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Ricoh SR5090, Field Service Manual

The Ricoh SR5090 Field Service Manual is a comprehensive guide for troubleshooting and maintenance of the Ricoh SR5090 printer. Available for free download from manualshive.com, this manual provides step-by-step instructions to help you keep your printer running smoothly and efficiently. Get your copy today and keep your printer in top condition.

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1.Detailed Descriptions 

43 

Saddle Stitching with This Finisher 

Previously, strong pressure had to be applied in order to shape the saddle; this could only be possible if 

the finisher is big. This finisher uses the method below to make a saddle without having to be large in 

size. 

1. 

Pressure is applied to the fold with a roller to form the saddle. 

2. 

Pressure is applied while the paper is buckled at the top and bottom with two rollers to form the 

saddle. The rollers move to front and back to strengthen the crease with two folds, not just one fold. 

 

Components 

 

Summary of Contents for SR5090

Page 1: ...Finisher SR5090 Booklet Finisher SR5100 Machine Code D3GD D3GC Field Service Manual Ver 1 0 Latest Release March 2019 Initial Release March 2019 Copyright c 2019 Ricoh Co Ltd...

Page 2: ......

Page 3: ...ose symbols and abbreviations are as follows Symbol What it means Clip ring Screw Connector Clamp E ring Flat Flexible Cable Timing Belt SEF Short Edge Feed LEF Long Edge Feed K Black C Cyan M Magenta...

Page 4: ......

Page 5: ...ral Layout 18 Electrical Component Layout 19 Transport Layout 24 Proof Transport Layout Drive 24 Proof Transport Layout Sensors 25 Shift Transport Layout Drive 25 Mechanisms 26 Shift Transport 26 Pre...

Page 6: ...73 Paper Stacking Holder HP Sensor 74 Stacking Sponge Roller HP Sensor 75 Staple Tray Paper Sensor S31 76 Feed out Belt HP Sensor 76 Leading Edge Guide HP Sensor 77 Upper Tray Height Limit Switch 78...

Page 7: ...3...

Page 8: ...the Previous Machine Improved Stackability of Stapled Sheets New Retraction Mode for the Delivery of Stapled Sheets To improve the stackability of stapled sheets the trailing edge alignment unit frame...

Page 9: ...During paper delivery they move to the home position The stacking sponge roller retracts slightly into the end fence On this machine when delivering stapled sheets the stacking sponge roller A and ac...

Page 10: ...ling are stacked the height of the stapled corner is higher and hits the paper guide edge guide or the next stapled booklet When one of the sensors detects paper the machine determines that the height...

Page 11: ...1 Detailed Descriptions 7 Storing Extra Staple Cartridges Thers is now a holder for storing extra cartridges This staple cartridge holder A is affixed to the inside of the finisher s front door...

Page 12: ...hing the Booklet Tray End Fence By the Customer The screw for securing the end fence A has been changed to a coin screw allowing the customer to detach and reattach the end fence Staple Near End Detec...

Page 13: ...5 or larger Paper size for the Finisher Shift Tray A3 SEF A4 SEF LEF A5 SEF LEF B4 JIS SEF B5 JIS SEF LEF B6 SEF 11 x 17 SEF 81 2 x 14 SEF 81 2 x 13 SEF 81 2 x 11 SEF LEF 81 4 x 14 SEF 81 4 x 13 SEF 8...

Page 14: ...16K SEF LEF 11 x 15 SEF 11 x 14 SEF 10 x 15 SEF 10 x 14 SEF 226 310 mm SEF 81 2 x 132 5 SEF 81 2 x 131 2 SEF Staple paper weight 52 3 105 0 g m2 14 0 lb Bond 28 0 lb Bond You can use a sheet of paper...

Page 15: ...With punch unit 41 kg 90 4 lb or less Booklet Finisher SR5100 Item Specifications Paper size for the Finisher Upper Tray A3 SEF A4 SEF LEF A5 SEF LEF A6 SEF B4 JIS SEF B5 JIS SEF LEF B6 JIS SEF 11 x...

Page 16: ...F 11 x 15 SEF 11 x 14 SEF 10 x 15 SEF 10 x 14 SEF SRA4 SEF LEF 226 310 mm SEF 81 2 x 132 5 SEF 81 2 x 131 2 SEF custom size Paper weight that can be shifted when delivered to the Finisher Shift Tray 5...

Page 17: ...100 sets A3 SEF A4 SEF B4 JIS SEF B5 JIS SEF 11 17 SEF 81 2 14 SEF 81 2 13 SEF 81 2 11 SEF 81 4 14 SEF 81 4 13 SEF 8 13 SEF 71 4 101 2 SEF LEF 8K SEF 16K SEF LEF 11 15 SEF 11 14 SEF 10 15 SEF 10 14 S...

Page 18: ...RA4 SEF 81 2 x 132 5 SEF 81 2 x 131 2 SEF LGT Custom size Vertical 182 0 330 2 mm 7 17 13 00 inches Horizontal 257 0 457 2 mm 10 12 18 00 inches Folding capacity of half folding function 1 sheet 64 0...

Page 19: ...7 SRA3 SEF 11 17 SEF 8 1 2 14 SEF 8 1 2 11 SEF 81 2 11 LEF 51 2 81 2 SEF 51 2 81 2 LEF Here is the key for the symbols Corner stapling booklet stapling paper shift proof tray punching possible Booklet...

Page 20: ...ble Punch Unit PU3090 Punch unit type Paper size 2 4 holes type 2 holes SEF A3 B4 JIS A4 B5 JIS A5 11 x 17 81 2 x 14 81 2 x 11 51 2 x 81 2 71 4 x 101 2 8 x 13 81 2 x 13 81 4 x 13 8K 16K 81 4 x 14 8 x...

Page 21: ...2 8 x 13 81 2 x 13 81 4 x 13 8K 16K 81 4 x 14 8 x 10 11 x 15 10 x 14 custom size 2 3 holes type 2 holes LEF A4 B5 JIS 81 2 x 11 71 4 x 101 2 16K custom size 2 3 holes type 3 holes SEF A3 B4 JIS 11 x 1...

Page 22: ...1 Detailed Descriptions 18 Layout General Layout No Name No Name 1 Punch Units 5 Corner Stapler 2 Side to Side Fold Roller 6 Shift Tray 3 Booklet Stapler 7 Proof Tray 4 Booklet Staple Tray...

Page 23: ...nent Layout No Part 1 Exit Motor 2 Transport Motor 3 Positioning Roller Motor 4 Controller Board 5 Pre stack Transport Motor 6 Entrance Transport Motor 7 Horizontal Transport Motor 8 Tray Lift Motor 9...

Page 24: ...10 LED 2 3 Lower Junction Gate Motor 11 Horizontal Transport Sensor 4 Proof Tray Full Sensor 12 Switchback Transport Sensor 5 Entrance Sensor 13 Transport Path Paper Sensor 6 LED 1 14 Proof Tray Exit...

Page 25: ...No Part 1 Paper Exit Guide Plate Motor 10 Stacking Sponge Roller HP Sensor 2 Paper Exit Guide Plate Limit Switch 11 Paper Stacking Holder Motor 3 Booklet Stack Height Sensor 1 12 Shift Tray Lower Lim...

Page 26: ...nsor 12 Booklet Guide Plate Sensor 4 Booklet Upper Transport Path Stack Sensor 13 Booklet LED 2 5 Booklet Jogger Motor 14 Booklet LED 3 6 Booklet Jogging HP Sensor 15 Booklet LED 4 7 Booklet Bottom Fe...

Page 27: ...nsport Motor 7 Press Fold Motor Punch Unit Option No Part 1 Punch Unit Movement Motor 2 Punch Unit HP Sensor 3 Punch Registration HP Sensor 4 Punch Registration Motor 5 Punch Registration Sensor 6 Pun...

Page 28: ...ight Through Path Orange Proof Path Green Pre stack Path Purple Corner Staple Path Pink Booklet Staple Path Proof Transport Layout Drive No Name No Name A Exit Motor C Entrance Transport Motor B Upper...

Page 29: ...e No Name A Proof Tray Full Sensor C Horizontal Transport Sensor B Proof Tray Exit Sensor D Entrance Sensor Shift Transport Layout Drive No Name No Name A Shift Motor shift only D Transport Motor B En...

Page 30: ...g Pre Stack Capacity 1 sheet Pre Stack Sizes A4 SEF LEF B5 SEF LEF LT SEF LEF Pre stack is performed in four steps as follows 1 The upper tray exit guide plate A moves up opens Paper comes through the...

Page 31: ...sheet comes through the entrance and reaches the relay transport path After that the shift roller A drops to press the pre stacked sheet and the following sheet Then with the pre stacked sheet the fo...

Page 32: ...essure between itself D and the relay transport roller C 4 The following sheet comes thorough the entrance and reaches the relay transport path After that the shift roller A drops to press the pre sta...

Page 33: ...tor A moves the tray up and down Paper Height Detection The Shift Tray Paper Height Sensor B uses an actuator the rise of the tray without paper To prevent the tray from rising too high due to a failu...

Page 34: ...at one point corner stapling are stacked the sensors prevents the sheets from hitting the paper guide edge guide or the next stapled booklet as they are stacked up When one of the sensors detects the...

Page 35: ...LG SEF LT SEF 12 x18 SEF SRA3 13 x19 2 SEF 182 to 488 mm 2 000 sheets Shift Tray Lower Limit Sensor 2 A4 LEF LT LEF Finisher SR5090 Number of Sheets Detected By Paper Size Length 500 sheets Shift Tray...

Page 36: ...P6 123 037 INPUT Check ON If the feeler remains up for 13 seconds the machine deems that the stacking limit has been reached This is meant for the correct detection of tray full for stacking Z folded...

Page 37: ...1 Detailed Descriptions 33 Pull in Roller Paper Stack Holder Components No Name No Name 1 Paper Stacking Holder 7 Paper Stacking Holder Lift Motor...

Page 38: ...lder motor rotates the paper stacking holder cam B to move the paper stacking holder A down 2 The paper stacking holder lift motor D rotates the stacking sponge roller cam to move the stacking sponge...

Page 39: ...e position At the same time the paper stacking holder motor rotates the holder cam E to lift the paper stacking holder B up to its home position until the paper stacking holder HP sensor C detects the...

Page 40: ...36 Corner Stapling Components No Name No Name 1 Positioning Roller Shift Motor 5 Drag Roller 2 Positioning Roller 6 Stapler 3 Exit Motor 7 Stapler Move HP Sensor 4 Corner Stapler Movement Motor 8 Posi...

Page 41: ...t with stack feed out pawl 3 Trailing Edge Fence 2 Feed out Belt Motor 4 Feed out Belt HP Sensor Edge Guide The paper is stapled in the corner with a part of it protruding from the paper exit The edge...

Page 42: ...etects the edge guide Stapler Movement The corner stapler movement motor A moves the stapler C along the guide rod B After a job finishes the stapler C returns to its HP the stapler move HP sensor D d...

Page 43: ...inst the trailing edge fence in order to hold paper in the stapling position Jogger The jogger motor A moves the jogger fences C to the ready position and waits for the first sheet As each sheet enter...

Page 44: ...the trailing edge fence B After a paper stack is output both the trailing edge fence B and stack feed out pawl A return to their home positions There are two ways of feeding out paper 1 By pawl exit...

Page 45: ...as detected that the staples have run out End it is reset when it detects staples replenished Staples used in the End status are not counted Number of Remaining Staples Maximum number Counted Number o...

Page 46: ...the estimated number of remaining staples in the new cartridge Automatic Counter Reset After reaching the near end status if the staples do not run out End even after the number of staples used exceed...

Page 47: ...her is big This finisher uses the method below to make a saddle without having to be large in size 1 Pressure is applied to the fold with a roller to form the saddle 2 Pressure is applied while the pa...

Page 48: ...Sensor 3 Shift Roller drive Motor 10 Bottom Fence 4 Booklet Upper Transport Path Stack Sensor 11 Jogger Fence 5 Booklet Jogger Motor 12 Booklet Stapler 6 Booklet Jogging HP Sensor 13 Booklet Guide Pla...

Page 49: ...rt paper The shift roller lift motor moves the shift roller unit A The shift roller drive motor rotates the shift roller B to transport paper to the bottom After the paper is transported the shift rol...

Page 50: ...ready position this depends on the paper size Bottom Fence Operation Stapling The stack is pushed by the stack junction gate to the bottom fence B in order to align it Then the booklet staplers C stap...

Page 51: ...Sensor Center Folding and Saddle Shaping Stack folding and saddle shaping is explained below For saddle shaping only see Saddle Shaping When the fold plate B pushes the center of the stack between th...

Page 52: ...e fold plate cam HP Sensor A goes on twice the cam rotated twice saddle shaping is half finished and the fold roller unit is at position D The press fold motor switches into reverse At the same time i...

Page 53: ...C It moves along a rail when it comes to the center the upper fold up descends and then pressure from a large spring folds the center of the stack With the pressure of the side to side fold roller ap...

Page 54: ...entangled on the shift tray The paper guide motor drives the paper guide cover to reduce the amount of curl and prevent the leading edges from curling and improve the output of stapled copies on the...

Page 55: ...access the following parts by executing SP 6 160 004 Positioning Roller A The paper exit guide plate moves upwards and the positioning roller pops up in front for easier access Stacking Sponge Roller...

Page 56: ...ustment 52 2 Replacement and Adjustment Covers Rear Upper Cover Rear Lower Cover 1 Remove the rear upper cover A 2 Remove the rear lower cover A Upper Cover 1 Remove the rear upper cover Rear Upper Co...

Page 57: ...t 53 2 Remove the 2 screws and release the 2 hooks 3 Open the front cover A and remove the 2 screws 4 Remove the upper cover A When you detach or reattach the upper cover be sure to check the location...

Page 58: ...et B 2 Remove the front door A 1 Holding the hinge at the upper part of the cover raise the edge of the upper cover 2 Pull out the cover from the pin B at the bottom Front Left Side Cover 1 Remove the...

Page 59: ...2 Replacement and Adjustment 55 Paper Guide Cover 1 Remove the rear upper cover Rear Upper Cover Rear Lower Cover 2 Push the guides in to the center 3 Remove the paper guide cover A...

Page 60: ...and Adjustment 56 Remove the hook A at the right side Lower Tray 1 Remove the lower tray A Proof Tray 1 Remove the following covers Upper cover Rear Upper Cover Rear Lower Cover Paper guide cover Pape...

Page 61: ...of tray A Shift Tray Upper Tray 1 Remove the shift tray A End Fence 1 Remove the rear lower cover Finisher SR5090 only Rear Upper Cover Rear Lower Cover 2 Remove the paper guide cover Paper Guide Cove...

Page 62: ...justment 58 4 Remove the shift tray bracket A 5 Disconnect the connector CN180 and release the harness 6 Remove the end fence A When you remove the end fence be careful with the harness beneath it Boo...

Page 63: ...2 Replacement and Adjustment 59 Finisher SR5090...

Page 64: ...or securing the harness has come off the end fence reattach it Make sure there is no slack left in the harness otherwise the harness may come into contact with the machine s roller shaft and become wo...

Page 65: ...Boards Controller Board PCB1 1 Remove the following covers Rear upper cover Rear Upper Cover Rear Lower Cover Rear lower cover Rear Upper Cover Rear Lower Cover 2 Remove the Controller Board A Booklet...

Page 66: ...rocedure below to make dip switch settings 1 Check the settings of the dip switch A on the old main board 2 Replace the controller board 3 Change the settings of dip switch A on the new controller boa...

Page 67: ...right corner of the board 6 Enter the SP mode Change the following SPs using the numbers on the label SP6 121 001 NV Adj Data Jog Position Factory Adj SP6 121 002 NV Adj Data Fold Position Factory Adj...

Page 68: ...t Left Side Cover End fence End Fence Rear lower cover Rear Upper Cover Rear Lower Cover 2 Pull out the saddle stitch unit A and remove the inner upper cover B Disconnect the harness from the back sid...

Page 69: ...e release motor bracket A from the rear side of the finisher 5 Remove the gear A and timing pulley B from the rear side of the finisher 6 Remove the pulley A from the rear side of the finisher 7 Remov...

Page 70: ...ound wire connectors and clamps 9 Remove the four clamps and then pull the harness A out through the hole B on the left side of the finisher 10 Pull the harness C out through the hole D on the left si...

Page 71: ...p the paper exit guide unit B 13 Remove the bearings on the sides A from the cutouts on the metal plate 14 Remove the corner stapling unit A When removing the stapler unit make sure to leave the harne...

Page 72: ...2 Replacement and Adjustment 68 Trailing Edge Alignment Unit 1 Remove the corner stapling unit Corner Stapling Unit 2 Remove the trailing edge alignment unit A...

Page 73: ...ling edge alignment unit from the corner stapling unit Trailing Edge Alignment Unit 2 Remove the stacking sponge roller lift motor A 3 Disconnect the harness B from the stacking sponge roller lift mot...

Page 74: ...t 70 2 Remove the bracket A 3 Remove the leading edge guide motor A with its bracket 4 Remove the leading edge guide motor A from the bracket B Paper Stacking Holder Motor 1 Remove the corner stapling...

Page 75: ...ent 71 2 Remove the paper stacking holder motor A Exit Motor 1 Remove the rear upper cover Rear Upper Cover Rear Lower Cover 2 Remove the exit motor A Feed out Belt Motor 1 Remove the corner stapling...

Page 76: ...and Adjustment 72 2 Remove the feed out belt motor A Jogger Motor 1 Remove the trailing edge alignment unit Trailing Edge Alignment Unit 2 Remove the feed out motor Feed out Belt Motor 3 Remove the j...

Page 77: ...arness as shown in the following figure A The sensor layout and harness routing has changed from the previous machine B so be careful not to route the harness as shown in the following figure B Shift...

Page 78: ...paper height sensor A Paper Stacking Holder HP Sensor 1 Remove the trailing edge alignment unit Trailing Edge Alignment Unit 2 Turn over the trailing edge alignment unit and then remove the paper sta...

Page 79: ...ensor A Stacking Sponge Roller HP Sensor 1 Remove the corner stapling unit Corner Stapling Unit 2 Remove the stacking sponge roller HP sensor together with the bracket A from the corner stapling unit...

Page 80: ...ignment unit Trailing Edge Alignment Unit 2 Remove the staple tray paper sensor together with the bracket A from the part with the trailing edge alignment unit x 1 x 1 3 Remove the staple tray paper s...

Page 81: ...Remove the feed out belt HP sensor A from the bracket Leading Edge Guide HP Sensor 1 Remove the trailing edge alignment unit Trailing Edge Alignment Unit 2 On the part with the corner stapling unit ro...

Page 82: ...sure to release the hook with a tool such as a ratchet screwdriver Upper Tray Height Limit Switch 1 Remove the corner stapling unit Corner Stapling Unit 2 Remove the bracket B and then remove the leve...

Page 83: ...2 Replacement and Adjustment 79 2 Remove the brackets B from the sub height sensors A beneath the end fence...

Page 84: ...e the harnesses and ground wire from the saddle stich unit 3 Open the front door A and pull out the saddle stitch unit B After pulling out the saddle stitch unit be sure to keep the harnesses within t...

Page 85: ...lacement and Adjustment 81 4 Remove the screws securing the finisher and saddle stitch unit 5 Lift up to remove the saddle stitch unit A Press Fold Motor 1 Remove the saddle stitch unit Saddle Stitch...

Page 86: ...xing bracket A on the saddle stitch unit 3 Remove the screw A shown in the photo below 4 Loosen the screw B to loosen the press fold motor belt C 5 Remove the clamps indicated by red arrows and connec...

Page 87: ...2 Replacement and Adjustment 83 6 Remove the screws on the press fold motor unit A...

Page 88: ...move the spacer A between the gears taking care not to touch the bracket 8 Remove the belt A Pulling down the bracket B securing the belt remove the belt from the gear Remove the belt from the gear ma...

Page 89: ...otor unit A 10 Remove the spring B from the press fold motor bracket A x 1 spring x 1 11 Remove the press fold motor A x 2 x 1 Booklet Jogger Motor 1 Remove the saddle stitch unit Saddle Stitch Unit 2...

Page 90: ...2 Replacement and Adjustment 86 3 Remove the booklet jogger motor A x 2...

Page 91: ...isconnect the cover support bracket 3 Remove the cover support bracket 4 Loosen do not remove the screws on both ends of the paper exit This will loosen the tray so you can move the tray slightly side...

Page 92: ...6 Disconnect the front end of the paper guide unit bracket B 7 At the rear open the clamps and disconnect the motor and sensor harnesses 8 Lay the unit A on flat clean surface so you can see the pape...

Page 93: ...2 Replacement and Adjustment 89 position sensor bracket 2 Paper Guide HP Sensor 1 Remove the paper guide cover Paper Guide Cover...

Page 94: ...2 Replacement and Adjustment 90 2 Remove the bracket A with the paper guide HP sensor 3 Open the clamp and disconnect the sensor x1 x1 4 Separate the sensor and bracket x3...

Page 95: ...Replacement and Adjustment 91 Paper Guide Motor The paper guide motor is at A 1 Remove the paper guide unit Paper Guide Unit 2 Remove sensor bracket x1 3 Unfasten the motor and disconnect the belt x2...

Page 96: ...2 Replacement and Adjustment 92 4 Remove the paper guide motor When you re install the motor make sure that the connector is pointing to the back of the unit...

Page 97: ...er 3 At the rear side remove the screw circled in the photo below from the stapler A 4 Push the stapler to the front side of the finisher 5 Remove the inner upper cover A Be sure to open the paper gui...

Page 98: ...serted to the cutout of the frame firmly 7 Release the clamp and then remove the 2 connectors 8 Remove the stapler unit A Be sure to open the paper guide B and its catches on the unit When removing th...

Page 99: ...2 Replacement and Adjustment 95...

Page 100: ...Unit 1 Remove the following covers Rear Upper Cover Rear Upper Cover Rear Lower Cover Rear Lower Cover Rear Upper Cover Rear Lower Cover 2 Remove the side to side detection unit A x 2 x 3 x 2 3 Remov...

Page 101: ...2 Replacement and Adjustment 97 4 Remove the punch unit controller board cover A x1 x2 5 Pull out the punch unit A x 2 x 3 x 2...

Page 102: ...f the Flat Fold Rollers Folding strength can be adjusted by adjusting the difference in the vertical alignment between the flat fold rollers 1 Remove the saddle stitch unit Saddle Stitch Unit 2 Remove...

Page 103: ...n to C the difference becomes 0 mm In this case the upper and lower rollers are aligned vertically If toner flakes off along the fold on the booklet as a result of excessive folding folding was too st...

Page 104: ...SP mode 2 Set the moving speed of the flat fold booklet unit for each paper size using SP6 114 001 to 010 Fold Speed Adj 2K 3K FIN SP Setting Items Selection Default Value SP6 114 001 Fold Speed Adj 2...

Page 105: ...Adjustment 1 Pull out the saddle stitch unit A 2 Remove the timing gear A x 1 3 Turn the knob A clockwise to move the flat fold roller unit B in the direction of the arrow 4 Move the flat fold roller...

Page 106: ...2 inscribed on the bracket 5 Check that the fold plate A has been moved in the direction of the arrow as far as it can go and the bushing C on the rear end of the fold plate shaft B is aligned with th...

Page 107: ...A x 1 7 Reassemble the finisher and connect it to the main machine 8 Turn ON the power of the main machine 9 After the finisher initialization is complete check that the flat fold roller unit fold pl...

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