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.
2

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
3

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.
4

• 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.
5

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.
6

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.
7

• 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
8

Trademarks
• Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft Corporation in the
United States and /or other countries.
• PostScript® is a registered trademark of Adobe Systems, Incorporated.
• PCL® is a registered trademark of Hewlett-Packard Company.
• Ethernet® is a registered trademark of Xerox Corporation.
• PowerPC® is a registered trademark of International Business Finishers Corporation.
• Other product names used herein are for identification purposes only and may be trademarks of their
respective companies. We disclaim any and all rights involved with those marks.
9

Field Service Manual Revision History
Field Service Manual Version 2
Perfect Binder Machine Code: D391 Field Service Manual Version 2 Revision History
Section Description
1Replacement and Adjustment > Common
Procedures > Trimming Unit > Step 6
Replaced with correct photo; photo of the
Signature Transport unit was falsely inserted
instead of the Trimmer unit.
2
Replacement and Adjustment > Common
Procedures > Signature Thickness Sensor
(S50) Recalibration > Steps 10 & 13
LED indication corrected
3
Replacement and Adjustment > Perfect Binder
Boards > When installing a new EEPROM in
Master Control Board
New section added describing the required
adjustments when replacing the EEPROM
4Replacement and Adjustment > Inserter >
Inserter Control Board
New section added describing the required
adjustments when replacing the Inserter
Control Board (Jam 255)
5Troubleshooting > Jams > Low Performance
Mode > Cancelling Low Performance Mode
Deleted the procedures described in this
section; refer to "Common Procedures > Setting
and Releasing Low Performance Mode".
6Troubleshooting > Service Board Basics >
Service Board LEDs Entire section revised
7Troubleshooting > Service Mode > Critical
Adjustments Introduction of the section revised
8
Troubleshooting > Service Mode > Critical
Adjustments > Adjustment 1: Cover Horizontal
Registration Position Adjustment
Correction of the paper sizes; Small size less
than 288mm --> 297mm or less, Large size
288mm --> 298mm or more
9
Troubleshooting > Service Mode > Critical
Adjustments > Adjustment 1: Cover Horizontal
Registration Position Adjustment
LED indication corrected; "The LEDs remain
OFF for 2 sec…" --> "The LEDs remain ON for
2 sec…" in the section "How Values of the
Settings Are Displayed"
10

Section Description
10
Troubleshooting > Service Mode > Critical
Adjustments > Adjustment 5: Glue Amount
Adjustment
Revised description of the glue amount
adjustment process
11
Troubleshooting > Service Mode > Critical
Adjustments > Adjustment 8: Glue Amount
Adjustment
Deleted; the adjustment is required only when
replacing the EEPROM and its procedure is
described in #3 above.
12
Troubleshooting > Output Checks > Perfect
Binder D391 Output Check > Bookbinder Test
Mode
Description added in the last part of the section;
"Cover is fed only from the lower tray" in the
table "SW2 Bank SW6: Cover Feed Source"
13 Details > Trimming Unit > Book Binding >
Trimmings Collection and Disposal
Correction of the figure; indication of 'index 3'
pointing the Trimmings Catcher
11

TABLE OF CONTENTS
Safety, Conventions, Trademarks......................................................................................................................1
Conventions....................................................................................................................................................1
Warnings, Cautions, Notes...........................................................................................................................3
General Safety Instructions............................................................................................................................3
Responsibilities of the Customer Engineer....................................................................................................4
Before Installation, Maintenance..................................................................................................................4
During Maintenance......................................................................................................................................5
After Installation, Servicing............................................................................................................................7
Safety Instructions for this Finisher.................................................................................................................8
Field Service Manual Revision History...........................................................................................................10
Field Service Manual Version 2.................................................................................................................10
1. Installation
Installation Requirements.................................................................................................................................17
Choosing a Location....................................................................................................................................17
Power Supply ..............................................................................................................................................18
What You Need...........................................................................................................................................18
Perfect Binder (D391) Installation..................................................................................................................19
Bookbinder Accessories..............................................................................................................................19
Bookbinder Installation................................................................................................................................19
Inserter-C1 (D391-18) Installation.................................................................................................................60
Inserter Accessories.....................................................................................................................................60
Inserter Installation.......................................................................................................................................61
Transit Pass Unit (D391-19) Installation........................................................................................................71
Relay Unit Accessories................................................................................................................................71
Relay Unit Installation..................................................................................................................................72
Docking, Completing the Installation..............................................................................................................81
Docking the Bookbinder..............................................................................................................................81
Filling Bookbinder Glue Supply Unit..........................................................................................................84
Testing the Breaker Switch..........................................................................................................................87
Final Check...................................................................................................................................................88
Preparing the Bookbinder for Moving............................................................................................................89
Setting the Bookbinder for Moving............................................................................................................89
Same Floor...................................................................................................................................................92
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Another Floor (by Elevator).........................................................................................................................94
Shipping the Bookbinder.............................................................................................................................95
2. Preventive Maintenance
PM Tables.........................................................................................................................................................97
3. Replacement and Adjustment
Basics................................................................................................................................................................99
Parts Dangerous to Touch...........................................................................................................................99
Using the Dials...........................................................................................................................................107
Common Procedures.....................................................................................................................................113
Setting and Releasing Low Performance Mode......................................................................................113
Inserter Unit................................................................................................................................................115
Front Doors ...............................................................................................................................................116
Covers........................................................................................................................................................119
Signature Path Exit Unit.............................................................................................................................122
Cover Transport Unit.................................................................................................................................126
Trimming Unit.............................................................................................................................................128
Opening Locked Doors Manually...........................................................................................................132
Signature Thickness Sensor (S50) Recalibration....................................................................................133
Resetting Counters.....................................................................................................................................137
Cover Skew Adjustment............................................................................................................................141
Path Entrance Motors....................................................................................................................................144
Vertical Transport Motor (M5 (INS)).......................................................................................................144
Entrance Motor (M10).............................................................................................................................145
Signature Path Exit Unit.................................................................................................................................146
Ripple Idle Rollers......................................................................................................................................146
TE Press Roller Unit....................................................................................................................................146
Anti-Static Brush.........................................................................................................................................151
Stacking Tray.................................................................................................................................................152
Switchback Roller......................................................................................................................................152
Anti-Static Brush.........................................................................................................................................153
Jogger Motors (Front/Back) (M4/M5)..................................................................................................155
Main Grip Unit...............................................................................................................................................156
Signature Thickness Sensor (S50)............................................................................................................156
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Grip Motor: Front (M23)..........................................................................................................................161
Grip Motor (Rear) (M24).........................................................................................................................166
Grip Unit Rotation Motor (M21)..............................................................................................................172
Main Grip Lift Motor (M22).....................................................................................................................174
Gluing Unit.....................................................................................................................................................175
Filters...........................................................................................................................................................175
Glue Heater...............................................................................................................................................176
Cover Transport Unit.....................................................................................................................................184
Switchback Rollers: Cover Transport.......................................................................................................184
Torque Limiter.............................................................................................................................................184
Anti-Static Brushes: Upper and Lower Right............................................................................................186
Anti-Static Brush: Left.................................................................................................................................188
Exit Rollers 1/2 Unit..................................................................................................................................189
Trimming Unit.................................................................................................................................................191
Torque Diode: Signature Rotation Unit....................................................................................................191
Blade Cradle.............................................................................................................................................195
Trimming Blade, Trimmings Catcher........................................................................................................200
Ball Screw..................................................................................................................................................210
Trimmings Buffer Motor (M37)................................................................................................................215
Horizontal Path Rollers..................................................................................................................................217
Exit Idle Roller Unit....................................................................................................................................217
Exit Roller, Horizontal Transport Roller 5................................................................................................218
Horizontal Transport Roller 4...................................................................................................................221
Left Cover Transport Path Guide Roller...................................................................................................223
Horizontal Transport Roller 1 and Idle Rollers........................................................................................224
Horizontal Transport Roller 2...................................................................................................................225
Horizontal Transport Roller 3...................................................................................................................228
Perfect Binder Boards....................................................................................................................................235
Master Control Board...............................................................................................................................236
When installing a new EEPROM in Master Control Board...................................................................236
Slave Control Board..................................................................................................................................258
Cutter Control Board.................................................................................................................................258
Relay Board...............................................................................................................................................259
14

Power Supply Unit 1.................................................................................................................................259
Power Supply Unit 2.................................................................................................................................261
Inserter............................................................................................................................................................263
Common Procedures.................................................................................................................................263
Feed Rollers...............................................................................................................................................265
Separation Rollers.....................................................................................................................................267
Pickup Rollers.............................................................................................................................................270
Inserter Control Board...............................................................................................................................273
4. Troubleshooting
Service Call Tables........................................................................................................................................275
Jams................................................................................................................................................................276
Handling Paper Jams................................................................................................................................276
When an Error Occurs..............................................................................................................................276
Low Performance Mode...........................................................................................................................283
Service Board Basics.....................................................................................................................................284
Service Board Switches............................................................................................................................284
Service Board LEDs...................................................................................................................................285
Service Mode.................................................................................................................................................311
Before You Begin.......................................................................................................................................311
Critical Adjustments...................................................................................................................................314
Other Adjustments.....................................................................................................................................340
Maintenance Mode..................................................................................................................................344
Output Checks...............................................................................................................................................348
Perfect Binder D391 Output Check.........................................................................................................348
Inserter D391 Output Check....................................................................................................................354
5. Service Tables
Service Program Mode.................................................................................................................................365
6. Details
Basics..............................................................................................................................................................367
Overview....................................................................................................................................................367
General Board Layout..............................................................................................................................368
Basic Operation........................................................................................................................................369
Exit Paths....................................................................................................................................................371
15

Downstream Delivery................................................................................................................................374
Blank Paper Handling...............................................................................................................................375
Automatic Exit............................................................................................................................................375
Book Binding..................................................................................................................................................377
Overview....................................................................................................................................................377
Cover Transport: Vertical Path..................................................................................................................379
Paper/Signature Transport......................................................................................................................380
Cover Transport and Registration............................................................................................................398
Gluing.........................................................................................................................................................404
Trimming Unit.............................................................................................................................................417
Jam Detection.................................................................................................................................................437
Overview....................................................................................................................................................437
Jams............................................................................................................................................................438
Power Supply.................................................................................................................................................443
Overview....................................................................................................................................................443
Electrical Circuit Protection Features........................................................................................................444
Energy Save Mode...................................................................................................................................444
Inserter-C1 (D391)........................................................................................................................................446
Overview....................................................................................................................................................446
Basic Electrical Layout...............................................................................................................................446
Basic Operation........................................................................................................................................447
Motors and Sensors..................................................................................................................................448
Paper Feed and Transport........................................................................................................................449
Paper Detection.........................................................................................................................................453
Motor, Sensor Locations...............................................................................................................................456
Inserter........................................................................................................................................................456
Bookbinder................................................................................................................................................460
7. Specifications
Specifications.................................................................................................................................................487
16

1. Installation
Installation Requirements
Choosing a Location
Required Space
Place the bookbinder near the power source, with at least the minimum amount of clearance around it, as
shown below:
These are minimum space requirements. More space is recommended for easier maintenance.
A At least 900 mm (36 in.) Allows proper cooling
B At least 1407 mm (56 in.) Allows opening and closing of drawers
17
1

Power Supply
Input voltage level
NA: 208V 60 Hz
EU: 220-240V 50/60 Hz
Permitted voltage Fluctuation: +10, -15 %
• The bookbinder must have an independent power source. Avoid multi-wiring.
•The bookbinder must be properly grounded at the power source.
What You Need
Here are some points to check before installation:
•The bookbinder is extremely heavy: 316 kg (695 lb.)
• At least four persons are needed to unload the bookbinder safely from its pallet.
• After removing the packing straps and cardboard cover, you will need a manual forklift to position
the pallet so there is approximately 2 meters (6.5 ft.) of free space to the right side of the bookbinder
when the ramps are pulled out as shown below.
• Once the bookbinder has been removed from the pallet, it can be pushed on its casters by two service
technicians.
1. Installation
18
1