Riso RP-255 User manual

Copyright : 2003 Riso Kagaku Corporation
All Rights Reserved. This Technical Manual was prepared and
written for the exclusive use of RISO International Group Certified
Dealers. Reproduction and/or transmittal of this material in any
form or by any means, including photocopying or recording of the
information is strictly prohibited without the consent of a member
of RISO International Group.
RISO INTERNATIONAL GROUP
RISO KAGAKU CORPORATION (JAPAN) RISO DEUTSCHLAND GMBH (GERMANY)
RISO, INC. (U.S.A.) RISO FRANCE (FRANCE)
RISO EUROPE LIMITED (U.K.) RISO IBERICA (SPAIN)
RISO HONG KONG (HONG KONG) RISO CANADA (CANADA)
RISO UK (U.K.) ZHUHAI RISO TECHNOLOGY (CHINA)
RISO THAILAND LIMITED (THAILAND) RISO AFRICA (SOUTH AFRICA)
RISO KOREA LIMITED (KOREA) RISOGRAPH ITALIA (ITALY)
RN
SERIES
TECHNICAL MANUAL
VERSION 2.0
JULY 2003

[Contents - 1]
CONTENTS
CHAPTER 1 ..................MAINTENANCE
CHAPTER 2 ..................MACHINE SUMMARY
CHAPTER 3 ..................MAIN DRIVE SECTION
CHAPTER 4 ..................FIRST PAPER-FEED SECTION
CHAPTER 5 ..................SECOND PAPER FEED SECTION
CHAPTER 6 ..................PRESS SECTION
CHAPTER 7 ..................PAPER EJECTION SECTION
CHAPTER 8 ..................PRINT DRUM SECTION
CHAPTER 9 ..................MASTER CLAMP SECTION
CHAPTER 10 ..................MASTER REMOVAL SECTION
CHAPTER 11..................FB ORIGINAL SCANNING SECTION (New Scanner)
CHAPTER 12 ..................FB ORIGINAL SCANNING SECTION (Previous Scanner)
CHAPTER 13 ..................AF SCANNING SECTION (RN25 Series)
CHAPTER 14 ..................AF SCANNING SECTION (RN20/21 Series)
CHAPTER 15 ..................MASTER MAKING SECTION
CHAPTER 16 ..................TIMING CHARTS
CHAPTER 17 ..................PANEL MESSAGES
CHAPTER 18 ..................TEST MODE
CHAPTER 19 ..................MISCELLANEOUS PRECAUTIONS
CHAPTER 20 ..................ELECTRICAL DIAGRAMS (RN25 Series)
CHAPTER 21 ..................ELECTRICAL DIAGRAMS (RN20/21 Series)
CHAPTER 22 ..................ELECTRICAL COMPONENTS

[Contents - 2]
CONTENTS
CHAPTER 1: MAINTENANCE
1. Work Precautions .....................................................................................................1-2
2. Jigs............................................................................................................................ 1-4
3. Important Precautions .............................................................................................. 1-6
4-1. Unpacking (RN25 series) ..................................................................................... 1-10
4-2. Unpacking (RN20/21 series) ................................................................................ 1-12
5. Installation Procedure for the RN-B4 Inkless Print Cylinder (Drum) .................... 1-13
6. Exterior Cover Removal ......................................................................................... 1-15
7. Opening the PCBs (RN25 series)......................................................................... 1-20
8. Removal of the Controller and Main PCBs (RN20/21 series) .............................. 1-22
CHAPTER 2: MACHINE SUMMARY
1-1. Specifications (RN25 Series) ...................................................................................2-2
1-2. Specifications (RN20/21 Series) ..............................................................................2-3
2. Cross-Sectional Diagram ........................................................................................ 2-4
3. Operation Outline ......................................................................................................2-5
4. Outline of Paper-feeding, Printing, and Paper-ejection Operations ........................2-6
5. Outline of Master-removal, Master-making, and Master-loading Operations ......... 2-7
CHAPTER 3: MAIN DRIVE SECTION
Mechanism ............................................................................................................................ 3-2
1. Main Drive Section .................................................................................................... 3-2
2. Main Motor Safety Mechanism .................................................................................. 3-3
3. Print Drum Position Check Mechanism ...................................................................3-4
Disassembly ..........................................................................................................................3-6
1. Removing the Main Motor Unit .................................................................................. 3-6
2. Removing the Flatbed Set Switch ............................................................................ 3-8
3. Removing the Print Drum Safety Switch ................................................................... 3-9
4. Removing the Main Belt ......................................................................................... 3-10
Adjustment .......................................................................................................................... 3-12
1. Print-Drum Position-A Adjustment ......................................................................... 3-12
CHAPTER 4: FIRST PAPER FEED SECTION
Mechanism ............................................................................................................................ 4-2
1. Paper Feed Tray Mechanism ...................................................................................4-2
2-1. Paper Feed Tray Elevation Mechanism (RN25 Series) ........................................... 4-3
2-2. Paper Feed Tray Elevation Mechanism (RN20/21 Series) ......................................4-4
3. Paper Feed Tray Safety Mechanism ......................................................................... 4-5
4. First Paper Feed Drive Mechanism ..........................................................................4-6
5. Paper Strip Mechanism ............................................................................................ 4-7
6. Paper Feed Pressure Adjust Lever ..........................................................................4-8

[Contents - 3]
CONTENTS
Disassembly ..........................................................................................................................4-9
1. Removing the Paper Feed Tray Unit ........................................................................ 4-9
2. Removing the Paper Width Potentiometer, Paper Detection Sensor, and
Paper Size Detection Sensor ................................................................................ 4-10
3. Removing the Pickup and Scraper Rollers ........................................................... 4-12
4-1. Removing the Feed Tray Descent Button and Upper Limit Sensor (RN25 Series)4-13
4-2. Removing the Feed Tray Descent Button and Upper Limit Sensor (RN20/21 Series)4-
14
5. Removing the Paper Feed Clutch ......................................................................... 4-15
6. Removing the Pickup Roller Shaft Ass’y ............................................................... 4-16
7. Removing the Elevator Motor ................................................................................. 4-17
8. Removing the Paper Feed Tray Lower Safety Switch ........................................... 4-18
9. Removing the Stripper Unit .................................................................................... 4-19
10. Removing the Stripper Pad Ass’y .......................................................................... 4-20
Adjustment .......................................................................................................................... 4-21
1-1. Upper Limit Sensor Position Adjustment (RN25 Series) ..................................... 4-21
1-2. Upper Limit Sensor Position Adjustment (RN20/21 Series) ................................ 4-22
2. Stripper Unit Adjustment ........................................................................................ 4-23
3. Paper-Feed Clutch ON Angle Adjustment ............................................................. 4-24
4. Paper-Feed Clutch ON Angle Adjustment (A3 size) .............................................. 4-24
5. Paper-Feed Clutch OFF Angle Adjustment ............................................................ 4-24
6. Paper-Width Potentiometer Compensation.......................................................... 4-25
CHAPTER 5: SECOND PAPER FEED SECTION
Mechanism ............................................................................................................................ 5-2
1. Second Paper Feed Mechanism .............................................................................. 5-2
2. Vertical Print Positioning Mechanism ....................................................................... 5-4
Disassembly ..........................................................................................................................5-6
1. Removing the Guide Roller Ass’y ............................................................................. 5-6
2. Removing the Paper Guide Plate Ass’y ................................................................... 5-7
3. Removing the Paper Sensor .................................................................................... 5-9
4. Removing the Timing Roller.................................................................................. 5-10
5. Removing the Print-Positioning Unit ..................................................................... 5-12
6. Removing the Vertical Centering Sensor .............................................................. 5-13
7. Removing the Print-Positioning Pulse Motor ........................................................ 5-14
8. Removing the Timing Gear ................................................................................... 5-15
Adjustment .......................................................................................................................... 5-16
1. Timing Cam Mounting Position ............................................................................. 5-16
CHAPTER 6: PRESS SECTION
Mechanism ............................................................................................................................ 6-2
1. Press Mechanism .................................................................................................... 6-2

[Contents - 4]
CONTENTS
2. Pressure Control Mechanism .................................................................................. 6-4
Disassembly ..........................................................................................................................6-5
1. Removing the Pressure Roller ................................................................................. 6-5
2. Removing the Pressure Solenoid ............................................................................ 6-6
3. Removing the Pressure Lever Ass’y ........................................................................ 6-7
4. Removing the Pressure Control Motor and Print Pressure Control Sensor ...........6-8
Adjustment .......................................................................................................................... 6-10
1. Mounting Position of the Pressure Lever Ass’y ..................................................... 6-10
CHAPTER 7: PAPER EJECTION SECTION
Mechanism ............................................................................................................................ 7-2
1. Paper Ejection Mechanism ...................................................................................... 7-2
2. Paper Separator Mechanism ................................................................................... 7-3
3. Paper-Ejection-Wing Mechanism ............................................................................ 7-4
Disassembly ..........................................................................................................................7-6
1. Removing the Paper Receiving Tray ........................................................................ 7-6
2. Removing the Suction Unit ....................................................................................... 7-7
3. Removing the Suction Fan ..................................................................................... 7-11
4. Removing the Transfer Plate ................................................................................. 7-12
5. Removing the Paper Ejection Motor and Encoder Sensor ................................... 7-13
6. Removing the Wing HP Sensor ............................................................................ 7-14
7. Removing the Paper-Ejection-Wing Shafts .......................................................... 7-15
8. Removing the Paper-Ejection-Wing Motor (RN25 Series) ................................... 7-17
9. Removing the Transfer Belts ................................................................................. 7-18
10. Removing the Separation Fan Unit ....................................................................... 7-19
11. Removing the Separator Fan and Paper Receiving Sensor ................................ 7-20
12-1. Removing the Separator (RN25 Series) ............................................................ 7-21
12-2. Removing the Separator (RN20/21 Series)) ...................................................... 7-23
13. Removing the Air-Pump Ass’y (RN25 Series) ....................................................... 7-25
Adjustment .......................................................................................................................... 7-28
1. Separator Mounting Position ................................................................................. 7-28
CHAPTER 8: PRINT DRUM SECTION
Mechanism ............................................................................................................................ 8-2
1. Master on Drum (Pre-printing) Check Mechanism .................................................. 8-2
2. Print Drum Set Mechanism ...................................................................................... 8-3
3. Ink Cartridge Set Switch PCB ...................................................................................8-4
4. Print Drum Rotating Mechanism .............................................................................. 8-5
5. Inking Mechanism .................................................................................................... 8-6

[Contents - 5]
CONTENTS
Disassembly ..........................................................................................................................8-7
1. Removing the Print Drum Front Cover, Ink Cartridge Guide Ass’y,
Drum Front Upper Cover .......................................................................................... 8-7
2. Removing the Ink Cartridge Set Switch Cover and Ink Cartridge Set Switch PCB ..8-9
3. Removing the Ink Cartridge Set Switch PCB Mounting Bracket ........................... 8-10
4. Removing the Swing Base Ass’y ............................................................................ 8-11
5. Removing the Ink Cartridge Guide Bottom Ass’y .................................................. 8-12
6. Removing the Ink Pump Unit and Inking Motor ..................................................... 8-13
7. Removing the Print Drum Set Sensor ................................................................... 8-14
8. Removing the Screen ............................................................................................ 8-15
9. Removing the Print Drum Body ............................................................................. 8-16
10. Removing the Ink Sensor PCB .............................................................................. 8-18
11. Removing the Squeegee Roller ............................................................................ 8-19
12. Removing the Print Drum Supports (R) and (F) .................................................... 8-22
Adjustment .......................................................................................................................... 8-25
1. Filter Cleaning ....................................................................................................... 8-25
2. Squeegee Gap Adjustment ................................................................................... 8-26
3. Ink Blocking Plate Position Adjustment ................................................................. 8-27
4. Squeegee Pressure Balance Adjustment ............................................................. 8-28
CHAPTER 9: MASTER CLAMP SECTION
Mechanism ............................................................................................................................ 9-2
1. Clamp Unit Home Positioning Mechanism ............................................................. 9-2
2. Clamp Plate Master Release Mechanism ............................................................... 9-3
3. Clamp Plate Master Clamp Mechanism .................................................................. 9-4
Disassembly ..........................................................................................................................9-5
1. Removing the Clamp Unit ........................................................................................ 9-5
2. Removing the Clamp Motor, Clamp Sensor A, Clamp Sensor B ............................ 9-6
CHAPTER 10: MASTER REMOVALSECTION
Mechanism ......................................................................................................................... 10-2
1. Master Removal Mechanism ................................................................................. 10-2
2. Master on the Drum (before Master Removal) Check Mechanism ...................... 10-3
3. Removed Master Vertical Transport Mechanism .................................................. 10-4
4. Disposed Master Compression Mechanism ....................................................... 10-5
5. Disposal Box Safety Switch ................................................................................... 10-8
Disassembly ....................................................................................................................... 10-9
1. Removing the Master Removal Hook ................................................................... 10-9
2. Removing the Master Removal Unit .................................................................... 10-10
3. Removing the Master Disposal Gate Housing ................................................... 10-14
4. Removing the Master Removal Roller (Bottom) ................................................. 10-15

[Contents - 6]
CONTENTS
5. Removing the Master Compression Plate .......................................................... 10-17
6. Removing the Motors ........................................................................................... 10-20
CHAPTER 11: FB ORIGINAL SCANNING SECTION (New Scanner)
Mechanism .......................................................................................................................... 11-3
1. Scanner Table Setting System ............................................................................... 11-3
2. Original Scanning Mechanism ............................................................................... 11-4
3. Flatbed Initialization Movement .............................................................................. 11-6
4. Stage-Glass Original Detection Mechanism .......................................................... 11-7
5. Flatbed Automatic Base Control ............................................................................. 11-7
6. FB Original Scanning Movement (Book Mode OFF) ............................................... 11-8
7. Book-Mode Pre-Scan Mechanism (RN25 Series) ................................................. 11-8
8. Book-Mode Scanning Mechanism (RN20/21 Series)............................................ 11-8
Disassembly ........................................................................................................................ 11-9
1. Removing the Scanner Unit ................................................................................... 11-9
2. Removing the Stage Glass ................................................................................... 11-10
3. Removing the Flatbed Original Detection Sensor ............................................... 11-11
4. Removing the Lamp ............................................................................................. 11-12
5. Removing the CCD Unit ....................................................................................... 11-13
6. Removing the FB/AF HP Sensor .......................................................................... 11-14
7. Removing the Flatbed Read Pulse Motor ............................................................ 11-15
Adjustment ......................................................................................................................... 11-16
1. FB Read Pulse Motor Speed Adjustment ............................................................. 11-16
2. FB Scan Start Position Adjustment ....................................................................... 11-16
3. FB Horizontal Scan Position Adjustment .............................................................. 11-16
CHAPTER 12: FB ORIGINAL SCANNING SECTION (Previous Scanner)
Mechanism ......................................................................................................................... 12-3
1. Scanner Table Setting System .............................................................................. 12-3
2-1. Scanning Mechanism (RN25 Series) ................................................................... 12-4
2-2. Original Scanning Mechanism (RN20/21 Series) ................................................ 12-6
3. Flatbed Initialization ............................................................................................... 12-8
4. Stage-Glass Original Detection Mechanism ......................................................... 12-9
5. FB Original Scanning Movement ......................................................................... 12-10
6. Book-Mode Pre-Scan Mechanism (RN25 Series) .............................................. 12-10
7. Book-Mode Scanning Mechanism (RN25 Series) .............................................. 12-10
Disassembly ..................................................................................................................... 12-12
1. Removing the Scanner Unit ................................................................................ 12-12
2. Removing the Stage Glass .................................................................................. 12-13
3. Removing the Flatbed Original Detection Sensor .............................................. 12-14
4-1. Removing the Lamp (RN25 Series) .................................................................... 12-15

[Contents - 7]
CONTENTS
4-2. Removing the Lamp (RN20/21 Series) .............................................................. 12-16
5-1. Removing the Lens Ass’y (RN25 Series) ........................................................... 12-18
5-2. Removing the Lens Ass’y (RN20/21 Series) ...................................................... 12-19
Adjustment ........................................................................................................................ 12-20
1. FB Image Elongation & Shrinkage Adjustment ................................................... 12-20
2. FB Scan Start Position Adjustment ...................................................................... 12-20
3. FB Horizontal Scan Position Adjustment ............................................................. 12-20
CHAPTER 13: AF SCANNING SECTION (RN25 Series)
Mechanism ......................................................................................................................... 13-2
1. AF Original Set Mechanism ................................................................................... 13-2
2. AF Set Detection Mechanism ................................................................................ 13-4
3. AF Original Scanning Mechanism (with Auto Base Control) ................................. 13-4
4. AF Original Scanning Mechanism ......................................................................... 13-5
Removal and Assembly ..................................................................................................... 13-7
1. Removing the Original Pickup Roller Frame ........................................................ 13-7
2. Removing the Original Pickup Roller .................................................................... 13-9
3. Removing the Original Stripper Roller ................................................................. 13-10
4. Removing the Original Stripper Pad Assembly .................................................... 13-11
5. Removing the Original IN Sensor ....................................................................... 13-12
6. Removing the AF Read Pulse Motor .................................................................... 13-13
7. Removing Other Rollers ...................................................................................... 13-14
Adjustment ........................................................................................................................ 13-21
1. AF Read Pulse-Motor Speed Adjustment (Image Elongation and Shrinkage
Adjustment) .......................................................................................................... 13-21
2. AF Scan Start-Position Adjustment ...................................................................... 13-21
3. AF Horizontal-Scanning Position Adjustment ..................................................... 13-21
4. AF Original IN Sensor Sensitivity Adjustment ...................................................... 13-22
CHAPTER 14: AF SCANNING SECTION (RN20/21 Series)
Mechanism ......................................................................................................................... 14-2
1. AF Original Set Mechanism ................................................................................... 14-2
2. AF Original Scanning Mechanism (with Automatic Base Control) ........................ 14-4
3. AF Original Scanning Mechanism ......................................................................... 14-5
Disassembly ....................................................................................................................... 14-6
1. Removing the Original Scraper Ass’y .................................................................... 14-6
2. Removing the Pickup Roller .................................................................................. 14-7
3. Removing the Original Stripper Roller ................................................................... 14-8
4. Removing the AF Original Detection, Read, and Original Ejection Sensors ........ 14-9
5. Removing the AF Original Registration Sensor .................................................. 14-10
6. Removing the AF Read Pulse Motor ..................................................................... 14-11
7.
Removing the Registration Roller, Original Read Roller, and Original Ejection Roller ..... 14-13

[Contents - 8]
CONTENTS
Adjustment ........................................................................................................................ 14-16
1. AF Scan Start Position Adjustment ...................................................................... 14-16
2. AF Horizontal Scan Position Adjustment ............................................................. 14-16
3. AF Image Elongation & Shrinkage Adjustment ................................................... 14-16
4. AF Read Sensor Sensitivity Adjustment .............................................................. 14-16
5. AF Image Skew Adjustment ................................................................................. 14-17
CHAPTER 15: MASTER MAKING SECTION
Mechanism ......................................................................................................................... 15-2
1. Master Making & Master Loading .......................................................................... 15-2
2. Scanner Table Set Detection Mechanism ............................................................. 15-4
3. Master Cutting Mechanism .................................................................................... 15-5
4. Thermal Print Head Elevation Mechanism ........................................................... 15-6
5. Master Positioning Mechanism ............................................................................. 15-8
6. Master Making ........................................................................................................ 15-9
Disassembly ...................................................................................................................... 15-11
1. Removing the Write Roller .................................................................................... 15-11
2. Removing the Load Roller (Bottom) .................................................................... 15-12
3. Removing the Cutter Unit .................................................................................... 15-14
4. Removing the Load Roller................................................................................... 15-15
5. Removing the Thermal Print Head ...................................................................... 15-16
6. Removing the Master Loading Unit ..................................................................... 15-17
7. Removing the Thermal Pressure Motor .............................................................. 15-18
Adjustment ........................................................................................................................ 15-19
1. Thermal Power of Thermal Print Head ............................................................... 15-19
2. Master Feeding Adjustments ............................................................................... 15-21
1) Master cut position adjustment ...................................................................... 15-21
2) Master clamp range adjustment .................................................................... 15-21
3-1) Master making image elongation & shrinkage adjustment
(RN25 Series) ....... 15-21
3-2) Master making image elongation & shrinkage adjustment (RN20/21 Series) ... 15-22
4) Write start position adjustment ...................................................................... 15-22
5) Master making length adjustment ................................................................. 15-23
CHAPTER 16: TIMING CHARTS
Initialization Operations ..................................................................................................... 16-2
1. Overall Initialization Operation ............................................................................... 16-2
2. Individual Initialization Operations......................................................................... 16-3
[Thermal Print Head Initialization Operation] .................................................... 16-3
[Master Compression Plate Initialization Operation] ........................................ 16-4
[Paper Ejection Wing Initialization Operation] ................................................... 16-5
[Clamp Unit Home Positioning Operation] ....................................................... 16-6

[Contents - 9]
CONTENTS
[Vertical Printing Position Initialization Operation] ............................................ 16-6
[Pressure Initialization Operation] ..................................................................... 16-7
Printing Operations ............................................................................................................ 16-9
1. Normal Overall Printing Operation ........................................................................ 16-9
2. Individual Printing Operations ............................................................................. 16-10
[Print Start Operation] ...................................................................................... 16-10
[Print In Progress - End Operation] ................................................................. 16-12
[Three-Cycle No-Paper Pickup Operation] ..................................................... 16-14
3. Elevator Operations ............................................................................................. 16-16
[Elevator Raise Operation] .............................................................................. 16-16
[Elevator Lower Operation] .............................................................................. 16-17
[Elevator Servo Operation] ............................................................................... 16-18
4. Print Drum Peripheral Operations....................................................................... 16-19
[Clamp Release] ............................................................................................. 16-19
[Master Clamp Operation] ............................................................................... 16-20
[Inking Operation (No Ink Detection)] .............................................................. 16-21
[Inking Operation (Overflow Detection)] .......................................................... 16-21
[Print Drum Solenoid Lock Release] .............................................................. 16-22
5. Print Adjustment Operations ................................................................................ 16-23
[Print Speed Change] ...................................................................................... 16-23
[Print Density Change] .................................................................................... 16-23
[Vertical Print Positioning Operation] .............................................................. 16-24
Master Removal Operations ............................................................................................ 16-25
1. Overall Timing in Normal Master Making ............................................................ 16-25
2. Individual Master Removal Operations ............................................................... 16-26
[Removed Master Vertical Transport Operation] ............................................. 16-26
[Disposed Master Compressing Operation] .................................................. 16-27
Master Making Operation ................................................................................................ 16-28
1. Overall Timing in Normal Master Making ............................................................ 16-28
2. Individual Master Making Operation .................................................................... 16-29
[Thermal Print Head Compression Operation] .............................................. 16-29
[Thermal Print Head Release Operation] ....................................................... 16-29
[Master Positioning Operation] ....................................................................... 16-30
[Master Cutting Operation] .............................................................................. 16-31
[Master Making Operation] .............................................................................. 16-32
CHAPTER 17: PANEL MESSAGES
Explanation of Panel Messages .......................................................................................... 17-2
1. Error-Code Displays .................................................................................................... 17-2
1. Error type .......................................................................................................... 17-2
2. Error point ......................................................................................................... 17-2