NC-001/NC-002

Risograph Numbering System

Operator/Technical
Manual
Version 1.0

Copyright: 1999 RISO, Inc.

All products are trademarks of their
respective companies. Specifications
subject to change without notice.

RISO Inc. Corporate Training

300 Rosewood Dr. Suite 210
Danvers, MA 01923

Item No: 1388

 TABLE OF CONTENTS
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Table Of Contents

SECTION 1: INTRODUCTION
1. Introduction ............................................................................... 1-1
2. Model Compatibility .................................................................. 1-1
3. A Few Words About Numbering ............................................... 1-1
4. Types of Numbering Heads....................................................... 1-2

SECTION 2: SAFETY INSTRUCTIONS

1. Emergency & First Aid Procedures .......................................... 2-1
2. Safe Operating Instructions ....................................................... 2-1
3. Hands-On Operations ............................................................... 2-1

SECTION 3: SPECIFICATIONS . ..................................................... 3-1

SECTION 4: UNPACKING
1. Carton Inspection...................................................................... 4-1
2. Unpacking ................................................................................ 4-1
3. Check List & Serial Number ..................................................... 4-1
4. Recommended Termperature ................................................... 4-1
5. Contents Check List ................................................................. 4-2

SECTION 5: SETUP PROCEDURES

1. Quick Start ............................................................................... 5-1
2. NC Insertion Instructions ........................................................... 5-1
3. Centering the Numbering Cylinder ............................................ 5-2
4. Drive Wheel Positioning ........................................................... 5-4
5. Numbering Head Positioning .................................................... 5-5
6. Installing the Ink Pads................................................................ 5-7
7. Positioning the Actuator Cam ................................................... 5-9

SECTION 6: DRIVE MECHANISM & DECLUTCHING DEVICE

1. System Overview ...................................................................... 6-1

SECTION 7: ACTUATOR CAM SYSTEM

1. System Overview ...................................................................... 7-1

SECTION 8: NUMBERING HEAD

1. System Overview ...................................................................... 8-1
2. The Numbering Head................................................................ 8-2
3. Installing Repeat & Skip Wheels ............................................... 8-3
4. Numbering Head Maintenance ................................................. 8-6
5. Numbering Head Lubrication .................................................... 8-6
 TABLE OF CONTENTS
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

SECTION 9: INKING SYSTEM

1. System Overview ...................................................................... 9-1
2. Ink Drive Wheel/Main Drive Wheel Contact ............................... 9-2

SECTION 10: TROUBLESHOOTING GUIDE.. .............................. 10-1

SECTION 11: ELECTRICAL SYSTEM

1. Wiring Diagram ...................................................................... 11-1
2. Dip Switch Settings ................................................................ 11-2

SECTION 12: NC-001 PARTS LIST

1. Figure A ................................................................................. 12-1
2. Figure B ................................................................................. 12-2
3. Figure C ................................................................................. 12-3
4. Accessories ........................................................................... 12-4

SECTION 13: NC-002 PARTS LIST

1. Figure A ................................................................................. 13-1
2. Figure B ................................................................................. 13-2
3. Figure C ................................................................................. 13-3
4. Accessories ........................................................................... 13-4
SECTION 1: Introduction

CONTENTS

1. Introduction ............................................................................... 1-1

2. Model Compatibility .................................................................. 1-1

3. A Few Words About Numbering ............................................... 1-1

4. Types of Numbering Heads....................................................... 1-2

 1. INTRODUCTION
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Introduction

1. Introduction

RISO, the world leader in the development of digital duplicating technology, is pleased to introduce sequential
numbering on demand with the NC Numbering System.

Used in tandem with the Risograph, the NC Numbering System provides quick and easy sequential numbering
on preprinted applications and the versatility to configure your job exactly how you want. It has room for up to
12 vertical or horizontal heads, prints in red or black inks, and can imprint up to seven digits. This speedy,
reliable, and easy to use accessory is a great way to enhance the productivity of your Risograph. Imagine, now
you can sequentially number forms, tickets, tags, pads, coupons, even envelopes -- all in-house, all under your
own control!

This manual contains important information about the installation, use, adjustment, parts, and maintenance of
your new numbering system and is intended to be your complete reference source after you have received
proper training from a certified RISO technician. It is not intended to be used as a self-training tool.

2. Model Compatibility

There are two versions of the NC Numbering System. The NC-001 is for use with ledger or A3 GR Series
Risographs only. The NC-002 is for use with legal or B4 GR Series Risographs only.

NC-001 NC-002
GR3770 GR2750
GR377 GR275
GR3770 A3 GR2750 B4

GR3750 GR1750
GR375 GR175
GR3750 A3 GR1750 B4

GR170 GR2710
GR1700 B4 GR271
GR2710 B4

GR1700

3. A Few Words About Numbering

Numbering operations are an important but often ignored part of the printing world. Until now, there were four
main ways of numbering documents:

• Hand-held numbering machines

• Off-line, table-top automatic numbering machines

• In-line press attachment numbering machines

• Stand-alone letterpress numbering presses

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 1. INTRODUCTION
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Hand-held numbering machines, though the least expensive, are useful only when numbering a very small
quantity of sheets.

The table-top, off-line systems are basically hand-held machines that were made automatic by adding a feeding
system, cam, and motor. These systems are often unreliable with costs approaching press attachment number-
ing system units.

In-line press attachment numbering machines are flexible and very reliable. They allow you to number as you
print, eliminating steps in the production process. However, they require the use of skilled labor and, combined
with longer set-up times, require a larger production volume in order to be cost effective.

Stand-alone letterpress numbering systems represent the ultimate solution to numbering needs. These dedi-
cated machines are very expensive, require skilled labor and, therefore, are the most appropriate for high-volume
numbering needs.

The NC Numbering System fits between off-line, table-top numbering machines and on-line press numbering
attachments. For a much lower price than the table-top or off-line machines, the NC Numbering System offers
reliability, flexibility, and ease of use.

Coupled with the Risograph Digital Duplicator, the numbering system provides quick set-up and fast production.
Some applications include tickets, forms, pads, invoices, and envelopes.

4. Types of Numbering Heads

Numbering heads print up to seven digits and may be used with black or red ink. The user is able to depress up
to three digits in order to print numbers with as few as four digits. There are four different numbering heads and
up to 12 heads can be installed per print application for complete versatility.

Straight and Convex

There are two categories of numbering heads: Horizontal Straight and Vertical Convex. Straight numbering
heads imprint numbers horizontally and Convex numbering heads imprint vertically.

Note: You cannot put a Horizontal Straight numbering head on the same Head holder ring as
a Vertical Convex numbering head.

Backward and Forward

The most common numbering heads, referred to as backward numbering, are those that number decrementally
(ex. 0999, 0998, 0997, 0996, 0995, etc.). There are also those that number incrementally, known as forward
numbering (ex. 0991, 0992, 0993, 0994, 0995, etc.). With the printing range from 0000001 to 9999999, number
0000001 is the first number printed and 9999999 is the last number printed. With the printing range from
9999999 to 0000001, number 9999999 is the first number printed and 0000001 is the last number printed.

Repeat Wheels
Some special applications require the same number to be printed repeatedly such as multiple copies of carbon-
less forms. In these cases, Repeat wheels are needed. These special wheels replace a wheel on the Number-
ing head and will increment the Numbering head every X activations. This wheel may repeat up to six activations.
(Example of repeat wheel of two: 991, 991, 992, 992, 993, 993, etc.).

Skip Wheels
There are some applications that require numbers to be skipped, for example, you may only need even num-
bers. Skip wheels are installed to enable the Numbering head to skip X numbers (ex. 992, 994, 996, 998, etc.).

1-2
 1. INTRODUCTION
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Designation Blocks
Designation blocks, used in conjunction with a polymer plate, enable you to imprint logos or special messages
while printing numbers. Applications include corporate logos, symbols, and addresses. Designation blocks can
be purchased through RISO Customer Service. Polymer plates can be purchased at any graphic arts store.

In order to let you take advantage of the combination that suits your needs best, Numbering heads, Repeat
wheels, Skip wheels, and Designation blocks are purchased separately from the numbering cylinder.

The following chart illustrates the parts needed for adding Numbering heads to the cylinder. Each numbering
system is shipped with the quantity of each part listed below. Additional quantities can be purchased through
RISO Customer Service.

Part No. Part Name Qty.

S-8960 Ink Roller Assembly (Red) 3

S-8961 Ink Roller Assembly (Black) 3
S-8950 Tripping Cam Assembly 1
S-8951 Head Holder Ring Assembly 1

S-8981 Numbering Head Horizontal-Straight Forward *

S-8980 Numbering Head Horizontal-Straight Backward *
S-8983 Numbering Head Vertical-Convex Forward *
S-8982 Numbering Head Vertical-Convex Backward *

1-3
SECTION 2: Safety Instructions

CONTENTS

1. Emergency & First Aid Procedures .......................................... 2-1

2. Safe Operating Instructions ....................................................... 2-1

3. Hands-On Operations ............................................................... 2-1

 2. SAFETY INSTRUCTIONS
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Safety Instructions
1. Emergency & First Aid Procedures

Ink contact with eyes: Immediately rinse eyes with clean water for 15-20 minutes. Retract eyelids
often. Obtain emergency medical attention if pain, blinking, tears, or redness persists.

Ink contact with skin: Wash skin thoroughly with mild soap and water. Flush with lukewarm water for
15 minutes.

2. Safe Operating Instructions

- Do not operate this machine without all guarding in place.

- Keep this unit and work area clean and free of spills to prevent accidents.
- Make sure that all safety decals are attached to their appropriate locations.
- Be alert and use common sense.
- Remove and insert accessory gently.
- Read NC positioning instructions before inserting numbering system into the Risograph.
- Make sure the numbering system is in the home position (12 o’clock position on the Indicator knob)
before inserting the numbering system into the Risograph.

3. Hands-On Operations

- Do not allow unauthorized personnel to operate, make adjustments, or repair this accessory.
- Do not remove fixed parts or guard on the numbering system except for Tripping cam, Numbering
head, Head holder ring, or Operating arm.
- Do not operate this accessory in any other manner than as described in this guide.
- Contact your dealer if you suspect any hazardous situations, if you experience problems, or if you
have any questions.

2-1
SECTION 3: Specifications
 3. SPECIFICATIONS
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

NC-001 / NC-002 Product Specifications

Numbering Head Heavy-duty rotary type

Type and Figure Size Gothic 3/16" (4.7 mm)

7-digit

Maximum # Heads/Ring Straight horizontal:

- 4 heads per ring
- Max. ring assemblies: 3

Convex vertical:
- 4 heads per ring
- Max. ring assemblies: 3

Numbering Margins Left and right: 0"

Top: 3/16" (4.7 mm)
Bottom: 12.2" (310 mm) from lead edge

Minimum distance Vertical forward: 1.75" (45 mm)

between numbers Vertical backward: 2.35" (59 mm)
Horizontal forward: 2.35" (59 mm)
Horizontal backward: 1.75" (45 mm)

Signature Attachment Area: 2"x1" (5 cm x 2.5 cm)

Print Speed Same as Risograph

60 up to 130 ppm
(3,600 to 7,800 prints/hour)

Safety Driver declutching device

Error diagnostic compliance with duplicator

Dimensions Length: 20" (50 cm)

Width: 10" (25 cm)
Height: 11.5" (29 cm)

Weight 20.1 lbs. (9.07 kg)

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 3. SPECIFICATIONS
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Accessories and Equipment

Numbering Heads Horizontal forward

Horizontal backward
Vertical forward
Vertical backward

Imprinting Designation block for polymer plate

Miscellaneous Additional ring and cam

Repeat wheels #2 to #6
Skip wheel
Red Inked Rollers
Black Inked Rollers

For part numbers, please refer to the NC Parts Manual.

(Specifications subject to change without notice.)

3-2
SECTION 4: Unpacking

CONTENTS

1. Carton Inspection...................................................................... 4-1

2. Unpacking ................................................................................ 4-1

3. Check List & Serial Number ..................................................... 4-1

4. Recommended Temperature .................................................... 4-1

5. Contents Check List ................................................................. 4-2

 4. UNPACKING
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Unpacking
1. Carton Inspection

Inspect the carton for any visual damage. In case of serious damage due to shipping, please contact
your shipping company.

2. Unpacking

Unpack numbering device as shown below.

3. Check List & Serial Number

Inspect the contents against your numbering device check list (located on top when opening the box).
Have your serial number available before contacting your dealer.

4. Recommended Temperature

Please wait until the unit reaches normal room temperature before using it.

4-1
 4. UNPACKING
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

5. Contents Check List

4-2
SECTION 5: Setup Procedures

CONTENTS

1. Quick Start ............................................................................... 5-1

2. NC Insertion Instructions ........................................................... 5-1

3. Centering the Numbering Cylinder ............................................ 5-2

4. Drive Disk Positioning .............................................................. 5-4

5. Numbering Head Positioning .................................................... 5-5

6. Installing the Ink Rollers ............................................................. 5-7

7. Positioning the Tripping Cam .................................................... 5-9

 5. SETUP PROCEDURES
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Setup Procedures
1. Quick Start

This section covers basic set-up and operation of the NC-001 and NC-002 numbering systems. These inte-
grated systems, specifically designed for GR Series Risographs, deliver automatic, high-speed, sequential
numbering of documents such as forms, tickets, and coupons.

NC systems come standard with the following items:

• One Tripping cam

• One Head holder ring assembly
• Assorted tools for installing and adjusting the Numbering cylinder and heads
• Six Ink rollers (3 red, 3 black).

In addition, you will need at least one 7-digit Numbering head (convex for vertical numbering, straight for horizon-
tal numbering). These are ordered through RISO Customer Service. Remember, you can add up to four heads
per ring for a maximum of 12 heads.

Although this section gives you the basics so you can get a quick start into the world of sequential numbering,
we recommend reading the complete operation guide before using this accessory in order to achieve optimal
results and ensure your complete satisfaction. Also, please use the NC Numbering System video in conjunction
with this guide for complete, simple, step-by-step instructions.

2. NC Insertion Instructions

NC numbering systems are the same size as Risograph print cylinders and, therefore, are inserted into the
Risograph in the same manner as a print cylinder.

Before inserting the Numbering system, however, please read the instructions on the following pages.

5-1
 5. SETUP PROCEDURES
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

3. Centering the Numbering Cylinder

A system may require minor adjustments before first use to ensure that the drum key in the machine aligns
properly with the drum key in the cylinder.

1. Line up the white dot on the Indicator knob with the Arrow on the cylinder plate. This ensures the
cylinder is locked in the proper position.

Arrow

Indicator knob

2. Slowly slide the Numbering cylinder into the Risograph until its back end comes just flush with the
edge of the Risograph cylinder opening.

flush here

5-2
 5. SETUP PROCEDURES
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

3. Use an allen wrench to adjust the Centering screws located on the back of the cylinder’s front
panel (left and right).

Centering screw (right)

Centering screw (left)

4. Once it is centered, gently slide the unit all the way into the Risograph and lower the handle.

5. Close the Risograph door and produce a test print to ensure the system is properly positioned.

5-3
 5. SETUP PROCEDURES
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

4. Drive Disk Positioning

1. If the Ink shafts are in place, remove them to allow more room for set up. This is done by
pulling each shaft towards the front of the cylinder until the opposite end pops out.

spring loaded
on this end

2. To establish the middle, fold your document in half lengthwise (the example uses letter size
8.5"x11" or A4 paper size, to be fed portrait).

fold mark

5-4
 5. SETUP PROCEDURES
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

3. Center the Drive disks to the edge of the paper with the fold mark aligned to the Center arrow on
the scale of the numbering system.

Center arrow

fold mark

4. Move the Drive disk so that at least 1/2 of its width is in contact with the paper (use the 3/16" allen
wrench provided).

NOTE: Always operate the NC with a Drive disk on each side of the Center arrow to ensure smooth
feeding.

5. Tighten the Drive disk screws.

5. Numbering Head Positioning

1. Identify the exact area for number placement by measuring vertically (from the top of the sheet)
and horizontally (from either the center or outside edge of the sheet).

Vertical Measurement Horizontal Measurement

5-5
 5. SETUP PROCEDURES
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

2. Remove the Head holder ring assembly from the numbering system using the 3/16" allen wrench.

3. Slide the Numbering head onto the Head holder ring and position it at the correct vertical
measurement using the scale on the ring. Tighten it with the allen wrench.

Scale

NOTE: You cannot put a Horizontal Straight numbering head on the same head holder assembly as a
Vertical Convex numbering head.

5-6
 5. SETUP PROCEDURES
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

3. Install the Head holder ring onto the Drive shaft making sure to align the attached Numbering head
in the proper horizontal measurement from the center of the graduated shaft and tighten the Head
holder ring screw.

6. Installing the Ink Rollers

1. Pull the Ink shaft toward the front of the cylinder until its opposite end pops out of the support.

spring loaded
on this end

2. Remove the pre-inked rollers from their protective covers and slide one onto each of the three Ink
shafts.

Ink shaft

Ink roller

5-7
 5. SETUP PROCEDURES
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

3. Reinstall the Ink shafts, align the Ink pads with the Numbering head, and position the Ink shaft
drivers so they contact one of the Drive disks.

Ink roller
Ink shaft driver
Numbering
head

Drive disk

4. Slide the Numbering system into the Risograph and run a test print. Review the print for proper
alignment.

5. Additional minor position adjustments can be made through the Risograph’s controls. If the
registration is out of alignment, use the vertical adjustment control on the Risograph operator
panel and/or the horizontal control on the feed table to correct number placement.

vertical horizontal
adjust control

5-8
 5. SETUP PROCEDURES
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

7. Positioning the Tripping Cam

1. Once the registration is correct, loosen the Tripping cam and slide it into alignment with the
Numbering head’s Operating arm. Make sure the Tripping cam glides smoothly over the Roller of
the Operating arm without interfering with the movement of the arm itself and tighten in place.

NOTE: To test the Tripping cam’s position, you will need to manually release the NC Latch mechanism
to allow free rotation of the cylinder.

Latch mechanism

2. Align the white dot on the Indicator knob with the Arrow on the cylinder plate to lock the drum back
in the proper position.

Arrow
Indicator knob

5-9
 5. SETUP PROCEDURES
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

3. To set the Numbering head to the correct beginning number, rotate the digits on the head with the
supplied pick. Now you are ready to print.

4. Slide the NC numbering system back into the Risograph and place the preprinted job on the
Risograph feed table.

5. Make sure the Risograph is in the PRINT position (not in master making mode), enter the desired
number of prints, and press Start. The Risograph, with the integrated numbering system, will
automatically complete the job.

5-10
SECTION 6: Drive Mechanism &
Declutching Device
CONTENTS

1. System Overview ...................................................................... 6-1

 6. DRIVE MECHANISM & DECLUTCHING DEVICE
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Drive Mechanism & Declutching Device

1. System Overview

The Declutching device is a safety feature that allows the drive mechanism to break free in the event of a bind. It
should be adjusted so that the driver breaks free before the Main Motor or a PCB burn out, but not so loosely
that it breaks free unnecessarily.

Ink shaft driver

Ink roller
Ink shaft
Declutching device

Lever
Pressure roller
Drive disk

Exploded View
A Ball
plunger screw (2)

B NC-Main shaft

C Driver groove (2)

D NC-Driver

A Ball plunger screw (2): These set screws can be adjusted to control clutch slippage. The tighter you set
them, the harder it will be for the drive to break free.

B Main shaft: Transfers the rotation from the Driver to the Drive disks and the Head holder ring. If the Main
shaft freezes for some reason, the slip clutch should break free so no damage occurs.

C Driver groove (2): The ends of the Ball plunger screws rest in these grooves.

D NC-Driver: Transfers rotation from the Risograph to the Ball plunger screws and Main shaft.

6-1
SECTION 7: Tripping Cam System

CONTENTS

1. System Overview ...................................................................... 7-1

 7. ACTUATOR CAM SYSTEM
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Tripping Cam System

1. System Overview

This system is responsible for incrementing the Numbering head.

F Tripping cam

A Latch

E Cam lever

D Cam
B Lever
C Plate

A Latch: When the Lever swings the Latch, the Latch catches the Cam lever and holds it in the locked position
(until the next full drum rotation in which the Pressure roller is not engaged).

B Lever: When the Pressure Roller engages, a bearing on its shaft contacts the Lever which in turn swings the
Latch.

C Plate: The Plate is attached to the end of the Cam lever. When adjusted properly, it will be caught by the
Latch as the Cam cycles (see specs. below).

Plate

Latch

.20 mm

D Cam: The Cam is responsible for moving the Cam lever down so it catches the Latch.

E Cam lever: The Cam lever and the Tripping cam are connected to the same shaft. Thus, when the Cam lever
is being held down by the Latch, the Tripping cam is also being held down.

F Tripping cam: When held in its down position, the Tripping cam contacts the Roller of the Operating arm
causing the Numbering head to increment.
7-1
SECTION 8: Numbering Head

CONTENTS

1. System Overview ...................................................................... 8-1

2. The Numbering Head................................................................ 8-2

2. Installing Repeat & Skip Wheels ............................................... 8-3

3. Numbering Head Maintenance ................................................. 8-6

4. Numbering Head Lubrication .................................................... 8-6

 8. NUMBERING HEAD
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Numbering Head
1. System Overview

The Numbering head is designed to print repeated, skipped, or sequential numbers on a variety of media and
can be adjusted vertically and horizontally to print almost anywhere on a page. Up to four Numbering heads can
be installed on one Head holder ring and each cylinder can accomodate up to three Rings (straight and convex
heads cannot be installed on the same ring).

A Roller D Numbering head

B Operating arm

C Head holder ring

A Roller: The Roller is attached to the Operator arm. It is the point of contact between the Tripping cam and
the Numbering head.

B Operating arm: When depressed, the Operating arm causes the Numbering head to increment.

C Head holder ring: The Numbering heads are secured to the Head holder ring.

D Numbering Head: The Numbering head prints the number or letter designation on the media.

8-1
 8. NUMBERING HEAD
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

2. The Numbering Head

8-2
 8. NUMBERING HEAD
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

3. Installing Repeat & Skip Wheels

1. Loosen both hex screws.

2. Remove the Operating arm.

Operating arm

3. Using Tool “F 16-62-0”, push the Tube shaft

until the Unit wheel can be removed from the
assembly.

Tool F 16-62-0

4. Remove Tool “F 16-62-0” and then the Unit

wheel.

Unit
wheel

8-3
 8. NUMBERING HEAD
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

5. Place the Skip or Repeat wheel in place

of the Unit wheel.

Skip or Repeat wheel

6. Use Tool “F 16-62-0” to realign all wheels.

7. Press the Tube shaft forcing the tool out of

the Numbering head (note that the Tube shaft
has alignment holes on each end to receive the
hex screws).

8. Reinstall the Operating arm.

8-4
 8. NUMBERING HEAD
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

9. Insert the blade of a screwdriver into the slot at

the end of the Operating arm shaft and tension
the shaft clockwise until the slot is vertical.
This will position the shaft’s alignment holes
with the hex screws.

10. Now tighten both hex screws while continuing

to hold the slot vertical with the screwdriver.

11. Install the Numbering head onto the Head

holder ring.

8-5
 8. NUMBERING HEAD
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

4. Numbering Head Maintenance

Maintaining the NC numbering system consists mainly of cleaning the numbering head and making sure the Flat
bar has a good reflection. A bad reflection will cause a false detection from the Risograph sensor and will
probably show a “Call Service” message such as “No Master” or “Print Cylinder”.

Cleaning the Numbering Head

In order for the Numbering head to operate properly, its components must be able to move freely. Regular
cleaning and oiling is necessary.

Clean the Numbering head by placing it in a cleaning and oiling solvent appropriate for printing equipment. Use
a brush to clean each wheel digit. Rotate each wheel manually using the plastic pick so that dirt between each
wheel will be dissolved and the oil will access the Tube shaft. Placing the Numbering head in the cleaning and
oiling solvent will also oil the return spring and the roller of the Operating arm.

There is no specific time for soaking, but if a fast cleaning is required, an aerosol cleanser can be used along
with a brush. Dip the brush into the solvent and clean the head that way. Then remove all excess solvent with a
rag and use a quick-dry aerosol.

The decision of when to clean the numbering head depends on the accumulation of ink on the head and on print
quality. An operator can tell if a head needs to be cleaned of ink residue by checking resistance when rotating
the numbers manually with the plastic pick.

Lubricating the Numbering Head

Note: To avoid excessive wear and ensure your heads print properly, clean and lubricate them frequently.

8-6
SECTION 9: Inking System

CONTENTS

1. System Overview ...................................................................... 9-1

2. Ink Shaft Drivers / Drive Disk Contact ....................................... 9-2

 9. INKING SYSTEM
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Inking System
1. System Overview

The Inking System is responsible for supplying ink to the Numbering heads. Both red and black Ink rollers are
available.

A Flat bar

Tripping cam

B Ink shaft drivers

9-2
G Front Ink shaft support

C Latch
mechanism
F Ink rollers

E Drive Disks

D Ink drive shaft

A Flat Bar: This solid aluminum bar acts as a reflector to fool the Risograph’s Master loading sensor. It
causes the sensor to detect there is a Master present even though there is not.

B Ink Shaft Driver (3): The Ink shaft drivers rest on the Drive disks and are responsible for rotation of the Ink
rollers.

C Latch Mechanism: When the NC unit is inserted and locked into the Risograph, this latch opens allowing
the cylinder to rotate.

D Ink Drive Shaft (3): These shafts transfer rotation from the Ink shaft drivers to the Ink rollers.

E Drive Disks: When the Risograph’s Pressure roller engages, it pushes the media against the NC’s Drive
disks where it is held in place, addressed by the Numbering head, and then sent on to the Paper Receiving
Area. The Drive disks can be adjusted with a 3/16” Allen wrench.

F Ink Roller Assembly (3): The Ink rollers apply ink to the Numbering heads as they revolve.

G Ink Shaft Support: The Ink drive shafts are connected to the Front and Rear Ink shaft supports. The Rear
Ink shaft support can be adjusted to increase or decrease contact between the Ink shaft drivers and the Drive
disks.

9-1
 9. INKING SYSTEM
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

2. Ink Shaft Drivers / Drive Disk Contact

1. Loosen the Allen screws on the Rear Ink shaft support.

2. Move the Ink shaft support up or down until correct contact between the Ink shaft drivers and the
Drive disks has been established.

Ink shaft
drivers

Allen screws

Drive disk

3. Tighten Allen screws to lock the Ink shaft support in position.

9-2
SECTION 10: Troubleshooting Guide
 10. TROUBLESHOOTING GUIDE
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Troubleshooting Guide
Symptom: Solution:

T-1 Check for mechanical binds in the drum drive.

Check/replace the Motor Control PCB.
Check/replace “A” sensor actuator.
Check/replace associated wires.

T-3 Check/replace the Motor Control PCB.

Check/replace associated wires.

T-4 Check/replace the Motor Control PCB.

Check/replace associated wires.

T-13 Check/replace the Motor Control PCB.

Check/replace associated wires.
Check/replace “C” sensor or actuator plate.

T-16 Check/replace the Motor Control PCB.

Check/replace associated wires.
Check/replace “C” sensor or actuator plate.

C-34 Paper jam on drum Check Risograph for paper path specifications.
Check numbering cylinder drive wheel alignment.

C-32 Paper jam in receiving area Check Risograph for paper path specifications.

C-52 Install print cylinder Check drum interlock and actuating lever.
Check/replace associated wires.

C-53 Install ink cartridge Check/replace the Motor Control PCB.

Check/replace associated wires.

Registration problems: lead to trail edge Check Risograph vertical print position (panel).
Check numbering head vertical position.

Registration problems: side-to-side Check Risograph horizontal print position (feed table).
Check numbering head horizontal position.

10-1
 10. TROUBLESHOOTING GUIDE
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

Symptom: Solution:

Voids - image area missing partial print Check/replace ink rollers.

Check Risograph pressure system adjustments.
Ensure ink shaft drive wheels are properly positioned.

Two-Up Mode won’t function properly Not applicable with numbering cylinder.

10-2
SECTION 11: Electical System

CONTENTS

1. Wiring Diagram ...................................................................... 11-1

2. Dip Switch Settings ................................................................ 11-2

 11. ELECTRICAL SYSTEM
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

1. Wiring Diagram
11-1
 11. ELECTRICAL SYSTEM
NC-001/NC-002 RISOGRAPH NUMBERING SYSTEM

2. Dip Switch Settings

11-2