-Rcv. Cover 035-15058-000 Fan Set SW Plate 035-15153-003 Fan Base; Separation 035-15156-002 Nozzle-Up; Separation 035-15157-106 Nozzle-Low; Separation 035-15161-006 Fan Base Support BKT 035-15162-002 Fan Base Shaft 035-51013-102 Wire; P-Rcv Sensor 444-33000-002 GP2A200LCS 490-41002-106 Fan
KS800
Fig.10 Suction Unit
KS800
Fig.10 Suction Unit

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 2 1 2 1 1 1 2 1 1 2 1 1 1 2 1 1 2
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
035-15018-009 De-electricity Brush ; Suction 80 020-13108-105 Belt Pulley;Suction 020-13110-100 Idle Shaft;Suction 020-13116-205 P.-E. Pulley; Suction 035-15002-102 Suction Base 035-15200-001 Suction Face Cover 80 035-15004-008 Suction Duct 035-15016-006 Suction Gear Shaft 035-15017-002 Drive Shaft; Suc-Belt 490-41002-106 Fan 607-15000-000 MetalF8*13/12*5;16*2 612-12207-003 Gear; m1*20*10 612-12313-008 Gear; m1*33*6 612-82308-001 Gear; m1*36+m1*15 629-93810-202 Transfer Belt;14*0.65*381 035-15201-008 Suction Wing F 80 035-15202-004 Suction Wing R 80 635-00410-002 Stepped Screw ; m4*10
I - 20
Version: March,2004
KS800
Fig.11 Squeegee Unit
KS800
Fig.11 Squeegee Unit

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 2
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
020-12502-306 Shaft Joint;Drum 020-12508-002 Stopper;Ink Distributor 020-12512-000 Metal Fix Plate 020-12513-006 Metal F;Drive Shaft 020-12514-100 Metal R;Drive Shaft 020-12521-602 Squeegee Roller 020-12522-102 Doctor Roller 020-12531-306 Drive Shaft; Squeegee 020-12534-100 Block F; Squeegee 020-12535-107 Block R; Squeegee 020-12536-200 Ink Blocking Plate(Front) 020-12537-207 Ink Blocking Plate(Rear) 020-12538-009 Adj.Plate;Doctor 020-12549-000 Adj.Plate(Rear);Doctor 020-60004-202 Drum PCB 035-16501-005 Center Shaft 035-16502-001 Main Frame; Drum 035-16503-202 Sqg. F Plate Ass'y 035-16506-201 Sqg. R Plate Ass'y 612-11102-003 Gear;m0.8*18*5 612-11401-000 Gear;m0.8*45*5 612-12303-002 Gear;m1*30*5 612-12304-009 Gear;OWC;m1*30*5 640-60030-004 O Ring ; P3-1.9 640-60100-100 O Ring ; P10-2.4 640-60180-006 O Ring ; P18-2.4
I - 22
Version: March,2004
KS800
Fig.12 Drum Area

33
I - 23
32
Version: March,2004
KS800
Fig.12 Drum Area

No. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 17 18 19 19 20 21 22 23 24 25 26
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 1 1 4 2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 2 2 1 1
020-12101-204 Drum Body 035-16111-002 Drum Body;AL 020-12104-505 Ink Blocking Sheet;B4 020-12113-008 Bearing Cap 020-12119-006 Main Gear;Squeegee 020-12125-308 Screen Hanger Plate 020-12126-002 Screw;Screw Hanger 020-12127-203 Spring ;Screen 020-12201-209 Clamp Plate Base 020-12205-204 Clamp Magnet 020-12213-100 Clamp Base C 020-12220-106 Clamp Plate 2 020-12344-000 Set Plate;Center Nozzle 020-12441-200 Drum Shaft Clamp 020-12449-006 Sleeve 32 035-16101-007 Drum Support F Ass'y 035-16103-107 Drum Support R Ass'y 035-16110-006 Drum Support R Ass'y;AL 035-16105-002 Drum Main Gear 035-16106-009 Compensator 035-16107-005 Pressure Cam 035-16108-001 Pressure Cam;A4 035-16109-008 Screen Ass'y 035-16201-001 M-Projection Plate 035-16304-005 Inking Hose dia.10 035-16305-001 Center Nozzle 035-16401-205 Drum U Support BKT F 035-16402-007 Drum U Support BKT R 035-51007-102 Wire; Ink Sensor
27 035-96321-002 Ink Pump Unit 28 444-30000-001 GP1A73A 29 640-60100-100 O Ring ; P10-2.4 30 640-61550-001 O Ring ; P115-2.4 31 665-02903-005 Power Band T14 32 020-12132-002 Seal tape0.5 33 035-16202-008 Friction Sheet
I - 24
Version: March,2004
KS800
Fig.13 Master Removal Area
KS800
Fig.13 Master Removal Area

No. 1 2 3 4 5 6
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 2 1 1 1 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
019-25533-005 Actuator Plate;Micro-SW 035-11103-303 M-Rmv Upper Cover 035-11109-000 Original Receive Tray 035-19077-000 BKT A;M-Rmv SW 80 035-19078-006 BKT B;M-Rmv SW 80 035-51025-003 M-Rmv Safety SW Ass'y
KS800
Fig.14 Master Disposal Box Area
KS800
Fig.14 Master Disposal Box Area

No. 1 2 3 4 5 6
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 2 1 2 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
035-99060-005 M-Disposal Box Ass'y 035-19071-001 *M-Disposal ; Guide 035-19073-101 *M-Disposal ; Link 035-19072-008 *M-Disposal ; Lever 035-19075-007 *M-Disposal ; Spring 035-19069-007 *M-Disposal ; Main Box Ass'y 035-19070-005 *M-Disposal Box ; Cover
KS800
Fig.15 Mater Removal Unit
KS800
Fig.15 Master Removal Unit

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 1 2 1 1 2 1 1 1 2 10 2 1 1 2 1 1 1 1 1 1 1 4 2 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1
035-11725-002 Sensor BKT L 80 035-19059-109 Frame ; M-Rmv U 80 035-19076-003 Stay ; M-Rmv U Frame 035-19060-000 M-Rmv Guide ; Lower 80 035-19061-006 M-Rmv Guide ; Upper 80 035-19008-105 M-Rmv Hook 035-19063-009 BKT F ; Trans-Roller 80 035-19064-005 BKT R ; Trans-Roller 80 035-19065-001 Spring Trans-Roller 80 035-19066-008 Trans-Roller ; Lower 035-19067-004 Trans-Roller ; Upper 035-19025-000 Wire; M-Rmv Link 035-19026-006 M-Rmv Link 035-19027-100 Collar; M-Rmv 035-19029-005 Hinge; M-Rmv 035-19033-100 Lever; M-Rmv 035-19034-009 Spring; M-Rmv Lever 035-19035-005 BKT; M-Rmv Lever 035-19036-001 Shaft A; M-Rmv Gear 035-19037-008 Shaft B; M-Rmv Gear 035-19038-004 Shaft; M-Rmv Lever 035-19047-208 BKT; M-Rmv Sensor 035-19058-005 Cover;M-Rmv Lever 444-30000-001 GP1A73A 444-31001-001 M-Rmv Sensor 607-13000-003 Metal;F6*10/9*4;12*1.5 612-03104-005 Gear; m1.25*14*6 612-12102-007 Gear; m1*17*6.5 612-12309-000 Gear; m1*37*9
30 612-82400-005 Gear; m1*41+m1*36 31 035-19062-002 M-Rmv Guide ; Upper2 80
I - 30
Version: March,2004
KS800
Fig.16 Clamp Unit
KS800
Fig.16 Clamp Unit

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 1 2 1 1 1 1 1 2 1 2 1 1 2 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
035-11701-103 Housing; Cam 035-11723-000 Shaft Clutch Plate Ass'y 035-11706-008 Arm; Clamp Plate 035-11707-101 Arm; M-Projection Plate 035-11708-000 Shaft; Arms 035-11709-007 Spring; Clamp Lever 035-11711-001 Shaft; Cam/Gear 035-11712-008 Clamp Cam 035-11713-004 Encoder; Clamp Motor 035-11721-104 Sensor BKT C 035-11722-003 Sensor BKT L 444-30000-001 GP1A73A 490-21005-001 Clamp Motor 607-15000-000 MetalF8*13/12*5;16*2 612-12311-005 Gear; m1*36*7 612-82307-005 Gear;m0.5*40+m1*16 612-82310-006 Gear; m1*36+m1*14 035-11962-004 Shaft ; 6*9.5*18 612-82313-005 Gear ; m1*21+m1*14
I - 32
Version: March,2004
KS800
Fig.17 Scanner Area

34 A 7 14 6 13 22 19 9 9 11 18 C 12 18 B A D 24 20 8 1 1 4 5 30 33 B 16 27 15 29 2 C E 3 23 5 26 26 31 22 28 32 21 26 E 26 10
Fig.17 Scanner Area
17
I - 33
11 28
25
Version: March,2004
KS800
Fig.17 Scanner Area

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 2 1 1 1 2 1 1 1 2 1 2 1 1 1 1 1 1 2 1 1 1 2 1 1 1 4 1 2 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 1
020-15702-101 Slide Rack ;Original Holder 035-17001-006 OF F Frame Ass'y 035-17003-009 OF R Frame Ass'y 035-17004-005 BKT; O-Det. Sensor 035-17005-001 Spring; Scanner 035-17006-008 Spring; Load Roller 035-17007-004 Spring; Ejc-Roller 035-17021-309 DFeeder Cover 035-17024-006 Original Guide 035-11108-003 Original Feed Tray 035-17015-007 Wh-Roller Holder 035-17016-003 White Roller 035-17019-002 Roller; L40 035-17020-000 Roller; L74 612-80800-006 Gear;m0.5*86+m0.5*49 612-11501-005 Gear; m0.8*52*7 035-17023-000 Cover Low; Wh-Roller 612-11205-007 Gear; m0.8*28*4 035-17025-002 Hook; DFeeder 035-17026-009 Scanner Holder L 035-17027-005 Scanner Holder R 035-17028-001 Spring; Hook 443-32005-003 GP2A25 444-60000-103 Image Scanner 490-33006-003 DFeed Motor 607-13000-003 Metal;F6*10/9*4;12*1.5 612-80801-002 Gear; m0.5*85+0.8*19 612-11402-007 Gear; m0.8*40*3 612-80900-000 Gear;m0.5*94+m0.5*48
30 612-12206-007 Gear; m1*24*4 31 035-17012-008 Org-Ejc-Roller 32 035-17009-007 Org-Load Roller 33 635-09308-103 Pan-head Tap Tight P Screw 3*8 34 035-17022-100 Cover Up; Wh-Roller
I - 34
Version: March,2004
KS800
Fig.18 Cutter Area
KS800
Fig.18 Cutter Area

No. 1 2 3 4
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
035-18301-003 Shaft; M-Guide 035-18302-000 M-Guide Plate; Lower 035-18303-200 M-Guide Plate; Upper 035-98004-101 Cutter Unit
KS800
Fig.19 Master Making Area
I - 37
55 54 49
Version: March,2004
KS800
Fig.19 Master Making Area

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 2 1 2 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 2 2 1 2 1 2 2 4 2 2
019-25533-005 Actuator Plate;Micro-SW 020-15252-009 De-electricity Brush;L 035-04007-102 Label;M-Set Guide 035-18101-101 Master Flange 035-18102-000 M-Flange Holder 035-18103-007 M-Flange Guide 035-18104-100 Tension Plate 035-18105-204 Tension Plate Ass'y 035-18107-100 Plate; Plunger 035-18108-203 Rubber; Tension 035-18109-102 Master Flange R 035-18110-100 De-electricity Brush;KS 035-18111-107 Master Tension Sheet 035-18201-009 Write Roller 035-18204-008 TPH Press-Plate 035-18205-306 TPH Position-Plate 035-18206-108 TPH Press-Shaft 035-18207-007 Press-sensor Plate 035-18208-003 TPH Press-Cam 035-18209-000 TPH Support Shaft 035-18210-008 Shaft Stopper 035-18304-207 Cutter Guide Plate 035-18305-009 Rev-gear Plate Ass'y 035-18401-202 Frame R Ass'y; M-M U 035-18404-104 Frame F Ass'y; M-M U 035-18406-000 Base; M-M U 035-18407-103 Cover; M-M U 035-18408-002 M-Tension Shaft 035-18410-007 Release Lever
30 035-18411-208 Base; M-M Upper U 31 035-18412-000 Cover; M-M Upper U 32 035-18413-103 Locking Plate Ass'y 33 035-18415-009 Shaft; M-Holder 34 035-18501-002 Spring ; TPH Pressure 35 035-18502-009 Spring R; M-M Upper U 36 035-18503-005 Spring F; M-M Upper U 37 035-18504-001 Tension Spring 38 035-18505-008 Spring ; Rev-gear Plate 39 035-51023-108 Safety SW Ass'y 40 443-32005-003 GP2A25 41 444-30000-001 GP1A73A 42 444-80300-308 TPH 43 490-33006-003 DFeed Motor 44 490-50001-104 M-Loading Solenoid 45 550-20118-104 TPH Seal 45 550-21519-005 TPH Seal;CH 46 607-07004-005 Metal; S8*10*15 47 607-13000-003 Metal;F6*10/9*4;12*1.5 48 612-00401-009 Gear; m0.5*48*4 49 612-11205-007 Gear; m0.8*28*4 50 612-80800-006 Gear;m0.5*86+m0.5*49 51 612-80801-002 Gear; m0.5*85+0.8*19 52 612-80900-000 Gear;m0.5*94+m0.5*48 53 635-17523-005 Stepped Screw;dia.5*2;M3*3 54 035-18416-005 Shaft; M-M U 55 035-18417-001 Washer;3.5*14*1.2
I - 38
Version: March,2004
KS800
Fig.20 Exterior Covers
KS800
Fig.20 Exterior Covers

No. 1 2 3 3 4 4
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 2 1 1 1 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
035-11013-002 BKT; C-Panel 035-11102-005 Rear Cover 035-11110-008 Front Cover ; KS800C Front Cover ; KS800 035-90002-002 Control Panel Unit KS800C Control Panel Unit KS800
KS800
Fig.21 Label
KS800
Fig.21 Label
No. 1 1-a 1-b 1-c 1-d 2
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
035-04016-004 Label ; Caution 80 035-04018-007 Label ; P-Rcv 80 Label; M-Replace 035-04017-000 Label ; M-Disposal 80 Label; Ink Replace 035-04019-003 Label ; PF-Press Adj. 80
KS800
Fig.22 Electrical Components
KS800
Fig.22 Electrical Components

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14 15 16 17 18 19 20
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 2 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 2 2
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
035-11011-000 Drum Rail; R 035-11012-006 Drum Rail; L 035-11014-009 BKT; P-Supply PCB 035-11015-005 BKT; Main PCB 035-11016-001 Cover; Main PCB 035-11025-000 BKT ; M-L Sensor 035-11023-008 Cover;P-Supply PCB 035-16301-006 BKT; Ink Bottle Guide 035-16302-002 Ink Bottle Guide 035-16303-009 Bottle Hook-Spring 035-16306-008 BKT; Ink Bottle Sensor 035-16307-004 Ink Bottle Sensor Plate 035-50506-105 Main-PCB-KS800 035-50505-001 P-Supply PCB XIII-N200 II 035-50504-102 P-Supply PCB XIII-N100 035-52001System ROM ; KS
I - 44
444-30000-001 GP1A73A 444-43000-302 KH0726 488-00033-104 Power Code; CH 035-14443-008 Clip ; ;BKT M-L Sensor 035-14444-004 Spring ; BKT M-L Sensor
Version: March,2004
KS800
Fig.23 Wire Harnesses
KS800
Fig.23 Wire Harnesses

No. 1 2 3 4 5 6 7
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark 1 1 1 1 1 1 1
No.
Part No.
Part Name(English)
Part Name(Chinese)
Q'ty Remark
035-51001-104 Wire; M-M Unit 035-51010-103 Wire; F 035-51011-100 Wire; R 035-51018-104 Wire; Main-Scanner 035-51024-201 Wire;M-Rmv Unit 435-00025-000 Noise Filter;SFC-6 035-51025-003 M-Rmv Safety SW Ass'y
Index
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
Part No. 000-06123-007 002-17017-203 011-11822-006 019-11812-106 019-25533-005 019-25533-005 019-25533-005 019-25533-005 020-11309-006 020-11513-002 020-11707-109 020-11708-008 020-11711-009 020-11721-004 020-12101-204 020-12104-505 020-12113-008 020-12119-006 020-12125-308 020-12126-002 020-12127-203 020-12132-002 020-12201-209 020-12205-204 020-12213-100 020-12220-106 020-12344-000 020-12441-200 020-12449-006 020-12502-306 020-12508-002 020-12512-000 020-12513-006 020-12514-100 020-12521-602 020-12522-102 020-12531-306 020-12534-100 020-12535-107 020-12536-200 020-12537-207 020-12538-009 020-12549-000 020-13108-105 020-13110-100 020-13116-205 020-15252-009 020-15702-101 020-60004-202 023-74001-046 035-04006-009 035-04007-102 035-04016-004 035-04019-003
KS800
Q'ty 2 1 1 2 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 4 2 1 1 1 1 1 1 2 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 2 1 1 1 1 1 1 Remark Fig.4 1 Fig.7 1 Fig.4 7 Fig.4 2 Fig.4 3 Fig.7 2 Fig.13 1 Fig.19 1 Fig.4 4 Fig.6 1 Fig.4 5 Fig.4 6 Fig.4 7 Fig.4 7 Fig.12 1 Fig.12 2 Fig.12 3 Fig.12 4 Fig.12 5 Fig.12 6 Fig.12 7 Fig.12 32 Fig.12 8 Fig.12 9 Fig.12 10 Fig.12 11 Fig.12 12 Fig.12 13 Fig.12 14 Fig.11 1 Fig.11 2 Fig.11 3 Fig.11 4 Fig.11 5 Fig.11 6 Fig.11 7 Fig.11 8 Fig.11 9 Fig.11 10 Fig.11 11 Fig.11 12 Fig.11 13 Fig.11 14 Fig.10 2 Fig.10 3 Fig.10 4 Fig.19 2 Fig.17 1 Fig.11 15 Fig.2 38 Fig.9 1 Fig.19 3 Fig.21 1 Fig.21 2
Part Name(English)
Stopper;Paper Guide Roller Cover Catch B; Front Stripper Pad;SR-29 Lock Ring Actuator Plate;Micro-SW Actuator Plate;Micro-SW Actuator Plate;Micro-SW Actuator Plate;Micro-SW Load Spring Lever;P.-F.-T. Housing; Stripper Spring;Stripper Stripper Pad Stripper Pad;Black Drum Body Ink Blocking Sheet;B4 Bearing Cap Main Gear;Squeegee Screen Hanger Plate Screw;Screw Hanger Spring ;Screen Seal tape0.5 Clamp Plate Base Clamp Magnet Clamp Base C Clamp Plate 2 Set Plate;Center Nozzle Drum Shaft Clamp Sleeve 32 Shaft Joint;Drum Stopper;Ink Distributor Metal Fix Plate Metal F;Drive Shaft Metal R;Drive Shaft Squeegee Roller Doctor Roller Drive Shaft; Squeegee Block F; Squeegee Block R; Squeegee Ink Blocking Plate(Front) Ink Blocking Plate(Rear) Adj.Plate;Doctor Adj.Plate(Rear);Doctor Belt Pulley;Suction Idle Shaft;Suction P.-E. Pulley; Suction De-electricity Brush;L Slide Rack ;Original Holder Drum PCB Motor ; Clump / M-Rmv Label;P-Rcv. Cover Label;M-Set Guide Label ; Caution 80 Label ; PF-Press Adj. 80
Part Name(Chinese)
Version :March,2004
Index
No. 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108
Part No. 035-11005-107 035-11006-006 035-11007-100 035-11008-106 035-11009-005 035-11010-003 035-11011-000 035-11012-006 035-11013-002 035-11014-009 035-11015-005 035-11016-001 035-11021-102 035-11022-001 035-11023-008 035-11025-000 035-11102-005 035-11103-303 035-11108-003 035-11109-000 035-11110-008 035-11701-103 035-11706-008 035-11707-101 035-11708-000 035-11709-007 035-11711-001 035-11712-008 035-11713-004 035-11721-104 035-11722-003 035-11723-000 035-11725-002 035-11962-004 035-12001-008 035-12003-000 035-12005-100 035-12007-103 035-12101-100 035-12102-106 035-12103-005 035-12104-001 035-12107-000 035-12108-309 035-12109-100 035-12110-001 035-12111-202 035-12112-101 035-12113-000 035-12114-007 035-12115-100 035-12121-003 035-12123-006 035-12124-100
KS800
Part Name(English)
Stay; Vertical Stay; Lower Stay; Middle Stay; Upper Plate; M-Shaft Catch Hook; Press-Spring Drum Rail; R Drum Rail; L BKT; C-Panel BKT; P-Supply PCB BKT; Main PCB Cover; Main PCB Cover; Suction Cover; Wire Harness Cover;P-Supply PCB BKT ; M-L Sensor Rear Cover M-Rmv Upper Cover Original Feed Tray Original Receive Tray Front Cover ; KS800C Housing; Cam Arm; Clamp Plate Arm; M-Projection Plate Shaft; Arms Spring; Clamp Lever Shaft; Cam/Gear Clamp Cam Encoder; Clamp Motor Sensor BKT C Sensor BKT L Shaft Clutch Plate Ass'y Sensor BKT L 80
Part Name(Chinese)
Shaft ; 6*9.5*18
Gear; m1*51L+m1*20L Gear; m1*66R+m2*28 Gear; m2*49*14 Gear; m1*20*8 Shaft; Timing Clutch BKT; Drive Gears Clutch Support Plate BKT; Pressure Hook Encoder Drum Rotation Lever Gear Shaft; Rotation Lever Shaft; Rotation Lever Cover; Drum Rotation Lever Gear plate; Drum rotation lever Link plate; Drum rotation lever Link shaft; Drum rotation lever Gear; m1*26*11 Cover;Rotation Lever Timing Clutch Support Plate Shaft ; M-Rmv
Version :March,2004
Index
No. 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162
Part No. 035-12125-009 035-12127-109 035-13001-001 035-13002-008 035-13003-306 035-13004-000 035-13005-007 035-13011-104 035-13101-502 035-13107-004 035-13111-303 035-13115-007 035-14103-304 035-14104-300 035-14115-000 035-14116-104 035-14117-003 035-14118-000 035-14119-103 035-14121-108 035-14123-003 035-14124-000 035-14201-101 035-14202-108 035-14207-207 035-14214-106 035-14215-200 035-14217-008 035-14218-004 035-14220-009 035-14221-005 035-14222-001 035-14230-004 035-14231-000 035-14240-000 035-14241-006 035-14244-005 035-14246-008 035-14247-004 035-14248-000 035-14249-007 035-14250-005 035-14251-109 035-14254-000 035-14255-007 035-14256-003 035-14305-004 035-14311-004 035-14312-000 035-14313-007 035-14402-000 035-14406-005 035-14407-001 035-14408-008
KS800
Q'ty 1 1 1 1 2 1 1 1 1 1 1 1 1 Remark Fig.2 42 Fig.2 45 Fig.3 4 Fig.3 5 Fig.3 6 Fig.3 7 Fig.3 8 Fig.3 1 Fig.3 9 Fig.3 10 Fig.3 11 Fig.3 12 Fig.6 4 Fig.6 5 Fig.4 9 Fig.6 10 Fig.6 2 Fig.6 3 Fig.6 6 Fig.6 7 Fig.6 8 Fig.6 9 Fig.4 10 Fig.4 11 Fig.5 1 Fig.5 2 Fig.5 3 Fig.5 4 Fig.4 13 Fig.5 5 Fig.5 6 Fig.4 14 Fig.4 20 Fig.4 15 Fig.4 16 Fig.4 48 Fig.4 52 Fig.4 50 Fig.4 45 Fig.4 51 Fig.4 46 Fig.4 44 Fig.4 47 Fig.4 43 Fig.4 49 Fig.4 12 Fig.4 17 Fig.2 13 Fig.2 14 Fig.4 18 Fig.4 19 Fig.4 21 Fig.4 22 Fig.4 23
Part Name(English)
BKT;M-Rmv Motor Spring ; M-Rmv Press-Roller Shaft Press-Balance Shaft Press-Roller Support Center Support Block Center Support Plate Pressure Roller Pressure Lever Ass'y Pressure Spring Press-Hook Plate Ass'y Spring; Hook Frame F ; PFT 80 Frame R ; PFT 80 Lock Pin L. O. Sheet Base Plate ; PFT 80 Plate ; PFT 80 Side Guide F ; PFT 80 Side Guide R ; PFT 80 Guide ; Fence 80 Lock Plate ; PFT Side Guide 80 Shaft; PFT Lever PFT Lever PF Set Lever Ass'y PF Adj. Screw Cover; Set Lever Sheet; Adj. Screw Set Lever BKT Ass'y PF Adj. Dial PF Adj. Collar Lock Plate Support Spring Shaft; Support Lever Roller; PFT Press-Adj. Lever BKT ; PFT Lever 80 Spring ; PF Press 80 Support Spring Lever ; PF Press Adj. Spring ; PF-Press Adj. Shaft ; PF Press Adj. Lever Cam ; PF Press-Adj. BKT ; PF Press-Adj. Plate ; PF Press-Adj. Shaft ; PFT PF Lever ; BKT ASS'Y PF-Support Roller PF-Clutch Support Plate Shaft ; PF-Clatch Shaft; Pichup Roller Timing Roller Guide Roller Spring Plate; Load Spring Guide Roller
Part Name(Chinese)
1
4 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 1 1
Version :March,2004
Index
No. 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216
Part No. 035-14409-004 035-14410-002 035-14411-009 035-14412-005 035-14413-001 035-14414-105 035-14415-101 035-14431-000 035-14432-006 035-14440-009 035-14443-008 035-14444-004 035-14445-000 035-14446-104 035-14452-007 035-14453-003 035-15002-102 035-15004-008 035-15016-006 035-15017-002 035-15018-009 035-15051-103 035-15052-002 035-15055-001 035-15057-004 035-15058-000 035-15058-000 035-15080-006 035-15090-001 035-15138-209 035-15139-205 035-15153-003 035-15156-002 035-15157-106 035-15161-006 035-15162-002 035-15200-001 035-15201-008 035-15202-004 035-15203-000 035-15204-007 035-15205-003 035-15206-000 035-15207-006 035-16101-007 035-16103-107 035-16105-002 035-16106-009 035-16107-005 035-16108-001 035-16109-008 035-16110-006 035-16111-002 035-16201-001
KS800
Q'ty 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 Remark Fig.4 24 Fig.4 25 Fig.4 26 Fig.4 27 Fig.4 28 Fig.4 29 Fig.4 30 Fig.4 33 Fig.4 34 Fig.4 32 Fig.22 19 Fig.22 20 Fig.4 31 Fig.4 42 Fig.4/white 7 Fig.4/red 7 Fig.10 5 Fig.10 7 Fig.10 8 Fig.10 9 Fig.10 1 Fig.7 4 Fig.7 5 Fig.7 6 Fig.7 7 Fig.7 8 Fig.9 2 Fig.7 9 Fig.7 10 Fig.8 3 Fig.8 4 Fig.9 3 Fig.9 4 Fig.9 5 Fig.9 6 Fig.9 7 Fig.10 6 Fig.10 16 Fig.10 17 Fig.8 1 Fig.8 2 Fig.8 5 Fig.8 6 Fig.8 7 Fig.12 15 Fig.12 16 Fig.12 17 Fig.12 18 Fig.12 19 Fig.12 19 Fig.12 20 Fig.12 16 Fig.12 1 Fig.12 21
Part Name(English)
Guide Roller BKT Support BKT F; G-Roller Support BKT R; G-Roller Guide Roller Shaft G-Roller S-Shaft Paper Gate Paper Gate Shaft PF Safety SW Plate Safety SW Protection P-Guide Upper Ass'y 80
Part Name(Chinese)
Clip ; ;BKT M-L Sensor Spring ; BKT M-L Sensor

P-Guide Lower Ass'y 80 Sheet ; P-Guide Stripper Pad;50 Stripper Pad;60 Suction Base Suction Duct Suction Gear Shaft Drive Shaft; Suc-Belt De-electricity Brush ; Suction 80 Separator Shaft ; Separator Separator Lever Ass'y Spring ; Separator Fan Set SW Plate Fan Set SW Plate Set Switch BKT Shaft; Belt Drive Gear P-Rcv-T BKT F P-Rcv-T BKT R Fan Base; Separation Nozzle-Up; Separation Nozzle-Low; Separation Fan Base Support BKT Fan Base Shaft Suction Face Cover 80
Suction Wing F 80 Suction Wing R 80

Paper Receiving Tray 80 Paper Base Stop 80 P-Rcv-T BKT 80 P-Ejection Guide Side Base ; P-Rcv-T Drum Support F Ass'y Drum Support R Ass'y Drum Main Gear Compensator Pressure Cam Pressure Cam;A4 Screen Ass'y Drum Support R Ass'y;AL Drum Body;AL M-Projection Plate
Version :March,2004
Index
No. 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270
Part No. 035-16202-008 035-16301-006 035-16302-002 035-16303-009 035-16304-005 035-16305-001 035-16306-008 035-16307-004 035-16401-205 035-16402-007 035-16501-005 035-16502-001 035-16503-202 035-16506-201 035-17001-006 035-17003-009 035-17004-005 035-17005-001 035-17006-008 035-17007-004 035-17009-007 035-17012-008 035-17015-007 035-17016-003 035-17019-002 035-17020-000 035-17021-309 035-17022-100 035-17023-000 035-17024-006 035-17025-002 035-17026-009 035-17027-005 035-17028-001 035-18101-101 035-18102-000 035-18103-007 035-18104-100 035-18105-204 035-18107-100 035-18108-203 035-18109-102 035-18110-100 035-18111-107 035-18201-009 035-18204-008 035-18205-306 035-18206-108 035-18207-007 035-18208-003 035-18209-000 035-18210-008 035-18301-003 035-18302-000
KS800
Part Name(English)
Friction Sheet BKT; Ink Bottle Guide Ink Bottle Guide Bottle Hook-Spring Inking Hose dia.10 Center Nozzle BKT; Ink Bottle Sensor Ink Bottle Sensor Plate Drum U Support BKT F Drum U Support BKT R Center Shaft Main Frame; Drum Sqg. F Plate Ass'y Sqg. R Plate Ass'y OF F Frame Ass'y OF R Frame Ass'y BKT; O-Det. Sensor Spring; Scanner Spring; Load Roller Spring; Ejc-Roller Org-Load Roller Org-Ejc-Roller Wh-Roller Holder White Roller Roller; L40 Roller; L74 DFeeder Cover Cover Up; Wh-Roller Cover Low; Wh-Roller Original Guide Hook; DFeeder Scanner Holder L Scanner Holder R Spring; Hook Master Flange M-Flange Holder M-Flange Guide Tension Plate Tension Plate Ass'y Plate; Plunger Rubber; Tension Master Flange R De-electricity Brush;KS Master Tension Sheet Write Roller TPH Press-Plate TPH Position-Plate TPH Press-Shaft Press-sensor Plate TPH Press-Cam TPH Support Shaft Shaft Stopper Shaft; M-Guide M-Guide Plate; Lower
Part Name(Chinese)
Version :March,2004
Index
No. 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324
Part No. 035-18303-200 035-18304-207 035-18305-009 035-18401-202 035-18404-104 035-18406-000 035-18407-103 035-18408-002 035-18410-007 035-18411-208 035-18412-000 035-18413-103 035-18415-009 035-18416-005 035-18417-001 035-18501-002 035-18502-009 035-18503-005 035-18504-001 035-18505-008 035-19008-105 035-19025-000 035-19026-006 035-19027-100 035-19027-100 035-19029-005 035-19033-100 035-19034-009 035-19035-005 035-19036-001 035-19037-008 035-19037-008 035-19038-004 035-19045-000 035-19046-309 035-19047-208 035-19058-005 035-19059-109 035-19060-000 035-19061-006 035-19062-002 035-19063-009 035-19064-005 035-19065-001 035-19066-008 035-19067-004 035-19069-007 035-19070-005 035-19071-001 035-19072-008 035-19073-101 035-19075-007 035-19076-003 035-19077-000
KS800
Part Name(English)
M-Guide Plate; Upper Cutter Guide Plate Rev-gear Plate Ass'y Frame R Ass'y; M-M U Frame F Ass'y; M-M U Base; M-M U Cover; M-M U M-Tension Shaft Release Lever Base; M-M Upper U Cover; M-M Upper U Locking Plate Ass'y Shaft; M-Holder Shaft; M-M U Washer;3.5*14*1.2 Spring ; TPH Pressure Spring R; M-M Upper U Spring F; M-M Upper U Tension Spring Spring ; Rev-gear Plate M-Rmv Hook Wire; M-Rmv Link M-Rmv Link Collar; M-Rmv Collar; M-Rmv Hinge; M-Rmv Lever; M-Rmv Spring; M-Rmv Lever BKT; M-Rmv Lever Shaft A; M-Rmv Gear Shaft B; M-Rmv Gear Shaft B; M-Rmv Gear Shaft; M-Rmv Lever BKT; M-Feed Sheet M-Feed Sheet BKT; M-Rmv Sensor Cover;M-Rmv Lever Frame ; M-Rmv U 80 M-Rmv Guide ; Lower 80 M-Rmv Guide ; Upper 80 M-Rmv Guide ; Upper2 80 BKT F ; Trans-Roller 80 BKT R ; Trans-Roller 80 Spring Trans-Roller 80 Trans-Roller ; Lower Trans-Roller ; Upper
Part Name(Chinese)
*M-Disposal ; Main Box Ass'y *M-Disposal Box ; Cover *M-Disposal ; Guide *M-Disposal ; Lever *M-Disposal ; Link *M-Disposal ; Spring
Stay ; M-Rmv U Frame BKT A;M-Rmv SW 80
Version :March,2004
Index
No. 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378
Part No. 035-19078-006 035-19079-002 035-50504-102 035-50505-001 035-50506-105 035-51001-104 035-51007-102 035-51010-103 035-51011-100 035-51013-102 035-51018-104 035-51023-108 035-51023-108 035-51023-108 035-51024-201 035-51025-003 035-51025-003 035-52001035-90002-002 035-92002-050 035-94302-000 035-96321-002 035-98004-101 035-99060-005 435-00025-000 443-32005-003 443-32005-003 444-30000-001 444-30000-001 444-30000-001 444-30000-001 444-30000-001 444-31001-001 444-33000-002 444-41001-107 444-43000-302 444-60000-103 444-80300-308 488-00033-104 488-90028-007 490-20002-106 490-21005-001 490-33006-003 490-33006-003 490-41002-106 490-41002-106 490-50001-104 490-51001-000 550-20118-104 550-21519-005 600-20061-009 607-07004-005 607-13000-003 607-13000-003
KS800
Q'ty 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 4 4 Remark Fig.13 5 Fig.1 11 Fig.22 14 Fig.22 14 Fig.22 13 Fig.23 1 Fig.12 26 Fig.23 2 Fig.23 3 Fig.9 8 Fig.23 4 Fig.4 35 Fig.7 11 Fig.19 39 Fig.23 5 Fig.23 7 Fig.13 6 Fig.22 15 Fig.20 4 Fig.2 34 Fig.4 36 Fig.12 27 Fig.18 4 Fig.14 Fig.23 6 Fig.17 23 Fig.19 40 Fig.12 28 Fig.15 24 Fig.16 12 Fig.19 41 Fig.22 16 Fig.15 25 Fig.9 9 Fig.2 16 Fig.22 17 Fig.17 24 Fig.19 42 Fig.22 18 Fig.6 11 Fig.2 7 Fig.16 13 Fig.17 25 Fig.19 43 Fig.9 10 Fig.10 10 Fig.19 44 Fig.2 18 Fig.19 45 Fig.19 45 Fig.3 13 Fig.19 46 Fig.2 19 Fig.4 37
Part Name(English)
BKT B;M-Rmv SW 80 M-Feed Sheet 80 P-Supply PCB XIII-N100 P-Supply PCB XIII-N200 II Main-PCB-KS800 Wire; M-M Unit Wire; Ink Sensor Wire; F Wire; R Wire; P-Rcv Sensor Wire; Main-Scanner Safety SW Ass'y Safety SW Ass'y Safety SW Ass'y Wire;M-Rmv Unit M-Rmv Safety SW Ass'y M-Rmv Safety SW Ass'y System ROM ; KS Control Panel Unit KS800C Main Motor Ass'y Pickup Roller Ass'y Ink Pump Unit Cutter Unit
Part Name(Chinese)
M-Disposal Box Ass'y

Noise Filter;SFC-6 GP2A25 GP2A25 GP1A73A GP1A73A GP1A73A GP1A73A GP1A73A M-Rmv Sensor GP2A200LCS Encoder Sensor KH0726 Image Scanner TPH
Power Code; CH
RS3-150-RS3 Main Motor Clamp Motor DFeed Motor DFeed Motor Fan Fan M-Loading Solenoid PF/M-Rmv Clutch
TPH Seal
TPH Seal;CH Bearing;608ZZ Metal; S8*10*15 Metal;F6*10/9*4;12*1.5 Metal;F6*10/9*4;12*1.5
Version :March,2004
Index
No. 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432
Part No. 607-13000-003 607-13000-003 607-13000-003 607-15000-000 607-15000-000 607-15000-000 607-15000-000 607-15000-000 607-16001-000 607-16001-000 607-16001-000 607-16002-007 607-70815-005 612-00401-009 612-03104-005 612-10012-000 612-11102-003 612-11205-007 612-11205-007 612-11303-009 612-11307-004 612-11401-000 612-11402-007 612-11501-005 612-12102-007 612-12206-007 612-12207-003 612-12303-002 612-12304-009 612-12309-000 612-12309-000 612-12311-005 612-12312-001 612-12313-008 612-12319-006 612-16100-009 612-16300-008 612-32100-000 612-80014-000 612-80015-007 612-80800-006 612-80800-006 612-80801-002 612-80801-002 612-80900-000 612-80900-000 612-81303-006 612-82307-005 612-82308-001 612-82310-006 612-82313-005 612-82400-005 612-82600-004 612-82701-005
KS800
Part Name(English)
Metal;F6*10/9*4;12*1.5 Metal;F6*10/9*4;12*1.5 Metal;F6*10/9*4;12*1.5 MetalF8*13/12*5;16*2 MetalF8*13/12*5;16*2 MetalF8*13/12*5;16*2 MetalF8*13/12*5;16*2 MetalF8*13/12*5;16*2 Metal;F10*15/14*6;18*2 Metal;F10*15/14*6;18*2 Metal;F10*15/14*6;18*2 Metal;F10*16/12.8*12:18*2 Washer;R-WAS8399H Gear; m0.5*48*4 Gear; m1.25*14*6 Gear; m1*31*8 Gear;m0.8*18*5 Gear; m0.8*28*4 Gear; m0.8*28*4 Gear ; m0.8*34*7 Gear ; m0.8*24*7 Gear;m0.8*45*5 Gear; m0.8*40*3 Gear; m0.8*52*7 Gear; m1*17*6.5 Gear; m1*24*4 Gear; m1*20*10 Gear;m1*30*5 Gear;OWC;m1*30*5 Gear ; m1*37*9 Gear; m1*37*9 Gear; m1*36*7 Gear; m1*39*8 Gear; m1*33*6 Gear ; m1*36*7 Gear; m2*18*8 Gear; m2*32*13 Gear; m1*16R*16 Gear;m1*57+m1*49 Gear;m1*41+m1*35 Gear;m0.5*86+m0.5*49 Gear;m0.5*86+m0.5*49 Gear; m0.5*85+0.8*19 Gear; m0.5*85+0.8*19 Gear;m0.5*94+m0.5*48 Gear;m0.5*94+m0.5*48 Gear ; m0.8*35+m0.8*15 Gear;m0.5*40+m1*16 Gear; m1*36+m1*15 Gear; m1*36+m1*14 Gear ; m1*21+m1*14 Gear; m1*41+m1*36 Gear; m1*65+m2*29 Gear; m1*70+m1*60
Part Name(Chinese)
Version :March,2004
Index
No. 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455
Part No. 629-93810-202 634-04030-002 635-00410-002 635-09308-103 635-09308-103 635-17523-005 638-90000-128 640-60030-004 640-60100-100 640-60100-100 640-60180-006 640-61550-001 660-01002-105 665-02903-005
KS800
Q'ty 2 1 2 1 1 4 1 2 1 1 2 2 4 2 1 1 1 1 1 1 1 1 1 Remark Fig.10 15 Fig.2 31 Fig.10 18 Fig.3 15 Fig.17 33 Fig.19 53 Fig.4 41 Fig.11 24 Fig.11 25 Fig.12 29 Fig.11 26 Fig.12 30 Fig.1 12 Fig.12 31 Fig.1 1 Fig.1 2 Fig.1 3 Fig.20 3 Fig.20 4 Fig.21 1-a Fig.21 1-b Fig.21 1-c Fig.21 1-d
Part Name(English)
Transfer Belt;14*0.65*381 Collar; dia.4*3
Part Name(Chinese)
Stepped Screw ; m4*10

Pan-head Tap Tight P Screw 3*8 Pan-head Tap Tight P Screw 3*8
Stepped Screw;dia.5*2;M3*3 Washer;18*10.4*0.4 O Ring ; P3-1.9 O Ring ; P10-2.4 O Ring ; P10-2.4 O Ring ; P18-2.4 O Ring ; P115-2.4
Rubber Foot TK-3215

Power Band T14 Main Frame; Front Main Frame; R Ass'y 80 Base Plate Front Cover ; KS800 Control Panel Unit KS800 Label ; P-Rcv 80 Label; M-Replace Label ; M-Disposal 80 Label; Ink Replace
New Part for KS800
Version :March,2004

KS800 Series Version 3.1

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Verfügbare Formate

KS800 Series Version 3.1

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SERIES

( KS500 / KS600 / KS800 )

KS Series (Version 3.1)

KS Series (Version 3.1)

KS Series (Version 3.1)

KS Series (Version 3.1)

KS Series (Version 3.1)

KS Series (Version 3.1)

KS Series (Version 3.1)

[Replacement of the Lithium Battery]

KS Series (Version 3.1)

2. Always connect electrical connectors firmly.

Press the ends.

Press the center, firmly.

KS Series (Version 3.1)

Assembly and installation

Replace mount screws

Pan-head screw or Binding-head screw

KS Series (Version 3.1)

Electrical system work

Wiring bundle band (bar lock ties)

KS Series (Version 3.1)

3. Exterior Cover Removal

A: Front cover B: Back cover C: Master removal cover

KS Series (Version 3.1)

KS Series (Version 3.1)

KS Series (Version 3.1)

Original Weight Paper Weight Image Area Paper Capacity

Machine Weight Dimensions [WxDxH]

KS Series (Version 3.1)

Original Weight Paper Weight Image Area Paper Capacity

Machine Weight Dimensions [WxDxH] Power Source

KS Series (Version 3.1)

Original Weight Paper Weight Image Area

Enlargement Parameters Reduction Parameters Paper Capacity

141%, 122%, 116% 71%, 82%, 87%, 94%

Machine Weight Dimensions [WxDxH] Power Source

KS Series (Version 3.1)

2. Cross Sectional Diagram

1 First Paper Feed Area:

2 Second Paper Feed Area:

3 Press (Printing) Area:

4 Paper Ejection Area:

5 Drum Area: 6 Master Clamp Area: 7 Master Disposal Area:

8 Image Scanning Area:

9 Master Making Area: 10 Master Loading Area:

KS Series (Version 3.1)

Set the original and press the Start key.

Master Carrier and Loading

KS Series (Version 3.1)

4. Paper Feed and Receiving

Separation fan Separator

KS Series (Version 3.1)

5. Master Removal and Feed

Master disposal box

KS Series (Version 3.1)

2. Clear of Copy and Master Counter:

KS Series (Version 3.1)

MAIN DRIVE SECTION

KS Series (Version 3.1)

KS Series (Version 3.1)

MAIN DRIVE SECTION

KS Series (Version 3.1)