Ricoh StreamPunch Pro Technical & Service Manual
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Ricoh StreamPunch Pro Technical & Service Manual

Ricoh StreamPunch Pro Technical & Service Manual

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Ricoh StreamPunch
Part No.
7712841
Rev No.
D1
Issue Date
04/01/2014
Technical Service Manual
™
Pro & Pro EX

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Summary of Contents for Ricoh StreamPunch Pro

  • Page 1 ™ Ricoh StreamPunch Pro & Pro EX Technical Service Manual Part No. 7712841 Rev No. Issue Date 04/01/2014...
  • Page 2 Copyright Notice Four Corporate Drive Lake Zurich, IL 60047 www.gbcconnect.com © Copyright 2011 GBC. All rights reserved. No part of this document may be photocopied or reproduced by any means, or translated to another language without prior written consent of GBC. All brand names, trademarks and registered trademarks are the property of their respective owners.

  • Page 3: Table Of Contents

    Table of Contents Preface Safety ..........Introduction .
  • Page 4 Repair and Adjustment Procedures Preparing the StreamPunch Pro for Service ....Separating the Punch from the Printer ......
  • Page 5 Entrance Motor ..........6.5 Exit Motor .

  • Page 6: Safety

    1. Safety These symbols are used in this documentation alert you to danger or important information. Warning: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious Injury. Warning: Risk of electrical shock. This warning statement indicates situations where there is a risk of death by electric shock.

  • Page 7: Introduction

    2. Introduction This service manual is provided for use by an authorized service technician for the repair and maintenance of the StreamPunch . The StreamPunch is an innovative, labor saving solution for punching paper in-line and includes the following design features: •...

  • Page 8: Long Edge Feed (Lef) Only

    4. Long Edge Feed (LEF) Only The StreamPunch is designed to punch LEF only. No exceptions. Attempting to punch a sheet size other than LEF will cause a misfeed. • Use a colored sheet insert (instead of the tab) in the job workflow for easier tab insertion after the job has been run.

  • Page 9: Die Sets

    5. Die Sets The StreamPunch is capable of punching a variety of hole-punch patterns by simply changing the Die Set. Die sets can be changed in seconds without tools. The Die Sets currently available are listed in below*. Standard North America Europe / Australia Plastic Comb 19 Hole Plastic Comb 20 Hole &...
  • Page 10 North America/LTR Units...

  • Page 11: Gbc Sales Contact Information

    • Support local trade shows or open houses. • Joint sales calls to add value to selling the printer, StreamPunch Pro and GBC finishing solutions. • Attend local sales meetings to connect with branch reps.

  • Page 12: Maintenance

    Section 1 Maintenance This section contains service call initial action procedures, cleaning and maintenance procedures, and service call final action procedures. 1.1 Initial Service Action At the start of every service call, you should perform the following. 1. If called for a problem, determine the exact nature of the service complaint. 2.

  • Page 13: Misfeed Service Action

    1.2 Misfeed Service Action To clear a misfeed, first press the Stop button on the printer and then check the printer screen to see the area of the misfeed. If the misfeed is in the printer or finisher only, follow the information on the screen to clear the misfeed.
  • Page 14 Figure 1.2 Bypass Open, Entrance Side. 6. Open the entrance paper Aligner panel latch [7] and clear obstructions in the Aligner. 7. Open the exit paper Aligner panel latch [8] and clear obstructions in each Aligner. Figure 1.3 Check Paper Path Through the Punch.
  • Page 15 8. Open the bottom U-channel by pressing the lever in [9] and lower the U- channel and clear the path. Figure 1.4 Open the Bottom U-Channel. 9. When all the paper is cleared, close the U-channel, Aligner Panels, and Bypass. 10.

  • Page 16: Die Set Service

    Die Set should be replaced with a new one. 1.3.1 Die Set Life Expectancy The StreamPunch Pro standard Die Sets have a minimum life expectancy of 500K cycles (sheets of paper punched). Heavy Duty die sets have a minimum life expectancy of 4M cycles (sheets of paper punched).

  • Page 17: Floating Pressure Bar Spring Replacement

    1.3.2.2 Floating Pressure Bar Spring Replacement The Die Sets use springs to hold the top plate above the pressure bar [1]. Detents in the top plate hold the springs in place [2]. Ensure all springs are in place. 1.6 Die Set Floating Pressure Bar Springs. To replace pressure bar springs: 1.

  • Page 18: Die Set Lubrication

    Figure 1.7 Check For Free Movement. Reinstall the Die Set into the punch and run several sheets of the customer’s paper through the punch. Inspect the holes. • Holes should be clean and even with no tearing or frayed edges. •...
  • Page 19 To lubricate standard Die Set pins that do not have felt pads: • Depress the Die Set [1] so that the pins protrude from the bottom plate. • Apply a drop of high quality machine oil to the end of each pin [2]. •...

  • Page 20: Hole Alignment Inspection

    1.3.5 Hole Alignment inspection Inspect the hole alignment on the customer’s punched paper. Fold the punched sheet of paper in half [1] and the punched holes should be aligned evenly along the edge and centered between the ends [2]. If the punched holes are not aligned, then the Die Set cradle must be adjusted.

  • Page 21: Inspection, Cleaning, And Lubrication

    1.4 Inspection, Cleaning, and Lubrication If operating properly, the StreamPunch Pro will punch the same types of copy paper and cover materials handled by the printer and run at the same speed. Hole quality will vary between different grades of paper.

  • Page 22: External Cleaning

    Do not use chemical cleaners or solvents as these may have a harmful effect. Use detergent sparingly to avoid contact with electrical components. Warning: Make sure you disconnect the StreamPunch Pro from its power source before cleaning. Failure to observe this warning could result in death or serious injury.

  • Page 23: Base Cleaning

    1.4.5 Base Cleaning Maintenance Schedule Clean every service call. Procedure Chips and paper dust falls to the bottom of the punch. Clean with a vacuum cleaner each time the machine is serviced. The customer can also do this between the technician’s visits.

  • Page 24: Die Guide Cleaning

    1.4.6 Die Guide Cleaning Maintenance Schedule Clean every 750K cycles. Procedure Remove the Die Set and clean the guide [1] with a vacuum cleaner. Figure 1.12 Die Guide.

  • Page 25: Door Latch Inspection

    To adjust the door latch, see “Door Latch” on page 4.2.1. Figure 1.13 Door Switch Tab and Switch. 1.4.8 Separating Punch from Printer Some procedures require separating the StreamPunch Pro from the printer and finisher. Refer to “Separating the Punch from the Printer” on page 4.1.1.

  • Page 26: Aligner Inspection And Cleaning

    1.4.10 Aligner Inspection and Cleaning Maintenance Schedule Clean every 750K cycles. Procedure Inspect for worn or damaged parts. Clean with alcohol or a soft cloth moistened with mild detergent and warm water as needed. To clean the Aligner Panels: 1. Lift the Aligner latches [1] to open the two panels. 2.

  • Page 27: Aligner Idler Roller Maintenance

    • Inspect for bent or damaged parts. Warning: Disconnect the StreamPunch Pro from power and retain the power cord in your possession for your safety. Failure to observe this warning could result in death or serious injury. To inspect the aligner idler rollers: 1.
  • Page 28 2. Ensure the torsion springs [1] are hooked over the bracket [2]. Some brackets may have 2 torsion springs attached. The legs of the springs should be resting on the roller shaft. Figure 1.16 Aligner Roller Torsion Spring Hooked on Bracket. To clean idler rollers: 1.
  • Page 29 1.4.10.2 Aligner Belt (Green Belt) Maintenance Maintenance Schedule Inspect and clean every 750K cycles. Procedure • Ensure the Aligner belts (green belt) are clean. • Inspect for frayed edges and wear. To clean the Aligner belts (green belt): 1. Clean the Aligner belt (green belt) [1] with a plastic scouring pad. Figure 1.17 Clean Aligner belt (Green Belt).
  • Page 30 2. Use the Drive Knob [2] to turn the belt. Figure 1.18 Turn Drive Knob. To adjust or replace the Aligner belt (green belt), see “Aligner Belt (Green Belt) Replacement” on page 4.5.3.

  • Page 31: Back Gauge Solenoid Inspection And Cleaning

    1.4.11 Back Gauge Solenoid Inspection and Cleaning Maintenance Schedule Clean every 750K cycles. Procedure • Inspect and ensure the Back Gauge solenoid linkage moves freely. Press linkage down and release [1]. Linkage should return. • Clean out the solenoid and surrounding area with a vacuum cleaner and canned air [2].

  • Page 32: Idler Roller Inspection And Cleaning

    1.4.12 Idler Roller Inspection and Cleaning Idler rollers press against the drive rollers and move the paper through the bypass [1] or the punch [2]. Maintenance Schedule Inspect and clean every 750K cycles. Procedure Inspect rollers for wear patterns or grooves. The roller surface should be even and have a textured surface.

  • Page 33: Idler Roller Removal And Cleaning

    1.4.12.1 Idler Roller Removal and Cleaning This procedure refers to the idler rollers [3] shown in the previous Illustration that are easily removed as assemblies. The idler rollers that are not easily removed should be cleaned while in the punch. See “Non-Removable Idler Roller Cleaning” on page 1.4.12.2.

  • Page 34: Non-Removable Idler Roller Cleaning

    1.4.12.2 Non-Removable Idler Roller Cleaning Some idler and the drive rollers, [1] are not easily removed but can be cleaned while in the punch. Figure 1.22 Inspect and Clean Idler Rollers. To clean non-removable idler rollers: 1. Separate the punch from the printer. 2.
  • Page 35 Figure 1.23 Turn Knobs to Clean Rollers.

  • Page 36: Drive Roller Inspection And Cleaning

    1.4.13 Drive Roller Inspection and Cleaning Drive rollers are located opposite to the idler rollers. Maintenance Schedule Inspect and clean every 750K cycles. Procedure Inspect for wear patterns or grooves. The roller surface should be even and not glazed. The drive rollers [1] should be inspected and cleaned when the idler rollers are removed.

  • Page 37: Energy Idler And Drive Rollers

    1.4.14 Energy Idler and Drive Rollers Maintenance Schedule Clean every 750K cycles. Procedure To clean the Energy Drive Roller: 1. Unhook one retaining spring [1] and then remove the idler roller assembly [2]. 2. Rotate and clean the drive rollers [3]. Figure 1.25 Removing Energy Idler Roller...

  • Page 38: Aligner Latch Inspection

    1.4.15 Aligner Latch Inspection Latches [1] on both sides of the punch hold the Aligner Panels in place, which in turn maintains even pressure on the idler rollers. Maintenance Schedule Inspect every 750K cycles. Procedure • Inspect the latches for worn or damaged parts. •...

  • Page 39: Optical Sensor Cleaning

    1.4.16 Optical Sensor Cleaning Maintenance Schedule Clean every 750K cycles. Procedure Inspect and clean per the maintenance schedule or as needed. Supplies Needed Canned air or vacuum cleaner Figure 1.28 Optical Sensor Locations (indicated by S prefix)
  • Page 40 Use canned air to blow the debris off each sensor. The illustration shows examples of four sensors [1]. Figure 1.29 Four Optical Sensors.

  • Page 41: Bypass Paper Path Inspection And Cleaning

    1.4.17 Bypass Paper Path Inspection and Cleaning Maintenance Schedule Clean every 750K cycles. Procedure • Inspect the Bypass panel [1], rollers [2], and entrance guide [not shown] for wear, damage, and obstructions. • Inspect the rollers for wear patterns or grooves. The surface should be rough and even.

  • Page 42: Punch Paper Path Inspection And Cleaning

    1.4.18 Punch Paper Path Inspection and Cleaning Maintenance Schedule Inspect and clean every 750K cycles. Procedure • Clean as needed. • Inspect the entire paper path through the punch. Look for wear, damage, and obstructions. • Inspect the rollers for wear patterns or grooves. •...
  • Page 43 • Confirm that the latch holds the U-channel tightly in place [3]. Figure 1.32 Inspect U-Channel Latch.

  • Page 44: Punch Drive Cam Lubrication

    To remove see “Punch Module Removal” on page 4.7.1. Warning: Disconnect the StreamPunch Pro from its power source before removing the Back Gauge assembly or Punch Module. Failure to observe this warning can result in severe injury or death and damage the punch.

  • Page 45: Timing Belt Inspection

    1.4.20 Timing Belt Inspection Maintenance Schedule Inspect every 750K cycles. Procedure Inspect all timing belts [1] for wear, missing teeth, frayed edges, and cracks. For replacement, see “Belt Replacement” on page 4.8. Figure 1.35 Timing Belt Locations.

  • Page 46: Final Service Action

    1.5 Final Service Action This section explains the actions a technician should take at the end of every service call. With each step, verify that the system runs smoothly and misfeed free. 1. Inspect each Die Set visually and lubricate as needed. See “Die Set Lubrication” on page 1.3.4.

  • Page 47: Fault Analysis Procedures

    Section 2 Fault Analysis Procedures Also called Repair Analysis Procedures, this section contains the basic troubleshooting information that a technician needs to isolate the root cause of a specific symptom. 2.1 Troubleshooting The tables that follow are arranged in order of the normal operational sequence. 2.1.1 General One of the first rules of troubleshooting is to first understand the normal operating sequence of the machine (see Principle of Operation).
  • Page 48 Paper jam LED is lit; customer A small piece of chad or torn paper is Separate the StreamPunch Pro from the or operator has been unable to blocking a sensor and/or the paper path. printer and the finisher, clean out the locate the misfeed.

  • Page 49: Back Gauge

    Backgage not functioning or connected Check main control board properly. 2.1.3 Die Set Under normal conditions, the StreamPunch Pro may experience one misfeed in 15000. Excessive misfeeding, such as one in every 1000, requires servicing. The cause may be the Die Set.

  • Page 50: Output Quality Analysis Procedures

    Section 3 Output Quality Analysis Procedures 3.1 Centering Punched Holes 3.1.1 Die Set Position Cradle Adjustment The die set position cradle is set in the factory. However, because of the punched hole spacing on the PB/C4 die sets, there is a minimal amount of paper on each edge of the punched paper.
  • Page 51 3. Before adjusting the die set position cradle, first note what direction the die set cradle must move according to the punched paper. 4. Remove the die. 5. Loosen the lock-down screw [1] of the Die Set Position Cradle. Figure 3.2 Die Set Position Cradle Adjustment. 6.
  • Page 52 Figure 3.3 Tighten the Lock-Down Screw. 8. Run a test of punched paper and recheck paper alignment. Re-adjust if necessary remembering to remove and replace the die each time.

  • Page 53: Repair And Adjustment Procedures

    Repair and Adjustment Procedures 4.1 Preparing the StreamPunch Pro for Service Most service requires that the StreamPunch Pro be separated from the printer and finisher and the rear cover be removed. Warning: Disconnect the unit from power and maintain the cord in your possession.

  • Page 54: Removing The Rear Cover

    4.1.2 Removing the Rear Cover Separate the punch from the printer and finisher first. Refer to “Separating the Punch from the Printer” on page 4.1.1. Procedure Tool Required • Phillips screwdriver or 1/4" hex head nut driver To remove the rear cover: 1.

  • Page 55: Door Latch

    4.2 Door Latch Procedure Ensure the door latch holds the door closed and that the activating bracket tab [1] depresses the door switch [2]. The tab should press the switch button just so that it is close to bottoming out. Figure 4.2 Door Latch and Switch.

  • Page 56: Door Latch And Switch Replacement

    • To move the door out, move the latch away from the front of the door. 4. Tighten the 2 screws [1] and close the door. 5. Test its operation. 4.2.2 Door Latch and Switch Replacement To replace the door switch: 1.

  • Page 57: Bypass Panel

    4.3 Bypass Panel Maintenance Schedule Clean every 750K cycles. Refer to “Bypass Paper Path Inspection and Cleaning” on page 1.4.17. Tools Needed • Phillips screwdriver or 1/4" nut driver • Flat bladed screwdriver • Needle nose pliers Procedure Separate the punch from the printer and remove the rear cover. See “Separating the Punch From the Printer”...
  • Page 58 3. From the rear of the punch, remove one of the E-rings from the Bypass shaft [3]. Figure 4.9 Remove E-Ring. 5. Slide the shaft [4] towards the end of the shaft without the E-Ring [5] until the other end of the shaft clears the nylon bushing and bracket. 6.
  • Page 59 Installation Note: Position the Bypass panel so that it is outside the shaft mounting brackets [7]. The nylon bushings [8] go through the mounting brackets, into the Bypass panel [9]. Installation Note: Make sure the nylon bushing is installed so that it protrudes through the mounting bracket of the rear frame into the Bypass panel [9].

  • Page 60: Bypass Idler Roller Replacement

    4.3.2 Bypass Idler Roller Replacement Idler rollers press against the drive rollers and move the paper through the bypass [1]. Rollers can be serviced without removing the Bypass panel. Maintenance Schedule Inspect and clean every 750K cycles. Refer to “Idler Roller Inspection and Cleaning” on page 1.4.12.

  • Page 61: Bypass Drive Roller Replacement

    4.3.3 Bypass Drive Roller Replacement Maintenance Schedule Inspect and clean every 750K cycles. Refer to “Drive Roller Inspection and Cleaning” on page 1.4.13. Tools Needed • Phillips screwdriver or 1/4" nut driver • Flat bladed screwdriver • Phillips screwdriver • Retaining ring pliers To remove the Bypass drive rollers: 1.
  • Page 62 2. Tilt the storage rack up at the exit side so that the 2 cable shield screws [2] can be removed. Figure 4.14 Removing the Cable Shield Screws 4. With the cable shield removed, remove the die storage rack being careful not to snag the exposed wires.
  • Page 63 6. Remove the 2 Phillips head screws [5] holding the lower bypass panel to exit aligner drive panel. These screws will also need to be removed when removing the Exit Aligner Drive Panel. Figure 4.17 Removing the Phillips Head Screws 7.
  • Page 64 9. Remove the E-rings [8] from the front of the bypass rollers. The roller assemblies can now be pushed towards the rear of the machine and removed. Take care to hold the bearings when removing the rollers. Figure 4.19 Removing the Bypass Drive Rollers 10.

  • Page 65: Punch Path Idler Roller Replacement

    4.4 Punch Path Idler Roller Replacement Idler rollers press against the drive rollers and move the paper through the StreamPunch Pro. Most can be serviced without disassembling punch components. Unplug unit and separate from the printer. Refer to “Separating the Punch from the Printer”...
  • Page 66 Figure 4.21 Release the Idler Roller Retaining Spring. 2. Pull the released shaft end out of the bushing fork [2], releasing the opposite end of the shaft from the other retaining spring. 3. To install idler roller assemblies reverse the steps. Type B Follow the same steps to remove Type B rollers.

  • Page 67: Aligner Panels

    The entrance side Aligner panel positions the paper in the Back Gauge for punching. The exit side Aligner panel positions the paper for the finisher. Prior to servicing the Aligner Panels, separate the StreamPunch Pro from the printer. Refer to “Separating the Punch From the Printer” on page 4.1.1.

  • Page 68: Aligner Panel Removal

    4.5.2 Aligner Panel Removal Removing the Aligner panels provides access to the paper path and the Aligner belt (green belt). The procedure is the same for the entrance and exit Aligner panels except that the exit side has a docking plate instead of a docking bracket, which must be removed first.
  • Page 69 Figure 4.24 Removing Entry Aligner Panel. 4. Remove the shaft nylon bushings [5]. 5. Remove the Aligner panel out the front of the punch. 6. Reverse the steps to install the Aligner panel.

  • Page 70: Aligner Belt (Green Belt) Replacement

    Aligner Belt (Green Belt) Replacement” on page 4.5.3.1 or “Paper Exit Side Aligner Belt (Green Belt) Replacement” on page 4.5.3.3. Caution: Disconnect the StreamPunch Pro from power and retain the power cord in your possession for your safety. Failure to observe this caution can result in injury.

  • Page 71: Paper Entrance Side Aligner Belt (Green Belt) Replacement

    4.5.3.1 Paper Entrance Side Aligner Belt (Green Belt) Replacement 1. Disconnect the entrance sensors wire from the side frame. 2. Remove the 4 screws that secure the front paper chute [1]. Figure 4.25 Remove 4 Paper Chute Screws. 3. To remove the J2 Latch, Door Latch [2]. a.
  • Page 72 Figure 4.26 Remove the Aligner Drive Belts 4. Loosen the belt idler [3]. 5. Remove the belt [4]. 6. Remove the rear top pulley [5]. 7. Remove the 2 screws revealed behind the pulley holding the bearing block to the frame.
  • Page 73 10. Remove the solenoid assembly from the shaft and let it hang. 11. Remove the 2 E-Rings and the knob of the Entrance Diverter assembly, slide the Diverter out and set it aside. The Aligner is the large sheet metal assembly that contains the Aligner belt (green belt) and Aligner.
  • Page 74 16. Remove the Aligner belt (green belt) assembly by removing the 4 screws [10]. The flex shaft can be removed from the bearing block at this stage, but it is recommended to leave the flexible shaft attached to the aligner roller assembly, unless it is being replaced.

  • Page 75: Replacing The Aligner Belt (Green Belt)

    4.5.3.2 Replacing the Aligner Belt (Green Belt) 1. Stretch the new Belt onto the Aligner Roller assembly [1], green side out. Rotate the Shaft [2] to confirm that the belt tracks properly. Figure 4.30 Replacing the Aligner belt (green belt).
  • Page 76 2. Slide the Aligner into place, loosely attach the 4 Pan Head Screws with the 4 Lock Washers and do the following. a. Check that the metal surface of the Aligner Roller assembly is flush with the Sheet Metal surface of the Paper Guide. A 12" metal ruler works well to check this adjustment.
  • Page 77 To install the Paper Guide assembly into the StreamPunch Pro: Reverse the steps as listed for removal taking care to ensure the following. 1. As you slide the Paper Guide assembly into place, do the following. a. Hook up the Sensor Harness to the Sensor on the back.

  • Page 78: Paper Exit Side Aligner Belt (Green Belt) Replacement

    4.5.3.3 Paper Exit Side Aligner Belt (Green Belt) Replacement 1. Remove only one (the one closest to the frame) of the E-Rings of the J5 latch on the right end (front door side). 2. Push the J5 latch in toward the front door until it clears the rear frame. 3.
  • Page 79 Figure 4.34 Removing the Aligner Drive Belt 7. Walk the belt off of the Aligner Pulley at the rear [2]. The pulleys can be removed if needed. 8. Remove the 2 screws that hold the block to the frame [3]. The coupler is now loose and the rear panel can be removed.
  • Page 80 10. Remove the 2 screws that secure this assembly to the lower bypass panel [5]. See Bypass Drive Roller Replacement on Page 4.3.3 on how to access these screws. 11. Gently pull the top of the panel so that the sensor can be disconnected. 12.
  • Page 81 When installing the Paper Guide assembly into the StreamPunch Pro, reverse the steps above and note the following: a. As you slide the Paper Guide assembly into place: – Hook up the Sensor Harness to the Sensor on the back.

  • Page 82: Back Gauge Assembly

    Back Gauge. This procedure also allows the removal of the Punch Module. To repair or replace the Back Gauge, separate the StreamPunch Pro from the printer and finisher and then remove the rear cover. See “Preparing the StreamPunch Pro for Service”...

  • Page 83: Back Gauge Removal

    4.6.1 Back Gauge Removal To remove the Back Gauge assembly: 1. Turn the Punch Cycle knob [1] so that the punch drive indicator [2] lines up the position indicator. Figure 4.37 Punch Cycle Knob and Drive Indicator. 2. Remove the Die Set and Chip Bin. 3.
  • Page 84 3. Remove the two Die Set Chip Brush bracket screws [4]. Figure 4.39 Die Set Chip Brush Bracket. Figure 4.40 Die Set Adjustment Bracket and Drive Flag Sensor Connection. 5. On the rear of the punch, unplug the drive flag sensor connector [5]. 6.
  • Page 85 6. Remove the 2 Back Gauge rear mounting screws [7]. Figure 4.41 Rear Back Gauge Mounting Screws. 7. Disconnect the Back Gauge connector from the control board [8]. Figure 4.42 Back Gauge Solenoid Connector on the Control Board. 9. Cut wire harness ties or release wire clamps as needed to free the solenoid wires.
  • Page 86 10. Cut the 2 harness ties or release clamp holding wires on rear frame [9]. Figure 4.43 Backgage Wires on Rear Frame. 11. Remove the grommet from the frame [10]. Note: If you are not replacing the Back Gauge or are removing it for access to the Punch Module, it is not necessary to pull the wire through the hole in the frame.
  • Page 87 13. Gently slide the Back Gauge assembly to the rear of the punch [12] so that it extends through the slot [13] and clears the wiring harness [14]. [14] [13] [12] Figure 4.45 Sliding Back Gauge Towards Rear of Punch. Caution: Do not damage the wires in the wiring harness.

  • Page 88: Testing

    4.6.1.1 Testing To test the Back Gauge: 1. Install a Die Set. 2. Rotate the punch drive knob to ensure the drive and cams turn easily. 3. Test for proper hole alignment to the paper edge by doing the following. a.

  • Page 89: Solenoid Spring Replacement

    4.6.2 Solenoid Spring Replacement Procedure Replace broken or missing springs. The springs are color coded and must be in the correct locations. [Red] [Silver] [Blue] Figure 4.47 Back Gauge Solenoid Springs.

  • Page 90: Back Gauge Paddle

    4.6.3 Back Gauge Paddle Procedure Deep or angled deep punches may be caused by a broken weld on the Paddle [1] shaft. Inspect the Paddle and press down on it while holding the linkage to keep the linkage from moving. If the paddle moves [2], replace the Back Gauge assembly. Figure 4.48 Testing for Broken Paddle Weld.

  • Page 91: Punch Module

    4.7 Punch Module 4.7.1 Punch Module Removal The Back Gauge assembly must be removed before removing the Punch Module. See “Back Gauge Assembly” on page 4.6. Tools Required • Phillips screw driver or 1/4" nut driver • Diagonal wire cutter •...
  • Page 92 4. Cut the cable ties or unclip the cable clamps on the left wiring harness [3] to free the Punch Module wiring. Figure 4.50 Wiring Harness at Rear of Punch. 5. Unplug the punch sensor cable [4] from the punch sensor, if not already removed.
  • Page 93 6. Remove the belts in the order shown in Figure 4.52. Figure 4.51 Order of Belt Removal.
  • Page 94 7. Remove the two rear Punch Module screws [5]. Figure 4.52 Punch Module Retaining Screws on Rear of Punch. 8. Remove the 4 power supply screws [6]. Figure 4.53 Power Supply. 9. Cut wire harness ties as needed to release the punch wiring. If the punch module is being removed for service then all wire ties/ cable clamps do not need to be released.
  • Page 95 10. Unplug the punch connector [6] from the control board if the punch module is being fully removed. Figure 4.54 Punch Connector on Control Board. 11. Carefully slide the Punch Module out the back of the punch. Ensure that the wiring harness does not get caught or prevent removal of the module.

  • Page 96: Clutch Replacement

    4.7.2 Clutch Replacement Procedure Replace if clutch is malfunctioning. Note: The clutch can be removed without removing the Punch Module. Tools Required • Phillips screwdriver or 1/4" nut driver • Hex wrench, 5/64" To remove the clutch: 1. Unplug the punch flag sensor connector [1]. Figure 4.56 Flag Sensor Connector on Rear of the Punch.
  • Page 97 2. Slide the fan [2] off the shaft. Figure 4.57 Punch Motor Fan. Installation Note: When installing the fan, be sure to align the flat of the fan hub with the flat on the shaft. Make sure the hub is facing away from the motor and that the fan does not hit the belt [3].
  • Page 98 4. Loosen the 2 pulley socket head set screws [5]. 5. Remove the pulley and its shaft key [6]. Figure 4.59 Drive Upper Pulley. 5. Remove the 2 clutch bracket screws [7]. Figure 4.60 Clutch Bracket. Installation Note: When installing the clutch bracket, ensure that the fork of the clutch engages the tab on the bracket [8].
  • Page 99 7. Loosen the 2 clutch socket head set screws [9], slide the clutch [10] off the shaft, and remove the shaft key [11]. Figure 4.61 Punch Clutch. 8. Cut wire ties or release the cable clamps as needed and unplug the clutch cable plug [12] from the control board connector J9.
  • Page 100 9. Slide the back portion of the clutch [13] off the shaft. The motor drive belt [14] can be removed at the same time. Figure 4.63 Drive Belt and Back Portion of Clutch. 10. To install the clutch, reverse these steps. Installation Note: When installing the clutch, be sure to install the shaft key.

  • Page 101: Punch Module Brake Replacement And Adjustment

    4.7.3 Punch Module Brake Replacement and Adjustment Procedure To replace the brake, first remove the clutch and related drives. See “Clutch Replacement” on page 4.7.2. The brake must be adjusted while on drive shaft. To adjust the brake, see “Punch Module Brake Adjustment” on page 4.7.3.2. Tools Needed •...
  • Page 102 3. Remove the E-Ring at the opposite end of the shaft [4]. 4. Slide the shaft out of the bearing bracket, away from the clutch end. 5. Slide the brake assembly off the shaft. Figure 4.65 Shaft E-Ring. 6. To install the brake assembly, reverse these steps.

  • Page 103: Punch Module Brake Adjustment

    4.7.3.2 Punch Module Brake Adjustment Procedure The brake can be adjusted without removing the brake from the shaft. The gap between the brake and the pad is 0.010" (0.25mm). To adjust the brake: 1. Loosen the 2 set screws [1] until the brake pad slides freely on the shaft. Figure 4.66 Brake Assembly Gap Adjustment.

  • Page 104: Punch Module Motor Replacement

    4.7.4 Punch Module Motor Replacement Procedure Replace motor when it malfunctions. To replace the Punch Module motor: 1. Cut any wire ties or release any cable clamps as necessary to release the motor wires. 2. Unplug motor wire connections from the capacitor [1]. Figure 4.67 Punch Capacitor.
  • Page 105 Installation Note: When installing the fan, be sure to align the flat of the fan hub with the flat on the shaft. Make sure the hub is facing away from the motor and that the fan does not hit the belt [3]. 4.

  • Page 106: Punch Module Motor Drive Belt Replacement

    4.7.4.1 Punch Module Motor Drive Belt Replacement Procedure Replace the belt when it is frayed, missing teeth, or worn out. To replace the Punch Module drive belts: 1. With the fan removed from the shaft, work the belt [1] off the clutch gear [2]. Figure 4.70 Motor Pulley and Belt.

  • Page 107: Punch Module Drive Roller Replacement

    4.7.5 Punch Module Drive Roller Replacement Procedure Inspect for wear patterns or grooves. The roller surface should be even and not glazed. Replace when the rollers exhibit these conditions. Tools Required • Phillips screw driver or 1/4" nut driver • Flat bladed screwdriver •...

  • Page 108: Entrance Rollers

    4.7.5.1 Entrance Rollers To replace the Punch entrance drive rollers: 1. Unhook the retaining springs [1] then remove the idler roller assembly [2]. 2. Unplug the sensor located inside the punch module [3]. Figure 4.72 Punch Entrance Rollers. 3. Remove the 2 screws at each end of the drive roller assembly [4]. It is recommended not to remove the idler roller bracket from the punch module.
  • Page 109 5. Slide the drive roller shaft and bracket towards the opposite end of the Punch Module [6] so that the end of the shaft clears the bearing at the end where you removed the E-Ring [5]. 6. Lift the drive roller and bracket out of the Punch Module [7]. 7.

  • Page 110: Exit Rollers

    4.7.5.2 Exit Rollers To replace the Punch exit drive rollers: 1. Move one retaining spring [1] to the side and then remove the idler roller assembly [2]. 2. Remove the 2 screws at each end of the idler roller assembly [3]. Figure 4.74 Remove Exit Roller.
  • Page 111 3. Remove the E-Ring at the end of the drive roller shaft [4]. Figure 4.75 Remove Exit Drive Roller Shaft E-Ring. 4. Slide the drive roller shaft and bracket towards the opposite end of the Punch Module [5] so that the end of the shaft clears the bearing at the end where you removed the E-Ring [4].

  • Page 112: Belt Replacement

    4.8 Belt Replacement Procedure Inspect all timing belts for wear, missing teeth, frayed edges, and cracks. The belts should be slightly loose with approximately 1/4” (6 mm) deflection. Belts that are too loose will not drive properly and belts that are too tight can wear out prematurely or damage their driven components.
  • Page 113 2. Remove the belts in order as shown in Figure 4.84. Figure 4.78 Order of Belt Removal. 3. To install and adjust the tension of the belts, reverse these steps.

  • Page 114: General Procedures

    3) Ensure the StreamPunch Pro is powered off. 4) Remove the plastic cover from the 9 pin connector on the back of the StreamPunch Pro and connect the other end of the null modem cable to this 9 pin connector.
  • Page 115 6) Launch Windows Application Hyper Terminal or Tera Term. Hyper Terminal is typically accessed through Programs>Accessories>Communications>HyperTerminal and is pre-installed on Windows 95/98, NT, 2000 and XP. Tera Term is a free emulation client that works on Windows 95/98, 2000, 2003, XP, Vista & 7. Use version 3.1.3 or later, which can be downloaded from http://www.ayera.com/teraterm/.
  • Page 116 Typing *.hex in file box will files in that folder. list the hex files in that folder. c) Select the appropriate StreamPunch Pro c) Select the appropriate StreamPunch Pro firmware file named *_Boot.hex firmware file named *_Boot.hex...
  • Page 117 14) Press “V” (Upper Case) to verify the firmware version number. BOOTLOADER>V StreamPunch Professional Ver.: 01.01 BOOTLOADER> 15) Once the upgraded version has been verified, shut off the StreamPunch Pro, disconnect the Null Modem cable, and turn on the StreamPunch Pro.

  • Page 118: Principle Of Operation

    5.2 Principle of Operation The StreamPunch Pro is a machine that punches various die set hole patterns into single sheets of paper. The punch has two paper paths. • The bypass section. • The punch path. The bypass moves the paper from the printer to the finisher without punching holes.

  • Page 119: Outputs

    Printer turns on StreamPunch Pro motor BC-3 only 5.2.4 Stepper #1 Control If punch is not enabled, the StreamPunch Pro will run in bypass mode (no punching). The printer will turn on both stepper motors. The time is measured for the leading edge of the first sheet to pass from sensor 1 to sensor 8.

  • Page 120: Punch Control

    5.2.5 Punch Control The punch cycle begins 20 msec after the leading edge of the sheet reaches Sensor 3. The brake is released, and the clutch is engaged. Sensor 9 now looks for the leading edge of its flag, and when seen, the clutch is disengaged, and the backstop is lowered.

  • Page 121: Specifications

    5.4 Specifications Refer to the User Manual. If any discrepancy exists, the User Manual specifications are to be considered the most current. Table 5.4.1 Punch Mode Paper weight Plain* 20lb bond – 80lb cover (75gsm – 216gsm) Coated* 24lb bond – 80lb cover (90gsm – 216gsm) Sheet size Letter configuration 279 ±0.75 x 216 ±0.75mm...

  • Page 122: Glossary Of Terms

    5.5 Glossary of Terms These terms are common to the punch and bindery industry. Cerlox The trade name GBC uses for its Plastic Binding Color coil A plastic coil that looks like a spring which is threaded through round holes punched in the document then the ends are cut off and crimped.

  • Page 123: Electrical Schematic

    Section 6 Electrical Schematic...

  • Page 124: Punch And Drive Motors

    6.1 Punch and Drive Motors 6.2 Switch and Power Supply...

  • Page 125: Die Set, Tray, And Door Interlock

    6.3 Die Set, Tray, and Door Interlock 6.4 Sensors...

  • Page 126: Entrance Motor

    6.5 Entrance Motor 6.6 Exit Motor...

  • Page 127: Solenoids, Clutch, Brake, And Ground

    6.7 Solenoids, Clutch, Brake, Counter, and Ground...

  • Page 128: Control Board Layout

    6.8 Control Board Layout CONNECTOR DESCRIPTION RICOH NUMBER MAIN AC POWER SWITCH CABLE VRC51393 24V PSU – AC POWER CABLE VRC51394 24V PSU – DC POWER CABLE VRC51395 COMMUNICATION CABLE, INTERNAL VR340028 TRANSPORT MOTOR HARD WIRED PUNCH MOTOR HARD WIRED...

  • Page 129: Installation And Set Up

    • Remove all shipping tape from doors and levers. 7.3 Cable Connections Review the table below to identify which section of the guide to refer to install the StreamPunch Pro/ Pro EX/ MP. Section Printers Finisher Pro C900 series, Pro C550/700 &...
  • Page 130 7.3.1 SR5000 Finisher The cables below are required to attach the StreamPunch Pro to this type of finisher. Finisher to StreamPunch cable Finisher to printer cable (longer version) p/n VR340046 p/n VRC57001 Remove the finisher rear cover and plug the 7 pin...
  • Page 131 There are two entrance paper guides provided with the StreamPunch Pro. Use the longer paper guide measuring about 14” long when used in conjunction with the SR5000 finisher. Install the paper guide, using the size #8 screws provided, to the lower entrance guide of the StreamPunch Pro.
  • Page 132 7.3.3 SR5020, SR5030, SR5040, SR5050, SR5060 Finishers Follow the same steps as in 7.3.1 but in step a) connect the 7 pin connector into CN110 on the finisher board. d) There are two entrance paper guides provided with the StreamPunch. Use the longer paper guide measuring about 14”...

  • Page 133: Installing The Sound Deadening Foam

    7.4 Installing the Sound Deadening Foam Supplied with the StreamPunch, you will find six strips of sound deadening foam are shipped loose for field installation. These are not attached at the factory to avoid compression and/or damage during shipping. To install, simply peal the back off to reveal the adhesive using the following steps as a reference.
  • Page 134 Apply one of the three longer strips to the left rear panel as shown. Exit side complete 7.4.2 Paper Entrance Side (Printer Side) Apply one of the two remaining long strips to the right side of the printer side of the StreamPunch as shown.

  • Page 135: Docking Bracket Installation

    7.5 Docking Bracket Installation The docking brackets are shipped in a separate bag along with size M4 mounting screws (not shown). There are 2 lengths supplied. You may need to use the longer screws for some printers when installing without the buffer pass unit.

  • Page 136: Leveling & Height Adjustment

    7.6 Leveling & Height Adjustment 7.6.1 Height Setting No height adjustment of the StreamPunch is required, for an installation site with a level floor, when docking upstream of the SR4050, SR5020, SK5010 or SR5030. If the floor is uneven then it is recommended to set the level of the StreamPunch using the downstream device as a reference.
  • Page 137 7.6.2 Adjusting the Casters Using a 9/16” (15mm) open ended wrench, loosen the jam nut(s) situated on the caster stud inside of the machine Using the 9/16” (15mm) wrench, rotate the caster stems to change the height. Re-tighten the jam nuts once the correct height is achieved.

  • Page 138: Final Steps

    (US) or www.ricoh-support.com/techuser/ (EU) or can be obtained by contacting Ricoh service. Special custom engine firmware must be installed if installing the StreamPunch with the Martini- C4 (MP 6001/7001/8001/9001). 7.7.2 Setting the Dip Switch If the unit is fitted with a dip-switch then the setting should be changed depending on the printer it is attached to.

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