Ricoh FD5000 User manual

Multi Folding Unit FD5000
Machine Code: D454-17
January 2009

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.
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 machine.
• This information provides tips and advice about how to best service the machine.
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.
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Safety During Operation
In this manual, the following important symbols and notations are used.
Switches and Symbols
Where symbols are used on or near switches on machines 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
machine 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 machine.
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Before Installation, Maintenance
Power
• Always disconnect the power plug before doing any maintenance procedure. After switching off the
machine, power is still supplied to the main machine and other devices. To prevent electrical shock,
switch the machine off, wait for a few seconds, then unplug the machine from the power source.
• Before you do any checks or adjustments after turning the machine off, work carefully to avoid injury.
After removing covers or opening the machine to do checks or adjustments, never touch electrical
components or moving parts (gears, timing belts, etc.).
• After turning the machine 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 machine 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 machine. 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 machine is operating.
Special Tools
• Use only standard tools approved for machine 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 machine or cause
injuries.
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During Maintenance
General
• Before you begin a maintenance procedure: 1) Switch the machine off, 2) Disconnect the power plug
from the power source, 3) Allow the machine to cool for at least 10 minutes.
• Avoid touching the components inside the machine that are labeled as hot surfaces.
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 machine 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 machine. Using
replacement devices not designed for use with the machine 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 machine 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).
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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 machines that use ozone filters if they are not
replaced at the prescribed time. Excessive ozone could cause personnel working around the machine
to feel unwell.
Power Plug and Power Cord
• Before servicing the machine (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 machine 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.
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• 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 machine. Emphasize the following
points.
• 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 machine 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 machine.
• 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 machine. They should never allow
paper clips, staples, or any other small metallic objects to fall into the machine.
Safety Instructions for this Machine
1. The installation must be done by trained service technicians.
2. This machine weighs 316 kg. (695 lb.). At least four persons are required to remove the machine
from its pallet and position it for installation.
3. To prevent fire hazards never use flammable solvents around the machine.
4. Never place any object on the machine.
5. If anything falls into the machine, turn off the main power switch on the right side of the machine, then
disconnect the power cord from the power source.
6. Locate the machine 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 machine should always
be used in a well ventilated room.
9. To avoid the dangers of fire and electrical shock, make sure that the machine is never exposed to:
• Excessive high temperatures and/or humidity
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• Dust
• Water
• Direct sunlight
• Open flame
• Corrosive gases
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 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.
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TABLE OF CONTENTS
Safety, Conventions, Trademarks......................................................................................................................1
Conventions....................................................................................................................................................1
Warnings, Cautions, Notes...........................................................................................................................2
General Safety Instructions............................................................................................................................2
Responsibilities of the Customer Engineer....................................................................................................3
Before Installation, Maintenance..................................................................................................................4
During Maintenance......................................................................................................................................5
After Installation, Servicing............................................................................................................................6
Safety Instructions for this Machine...............................................................................................................7
1. Replacement and Adjustment
Exterior and Inner Covers................................................................................................................................13
Front Door Upper Cover.............................................................................................................................13
Top Cover.....................................................................................................................................................14
Inner Upper Cover.......................................................................................................................................15
Front Door.....................................................................................................................................................15
Folding Unit Cover.......................................................................................................................................16
Inner Lower Cover.......................................................................................................................................16
Rear Upper Cover.......................................................................................................................................17
Rear Lower Cover .......................................................................................................................................17
Top Rear Cover............................................................................................................................................18
Top Tray........................................................................................................................................................18
Top Tray Right Cover...................................................................................................................................19
Pulling Out the Folding Unit Drawer...........................................................................................................20
Electrical Components: Rear Side...................................................................................................................21
Main Board..................................................................................................................................................21
Horizontal Transport Motor........................................................................................................................21
Top Tray Exit Motor.....................................................................................................................................22
Top Tray Transport Motor...........................................................................................................................23
Entrance JG (Junction Gate) Motor............................................................................................................25
Dynamic Roller Lift Motor............................................................................................................................25
Crease Motor...............................................................................................................................................26
Dynamic Roller Transport Motor................................................................................................................27
Registration Roller Release Motor..............................................................................................................28
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Registration Roller Transport Motor............................................................................................................29
Electrical Components: 1st Stopper................................................................................................................31
Fold Plate Motor..........................................................................................................................................31
Direct-Send JG Motor.................................................................................................................................31
1st Fold Motor..............................................................................................................................................33
FM6 Pawl Motor..........................................................................................................................................33
2nd Fold Motor............................................................................................................................................34
Jogger Fence Motor....................................................................................................................................35
1st Stopper Unit...........................................................................................................................................36
Positioning Roller Motor..............................................................................................................................39
1st Stopper Motor........................................................................................................................................40
Jogger Fence HP Sensor.............................................................................................................................40
Positioning Roller HP Sensor.......................................................................................................................42
1st Stopper Paper Sensor............................................................................................................................42
1st Stopper HP Sensor.................................................................................................................................43
Registration Sensor......................................................................................................................................44
Electrical Components: 2nd Stopper..............................................................................................................46
2nd Stopper Unit..........................................................................................................................................46
2nd Stopper Motor......................................................................................................................................48
2nd Stopper HP Sensor...............................................................................................................................49
2nd Stopper Paper Sensor..........................................................................................................................50
Bypass Exit Paper Sensor............................................................................................................................51
Electrical Components: 3rd Stopper ..............................................................................................................53
3rd Stopper Unit..........................................................................................................................................53
3rd Stopper Motor......................................................................................................................................54
3rd Stopper Paper Sensor..........................................................................................................................55
3rd Stopper HP Sensor................................................................................................................................56
Direct-Send JG (Junction Gate) HP Sensor................................................................................................57
Registration Roller HP Sensor......................................................................................................................58
Fold Plate HP Sensor...................................................................................................................................59
Entrance JG (Junction Gate) HP Sensor.....................................................................................................60
Top Tray Exit Sensor....................................................................................................................................60
Entrance Sensor...........................................................................................................................................62
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Top Tray Exit Sensor....................................................................................................................................62
Electrical Components: Main 1.......................................................................................................................64
Top Tray Full Sensor (E)...............................................................................................................................64
Top Tray Full Sensor (R)...............................................................................................................................65
Vertical Path Paper Sensor..........................................................................................................................65
Horizontal Path Paper Sensor.....................................................................................................................66
Horizontal Path Exit Sensor.........................................................................................................................67
Discharge Brush 1........................................................................................................................................68
Discharge Brush 2........................................................................................................................................69
Discharge Brush 3........................................................................................................................................70
PSU................................................................................................................................................................70
First Fold Unit................................................................................................................................................71
Dynamic Roller HP Sensor..........................................................................................................................74
Electrical Components: Main 2.......................................................................................................................76
Bypass Entrance Paper Sensor...................................................................................................................76
First/ Second/ Third Fold Roller................................................................................................................78
Fourth / Fifth Fold Roller.............................................................................................................................81
Crease Rollers..............................................................................................................................................86
Fold Adjustments..............................................................................................................................................91
Fine Fold Adjustment....................................................................................................................................91
Skew Adjustment............................................................................................................................................105
Manual Adjustments by Service Technician............................................................................................105
2. Details
Overview........................................................................................................................................................117
Motors, Rollers...........................................................................................................................................117
Junction Gates, Junction Gate Solenoids................................................................................................118
Stoppers, Stopper Motors........................................................................................................................119
Paper Path......................................................................................................................................................120
Paper Registration.....................................................................................................................................120
Pre-Stacking...............................................................................................................................................121
Junction Gates...........................................................................................................................................127
Paper Folding.................................................................................................................................................134
Flex-Nip Folding........................................................................................................................................134
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Stopper Locations......................................................................................................................................135
Folding Methods.......................................................................................................................................135
Crease Rollers............................................................................................................................................144
Tray Full..........................................................................................................................................................145
Electrical Components...................................................................................................................................146
Transport Sensors......................................................................................................................................146
Operation Sensors....................................................................................................................................147
Motors, Solenoids.....................................................................................................................................148
Paper Transport Motors............................................................................................................................149
Fold Motors................................................................................................................................................150
Motors, Solenoids Around the Top Tray.................................................................................................151
Motors, Sensors Top.................................................................................................................................152
Motors, Sensors Bottom............................................................................................................................153
Sensors Around Top Tray.........................................................................................................................154
Fold Motors, Sensors, Solenoids.............................................................................................................155
Boards, Switches, Fan...............................................................................................................................157
Component List..........................................................................................................................................157
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1. Replacement and Adjustment
Exterior and Inner Covers
Front Door Upper Cover
1. Open the front door [A].
2. Hinge cover [A] ( x 1)
13
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3. Cross-piece [A] ( x 2)
4. Front door upper cover [A] ( x 2)
Top Cover
1. Open the front door.
2. Hinge cover (* p.13 "Front Door Upper Cover")
3. Cross-piece (* p.13 "Front Door Upper Cover")
1. Replacement and Adjustment
14
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4. Top cover [A] ( x 2)
Inner Upper Cover
1. Top cover (* p.14)
2. Remove the knobs [A] ( x 1 each).
3. Inner upper cover [B] ( x 2)
•Release the hooks [C] to remove the inner upper cover.
Front Door
1. Top cover (* p.14)
2. Inner upper cover (* p.15)
Exterior and Inner Covers
15
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3. Remove the screw [A].
4. Loosen three screws [B].
5. Lift up the hinge bracket [C].
6. Front door [D]
Folding Unit Cover
1. Open the front cover.
2. Remove the knob [A] ( x 1).
3. Remove four knobs [B] ( x 1 each).
4. Folding unit cover [C] ( x 3, hook x 2)
Inner Lower Cover
1. Open the front cover.
1. Replacement and Adjustment
16
1

2. Inner lower cover [A] ( x 1, hook)
Rear Upper Cover
1. Rear upper cover [A] ( x 4)
Rear Lower Cover
1. Rear upper cover (* p.17)
Exterior and Inner Covers
17
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2. Rear lower cover [A] ( x 3)
Top Rear Cover
1. Rear upper cover (* p.17)
2. Top rear cover [A] ( x 4)
Top Tray
1. Top rear cover (* p.18)
2. Inner upper cover (* p.15)
1. Replacement and Adjustment
18
1