2 Machine Specification Chapter 2Page 2-7 Resolutions: D600dpi models & 300dpi models “D” = Device 300 x 600dpi Machine Types: 600dpi - A3 model 300dpi - A4 model Operation Panel: LED display Original Type: Book & sheet Printing Speed: 5 speeds (Approx. 60, 80, 100, 120, 130) Image Processing Mode: Line, Photo, Duo, Pencil Ink Cartridge: 1,000 millilitres per cartridge Only for 600dpi machine From now on the term 600dpi will be used
3 Optional Accessories Chapter 2Page 2-6 Available Options Colour Cylinder (Drum) Auto Document Feeder AF-V Feeds up to 50 originals automatically Job Separator IV:N Key Card Counter IV:N Special Paper Feed Kit Use for thick paper such as cards and envelopes. Replace with this when thick paper needs to pass through the machine. Stand Printer Control Board RISORINC3N Use to connect a computer to the machine using a parallel cable. RISO PRINTER Network Interface Card RISORINC-NET Use 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 1.Unlocking the scanner lock screw. 2.Scanner carriage test mode release.
5 Specifications Chapter 2 See Specification Sheet Page 2-7 Preparing to Print 1.Power Switch. 2.Open and set paper feed tray. 3.Load paper & position the guides. 4.Paper feed pressure adjustment.Normal / Card 5.Open paper receiving tray. Basic Operation 1.How to scan originals.Line / Photo / Duo 2.Reduce & Enlargement. 3.Print Positioning. 4.Consumable replacement. 5.Drum removal. 6.Master making unit release.
6 Speed Density Print Position RZ370 Conpane Reduce/Enlarge Ink Saving Mode Pencil Mode Proof Copy Master Making/ Print Mode
7 Main Drive Chapter 3Page 3-1 Main Motor Print Drum Air Pump 1 st & 2 nd Paper Feed Gear (Paper Separation) Timing Belt Gear Printing Speed: 60cpm to 130cpm in 5 steps
8 Print Drum (Main Pulley / Main Shaft) Timing Belt Air PumpMain Motor Paper Feed Area
9 Main Drive Position B Machine home position 1.Paper Feed Section 2.Printing Section 3.Air Pump unit 4.Position B sensor TM 801 & 892 1 2 3 4 Timing Positions Disassemble & Reassemble Main Drive Please Note: Position B = Drum Release
10 2 Pos B Printing section Markings on the plastic gears Align – marking against = markings on the two gears 1 Pos B Paper feed section Markings on plastic gears Align dots together 4 Pos B sensor Position B sensor actuator 3 Pos B Air pump
11 Main Motor Safety Switches Page 3-4 1.Rear Cover Safety Switch (L & R) (TM 005) 2.Master Removal Box Safety Switch (TM 423) 3.Master Making Unit Safety Switch (TM 409) 4.Print Drum Safety Switch (TM 820) Stops the four following motors: Main Motor Clamp motor Master compression motor Master disposal motor
14 10 7 11 3 2 1 10 8 5 4 6 9 Paper feed tray button Paper feed Pressure sensor Paper feed tray button Paper feed tray Upper safety SW Upper limit Sensor A Upper limit Sensor B Horizontal print position Knob Paper detection sensor Paper width potentiometer Paper size detection sensor Elevator motor Paper feed tray lower limit sensor Paper feed tray Lower safety SW
15 Paper Feeding Section First Paper Feed 1.Three paper feed positions: Card 600 dpi only, Normal, Custom 600dpi only. 2.No double feed detection sensor or stack feed switch. 3.Paper feed clutch (TM688) 3 Paper feed clutch Disassemble & Reassemble Paper Feed & Drive Assy
16 Paper Feeding Section Chapter 5Page 5-1 Second Paper Feed Page 5-2 1. Paper sensor (TM 605) 1 Guide roller Timing roller Paper sensor Disassemble & Reassemble Second Paper Feed
17 Paper Feeding Section Vertical Print Positioning Page 5-4 1.Print positioning pulse motor (TM 900 & 901) 2.Vertical centreing sensor (TM 831) 2 1 Positions printed image up or down Print positioning Pulse motor Vertical centreing sensor Disassemble & Reassemble Vertical Print Drive
18 Image UP Image DOWN Print positioning pulse motor CW Image DOWN CCW Image UP Print positioning wheel assy Vertical centreing sensor
19 Printing Section Chapter 6Page 6-1 Printing Pressure Page 6-2 1.Print pressure pulse motor 600dpi only (TM 904, 905 & 908) 2.Print pressure HP sensor 600dpi only (TM 830) 3.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 Pressure solenoid is OFF (Pressure roller is DOWN) Pressure solenoid is ON (Pressure roller is UP) 1 2 3 Print pressure Pulse motor Print pressure HP sensor Pressure solenoid Levers Engaged Levers disengaged Pressure cam Pressure solenoid Hook lever Pressure lever
22 Printing Section Chapter 8 Print Drum Lock Mechanism, etc. Page 8-6 1.Print 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 off Disassemble & 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. Push screw driver through the hole. IMPORTANT: Please ensure print drum is in Position B before removing.
25 Printing Section Chapter 8 Page 8-1 Print Drum Page 8-2 1.Print drum position B lock release lever 2.Ink sensor (TM 809) 3.Overflow sensor (TM 810) 4.Ink pump unit (TM 887 & 888) 5.Ink bottle set switch (TM 811) 6.Rollers & Ink blocking plates Disassemble & Reassemble Print Drum
26 1 Print drum position B lock release lever Push the lever down to release the print drum from position B.
27 5 2 3 4 Ink bottle set SW Overflow sensor Ink sensor Ink pump unit
28 6 Rollers & Ink blocking plate Ink blocking plate Fixed position No adjustment Ink blocking plate Doctor roller adjustment Gap adjustment between Squeegee roller and drum body Doctor roller Squeegee roller Driven roller
33 TOP View BOTTOM View 8 Paper ejection sensor 7 5 6 Paper ejection motor Paper ejection encoder sensor Suction fan
34 Fixed Position Manually adjustable 300dpi machine 600dpi machine Adjust paper ejection wing dial according to the type & size of paper Metric Machine Paper Ejection Wings For ordinary paper widths equal to or larger than B4, set to A3 B4 Metric Machine For ordinary paper widths equal to or smaller than B4, set to A4 B5 Metric Machine For thick paper, set to
35 Paper Receiving Tray Paper Guides The paper guide positions must be readjusted if the horizontal print position is adjusted by sliding the paper feed tray. Paper Arrangers Available only on 600dpi machines
36 Paper Receiving Tray Corrugators The corrugators are available only on the 300dpi machines. Note: Normal PaperCorrugators in position (DOWN) Thick PaperCorrugators put away (UP)
37 Master Making Section Chapter 14Page 14-1 Pulling the Master Making Unit out 1.Master making unit removal button (TM 410) 2.Master making unit safety switch (TM 409) 3.Master making unit set sensor (TM 408) 4.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. Note: Master making unit can be released manually by serviceman
40 3 2 3 4 1 2 4 1 Master making unit Safety switch Master making unit Set sensor Master making unit Safety switch Master making unit Release button Master making unit Set sensor Master making unit Release button Master making unit Solenoid Master making unit Solenoid
41 Master Making Section Write Pulse Motor, Load Pulse Motor & Cutter Unit Page 14-4 1. Write pulse motor (TM 462 & 463) TM 466 2. Load pulse motor (TM 464) 3. Cutter unit (TM 480)TM 486 & 487 Disc blade shuttle cutter unit only 4. Cutter HP switch (TM 403) 5. Cutter stop position switch (TM 404) Disc blade shuttle cutter unit only Disassemble & Reassemble Master Making Section Remove 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)
42 2 3 1 Write pulse motor Cutter unit Load pulse motor
43 Rotary blade type cutter unit used on A3 machines Shuttle type blade type cutter unit used on A4/B4 machines Rotary blade Disc blade shuttle 3 4 4 Cutter HP switch Cutter unit Cutter HP switch 2 Cutter stop position switch
44 Master Making Section Master Making Unit Page 14-31 1.Master making unit Master making unit is removable from the machine by detaching flat cable wire harness from the unit and removing four mounting screws. 1 Master making unit Master making unit has been removed and placed on table.
45 Master Making Section Sensors to detect the Master Material, etc. 1.Master detection sensor (TM 401) 2.Master end sensor (TM 402) 3.Master positioning sensor (TM 400) 4.Master making upper unit set sensor (TM 407) 5. Master flanges F & RBuilt on the machine
46 3 2 1 5 2 4 Master making upper unit set sensor Master positioning sensor Bottom View Master end sensor (Rcv.) Master detection sensor Master end sensor (Send) Master flanges F & R
47 Master Making Section Thermal Print Head (TPH) Area Page 14-12 1.TPH (TM 9874 + 1234) (TM 80 to 85) 300 dpi machine = 80 & 81 only 2.Thermal Pressure Motor (TM 460 & 461) 3.TPH Pressure Sensor (TM 406) The TPH comes down against the Write Roller only during the master-making process. Disassemble & Reassemble TPH Assy
48 1 TPH Springs to pull down the TPH 2 3 Thermal Pressure Motor TPH Pressure Sensor Eccentric Cam to Raise the TPH
49 Master Making Section Master Transfer Rollers Page 14-20 1.Write Roller 2.Master Stocker Roller 3.Load Roller 4.Clamping Guide Roller 5.Stocker Solenoid (TM 489) Stocker solenoid activates only when the leading edge of the master material transfers to the Load roller. Master making starts before the leading edge of the master material is clamped on the print drum. Driven by Write Pulse Motor Please Note: Position A = Master Loading
50 Master Making Unit 1 Write roller 2 Master stocker roller Stocker solenoid 5 3 Load roller 4 Clamping guide roller Metal Shaft Master positioning sensor Cutter unit TPH Master Roll
51 5 Stocker solenoid The cover plate lifts up to close the Stocker entrance when the solenoid activates.
52 Master Making Section Chapter 9Page 9-1 Master Clamp Unit Page 9-2 1.Clamp motor (TM 863, 864, 883 & 884) 2.Clamp sensor A (TM 803) 3.Clamp sensor B (TM804) 4.Clamp guiding plate 5.Position A compensator arm 6.Clamp plate 7.Master ejection plate Disassemble & Reassemble Master Clamp Unit
53 1 3 2 5 4 Clamp motor Clamp sensor B Clamp sensor A Position A compensator arm Clamp guiding plate Master removal action is made while the print drum is rotating Master clamping action is made when the print drum is stationary with the position A compensator arm holding the print drum in the position A position. FRONT view BACK view
54 Master removal action is made the print drum is rotating. Master clamping action is made when the print drum is stationary with the Position A compensator arm holding the print drum in the Position A position. 7 6 Position A compensator block Master ejection plate Clamp plate Roller for master ejection plate Roller for clamp 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 RISOiQualitySystem equipped printers and their supplies - ink and masters – via tiny integrated RF-tags Embedded in the ink bottle and master roll. This two-way communication provides a host of important benefits that include : Assurance of optimum print quality Prevention of operator error for supplies Warning of shortage in remaining volume Minimal 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 parameters but only to a limited extent. The RISOiQualitySystem not only offers real-time adjustment all of the time, it also achieves improved print quality. INK The 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. MASTER The 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 OPTIMUM PRINT PRESSURE CONTROL Print 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 CONTROL Information 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 Features 1.Ink colour indicationThanks to the The RISOiQualitySystem, printers with LCD 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 adjustmentData 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 4.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. 5.Print press roller auto adjustment to optimise first print quality The 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. 6.Print press roller auto adjustment for superior outputThe printer reads information on master character and ink viscosity, character and colour from the RISOiQualitySystem 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 parameters H1 : Ink colour setting Select the same colour as that of the currently installed drum. 1: Black2: Colour H2 : 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. 1 (Light) to 5 (Dark)
60 H4 : Master making density setting Set the reference density for the master making process 1 (Light) to 10 (Dark) H5 : Print density adjustment (master) Perform fine adjustment to optimise print density for testing according master. 1 (Light) to 5 (Dark) H6 : Test printing print density adjustment (master) Perform adjustment of print density for test printing according to master. This adjustment is independent of H5. 1 (Light) to 5 (Dark) 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 display returns to normal and is available for standard operations.
61 Master Disposal Area Chapter 10Page 10-1 Master Disposal Unit Page 10-2 1. Master disposal box safety switch (TM 423) 2. Master disposal motor (TM470) 3.Master disposal motor encoder sensor (TM 426) 4.Master disposal jam sensor (TM 420) 5. Master compression motor (TM 490, 491 & 493) 6.Master compression motor encoder sensor (TM 425) 7.Master compression plate HP sensor (TM 421) 8. Master loading sensor (TM 806) 9.Master disposal roller release lever 10. Master disposal roller lock lever Removing jammed master on the disposal rollers. (For the machine operator) Disassemble & Reassemble Master Disposal Section
62 1 Master disposal box safety switch 10 Master disposal roller lock lever 9 Master disposal roller Release lever
63 3 2 7 5 6 Master compression motor encoder sensor Master disposal motor encoder sensor Master disposal motor Master compression plate HP sensor
64 4 8 Master loading sensor Master disposal jam sensor Master making unit (BOTTOM View)
65 Master Disposal Area Master Disposal Box Full Detection 1.Disposal box capacity Approx. 100 masters 2.Removed master Not counted 3.Full detection Master compression motor encoder sensor END POSITION of the Master compression plate Preset pulse count of the Master compression motor encoder sensor. FULL POSITION of the Master compression plate Preset pulse count of the Master compression motor encoder sensor. BOX FULL MESSAGE Speed 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 Original Scanning Section Chapter 11Page 11-1 Flat Bed Scanning Page 11-2 1. Scanner carriage HP sensor (TM 200) 2.Original detection sensor (TM 201) 3.Stage cover sensor (TM 209) 4.Scanner carriage (TM 280, 281, 282, 283 & 284) 5.Scanner lamp (TM 260) 600 dpi only Shading compensation Both 600 dpi & 300dpi. ABC (Auto Base Control) 600dpi 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 Section 300dpi 600dpi Main Scan Sub Scan = D600dpi
68 Test Mode Chapter 17Page 17-1 Important Test Modes Page 17-2 1.REv information extract onto CF card (TM 099) 2.Jam message clear (TM 110) 3.User area memory clear (TM 111) 4.Normal area test mode data clear (TM 112) 5.Protected area test mode entering (TM 9874) The existing setting should be noted down on a piece of paper before activating these to test modes. 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 each machine before shipment. There is a plan for the future that existing normal area test mode settings can be downloaded onto CF card.
69 Test Mode 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:No. 0001 - 0999 Options Test Mode:No. 3000 - 3599 Protected Test Mode:No. 1900 - 1999 An access code of No. 9874 needs to be input in order to get into the Protected area Test Mode.
70 Test Mode Activation & Exit Normal Area Test Mode
73 Other Precautions Chapter 18Page 18-1 1.Power saving (Low power) mode. With no error status on the machine, if no operation is made on the machine for 30 seconds, the 24 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. 2.Battery replacement Replace the battery on the mechanical PCB with the machine power ON. (RZ3 series only) 3.Replacement of the mechanical control PCB When 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.