AIRMATIC RB655 User manual

CONFIDENTIAL
SERVICE MANUAL
REBAR TYING TOOL
Model: RB655
Specifications and parts may be changed for improvement.

CONTENTS
P1 EXPLODED VIEW AND SPARE PARTS LIST
P2 PARTS LIST
P3 DIFFERENCES OF THE TOOL PERFORMANCE
BETWEEN THE RB655AND RB650A
P4 DIFFERENT PARTS BETWEEN RB650AAND RB655
P8 RB655 TYING TIMES INDICATION MODE
P9 RB650/RB650A/RB655 TOOL CHECKER
P11 TOOLS AND ADHESIVE REQUIRED FOR RB655 TOOL REPAIR
P12 MUST DO MAINTENANCE BEFORE THE TOOL REACHES 500,000 TIES
P13 HOW TO CLEAN UP THE FEEDING GEAR AREA
P17 HOW TO CLEAN UP THE CUTTER AREA
P20 SELF-WARM-UP PROGRAM
P21 [HOW TOASSEMBLE THE TOOL]
1. MAIN SWITCH BASE ASSY
P24 2. TWISTER ASSY / FEED ASSY
P30 3. MAGAZINEASSY
P38 4. SENSOR BASE ASSY
P39 5. JAW BASE ASSY
P40 6. ARM ASSY
P49 - ADJUSTMENT OF WIRE GUIDE UNIT
P50 7. COVERASSY
P58 8. TWISTING MOTOR ASSY
P62 [HOW TO ATTACH THE EACH ASSEMBLY TO THE FRAME
P77 BEEP SOUND REFERENCE
P78 TROUBLE SHOOTING OF RB655
P81 PROCESS OF TYING ACTION
P83 RECOMMENDED INITIAL STOCK PARTS LIST
P85 TIGHTENING TORQUE CHART

115
114
162
119
205
118
155
10
121
117
120
116
168
157
167
140
161 11
16
88
142
143
56
149
72
191 173
77
36
74
75
76
36
191
182
71 73 153
147
145 154
146
39
39
110
11
100
103 101
96
36 111 99 104 98
100
97
95
113
8
11
102 73
112
106
69
56
70
61 36
55
58
210
87
66
63
64
59
67
85
60
65
62
193
57
171
172
170
179
151
201
179
152
180
40 43 208
41 39
38 10
84
82
167
169
83
40
42
9
38
39
202
9
135
56
56 109
108
107
203
19
105 192
36
51
5049
54
45 39
89
86
39
53
46
48
52
47
57
44
33
207
32
6
32
2
4
3
1
31
19
211
209
142
148
144
142 11
11
135
9
9
135
90
135
174
143
80
76
191 73 36
81
36
78
77 191
79
166
141
BODY R ASSY
Parts marked
are included in the
BODY R ASSY
160
163
143
57
56
164
135
56
9
9
57
56
57
150
134
135
135
124
123
136
125
122
134
165
133 132
130
183
137
138
139
10
129
128
184
136 185
116
127
131
187
175
177
188
189
176 181 178
188
189
EXPLODED VIEW AND SPARE PARTS LIST
- 1 -

RB655 Parts list
IND Code Description IND Code Description IND Code Description
1 RB70025 PLANET CAGE B UNIT 84 RB70081 SENSOR BOAD E UNIT 149 RB10795 GRIP COVER L
2 BB40427 T-BOLT 4 X 8 85 KK33329 TORSION SPRING 3329 150 RB10796 GRIP COVER R
3 KK23847 COMP. SPRING 384
7
86 LL62013 PLAIN BEARING B-F3-1 153 RB10854 TRIGGER
4 RB10344 KEY PLATE 87 RB11768 ARM B SET SCREW 154 RB10855 TRIGGER LOC
K
6 RB70027 SUN GEAR UNIT 88 RB10739 ARM A SET SCREW 155 RB70367 MAIN BOARD UNI
T
7 RB70029 MAGAZINE HOLDER UNI
T
89 RB10740 WIRE GUIDE LEVER 157 RB70101 TRIGGER SWITCH
8 AA21102 PAN-HEAD SCREW 3X4 90 CC49118 HEX NUT 3X7.
5
160 RB10423 LABEL, MAIN SWITCH
9 FF51652 PIN 1652 95 RB70278 FEEDING GEAR BASE ASSY 161 RB10421 LABEL, FCC (USA)
10 AA31714 SCREW 2X4 96 RB70299 FEEDING GEAR B UNIT 162 RB10799 TORQUE ADJUSTMENT LABEL
11 CC41104 HEX.NUT 1-3 FOR HD-12/1
7
97 FF41728 STEP PIN 1728 163 RB11921 NAME LABEL (USA)
16 CC41101 HEX NUT 1-5 98 RB10775 RELEASE LEVER 164 RB10846 WIRE LOADING LABEL
19 JJ21603 C-RING 20 99 BB40420 BOLT 4 X 16 165 RB10847 WIRE SETTING LABEL
31 RB10725 INTERNAL GEAR B 100 EE39121 PLAIN WASHER 5 166 RB10962 ARM CAUTION LABEL
32 RB10726 PLANET GEAR B 101 EE39168 WASHER 4.2X1.3X1 167 RB70084 HARNESS 11P UNIT
33 RB10776 GEAR RETAINER 102 FF51628 HOLLOW PIN 1628 168 RB70085 HARNESS 7P UNIT
36 BB40481 BOLT 3X5 103 JJ10514 E-RING 3 CF 169 RB70086 HARNESS 3P UNIT
38 FF41822 STEP PIN 1822 104 KK23851 COMP. SPRING 3851 170 RB70339 FAN UNIT
39 JJ10113 E-RING 2.5 105 LL11181 WHEEL 6704 171 RB11884 FILTER
A
40 KK33249 TORSION SPRING 3249 106 RB10043 STEP PIN 172 RB11885 FILER B
41 RB10370 JAW BASE 107 RB10338 INTERNAL GEAR 173 RB11004 PROTECTOR C
42 RB10735 JAW B 108 RB10341 PLANET GEAR 174 EE39830 WASHER 5.1X 9
43 RB10779 JAW A 109 RB10484 GEAR PRESS WHEEL 175 RB11777 STOPPER PLATE
44 RB70056 MOTOR GEAR B UNIT 110 RB10770 FEED GEAR A 176 RB10718 SLEEVE GUIDE
45 RB70026 ARM A UNIT 111 RB10774 WIRE GUIDE C 177 RB11762 HOOK L
46 RB70036 WIRE GUIDE A2 UNIT 112 RB10852 RELEASE STOPPER 178 RB11763 HOOK R
47 RB70276 WIRE GUIDE UNIT 113 RB70079 SENSOR BOARD C UNIT 179 RB11886 FAN PROTECTOR
48 AA22415 SCREW 3X8 114 RB70087 WARNING LED UNIT 180 RB11883 FILTER COVER
49 AA71408 SCREW 3 X 3 115 RB70341 MAIN SWITCH UNIT 181 RB10724 SLEEVE COVER
50 EE31801 WASHER 3.2X7 116 AA31721 SCREW 3X6 182 RB11003 PROTECTOR B
51 FF41729 SETP PIN 1729 117 AA74410 SCREW 3X6 183 CK10198 SCREW 3X10
52 KK23849 COMP. SPRING 384
9
118 RB10400 LEAF SPRING 184 RB11775 BINDING HEAD SCREW
53 RB10737 WIRE GUIDE A1 119 RB10536 MAIN SWITCH BASE 185 RB11776 MAGAZINE LEAF SPRING
54 RB10743 WIRE GUIDE BASE 120 RB10537 JOINT, DIAL 187 RB81108 MAGAZINE COVER KI
T
55 RB70039 ARM B UNIT 121 RB10853 TORQUE DIAL 188 FF31559 PIN 1559
56 BB40425 BOLT 3X10 122 RB81102 MAGAZINE ASS
Y
189 FF51656 PIN 1656
57 BB40810 BOLT 3X16 123 RB10783 PROTECTOR 191 JJ10510 RETAINING RING 2.
3
58 CC41103 HEX. NUT 1-4 124 RB10785 BUSH A 192 RB70217 MAGNET HOLDER UNIT
59 FF41730 STEP PIN 1730 125 RB10786 BUSH B 193 RB11666 ARM COVER
60 JJ10509 E-RING 4CF 126 RB10787 SENSOR COVER 201 RB70349 TWISTING MOTOR TD5046 UNIT
61 RB10746 WIRE GUIDE B 127 RB10791 SENSOR COVER PLATE 202 RB70351 FEEDING MOTOR RS-55VC UNI
T
62 RB10747 ARM C 128 RB10792 RETAINING RING 203 RB70222 FEED GEAR SHAFT
63 RB10748 FIXED CUTTE
R
129 RB70082 SENSOR BOARD F UNIT 205 RB70113 MAIN SWITCH BASE ASSY
64 RB10749 CUTTER 130 AA32708 SCREW 2.6X6 207 RB70284 TWISTER ASSY
65 RB10750 CUTTER CONNERCTING ROD 131 RB81103 MAGAZINE COVER ASS
Y
208 RB70033 FINGER BASE ASSY
66 RB70277 CUTTER LEVER UNIT 132 RB11774 MAGAZINE COVER LOC
K
209 RB70281 ARM A ASS
Y
67 RB11767 CUTTER SHAFT 133 RB10806 ADJUST RING 210 RB70285 ARM B ASS
Y
69 RB10754 CURL GUIDE
A
134 BB40405 BOLT 5X25 211 RB70283 TWISTER A ASSY
70 RB10755 CURL GUIDE B 135 EE32104 WASHER 2-3
71 RB70041 COVER L UNIT 136 EE39172 WASHER 5.1X12X1.2
72 RB70042 MAGNET HOLDER L UNIT 137 EE39602 WASHER 7
73 KK23850 COMP. SPRING 3850 138 FF31289 PIN 1289
74 KK33328 TORSION SPRING 3328 139 KK33327 TORSION SPRING 3327
75 RB70369 TWIST GUIDE COVER L 140 RB81106 FRAME L ASSY (USA)
76 RB10759 TWIST GUIDE SHAFT 141 RB81107 FRAME R ASSY (USA)
77 RB11667 SENSOR ROD 142 BB40410 BOLT 3X8
78 RB70044 COVER R UNIT 143 BB40811 BOLT 3X25
79 RB70045 MAGNET HOLDER R UNIT 144 RB10970 ELECTRODE BLOCK
80 KK33330 TORSION SPRING 3330 145 KK23656 COMPRESSION SPRING 365
6
81 RB70370 TWIST GUIDE COVER R 146 RB10213 WINDOW
82 RB10765 SENSOR BASE 147 RB81034 MOTOR COVER ASSY
83 RB70080 SENSOR BOARD D UNIT 148 RB11769 ELECTRODE PLATE
- 2-
* You can get most updated list at www.maxusacorp.com

-3 -
Differences of the tool performance
between the RB655 and RB650A
Difference RB650A RB655
1 Tying times
per charge
Tying times per charge was
increased by about 40%. This was
achieved by following factors;
1) Improvement of the work
efficiency of the Twisting motor and
Feeding motor.
2) The PC board has new program
which reduces required electric
current.
Thanks to the increase of tying times
per charge, the total tying times per
battery life is also increased by
about 40%
430 to 530
ties
600 to 700
ties
(30% more)
2 Lifetime of the
motors
Twisting motor of RB655 is
brushless motor and its lifetime is
more than 5 times longer than
Twisting motor of RB650A.
Feeding motor of RB655 is regular
motor but work efficiency is
improved.
The lifetime of the Feeding motor of
RB655 is about 25% longer than the
Feeding motor of RB650A.
Twisting
Motor:
70,000 to
100,000 ties
Feeding
Motor:
200,000 to
250,000 ties.
Twisting
Motor:
500,000 ties or
more.
Feeding
Motor:
250,000 to
300,000 ties.
3 Inside
temperature
of the tool
The heat created by tool operation is
reduced by increase of the work
efficiency of the motors.
260 F
194F
(30% less)
4 Performance
in cold
weather
The rotation of the Twisting motor on
RB655 is controlled by PC board.
Also the reduction of the required
electric current enables stable
operation in cold weather.
14F
- 4F
*These numbers are
when the tool is used
with a brand new battery
Temperature of Twisting
Motor after 2 hours use;
(30 ties/Min.)
Warm-up is required if it is
below

ITE
MPart # Wire
colo
r
ITEM
No. Part # Wire
colo
r
Note
The length of wire harness is different. The longer wire is placed on the groove of Twisting Motor housing.
155 RB70367
Yellow
Blue
Red
Black
Green
RB655
Twisting motor of RB655 is DC Brushless motor. The Brushless motor does not have wearing parts and lasts more than 500,000 ties. Also, the Brushless motor requires less electricity and increases tying times per charge. Feeding Motor on RB655 has better efficiency and requires less electricity. NOT interchangeable with Feeding Motor of RB650A. Main board and Sub board is not supplied individualy. White color wire is added for running Brushless motor.
Picture
RB70351
Black
Purple
White
Red
Brown
Yellow
Blue
Yellow
Brown
Blue
Purple
White
White color wire and connector are added.
201 202
Brown
Green
RB70349201
202
RB650A
Yellow
Blue
Picture
Twisting
Motor RB70031
Feed Motor RB70048
Board Unit
Main Board
Sub Board
Bunkered
155 156 158
RB70195 RB70196 RB10833
Main
Switch 115 RB70091 115 RB70341
Brown
< Different
p
arts between RB650A and RB655
(
1/4
)
- 4-
Connector to sensor of rotation

ITE
MPart # ITEM
No. Part # Note
< Different parts between RB650A and RB655
(
2/4
)
- 5-
Picture Picture
152 RB11882
Motor
Housing R 152 RB81033
Motor
Housing L 151 RB81032 151 RB70354
141
CE
RB81105
USA
RB81107
Frame R
Assy 141
CE
RB81069
USA
RB81068
Frame L
Assy 140
CE
RB70119
USA
RB70120
140
CE
RB81104
USA
RB81106
RB650A RB655
The amount of glass fiber in plastic material is increased and protect rubber is removed. The amount of glass fiber in plastic material is increased and protect rubber is removed.

ITE
MPart # ITEM
No. Part # Note
< Different
p
arts between RB650A and RB655
(
3/4
)
- 6-
RB650A
172 RB11885
Filter B
(Sponge)
171 RB11884
Filter A
(wire mesh) 171 RB11002
180 RB11883
Filter Cover
Fan
Protector 179 RB11886
170 RB70339
Fan Unit 170 RB81031
Picture Picture
RB655
This part holds Filter A and Filter B in place. Connector on Fan Unit is directly connected to the PC board. (Without connection cable) Same as the sponge part of RB650A, these two parts protect Fan unit. To prevent dust from getting inside this sponge was added.

ITE
MPart # ITEM
No. Part # Note
- 7-
< Different
p
arts between RB650A and RB655
(
4/4
)
Placement
of red wire
harness of
Main
Switch
Connection
of the motor
rotation
sensor and
fan unit to
PC board
75 81
RB70369 RB70370
Twist Guide
Cover L
Twist Guide
Cover R
75 81
RB70178 RB70179
Motor
Housing
Assy
To improve wire pulling action, the shape of the Twisg Guide Cover L and R were changed. Wire harness on Main Switch is placed on the groove of Motor housing.
RB655RB650A
Picture Picture
Connector for motor rotation sensor
Connector to Fan

[RB655 Tying times indication mode]
With the beep sound and LED blinks, total tying times can be read without opening tool frame.
Readable tying times: Minimum 1,000 ties Maximum 999,000 ties
How to go to the "Tying times indication mode"
1) Turn the Main Switch off and remove battery. 4) With using a screw driver, keep the Twist Guide Cover open
2) Remove Tie wire from Magazine. as the picture below shows.
3) Set the Torque adjust dial to the position "1". 5) Set the battery to the tool.
6) Keep pulling the trigger and turn the Main Switch on.
How to read the tying times
Tool shows each digit indication first (LED blinks only) followed by number indication (LED and beep).
Example) # of ties is 16,300 ties.
LED blinks : 3 times LED
Beep
LED blinks : 2 times LED
Beep
LED blinks : one time LED
Beep
LED blinks : 2 times
(Rapid)
Sum #1, #2 and #3 = 16,000 ties. (300 ties can not be read with this program. It can be read by Checker box)
After the rapid 2-time blink (#4), tool repeats indication from #1.
#4 End
56
#3 Digit of 1,000
#1
Number indication is
6 times which means
6,000 ties
Note
Number indication is
one time which
means 10,000 ties
No indication
because # of ties
does not reach
100,000.
#2 Digit of 10,000
Then, the tool start showing how many ties has been made with LED blinks and beep sound.
34 89
Digit indication: LED blinks only (No beep)
7
Number indication: LED blinks and beep sound
Digit of 100,000
12
- 8-

- 9 -
RB650/RB650A/RB655 tool checker
No. Name Function
1 AC CODE
2 Not for use
3 POWER SWITCH Power switch
4 DISPLAY Display the information of the tool status
5 CONNECTOR Connector to Main Board inside of the tool
6 “BINDS” BUTTON Press to see total number of ties made by a tool
7 “POWER” BUTTON Press to see how many times a tool is powered on
8
”ERR” BUTTON Press to see total number of each error happened on a tool (With pressing the button, each error number will be shown
in turn)
1.MOTOR LOCK ERROR
2.TWISTING ACTION ERROR
3.TWIST GUIDE COVER OPEN ERROR
4.FEEDING FUNCTION ERROR
5.REEL SENSOR ERROR
6.CPU OVERHEAT
7.FET OVERHEAT
9 “LAST-ERR” BUTTON Press to see the last error
10 “VERSION” BUTTON Press to see the version of the program in Main Board
4
8
7
6
5
1
2
9
10
3

- 10 -
Procedure
1. Connect the connector to the Main Board of RB650 / RB650A/ RB655.
2. Power switch on.
Description on display Status
DATA RCV READY Ready to work
DAT RCV TIME OUT
CMD RCV TIME OUT
UNKNOW ANS RCV Error
Press buttons to see the tool information

- 11 -
Tools and adhesive required for RB655 tool repair
TOOL
NAME SIZE
1.5 mm
2.5 mm
3.0 mm
<1> HEXAGONAL BAR WRENCH
4.0 mm*
5.5 mm
<2> HEXAGONAL NUT DRIVER 6.0 mm
<3> SCREW DRIVER + , -
<4> HIGH PRECISION SCREW DRIBER + , -
1.5 mm XB93116
2.5 mm XB93117
3.0 mm XB93118
HEXAGONAL BAR WRENCH
4.0 mm* XB93119
5.5 mm XB93120
6.0 mm XB93121
HEXAGONAL NUT DRIVER 7.0 mm* XB93122
SCREW DRIVER + (1) XB93123
SCREW DRIVER + (2) XB93124
<5>
SCREW DRIVER
- XB93125
<6> TORQUE DRIVER (LARGE)
<7> TORQUE DRIVER (SMALL)
<8> CONNECTOR TWEEZERS
Repair
Tool kit
Available
From
Max USA
XB93101
<9> PINCHERS & PLIERS
<10> HAMMER & PIN-PUNCH 2.5 mm
<11> C-RING PLIERS
The tools with * are not required for RB395 repair but required for RB650A/RB655 repair.
ADHESIVE
<A> 3M “DP-810” orAraldite (EPOXY-ADHESIVE)
<B> LOCTITE BLUE (242)
<C> LOCTITE PURPLE (222MS)
GREASE
GREEN MOLYKOTE GREASE (PG-662)
(SPECIAL GREASE AVAILABLE AT MAX USA)
XB93112

Must Do Maintenance before the tool reaches 500,000 tie
s
RB10749 CUTTER
The edge of the Cutter is worn out, the cutting load becomes higher then the tool can not to cut the wire. (The overcurrent beep sound may be heard when cutting load is too high and the cutting action is prevented.)
At around 200,000 ties, replace the Cutter with a new one. It is recommeded to replace Feeding Motor at the same time.
RB10748 FIXED CUTTER
The edge of the Cutter is worn out, the cutting load becomes higher then the tool can not to cut the wire. (The overcurrent beep sound may be heard when cutting load is too high and the cutting action is prevented.)
When replacing the Cutter (RB10749) at around 200,000 ties, reverse the direction of the Fixed Cutter. Also clean up the Cutters and apply small amount of the Molykote grease. At around 500,000 ties the Fixed Cutter should be replaced with a new one.
-Maintenance of the area
around the HOOKS
The dust/metal powder around the Hooks makes movement of the Hooks not smooth, and the load on the Twisting Motor to open and close the Hooks becomes higher. It the load becomes too high, the wire cannot be cut. (The overcurrent beep sound may be heard when cutting load is too high and the cutting action is prevented.)
At around 200,000 ties, clean the Hooks with degreaser like Paslode Degreaser Cleaner then apply Molykote grease.
RB70351 FEEDING MOTOR
The tool can not feed the wire because the brush of the Feeding Motor is worn out. At initializing action, feeding error beep sound may be heard. (The Twisting Motor is brushless motor and does not have wearing part.)
At around 200,000 ties, replace the Feeding Motor with a new one. It is recommeded to replace Cutter at the same time.
-The maintenance for FEEDING
MOTOR
Due to the dust on Feeding Gears, the feed sensor may not sence all of the magnets around the gear then the tool may feed more wire than required.
When replacing the Feeding Motor with a new one. Open the Motor Cover of the Feeding Motor and clean up the magnets around the Feeding Gear with compressed air.
RB11762 HOOK L RB11763 HOOK R RB70275 CENTER HOOK RB81102 MAGAZINE ASSY RB81103 MAGAZINE COVER ASSY
- 12 -
Part code Part name Phenomenon The recommended maintenance
and its frequency
Inside of the Magazine and Magazine Cover is worn out and hte play between Magazine and Magazine Cover becomes larger. It leads to too much friction on wire at wire pulling action and may create weak tie.
At around 500,000 ties, the Magazine and magazine Cover need to be replaced with new ones.
When the Hooks are worn out, the space between Center Hook and Hook becomes wider when the Hooks catch the wire. Due to this, the strength of cramping wire decreases and the tip of the wire may be released from the Hooks during the twisting action.
At around 500,000 ties, the Hooks need to be replaced with new ones.

- 13 -
1. Remove the Sensor Cover from the Magazine by squeezing the two legs of the cover.
HOW TO CLEAN UP THE FEEDING GEAR AREA (1/4)
2. Pull out the connector of the reel sensor.
3. Remove the tow bolts and disassemble the magazine from the
tool.

- 14 -
4. Remove the four bolts and remove the cover of Twisting Motor.
5. Pull out the connector at the feed sensor.
6. Blow away dust around the gears with compressed air.
7. Blow away iron powder on the magnets.
HOW TO CLEAN UP THE FEEDING GEAR AREA (2/4)

- 15 -
BB40425 50-100cN.m BB40425
100-150cN.m
BB40810 50-100cN.m
8. Clean up the internal gears and apply Molykote grease. Then connect the feed sensor connector and reassemble the feed gears and feed motor.
9. Tighgten the bolts with proper torque.
HOW TO CLEAN UP THE FEEDING GEAR AREA (3/4)

- 16 -
Pay attention not to
p
inch
BB40405 200-250cN.m
BB40405 200-250cN.m
10. Assemble the magazine to the tool and connect the reel sensor connector then close the cover of the connector.
HOW TO CLEAN UP THE FEEDING GEAR AREA (4/4)

- 17 -
HOW TO CLEAN UP THE CUTTER AREA (1/3)
1. Remove the two bolts and slide out the Cover R.
2. Remove the bolt and take the Cover on the cutter area.
3. Remove the pin, Cutter and Fixed Cutter.

- 18 -
4. Degrease and clean up the Cutter parts. Apply Molykote grease on Fixed Cutter and reassemble them.
HOW TO CLEAN UP THE CUTTER AREA (2/3)