Technical Training Presented by Lars Hanson

Machine Specification Chapter 2 Page 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 From now on the term 600dpi will be used Only for 600dpi machine

Optional Accessories Chapter 2 Page 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.

Machine Installation Notice Sheet Following two steps are un-necessary Unlocking the scanner lock screw. Scanner carriage test mode release.

Specifications Chapter 2 See Specification Sheet Page 2-7 Preparing to Print Power Switch. Open and set paper feed tray. Load paper & position the guides. Paper feed pressure adjustment. Normal / Card Open paper receiving tray. Basic Operation How to scan originals. Line / Photo / Duo Reduce & Enlargement. Print Positioning. Consumable replacement. Drum removal. Master making unit release.

RZ370 Conpane Master Making/ Print Mode Reduce/Enlarge Ink Saving Mode Density Pencil Mode Speed Print Position Proof Copy

Main Drive Chapter 3 Page 3-1 Main Motor Timing Belt Gear Print Drum 1st & 2nd Paper Feed (Paper Separation) Gear Air Pump Printing Speed: 60cpm to 130cpm in 5 steps

Print Drum Paper Feed Area Timing Belt Air Pump Main Motor (Main Pulley / Main Shaft) Paper Feed Area Timing Belt Air Pump Main Motor

Disassemble & Reassemble Main Drive Timing Positions Position B Machine home position 1 Paper Feed Section Printing Section Air Pump unit Position B sensor TM 801 & 892 2 Please Note: Position B = Drum Release Go through main timing marks and set-up. When working on drive system, jig what side your not working on. 4 Disassemble & Reassemble Main Drive 3

Markings on plastic gears Markings on the plastic gears 2 1 Pos B Paper feed section Markings on plastic gears Markings on the plastic gears 2 Align – marking against = markings on the two gears Align dots together Pos B Printing section 4 Position B sensor actuator Pos B Air pump 3 Pos B sensor

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 Motor Clamp motor Master compression motor Master disposal motor

1 1 4 3 2 Rear Cover Safety Switch (L) Rear Cover Safety Switch (R) Print Drum Safety Switch 3 Master Making Unit Safety Switch Master Removal Box Safety Switch 2

Paper Feeding Section Chapter 4 Page 4-1 Paper Feed Tray Area Page 4-2 Paper detection sensor (TM 600) Paper width potentiometer (TM 9874 + 1102 & 1103) Paper size detection sensor (TM 601) Upper limit sensor A 600dpi only (TM 602) (TM 740) Upper limit sensor B (TM603) Lower limit sensor (TM 604) Paper feed pressure sensor 600dpi only (TM 614) Paper feed tray upper safety switch (TM 607) Paper feed tray lower safety switch (TM 608) Paper feed tray button (TM 609) Elevator motor (TM 682 & 683) Set-up table height, Paper width potentiometer.

Horizontal print position Knob 9 Paper feed tray button 10 7 10 8 Paper feed tray button Paper feed Pressure sensor Paper feed tray Upper safety SW Paper detection sensor 1 4 5 Upper limit Sensor A Paper width potentiometer 2 Upper limit Sensor B 3 Paper size detection sensor Horizontal print position Knob Paper feed tray Lower safety SW 9 11 6 Elevator motor Paper feed tray lower limit sensor

Disassemble & Reassemble Paper Feed & Drive Assy Paper Feeding Section First Paper Feed Three 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 Assy 3 Paper feed clutch

Disassemble & Reassemble Second Paper Feed Paper Feeding Section Chapter 5 Page 5-1 Second Paper Feed Page 5-2 1. Paper sensor (TM 605) Disassemble & Reassemble Second Paper Feed Guide roller Timing roller Adjust G lever. Paper sensor 1 Timing roller

Disassemble & Reassemble Vertical Print Drive Paper Feeding Section Vertical Print Positioning Page 5-4 Print positioning pulse motor (TM 900 & 901) Vertical centreing sensor (TM 831) Disassemble & Reassemble Vertical Print Drive Print positioning Pulse motor 1 2 Vertical centreing sensor Positions printed image up or down

Image UP Image DOWN CW Image DOWN CCW Image UP Print positioning pulse motor Image UP CW Image DOWN CCW Image UP Image DOWN Print positioning wheel assy Vertical centreing sensor

Disassemble & Reassemble Press Section Printing Section Chapter 6 Page 6-1 Printing Pressure Page 6-2 Print 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

1 2 3 Pressure solenoid is ON (Pressure roller is UP) Pressure solenoid is OFF (Pressure roller is DOWN) 1 Print pressure Pulse motor Print pressure HP sensor 2 Levers Engaged Levers disengaged Pressure solenoid 3 Pressure cam Pressure solenoid Hook lever Pressure lever

300 dpi machine 600 dpi machine Printing pressure Printing pressure Manually Adjusted Printing pressure Pulse motor Adjusted Remove pressure roller and advise how to clean.

Disassemble & Reassemble Lock Mechanism Printing Section Chapter 8 Print Drum Lock Mechanism, etc. Page 8-6 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

2 4 1 3 5 2 5 1 3 4 Print drum safety SW Print drum Release button Print drum lock solenoid 1 Print drum lock sensor 3 5 Front door safety SW Print drum safety SW 2 5 1 Front door set SW Print drum lock solenoid 3 Print drum Release button 4 Print drum lock sensor

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.

Disassemble & Reassemble Print Drum Printing Section Chapter 8 Page 8-1 Print Drum Page 8-2 Print drum position B lock release lever Ink sensor (TM 809) Overflow sensor (TM 810) Ink pump unit (TM 887 & 888) Ink bottle set switch (TM 811) Rollers & Ink blocking plates Adjust Squeegee roller gap, squeegee pressure and advise precautions on drum body assembly. Disassemble & Reassemble Print Drum

Push the lever down to release the print drum from position B. Print drum position B lock release lever 1 Push the lever down to release the print drum from position B.

3 2 Overflow sensor Ink sensor 5 Ink bottle set SW 4 Ink pump unit

Rollers & Ink blocking plate Doctor roller adjustment Ink blocking plate 6 Rollers & Ink blocking plate Gap adjustment between Squeegee roller and drum body Ink blocking plate Fixed position No adjustment Doctor roller Squeegee roller Driven roller

Adjustments page 8-27 Squeegee Pressure = 0.2 plus/minus 0.05 A3 0.3 plus/minus 0.05 A4/B4 Squeegee Gap Adjustment = 0.06 plus/minus 0.02 A3 0.08 plus/minus 0.02 A4/B4

Disassemble & Reassemble Suction Unit & Paper Separation Paper Receiving Area Chapter 7 Page 7-1 Paper Separation, Suction Unit & Receiving Tray Page 7-2 Separator Separator Arm Air Pump Unit Air blow timing fixed by Position B setting Separation 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 sensor Paper Receiving Tray Paper Arrangers 400dpi Corrugators 300dpi Disassemble & Reassemble Suction Unit & Paper Separation

2 1 3 Separator arm Separator Air pump unit Adjust separator. Go through up and down movement of separator. Remove air blast o-ring.

Separation fan 4

TOP View 8 6 7 5 BOTTOM View Paper ejection sensor Paper ejection motor 6 Paper ejection encoder sensor 7 5 Suction fan BOTTOM View

Paper Ejection Wings 600dpi machine Manually adjustable 300dpi machine Adjust paper ejection wing dial according to the type & size of paper Paper Ejection Wings Metric Machine 600dpi machine 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 Manually adjustable 300dpi machine Metric Machine For thick paper, set to Fixed Position

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 Arrangers Available only on 600dpi machines

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)

Master Making Section Chapter 14 Page 14-1 Pulling the Master Making Unit out Master 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.

Press the master making unit release button to pull the unit out of the machine.

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

3 2 1 4 3 2 1 4 Master making unit Safety switch Master making unit Set sensor 2 Master making unit Release button 1 4 Master making unit Solenoid 3 2 Master making unit Set sensor Master making unit Safety switch Master making unit Release button 1 4 Master making unit Solenoid

Write Pulse Motor, Load Pulse Motor & Cutter Unit Page 14-4 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 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) Disassemble & Reassemble Master Making Section

Cutter unit 2 Load pulse motor 3 1 Write pulse motor

4 3 4 2 Rotary blade type cutter unit used on A3 machines Cutter HP switch 4 Rotary blade 3 Cutter unit Shuttle type blade type cutter unit used on A4/B4 machines 4 Cutter HP switch Cutter stop position switch 2 Disc blade shuttle

Master Making Unit Page 14-31 Master Making Section Master Making Unit Page 14-31 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.

Sensors to detect the Master Material, etc. Master Making Section Sensors 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

Bottom View 2 3 4 1 5 2 Master end sensor (Rcv.) Master positioning sensor 4 Master making upper unit set sensor 1 Master detection sensor 5 2 Master end sensor (Send) Master flanges F & R

Disassemble & Reassemble TPH Assy Master Making Section Thermal Print Head (TPH) Area Page 14-12 TPH (TM 9874 + 1234) (TM 80 to 85) 300 dpi machine = 80 & 81 only Thermal Pressure Motor (TM 460 & 461) TPH Pressure Sensor (TM 406) The TPH comes down against the Write Roller only during the master-making process. Adjust TPH. Disassemble & Reassemble TPH Assy

1 3 2 TPH Springs to pull down the TPH Eccentric Cam to Raise the TPH TPH Pressure Sensor Thermal Pressure Motor

Master Transfer Rollers Page 14-20 Master Making Section Master Transfer Rollers Page 14-20 Write Roller Master Stocker Roller Load Roller Clamping Guide Roller 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 Driven by Write Pulse Motor Please Note: Position A = Master Loading

Master Making Unit 4 1 3 2 5 Clamping guide roller Master positioning sensor TPH Cutter unit 1 Metal Shaft 3 Master Roll 2 Write roller 5 Load roller Master stocker roller Stocker solenoid

The cover plate lifts up to close the Stocker entrance when the solenoid activates. 5 Stocker solenoid

Disassemble & Reassemble Master Clamp Unit Master Making Section Chapter 9 Page 9-1 Master Clamp Unit Page 9-2 Clamp motor (TM 863, 864, 883 & 884) Clamp sensor A (TM 803) Clamp sensor B (TM804) Clamp guiding plate Position A compensator arm Clamp plate Master ejection plate Disassemble & Reassemble Master Clamp Unit

Master removal action is made while the print drum is rotating FRONT view BACK view 2 4 3 1 5 Clamp sensor A Clamp guiding plate Clamp sensor B Clamp motor Position A compensator arm 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.

Master removal action is made the print drum is rotating. Position A compensator block Roller for clamp plate 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. Roller for master ejection plate 7 6 Master ejection plate Clamp plate

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

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.

The RISO i Quality System – Functions and Features 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 Ink colour indication Thanks 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 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.

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 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. Print press roller auto adjustment for superior output The 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.

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: Black 2: 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.

Step 2 : Press the start key to complete entry. 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. 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.

Disassemble & Reassemble Master Disposal Section Master Disposal Area Chapter 10 Page 10-1 Master Disposal Unit Page 10-2 1. 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 lever 10. Master disposal roller lock lever Removing jammed master on the disposal rollers. (For the machine operator) Disassemble & Reassemble Master Disposal Section

10 9 1 Master disposal roller lock lever Master disposal roller Release lever 1 Master disposal box safety switch

7 2 3 5 6 Master compression plate HP sensor Master disposal motor encoder sensor 3 5 6 Master compression motor encoder sensor Master compression motor

Master making unit (BOTTOM View) 8 4 Master loading sensor Master disposal jam sensor Master making unit (BOTTOM View)

Master Disposal Box Full Detection Master Disposal Area Master Disposal Box Full Detection Disposal box capacity Approx. 100 masters Removed master Not counted 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 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

Disassemble & Reassemble Scanning Section Original Scanning Section Chapter 11 Page 11-1 Flat Bed Scanning Page 11-2 1. 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) 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 Main Scan Sub Scan 600dpi = D600dpi

4 5 3 1 2 Scanner lamp Stage cover sensor Scanner carriage Scanner carriage HP sensor 2 Original detection sensor

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 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.

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.

Test Mode Activation & Exit Normal Area Test Mode

Panel Messages CHAPTER 16 Page 16-1

Panel Messages CHAPTER 16 Page 16-2

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, 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. Battery replacement Replace the battery on the mechanical PCB with the machine power ON. (RZ3 series only) 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.