Riso WEB Version

CHAPTER 8: DRUM SECTION

CONTENTS

1. Theory of Operation
1. Master on Drum (in printing) Check Mechanism ................................................... 1
2. Ink Bottle Set Check Mechanism .......................................................................... 2
3. Ink Supply Mechanism .......................................................................................... 3
4. Squeegee Roller Rotation Mechanism .................................................................. 5
2. Removal and Assembly
1. Drum Unit .............................................................................................................. 7
2. Screen ................................................................................................................... 8
3. Drum Body ............................................................................................................ 9
4. Ink sensor PCB ................................................................................................... 11
5. Ink Bottle Guide ................................................................................................... 12
6. Ink bottle set Sensor ............................................................................................ 12
7. Drum Support F & Drum Support R ..................................................................... 13
8. Squeegee Roller .................................................................................................. 14
9. Ink Pump Unit ...................................................................................................... 17
10. Inking Motor ...................................................................................................... 18
3. Adjustment
1. Squeegee Gap .................................................................................................... 19

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DRUM SECTION
THEORY OF OPERATION

1. Theory of Operation
1. Master on Drum (in printing) Check Mechanism
1. Master Sensor
> Master Sensor [B] checks the presence of master on the Drum before the start of printing.
> 134 Drum rotation after the first Position-A, the Master Sensor [B] looks for the master [A] on
the Drum.
> The result (whether the master [A] is found or not) is memorized until the Drum is pulled out of
the machine or the power is turned off.
> If no master is detected on the Drum, [J1] is indicated on the Operation panel and stops the
printing operation.
AAaaa
A

Drum angle = 134

(From position-A)

A: Master
B: Master sensor
Drum angle = 134
(From Position-A)

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THEORY OF OPERATION

2. Ink Bottle Set Check Mechanism

1. Ink bottle Set Sensor
> Ink bottle set sensor[A] checks the presence of the Ink bottle[C] in the Ink bottle guide[B].
> There is an actuator plate[D] on the bottle set sensor ass'y as shown on below figure.
> The machine will judge by the sensor staus, whether Ink bottle [C] is installed or not.

If the Ink bottle [C] is not installed, the machine will indecate 'C5'.

B
In case No bottle is installed A

Ink bottle set sensor detects the actuator

plate

In case bottle is installed

The actuator plate is released by ink

bottle thus Ink bottle set sensor does not
detect the actuator plate
C

A: Ink bottle set sensor

B: Ink bottle guide
C: Ink bottle
D: Actuator plate

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DRUM SECTION
THEORY OF OPERATION

3. Ink Supply Mechanism

1. Ink Sensor PCB
> Ink sensor on the Ink sensor PCB [I] checks the presence of ink in the Drum.
> Overflow sensor [H] checks the ink overflow in the Drum.

2. Inking Motor
> Inking motor [C] activates the Ink pump to supply the ink into the Drum when ink is not
detected by the Ink sensor [G].
> Ink from the Ink bottle is pumped through the Ink hose [F] into the Drum, on top
of the Squeegee roller [A], through Ink distributor [E].
> The Inking motor [C] stops when the Ink sensor [C] detects ink.

3. Ink Supply to the Inner Surface of the Drum

> The ink supplied on the Squeegee roller [A] is transferred onto the Drum inner surface by the
rotation of both the Squeegee roller [A] and Drum.
> Excess ink is then made into a long roll of ink tube around a thin Driven shaft [D] located
between the Squeegee roller [A] and Doctor roller, [A] and this excess roll of ink tube is
checked by the Ink sensor [G] and Overflow sensor [H].

4. Ink Overflow
> If an excess amount of ink is supplied in the Drum and Overflow sensor [H] detects the ink,
the machine stops with [E 4] indication on the Operation panel.

(refer to the Timing Chart on page 8-4)

J
G E F A

I
A: Squeegee roller
B: Doctor roller D
C: Inking motor
D: Driven shaft
E: Ink distributor
F: Long roll of ink tube
G: Ink sensor B
H: Overflow sensor
I: Ink sensor PCB
J: Ink bottle

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THEORY OF OPERATION

Inking Timing Chart

Drum rotation starts Drum stops

ON
Main motor
Blocked Blocked Blocked
Position-A Open
sensor
Ink detected
Ink sensor No detection
1 2 3 4 5
Inking motor ON
OFF

1 The Inking motor does not activate at the start of Main motor even though the Ink sensor is not
detecting the ink.

2 The Inking motor activates when the light path of the Position-A sensor changes from "blocked" to
"open" with the rotation of the Drum if the Ink sensor is not detecting the ink.

3 The inking motor stops when the Ink senser becomes detecting the ink.

4 The Inking motor activates when the Ink sensor no longer detects the ink during printing.

5 The Inking motor turns off when the Main motor is turned off.
> If Ink sensor does not detect ink within 20 seconds after the Inking motor is activated, the machine
assumes that the Ink Cartridge is empty and [C 8] is indicated.
If the machine power is turned OFF before the 20 second count, the counting continues from that point
when the machine is turned ON again.
> If Overflow sensor detects ink for more than 0.5 seconds, the machine assumes that the ink has over
flown within the Drum and displays error message [E 4].
> If excess current is detected for more than 2.5 seconds after the Inking motor is activated, the machine
assumes that the Inking motor has locked and indicates error message [E 16].

C B

Ink is sucked in

A
A: Inner rotor D
Ink is pushed out
B: Outer rotor
C: Ink "IN" The ink sucked in is carried between the Outer and Inner
D: Ink "OUT" rotors of the Ink pump and as the gap between the rotors
becomes small, the ink is pushed out.

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THEORY OF OPERATION

4. Squeegee Roller Rotation Mechanism

1. Rotation of the Squeegee Roller
Through the gears, the drive of the Main motor [K] is transferred to the Squeegee roller gear [C]
via the Intermediate gear A [F], gear B [G], gear C [H], gear D [I] and rotates the Squeegee roller
[A].
The Squeegee roller gear R [C] has one way clutch which prevents the Squeegee roller [A] from
rotating when the Drum is accidentally rotated in the opposite way by hand.

2. Rotation of the Driven Shaft

With the rotation of the Squeegee roller [A], the Squeegee roller gear F [D] transfers the rotation
to the gear on the Driven shaft [L] and rotates the shaft.
L
D
B

A
F

C
G

A: Squeegee roller
K
B: Doctor roller
C: Squeegee roller gear R [with one way clutch] J I
D: Squeegee roller gear F
E: Drum main gear
F: Intermediate gear A
G: Intermediate gear B
H: Intermediate gear C
I: Intermediate gear D
J: Main motor gear
K: Main motor
L: Driven shaft

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DRUM SECTION
REMOVAL AND ASSEMBLY
2. Removal and Assembly

1.1. Drum Unit

1. Disconnect the power supply from the machine.
2. Remove the Back cover and the Front cover (See page 1-6)
3. Slide out the Master removal unit to prevent the Master
removal hooks from being damage by the Drum unit.
4. Remove the Separeter spring to keep away the Sparater
from the Drum. (Refer to page 7-3)
5. Remove the following items from the machine;
>Power supply PCB [C]
>Main PCB cover [D], the Main PCB [E]
with Main PCB bracket [F]
>Load spring plate [A]
>Ink bottle guide (See page 8-11)

C
A: Load spring plate A
B:Power supply cover
C:Power supply PCB
D: Main PCB cover
E: Main PCB B
F

E
6. Disconnect connector of A detection sensor
D
and connector of Inking motor[G].
7. Remove four mounting screws of the Drum
unit [H] then pull out the drum unit from the
machine.

F: Main PCB brackett

G: Inking motor
H: Drum unit
G

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REMOVAL AND ASSEMBLY

2. Screen
1. Make a confidential master on the Drum.
2. Remove the Drum from the machine (See page 8-7)
3. Remove the two Screen springs [B].
4. Remove two mounting screws (regular screws) of the Clamp plate base [C] which are also
holding down the Screen [A] to the Drum.
If neccessary loosen two Special screws [D] which are also on the Clamp plate base [C].
5. Pull out the Screen [B] from under the Clamp plate base [C], and remove the Screen [B].

Precaution in Assembly
> Do not bend, wrinkle or damage the Screen [B].

A
C

A: Screen D
B: Screen springs
C: Clamp plate base
D: Special screw

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DRUM SECTION
REMOVAL AND ASSEMBLY

3. Drum Body
1. Make a confidential master on the Drum.
2. Remove the Drum from the machine.(See page 8-7)
3. Remove the Screen from the Drum. (page 8-8)
4. Remove two Special screws [E] from the Clamp plate base [A] and remove the base.
5. Remove remaining ten regular mounting screws and two more Special screws [E] holding the
Drum body [B] to the Drum support F [C] and R [D].
6. Separate the Drum body from the Drum supports [C][D], carefully to avoid damaging the Drum
body [B].

(Refer to page 8-9 for the "Precaution in Assembly")

A: Clamp plate base

E
B: Drum body
C: Drum support F
D: Drum Support R
E: Special screw

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REMOVAL AND ASSEMBLY

Precaution in Assembly
> Do not bend or damage the Drum body.
> The Drum body has and marks with F engraved next to one of the two arrow marks.
The F mark indicates the "front" (Operation panel side).
> Mount the screws on the two holes marked and first.
Then mount the two Special screws [A] next to the first two screws.

A: Special screws
A

> After the first and second set of the screws are in, temporary hook the Screen springs [B]
in the manner shown by the illustration below.
This is to pull and fit the Screen evenly on the Drum supports F and R.

B:Screen spring

> Mount the remaining screws and remove the two temporary mounted Screen springs.
> Mount the last two remaining screws and hook the Screen springs to complete the assembly.
If necessary, refer to page 8-8 to check how the springs were hooked on the Drum.

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REMOVAL AND ASSEMBLY

4. Ink Sensor PCB

1. Make a confidential master on the Drum.
2. Remove the Drum from the machine. (See page 8-7)
3. Remove the Screen. (See page 8-8)
4. Remove the Drum body. (See page 8-9)
5. Disconnect the Connector of the Ink sensor PCB [A].
6. Remove two mounting screws of the Ink sensor cover and remove the cover with the PCB in it.
7. Remove Ink sensor PCB [A] from the Ink sensor cover.
CAUTION:
Use special caution not to break or bend the two sensor antennas.
If they are bent, straighten them out with fingers.

Precaution in Assembly
> The Ink sensor and Overflow sensor antennas should both be standing at a right angle to the
PCB.
> The two antennas must not be touching the Doctor roller or Driven shaft.

A: Ink sensor PCB

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DRUM SECTION
REMOVAL AND ASSEMBLY

5. Ink Bottle Guide

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

A AA

A: Ink bottle guide

6. Ink Bottle Set Sensor

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

B:Ink bottle set sensor ass'y

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REMOVAL AND ASSEMBLY

7. Drum Support F & Drum Support R

1. Make a confidential master on the Drum.
2. Remove the Drum from the machine (See page 8-7)
3. Remove following parts fron Drum unit;
>Screen ass'y (See page 8-8)
>Drum body (See page 8-9)
>Ink sensor PCB (See page 8-11)

4. Disconnect the Connector of the Ink sensor PCB and pull out the Intermediate wire harness
from the Drum U support BKT R [A].
5. Loosen the Mounting screws [G1,2,3,4: cap screw]of Drum Shaft Clampers [F] to Drum support
BKTs.
6. Loosen the Mounting screws [H1 & 2:set screw] of Drum Shaft Clampers [F] to the Drum center
shaft [I].
7. Remove Drum Support BKT R [A] and F [D] from the Drum center shaft [I].
8. Remove Drum Support R [A] Ass'y [B] and Drum Support F Ass'y [C] from the Drum center
shaft [I].

H2
A
1

B G3
1

G4
E

H1
1

G11

G2
D
A:Drum U Support BKT R
B:Drum Support R Ass'y
C:Drum Support F Ass'y
D:Drum U Support BKT F
E:Intermediate wire harness
F:Drum Shaft Clampers
G1-4: Mounting screws (cap screw)
H1-2: Mounting screws (set screw)
I :Drum center shaft

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REMOVAL AND ASSEMBLY

8. Squeegee Roller
1. Make a confidential master on the Drum.
2. Remove the Drum from the machine (See page 8-7), and remove Ink bottle from the Drum.
3. Remove Ink bottle guide (See page 8-12)
4. Remove Drum support F & Drum support R (See page 8-13)
5. Remove following parts from the Drum unit.
> Ink pump unit (See page 8-17)
> Screen (See page 8-8)
> Drum body (See page 8-9)

6. Remove Ink sensor PCB[K] (page 8-11)

7. Remove Ink blocking plates [F/G].
8. Loosen securing screw on both side of Drum shaft joint then remove two mounting screws each
from the Squeegee frames [I/J] on both ends.
9. Remove Center shaft ass'y [A].
10. Remove both side of mounting screws and pull out Drive shaft gear [L] then remove Drive shaft
[B] from the Squeegee unit.
11.Remove Squeegee drive gear [D] and Squeegee idler [E] from rear side of Squeegee roller shaft
[M].
12. Remove Transfer gear [H] from front side of Squeegee roller shaft [M].

(Continue to page 8-15)

A: Center shaft
B: Drive shaft
C: Drum shaft joint
D: Squeegee drive gear
E: Squeegee idler
C
F: Ink blocking plate F
K
G: Ink bolcking plate R B
H: Transfer gear
I: Squeegee frame F
J:Squeegee frame R
K: Ink sensor PCB A
L: Drive shaft gear
M: Squeegee Roller

G
F
J
L

H M

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REMOVAL AND ASSEMBLY

14. Remove four screws each from the Drum main frames [C].
15. Remove the Squeegee frame R [A] and the Squeegee frame F [E].
16. Slowly take out the Squeegee roller [B].
17. The Doctor roller [D] will also come apart from the Squeegee unit.

CAUTION:
Two O-rings [H] may fall off from the Squeegee block F [F] and R [G] when the Doctor roller [D]
is removed.
Do not lose these O-rings [H].

B G A

REAR
C

H F
C

A: Squeegee frame R
B: Squeegee roller
C: Drum Main Frame
D: Doctor roller
FRONT E E: Squeegee frame F
F: Squeegee block F
G:Squeegee block R
H:O-ring

Precaution in Assembly
> Do not forget to return the two O-rings [H] in their original positions.

Adjustments after Assembly

> Squeegee gap adjustment is required. (See page 8-19)

(Continue to page 8-16)

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REMOVAL AND ASSEMBLY

Precaution in Assembly
> When tightening the Drum shaft clampers [A], use the Adj. shaft [C] as a JIG to set the
position.
> Bring the Drum to the Position-A.
Tighten both side of the Drum shaft clamper[A] of the Drum with four screws after placing the
JIG[C] through the holes on the Drum U support BKT R [D], Drum support R ass'y [G], Drum
support F ass'y [F] and the Drum U support BKT F [E].

REAR FRONT

1
1 A A

B
B

A:Drum shaft clamper

B:Center shaft F
C:Drum grip shaft (JIG) E
D:Drum U support BKT R G
D
E:Drum U support BKT F
C
F:Drum support F ass'y
G:Drum support R ass'y
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REMOVAL AND ASSEMBLY

9. Ink Pump Unit

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

A: Ink pump unit

B: Ink bottle guide

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REMOVAL AND ASSEMBLY

10. Inking Motor

1. Remove the Front cover.(See page 1-6)
2. Remove the Ink bottle and remove the Ink bottle guide.(See page 8-12)
3. Remove the Ink pump unit [A]. (See page 8-17)
4. Remove two mounting screws of the Inking motor [B] and remove the motor.

A:Ink pump unit

B:Inking motor

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DRUM SECTION
ADJUSTMENT

3. Adjustment
1. Squeegee Gap
1. Make a confidential master on the Drum.
2. Remove the Drum from the machine.(See page 8-7)
3. Remove the Screen. (See page 8-8)
4. Remove the Drum body. (See page 8-9)
5. Clean out the ink from the Squeegee unit.
6. Using thickness gauge, measure the gap between the Squeegee roller and Doctor roller.
The gap should be 0.08 mm ± 0.02 mm.
If not, the gap should be adjusted.
7. To adjust, loosen the securing screw [B] of the Doctor roller adjust plate [A] located at both ends
of the Squeegee unit by 3.0 mm Allen wrench.
8. Move the adjust plate [A] by inserting a rod, such as 2.5mm Allen wrench [D], in the Adj. hole [C]
on the plate to change the Squeegee gap.
9. Tighten the securing screw of the two Doctor roller adjust plates after the adjustment is done.

Caution in Adjustment
> The Squeegee gap between the Squeegee roller and Doctor roller should be equal throughout
the length of the two rollers.

Results of Incorrect Adjustment

> If the gap is too big:
Too much gap will allow excess amount of ink to get on the inner surface of the Drum and
results in ink leakage from the Drum.
> If the gap is too small:
Not enough ink transfers on the inner surface of the Drum and the prints may come out with
uneven print density.

C B A A: Doctor roller adjust plate

B: Securing screw
C: Adj. hole
D: 2.5mm Allen wrench

NARROWER
C

0.08 mm ± 0.02mm

(REAR) WIDER

C
NARROWER

0.08 mm ± 0.02mm (FRONT)

WIDER

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