CZ180 CV1860: Technical Manual

CZ180
CV1860
TECHNICAL MANUAL
REVISION 1.0
AUGUST 2007
Copyright: 2007 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 DEUTSCHLAND GMBH (GERMANY)

RISO, INC. (U.S.A.) RISO FRANCE (FRANCE)
RISO EUROPE LIMITED (U.K.) RISO IBERICA (SPAIN)
RISO HONG KONG LIMITED (HONG KONG) RISO CANADA (CANADA)
RISO U.K. (U.K.) ZHUHAI RISO TECHNOLOGY (CHINA)
RISO THAILAND LIMITED (THAILAND) RISO AFRICA (SOUTH AFRICA)
RISO KOREA LIMITED (KOREA) RISOGRAPH ITALIA (ITALY)
RISO Inc. Technical Services & Support US.RISO.COM
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CONTENTS
Chapter 1 MAINTENANCE
Chapter 2 MACHINE SUMMARY
Chapter 3 MAIN DRIVE
Chapter 4 FIRST PAPER FEED
Chapter 5 SECOND PAPER FEED
Chapter 6 PRINTING PRESSURE
Chapter 7 PAPER EJECTION
Chapter 8 PRINT DRUM
Chapter 9 MASTER CLAMPING
Chapter 10 MASTER REMOVAL
Chapter 11 ORIGINAL SCANNING
Chapter 12 MASTER MAKING
Chapter 13 PANEL MESSAGE
Chapter 14 TEST MODE
Chapter 15 ELECTRICAL COMPONENTS
Chapter 16 PCBs
Chapter 17 OTHER PRECAUTIONS
Chapter 18 APPENDIX

Preface
This manual provides Technical Service Information for the digital duplicator Model CZ180 and
CV1860 series.
This manual provides procedures for removing and installing major components. Following these procedures
will minimize machine malfunctions. This information and format will also increase technical representatives'
awareness and experience regarding repairs necessary to insure end-user satisfaction.

CHAPTER 1: MAINTENANCE
CONTENTS
1. Preface....................................................................................................2
2. Warning...................................................................................................3
Important Safety Precautions.............................................................3
3. Work Precautions....................................................................................4
4. Installation location..................................................................................6
5. JIGs ��7
6. Installation Procedures............................................................................8
CZ180................................................................................................8
CV1860............................................................................................10
Inkless Drum (CZ180)......................................................................13
Inkless Drum (CV1860)....................................................................14
RISORINC Printer Control Board.....................................................15
7. External Cover Removal........................................................................18
Front Cover......................................................................................18
Rear Cover.......................................................................................18
Master Removal Upper Cover.........................................................18
Scanner Unit Cover..........................................................................18
Master Removal Lower Cover.........................................................18
Master Making Unit Cover...............................................................18
Operation Panel Unit........................................................................18
8. PCB Bracket Open Procedure...............................................................19
9. Screws Which are NOT to be Loosened or Removed...........................20
CZ180 / CV1860 Rev. 1.0 1-


1. Preface
This manual provides Technical Service Information for the digital duplicator Model CZ180 and CV1860
series.
This manual provides procedures for removing and installing major components. Following these
procedures will minimize machine malfunctions. This information and format will also increase technical
representatives' awareness and experience regarding repairs necessary to insure end-user satisfaction.
1- CZ180 / CV1860 Rev. 1.0


2. 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.
II. Protection of the machine:

Make sure to turn OFF the power to the machine before plugging or unplugging the electrical
connectors, or when connecting a Meter.

2. Always connect electrical connectors firmly.
I. To avoid electrical failure:

The connectors must be connected firmly together and onto the PCBs.
Press on the ends of the connectors and then on the middle to ensure a firm fit.
II. Protection of the electrical components:

The electrical components may be damaged due to short circuits caused by a loose
connector.
Wire harness connector
FIRST
Press the ends.
THEN
Press the center, firmly.
CZ180 / CV1860 Rev. 1.0 1-


3. Work Precautions
When conducting maintenance work, be careful to avoid injury caused by springs or the sharp edges
of sheet metal.
Inspection
If you discover any defects or problems during an inspection, fix the problems or if necessary take
steps such as replacing a part.
Removal
Check the problem area. At the same time, examine the cause of the problem and determine whether
the part needs to be removed or disassembled. Next proceed according to the procedures presented
in the Technical Manual. In cases where, for example, it is necessary to disassemble areas with large
numbers of parts, parts which are similar to each other, or parts which are the same on the left and
right, sort the parts so that you do not mix them up during reassembly.
(1) Carefully sort the removed parts.
(2) Distinguish between parts which are being replaced and those which will be reused.
(3) When replacing screws, etc., be sure to use the specified sizes.
Assembly and Installation

Unless specified otherwise, perform the removal procedures in reverse during assembly and
installation. In cases where protrusions or holes are provided to assist
in positioning parts, use them for accurate positioning and securing.
(Protrusions and holes for positioning parts Half pierced section)
Tools
Using tools other than those specified can lead to injury or damage
screws and parts. Have all the tools necessary for the work available.
Type Tip Shaft length, Type Remarks

size etc. Steel scale 150 mm
Phillips No. 2 (250 mm) Feeler gauge
screwdriver No. 2 (100 mm–150 Radial cutting pliers

Pliers
No. 2 mm)
Nipper
No. 1 (stubby type) Small flashlight
(75 mm–100 Multimeter
mm) Soldering iron 20 W–30 W

Standard 6 mm (100 mm–150 File Flat, round
screwdriver 3 mm mm)
1.8 (100 mm–150
mm mm)
(precision
type)
1- CZ180 / CV1860 Rev. 1.0


Electrical system work

Wiring bundle bands
> After removing wire bundles, fasten them with
wire bundle bands (bar lock ties) so that they (bar lock ties)
will not sag.
> When installing parts, be careful to avoid
pinching or damaging the wire bundles.
> If a fuse blows, always replace it with one with
the specified capacity.
> Using a fuse with a larger capacity can not only
damage parts, but may cause fires.
> Be careful not to drop image scanners, thermal
print heads, and other sensors as they can be
easily damaged.
Sensor types Interrupt types Actuator types

> Photoelectric sensors may be broadly divided
Receiver
into the following four types: interrupt types
(U-shaped), actuator types, reflective types, Receiver
and transmitting types.
Sender
> Magnetic sensors use Hall ICs, which react to Sender
the magnetic force in magnets.
> Always turn off the power before plugging or Reflective types Transmitting types
unplugging sensor connectors. Sender
Sender
Receiver
Receiver
Switch types
> Micro-switches may be divided between
normally open (N.O.) types and normally
closed (N.C.) types.
> With an (N.O.) connection, an internal contact
is connected when the switch actuator is N.C. N.C.
pressed. N.O. N.O.
> With an (N.C.) connection, an internal contact COM COM
is disconnected when the switch actuator is
pressed.
Note
The machine is comprised of many gears. When inspecting or replacing parts, apply grease to the gears.
If they are not properly greased, the gears may make abnormal sounds, and malfunctions or mechanical
problems may occur.
CZ180 / CV1860 Rev. 1.0 1-


4. Installation location
Do not install the machine in any of the following locations.

(1) Those subject to direct sunlight or any bright location such as by a window (If you must install in
such a location, put a curtain or the like over the window.).
(2) Those where the temperature changes drastically.
(3) Those that are too hot, cold, humid, or dry.
RECOMMENDED:
Temperature range: 15 degrees Celsius - 30 degrees Celsius
Humidity range: 40% - 70% No condensation allowed
(4) Those with radiant heat sources and any locations in the direct path of air from air conditioners or
heaters.
(5) Any poorly ventilated location.
(6) Dusty atmosphere.
(7) Any tilted location.
(Installation height difference: 10 mm max. front - rear, 10 mm max. left - right).
Electrical connection
> Plug the plug securely into the socket so that there is no problem with the contact in the power
supply plug section.
> Do not use any triplets or extension cords.
> Do not allow any other machine to stand on or crush the power cord.
Ground connection
> Always ground this machine to prevent electrical shock in case of an electrical leakage.
1- CZ180 / CV1860 Rev. 1.0


5. JIGs
021-16007-005 Spring; Screen (2 pieces required)

Cut the ring end to make into hook, as shown on the
photograph, and attach wire tie bar on the other end.
015-26128-008
Drum Shaft JIG
CZ180 / CV1860 Rev. 1.0 1-


6. Installation Procedures
CZ180 & CZ180(120)
RISO CZ Installation Procedure

The following procedures are required Equipment
before turning on the printer.
Use the following pieces of equipment in the package.
1. Noise Absorber ......................................... 1 pc.
Nobody but Riso-authorized service
2. Stabilizer ................................................... 2 pcs.
representatives is allowed to install this unit.
3. Double-washered screw ............................ 2 pcs.
・When installing CZ100 in countries with 100-120V electricity,

CAUTION! the voltage setting is required. Otherwise, it may cause damage to the printer.
・Do not turn the power ON without removing shock absorbing sheets.
Otherwise, it may cause damage to the printer.
《Voltage Setting》(Only for CZ100 installing in 100-120V countries)
1. Remove the Rear Cover.
230V
115V
2. Set the Voltage Switch to 115V.
3. Replace the Rear Cover.

< This caution is only for 100-120V machine. >
《Installation of the Printer》

1. Place the Noise Absorber on a stand.
2. Mount the printer on the position illustrated in the left.

(The Noise Absorber is squashed between the stand
and the printer )
1 The Noise Absorber is aligned to the Bottom Stay.
2 The Noise Absorber is between the Rubber Feet.
Important: The Rubber Feet of the printer should

Noise Absorber
not step on the Noise Absorber.
1 2
Noise Absorber Bottom Stay Rubber Foot Noise Absorber
3. Secure the Stabilizers on the bottom of the Paper

Feed Tray. (Double-washered screw M3 x 8, 2pcs.)
Important:
・ The Stabilizers should be attached without

Stabilizer gaps between the Stabilizers and the stand.
・Decide the direction of Stabilizers

depending on the stand type referring
to the illustration in the left.
For the stand type CR For the other stands
042-36102-306 1
1- CZ180 / CV1860 Rev. 1.0


4. Remove the Shock Absorbing Sheet from the CCD

Shock Absorbing Sheet
Unit.
5. Remove the Shock Absorbing Sheet from the TPH

Unit.
Shock Absorbing
Sheet
6. Remove the Tapes on the Paper Ejection Wing.
Tapes
7. Remove the Shock Absorbing Sheet from the

Disposal Unit.
Shock Absorbing Sheet
When pulling out the Drum after the above installation procedure, always turn on
CAUTION! the POWER and press the DRUM RELEASE key [ ] on the control panel.
Otherwise, the machine may be damaged.
CZ180 / CV1860 Rev. 1.0 1-


CV1860
1 - 10 CZ180 / CV1860 Rev. 1.0


CZ180 / CV1860 Rev. 1.0 1 - 11


1 - 12 CZ180 / CV1860 Rev. 1.0


Inkless Drum (CZ180)
Installation Procedure for The CZ Series

Inkless Print Cylinder (Drum)
Types of Applicable Printers Packing List
The following printer models are the intended basic This package contains the following items.
units for installing the CZ series inkless Print cylinder 1. Print cylinder (drum) ................................... 1 unit
(drum). 2. Ink color indication label ...................... 1 sheet
3. Installation guide (This manual) ................ 1 copy
RISO KAGAKU CORPORATION Models
RISO CZ series
Nobody but Riso-authorized service

representatives is allowed to install this unit.
1. Print Cylinder (Drum) Preparation Bottle SW cover

Important: When installing a black ink cartridge, this procedure is not necessary.
Please skip to the procedure 2.
1) Remove the Print cylinder (drum) cover, the Bottle SW cover, and the Bottle guide.
Note: Disconnect the connecter of the Bottle Set SW wireharness from the Bottle guide.
2) Depending on the ink color, cut off the corresponding Jumper wireharness referring to
the table below. Bottle guide
Important: Be sure to cut off the Jumper wireharness from the joint and remove
completely.
Print cylinder (drum) cover
Connecter of the Bottle Set
SW wireharness
3) Fix the Bottle guide, the Bottle SW cover, and the Print cylinder (drum) cover.
Important: Be sure to connect the connecter of the Bottle Set SW wireharness Jumper wireharness
to the Bottle guide.
2. Insert an Ink cartridge

1) Set an ink cartridge to the Print cylinder (drum).
Be sure to lead ink to the nozzle of the cartridge in advance.
Important: Be sure that the Print Cylinder (drum) temperature is above 59 °F (10 °C).
2) Install the Print cylinder (drum) in the printer.
3) Start the test mode.
Note: If the error code No. d04-534 appears on the control panel, remove the Print
cylinder (drum) and then check the ink cartridge and the Jumper wireharness.
4) Input the test item code No.887 and press the start key .
3. Operation Check
1) Make a master with Riso test chart No.15 and print 200 copies at speed 2.
2) Check density balance.
/ RED
4. Labeling
Ink color indication label
Affix an ink color indication label on the Print cylinder (drum) cover as illustrated.
042-36201-002
CZ180 / CV1860 Rev. 1.0 1 - 13


Inkless Drum (CV1860)
1 - 14 CZ180 / CV1860 Rev. 1.0


RISORINC Printer Control Board
CZ180 / CV1860 Rev. 1.0 1 - 15


1 - 16 CZ180 / CV1860 Rev. 1.0


CZ180 / CV1860 Rev. 1.0 1 - 17


7. External Cover Removal
Front Cover
1. Remove the Drum.
2. Turn OFF the machine power and detach the Front Cover. (M3x8 screws; 6 pcs)
Rear Cover
1. Turn OFF the machine power and detach the Rear Cover. (M3x8 screws; 5 pcs)
Master Removal Upper Cover

1. Turn OFF machine power and detach the Master Removal Upper Cover. (M3x8 screws; 2 pcs)
Scanner Unit Cover

1. Turn OFF machine power and detach the Master Removal Upper Cover. (M3x8 screws; 2 pcs)
2. Detach the Scanner Upper Frame Cover. (M3x8 screws; 4 pcs)
3. Detach the Scanner Unit Cover. (M3x8 screws; 4 pcs)
Master Removal Lower Cover

1. Turn OFF the machine cover and remove the Master Disposal Box.
2. Detach the Master Removal Lower Cover. (M3x8 screws; 4 pcs)
Master Making Unit Cover

1. Turn OFF the machine power and detach the grip handle. (M3x6 screw; 1 pc)
2. Detach the Master Making Unit Cover. (M3x8 screws; 2 pcs)
Operation Panel Unit

1. Turn OFF the machine power and detach the Front Cover. (M3x8 screws; 6 pcs)
2. Detach the Operation Panel Unit. (M3x8 screws; 2 pcs)
Scanner Unit Cover

Operation Panel Unit
Master Removal Upper Cover
Rear Cover
Master Making Unit Cover

Front Cover
Master Removal Lower Cover
1 - 18 CZ180 / CV1860 Rev. 1.0


8. PCB Bracket Open Procedure

1. Turn OFF the machine power and detach the Rear Cover. (M3x8 screws; 5 pcs)
2. Remove the mounting screws (M3x8 screws; 4 pcs) and swing open the PCB Bracket.
Precaution in Assembly:
1) To prevent the wire harness from getting damaged, place the wire harness from the Copy
Counter on top of the Master Counter to prevent the wire harness from dropping onto the wire
harness clamper located on the top portion of the PCB Bracket. Otherwise the Copy Counter
wire harness will be damaged when the PCB Bracket is opened.
Copy Counter Master Counter Rear Upper Wire Harness This is NOT good.
2) To prevent the Power Switch Wire Harness from being pinched or cut by the Pressure Spring
when the PCB Bracket is closed, the Power Switch Wire Harness should be placed under the
rear bottom wire harness and main motor relay wire harness when leading the Power Switch Wire
Harness out through the Handle Mounting Bracket-B.
Main Motor Relay Wire Harness
Rear Bottom Wire Harness
Power Switch Wire Harness
Handle Mounting Bracket-B
CZ180 / CV1860 Rev. 1.0 1 - 19


9. Screws Which are NOT to be Loosened or Removed
The Master-Making Unit Side Frame and the Rear Stay are both mounted on the machine using JIGs
at the factory, using screws which cannot be loosened or removed using regular screw drivers.
These special screws should never be loosened or removed.
Master-Making Unit Side Frame Rear Stay
1 - 20 CZ180 / CV1860 Rev. 1.0


CHAPTER 2: MACHINE SUMMARY
CONTENTS
1. Cross-Sectional Diagram.........................................................................2
2. Operation Outline.....................................................................................3
3. Outline of Paper-feeding, Printing, and Paper-ejection Operations.........3
4. Master-removal operation........................................................................4
5. Master-making operation.........................................................................4
6. Master-loading operation.........................................................................4
7. Machine Specification..............................................................................6
1) CZ180............................................................................................6
2) CV1860..........................................................................................8
CZ180 / CV1860 Rev. 1.0 2-


1. Cross-Sectional Diagram
(6) Clamp unit
(7) Master-removal section (8) Scanning section
(2) Second paper-feed area

(9) Master-making section
(1) First paper-feed area (4) Paper-ejection section
(5) Print drum (3) Press section
(1) First paper-feed area:

Sends paper from the paper-feed tray one sheet at a time.
(2) Second paper-feed area:
Stops the paper sent from the first paper-feed stage, and accurately feeds it to the print drum and
pressure section.
(3) Press section:
The pressure roller presses the paper firmly against the print drum for printing.
(4) Paper-ejection section:
Removes the printed paper from the print drum using the separator, and sends it to the paper-
receiving tray.
(5) Print drum:
Supplies ink from the ink cartridge to the surface of the print drum for printing.
(6) Clamp unit:
Clamps the leading edge of a master onto the drum.
(7) Master-removal section:
Peels the master from the print drum after use, and discharges it into the master disposal box.
(8) Scanning section:
The original image is scanned on the Auto Document Feeder (AF) unit).
(9) Master-making section:
Transports and creates a master using the thermal print head, then sends the produced master to
the print drum, and cuts the master material.
2- CZ180 / CV1860 Rev. 1.0


2. Operation Outline
1) Set an original, and press the Start key.
2) Master removal operation

Removes the used master from the print drum, and sends it to the master disposal box.
3) Master-making operation
The original is scanned by the image sensor, and the image is transferred onto a master by the
thermal print head.
4) Master loading operation

The produced master is wound around the print drum and cut.
The proof-print is printed.
5) Printing operation
Paper is fed from the paper-feed tray one sheet at a time for printing. The printed paper is ejected
out onto the paper-receiving tray.
3. Outline of Paper-feeding, Printing, and Paper-ejection Operations
1) When the print drum rotates, the scraper roller and pickup roller also turn to feed paper. The
stripper pad allows only one sheet to pass through to the second paper-feed area.
2) The paper sent from the first paper-feed area contacts the timing roller and guide roller, and stops
temporarily. This causes slight buckling of the paper.
3) The timing roller and guide roller start rotating, feeding paper to the pressure section. (This
operation is referred to as the 都econd paper-feed・ To prevent tension from being placed on the
end of the paper, the scraper roller and pickup roller are free to spin.)
4) When the paper is fed further in from the second paper-feed area, the pressure roller rises to
clamp the paper between the drum and pressure roller to start the printing operation.
5) The printed paper is removed from the print drum by the separator and separation fan. When the
pressure roller rises, the guide roller also moves up to prevent tension from being placed on the
tailing end of the paper.
6) Then, the suction fan pulls in the air to keep the paper firmly on the transfer belts while the paper
is carried to the paper-receiving tray.
7) The next sheet of paper is sent to the first paper-feed area, and the guide roller lowers.
CZ180 / CV1860 Rev. 1.0 2-


4. Master-removal operation
1) The clamp plate holding the leading edge of the master opens, and the master-release bar rises
to lift the master out from under the clamp plate
2) The vertical transport rollers and print drum rotate, thereby separating the master from the print
drum and sending it to the master disposal box.
3) The motion of the compression plate starts, pressing the master into the master disposal box.
5. Master-making operation
1) The image sensor scans the original, and the thermal print head transfers the image onto a
master.
2) The master is sent into the master stocker room.
6. Master-loading operation
1) The leading edge of the master is sent to a the clamp plate on the print drum, and the leading
edge is clamped.
2) The print drum rotates to wind the master around it.
3) The cutter cuts the master.
2- CZ180 / CV1860 Rev. 1.0


MEMO
CZ180 / CV1860 Rev. 1.0 2-


7. Machine Specification
1) CZ180
2- CZ180 / CV1860 Rev. 1.0


Specifications
RISO CZ180
Master-making/printing High-speed digital master-making/fully automatic stencil printing

methods
Original Type Sheet
Original Size Max. 310 mm ⋅ 435 mm
Min. 90 mm ⋅ 140 mm
Original Paper Weight 50 g/m2-107 g/m2
Original paper capacity 10 sheets (64 g/m2, up to 1 mm high)
Print Paper Size Max. 297 mm ⋅ 420 mm
Min. 100 mm ⋅ 148 mm
Paper Supply Capacity 1000 sheets (64 g/m2)
Paper Receive Capacity 800 sheets (64 g/m2)
Print Paper Weight 50 g/m2-157 g/m2
Image Processing Mode Line, Photo, Duo, Pencil
Master-making Time Approx. 37 sec. (for A4/portrait/100% reproduction ratio)
Printing Area Max. 251 mm ⋅ 357 mm
Print Reproduction Ratio 100% reproduction ratio
Standard reproduction ratio(enlargement): 141%, 122%, 116%
Standard reproduction ratio(reduction): 94%, 87%, 82%, 71%
Print Speed Approx. 60-130 pages per minute (three steps variable)
Print Position Adjustment Vertical: ±10 mm Horizontal: ±10 mm (for B4 portrait in centre position)
Ink Supply Fully automatic (800 ml per cartridge)
Master Supply/Disposal Fully automatic (approx. 200 sheets per roll)
Master Disposal Capacity 30 sheets
User Interface LED panel
Optional Accessories Colour Drum
Job Separator
Network Interface Card RISORINC-NET
Printer Control Board RISORINC3N
Power Source CZ180 : 220-240V AC, 50-60 Hz, 1.0 A
CZ180(120) : 100-120V AC, 50-60 Hz, 2.0 A
Dimensions When in use: 1270 mm (W) ⋅ 645 mm (D) ⋅ 510 mm (H)
When in storage: 655 mm (W) ⋅ 645 mm (D) ⋅ 500 mm (H)
Weight Approx. 62 kg
Notes
• As we are constantly improving our products, the machine may differ in some respects from the illustrations used
in this manual.
• The specifications are subject to change without prior notice.
CZ180 / CV1860 Rev. 1.0 2-


2) CV1860
2- CZ180 / CV1860 Rev. 1.0


CZ180 / CV1860 Rev. 1.0 2-


MEMO
2 - 10 CZ180 / CV1860 Rev. 1.0


CHAPTER 3: MAIN DRIVE
CONTENTS
MECHANISM................................................................................................2
1. Main Drive......................................................................................2
2. Main Motor Safety Switch...............................................................2
3. Print Drum Positions.......................................................................3
4. Print Drum Locking Mechanism.....................................................3
DISASSEMBLY............................................................................................4
1. Intermediate Gear..........................................................................4
2. Main Motor Unit..............................................................................6
3. Drum Safety Switch........................................................................7
ADJUSTMENT..............................................................................................8
1. Position-B Adjustment (Print drum removal position)....................8
CZ180 / CV1860 Rev. 1.0 3-


MECHANISM
1. Main Drive
1) Drum Rotation
With the rotation of the Main motor, the drive from the main motor is transferred to the Drum main
gear from the Main motor gear via Intermediate gear in the between.
2) Main Motor FG Sensor

The FG sesnor on the Main motor checks the Main motor rotation speed and Drum angle position.
2. Main Motor Safety Switch

1) Following four Safety switches must be activated to run the Main motor.
1. Master making unit safety switch
2. Master removal unit safety switch
3. Drum safety switch
4. Rear cover safety switch (2 pieces as one set)
2) The same four Safety switches act also as Safety switches for the Thermal power of the TPH.
Master making unit safety switch
Rear cover safety switch
Master removal unit safety switch
Drum safety switch
3- CZ180 / CV1860 Rev. 1.0


3. Print Drum Positions

1) The Print drum angle positions are checked by Position-A sensor and Main motor FG sensor.
2) The 0 degrees of the print drum is called the Position-A. One drum rotation from the Position-A
to the next Position-A equals to 360 degrees.
3) With the activation of the Position-A sensor, the Main motor FG sensor pulse count is reset and
from the pulse count of the Main motor FG sensor, the machine calculates the Print drum angle.
4) POSITION-A : The position-A of the print drum is when the Position-A sensor light path is
blocked by the sensor actuator.
5) POSITION-B : The position-B of the print drum is 270 degrees rotation from the position-A,
calculated by the Main motor FG sensor.
This is the position where the Print drum is pulled out or pushed into the machine.
4. Print Drum Locking Mechanism

1) The Print drum is designed to unlock only when it is at Position-B.
2) At any other Drum positions, the flange around the Drum main gear prevents the Intermediate
gear from disengaging from the Drum main gear.
3) Only when the Print drum is at Position-B, the flange on the Drum main gear does not interfere
against the Intermediate gear, allowing the Print drum to be pulled out from the machine.
4) There are Eye-markings on both the Drum main gear and Intermediate gear and they meet only
when the Print drum is at Position-B.
5) For some reasons if the Intermediate gear is rotated manually with the Print drum out of the
machine, the Intermediate gear must be manually back so that the Eye-markings between the
Drum main gear and Intermediate gear meet with each other. the Print drum can be inserted
back into the machine when these Eye-markings meet with each other.
CZ180 / CV1860 Rev. 1.0 3-


DISASSEMBLY
1. Intermediate Gear
REMOVAL
1) Remove the Drum from the machine, turn OFF the machine power and unplug the power cord
from the machine.
2) Remove the Rear cover. (M3x8 screws; 5 pcs)
3) Swing open the PCB bracket. (M3x8 screws; 4 pcs)
4) Remove the mounting screw of the Intermediate gear shaft assembly and remove the
Intermediate gear shaft assembly. (M4x8 screw; 1 pc)
5) Remove the Intermediate gear out from the machine through the drum opening in front of the
machine.
Precaution in Assembly
1) Match the Eye-markings between the Drum main gear and Intermediate gear. (Ref: Photograph
on next page.)
2) Confirm that the Intermediate gear is at Position-B by inserting Allen wrench through the hole on
the back of the machine. (Ref: Photograph on next page.)
Make sure to remove the Allen wrench out from the machine once the Position-B is confirmed.
Leaving the Allen wrench on the machine will damage the machine when the power is turned ON.
3) Attach the Intermediate gear shaft assembly firmly on the machine.
Drum main gear

Print drum
Intermediate gear
Main motor
Main gear
3- CZ180 / CV1860 Rev. 1.0


Intermediate gear shaft assembly
< View from the back of the machine >
< View from the front of the machine >
Drum main gear

Positioning marks Hole for Allen wrench
Intermediate gear

Print drum
Drum main gear Positioning marks
Hole for Allen wrench
Intermediate gear
Positioning marks
Main gear
CZ180 / CV1860 Rev. 1.0 3-


2. Main Motor Unit

REMOVAL
from the machine.
4) Remove the following parts.
Separation fan unit (Refer to Chapter-7)
Suction unit (Refer to Chapter-7)
Intermediate gear (Refer to page 3-4)
5) Rotate the Pressure lever assembly in the clockwise direction just a little by hand, just enough to
disengage the Pressure lever assembly from the Solenoid lever.
6) Push down on the Solenoid lever to disengage from the Pressure lever assembly, and release
hand from the Pressure lever assembly, slowly as not to injure your hands.
7) Carefully remove the Pressure spring.
8) Remove the Spring from the Sector gear.
9) Disconnect the connectors from the Vertical print positioning HP sensor and Vertical print
positioning pulse motor.
10) Remove E-ring from the Timing connection plate and remove the plate from the Sector gear. (6mm
dia. E-ring; 1 pc)
11) Remove the mounting screws from the Vertical print positioning base unit and remove the unit
from the machine. (M4x6 screw; 1 pc) (M3x6 screws; 3 pcs)
12) Disconnect the two connectors of the Main motor, remove the mounting screws, and remove the
Main motor from the machine. (M4x8 screws; 4 pcs : Refer to the photograph on next page.)
1) Refer to page No. 3-4 for the precaution in attaching the Intermediate gear.
Adjustment after the Assembly

1) Sector gear position adjustment. (Refer to Chapter 5)
Pressure spring Pressure lever assembly
Suction Unit
Solenoid lever
Vertical print positioning base unit
3- CZ180 / CV1860 Rev. 1.0


Main motor
Mounting screw Mounting screw
3. Drum Safety Switch

REMOVAL
from the machine.
4) Disconnect the connector from the Drum safety switch.
5) Remove mounting screw of the Drum safety switch bracket and remove the bracket with the
switch attached. (M3x6 screw; 1 pc)
6) Detach the Drum safety switch from the bracket by removing the mounting screws. (M3x16
screws; 2 pcs)
1) Do not bend the Drum safety switch bracket, which acts as spring plate.
Drum safety switch
CZ180 / CV1860 Rev. 1.0 3-


ADJUSTMENT
1. Position-B Adjustment (Print drum removal position)

CHECK and ADJUSTMENT
1) Using Test Mode No. 0892, stop the Print drum at Position-B.
2) Confirm that the Print drum can be pulled out from the machine and inserted back in the machine
smoothly.
3) If the Print drum cannot be pulled out smoothly or inserted back smoothly, make the Position-B
adjustment using Test Mode No. 0942.
4) After the adjustment is completed, repeat the adjustment procedure until the Position-B
adjustment is correctly make.
Precaution in Adjustment
1) Basically the machine is designed to have the Position-B adjusted correctly with the parameter
setting at [0] on Test Mode No.0942 (Drum angle = 270 degrees), but this may vary slightly
between the machines and this adjustment may become necessary.
2) The Position-B is calculated by the Main motor FG sensor pulse count from Postion-A sensor.
If the position of the Print drum is way off from the normal Position-B, the Postion-A sensor and
Main motor FG sensor should be checked.
3- CZ180 / CV1860 Rev. 1.0


CHAPTER 4: FIRST PAPER FEED
CONTENTS
MECHANISM................................................................................................2
1. Paper feed tray elevation mechanism............................................2
2. First paper feed movement............................................................3
3. Scraper mechanism.......................................................................4
4. Paper feed pressure adjustment....................................................4
DISASSEMBLY............................................................................................5
1. Removal of Elevator link plates......................................................5
2. Removal of Paper feed tray unit.....................................................6
3. Removal of Paper detection sensor...............................................7
4. Removal of Pickup roller and Scraper roller...................................8
5. Removal of Stripper pad.................................................................9
6. Removal of Upper limit sensor.....................................................10
7. Removal of Lower limit sensor.....................................................11
8. Removal of Elevator motor unit....................................................12
9. Removal of Paper feed clutch......................................................13
10. Removal of Pickup roller shaft assembly...................................14
11. Removal of Guide plate..............................................................15
12. Removal of Paper sensor...........................................................17
ADJUSTMENT............................................................................................18
1. Elevator Upper-limit Sensor Position Adjustment.........................18
2. Paper Feed Clutch OFF Angle Adjustment..................................18
3. Paper Feed Clutch ON Angle Adjustment....................................18
4. Paper Sensor Sensitivity Adjustment...........................................19
CZ180 / CV1860 Rev. 1.0 4-


MECHANISM
1. Paper feed tray elevation mechanism

Paper detection sensor confirms whether paper is set on the Paper feed tray.
By pressing the print START button when the Paper detection sensor is ON (paper is detected), the
elevator motor is activated to bring up the paper feed tray until the Scraper plate assembly blocks the
light path of the Upper limit sensor.
The Elevator motor is activated intermittently during the printing job to keep the Upper limit sensor
light path blocked.
When the paper runs out from the Paper feed tray (the Paper detection sensor becomes OFF), the
Elevator motor is activated to bring the Paper feed tray down.
During the machine idle condition, if the Paper feed tray button is pressed, the elevator motor is
activated until the tray lowers down to the Lower limit position in which the light path of the Lower limit
sensor is blocked.
Upper limit sensor

Paper detection sensor
Elevator motor
Paper feed table
Lower limit sensor
4- CZ180 / CV1860 Rev. 1.0


2. First paper feed movement

With the start of the printing action, the Main motor activates to rotate the Print drum in the clockwise
direction, as viewed from the operator side of the machine.
As the Print drum rotates a given angle from the drum A-position, the Paper feed clutch activates to
rotate the Scraper roller and Pickup roller.
The Paper feed clutch turns OFF after the print drum rotates for a given angle after the Paper sensor
detects the leading edge of the paper.
The paper feeding motion stops with the leading edge of the paper hitting against the Guide roller and
Timing roller.
When the paper transfers to the second paper feed area, the one-way clutch in the Scraper roller and
Pickup roller allow the rollers to rotate freely to prevent the first paper feed area from applying brake
on the paper.
Main motor Pickup roller
Paper sensor Scraper roller
Paper feed clutch
CZ180 / CV1860 Rev. 1.0 4-


3. Scraper mechanism
The Scraper roller pulls the paper in between the Pickup roller and the Stripper pad.
The paper is then pinched between the Pickup roller and the Stripper pad to allow the Pickup roller to
feed only the top one sheet of paper into the machine.
The Stripper pad has a spring underneath, which pushes the Stripper pad against the Pickup roller to
separate the top sheet from the rest.
The Stripper unit has a pressure adjustment knob which allows the stripper pressure to be adjusted in
three strengths, by sliding the knob vertically up or down.
4. Paper feed pressure adjustment

There is Paper feed pressure lever in the far left of the Stripper unit. Sliding the lever to the left [Normal-
weak] or right [Card - strong] changes the paper feed pressure (stripper pressure).
Pickup roller
Paper feed pressure lever
Scraper roller
Stripper unit
Stripper pressure adjustment knob
4- CZ180 / CV1860 Rev. 1.0


DISASSEMBLY
1. Removal of Elevator link plates

Removal
1) Lower the Paper feed tray, switch OFF the machine power, remove master disposal box, and
detach the following parts.
Front cover (M3x8 screws; 6 pcs)
Rear cover (M3x8 screws; 5 pcs)
Master removal lower cover (M3x8 screws: 4 pcs)
2) Remove the rollers from the front and rear. (3mm E-ring; 2 pcs)
3) Pull and remove the Elevator link plates from the machine.
1) Fit the U-shaped slot on the Elevator link plates through the pins on the Elevator frame (F)
assembly and (E) assembly.
E-ring
Roller
Roller
Elevator junction plate
Elevator frame (F) assembly
Elevator junction plate
CZ180 / CV1860 Rev. 1.0 4-


2. Removal of Paper feed tray unit

Removal
1) Lower the Paper feed tray all the way down, pull the Print drum out and switch OFF the machine
power.
2) Remove the Front cover. (M3x8 screws: 3 pcs)
3) Unplug the wire harness connector of the Paper detection sensor, cut off the wire band, and
gently pull the wire harness towards the Paper feed tray.
4) Remove the E-rings from the shaft of the Paper feed tray on both sides of the tray, and detach the
Paper feed tray unit from the shaft. (6mm E-ring; 2 pcs)
Paper detection sensor wire harness
E-ring
4- CZ180 / CV1860 Rev. 1.0


3. Removal of Paper detection sensor

Removal
1) Lower the Paper feed tray all the way down, pull Print drum out and switch OFF machine power.
2) Detach the following parts.
Paper feed tray unit (6mm E-ring; 2 pcs)
3) Remove the mounting screws from the Paper feed tray cover and remove the cover. (M3x6
screws; 6 pcs & M3x8 screws; 2 pcs)
4) Detach the Paper detection sensor by gently widening the plastic mounting hook and
disconnecting the wire harness connector.
1) Fit the Paper detection sensor firmly between the mounting hooks.
2) Match the positioning pins and positioning holes when attaching the Paper feed tray cover.
3) Wire the Paper detection sensor wire harness in correct path and make sure to attach new wire
band in the original position.
4) Firmly attach the wire harness of the Paper detection sensor onto the Elevator spring bracket (front)
using a wire band.
When tying the wire band, make sure that the length of the wire harness between A and B (refer
to the photo) is not too long and not too short. The wire should be between 60mm to 53mm in
length between A and B. This is to prevent the wire harness from touching the paper or giving too
much tension on the wire harness.
Paper feed table cover Paper detection sensor
Paper detection sensor wire harness
Mount wire band so the distance of the wire harness

from A to B is between 60mm to 53mm.
Wire harness band 100mm
CZ180 / CV1860 Rev. 1.0 4-


4. Removal of Pickup roller and Scraper roller

Removal
1) Lower the Paper feed tray all the way down and turn OFF the machine power.
Removing the Scraper roller
1) Remove the plastic clip, which holds the Scraper roller in place.
2) Slide out the Scraper roller from the Scraper shaft.
Removing the Pickup roller
1) Slide the plastic Paper guide roller from the Pickup roller shaft.
2) Remove the plastic clip, which holds the Pickup roller in place.
3) Slide out the Pickup roller from the Pickup roller shaft.
1) Both the Scraper and Pickup rollers contain one-way bearing. Putting them back on the shaft in
the wrong way will cause the rollers not to rotate even though the shaft rotates.
2) To check whether the rollers are mounted in correct way, check by rotating the rollers on the shaft
in the direction shown on the photograph. If the rollers rotate freely, the mounting direction is
correct.
Pickup roller
4- CZ180 / CV1860 Rev. 1.0


5. Removal of Stripper pad

Removal
1) Lower the Paper feed tray all the way down and turn OFF the machine power.
2) Remove both the Scraper and Pickup roller.
3) Remove the Stripper pad mount, carefully not to damage the Stripper spring located underneath.
4) Detach the Stripper pad from the Stripper pad mount.
(Double sided adhesive tape is used)
1) Set the Stripper spring first, and then mount the Stripper pad mount over the spring.
Stripper pad
Stripper pad base
Stripper spring
CZ180 / CV1860 Rev. 1.0 4-


6. Removal of Upper limit sensor

Removal
1) Lower the Paper feed tray all the way down, turn OFF the machine power and remove the Master
removal lower cover. (3x8 screws; 2 pcs)
2) Remove the mounting screws from the sensor bracket and remove the sensor with the bracket.
(M3x6 screw; 1 pc)
3) Detach the Upper limit sensor from the bracket and disconnect the wire harness connector.
1) Match the positioning pins and positioning holes when attaching the Upper limit sensor bracket
back in position.
2) If the wire harness band was cut in above removal procedure, make sure to tie the sensor wire
harness back on the Paper feed stay using a new wire harness band.
3) In doing so, make sure that the wire harness does not sag under the dotted line shown on the
photograph.
4) This is to prevent the wire harness from being pinched by the Master removal lower cover.
Adjustment after installation

1) Make adjustment on the Upper limit sensor position.
Upper limit sensor wire harness Paper feed stay
Wire harness band
The wire should not go under the red dotted line on the photograph.
Upper limit sensor position
Upper limit sensor
4 - 10 CZ180 / CV1860 Rev. 1.0


7. Removal of Lower limit sensor

Removal
1) Bring up the Paper feed table all the way up using Test Mode No.708 (Elevator motor activation
in the up-direction).
2) Pull the Print drum out of the machine, turn OFF the machine power and remove the Rear cover
(M3x8 screws; 5 pcs)
3) Unplug the wire harness connector of the Lower limit sensor.
4) Remove the Paper feed lower hinge. (M3x6 screws; 2 pcs)
5) Remove the Lower limit sensor
Lower limit sensor bracket
Lower limit sensor
CZ180 / CV1860 Rev. 1.0 4 - 11


8. Removal of Elevator motor unit

Removal
1) Lower the Paper feed tray all the way down, pull the Print drum out and turn OFF the machine
power.
3) Swing open the PCB Bracket on the rear of the machine. (M3x8 screws: 4 pcs)
4) Remove the Elevator springs from front and rear.
5) Unplug the wire harness connector of the Elevator motor and remove the Elevator motor unit.
1) Match the positioning pins and holes in attaching the Elevator motor unit back on the machine.
Elevator motor unit
Mounting screw
Mounting screw
Mounting screw
4 - 12 CZ180 / CV1860 Rev. 1.0


9. Removal of Paper feed clutch

Removal
1) Turn OFF the machine power and remove the Rear cover. (M3x8 screws; 5 pcs)
2) Swing open the PCB Bracket on the rear of the machine. (M3x8 screws: 4 pcs)
3) Disconnect the wire harness connector of the Paper feed clutch.
4) Remove the E-ring from the Pickup shaft and slide the Paper feed clutch off the Pickup shaft.
(5mm dia. E-ring; 1 pc)
1) Match the D-shaped cut on the Paper feed clutch with that on the Pickup shaft.
2) Slide the slit on the Paper feed clutch through the bracket plate to prevent the clutch from
rotating..
Pickup shaft Paper feed clutch
CZ180 / CV1860 Rev. 1.0 4 - 13


10. Removal of Pickup roller shaft assembly

Removal
1) Lower the Paper feed tray all the way down and turn OFF the power.
Master removal lower cover. (M3x8 screws; 4 pcs)
Pickup roller, and Scraper roller.
Upper limit sensor
Paper feed clutch
3) Remove E-ring (8mm dia.; 1 pc) from the Pickup shaft on the drive side of the machine, and
remove the Metal bushing.
4) Remove the E-ring (8mm dia., 1 pc) from the Pickup shaft bracket, and remove the Metal bushing.
5) Slide the Pickup shaft towards the drive side of the machine.
6) Remove the Pickup shaft out of the machine through the opening above the Paper feed tray.
Adjustment after the assembly

1) Make adjustment on the Upper limit sensor position.
Pickup shaft assembly
Metal bushing
Pickup shaft
Pickup shaft bracket
4 - 14 CZ180 / CV1860 Rev. 1.0


11. Removal of Guide plate

Removal
1) Pull the Print drum out of the machine, turn OFF the machine power and remove the following
parts.
Master removal lower cover (M3x8 screws; 4 pcs)
Paper feed tray unit
Paper feed clutch
Pickup roller shaft assembly
Elevator motor unit
Timing spring
2) Remove the front and rear Elevator spring brackets. (M3x6 screws; 2 pcs)
3) Remove the Pickup shaft support bracket. (M3x6 screw; 1 pc)
4) Remove the Elevator rollers from the front and rear Elevator frame assemblies. (6mm dia.
E-rings; 4 pcs)
5) Remove Guide roller assembly (6mm dia. E-ring; 2 pcs).
6) Disconnect the wire harness connector of the Guide plate and remove the Guide plate. (M3x6
screws; 7 pcs)

1) Hook the hook of the Guide plate on the metal bearing of the Timing roller.
2) Match the height of the gears on the front and rear Elevator frames.
[ Refer to the photographs on the next page.]
CZ180 / CV1860 Rev. 1.0 4 - 15


Elevator spring bracket (rear) Upper limit sensor Pickup shaft bracket
Elevator roller Guide plate connector Guide roller assembly

Elevator frame (F) assembly
Guide plate
4 - 16 CZ180 / CV1860 Rev. 1.0


12. Removal of Paper sensor

Removal
1) Pull out the Print drum, turn OFF the machine power and remove following parts.
[Slide the Paper feed pressure lever to the center position and push down the
Master removal box lever down in removing the Master removal lower cover.]
Paper feed clutch
Pickup roller shaft assembly
Elevator motor unit
Guide plate
2) Unplug the wire harness connector of the Paper sensor from the Guide plate.
3) Detach the Guide plate upper assembly from the Guide plate. (3x6 screws; 2 pcs)
4) Remove the Paper sensor mounting cover (upper) from the Guide plate. (3x6 screws; 1 pc)
5) Remove the Paper sensor (receive).
6) Remove the Paper sensor mounting cover (lower) from the Guide plate. (3x6 screws; 1 pc)
7) Detach the Paper sensor (send).
1) Hook the Paper sensor on the hook plate of the Guide plate.
Adjustment after the assembly

1) Perform the Paper sensor sensitivity automatic adjustment.
Guide plate
Paper sensor (receive) Paper sensor (send)
CZ180 / CV1860 Rev. 1.0 4 - 17


ADJUSTMENT
1. Elevator Upper-limit Sensor Position Adjustment

1) Remove all the papers from the Paper feed tray and slide the Paper feed pressure adjustment
lever to the NORMAL position.
2) Raise the Paper feed tray all the way up, using Test Mode No.681 (Paper feed tray elevation).
3) After the Paper feed tray stops at the upper limit position, measure the space between the Pickup
roller and Paper feed tray. The measurement of the space should be 1.8mm plus or minus 0.3mm.
4) If the measurement is not within the set value, remove the Master disposal box and Master
removal lower cover.
5) Loosen the mounting screw of the Upper limit sensor bracket and slide the sensor bracket up or
down to make the adjustment.
1) The space to check is the gap between the Paper feed tray and Pickup roller. Do not confuse the
Scraper roller with the Pickup roller.
Results of incorrect adjustment
1) If the gap is too small, the paper feed pressure becomes too high. This may result in multiple
feeding of papers.
2) On the contrary, if the gap is too big, the paper feed pressure becomes too weak. This may result
in paper not feeding at all.
2. Paper Feed Clutch OFF Angle Adjustment

1) Perform printing and confirm that the paper is fed smoothly into the second paper feed area.
2) If the paper buckle made before the Timing and Guide rollers is too less or too much, the paper
may not feed smoothly and cause print registration problem. If such a problem occurs, activate
Test Mode No.742 (Paper feed clutch OFF angle adjustment) and make an adjustment.
3) Refer to the Chapter on the Test Modes for the details on Test Mode No.742
4) Repeat from step (1) until good result is obtained.

1) Too much or too little paper buckle at the Timing and Guide rollers may result in paper jamming
at second paper feed area and/or print registration problem.
3. Paper Feed Clutch ON Angle Adjustment

1) Perform printing and confirm that the paper feeds smoothly through the first paper feed area.
2) If the paper feed timing is not smooth through the first paper feed area, activate Test Mode
No.741 (Paper feed clutch OFF angle adjustment) and make an adjustment.
3) Repeat from step (1) until good result is obtained.

1) Incorrect paper feed timing at the first paper feed area may result in paper jamming or print
registration problem.
4 - 18 CZ180 / CV1860 Rev. 1.0


4. Paper Sensor Sensitivity Adjustment

Adjust the Paper sensor sensitivity adjustment when the Paper sensor is replaced.
1) Make the adjustment using a Test Mode.

2) The Test Mode makes an automatic sensitivity adjustment on the Paper sensor.
3) Set a piece of paper, which is used the most often, between the Paper sensor SEND and
RECEIVE.
4) Activate Test Mode No.705 (Paper sensor sensitivity automatic adjustment).
5) Press the [C] key of the numeric keypad on the machine operation panel.
6) Then change the Test Mode number to No.722 (Paper sensor A/D display) and activate.
7) Confirm that the number displayed on the LED display of the operation panel is between 236 and
260 with the paper between the SEND and RECEIVE of the Paper sensor.
If not, try the adjustment again. Using the paper, which is out of specification (not fit for the
machine) may result in incorrect adjustment.
CZ180 / CV1860 Rev. 1.0 4 - 19


MEMO
4 - 20 CZ180 / CV1860 Rev. 1.0


CHAPTER 5: SECOND PAPER FEED
CONTENTS
MECHANISM................................................................................................2
1. Second Paper Feed Mechanism....................................................2
2. Vertical Printing Position Mechanism.............................................2
DISASSEMBLY............................................................................................4
1. Load Spring....................................................................................4
2. Timing Cam....................................................................................4
3. Guide Roller Assembly...................................................................5
4. Vertical Print Positioning Base Unit................................................6
5. Vertical Print Positioning Pulse Motor............................................7
6. Sector Gear....................................................................................8
7. Timing Roller..................................................................................9
ADJUSTMENT............................................................................................10
1. Mounting position adjustment of Timing cam...............................10
CZ180 / CV1860 Rev. 1.0 5-


MECHANISM
1. Second Paper Feed Mechanism

1) With the activation of the Main motor during a printing job, the Main cam makes clockwise rotation
(looking from the rear of the machine).
2) The Main cam rotation moves the Sector gear back and forth via Cam follower arm. The
movement of the Sector gear rotates the Timing cam.
3) The Timing cam contains a one-way bearing. The one-way bearing allows the Timing roller to
rotate when the Timing cam makes counter-clockwise rotation, and the Timing roller stays still
when the Timing cam makes clockwise rotation.
4) Furthermore, the rotation of the Timing roller is designed to comes to a stop immediately after
the Timing cam finishes the counter-clockwise rotation. This is due to the Load spring applying
constant load (braking action) on the Timing roller.
5) The Guide roller, a free-rotating roller, rotates with the Timing roller when the Guide roller is in
contact with the Timing roller.
6) As the Timing cam rotates, the high portion of the Timing cam pushes the Guide roller up away
from the Timing roller.
7) While in printing, during the first paper feed action, the Guide roller comes down to make contact
with the Timing roller. Then the second paper feed action starts by the Timing roller and Guide
roller sending the paper into the machine. With the finish of the Timing roller rotation, the high
portion of the Timing cam raises the Guide roller away from the Timing roller to finish the second
paper feed.
2. Vertical Printing Position Mechanism

1) With the push of the print position adjustment key, the Print positioning motor activates to rotate
the Print positioning cam. The rotation of the Print positioning cam moves the Print positioning
plate.
2) When the Print positioning plate moves from its default position, the Print positioning lever
changes the contact timing between the Main cam and Cam follower arm.
3) The change in the contact timing between the Main cam and Cam follower arm affects the Timing
roller rotation start timing. The second paper feed timing is changed and this results in the
change of the vertical print position.
4) In addition, the Vertical centering sensor determines the vertical print center position.
5) The vertical print center position is the position at the exact moment when the light path of the
Vertical centering sensor becomes unblocked
5- CZ180 / CV1860 Rev. 1.0


Guide roller spring
Intermediate gear
Timing lever assembly
Main cam
Guide roller
Timing Cam
Timing gear spring
Timing gear
Vertical print positioning
lever assembly
CZ180 / CV1860 Rev. 1.0 5-


DISASSEMBLY
1. Load Spring
REMOVAL
1) Pull out the Print drum, turn the machine power OFF and remove the Front cover. (M3x8 screws;
6 pcs)
2) Remove E-ring and collar from the Timing roller shaft. (8mm dia. E-ring; 1 pc)
3) Remove the Load spring from the Timing roller.
1) Do not make mistake in the direction of the Load spring during the assembly.
Load spring
2. Timing Cam
REMOVAL
1) Turn OFF the machine power and remove Rear cover. (M3x8 screws; 5 pcs)
2) Open the PCB bracket on the rear of the machine. (M3x8 screws; 4 pcs)
3) Remove the Guide roller spring.
4) Remove E-ring from the Timing roller shaft and detach the Timing cam. (6mm dia E-ring; 1 pc)
Adjustments after Assembly

1) Timing cam mounting position adjustment.
Guide roller spring
Timing Cam
Timing roller shaft
5- CZ180 / CV1860 Rev. 1.0


3. Guide Roller Assembly

REMOVAL
1) Pull out the Print drum, turn the machine power OFF and remove following part.
Rear cover. (M3x8 screws; 5 pcs)
3) Remove the Guide roller spring.
4) Remove the mounting screws of the Timing lever assembly. (M4x8 screw; 1 pc)
5) Remove E-ring and metal bushing, which can be seen after removing the Timing lever assembly,
from the Guide roller spindle shaft. (8mm dia. E-ring; 1 pc)
6) Remove E-ring and metal bushing, from the Guide roller spindle shaft on the front of the machine.
(8mm dia. E-ring; 1 pc)
7) Detach the Guide roller assembly from the machine by once sliding the Guide roller spindle shaft
to the rear of the machine to clear the front end out of the machine.
Mounting screw
Guide roller assembly
CZ180 / CV1860 Rev. 1.0 5-


4. Vertical Print Positioning Base Unit

REMOVAL
3 Remove the Sector gear spring.
4) Disconnect the wire harness connectors of the Vertical print positioning HP sensor and Vertical
print positioning pulse motor.
5) Remove E-ring from the Cam follower arm and remove the Cam follower arm from the Sector
gear. (6mm dia. E-ring; 1 pc)
6) Remove Mounting screw of the Vertical print positioning base unit and remove the unit. (M4x6
screw; 1 pc) (M3x6 screws; 3 pcs)
1) When mounting the Vertical print positioning base unit back on the machine, rotate the Sector
gear all the way in clockwise direction.
Adjustment after Assembly

1) Mounting position adjusting of Timing Cam.
Sector gear
Vertical print positioning lever assembly
Vertical print positioning plate assembly
Timing connection late
Vertical print positioning pulse motor

Vertical print positioning HP sensor
Vertical print positioning cam
5- CZ180 / CV1860 Rev. 1.0


5. Vertical Print Positioning Pulse Motor

REMOVAL
3) Remove the Sector gear spring.
4) Disconnect the wire harness connectors of the Vertical print positioning HP sensor and Vertical
print positioning pulse motor.
5) Remove E-ring from the Cam follower arm and remove the Cam follower arm from the Sector
gear. (6mm dia. E-ring; 1 pc)
6) Remove Mounting screw of the Vertical print positioning base unit and remove the unit. (M4x6
screw; 1 pc) (M3x6 screws; 3 pcs)
7) From the Vertical print positioning base unit, remove both the Vertical print positioning cam and
Intermediate gear. (6mm & 4mm dia. E-rings; 1 pc each)
8) Remove Mounting screws of the Vertical print positioning pulse motor, and detach the motor.
(M3x6 screw; 2 pcs)
1) Insert the pin on the Print positioning plate into the whirl groove of the Print positioning cam.
Vertical print positioning pulse motor
CZ180 / CV1860 Rev. 1.0 5-


6. Sector Gear
REMOVAL
3) Remove following parts
Timing cam (6mm dia. E-ring; 1 pc)
4) Remove the Sector gear spring and detach the Sector gear by removing E-ring. (6mm dia. E-ring;
1 pc)

1) Mounting position adjusting of Timing cam
Timing cam
Sector gear
5- CZ180 / CV1860 Rev. 1.0


7. Timing Roller
REMOVAL
1) Turn the machine power OFF, pull out the print drum and remove following parts.
Guide plate
Load spring, Guide roller spring and Sector gear spring
Timing Cam (6mm dia. E-ring; 1 pc)
Paper feed clutch
Sector gear
Guide roller assembly
2) Remove E-ring from spur gear, and detach spur gear from the shaft. (6mm E-ring; 1 pc)
3) Remove E-ring from Timing roller on both ends, and detach Metal bushing from both ends. (8mm
E-ring; 2 pcs)
4) Slide the Timing roller to the rear once, and remove from the Timing roller out of the machine
through the opening above the paper feed tray.

1) Mounting position adjustment of Timing cam
Timing roller
Timing roller
CZ180 / CV1860 Rev. 1.0 5-


ADJUSTMENT
1. Mounting position adjustment of Timing cam

1) Bring the vertical print position to the center, bring the print drum to position-B, turn OFF the
machine power and remove the Rear cover. (M3x8 screw; 5 pcs)
3) Confirm that eye-marking on the Timing Cam matches with that of the Sector gear.
4) If the eye-marking do not match, remove Timing cam from the Timing roller shaft. (6mm dia.
E-ring; 1 pc)
5) Lift the Timing lever assembly and mount the Timing cam back on the Timing roller shaft, aligning
the Eye marking on the cam with that on the Sector gear.
6) Mount the E-ring back on the Timing roller shaft.
Symptom of incorrect adjustment

1) If the mounting position of Timing cam is bad, the up-and-down motion of the Guide roller goes
off timing. This will result in paper jam, print registration problem and/or smeared image prints.
5 - 10 CZ180 / CV1860 Rev. 1.0


CHAPTER 6: PRESS SECTION
CONTENTS
MECHANISM................................................................................................2
1. Press Mechanism...........................................................................2
DISASSEMBLY............................................................................................3
1. Pressure Roller...............................................................................3
2. Pressure Solenoid..........................................................................4
3. Pressure Lever Assembly..............................................................5
4. Pressure Roller Assembly..............................................................6
ADJUSTMENT..............................................................................................7
1. Pressure lever assembly position...................................................7
CZ180 / CV1860 Rev. 1.0 6-


MECHANISM
1. Press Mechanism
At the start of the printing job, when the START button is pressed, the Main motor activates to rotate
the Drum and also to feed the paper. When the Paper sensor detects the paper coming in and as the
Clamp plate base assembly comes near the Pressure roller, the Pressure lever assembly is pushed
by the Pressure cam. The Solenoid lever is then disengaged from the Pressure lever assembly. The
Pressure solenoid is activated ON and pulls the Solenoid lever down, away from the Pressure lever
assembly.
The Pressure lever assembly is pulled by the Pressure spring and that rotates the Pressure shaft in
the counter-clockwise direction (looking from the back of the machine) to lift the Pressure roller up.
The Pressure roller then pushed against the Drum.
During the printing, as the Clamp plate on the Drum rotates to the Pressure roller, the Pressure cam
pushes against the Pressure lever to bring the pressure roller down. This is to prevent the Clamp
plate from hitting against the Pressure roller.
The Pressure solenoid stays activated ON all through the printing job to keep the Solenoid lever
down, away from the Pressure lever assembly.
The Pressure solenoid turns OFF only when the Paper sensor no longer detects the paper coming,
such as at the end of a printing job or when paper jamming occurs.
(1) Lifting the Pressure roller

The Pressure solenoid is activated throughout the printing.
The solenoid pulls the Solenoid lever down and disengages Pressure lever assembly from the
Solenoid lever. The pressure spring pulls back the Pressure lever assembly and rotates the Pressure
shaft which is acting as a pivot.
The rotation of the Pressure shaft lifts the Pressure roller up against the Drum.
(2) Lowering the Pressure roller

The Pressure roller is lowered by force, away from the Drum, by the high part of the Pressure can.
During the Drum rotation, when the Clamp plate of the drum comes close to the Pressure roller, the
high part of the Pressure cam pushes the Pressure lever assembly down, rotating the Pressure shaft
clockwise to bring the Pressure roller down, away from the Drum.
6- CZ180 / CV1860 Rev. 1.0


DISASSEMBLY
1. Pressure Roller
REMOVAL
1) Remove the Drum out of the machine and turn OFF the machine power.
2) Remove the mounting screw of the Pressure roller from the Pressure roller bracket through a hole
on the machine frame under the Drum opening on the operator side of the machine.
3) Slide the Pressure roller towards the operator side of the machine to disengage the bearing from
the bracket and then lift and remove the Pressure roller from the machine.
Intermediate gear Pressure roller
Pressure lever assembly
Pressure spring
Solenoid lever
Pressure solenoid
Pressure cam
Lock screw Pressure roller Lock screw Pressure roller bracket
CZ180 / CV1860 Rev. 1.0 6-


2. Pressure Solenoid
REMOVAL
1) Turn OFF the machine power and remove the Rear cover of the machine. (M3x8 screws; 5 pcs)
3) Using hand, disengage the Pressure lever assembly from the Solenoid lever by pushing down the
Solenoid lever while pulling on the Pressure lever assembly.
4) Carefully, remove the Pressure spring.
5) Disconnect the wire harness connector of the Pressure solenoid.
detach the Solenoid base assembly by removing the mounting screws. (M3x6 screws; 2 pcs)
6) Remove the Solenoid spring from the Solenoid base assembly.
Detach the Pressure solenoid by removing the mounting screws. (M3x6 screws; 2 pcs)
Precaution before assembly

1) Match the positioning hole against the positioning pin.
Pressure spring
Solenoid base assembly
Solenoid lever
Mounting screw
Mounting screw
Mounting screw
Mounting screw
6- CZ180 / CV1860 Rev. 1.0


3. Pressure Lever Assembly

REMOVAL
1) Remove the Drum out of the machine and turn OFF the machine power.
3) Open the PCB bracket on the rear of the machine. (M3x8; 4 pcs)
4) Being careful not to injure yourself, use your hand to push on the Pressure lever and push the
Solenoid lever down to unhook the both from each other.
5) Pay caution not to injure yourself, remove the Pressure spring.
6) Loosen the set screws on the Pressure lever assembly and remove the Pressure lever assembly
from the machine. (M6x8 set screws; 2 pcs)

1) Mounting position of Pressure lever assembly.
Set screw
Set screw
CZ180 / CV1860 Rev. 1.0 6-


4. Pressure Roller Assembly

REMOVAL
1) Remove the Drum out of the machine and turn OFF the machine power. Then remove following
parts.
2) Remove C-ring from both ends of Pressure shaft assembly, and detach Metal bushing from the
both ends. (14mm dia. C-ring; 2 pcs)
3) Slide the Pressure shaft assembly towards to the rear of the machine to free the front end of the
shaft. Then bring the assembly out from the large opening for the print drum.

1) Pressure lever assembly mounting position adjustment.
C-ring
6- CZ180 / CV1860 Rev. 1.0


ADJUSTMENT
1. Pressure lever assembly position

1) Make confidential master on the Drum.
2) Bring the Drum to Position-B.
3) Turn the machine power OFF, and remove the Rear cover (M3x8 screws; 5 pcs)
4) Open the PCB bracket on rear of the machine. (M3x8 screws; 4 pcs)
5) Being careful not to injure yourself, use your hand to push on the Pressure lever and push the
Solenoid lever down to unhook the both from each other.
6) Confirm that the gap between the pressure cam and Cam follower on the Pressure lever
assembly is 2.5 mm plus/minus 0.5mm.
7) If the gap is too narrow or too big, loosen the two set screws on the Pressure lever assembly.
8) Place a 3mm Allen wrench or 3mm thick plate between the Pressure cam and Cam follower, and
hook a thinner Allen wrench in the hole on the end of the Pressure shaft to rotate the shaft.
9) Rotate the Pressure shaft in the direction shown to lift the Pressure roller up against the Drum.
10) While lifting the Pressure roller against the Drum, tighten the two set screws on the Pressure
lever assembly. The Pressure lever assembly should be pushed all the way in when tightening
the two set screws.
Results of Incorrect Adjustment

1) If the gap is smaller than 2.5mm plus/minus 0.5mm, the printing pressure may become too weak
and print density problem may occur.
Also, the Pressure roller may land against the Drum in incorrect position and may cause ink
leakage from the Drum.
2) If the gap is too big, the Pressure roller may hit the Clamp plate of the Drum during printing and
damage the Clamp plate.
Allen wrench
Pressure cam
3mm Alen wrench
Allen wrench
Pressure shaft Bearing
CZ180 / CV1860 Rev. 1.0 6-


MEMO
6- CZ180 / CV1860 Rev. 1.0


CHAPTER 7: PAPER EJECTION SECTION
CONTENTS
MECHANISM................................................................................................2
1. Paper Ejection Mechanism.............................................................2
2. Paper Separation Mechanism........................................................3
DISASSEMBLY............................................................................................4
1. Suction unit.....................................................................................4
2. Suction Fan....................................................................................4
3. Paper Ejection Motor......................................................................5
4. Paper ejection motor FG sensor....................................................6
5. Suction belt.....................................................................................6
6. Paper receiving sensor...................................................................8
7. Separation fan unit.........................................................................9
8. Separation fan................................................................................9
9. Separator......................................................................................10
10. Paper receiving tray unit.............................................................12
ADJUSTMENT............................................................................................13
1. Separator position........................................................................13
CZ180 / CV1860 Rev. 1.0 7-


MECHANISM
1. Paper Ejection Mechanism

(1) Paper Separation from the Drum
The paper is separated from the Drum by the Paper separation fan and Separator.
(2) Paper Ejection

Suction fan pulls the paper, separated from the Drum, on to the Suction unit.
The Transfer belts on the Suction unit, driven by Paper ejection motor, ejects the paper onto the
Paper receiving tray.
(3) Paper Receiving Sensor

Paper receiving sensor checks whether the paper is separated from the Drum and ejected
correctly or jammed.
Separation fan
Suction belt
Paper ejection motor

Suction fan
7- CZ180 / CV1860 Rev. 1.0


2. Paper Separation Mechanism

(1) Separator
The tip of the Separator is close to the Drum when it separates a paper from the Drum.
When the Clamp plate on the Drum comes close to the Separator, the Separator cam which is
attached on the Intermediate cam pushes the Separator away from the Drum.
(2) Separator Release Lever

When the Drum is being pulled out, the Release lever becomes free and the Release spring pulls
the Release lever.
The Release lever then pushes against the Release arm and rotates the Separator shaft down.
The rotation of the Separator shaft moves the tip of the Separator away from the Drum.
Release arm
Paper separator arm assembly
Separator lever
Separator shaft
Separator
Intermediate gear
Separator cam
Main motor
Release arm Release lever
CZ180 / CV1860 Rev. 1.0 7-


DISASSEMBLY
1. Suction unit
REMOVAL
1) Turn OFF the machine power.
2) Remove the Paper ejection cover. (M3x6 screws; 2 pcs)
3) Unplug the wire harness connector of Suction unit.
4) Remove the mounting screws of the Suction unit and detach the unit from the machine by sliding
it out . (M3x6 screws; 2 pcs)
1) In mounting the Suction unit back on the machine, hook the leading edge of the unit correctly on
the metal angle inside the machine.
Suction unit
Paper ejection cover
2. Suction Fan
REMOVAL
1) Turn OFF the machine power, and remove following parts.
Paper ejection cover (M3x6 screws; 2 pcs)
Suction unit (M3x6 screws; 2 pcs)
2) Turn over the Suction unit and unplug the wire harness connector of the Suction fan.
3) Remove the mounting screws, and remove the Suction fan. (M4x40 screws; 2 pcs)
Suction fan
7- CZ180 / CV1860 Rev. 1.0


3. Paper Ejection Motor

REMOVAL
2) Detach the left and right Paper ejection wings. (Thumb screws; 1 each)
3) Unhook the Timing belt from the motor.
4) Remove the Driven shaft assembly.
5) Detach the Suction face cover. (M3x6 screws; 4 pcs)
6) Unplug the wire harness connector of the Paper ejection motor.
7) Remove the mounting screws of the Paper ejection motor and detach the motor. (M3x5 screws; 2
pcs)
1) Make sure that the joint portion of the wire band to go around the Paper ejection motor should
face the bottom of the unit (on the Suction fan side), as shown on the last photograph.
Suction unit top plate
Paper ejection wing
Driven shaft
Driving shaft
Timing belt
Joint portion of the wire band
CZ180 / CV1860 Rev. 1.0 7-


4. Paper ejection motor FG sensor

REMOVAL
6) Unplug the wire harness connector of the Paper ejection motor.
7) Remove the mounting screws, and detach the Paper ejection motor. (M3x5 screws; 2 pcs)
8) Unplug the wire harness connector from the Paper ejection sensor, and detach the sensor.
Paper ejection motor FG sensor
5. Suction belt
REMOVAL
6) Remove the E-ring and Metal bushing from the Driving shaft and remove the Driving shaft. (4mm
dia. E-ring; 1 pc)
7) Remove the Suction face cover completely from the Suction unit with the Suction belts attached.
8) Slide the Suction belts off from the Suction face cover.
Precaution in Removal
1) Pay caution not to scratch the Suction belts against the sharp edges on the Suction face cover to
prevent damage on the belts.
[ Refer to the three photographs on the next page.]
7- CZ180 / CV1860 Rev. 1.0


Suction unit
Suction belt
CZ180 / CV1860 Rev. 1.0 7-


6. Paper receiving sensor

REMOVAL
6) Turn over the Suction unit.
7) Unplug the wire harness connector from the Paper ejection sensor, and remove the sensor by
carefully unhooking the legs.
Paper ejection sensor
7- CZ180 / CV1860 Rev. 1.0


7. Separation fan unit

REMOVAL
2) Remove the mounting screws of the Separation fan unit and slide the unit out from the machine.
3) Unplug the wire harness connector of the Separation fan unit and remove the unit.
1) Make sure to hook the leading edge of the Separation fan unit on the mount when mounting the
unit back on the machine.
Separation fan unit
Separation fan unit
8. Separation fan
REMOVAL
1) Turn OFF the machine power, and remove following part.
Separation fan unit (M3x8 screws; 2 pcs)
2) Remove mounting screws, and remove the air blow nozzle. (M3x8 screws; 2 pcs)
3) Remove mounting screws from the Separation fan. (M4x40 screws; 2 pcs)
4) Unplug the wire harness connector of the Separation fan and remove the fan.
Air blow nozzle
Separation fan
CZ180 / CV1860 Rev. 1.0 7-


9. Separator
REMOVAL
1) Pull the Print drum out of the machine, turn OFF the machine power and remove following parts.
2) Open the PCB bracket on the rear of the machine.
3) Carefully, using hand, push the Pressure lever assembly and Solenoid lever down to disengage
from each other.
4) Carefully, remove the Pressure spring.
5) Detach two Separator springs.
6) Remove E-ring on the front end of the Separator shaft, and remove the Metal bushing. (6mm dia.
E-ring; 1 pc)
7) Slide the Separator shaft to the rear, and remove the mounting screw of Separator lever, and
detach the Separator lever. (M4x8 screw; 1 pc)
8) Remove the Separator shaft out from the machine by sliding it towards the front of the machine.
9) Remove mounting screw of Release arm, and detach it from Separator shaft. (M3x10 screw; 1
pc)
10) Remove mounting screw of Separator, and detach it from the Separator shaft. (M3x10 screw; 1
pc)
1) Mount the Release arm by hooking it on the Release lever.

1) Separator position adjustment
Hook
Pressure spring
7 - 10 CZ180 / CV1860 Rev. 1.0


Separator shaft
Separator lever
Separator springs
Release arm Release lever
Separator shaft
Separator
Release lever
Release arm
CZ180 / CV1860 Rev. 1.0 7 - 11


10. Paper receiving tray unit

REMOVAL
2) Remove mounting screws from Paper receiving tray lock plates (front & rear) and detach these
lock plates. (M3x6 screws; 4 pcs)
3) Slide the Paper receiving tray out from the machine.
1) Match the positioning holes and pins when mounting the Paper receiving tray lock plates (front &
rear).
Paper receiving tray lock plate; front Paper receiving tray lock plate; front
7 - 12 CZ180 / CV1860 Rev. 1.0


ADJUSTMENT
1. Separator position
1) Before making any print job operation, check and confirm that the tip of the Separator is not
touching the Drum.
If the Separator is touching the Drum, do not make any prints, but go directly to the adjustment
procedure which follows.
2) If the Separator is confirmed not touching the Drum, using Test Chart No. 15, make a master and
print.
Confirm that the papers do not stick onto the Print drum and that the Separator does not make a
vertical black line in the center of the prints.
3) If the papers stick onto the Drum, or a vertical black line appears on the center of the prints, make
an adjustment by bringing the Drum to Position-B.
Then turn OFF the machine power and remove the Rear cover. (M3x8 screws; 5 pcs)
3) Open the PCB Bracket on the rear of the machine. (M3x8 screws; 4 pcs)
4) Loosen the mounting screw of the Separator positioning plate
5) Slide the Separator positioning plate to adjust the Separator position, so that the tip of the
Separator is 1.0mm to 2.0mm away from the Drum surface.
Results of Incorrect Adjustment

1) If the tip of the Separator is in contact with the Drum, the Separator will scratch the surface of the
master on the Drum, creating a black line in the center of the printed copies and may damage the
screens.
2) If the tip of the Separator is placed too far off the Drum, printed copies will not separate from the
Drum, causing paper jams.
CZ180 / CV1860 Rev. 1.0 7 - 13


MEMO
7 - 14 CZ180 / CV1860 Rev. 1.0


CHAPTER 8: PRINT DRUM
CONTENTS
MECHANISM................................................................................................2
1. Master on Drum (in printing) Check Mechanism............................2
2. Ink Bottle Set Check Mechanism...................................................2
3. Drum Rotation Mechanism.............................................................2
4. Ink Supply Mechanism...................................................................2
5. Drum Idling Mechanism..................................................................2
DISASSEMBLY............................................................................................4
1. Ink Bottle Guide..............................................................................4
2. Ink Bottle Set Switch......................................................................4
3. RF-PCB..........................................................................................5
4. Inking Motor....................................................................................6
5. Drum Set Sensor............................................................................7
6. Drum Screen..................................................................................8
7. Drum Body.....................................................................................9
8. Ink Sensor PCB............................................................................10
9. Drum Flanges F (front) & R (rear)...............................................11
10. Squeegee Roller.........................................................................14
ADJUSTMENT............................................................................................16
1. Cleaning the Filter........................................................................16
2. Squeegee Gap Adjustment..........................................................17
3. Ink blocking plate position adjustment..........................................17
CZ180 / CV1860 Rev. 1.0 8-


MECHANISM
1. Master on Drum (in printing) Check Mechanism

Master Sensor checks the presence of master on the Drum before the start of printing.
At 74.6 degrees Drum rotation after the first Position-A, the Master Sensor looks for the master on the
Drum.
The result (whether the master is found or not) is memorized until the Drum is pulled out of the
machine or the power is turned off. While the machine knows that there is a master on the Drum, the
master on the Drum check procedure is omitted.
If no master is detected on the Drum, an error message is indicated on the panel display and stops
the printing operation.
2. Ink Bottle Set Check Mechanism

The ink bottle is set in position when it is inserted into the Drum and rotated in clockwise direction.
When the ink bottle is set in position, one part of the ink bottle pushes the Bottle set switch, and the
ink bottle is recognized by the machine.
3. Drum Rotation Mechanism

The Drum is rotated by the Main motor with the gears transferring the drive. As the Drum rotates, the
Squeegee roller, inside the Drum, starts it rotation.
As the Squeegee roller rotates, the drive is transferred by a gear to the Driven shaft, which is located
above the Squeegee roller.
The Squeegee drive gear R contains a one-way bearing, which prevents the Squeegee roller from
rotating when the Drum is rotated manually by hand in the opposite direction.
4. Ink Supply Mechanism

While the Drum is being rotated by the Main motor, if the amount of ink within the Drum reduces and
the Ink sensor no longer touches the bead of ink, the Inking motor activates to pump the ink into the
Drum. The ink pumped by the Inking pump travels through the hose and goes into the Center shaft
of the Drum. The ink then drops onto the Squeegee roller from the distributor holes on the Center
shaft.
The Inking motor stops when the Ink sensor detects the bead of ink.
The ink dropped onto the Squeegee roller is made into an ink bead between the Squeegee roller
and Doctor roller. The ink is wrapped around the Driving shaft to be made into an even thickness ink
bead. A small gap between the Squeegee roller and Doctor roller allows the ink to cover the inner
surface of the Drum.
An Overflow sensor is located within the Drum to detect excess amount of ink to prevent ink-overflow.
If an overflow is detected, the machine is stopped with an error code display.
5. Drum Idling Mechanism

The purpose of the idling is to assist the Drum to produce solid images even after the machine has
been not in use for a long time.
When the idling feature is selected ON, the machine makes a confidential master on the Drum at the
start of the master making. The Drum is then rotated for a give number of times with the Pressure
roller pressed against the Drum.
The given number of Drum rotation during the idling movement is fixed 10 time plus the additional
rotations by the RF Tag command.
8- CZ180 / CV1860 Rev. 1.0


Overflow sensor
Ink sensor
Inking motor
Driving shaft Intermediate gear
Main gear
Squeegee roller
Main motor
CZ180 / CV1860 Rev. 1.0 8-


DISASSEMBLY
1. Ink Bottle Guide

REMOVAL
1) Remove the Drum out from the machine and pull out the ink bottle.
2) Remove the Drum cover. (M3x8 screws; 4 pcs)
3) Remove the Bottle switch cover. (M3x8 screws; 2 pcs)
4) Detach the Ink bottle guide. (M3x8 screws; 3 pcs)
5) Unplug the Bottle set switch wire harness.
Ink bottle guide
Ink bottle switch cover
2. Ink Bottle Set Switch

REMOVAL
1) Remove the Ink bottle guide. (Ref: Above procedure)
2) Remove the upper Bottle guide. (M3x8 screw; 1 pc)
3) Remove the lower Bottle guide. (M3x8 screws; 2 pcs)
4) Remove the Bottle set switch. (M3x8 screws; 2 pcs)
Ink bottle set switch

Ink bottle guide
8- CZ180 / CV1860 Rev. 1.0


3. RF-PCB
REMOVAL
4) Unplug the RF-PCB wire harness.
5) Remove the Antenna holder and Spring. (stepped screws; 2 pcs)
6) Carefully, release the hooks on the Antenna holder and remove the RF-PCBs.
Antenna holder RF-PCB (antenna assembly)
Antenna holder (lower)

Antenna assembly
RF-PCB (antenna assembly)
Antenna holder (upper)
CZ180 / CV1860 Rev. 1.0 8-


4. Inking Motor
REMOVAL
5) Remove the upper and lower Ink bottle guides. (M3x8 screws; 3 pcs)
7) Remove the Holder bracket. (M3x8 screws; 2 pcs)
8) Remove the Ink intake nozzle bracket. (M3x8 screws; 3 pcs)
9) Remove the Ink bottle base. (M3x8 screws; 4 pcs)
10) Remove the Grip handle. (M4x8 screws; 4 pcs)
11) Unplug the Inking motor wire harness connector and remove the mounting screws of the Inking
motor to detach the Inking motor. (M4x10 screws; 2 pcs)
1) Using a wire harness band of about 100mm in length, fix the RF-wire harness firmly on the Holder
bracket. This is to prevent the wire harness from being pinched or cut when mounting the Ink
bottle guide.
Holder bracket plate
Ink bottle base
8- CZ180 / CV1860 Rev. 1.0


Inking motor
Grip handle
Wire harness band
5 mm
to2
15
5. Drum Set Sensor

REMOVAL
1) Remove the Inking motor. (Ref: Previous page)
2) Remove the Drum lock spring from the Drum hook right.
3) Remove the Drum hook right. (6mm dia. E-ring; 1 pcs)
4) Carefully, release the hooks on the Drum set sensor and remove the sensor.
1) In mounting back the Inking motor, use a wire harness band of about 100mm in length and fix
the RF-wire harness firmly on the Holder bracket. This is to prevent the wire harness from being
pinched or cut when mounting the Ink bottle guide. (Ref: Inking motor removal)
Drum set sensor

Drum lock spring
Drum hook (right)
Inking motor
CZ180 / CV1860 Rev. 1.0 8-


6. Drum Screen
REMOVAL
1) Make a confidential master on the Drum and remove the Drum from the machine.
2) Remove the Screen hanger and Screen assembly from the Drum. (M4x8 screws: 4 pcs)
1) Do not fold the Screen. The Screen is no longer useful if a crease is made.
2) The mounting screws should be matched to those in the front.
3) Use the Screen Jig to keep the Screen wrapped tightly around the Drum when mounting the
Screen hanger on the drum.
Screen hanger Screen JIG
Hook
Hook
8- CZ180 / CV1860 Rev. 1.0


7. Drum Body
REMOVAL
1) Remove the Drum out from the machine, and remove following parts.
Clamp plate base unit (M4x8 screws; 4 pcs)
Drum screen (M4x8 screws; 4 pcs)
2) Remove the Drum body from the Drum. (M4x8 screws; 6 pcs)
1) The Drum body has this arrow marks engraved on the front and rear.
The arrow mark on the front has alphabet [F] engraved next to it.
2) The Drum body should be attached onto the Drum with the [F] engrave to the front of the Drum.
The arrow marks on the Drum body should meet with the arrow mark on the Drum flange surface.
The first two screws to be tightened are those at these arrow marks.
3) Use the Screen Jig to keep the Drum body wrapped tightly around the Flanges when mounting
the Drum body with the remaining screws. Make sure that the Drum body fits tightly on the
Flanges with no loose fits.
4) The Clamp plate base assembly should be pushed towards the rear of the Drum, as there is a
small play in mounting the assembly.
Drum body
Imprinted marking
Imprinted marking
Screen JIG
Hook
Hook
CZ180 / CV1860 Rev. 1.0 8-


8. Ink Sensor PCB

REMOVAL
3) Remove following parts.
Drum body (M4x8 screws; 6 pcs)
4) Unplug the Ink sensor wire harness connector.
5) Remove the Ink sensor assembly. (M3x8 screws; 2 pcs)
6) Remove the Ink sensor cover.
7) Remove the Ink sensor PCB. (M3x6 screws; 2 pcs)
1) The Ink sensor and Overflow sensor needles must be straight. Do not deform or bend the sensor
needles.
2) If the needles are bent, straighten then out by hand before installing the Ink sensor PCB back on
the Drum.
Checks after Assembly

1) Make sure that the Ink sensor is not touching the Doctor roller or Driving shaft, as that would
cause the Ink sensor to make false detection.
2) In normal condition, the tip of the Ink sensor should be 5mm plus/minus 0.5mm from the outer
surface of the Driven shaft. The tip of the Overflow sensor should be 10mm plus/minus 1mm
from the outer surface of the Driving shaft.
* As shown on the photograph, the Ink sensor and Overflow sensor should be 90 degrees against the
Ink sensor PCB.
Overflow sensor Ink sensor PCB Ink sensor
8 - 10 CZ180 / CV1860 Rev. 1.0


9. Drum Flanges F (front) & R (rear)

REMOVAL
4) Remove the Ink bottle switch cover. (M3x8 screws; 2 pcs)
13) Remove the Ink pump base. (M3x8 screws; 2 pcs)
Pump base
14) Unplug the Ink sensor wire harness connector.

15) Remove the Ink sensor assembly. (M3x8 screws; 2 pcs)
16) Remove the wire harness band from the Ink sensor relay wire harness, and detach the Side
channel. (M4x8 screws; 4 pcs)
17) Unplug the Drum wire harness connector, and remove the Rear support plate. The order of the
screws to remove are: IB-lock screw 4x5, set screw, and then Cap screw. Only the top IB-lock
screw M4x5 needs to be removed.
18) Remove the Front support plate. The order of the screws to remove are: IB-lock screw 4x5, set
screw, and then Cap screw. Only the top IB-lock screw M4x5 needs to be removed.
19) Remove the Drum frange R.
20) Remove the Drum frange F.
[ Refer to the photographs on the next page for the instructions given above.]
[ Also refer to the Precautions, which follow after the photographs.]
CZ180 / CV1860 Rev. 1.0 8 - 11


Rear frame
Drum support R
Side channel
Rear frame
IB lock
Set screw
Cap screw
Drum support F
Front frame
8 - 12 CZ180 / CV1860 Rev. 1.0


1) Use the Drum Shaft JIG when mounting the screws back onto the Drum shaft clamper.
( Dram shaft Jig = 015-26128-008 Drum Shaft JIG )
2) With the Drum at position-B, insert the Drum Shaft JIG through the Front support plate, Drum
flange-F, Front frame, Rear frame, Drum flange-R and Rear support plate. Then tighten the
screws on the front and rear Drum shaft clamper.
4) Using three wire harness lock bands of each about 100mm long, fix the position of the Ink sensor
relay wire harness to the Support frame and Rear support plate.
5) Make sure that the Ink sensor relay wire harness does not have any slack in the area indicated by
the dotted line on the photograph, and that the wire harness lock band tie area does not protrude
outside the bracket. This is to protect the wire harness.

1) Squeegee gap adjustment
2) Ink blocking plate position adjustment Drum support R
Drum support F
3) Squeegee pressure balance adjustment Rear frame
Drum JIG shaft
The tie portion of the wire band should not go out of the metal plate.
Support frame Wire harness band Rear frame
Ink sensor relay wire harness

The wire should not have any slack in the
area indicated by red dotted line on the
photograph.
CZ180 / CV1860 Rev. 1.0 8 - 13


10. Squeegee Roller

REMOVAL
Drum Flanges F (front) & R (rear)
4) Remove the Gear.
5) Remove the mounting screws of the front & rear Frame and Shaft joint. (M4x12 screws; 2 pcs
each)
6) Loosen the front and rear Shaft joints, slide them inside, and lift the Center shaft out of the Drum
assembly. (M4x4 set screws; 2 pcs)
7) Remove the Driving shaft. (M3x8 screws; 2 pcs)
8) Remove the Rear frame. (M3x8 screws; 6 pcs)
9) Remove the Squeegee roller.
1) Fix the Ink sensor wire harness in position by wire band.
2) Keep the frame twisting to within 0.1mm.
3) The Center shaft should be firmly inserted in the U-shaped cutout on the front and rear frame.

1) Squeegee gap adjustment
2) Ink blocking plate position adjustment
Slide the Shaft joint inward.
Lift the Center shaft up.

Mounting screw
Front frame
8 - 14 CZ180 / CV1860 Rev. 1.0


Shaft joint Center shaft
Squeegee roller
Driving shaft
Front frame
Squeegee roller
Rear frame
CZ180 / CV1860 Rev. 1.0 8 - 15


ADJUSTMENT
1. Cleaning the Filter

CLEANING
12) Remove the Intake nozzle, remove the Filter, and clean the Filter.
Symptom of clogged Filter

1) If dust clogs the Filter, the ink cannot be filled into the Drum and the prints become light.
Mounting screw of the Intake nozzle
Filter
Intake nozzle
Mounting screw of the Intake nozzle
Inking motor
8 - 16 CZ180 / CV1860 Rev. 1.0


2. Squeegee Gap Adjustment

1) Remove the Drum out of the machine, and remove the Screen and Drum body from the Drum.
2) Clean out all the ink off the Squeegee unit.
3) Using a feeler gauge, check and confirm that the gap between the Squeegee roller and Doctor
roller is 0.08mm plus/minus 0.02mm.
The gap should be equal in the front and rear.
4) If the gap is out of the above range, make adjustment by loosening the screw on the Doctor roller
adjustment plate.
5) Insert an Allen wrench in the hole of the Doctor roller adjustment plate and gently swing the plate
until correct gap is obtained.
6) Tighten the screws.

1) If the gap is too big, too much ink is supplied onto the inner surface of the Drum. This will cause
the master on the Drum to slip and cause the master to come loose from the Clamp plate too
quickly.
2) If the gap is too small, not enough ink is transferred onto the inner surface of the Drum. This will
cause light prints to come out in the beginning of a print job.
3. Ink blocking plate position adjustment

ADJUSTMENT
(FRONT)
1) Remove the Drum out of the machine, and remove following parts.
Drum cover
Grip handle
2) From a hole on the front Drum support, loosen the screw of the Ink blocking plate F.
3) Insert tip of a flat-head screw driver in the slit of the Ink blocking plate F. Then move the Ink
blocking plate F until it hits against the inner surface of the Drum. Then tighten the screw.
(REAR)
1) Remove the Drum out of the machine. From the hole on the rear Drum support, loosen the screw
of the Ink blocking plate R.
3) Insert tip of a flat-head screw driver in the slit of the Ink blocking plate R. Then move the Ink
blocking plate R until it hits against the inner surface of the Drum. Then tighten the screw.

1) If the Ink blocking plates are not firmly against the inner surface of the Drum, the Ink blocking
plate is not able to scrape the ink back into the Drum and will cause the ink to pool outside the
Squeegee roller. The ink will eventually leak out from the Drum.
CZ180 / CV1860 Rev. 1.0 8 - 17


MEMO
8 - 18 CZ180 / CV1860 Rev. 1.0


CHAPTER 9: CLAMP UNIT
CONTENTS
MECHANISM................................................................................................2
1. Clamp Unit Home Position Movement...........................................2
2. Clamp Plate Master Release Movement........................................2
3. Clamp Plate Master Clamp Mechanism.........................................3
DISASSEMBLY............................................................................................4
1. Clamp Unit......................................................................................4
2. Clamp Motor...................................................................................5
3. Clamp Sensor.................................................................................6
CZ180 / CV1860 Rev. 1.0 9-


MECHANISM
1. Clamp Unit Home Position Movement

Clamp open arm and Master release arm positions of the Clamp unit are checked by the Clamp
sensor to see if they are in home position every time the machine power is turned ON or the START
button is pressed for confidential or normal master making.
The Clamp unit is at its home position when the light path of the Clamp sensor is blocked.
If the light path of the sensor is open, the Clamp motor is activate to move the arms until the light path
of the sensor becomes blocked.
2. Clamp Plate Master Release Movement

When the START button is pressed for confidential or regular master making, the Drum rotates to
Position-A.
The Clamp open arm comes down first and opens the Clamp plate to free the leading edge of the
master. Next, the Master release arm comes down and raises the Master release bar to push the
leading edge of the master out of the Clamp plate.
The Clamp motor continues to rotate the Clamp cam assembly until both the Clamp open arm and
Master release arm are lifted to close the Clamp plate and Master release bar. The master release
movement is completed when the light path of the Clamp sensor becomes blocked and the Clamp
motor stops.
Clamp cam
Clamp motor
Clamp plate opener arm
Print drum
Master release plate
Position-A
9- CZ180 / CV1860 Rev. 1.0


3. Clamp Plate Master Clamp Mechanism

The master clamp movement is made after the master is removed from the Drum.
With the activation of the Clamp motor in the forward movement, the Clamp open arm is pushed down
to open the Clamp plate. The Clamp motor stops and waits for the master material.
The Load pulse motor on the Master making unit sends given length of the master material towards
the print drum.
Clamp motor rotates in reverse to close the Clamp plate and stops.
The leading edge of the master is clamped on the Drum.
At that point, the Clamp unit is back to its home position.
Position-B
CZ180 / CV1860 Rev. 1.0 9-


DISASSEMBLY
1. Clamp Unit
REMOVAL
1) Turn OFF the machine power and remove the Rear cover. (M3x8 screws: 5 pcs.)
3) Unplug the wire harness connectors of the Clamp motor and Clamp sensor.
4) Remove the mounting screws of the Clamp unit and remove the unit. (M3x6 screws; 3 pcs)
1) Match the positioning hole against the positioning pin in attaching the Clamp unit back on the
machine.
Mounting screw
Clamp motor
Mounting screw
Clamp sensor
Mounting screw
9- CZ180 / CV1860 Rev. 1.0


2. Clamp Motor
REMOVAL
1) Turn OFF the machine power and remove following parts.
Rear cover (M3x8 screws: 5 pcs.)
Clamp unit (M3x6 screws; 3 pcs)
2) Remove E-ring from the Clamp gear and detach the gear. (4mm dia. E-ring; 1 pc)
3) Detach the Clamp motor. (M3x5 screws; 2 pcs)
1) When mounting the Clamp gear back on the Clamp unit, make sure that both the Clamp open
arm and Master release arm are in fully raised position.
Clamp motor
Mounting screw
CZ180 / CV1860 Rev. 1.0 9-


3. Clamp Sensor
REMOVAL
Rear cover (M3x8 screws: 5 pcs.)
Clamp unit (M3x6 screws; 3 pcs)
2) Remove E-ring from the Clamp gear and detach the gear. (4mm dia. E-ring; 1 pc)
3) Rotate the Clamp cam and move the actuator plate out from the Clamp sensor.
4) Detach the Clamp sensor.
1) When mounting the Clamp gear back on the Clamp unit, make sure that both the Clamp open
arm and Master release arm are in fully raised position.
Clamp cam
Clamp sensor actuator plate
Clamp sensor
9- CZ180 / CV1860 Rev. 1.0


CHAPTER 10: MASTER REMOVAL
CONTENTS
MECHANISM................................................................................................2
1. Master Removal Unit Home Positioning Mechanism.....................2
2. Master on the Drum (before master removal) Check Mechanism..4
3. Clamp Plate Master Release Mechanism......................................4
4. Master Removal Mechanism..........................................................4
5. Disposed Master Compressing Mechanism...................................5
6. Master Disposal Box Set Mechanism.............................................5
DISASSEMBLY............................................................................................6
1. Master Removal Unit......................................................................6
2. Master Removal Sensor.................................................................9
3. Master Removal FULL Sensor.......................................................9
4. Master Compression HP Sensor..................................................10
5. Master Removal Motor FG Sensor...............................................10
6. Master Compression Motor..........................................................11
7. Master Removal Motor.................................................................12
8. Master Compression Plate...........................................................13
9. Pulley Shaft, Mater Removal Roller (upper) and O-ring Belt........14
10. Master Removal Hook and Master Loading Sensor...................16
11. Master Removal Roller (bottom) and O-ring Belts.....................17
12. Master removal unit Safety switch..............................................18
CZ180 / CV1860 Rev. 1.0 10 -


CHAPTER 10: MASTER REMOVAL SECTION
MECHANISM
1. Master Removal Unit Home Positioning Mechanism

The Master removal unit returns to its home position each time the power is turned ON, All Reset
Button is pressed, or Master removal cover is opened and closed.
1) When the Master compression plate is already at home position.

Compressing motor is activated to rotate the Master compression plate down until the actuator
disk on the Master compression plate blocks the light path of the Master compression HP sensor,
and then stops. Then the motor rotates in the opposite direction to raise the Master compression
plate to the horizontal position until the actuator disk on the Master compression plate escapes
from the light path of the Master compression HP sensor.
Master compression HP sensor (receive) Master compression plate
10 - CZ180 / CV1860 Rev. 1.0


2) When the Master compression plate is all the way down.

The motor rotates the Master compression plate down, but since the actuator disk is already past
the Master compression HP sensor from the start, the light path of the sensor cannot be blocked
by the disk. The motor stops and then rotates in the opposite direction to raise the Master
compression plate to the horizontal position.
The motor stops and completes the home positioning movement when the actuator disk escapes
from the light path of the Master compression HP sensor.
Master compression HP sensor (receive)
3) When the Master compression plate is at a halfway position.

The disk is already blocking the Master compression HP sensor.
The motor moves the Master compression plate all the way down until the disk escapes from
the light path of the Master compression HP sensor. The motor stops and then rotates in the
opposite direction to raise the Master compression plate to the horizontal position until the
actuator disk escapes from the light path of the Master compression HP sensor.
CZ180 / CV1860 Rev. 1.0 10 -


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

Master sensor checks the presence of the master on the Drum when the Start button is pressed for
confidential master making or normal master making.
The sensor looks for the master on the Drum when the Drum rotates 74.6 degrees from the
Position-A. If the machine already knows the presence of the master on the Drum from the earlier
machine operations, this master check movement is skipped.
When master is detected on the Drum, the machine makes master removal action. The Master
removal sensor is active during the master removal action.
When no master is detected on the Drum, the machine skips the master removal action and goes
directly into master making.
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 comes down first and opens the Clamp plate to free the leading edge of the
master from the Clamp plate. Next, the Master release arm comes down and raises the Master
release bar to push the leading edge of the master out of the Clamp plate.
The Clamp motor continues to rotate the Clamp cam assembly until both the Clamp open arm
and Master release arm are lifted to closes the Clamp plate and the Master release bar.
The master release movement is completed when the light path of the Clamp sensor becomes
open and the Clamp motor stops.
If the master was not found during the master on the drum check before the printing, the machine
goes into master clamping action without making master removal movements.
4. Master Removal Mechanism

1) Master Removal Motor
After the leading edge of the master is released from the Clamp plate, the Master removal motor
activates to rotates the Vertical transport roller (top), Vertical transport roller (bottom), Pulley shaft
and O-ring belts.
2) Main Motor
The Main motor rotates the Drum the same time the Master removal motor activates. By the
rotation of the Drum, the leading edge of the master comes in contact with the O-ring belts.
and the separation of the master from the Drum starts.
The Main motor and Master removal 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.
3) Master Removal Hooks and O-ring Belts
The master removed from the Drum is guided in between the Vertical transport rollers (top) and
(bottom) by the Master removal hooks and O-ring belts.
4) Master Removal Sensor
Master removal sensor checks the presence of the removed master in front of the Master
disposal box to check for master removal jams. The Master removal sensor looks for presence
of removed master twice, The first time is at 70 degrees Drum rotation from Position-A and the
second time is at 90 Drum rotation from Position-A.
10 - CZ180 / CV1860 Rev. 1.0


5. Disposed Master Compressing Mechanism

1) Compression Motor
As the master is removed from the Drum and transferred into the Master disposal box, the
Compressing motor activates and rotates the Master compression plate down to compress the
disposed master in the Master disposal box. The Compression motor stops when the Actuator
disk on the Master compression plate escapes from the light path of the Master compression
HP sensor. The Compression motor then rotates in the opposite direction and lifts the Master
compression plate back to the home position.
2) Master Full Detection Sensor
If the Master full detection sensor does not detect Master compression plate at all during the
disposed master compressing movement, the machine assumes that the Master disposal box is
full.
Master removal FULL detection sensor Compression motor
6. Master Disposal Box Set Mechanism

1) Disposal Cover Set Switch
Disposal cover set switch checks the presence of the Master disposal box and whether the
Master disposal upper cover is opened or closed. When the Master disposal box is set in the
machine, it pushes the Switch lever and lifts the Disposal cover set switch.
The lifted Disposal cover set switch can then be pressed when the Master removal unit is closed.
2) Master Removal Unit Safety Switch
As with the Disposal cover set switch, the Master removal unit safety switch is lifted when the
Master disposal box is set in the machine. The lifted Master removal unit safety switch can then
be pressed when the Master removal unit is closed.
CZ180 / CV1860 Rev. 1.0 10 -


DISASSEMBLY
1. Master Removal Unit

Be careful not to catch the wire harness when removing the unit.
REMOVAL
[ Removing the Master removal assembly (upper)]
1) Lower the paper feed tray, turn OFF the machine power, remove the Master disposal box and
following parts.
Master removal upper cover (M3x8 screws; 2 pcs)
Scanning upper frame cover (M3x8 screws; 4 pcs)
Scanner unit cover (M3x8 screws; 4 pcs)
2) Open the PCB bracket on back of the machine. (M3x8 screws; 4 pcs)
3) Unplug the Master disposal wire harness connector.
4) Remove the Housing stay-A. (M3x6 screws; 2 pcs)
5) Keeping the Master removal assembly (upper) opened, unhook the two Springs. Then remove
the Master removal assembly (upper) by lowering it down.
[ Removing the Master removal assembly (bottom)]

6) Unplug the wire harness connector of Master loading sensor.
7) Remove the Master removal assembly (bottom) by removing wire harness and screws. (M3x6
screws; 2 pcs)
Precautions in Assembly
The precautions for the assembly continue after the photographs for the removal procedures.
View with the cover removed
10 - CZ180 / CV1860 Rev. 1.0


Housing stay A
Master removal upper assembly
Print drum
View from the TOP
Master removal bottom assembly
CZ180 / CV1860 Rev. 1.0 10 -


1) When wiring the Master removal unit wire harness, the blue colored wire harness should be wired
in the manner explained below.
2) Wire the blue colored wire harness through the wire saddle as shown on the photograph.
3) Give some sag (looseness) on the wire harness used on the Master removal unit, which moves
with the open and close movement of the Master removal unit.
Position the blue wire tie at this area
Edge saddle
View from the top
Master removal sensor Master removal motor FG sensor
Master removal FULL detection sensor Master compression HP sensor
10 - CZ180 / CV1860 Rev. 1.0


2. Master Removal Sensor

REMOVAL
1) Turn OFF the machine power and remove the Master removal upper cover. (M3x8 screws; 2 pcs)
2) Unplug the wire harness connector of Master removal sensor.
3) Then detach the sensor by removing the mounting screw. (M3x6 screw; 1 pc)
Master removal sensor
3. Master Removal FULL Sensor

REMOVAL
2) Remove the sensor by unhooking the legs and unplugging the wire harness connector.
Removed view of Master removal

FULL detection sensor
CZ180 / CV1860 Rev. 1.0 10 -


4. Master Compression HP Sensor

REMOVAL
2) Remove the Gear cover (front). (M3x6 screws; 2 pcs)
3) Remove the mounting bracket. (M3x6 screw; 1 pc)
Master compression HP sensor
5. Master Removal Motor FG Sensor

REMOVAL
Removed view of Master removal

motor FG sensor
10 - 10 CZ180 / CV1860 Rev. 1.0


6. Compression Motor
1) Watch out for the Compression plate, which hangs free when the Gear to the Compression motor
is removed.
View of the Master compression

plate hanging down.
REMOVAL
2) Remove the Gear cover (rear). (M3x6 screws; 2 pcs)
3) Remove the gear.
4) Unplug the wire harness connector of Compression motor, and remove the motor. (M3x5 screws;
2 pcs)
1) When mounting the Gear back on the unit, make sure that the Master compression plate is
positioned level against the Master removal housing.
Compression motor
Compression motor
Mounting screw
Mounting screw
CZ180 / CV1860 Rev. 1.0 10 - 11


7. Master Removal Motor

1) Watch out for the Master compression plate, which hangs free when the Gear to the Master
compression motor is removed.
View of the Master compression plate hanging down.
REMOVAL
3) Remove the Gear and Gear-35. (6mm dia. E-ring; 1 pc) (M3x12 screw; 1 pc)
5) Remove 2 pcs of Gears and the Belt. (4mm dia. E-ring; 2 pcs)
6) Remove the Master removal motor cover. (M3x6 screws; 2 pcs)
7) Remove the cord clamp of the Master removal motor, unplug the motor wire harness connector,
and remove the Master removal motor. (M3x5 screws; 2 pcs)
Master removal motor
Master removal motor cover
10 - 12 CZ180 / CV1860 Rev. 1.0


8. Master compression plate

REMOVAL
3) Remove the Gear and Gear-35. (6mm dia. E-ring; 1 pc) (M3x12 screw; 1 pc)
5) Remove the Housing stay-B. (M3x6 screws; 4 pcs)
6) Remove the sensor actuator plate. (M3x12 screw; 1 pc)
7) Remove the E-rings from the both ends of the Compression shaft, remove the metal bushing.
Then remove the Master compression plate together with the Compression shaft. (6mm dia.
E-ring; 2 pcs)
8) Remove Compression spring from the Master compression plate. (M3x6 screws; 2 pcs)
9) Remove the mounting screws of the Master compression plate holder, and remove the Master
compression plate from the Compression shaft. (M3x6 screws; 2 pcs)
1) The Master compress plate should face the correct way.
2) The Compress spring should face in correct way, and where to hook the spring should not be
mistaken.
Gear 35
Housing stay B
Sensor actuator plate
Compression shaft
CZ180 / CV1860 Rev. 1.0 10 - 13


Master compression plate
Compression spring
Compression spring
9. Pulley Shaft, Mater Removal Roller (upper) and O-ring Belt.
PULLEY SHAFT
Gear cover (front). (M3x6 screws; 2 pcs)
Gear cover (rear). (M3x6 screws; 2 pcs)
2) Remove the Pulley shaft stopper ring, slide the Pulley shaft aside and pull the shaft out through
the O-ring belts. (4mm diameter stopper ring; 1 pc)Hook the O-ring belts correctly in the groove
of the belt pulleys.
Pulley bracket (upper)
Clip
Pulley shaft
10 - 14 CZ180 / CV1860 Rev. 1.0


MASTER REMOVAL ROLLER (UPPER)

- continued from previous page -
3) Remove the O-ring belts (4 pcs) from the pulleys on the Pulley mounting bracket.
4) Remove the stopper ring from the Master removal roller (upper), slide the metal bushing and
remove the Master removal roller (upper). (4mm dia stopper ring; 1 pc)
5) Slide the Master removal roller (upper) out through the O-ring belts.
Master removal roller (upper)
Clip
Pulley shaft
O-RING BELTS
- continued from above -
6) Remove the O-ring belts by removing the Pulley shaft and Master removal roller (upper).
Hook the O-ring belts correctly in the groove of the belt pulleys.
CZ180 / CV1860 Rev. 1.0 10 - 15


10. Master Removal Hook and Master Loading Sensor

MASTER REMOVAL HOOK
Master removal assembly (lower). (M3x6 screws; 2 pcs)
2) Remove the mounting screw of the Master removal hook and detach the Master removal hook
from the Master removal assembly (lower). (M3x10 screws; 2 pcs)
1) The wire harness of the Master loading sensor should go through behind the Master removal
hooks.
2) Match the positioning pins and holes.
Master removal hook
MASTER LOADING SENSOR

3) Remove the Master loading sensor cover. (M3x6 screws; 1 pcs)
4) Remove the mounting screw of the Mater loading sensor and remove the sensor. (M3x8 screw; 1
pc)
1) The wire harness of the Master loading sensor should go through behind the Master removal
hooks.
2) Match the positioning pins and holes.
Master loading sensor

Master loading sensor cover
Wire harness of Master loading sensor
Master removal hook
10 - 16 CZ180 / CV1860 Rev. 1.0


11. Master Removal Roller (lower) and O-ring Belts

O-RING BELTS
Master removal assembly (lower). (M3x6 screws; 2 pcs)
2) Being careful of the Roller lower spring, remove four E-rings from the Spring plate and remove
the Spring plate.
3) Remove the O-ring belts.
Master removal hook
MASTER REMOVAL ROLLER (LOWER)

4) Remove E-ring and remove the Gear. (4mm E-ring; 2 pcs)
5) Remove E-ring, and metal bushing. Then remove the Master removal roller (lower).
1) Hook the O-ring belts correctly in the groove of the Master removal roller (lower).
Master removal roller (lower)
CZ180 / CV1860 Rev. 1.0 10 - 17


12. Master removal unit Safety switch

REMOVAL
1) Lower the paper feed tray, turn OFF the machine power and remove following parts.
2) While keeping the Master removal unit opened, unplug the wire harness connector of the Master
removal unit safety switch. Remove the mounting screws and detach the Safety switch assembly.
3) Remove the switch from the Master removal unit safety switch assembly. (M3x16 screws; 2 pcs)
Master removal lower cover
Switch
10 - 18 CZ180 / CV1860 Rev. 1.0


CHAPTER 11: SCANNING SECTION
CONTENTS
MECHANISM................................................................................................2
1. Original Loading Mechanism..........................................................2
3. Image Scanning Mechanism..........................................................4
DISASSEMBLY............................................................................................6
1. Image Scanner...............................................................................6
2. AF Stripper Solenoid......................................................................8
3. Original Detection Sensor..............................................................9
4. Original IN Sensor..........................................................................9
5. Stripper Roller..............................................................................10
6. Original Pickup Roller...................................................................11
7. Original Stripper Pad....................................................................12
8. Read Pulse Motor.........................................................................14
ADJUSTMENT............................................................................................15
1. AF Scan Start-Position Adjustment..............................................15
2. AF Horizontal-Scan Position Adjustment.....................................15
3. AF Read Pulse Motor Speed Adjustment (Elongation & Shrinkage).....15
CZ180 / CV1860 Rev. 1.0 11 -


MECHANISM
1. Original Loading Mechanism

1) When the original is placed on the Original tray, the Original detection sensor is activated and the
original is automatically loaded on the AF unit.
2) The AF stripper solenoid activates to lower the Shutter and Original feed arm comes down to hold
the original.
3) The Image scanner LED turns ON to make shading compensation.
4) With the press of the START key, the Read pulse motor activates to rotate the Original pickup
roller and Original stripper roller to feed the original.
5) The original, if fed in multi-layer, is stripped into one sheet by the Stripper roller and Original
stripper pad.
6) As the original keeps feeding, the Original IN sensor detects the original and turns OFF the AF
stripper solenoid to raise the Shutter and Original feed arm.
7) After a given rotation of the Read pulse motor, the motor turns OFF to finish the Original loading
movement.
2. Original Scanning Mechanism

1) The Drum starts to rotate after the original loading action is completed. At the same time, the
Read pulse motor activates to rotate the Original pickup roller, Stripper roller and Exit roller to
feed the original through the AF unit.
2) At the same time, the Write pulse motor activates ON to feed the master material within the
Master making unit.
3) As the Write pulse motor activates for a given amount to send the master 2mm forward, the read
& write signal goes ON. The Image scanner starts to scan the original and the master-making is
also activated.
3) As the original is about to come out of the AF unit, the Original IN sensor detects the tail edge
of the original. After a given time from the detection of the original tail edge by the Original IN
sensor, the read & write signal turns OFF. The Image scanner LED turns OFF to end the original
scanning.
3) The Read pulse motor keeps rotating to eject the original.
4) After a given time, the Read pulse motor stops to end the scanning movement.
11 - CZ180 / CV1860 Rev. 1.0


Shutter
Stripper roller
Original IN sensor
Original detection sensor
Read pulse motor
Original feed arm
Original pickup roller
Image senser
Stripper solenoid
Spring
Original IN sensor
Original stripper pad
Stripper roller
Original feed arm
Read pulse motor
Image sensor
Shutter
TPH
CZ180 / CV1860 Rev. 1.0 11 -


3. Image Scanning Mechanism

1) The image scanning is done by a contact image scanner (CIS) which emits greenish-yellow light
from Fluorescent lamp.
CIS (Contact Image Sensor) sliced view
Cover glass
Original Dust prevention sponge
Scanner glass
Lens
LED
Spacer
Frame
Photo conductor
11 - CZ180 / CV1860 Rev. 1.0


MEMO
CZ180 / CV1860 Rev. 1.0 11 -


DISASSEMBLY
1. Image Scanner
REMOVAL
Scanner upper frame cover (M3x8 screws; 4 pcs)
2) Open the Scanner frame assembly.
3) Remove the Scanning guide plate assembly. (M3x6 screws; 4 pcs)
4) Unplug the wire harness connector of Original IN sensor and Original detection sensor.
5) Remove the Image scanner glass and CIS spacers (2 pcs).
6) Remove the Image scanner by removing the mounting screws. (M3x8 screws; 4 pcs)
7) Remove the wire harness from the Image scanner.
1) In mounting the Image scanner back on the AF unit, the Image scanner should be pushed
towards the rear of the machine and towards the Master removal unit.
2) Make sure that the Scanner glass is wiped clean before the attachment.
Use dry cloth or cloth with alcohol to clean the Scanner glass.
3) Do not misplace the small black colored CIS spacer.
4) In mounting back the Scanning guide plate assembly, make sure that the Scanner glass is
positioned correctly in the rectangular hole on the guide plate.
5) Make sure to hook the Link onto the plunger of the Solenoid.
Operation check of the Solenoid

1) Pull the solenoid plunger to confirm that the Shutter comes down when the plunger is pulled.
11 - CZ180 / CV1860 Rev. 1.0


Scanner guide plate assembly
Image sensor
Scanner glass
Scanner guide plate assembly Original IN sensor
AF cover set sensor
Scanner glass
CIS spacer
Image sensor
CZ180 / CV1860 Rev. 1.0 11 -


2. AF Stripper Solenoid
REMOVAL
2) Unplug the wire harness connector of the AF stripper solenoid.
3) Open the Master making unit and remove the mounting screws of the AF stripper solenoid to
detach the solenoid. (M3x6 screws; 2 pcs)
1) Make sure to hook the Link onto the plunger of the Solenoid.
Operation check of the Solenoid

1) Pull the solenoid plunger to confirm that the Shutter comes down when the plunger is pulled.
Stripper solenoid
Solenoid plunger
Stripper solenoid
Link assembly
11 - CZ180 / CV1860 Rev. 1.0


3. Original Detection Sensor

REMOVAL
5) Remove the Original detection sensor form the Scanning guide plate assembly.
Scanner guide plate assembly
4. Original IN Sensor
REMOVAL
5) From the Scanning guide plate assembly, remove the Shutter shaft assembly, Shutter and
Shutter spring. (3mm dia. E-ring; 1 pc)
6) Remove the Original IN sensor from the Scanner guide plate assembly by removing the mounting
screw. (M3x12 screw; 1 pc)
1) Mount the Shutter spring in correct direction.
Sutter shaft assembly

Shutter spring
Shutter
Original IN sensor
CZ180 / CV1860 Rev. 1.0 11 -


5. Stripper Roller
REMOVAL
5) Remove E-ring from the Original stripper roller shaft and remove the Gear and Joint disc. (4mm
E-ring; 1 pc)
6) Remove E-ring from the Original stripper roller shaft, slide the shaft to the rear of the machine and
remove the Original stripper roller shaft upwards. (4mm dia. E-ring; 1 pc)
7) Remove the spur gear from the Original stripper roller shaft. (M3x4 set screw; 1 pc)
Gear
Joint disc
Stripper roller
11 - 10 CZ180 / CV1860 Rev. 1.0


6. Original Pickup Roller

REMOVAL
5) Remove E-ring from the Shutter shaft assembly and being careful of the Spring, remove the
Shutter shaft assembly. (3mm dia. E-ring; 1pc)
6) Remove the Shutter.
7) Remove the Gear. (3mm dia. E-ring; 1 pc)
8) Remove E-rings from both ends of the Original pickup roller, Rear on the rear of the unit, metal
bushing, and then remove the Original pickup roller. (3mm dia E-rings; 2 pcs)
1) Pay caution to the direction of the Shutter spring.
Metal bushing
Metal bushing
Gear
CZ180 / CV1860 Rev. 1.0 11 - 11


7. Original Stripper Pad

REMOVAL
1) Turn OFF the machine power and remove following part.
2) Remove the Lock plate spring, E-ring and Lock lever (upper), (4mm E-ring; 1 pc)
3) Remove the Original stripper drive plate assembly, being careful not to loose the screw. (M3x6
screw; 1 pc)
4) Remove the Original stripper pad bracket, being careful not to loose the screw. (M3x6 screw; 1
pc)
5) Detach the Original stripper bracket from the Original stripper pad bracket. (M3x6 screws; 2 pcs)
6) Remove the Original stripper roller pressure wheel and Original stripper pad from the Original
stripper pad bracket. (M3x6 screws; 2 pcs)
1) When mounting the Original stripper pad bracket and Original stripper drive plate assembly, be
careful of the direction of the Spring to be attached.
Lock lever (upper)
Lock spring plate
AF frame assembly
Original feed plate assembly
Original feed shaft plate
11 - 12 CZ180 / CV1860 Rev. 1.0


Spring A
Spring B
Original feed arm
Original stripper pad Original feed shaft pin
Stripper roller pressure wheel
Original stripper pad bracket
Original stripper pad
Bracket assembly
Original scraper roller pressure wheel

Spring B
Original feed arm
Spring A
The Original feed shaft pin holds Spring-A and Spring-B while the
U-shaped portion of the Original feed arm goes through.
CZ180 / CV1860 Rev. 1.0 11 - 13


8. Read Pulse Motor

REMOVAL
2) Remove the Timing belt.
3) Unplug the wire harness connector of Read pulse motor.
4) Remove the Ejection roller pulley. (4mm dia. E-ring; 1 pc)
5) Remove two Gears. (4mm dia. E-ring; 2 pcs)
6) Remove the Read pulse motor. (3x6 screws; 2 pcs)
Original ejection roller pulley
Read pulse motor
Gear
Gear
Timing belt
Read pulse motor
11 - 14 CZ180 / CV1860 Rev. 1.0


ADJUSTMENT
1. AF Scan Start-Position Adjustment

Checks and Procedure
1) Scan and print an Original with no white margin on the top.
2) Looking at the printed image, confirm that top 4mm plus or minus 2mm of the Original is erased.
3) If the area erased is out of the range, use following Test Mode to make the adjustment.
Test Mode No. 0381 [AF scan start-position adjustment]

This Test Mode adjusts the amount of the top image skipped in the scanning operation.
Adjustable range: -20 to +20 (1 = 0.1mm) + number increases the amount of the image erased.
Default setting: 0 (0mm)
2. AF Horizontal-Scan Position Adjustment

1) Place B4-size papers on the paper feed tray (or larger papers if B4-size paper is not available),
making sure that the side guide plates are firmly against the papers.
2) Use Test Chart No.14 and make master and print.
3) Fold the printed paper in half (vertically) and confirm that the center-line of the image is within
plus or minus 3mm from the center fold.
4) If the center-line of the printed image is out of the range from the center fold of the paper, make
adjustment using following test mode.
Test Mode No. 0380 [AF Horizontal-Scan Position Adjustment]

This Test Mode adjusts the center position in scanning the Original.
Adjustable range: -30 to +30 (5 = 0.5mm) + number moves the image to the LEFT.
Default setting: 0 (0mm)
3. AF Read Pulse Motor Speed Adjustment (Elongation & Shrinkage)

1) Use Test Chart No.14 and make master and print.
2) Compare the prints with the Original. Confirm that the elongation or shrinkage of the prints
against the Original is within 1.4% (Example: If length of 300mm is used for the comparison, the
elongation or shrinkage should be within 4.2mm)
3) If the elongation or shrinkage is more than 1.4%, make an adjustment using following Test Mode.
Test Mode No.0382

This Test Mode adjusts the speed of the Original scanning (speed of the Read pulse motor).
Adjustable range: -100 to +100 (1 = 0.1%) + number elongates the image.
Default setting: 0 (0%)
Rough guidance in changing 1 mm:
A3 : plus or minus 0.2%
B4 : plus or minus 0.3%
A4 : plus or minus 0.3%
Ledger : plus or minus 0.2%
Legal: plus or minus 0.3%
CZ180 / CV1860 Rev. 1.0 11 - 15


MEMO
11 - 16 CZ180 / CV1860 Rev. 1.0


CHAPTER 12: MASTER MAKING SECTION
CONTENTS
MECHANISM................................................................................................2
1. Master Making Unit Mechanism.....................................................2
2. Detection Mechanism.....................................................................3
3. Master Cutter Mechanism..............................................................3
4. Master Set Mechanism...................................................................4
5. Master-making Mechanism............................................................4
DISASSEMBLY............................................................................................5
1. Master Making Unit Safety Switch..................................................5
2. Thermal Print Head (TPH).............................................................6
3. RF-Tag Antenna PCB....................................................................7
4. Write Pulse Motor Assembly..........................................................8
5. Load Pulse Motor Assembly...........................................................9
6. Master Positioning Sensor Assembly...........................................10
7. Cutter Guide Assembly................................................................11
8. Master End Sensor.......................................................................11
9. Write Roller...................................................................................12
10. Master stocker roller (bottom)....................................................13
11. Load Roller (bottom)...................................................................14
12. Master loading roller...................................................................15
13. Cutter Unit..................................................................................16
ADJUSTMENT............................................................................................17
1. Thermal Power of Thermal Print Head (TPH)..............................17
2. Master Clamp Range Adjustment................................................17
3. Write Start Position Adjustment....................................................17
4. Master Cut Length Adjustment.....................................................18
5. Master Making Image Elongation and Shrinkage.........................18
6. Master Making Length Adjustment...............................................18
CZ180 / CV1860 Rev. 1.0 12 -


MECHANISM
1. Master Making Unit Mechanism
Master end sensor

Load pulse motor
Master positioning sensor
Load roller (upper)

Load roller (lower)
Master loading roller
TPH
Master stocker roller (top)
Master stocker roller (bottom)
Write roller
Cutter motor
Write pulse motor
12 - CZ180 / CV1860 Rev. 1.0



Load roller (upper)
Master positioning sensor

Master end sensor
Master stocker roller (top)
TPH
Write roller
Cutter
Load roller (lower)
Load roller (lower)
2. Detection Mechanism
1) The set detection of the Master-making upper unit is detected by the Master-making unit safety
switch. When the Master-making upper unit is closed, the master set movement starts.
2) The master end detection is made by the Master end sensor detecting the black end-mark on the
master material at the end of the master roll.
When the Master end sensor detects the black marking on the master material, the machine
displays a panel message to inform the operator to replace the master roll.
3. Master Cutter Mechanism

1) The master cutting is done by a Cutter unit in which a Cutter blade disc slides on a rail.
2) Two switches are used to detect the position of the Cutter blade disc. One is the Cutter HP
switch and the other is the Cutter stop position switch. The Cutter blade disc rests at the HP
switch position. With the start of the master cutting operation, the Cutter motor slides the Cutter
blade disc to the other end of the Cutter unit and stops when the Cutter stop position switch is
activated by the Cutter blade disc. The Cutter blade disc then slides back to the HP switch with
the reverse rotation of the Cutter motor. The Cutter blade disc stops at the HP switch.
CZ180 / CV1860 Rev. 1.0 12 -


4. Master Set Mechanism

1) When the Master-making upper unit is closed, the Master-making unit safety switch becomes ON,
and following movements are made.
2) The Write pulse motor rotates in the forward direction and sends the master forward. (The Write
pulse motor rotates the Write roller and Master stocker roller.)
The Write pulse motor stops when the leading edge of the master material is detected by the
Master positioning sensor.
3) The Write pulse motor then rotates in the opposite direction to bring back the leading edge of the
master material 5mm away form the Master positioning sensor.
4) This 5mm distance can be adjusted or changing by using Test Mode No.540
5) The master set movement after master cutting is made in the following steps.
6) After cutting the master material and when the Cutter blade disc activates the Cutter stop position
switch, the Write pulse motor rotates in the reverse direction to bring the master material back
3.6mm away from the Cutter unit.
7) The Cutter motor activates in the reverse direction to bring the Cutter blade disc back to the HP
position.
8) The Write pulse motor then rotates in the forward direction to send the master material forward
until the Master positioning sensor detects the leading edge of the master material. The Write
pulse motor rotates in the reverse direction to bring the leading edge of the master material back
5mm away from the Master positioning sensor.
5. Master-making Mechanism
The movements from the master-making to master-loading on the drum is made in the following
sequence.
1) With the start of the master-making, the Write pulse motor sends the master material forward.
The leading edge of the master material is detected by the Master positioning sensor. The
master continues to feed forward for a set length after the detection by the Master positioning
sensor. The Write pulse motor stops and waits.
2) When ready to make the master, both the Write pulse motor and Load pulse motor activates to
send the master material further forward while the master is being made until the leading edge of
the master material arrives at the master-making position.
3) When the leading edge of the master arrives at the master loading position, the Load pulse motor
stops while the Write pulse motor keeps on sending the master material forward. The master
making continues and oncoming master goes into stocker room.
4) When the Drum arrives to Position-A and Clamp plate opened, ready to clamp the master, the
Load pulse motor active to send the leading edge of the master forward, under the clamp plate.
The Clamp plate is then closed to clamp the leading edge of the master.
5) As the Clamp HP sensor goes ON, the Separation fan activates.
6) After the master making is completed, the master material is sent further forward until the cutting
position of the master material arrives to the Cutter unit.
7) The Main motor rotates the Drum, with the newly wrapped master on the surface, to a position
74.6 degrees from Position-A and stops for the Master loading sensor to check the presence of
master on the Drum.
8) If the Master loading sensor detects master on the Drum, the Cutter unit cuts the master, and
then the Main motor activates again to rotate the Drum to wrap rest of the master on the Drum.
12 - CZ180 / CV1860 Rev. 1.0


DISASSEMBLY
1. Master Making Unit Safety Switch

1) Remove the Drum from the machine, turn OFF the machine power and remove the Front cover
from the machine. (M3x8 screws; 6 pcs)
2) Unplug the wire harness connector of the Master making unit safety switch, remove the mounting
screw and remove the switch assembly. (M3x6 screws; 2 pcs)
3) From the switch from the Master making unit safety switch assembly. (M3x14 screws; 2 pcs)
Master making unit safety switch assembly
CZ180 / CV1860 Rev. 1.0 12 -


2. Thermal Print Head (TPH)

1) Open the Master making upper unit and detach the TPH ground wire. (M3x6 screw; 1 pc)
2) Remove the TPH support plate. (M3x6 screw; 1 pc)
3) Slide the TPH all the way towards the Master roll holder and release the two hooks on the TPH
assembly from the stay.
4) Rotate the TPH downward and release the center plate from the stay to release the TPH from the
machine.
5) Unplug the two TPH wire harness connectors.
TPH ground wire
TPH holding plate
View of the TPH removed
12 - CZ180 / CV1860 Rev. 1.0


3. RF-Tag Antenna PCB

2) Unplug the wire harness connector of the RF-Tag Antenna.
3) Open the Master making upper unit.
4) Remove the Master holder unit (front). (M3x8 screws; 2 pcs)
5) Remove the RF-Tag Antenna PCB from the Master holder unit (front) by carefully releasing the
hooks.
Master holder assembly (front)
Unit main frame
Master holder assembly (front)

Antenna assembly
RF-PCB
Master holder (front)
CZ180 / CV1860 Rev. 1.0 12 -


4. Write Pulse Motor Assembly

2) Unplug the wire harness of the Write pulse motor by releasing the wire harness from the wire
saddle.
3) Removing the mount screws, remove the Write pulse motor assembly together with the Timing
belt. (M3x6 screws; 2 pcs)
1) In mounting the Write pulse motor, tighten the mounting screws lightly, give adequate tension
on the Timing belt, and then tighten the mounting screws while rotating the Write pulse motor
assembly in counter-clockwise direction.
Mounting screw
Write pulse motor assembly
Mounting screw
12 - CZ180 / CV1860 Rev. 1.0


5. Load Pulse Motor Assembly

2) Open the PCB bracket on the back of the machine. (M3x8 screws; 4 pcs)
3) Unplug the wire harness connector of the load pulse motor.
4) Remove the mounting screws and remove the Load pulse motor assembly. (M3x6 screws; 2 pcs)
Load pulse motor assembly
Mounting screw
Mounting screw
CZ180 / CV1860 Rev. 1.0 12 -


6. Master Positioning Sensor Assembly

1) Remove the Master removal upper cover. (M3x8 screws; 2 pcs)
2) Remove the Master scanning upper frame cover. (M3x8 screws: 4 pcs)
3) Remove the Scanner unit cover. (M3x8 screws; 4 pcs)
5) Open the Master making upper unit. By removing the Housing stay-A in the previous step, the
unit will open wider.
6) Remove the mounting screw of the Master positioning sensor assembly. (M3x6 screw; 1pc)
7) Unplug the wire harness connector of the Master end sensor and Master positioning sensor, and
detach the Master positioning sensor bracket.
8) Remove the Maser positioning sensor from the bracket. (M3x6 screw; 1 pc)
Housing stay A
Master positioning sensor Master positioning sensor bracket assembly
12 - 10 CZ180 / CV1860 Rev. 1.0


7. Cutter Guide Assembly

2) Remove the Master removal upper cover. (M3x8; 2 pcs)
7) Remove the Master positioning sensor bracket and unplug two wire harness connectors. (M3x6
screw; 1 pc)
8) Remove the Cutter guide assembly. (M3x6 screws; 2 pcs)
Cutter guide assembly

Mounting screw
8. Master End Sensor

Master positioning sensor bracket (M3x6 screw; 1 pc)
Unplug the wire harness connector of the Master end sensor.
Cutter guide assembly (M3x6 screws; 2 pcs)
7) Remove the Master end sensor assembly. (M3x6 screw; 1 pc)
Master end sensor assembly
CZ180 / CV1860 Rev. 1.0 12 - 11


9. Write Roller
1) Remove the Drum from the machine, turn OFF the machine power and remove following parts.
Front Cover (M3x6 screws; 6 pcs)
Write pulse motor assembly (M3x6 screws; 2 pcs)
2) Remove the Write roller pulley. (M3x6 screw; 1 pc)
3) Remove the Guide plate by removing two plastic clips and sliding the metal bushing.
4) Remove E-ring from the machine frame. (8mm E-ring; 1 pc)
5) Remove the Write roller assembly.
Pulley
Guide plate
Machine frame
Write roller assembly
12 - 12 CZ180 / CV1860 Rev. 1.0


10. Master stocker roller (bottom)

8) Remove the Pulley assembly and E-ring on the back. (4mm dia. E-ring)
9) Remove the E-ring under the Master stocker roller (bottom), and slide the roller to the front and
remove the roller. (4mm dia. E-ring; 2 pcs)
Pulley assembly
CZ180 / CV1860 Rev. 1.0 12 - 13


11. Load Roller (bottom)

Load pulse motor assembly (3x6 screws; 2 pcs)
8) Detach the Load roller gear by removing the mounting screw. (M3x6 screw; 1 pc)
9) Remove the E-rings of the Load roller (bottom) and remove the roller. (6mm dia. E-ring; 2 pcs)
Load roller gear
E-ring
Load roller (lower)
12 - 14 CZ180 / CV1860 Rev. 1.0


12. Master loading roller

7) Remove following part.
Load pulse motor assembly (3x6 screws; 2 pcs)
8) Detach the Master loading roller gear by removing the mounting screw. (M3x6 screw; 1 pc)
9) Remove the Master loading guide.
10) Remove the plastic clip on the front and detach the Master loading roller. (4mm dia. plastic clip; 1
pc)
Master loading roller gear
Master removal unit
Master loading guide
Clip
CZ180 / CV1860 Rev. 1.0 12 - 15


13. Cutter Unit

1) Remove the Drum from the machine, turn OFF the machine power and remove following parts.
Front Cover (M3x6 screws; 6 pcs)
2) Unplug the two wire harness connectors of the Cutter unit.
3) Remove the mounting screw of the Cutter unit and remove the Cutter unit from the front of the
machine. (M3x6 screws; 1 pc)
Mounting screw
Cutter unit
12 - 16 CZ180 / CV1860 Rev. 1.0


ADJUSTMENT
1. Thermal Power of Thermal Print Head (TPH)

This adjustment must be made each time the TPH is replaced.
1) Start up Test Mode and input 9874 to enter into Protected Test Mode.
2) Then enter Test Mode No. 1234 [TPH Thermal Power Adjustment] and input the resistant value
imprinted on the sticker attached on the TPH.
Adjustable range: 1200 ohm to 2200 ohm

Make sure to input the correct value.
2. Master Clamp Range Adjustment

Checks and Adjustment
1) Make a marking on the center of the master where it is clamped by the Clamp plate on the Drum.
2) Measure the length of the master from the leading edge to the marking made on the master.
The length should be 20mm plus or minus 1mm.
3) If the measured length is out of the range, use Test Mode No. 0543 [Master Clamp Range
Adjustment] to make an adjustment.
Adjustable range: -100 to +100 (1 = 0.1mm)

+ value increases the master clamp amount.
3. Write Start Position Adjustment

1) Use Test Mode No.0080 to make a master.
2) Remove the master from the Clamp plate.
3) Measure the distance from the leading edge of the master to the top edge of the image burnt on
the master.
4) The distance should be 84mm plus or minus 1mm.
If the measured distance is out of the range, use Test Mode No.0541 [Write Start Position

+ value brings the image up.
Master clamp range adjustment must be made before making this Write start position adjustment.
CZ180 / CV1860 Rev. 1.0 12 - 17


4. Master Cut Length Adjustment

1) The normal length of the master is 461mm plus or minus 7mm.
Depending on the Drum and the amount of master under the clamp, the length of white margin at
the tail of the master on the drum differs.
2) If the white margin at the tail of the master on the Drum is too small and if that is causing the ink
to seep out during the printing, the total master length needs to be increased.
3) On the other hand, if the white margin of the master at the tail of the Drum is too much, the tail
end of the master will touch the Master removal unit and gets the ink transferred, causing the ink
to land on the print papers. If this is happening, the total length of the master needs to be made
shorter.
4) Use Test Mode No. 0544 [Master Cut Length Adjustment] to make an adjustment.

+ value makes the total length of the master longer.
5. Master Making Image Elongation and Shrinkage

1) Use Test Mode No.0081 to make master and prints.
2) Check the master making elongation or shrinkage by measuring from the top horizontal line
to the 32nd horizontal line from the top (length of 31 blocks) should be 336mm plus or minus
1%(3.36mm).
3) If the measured distance is out of the range, use Test Mode No.0547 [Write Pulse Motor Speed
Adjustable range: -100 to +100 (1 = 0.1%)

+ value speeds up the Write pulse motor and elongates the image.
As an example, for a measured length of 334mm, which is 2mm short of the target length,
increasing the value by +6 (0.6%) will correct the shrank image to approx. 336mm.
6. Master Making Length Adjustment

1) Use Test Mode No.0080 to make a master.
2) Peel off the master from the Drum and measure the distance from the leading edge of the top
image to the tail edge of the last image on the master.
3) The distance should be 357mm.
4) If the measured length is out of the range, use Test Mode No.0542 [Master Making Length
Adjustment] and make an adjustment.

+ value increases the master making length.
12 - 18 CZ180 / CV1860 Rev. 1.0


CHAPTER 13: PANEL MESSAGE
CONTENTS
1. Error Type & Error Point..........................................................................2

Example.............................................................................................2
2. Error Display Method...............................................................................3
3. Error Type................................................................................................4
4. Error Point................................................................................................5
5. Paper Jam Error Display Method.............................................................6
6. Detailed List of Panel Messages.............................................................7
1) Serviceman Call Errors (Pxx).........................................................7
2) Jam Errors (Axx)..........................................................................13
3) Option Errors (Bxx)......................................................................16
4) Consumable Errors (Cxx).............................................................18
5) Set Check Errors (Dxx)................................................................19
6) Warning Errors (Exx : Serviceman Call Errors)............................22
7) Warning Errors (Fxx : Others)......................................................22
8) Parameter Errors (Hx)..................................................................23
9) Errors Saved in Memory..............................................................23
CZ180 / CV1860 Rev. 1.0 13 -


1. Error Type & Error Point
Example
Error Type : Indicates what type of error has occurred.
Error Point : Indicates where the error has occurred.
Example : P01-520 (Main Motor Lock)
Error Type Error Point
P01-520
13 - CZ180 / CV1860 Rev. 1.0


2. Error Display Method
Error Display Method
The LED is lit to indicate LED Area

where the error occurred.
1 Paper Feed Tray
3 4 2 Print Drum
3 Master Removal Cover
6
4 Scanning Area
5 5 Master Removal
2
6 Master Making
7 7 Job Separator
1 8 Paper Feed
8 9
9 Paper Ejection
SET / TROUBLE indication LED (Blinking) SET / TROUBLE indication LED (Blinking or Lit)
Note:
For the INK and MASTER remaining amount indication,
both blinking and solid light method is used.
Blinking : Less than 10% remaining

Solid light : Empty
Example: T01-529 (Main Motor Lock)
3 4
6
5
2 While pressing the (*) asterisk key,
the display keeps changing between
7
Error Type and Error Point in one
1 second interval.
8 9
2 : Solid Light
: Blinking Light
CZ180 / CV1860 Rev. 1.0 13 -


3. Error Type
[ERROR TYPE]
The panel messages starts with Error Type
INFORMATION
DESCRIPTION
TYPE SYMBOL
Serviceman Call Error
P-xx Repair by the serviceman is required to correct the problem.
Jam Error
Jam errors which occurs during the machine usage, and these can
A-xx be corrected by the operator by following the troubleshooting steps
given on the Users Guide.
Option Error
Error created from the optional units connected to the main unit,
b-xx such as jam errors and connection errors.
Checking the connections, turning the power ON again or pressing
the RESET key may correct the problem.
Consumable Error
Master roll is empty.
Consumable Error
Master disposal box is full.
c-xx
Consumable Error
Ink bottle is empty.
Consumable Error
No paper on paper feed tray.
Set Error
d-xx One or more of the set switch or sensor is in OFF state.
Warning
E-xx Another type of serviceman call error, in which if the machine is kept
used in this state may cause a problem.
Warning
F-xx The machine is not in a fit state to operate the job requested.
Supply Parameter Input Request
Hxxx A parameter value needs to be input to continue the job operation.
Jam Error
The A-07, A-08, A-09 and A-10 jam error displays are replaced by
Jxx Jxx display. When Jxx display is made, it could be only one of these
four A-xx error or mixture of these four errors.
13 - CZ180 / CV1860 Rev. 1.0


4. Error Point
[ERROR POINT]
The error type is followed by Error Point
ERROR
UNIT
POINT
0 xx System (Hardware, Software, Communication) & Operation Panel.
1 xx Scanning (Scanner, AF Unit) & Image Processing.
2 xx Master Making
3 xx Master Removal
4 xx Paper Feed & Paper Ejection
5 xx Print Drum
6 xx Print Adjustments (Printing Position & Density)
7 xx Options (KeyCard Counter, etc.)
CZ180 / CV1860 Rev. 1.0 13 -


5. Paper Jam Error Display Method
When A-code errors, listed bellow, occur, they are substituted by Jxx error codes.
The two-digit error-type number which follows after the J is the sum of the Corresponding Values
for each of these A-code errors.
Pressing the [*] asterisk key on the operation panel will display the details of the Jxx errors.
Error Corresponding
Error Description Bit
Type Value
A 07 Paper feed jam 3 8
A08 Paper jammed on Drum 2 4
A09 Paper ejection jam 1 2
A10 Original jam 0 1
For above four jam errors, even though only one error occurs, the error type code of Axx is
substited by Jxx error code.
Example:
When A09 (Paper ejection jam) occurs, the error type code displayed is J02.
When A07 (Paper feed jam) occurs, the error type code displayed is J08.
The LED lamp to indicate the place of the problem is determined by the error type number.
Example:
When A09 (Paper ejection) jam occurs, the LED lamp lit is number 9 on the operation panel.
The error type code displayed is J02 (Paper ejection error).
3 4
6
5
2
7 While pressing the (*) asterisk key,
1
8 9
the Error Point is displayed.
9 : Solid Light
: Blinking Light
When paper feed jam (A07) and paper jam on the drum (A08) errors occur simultaneously,
No.2 and No.8 LEDs light in solid and LED in front of the Jam symbol mark blinks.
On the panel display, J12 is displayed.
3 4
6
5
2
While pressing the (*) asterisk key,
7
1
the Error Point is displayed.
8 9
2 8 : Solid Light
: Blinking Light
13 - CZ180 / CV1860 Rev. 1.0


6. Detailed List of Panel Messages
1) Serviceman Call Errors (Pxx)
Error Type P01 [Main motor lock]

P01-xxx
!!System Error!!
Description
Press Reset Key
If Recovery has Failed, Call Service
To reset
Press Reset Key
display
Error Point Error Conditions
520 Main encoder sensor does not go ON/OFF within 10 milliseconds after the main motor activates.
521 Position-A sensor status does not change even after 3,033 pulses after the main motor activates.
Clamp unit is not at the home position while the print drum is in operation (except during master
524
disposal).
537 Print drum failed to stop at Position-A.
Error Type P02 [Elevator motor lock]

P02-xxx
!!System Error!!
Description
Press Reset Key
To reset
Press Reset Key or turn OFF and ON the power.
display
400 Both the upper and lower limit sensors are ON at the same time.
401 Overload current was detected in the elevator motor.
The lower-limit sensor does not go OFF within 2 seconds after the elevator motor operates in the
404
raising direction from the lower-limit position.
The upper-limit sensor does not go ON within 12 seconds after the elevator motor operates in the
405
raising direction.
The upper-limit sensor does not go OFF within 2 seconds after the elevator motor operates in the
406
lower direction from the upper-limit position.
The lower-limit sensor does not go ON within 12 seconds after the elevator motor operates in the
407
lowering direction.
The upper-limit sensor is OFF continuously for over 2 seconds during operation of the elevator
408
servo action to raise the feed tray.
CZ180 / CV1860 Rev. 1.0 13 -


Error Type P03 [Clamp motor lock]

P03-xxx
!!System Error!!
Description
Press Reset Key
To reset
Press Reset Key
display
Clamp sensor is OFF after the completion of the clamp unit initialization or home positioning
500
movement.
501 Clamp sensor does not go OFF within 1 second from the time the clamp motor operates.
502 Clamp sensor does not go ON within 2.5 seconds from the time the clamp motor operates.
504 At the start of Clamp plate open action, the detection of clamp sensors is OFF.
At the start of print drum Position-A compensation movement, the detection of clamp　sensor is
505
OFF.
506 At the start of Clamp unit Home-positioning movement, the detection of clamp sensor is ON.
507 Clamp sensor is OFF after the clamp open action is completed.
508 Clamp sensor is ON after the Position-A compensating movement is completed.
515 The Drum is not in the Position-A nor in the Position-B when the Clamp motor starts to operate.
Error Type P04 [Ink overflow]

P04-xxx
!!System Error!!
Description
Press Reset Key
To reset
Press Reset Key after correcting the ink overflow condition. (No ink on the ink overflow sensor.)
display
The overflow sensor is ON for a set number of times in succession during the 10-millisecond-
513
interval overflow-sensor check.
Error Type P05 [Vertical print positioning pulse motor lock]

P05-xxx
!!System Error!!
Description
Press Reset Key
To reset
Press Reset Key or turn the power OFF and ON.
display
The vertical-centering sensor does not switch ON even when the vertical-positioning pulse motor
603
activated in the image-down direction for 5.0 seconds during vertical home positioning movement.
The vertical-centering sensor does not switch OFF even when the vertical-positioning pulse motor
604
activated in the image-up direction for 5.0 seconds during vertical home positioning movement.
Even though the vertical positioning motor stopped according to the vertical centering sensor
605
detection, the stopping position does not correspond with the programmed position.
612 The print positioning key is pressed with vertical-print-position information undefined.
13 - CZ180 / CV1860 Rev. 1.0


Error Type P08 [Communication error with CI]

P08-xxx
!!System Error!!
Description
Press Reset Key
To reset
Turn the power OFF and ON.
display
951 The file is not a correct RINC data.
Error Type P12 [Master disposal area motor lock]

P12-xxx
!!System Error!!
Description
Press Reset Key
To reset dis-
Press Reset Key.
play
301 Master compression motor lock when moving compression plate up.
The master compression HP sensor does not go OFF within 3 seconds after the master compres-
302
sion motor rotates in the reverse direction.
Master compression HP sensor does not go ON within 1 second after the master compression mo-
305
tor operates in the return direction.
Master compression HP sensor does not go OFF within 3 seconds after the master compression
306
motor operates in the compress direction.
Master-compression-motor encoder sensor count did not change as the master compression motor
309
activated in the compress direction and moved out from the home position.
The master compression HP sensor does not go ON even after 1 second after the master compres-
313
sion motor rotates in the compress direction.
Master-compression-motor encoder sensor count did not change within 10 milliseconds after the
316
master compression motor activated.
CZ180 / CV1860 Rev. 1.0 13 -


Error Type P13 [Cutter motor lock]

P13-xxx
!!System Error!!
Description
Press Reset Key
To reset
Press Reset Key.
display
Master-positioning sensor is ON when the print drum rotates through the preset angle following
205
master cutting.
221 The cutter HP switch and cutter stop position switch are both ON at the same time.
Cutter HP switch does not go ON within 450 milliseconds after the cutter home positioning operation
222
started.
Cutter HP switch does not go OFF within 500 milliseconds after the cutter operation started from
231
the HP position.
Cutter stop position switch does not go ON even after 2 seconds after the cutting movement
232
started.
Cutter stop position switch does not go OFF even after 500 milliseconds after the cutter HP
233
movement started.
234 Cutter HP switch does not go ON even after 2 seconds from the cutter HP movement started.
Error Type P17 [Solenoid counter not connected]

P17-xxx
!!System Error!!
Description
Press Reset Key
To reset
Connect the solenoid counter.
display
020 Master counter (solenoid counter) is not connected.
021 Copy counter (solenoid counter )is not connected.
Error Type P20 [Paper-ejection-section motor lock]

P20-xxx
!!System Error!!
Description
Press Reset Key
To reset
Press Reset key
display
Paper-ejection encoder sensor status does not change within 10 milliseconds after the paper-
437
ejection motor is activated.
13 - 10 CZ180 / CV1860 Rev. 1.0


Error Type P24 [Inking motor lock]

P24-xxx
!!System Error!!
Description
Press Reset Key
To reset dis-
Press Reset key or turn the power OFF and ON.
play
Inking-motor FG sensor status does not change within 20 milliseconds after the inking-motor is acti-
539
vated.
Error Type P93 [NET-C / NET-D hardware error]

P93-xxx
!!System Error!!
Description
Press Reset Key
To reset
Turn the power OFF and ON.
display
932 No reply from the network interface card while accessing to the network interface card.
Error Type P96 [Data not input]

P96-xxx
!!System Error!!
Description
Press Reset Key
To reset
Input the parameters using test mode.
display
171 TPH resistance value not input.
172 Scanner adjustment not completed.
CZ180 / CV1860 Rev. 1.0 13 - 11


Error Type P98 [Hardware error]

P98-xxx
!!System Error!!
Description
Press Reset Key
To reset dis-
Turn power OFF and ON.
play
No reply from optional SH3M PCB. If SH PCB signal is detected at machine power ON, but if the
002 PCB communication terminates and P98-069 error is detected, the error point is rewrote to this
P98-002 error message.
005 Hardware error
006 EEPROM check-sum error
025 Defective RF PCB (Unsuccessful initial communication with RF PCB).
034 Unable to write on EEPROM on the machine. (Cannot access EEPROM).
035 CRC error on EEPROM on the machine (Defective EEPROM data).
039 Incorrect EEPROM.
053 Unsuccessful data readout from the Memory setting (program, mode, user paper).
054 Unsuccessful data writing of the Memory setting (program, mode, user paper).
063 Test mode setting is beyond the adjustable range.
064 Communication error between SH PCB and MCTL PCB.
065 Communication error between SH PCB and MCTL PCB (01) - on MCTL PCB side.
074 Communication error between SH PCB and MCTL PCB (10) - on SH PCB side.
119 Defective image PCB (memory check error on the image processing IC).
121 Scanner adjustment error (1)
122 Scanner adjustment error (2)
245 Timeout error on master transfer during master-making (related to Write pulse motor).
246 Timeout error on master transfer during master-making (related to Load pulse motor).
934 Communication error between MCTL PCB and RF PCB. (on RF PCB side)
935 Communication error between MCTL PCB and RF PCB. (on MCTL PCB side)
938 EEPROM version down.
13 - 12 CZ180 / CV1860 Rev. 1.0


2) Jam Errors (Axx)
Error Type A01 [Master feed error]

A01-xxx
Description Master Mis-Feed
Pull Out Master Making Unit and Rewind Master Roll, then Reset Master in Place.
To reset Open the master-making unit and rewind the master material on the master roll, and then reset the
display master, or turn OFF the power and power back ON.
Master-positioning sensor does not go ON even after the write pulse motor is activated during the
201
master-positioning, master-cut, or master-loading operation.
Master-positioning sensor does not go OFF even when the write pulse motor is reversed during the
202
master-positioning or at start of master-making operation.
211 Master-positioning sensor is ON during standby.
214 Master-positioning sensor is ON at the start of master making.
Even though the Write pulse motor stopped, the pulse count did not match with the programmed
215
pulse count.
Error Type A02 [Master loading error]

A02-xxx
Description Master Loading Error
Pull Out Print Cylinder and Discard Master.
To reset
Pull out the print cylinder and set it back.
display
Master-loading sensor was OFF when the master was checked at a specified drum angle during
509
the master-loading operation.
Error Type A04 [Master disposal error]

A04-xxx
Description Master Disposal Error
Pull Out Print Cylinder and Discard Master.
To reset dis-
Pull out the print drum and push it back in.
play
303 Check Print Drum - Master removal error / Master disposal jam.
Error Type A05 [Master present in the master disposal area]

A05-xxx
Description Master Jammed in Disposal Unit
Pull Out Master Disposal Box and Remove Jammed Master
To reset dis- Pull out master disposal box and place it back after removing the jammed master in the master
play disposal area, or turn OFF the power and power back ON.
304 Master disposal box check request after master removal error or master disposal jam.
312 Master disposal jam sensor was ON at the start of the master making.
CZ180 / CV1860 Rev. 1.0 13 - 13


Jxx Error Display

Error Type A07 [Paper feed error]
Paper-ejection sensor was OFF when the paper should have arrived, and the paper sensor was ON
409
when the machine stopped (Paper misfeed).
412 Paper sensor was OFF when a paper misfeed was detected (paper misfeed).
418 The paper sensor was ON at the start of machine operation when the START button was pressed.
Jxx Error Display

Error Type A08 [Paper jam on print drum]
Paper-ejection sensor was OFF when paper should have arrived, and the paper sensor was OFF
410
when the machine stopped (paper jam on the print drum).
Jxx Error Display

Error Type A09 [Paper ejection error]
411 Paper-ejection sensor was ON when the paper should have left the paper-ejection sensor.
Paper-ejection sensor was ON at the start of machine operation when the START button was
417
pressed.
Jxx Error Display

Error Type A10 [AF original feed error]
102 The original is pulled out from the AF unit before the scanning is completed.
103 Original jammed under Original IN sensor.
107 Original does not arrive to the Original IN sensor.
Error Type A16 [Waiting for the master to be removed from the drum]
A16-xxx
Description Master Remains on Print Cylinder (Drum)
Pull Out Print Cylinder and Remove Master
To reset
Pull out the print cylinder (drum), remove the master around it and insert it back.
display
525 Waiting for the master to be removed from the print cylinder (drum).
13 - 14 CZ180 / CV1860 Rev. 1.0


Error Type A17 [Cutter error]

A17-xxx
Description System Error in Master Making Unit
Take Out Master and then Close Master Making Unit Cover
To reset dis-
Open the Master making unit, remove the master and close the master making unit.
play
Cutter HP switch is OFF when master-making starts, when the master material is set in the master
209
making unit, or when the machine goes into idle condition.
213 Master material is not set in position when the machine goes into idle condition.
Error Type A34 [Requesting for the master to be reset]

A34-xxx
Description Master Not Set in Place
Insert Lead Edge of Master into Master Entrance and Close Master Making Unit
To reset dis-
Open the Master making unit, re-insert the master material into the master making unit.
play
218 Reqesting for the leading edge of the master material to be set in the master making unit.
CZ180 / CV1860 Rev. 1.0 13 - 15


3) Option Errors (Bxx)
Error Type B22 [Job separator: Power off]

B22-xxx
Description !! Job Separator is OFF !!
Turn On Power Switch of it
To reset dis-
Press Reset Key and check and switch ON the power of Job Separator.
play
With the [Tape separation] function set ON, no power is supplied to the job separator when start
721
key is pressed.
After cluster-A signal turned ON, BUSY-signal stayed [L] more than 7 seconds. (Power to job sepa-
727
rator was turned OFF while the tape is being ejected.)
Error Type B23 [Job separator: No tape]

B23-xxx
Description No Paper Tape in Job Separator
Replace Tape Roll
To reset
Press Reset Key and set paper tape in Job Separator.
display
With the [Tape separation] function set ON, no tape detected in the job separator when the start key
722
is pressed.
723 No tape remains in job separator upon completion of the tape-ejection operation.
Error Type B24 [Job separator: Tape jam]

B24-xxx
Description Paper Tape Jam in Job Separator
Remove Paper Tape
To reset
Press Reset Key and remove the jammed tape.
display
724 Tape jam detected when the start key is pressed with the [Tape separation] function set to ON.
The tape-jam detection signal is [H] for more than 1.2 seconds after cluster-A signal turns ON.
725
(Tape misfeed).
Job separator tape-jam detection signal is [L] when the BUSY signal changes from [L] to [H] (or
726
after 7 sec. at [L]) after the cluster-A signal goes ON. (Tape misfeed).
13 - 16 CZ180 / CV1860 Rev. 1.0


Error Type B31 [Network cable not connected]

B31-xxx
Description !! No Linked Printer Detected !!
Check Cable Connection and Power Supply for Linked Printer
To reset
Press Reset Key and connect the network cable.
display
916 Network cable is not connected when the machine is powered ON.
Error Type B32 [NIC - Communication error]

B32-xxx
Description !! No Linked Printer Detected !!
Check Cable Connection and Power Supply for Linked Printer
To reset
Press Reset Key, and check the network cable and linked printer.
display
917 Communication error on the network.
Error detected by Network Interface Card (NIC) - NAK (no acknowledgement was received).
920
No reply from the other end, TCP/IP error, communication interrupted, etc.
Error Type B33 [IP address set up error]

B33-xxx
Description No IP Address Assigned to This Printer
Contact Your Network Administrator
To reset
Press Reset Key, and enter the IP address..
display
931 DHCP is ON, but DHCP server is not found.
CZ180 / CV1860 Rev. 1.0 13 - 17


4) Consumable Errors (Cxx)
Error Type C01 [Replace ink cartridge]

C01-xxx
Description No Ink
Replace Ink Cartridge
To reset dis-
Remove the empty ink cartridge and replace with a new one.
play
The ink sensor did not go ON even when inking was performed for a preset duration. (No ink de-
512
tected.)
563 Ink remaining amount is zero from the information on the RF-Tag.
574 Inkless error was detected 5 times consecutively on one same ink cartridge.
Error Type C02 [Replace master roll]

C02-xxx
Description No Master
Replace Master Roll
To reset
Remove the empty master roll and replace with a new one.
display
The master end was detected twice in succession at 10-milliseconds intervals during master
200
transport. (Master material is fully used from the master roll.)
240 Master remaining amount is zero from the RF-Tag information.
253 Masterless error was detected twice consecutively on one same master-roll.
Error Type C03 [Master disposal box full]

C03-xxx
Description Master Disposal Box is Full
Empty Master Disposal Box
To reset Remove master disposal box from the machine, throw away the disposed master from the disposal
display box and return the disposal box in the machine after an interval of over 5 seconds.
308 Master FULL sensor never went ON during the master compress action. (Mater disposal box full.)
The master disposal software counter counted 30 disposed masters. (Master disposal box full by
311
the software count.)
Error Type C04 [No paper on the Standard paper Feed Tray]
C04-xxx
Description
Add Paper
To reset
Add paper on the standard paper feed tray.
display
402 Paper detection sensor is OFF (not detecting paper).
13 - 18 CZ180 / CV1860 Rev. 1.0


5) Set Check Errors (Dxx)
Error Type D01 [Print drum not set]

D01-xxx
Description
Set Print Cylinder (Drum) in Place
To reset
Set the print drum in the machine.
display
Print drum is not set in the machine (drum connection signal, drum safety switch, and drum set
526
sensor are OFF.)
527 Print drum connection signal is OFF when the print drum was inserted in the machine.
528 Print drum safety switch is OFF when the print drum was inserted in the machine.
Print drum set sensor is OFF when the print drum was inserted in the machine (time-out: 5
529
seconds).
Print drum connection signal does not go OFF within 5 seconds after the print drum safety switch
went OFF when the print drum was pulled out.
530
Or, the print drum safety switch does not go ON within 5 seconds after the print drum connection
signal went ON when the print drum was inserted in the machine.
Error Type D02 [Incorrect print drum]

D02-xxx
Description Wrong-Type Print Cylinder Installed
Replace with Correct Type
To reset dis-
Set correct print drum in the machine.
play
532 Incorrect print drum is used.
Error Type D03 [Ink cartridge not set]

D03-xxx
Description
Install Ink Cartridge
To reset
Install ink cartridge in the print drum.
display
533 Bottle set switch is OFF.
Error Type D04 [Incorrect ink cartridge]

D04-xxx
Description Wrong-type Ink Cartridge Installed or Cannot Read Ink Info
Replace Ink Cartridge or Contact dealer/Riso office
To reset
Replace with correct ink cartridge.
display
534 Incorrect ink cartridge is used.
560 Ink RF-Tag is not detected on ink bottle.
561 Ink RF-Tag communication error (communication with the ink cartridge was interfered by noise).
562 Wrong ink cartridge information on the Ink RF-Tag.
564 Detected a mismatch in the Ink RF-Tag serial number.
575 RF-Tag software error.
CZ180 / CV1860 Rev. 1.0 13 - 19


Error Type D05 [Master not set]

D05-xxx
Description
Set Master in Place
To reset Insert leading edge of the master material into the master entrance and close the master making
display unit.
210 Master material is set in the machine before RF-Tag was detected by the machine.
Error Type D07 [Master disposal box not set]

D07-xxx
Description
Set Master Disposal Box in Place
To reset dis-
Set master disposal box in the machine.
play
310 Master disposal unit safety switch is OFF.
Error Type D08 [Master making unit not set]

D08-xxx
Description
Set Master Making Unit in Place
To reset
Insert the master making unit in the machine.
display
224 Master making unit is opened. (Master making unit safety switch is OFF).
Error Type D13 [Rear cover not closed]

D13-xxx
Description Rear Cover of Main Body is Off
Call Service
To reset Close the rear cover of the machine to activate the rear cover (serviceman safety)
display switch. [Field serviceman has to close and screw-on the rear cover]
009 The rear cover is opened. (Rear cover safety switch is OFF).
Error Type D17 [Incorrect master roll]

D17-xxx
Description Wrong-type Master Installed or Cannot Read Master Info
Replace Master Roll or Contact dealer/Riso office
To reset
Set correct master roll in the machine.
display
236 Incorrect master roll.
237 Master roll RF-Tag not detected.
238 Master roll RF-Tag communication error. (Communication interrupted by noise)
239 Incorrect information on the Master roll RF-Tag.
241 Mismatch in the Master roll RF-Tag serial number information.
256 Master roll RF-Tag software error.
13 - 20 CZ180 / CV1860 Rev. 1.0


Error Type D23 [AF Cover Not Closed]

D23-xxx
Description
Close the AF Cover
To reset
Close the AF cover.
display
177 The AF cover is opened.
CZ180 / CV1860 Rev. 1.0 13 - 21


6) Warning Errors (Exx : Serviceman Call Errors)
Error Type E02 [Maintenance call]

E02-xxx
Description !!Maintenance!!
Call Service
To reset
Press Reset Key, and also reset the maintenance call value setting by test mode.
display
Master counter reached the value set for the maintenance call (value set by test mode). [The
011 message appears when either the power is turned ON, the unit is reset, or when the machine
operation ended.]
Copy counter reached the value set for the maintenance call (value by set test mode). [The
012 message appears when either the power is turned ON, the unit is reset, or when the machine
operation ended.]
7) Warning Errors (Fxx : Others)
Error Type F01 [No master on print cylinder (drum)]

F01-xxx
Description No Master on Print Cylinder (Drum)
Make a New Master
To reset dis-
Make a new master with an original.
play
015 There is no master on the print drum at the start of printing.
Error Type F05 [Print quantiy under Minimum Print Quantity]

F05-xxx
Description
Enter Print Quantity Over The Programmed Minimum Value
To reset
Enter print quantity value over the programmed minimum value.
display
019 In master making, the print quantity selected is less than the minimum print quantity.
Error Type F21 [Next Original not set on AF for Multi-Up]

Description F21-xxx
To reset dis- Set original on the AF.
play Or press STOP key (time-out exists for pressing the STOP key).
032 Next original is not set on AF when multi-up is selected.
13 - 22 CZ180 / CV1860 Rev. 1.0


8) Parameter Errors (Hx)
Message H1 [Ink color setting]

H1-566
Description
Select the same color as the Print Cylinder (Drum) currently in use.
To reset dis-
Enter the required parameter value.
play
Message H4 [Master Density]

H4-242
Description
Select the standard density to be applied during master-making.
To reset dis-
Enter the required parameter value.
play
9) Errors Saved in Memory
Following six (6) Error Types are backed up in memory and these error messages cannot be reset by
turning OFF the power. The cause for the message must be solved to reset the error display.
Error Type Error Description

A04 Master removal error
A05 Master present in the master disposal area
A08 Paper jam on print drum

C01 Replace ink cartridge
C02 Replace master roll
C03 Master disposal box full
CZ180 / CV1860 Rev. 1.0 13 - 23


MEMO
13 - 24 CZ180 / CV1860 Rev. 1.0


CHAPTER 14: TEST MODE
CONTENTS
1. Operating Method....................................................................................2
1) Launching the Normal Test Mode..................................................2
2) Launching the Protected Area Test Mode......................................2
2. List of the Test Modes..............................................................................3
1) System & Panel Test Modes..........................................................3
2) Imaging & Scanning Test Modes....................................................6
3) Master-making & Master-disposal Test Modes.............................9
4) Paper-feed and Paper-ejection Test Modes.................................12
5) Print-drum & Print-adjustment Test Modes..................................14
6) Protected Area Test Modes..........................................................17
7) Test Modes for the Optional Unit (Job Separator)........................18
3. User Mode List.......................................................................................19
CZ180 / CV1860 Rev. 1.0 14 -


1. Operating Method
1) Launching the Normal Test Mode

To start Test Mode, switch ON the machine power while simultaneously pressing the left and right
keys of the vertical print positioning.
The firmware version number is displayed when the Test Mode is launched.
Press the Stop Key or Cancel Key to go into standby mode.
From the standby mode, enter the required test mode number and press Start Key to activate.
Press the Stop Key or Cancel Key to return back to the standby mode.
Enter next desired test mode number to continue using the test mode, or press the Reset Key for one
second to escape out from the Test Mode.
The Reset Key must be pressed (for 1 second) to escape out from the Test Mode only when the ma-
chine is in the standby mode of the test mode.
2) Launching the Protected Area Test Mode

Launch the machine into normal test mode and to the standby mode.
Enter the four digit password to go into the Protected Area Test Mode, which is 9874, and press the
Start Key. The Protected Area Test Mode is launched.
Enter the desired protected area test mode number and press the Start Key to activate.
To escape out from the Protected Area Test Mode, press the Stop Key or Cancel Key and then press
the Cancel Key for one second. This will return the machine back to the normal machine operating
condition.
14 - CZ180 / CV1860 Rev. 1.0


2. List of the Test Modes
1) System & Panel Test Modes
No. Sensors, switches Detection status

Solenoid counter connection
0002 Solenoid counter connected
signal
0003 24V A output signal 24V-A ON (24V output)
0004 24V B output signal 24V-B ON (24V output)
Switch ON (main unit rear cover is installed)
0005 Rear cover safety SW
Other safety switches must be ON for this check.
No. Unit check
Test Print A (checkered)
0080
Creates Test pattern 1 (Checker Flag)
Test Print B (cross stripes)
0081
Creates Test pattern 2 (Cross Lines)
Test Print C (Dot1)
0082
Creates Test pattern 3 (Dot 1 )
Test Print D (Dot2)
0083
Creates Test pattern 4 (Dot 2 )
Test Print E (Dot 1 x Dot 1)
0084
Creates Test pattern 5 (Dot 1 x Dot 1 )
Test Print F (Dot 2 x Dot 2 )
0085
Creates Test pattern 6 (Dot 2 x (Dot 2)
Test Print 18% dots
0086
Creates Test pattern B4 18% dots
Paper-Feed Test (continuous feeding)
Prints continuously.
0087 * The Speed key is enabled.
* If the rear cover safety switch is OFF, the operation begins when the rear cover safety switch is turned
ON within 10 seconds after the START key is turned ON.
Low-Speed Printing Operation
0088
Prints continuously at 15 rpm.
Continuous master-making & printing
Continuous master-making & printing with test mode master-making without using original on the AF
unit.
0090
* The printing quantity is set by Test Mode No. 0147.
* The test mode master-making type is selected by Test Mode No. 0148.
Unit Initialization
Initializes the mechanical moving units to their home positions.
0094 [ Scanner, thermal print head, compression plate, clamp units and
vertical print position.]
System Configuration Data Output

0095
Creates a master for the CI system data.
CZ180 / CV1860 Rev. 1.0 14 -


No. Data clear Details

Clearing Jam Status Data
This test mode can be used to temporary clear error display. For acutal
0110
Forcibly clears the jam. correction of the problem, the cause for the display should be corrected.
Consumables error displays cannot be cleared.
Clearing User Memory
0111 Initializes data in user area memory to the programming defaults
User area memory clear
Record all the settings before the test mode activation.
Clearing Normal Area Test-Mode Data Memory [MACHINE]
Initializes all normal area test mode settings on the machine EEPROM to
Normal area test mode memory their programming default values.
0112
clear for test modes on the The initializing is effective after rebooting the machine.
machine. The protected area test modes stay unchanged.
Record all the settings before the test mode activation.
Maintenance Count Clear (master making)
0113 Maintenance Call master count
Clears the master-making maintenance-call message.
clear
Maintenance Count Clear (printing)
0114 Maintenance Call copy count
Clears the printing maintenance-call message.
clear
No. Data check Details
0124 Machine Serial Number 1 Displays the left 4 digits of the machine serial number.
0125 Machine Serial Number 2 Displays the left 4 digits of the machine serial number.
Displays whether there is any Job Separator connection.
0128 Job Separator connection status
0: not connected 1: connected
Displays whether there is any NIC connection.
0129 NIC connection status
0: not connected 1: connected
MCTL PCB program version Displays Mechanical control PCB program version. Example: Displays
0130
display "0101" for Ver.1.01
0131 System program version display Displays ROSA program version. Example: Displays "0101" for Ver.1.01
Maintenance Call master-making
Displays the present master-making quantity done from the time the
0137 quantity display (total quantity at
Maintenance Call setting is initialized.
present.)
Maintenance Call print quantity Displays the present print quantity done from the time the Maintenance Call
0138
display (total quantity at present.) setting is initialized.
14 - CZ180 / CV1860 Rev. 1.0


No. Data setting

Maintenance - Master Count Entry
Description Selects the maintenance call count for master-making.
0143 Range: 0 to 9999 (0 to 999,900 master-making)
Setting Unit: 1 (100 master-making)
Default: 0 (No Entry)
Maintenance - Copy Count Entry
Description Selects the maintenance call count for printing.
0144 Range: 0 to 9999 (0 to 9,999,000 copies)
Setting Unit: 1 (1,000 copies)
Default: 0 (No Entry)
Print Quantity Selection (ref: Test Mode No.0090)
Selects the print quantity for the continuous master-making & printing
Description
0147 operation by Test Mode No. 0090.
Selectable range : 1 to 100 (1 to 100 prints)
Setting
Default : 3 (3 prints)
Master-Making Type Selection (ref: Test Mode No.0090)
Selects the type of image for the continuous master-making & printing
Description
operation by Test Mode No. 0090.
Selectable range : 0 to 6
0 : Image by Test Mode No.0080.
0148 2 : Image by Test Mode No.0082.
Setting 3 : Image by Test Mode No.0083.
5 : Image by Test Mode No.0085. (For now is No.0081)
6 : Image by Test Mode No.0086. (For now is No.0081)
Default : 1 (Image by Test Mode No.0081)
Counter Action Control
Stops both the mechanical & soft counter. Once the power is turn OFF and
Description
0155 turned back ON, the setting automatically changes back to Counter Active.
0: Stops the counter
Setting
1: Activates the counter (default)
Program Print Auto-Repeat Setting
Selection to keep the program printing active or to change to inactive after
Description
0161 one master-making with Auto-Print OFF.
0 : Stays active (default)
Setting
1 : Change to inactive
CZ180 / CV1860 Rev. 1.0 14 -


2) Imaging & Scanning Test Modes
No. Sensor switch check Detection status

0201 Original Det. Sensor Detecting (original present)
0210 Original IN Sensor Detecting (original present)
0211 AF Cover Set Sensor Detecting (AF cover closed)
No. Motor, solenoid Remarks
0260 AF Scanner lamp Switches ON/OFF scanner lamp
0261 AF Read Pulse Motor (CW) Rotates the motor in clockwise (normal) direction
0262 AF Read Pulse Motor (CCW) Rotates the motor in counter-clockwise (reverse) direction
0263 AF Stipper Solenoid Switches ON/OFF the solenoid

No. Unit check
AF Cycle Continuous Action
0284
Repeats the AF original feed action until the original runs out from the AF original feed tray.
No. Data setting

Line-Copy Slice Level Adjustment
Description Sets the slice level for line mode.
0340 Range : - 8 to + 8 (Larger valudes for lighter print.)
Setting Unit : 1
Default : 0
Auto Base Control (ABC) Slice Level Adjustment
Description Sets the slice level for ABC.
0341 Range : - 8 to + 8 (Larger valudes for lighter print.)
Setting Unit : 1
Default : 0
Shading Compensation Averaging
Range : 0 to +16 (0 = One type shading compensation only)
0342
Description Unit : 1
Default : 8 (Averages out values from 9 times shading compensation).
Auto Base Control (ABC) Slice Level Adjustment for Reduction Size Master-Making.
This test mode setting becomes effective for master-making in Line Mode, Auto Scanning
Density and Reduced Reproduction Size.
The purpose of this test mode is to prevent thin lines from disappearing when the
0343
Description reproduction size is reduced.
Range : - 8 to + 8 (Larger valudes for lighter print.)
Unit : 1
Default : -5
Halftone Curve Selection (Photo)
Description Selects the matrix forming the halftone-curve base for photo mode.
0350 Range: 0 to 8
Setting Unit : 1
Default : 4
Halftone Curve Selection (Duo)
Description Selects the matrix forming the halftone-curve base for DotDuo mode.
0352 Range : 0 to 8
Setting Unit : 1
Default : 4
14 - CZ180 / CV1860 Rev. 1.0


Edge Emphasis Threshold Offset for Line-Mode printing (for master-making density setting 1 to 2)
Description Selects the matrix forming the halftone-curve base
0364 Range : 0 to 7
Setting Unit : 1
Default : 1
Edge Emphasis Threshold Offset for Line-Mode printing (for master-making density setting 3 to 5)
0365 Range : 0 to 7
Setting Unit : 1
Default : 3
Edge Emphasis Threshold Offset for Line-Mode printing (for master-making in Duo mode)

0366 Range : 0 to 7
Setting Unit : 1
Default : 2
Edge Emphasis Threshold Offset for Line-Mode printing (for master-making in Pencil original mode)

0367 Range : 0 to 7
Setting Unit : 1
Default : 2
ABC Edge Emphasis Filter when ABC is activated.
Selects the matrix forming the halftone-curve filter when ABC is activated (Line Mode, Density
Description
at auto).
0369
Range : 0 to 255
Setting Unit : 1
Default : 205
ABC Edge Emphasis Filter when ABC is activated (under the border-line)
Description
at auto) for when the border-line is under the setting made by Test Mode No.0369.
0370
Range : 0 to 7
Setting Unit : 1
Default : 1
ABC Edge Emphasis Filter when ABC is activated (over the border-line)
Description
at auto) for when the border-line is over the setting made by Test Mode No.0369.
0371
Range : 0 to 7
Setting Unit : 1
Default : 3
ABC Slice Level (super-black)
Description Sets the slice level when super-black histogram is produced in prescanning.
0372 Range : -16 to +16

Setting Unit : 1
Default : 0
CZ180 / CV1860 Rev. 1.0 14 -


AF Horizontal Scan Position Adjust
Description Adjusts the original horizontal scan position on the AF unit.
Range : -30 to +30 (-3.0mm to +3.0mm)

0380
(+ is to the left )
Setting
Unit : 5 (0.5mm)
Default : 0 (0mm)
AF Scan Start Position Adjust
Description Adjusts the original scanning start position on the AF unit (amount of top image omitted)
Range : -20 to +20 (-2.0mm to +2.0mm)

0381
(+ omits more top image of the original and moves the printed image
Setting 　　　　　　　　 up)
Unit : 1 (0.1mm)
Default: 0 (0mm)
AF Scanning Speed Adjustment
Adjusts the original scanning speed on the AF unit (Adjust the speed of AF Read Pulse
Description
Motor)
Range : -100 to +100 (-10.0% to +10.0%)
0382 ( + elongates the image)
Unit : 1 (0.1%)
Setting
Default : 0 (0%)
Rough reference in changing the elongation or shrinkage by 1mm is:
A3=0.2%, B4=0.3%, A4=0.3%, Ledger=0.2%, Legal=0.3%
Center dotted line
Adds center dotted line on the prints during master-making or printout from linked printer.
(The dotted line is added only when the original is scanned on the AF unit.)
Description Make sure to return the parameter setting back to [ 0 ] after using setting [ 1 ] to make
0386
the center line for an adjustment. Otherwise the machine makes the center dotted line on
all printings made from AF scanning.
0: No center dotted line (default)

Setting
1: Adds center dotted line
14 - CZ180 / CV1860 Rev. 1.0


3) Master-making & Master-disposal Test Modes
No. Sensor switch check Detection status
0400 Master-positioning sensor Sensor light reflected (Master present) / No reflection ( No master)
0402 Master end sensor Sensor light blocked (Master end seal detected)
0403 Cutter HP Switch Switch pressed (Cutter at home position)
0404 Cutter stop position switch Switch pressed (Cutter at end position)
Switch pressed (Master-making unit upper cover is closed).
0409 Master-making-unit safety SW
0420 Master-disposal jam sensor Sensor light is not blocked (Master is detected - jammed)
0421 Master-compression HP Sensor Sensor light blocked (Master compression plate at HP)
0422 Master disposal box FULL sensorSensor ON (Master disposal box FULL)
Switch ON (Master-Disposal Box set in position).
0423 Master-disposal BOX safety SW
Master-compression motor FG
0425 Sensor light blocked (Encoder disc is detected)
sensor
0426 Master-removal motor FG sensorSensor light blocked (Encoder disc is detected)
No. Motor, solenoid Remarks
Write pulse motor in feed
0462 Rotates in master feeding direction (clockwise direction)
direction
Write pulse motor in return
0463 Rotates in master returning direction (counter-clockwise)
direction
Load pulse motor in feed
0464 Rotates in master feeding direction (clockwise direction)
direction
Write pulse motor + Load pulse Rotates both the Write & Load pulse motors in master feed direction
0466
motor in feed direction (clockwise direction)
Master removal motor in feed Rotates in the direction to feed the removed master towards the master
0470
direction disposal box (clockwise direction)
No. Unit check
Cutter motor 1 cycle motion
0480
Performs one cutting motion.
Master compression plate home positioning
0490
Moves master compression plate to the home position.
Master compression plate continuous movement
0493
Repeats disposal compression action with interval of 3 seconds between the each.
Cutter motor ON action (cut direction)

[This test mode is for checking the motor as one independent part. Disconnect the motor from the cutter unit
0494
before activation.]
Rotates the cutter motor in the cut direction (maximum 10 seconds)
Master compression motor ON action (cut direction)

[This test mode is for checking the motor as one independent part. Disconnect the motor from the master
0495
disposal unit before activation.]
Rotates the master compression motor in the cut direction (maximum 10 seconds)
CZ180 / CV1860 Rev. 1.0 14 -



0521 TPH thermistor temperature data Displays the temperature of the TPH thermistor in [degrees Celsius]
Displays the voltage applied to the TPH when the power to the TPH is
0524 TPH power voltage
switched ON. (The display is voltage x 100. Example: 10V=1000.)
No. Data setting
Master Leading-Edge Position Adjust
Adjusts return amount of the master material from the Master positioning sensor after the master
Description is set or master cutting operation is made. The pulse is counted from the time the Master
positioning sensor no longer detect the master leading edge.
0540
Range : 0 to 100 (0mm to +10.0mm)
(+ value returns the master material further back from the sensor)
Setting
Unit : 1 (0.1mm)
Default : 50 (5.0mm)
Write start-position adjustment
Adjusts the master-making start position on the master material by changing the rotation
Description amount of the Write pulse motor in CW or CCW direction before the write-signal goes on. (This
adjustment does not affect the master-clamp-amount.)
Range : -50 to +50 (-5.0mm to +5.0mm)

0541 (+ values return the master material back more before the write signal
goes on. The master-making starts from closesr to the leading edge of
Setting the master material. As a result, the printed image position on the paper
comes up.)
Unit : 1 (0.1mm)
Default : -5 (-0.5mm)
Master-making length adjustment
Description Adjusts the master-making area length.
Range : -100 to +100 (-10.0mm to +10.0mm)
0542
(+ values increase master-making area length)
Setting
Unit : 1 (0.1mm)
Default : 0 (0mm)
Master-clamp-amount adjustment
Adjusts the master-clamp amount under the clamp plate during master loading onto the drum.
Description
(This adjustment affects the master-write-start-position)
0543 Range : -100 to +100 (-10.0mm to +10.0mm)
(+ values increase clamping amount)
Setting
Unit : 1 (0.1mm)
Default : 10 (1.0mm)
Master cut length adjustment
Description Adjusts the total length of one master (changes the master cut timing against the drum angle).
Range : -200 to +200 (-20.0mm to +20.0mm)
0544
(+ values increase the master length).
Setting
Unit : 1 (0.1 mm)
Default : -35 (-3.5mm)
Master-making speed adjustment (Image elongation & shrinkage)
Description Image elongation and shrinkage in making master. (Adjusts the speed of the write pulse motor.)
0547 Range : -100 to +100 (-10.0% to +10.0%)

( + values elongate the image in master making.).
Setting
Unit : 1 (0.1%)
Default : -5 (-0.5%)
14 - 10 CZ180 / CV1860 Rev. 1.0


Thermal Print Head (TPH) over-heat temperature
Sets the temperature reference parameter to judge TPH over-heat. If the machine detects the
TPH temperature to be above this parameter, the machine displays a message and stops the
Description
master-making job.
0552 Turning the machine power OFF and then ON will reset the error message.
Range : 0 to 255 (0 degrees Celcius to 255 degrees Celcius)

(Master compression plate 65° to 100° from HP position).
Setting
Unit : 1 (1 degrees Celcius)
Default : 45 (45 degrees Celcius)
Thermal Print Head (TPH) over-heat temperature detection Enable or Disable selection.
Description Selection of enabling or disabling the TPH over-heat detection by Test Mode No.0552.
0553 Range : 0 or 1
Setting 0 = Disable 1=Enable
Default : 1 (Enable)
Master return amout after cutter blade disc cuts the master and stops at the cutter-stop-position.
Sets the master return amout after cutter cuts the master and stops at the cutter-stop-position,
Description before the cutter returns to the HP position. (This is to prevent the leading edge of the master
from jamming on the cutter blade disc when the blade returns to the HP position.)
0554
Range : -36 to +36 (-3.6mm to +3.6mm)
(+ value returns the master material away from the cutter unit in addition to the standard return
Setting amount programmed.)
Unit : 1 (0.1mm)
Default : 0 (0mm)
Master removal motor speed selection
Description Selects the master-disposal-motor speed in relation to the print drum rotation speed.
0578 Range : 0 to 2
0: Same speed as the print drum speed.
Setting
1: 10% faster than the print drum speed. (default)
2: 20% faster than the print drum speed.
Master disposal box FULL software count Enable or Disable selection.

Description Selection of enabling or disabling the software count FULL detection.
0585 Range : 0 or 1
Setting 0 = Disable 1=Enable
Default : 1 (Enable)
CZ180 / CV1860 Rev. 1.0 14 - 11


4) Paper-feed and Paper-ejection Test Modes

0600 Paper detection sensor Sensor light reflected (paper detected)
Sensor light blocked (Sensor detecting paper feed tray at maximum up
0602 Elevator upper-limit sensor A
position)
Sensor light blocked (Sensor detecting paper feed tray at maximum down
0604 Elevator lower-limit sensor
position)
0605 Paper sensor Sensor light blocked (paper detected)
0606 Paper-ejection sensor Sensor light blocked (paper detected)
0612 Paper-ejection FG sensor Sensor light blocked (detecting encoder disc)
No. Motor solenoid system Remarks
0660 Paper ejection motor Rotates the motor.
0661 Suction fan Activates the fan.
0662 Separation fan Activates the fan.
No. Unit check
Paper feed tray maximum up positioning
0681
Raises the paper feed tray to the maximum up position by pressing START key.
Paper feed tray elevation up & down
0682
Raises and lowers the paper-feed tray repeatedly until STOP button is pressed.
Paper feed tray maximum down positioning
0683
Lowers the paper feed tray to the maximum down position by pressing by pressing START key.
Paper-feed clutch ON/OFF action
0688
Presses START key to turn ON the clutch. The clutch automatically switches off after 10 seconds.
Paper sensor sensitivity automatic adjustment
0705 Automatically adjusts the paper sensor sensitivity by activating the test mode with one clean sheet of
white paper of which the operator normally uses.
Elevator motor ON action
0708 Rotates the elevator motor for 10 seconds.

[This test mode is for checking the motor as one independent part. Disconnect the motor from the cutter
unit before activation.]
0722 Paper sensor Displays the A/D value of the paper sensor.
No. Data setting
Paper-feed-clutch ON angle
Description Adjusts the drum angle timing for activating the paper-feed clutch.
0741 Range : -200 to +200 (-20.0° to +20.0°)
(+ values delay clutch ON timing )
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
Paper-feed-clutch OFF angle
Description Adjusts the drum angle timing for deactivating the paper-feed clutch.
0742 Range : -200 to +200 (-20.0° to +20.0°)
(+ values delay clutch OFF timing )
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
Paper feed retries after one paper feed action on 1st paper feed area.
Sets the number of times the 1st paper feeding is tried when no paper feed
Description
occurs.
Range : 1 to 3
1: No paper feed retry action. (default)
The machine displays paper feed jam on the first
0743 paper feed try.
2: One more paper feed action.
Setting
Paper jam display if no paper feeds after second
paper feed try.
3: Two more tries.
Paper jam display if no paper feed after third
paper feed try.
14 - 12 CZ180 / CV1860 Rev. 1.0


Paper feed jam detection angle. (Paper feed jam at Paper sensor)
Adjusts the drum angle timing for detecting the paper feed jam by paper
Description sensor. (Paper IN)
0751
Range : -200 to +200 (-20.0° to +20.0°)
Setting Unit : 5 (0.5°)
Default : 0 (0°) (+ values delay detection timing )
Paper ejection jam detection angle (1).
Description Adjusts the drum angle timing for the Paper ejection sensor to check the
0753 paper to come.
Range : -500 to +500 (-50.0° to +50.0°)
Paper receiving jam detection angle (2).
Adjusts the drum angle timing for the Paper ejection sensor to check the
Description
paper to go out.
0754
Range : -500 to +500 (-50.0° to +50.0°)
Paper-ejection motor speed adjustment (Proof-Print)
Description Speed ratio between the suction belt and drum.
0: 1.59 times the drum speed.
0755 1: 2.19 times the drum speed.
Setting 2: 2.39 times the drum speed.
3: 2.79 times the drum speed. (default)
Paper-ejection motor speed adjustment (Print speed No.1)
3: 1.39 times the drum speed. (default)
Setting 2: 1.19 times the drum speed. (default)
Elevator motor overcurrent detection ON/OFF selection
Description ON or OFF of the Elevator motor overcurrent detection.
0776 Range : 0 or 1
Setting 0: OFF - No detection
1: ON - Detection (default)
CZ180 / CV1860 Rev. 1.0 14 - 13


5) Print-drum & Print-adjustment Test Modes

0800 Position-A sensor Blocked (detection plate detected) Drum is at position-B.
0801 Main motor FG sensor Blocked (detection plate detected)
0802 Main-motor limit sensor Blocked (encoder disc detected)
0803 Clamp sensor Blocked (disc detected)
0806 Master loading sensor Light reflected (master on the drum)
0809 Ink sensor In contact with ink (ink present )
0810 Overflow sensor In contact with ink (ink present )
0811 Ink bottle set switch Switch pressed.
0812 Inking motor FG sensor Blocked (encoder disc detected)
0816 Drum free rotation SW Pressed
0819 Print-drum connection signal Connected
Switch ON (drum installed).
0820 Print-drum safety switch
0831 Vertical-Centering Sensor Blocked (detection plate present)
0836 Drum set sensor Blocked (Drum installed)
No. Motor solenoid system Remarks
0861 Main-motor action (30 rpm) Print drum rotation at speed of 30rpm.
Clamp-motor action (Normal
0863 Clamp motor rotates in the normal (CCW) direction.
direction)
Clamp-motor action (Opposite
0864 Clamp motor rotates in the opposite (CW) direction.
direction)
No. Unit check
Variable print-drum rotation
0880
Print speed key changes the drum rotation speed.
Position-A action of the print drum
0881
Stops the print drum at position-A.
Inking motor ON action
0882
Activates the inking motor for 10 seconds.
Clamp home positioning action
0883
Resets the clamp unit to the home position.
Clamp unit cycle action (3 step cycle)
Make sure to bring the print drum to Position-A by test mode No. 0881 before activating this test mode to
prevent machine damage.
0884 Press START key each time to perform the operations specified below.
Step 1: From clamp plate closed position to clamp open.
Step 2: From Clamp open position to Position-A compensation action.
Step 3: From Position-A compensation action to clamp closed position.
Pressure solenoid ON/OFF action.
0886 Press START key to switch ON the pressure solenoid. The solenoid switches OFF automatically 10
seconds later.
Print drum inking action
Performs the inking operations in following sequence by one press of the START key:
1. Pumps in the ink into print drum while rotating the drum until the Ink Sensor detects Ink,
0887 without pressure roller touching the print drum.
2. Makes a confidential master on the print drum.
3. From the time the ink sensor detects the ink again, the print drum makes 10 rotations
with the Pressure Roller pressing against the print drum.
4. The print drum stops at Position-B.
Print drum ink-drainage action.
Performs the ink drainage from the print drum in following sequence by one press of the START key:
0888 1. Makes TPH test mode image on the master and wraps around the print drum.
2. Printing is started with no inking motion and with the ink sensor deactivated.
3. The printing is continued until the STOP key is pressed.
4. The print drum stops at Position-B.
14 - 14 CZ180 / CV1860 Rev. 1.0


Machine Position-B stop. (The position in which the print drum can be removed from the machine.)
0892
Stops the print drum at machine Position-B. (The test mode can be activated with or without print drum
in the machine.)
Vertical-centering action
0900
Moves the vertical print position to the home (center) position.
Vertical print position one cycle action.
0901 Makes one cycle vertical print positioning movement. (Maximum to each way and back to home
position)
0921 Print-drum angle display Displays the present print-drum angle. (example: 1800 = 180°)
Print-drum ink temperature Displays the temperature of the ink in the print drum in degrees Celsius [°
0923
display C].
Displays the amount of ink left in the ink bottle in percentage (%) [Ink TAG
0925 Ink remaining volume display
information]
Inking motor FG count Displays the inking motor FG count value read from the ink bottle tag. (1
0926 (Displays 10,000th count count = 0.1 ml)
number) Example: For the 12,648 FG count, [ 9 ] is displayed.
Inking motor FG count Displays the inking motor FG count value read from the ink bottle tag. (1
0927 (Displays up to 1,000th count count = 0.1 ml)
number) Example: For the 12,648 FG count, [ 2648 ] is displayed.
No. Data setting

Master loading sensor detection timing adjustment
Description Adjusts the angle to detect master on the print drum by master loading sensor.
0940
Range : -200 to +100 (-20.0° to +10.0°)
(+ delays the detection timing))
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
Print-drum Position-A adjustment
Description Adjusts the print-drum Position-A stop position.
Range : -40 to +40 (-4.0° to +4.0°)
0941
(+ moves drum forward in over-run direction)
Setting
Unit : 5 (0.5°)
Default : -20 (-2.0°)
Print-drum position-B adjustment
Description Adjusts the print-drum Position-B stop position.
Range : -40 to +40 (-4.0° to +4.0°)
0942 (+ moves drum forward in over-run direction from machine Position-B, which is 270 degrees
Setting from Position-A.)
Unit : 5 (0.5°)
Default : -20 (-2.0°)
CZ180 / CV1860 Rev. 1.0 14 - 15


Inking time adjustment (In normal printing)

Sets the timer for the Replace Ink Bottle message to come out after the Ink sensor stops
Description
detecting the ink bead in the Drum.
0943
Range : 1 to 60 (1 second to 60 seconds)
Setting Unit : 1 (1 second)
Default : 15 (15 seconds)
Inking time adjustment (Right after replacing the ink bottle)
Sets the timer for the Replace Ink Bottle message to come out after the Ink sensor stops
Description
detecting the ink bead in the Drum.
0944
Range : 5 to 60 (5 seconds to 60 seconds)
Setting Unit : 1 (1 second)
Default : 30 (30 seconds)
Ink overflow detection frequency adjustment
Sets the number of detection times for the overflow sensor to determine that an ink overflow
Description
has occurred in the print drum.
0945
Range : 1 to 200 (1 time to 200 times)
Setting Unit : 1 (1 time)
Default : 50 (50 times)
Clamp unit hope position stop timing adjustment.
Sets the Clamp motor [stop] timing when the Clamp sensor status changes from OFF to ON
Description
and then finally to OFF.
0952
Range : 0 to 400 (0 milisecond to 400 miliseconds)
Setting Unit : 10 (10 miliseconds)
Default : 200 (200 miliseconds)
Clamp unit clamp-plate-open-action-position stop timing adjustment
Description Sets the Clamp motor [stop] timing when the Clamp sensor status changes from OFF to ON.
0953 Range : 350 to 950 (350 milisecond to 950 miliseconds)

Setting Unit : 10 (10 miliseconds)
Default : 550 (550 miliseconds)
Vertical print position HP adjustment.
Description Sets the HP (center) position of the vertical print position.
Range : -50 to +50 (-5.0 mm to +5.0 mm)
0970 (+ values move the printed image up)
Setting
Unit : 1 (0.1 mm)
Default : 0 (0 mm)
14 - 16 CZ180 / CV1860 Rev. 1.0


6) Protected Area Test Modes

< With the machine in normal test mode at standby mode, enter 9874 and press the Start Key to enter
into the Protected Area Test Mode. >
No. Data setting

TPH master-making horizontal position adjustment
Description Sets the TPH master-making position to the center
1233 Range : -23 to +23 (-2.3mm to +2.3mm)

(+ values bring the master-making image to the left)
Setting
Unit : 1 (0.1mm)
Default : 0 (0mm)
TPH resistance input
Description Sets TPH resistance.

1234
Range : 1200 to 2200 (1200 ohm to 2200 ohm)
Setting Unit : 1 (1 ohm)
Default : 1200 (1200 ohm)
CZ180 / CV1860 Rev. 1.0 14 - 17


7) Test Modes for the Optional Unit (Job Separator)

3100 Job separator tape jam sensor Jammed tape is detected
Job separator tape detection

3101 Tape is detected
sensor
3102 Job separator power switch Power is supplied to the Job separator
3103 Job separator connection signal Job separator is connected
No. Unit check
Tape output
3140
Outputs one tape. (The stamping action by Test Mode No.3170 applies.)
No. Data setting
Stamping quantity
Sets number of times the Stamper stamps per one tape cut.
(This test mode is active only for stamping action check by serviceman when using Test
Description
Mode No.3140 to check tape output.) This test mode parameter setting is inactive in normal
3170
machine usage.)
0: No stamping (default)
Setting 1: One stamping
2: Two stamping
Activate or deactivate the tape jammed message
Description Activates or deactivates the Tape Jam message while using the Job Separator.
3171
0: Does not indicate the jammed message on operation panel.
Setting
1: Indicates the jammed message on operation panel. (default)
14 - 18 CZ180 / CV1860 Rev. 1.0


3. User Mode List

Given below is the list of User Modes. The blue-colored shaded selection are the default settings.
NO. DESCRIPTION SELECTION
1 2 3
1 Printing Speed _ _ _
(60 rpm) (90 rpm) (130 rpm)
2 Auto Process OFF ON _ _ _ _
9
3 Scanning Contrast 1 2 3 4 5
(AUTO)
4 2-UP Waiting Time OFF 15 sec. 30 sec. _ _ _
5 Auto Reset Time OFF 3 min. 5 min. _ _ _
Minimum Print Quantity

6 (When activated by Test OFF 10 20 30 40 50
Mode)
7 Buzzer Sound Level 2 Level 1 Level 0 _ _ _
8 AF Auto Master Making OFF ON _ _ _ _
Job Separator
9 OFF ON _ _ _ _
(When the unit is connected)
10 Idling OFF ON _ _ _ _
Weak Medium Strong

11 Separator Fan OFF _ _
(20%) (50%) (100%)
30 Copy Counter Refer to the User Guide
31 Master Counter Refer to the User Guide
User Mode Clear

99 Press [ 99 ], then [ + ] key, then [ Start ] key.
(Initialize to default)
= Program default setting.
CZ180 / CV1860 Rev. 1.0 14 - 19


MEMO
14 - 20 CZ180 / CV1860 Rev. 1.0


CHAPTER 15: ELECTRICAL COMPONENTS
CONTENTS
1. Motors, Fan, Solenoid & Clutches...........................................................2

2. Sensors....................................................................................................4
3. Switches & Sensor...................................................................................6
CZ180 / CV1860 Rev. 1.0 15 -


1. Motors, Fan, Solenoid & Clutches
AF read pulse motor AF stripper solenoid
Load pulse motor

Master compression motor
Clamp motor
Elevator motor
Paper feed clutch
Print positioning motor
Write pulse motor
Main motor Cutter motor
Pressure solenoid Inking motor

Sparation fan
Suction fan
15 - CZ180 / CV1860 Rev. 1.0


Motor
Part Name Function Test Mode
AF Read pulse motor Rotation of AF Pickup, Stripper & Feed rollers. 0261
0863 &
Clamp motor Movement of Clamp cam & Position-A compensation plate.
0864
Inking motor Inking pump drive 0882
Elevator motor Elevation of Paper feed tray. 0682
Cutter motor Cutter movement 0480
Load pulse motor Rotation of Load roller & Master loading roller. 0464
0462 &
Write pluse motor Rotation of Write roller.
0463
Paper ejection motor Suction belt drive. 0660
Main motor Main drive of the machine. 0861
Print positioning motor Changes the vertical print position. 0901
Master compression motor Master compression action in Master disposal box. 0493
Master removal motor Rotates the master removal rollers. 0470
Fan, Solenoid, Clutch

Part Name Function Test Mode
AF stripper solenoid Original shutter movement 0263
Separation fan Assists removing master from the print drum. 0662
Suction fan Suction of the paper onto the transfer belt. 0661
Pressure solenoid ON/OFF of vertical movement of the Pressure roller. 0886
Paper feed clutch Rotation of Scraper & Pickup rollers. 0688
CZ180 / CV1860 Rev. 1.0 15 -


2. Sensors
Image scanner Original detection sensor

Master removal motor FG sensor Master positioning sensor
Master removal jam sensor Original IN sensor
Master end sensor AF Cover set sensor
Position-A sensor
Clamp sensor
Master removal FULL detection sensor
Master loading sensor

Master compression HP sensor
Upper limit sensor
Vertical print positioning

HP sensor
Lower limit sensor
Paper detection sensor

RFID (master)
Inking motor FG sensor
Drum set sensor
RFID (ink)
Paper sensor (send)
Paper sensor (receive) Thermal print head
Paper ejection motor FG sensor
15 - CZ180 / CV1860 Rev. 1.0


Sensors
Parts Name Sensor Type Function
Upper limit sensor Interrupt Paper feed tray upper limit detection
Paper detection sensor Reflective Paper on the paper feed tray detection
Paper sensor Transmit First paper feed status detection
Drum set sensor Interrupt Print drum lock detection
Paper ejection sensor Reflective Paper ejection status detection
Paper ejection motor FG sensor Interrupt Paper ejection motor speed detection
Inking motor FG sensor Interrupt Inking motor rotation status detection
Position-A sensor Interrupt Print drum position-A detection
Clamp sensor Interrupt Clamp unit movement detection
Lower limit sensor Interrupt Paper feed tray lower limit detection
Vertical print positioning HP sensor Interrupt Vertical print position center detection
Master removal motor HP sensor Interrupt Master removal motor speed detection
Master compression HP sensor Interrupt Master compression plate HP detection

Master removal FULL detection
Interrupt Master disposal box FULL detection
sensor
Master removal jam sensor Actuator Master removal status detection
Master loading sensor Reflective Master on the print drum detection
AF Cover set sensor Interrupt AF upper cover open/close detection
Original IN sensor Reflective Original positioning detection
Original detection sensor Actuator Original on the AF unit detection
Master positioning sensor Reflective Master positioning detection & Master cut detection
Master end sensor Interrupt Master roll end detection
CZ180 / CV1860 Rev. 1.0 15 -


3. Switches & Sensor
Cutter HP switch Master making unit safety switch
Cutter stop position switch

Drum safety switch
Ink bottle set switch

Ink sensor & Overflow sensor
15 - CZ180 / CV1860 Rev. 1.0


Other Switches & Sensors
Part Name Function Test Mode No.
Rear cover safety switch Rear cover detection. 0005

Master disposal box and Master disposal unit set detection.
Master removal unit safety switch 0423
Also acts as interlock switch.
Drum safety switch Print drum set detection. Also acts as interlock switch. 0820
Master making unit safety switch Master making unit set detection. Also acts as interlock switch. 1409
Cutter HP switch Cutter home position detection. 0403
Cutter stop position switch Cutter stop position detection. 0404
Ink bottle set switch Ink bottle set detection. 0811
Ink sensor Ink bead (in the print drum) status detection. 0809
Overflow sensor Ink overflow in the print drum detection. 0810
CZ180 / CV1860 Rev. 1.0 15 -


MEMO
15 - CZ180 / CV1860 Rev. 1.0


CHAPTER 16: WIRING DIAGRAMS
CONTENTS
1. Power Supply PCB (PHOTOGRAPH).....................................................2

2. Mechanical Control PCB (PHOTOGRAPH).............................................3
3. Connection between PCBs......................................................................4
4. Power Supply...........................................................................................5
5. Main Components Area...........................................................................6
6. CN8 and CN12 of Mechanical Control PCB............................................7
7. Print Drum Area.......................................................................................8
8. Master Making Area.................................................................................9
9. Master Removal Area............................................................................10
10. Paper Ejection Area...............................................................................11
11. Operation Panel Area............................................................................12
12. Options..................................................................................................13
13. Fuses .....................................................................................................14
CZ180 / CV1860 Rev. 1.0 16 -


1. Power Supply PCB (PHOTOGRAPH)
16 - CZ180 / CV1860 Rev. 1.0


2. Mechanical Control PCB (PHOTOGRAPH)
Note: CV1860 Mechanical Control PCB differs from that used on CZ180.
The photograph given below is that used on CZ180.
[ Photograph of CZ180 Mechanical Control PCB ]
CZ180 / CV1860 Rev. 1.0 16 -


Overall Wiring Diagram
Main Unit Wiring

Diagram: 042-50000-07
CN19 CN11 CN6 Paper Ejection Area Wiring

Master-Making Rear Diagram: 042-50000-06
FRONT-IL
Pulse Motor Bottom
Paper Ejection Area
CN5
DC Motor, Clutch
CN9
CN15
DEBUG

Master Removal Area
CN7
CN14 Master Removal Area Wiring
Diagram: 042-50000-08
3. Connection between PCBs
DEBUG I/F
RISO Inc. Technical Services & Support

Front
CN8
Front Area Wiring CN22
Diagram: 042-50000-05
RFID DOWNLOAD
RFID Operation Panel Wiring

Panel I/F
CN1
Diagram: 042-50000-09
CN12
CN20
PROGRAM-DOWNLOAD
16 -
Print Drum Print Drum Wiring
CN21
Diagram: 042-50000-04
MECHANICAL CONTROL PCB
042-50500
to Main Motor
MECHANICAL CONTROL PCB (C)
042-50503 Master Making Unit
CN6
CN10
(Upper Rear)
Master Making Unit Wiring
Power Control Diagram: 042-50000-03
CN3
CN4
CN2
Contact Image Scanner (CIS)
Power Supply Area
CN17
Wiring diagram 042-50000-02
CN7
Power Input
CN1
CN13
TPH
CN18
CN5 CN9 RIP-VIDEO Job Separator SH I/F

CN16 CN3 CN2
Options Wiring Diagram: 042-50000-10
CZ180 / CV1860 Rev. 1.0

US.RISO.COM
Power Supply Area
Interlock Wire Harness 042-53008
4. Power Supply
XR4P-Y 04 Main Motor Relay 24V 15

03 N.C Diagram: 042-50000-07
Image Control PCB Power (not used) CN7 02 N.C
01 Main Motor Relay Drive 18
CZ180 / CV1860 Rev. 1.0

GND
(Mechanical Control PCB CN19)
Bottom Rear Wire Harness 042-53004 01 VH4P
+5.1V 02
Main Motor FG Sensor
GND

XR3P-Y 03
CT3P Relay Connector CN8
03 +24V-A 04
01 GND
Diagram: 042-50000-07 02 Photo Interrupt
02 OUT
(Mechanical Control PCB CN6) 01 Type Master Making Unit Wire Harness 042-28057
03 VCC
01 -S 01
DF1B20P 02 GND 02
Main Motor Wire Harness 042-53010
03 GND 03
VL2P VL2P 04 GND 04
blue M-OUT(-) 01
01 01 05 GND 05
DC red M-OUT(+) 02
02 02 CN3 06 GND 06

07 GND 07
08 N.C
Main Motor 09 N.C
10
N.C Diagram: 042-50000-03
CN5 (TPH Power)
11 N.C
12 N.C
13 N.C
Mechanical Control PCB Power Wire Harness 042-53014 14 Vh 08
15 Vh 09
16 Vh 10
CZ10P-Y 01 GND 10 17 Vh 11
02 /POWER FAIL 09 XR10P-Y 18 Vh 12
03 /TPH_CTL 08 19 Vh 13
04 /24V-ON 07 20 +S 14
05 SLEEP 06
06 DA CLK 05
POWER SUPPLY
CN4 07 DA LAT 04 CN2
16 -
08 DA DAT 03
PCB
09 GND 02 PS15-N200
10 PWM 01
Option Wire Harness 042-53011
023-50073 VH3P 01 GND 01
02 +5.1V 02 Diagram: 042-50000-10
(Power: 200V) CN9 03 PF 03
(Option Power Supply)
Mechanical Control PCB Power Wire Harness 042-53014
01 GND 01
VH9P 02 GND 02 VH9P
03 5V 03
04 5V 04
05 PGND 05
CN13 06 PGND 06 CN1
07 24V-B 07
08 24V-A 08
09 24V-OP 09
CN6 power supply pin
01
AC(L)-SW-IN 1 VH7P
02
MECHANICAL CONTROL 03
N.C
+S 01 XH3P AC(N)-SW-IN 3 04
N.C 02 N.C
for TPH Power Adjustment CN6 05 POWER CORD (C)
PCB -S 03 AC(N)-SW-OUT 5
CN4 06
07
N.C 488-00049
AC(L)-SW-OUT 7
POWER CORD (E)

488-00048
MAIN SWITCH
02
Power Supply Switch Wire Harness 042-53009
3 4
04
2 03
1
01
Power Supply Switch

US.RISO.COM
Main Unit Interlock Wire Harness 042-53008
Upper Rear Wire Harness 042-53005
XR4P-Y Relay Connector
CZ11P-Y CZ 18P-Y 01 Drum Safety Switch
04 01
XR2P-H Relay Connector N.C
02 03 02
red 01
Elevator Motor OUT 1 01 N.C
02 N.C 02 03 Drum Safety Switch
Elevator Motor black 02 Elevator Motor OUT 2 02 03 Drum Safety Switch 01
DC 01 04

04 Master Making Unit Safety Switch 04 01
N.C 03 02
05
N.C N.C 02 03
Master Making Unit Safety Switch
XR2P-Y Relay Connector 06 Master Making Unit Safety Switch 01 04
red Clamp Motor OUT 1 03
01 02
Clamp Motor black 02 Clamp Motor OUT 2 04 XR4P-Y Relay Connector
DC 01 07 Master Disposal Box Safety Switch 04 01
N.C 03 02
08 Master Disposal Box Safety Switch
N.C 05 N.C N.C 02 03
XR4P-Y 09 Master Disposal Box Safety Switch
01 04
04 Paper Feed Clutch 06 XR4P-Y Relay Connector
03
CN9 CN19 10 Rear Cover Safety Switch
N.C 04 01

Paper Feed Clutch 02 N.C 11 N.C 03 02
Paper Feed Clutch N.C Rear Cover Safety Switch (left)
01 07 N.C 02 03
01 04
5. Main Components Area

04 01
N.C 03 02
Master Counter XR 2P-Y N.C 02 03

Rear Cover Safety Switch (right)
12 Rear Cover Safety Switch
02 Master Counter + 08 01 04
13
N.C
14
01 Master Counter 09 N.C

15 Main Motor Relay 24V 04
16
N.C
17 Diagram: 042-50000-02
Copy Counter XR 2P-Y N.C 01
18 Main Motor Relay Drive
02 Copy Counter + 10 (Power Supply Unit CN7)
01 Copy Counter 11
Master Making Unit Wire Harness 042-28057 Bottom Rear Wire Harness 042-53004
XR3P-Y
03
GND
XR8P-Y 02 Photo Interrupt
XR6P-Y CZ17P-Y OUT Lower Limit Sensor
Load Pulse A 01 Type
06 01 Bottom Rear Relay VCC
A
16 -
05 Load Pulse B 02 Wire Harness 042-53003
PM B
XR3P-Y
+24V
04 N.C 01 GND 03
17 01 GND
Load Pulse Motor 03 N.C 02 Lower Limit Sensor 02 Photo Interrupt
+24V Load Pulse /A 16 02 OUT Vertical Print Positioning HP Sensor
03 5V 01 Type
/A
02 03 15 03 VCC
Load Pulse /B 04 GND
/B 01 04 CN11 CN6 14 04
05 Vertical Centering Sensor
13 05
06 5V XR6P-Y
XR6P-Y 12 06
07 Vertical Print Positioning Pulse A 06
11 07 A
06 Read Pulse A 05 08 Vertical Print Positioning Pulse B 05 B
A 10 08
Read Pulse B 09 N.C PM
05 06 09 09 N.C 04 +24V
PM B
10 N.C N.C 03 +24V Vertical Print Positioning Pulse Motor
Read Pulse Motor +24V
04 N.C 08 10 Vertical Print Positioning Pulse /A
11 02 /A
03 N.C 07 11
+24V 12 Vertical Print Positioning Pulse /B 01 /B
02 Read Pulse /A 07 06 12
/A 13 Pressure Solenoid
Read Pulse /B 05 13
01 08 14 Pressure Solenoid
/B 04 14
15 GND XR2P-Y Relay Connector
03 15
16 Main Motor FG Sensor 02 01
02 16 SOL
17 5V 02
Pressure Solenoid
01 17 01
CZ17P-Y Relay Connector XR3P-Y

03
02
01
Diagram: 042-50000-02
MECHANICAL CONTROL (Main FG Sensor)
PCB
CZ180 / CV1860 Rev. 1.0

US.RISO.COM
CN8 & CN12 (Mechanical Control PCB)
Front Wire Harness 042-53002

Paper Detection Sensor Wire Harness042-12601
CZ 24P XR 3P-H
A01 GND 03 01 03
(12P DOUBLE) GND
A02 Paper Detection Sensor 02 Photo Interrupt
CN8-A CZ12P-Y 02 02
A03 5V
OUT Paper Detection Sensor
01 03
01 VCC Sensor
CN8-B CZ12P-H
ZH3P
CZ180 / CV1860 Rev. 1.0

03 Anode
XR5P-Y,CT5P Relay Connector
Paper Sensor Wire Harness 042-12602
N.C
02 Anode

A04 5V
SEND
05 01 01 Cathode
A05 Paper Sensor (send)
04 02
A06 5V 03 03
ZH3P Paper Sensor
A07 Paper Sensor (receive) 01
02 04 Collector
A08 GND N.C
02 Emitter
01 05 N.C RECEIVE
03
Emitter

black
white
Cutter Stop Position Switch
A09 Cutter Stop Position Switch 04 01
A10 GND 03 02
A11 Cutter HP Switch
02 03
CN8 A12 GND 01 04 brown
orange
Cutter HP Switch

B01 Cutter Motor (-) red
02 01
16 -
B02 Cutter Motor (+) blue DC Cutter Motor
01 02
B03
6. CN8 and CN12 of Mechanical Control PCB
N.C XR6P-Y
B04 Write Pulse Motor A-phase 6 A

B05 Write Pulse Motor B-phase 5 PM
B
B06 N.C +24V
N.C Write Pulse Motor
MECHANICAL B07 N.C
N.C +24V
B08 Write Pulse Motor /A-phase 2
/A
CONTROL PCB B09 Write Pulse Motor /B-phase 1
/B
B10
N.C
B11
N.C
B12
N.C
CZ 8P-Y Front Wire Harness 042-53002 RF Wire Harness 042-53007 RF Antenna Wire Harness 042-53015
CZ7P Relay Connector
01 5V 07 1 red RF-SIG
07 01 SH 2P
02 HELD_TXD 06 CN1 2 yellow GND
06 02
03 HELD_RXD 05
05 03
04 HELD_SCK 04 SH 7P
04 04 042-50502 Antenna
05 HELD_SCK_CHG 03 CN2
CN12 03 05
06 HELM_ON 02
02 06
07 GND 01
01 07
08
N.C
042-50501 RF PCB
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PRINTING SECTION
Drum Wire Harness
042-17218 XR3P-Y
03 GND
02 OUT Photo Interrupt Sensor
01 VCC Inking Motor FG Sensor
Front Wire Harness
042-53002 RWZ33P-PLUG RWZ33P-SOCKET XR2P-Y relay connector red
02 01
CZ17P-Y CZ17P-Y 02 black DC Inking Motor
01
7. Print Drum Area
N.C 17 01 N.C
CZ30P XR2P-H, CT2P relay connector
N.C 16 02 Bottle Set Switch Wire Harness 042-17219
(15P double) GND N.C 01
A01 02 01
15 03 03
CN3-A CZ15P-Y A02 Inking Motor FG 01 02 Bottle Set Switch
14 04 02
N.C
CN3-B CZ15P-H A03 5V
13 05
Inking Motor(+) XR5P-Y relay connector Ink Sensor Relay Wire Harness 042-17220 XR4P-Y

A04 12 06 05
05 01 GND
A05 Inking Motor 04
11 07 04 02 Overflow Sensor (S)
A06 Bottle Set Sensor 03 03 03 Ink Sensor (L)
10 08 Ink Sensor
GND 02 04 02
A07 09 09
Thermister
01 05 01
A08 GND VCC
08 10
A09 Overflow Sensor

07 11 XR3P-H
A10 Ink Sensor 03
06 12 GND
Drum Thermister 02
A11 05 13
OUT Photo Interrupt Sensor Drum Set Sensor
01
VCC

A12 5V
CN21 04 14
A13 GND 15
03
A14 Drum Set Sensor 16
02
A15 5V 17
01
CZ16P-H CZ16P-H
16 01 CZ7P-Y relay connector RF Antenna Wire Harness 042-53015
N.C N.C RF Wire Harness 042-53007
B01 HEL_5V 07 01 07
15 02 SH2P
B02 HELD_TXD 06 1 red RF-SIG
14 03 06 02
B03 HELD_RXD 05 CN1 2 yellow GND
13 04 05 03
B04 HELD_SCK 04
12 05 04 04
B05 HELD_SCK_CHG 05 03 SH7P
11 06 03 042-50502
HELD_REG_CTRL
16 -
B06 06 02 CN2
10 07 02 Antenna
B07 GND 01
09 08 01 07
B08 Drum Connection Signal
08 09
B09 GND
07 10 042-50501
B10 Drum Identification Signal 1 RF-PCB
06 11
B11 GND
05 12
B12 Drum Identification Signal 2
04 13 CZ6P-H relay connector
B13 GND
03 14 06 01
B14 Drum Identification Signal 3 Color Drum Jumper Wire
02 15 05 02
B15 GND 04 03
01 16 042-17221
03 04
02 05 Cut the jumper wire according to the color.
01 06
MECHANICAL
CONTROL PCB
CZ180 / CV1860 Rev. 1.0

US.RISO.COM
MASTER MAKING AREA
Master Making Unit Wire Harness 042-28057
PH12P GLED
CZ12P CZ40P A01
Master Making Unit
01 01 N.C
02 02 (20P DOUBLE) A02
VLED N.C Wire Harness 042-28057 Master Positioning / Master End Sensor Wire Harness 042-28058
A03
03 GND 03 CN10-A CZ20-Y N.C
04 /TR 04 XR6P-Y relay connector XR3P-Y
05 05
CN10-B CZ20-H A04 GND 03
GND 06 01 GND
06 /RS 06 A05 Master Positioning Sensor 02
05 02 OUT Reflect Type Master Positioning Sensor
07 07 A06 5V 01
GND 04 03 VCC
08 /M 08 A07 GND
CN17 03 04
09 GND 09 A08 Master End Sensor XR3P-Y
CZ180 / CV1860 Rev. 1.0

02 05 03
10 +5V 10 A09 5V GND
01 06 02 Photo Interrupt
11 GND 11 OUT Master End Sensor
01 VCC
Type
OS

12 12 XR3P-Y
A10 GND 03
GND
A11 Original Detection Sensor 02
8. Master Making Area
OUT Actuator Type Original Detection Sensor

A12 5V 01
VCC
A13 Original Stripper Solenoid
A14 Original Stripper Solenoid (+) XR2P-Y relay connector
Contact Image 02 01
A15 GND SOL Original Stripper Solenoid
01 02
A16 Original IN Sensor
Scanner (CIS) XR3P-Y
A17 5V 03
LIB06A299B GND
A18 GND 02 Photo Interrupt
OUT
444-60002-009 A19 Upper Cover Set Sensor 01 Type Original IN Sensor
VCC

A20 5V
XR3P-H
03
GND
02 Photo Interrupt
OUT Upper Cover Set Sensor
01 Type
CN10 VCC
Rear Upper Wire Upper Limit Sensor Wire Harness 042-53006

CZ20P-H Relay Connector Harness 042-53005 XR3P-Y Relay Connector XR3P-Y
B01 GND 03
20 01 03 01 GND
B02 Upper Limit Sensor 02 Photo Interrupt
19 02 02 02 OUT Upper Limit Sensor
B03 5V 01 Type
18 03 01 03 VCC
B04 GND
17 04 XR3P-Y Relay Connector XR3P-Y
B05 Master Loading blue 03
16 05 03 01 green GND
B06 5V 02
15 06 02 02 yellow OUT Reflect Type Master Loading Sensor
Master Making Unit Wire Harness 042-28057 B07 GND 01 VCC
14 07 01 03
B08 Position-A Detection
13 08
01 -S 01 B09 5V XR3P-Y
VH-14 12 09 03 GND
02 GND 02 B10 GND
11 10 02 OUT Photo Interrupt
16 -
03 GND 03 B11 C Position-A Sensor
10 11 01 Type
GND B12 5V VCC
04 04 09 12
05 GND 05 B13 XR3P-Y
08 13 N.C
06 GND 06 B14 03
07 14 N.C GND
07 GND 07 B15 02 Photo Interrupt
06 15 N.C OUT Clamp Sensor
B16 01 Type
05 16 N.C VCC
B17
04 17 N.C
B18
03 18 N.C
B19
N.C N.C 02 19 N.C
Diagram: 042-50000-02 B20
Power Connector N.C N.C 01 20 N.C
(Power Supply Unit CN5)
08 Vh 14
09 Vh 15
10 Vh 16
11 Vh 17
12 Vh 18
13 Vh 19
14 +S 20
MECHANICAL
CONTROL PCB
TPH
KYT-256-12GAE1-RS2
444-80003-109
Master Making Unit Wire Harness 042-28057

Mini CT16P 16 +5V 01
Mini CT16P
15 GND 02
14 DATA_IN 03
13 GND 04
12 /LATCH 05
11 GND 06
10 CLK 07
09 GND 08
Signal Connector 08 /STB4 09 CN18
07 /STB3 10
06 THERM 11
05 THERM 12
04 /STB2 13
03 /STB1 14
02 +5V 15
01 +5V 16
US.RISO.COM
Master Disposal
XR3P-Y
03
GND
Master Removal Unit Wire Harness 042-24102 02 Photo Interrupt
OUT Master Removal FULL Sensor
01 Type
VCC
CZ19P-Y
01 GND
XR3P-Y
02 Master Removal FULL Sensor 03
GND
03 5V 02 Photo Interrupt
OUT Master Compression HP Sensor

04 GND Type
9. Master Removal Area
01 VCC
05 Master Compression HP Sensor
06 5V
XR3P-Y
07 GND
03
GND
08 Master Removal Jam Sensor 02
OUT Actuator Type Master Removal Jam Sensor
09 5V 01
VCC

CN7 10 GND
11 Master Removal Motor FG Sensor
XR3P-Y
12 5V 03 GND
13 Master Removal Motor OUT 2 02 OUT Photo Interrupt Master Removal Motor FG Sensor
14 Master Removal Motor OUT 1 01 VCC Type
15 Master Compression Motor OUT 2
16 Master Compression Motor OUT 1
17
N.C 02 01 red
18 black Master Removal Motor
N.C 01 02 DC
16 - 10
19
N.C

02 01 red
black Master Compression Motor
01 02 DC
MECHANICAL CONTROL
PCB
CZ180 / CV1860 Rev. 1.0

US.RISO.COM
Paper Ejection Section
CZ180 / CV1860 Rev. 1.0

10. Paper Ejection Area
CZ14P-Y

Paper Ejection Wire Harness 042-53001
SEPARATION UNIT
01 Separation Fan
04 01
02 GND
03 02
02 03 Separation Fan
03 N.C
N.C
04 Separation Fan PWM
01 04
CN5
16 - 11
04 01
Paper Ejection Wire Harness 042-53001 03 02
Suction Unit Wire Harness 042-21701 N.C 02 03 Suction Fan

XR10P-Y Relay Connector N.C 01 04
05 Suction Fan
10 01
06 GND XR2P-Y Relay Connector
09 02
07 Paper Ejection Motor 2 02
red
08 03 01
08 Paper Ejection Motor 1 black DC Paper Ejection Motor
07 04 01 02
09 GND
06 05
10 Paper Ejection Motor FG Sensor XR3P-Y
05 06
11 5V 03
04 07 GND
12 GND 02 Photo Interrupt
03 08 OUT Paper Ejection Motor FG Sensor
13 Paper Ejection Sensor
02 09
01 VCC Type
14 5V
01 10
MECHANICAL CONTROL XR3P-H
03
PCB GND
02 Reflecting
OUT Paper Ejection Sensor
01 VCC Type
SUCTION UNIT
US.RISO.COM
OPERATION PANEL AREA
Front Wire Harness 042-53002

CZ7P-Y CZ7P-Y
01 GND POWER 07
02 GND POWER 06
CN1 03 RESET 05 CN1

04 PANEL_RXD 04
11. Operation Panel Area
05 PANEL_TXD 03
06 5V POWER 02
07 5V POWER 01

16 - 12
MECHANICAL PANEL-PCB
CONTROL PCB 042-37031
CZ180 / CV1860 Rev. 1.0

US.RISO.COM
OPTIONS AREA
12. Options
01 D0 01
MECHANICAL CONTROL PCB 02 D2 02
03 D4 03
04 D6 04
Option Wire Harness 042-53011 05 GND 05
06 D8 06
07 D10 07
CZ17P 01 GND 16
MiniCT16P 08 D12 08
02 TXD 15
09 D14 09
03 /RTS 14
3.3V 10
CZ180 / CV1860 Rev. 1.0

04 13 10
GND
11 3.3V 11
CN20 05 RXD 12
12 A0 12
MECHANICAL-CTL-PCB(C) MECHANICAL-CTL-PCB 06 /CTS 11

042-50503 13 A2 13
042-50500 07 SCK 10
CN22 GND 01 GND 14 A4 14
08 GND 09
/CD1 02 D3 15 GND 15
01 01 09 /VIPRQ 08
D11 03 D4 CN2 CN2 16 A6 16
02 02 10 /VISRQ 07
D12 04 D5 17 A8 17
03 03 11 GND 06
D13 05 D6 18 A10 18
04 04 12 WAKE-UP SWITCH 05
D14 06 D7 19 A12 19
05 05 13 WAKE-UP SWITCH SIGNAL 04
D15 07 /CE1 20 GND 20
14 WAKE-UP LED 03
/CE2 08 A10 21 /BUSY 21
15 GND 02
/VS1 09 /DE 22 /OE 22
16 /SH_SLEEP 01

/IORD 10 A11 23 /LB 23
17 MD2
CN14 /IOWR 11 A9 N.C 24 GND 24
25 /INTRET 25
NET-C PCB
01 5V A17 12 A8
02 TXD A18 13 A13
CN10 26 D1 26 102-50506
03 RXD A19 14 A14 27 D3 27
A20 15 /WE 28 D5 28
04 GND
A21 16 READY Option Wire Harness 042-53011 29 D7 29
Vcc 17 Vcc 30 GND 30
VPP 18 VPP1 CZ15P 01 AUX 12 31 D9 31
02
MiniCT12P
A22 19 A16 GND 11 32 D11 32
CN15 A23 20 A15 03 DCLK 10 33 D13 33
A24 21 A12 04 /HE 09 34 D15 34
01 GND
A25/CSEL 22 A7 05 GND 08 35 3.3V 35
02 /VSYNC
/VS2 23 A6 06 SDATA 07 36 3.3V 36
03 GCLK
RESET 24 A5 07 /HSYNC 06 37 A1 37
04 /HSYNC
/WAIT 25
CN16 08 GND 05 38 A3 38
05 GND A4 CN3
/INPACK 26 09 /VSYNC 04 39 A5 39
06 D7 A3
/REG 27 10 PDATA 03 40 GND 40
07 GND A2
BVD2 28 11 GND 02 41 A7 41
08 D6 A1
12 /RIP Detection Signal 01 42 A9 42
16 - 13
09 GND BVD1 29 A0
30 13 N.C 43 A11 43
10 D5 D8 D0
31 14 44 /RESET 44
11 GND D9 D1 N.C
15 45 GND 45
12 D4 D10 32 D2 N.C
13 GND /CD2 33 WP 46 /CE 46
14 D3 GND 34 GND 47 R/W 47
GND 35 GND
Option Wire Harness 042-53011 48 /UB 48
15 GND VH3P
16 D2 D3 36 /CD1 01 49 /CONNECT 49
GND 01
17 GND D4 37 D11 042-50000-02 02 +5.1V 02
50 /INT 50
18 D1 D5 38 D12 (POWER SUPPLY UNIT CN9) 03 PF 03
CN7
19 GND D6 39 D13
20 D0 D7 40 D14 Board to Board
/CE1 41 D15
A10 42 /CE2
/OE 43 /VS1
A11 44 /IORD
A9 45 /IOWR XH12P 01 GND(5V) 01 XH12P
A8 46 A17 02 N.C 02
A13 47 A18 03 A-signal 03
SH3M-PCB
A14 48 A19 04 B-signal 04
/WE 49 A20 05 GND(5V) 05
023-50038
READY 50 A21 06 +5V 06
VCC 51 Vcc CN3 07 GND(24V) 07
VPP1 52 VPP 08 +24V-OP 08
A16 53 A22 09 BUSY 09 Job SH3M2-PCB(C)
A15 54 A23 10 Tape Jam 10
A12 55 A24 11 Tape Detection 11
Separator-IV 023-50111
A7 56 A25/CSEL 12 Sorter Detection 12
A6 57 /VS2
A5 58 RESET
A4 59 /WAIT
A3 60 /INPACK
Job Separator-IV External
A2 61 /REG
A1 62 BVD2
Wire Harness 113-51000
A0 63 BVD1
D0 04 D8
D1 65 D9
D2 66 D10
WP 67 /CD2
GND 68 GND
US.RISO.COM
13. Fuses
Power Suppy PCB Fuse List
Fuse No. System Status after power reset Connecting part
F001 Primary Power does not go ON. Main power supply.

power
250 Volts system
6.3 A
F101 24V - A T98 - 947 Suction Fan
24V-A does not turn ON. Pressure Solenoid

250 Volts
Paper Feed Clutch
3.15 A
Copy Counter
Master Counter
F102 24V - B T98 - 948 Elevator Motor
250 Volts 24V-B does not turn ON. Clamp Motor

6.3 A Master Compression Motor
Paper Ejection Motor
Master Removal Motor
Read Pulse Motor
Write Pulse Motor
Vertical Print Positioning Motor
Load Pulse Motor
Separation Fan
Original Stripper Solenoid
16 - 14 CZ180 / CV1860 Rev. 1.0


CHAPTER 17: OTHER CAUTIONS
CONTENTS
1. Machine Firmware Downloading (Mechanical Control PCB)...................2

Downloading Procedure.....................................................................2
Precaution in firmware downloading..................................................2
2. Replacing the Mechanical Control PCB...................................................3
CZ180 / CV1860 Rev. 1.0 17 -


1. Machine Firmware Downloading (Mechanical Control PCB)

Downloading Procedure The method given below is for CZ180.
1) Turn OFF the machine power. The method is different for CV1860.
2) Remove the Rear Cover. (M3x8 screws; 5 pcs)
3) Insert the CF card containing the correct machine firmware into the CF card slot of the Mechanical
control PCB. The CF card needs to be put in a card adopter before the insertion.
4) Turn ON the machine power and let the firmware download automatically.
5) Confirming that the downloading ended in success, turn OFF the machine power and remove
the CF card from the PCB slot. The confirmation of the downloading process can be made by
watching the three LEDs shown on the chart below.
6) Put back the Rear Cover on the machine to complete the downloading procedure.
Precaution in firmware downloading

1) If the version number of the firmware now on the machine is identical with the one in the CF card,
the downloading process will not take. The red ERROR LED blinks and nothing happens. In this
case, turn OFF the machine power and remove the CF card. Turn the machine power back ON
and resume normal operation with the existing machine firmware.
Name of the LEDs on PCB GREEN 1 GREEN 2 ERROR
Firmware ready to download

NORMAL
DOWNLOADING Firmware being downloaded
CONDITION
Firmware downloading completed
CF card set incorrectly
Machine data not found
Incorrect data
ERROR
Download failure
CONDITIONS
Incorrect data size
File system error
Other error
Mechanical communication error
LED LOCATION
CF card : ON
slot
ERROR : BLINK
LED H8 : OFF
LED LED
GREEN 1
GREEN 2
Mechanical
Control PCB
17 - CZ180 / CV1860 Rev. 1.0


2. Replacing the Mechanical Control PCB

2) Remove the Rear Cover. (M3x8 screws; 5 pcs)
3) Remove EEPROM from the existing Mechanical Control PCB and detach the PCB from the
machine.
4) Put the EEPROM, removed from the previous PCB, onto the new Mechanical Control PCB.
5) Attach the new Mechanical Control PCB on the machine and insert CF card in an adopter in the
slot of the PCB and download the machine firmware.
[ Refer to the previous page for the firmware downloading procedure.]
6) After the firmware downloading is successfully completed, turn ON the machine power and
confirm that the machine goes into normal operating condition.
CZ180 / CV1860 Rev. 1.0 17 -


MEMO
17 - CZ180 / CV1860 Rev. 1.0


CHAPTER 18: APPENDIX
CONTENTS
RISO i Quality System..................................................................................2

1) Printing Density Control.................................................................2
2) Drum Idling Control........................................................................2
3) Thermal Power Control on TPH.....................................................2
4) Elongation and Shrinkage Control in Master Making.....................2
5) Ink and Master Remaining Amount Display is Controlled..............2
6) Inkless Timer Control.....................................................................2
7) Additional Information on the RISO i Quality System.....................2
CZ180 / CV1860 Rev. 1.0 18 -


RISO i Quality System

With the RF-tag on the master roll and ink bottle, the machine is designed to give best performance for
each operating condition in real time.
Listed below are the major performance feature of the RISO i Quality System.
1) Printing Density Control

Depending on the condition of the machine, the printing speed is controlled before the selected
printing speed is achieved.
This is to produce solid image prints with less wasted printing papers.
2) Drum Idling Control

Depending on the working condition, the condition of the ink in the Drum differs. To give best print
outs, the number of Drum rotation during the Drum idling action is changed to produce solid image
prints with less wasted printing papers.
3) Thermal Power Control on TPH

The TPH thermal power is controlled to match with each master roll and its condition.
4) Elongation and Shrinkage Control in Master Making

Depending on the amount of mater material remaining on the master roll, the speed of the Write pulse
motor is controlled to reduce the image elongation and shrinkage in master making.
5) Ink and Master Remaining Amount Display is Controlled

More precise information is given on the operation panel of the machine on the remaining amount of
the ink and master to the operator.
6) Inkless Timer Control

Depending on the amount of ink left in the ink bottle, the inkless timer is controlled before displaying
the ink bottle replacement panel message to reduce the false replacement message display. The
same control is used also to prevent pumping in excess air into the Drum when the ink amount left in
the ink bottle is close to empty.
7) Additional Information on the RISO i Quality System

In the case when adequate information is not achieved from the RF-tag, the machine panel message
indicates [H01-566] for the ink and [H04-242] for the master.
If these [H] displays are indicated, input the necessary parameter setting to continue the printing or
master-making operation.
[H01-566] Input either 1 (black ink) or 2 (color ink)
[H04-242] Input a parameter number in the range of 1 (light) to 10 (dark)
18 - CZ180 / CV1860 Rev. 1.0



CZ180 / CV1860
Technical Manual
(Rev. 1.0)
Published August 2007
Reproduction and duplication prohibited.
Edited and published by: RISO Education Center,
Riso Kagaku Corporation.
The contents of this manual are subject to change

without notice to permit product improvements.

CZ180 CV1860: Technical Manual

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CZ180

Copyright: 2007 Riso Kagaku Corporation

RISO INTERNATIONAL GROUP

RISO KAGAKU CORPORATION (JAPAN) RISO DEUTSCHLAND GMBH (GERMANY)

RISO Inc. Technical Services & Support US.RISO.COM

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Chapter 2 MACHINE SUMMARY

Chapter 3 MAIN DRIVE

Chapter 4 FIRST PAPER FEED

Chapter 5 SECOND PAPER FEED

Chapter 6 PRINTING PRESSURE

Chapter 7 PAPER EJECTION

Chapter 8 PRINT DRUM

Chapter 9 MASTER CLAMPING

Chapter 10 MASTER REMOVAL

Chapter 11 ORIGINAL SCANNING

Chapter 12 MASTER MAKING

Chapter 13 PANEL MESSAGE

Chapter 14 TEST MODE

Chapter 15 ELECTRICAL COMPONENTS

Chapter 17 OTHER PRECAUTIONS

RISO Inc. Technical Services & Support US.RISO.COM

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RISO Inc. Technical Services & Support US.RISO.COM

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CZ180 / CV1860 Rev. 1.0 1-

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1- CZ180 / CV1860 Rev. 1.0

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Important Safety Precautions

1. Always disconnect electrical supply before placing hands in the machine.

II. Protection of the machine:

I. To avoid electrical failure:

II. Protection of the electrical components:

Wire harness connector

Press the ends.

Press the center, firmly.

CZ180 / CV1860 Rev. 1.0 1-

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Assembly and Installation

(Protrusions and holes for positioning parts Half pierced section)

Type Tip Shaft length, Type Remarks

screwdriver No. 2 (100 mm–150 Radial cutting pliers

mm) Soldering iron 20 W–30 W

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Electrical system work

Sensor types Interrupt types Actuator types

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Do not install the machine in any of the following locations.

1- CZ180 / CV1860 Rev. 1.0

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021-16007-005 Spring; Screen (2 pieces required)

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CZ180 & CZ180(120)

RISO CZ Installation Procedure

・When installing CZ100 in countries with 100-120V electricity,

2. Set the Voltage Switch to 115V.

3. Replace the Rear Cover.

《Installation of the Printer》

2. Mount the printer on the position illustrated in the left.

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