Ricoh RB5020 User manual

Ring Binder RB5020
Machine Code: D737
SERVICE MANUAL
V1 1
May 2015

Revision History
This is the Revision History for the Ring Binder RB5020 service manual.
Version Date Changes
Ver. 1.1 31 Mar 2015
Text, Illustrations. In procedures the order of the text and
illustrations has been reversed. For each step, the text description
(action) is followed by the relevant illustration. The callouts [A], [B],
[C] in text refer to the illustration below, not above.
Added safety caution:
• Never not touch solder connections or electronic parts on the
PSU after removing it because electrical charge can remain
on the PSU even after it has been removed.
• After removing the PSU, never place put it on a conductive
material such as metal.
1

Symbols, Abbreviations and Trademarks
Conventions
Symbol What it means
Binding screw (shoulder hexagonal head)
Binding screw (round flathead)
Black screw (heavy, fusing unit, TCRU)
Bushing
C-ring
Clip
Connector
E-ring
FFC (Flat Film Connector)
FFC (Flat Film Connector)
FFC (Flat Film Connector)
Gear
Harness clamp
Harness clamp: metal: fusing unit
Hook (or tab release: sensors)
Knob screw (black)
Knob screw (sliver)
Pivot screw
Screw: most common: silver
Shoulder screw
2

Symbol What it means
Shoulder screw (black)
Spring
Standoff
Stud screw
Tapping screw (for plastic)
Timing belt
Washer
The notations "SEF" and "LEF" describe the direction of paper feed. The arrows indicate the direction of
paper feed.
In this manual "Main Scan" means "Horizontal" and "Sub Scan" means "Vertical", both relative to the
direction of paper feed.
3

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 machine 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 machine.
• This information provides tips and advice about how to best service the machine.
Safety Label
To avoid injury, keep the fingers of your other hand clear of the cartridge cover when you close
it.
4

To avoid injury, avoid touching the parts at the indicated location.
To avoid injury, never touch the ring binder tray while the ring binder is operating.
To avoid injury, never put your hand into the paper exit when removing bound booklets.
Commonly Used Terms and Abbreviations
Here is a list of commonly used terms and abbreviations that are used throughout the Field Service
Manual and Appendices.
Terms Meaning
(ccw) Counter-clockwise rotation of a drum, roller, gear, etc.
(cw) Clockwise rotation of a drum, roller, gear, etc.
BF Booklet Finisher SR5060 (D734)*1
BW Black and white (monochrome) copying or printing
Bank Paper Bank (1st, 2nd, 3rd Tray of the main machine)
CIT Cover Interposer Tray CI5030 (D738)*1
CIT-PB Cover Interposer Tray for Perfect Binder Type S1 (D736-2)*1
FIN Finisher SR5050 (D735) (corner staple only, no booklets)*1
ITB Image Transfer Belt
JG Junction Gate
LCIT Large Capacity Input Tray.
LCIT RT5080 (D732) or LCIT RT5070 (D733)*1
LD Laser Diode (Laser Unit)
LE Leading Edge
LSDB Laser Synchronization Detection Board (Laser Unit)
MFU Multi Folding Unit FD5020 (D740)*1
PCDU Photoconductor Development Unit
PB Perfect Binder GB5010 (D736)*1
5

Terms Meaning
PFU Paper Feed Unit (Tray 1, Tray 2, Tray 3)
PTB Paper Transport Belt (between PTR and fusing unit)
PTR Paper Transfer Roller
RB Ring Binder RB5020 (D737)
TCRU Trained Customer Replacement Units
TE Trailing Edge
TM/P ID sensor. "ID sensor" is used in this manual. However, you may see "TM/P" in the SP
codes on the operation panel.
TPU Transit Path Unit for Perfect Binder Type S1 (D736)*1
TRM Trimmer Unit 5040 (D520)*1
VTU Vertical Transport Unit
*1Optional peripheral devices.
Trademarks
• Microsoft®, and Windows® 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 Machines 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.
6

TABLE OF CONTENTS
Revision History...................................................................................................................................................1
Symbols, Abbreviations and Trademarks ........................................................................................................2
Conventions.................................................................................................................................................... 2
Warnings, Cautions, Notes...........................................................................................................................4
Safety Label............................................................................................................................................4
Commonly Used Terms and Abbreviations..................................................................................................5
Trademarks..................................................................................................................................................... 6
1. Replacement and Adjustment
Common Procedures........................................................................................................................................11
Before You Begin......................................................................................................................................... 11
Handling the Binder Unit.................................................................................................................... 11
Standoffs on Harnesses...................................................................................................................... 12
Ring Cartridge..............................................................................................................................................13
Rear Cover................................................................................................................................................... 14
Top Cover.....................................................................................................................................................14
Removing the Binder Unit............................................................................................................................17
Binder Unit Covers.......................................................................................................................................19
Clamp Unit Cover............................................................................................................................... 20
Pre-Bind Jogger Left Cover.................................................................................................................20
Pre-Bind Jogger Bottom Cover...........................................................................................................21
Pre-Bind Jogger Front Cover.............................................................................................................. 21
Pre-Bind Jogger Top Cover................................................................................................................ 22
Ring Supply Unit Upper Right Cover................................................................................................. 23
Ring Supply Unit Right Cover.............................................................................................................23
Separating Pre-Bind Jogger from Binder Unit........................................................................................... 24
Clamp Unit....................................................................................................................................................26
Pre-Punch Jog Unit....................................................................................................................................... 28
Punch Unit.....................................................................................................................................................30
SP6504 Adjustment.....................................................................................................................................31
Checking the Position of the Punched Holes.....................................................................................31
Hole Position Adjustment.................................................................................................................... 32
Sensors..............................................................................................................................................................34
Pre-Punch Jogger HP Sensor (S301)......................................................................................................... 34
7

Chad Box Sensor (S308)............................................................................................................................35
Pre-Bind Jogger Sensors..............................................................................................................................35
Side Fence 1 HP Sensor (S601)........................................................................................................35
Paddle Roller HP Sensor (S602)....................................................................................................... 37
Clamp HP Sensor (S603)...................................................................................................................38
Alignment Pin HP Sensor (S604), Alignment Pin Up Sensor (S610)..............................................39
Shutter HP Sensor (S605).................................................................................................................. 42
50-Sheet Detection Sensor (S606)................................................................................................... 43
Stack Thickness Sensor (S607)..........................................................................................................44
Paper LE Detect Sensor (S609)..........................................................................................................46
Stack Tamper HP Sensor (S612).......................................................................................................47
Shutter HP Sensor (S613).................................................................................................................. 49
Runout Roller HP Sensor (S614)........................................................................................................49
Ring Supply Unit Sensors............................................................................................................................ 50
Ring Cartridge Sensor (S801)........................................................................................................... 50
Ring Cartridge Type Sensor (S805)..................................................................................................51
Rings Reversed Sensor (S802).......................................................................................................... 52
50/100 Ring Detection Sensor (S804)........................................................................................... 53
Ring Near-End Sensor (S803)...........................................................................................................54
Clamp Unit Sensors..................................................................................................................................... 55
Binder Unit HP Sensor (S701)........................................................................................................... 55
Bind Timing Sensor (S702)................................................................................................................ 56
Ring Switch HP Sensor (S706)...........................................................................................................57
Ring Switch Timing Sensor (S707).................................................................................................... 58
Output Belt Sensors..................................................................................................................................... 59
Output Belt 1 HP Sensor (S401)........................................................................................................59
Output Belt 2 HP Sensor (S402)........................................................................................................61
Output Belt Unit Entrance Sensor (S404)......................................................................................... 62
Output Belt Rotation HP Sensor (S403)............................................................................................ 64
Stacker Unit Sensors.................................................................................................................................... 67
Obstacle Detection Switch (S506)....................................................................................................67
Book Position Sensor Pair (S507E/S507R)..................................................................................... 69
Stack Height Sensor Pair (S052E/S502R)...................................................................................... 72
8

Stacker Detect Sensor (S504)............................................................................................................76
Tray Detection Sensor (S505)........................................................................................................... 78
Motors...............................................................................................................................................................80
Pre-Punch Jog Unit Motor............................................................................................................................80
Side Jogger Motor (M302)............................................................................................................... 80
Pre-Bind Jogger Motors...............................................................................................................................81
Paddle Roller Motor (M601).............................................................................................................81
Alignment Pin Motor (M602)............................................................................................................ 82
Paddle Roller Lift Motor (M603)....................................................................................................... 83
Side Fence 1 Motor (M604)............................................................................................................. 86
Side Fence 2 Motor (M606)............................................................................................................. 88
Spine Clamp Motor (M605)............................................................................................................. 91
Runout Roller Motor (M609)............................................................................................................. 93
Stack Tamper Motor (M607)............................................................................................................ 94
Shutter Motor (M608)........................................................................................................................95
Runout Press Roller Motor (M610)....................................................................................................97
Fan Motor (M611)............................................................................................................................. 99
Clamp Unit Motors...................................................................................................................................... 99
Clamp Unit Motor (M701)................................................................................................................ 99
50/100 Clamp Adjust Motor (M702).......................................................................................... 101
Boards............................................................................................................................................................ 103
Main Control Board..................................................................................................................................103
Binder Control Board................................................................................................................................103
Removing the Binder Control Board............................................................................................... 103
Doing the SP adjustments.................................................................................................................104
PSU............................................................................................................................................................. 105
9

10

1. Replacement and Adjustment
Common Procedures
Before You Begin
Handling the Binder Unit
Pulling out the Binder Unit
1. Open the front door.
2. Grip handle Mc8 and slowly pull the binder unit out of the finisher until it stops. (There are no wires
attached to the binder unit.)
Pushing in the Binder Unit
1. Check the right side of the binder unit and confirm that all the screws are installed and that the
binder unit is squarely mounted on its two rails.
2. Grip handle Mc8 and slowly push the binder unit into the finisher until it stops.
11

• Always grip handle Mc8 when pulling out or pushing in the binder unit.
• Never touch any other surface of the binder unit when it is moving.
• To avoid injury the fingers, never push on the top of the binder unit to slide it back into the
finisher as shown above.
Standoffs on Harnesses
Some harnesses are locked by plastic bands [1] to plastic standoffs that are attached to the frame.
When releasing a harness, do not remove the band:
• Use a pair of needle-nose pliers to press in the base of the stand off and lift it out of its hole.
• The base of a removed standoff can be quickly re-inserted into its hole.
If you must remove the band:
• Press the end of the band loop.
• Use a sharp tool to press down the lock band below (or above) the looped band to separate the
serrations of the bands and release the loop.
1. Replacement and Adjustment
12

Ring Cartridge
Always remove the ring cartridge before removing the binder unit for servicing.
1. Open the right front door.
2. Lower the release [1].
3. Pull out the ring cartridge [1] and lift it out of the frame.
Common Procedures
13

Rear Cover
1. Remove the rear cover
[1] Left, rear edge( x1).
[2] Rear cover ( x7).
Top Cover
1. Remove the rear cover
[1] Left, rear edge( x1).
[2] Rear cover ( x7).
1. Replacement and Adjustment
14

2. Disconnect the top cover at the rear:
[1] Right rear corner ( x1)
[2] Left rear corner ( x1).
3. Disconnect the top cover at the front right corner [1] ( x1)
Common Procedures
15

4. At the front left corner, remove:
[1] Door plate ( x3)
[2] Left door
[3] Top cover ( x3)
5. Lift off the top cover [1].
1. Replacement and Adjustment
16

Removing the Binder Unit
It is recommended that the binder unit be removed for all servicing and maintenance.
• Some of the binder unit covers can be removed with the binder unit still mounted on the rails.
• However, the binder unit wobbles on the rails and slips easily back into the machine and does not
provide a stable platform for removing sensors or motors.
1. Open the right front door.
2. Pull out the binder until it stops.
3. Remove:
[1] Stopper ( x2)
[2] Binder unit screws ( x6)
4. Lift the binder unit by its handles [1] and [2], pull it straight up and then slightly to the left to
disengage the right side of the unit from the frame and rail.
• The binder unit is heavy and weighs about 22 kg (50 lb.)
Common Procedures
17

5. Hold the binder unit from the rear with a firm grip under the top and bottom of the unit as shown
below.
6. Lay the binder on its right side with its rubber stoppers down.
1. Replacement and Adjustment
18

Binder Unit Covers
Binder Unit Covers
Common Procedures
19