KZ30 Technical Manual Rev.1.2

Imagetec Solutions Australia
RISO
57A01C
&
KZ30
TECHNICAL MANUAL
REVISION 1.2
OCTOBER, 2011
Copyright : 2011 Riso Kagaku Corporation

All Rights Reserved. This Technical Manual was prepared
and written for the exclusive use of RISO International
Group Certified Dealers. Reproduction and/or transmittal
of this material in any form or by any means, including
photocopying or recording of the information is strictly
prohibited without the consent of a member of RISO
International Group.
RISO INTERNATIONAL GROUP

RISO KAGAKU CORPORATION (JAPAN) RISO DEUTSCHLAND GMBH (GERMANY)
RISO, INC. (U.S.A.) RISO FRANCE (FRANCE)
RISO KAGAKU CORP. LONDON OFFICE (U.K.) RISO IBERICA (SPAIN)
RISO HONG KONG (HONG KONG) RISO CANADA (CANADA)
RISO UK (U.K.) ZHUHAI RISO TECHNOLOGY (CHINA)
RISO THAILAND LIMITED (THAILAND) RISO AFRICA (SOUTH AFRICA)
RISO KOREA LIMITED (KOREA) RISOGRAPH ITALIA (ITALY)
KZ30 (Rev. 1.2)

KZ30 (Rev. 1.2)

Imagetec Solutions Australia MAINTENANCE
CHAPTER 1: MAINTENANCE
CONTENTS
PREFACE...........................................................................................................1-3
1. Warning.........................................................................................................1-4
2. Work Precautions.........................................................................................1-5
3. Jigs.................................................................................................................1-7
4. Exterior Cover Removal...............................................................................1-8
1) Print Drum..............................................................................................1-8
2) Front Cover.................................................................................. 1-10
3) Rear Cover................................................................................... 1-10
4) Master Removal Unit Cover......................................................... 1-11
5) Master Making Unit Cover............................................................ 1-11
6) Operation Panel Assembly........................................................... 1-12
5. Pressure Spring Removal..........................................................................1-13
[��
1-1 ] KZ30 (Rev. 1.2)
MAINTENANCE Imagetec Solutions Australia
KZ30 (Rev. 1.2) [��

1-2 ]
PREFACE
This manual provides Technical Service Information for RISO 57A01C and KZ30 digital
duplicator.
This manual is published as a reference guide for use by certified field servicemen trained under
RISO International Group technical trainers.
This manual includes procedures for removal, installation and adjustments of major components
found on the machine. Following these procedures will prevent injuries and malfunctions on the
machine, as well as to achieve end-user satisfaction.
[��
1-3 ] KZ30 (Rev. 1.2)
1. Warning
Important Safety Precautions
1. Always disconnect electrical supply before placing hands in the

machine.
I. To avoid injuries:
Be sure to disconnect the electrical power before disassembling, assembling,
or when making adjustments on the machine.
II. Protection of the machine:

Make sure to turn OFF the power to the machine before plugging or unplugging
the electrical connectors, or when connecting a Meter.
2. Always connect electrical connectors firmly.
I. To avoid electrical failure:

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

The electrical components may be damaged due to short circuits caused by
a loose connector.
Wire harness connector
FIRST
Press the ends.
THEN
Press the center, firmly.
KZ30 (Rev. 1.2) [��

1-4 ]
2. Work Precautions
Lifting the machine

The machine should be lifted by two persons, one person on the paper-feed side and the other person on
the paper-receive side.
There is a beam running across on the paper-feed side and also on the paper-receive side.
These metal beams should be grabbed firmly by both hands by each person.
Grab the metal beams as shown on the photograph on the LEFT. Do not grab the metal beams as
shown on the photograph on the RIGHT. If grabbed as shown on the RIGHT, hands and fingers may
be cut and injured by the sharp edges of the metal beam.
GOOD BAD
Inspection
If inspection finds a defective or problem part, correct it. Replace parts as necessary.
Removal
(1) Carry out work according to the procedures in the technical manual.
(2) Arrange the removed parts carefully and in order.
(3) Distinguish parts to be replaced and those to be reused.
(4) When replacing screws and E-rings, use the specified size.
Assembly and installation Positioning pin
Unless otherwise specified, assembly and installation follow the

reverse order of removal. When there is a protruding section
and a hole for positioning a part, align them correctly before
fastening.
(The pin, which positions the part to attach, is referred to as
Positioning pin.)
[��
1-5 ] KZ30 (Rev. 1.2)
Self-tapping screws
Self-tapping screws are used in many places on the machine.

The self-tapping screws, if incorrectly handled, will damage the screw hole on the machine frame.
When mounting the self-tapping screws, first rotate the screw in the counter-clockwise direction to find the
thread on the screw hole. Then start rotating the screw in the clockwise direction to tighten. This is to
prevent the tapping screw from making new screw thread on the screw hole and damaging the original screw
thread on the screw hole
Self-tapping screw Pan-head screw

< Caution is needed in mounting the Binding-head screw
self-tapping screws.> < These are not self-tapping screws.>
Electrical system work

> After replacing electrical wires, fasten them with bands (bar lock ties) so that they do not sag.
> When installing parts, be careful to avoid pinching and damaging the electrical wires.
> If a fuse blows, always replace it with one of the specified capacity.
> Using a larger fuse will not only damage the machine components, but may also cause fires.
> Image scanner, thermal heads, and sensors are extremely vulnerable to shock, so do not handle
them roughly or drop them.
> Always turn OFF the machine power before working on the machine and when plugging or unplugging
sensor connectors.
Wiring bundle band
(bar lock ties)
KZ30 (Rev. 1.2) [��

1-6 ]
3. Jigs
List of the Jigs needed to maintenance this machine.
1.
021-16007-005 Spring; Screen (2 pieces required)

Cut the ring end to make into hook, as shown on the
photograph, and attach wire tie bar on the other end.
<Refer to the Chapter on the Print Drum>
2.
051-75008-006 Drum Shaft Jig (8mm diameter)

Needed to align the Print drum (Front & Rear).
OR
PLUS
Rectangular Box
Needed to align the Print drum Rear.
015-26128-008 Drum Shaft Jig (8mm diameter)
Needed to align the Print drum Front.
[��
1-7 ] KZ30 (Rev. 1.2)
4. Exterior Cover Removal

Disconnect the power supply from the machine and remove the cover.
1) Print drum
2) Front cover
3) Rear cover
4) Master removal unit cover Master making unit cover
5) Master making unit cover
6) Operation panel
Operation panel
Rear cover
Master removal unit cover
Front cover
(Already removed on the photograph.)
1) Print Drum (1 screw)

1. Swing open the Separation fan unit.
2. Look into the machine from the paper ejection opening of the machine to find the Print drum lock
mechanism. (Refer to the next page for the view of the Lock mechanism.)
3. Loosen the screw of the Print drum lock and remove the lock.
Separation fan unit
Swing open
Look into the machine
< Paper Ejection Side of the Machine >
KZ30 (Rev. 1.2) [��

1-8 ]
4. Slowly pull out the Print drum, straight, all the way out until it stops.
Grab the tail end of the Drum.
< Do not lift the Print drum or the Print drum will fall off the machine. >
< View of the Lock >

Hold onto the Lock mechanism The Lock can be removed.
and loosen the screw.
5. Firmly holding the front and tail end of the Print drum, lift the front end of the Print drum a little
and disengage the Print drum from the guide rail to remove it out of the machine.
Pull out the Drum straight Grab the tail end of the Drum. The grip on the rear of the
and keep holding the front Print drum.
grip.
Hold firmly
ont
t h e fr out.
Lift slide
and
Hold firmly < Print Drum >
[��
1-9 ] KZ30 (Rev. 1.2)
2) Front Cover (8 screws)
Remove the Print Drum from the machine first.
< Front View > < Rear View >
The front cover can be

separated into three pieces.
< Front View >
3) Rear Cover (6 screws)
< Front View > < Rear View >
The rear cover can be

separated into two pieces.
< Front View >
KZ30 (Rev. 1.2) [��

1-10 ]
4) Master Removal Unit Cover (4 screws)
5) Master Making Unit Cover (5 screws)
1 screw from the top.
2 screws on the back.

2 screws in the front.
[��
1-11 ] KZ30 (Rev. 1.2)
6) Operation Panel Assembly (2 screws)

1. Disconnect one connector from the bottom of the Operation Panel.
2. Remove two screws on the operation panel bracket to detach the Operation panel assembly
from the machine.
Connector to the Operation panel.

(View from underneath the panel)
< Operation Panel - left view >
Operation panel bracket
< Operation Panel - front view >
KZ30 (Rev. 1.2) [��

1-12 ]
5. Pressure Spring Removal

To avoid injury in removing the Pressure spring from the machine, never use bare hands to unhook the
spring.
One recommendation is to use a piece of strong rope. (refer to the photograph below.)
Long nosed pliers can also be used, but the spring may slip out from the pliers and may not work as well
as a strong rope.
Remove the Paper receiving tray and Suction unit

from the machine prior to the Pressure spring removal
for easier access to the sprint access and safety.
Strong piece of Rope.
Pressure spiring
Thread the rope through the Spring. Wrap the rope around the Spring loop.
Pull on the rope to unhook the Spring. Remove the rope.
Follow the instruction in the opposite order in hooking the Pressure spring back on the machine.
[��
1-13 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

1-14 ]
Imagetec Solutions Australia MACHINE SUMMARY
CHAPTER 2: MACHINE SUMMARY
CONTENTS
1. Specifications...............................................................................................2-3
RISO 57A01C ......................................................................2-3
RISO KZ30............................................................................................2-4
2. Cross Sectional Diagram.............................................................................2-5
3. Machine Operations.....................................................................................2-6
4. Paper Feed and Receiving...........................................................................2-7
5. Master Removal and Feed...........................................................................2-8
6. Counter Indication........................................................................................2-9
1. Indicate Copy and Master Counter:........................................................2-9
2. Stopping of the Copy and Master Software Counter
during the machine repair:.................2-9
[��
2-1 ] KZ30 (Rev. 1.2)
MACHINE SUMMARY Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

2-2 ]
1. Specifications
RISO 57A01C
[��
2-3 ] KZ30 (Rev. 1.2)
KZ30 (Rev. 1.2) [��

2-4 ]
2. Cross Sectional Diagram

Document feeder
Cutter unit
Image scanner Thermal print head

Original rack
Master disposal box 8
Write roller
6
Master roll
7 9
10
5
1 2
Separator
4
Paper feed tray

Paper receiving tray
Pickup roller Suction unit

Pressure roller
Timing roller
Guide roller
1 First Paper Feed Area: Feeds single sheets of paper to the second paper feed area via Pickup
roller and Stripper pad.
2 Second Paper Feed Area: Controls the vertical print position and feeds paper to the print area via
the Timing and Guide rollers.
3 Press (Printing) Area: Uses the Pressure roller to press paper against the master on the
Drum. The Drum rotates with the Pressure roller and prints an image
on paper.
4 Paper Ejection Area: Separates a printed paper from the Drum, and transports it onto the
paper receiving tray.
5 Drum Area: Supplies the Drum surface with ink from an Ink cartridge.
6 Master Clamp Area: Clamps the leading edge of the master.
7 Master Disposal Area: Separates used master from the Drum and disposes it into the Master
disposal box.
8 Image Scanning Area: Carries an original and scans it with the Image scanner and converts
the image information into digital data.
9 Master Making Area: Makes a master with the Thermal print head.
10 Master Loading Area: Feeds the prepared master material to the Drum and cuts it to an
appropriate length.
[��
2-5 ] KZ30 (Rev. 1.2)
3. Machine Operations
Set the original and press the Start key.
Master Disposal Master Making
The original is scanned by the image

The used master is removed from the
scanner and the image is made on the
drum and stored in the disposal box.
master with the thermal print head.
Master Carrier and Loading
The made master is wrapped onto the

drum and cut.
Also, a proof print is printed.
Printing
Paper is fed one sheet at a time from

the Paper feed tray, printed, and stored
on the paper receiving tray.
KZ30 (Rev. 1.2) [��

2-6 ]
4. Paper Feed and Receiving
Pickup roller Drum

The Drum is rotated and a sheet of paper is fed from
the first paper feed area to the second paper feed area
by Pickup rollers, and Stripper pad.
Stripper pad
Guide roller The paper feed to the second paper feed area is
stopped by the Guide and Timing rollers to form a
buckle. The paper then waits until the rotation of the
Guide roller starts.
Timing roller
The Guide and Timing rollers in the second paper feed

area are rotated and the paper is fed to the printing
area.
Pressure roller
While the paper is being fed from the second paper
feed area, the Pressure roller rises and printing starts.
(The Pressure roller contacts the Drum and starts
rotating.)
Separation fan After the Pressure roller contacts the Drum to start
printing, the Separator approaches the Drum and the
Separation fan starts to blow.
Separator
The Guide roller goes up to release the paper.
(The paper is then transferred by the rotation of the
Drum.)
The printed paper is separated from the Drum by the

Separator and with a help of the air blow from the
Separation fan.
It is then transported onto the Paper receiving tray by
the Transfer belts using Suction fan.
Transfer belt
The Timing roller contacts with the Guide roller to feed
the next sheet of paper.
[��
2-7 ] KZ30 (Rev. 1.2)
5. Master Removal and Feed
Clamp plate Master projection shaft

Master roll Master Removal
The Clamp plate opens and Master release
shaft releases the master from the Clamp
plate.
Vertical
transport roller Master
The Drum and Vertical transport rollers starts
rotating and removes the master from the
Drum and feed it into the Master disposal
Master box.
disposal box
The Master compressing plate starts

compressing the removed master within the
Master removal box.
TPH
Master Making
The Image scanner scans the image on the
original and Thermal print head (TPH) makes
the image on the master material.
The Master tension plate drops down and
applies tension on the master material.
Master Loading
The master is transferred onto the Drum and
the leading edge is clamped by the Clamp
plate.
The Drum rotates to wrap the master on the

Drum.
Cutter
The Cutter cuts the master.
KZ30 (Rev. 1.2) [��

2-8 ]
6. Counter Indication
1. Indicate Copy and Master Counter:
The Copy and Master Counter on the machine is displayed on the LED panel of the machine by the Custom
Setting of the user mode.
Item No. 30: Total Copy Count Display < Sample Instructions >
The total number of pages printed with the machine is
1. Press the CUSTOM key 3. Press the + key to display
EXA
displayed. MPL
E
on the Control Panel. the first 3 digit numbers.
The total number of counter is shown on the Display.
This number is displayed on two screens, consisting 135
of an under bar + 3-digit number and 4-digit number.
Example:
If 1,357,900 pages: _135 ---> 7900.
Item No. 31: Total Master Count Display

The total number of masters generated with the NOTE: To exit the Custom
Setting mode, turn off the
machine is displayed. indicator by pressing the 4. Press again the + key to
CUSTOM key. display the remaining 4
- same description as the Total Counter - digit numbers.
Item No. 32: Average Display Function

2. Enter Item No. 30, 31 or 32
depending on which
counter to display.
7900
Displays the average number of pages printed for
each master made on the machine.
- same description as the Total Counter -
30 -
Refer to the operation steps described on the right.
2. Stopping of the Copy and Master Software Counter during the machine repair:
During the machine servicing, if the Copy Counter and Master Counter on the customer's machine needs to
be stopped in order that the serviceman can make the master and prints to check the machine condition and
not wishing to increase the counter reading for those confirmation prints, the software counter can be stopped
tentatively by Test Mode No. 155 [Counter Action Control].
Selecting [0] on the Test Mode No. 155 will stop the counter action while the machine power is kept ON.
Turning the machine power OFF and then ON will automatically return the test mode setting back to the
default setting of [1], which allows the counter to activate.
Test Mode No. 155 [Counter Action Control]

0 : Stops the counter
1 : Activates the counter
< The setting automatically returns back to the default [1] setting when the machine power
is turned OFF and ON. >
[��
2-9 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

2-10 ]
Imagetec Solutions Australia MAIN DRIVE SECTION
CHAPTER 3: MAIN DRIVE SECTION
CONTENTS
Theory of Operation..........................................................................................3-3
1. Main Drive..............................................................................................3-3
2. Main Motor Safety Switch......................................................................3-4
3. Drum Positions.......................................................................................3-5
4. Print Drum Locking Mechanism.............................................................3-5
Removal and Assembly....................................................................................3-7
1. Main Drive Gears...................................................................................3-7
2. Main Motor Unit....................................................................................3-10
3. Master Removal Unit Safety Switch.....................................................3-12
4. Master Making Unit Safety Switch.......................................................3-13
5. Separation Unit Safety Switch.............................................................3-14
6. Print Drum Safety Switch.....................................................................3-15
[��
3-1 ] KZ30 (Rev. 1.2)
MAIN DRIVE SECTION Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

3-2 ]
Theory of Operation
1. Main Drive
The main motor drives the following components of the machine.
* First paper feed unit
* Second paper feed unit
* Print drum
* Pressure roller (up & down motion)
* Paper ejection suction belt
Print drum
Pressure roller
Suction belt
Main motor (behind the frame)

Second paper feed (Timing roller) First paper feed (Pickup roller)
Main motor shaft
[��
3-3 ] KZ30 (Rev. 1.2)
2. Main Motor Safety Switch

Following all four Safety switches must be activated to run the Main motor.
* Master removal unit safety switch
* Master making unit safety switch
* Separation unit safety switch
* Print drum safety switch
The same four switches act also as Safety switches for the Thermal power.
Separation unit safety switch

Master removal unit safety switch
Master making unit safety switch
Print drum safety switch
KZ30 (Rev. 1.2) [��

3-4 ]
3. Drum Positions
1) Sensors for the Drum positioning
The position of the Drum is determined by the Position-A sensor and Encoder sensor on the Main
motor.
2) Position-A
* This is the position where the Clamp plate is at the top of the Drum.
* This position is also referred as the 0 .
* The Clamp plate opens and closes at this position.
* This is the position where the light path of the Position-A sensor is cut by the Position-A
plate on the Drum.
Drum position-A of the Print Drum

Position-A plate
REAR
Position-A sensor
Drum angle
FRONT 0
4. Print Drum Locking Mechanism

1) The Print drum is designed to unlock only when it is at Position-B.
2) At any other Drum positions, the flange around the Drum main gear prevents the Intermediate
gear from disengaging from the Drum main gear.
3) Only when the Print drum is at Position-B, the flange on the Drum main gear does not interfere
against the Intermediate gear, allowing the Print drum to be pulled out from the machine.
4) When the Print drum is pulled out of the machine, the lock mechanism locks the Print drum at
Position-B so that the Print drum does not rotate while it is pulled out of the machine.
Lock mechanism
on the Print drum.
2
View under the Print drum Releasing the Drum hook
[��
3-5 ] KZ30 (Rev. 1.2)
Drum A-Positioning Movement Timing Chart
(a) (b)
End of movement
270 0 (Position-A) 90 180 270 340 0 (Position-A)
Drum angle
(Encoder sensor)
Blocked
Open
Position-A sensor
ON
Main motor
OFF
15 rpm
1.95 rpm
(a) If the light path of the Position-A sensor is cut when the last paper is counted, the Main motor speed
becomes from printing to 15 rpm to stop the drum rotation.
(b) When the Drum rotates to 340, the drum rotation speed becomes 1.95 rpm to stop the drum at the
Drum- A position (at Drum 0 ) exactly. Then Main motor turns off.
> If the Encoder sensor does not output the Main motor rotation signal within 1.2 seconds, the machine
assumes that the Main motor has locked and displays error message [P 01].
> If over load current is detected and the Encoder sensor does not output th Main motor rotation signal
for 0.1 seconds, the machine assumes that the Main motor has locked and displays error message
[P 01].
KZ30 (Rev. 1.2) [��

3-6 ]
Removal and Assembly

1. Main Drive Gears
1. Turn OFF the machine power and disconnect the power cord from the machine..
2. Remove the Rear cover.
3. Remove the Power supply unit. (4 screws and unhook wire harness from the wire saddles.)
Power supply unit
4. Remove the FG Sensor (Encoder sensor)
Remove 2 screws to detach

Encoder cover.
Screw Connector FG Sensor disc

Spacer
Insert thin rod to prevent Main
Screw
motor shaft from turning.
[��
3-7 ] KZ30 (Rev. 1.2)
5. Remove the Paper feed clutch support plate. (3 screws)
Paper feed clutch

support plate
6. Disconnect the connector and remove the Paper feed clutch.
In assembly, make sure to locate the clutch hook in the hook lock to
fix the clutch in position. The hook faces down.
7. Remove the Timing clutch support plate (4 screws), disconnect the connector and remove the Timing
clutch.
In assembly, make sure to locate the clutch

hook in the hook lock to fix the clutch in
position. The hook faces up.
Timing clutch support plate
KZ30 (Rev. 1.2) [��

3-8 ]
8. Disconnect wire harness clamps from the Drive gear bracket and remove the bracket. (8 screws)
Drive gear bracket
9. Remove the E-rings and remove the Gears.
[��
3-9 ] KZ30 (Rev. 1.2)
2. Main Motor Unit

3. Remove the Paper receiving tray.
4. Remove Suction cover.
5. Remove Suction unit.
- continues to next page -
Suction cover
Suction unit
KZ30 (Rev. 1.2) [��

3-10 ]
6. Remove the Drive gear bracket by following the instructions given on pages from 3-7 to 3-9.
Drive gear bracket
7. Remove the mounting screws, disconnect the connector and remove the Main motor out from the
opening in the paper receiving area. (3 screws)
[��
3-11 ] KZ30 (Rev. 1.2)
3. Master Removal Unit Safety Switch

1. Turn OFF the machine power and disconnect the power cord from the machine.
2. Remove the Master removal unit cover.
3. Open the Master removal unit, disconnect the Connector of the Master removal unit safety switch and
remove the switch assembly. (1 screw)
4. Open the Master removal unit safety switch assembly and remove the switch. (2 screws)
Master removal unit Master removal unit safety switch assembly
Master removal unit safety switch assembly Master removal unit safety switch
KZ30 (Rev. 1.2) [��

3-12 ]
4. Master Making Unit Safety Switch

2. Remove the Master removal unit from the machine. (Refer to the Chapter on Master making unit.)
3. Disconnect the Connector of the Master making unit safety switch.
4. Remove two mounting screws of the Master making unit safety switch and remove the switch.
Precautions in Assembly
Install the switch in the correct direction.
Master making unit safety switch Master making unit
[��
3-13 ] KZ30 (Rev. 1.2)
5. Separation Unit Safety Switch

2. Remove the Front cover.
3. Remove the Mechanical control PCB.
4. Open the Separation unit as shown on the photograph below.
5. Disconnect the connector, remove the Separation unit switch assembly from the machine (1 screw)
and remove the switch from the bracket.
Master removal unit

safety switch assembly
Separation unit
Mechanical control PCB assembly
KZ30 (Rev. 1.2) [��

3-14 ]
6. Print Drum Safety Switch

3. Disconnect the connector and remove the Print drum safety switch. (1 screw)
CAUTION:
Do not deform the sensor bracket, as it acts as metal spring when the Print drum in inserted in the
machine.
[��
3-15 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

3-16 ]
Imagetec Solutions Australia FIRST PAPER FEED SECTION
CHAPTER 4: FIRST PAPER FEED SECTION
CONTENTS
1. Theory of Operation.....................................................................................4-3
1. Paper Feed Tray Positions (Upper / Lower)..........................................4-3
2. First Paper Feed Drive Mechanism.......................................................4-4
3. Paper Pickup System.............................................................................4-6
4. Paper Feed Pressure Select System.....................................................4-7
2. Removal and Assembly...............................................................................4-9
1. Paper Feed Tray Unit.............................................................................4-9
2. Pickup Roller Assembly.......................................................................4-10
3. Pickup Roller and Paper Feed Support Roller ....................................4-11
4. Stripper Pad.........................................................................................4-12
5. Paper Feed Clutch ..............................................................................4-13
3. Adjustment..................................................................................................4-15
1. Paper Feed Clutch ON/OFF Timing . ..................................................4-15
[��
4-1 ] KZ30 (Rev. 1.2)
FIRST PAPER FEED SECTION Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

4-2 ]
1. Theory of Operation
1. Paper Feed Tray Positions (Upper / Lower)
Paper Feed Tray Set Lever
> Raising the Paper feed tray set lever raises the Paper feed tray to the upper limit position.
The Paper feed tray (paper) touches the Pickup roller.
> Lowering the Paper feed tray set lever lowers the Paper feed tray to the lower limit position.
The Paper feed tray (paper) releases down from the Pickup roller.
Paper feed tray set lever
Paper feed tray
Paper feed tray UP Paper feed tray DOWN
Paper feed tray set lever
[��
4-3 ] KZ30 (Rev. 1.2)
2. First Paper Feed Drive Mechanism

Paper Feed Clutch
> The drive from the Main motor is transferred to the Pickup roller shaft by the gears.
> The Paper feed clutch activates at a given Print drum angle from drum position-A to rotate the Pickup
roller shaft to feed the papers.
This Drum angle is determined by the count signal from the motor encoder sensor.
> The Paper feed clutch is deactivated as the Print drum rotates for a certain set degrees from the
Drum position-A.
> The Paper feed clutch activation and deactivation timings change according to the printing speed.
End of First Paper Feed

> The First paper feed ends when the Paper feed clutch deactivates.
> The leading edge of the paper rests against the Guide roller and Timing roller and makes a buckle.
> The Pickup roller rotates freely in the direction of paper feed by the one-way bearing on the roller to
avoid applying brake on the paper when the Second paper feed takes over the paper feed.
Pickup roller
Pickup roller shaft
Main motor Paper feed clutch
KZ30 (Rev. 1.2) [��

4-4 ]
First Paper Feed Timing Chart
Press "START" key

Drum rotation starts from Drum Position-A
1-1 79.3 2-1 157.8 1-1 79.3 2-1 157.8
Drum rotation 0 1-2 76.7 2-2 155.2 0 1-2 76.7 2-2 155.2 0
ON
Main motor Blocked

Open
Position-A Sensor
ON
Paper feed clutch
[In case the drum rotation speed is 60 r.p.m.]
1-1 The Paper feed clutch activates each time the Drum rotates 79.3 plus/minus C from the A position.
The angle "C" can be adjusted by Test Mode No. 741, which adjusts the ON timing of the Paper feed
clutch.
2-1 The Paper feed clutch is deactivated when the Drum rotates 157.8 plus/minus C from the A position.
The angle "C" can be adjusted by Test Mode No. 742, which adjusts the paper buckle amount.
[In case the drum rotation speed is 90 r.p.m.]
1-2 The Paper feed clutch activates each time the Drum rotates 76.7 plus/minus C from the A position.
The angle "C" can be adjusted by Test Mode No. 744, which adjusts the ON timing of the Paper feed
clutch.
2-2 The Paper feed clutch is deactivated when the Drum rotates 155.2 plus/minus C from the A position.
The angle "C" can be adjusted by Test Mode No. 745, which adjusts the paper buckle amount.
Guide roller Print drum

Pickup roller
Paper
Stripper pad
Timing roller
[��
4-5 ] KZ30 (Rev. 1.2)
3. Paper Pickup System
Feeding
> The papers on the Paper feed tray are fed by the Pick roller, in several layers, in between the Pickup
roller and Stripper pad.
Pick-up
> The top sheet is separated from the rest by the Pickup roller and Stripper pad.
> The Stripper pad is pushed against the Pickup roller [A] by the Stripper spring to provide
resistance against paper feed, by which only a single sheet of paper is fed from the paper
stack.
Pickup roller
Paper
Stripper pad
Stripper spring
KZ30 (Rev. 1.2) [��

4-6 ]
4. Paper Feed Pressure Select System
Paper Feed Pressure Adjust Lever

> The Paper feed pressure adjust lever is located on the front side of the machine, and it
changes the pressure of the Paper feed tray applied against the Pickup roller, as a result the
pressure against the papers on the Paper feed tray is changed.
> When the Paper feed pressure adjust lever is positioned at upper position, the Pressure spring is
loose and applies less pull on the paper feed tray. This is the setting for thin papers.
> As the Paper feed pressure lever is shifted down, the Pressure spring stretches and pulls the Paper
feed tray stronger against the Pickup roller.
The lever, at all the way down position is for thick papers.
> The Paper feed pressure adjust lever at in-between-positions are for normal thickness papers.
Pressure spring
Paper feed pressure adjust lever Paper feed tray set lever
Paper feed pressure
Thin paper: When using Thin paper.
Standard paper 1:
When using Coarse paper.
Standard paper 2:
When using standard paperS
Thick paper: When using Thick paper
[��
4-7 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

4-8 ]
2. Removal and Assembly

1. Paper Feed Tray Unit
2. Lower the Paper feed tray.
3. Remove the Paper feed tray unit from the both side of the Lock pins.
Precaution in Assembly
> Make sure to hook the the Paper feed tray unit to the both side of the Lock pins firmly in position.
Lock pin
Paper feed tray unit
[��
4-9 ] KZ30 (Rev. 1.2)
2. Pickup Roller Assembly

2. Lower the Paper feed tray.
4. Remove the Paper feed tray from the machine.
5. Remove Lock rings on the right end of the Pickup roller shaft and remove the Metal.
6. Slide the Pickup roller shaft to the rear side of the machine and remove the Pick up roller
assembly.
Lock ring
Metal
Paper feed tray
Pickup roller shaft
KZ30 (Rev. 1.2) [��

4-10 ]
3. Pickup Roller and Paper Feed Support Roller

2. Remove the Pickup roller assembly.
3. Slide the Paper feed support rollers from the Pickup roller shaft.
4. Remove Lock ring from the Pickup roller shaft.
5. Slide the Pickup roller out from the shaft.
> Core of the Pick up roller has a slit for a Pin on the left-hand-side side when the roller is installed.
If the roller is put back on the shaft turned around, the Pick up roller cannot be positioned correctly
and the the Lock ring cannot be installed.
When mounted correctly on the shaft, the pin fits in the Pickup roller shaft and the Lock ring can be
installed.
Pin
Lock ring
Paper feed support roller
Pickup roller
Paper feed support roller
[��
4-11 ] KZ30 (Rev. 1.2)
4. Stripper Pad
2. Lower the Paper feed tray all the way down.
3. Remove the Lock ring of the Pickup roller then slide the roller towards the rear of the machine and
remove the Pin.
4. Remove the Stripper pad base carefully, not to damage the Stripper spring.
5. Remove the Stripper Pad from the Stripper pad base.
> Set the Stripper spring correctly in the machine before setting the Stripper pad base back in place.
> Make sure to fit the Pickup roller in correct position then inserting the Lock ring.
Stripper pad
Stripper pad base
Stripper spring
KZ30 (Rev. 1.2) [��

4-12 ]
5. Paper Feed Clutch

1. Disconnect the power supply from the machine.
2. Remove Back cover.
3. Remove the Paper feed Clutch support plate. (3 screws)
4. Disconnect the Connector of the Paper feed clutch.
5. Remove the Paper feed clutch from the shaft.
> Mount the hook on the clutch into the hook lock holes to prevent the clutch from rotating. (Refer to the
photograph below)
Paper feed clutch support plate
Paper feed clutch
Hook on the Clutch
[��
4-13 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

4-14 ]
3. Adjustment
1. Paper Feed Clutch ON/OFF Timing

Use the Paper feed clutch ON and/or OFF timing adjustment test mode to control the paper buckle
amount.
The paper buckle is made on the tip of the paper when the first paper feed action ends.
The tip of the paper rests against the Timing roller and Guide roller and makes the buckle.
If not enough buckle is made, the second paper feed will not take the paper, and cause paper jam.
If too much buckle is made, the tip of the paper will fold and cause paper jam.
Paper feed clutch ON timing:

For the 60 r.p.m. printing, use test mode No.741.
The larger parameter numbers for these two test modes make the clutch ON timing earlier, and increase
the paper buckle amount.
Paper feed clutch OFF timing:

The smaller parameter numbers for thee two test modes make the clutch OFF timing delayed, and
increases the paper buckle amount.
NOTE:
The paper buckle amount is also affected by the Timing clutch ON timing adjustment (next Chapter).
The Timing clutch ON timing adjustment will affect the image position on the paper, so do not use that
adjustment for the paper buckle amount adjustment.
But keep in mind that if the Timing clutch ON timing adjustment is made to control the image position, the
Paper feed clutch ON/OFF timing adjustment may have to be adjusted for proper paper buckle amount.
[��
4-15 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

4-16 ]
Imagetec Solutions Australia SECOND PAPER FEED SECTION
CHAPTER 5: SECOND PAPER FEED SECTION
CONTENTS
1. Second Paper Feed Drive Mechanism..................................................5-3
2. Vertical Printing Position........................................................................5-4
1. Load Spring . .........................................................................................5-5
2. Timing Clutch ........................................................................................5-6
3. Paper Guide Plate . ...............................................................................5-7
4. Paper Gate . ..........................................................................................5-8
5. Timing Roller / Guide Roller...................................................................5-9
3. Adjustment .................................................................................................5-10
1. Print Position (Timing Clutch ON timing)...............................................5-10
[��
5-1 ] KZ30 (Rev. 1.2)
SECOND PAPER FEED SECTION Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

5-2 ]
1. Second Paper Feed Drive Mechanism

1. Drive
> Timing clutch makes clockwise rotation (looking from the rear of machine) with the turn of the Main
motor.
> The Timing gear rotation is transferred to the Timing gear via the Timing clutch.
> The Timing roller rotates Guide roller.
2. Timing Clutch
> After given time from the end of the first paper feed, the Timing clutch activates to rotate the Timing
roller.
3. Timing Roller
> The Timing roller contains Load spring which applies brake on the roller at all times.
It stops the rotation of the roller as soon as the Timing clutch goes off.
4. Guide Roller
> The Guide roller is always in contact with the Timing roller.
> The rotation of the Guide roller is received from the Timing roller.
> The Guide roller rotation stops when the Timing clutch goes off to stop the Timing roller.
Paper gate
Load spring
Guide roller
Timing roller
Main motor Timing clutch
Timing gear
[��
5-3 ] KZ30 (Rev. 1.2)
2. Vertical Printing Position

1. Timing Clutch
> The print position is depending on when the Timing clutch goes on.
> Normally the Timing clutch goes ON when the drum angle becomes 160.3 degrees and goes OFF
when the drum angle becomes 61.3 degrees in case the drum speed is 60 r.p.m.
> When the drum rotation speed is 90 r.p.m., the Timing clutch goes ON at the drum angle 157.7
degrees and goes OFF at the drum angle 58.7 degrees.
2.Print Position
> Print position can be changed by pressing the print position adjustment key or on the
control panel.
> When the key is pressed, the Timing clutch ON timing becomes earlier and the print position
moves down.
> When the key is pressed, the Timing clutch ON timing becomes late and the print position moves
up.
0 90 180 270 360

Drum rotation
79.3 (76.7) 157.8 (155.2)

78.5
Paper feed clutch 1st
160.3 (157.7)
Paper feed clutch 2nd
61.3
(58.7)
Paper gate
Guide roller
Timing roller
Timing clutch
Timing clutch gear
KZ30 (Rev. 1.2) [��

5-4 ]
1. Load Spring
1. Tun OFF the machine power and disconnect the power cord from the machine.
2. Remove Front cover.
3. Remove Print drum.
4. Remove E-ring and Washer from the Timing roller shaft.
6. Remove the Load spring from the shaft.
> Install the Load spring in the correct direction.
Load spring
washer
E-ring
[��
5-5 ] KZ30 (Rev. 1.2)
2. Timing Clutch
1. Turn OFF the machine power and disconnect power cord from the machine.
2. Remove Rear cover.
3. Remove the Timing clutch support plate. (4 screws)
4. Disconnect connector and remove the Timing clutch.
Caution in Assembly
> Make sure to lock the hook on the Timing clutch into the clutch lock hole to prevent clutch body from
rotating.
Hook on the timing clutch
Timing clutch support plate Timing clutch
KZ30 (Rev. 1.2) [��

5-6 ]
3. Paper Guide Plate

2. Remove following parts from the machine.
> Rear cover
> Paper feed tray unit
> Paper feed clutch with the bracket
> Pick up roller assembly
> Print drum
3. Remove the Paper guide plate upper. (2 screws)
4. Remove 2 mounting screws from the Paper guide plate lower.
5. Slide out the Master removal unit and remove the Paper gate. (1 screw)
6. Take out the Paper guide plate lower from the the Paper feed tray side while raising the Guide roller
by hand.
Paper gate
Paper feed clutch
Paper guide plate lower
Paper guide plate upper
Pickup roller assembly
Paper feed tray
[��
5-7 ] KZ30 (Rev. 1.2)
4. Paper Gate
2. Remove the Print drum.
3. Slide out the Master removal unit.
4. Remove the mounting screw of the Paper gate and remove the Paper gate.
Precautions before Assembly

> Do not secure the mounting screw too much to prevent the plastic Paper gate from breakage.
Mounting screw
Paper gate
KZ30 (Rev. 1.2) [��

5-8 ]
5. Timing Roller / Guide Roller

3. Remove the Paper guide plate (upper & lower).
4. Remove the Paper gate.
5. Remove following parts from the Timing roller shaft.
> Load spring
> One-way gear and Metal
6. Remove the Timing roller
7. After removing the Timing roller, remove the E-rings and Bushings from both sides of the Guide roller
shaft.
8. Remove the Guide roller assembly.
> Install the Load spring [G] in the correct direction.
> Check if paper is fed correctly or not after assembled all parts. If not, disassemble all parts again
and then re-assemble the parts.
E-ring
Bushing (short) Load spring

Bushing (long)
E-ring
Bushing (short)
Bushing (long)
One-way gear
Timing roller
Guide roller
[��
5-9 ] KZ30 (Rev. 1.2)
3. Adjustment
1. Print Position (Timing Clutch ON timing)
Vertical print position can be adjusted by changing the Timing clutch activate timing.
The Timing clutch activate timing can be changed by using TEST MODE No.789 or No.791.
Test No.789 is for when the machine runs at 60 r.p.m. and Test No.791 is for when the machine runs at
90 r.p.m..
Adjustment Procedure
1. Turn OFF the machine power.
2. Go into Test Mode by turning the machine power ON by pressing and key on the control panel.
3. With B4 size paper on teh paper feed tray, enter Test Mode No.80 to make a master with checker-
flag image.
4. Press [Reset] key to escape from the Test Mode. Make about 5 prints at speed No.1 (60 r.p.m) and
another 5 prints at speed No.2 (90 r.p.m.).
5. For the both set of prints, measure the distance from the top of the paper to where the print image
starts.
6. The image should print 10mm from the top edge of the papers. If not, adjustments using Test Modes
No.789 and/or No.791 is necessary.
7. In the case the white margin is less than 10mm, smaller parameter number should be input for those
test modes. Smaller parameter numbers make the Timing clutch ON timing faster and increase the
white margin.
8. In the case the white margin is more than 10mm, larger parameter number should be input for those
test modes. Larger parameter numbers make the Timing clutch ON timing to delay and decrease the
white margin.
Result of Incorrect Adjustment

> Incorrect adjustment may cause blurry top image, stained pressure roller caused by image shifting
down on the paper, or paper not separated from the Print drum (paper jam) caused by too small
white margin on the top of the paper.
KZ30 (Rev. 1.2) [��

5-10 ]
Imagetec Solutions Australia PRESS SECTION
CHAPTER 6: PRESS SECTION
CONTENTS
1. Press Mechanism..................................................................................6-3
1. Pressure Roller......................................................................................6-5
2. Pressure Lever Assembly......................................................................6-6
3. Pressure Shaft Assembly.......................................................................6-7
3. Adjustment....................................................................................................6-9
1. Pressure Lever Assembly Position........................................................6-9
[��
6-1 ] KZ30 (Rev. 1.2)
PRESS SECTION Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

6-2 ]
1. Press Mechanism
1. Pressure Lever and Pressure Roller
> The Pressure lever is mounted on the Pressure shaft. The Pressure roller is mounted on the
Pressure assembly, which is fixed on the Pressure shaft.
> While the Main motor is making the Print drum rotation without paper (not in printing process),
the Pressure hook engages with the Pressure lever so that the Pressure roller stays down.
> When paper comes in and pushes the Paper gate up, the Pressure hook rises. Then the Pressure
lever is released and the Cam follower of the Pressure lever assembly touches against the Pressure
cam. The Pressure roller is pushed up and hits against the Print drum to make the print.
> The Pressure spring pulls the Pressure roller up against the Print drum.
> Once the Pressure lever is released from the Pressure hook, movement of the Pressure lever is
controlled by the Pressure cam.
> The Pressure roller is lowered down by the Pressure cam where the Clamp plate on the Drum comes
near the Pressure roller to prevent damaging the Clamp plate.
> The Pressure hook comes down when the printing job is completed and paper is no longer fed from
the Paper feed tray. The Pressure hook engages with the Pressure lever to keep the Pressure roller
away from the Print drum.
Pressure shaft
Paper gate
Pressure shaft assembly Pressure roller Pressure cam
Cam follower
Paper gate is pushed up by

paper, and Pressure hook is
raised.
Pressure assembly Then the Pressure lever is
raised by the Pressure cam
to press the Pressure roller
against the Print drum to
make the prints.
When the printing job ends

Pressure spring and the paper is no longer
Main motor fed, the Pressure hook
comes down to hook against
Pressure lever assembly the Pressure lever.
The Pressure roller no
longer goes up against the
Print drum.
Pressure hook
[��
6-3 ] KZ30 (Rev. 1.2)
Lifting the Pressure Roller

The Paper gate is pushed up by paper throughout the printing.
So the Pressure lever becomes free.
Print drum
The Pressure spring pulls back the Pressure lever and rotates
the Pressure shaft which is acting as a pivot. Pressure shaft
The rotation of the Pressure shaft lifts the Pressure roller up
against the Drum.
Pressure cam
Pressure roller
Pressure spring
Pressure hook rotates up when the paper comes in.

Pressure lever assembly
Lowering the Pressure Roller

The Pressure roller is lowered by force, away from the Drum[C],
by the high part of the Pressure cam.
During the Drum rotation, when the Clamp plate of the Drum
comes close to the Pressure roller, the high part of the
Pressure cam pushes the Pressure lever down, rotating the
Pressure shaft counter-clockwise to bring the Pressure roller
down, away from the Drum.
Then Pressure lever is lowered by Pressure cam.
Pressure hook rotates down when the paper no longer comes.
KZ30 (Rev. 1.2) [��

6-4 ]

1. Pressure Roller
4. Remove the Suction unit.
5. Remove the Pressure spring.
6. Remove mounting screw of the Pressure roller from the Pressure shaft assembly through a hole on
the drive side of the machine frame.
7. Take out the Pressure roller from the Drum opening side of the machine, or from the top of the
machine after sliding the Master removal unit outward to open the top of the machine.
Screw
Pressure roller
[��
6-5 ] KZ30 (Rev. 1.2)
2. Pressure Lever Assembly

3. Remove the Print drum from the machine.
5. Remove two set screws from the Pressure lever assembly.
6. Turn the Pressure lever in clockwise direction (Pressure lever shows up behind the gear) then
remove the Pressure lever assembly from the Pressure shaft.
Adjustment after the Assembly

> Adjust the position of the Pressure lever assembly. (Refer to the adjustment section on this Chapter.)
Set screws
KZ30 (Rev. 1.2) [��

6-6 ]
3. Pressure Shaft Assembly

2. Remove the Print drum from the machine.
3. Remove both the Front and Rear covers.
5. Remove the Pressure lever assembly. (Refer to the previous page)
6. Remove E-rings from both ends of the Pressure shaft assembly and remove the Bushings.
7. Remove the Suction unit.
9. Slide the Pressure shaft assembly towards the rear (drive side) of the machine once, and then
remove it out from the Paper receiving side of the machine.
Adjustment after the Assembly

> Adjust the position of the Pressure lever assembly. (Refer to the adjustment section on this Chapter.)
E-ring
Bushing
Pressure shaft assembly
Bushing
E-ring
Pressure spring
Pressure lever assmbly
[��
6-7 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

6-8 ]
3. Adjustment
1. Pressure Lever Assembly Position
1. Make confidential master on the Drum.
2. Bring the Print drum to B-position.
5. Remove the Suction unit and disengage the Pressure spring.
6. Using finger, disengage the Pressure lever from the Hook lever by pushing up the Hook lever to
disengage the Pressure lever.
7. Hook the Pressure lever, so that the Pressure roller hits against the Print drum.
8. Confirm that the gap between the Pressure cam and Cam follower on the Pressure lever is between
2 mm to 2.5 mm.
9. If the gap is too small or big, loosen the two set screws on the Pressure lever assembly.
10. Place 2.0 mm or 2.5 mm Allen key (or 2.0 mm to 2.5 mm thick plate) between the Pressure cam and
Cam follower and push up the Pressure lever assembly against the Pressure cam.
11. While pushing the Pressure lever assembly tightly against the Pressure came with the Allen key or
plate in between (refer to the above), tighten the two set screws on the Pressure lever assembly.
12. Remove the 2.0 mm or 2.5 mm Allen key (or 2.0 mm to 2.5 mm thick plate), which was inserted
between the Pressure cam and Cam follower.
13. Confirm that the gap between the Pressure cam and Cam follower on the Pressure lever is between
2 mm to 2.5 mm.
If not, repeat the above procedures until correct gap is obtained.
Results of Incorrect Adjustment

> If the gap is smaller than 2 mm, the Pressure roller leaves from the Drum too early. As a result,
the tailing edge of the paper may not be printed clearly.
> If the gap is too big, the Pressure roller may hit the Clamp plate of the Drum during printing and
damage the Clamp plate.
Rotate the Print drum to the B-position

Adjust the gap between the Pressure cam before turning the machine power OFF.
and Cam follower to 2.0 mm to 2.5 mm by (The Print drum in the sketch is
inserting 2.0 mm or 2.5 mm Allen wrench still not in Position-B.)
or plate between the Cam and Cam
follower. Hook lever
Pressure cam
2.0 mm to 2.5 mm gap

m
.5 m
o2
mtm
Pressure assembly
2.0
Cam follower
B-position
[��
6-9 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

6-10 ]
Imagetec Solutions Australia PAPER EJECTION SECTION
CHAPTER 7: PAPER EJECTION SECTION
CONTENTS
1. Paper Ejection Mechanism....................................................................7-3
2. Paper Separation Mechanism................................................................7-4
1. Suction Unit............................................................................................7-5
2. Transfer Belt..........................................................................................7-6
3. Suction Fan............................................................................................7-7
4. Separation Fan Unit...............................................................................7-8
5. Separation Fan......................................................................................7-9
6. Paper Receiving Sensor........................................................................7-9
7. Separator.............................................................................................7-10
3. Adjustment..................................................................................................7-11
1. Separator Position...............................................................................7-11
[��
7-1 ] KZ30 (Rev. 1.2)
PAPER EJECTION SECTION Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

7-2 ]
1. Paper Ejection Mechanism
1. Paper Separation from the Drum
> The paper is separated from the Drum by the Paper separation fan and Separator.
2. Paper Ejection
> Suction fan pulls the paper, separated from the Drum, on to the Suction unit.
> The Transfer belts on the Suction unit, driven by the Main motor, ejects the paper onto the Paper
receiving tray.
> Drive speed of the Transfer belt is 1.6 times as the Drum rotation speed.
3. Paper Receiving Sensor

> Paper receiving sensor checks whether the paper is separated from the Drum and ejected correctly
or jammed.
Separation fan
Separator
Paper receiviing sensor
Transfer belts
Suction fan
[��
7-3 ] KZ30 (Rev. 1.2)
2. Paper Separation Mechanism

1. Separator
> The tip of the Separator is close to the Drum when it separates a paper from the Drum.
> When the Clamp plate on the Drum comes close to the Separator, the Drum support left which is
attached on the Drum pushes the Separator away from the Drum.
Separator lever assembly

Separator
Drum support left
Separator shaft
KZ30 (Rev. 1.2) [��

7-4 ]

1. Suction Unit
4. Remove the Suction unit cover.
5. Disconnect the Connector of the Suction unit.
6. Remove two mounting screws of the Suction unit and remove the unit by sliding it out.
> Hook the Suction unit on both side of the plates on the machine frame.
> Insert the Feet of the Suction unit cover into the slit holes in the machine Base plate.
Base plate
Suction unit
Feet of Scution cover

Suction unit cover
[��
7-5 ] KZ30 (Rev. 1.2)
2. Transfer Belt
4. Remove two mounting screws of the De-electricity brush and remove the brush.
5. Remove the Jump wings.
6. Remove four mounting screws of the Suction face cover.
7. Lift the face cover and remove the Belt driven shaft by unhooking the Transfer belts.
8. Remove E-ring of the Belt pulley shaft and remove the Bushing.
9. Slide the Belt pulley shaft and remove the Transfer belts from the Suction face cover.
> Match the half-pierced section on the Suction face cover with its counter part.
> Match the half-pierced section on the De-electricity brush with its counter part.
Jump wings Suction face cover
Transfer belts
Belt pulley shaft
E-ring
Bushing
Belt driven shaft
De-electricity brush
KZ30 (Rev. 1.2) [��

7-6 ]
3. Suction Fan
4. Turn over the Suction unit and disconnect the Connector of the Suction fan.
5. Remove two mounting screws of the Suction fan and remove the fan.
Suction unit Suction fan
[��
7-7 ] KZ30 (Rev. 1.2)
4. Separation Fan Unit

3. Disconnect the Connector of the Separation fan unit.
4. Remove two mounting screws of the Separation fan unit and remove the unit.
> Match the half-pierced section on hinge of the Separation fan unit with its counter part.
Hinge of Separation unit
Separation fan unit
KZ30 (Rev. 1.2) [��

7-8 ]
5. Separation Fan
1. Remove the Separation fan unit.
2. Disconnect the Connector of the Separation fan.
3. Remove two mounting screws of the Separation fan and remove the fan.
6. Paper Receiving Sensor

2. Disconnect two mounting screws of the Separation fan.
3. Lift the fan and disconnect the Connector of the Paper receiving sensor.
4. Press the center hook of the Paper receiving sensor socket and lift the sensor out.
Separation fan
Paper receiving sensor
Separation fan unit
[��
7-9 ] KZ30 (Rev. 1.2)
7. Separator
2. Remove the Back cover and Front cover.
5. Remove the Separation spring.
6. Remove E-ring from the drive side of the Separator shaft.
7. Slide the Separation shaft towards the rear (machine drive side) and remove the Separation shaft.
E-ring
Separation shaft
Separator spring
KZ30 (Rev. 1.2) [��

7-10 ]
3. Adjustment
1. Separator Position
1. Using Test Chart No.8 or No.14, make a master and prints.
2. Adjust the printing position by the Print position button on the Operation panel, so that there is
10 mm white margin on the top of the prints.
3. Confirm that the paper separates from the Drum and there is no black line on the center of the
prints.
4. If the paper does not separate from the Drum, or there is a black line on the center of the prints, an
adjustment on the Separator position is necessary.
5. For the adjustment, turn OFF the machine power and disconnect the power cord from the machine
and remove the machine Front cover and Print drum cover.
6. Loosen the mounting screw of the Separator plate and slide the plate.
7. Tighten the mounting screw of the plate when the space between the tip of the Separator is between
1.0 mm and 2.0 mm from the Drum surface and not touching it.
Precaution in Adjustment
> Printed papers using Test Chart No.8 / No.14 original should separate from the Print drum when
the top white margin on the prints are adjusted to 10 mm by the Print position button.
Results of Incorrect Adjustment

> If the tip of the Separator is in contact with the Drum, the Separator will scratch the surface of the
master on the Drum, creating a black line in the center of the printed copies and may damage the
Drum screen.
> If the tip of the Separator is placed too far off from the Drum, printed copies will not separate from the
Drum, causing paper jams.
Print drum
Print drum
Separator
Separator
Separator lever
Print drum
Slid
Front of the machine,

e th
Separator plate
near the Print drum .
e pl
Mounting screw
ate
UP
or D
OW
N
[��
7-11 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

7-12 ]
Imagetec Solutions Australia PRINT DRUM
CHAPTER 8: PRINT DRUM
CONTENTS
MECHANISM......................................................................................................8-3
1. Master on Drum (in printing) Check Mechanism......................................8-3
2. Ink Bottle Set Check Mechanism.............................................................8-3
3. Drum Rotation Mechanism......................................................................8-3
4. Ink Supply Mechanism.............................................................................8-3
DISASSEMBLY...................................................................................................8-5
1. Ink Bottle Guide.......................................................................................8-5
2. Ink Bottle Set Switch................................................................................8-5
3. RF-PCB....................................................................................................8-6
4. Inking Motor.............................................................................................8-7
5. Drum Set Sensor.....................................................................................8-8
6. Drum Screen............................................................................................8-9
7. Drum Body.............................................................................................8-10
8. Ink Sensor PCB.....................................................................................8-11
9. Drum Flanges F (front) & R (rear).........................................................8-12
10. Squeegee Roller..................................................................................8-16
ADJUSTMENT..................................................................................................8-18
1. Cleaning the Filter..................................................................................8-18
2. Squeegee Gap Adjustment....................................................................8-19
3. Ink blocking plate position adjustment...................................................8-19
[��
8-1 ] KZ30 (Rev. 1.2)
PRINT DRUM Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

8-2 ]
MECHANISM
1. Master on Drum (in printing) Check Mechanism

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

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

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

While the Drum is being rotated by the Main motor, if the amount of ink within the Drum reduces and
the Ink sensor no longer touches the bead of ink, the Inking motor activates to pump the ink into the
Drum. The ink pumped by the Inking pump travels through the hose and goes into the Center shaft
of the Drum. The ink then drops onto the Squeegee roller from the distributor holes on the Center
shaft.
The Inking motor stops when the Ink sensor detects the bead of ink.
The ink dropped onto the Squeegee roller is made into an ink bead between the Squeegee roller
and Doctor roller. The ink is wrapped around the Driving shaft to be made into an even thickness ink
bead. A small gap between the Squeegee roller and Doctor roller allows the ink to cover the inner
surface of the Drum.
An Overflow sensor is located within the Drum to detect excess amount of ink to prevent ink-overflow.
If an overflow is detected, the machine is stopped with an error code display.
[��
8-3 ] KZ30 (Rev. 1.2)
Overflow sensor
Ink sensor
Inking motor
Driving shaft
Squeegee roller
KZ30 (Rev. 1.2) [��

8-4 ]
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
[��
8-5 ] KZ30 (Rev. 1.2)
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)
KZ30 (Rev. 1.2) [��

8-6 ]
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
[��
8-7 ] KZ30 (Rev. 1.2)
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
KZ30 (Rev. 1.2) [��

8-8 ]
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
[��
8-9 ] KZ30 (Rev. 1.2)
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
KZ30 (Rev. 1.2) [��

8-10 ]
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.
Actual Ink Sensor PCB looks different.

< This is only a sample photograph >
Overflow sensor Ink sensor PCB Ink sensor
[��
8-11 ] KZ30 (Rev. 1.2)
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.]
KZ30 (Rev. 1.2) [��

8-12 ]
Rear frame
Drum support R
Side channel
Rear frame
IB lock
Set screw
Cap screw
Drum support F
Front frame
[��
8-13 ] KZ30 (Rev. 1.2)
1) Use the Drum Shaft JIG when mounting the screws back onto the Drum shaft clamper.
( Dram shaft Jig = 015-75008-006 Drum Shaft JIG )
2) With the Drum at position-B, insert the Drum Shaft JIG through the Front support plate, Drum
flange-F, Front frame, Rear frame, Drum flange-R and Rear support plate. Then tighten the
screws on the front and rear Drum shaft clamper.
4) Using three wire harness lock bands of each about 100mm long, fix the position of the Ink sensor
relay wire harness to the Support frame and Rear support plate.
5) Make sure that the Ink sensor relay wire harness does not have any slack in the area indicated by
the dotted line on the photograph, and that the wire harness lock band tie area does not protrude
outside the bracket. This is to protect the wire harness.
Adjustments after Assembly

1) Squeegee gap adjustment
2) Ink blocking plate position adjustment Drum support R
Drum support F
3) Squeegee pressure balance adjustment Rear frame
Actual Print drum look different.

This is only a sample photograph.
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.
KZ30 (Rev. 1.2) [��

8-14 ]
The recommended Drum Shaft Jig is 051-75008-006.
051-75008-006 Drum Shaft Jig
If older version Drum Shaft Jig 015-26128-008, it works only for the Drum support F (front).
It will not work for the Drum support R (rear).
Drum Shaft Jig 015-26128-008
With the Drum Shaft Jig 015-26128-008 inserted

in the drum, as much as it can go in, the rear
portion of the Print drum must be supported by a
rectangular block to align the rear portion of the
Print rum.
[��
8-15 ] KZ30 (Rev. 1.2)
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.
Adjustments after Assembly

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

Mounting screw
Front frame
KZ30 (Rev. 1.2) [��

8-16 ]
Shaft joint Center shaft
Squeegee roller
Driving shaft
Front frame
Squeegee roller
Rear frame
[��
8-17 ] KZ30 (Rev. 1.2)
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
KZ30 (Rev. 1.2) [��

8-18 ]
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.
Results of incorrect adjustment

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.
Results of incorrect adjustment

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.
[��
8-19 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

8-20 ]
Imagetec Solutions Australia CLAMP UNIT
CHAPTER 9: CLAMP UNIT
CONTENTS
MECHANISM......................................................................................................9-2
1. Clamp Unit Home Position Movement.....................................................9-2
2. Clamp Plate Master Release Movement.................................................9-2
3. Clamp Plate Master Clamp Mechanism...................................................9-3
DISASSEMBLY...................................................................................................9-4
1. Clamp Unit...............................................................................................9-4
2. Clamp Motor............................................................................................9-5
3. Clamp Sensor..........................................................................................9-6
[��
9-1 ] KZ30 (Rev. 1.2)
CLAMP UNIT Imagetec Solutions Australia
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
KZ30 (Rev. 1.2) [��

9-2 ]
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
[��
9-3 ] KZ30 (Rev. 1.2)
DISASSEMBLY
1. Clamp Unit
REMOVAL
1) Turn OFF the machine power, disconnect the power cord from the machine and remove the Rear
cover.
2) Unplug the wire harness connectors of the Clamp motor and Clamp sensor.
3) Remove the mounting screws of the Clamp unit and remove the unit. (M3x6 screws; 3 pcs)
1) Match the positioning hole against the positioning pin in attaching the Clamp unit back on the
machine.
Mounting screw
Clamp motor
Mounting screw
Clamp sensor
Mounting screw
Apply grease.
10
8
6
7 A
6 B
16 15
9
1
5
4
3
Print drum
14
A
14
B
13
11
12
KZ30 (Rev. 1.2) [��

9-4 ]
2. Clamp Motor
REMOVAL
1) Turn OFF the machine power, disconnect the power cord from the machineand remove following
parts.
Rear cover
Clamp unit (M3x6 screws; 3 pcs)
2) Remove E-ring from the Clamp gear and detach the gear.
3) Detach the Clamp motor.
1) When mounting the Clamp gear back on the Clamp unit, make sure that both the Clamp open
arm and Master release arm are in fully raised position.
Clamp motor
Mounting screw
[��
9-5 ] KZ30 (Rev. 1.2)
3. Clamp Sensor
REMOVAL
1) Turn OFF the machine power, disconnect the power cord from the machinand remove following
parts.
Rear cover
Clamp unit (M3x6 screws; 3 pcs)
2) Remove E-ring from the Clamp gear and detach the gear.
3) Rotate the Clamp cam and move the actuator plate out from the Clamp sensor.
4) Detach the Clamp sensor.
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
KZ30 (Rev. 1.2) [��

9-6 ]
Imagetec Solutions Australia MASTER REMOVAL SECTION
CHAPTER 10: MASTER REMOVAL SECTION
CONTENTS
1. Theory of Operation...................................................................................10-3
1. Master Removal Unit Mechanism........................................................10-3
2. Master on the Drum (before master removal) Check Mechanism....... 10-4
3. Master Removal Mechanism...............................................................10-5
4. Master Disposal Box Set Mechanism..................................................10-6
2. Removal and Assembly.............................................................................10-7
1. Master Removal Unit...........................................................................10-7
2. Master Removal Motor Assembly........................................................10-8
3. Master Removal Sensor......................................................................10-9
4. Disposal Box Set Sensor ..................................................................10-10
5. Master Removal Hook.......................................................................10-11
6. Vertical Transport Roller (Upper).......................................................10-12
7. Vertical Transport Roller (Lower).......................................................10-12
[��
10-1 ] KZ30 (Rev. 1.2)
MASTER REMOVAL SECTION Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

10-2 ]
1. Master Removal Unit Mechanism
> The Master removal unit removes the master on the drum each time the master making operation is
made.
> The Master removal hooks guide the removed master towards the Master disposal box.
> The Transportation roller upper and lower are engaged via gears. And rotation of the transportation
roller upper and lower is made by the Mater removal motor.
Transportation roller upper Transportation roller lower Master removal unit
Master removal hook
Master removal motor
Master disposal box
[��
10-3 ] KZ30 (Rev. 1.2)
2. Master on the Drum (before master removal) Check Mechanism

1. Master Sensor
> Master sensor checks the presence of the Master on the drum when the Start button is pressed for
confidential master making or normal master making.
> The sensor looks for the presence of the Master on the drum when the drum angle is at 107 degrees
from the A-position, where the black colored Light absorber strip is on the drum.
> If the machine already knows the presence of the Master on the drum from the earlier machine
operations, this Master checking movement is skipped.
2. When master is detected on the Drum

> The machine goes into master removal and Master removal sensor becomes active.
3. When master is not detected on the Drum

> The machine goes into master removal but the Master removal sensor is inactive.
Master sensor
Master
Print drum
Light absorber strip

Drum angle = 107 degrees from A-position
Master
Master sensor
Print drum
107
KZ30 (Rev. 1.2) [��

10-4 ]
3. Master Removal Mechanism

1. Master Removal Motor
> The Master removal motor rotates the Vertical transport roller upper and lower via gears.
> By the rotation of the Drum, the leading edge of the master comes in between the Vertical
Transport roller upper and lower and the separation of the master from the Drum starts.
> The 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.
2. Master Removal Hooks

> The master removed from the Drum is guided in between the Vertical transport roller upper and lower
by the Master removal hooks.
3. 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 the presence of removed master at Drum rotation angle 114
degrees and 134 degrees from Position-A.
If the Master removal sensor does not detect the presence of the removed master at both of these
drum angles, the master removal error is detected.
Transportation roller upper

Transportation roller lower
Master removal unit
Master removal hook
[��
10-5 ] KZ30 (Rev. 1.2)
4. Master Disposal Box Set Mechanism

1. Disposal Box Set Sensor
> Disposal box set sensor checks the presence of the Master disposal box in the machine.
> When the Master disposal box is set in the machine, the metal leg blocks the light path of the
Disposal box set sensor.
Master removal unit
Master disposal box
Metal leg
Master disposal box set sensor
KZ30 (Rev. 1.2) [��

10-6 ]

1. Master Removal Unit
2. Pull up the Master removal unit lever then slide the Master removal unit out.
3. Remove Master removal cover.
4. Disconnect the Connector of the Master removal unit.
5. Remove the four mounting screws (4 screws) of the Master removal unit.
6. Remove the Master removal unit from the machine.
Connector
Screw Screw
Screw
Screw
Master removal unit
[��
10-7 ] KZ30 (Rev. 1.2)
2. Master Removal Motor Assembly

3. Disconnect the Connector of the Master removal motor.
4. Remove two mounting screws of the Master removal motor assembly and remove the motor
assembly from the machine.
> Match the half-pierced section when mounting the motor assembly back on the machine.
Master removal motor assembly
KZ30 (Rev. 1.2) [��

10-8 ]
3. Master Removal Sensor

2. Remove the Master removal unit cover and Master disposal box.
3. Slide the Master removal unit from the machine.
4. Disconnect the Connector of the Master removal sensor.
5. Remove the mounting screw of the Master removal sensor bracket and remove the bracket.
6. Remove the sensor from the bracket.
> Match the half-pierced section of the Master removal sensor bracket with its counter part.
Screw Master removal unit
Connector
Sensor bracket
Master removal sensor
[��
10-9 ] KZ30 (Rev. 1.2)
4. Disposal Box Set Sensor

2. Remove the Master removal unit cover.
3. Remove the Master removal guide lower (3 screws).
4. Disconnect the Connector of the Disposal box set sensor.
5. Remove the two mounting screws of the Disposal box set sensor bracket and remove the bracket.
6. Remove the sensor from the bracket.
> Match the half-pierced section of the Disposal box set sensor bracket with its counter part.
Master removal unit
Master removal guide lower
Disposal box set sensor bracket
Disposal box set sensor
Connector
KZ30 (Rev. 1.2) [��

10-10 ]
5. Master Removal Hook

2. Remove Master removal unit.
3. Remove the Master removal guide lower.
4. Gently disengage the Master removal hooks from the Master removal guide lower.
> Do not apply unnecessary force to the Master removal hooks to avoid any damage on the hooks.
Master removal guide lower
Master removal hooks
[��
10-11 ] KZ30 (Rev. 1.2)
6. Vertical Transport Roller (Upper)

2. Remove the Master disposal box.
3. Remove the Master removal unit.
4. Remove the Master removal sensor.
6. Remove the Master removal guide upper.
7. Remove E-rings from both ends of the Vertical transport roller (Upper) and remove the Bushing.
8. Remove the Vertical transport roller (Upper).
7. Vertical Transport Roller (Lower)

1. Turn OFF the machine power, disconnect the power cord from the machine.
2. Remove the Master disposal box.
3. Remove the Master removal unit.
4. Remove the Master removal sensor.
6. Remove the Master removal guide upper.
7. Remove the Vertical transport roller (Upper).
8. Remove E-ring then remove the Transport roller gear.
9. Remove E-ring of the Vertical transport roller (Lower) and remove the Bushing.
10. Remove the Vertical transport roller (Lower).
Vertical transport roller (Upper)
Vertical transport roller (Lower)
Master removal unit
Master removal guide upper
KZ30 (Rev. 1.2) [��

10-12 ]
Imagetec Solutions Australia IMAGE SCANNING SECTION
CHAPTER 11: IMAGE SCANNING SECTION
CONTENTS
1. Original Loading Mechanism...............................................................11-3
2. Original Scanning Mechanism.............................................................11-4
1. Image Scanner Unit.............................................................................11-5
2. Original IN Sensor................................................................................11-6
3. Pickup Roller........................................................................................11-7
4. Eject Roller Upper................................................................................11-7
5. Document Feeder Hook.......................................................................11-7
6. Load Roller...........................................................................................11-8
7. Eject Roller Lower................................................................................11-8
8. Read Pulse Motor..................................................................................11-9
[��
11-1 ] KZ30 (Rev. 1.2)
IMAGE SCANNING SECTION Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

11-2 ]
1. Original Loading Mechanism
An original placed on the Original rack Is automatically fed when the master making process is started.
1. Shading Compensation
> When the Original IN sensor detects the original, the LED of the Image scanner turns ON and the
shading compensation takes place.
2. Original Loading
> After the shading compensation is done, the Read pulse motor Activates to start feeding the original
by rotating the Pickup roller and Load roller.
> The original put on the Original rack is fed into between the Image scanner and the white Shading
sheet. Then the original is fed towards the Eject roller upper and lower.
> The Eject roller upper and lower ejects the original out.
Original detection sensor
Shading sheet
Image scanner
Pickup roller
Eject roller upper
Load roller
Originl feed tray
Eject roller lower
Original IN sensor
Read pulse motor
[��
11-3 ] KZ30 (Rev. 1.2)
2. Original Scanning Mechanism

When the master removal is completed, the Read pulse motor turns ON to feed the original onto the
Image scanner.
And after completing the master removal, the Drum rotates to place the master onto the Drum until the
Original scanning ends. Then original loading movement is completed.
1. Read pulse motor

> The Drum comes back to the position-A after the master removal is completed, the Read pulse
motor activates to rotate the Load roller and Eject roller to feed the Original and to eject.
> The Read/Write start signal turns ON and the image scanning is started by the Image scanner.
2. Original IN sensor
> After the tailing edge of the Original clears out from the Original IN sensor, the Read/Write start signal
and the Image scanner LED are turned OFF to stop the image scanning.
> The Read pulse motor stops after the original scanning movement ends.
Image scanner
Original IN sensor
Eject roller upper
Eject roller lower
Read pulse motor
KZ30 (Rev. 1.2) [��

11-4 ]

1. Image Scanner Unit
2. Remove the Master making unit from the machine. (Refer to the next chapter.)
3. From the front of the Master making unit, remove two gears. (See the photograph below.)
5. Remove one mounting screw from the front and two mounting screws from the back of the unit.
Caution:
The Image scanner is to be taken off with the brackets attached. Do not remove the brackets, as they
are factory adjusted in position at the Factory.
6. Disconnect the Connector and remove the Image scanner unit.
Master making unit
Two gears to remove
Do not remove these two screws Do not remove these two screws
One Screw in the front

Two Screws in the rear
Connector
Image scanner unit

< Do not remove the brackets >
[��
11-5 ] KZ30 (Rev. 1.2)
2. Original IN Sensor
1. Turn OFF the machine power and disconnect the poer cord from the machine.
2. Remove the Master making unit cover.
3. Remove the mounting screw of the Original IN sensor.
4. Disconnect the connector of the Original IN sensor and remove the sensor.
Connector Original IN sensor Screw Master Making unit
KZ30 (Rev. 1.2) [��

11-6 ]
3. Pickup Roller
1. Remove the Document feeder from the Master making unit.
2. Remove the Document feeder top cover.
3. Remove the Pick up roller spring plate and then remove the Pick up roller.
4. Eject Roller Upper

3. Remove the Eject roller spring plate and then remove the Eject roller upper.
5. Document Feeder Hook

3. Remove the Hook springs.
4. Remove the Document feeder hook.
Lift up gently
Document feeder top cover
Document feeder
Document feeder bottom cover Pickup roller Pickup roller spring plate Document feeder hook
Ejecton roller spring plate Ejection roller Hook spring
[��
11-7 ] KZ30 (Rev. 1.2)
6. Load Roller
2. Remove the document feeder.
3. Remove the Master making unit from the machine. (Refer to the next Chapter.)
4. Remove two gears from the front of the Master making unit. (E-rings)
5. Remove the Gear from the Load roller shaft in the front of the Master making unit. (E-ring)
6. Remove Bushing from the Load roller shaft in the rear of the Master making unit. (E-ring)
7. Remove the Load roller.
7. Eject Roller Lower

1. Follow the procedure for the Load roller removal (given above) up to step No.4.
2. Remove the Gear from the Eject roller shaft in the front of the Master making unit. (E-ring)
Caution: Make sure not to drop the Pin on the shaft which engages with the Gear.
3. Remove Bushing from the Eject roller shaft in the rear of the Master making unit. (E-ring)
4. Remove the Eject roller.
Precaution in Assembly:
Make sure to insert the Pin back on the Ejection roller, which fits onto the Gear.
The two Gears to remove

Gears to remove on Load roller and Eject roller
Eject roller
Watch out for the Pin
Load roller
< FRONT OF THE MASTER MAKING UNIT >
Bushings to remove on the Load roller and Eject roller.
Load roller Eject roller
< BACK OF THE MASTER MAKING UNIT >
KZ30 (Rev. 1.2) [��

11-8 ]
8. Read Pulse Motor

2. Remove the document feeder.
3. Remove the Master making unit from the machine. (Refer to the next Chapter.)
4. Disconnect the connector of the Read pulse motor.
5. Remove two mounting screws of the Read pulse motor and remove the motor.
> Connector of the Read pulse motor should face to the Image scanner side when install the motor.
Connector Read pulse motor
Screws
[��
11-9 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

11-10 ]
Imagetec Solutions Australia CUTTER SECTION
CHAPTER 12: CUTTER SECTION
CONTENTS
1. Cutter Home Positioning Mechanism...................................................12-3
2. Cutting Mechanism..............................................................................12-4
1. Cutter Unit............................................................................................12-5
[��
12-1 ] KZ30 (Rev. 1.2)
CUTTER SECTION Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

12-2 ]
1. Cutter Home Positioning Mechanism
1. Home Position Switch
> Each time the machine power is turned ON or All Reset Button is pressed, the Home position switch
checks the position of the Cutter.
> The Cutter position is checked by the Home position switch and the End position switch of which are
located the opposite ends of the Cutter rail.
2. Home Position
> The Home position of the Cutter is where the Home position switch is detected.
> If the Home positioning switch is not detected, the Cutter motor activates and rotates the Cutter gear
until the Home position switch becomes detected.
End position switch Cutter unit Home position switch
Cutter
Cutter gear
Cutter motor
Home position switch
[��
12-3 ] KZ30 (Rev. 1.2)
2. Cutting Mechanism
1. Master Cutting
> Cutter motor activates and cuts the master each time the master loading is made on the Drum.
2. Cutter Motor
> As the Cutter motor activates, it rotates the Cutter gear and the housing of the Cutter presses against
the actuator of the End position switch.
> Then the Cutter motor activates again and return to the Home position switch.
> The Cutter motor then stops at the Home position switch and the cutting motion ends.
End position switch Cutter unit
Cutter Home position switch Cutter gear Cutter motor
KZ30 (Rev. 1.2) [��

12-4 ]

1. Cutter Unit
2. Remove the Front cover.
3. remove the Print drum from the machine.
4. Open the Master making unit.
5. Disconnect the Connector of the Cutter unit.
6. Remove the mounting screws of the Cutter unit and remove the unit.
> Match the half-pierced sections of the Cutter unit with its counter part.
Connector
Cutter unit
Screw
[��
12-5 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

12-6 ]
Imagetec Solutions Australia MASTER MAKING SECTION
CHAPTER 13: MASTER MAKING SECTION
CONTENTS
1. Master Making.....................................................................................13-3
2. TPH Positioning...................................................................................13-4
3. Thermal Power Safety Switches..........................................................13-5
1. Write Roller..........................................................................................13-7
2. Thermal Print Head (TPH)...................................................................13-8
3. TPH Position Sensor............................................................................13-9
3. Adjustment................................................................................................13-11
1. Thermal Power of Thermal Print Head..............................................13-11
[��
13-1 ] KZ30 (Rev. 1.2)
MASTER MAKING SECTION Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

13-2 ]
1. Master Making
When the START key is pressed for master making, the Drum rotates to remove the master on the Drum.
At the same time the TPH-Control signal is turned ON to supply heating power to the Thermal print head.
1. Start of the Master Making

> While the Drum is rotates to remove the master on the Drum, the Write pulse motor activates and
starts feeding the master material.
> At the same time the original starts feeding through the AF unit for scanning.
> As the Write pulse motor activates and feeds the master for, the Read & Write start signal is turned
ON and the Thermal print head begins making image on the master material.
2. End of the Master Making

> After a certain set time, the Master tension plate solenoid activates and swings down the Master
tension plate.
> The master runs through the Master tension plate and as the Master tension plate swings down, it
gives tension on the master while the master is loaded on the Drum.
> Either the original scanning ends or if the Write pulse motor activates for the maximum master making
length, both the TPH-Control signal and Read & Write start signal turn OFF.
> The Write pulse motor is still activated until full length of master material is transferred.
The Write pulse motor then stops and completes the master making process.
Thermal print hed (TPH)
Write roller
Master roll
Write pulse motor
[��
13-3 ] KZ30 (Rev. 1.2)
2. TPH Positioning
The TPH moves down and up when master feeding is necessary or the master making process is ended.
When the TPH unit is at the home position, the TPH unit is away from the Write roller.
When the Master making starts, the TPH unit [C] is lowered by the Write pulse motor.
Rotation of the Write pulse motor is transferred to the TPH position cam via gears on the Master making
unit.
1. TPH position sensor

> The TPH position sensor [A] checks whether if the TPH stays upper or not.
> If the light path of the TPH position sensor is changed from "unblocked" to "blocked", the machine
assumes that the TPH is at upper position. (The TPH is away from the Write roller)
> If the light path of the TPH position sensor is changed from "blocked" to "unblocked", the machine
assumes that the TPH is at lower position. (The TPH is touching the Write roller)
TPH positioning sensor

Spring force
TPH position cam

Sensor blocked
Sensor opened Touching
Space
TPH unit Write roller
KZ30 (Rev. 1.2) [��

13-4 ]
3. Thermal Power Safety Switches

1. Safety Switches
> The actuators of all four safety switches must be pressed in order to feed electrical power to the TPH
unit.
> These four switches also acts as Main motor safety switches.
Separation unit safety switch

[��
13-5 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

13-6 ]

1. Write Roller
2. Open the Master making unit and remove the Master roll.
3. On the front side, remove the plastic Lock ring from the Whit roller shaft and remove the collar and
the metal from the shaft.
4. Remove the Write roller assembly by lifting the assembly from the machine.
> Match the flat part of the Bushing on the rear side of the roller shaft to keep clear of the flat-cut
surface on the Bushing. (Refer to the photographs below)
Write roller
Lock ring
Bushing
Flat-cut area on the Bushing

REAR
Correct E-ring position

Collar
Collar
Bushing
wrong E-ring position
FRONT
[��
13-7 ] KZ30 (Rev. 1.2)
2. Thermal Print Head (TPH)

Precautions in Removal
> Do not touch the Connector pins on the TPH assembly, as static electricity may damage the TPH
assembly.
> Do not contact the heat emitting portion of the TPH assembly against hard surfaces.
2. Open the Master making unit.
3. Disconnect two TPH connectors from the TPH assembly.
4. Remove the screw of the Ground wire.
5. Remove the two TPH assembly mounting screws.
6. Slide the TPH assembly up to release from the Master making unit.
7. Remove two mounting screws from the TPH mounting plate from the TPH .
Adjustment after Assembly

> Thermal power adjustment of the TPH must be done after replacing the TPH assembly.
TPH assembly mounting screws
TPH assembly
TPH connector Ground wire TPH connector
TPH mounting plate TPH
TPH assembly
KZ30 (Rev. 1.2) [��

13-8 ]
3. TPH Position Sensor

2. Remove the Master making unit cover.
3. Remove the connector of the TPH position sensor.
4. Remove the TPH position sensor from the Master making unit by gently unhooking the sensor legs
from the Master making unit.
Master making unit
TPH position sensor
Connector
Gently unhook the sensor legs from the machine frame.
[��
13-9 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

13-10 ]
3. Adjustment
1. Thermal Power of Thermal Print Head
Thermal power must be adjusted each time the Thermal print head is replaced.
1. Turn ON the machine power by going into Test Mode.

2. Enter 9874 to go into protected area test mode.
3. Select Test Mode No. 1234. Enter the resistance number (ohm number) on imprinted on the sticker
on the new TPH unit. Then press the START key to save the newly input resistance number.
4. To double confirm, check Test Mode No. 1234 again and reconfirm that newly input resistance
number is memorized.
[��
13-11 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

13-12 ]
Imagetec Solutions Australia MASTER CLAMP / LOADING
CHAPTER 14: MASTER CLAMP / LOADING
CONTENTS
1. Master Making Unit Set Mechanism....................................................14-3
2. Master Positioning Mechanism............................................................14-4
3. Master Feeding Mechanism.................................................................14-5
4. Master Loading on the Drum Mechanism............................................14-6
5. Master Advance after Master Cutting..................................................14-7
1. Master Making Unit..............................................................................14-9
2. Master Making Unit Safety Switch.....................................................14-12
3. Write Pulse Motor..............................................................................14-13
4. Master Positioning Sensor.................................................................14-14
5. Master Loading Solenoid...................................................................14-15
6. Master End Sensor............................................................................14-16
[��
14-1 ] KZ30 (Rev. 1.2)
MASTER CLAMP / LOADING Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

14-2 ]
1. Master Making Unit Set Mechanism
> When the Master making unit is closed, the Master making unit safety switch is also pressed by the
Master making unit upper frame.
When the Master making unit safety switch is not pressed, the power to the Main motor and TPH is
terminated.
2. Master End Sensor

> The Master end sensor detects the black strip on the master material at the very end of the master
roll and indicates the "Replace master roll" message,
Master end sensor
Master making unit upper frame
[��
14-3 ] KZ30 (Rev. 1.2)
2. Master Positioning Mechanism

1. Master Positioning
> The leading edge of the master material rests against the Master tension plate just after the master
loading.
> As the START button is pressed for normal master making or confidential master making, the Master
loading solenoid activates to release the Mater tension plate from master and the Write pulse motor
activates and rotates the Write roller to feed the master material.
> When the Master positioning sensor detects the leading edge of the master, the Master loading
solenoid and the Write pulse motor turn OFF and completes the master positioning movement.
Leading edge of the master material
Write roller
Master tension plate
Master loading solenoid
Master positioning sensor
Write pulse motor
KZ30 (Rev. 1.2) [��

14-4 ]
3. Master Feeding Mechanism
1. Start of Master Feeding

> At the Drum position-A, the Write pulse motor activate to rotates the Write roller to feed the master
material.
> The Master loading solenoid activates when the lead edge of the master is fed onto the Mater
positioning sensor or the Clamp plate.
2. End of Master Feeding

> The Write pulse motor turns OFF when the master feeding operation ends.
The leading edge of the master rests under the Clamp plate.
Master material Clamp plate
[��
14-5 ] KZ30 (Rev. 1.2)
4. Master Loading on the Drum Mechanism

As the Write pulse motor activates for a certain set time after the Clamp plate clamps the master, the
Main motor activates to load the master on the Drum.
1. Drum angle 107 degrees from A-position

> During the master loading, when the Drum comes to 107 degrees from the A-position, the Master
sensor checks for any master loading error.
> The Write pulse motor keeps feeding the master, and if no master loading is detected, the Main motor
stops at position-A and master loading error message is displayed.
2. Master cutting
> The Cutter unit cuts the master when maximum master length is made.
> The Main motor keeps rotating and loads the remaining length of master on the Drum while making
one proof print.
Clamp plate TPH

Master Loading Movement
Print drum 1. After the master is clamped on the

Drum and Write pulse motor rotates
Position-A
for a set amount, the Drum rotates
Write roller
to start the master loading.
Master sensor 2. At Drum position 107 degrees

from Position-A, the Master sensor
107 degrees checks for any master loading error,
while the Write pulse motor keeps
feeding the master.
3. Cutter motor activates to cut the

master at the maximum master length.
Cutter unit
KZ30 (Rev. 1.2) [��

14-6 ]
5. Master Advance after Master Cutting

If the master cutting is confirmed by the Master positioning sensor after the master cutting, the master
material from the master roll is moved forward until the leading edge is under the Master positioning
sensor.
1. Write Pulse Motor

> After the master is cut, the Write pulse motor rotates to move the master material forward.
> The Write pulse motor activates for 5 seconds as its maximum time, by which time the leading edge
of the master material is under the Master positioning sensor.
TPH
Write roller
Master roll Write pulse motor
[��
14-7 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

14-8 ]

1. Master Making Unit
2. Slide open the Master removal unit.
3. Remove the Rear cover and Front cover.
4. Remove the Master making unit cover and remove the Master roll.
5. Open the Master making unit and remove the Cutter unit.
6. Disconnect the wire harness connectors from the Mechanical control PCB, Power supply unit and
Operation panel area, as shown on the photographs attached on the following pages.
7. Remove 6 mounting screws from the Mater making unit back cover and remove the cover.
8. Slide the Master making unit out from the machine.
Photographs continue on next two pages.

Cutter unit
Master making unit
[��
14-9 ] KZ30 (Rev. 1.2)
Master making unit back cover
KZ30 (Rev. 1.2) [��

14-10 ]
Under the Operation panel
Cutter unit
Power supply unit
Mechanical control PCB
Mechanical control PCB
Master making unit
[��
14-11 ] KZ30 (Rev. 1.2)

2. Remove the Master making unit.
3. Disconnect the Connector of the Master making unit safety switch.
4. Remove two mounting screws of the Master making unit safety switch and remove the switch.
Master making unit
KZ30 (Rev. 1.2) [��

14-12 ]
3. Write Pulse Motor

2. Remove Master making unit.
3. Disconnect the Connector of the Write pulse motor.
4. Remove two mounting screws of the Write pulse motor and remove the motor.
> Keep little backlash between the motor gear and the drive gear when installing the motor on the
Master making unit.
Master making unit
Drive gear
Motor gear Write pulse motor
[��
14-13 ] KZ30 (Rev. 1.2)
4. Master Positioning Sensor

3. Disconnect the connector of the Master positioning sensor.
4. Remove the mounting screw of the Master positioning sensor and remove the sensor from the Cutter
guide plate. (Insert the screw drive through the cut-out opening to access to the mounting screw.)
Master making unit
Connector
Mounting screw
Insert the screw driver from the cut-out opening
KZ30 (Rev. 1.2) [��

14-14 ]
5. Master Loading Solenoid

3. Disconnect the Connector of the Master loading solenoid.
4. Remove two mounting screws of the Master loading solenoid and remove the solenoid from the
Master making unit.
Master making unit
[��
14-15 ] KZ30 (Rev. 1.2)
6. Master End Sensor

3. Open the Master making unit and remove the master roll.
4. Disconnect the Connector of the Master end sensor and remove the sensor from the sensor
bracket on the machine.
<Refer to the next page for the view of the sensor hook location.>
> Do not damage the hooks of the Master end sensor when installing the sensor on the sensor
bracket on the machine.
Master making unit
Master end sensor
Hooks
KZ30 (Rev. 1.2) [��

14-16 ]
Master making unit Master end sensor
Hooks
[��
14-17 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

14-18 ]
Imagetec Solutions Australia PANEL MESSAGE
CHAPTER 15: PANEL MESSAGE
CONTENTS
1. Error Type & Error Point............................................................................15-3

2. Error Display Method.................................................................................15-4
3. Error Type....................................................................................................15-5
4. Error Point...................................................................................................15-6
5. Paper Jam Error Display Method..............................................................15-7
6. Detailed List of Panel Messages...............................................................15-8
1) Serviceman Call Errors (Pxx)...............................................................15-8
2) Jam Errors (Axx)................................................................................15-13
3) Consumable Errors (Cxx)..................................................................15-15
4) Set Check Errors (Dxx)......................................................................15-16
5) Warning Errors (Exx : Serviceman Call Errors).................................15-18
6) Warning Errors (Fxx : Others)............................................................15-18
7) Parameter Errors (Hx)........................................................................15-19
8) Errors Saved in Memory....................................................................15-19
[��
15-1 ] KZ30 (Rev. 1.2)
PANEL MESSAGE Imagetec Solutions Australia
KZ30 (Rev. 1.2) [��

15-2 ]
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
[��
15-3 ] KZ30 (Rev. 1.2)
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
KZ30 (Rev. 1.2) [��

15-4 ]
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.
[��
15-5 ] KZ30 (Rev. 1.2)
4. Error Point
[ERROR POINT]
The error type is followed by Error Point
ERROR
UNIT
POINT
0 xx System (Hardware, Software, Communication) & Operation Panel.
1xx Scanning (Scanner, AF Unit) & Image Processing.
2xx Master Making
3xx Master Removal
4xx Paper Feed & Paper Ejection
5xx Print Drum
6xx Print Adjustments (Printing Position & Density)
7xx Options (KeyCard Counter, etc.)
KZ30 (Rev. 1.2) [��

15-6 ]
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 0� Paper feed jam 3 8
A08 Paper jammed on Drum 2 �
A0� 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 �
�
5
2
� While pressing the (*) asterisk key,
1
8 �
the Error Point is displayed.
� : 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 �
�
5
2
While pressing the (*) asterisk key,
�
1
the Error Point is displayed.
8 �
2 8 : Solid Light
: Blinking Light
[��
15-7 ] KZ30 (Rev. 1.2)
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 main motor activates for 1 drum rotation.
536 Print drum failed to stop at Position-A.
537 Print drum failed to stop at Position-B.
Print drum angle cannot be detected even though the Position-A sensor detected the Print drum 3
582
times.
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.
KZ30 (Rev. 1.2) [��

15-8 ]
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 P12 [Master disposal area motor lock]

P12-xxx
!!System Error!!
Description
Press Reset Key
To reset
Press Reset Key.
display
300 Overload on the Master removal motor.
Error Type P13 [Cutter motor lock]

P13-xxx
!!System Error!!
Description
Press Reset Key
To reset
Press Reset Key.
display
221 The cutter HP switch and cutter stop position switch are both ON at the same time.
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.
[��
15-9 ] KZ30 (Rev. 1.2)
Error Type P14 [Scanner error]

P14-xxx
!!System Error!!
Description
Press Reset Key
To reset
Press Reset key or turn the power OFF and ON.
display
104 Offset adjustment error.
125 A/D reference adjustment unfinished in time.
126 Gain adjustment not unfinished in time.
Error Type P19 [Master making area motor lock]

P19-xxx
!!System Error!!
Description
Press Reset Key
To reset
display
TPH position sensor status did not change even after the TPH pressure motor activated for 2
207
seconds.
Error Type P24 [Inking motor lock]

P24-xxx
!!System Error!!
Description
Press Reset Key
To reset
display
Inking-motor FG sensor status does not change within 20 milliseconds after the inking-motor is
539
activated.
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.
KZ30 (Rev. 1.2) [��

15-10 ]
Error Type P97 [PC card access error]

P98-xxx
!!System Error!!
Description
Press Reset Key
To reset
Turn power OFF and ON.
display
939 PC card not inserted.
940 PC card device data double ID error (data error as PCMCIA card).
941 PC device error (not detected as PC card).
942 File production error (same file name already exists).
943 PC card not formatted correctly.
944 PC card ID error.
945 PC card error (detected as PC card, but unable to make access).
946 PC card capacity error (not enough blank area).
990 File does not exist in the specified drive.
991 Accessed into a non-opened file).
992 File pointer to save the data is already in use.
993 Read address is not correctly set up.
994 File delete arror (file is not correctly deleted).
Error Type P98 [Hardware error]

P98-xxx
!!System Error!!
Description
Press Reset Key
To reset
display
No reply from optional neoROSA. If neoROSA 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 Possible 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).
038 Machine information between the EEPROM and PCB does not match.
039 Incorrect EEPROM.
041 5 volt power not available. Possibility of faulty 5 volt fuse.
045 5 volt power does not go OFF when the machine tries to go into sleep mode.
063 Test mode setting is beyond the adjustable range.
064 Communication error between neoROSA and MCTL PCB.
065 Communication error between neoROSA and MCTL PCB (01) - on MCTL PCB side.
[��
15-11 ] KZ30 (Rev. 1.2)
Error Type P98 [Hardware error]

P98-xxx
!!System Error!!
Description
Press Reset Key
To reset
display
074 Communication error between neoROSA and MCTL PCB (10) - on neoROSA side.
098 Machine serial number information does not match between the backup data and EEPROM.
119 Defective image PCB (memory check error on the image processing IC).
121 Scanner adjustment error (IFLG does not change within set time).
122 Scanner adjustment error (IMFLGdoes not change within set time).
245 Timeout error on master transfer during master-making (related to Write pulse motor).
921 USB controller chip does not reply. May need to replace neoROSA.
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)
937 Serial number not set.
938 EEPROM version down.
947 24V-A does not go ON. (possibility of 24v fuse broken on A-series)
948 24V-B does not go ON. (possibility of 24v fuse broken on B-series)
949 42V-A does not go OFF.
950 42V-B does not go OFF.
952 Check-sum error on neoROSA PCB flash memory.
953 Write error on the neoROSA PCB flash memory.
960 Read error on the neoROSA PCB flash memory.
961 Flash memory on neoROSA PCB not used.
Error Type P99 [Software error]

P99-xxx
Software error
Description
Press Reset Key
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.
KZ30 (Rev. 1.2) [��

15-12 ]
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.
258 Master end tape detected twice in a row.
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
Pull out the print drum and push it back in.
display
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 Pull out master disposal box and place it back after removing the jammed master in the master
display 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.
[��
15-13 ] KZ30 (Rev. 1.2)
Jxx Error Display

Error Type A07 [Paper feed error]
410 Paper-ejection sensor was OFF when the paper should have arrived. (Paper misfeed).
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.
Jxx Error Display

Error Type A10 [AF original feed error]
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).
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
Open the Master making unit, remove the master and close the master making unit.
display
Master positioning sensor is ON after master cutting and Print drum returns back to Position-A.
205
(Master cut error)
209 Cutter HP switch is OFF when master making started or when the master material was set.
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
Open the Master making unit, re-insert the master material into the master making unit.
display
When the Master making unit safety switch turned from OFF to ON, the Master position sensor was
206
ON. (Master setting error)
218 Requesting for the leading edge of the master material to be set in the master making unit.
KZ30 (Rev. 1.2) [��

15-14 ]
3) Consumable Errors (Cxx)
Error Type C01 [Replace ink cartridge]

C01-xxx
Description No Ink
Replace Ink Cartridge
To reset
Remove the empty ink cartridge and replace with a new one.
display
The ink sensor did not go ON even when inking was performed for a preset duration. (No ink
512
detected.)
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.
The master disposal software counter counted maximum. (Master disposal box full by the software
311
count.)
[��
15-15 ] KZ30 (Rev. 1.2)
4) 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.
Error Type D03 [Ink cartridge not set]

D03-xxx
Description
Install Ink Cartridge
To reset
Install ink cartridge in the print drum.
display
533 Ink 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 Incorrect information on the Ink RF-Tag.
564 Detected a mismatch in the Ink RF-Tag serial number.
575 RF-Tag software error.
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.
237 Master RF-TAG missing
Error Type D06 [Paper separation unit not set]

D06-xxx
Description
Set Paper Separation Unit in Place
To reset
Set the Paper separation unit in place so the sfety switch is pressed.
display
427 Paper separation unit safety switch is OFF.
KZ30 (Rev. 1.2) [��

15-16 ]
Error Type D07 [Master disposal box not set]

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

D08-xxx
Description
Set Master Making Unit in Place
To reset
Set the Master making unit in place.
display
224 Master making unit is opened. (Master making unit safety switch is OFF).
Error Type D10 [Master removal unit not set]
D10-xxx
Description
Set Master Removal Unit in place
To reset
Set the Master removal unit in place.
display
314 Master removal safety switch is OFF.
Error Type D12 [Print drum not fully inserted]
D12-xxx
Description
Set Print Drum in Machine
To reset
Insert the Print drum firmly in the machine.
display
Print drum set sensor stays OFF even after the print drum set signal and print drum safety switch
529
went ON.
Either the print drum set signal or print drum safety switch is OFF while the other is ON.
530
(Print drum not fully inserted in position.)
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.
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.
[��
15-17 ] KZ30 (Rev. 1.2)
5) Warning Errors (Exx : Serviceman Call Errors)
Error Type E03 [Setup wizard]
E03-xxx
Description
Setup Wizard
To reset
Complete the setup wizard.
display
046 Setup wizard not finished.
6) 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
Make a new master with an original.
display
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.
KZ30 (Rev. 1.2) [��

15-18 ]
7) 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
Enter the required parameter value.
display
Message H4 [Master sensitivity setting]

H4-242
Description
Select the master sensitivity parameter.
To reset
Enter the required parameter value.
display
8) Errors Saved in Memory
Following three (3) Error Types are backed up in memory and these error messages cannot be reset by turning
OFF the power. The cause for the message must be solved to reset the error display.
Error Type Error Description
C01 Replace ink cartridge
C02 Replace master roll
C03 Master disposal box full
[��
15-19 ] KZ30 (Rev. 1.2)
MEMO
KZ30 (Rev. 1.2) [��

15-20 ]
Imagetec Solutions Australia TEST MODE
CHAPTER 16: TEST MODE
CONTENTS
1. Operating Method......................................................................................................16-3
1) Launching the Normal Test Mode............................................................................16-3
2. List of the Test Modes...............................................................................................16-4
1) System & Panel Test Modes....................................................................................16-4
2) Imaging & Scanning Test Modes.............................................................................16-7
3) Master-making & Master-disposal Test Modes.....................................................16-10
4) Paper-feed and Paper-ejection Test Modes..........................................................16-13
5) Print-drum & Print-adjustment Test Modes............................................................16-15
6) Protected Area Test Modes....................................................................................16-18
[ 16-1 ] KZ30 (Rev. 1.2)

TEST MODE Imagetec Solutions Australia
MEMO
KZ (Revision 1.2) [ 16-2 ]

1. Operating Method
1) Launching the Normal Test Mode

To start Test Mode, switch ON the machine power while simultaneously pressing the left and right keys of
the vertical print positioning.
The firmware version number is displayed when the Test Mode is launched.
Press the Stop Key or Cancel Key to go into standby mode.
From the standby mode, enter the required test mode number and press Start Key to activate.
Press the Stop Key or Cancel Key to return back to the standby mode.
Enter next desired test mode number to continue using the test mode, or press the Reset Key for one
second to escape out from the Test Mode.
The Reset Key must be pressed (for 1 second) to escape out from the Test Mode only when the machine
is in the standby mode of the test mode.
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.
[ 16-3 ] KZ (Revision 1.2)

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

0003 24V A output signal 24V-A ON (24V output)
0004 24V B output signal 24V-B ON (24V output)
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 tur ned
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.
KZ (Revision 1.2) [ 16-4 ]

No. Data clear Details

Clearing Jam Status Data
This test mode can be used to temporary clear error display. For acutal cor�
0110
Forcibly clears the jam. rection of the problem, the cause for the display should be corrected.
Consumable 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 ma� The initializing is effective after rebooting the machine.
chine. The protected area test modes stay unchanged.
Record all the settings before the test mode activation.
No. Data check Details
Displays the last changed Test Mode number and its new setting.
Data setting change The Test Mode No. and the setting are displayed alterately. This does not
0120
confirmation apply to the program default settings. Test modes 1200’s & 5480 and up
are reflected on this test mode.
Displays the Error type and Error number of the last displayed error (only
0122 Error history
the last one error.)
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.
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
The digits from ten thousand and digits thousand and under will display
0137 Master count (software) display alternately.
Beep sound will be heard when digits ten thousand and over are displayed.
The digits from ten thousand and digits thousand and under will display
0138 Copy count (software) display alternately.
Beep sound will be heard when digits ten thousand and over are displayed.
[ 16-5 ] KZ (Revision 1.2)

No. Data setting

Print Quantity Selection (ref: Test Mode No.0090)
Selects the print quantity for the continuous master-making & printing
Description
0147 operation by Test Mode No. 0090.
Selectable range : 1 to 100 (1 to 100 prints)
Setting
Default : 3 (3 prints)
Master-Making Type Selection (ref: Test Mode No.0090)
Selects the type of image for the continuous master-making & printing
Description
operation by Test Mode No. 0090.
Selectable range : 0 to 6
0 : Image by Test Mode No.0080.
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)
Slow Start Printing Action
Description Activates or deactivates the slow-start printing action.
0151 0: Inactive (default)
Setting
1: Active
Counter Action Control
Stops the software counter by setting to [0]. Once the power is turn OFF
Description and turned back ON, the setting automatically changes back to the default
0155
setting of Counter Active [1].
0: Stops the counter
Setting
1: Activates the counter (default)
Master Making Action Standby
After selecting the Master-making mode, the machine resets itself from
Description
the master-making mode after the selected time frame has passed.
0162 Range : 0 to 180 seconds (0 = no standby)
Setting Unit : 1 = 1 second
Default : 180 (180 seconds)
KZ (Revision 1.2) [ 16-6 ]

2) Imaging & Scanning Test Modes

No. Sensor switch check Detection status
0210 Original IN Sensor Detecting (original present)
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
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
Description
Density and Reduced Reproduction Size.
The purpose of this test mode is to prevent thin lines from disappearing when the
0343 reproduction size is reduced.
Setting Range : - 8 to + 8 (Larger valudes for lighter print.)
Unit : 1
Default : -5
[ 16-7 ] KZ (Revision 1.2)

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 : 3
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 : 5
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 : 3
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 : 5
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
KZ (Revision 1.2) [ 16-8 ]

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)
0381 Range : -20 to +20 (-2.0mm to +2.0mm)

(+ omits more top image of the original and moves the printed image up)
Setting
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)
0382 Range : -100 to +100 (-10.0% to +10.0%)
( + elongates the image)
Setting
Unit : 1 (0.1%)
Default : 0 (0%)
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
0386 The setting returns back automatically to the default setting when the machine power is
turned OFF.
0: No center dotted line (default)

Setting
1: Adds center dotted line
Black line erasing
0387 Description Activates or deactivates the black line erasing feature.
0: Active
Setting
1: Inactive (default)
[ 16-9 ] KZ (Revision 1.2)

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)
0406 TPH Pressure sensor ON (sensor light path blocked) / OFF (sensor light path open)
0407 Master-making-unit safety SW Switch pressed (Master-making unit upper cover is closed).
0420 Master-disposal jam sensor Sensor light is not blocked (Master is detected - jammed)
Switch ON (Master-Disposal Box set in position).

0423 Master-disposal BOX safety SW
Other safety switches must be ON for this check.
0424 Master-disposal box set sensor ON (master-disposal box is set) / OFF (master-dispoasal box not set)
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
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-making pressure - Pressurizing action
0481
Moves the TPH to pressurized position.
Master-making pressure - Depressurizing action
0482
Moves the TPH to depressurized position.
Master-making solenoid ON/OFF action
0487
Pressing the START Key activates the solenoid for 10 seconds and then automatically deactivates.
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 disposal software count clear

0510
Resets the master-disposal software count to 0.
KZ (Revision 1.2) [ 16-10 ]


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.)
0528 Master disposal software count Displays the master disposal software count.
Displays the master remaining amount in percentage (information from the

0529 Master remaining amout display
Tag on the master roll).
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 : 0 (0mm)
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 from the present amount)
Setting
Unit : 1 (0.1mm)
Default : 0 (0 mm)
Master-making rear margin adjustment
Adjusts the white margin on the rear (left-hand side on the print) in the master-making process.
0546
Range : -100 to +100 (-10.0mm to +10.0mm)
Setting Unit : 1 (0.1 mm)
Default : 0 (0 mm)
[ 16-11 ] KZ (Revision 1.2)

Master-making speed adjustment (Image elongation & shrinkage)

Description Image elongation and shrinkage in making master. (Adjusts the speed of the write pulse motor.)
Range : -100 to +100 (-10.0% to +10.0%)
0547
( + values elongate the image in master making.).
Setting
Unit : 1 (0.1%)
Default : 0 (0 %)
Master buckle amount adjustment in master loading on the Print drum.
Adjusts the timing between the Write pulse motor activation and Print drum rotation start timing.
0549 Range : 0 to 80 (0 mm to to 1.6 mm)
( + values increases the buckle amount.)
Setting
Unit : 5 (0.1 mm)
Default : 0 (0 mm)
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 removal roller stop angle
Description Adjusts the Master removal roller stop timing in relation to the Print drum angle.
0570
Range : -50 to 0
Setting Unit : 1 (1 degrees)
Default : 0 (0 degrees)Msterdsfsfssdfsfsfsssfsf
Master disposal box FULL detenction by master disposal software count
Sets the master disposal box FULL detection timing
0584
Range : 10 to 30
Setting Unit : 1 (1 master disposal count)
Default : 20 (20 master disposal count )
KZ (Revision 1.2) [ 16-12 ]

4) Paper-feed and Paper-ejection Test Modes

0606 Paper-ejection sensor Sensor light blocked (paper detected)
0607 Paper feed Safety Switch ON (switch activated) / OFF (switch deactivated).
0621 Master removal Safty Switch ON (switch activated) / OFF (switch deactivated).
No. Motor solenoid system Remarks
0661 Suction fan Activates the fan.
0662 Separation fan Activates the fan.
No. Unit check
Paper feed path area Fan ON action.
0680
Pressing the START key runs the Separtation Fan and Suction Fan. Press STOP key to deactivate.
First Paper-feed clutch ON/OFF action
0688
Presses START key to turn ON the clutch. The clutch automatically switches off after 10 seconds.
Second Paper-feed clutch ON/OFF action
0691
Presses START key to turn ON the clutch. The clutch automatically switches off after 10 seconds.
No. Data setting
First Paper-feed-clutch ON angle (speed 1)
Description Adjusts the drum angle timing for activating the paper-feed clutch.
0741 Range : -100 to +100 (-10.0° to +10.0°)
(+ values delay clutch ON timing )
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
First Paper-feed-clutch OFF angle (speed 1)
Description Adjusts the drum angle timing for deactivating the paper-feed clutch.
0742 Range : -100 to +100 (-10.0° to +10.0°)
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
First Paper-feed-clutch ON angle (speed 2)
0744 Range : -100 to +100 (-10.0° to +10.0°)
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
First Paper-feed-clutch OFF angle (speed 2)
0745 Range : -100 to +100 (-10.0° to +10.0°)

Setting
Unit : 5 (0.5°)
Default : 0 (0°)
First Paper-feed-clutch ON angle (Proof Print)
0749 Range : -100 to +100 (-10.0° to +10.0°)
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
Paper feed IN jam detection angle. (Paper feed jam at Paper sensor)
Adjusts the drum angle timing for detecting the paper feed jam by paper
Description
0751 sensor. (Paper IN)
Range : -200 to +200 (-20.0° to +20.0°)
Setting Unit : 5 (0.5°)
Default : 0 (0°) (+ values delay detection timing )
[ 16-13 ] KZ (Revision 1.2)

Paper feed OUT jam detection angle. (Paper feed jam at Paper sensor)
Description
0752 sensor. (Paper OUT)
Range : -200 to +200 (-20.0° to +20.0°)
Paper receiving IN jam detection angle
Description ejection sensor. (Paper IN)
0753
Range : -500 to +500 (-50.0° to +50.0°)
Paper receiving OUT jam detection angle
Description ejection sensor. (Paper OUT)
0754
Range : -500 to +500 (-50.0° to +50.0°)
First Paper-feed-clutch OFF angle (Proof Print)
0778 Range : -100 to +100 (-10.0° to +10.0°)
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
Second Paper-feed-clutch ON angle (Proof Print)
0783 Range : -100 to +100 (-10.0° to +10.0°)
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
Second Paper-feed-clutch OFF angle (Proof Print)
0784 Range : -100 to +100 (-10.0° to +10.0°)
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
Second Paper-feed-clutch ON angle (Speed 1)
0789 Range : -100 to +100 (-10.0° to +10.0°)
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
Second Paper-feed-clutch OFF angle (Speed 1)
0790 Range : -100 to +100 (-10.0° to +10.0°)
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
Second Paper-feed-clutch ON angle (Speed 2)
0791 Range : -100 to +100 (-10.0° to +10.0°)
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
Second Paper-feed-clutch OFF angle (Speed 2)
0792
Range : -100 to +100 (-10.0° to +10.0°)
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
KZ (Revision 1.2) [ 16-14 ]

5) Print-drum & Print-adjustment Test Modes

0800 Position-A sensor Blocked (detection plate detected) Drum is at position-B.
0802 Main motor FG sensor Blocked (detection plate detected)
0803 Clamp sensor A 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
Other safety switches must be ON for this check.
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.
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.
[ 16-15 ] KZ (Revision 1.2)

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.)
Print Drum free rotation

0896
Rotates the Print drum at the speed of 10 rpm. Press the STOP key to end the rotation.
Clamp plate open-position Print drum stop

0909
Rotates and stops the Print drum at a timing 550ms from the Clamp sensor OFF position.
Master release arm open-position Print drum stop
0910
Rotates and stops the Print drum at a timing 1000ms from the Clamp sensor OFF position.
0921 Print-drum angle display Displays the present print-drum angle. (example: 1800 = 180°)
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, [ 1 ] 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 : -35 to +35 (-3.5° to +3.5°)
0941
(+ moves drum forward in over-run direction)
Setting
Unit : 5 (0.5°)
Default : 5 (0.5°)
Print-drum position-B adjustment
Description Adjusts the print-drum Position-B stop position.
0942 Range : -35 to +35 (-3.5° to +3.5°)

(+ moves drum forward in over-run direction)
Setting
Unit : 5 (0.5°)
Default : 0 (0°)
KZ (Revision 1.2) [ 16-16 ]

Inking time adjustment (In normal printing) - When ink in the ink bottle is in large amount.
Sets the timer for the Replace Ink Bottle message to come out after the Ink sensor stops
Description detecting the ink bead in the Drum.
0943 <When the ink left in the Ink bottle is in large amount , which is set by Test Mode No. 0948>
Range : 5 to 60 (1 second to 60 seconds)

Setting Unit : 1 (1 second)
Inking time adjustment (Right after replacing the ink bottle)
0944 <When the ink left in the Ink bottle is in large amount , which is set by Test Mode No. 0948>
Range : 5 to 60 (5 seconds to 60 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)
Inking time adjustment (In normal printing) - When the ink in the ink bottle is in small amount.
0946 <When the ink left in the Ink bottle is in small amount , which is set by Test Mode No. 0948>
Range : 5 to 60 (1 second to 60 seconds)

Print drum rotation quantity after Ink bottle is removed and inserted back.
Sets the number of Print drum free rotation after the Ink bottle is removed and inserted
Description
back in the Priint drum.
0947
Range : 0 to 10 (0 rotation to 10 rotations)
Setting Unit : 1 (1 rotation)
Default : 0 (0 rotation)
Inkless time selection
Description Setting of the ink amount in Ink bottle (in %) whether Large amount or Small amount.
Range : 1 to 100 (1% to 100%)

0948 Unit : 1 (1%)
Setting Default : 25 (25%)
< In this default setting, ink remaining under 25% is determined as ink in the Ink bottle as
small amount. Over 25% will be determined as ink in large amount is left in the ink bottle. >
[ 16-17 ] KZ (Revision 1.2)

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

Memory Initialization
1198
Description Initializes the memory on the Mechanical Control PCB.
Millimeter paper machine / Inch paper machine selection.
Selecting whether the machine is for Millimeter paper size machine or Inch paper size
Description
1201 machine.
Range : 0 or 1 (0 = Millimeter paper size machine / 1 = Inch paper size machine)

Setting
Default : 0 (Millimeter paper size machine)
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)
KZ (Revision 1.2) [ 16-18 ]

Imagetec Solutions Australia ELECTRICAL COMPONENTS
CHAPTER 17: ELECTRICAL COMPONENTS
CONTENTS
1. Sensors................................................................................................17-3
2. Switches...............................................................................................17-4
3. Clutches & Solenoids...........................................................................17-5
4. Motors & Fan.......................................................................................17-6
[��
17-1 ] KZ30 (Rev. 1.2)
ELECTRICAL COMPONENTS Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

17-2 ]
1. Sensors
Original IN sensor Master positioning sensor
TPH position sensor Clamp sensor
Main motor encoder

Master end sensor
Master disposal box set sensor
Master sensor
Position-A sensor
Ink bottle set sensor
Ink sensor
Ink overflow sensor
[��
17-3 ] KZ30 (Rev. 1.2)
2. Switches
Separation base safety switch
KZ30 (Rev. 1.2) [��

17-4 ]
3. Clutches & Solenoids
Paper feed clutch
Timing clutch
[��
17-5 ] KZ30 (Rev. 1.2)
4. Motors & Fan
Write pulse motor
Cutter motor
Read pulse motor
Separation fan
Suction fan Clamp motor
Main motor
Ink motor
KZ30 (Rev. 1.2) [��

17-6 ]
Imagetec Solutions Australia WIRING DIAGRAM
CHAPTER 18: WIRING DIAGRAM
CONTENTS
1. Overall Diagram...................................................................................18-3
2. Power Supply.......................................................................................18-4
3. Paper Feed & Paper Ejection..............................................................18-5
4. Print Drum Area...................................................................................18-6
5. Master Making Area.............................................................................18-7
6. Options.................................................................................................18-8
[��
18-1 ] KZ30 (Rev. 1.2)
WIRING DIAGRAM Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

18-2 ]
1. Overall Diagram
Paper Feed Interlock Panel

&
Ejection
Area Rear I/F Front/

Master Making
Mechanical
Control Master Making
Motor
PCB Area
Print Drum
Diagram Drum I/F
Area
Scanner
(CIS)
Options NeoROSA TPH
Power Supply Unit
[��
18-3 ] KZ30 (Rev. 1.2)
2. Power Supply
Rear wire harness R Option power wire harness
neoROSA power
RIP power
Rear wire harness R (not used)
Main motor
Rear wire harness R
Mechanical
Control PCB
Power switch wire harness
Power switch
Not used
TPH wire harness
Power Power cord
TPH
Power
Supply
Unit
KZ30 (Rev. 1.2) [��

18-4 ]
KZ30 (Rev. 1.2)
WIRING DIAGRAM
Interlock wire
Rear wire harness L
Rear wire harness L harness
Mini CT28P
14P double CT-2P
CT-4P CT-3P CN1-A miniCT-14P GRAY
CN1-B miniCT-14P BLUE
Master removal
Print drum motor
safety switch
CT-4P
Master making unit CT-2P
safety switch Clamp motor
CT-4P
Separation unit
CT-2P
safety switch
Paper feed
CT-4P CT-4P CT-3P
clutch
Master removal unit
safety switch
CT-2P
Front wire harness R
Front wire harness L
Timing clutch

Clamp
sensor
[��
18-5 ]
Position-A
sensor
Encoder
sensor
wire harness L
CT-3P
Paper receiving
3. Paper Feed & Paper Ejection
sensor
CT-2P
Separation
fan
CT-2P
Suction
Mechanical fan
Control
PCB
4. Print Drum Area
Rear wire harness L
Drum wire harness

Double
Ink motor FG
Ink motor
Bottle set switch wire harness
Bottle set
switch
Ink sensor wire harness
GND
Overflow SNR
Ink sensor Ink sensor
Thermister
VCC
Drum set
sensor
Rear wire harness L Drum wire harness
RF Tag
Mechanical
Control Drum jumper
wire harness
PCB
KZ30 (Rev. 1.2) [��

18-6 ]
5. Master Making Area
Scanner wire harness
Panel PCB
Front wire harness R Cutter Motor

CT-6P
Cutter SW
Scanner
(CIS) Cutter HP SW
Master Positioning
Sensor
Master End
sensor
Master Making
Solenoid
TPH
TPH wire harness Positioning
Sensor
Original IN
Sensor
Front wire harness L
To power supply CT-3P
Master
wiring diagram Sensor
Mechanical Master removal
wire harness Maser Removal
Control CT-6P Box Set
Sensor
PCB Maser Removal
Jam
Sensor
Master removal jam sensor wire harness
TPH wire harness

CT-6P
RF-Tag
Read pulse motor

TPH
Write pulse motor
[��
18-7 ] KZ30 (Rev. 1.2)
6. Options
Not Used Option wire harness
(15P double) (15P double)
Not Used
Not Used
Mechanical
Control
PCB
Option power wire harness
To power supply
wiring diagram
KZ30 (Rev. 1.2) [��

18-8 ]
Imagetec Solutions Australia OTHER PRECAUTIONS
CHAPTER 19: OTHER PRECAUTIONS
CONTENTS
1. Replacement of PCBs................................................................................19-3
1. Mechanical Control PCB......................................................................19-3
2. NeoROSA PCB (option).......................................................................19-4
2. Firmware Installation..................................................................................19-6
1. Mechanical Control PCB......................................................................19-6
2. NeoROSA PCB (option).......................................................................19-7
(1) Firmware Installation Procedure for the
CHINA destination machine.......................................................19-7
(2) Firmware Installation Procedure for the
machine destinations other than CHINA....................................19-8
[��
19-1 ] KZ30 (Rev. 1.2)
OTHER PRECAUTIONS Imagetec Solutions Australia
MEMO
KZ30 (Rev. 1.2) [��

19-2 ]
1. Replacement of PCBs
1. Mechanical Control PCB
1. Replacement Procedure
CAUTION: Do not turn ON the machine power in normal operation mode until Step-14 given below.
1) Turn OFF the machine power.
2) Remove static electricity from the body before touching the PCB.
3) Remove the Front Cover and Print Drum from the machine.
4) Detach the Mechanical Control PCB from the machine and remove both the EEPROM and
EPROM from the existing PCB.
5) Mount the previously removed EEPROM and EPROM on the new Mechanical Control PCB.
6) Attach the new Mechanical Control PCB on the machine.
7) Turn ON the machine power by going into Test Mode.
8) Activate Test Mode No. 9874 to go into the protected area test mode.
9) Then activate Test Mode No. 1198 [Memory Initialization] to initialize the memory on the
Mechanical Control PCB.
10) Turn OFF the machine power and then turn the machine power back ON by going into Test Mode.
11) Insert the Print Drum back in the machine and activate Test Mode No. 0883 [Clamp Home
Position Action] to reset the clamp unit to the home position.
13) Mount the Front Cover and Print Drum Lock Mechanism back on the machine.
14) Turn ON the machine power in normal operation mode and if the machine boots up in normal
condition, the Mechanical Control PCB replacement procedure is completed.
Mechanical Control PCB EEPROM

Along with the other important
data, the EEPROM contains the
EPROM Test Mode settings.
The EPROM contains
the Machine firmware.
< View with the Front Cover and Print Drum removed.>
[��
19-3 ] KZ30 (Rev. 1.2)
2. NeoROSA PCB (option)

4) Detach the Mechanical Control PCB Bracket with both the Mechanical Control PCB and
NeoROSA PCB attached. (4 screws)
5) Remove the NeoROSA PCB from the Mechanical Control PCB Bracket. (5 screws)
6) Mount the new NeoROSA PCB.
NOTE: For the China model machine, a CF Card Adapter JIG should be mounted on the
NeoROSA PCB and a CF Card, containing the NeoROSA firmware, installed.
For the machines to the other destination countries, the CF Card slot is build-in on the
NeoROSA PCB. So mount a CF Card, containing the NeoROSA firmware, in the CF
Card slot.
7) Install the firmware in the NeoROSA PCB. <Refer to the pages to follow for the firmware
installation procedure.>
8) After the firmware downloading is completed, turn OFF the machine power and remove the CF
Card from the NeoROSA PCB.
NOTE: For the China model machine, make sure to remove the CF Card Adapter JIG from the
NeoROSA PCB.
9) Turn ON the machine power by going into test mode.
10) Activate Test Mode No. 0110 [Clearing Jam Status Data] to clear any jam error displays.
Caution: Do not activate Test Mode No. 0111 [Clearing User Memory] nor
No. 0112 [Normal Area Test-Mode Data Memory Clear].
11) Turn ON the machine power in normal operation mode and if the machine boots up in normal
condition, the NeoROSA PCB replacement procedure is completed.
Screw Screw
Mechanical Control PCB Bracket with

both the Mechanical Control PCB and
NeoROSA PCB attached.
Screw
Screw
< View with the Front Cover and Print Drum removed.>
KZ30 (Rev. 1.2) [��

19-4 ]
Mechanical Control PCB Bracket

Mechanical Control
PCB
SCREW SCREW
SCREW SCREW
SCREW
< REAR View > < FRONT View >

NeoROSA PCB
NeoROSA PCB for China Market. NeoROSA PCB for other countries.
CF Card Slot does not exist. CF Card Slot exists on the PCB.
CF Card Adapter JIG is required to insert a CF Card. Adapter JIG is not required.
Refer to the page on the Firmware Installation, in this Chapter, for the information on
the CF Card Adapter JIG and on the Firmware installation procedure.
[��
19-5 ] KZ30 (Rev. 1.2)
2. Firmware Installation
1. Mechanical Control PCB
Note: The machine firmware program is contained in the EPROM, which is mounted on the Mechanical
Control PCB.
3) Remove the existing EPROM from the PCB.
4) Mount the new EPROM containing the new machine firmware.
5) Turn ON the machine power in normal operation mode, and confirm that the machine boots up in
normal condition to complete the procedure.
EPROM
< Mechanical Control PCB >
KZ30 (Rev. 1.2) [��

19-6 ]
2. NeoROSA PCB (option)
Note: CF Card is required to install firmware on the NeoROSA PCB.

For the China destination machine, a CF Card Adapter JIG is required.
For the machines to the other destinations, the NeoROSA PCB already has built-in CF Card slot,
so no adapter JIG is required.
(1) Firmware Installation Procedure for the CHINA destination machine.
4) Detach the Mechanical Control PCB Bracket with both the Mechanical Control PCB and
NeoROSA PCB attached. (4 screws)
5) Remove the NeoROSA PCB from the Mechanical Control PCB Bracket. (5 screws)
6) Mount the CF Card Adapter JIG on the NeoROSA PCB.
NOTE: There are two types of CF Card Adapter JIGs available. One is to use with CF Card
mounted on a CF Card Adapter. The other is to use with CF Card without the adapter.
7) Install back on the machine, the Print Drum, Mechanical Control PCB Bracket with the Mechanical
Control PCB and NeoROSA PCB with the CF Card Adapter JIG attached.
8) Turn ON the machine power while pressing the START/WAKE-UP button on the Operation Panel.
9) "Call Service" LED on the operation panel lights to indicate that the firmware is being installed on
the NeoROSA PCB.
10) After a while, beep sound is made. -- This means that the firmware is installed.
12) Repeat from above Step-2 and remove the CF Card and the CF Card Adapter JIG from the
machine.
13) Install all the required items back on the machine and turn ON the machine power in normal
operation mode, and confirm that the machine boots up in normal condition to complete the
procedure.
CF Card
CF Card Adapter
JIG for CF Card
without adapter.
CF Card Adapter
CF Card
Adapter
CF Card
JIG for CF Card

with adapter.
How the CF Card
+ =
Adapter JIG is
mounted on the
NeoROSA PCB
NeoROSA PCB < View of the JIG for CF Card with the adopter.>
< CHINA Type >
[��
19-7 ] KZ30 (Rev. 1.2)
2. NeoROSA PCB (option) - continued.
(2) Firmware Installation Procedure for the machine destinations other than CHINA.
2) Insert the CF Card, containing the NeoROSA firmware, in the CF Card slot of the NeoROSA PCB.
< The CF Card need not have an adopter when inserting it in the slot on the PCB.>
4) Turn ON the machine power while pressing the START/WAKE-UP button on the Operation Panel.
5) "Call Service" LED on the operation panel lights to indicate that the firmware is being installed on
the NeoROSA PCB.
6) After a while, beep sound is made. -- This means that the firmware is installed.
8) Remove the CF Card from the NeoROSA PCB.
9) Turn ON the machine power in normal operation mode, and confirm that the machine boots up in
normal condition to complete the procedure.
Only the CF Card
CF Card Adapter CF Card
< Use only the CF Card. CF Card Adapter is not necessary >
KZ30 (Rev. 1.2) [��

19-8 ]
KZ30 (Rev. 1.2)

RISO 57A01C & KZ30 Technical Manual

(Rev. 1.2)
Published October 2011
Reproduction and duplication prohibited
Edited and published by: Overseas Technical Department,
RISO KAGAKU CORPORATION
The contents of this manual are subject to change without notice
KZ30 (Rev. 1.2)


KZ30 Technical Manual Rev.1.2

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Imagetec Solutions Australia

Copyright : 2011 Riso Kagaku Corporation

RISO INTERNATIONAL GROUP

KZ30 (Rev. 1.2)

KZ30 (Rev. 1.2)

KZ30 (Rev. 1.2) [������

Important Safety Precautions

1. Always disconnect electrical supply before placing hands in the

II. Protection of the machine:

2. Always connect electrical connectors firmly.

I. To avoid electrical failure:

II. Protection of the electrical components:

Wire harness connector

Press the ends.

Press the center, firmly.

KZ30 (Rev. 1.2) [������

Lifting the machine

Assembly and installation Positioning pin

Unless otherwise specified, assembly and installation follow the

Self-tapping screws are used in many places on the machine.

Self-tapping screw Pan-head screw

Electrical system work

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

<Refer to the Chapter on the Print Drum>

051-75008-006 Drum Shaft Jig (8mm diameter)

4. Exterior Cover Removal

Master removal unit cover

1) Print Drum (1 screw)

Separation fan unit

Look into the machine

< Paper Ejection Side of the Machine >

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< View of the Lock >

Hold firmly < Print Drum >

2) Front Cover (8 screws)

Remove the Print Drum from the machine first.

< Front View > < Rear View >

The front cover can be

< Front View >

3) Rear Cover (6 screws)

< Front View > < Rear View >

The rear cover can be

< Front View >

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4) Master Removal Unit Cover (4 screws)

5) Master Making Unit Cover (5 screws)

1 screw from the top.

2 screws on the back.

6) Operation Panel Assembly (2 screws)

Connector to the Operation panel.

< Operation Panel - left view >

Operation panel bracket

< Operation Panel - front view >

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5. Pressure Spring Removal

Remove the Paper receiving tray and Suction unit

Strong piece of Rope.

Pull on the rope to unhook the Spring. Remove the rope.

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CHAPTER 2: MACHINE SUMMARY

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2. Cross Sectional Diagram

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