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Ricoh RB5020 Service Manual

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

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Summary of Contents for Ricoh RB5020

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

  • Page 2: Revision History

    Revision History This is the Revision History for the Ring Binder RB5020 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 (action) is followed by the relevant illustration. The callouts [A], [B], [C] in text refer to the illustration below, not above.

  • 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

    Warnings, Cautions, Notes In this manual, the following important symbols and notations are used. • A Warning indicates a potentially hazardous situation. Failure to obey a Warning could result in death or serious injury. • A Caution indicates a potentially hazardous situation. Failure to obey a Caution could result in minor or moderate injury or damage to the machine or other property.

  • Page 6: Commonly Used Terms And Abbreviations

    To avoid injury, avoid touching the parts at the indicated location. To avoid injury, never touch the ring binder tray while the ring binder is operating. To avoid injury, never put your hand into the paper exit when removing bound booklets. Commonly Used Terms and Abbreviations Here is a list of commonly used terms and abbreviations that are used throughout the Field Service Manual and Appendices.

  • Page 7: Trademarks

    Terms Meaning Paper Feed Unit (Tray 1, Tray 2, Tray 3) Paper Transport Belt (between PTR and fusing unit) Paper Transfer Roller Ring Binder RB5020 (D737) TCRU Trained Customer Replacement Units Trailing Edge TM/P ID sensor. "ID sensor" is used in this manual. However, you may see "TM/P" in the SP codes on the operation panel.

  • Page 8: Table Of Contents

    TABLE OF CONTENTS Revision History..............................1 Symbols, Abbreviations and Trademarks ......................2 Conventions..............................2 Warnings, Cautions, Notes...........................4 Safety Label............................4 Commonly Used Terms and Abbreviations....................5 Trademarks..............................6 1. Replacement and Adjustment Common Procedures............................11 Before You Begin............................11 Handling the Binder Unit........................11 Standoffs on Harnesses........................12 Ring Cartridge..............................13 Rear Cover..............................
  • Page 9 Chad Box Sensor (S308)..........................35 Pre-Bind Jogger Sensors..........................35 Side Fence 1 HP Sensor (S601)......................35 Paddle Roller HP Sensor (S602)....................... 37 Clamp HP Sensor (S603)........................38 Alignment Pin HP Sensor (S604), Alignment Pin Up Sensor (S610)..........39 Shutter HP Sensor (S605)........................42 50-Sheet Detection Sensor (S606)....................43 Stack Thickness Sensor (S607)......................44 Paper LE Detect Sensor (S609)......................46 Stack Tamper HP Sensor (S612).......................47...
  • Page 10 Stacker Detect Sensor (S504)......................76 Tray Detection Sensor (S505)......................78 Motors................................80 Pre-Punch Jog Unit Motor..........................80 Side Jogger Motor (M302)....................... 80 Pre-Bind Jogger Motors..........................81 Paddle Roller Motor (M601)......................81 Alignment Pin Motor (M602)......................82 Paddle Roller Lift Motor (M603)....................... 83 Side Fence 1 Motor (M604)......................86 Side Fence 2 Motor (M606)......................

  • Page 12: Common Procedures

    1. Replacement and Adjustment Common Procedures Before You Begin Handling the Binder Unit Pulling out the Binder Unit 1. Open the front door. 2. Grip handle Mc8 and slowly pull the binder unit out of the finisher until it stops. (There are no wires attached to the binder unit.) Pushing in the Binder Unit 1.

  • Page 13: Standoffs On Harnesses

    1. Replacement and Adjustment • Always grip handle Mc8 when pulling out or pushing in the binder unit. • Never touch any other surface of the binder unit when it is moving. • To avoid injury the fingers, never push on the top of the binder unit to slide it back into the finisher as shown above.

  • Page 14: Ring Cartridge

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

  • Page 15: Rear Cover

    1. Replacement and Adjustment Rear Cover 1. Remove the rear cover [1] Left, rear edge( x1). [2] Rear cover ( x7). Top Cover 1. Remove the rear cover [1] Left, rear edge( x1). [2] Rear cover ( x7).
  • Page 16 Common Procedures 2. Disconnect the top cover at the rear: [1] Right rear corner ( [2] Left rear corner ( x1). 3. Disconnect the top cover at the front right corner [1] (...
  • Page 17 1. Replacement and Adjustment 4. At the front left corner, remove: [1] Door plate ( [2] Left door [3] Top cover ( 5. Lift off the top cover [1].

  • Page 18: Removing The Binder Unit

    Common Procedures Removing the Binder Unit It is recommended that the binder unit be removed for all servicing and maintenance. • Some of the binder unit covers can be removed with the binder unit still mounted on the rails. • However, the binder unit wobbles on the rails and slips easily back into the machine and does not provide a stable platform for removing sensors or motors.
  • Page 19 1. Replacement and Adjustment 5. Hold the binder unit from the rear with a firm grip under the top and bottom of the unit as shown below. 6. Lay the binder on its right side with its rubber stoppers down.

  • Page 20: Binder Unit Covers

    Common Procedures Binder Unit Covers Binder Unit Covers...

  • Page 21: Clamp Unit Cover

    1. Replacement and Adjustment Pre-Bind Jogger Front Cover Top Cover Left Cover Bottom Cover Clamp Unit Clamp Unit Cover Ring Supply Unit Right Cover Upper Right Cover Clamp Unit Cover 1. Open the right front door. 2. Remove the ring cartridge. 3.

  • Page 22: Pre-Bind Jogger Bottom Cover

    Common Procedures Pre-Bind Jogger Bottom Cover 1. Open the right front door. 2. Remove the ring cartridge. 3. Remove the binder unit from its rails and set it on a flat surface. page 17 4. Remove the pre-bind jogger bottom cover [1] ( x4).

  • Page 23: Pre-Bind Jogger Top Cover

    1. Replacement and Adjustment 5. Remove the pre-bind jogger front cover [1] ( x2). Pre-Bind Jogger Top Cover 1. Open the right front door. 2. Remove the ring cartridge. 3. Remove the binder unit from its rails and set it on a flat surface. (page 17) 4.

  • Page 24: Ring Supply Unit Upper Right Cover

    Common Procedures Ring Supply Unit Upper Right Cover 1. Open the right front door. 2. Remove the ring cartridge. 3. Remove the binder unit from its rails. (page 17) 4. Lay the binder unit down on its left side (stoppers up). 5.

  • Page 25: Separating Pre-Bind Jogger From Binder Unit

    1. Replacement and Adjustment Separating Pre-Bind Jogger from Binder Unit Follow this procedure to separate the pre-bind jogger from the binder unit. 1. Open the right front door and remove the ring cartridge. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3.
  • Page 26 Common Procedures 7. Slide the hooks [1] of the pre-bind jogger off the studs on both sides, and lift off binder unit. 8. Set the separated pre-bind jogger [1] on a clean flat surface. 9. If you replace the pre-bind jogger, do SP 6505 to 6507.

  • Page 27: Clamp Unit

    1. Replacement and Adjustment Clamp Unit 1. Open the right front door and remove the ring cartridge. 2. Remove the binder unit from its rails and set it on a flat surface. page 17 3. Separate the pre-bind jogger from the binder unit. (page 24) 4.
  • Page 28 Common Procedures 6. Disconnect the clamp unit at the bottom. [1] Left ( [2] Right ( 7. Remove the clamp unit from the binder unit and lay it on a flat surface.

  • Page 29: Pre-Punch Jog Unit

    1. Replacement and Adjustment Pre-Punch Jog Unit 1. Remove the rear cover. 2. Loosen the motor bracket [1] ( x2). 3. While turning the loosened bracket slightly to the right, disconnect the timing belt [2] from the gear. 4. Disconnect the motor and sensor [3] ( x2).
  • Page 30 Common Procedures 9. At the rear, remove the rear screws [1] ( x2). 10. Raise the pre-punch jog unit [1] slightly and slowly pull it out of the finisher. 11. Set the pre-punch jogger unit [1] on a flat surface.

  • Page 31: Punch Unit

    1. Replacement and Adjustment 12. After replacing the pre-punch jog unit, do SP6504. (See "SP6504 Adjustment" in "Common Procedures".) Punch Unit 1. Open the left and right front doors. 2. Remove the screws of the punch unit [1] ( x2). 3.

  • Page 32: Sp6504 Adjustment

    Common Procedures SP6504 Adjustment These adjustments must be done after one or more of the following items has been replaced: • Binder unit control board (sub board) • Ring binder main board • Pre-punch jogger unit • Pre-punch jogger HP sensor (S301) 1.

  • Page 33: Hole Position Adjustment

    1. Replacement and Adjustment • After the following adjustment, keep the front door of the Ring Binder closed and turn main power switch OFF and ON. 1. Do SP6504 and enter the number printed on the label attached to the punch unit. (For more details about SP6504, please refer to Section 5 of the main machine service manual.) 2.
  • Page 34 Common Procedures 1. Close the front door of the Ring Binder. • After the following adjustment, keep the front door of the Ring Binder closed and turn main power switch OFF and ON. 2. Use a micrometer to measure X at [1].

  • Page 35: Sensors

    1. Replacement and Adjustment Sensors Pre-Punch Jogger HP Sensor (S301) 1. Remove the rear cover. (page 14) 2. Remove the pre-punch jogger unit. (page 28) 3. Set the pre-punch jogger unit on a flat surface. 4. Turn over the pre-punch jogger unit 5.

  • Page 36: Chad Box Sensor (S308)

    Sensors Chad Box Sensor (S308) 1. Remove the rear cover. (page 14) 2. Remove the main control board bracket [1] ( x 27, x8). 3. Remove the sensor ( x1). Pre-Bind Jogger Sensors Side Fence 1 HP Sensor (S601) 1. Open the right front door. 2.
  • Page 37 1. Replacement and Adjustment 4. Disconnect and move aside the harnesses and clamps ( x2, x2). 5. Remove the screw ( x1). 6. Remove: [1] Sensor bracket ( [2] Sensor (...

  • Page 38: Paddle Roller Hp Sensor (S602)

    Sensors Paddle Roller HP Sensor (S602) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3. Separate the pre-bind jogger from the binder unit. (page 24) 4.

  • Page 39: Clamp Hp Sensor (S603)

    1. Replacement and Adjustment Clamp HP Sensor (S603) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3. Remove the pre-bind jogger left cover. (page 20) 4.

  • Page 40: Alignment Pin Hp Sensor (S604), Alignment Pin Up Sensor (S610)

    Sensors 6. Remove the sensor ( Alignment Pin HP Sensor (S604), Alignment Pin Up Sensor (S610) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3. Remove the pre-bind jogger left cover. 4.
  • Page 41 1. Replacement and Adjustment 5. Remove: 6. Push up the arms of the scissors lift to raise the actuator away from the sensor on the right.
  • Page 42 Sensors 7. Under the unit base remove the sensor bracket screws ( x2). 8. Remove: [1] Alignment pin HP sensor (S604) ( x1, [2] Alignment pin up sensor (S610) ( x1,...

  • Page 43: Shutter Hp Sensor (S605)

    1. Replacement and Adjustment Shutter HP Sensor (S605) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. 3. Remove the pre-bind jogger unit bottom cover. 4. Remove the sensor bracket [1] ( x1).

  • Page 44: 50-Sheet Detection Sensor (S606)

    Sensors 50-Sheet Detection Sensor (S606) 1. Open the right front door. 2. Pull the binder unit out on its rails. 3. Rotate lock lever Mc7 so that you can see the screws of the front cover [1]. 4. Remove the front cover ( x2).

  • Page 45: Stack Thickness Sensor (S607)

    1. Replacement and Adjustment 6. Remove sensor bracket screw [3] ( x1). 7. Remove the sensor bracket. 8. Remove the sensor ( x1). Stack Thickness Sensor (S607) 1. Open the right front door. 2. Pull the binder unit out on its rails. 3.
  • Page 46 Sensors 4. Lower lever Mc7 [1] to move the actuator [2] away from the sensor. 5. Remove sensor bracket screw [3] ( x1). 6. Remove the sensor bracket.

  • Page 47: Paper Le Detect Sensor (S609)

    1. Replacement and Adjustment 7. Remove the sensor ( x1). Paper LE Detect Sensor (S609) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3. Remove the pre-bind jogger left cover. (page 20) 4.

  • Page 48: Stack Tamper Hp Sensor (S612)

    Sensors Stack Tamper HP Sensor (S612) 1. Open the right front door. 2. Pull the binder unit out on its rails. 3. Remove sensor cover [1] ( x1).
  • Page 49 1. Replacement and Adjustment 4. Remove: [1] Spring x1 [2] Sensor bracket [3] Sensor ( x1,...

  • Page 50: Shutter Hp Sensor (S613)

    Sensors Shutter HP Sensor (S613) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. 3. Turn the actuator [1] to the left or right until the cutout is over the sensor. 4.

  • Page 51: Ring Supply Unit Sensors

    1. Replacement and Adjustment 3. Remove the pre-bind jogger bottom cover. 4. Remove the sensor bracket [1] ( x1). 5. Remove the sensor ( x3). Ring Supply Unit Sensors Ring Cartridge Sensor (S801) 1. Open the right front door. 2. Remove the binder unit from its rails. (page 17) 3.

  • Page 52: Ring Cartridge Type Sensor (S805)

    Sensors 5. Remove the sensor ( x3). Ring Cartridge Type Sensor (S805) 1. Open the right front door. 2. Remove the binder unit from its rails. (page 23) 3. Lay the binder unit on its left side, and remove the ring supply unit right cover. (page 23) 4.

  • Page 53: Rings Reversed Sensor (S802)

    1. Replacement and Adjustment 5. Remove the sensor [1] ( x3). Rings Reversed Sensor (S802) 1. Open the right front door. 2. Remove the binder unit from its rails. (page 17) 3. Lay the binder unit on its left side, and remove the ring supply unit right cover. (page 23) 4.

  • Page 54: 50/100 Ring Detection Sensor (S804)

    Sensors 5. Remove the sensor [1] ( x1). 50/100 Ring Detection Sensor (S804) 1. Open the right front door. 2. Remove the binder unit from its rails. (page 17) 3. Lay the binder unit on its left side, and remove the right cover. (page 23) 4.

  • Page 55: Ring Near-End Sensor (S803)

    1. Replacement and Adjustment 5. Remove the sensor [1] ( x1). Ring Near-End Sensor (S803) 1. Open the right front door. 2. Remove the binder unit from its rails. (page 17) 3. Lay the binder unit on its left side and remove the right cover. (page 23) 4.

  • Page 56: Clamp Unit Sensors

    Sensors 5. Disconnect the sensor ( x3). Clamp Unit Sensors Binder Unit HP Sensor (S701) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3. Remove the clamp unit cover. (page 20) 4.

  • Page 57: Bind Timing Sensor (S702)

    1. Replacement and Adjustment 5. Pull the bracket straight out. 6. Remove the sensor ( x3). Bind Timing Sensor (S702) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3.

  • Page 58: Ring Switch Hp Sensor (S706)

    Sensors 5. Pull the bracket straight out. 6. Remove the sensor ( x3). Ring Switch HP Sensor (S706) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3.

  • Page 59: Ring Switch Timing Sensor (S707)

    1. Replacement and Adjustment 5. Pull the bracket straight out and turn it over. 6. Remove the sensor ( x3). Ring Switch Timing Sensor (S707) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3.

  • Page 60: Output Belt Sensors

    Sensors 5. Pull the bracket straight out and turn it over. 6. Remove the sensor ( x3). Output Belt Sensors Output Belt 1 HP Sensor (S401) 1. Open the right and left front doors. 2. Remove base cover [1] ( x3).
  • Page 61 1. Replacement and Adjustment 3. Raise output tray 1 [1] until it stops and remains open. 4. Remove the sensor bracket [2] ( x1). 5. Remove the sensor ( x1, x3).

  • Page 62: Output Belt 2 Hp Sensor (S402)

    Sensors Output Belt 2 HP Sensor (S402) 1. Open the right and left front doors. 2. Remove base cover [1] ( x3). 3. Raise output tray 1 [1] until it stops and remains open. 4. Remove the sensor bracket [2] ( x1).

  • Page 63: Output Belt Unit Entrance Sensor (S404)

    1. Replacement and Adjustment 5. Remove the sensor ( x1, x3). Output Belt Unit Entrance Sensor (S404) 1. Open the right and left front doors. 2. Remove base cover [1] ( x3).
  • Page 64 Sensors 3. Raise output tray 1 [1] until it stops and remains open. 4. Remove the sensor bracket [2] ( x1). 5. Remove the sensor ( x1, x1).

  • Page 65: Output Belt Rotation Hp Sensor (S403)

    1. Replacement and Adjustment Output Belt Rotation HP Sensor (S403) 1. Remove the rear cover. 2. At the front, remove the stacker cover [1]. • The screw at [2] has a washer. Do not lose the washer. Be sure to reinstall the screw with the washer at this corner.
  • Page 66 Sensors 3. Spin the timing belt of the tray lift motor to lower the tray. (This may take about 1 minute.) 4. Remove the screws of the panel [1] ( x4).
  • Page 67 1. Replacement and Adjustment 5. At the back of the finisher, remove the panel rear screw ( x1). 6. Remove the panel. 7. Remove the sensor bracket [1] ( x1).

  • Page 68: Stacker Unit Sensors

    Sensors 8. Remove the sensor ( x1, x1). Stacker Unit Sensors Obstacle Detection Switch (S506) 1. Remove the rear cover. 2. Spin the timing belt of the tray lift motor to lower the tray. (This may take about 1 minute.)
  • Page 69 1. Replacement and Adjustment 3. Remove the cover ( x2). 4. Remove the sensor bracket [1] ( x2). 5. Remove the micro-switch (Standoff x1, x2).

  • Page 70: Book Position Sensor Pair (S507E/S507R)

    Sensors Book Position Sensor Pair (S507E/S507R) Book Position Sensor (S507E) 1. Remove panel [1] from the left side of the finisher ( x4). 2. Remove the sensor bracket [1] ( x1).
  • Page 71 1. Replacement and Adjustment 3. Remove the sensor ( Book Position Sensor (S507R) 1. Remove the rear cover. 2. Remove: [1] Red connector ( [2] Black connector ( [3] Red, black connector ( [4] Lower screws ( [5] Upper screws (...
  • Page 72 Sensors 3. Remove the sensor bracket ( x1). 4. Remove the sensor ( x1).

  • Page 73: Stack Height Sensor Pair (S052E/S502R)

    1. Replacement and Adjustment Stack Height Sensor Pair (S052E/S502R) Stack Height Sensor (S502E) 1. Remove panel [1] from the left side of the finisher ( x4). 2. Remove the sensor [1] ( x1).
  • Page 74 Sensors Stack Height Sensor (S502R) 1. Remove the rear cover. 2. At the front, remove the stacker cover [1]. • The screw at [2] has a washer. Do not lose the washer. Be sure to reinstall the screw with the washer at this corner.
  • Page 75 1. Replacement and Adjustment 4. Remove the screws of the panel [1] ( x4). 5. At the back of the finisher, remove the panel rear screw ( x1).
  • Page 76 Sensors 6. Remove the panel. 7. Remove the sensor bracket [1] ( x1). 8. Remove the sensor ( x1, x1).

  • Page 77: Stacker Detect Sensor (S504)

    1. Replacement and Adjustment Stacker Detect Sensor (S504) 1. Remove the rear cover. 2. Spin the timing belt of the tray lift motor to lower the tray. (This may take about 1 minute.) 3. Remove the cover ( x2).
  • Page 78 Sensors 4. Remove the sensor bracket [1] ( x2). 5. Remove the sensor ( x1).

  • Page 79: Tray Detection Sensor (S505)

    1. Replacement and Adjustment Tray Detection Sensor (S505) 1. Remove the rear cover. 2. Spin the timing belt of the tray lift motor to lower the tray. (This may take about 1 minute.) 3. Remove the cover ( x2). 4. Remove the sensor bracket [1] ( x2, Spring x1).
  • Page 80 Sensors 5. Remove the sensor ( x1, x1).

  • Page 81: Motors

    1. Replacement and Adjustment Motors Pre-Punch Jog Unit Motor Side Jogger Motor (M302) 1. Remove the rear cover. 2. Remove the pre-punch jogger unit. (page 28) 3. Set the pre-punch jogger unit on a flat surface. 4. Turn the pre-punch jog unit over. 5.

  • Page 82: Pre-Bind Jogger Motors

    Motors Reinstallation 1. Reattach the motor as shown above, so that the motor connector [1] is positioned properly. Pre-Bind Jogger Motors Paddle Roller Motor (M601) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3.

  • Page 83: Alignment Pin Motor (M602)

    1. Replacement and Adjustment 6. Remove the motor ( x1). Alignment Pin Motor (M602) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3. Remove the pre-bind jogger left cover. (page 20) 4.

  • Page 84: Paddle Roller Lift Motor (M603)

    Motors 5. Remove the motor bracket and motor ( x2). 6. Remove the motor bracket ( x2). Paddle Roller Lift Motor (M603) 1. Open the right front door.
  • Page 85 1. Replacement and Adjustment 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3. Separate the pre-bind jogger from the binder unit. (page 24) 4. Lay the jogger unit on its left side. 5.
  • Page 86 Motors 8. Remove the paddle roller lift assembly. 9. Disconnect the motor and bracket [1] and remove them from the paddle roller lift assembly ( x3). 10. Remove the motor from the bracket ( x2).

  • Page 87: Side Fence 1 Motor (M604)

    1. Replacement and Adjustment Side Fence 1 Motor (M604) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3. Remove the pre-bind jogger left cover. 4. Below the left corner of the fan [1], loosen (Do not remove!) the screw to release tension on the timing belt.
  • Page 88 Motors 5. Disconnect the motor and remove the screws ( x2). 6. Remove the motor. 7. Separate the bracket and the motor ( x2).

  • Page 89: Side Fence 2 Motor (M606)

    1. Replacement and Adjustment Re-installation 1. Make sure the tension screw [1] is completely to the left, then tighten it. This provides maximum exposure of the belt [2] below the hole, and prevents it from moving when the motor is re-installed. 2.
  • Page 90 Motors 4. Behind the white gears, loosen (Do not remove!) the screw to release tension on the timing belt. 5. Disconnect the motor and remove the screws ( x2). 6. Remove the motor.
  • Page 91 1. Replacement and Adjustment 7. Separate the bracket and the motor ( x2). Re-installation 1. Make sure the tension screw [1] is completely to the down, then tighten it. This provides maximum exposure of the belt [2] below the hole, and prevents it from moving when the motor is re-installed.

  • Page 92: Spine Clamp Motor (M605)

    Motors 3. Loosen the tension screw, push it up to apply tension to the belt, then re-tighten the screw. Spine Clamp Motor (M605) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. page 17 3.
  • Page 93 1. Replacement and Adjustment 7. Turn lever Mc7 to expose the front cover. 8. Remove the front cover ( x2). 9. Remove the screws [1] and remove the motor bracket [2] ( x2). 10. Separate the bracket and the motor ( x2).

  • Page 94: Runout Roller Motor (M609)

    Motors Runout Roller Motor (M609) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3. Remove the pre-bind jogger left cover. (page 20) 4. Remove the pre-bind jogger bottom cover. (page 21) 5.

  • Page 95: Stack Tamper Motor (M607)

    1. Replacement and Adjustment 8. Separate the bracket and the motor ( x2). Stack Tamper Motor (M607) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3.

  • Page 96: Shutter Motor (M608)

    Motors 5. Separate the bracket and the motor ( x2). Shutter Motor (M608) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3. Disconnect: [1] Motor [1] ( x1, [2] Sensor [2] (...
  • Page 97 1. Replacement and Adjustment 4. Disconnect the motor bracket ( x2). 5. While holding the motor [1] on the left, pull out the spring-loaded cam follower [2] then remove the bracket [3] with the motor. 6. Separate the bracket and the motor ( x2).

  • Page 98: Runout Press Roller Motor (M610)

    Motors Runout Press Roller Motor (M610) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3. Remove the pre-bind jogger left cover. 4. Disconnect the pin alignment motor [1], and the runout press roller motor [2] ( x1).
  • Page 99 1. Replacement and Adjustment 6. Remove the pin alignment motor. 7. Remove the runout press roller motor bracket. 8. Remove the timing gear [1], then separate the bracket [2] and the motor ( x2).

  • Page 100: Fan Motor (M611)

    Motors Fan Motor (M611) 1. Open the right front door and pull out the binder unit. 2. Remove the left cover of the pre-bind jogger unit. (page 20) 3. Remove the fan motor ( x2). Clamp Unit Motors Clamp Unit Motor (M701) 1.
  • Page 101 1. Replacement and Adjustment 4. Release the harnesses [1] ( x4). 5. Remove screws [2] and [3] from the left and right ends of the brace. 6. Pull off the brace [4] to expose the motor [5]. 7. Mark the shaft and timing gear [1] with a black marker. (This will make it easier to reattach the gear at reinstallation.) 8.

  • Page 102: 50/100 Clamp Adjust Motor (M702)

    Motors 10. Remove the motor. 50/100 Clamp Adjust Motor (M702) 1. Open the right front door. 2. Remove the binder unit from its rails and set it on a flat surface. (page 17) 3. Remove the clamp unit. (page 26) 4.
  • Page 103 1. Replacement and Adjustment 7. Disconnect the harnesses and remove the motor ( x2).

  • Page 104: Boards

    Boards Boards Main Control Board 1. Remove the rear cover. (page 14) 2. Remove the main control board ( x all, x1 at upper right corner). 3. After you install the new board, do SP6504 to SP6507. (See Section 5 of the main Service Manual.) •...

  • Page 105: Doing The Sp Adjustments

    1. Replacement and Adjustment 3. Remove the binder control board from the side of the binder unit ( x All, x1 at upper left corner). 4. Install the new board. Doing the SP adjustments 1. Locate the label attached to the bottom cover of the pre-bind jogger unit. 2.

  • Page 106: Psu

    Boards • The A4 punch unit must be installed for punching and binding A4 sheets; the LT punch unit must be installed for punching and binding LT sheets. Also, the proper size rings (A4 or LT) must be installed in the ring cartridge. 3.
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