2 Machine Specification Chapter 2 Page 2-7 Resolutions: D600dpi models & 300dpi models“D” = Device x 600dpiMachine Types: 600dpi - A3 model300dpi - A4 modelOperation Panel: LED displayOriginal Type: Book & sheetPrinting Speed: 5 speeds (Approx. 60, 80, 100, 120, 130)Image Processing Mode: Line, Photo, Duo, PencilInk Cartridge: 1,000 millilitres per cartridgeFrom now on the term 600dpiwill be usedOnly for 600dpi machine
3 Optional Accessories Chapter 2 Page 2-6 Available OptionsColour Cylinder (Drum)Auto Document Feeder AF-VFeeds up to 50 originals automaticallyJob Separator IV:NKey Card Counter IV:NSpecial Paper Feed KitUse for thick paper such as cards and envelopes. Replace with this when thick paper needs to pass through the machine.StandPrinter Control Board RISORINC3NUse to connect a computer to the machine using a parallel cable.RISO PRINTER Network Interface Card RISORINC-NETUse to directly connect the machine to the network.This comes with RISO-MONITOR software.
4 Machine Installation Notice Sheet Following two steps are un-necessary Unlocking the scanner lock screw.Scanner carriage test mode release.
5 Specifications Chapter 2 See Specification Sheet Page 2-7Preparing to PrintPower Switch.Open and set paper feed tray.Load paper & position the guides.Paper feed pressure adjustment. Normal / CardOpen paper receiving tray.Basic OperationHow to scan originals. Line / Photo / DuoReduce & Enlargement.Print Positioning.Consumable replacement.Drum removal.Master making unit release.
7 Main Drive Chapter 3 Page 3-1 Main MotorTiming BeltGearPrint Drum1st & 2nd Paper Feed(Paper Separation)GearAir PumpPrinting Speed: 60cpm to 130cpm in 5 steps
8 Print Drum Paper Feed Area Timing Belt Air Pump Main Motor (Main Pulley / Main Shaft)Paper Feed AreaTiming BeltAir PumpMain Motor
9 Disassemble & Reassemble Main Drive Timing PositionsPosition B Machine home position1Paper Feed SectionPrinting SectionAir Pump unitPosition B sensorTM 801 & 8922Please Note:Position B = Drum ReleaseGo through main timing marks and set-up.When working on drive system, jig what side your not working on.4Disassemble & Reassemble Main Drive3
10 Markings on plastic gears Markings on the plastic gears 2 1Pos B Paper feed sectionMarkings on plastic gearsMarkings on the plastic gears2Align – marking against = markings on the two gearsAlign dots togetherPos B Printing section4Position B sensor actuatorPos B Air pump3Pos B sensor
11 Main Motor Safety Switches Page 3-4 Rear Cover Safety Switch (L & R) (TM 005)Master Removal Box Safety Switch (TM 423)Master Making Unit Safety Switch (TM 409)Print Drum Safety Switch (TM 820)Stops the four following motors:Main MotorClamp motorMaster compression motorMaster disposal motor
15 Disassemble & Reassemble Paper Feed & Drive Assy Paper Feeding SectionFirst Paper FeedThree paper feed positions: Card 600 dpi only, Normal, Custom 600dpi only.No double feed detection sensor or stack feed switch.Paper feed clutch (TM688)Disassemble & Reassemble Paper Feed & Drive Assy3Paper feed clutch
16 Disassemble & Reassemble Second Paper Feed Paper Feeding Section Chapter 5 Page 5-1Second Paper Feed Page 5-21. Paper sensor (TM 605)Disassemble & Reassemble Second Paper FeedGuide rollerTiming rollerAdjust G lever.Paper sensor1Timing roller
17 Disassemble & Reassemble Vertical Print Drive Paper Feeding SectionVertical Print Positioning Page 5-4Print positioning pulse motor (TM 900 & 901)Vertical centreing sensor (TM 831)Disassemble & Reassemble Vertical Print DrivePrint positioningPulse motor12Vertical centreing sensorPositions printed imageup or down
18 Image UP Image DOWN CW Image DOWN CCW Image UP Print positioning pulse motorImageUPCW Image DOWNCCW Image UPImageDOWNPrint positioning wheel assyVertical centreing sensor
19 Disassemble & Reassemble Press Section Printing Section Chapter 6 Page 6-1Printing Pressure Page 6-2Print pressure pulse motor 600dpi only (TM 904, 905 & 908)Print pressure HP sensor 600dpi only (TM 830)Pressure solenoid (TM 886)Print pressure pulse motor rotates for set pulses from the HP sensor position according to the selected printing density.Pressure solenoid stays activated (stays on) all through the printing job until the machine stops.Disassemble & Reassemble Press Section
20 1 2 3 Pressure solenoid is ON (Pressure roller is UP) Pressure solenoid is OFF(Pressure roller is DOWN)1Print pressurePulse motorPrint pressureHP sensor2Levers EngagedLevers disengagedPressuresolenoid3Pressure camPressure solenoidHook leverPressure lever
21 300 dpi machine 600 dpi machine Printing pressure Printing pressure Manually AdjustedPrinting pressurePulse motor AdjustedRemove pressure roller and advise how to clean.
22 Disassemble & Reassemble Lock Mechanism Printing Section Chapter 8Print Drum Lock Mechanism, etc. Page 8-6Print drum lock solenoid (TM 885)2. Print drum safety switch (TM 820)3. Print drum lock sensor (TM 807)4. Print drum release button (TM 818)5. Front door set switch (TM 817)The print drum can be manually pulled out from the machine by a serviceman with the machine power offDisassemble & Reassemble Lock Mechanism
24 How to release the Print Drum manually from the machine. 1.Confirm that the print drum is at Position B(If not, bring the drum to Position B)2. Push in a screw driver in the hole indicated below.3. The print drum disengages from the lock.IMPORTANT:Please ensure print drum is in Position B before removing.Push screw driver through the hole.
25 Disassemble & Reassemble Print Drum Printing Section Chapter 8 Page 8-1Print Drum Page 8-2Print drum position B lock release leverInk sensor (TM 809)Overflow sensor (TM 810)Ink pump unit (TM 887 & 888)Ink bottle set switch (TM 811)Rollers & Ink blocking platesAdjust Squeegee roller gap, squeegee pressure and advise precautions on drum body assembly.Disassemble & Reassemble Print Drum
26 Push the lever down to release the print drum from position B. Print drum position B lock release lever1Push the lever down to release the print drum from position B.
27 32Overflow sensorInk sensor5Ink bottle set SW4Ink pump unit
28 Rollers & Ink blocking plate Doctor roller adjustmentInk blocking plate6Rollers & Ink blocking plateGap adjustment between Squeegee roller and drum bodyInk blocking plateFixed position No adjustmentDoctor rollerSqueegee rollerDriven roller
30 Disassemble & Reassemble Suction Unit & Paper Separation Paper Receiving Area Chapter 7 Page 7-1Paper Separation, Suction Unit & Receiving Tray Page 7-2SeparatorSeparator ArmAir Pump Unit Air blow timing fixed by Position B settingSeparation Fan (TM 662)Suction Fan (TM 661)Paper Ejection Motor (TM 660)Paper Ejection Encoder Sensor (TM 612)Paper Ejection Sensor (TM 606)Paper Ejection Wing Reflecting type sensorPaper Receiving Tray Paper Arrangers 400dpi Corrugators 300dpiDisassemble & Reassemble Suction Unit & Paper Separation
31 2 1 3 Separator arm Separator Air pump unit Adjust separator. Go through up and down movement of separator. Remove air blast o-ring.
33 TOP View 8 6 7 5 BOTTOM View Paper ejection sensor Paper ejection motor6Paper ejection encoder sensor75Suction fanBOTTOM View
34 Paper Ejection Wings 600dpi machine Manually adjustable 300dpi machine Adjust paper ejection wing dial according to the type & size of paperPaper Ejection WingsMetric Machine600dpi machineFor ordinary paper widths equal to or larger than B4, set to A3 B4Metric MachineFor ordinary paper widths equal to or smaller than B4, set to A4 B5Manually adjustable300dpi machineMetric MachineFor thick paper, set toFixed Position
35 Paper Receiving Tray Paper Guides Paper Arrangers The paper guide positions must be readjusted if the horizontal print position is adjusted by sliding the paper feed tray.Paper ArrangersAvailable only on 600dpi machines
36 Paper Receiving Tray Corrugators Note: The corrugators are available only on the 300dpi machines.Note:Normal Paper Corrugators in position (DOWN)Thick Paper Corrugators put away (UP)
37 Master Making Section Chapter 14 Page 14-1 Pulling the Master Making Unit outMaster making unit removal button (TM 410)Master making unit safety switch (TM 409)Master making unit set sensor (TM 408)Master making unit solenoid (TM 488)The Master making unit can be manually pulled out from the machine by a serviceman with the machine power off.
38 Press the master making unit release button to pull the unit out of the machine.
39 Pulling out the master making unit manually Push screw driver through the hole.Advise precautions when removing master making unit. Only drum unit or master making unit can be out at one time.Note:Master making unit can be released manually by serviceman
40 3 2 1 4 3 2 1 4 Master making unit Safety switch Master making unit Set sensor2Master making unitRelease button14Master making unitSolenoid32Master making unitSet sensorMaster making unitSafety switchMaster making unitRelease button14Master making unitSolenoid
41 Write Pulse Motor, Load Pulse Motor & Cutter Unit Page 14-4 Master Making SectionWrite Pulse Motor, Load Pulse Motor & Cutter Unit Page 14-41. Write pulse motor (TM 462 & 463)TM 4662. Load pulse motor (TM 464)3. Cutter unit (TM 480) TM 486 & 487 Disc blade shuttle cutter unit only4. Cutter HP switch (TM 403)5. Cutter stop position switch (TM 404) Disc blade shuttle cutter unit onlyRemove Master Making Unit & place on table.Please Note:Drum & Master making unit is not to be out of machine at the same time. (machine may tip over)Disassemble & Reassemble Master Making Section
42 Cutter unit2Load pulse motor31Write pulse motor
43 4 3 4 2 Rotary blade type cutter unit used on A3 machines Cutter HP switch4Rotary blade3Cutter unitShuttle type blade type cutter unit used on A4/B4 machines4Cutter HP switchCutter stop position switch2Disc blade shuttle
44 Master Making Unit Page 14-31 Master Making SectionMaster Making Unit Page 14-31Master making unitMaster making unit is removable from the machine by detaching flat cable wire harness from the unit and removing four mounting screws.1Master making unitMaster making unit has been removed and placed on table.
45 Sensors to detect the Master Material, etc. Master Making SectionSensors to detect the Master Material, etc.Master detection sensor (TM 401)Master end sensor (TM 402)Master positioning sensor (TM 400)Master making upper unit set sensor (TM 407)5. Master flanges F & R Built on the machine
46 Bottom View 2 3 4 1 5 2 Master end sensor (Rcv.) Master positioning sensor4Master making upper unit set sensor1Master detection sensor52Master end sensor(Send)Master flanges F & R
47 Disassemble & Reassemble TPH Assy Master Making SectionThermal Print Head (TPH) Area Page 14-12TPH (TM ) (TM 80 to 85) 300 dpi machine = 80 & 81 onlyThermal Pressure Motor (TM 460 & 461)TPH Pressure Sensor (TM 406)The TPH comes down against the Write Roller only during themaster-making process.Adjust TPH.Disassemble & Reassemble TPH Assy
48 1 3 2 TPH Springs to pull down the TPH Eccentric Cam to Raise the TPH TPH Pressure SensorThermal Pressure Motor
49 Master Transfer Rollers Page 14-20 Master Making SectionMaster Transfer Rollers Page 14-20Write RollerMaster Stocker RollerLoad RollerClamping Guide RollerStocker Solenoid (TM 489)Stocker solenoid activates only when the leading edge of the mastermaterial transfers to the Load roller.Master making starts before the leading edge of the master materialis clamped on the print drum.Driven by Write Pulse MotorDriven by Write Pulse MotorPlease Note:Position A = Master Loading
51 The cover plate lifts up to close the Stocker entrance when the solenoid activates. 5Stocker solenoid
52 Disassemble & Reassemble Master Clamp Unit Master Making Section Chapter 9 Page 9-1Master Clamp Unit Page 9-2Clamp motor (TM 863, 864, 883 & 884)Clamp sensor A (TM 803)Clamp sensor B (TM804)Clamp guiding platePosition A compensator armClamp plateMaster ejection plateDisassemble & Reassemble Master Clamp Unit
53 Master removal action is made while the print drum is rotating FRONT viewBACK view24315Clamp sensor AClamp guiding plateClamp sensor BClamp motorPosition A compensator armMaster removal action is made while the print drum is rotatingMaster clamping action is made when the print drum is stationary with theposition A compensator arm holding the print drum in the position Aposition.
54 Master removal action is made the print drum is rotating. Position A compensator blockRoller for clamp plateMaster removal action is madethe print drum is rotating.Master clamping action is made when theprint drum is stationary with the PositionA compensator arm holding the print drumin the Position A position.Roller for master ejection plate76Master ejection plateClamp plate
55 The RISOiQualitySystem built into all new RZ series models is a radical new way to ensure that the users of RISO printers get the very best performance from their RISO printers, automatically.The System allows two-way communication between RISOiQualitySystemequipped printers and their supplies - ink and masters – via tiny integrated RF-tagsEmbedded in the ink bottle and master roll.This two-way communication provides a host of important benefits that include :Assurance of optimum print qualityPrevention of operator error for suppliesWarning of shortage in remaining volumeMinimal paper waste
56 The RISO i Quality System – real time control for ultimate quality What is an RF-tag?An RF-tag (= Radio Frequency-tag) is a film that contains an IC chip and an antenna.Various data for activating the RISOiQualitySystem are stored in the IC chip, and this data is sent to and received from the RISO printer via the antenna.About Supplies…Each Riso ink has its own character and viscosity, requiring individual and precise adjustment of print pressure, idling time and operating speed to obtain maximum print quality. In addition, the sensitivity of masters varies between the start and the end of the roll. Current RISO printers adjust for these parametersbut only to a limited extent. The RISOiQualitySystem not only offers real-time adjustment all of the time, it also achieves improved print quality.INKThe RF-tag embedded on the ink bottle communicates data such as colour, viscosity, etc. to the printer, preventing the selection of the incorrect colour and assuring optimum print quality.MASTERThe RF-tag in the master roll stores and communicates data including master character and position on the roll for real-time adjustment of the master making parameters. This allows optimum print quality.
57 The RISO i Quality System – Functions and Features OPTIMUM PRINT PRESSURE CONTROLPrint pressure is automatically optimised based on data received from the RF-tag in the ink bottle and the master roll to assure optimum results.OPTIMUM TPH POWER CONTROLInformation from the RF-tag in the master roll is used to optimise the power of the thermal head based on the real-time condition of the master materials.The RISO i Quality System – Functions and FeaturesInk colour indication Thanks to the The RISOiQualitySystem, printers withLCD panels now can show the ink colour on the control panel.2. Prevention of mis-insertion of ink bottle If the user tries to insert an ink bottle of the wrong colour – for instance placing a RED ink bottle in a drum used for BRIGHT RED – the machine returns an error message and prevents mis-operation. This assures reliable and consistent colour reproduction.3. Thermal head energy auto adjustment Data stored in the master rolls RF-tag includes the date of manufacture, position on the roll and master character. This information is used to automatically adjust the power of the thermal head to suit, resulting in optimised masters, every time and best possible print quality.
58 Idling time auto adjustment by interval from previous use ink character The RISOiQualitySystem automatically adjusts idling time according to the combination of time elapsed since last use, ink colour and ink characteristics, to assure optimum quality from the start of a print run and to minimise paper wastage.Print press roller auto adjustment to optimise first print qualityThe RISOiQualitySystem combines information on ink viscosity, character and colour with details on master characteristics and data as to when the printer was last used to adjust warm up action and optimise pressure of the print roller for maximum quality from the beginning of the print run, to minimise paper wastage.Print press roller auto adjustment for superior output The printer reads information on master character and ink viscosity, character and colour from theRISOiQualitySystem and uses this to automatically set the optimum print pressure of the print roller for maximum output quality.7. Precise, real-time feedback on remaining supplies A further advantage of the RISOiQualitySystem is precise real-time feedback on the amount of ink and masters remaining. When the remaining volume of supplies is near to the end, the RISO printer indicates the caution display so that the users need never run out of ink or masters un-expectedly.
59 Manual data input procedure for LED models To optimise print quality, the printer receives information from supplies via the RF-tag. If that data is un-available for any reason, the“i” indicator fails to light and an “H” is shown in the print quantity display.Step 1: Enter a parameter using the print quantity keys.Manual input parametersH1 : Ink colour settingSelect the same colour as that of the currently installed drum.1: Black 2: ColourH2 : Print density adjustment (ink)Perform fine adjustment to optimise print density according to ink.1 (Light) to 5 (Dark)H3 : Test printing print density adjustment (ink)Perform adjustment of print density for test printing according to ink type and colour. This adjustment is independent to H2.
60 Step 2 : Press the start key to complete entry. H4 : Master making density settingSet the reference density for the master making process1 (Light) to 10 (Dark)H5 : Print density adjustment (master)Perform fine adjustment to optimise print density for testing accordingmaster.1 (Light) to 5 (Dark)H6 : Test printing print density adjustment (master)Perform adjustment of print density for test printing according tomaster. This adjustment is independent of H5.Step 2 : Press the start key to complete entry.If the next number appears, repeat steps 1 and 2.Step 3 : When all data necessary is input, the print quantity displayreturns to normal and is available for standard operations.
61 Disassemble & Reassemble Master Disposal Section Master Disposal Area Chapter 10 Page 10-1Master Disposal Unit Page 10-21. Master disposal box safety switch (TM 423)2. Master disposal motor (TM470)Master disposal motor encoder sensor (TM 426)Master disposal jam sensor (TM 420)5. Master compression motor (TM 490, 491 & 493)Master compression motor encoder sensor (TM 425)Master compression plate HP sensor (TM 421)8. Master loading sensor (TM 806)Master disposal roller release lever10. Master disposal roller lock leverRemoving jammed master on the disposal rollers.(For the machine operator)Disassemble & Reassemble Master Disposal Section
63 7 2 3 5 6 Master compression plate HP sensor Master disposal motor encoder sensor356Master compression motorencoder sensorMaster compression motor
64 Master making unit (BOTTOM View) 84Master loading sensorMaster disposal jam sensorMaster making unit (BOTTOM View)
65 Master Disposal Box Full Detection Master Disposal AreaMaster Disposal Box Full DetectionDisposal box capacity Approx. 100 mastersRemoved master Not countedFull detection Master compression motor encoder sensorEND POSITION of the Master compression platePreset pulse count of the Master compression motor encoder sensor.FULL POSITION of the Master compression plateBOX FULL MESSAGESpeed of the Master compression motor encoder sensor disc.FULL indication display When the encoder disc rotation slows down to a preset speed Per one rotation before the master compression plate arrives to the FULL POSITION
66 Disassemble & Reassemble Scanning Section Original Scanning Section Chapter 11 Page 11-1Flat Bed Scanning Page 11-21. Scanner carriage HP sensor (TM 200)Original detection sensor (TM 201)Stage cover sensor (TM 209)Scanner carriage (TM 280, 281, 282, 283 & 284)Scanner lamp (TM 260) dpi onlyShading compensation Both 600 dpi & 300dpi.ABC (Auto Base Control) dpi machine only.Different scanner unit between 600 dpi & 300 dpi.No original size detection sensor.Image making area is set by:1. Paper size detected on the paper feed tray.2. Original size detected by the optional auto feeder (AF) original size detection sensor.Disassemble & Reassemble Scanning Section300dpiMain ScanSub Scan600dpi= D600dpi
68 Test Mode Chapter 17 Page 17-1 Important Test Modes Page 17-2 REv information extract onto CF card (TM 099)Jam message clear (TM 110)User area memory clear (TM 111)Normal area test mode data clear (TM 112)Protected area test mode entering (TM 9874)The existing setting should be noted down on a piece of paper before activating these to testmodes. Activating these two test modes will reset the settings back to program default settings.Note: Factory default setting differs from the program default settings Factory adjusts eachmachine before shipment.There is a plan for the future that existing normal area test mode settings can be downloaded ontoCF card.
69 Starting up the Test Mode To access Test Mode, press the two print position keys at the same time and turn the machine power ON.Standard Test Mode: NoOptions Test Mode: NoProtected Test Mode: NoAn access code of No needs to be input in order to get into the Protected area Test Mode.
73 Other Precautions Chapter 18 Page 18-1 Power saving (Low power) mode.With no error status on the machine, if no operation is made on the machine for 30 seconds, the24 volt supply to the machine components is terminated. There is no sign for this power saving mode, so when using a multi-meter to check 24 volts on the machine this must be kept in mind.Also when servicing machine, NO DRUM FREE ROTATION (FREE SWITCH) is accessible when in power saving mode. TO ACTIVATE 24 VOLTS, TOUCH KEYPAD.Battery replacementReplace the battery on the mechanical PCB with the machine power ON. (RZ3 series only)Replacement of the mechanical control PCBWhen the mechanical control PCB is replaced, it is necessary to record all the user mode and test mode settings. Therefore it is important to memo down all the user mode settings prior to the replacement of the mechanical control PCB.The protected area test mode (those test modes which needs 9874 to be activated in advance)are memorised in the EEPROM, so these do not need to be re-entered.