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Ricoh SR4080 Field Service Manual

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Finisher SR4080
Machine Code: D610
Field Service Manual
May, 2016

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Summary of Contents for Ricoh SR4080

  • Page 1 Finisher SR4080 Machine Code: D610 Field Service Manual May, 2016...

  • Page 3: Safety, Conventions, Trademarks

    Safety, Conventions, Trademarks Conventions Common Terms This is a list of symbols and abbreviations used in this manual. Symbol, Abbreviation Meaning Blue screw Bushing C-ring Connector E-ring Flexible film cable Harness clamp Hook Screw Spring Timing belt Junction Gate Long Edge Feed Short Edge Feed Trailing Edge of paper...

  • Page 4: Warnings, Cautions, Notes

    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.

  • Page 5: Responsibilities Of The Customer Engineer

    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). •...

  • Page 6: Installation, Disassembly, And Adjustments

    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.

  • Page 7: Organic Cleaners

    • 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.

  • Page 8: After Installation, Servicing

    • 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. •...

  • Page 9: Safety Instructions For This Machine

    • 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. •...
  • Page 10 • 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.

  • Page 11: Table Of Contents

    TABLE OF CONTENTS Safety, Conventions, Trademarks........................1 Conventions..............................1 Common Terms............................1 Warnings, Cautions, Notes...........................2 General Safety Instructions..........................2 Responsibilities of the Customer Engineer....................3 Reference Material for Maintenance....................3 Before Installation, Maintenance........................3 Power..............................3 Installation, Disassembly, and Adjustments..................4 Special Tools............................4 During Maintenance............................4 General..............................
  • Page 12 Stack Feed-out Belt............................21 Jogger Fence ...............................21 Sensors ................................23 Stack Height 1 Sensors, Exit Guide Open Sensor..................23 Upper Tray Paper Limit and Exit Sensor.....................24 Shift Tray Exit Sensor........................... 24 Entrance and Stapler Tray Entrance Sensors.....................25 Pre-Stack Paper Sensor..........................27 Motors................................30 Shift Tray Motor............................
  • Page 13 Stapler..............................43 Mechanical Layout............................45 Electrical Component Description......................46 Drive Layout..............................50 Main Mechanisms............................52 Tray and Stapler Junction Gate........................52 Paper Pre-Stacking............................53 Jogger Unit Paper Positioning........................54 Stapling................................56 Stapler Unit Movement..........................56 Stapler................................58 Feed Out...............................62 Stapling Z-Folded Paper..........................63 Stack Output..............................64 Paper Exit and Stacking..........................

  • Page 15: Replacement And Adjustment

    1. Replacement and Adjustment Door, Covers, Trays Front Door, Left Inner Cover, Inner Cover 1. Remove the front door screw [A]. 2. Remove the front door [B]. 3. Remove the front door. 4. Remove the left inner cover [C]. 5. Remove the inner cover [A].

  • Page 16: Side Table And Upper Tray

    1. Replacement and Adjustment Side Table and Upper Tray 1. Remove the side table [A]. Slide to the right to remove it. 2. Click the release lever [B] and remove the upper tray [C].

  • Page 17: Left Covers, Rear Cover, Top Cover

    Door, Covers, Trays Left Covers, Rear Cover, Top Cover 1. Remove the left upper panel [A]. 2. Remove the left upper cover [B]. 3. Remove the door and left inner cover. page 13 4. Remove the rear cover [F]. 5. Remove the left lower cover [C]. 6.
  • Page 18 1. Replacement and Adjustment...

  • Page 19: Rollers

    Rollers Rollers Shift Positioning Roller 1. Above the shift tray, pull the roller mount [A] out. 2. Remove the rollers [B] and [C]. Positioning Roller 1. Open the front door. 2. Remove the snap ring [A]. 3. Release the rubber belt [B]. 4.

  • Page 20: Alignment Brush Roller

    1. Replacement and Adjustment Alignment Brush Roller 1. Open the front door and pull out the staple unit. 2. Remove the rear cover. 3. Remove the main board and all connectors. 4. Remove the screw [A] and tension spring [B] for the tension bracket [C], and release the tension of the timing belt.
  • Page 21 Rollers 6. Remove the inner cover [A]. 7. Open the guide [B], then remove the alignment brush roller assembly [C]. 8. Remove the alignment brush roller [D].
  • Page 22 1. Replacement and Adjustment...

  • Page 23: Stack Feed-Out Belt, Jogger Fence

    Stack Feed-out Belt, Jogger Fence Stack Feed-out Belt, Jogger Fence Stack Feed-out Belt 1. Open the front door. 2. Pull out the jogger and stapler unit. 3. Remove the inner cover [A]. 4. Remove the sensor bracket [B]. 5. Remove the front guide [C]. 6.
  • Page 24 1. Replacement and Adjustment...

  • Page 25: Sensors

    Sensors Sensors Stack Height 1 Sensors, Exit Guide Open Sensor Stack Height Sensors 1 and 2 1. Remove the top cover. 2. Remove the left upper panel and left upper cover. 3. Remove the protector plate [A]. 4. Remove the sensor feeler [B]. 5.

  • Page 26: Upper Tray Paper Limit And Exit Sensor

    1. Replacement and Adjustment Upper Tray Paper Limit and Exit Sensor Upper Tray Paper Limit Sensor 1. Remove the top cover. 2. Remove the sensor cover [A]. 3. Remove the sensor bracket [B]. 4. Replace the upper tray paper limit sensor [C]. Upper Tray Exit Sensor 1.

  • Page 27: Entrance And Stapler Tray Entrance Sensors

    Sensors 7. Remove the guide stay [A]. 8. Replace the shift tray exit sensor [B]. Entrance and Stapler Tray Entrance Sensors Entrance Sensor...
  • Page 28 1. Replacement and Adjustment 1. Disconnect the finisher from the copier. 2. Remove the sensor bracket [A]. 3. Replace the entrance sensor [B]. Stapler Tray Entrance Sensor 1. Open the front door. 2. Remove the sensor bracket [A]. 3. Replace the stapler tray entrance sensor [B].

  • Page 29: Pre-Stack Paper Sensor

    Sensors Pre-Stack Paper Sensor 1. Remove the rear cover. 2. Remove the main board [A]. 3. Release the guide [A].
  • Page 30 1. Replacement and Adjustment 4. Open the front door. 5. Remove the left vertical transport guide [A]. 6. Remove the middle vertical transport guide [B]. 7. Replace the pre-stack paper sensor [C].
  • Page 31 Sensors...

  • Page 32: Motors

    1. Replacement and Adjustment Motors Shift Tray Motor 1. Remove the front door and rear cover. page 13 2. Remove shift motor [A]. Stacking Roller, Roller Drag Motors, Return HP Sensor 1. Do the procedures to remove the front door and all covers, with the exception of the left lower cover and top cover (labeled [C] and [E]).
  • Page 33 Motors 7. Remove the end fence [A] and plate [A]. 8. Disengage the end fence races [B] from the rollers [C] behind the fence. 9. Remove the upper stay [E]. 10. Remove the lower stay [F].
  • Page 34 1. Replacement and Adjustment 11. Remove the cover [A]. 12. Remove the stacking roller/drag motor stay [B]. 13. Make sure the motor and sensor connectors are disconnected before removing. 14. Remove the stacking motor bracket [A]. 15. Remove the stacking motor [B]. 16.
  • Page 35 Motors...

  • Page 36: Z-Fold Jogger Unit

    1. Replacement and Adjustment Z-Fold Jogger Unit Z-Fold Jogger Unit Cover 1. Open the front door. 2. Pull out the stapler tray unit [A]. 3. Remove the Z-fold jogger unit cover [B]. Z-Fold Jogger Unit 1. Open the front door and pull out the stapler tray unit. 2.

  • Page 37: Top Fence Motor

    Z-Fold Jogger Unit Top Fence Motor 1. Open the front door and pull out the stapler tray unit. 2. Remove the Z-fold jogger unit cover. 3. Remove the motor bracket [A]. 4. Remove the jogger top fence motor [B]. Bottom Fence Motor 1.
  • Page 38 1. Replacement and Adjustment 2. Remove the jogger bottom fence motor [A].

  • Page 39: Stapler

    Stapler Stapler Stapler Removal 1. Open the front door and pull out the staple tray. 2. Remove the stapler unit harness cover [A]. 3. Remove the stapler cover [B]. 4. Lift the stapler off of the pegs [C]. Staple Waste Hopper Sensor 1.

  • Page 40: Stapler Rotation Hp Sensor, Stapler Return Sensor

    1. Replacement and Adjustment Stapler Rotation HP Sensor, Stapler Return Sensor 1. Remove the stapler unit. (See above.) 2. Remove the stapler mount bracket [A]. 3. Replace the stapler rotation HP sensor [B]. 4. Replace the stapler return sensor [C].

  • Page 41: Punch Unit B531 (Option)

    Punch Unit B531 (Option) Punch Unit B531 (Option) Punch Position Adjustment The position of the punched holes can be adjusted in two ways. Front to Rear Adjustment Three spacers [A] are provided with the punch unit for manual adjustment of the hole position in the main scan direction: •...

  • Page 42: Output Jogger Unit B513 (Option)

    1. Replacement and Adjustment Output Jogger Unit B513 (Option) Jogger Unit 1. Remove the jogger unit cover [A]. 2. Remove the jogger unit [A]. Jogger Unit PCB 1. Remove the jogger unit from the finisher. (See above.) 2. Remove the jogger unit control PCB [A].

  • Page 43: Shift Jogger Motor, Fence Lift Motor

    Output Jogger Unit B513 (Option) DIP Switches DPS100 Description Default Free run: A4 LEF, staple mode Free run: staple and tray shift • Do not use any other settings. Shift Jogger Motor, Fence Lift Motor 1. Remove the jogger unit from the finisher. (See above.) 2.
  • Page 44 1. Replacement and Adjustment...

  • Page 45: Detailed Descriptions

    2. Detailed Descriptions Overview Specifications Upper Tray Paper Capacity (80 g/m 500 sheets (A4, 8.5" x 11" and smaller) 250 sheets (B4, 8.5" x 14" and larger) Paper Size A3 to A6 SEF, 11" x 17" to 5.5" x 8.5", 12" x 18" Paper Weight 52 to 216 g/m (14 to 58 lb)
  • Page 46 2. Detailed Descriptions Stapling Paper Size A3 to B5 11" x 17" to 8.5" x 11" Stapling Paper Weight 64 to 80 g/m (17 to 20 lb) Staple Position 4 Modes • 1 Staple: Front, Rear, Rear-Oblique • 2 Stapes: 2 locations Staple Capacity 5000 staples/cartridge Staple Supply...

  • Page 47: Mechanical Layout

    Overview Mechanical Layout Part Part Upper Tray Staple Waste Hopper Middle Transport Rollers Stapler Upper Tray Exit Roller Alignment Brush Roller Upper Transport Rollers Positioning Roller Tray Junction Gate Stack Feed-out Belt Stapler Junction Gate Shift Tray Drive Belt...

  • Page 48: Electrical Component Description

    2. Detailed Descriptions Part Part Entrance Rollers Lower Transport Rollers Punch Unit Shift Tray Pre-stack Junction Gate Shift Tray Exit Roller Punch Waste Hopper Jogger Top Fence Pre-stack Tray Jogger Bottom Fence Stack Plate Electrical Component Description The following table lists all electrical components and briefly describes their function. Symbol Name Function...
  • Page 49 Overview Stack Plate – Rear Presses down the rear corner of the edge for stapling. Stapler Rotation Rotates the stapler 45 degrees for oblique stapling. Staple Hammer Drives the staple hammer. Drives the punch shaft and roller. Punch Unit B531 Punch (option).
  • Page 50 2. Detailed Descriptions Symbol Name Function Exit Guide Open Detects whether the guide plate is opened or not. Detects the shift tray home position for standby mode Staple Mode HP 1 and for staple mode. Detects the shift tray home position for standby mode Staple Mode HP 2 and for staple mode.
  • Page 51 Overview Symbol Name Function Stapler Return Detects the on timing of the stapler return solenoid. Staple Waste Hopper Detects when the staple waste hopper is full. Detects when the punch waste hopper is full and detects Punch Waste Hopper when the punch tray is set. Punch Unit B531 (option). Detects the cam home position for the 2-hole punch.

  • Page 52: Drive Layout

    2. Detailed Descriptions Symbol Name Function Switches the current job off and on to allow time for the Emergency Stop operator to remove paper from the shift tray. Drive Layout Part Part Upper Transport Roller 2 Lower Transport Roller 1 Upper Tray Exit Roller Transport Roller 1 Lower Transport Roller 2...
  • Page 53 Overview Part Part Shift Tray Exit Motor Upper Transport Roller 1 Shift Tray Exit Roller Upper Transport Motor Shift Tray Stack Feed-out Motor Shift Motor Jogger Motor Staple Tray Exit Roller Jogger Fence Positioning Roller Stack Plate Motor Lower Transport Roller 3 Stapler Motor Lower Transport Motor Stack Feed-out Belt...

  • Page 54: Main Mechanisms

    2. Detailed Descriptions Main Mechanisms Tray and Stapler Junction Gate Depending on the finishing mode, the copies are directed up, straight through, or down by the combinations of open and closed junction gates.

  • Page 55: Paper Pre-Stacking

    Main Mechanisms Selected Operation Mode Solenoid/Gate Upper Tray Sort/Stack Staple Stapler junction gate solenoid Stapler junction gate Closed Closed OPEN Tray junction gate solenoid Tray junction gate OPEN Closed Closed Paper Pre-Stacking • This mechanism improves productivity in staple mode. It is only used when copying on A4, LT, or B5 (all LEF).

  • Page 56: Jogger Unit Paper Positioning

    2. Detailed Descriptions • The pre-stack paper stopper is released about 40 mm after the 2nd sheet turns on the pre-stack stopper sensor [F], and the two sheets of copy paper are sent to the stapler tray. All sheets after the 2nd sheet go to the stapler tray via the paper guide [E].
  • Page 57 Main Mechanisms...

  • Page 58: Stapling

    2. Detailed Descriptions Stapling Stapler Unit Movement Side-to-Side • The stapler motor [A] moves the stapler [B] from side to side. After the start key is pressed, the stapler moves from its home position to the stapling position. • If two-staple-position mode is selected, for the first stack the stapler moves to the rear stapling position first, staples, moves to the front position, staples and waits at the front.
  • Page 59 Stapling Rotation (2) When the staple end condition arises, the stapler motor moves the stapler to the front and the stapler rotation motor rotates the stapler unit to clockwise to remove the staple cartridge [A]. This allows the user to add new staples. Once the staples have been installed, and the front door closed, the stapler unit returns to its home position.

  • Page 60: Stapler

    2. Detailed Descriptions Stapler When the aligned copies are brought to the stapling position by the positioning roller and jogger fences, the staple hammer motor [A] starts stapling. During stapling, the stapler trims off the excess length [B] of the staples by lowering the cutter [C].
  • Page 61 Stapling This excess length depends on the number of copies in the set; there will be very little for a stack containing 100 sheets. The staple waste drops into the tray [A] in the stapler. When the stapler unit returns to its home position, the tray hits the shaft [B] and the tray opens.
  • Page 62 2. Detailed Descriptions The stapler has a staple end sensor [A], cartridge set sensor [B] and staple hammer HP sensor [C].
  • Page 63 Stapling When a staple end or no cartridge condition is detected, a message is displayed advising the operator to install a staple cartridge. If this condition is detected during a copy job, the indication will appear, and the copy job will stop. The staple cartridge has a clinch area [A] where jammed staples collect.

  • Page 64: Feed Out

    2. Detailed Descriptions Feed Out • After the copies have been stapled, the stack feed-out motor [A] starts. • The pawl [B] on the stack feed-out belt [C] transports the set of stapled copies up and feeds it to the shift tray exit roller [D].

  • Page 65: Stapling Z-Folded Paper

    Stapling Stapling Z-Folded Paper *c6020 Here is the operation sequence for jogging and stapling Z-folded sheets: The lower jogger fence lifts to receive the Z-folded sheets. The top fence moves down, to the horizontal position. A sheet of paper goes into the stapler tray. The positioning roller turns when each sheet is fed to the stapler tray.

  • Page 66: Stack Output

    2. Detailed Descriptions Stack Output Paper Exit and Stacking • The stacking roller assembly [A] is fastened to a plate [B] on a shaft by a spring [C]. The cam [D], in contact with the bottom of the plate, is connected to the stacking roller drag motor [E] via a timing belt.

  • Page 67: Shift Tray

    Stack Output Shift Tray Overview • The shift tray lift motor [A] controls the vertical position of the shift tray [B] through gears and timing belts [C]. • After the main switch is turned on, or when the stack is removed from the tray, the end of the feeler on the tray falls and its actuator [D] rotates up into staple mode HP sensor 2 [E] (S7) and switches it •...
  • Page 68 2. Detailed Descriptions • The shift tray moves to home position, which is when the actuator [F] has just exited the shift mode home position sensor [G] (S12). • During feed-out, the tray is lowered automatically at prescribed intervals; sensor [D] (S7) is ignored.

  • Page 69: Shift Tray Lower Limit Detection

    Stack Output Shift Tray Lower Limit Detection • This machine has two shift tray lower limit sensors: shift lower limit sensor [A] (S9) for large paper (B4 and larger) and shift lower limit sensor [B] (S11) for small paper (smaller than B4). (Sensor [C] (S10) is not used.) •...

  • Page 70: Jam Conditions

    2. Detailed Descriptions • The next set of copies is then delivered. The motor turns on, repeating the same process and moving the tray back to the previous position. Jam Conditions 1. The entrance sensor does not turn on when the copier has fed paper 426 mm after the copier exit sensor turned off.

  • Page 71: Punch Unit B531 (Option)

    Punch Unit B531 (Option) Punch Unit B531 (Option) Punch Unit Drive The punch unit makes 2 or 3 holes at the trailing edge of the paper. The number of holes depends on a selection made on the operation panel. • The cam [A] has 2 punches on one side and 3 punches on the other, and is turned by the punch motor [B].

  • Page 72: Punch Waste Collection

    2. Detailed Descriptions Punch Waste Collection Punch waste is collected in the punch waste hopper [A] positioned under the punch unit. • When the level of the punch waste in the hopper rises as far as the hole [B] in the hopper, the punch waste sensor [C] turns on, stops the job, and triggers a messageto indicate that the hopper is full and must be removed and emptied.

  • Page 73: Output Jogger Unit B513 (Option)

    Output Jogger Unit B513 (Option) Output Jogger Unit B513 (Option) Jogger Unit Mechanical Layout Part Shift Jogger Fence Lift Motor Shift Jogger Motor Timing Belt Shift Jogger Motor Shift Jogger Fence Timing Belt Shift Jogger Fences Shift Jogger HP Sensor Shift Jogger Lift HP Sensor Jogger Unit Drive •...
  • Page 74 2. Detailed Descriptions • At the end of the job, the jogger fence lift motor [F] switches on and raises the fences until the actuator [G] leaves the slot of the shift jogger fence lift HP sensor [H] and shuts off the shift jogger fence lift motor.

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