Riso WEB Version

CHAPTER 11: MASTER REMOVAL SECTION

CONTENTS

1. Theory of Operation
1. Master Removal Unit Mechanism .......................................................................... 1
2. Master on the Drum (before master removal) Check Mechanism ......................... 2
3. Clamp Plate Master Release Mechanism ............................................................. 4
4. Master Removal Mechanism ................................................................................. 6
5. Master Disposal Box Set Mechanism .................................................................... 8
2. Removal and Assembly
1. Master Removal Unit ............................................................................................. 9
2. Master Removal Clutch ....................................................................................... 10
3. Master Removal Sensor ...................................................................................... 11
4. Disposal Box Set Sensor ..................................................................................... 11
5. Master Removal Hook ......................................................................................... 12
6. Vertical Transport Roller (Upper) ......................................................................... 13
7. Vertical Transport Roller (Lower) ......................................................................... 13
8. Master Removal Guide (Lower) ........................................................................... 13

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KS Series (Version 3.1)
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MEMO

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KS Series (Version 3.1)
 Riso WEB Version

MASTER REMOVAL SECTION

THEORY OF OPERATION

1. Theory of Operation
1. Master Removal Unit Mechanism
> The Master removal unit [A] removes the master on the drum each time the master making
operation is made.
> The Master removal hooks [D] guide the removed master towards the Master disposal box [C].
> The Transpotation roller upper [E] and lower [F] are engaged via gears. And rotation of the
transpotation roller upper and lower is made by the rotation of the Main motor via the Mater
removal clutch [B].

A
C (for KS500)

A
B
(for KS600)
One for KS800 looks a
little different.

D
C

(for KS500 & KS600)

(KS800 uses master removal motor
instead of a clutch.)

A:Master removal unit

B:Master removal clutch
C:Master disposal box
D:Master removal hook
E:Transpotation roller upper
F:Transpotation roller lower OVERSEAS TECH. DEPT. WEB SITE
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MASTER REMOVAL SECTION

THEORY OF OPERATION

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

1. Master Sensor
> Master sensor [B] checks the presence of the Master [D] on the drum when the Start button is
pressed for confidential master making or normal master making.
> The sensor [B] looks for the Master [D] on the drum when the Drum rotates 134 from the
Position-A.
> If the machine already knows the presence of the Master [D] on the drum from the earlier
machine operations, this Master checking movement is skipped.

2. When master is detected on the Drum

> The machine goes into master removal and Master removal sensor becomes active.

3. When master is not detected on the Drum

> The machine skips the master removal movement and goes directly into master making.

A:Light absorber strip

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

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MASTER REMOVAL SECTION

THEORY OF OPERATION

Master on the Drum Check Timing Chart (before master removal)

Press START button

1 Blocked
Blocked
Position-A sensor Open

Drum at 134
2
Master sensor
~

~
Detecting
master

Main motor OFF

ON

1 The Drum is at Position-A when the START button is pressed.

2 If the light of the Master sensor is reflected back (detecting master) at Drum 134 , the Master removal
sensor becomes active and checks the master during the master removal.
If the light of the Master sensor is not reflected back (master not detected) at Drum 134 , master removal
movement will be skipped.

If the machine knows the presence of master on the Drum from earlier machine movements, this master
* on the Drum check movement is skipped.

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MASTER REMOVAL SECTION

THEORY OF OPERATION

3. Clamp Plate Master Release Mechanism

1. Master on the Drum check
> When the START button is pressed for confidential or regular master making, the Drum rotates
and presence of the master on the Drum is checked.
> If a master is found on the Drum, the master release movement is made after the Drum returns
to Position-A.

2. Clamp open arm & Master release arm

> The Clamp open arm [B] comes down first and opens the Clamp plate [C] to free the leading
edge of the master.
> Next, the Master release arm [D] comes down and raises the Master release bar [E] to push
the leading edge of the master out of the Clamp plate [C].
> The Clamp motor continues to rotate the Clamp cam ass'y [A] until both the Clamp open arm
[B] and Master release arm [D] are lifted to closes the Clamp plate [C] and the Master release
bar [E].
> The master release movement is completed when the light path of the Clamp sensor L [G]
becomes open and the Clamp motor stops.

A 1

D
1

B
E

1
G

A:Clamp cam ass'y 1

B:Clamp open arm

C:Clamp plate 1

D:Master release arm

E:Master release bar
F:Clamp sensor C
G:Clamp sensor L

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MASTER REMOVAL SECTION

THEORY OF OPERATION

Clamp Plate Master Release Timing Chart

Start button Start button

is pressed is pressed

0 180 270 0 180 270 0

Clamp encoder

Open
Blocked
Clamp sensor L

Clamp sensor C 4 123

123
1 123
123
123456789012345678901234
3

Max. 10sec 1234 2 Max. 10sec

123 123
1234567890123456
123
123

Max. 10sec

1 If the Start button is pressed when the light path of the Clamp sensor L is not blocked and the Clamp
sensor C is blocked, the Clamp motor is activated to make the light path of the Calmp sensor L and C
unblocked within 10 seconds. If the both could not be opened within 10 seconds, the machine
assumes that the Clamp motor has locked and displays error message [E 3].

2 If the light path of Clamp sensor L and C does not become blocked within 10 seconds after the light
path of the Clamp sensor L and C became opened, the machine assumes that the Clamp motor has
locked and displays error message [E 3].

3 If the light path of Clamp sensor C does not become blocked and that of Clamp sensor L does not
become open within 10 seconds after the light path of the Clamp sensor L and C became blocked, the
machine assumes that the Clamp motor has locked and displays error message [E 3].

4 When START button is pressed, the machine confirms whether the light path of Clamp sensors L and C
are opened or not. If the light paths of Clamp sensors L and C are not both open, the machine will
display [E 3] immediately.

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MASTER REMOVAL SECTION

THEORY OF OPERATION

4. Master Removal Mechanism

1. Master Removal Clutch
> The Main motor rotatates the Vertical transport roller upper [B] and lower [A] via the Mater
removal clutch [E].
> By the rotation of the Drum, the leading edge of the master comes in between the Vertical
Transport roller upper [B] and lower [A] and the separation of the master from the Drum starts.
> The Main motor stops to complete the master removal movement when the Drum comes back
to the Position-A after making one rotation to remove the master.

2. Master Removal Hooks

> The master removed from the Drum is guided in between the Vertical transport roller upper [B]
and lower [A] by the Master removal hooks [D].

3. Master Removal Sensor

> Master removal sensor [C] checks the presence of the removed master in front of the Master
disposal box to check for master removal jams.
> The Master removal sensor [C] looks for presence of removed master at134 Drum rotation
from Position-A.

Sketch of master disposal box for KS500.

(That for KS600 & KS800 looks different.)

A D

E
A:Vertical transport roller (lower)
B:Vertical transport roller (upper)
C:Master removal sensor
D:Master removal hook
E:Master removal clutch

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MASTER REMOVAL SECTION

THEORY OF OPERATION

Master Removal Timing Chart

0 1
134
1
315 1 0
1 1
1 1 Blocked
1
1 1
1 Open 1
1
Position-A sensor 1 1
1 1
1 1
1 1
1 1
1
1 1
1 1
1
1 1
1 1
1 1
1 1
1 1
1 ON 1
1 1
123 1
12
123 123
123
1 1.95rpm
123
12345671
121234567890123456789012345678901212
123
1 1
123123456789012
123
1
Main motor 1
1 1
1 OFF
15rpm11 15rpm 1
1
1 1
1 1
1 1
1 1
1 1
1 1
1 ON 1
1 1
1
1 1
1 1
1
Master removal 1
1 1
1 OFF
1 1
clutch 1
1 1
1
1 1
1 1
1 1
1 1
1
Detecting1 removed master 1
1 1
1 1
1 1 12345678901
12
1 1
1 12345678901
12345678901
Master removal 12
1
12
1 1
1
2 12345678901
12345678901
12345678901
sensor 12345678901
12345678901
12345678901

1 During the initializing of the drum towards the position A in the master removal operation, if removed
master is detected by Master sensor at Drum angle 134 , the Master removal sensor looks for the
removed master.
If removed master is not detected by the Master removal sensor at Drum 134, the machine assumes
master removal error has occurred and displays the message [J 9].

2 When the Drum returns to Position-A and the Master removal sensor confirms the removed master has
cleared through the sensor.
If the Master removal sensor still detects removed master, the machine assumes removed master has
jammed at master removal area and displays message [J10].

If Master removal sensor detects removed master when the Start button is pressed, the machine
* assumes that the removed master is jammed and the message [J10] is displayed.

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MASTER REMOVAL SECTION

THEORY OF OPERATION

5. Master Disposal Box Set Mechanism

1. Disposal Box Set Sensor
> Disposal box set sensor checks the presence of the Master disposal box and whether the
Master disposal box is opened or closed.
> When the Master disposal box is set in the machine, its tip blocks light path of the Disposal
box set sensor.

Sketch of master
disposal box for KS500.
B

Sketch of master disposal

box for KS600.
(That for KS500 and KS800 looks different.)

A:Disposal box set sensor

B:Master disposal box
C:Tip
D:Master removal unit (closed)

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MASTER REMOVAL SECTION

REMOVAL AND ASSEMBLY

2. Removal and Assembly

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

Sketch of master disposal

box for KS600.
(That for KS500 and
KS800 looks different.)

A:Master removal unit

B:Master Disposal Box
C:Master removal unit lever
D:Connector

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MASTER REMOVAL SECTION

REMOVAL AND ASSEMBLY

KS800 uses Master removal

2. Master Removal Clutch KS500 & KS600 only motor instead of a clutch.
1. Disconnect the power supply from the machine.
2. Remove the Back cover. (See page 1-6)
3. Remove the Master removal unit.( See page 11-9)
4. Remove the E-ring [F] and remove M-R gear [E].
5. Remove two mounting screws of the Clutch B bracket [A] and remove the bracket.
6. Disconnect the Connector of the Master removal clutch [C].
7. Remove the Master removal clutch [C].

Precaution in Assembly
> Mount the slit on the Master removal clutch [C] over the Clutch B bracket [A].

A B

E
C
(for KS500 & KS600)
(KS800 uses master removal motor
instead of a clutch.)
A:Clutch B BKT
B:Metal
C:Master Removal Clutch
D:Metal
E:M-R Gear
F:E-ring

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MASTER REMOVAL SECTION

REMOVAL AND ASSEMBLY

3. Master Removal Sensor

1. Disconnect the power supply from the machine, and remove Master removal cover.(See page 1-
6)
2. Slide the Master removal unit out.
3. Disconnect the Connector of the Master removal sensor [C].
4. Remove the mounting screw of the Master removal sensor bracket and remove the bracket.
5. Remove the sensor from the bracket.
Precaution in Assembly
> Match the half-pierced section of the Master removal sensor bracket with its counter part.

4. Disposal Box Set Sensor

1. Disconnect the power supply from the machine, and remove Master removal cover.(See page 1-
6)
2. Disconnect the Connector of the Disposal box set sensor [A].
3. Remove the mounting screw of the Disposal box set sensor bracket and remove the bracket.
4. Remove the sensor [A] from the bracket.

A:Disposal box set sensor

B:Master removal Unit
C:Master removal sensor

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MASTER REMOVAL SECTION

REMOVAL AND ASSEMBLY

5. Master Removal Hook

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

A:Master removal unit

B:Master removal hooks

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MASTER REMOVAL SECTION

REMOVAL AND ASSEMBLY

6. Vertical Transport Roller (Upper)

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

7. Vertical Transport Roller (Lower)

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

8. Master Removal Guide (Lower)

1. Disconnect the power supply from the machine.
2. Remove the Master disposal box [F].
3. Remove the Master removal unit.(See page 11-9)
4. Remove the Master removal sensor. (See page 11-11)
5. Remove the Master removal guide (Upper)[A].
6. Remove the Vertical transport roller (Upper) [B] and (Lower) [C].
7. Remove three mounting screws then remove the Master removal guide(Lower) [E].

A D

A:Master removal guide (Upper) F

C
B:Vertical transport roller (Upper)
C:Vertical transport roller (Lower) Sketch of master disposal box for KS500.
G D:Master removal unit (That for KS600 & KS800 looks different.)
E:Master removal guide (Lower)
F:Master disposal box
G:Transport roller gear
H:Master removal sensor
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MEMO

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