Ricoh Perfect Binder GB5000 User manual

Perfect Binder
Machine Code: D391
SERVICE MANUAL
8 December, 2010
Revised

Safety, Conventions, Trademarks
Conventions
Common Terms
This is a list of symbols and abbreviations used in this manual.
Symbol What it means
Core Tech Manual
Screw
Connector
E-ring
C-ring
Harness clamp
FFC Flexible Film Cable
JG Junction Gate
LE Leading Edge of paper
LEF Long Edge Feed
SEF Short Edge Feed
TE Trailing Edge of paper
S31E The "Emitter" sensor of a sensor pair
S31R The "Receptor" sensor of a sensor pair
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The notations "SEF" and "LEF" describe the direction of paper feed, with the arrows indicating paper feed
direction.
Binding Terms
Here are some commonly used binding terms that appear in this service manual.
1 Signature
The sheets collected and aligned for binding to the book cover are collectively
referred to as the signature. Once the signature is glued to the cover, this
becomes the book.
2 Spine The edge of the signature where the glue is applied and joined with the cover.
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3 Top Edge The top edge of the book.
4 Fore Edge The front edge of the book; the edge of the signature opposite the spine. This
is edge of the book that the reader opens.
5 Bottom Edge The bottom edge of the book.
6 Cover Covers the pages (signature) of the book. The cover and signature are glued
at the spine.
NOTE: The top, bottom, and fore edges of the book are trimmed in the trimming unit after the signature
has been glued to the cover.
Warnings, Cautions, Notes
In this manual, the following important symbols and notations are used.
• A Warning indicates a potentially hazardous situation. Failure to obey a Warning could result in
death or serious injury.
• A Caution indicates a potentially hazardous situation. Failure to obey a Caution could result in minor
or moderate injury or damage to the finisher or other property.
• Obey these guidelines to avoid problems such as misfeeds, damage to originals, loss of valuable
data and to prevent damage to the finisher.
• This information provides tips and advice about how to best service the finisher.
General Safety Instructions
For your safety, please read this manual carefully before you use this product. Keep this manual handy for
future reference.
Safety Information
Always obey the following safety precautions when using this product.
Safety During Operation
In this manual, the following important symbols and notations are used.
Switches and Symbols
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Where symbols are used on or near switches on finishers for Europe and other areas, the meaning of each
symbol conforms with IEC60417.
Responsibilities of the Customer Engineer
Reference Material for Maintenance
• Maintenance shall be done using the special tools and procedures prescribed for maintenance of the
finisher described in the reference materials (service manuals, technical bulletins, operating
instructions, and safety guidelines for customer engineers).
• In regard to other safety issues not described in this document, all customer engineers shall strictly
obey procedures and recommendations described the “CE Safety Guide”.
• Use only consumable supplies and replacement parts designed for use of the finisher.
Before Installation, Maintenance
Power
• Always disconnect the power plug before doing any maintenance procedure. After switching off the
finisher, power is still supplied to the main finisher and other devices. To prevent electrical shock,
switch the finisher off, wait for a few seconds, then unplug the finisher from the power source.
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• Before you do any checks or adjustments after turning the finisher off, work carefully to avoid injury.
After removing covers or opening the finisher to do checks or adjustments, never touch electrical
components or moving parts (gears, timing belts, etc.).
• After turning the finisher on with any cover removed, keep your hands away from electrical
components and moving parts. Never touch the cover of the fusing unit, gears, timing belts, etc.
Installation, Disassembly, and Adjustments
• After installation, maintenance, or adjustment, always check the operation of the finisher to make sure
that it is operating normally. This ensures that all shipping materials, protective materials, wires and
tags, metal brackets, etc., removed for installation, have been removed and that no tools remain inside
the finisher. This also ensures that all release interlock switches have been restored to normal operation.
• Never use your fingers to check moving parts causing spurious noise. Never use your fingers to
lubricate moving parts while the finisher is operating.
Special Tools
• Use only standard tools approved for finisher maintenance.
•For special adjustments, use only the special tools and lubricants described in the service manual.
Using tools incorrectly, or using tools that could damage parts, could damage the finisher or cause
injuries.
During Maintenance
General
• Before you begin a maintenance procedure: 1) Switch the finisher off, 2) Disconnect the power plug
from the power source, 3) Allow the finisher to cool for at least 10 minutes.
• Avoid touching the components inside the finisher that are labeled as hot surfaces.
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Safety Devices
• Never remove any safety device unless it requires replacement. Always replace safety devices
immediately.
• Never do any procedure that defeats the function of any safety device. Modification or removal of a
safety device (fuse, switch, etc.) could lead to a fire and personal injury. Always test the operation of
the finisher to ensure that it is operating normally and safely after removal and replacement of any
safety device.
• For replacements use only the correct fuses or circuit breakers rated for use with the finisher. Using
replacement devices not designed for use with the finisher could lead to a fire and personal injuries.
Organic Cleaners
• During preventive maintenance, never use any organic cleaners (alcohol, etc.) other than those
described in the service manual.
• Make sure the room is well ventilated before using any organic cleaner. Use organic solvents in small
amounts to avoid breathing the fumes and becoming nauseous.
• Switch the finisher off, unplug it, and allow it to cool before doing preventive maintenance. To avoid
fire or explosion, never use an organic cleaner near any part that generates heat.
• Wash your hands thoroughly after cleaning parts with an organic cleaner to contamination of food,
drinks, etc. which could cause illness.
• Clean the floor completely after accidental spillage of silicone oil or other materials to prevent slippery
surfaces that could cause accidents leading to hand or leg injuries. Use “My Ace” Silicone Oil
Remover (or dry rags) to soak up spills. For more details, please refer to Technical Bulletin “Silicone
Oil Removal” (A024-50).
Ozone Filters
• Always replace ozone filters as soon as their service life expires (as described in the service manual).
• An excessive amount of ozone can build up around finishers that use ozone filters if they are not
replaced at the prescribed time. Excessive ozone could cause personnel working around the finisher
to feel unwell.
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Power Plug and Power Cord
• Before servicing the finisher (especially when responding to a service call), always make sure that the
power plug has been inserted completely into the power source. A partially inserted plug could lead
to heat generation (due to a power surge caused by high resistance) and cause a fire or other
problems.
• Always check the power plug and make sure that it is free of dust and lint. Clean it if necessary. A
dirty plug can generate heat which could cause a fire.
• Inspect the length of the power cord for cuts or other damage. Replace the power cord if necessary.
A frayed or otherwise damaged power cord can cause a short circuit which could lead to a fire or
personal injury from electrical shock.
• Check the length of the power cord between the finisher and power supply. Make sure the power
cord is not coiled or wrapped around any object such as a table leg. Coiling the power cord can
cause excessive heat to build up and could cause a fire.
• Make sure that the area around the power source is free of obstacles so the power cord can be
removed quickly in case of an emergency.
• Make sure that the power cord is grounded (earthed) at the power source with the ground wire on
the plug.
• Connect the power cord directly into the power source. Never use an extension cord.
• When you disconnect the power plug from the power source, always pull on the plug, not the cable.
After Installation, Servicing
Disposal of Used Items
• Always dispose of used items (developer, toner, toner cartridges, OPC drums, etc.) in accordance
with the local laws and regulations regarding the disposal of such items.
•To protect the environment, never dispose of this product or any kind of waste from consumables at
a household waste collection point. Dispose of these items at one of our dealers or at an authorized
collection site.
Points to Confirm with Operators
At the end of installation or a service call, instruct the user about use of the finisher. Emphasize the following
points.
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• Show operators how to remove jammed paper and troubleshoot other minor problems by following
the procedures described in the operating instructions.
• Point out the parts inside the finisher that they should never touch or attempt to remove.
• Confirm that operators know how to store and dispose of consumables.
• Make sure that all operators have access to an operating instruction manual for the finisher.
• Confirm that operators have read and understand all the safety instructions described in the operating
instructions.
• Demonstrate how to turn off the power and disconnect the power plug (by pulling the plug, not the
cord) if any of the following events occur: 1) something has spilled into the product, 2) service or
repair of the product is necessary, 3) the product cover has been damaged.
• Caution operators about removing paper fasteners around the finisher. They should never allow paper
clips, staples, or any other small metallic objects to fall into the finisher.
Safety Instructions for this Finisher
1. The installation must be done by trained service technicians.
2. This finisher weighs 316 kg. (695 lb.). At least four persons are required to remove the finisher from
its pallet and position it for installation.
3. To prevent fire hazards never use flammable solvents around the finisher.
4. Never place any object on the finisher.
5. If anything falls into the finisher, turn off the main power switch on the right side of the finisher, then
disconnect the power cord from the power source.
6. Locate the finisher on a sturdy flat surface where it will not be exposed to excessive vibration.
7. To avoid fire hazard, confirm that the ventilation ports are not blocked, so air can flow freely.
8. Gas generated by the molten glue can irritate the eyes, throat, and nose. The finisher should always
be used in a well ventilated room.
9. To avoid the dangers of fire and electrical shock, make sure that the finisher is never exposed to:
• Excessive high temperatures and/or humidity
• Dust
• Water
• Direct sunlight
• Open flame
• Corrosive gases
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