Ricoh SR5060 Field Service Manual
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Ricoh SR5060 Field Service Manual

Booklet finisher, finisher, machine code: d734/d735
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Booklet Finisher SR5060
Finisher SR5050
Machine Code: D734/D735
Field Service Manual
V1.1
May 2015

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Summary of Contents for Ricoh SR5060

  • Page 1 Booklet Finisher SR5060 Finisher SR5050 Machine Code: D734/D735 Field Service Manual V1.1 May 2015...

  • Page 2: Revision History

    Revision History This is the Revision History for the Booklet Finisher SR5050/SR5060 service manual. Version Date Changes Text, Illustrations. In procedures the order of the text and illustrations has been reversed. For each step, the text description Ver. 1.1 31 Mar 2015 (action) is followed by the relevant illustration.

  • Page 3: Symbols, Abbreviations And Trademarks

    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...
  • Page 4 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.

  • Page 5: Warnings, Cautions, Notes

    To avoid injury, keep your hands clear of the hinges when opening and closing the finisher door. To avoid injury, avoid the indicated parts that become hot during operation and locations where you could pinch your hand or fingers. Booklet Finisher SR5060 Front...

  • Page 6: Commonly Used Terms And Abbreviations

    To avoid injury, keep your hands clear of the hinges when opening and closing the finisher door. To avoid injury, avoid the indicated parts that become hot during operation and locations where you could pinch your hand or fingers. Left Side To avoid injury, never touch the booklet tray during operation.
  • Page 7 (ccw) Counter-clockwise rotation of a drum, roller, gear, etc. (cw) Clockwise rotation of a drum, roller, gear, etc. Booklet Finisher SR5060 (D734)* Black and white (monochrome) copying or printing Bank Paper Bank (1st, 2nd, 3rd Tray of the main machine)

  • Page 8: Trademarks

    Terms Meaning 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. Transit Path Unit for Perfect Binder Type S1 (D736)* Trimmer Unit 5040 (D520)* Vertical Transport Unit Optional peripheral devices.

  • Page 9: Table Of Contents

    TABLE OF CONTENTS Revision History..............................1 Symbols, Abbreviations and Trademarks ......................2 Conventions..............................2 Warnings, Cautions, Notes...........................4 Finisher SR5050............................ 4 Booklet Finisher SR5060........................4 Commonly Used Terms and Abbreviations....................5 Trademarks..............................7 1. Replacement and Adjustment Common Procedures............................13 Overview..............................13 Covers................................15 Rear Upper Cover..........................15 Rear Lower Cover..........................
  • Page 10 Shift Tray.............................. 34 Shift Tray Base............................. 35 Left Lower Cover..........................38 End Fence............................39 Drag Roller Unit............................41 Horizontal Paper Feed.............................45 Entrance................................45 Entrance Roller Motor(........................45 Entrance Sensor...........................49 Registration..............................50 Registration Motor..........................50 Horizontal Transport Motor....................... 52 Proof Tray................................54 Proof Tray Motors............................54 Proof Tray JG Motor........................... 54 Proof Tray Vertical Transport Motor....................
  • Page 11 Shift Jogger Motor..........................74 Shift Tray Jogger Fence HP Sensor....................76 Shift Jogger Retraction Motor......................76 Shift Jogger Fence Retract HP Sensor....................78 Shift Tray Operation............................ 78 Shift Tray Lift Motor..........................78 Paper Height Sensors 1, 2, 3 (Shift, Staple, Z-Fold)............... 80 Paper Height Sensor (TE), Shift Tray Upper Limit Switch..............
  • Page 12 Stapler Rotation Motor........................118 Staple Trimmings Hopper Full, Hopper Set Sensor............... 119 Stapler Movement Sensors......................121 Corner Stapled Stack Feed Out.......................124 Stack Transport Motor........................124 Stack Transport Unit HP Sensor....................... 125 Stack Feed-Out Belt Motor......................126 Stack Feed-Out Belt HP Sensor....................... 128 Stack Junction Gate Motor......................
  • Page 13 Booklet Exit..............................156 Fold Roller Motor..........................156 Boards................................159 Main Board..............................159 Punch Unit PCB............................161 Shift Tray Jogger Unit PCB........................161 PSU................................162 Switches................................166 Front Door Switch............................166 Emergency Shift Tray Stop Switch......................167 Rollers and Brushes............................168 Rollers................................. 168 Drag Roller............................168 Positioning Roller..........................168 Alignment Brush Roller........................169 Discharge Brushes.............................

  • Page 14: Common Procedures

    1. Replacement and Adjustment Common Procedures Overview Front Left Rear Right...
  • Page 15 1. Replacement and Adjustment [A] Open the front door. [B] Adjustable caster [C] Pull the stack/stapler unit out (pull handle Rb12). • Inner covers: [A] Upper: Rb2, Rb8 [B] Center: Rb14, Rb16 [C] Lower Rb10, Rb11...

  • Page 16: Covers

    Common Procedures Covers Rear Upper Cover 1. Screw covers [A] (hooks) 2. Rear upper cover [B] ( • The rear upper cover must be removed before the rear lower cover.

  • Page 17: Rear Lower Cover

    1. Replacement and Adjustment Rear Lower Cover Preparation • Rear upper cover 1. Rear lower cover [A] ( x4). The screw near the power connection point is difficult to see. Re-installation 1. Engage both tabs on the bottom of the rear lower cover before fastening the screws.

  • Page 18: Lower Inner Cover: Rb10, Rb11

    Common Procedures Lower Inner Cover: Rb10, Rb11 1. Remove handles Rb11, Rb12 ( x1 each, Pin x1 each). 2. Make sure that the pins [A] are removed and stored with the screws. 3. Remove the cover ( x2, Tabs x2).

  • Page 19: Center Inner Cover: Rb14, Rb16

    1. Replacement and Adjustment Center Inner Cover: Rb14, Rb16 Preparation • Lower inner cover 1. Remove: [A] Rb16 [B] Rb 14 ( x1) [C] Cover (...

  • Page 20: Upper Inner Cover: Rb2, Rb8

    Common Procedures Upper Inner Cover: Rb2, Rb8 1. Remove: [A] Rb2, Rb8. If these tab releases are stiff, use the point of a sharp tool to release these knobs, then pull them off. Work carefully to avoid breaking the tab releases. [B] Cover ( Front Door 1.

  • Page 21: Proof Tray

    1. Replacement and Adjustment 2. Remove the clip [A]. 3. Lift off the door [B] from its bottom post. Proof Tray 1. Proof tray [A] ( Corner Strip Cover Preparation • Front door page 19) • Proof tray page 20) 1.

  • Page 22: Top Right Cover

    Common Procedures 3. Twist the cover away from the corner. Top Right Cover 1. Top right cover [A] (...

  • Page 23: Top Rear Cover

    1. Replacement and Adjustment Top Rear Cover Preparation Remove: • Proof tray (page 20) • Top right cover (page 21) • Rear upper cover (page 15) 1. Top rear cover [A] ( x2). Shift Tray Jogger Unit 1. Top rear cover page 22) 2.

  • Page 24: Left Upper Cover

    Common Procedures 3. Lift the jogger unit [A] off ( x1). Left Upper Cover Preparation Remove: • Proof tray (page 20 • Shift tray jogger unit (page 22) 1. Remove the left upper cover [B] ( x2).

  • Page 25: Upper, Lower Right Panels

    1. Replacement and Adjustment Upper, Lower Right Panels • The lower right panel covers the PSU, which retains residual voltage after the system is switched off. • Before removing the right panel for any procedure, switch the machine off and wait 30 min. for the charge on the PSU to dissipate.

  • Page 26: Shift Tray

    Common Procedures 2. Remove lower right panel [B] ( x6). Shift Tray 1. While supporting the tray with one hand, pull gear [A] toward you to release the tray. 2. Lower the tray [B] slowly until it stops, then remove it. (...

  • Page 27: Booklet Tray

    1. Replacement and Adjustment Booklet Tray 1. The booklet tray is the lower tray. 2. At the rear [A] remove rear cover ( x1).
  • Page 28 Common Procedures 3. At rear [A] disconnect tray ( x1, x1). 4. At front [A] remove front cover ( x1). 5. Disconnect tray bracket at front [A], rear [B] ( x2).

  • Page 29: Booklet Unit

    1. Replacement and Adjustment 6. Lift tray off the side of the machine. Booklet Unit Booklet Stapler The booklet stapler weighs about 3 kg (6.6 lb.) Preparation • Open the front door. • Pull stack/stapler unit out with Rb12. 1. Remove both booklet staplers. 2.

  • Page 30: Booklet Unit Removal

    Common Procedures 3. Remove stapler unit [A] ( 4. Make sure connector [B] is disconnected. 5. Remove the stapler unit with its handle [C]. 6. Lay the unit on a flat, clean surface. Booklet Unit Removal Preparation...
  • Page 31 1. Replacement and Adjustment • Open the front door. • Front door (page 19 • Corner strip cover (page 20) • Lower inner cover Rb10, Rb11 (page 17) • Booklet stapler (recommended) (page 28) • The booklet unit weighs about 18 kg (40 lb.) with the booklet stapler installed. •...
  • Page 32 Common Procedures 6. Disconnect the connectors [B] ( x2). 7. Pull the stack/staple unit out until it stops. 8. Remove: [A] Rear ( [B] Front (...

  • Page 33: Handling And Moving The Booklet Unit

    1. Replacement and Adjustment 9. Grip the unit [A] at , slide it to the right, and set it down on the floor. Handling and Moving the Booklet Unit • The metal edges of the booklet unit are sharp and can easily cut your hands or fingers. Always handle the unit carefully.

  • Page 34: End Fence

    Common Procedures End Fence Preparation • Booklet tray (page 26) • Shift tray jogger unit. (page 22) • Pull stack/stapler unit out with handle Rb12. Exit Roller Cover 1. This is the exit roller cover [A]. 2. Remove: [A] Rear ( [B] Front (...

  • Page 35: Shift Tray

    1. Replacement and Adjustment 3. Remove the cover. Shift Tray 1. Support the shift tray with your hand. 2. At the left rear corner, pull the gear [A] toward to release the tray, then lower the tray. 3. Remove the screws [B] ( 4.

  • Page 36: Shift Tray Base

    Common Procedures Shift Tray Base 1. This is the shift tray base [A]. 2. Rear cover [A] ( x1). 3. Slide the cover off. You do not need to remove the screw.
  • Page 37 1. Replacement and Adjustment 4. Front cover [A] ( 5. Slide the cover off. You do not need to remove the screw. 6. Front belt clamp [A] ( 7. Rear belt clamp [A] (...
  • Page 38 Common Procedures 8. At the front, pull the belt [A] out and set it behind the plate. 9. Front base plate [A] ( 10. Disconnect the rear end of the base [A] from the side fence (you do not need to remove the plate).

  • Page 39: Left Lower Cover

    1. Replacement and Adjustment Left Lower Cover 1. Disconnect metal bracket ( x2). 2. Remove bracket.

  • Page 40: End Fence

    Common Procedures 3. Remove left, lower cover. End Fence 1. Disconnect: [A] Motor ( x 1, [B] Half-turn sensor ( x 1,...
  • Page 41 1. Replacement and Adjustment 2. Rear: [A] Top ( [B] Center ( [C] Bottom ( 3. Front: [A] Top ( [B] Center ( [C] Bottom (...

  • Page 42: Drag Roller Unit

    Common Procedures Re-installation 1. When you re-attach the exit roller cover [A]: • Make sure the small mylar is set as shown. • Make sure the large mylars are set as shown. Drag Roller Unit Preparation • End fence page 33 1.
  • Page 43 1. Replacement and Adjustment 2. Harness connectors ( x6) 3. Connectors (...
  • Page 44 Common Procedures 4. Free harnesses [A] ( x2). 5. Disconnect small harness [B] ( 6. Remove: [A] Front ( [B] Rear ( 7. Remove the drag roller unit.
  • Page 45 1. Replacement and Adjustment...

  • Page 46: Horizontal Paper Feed

    Horizontal Paper Feed Horizontal Paper Feed Entrance Entrance Roller Motor( Preparation • Rear upper cover (page 15) • Rear lower cover (page 16) • Right panels (page 24) 1. The entrance roller motor is under the paper entrance guide. 2. A tension spring is attached to the motor bracket behind the main control board. The main control board mounting bracket must be removed in order to remove and re-attach this spring.
  • Page 47 1. Replacement and Adjustment 3. Disconnect the main board ( x17, x44). 4. Disconnect the board bracket at the top [A] and upper left corner [B] ( x2).
  • Page 48 Horizontal Paper Feed 5. Disconnect the board bracket at lower left corner [A] and right edge of the board [B] ( x2). 6. Remove the bracket with main board attached. 7. On the other side of the frame [A] disconnect the motor ( x1).
  • Page 49 1. Replacement and Adjustment 10. Twist and push the bracket through frame [B]. 11. Remove bracket (with motor attached) from under entrance guide. 12. Separate motor and bracket ( x2).

  • Page 50: Entrance Sensor

    Horizontal Paper Feed Entrance Sensor 1. The entrance sensor port is above the paper guide. 2. Remove: [A] Sensor bracket ( [B] Sensor (...

  • Page 51: Registration

    1. Replacement and Adjustment Registration Registration Motor Preparation Remove: • Rear upper cover (page 15) 1. The registration motor above the main board bracket at the rear. 2. Disconnect motor ( x1).
  • Page 52 Horizontal Paper Feed 3. Disconnect bracket ( x2). 4. Remove motor ( x1).

  • Page 53: Horizontal Transport Motor

    1. Replacement and Adjustment Horizontal Transport Motor Preparation • Rear upper cover (page 15) 1. The horizontal exit motor is above the right upper corner of the main board. 2. Disconnect motor bracket ( x2). 3. Disconnect and remove motor ( x1).
  • Page 54 Horizontal Paper Feed...

  • Page 55: Proof Tray

    1. Replacement and Adjustment Proof Tray Proof Tray Motors Proof Tray JG Motor Preparation • Rear upper (cover (page 15) • Punch unit PCB (page 161) 1. The proof tray JG motor is located here. 2. Disconnect motor [A] ( 3.

  • Page 56: Proof Tray Vertical Transport Motor

    Proof Tray 4. Remove: [A] Motor with bracket [B] Bracket ( Proof Tray Vertical Transport Motor The proof tray vertical transport motor is located here, partially covered by the punch unit PCB (if the punch unit has been installed.)
  • Page 57 1. Replacement and Adjustment Preparation Remove: • Rear upper cover (page 15) • Top rear cover (page 22) • Punch unit PCB (page 161) 1. Disconnect motor and bracket ( x2). 2. Remove motor ( x1).

  • Page 58: Proof Tray Exit Motor

    Proof Tray Proof Tray Exit Motor Preparation Remove: • Rear upper cover (page 15) • Rear lower cover (page 16) • Top rear cover (page 22) 1. The proof tray exit motor is located here. 2. Disconnect motor and harness in front of motor [A] ( x2).

  • Page 59: Proof Tray Sensors

    1. Replacement and Adjustment 4. Remove motor ( x1). Proof Tray Sensors Proof Tray JG HP Sensor Preparation • Rear upper cover (page 15) 1. The proof tray junction gate HP sensor is located here.
  • Page 60 Proof Tray 2. Disconnect sensor and bracket and then remove bracket (with sensor attached) ( x2). 3. Separate sensor and bracket ( x4).

  • Page 61: Proof Tray Exit Sensor, Proof Tray Full Sensor

    1. Replacement and Adjustment Proof Tray Exit Sensor, Proof Tray Full Sensor Preparation Remove: • Upper inner cover (page 19) • Top rear cover (page 22) • Shift tray jogger unit (page 22) • Left upper cover (page 23) • Proof tray (page 20) 1.
  • Page 62 Proof Tray 5. Use a pencil or marker to mark the color and location of the harnesses. 6. Disconnect a standoff to create slack in the harnesses. 7. Disconnect the bracket and sensors [A] ( x4, x2). 8. Remove: [A] Tray full sensor ( [B] Tray exit sensor (...
  • Page 63 1. Replacement and Adjustment...

  • Page 64: Shift Tray

    Shift Tray Shift Tray Shift Tray Side-to-Side Movement Shift Motor Preparation • Remove end fence (page 33) 1. The shift motor is visible inside the machine, but the end fence must be removed for servicing this motor. 2. Lay the end fence on a flat surface. 3.

  • Page 65: Shift Tray Hp Sensors (Front, Rear)

    1. Replacement and Adjustment 4. Turn the bracket over and remove the motor [A] ( Shift Tray HP Sensors (Front, Rear) These sensors are mounted on the same bracket as the shift motor. Preparation • Remove end fence (page 33) 1.

  • Page 66: Shift Tray Exit

    Shift Tray Shift Tray Exit Shift Tray Exit Motor Preparation • Rear upper cover (page 15) 1. The shift tray exit motor is under the shift tray lift motor board. 2. Disconnect motor [A] ( x1). 3. Disconnect bracket [B] ( x2).

  • Page 67: Shift Tray Exit Sensors (Long And Short)

    1. Replacement and Adjustment 4. Remove motor ( x1). Shift Tray Exit Sensors (Long and Short) Preparation • Remove proof tray (page 20) 1. Lift arm [A] ( x1)
  • Page 68 Shift Tray 2. At the front, remove the bushing ( x1). 3. At the rear, remove: [A] Gear ( x1, [B] Bushing (...
  • Page 69 1. Replacement and Adjustment 4. At the rear, disconnect the sensor harness. 5. Pull it though the hole into the machine. 6. Pull the plate assembly out from the front of the machine.
  • Page 70 Shift Tray 7. Lay the assembly on a flat surface. 8. Remove the plate [A]. 9. Remove: [A] Exit sensor (long) ( [B] Exit sensor (short) (...

  • Page 71: Drag Roller Motors, Sensors

    1. Replacement and Adjustment Drag Roller Motors, Sensors Preparation Remove: • End fence (page 20) • Drag roller unit (page 41) These three components require removal of the drag roller unit. Drag roller motor Drag roller drive motor Drag roller HP sensor...

  • Page 72: Drag Roller Motor

    Shift Tray Drag Roller Motor 1. Free the motor and fan harnesses ( x1). 2. Remove the fan ( x2). 3. Remove bracket (with motor attached) ( x2).

  • Page 73: Drag Roller Drive Motor

    1. Replacement and Adjustment 4. Separate motor and bracket ( x2). Drag Roller Drive Motor 1. Disconnect motor at [A] ( x1). 2. Turn the unit over, and then disconnect at [B] ( x1).

  • Page 74: Drag Roller Hp Sensor

    Shift Tray 3. This disconnects the motor. Drag Roller HP Sensor 1. Remove: [A] Sensor bracket ( [B] Sensor (...

  • Page 75: Shift Tray Jogger Unit

    1. Replacement and Adjustment Shift Tray Jogger Unit Shift Jogger Motor This motor [A] is on top of the shift tray jogger unit, near the center. Preparation • Shift tray jogger unit (page 22 • This is the location of the motor with the shift jogger unit removed.
  • Page 76 Shift Tray 1. Turn the unit over and disconnect the motor ( x1). 2. Disconnect motor [A] (...

  • Page 77: Shift Tray Jogger Fence Hp Sensor

    1. Replacement and Adjustment Shift Tray Jogger Fence HP Sensor Preparation • Shift tray jogger unit (page 22) 1. Remove sensor [A] ( Shift Jogger Retraction Motor This is the motor on the end of the shift tray jogger unit. Preparation •...
  • Page 78 Shift Tray 2. Disconnect the retraction HP sensor on the same bracket as the motor [A] ( 3. Disconnect motor bracket [A] (...

  • Page 79: Shift Jogger Fence Retract Hp Sensor

    1. Replacement and Adjustment Shift Jogger Fence Retract HP Sensor Preparation • Shift tray jogger unit (page 22) • Remove sensor [A] ( • If it is difficult to remove the sensor directly from the frame (or re-install), do the procedure in the previous section to remove the shift jogger retraction motor bracket.
  • Page 80 Shift Tray 2. Disconnect the motor drive board ( x1). 3. Remove: [A] Rear ( [B] Front (...

  • Page 81: Paper Height Sensors 1, 2, 3 (Shift, Staple, Z-Fold)

    1. Replacement and Adjustment 4. Pull the motor and drive board motor out. Paper Height Sensors 1, 2, 3 (Shift, Staple, Z-Fold) Preparation • Proof tray (page 20) 1. Remove the protector plate [A] ( x1). 2. Remove feeler [A] ( x1).

  • Page 82: Paper Height Sensor (Te), Shift Tray Upper Limit Switch

    Shift Tray 3. Remove sensor bracket [A] ( x1, Standoffs x2) 4. Sensors ( x1 each) Paper Height Sensor 1: Staple Mode Paper Height Sensor 2: Shift Mode Paper Height Sensor 3: Z-Fold Mode Paper Height Sensor (TE), Shift Tray Upper Limit Switch The actuator of the paper height sensor performs two functions: •...
  • Page 83 1. Replacement and Adjustment Preparation • End fence (page 33) • Drag roller unit (page 41) Paper Height Sensor (TE) 1. Open clamps above motor ( x2). 2. Disconnect ( x2). 3. Remove sensor [A] ( x1).
  • Page 84 Shift Tray Shift Tray Limit Switch 1. The switch is located at [A]. 2. Open the clamps ( x3). 3. Disconnect switch ( x1).
  • Page 85 1. Replacement and Adjustment 4. Remove lever screw ( x1). 5. Disconnect switch ( x2).

  • Page 86: Shift Tray Full Sensors 1, 2, 3, 4 (500)

    Shift Tray Shift Tray Full Sensors 1, 2, 3, 4 (500) The tray full sensors are all mounted on the same vertical stay at the left rear corner of the finisher: • Shift Tray Full Sensor (500) • Shift Tray Full Sensor (1000) •...
  • Page 87 1. Replacement and Adjustment 2. The four sensors, ( x1 each, x5 each) Shift Tray Full Sensor (500) Shift Tray Full Sensor (1000) Shift Tray Full Sensor (1500) Shift Tray Full Sensor (2500)
  • Page 88 Shift Tray...

  • Page 89: Pre-Stacker

    1. Replacement and Adjustment Pre-Stacker Pre-Stack Motors The pre-stack motor is visible from the right side of the finisher below the lock bar. Pre-Stack Motor Preparation Remove: • Rear upper cover (page 15) • Rear lower cover (page 16) • Right panels (page 24) 1.
  • Page 90 Pre-Stacker 2. Remove main board ( x17, x44, x8). 3. Remove upper bracket screw [A] ( x1). 4. Remove lower bracket screw [B] ( x1).
  • Page 91 1. Replacement and Adjustment 5. Disengage belt [A] ( x1). 6. Remove bracket [B] (with motor attached). 7. Separate bracket and motor ( x2).

  • Page 92: Pre-Stack Release Motor, Pre-Stack Roller Hp Sensor

    Pre-Stacker Pre-Stack Release Motor, Pre-Stack Roller HP Sensor The pre-stack release motor and pre-stack roller HP sensor are behind the main board. Preparation Remove: • Rear upper cover (page 15) • Rear lower cover (page 16) • Main board (page 159 Pre-stack Release Motor 1.
  • Page 93 1. Replacement and Adjustment 3. Remove e-ring ( x1). 4. Slowly, remove bracket and cam follower. Be careful to prevent the bushing and bearing of the cam follower from falling.
  • Page 94 Pre-Stacker 5. Separate the bushing and cam follower from the bracket. 6. Separate motor and bracket ( x2).
  • Page 95 1. Replacement and Adjustment Re-installation 1. Attach bracket [A] ( x2). 2. Remove sensor bracket (with sensor attached) ( x1). 3. Set cam follower [A]. Make sure that it swings freely up and down. 4. Set the gear ( x1). 5.
  • Page 96 Pre-Stacker Pre-stack Roller HP Sensor 1. Disconnect sensor harness ( 2. Remove sensor bracket ( 3. Sensor (...
  • Page 97 1. Replacement and Adjustment...

  • Page 98: Corner Stapler Unit

    Corner Stapler Unit Corner Stapler Unit Corner Stapler Unit Entrance Stapler JG Motor The stapler junction gate motor is behind the punch unit PCB. Preparation Remove: • Rear upper (cover (page 15) • Punch unit PCB (page 161) 1. Open the harness clamps of the motor [A] ( 2.

  • Page 99: Stapler Jg Hp Sensor

    1. Replacement and Adjustment 3. Remove motor bracket [A] ( • Slowly, pull the bracket away. • Make sure the Teflon collar [B] does not fall off the end of the junction gate shaft. Remove it so that it does not accidentally slip off the end of the shaft. Stapler JG HP Sensor Preparation Remove:...

  • Page 100: Stapling Tray Entrance Sensor

    Corner Stapler Unit Stapling Tray Entrance Sensor Preparation 1. Pull out the stack/staple unit. 2. Disconnect bracket [A] ( x1). 3. Disconnect harness, sensor [B] ( x1, x1).

  • Page 101: Stapling Tray Entrance Motor

    1. Replacement and Adjustment 4. Remove sensor ( x1). Stapling Tray Entrance Motor The stapling tray entrance motor is on the back of the stack/staple unit.
  • Page 102 Corner Stapler Unit Preparation Remove: • Rear upper cover (page 15) • Rear lower cover (page 16) • Main board (page 159) 1. Disconnect the motor ( x1). 2. Disconnect motor bracket ( x2). 3. Remove motor ( x1).

  • Page 103: Corner Stapler Side-To-Side Jogging

    1. Replacement and Adjustment Corner Stapler Side-to-Side Jogging Front Jogger Fence Motor The front jogger fence motor is behind the front plate of the stack/staple unit. Preparation • Remove booklet unit (page 29) 1. Disconnect bracket and motor ( x2, x2).
  • Page 104 Corner Stapler Unit 2. Disconnect bracket ( x2). 3. Remove bracket (with motor attached) ( x1). 4. Separate motor and bracket ( x2).

  • Page 105: Jogger Fence Hp Sensor (Front)

    1. Replacement and Adjustment Jogger Fence HP Sensor (Front) Preparation • Remove booklet unit (page 29) 1. Disconnect: Rear Jogger Fence Motor The rear jogger fence motor is mounted on the rear plate of the stack/staple unit.
  • Page 106 Corner Stapler Unit Preparation • Remove booklet unit (page 29) 1. Move the harnesses ( x3). 2. Disconnect bracket ( x2).
  • Page 107 1. Replacement and Adjustment 3. Remove bracket (with motor attached), and then disconnect motor ( x1). 4. Separate motor and bracket ( x2).

  • Page 108: Jogger Fence Hp Sensor (Rear)

    Corner Stapler Unit Jogger Fence HP Sensor (Rear) Preparation • Remove booklet unit (page 29) 1. Disconnect and remove the sensor:...

  • Page 109: Corner Stapling Bottom, Top Jogging

    1. Replacement and Adjustment Corner Stapling Bottom, Top Jogging Positioning Roller Rotation Motor The positioning roller rotation motor is under the motor cover on the right side of the stack/staple unit. Preparation • Open the front door. • Pull out the stack/staple unit with handle Rb12. 1.

  • Page 110: Positioning Roller Motor

    Corner Stapler Unit Positioning Roller Motor The positioning roller motor is under the motor cover on the right side of the stack/staple unit. Preparation • Open the front door. • Pull out the stack/staple unit with handle Rb12. • Right panel (page 24) 1.

  • Page 111: Positioning Roller Hp Sensor

    1. Replacement and Adjustment 2. Remove motor [A] ( Positioning Roller HP Sensor Preparation • Open the front door. • Pull out the stack/staple unit with handle Rb12. 1. Remove motor cover [A] ( x2).

  • Page 112: Leading Edge Stopper Hp Sensor, Staple Tray Paper Sensor

    Corner Stapler Unit 2. Remove sensor [A] ( Leading Edge Stopper HP Sensor, Staple Tray Paper Sensor Preparation • Remove booklet unit (page 29) • The Leading edge stopper HP sensor shares the same bracket with the stack feed-out belt HP sensor.

  • Page 113: Top Fence Hp Sensor

    1. Replacement and Adjustment 2. Remove leading edge stopper HP sensor x5). 3. Remove staple tray paper sensor ( x1, x5). Top Fence HP Sensor Preparation • Remove booklet unit (page 29) 1. This sensor is in the center of the unit.
  • Page 114 Corner Stapler Unit 2. Disconnect bracket ( x1). 3. Pull bracket away, and then disconnect harness ( x1, x1).

  • Page 115: Corner Stapling

    1. Replacement and Adjustment 4. Separate bracket and sensor ( x4). Corner Stapling Corner Stapler Preparation • Pull the stack/staple unit with handle Rb12. 1. Remove the stapler cartridge [A].
  • Page 116 Corner Stapler Unit 2. Remove cover [A] ( 3. Disconnect the stapler [A] ( x2).

  • Page 117: Corner Stapler Movement Motor

    1. Replacement and Adjustment 4. Lift the stapler off its posts but do not pull it away because one harness is still attached inside the stapler. 5. Disconnect harness [A] ( Corner Stapler Movement Motor The corner stapler movement motor is at the bottom of the corner stapler unit. Preparation •...
  • Page 118 Corner Stapler Unit Re-installation 1. Re-attachment of the motor is difficult. Removal of this brace is recommended before you re-attach the motor. 2. Disconnect and remove bracket: [A] Front ( [B] Rear (...

  • Page 119: Stapler Rotation Motor

    1. Replacement and Adjustment Stapler Rotation Motor You can see the stapler rotation motor on the bottom of the corner stapler unit next to the corner stapler. Preparation • Open the front door. • Pull out the stack/staple unit with handle Rb12. 1.

  • Page 120: Staple Trimmings Hopper Full, Hopper Set Sensor

    Corner Stapler Unit Staple Trimmings Hopper Full, Hopper Set Sensor Preparation • Open the front door. • Pull out the stack/staple unit with handle Rb12. • Rear upper cover (page 15) • Rear lower cover (page 16) Trimmings Hopper Unit 1.
  • Page 121 1. Replacement and Adjustment 3. Gather the disconnected harness [A]. 4. Disconnect the trimmings collection unit [B] ( x2). 5. Disconnect tab [A] (Tab x1, x2). 6. Release hinge shaft [B] ( x1).

  • Page 122: Stapler Movement Sensors

    Corner Stapler Unit 7. Open the unit. 8. Detach: Hopper set sensor ( Hopper full sensor Stapler Movement Sensors Common procedures • Corner Stapler HP Sensor • Corner Stapler Rotation HP Sensor (Rear) • Corner Stapler Rotation HP Sensor (Front) Preparation •...
  • Page 123 1. Replacement and Adjustment 4. Remove spring [A]. 5. Loosen screw [B] (do not remove it). 6. Rotate the plate down to relieve tension on the belt. 7. Disconnect the belt at the front and back. 8. Lift the stapler mount [A] off its rails and turn it toward the rear so you can see the back of the mount.
  • Page 124 Corner Stapler Unit 9. Remove sensor bracket [A] ( x2). Three sensors are on this bracket: Rotation HP sensor (rear) ( Rotation HP sensor (front) ( Stapler HP sensor ( Re-installation 1. When you set the stapler mount on its rails, make sure the belt [A] is not tangled and above the two rollers.

  • Page 125: Corner Stapled Stack Feed Out

    1. Replacement and Adjustment Corner Stapled Stack Feed Out Stack Transport Motor Preparation • Rear upper cover (page 15) • Rear lower cover (page 16) 1. The motor is located near the right edge of the main board. 2. Disconnect motor ( x1).

  • Page 126: Stack Transport Unit Hp Sensor

    Corner Stapler Unit 4. Remove motor ( x1). Stack Transport Unit HP Sensor Preparation • Rear upper cover (page 15) • Stack transport motor (page 124) 1. Remove sensor bracket and sensor [A] ( x1). 2. Remove the sensor (...

  • Page 127: Stack Feed-Out Belt Motor

    1. Replacement and Adjustment Stack Feed-Out Belt Motor The stack feed-out belt motor is behind the front plate of the corner stack/staple unit. Preparation • Booklet unit (page 29) 1. Disconnect motor ( x1).
  • Page 128 Corner Stapler Unit 2. At front [A] disconnect bracket ( x2). 3. Remove bracket (with motor attached) from rear [B] ( x1). 4. Separate motor and bracket ( x2).

  • Page 129: Stack Feed-Out Belt Hp Sensor

    1. Replacement and Adjustment Stack Feed-Out Belt HP Sensor Preparation • Remove booklet unit (page 29) 1. The sensor is to the left of the three belts. 2. Disconnect and remove sensor ( x1).

  • Page 130: Stack Junction Gate Motor

    Corner Stapler Unit Stack Junction Gate Motor The stack junction gate motor is on the back of the finisher. Preparation • Rear upper cover (page 15) 1. Remove motor [A] ( x2).

  • Page 131: Stack Jg Hp Sensor

    1. Replacement and Adjustment 2. Separate the bracket and motor [A] ( x2). Stack JG HP Sensor Preparation • Rear upper cover (page 15) 1. If the actuator [A] is in the gap of the sensor, rotate gear and belt [B] until the actuator is out of the gap.

  • Page 132: Corner Stapled Stack Exit To Shift Tray

    Corner Stapler Unit 3. Remove sensor [A] ( x5). Corner Stapled Stack Exit to Shift Tray Exit Guide Motor The exit guide motor assembly is at the left rear corner of the finisher.
  • Page 133 1. Replacement and Adjustment Preparation • Proof tray (page 20) 1. Disconnect the harnesses ( x1). 2. Disconnect sensor harness [A] (...
  • Page 134 Corner Stapler Unit 3. Disconnect and remove rocker arm [A] ( x1). 4. Remove the exit guide plate assembly [A] ( x2). 5. Disconnect motor [A] ( 6. Separate the motor [B] and bracket ( x2).

  • Page 135: Exit Guide Hp Sensor

    1. Replacement and Adjustment Exit Guide HP Sensor Preparation • Proof tray (page 20 1. Remove the exit guide motor assembly (see the previous procedure) 2. Remove sensor bracket [A] ( 3. Remove sensor [B] ( x5).

  • Page 136: Booklet Unit

    Booklet Unit Booklet Unit Booklet Stapler Preparation • Remove booklet unit (page 29) • This procedure describes removal of the booklet stapler after the booklet unit has been removed. • Actually, the booklet stapler can be easily removed before removing the booklet unit. •...

  • Page 137: Booklet Unit Transport, Entrance

    1. Replacement and Adjustment Booklet Unit Transport, Entrance Fold Unit Entrance Sensor Preparation • Booklet unit (page 29) • Booklet stapler (page 28) 1. Remove sensor bracket [A] ( x1). 2. Remove sensor [B] ( Booklet Side-to-Side Jogging Booklet Stapler Side Fence Motor The booklet stapler side fence motor is on the back of the booklet unit.
  • Page 138 Booklet Unit Preparation • Booklet unit (page 29) 1. Remove motor [A] ( 2. Separate motor [A] from the bracket ( x2).

  • Page 139: Booklet Stapler Side Fence Hp Sensor (Front)

    1. Replacement and Adjustment Booklet Stapler Side Fence HP Sensor (Front) Preparation • Booklet unit page 29) • Booklet stapler (page 28) 1. Remove: [A] Sensor bracket ( [B] Sensor ( Booklet Stapler Jogger HP Sensor (Rear) Preparation • Booklet unit (page 29) •...

  • Page 140: Booklet Bottom, Top Jogging

    Booklet Unit [A] Sensor bracket ( [B] Sensor ( Booklet Bottom, Top Jogging Booklet Stapler Bottom Fence Motor The booklet stapler bottom fence motor is on the back of the booklet unit. Preparation • Booklet unit (page 29) 1. Remove motor [A] ( x1).

  • Page 141: Booklet Stapler Bottom Fence Hp Sensor

    1. Replacement and Adjustment 2. Separate the motor [A] from the bracket ( x2). Booklet Stapler Bottom Fence HP Sensor Preparation • Booklet unit (page 29) • Booklet stapler (page 28) 1. The bottom fence HP sensor is fastened to the right plate of the booklet unit.
  • Page 142 Booklet Unit 2. On the right side, remove brace [A] so that you can see the sensor pawls ( x2). 3. Release the pawls [B] and push them through the plate ( x5). 4. Disconnect the sensor ( x1).

  • Page 143: Booklet Stapler Top Fence Motor

    1. Replacement and Adjustment Booklet Stapler Top Fence Motor The top fence motor and sensor are on top of the booklet unit. Preparation • Booklet unit (page 29) 1. Remove sensor bracket [A] ( 2. Separate motor [A] from the bracket (...

  • Page 144: Booklet Top Fence Hp Sensor

    Booklet Unit Booklet Top Fence HP Sensor Preparation • Booklet unit (page 29) 1. Remove sensor bracket [A] ( x1). 2. Remove sensor [B] ( x1, Booklet Press for Stapling Booklet Stapler Clamp Roller Motor, Booklet Stapler Exit Sensor The booklet stapler clamp roller motor and booklet stapler exit sensor cannot be removed until the motor base has been removed.
  • Page 145 1. Replacement and Adjustment Preparation • Booklet unit (page 29) Motor Base Plate 1. Remove cover [A] ( x2). 2. Disconnect sensor bracket [A] and harness [B] ( x1).
  • Page 146 Booklet Unit 3. Disconnect motor harness [A] ( x1). 4. Pull belt until you can see through the hole that the edge of the actuator below the hole is aligned as shown. • The edge of the actuator and the line on the left side of the hole must be aligned. •...
  • Page 147 1. Replacement and Adjustment 5. Remove: [A] Rear ( [B] Front ( 6. Remove base plate [A]. 7. Remove end-piece [B].
  • Page 148 Booklet Unit Exit Sensor A guide shaft blocks access to the exit sensor bracket [A]. 8. Remove guide shaft screw [A] ( x1). 9. Rotate then slide the guide shaft [B] to the rear until you have enough space to remove the bracket screw.
  • Page 149 1. Replacement and Adjustment 10. Use a short screwdriver to remove the exit sensor bracket [A] ( x1). 11. Disconnect the exit sensor [B] ( x5). Booklet Stapler Clamp Roller Motor Preparation 12. Lay the motor base plate [A] on a flat surface. 13.
  • Page 150 Booklet Unit 14. Remove motor [A] ( x1). Re-installation 1. To make sure there is no pressure on the base plate, pull belt until you can see through the hole that the edge of the actuator below the hole is aligned as shown.
  • Page 151 1. Replacement and Adjustment 2. Turn gear [A] so that you can see the cut-out. The post of the linkage must be re-inserted here when the motor base plate is re-installed. 3. After the motor base plate [A] has been re-installed, the linkage will not be straight. It will slant slightly from rear to front.

  • Page 152: Booklet Stapler Clamp Roller Hp Sensor

    Booklet Unit 5. Re-attach end-piece [A] at the front before you re-attach any other screws. Booklet Stapler Clamp Roller HP Sensor Preparation • Booklet unit (page 29) 1. Remove cover [A] ( x2).
  • Page 153 1. Replacement and Adjustment 2. Remove sensor bracket [A] ( x1). 3. Remove sensor [A] ( x5).

  • Page 154: Booklet Folding

    Booklet Unit Booklet Folding Fold Roller Motor The fold plate motor is on the back of the booklet unit, below the fold roller motor. Preparation • Booklet unit (page 29) 1. Disconnect motor [A] ( x1).

  • Page 155: Fold Plate Cam Hp Sensor

    1. Replacement and Adjustment 2. Remove the motor. Fold Plate Cam HP Sensor Preparation • Booklet unit (page 29) • Fold roller motor (described in the previous section) 1. Remove sensor bracket [A] ( x1). 2. Sensor (...

  • Page 156: Fold Plate Hp Sensor

    Booklet Unit Fold Plate HP Sensor Preparation • Booklet unit (page 29) 1. Remove: [A] Rear ( [B] Front ( 2. Remove cross-brace [A] (...

  • Page 157: Booklet Exit

    1. Replacement and Adjustment 3. Sensor [A] ( Booklet Exit Fold Roller Motor The fold roller motor is on the back of the booklet unit, above the fold plate motor.
  • Page 158 Booklet Unit Preparation • Booklet unit (page 29) 1. Disconnect motor [A] ( x1). 2. Remove the motor.
  • Page 159 1. Replacement and Adjustment...

  • Page 160: Boards

    Boards Boards Main Board Preparation • Rear upper cover (page 15) • Rear lower cover (page 16) 1. The main board is on the back of the machine. 2. Disconnect the board ( x44). • There are approximately 17 clamps around the board. •...
  • Page 161 1. Replacement and Adjustment 3. Disconnect the board ( x8). 4. Remove the board.

  • Page 162: Punch Unit Pcb

    Boards Punch Unit PCB Preparation • Rear upper cover (page 15) • Rear lower cover (page 16) 1. Remove the punch unit PCB ( x4). Shift Tray Jogger Unit PCB Preparation • Shift tray jogger unit (page 74) 1. Lay the shift jogger unit [A] on a flat surface. 2.

  • Page 163: Psu

    1. Replacement and Adjustment 3. Remove PCB [A] ( x2). Preparation • Switch the system off. • Disconnect the finisher from its power source. • Wait at least 30 minutes. • Right panels (page 24) • The PSU will retain residual charge, even after the machine has been turned off. •...
  • Page 164 Boards 2. Disconnect the board ( x3, x5). • Be sure to re-connect the bayonet connectors at White over Black. 3. At the rear [A] disconnect the fan ( x1, x1).
  • Page 165 1. Replacement and Adjustment 4. Disconnect the board bracket: [A] Rear ( [B] Front ( 5. Remove the bracket (with board attached).
  • Page 166 Boards 6. Separate board and bracket ( x5).

  • Page 167: Switches

    1. Replacement and Adjustment Switches Front Door Switch Preparation • Open the front door. • Upper inner cover (page 19) 1. Locate the door switch [A] on the front. 2. Inside the finisher, disconnect switch [B] ( x4). 3. Pinch both sides of the switch and push it out.

  • Page 168: Emergency Shift Tray Stop Switch

    Switches Emergency Shift Tray Stop Switch Preparation • Shift tray jogger unit (page 74) • Left upper cover (page 23) 1. The switch [A] is on the front end of the left upper cover. 2. Turn the cover over. 3. Remove the switch [A] ( x1).

  • Page 169: Rollers And Brushes

    1. Replacement and Adjustment Rollers and Brushes Rollers Drag Roller 1. Replace: [A] Rear ( x1, Belt x1) [B] Front ( x1, Belt x1) Positioning Roller Preparation • Open the front door. • Pull out the stack/staple unit with handle Rb12. 1.

  • Page 170: Alignment Brush Roller

    Rollers and Brushes 2. Replace sponge roller [A] ( x1, Alignment Brush Roller Preparation • Open the front door. • Lower inner cover Rb10, Rb11 (page 17) • Center inner cover Rb14, Rb 16 (page 18) • Right panel (page 24) Rear 1.
  • Page 171 1. Replacement and Adjustment Front 1. Remove the bushing [A] ( x1). 2. Remove the alignment brush roller. Re-installation 1. The end of the shaft with the flat bevel is the rear end of the shaft where the gear and belt must be re-attached.

  • Page 172: Discharge Brushes

    Rollers and Brushes 2. When you re-install the brush roller [A], make sure that pawl [B] of the guide is below plate [C]. Discharge Brushes Shift Tray Exit 1. Remove discharge brush [A] ( x2).

  • Page 173: Corner Stapler Entrance

    1. Replacement and Adjustment Corner Stapler Entrance Preparation • Open the front door. • Pull out the stack/staple unit with handle Rb12. 1. Remove cover [A] ( 2. Raise Rb13 [A]. 3. Remove discharge brush [B] (...

  • Page 174: Booklet Unit Exit

    Rollers and Brushes Booklet Unit Exit Preparation • Booklet unit 1. The discharge brush [A] is on the left side of the booklet unit. 2. Remove: [A] Rear ( [B] Front (...

  • Page 175: Special Adjustments

    1. Replacement and Adjustment Special Adjustments Horizontal Skew Adjustment The booklet unit is adjusted for optimum performance before the finisher is shipped from the factory. Do this adjustment only if the edges of folded booklets are not even. 1. Run a fold/staple job through the booklet unit with A3 (or DLT) paper. 2.

  • Page 176: [A] Adjustment: Rear Fence Low

    Special Adjustments 2. Remove the screw. • There is only one screw to remove. Check both holes. • The screw may be at the front or at the rear, depending on where it was attached before shipping from the factory. [A] Adjustment: Rear Fence Low 1.

  • Page 177: [B] Adjustment: Front Fence Low

    1. Replacement and Adjustment • Every notch adjusts the height 0.1 mm. Turning the adjustment screw to the right may raise the rear fence so the holes at the rear will no longer be aligned. 2. Re-attach the screw in the front hole where the holes are aligned. [B] Adjustment: Front Fence Low 1.

  • Page 178: Vertical Skew Adjustment

    Special Adjustments 2. Re-attach the screw at the front hole. Vertical Skew Adjustment The booklet unit is adjusted for optimum performance before the finisher is shipped from the factory. Do this adjustment only if the edges of folded booklets are not even. 1.

  • Page 179: Base Fence Replacement

    1. Replacement and Adjustment 4. Measure the amount of skew. 5. Enter the SP mode • Europe, Asia: Use SP6201-8 (this is for A3 paper). • North America: Use SP 6201-15 (this is for DLT paper). • The illustration above shows the effects of +/- adjustment with SP6201. •...
  • Page 180 Special Adjustments • Only replacement of the front fence is described here. The replacement procedure for the rear base fence is the same. Preparation 1. Pull out the stack/staple unit with handle Rb12. 2. Remove entrance guide plate [A] 3. Now you can access the front and rear of the base fence. •...
  • Page 181 1. Replacement and Adjustment 5. Look at the lower right corner of the staple unit. 6. Remove the screws, and then carefully remove the front of the base fence [A] ( x3). • Work carefully to prevent pressure spring [B] from flying off.
  • Page 182 Special Adjustments 7. The new base fence is embossed with groups of lines [1], [2], [3]. • The pitch of the lines [1], [2], [3] is 0.5 mm [A]. 8. Attach the new front base fence ( x4).
  • Page 183 1. Replacement and Adjustment • Pay attention to the use and order of screw attachment. • Screw [A] is attached last. • Screws [B] and [C] are used to adjust the position of the base fence. • Leave screw [D] loose. 9.
  • Page 184 MEMO...
  • Page 185 MEMO...

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