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SERVICE MANUAL

1. IND Code Description IND Code Description IND Code Description 1 RB70025 PLANET CAGE UNIT 84 RB70081 SENSOR BOAD E UNIT 149 RB10795 GRIP COVERL 2 40427 T BOLT 4X8 85 KK33329 TORSION SPRING 3329 150 RB10796 GRIP COVERR 3 KK23847 COMP SPRING 3847 86 1162013 PLAIN BEARING B F3 1 153 RB10854 TRIGGER 4 RB10344 KEY PLATE 87 RB11768 ARM SET SCREW 154 RB10855 TRIGGER LOCK 6 RB70027 SUN GEAR UNIT 88 RB10739 ARM A SET SCREW 155 RB70367 MAIN BOARD UNIT 7 RB70029 MAGAZINE HOLDER UNIT 89 RB10740 WIRE GUIDE LEVER 157 RB70101 TRIGGER SWITCH 8 AA21102 PAN HEAD SCREW 3X4 90 CC49118 HEX NUT 3X7 5 160 RB10423 LABEL MAIN SWITCH 9 FF51652 PIN 1652 95 RB70278 FEEDING GEAR BASE ASSY 161 RB10421 LABEL FCC USA 10 AA31714 SCREW 2X4 96 RB70299 FEEDING GEAR B UNIT 162 RB10799 TORQUE ADJUSTMENT LABEL 11 41104 HEX NUT 1 3 FOR HD 12 17 97 FF41728 STEP PIN 1728 163 RB11921 NAME LABEL USA 16 41101 HEX NUT 1 5 98 RB10775 RELEASE LEVER 164 RB10846 WIRE LOADING LABEL 19 JJ21603 C RING 20 99 BB40420 BOLT 4 X 16 165 RB10847 WIRE SETTING LABEL 31 RB10725 INTERNAL GEAR B 100 EE39121 PLAIN WASHER 5 166 RB10962 ARM CAUTION LABEL 32 RB10726 PLANET GEAR B 101 EE39168 WASHER 4 2X1 3X1 167 RB70084 HARNESS 11P UNIT 33 RB107
2. 1 Remove the Sensor Cover from the Magazine by squeezing the two legs of the cover 3 Remove the tow bolts and disassemble the magazine from the 2 Pull out the connector of the reel sensor HOW TO CLEAN UP THE FEEDING GEAR AREA 2 4 4 Remove the four bolts and remove the cover of Twisting Motor 5 Pull out the connector at the feed sensor 6 Blow away dust around the gears with compressed air 7 Blow away iron powder on the magnets 14 HOW TO CLEAN UP THE FEEDING GEAR AREA 3 4 BB40425 100 150cN m 8 Clean up the internal gears and apply Molykote grease Then connect the feed sensor connector and reassemble the feed gears and feed motor 9 Tighgten the bolts with proper torque 5 HOW TO CLEAN UP THE FEEDING GEAR AREA 4 4 Pay attention not to pinch BB40405 200 250cN m 10 Assemble the magazine to the tool and connect the reel sensor connector then close the cover of the connector HOW TO CLEAN UP THE CUTTER AREA 1 3 1 Remove the two bolts and slide out the Cover R a FAL I As 3 Remove the pin Cutter and 2 Remove the bolt and take the Fixed Cutter Cover on the cutter area 17 HOW TO CLEAN UP THE CUTTER AREA 2 3 4 Degrease and clean up the Cutt
3. RB10370 JAW BASE 10113 E RETAINING RING 2 5 FF41822 STEP PIN 1822 JJ10113 E RETAINING RING 2 5 FF41822 STEP PIN 1822 KK33249 AWB TORSION COIL SPRING 3249 Hook a longer spring leg onto the lower side of the Jaw B ASSEMBLY PROCEDURE 1 Place a Jaw A and a Torsion Coil Spring 3249 on a Jaw Base put a Step Pin 1822 through it and fix with an E Retaining Ring 2 5 2 Assemble similarly on the Jaw B side Note Pay attention to the Jaw A and B mounting positions Check the movements of the Jaws A and B Make sure that the E Retaining Ring 2 5 has been firmly fit into a groove 39 Arm Assy Temporary fixing bolt Bolt 3x RB10755 B70039 R CURL GUIDE BJ ARM B UNIT RB10754 CURL GUIDE A I a BB40425 BOLT 3 x 10 ASSEMBLY PROCEDURE 1 Place a Curl Guide B and an Arm B on a Curl Guide A to align their holes 2 Fix a Temporary Fixing Bolt into a hole shown in the figure to position 3 Tighten with a Bolt 3 x 10 Tightening torque 150 200 cN m 4 Remove the Temporary Fixing Bolt Note Pay attention to the direction of the Curl Guide B TORQUE ADHESIVE 150 200 cN m Not required 40 Arm Assy Continued RB10746 WIRE GUIDE B BB40481 HEX BOLT 3 x 5 Put the temporary fixing bolt through ASSEMBLY PROCEDURE 1 Align the dowels of an Arm B Unit with the holes in a Wire Guide B 2 Put
4. Procedure 1 Connect the connector to the Main Board of RB650 RB650A RB655 Description on display Status DATA RCV READY Ready to work DAT RCV TIME OUT CMD RCV TIME OUT Error UNKNOW ANS RCV Press buttons to see the tool information 240 Tools and adhesive required for RB655 tool repair SZE 1 5mm lt 1 gt HEXAGONAL BAR WRENCH 290010 3 0 4 0 5 5 lt 2 gt HEXAGONAL DRIVER 6 0 mm lt 3 gt SCREW DRIVER lt 4 gt HIGH PRECISION SCREW DRIBER XB93116 XB93117 XB93118 Repair XB93119 Tool kit XB93120 HEXAGONAL NUT DRIVER XB93121 Available HEXAGONAL BAR WRENCH XB93122 From SCREW DRIVER 1 XB93123 Max USA SCREW DRIVER 2 XB93124 SCREW DRIVER XB93125 XB93101 TORQUE DRIVER LARGE TORQUE DRIVER SMALL CONNECTOR TWEEZERS lt 9 gt PINCHERS amp PLIERS lt 10 gt HAMMER amp PIN PUNCH 2 5mm lt 11 gt C RING PLIERS The tools with are not required for RB395 repair but required for RB650A RB655 repair ADHESIVE lt A gt DP 810 or Araldite EPOXY ADHESIVE lt B gt LOCTITE BLUE 242 lt C gt LOCTITE PURPLE 222MS GREEN MOLYKOTE GREASE PG 662 SPECIAL GREASE AVAILABLE AT MAX USA XB93112 11 ust Do Maintenance before the tool reaches 500 000 ties RB10749
5. Do the three wire harnesses Yellow Bule White connected same color wire of the Main Board firmly When the x Twister is Twister not in its goes back to Twister goes back to home Bip bip bip Slow Does the Connector of Harness PC boards can not detect the position of the Twister Connect the connectors firmly hi its home position then stops lt Tsister movement error 11P unit 3P connected firmly to ome position beep gt the Sensor board A unit Yes 1 Harness 11P unit is cut or Sensor board A unit is broken 1 Replace Harness 11P unit with a new one Position 2 Twister is locked 2 Remove foreign substances which lock Twister 2 Feed nooks Gearfeeds Twister goes back tohome beep Are the Hooks are in horizontal No Tie wire got entangled around the Hooks Remove the tie wire from the Hooks ME wire position and feeds wire but the ition Yes 1 The Cutter Ring steel plate on the Twister is not assembled between 1 Assemble the Wire Guide Lever correctly position tip of the tie wire does not the legs of the Wire Guide Lever come out from the Arm 2 Wire Guide Unit is deformed and the gap between the silver on the2 Replace the Wire Guide Unit with a new one Wire Guide Unit and Arm A is too large Other problems are same as the case of Twister is in its home position 1 The Hooks do not catch the Bip beee Bip beee Does the connector on Twisting No The PC boards can not detect the rot
6. LL62013 PLAIN BEARING B F3 1 4 RB10344 KEY PLATE 87 RB11768 ARM B SET SCREW 6 RB70027 SUN GEAR UNIT 88 RB10739 ARM A SET SCREW 7 RB70029 MAGAZINE HOLDER UNIT 89 RB10740 WIRE GUIDE LEVER 8 AA21102 PAN HEAD SCREW 3X4 90 CC49118 HEX NUT 3X7 5 5 9 FF51652 PIN 1652 10 95 70278 FEEDING GEAR BASE ASSY 10 1714 SCREW 2X4 96 RB70299 FEEDING GEAR B UNIT 11 CC41104 HEX NUT 1 3 FOR HD 12 17 10 97 FF41728 STEP PIN 1728 16 CC41101 HEX NUT 1 5 10 98 RB10775 RELEASE LEVER 19 JJ21603 C RING 20 99 BB40420 BOLT 4 X 16 5 31 RB10725 INTERNAL GEAR B 100 9121 PLAIN WASHER 5 5 32 RB10726 PLANET GEAR 5 101 EE39168 WASHER 4 2X1 3X1 5 33 RB10776 GEAR RETAINER 102 FF51628 HOLLOW PIN 1628 36 BB40481 BOLT 3X5 10 103 JJ10514 E RING CF 10 38 FF41822 STEP PIN 1822 104 KK23851 COMP SPRING 3851 5 39 JJ10113 E RING 2 5 10 105 1111181 WHEEL 6704 40 KK33249 TORSION SPRING 3249 106 RB10043 STEP PIN 41 RB10370 JAW BASE 107 RB10338 INTERNAL GEAR 42 RB10735 B 108 RB10341 PLANET GEAR 43 RB10779 JAW A 109 10484 GEAR PRESS WHEEL 44 RB70056 MOTOR GEAR B UNIT 5 110 RB10770 FEED GEAR A 45 RB70026 ARM A UNIT 111 RB10774 WIRE GUIDE C 46 RB70036 WIRE GUIDE A2 UNIT 112 RB10852 RELEASE STOPPER 47 RB70276 WIRE GUIDE UNIT 10 113 RB70079 SENSOR BOARD C UNIT 48 AA22415 SCREW 3X8 20 114 RB70087 WARNING LED UNIT 49 71408 SCREW3
7. Twisting Twisting brushless motor and its lifetime is Motor Motor more than 5 times longer than 70 000 to 500 000 ties or Twisting motor of RB650A 100 000 ties more 2 Lifetime of the Feeding motor of RB655 is regular Feeding Feeding motors motor but work efficiency is Motor Motor improved 200 000 to 250 000 to The lifetime of the Feeding motor of 250 000 ties 300 000 ties RB655 is about 25 longer than the Feeding motor of RB650A Temperature of Twisting Inside The heat created by tool operation is Motor after 2 hours use reduced by increase of the work 30 ties Min 3 temperature efficiency of the motors i of the tool 260 F 194F 30 less The rotation of the Twisting motor on Warm up is i uired if it is Performance RB655 is controlled by PC board below d 4 in cold Also the reduction of the required electric current enables stable weather operation in cold weather 14F 4F RB650A RB655 Twisting Motor RB70031 Picture Yellow RB70349 Picture Connector to sensor of rotation Yellow Twisting motor of RB655 Blue is DC Brushless motor The Brushless motor White does not have wearing White color wire and connector are added parts and lasts more than 500 000 ties Also the Brushless motor requires less electricity and increases tying times per charge Feed Motor 202 RB70048 RB70351 Purple Brown Feeding Motor on RB655
8. becomes wider when the Hooks catch the wire Due to this the strength cramping wire decreases and the tip of the wire may be released from the Hooks during the twisting action RB70275 CENTER HOOK Inside of the Magazine and Magazine Cover is worn out and hte play between Magazine and Magazine Cover becomes larger It leads to too much friction on wire at wire pulling action and may create weak tie The recommended maintenance and its frequency At around 200 000 ties replace the Cutter with a new one It is recommeded to replace Feeding Motor at the same time When replacing the Cutter RB10749 at around 200 000 ties reverse the direction of the Fixed Cutter Also clean up the Cutters and apply small amount of the Molykote grease At around 500 000 ties the Fixed Cutter should be replaced with a new one At around 200 000 ties clean the Hooks with degreaser like Paslode Degreaser Cleaner then apply Molykote grease At around 200 000 ties replace the Feeding Motor with a new one It is recommeded to replace Cutter at the same time When replacing the Feeding Motor with a new one Open the Motor Cover of the Feeding Motor and clean up the magnets around the Feeding Gear with compressed air At around 500 000 ties the Hooks need to be replaced with new ones At around 500 000 ties the Magazine and magazine Cover need to be replaced with new ones HOW TO CLEAN UP THE FEEDING GEAR AREA 1 4
9. Center Hook is worn out Replace Hook L or Center Hook with a new one Hooks and the wire goes back to Magazine Feeding Motor D need Tool pulls wire but then stops bip bip bip Is the connector on Sensor Board C No sensor at Feeding Gear does not work Connect the connectors firmly P and emits beep sound Triple repetitive beep connected firmly Yes 1 Harness 7P unit is cut 1 Replace Hamess 7P unit or Sensor board C unit lt Feeding action error gt Sensor board C unit is broken 2 Since the capacity of the battery is not enough the Feeding gear 2 Charge the battery or replace the battery with a new one can not rotate by regulated times Not pull enough No beep Is the tie wire deformed No 1 V shape groove of the Feeding Gear is worn out 1 Replace the Feeding Gear Tool makes big ta loose Magazine 2 The spring at Feeding Gear is worn out 2 Replace the spring tie Yes The play between the Magazine and Magazine Cover is too big Turn the Adjust Ring to tighter position and reduce the play Wire can not be cut Bip bip bip bip load to cut the e is too high 1 Replace the Cutter with a new one Fast single beep 1 Cutter is worn out 2 Clean up the Hooks with Paslode Degreaser Cleaner and then apply lt Overcurrent error beep gt 2 Hook parts are too dirty Molykote grease Cutting tie wire No beep Does the tool repeat the initi No Cutter Lever is worn out Replace Cutte
10. HOOK R 179 RB11886 FAN PROTECTOR 180 RB11883 FILTER COVER 181 RB10724 SLEEVE COVER 182 RB11003 PROTECTORB 183 CK10198 SCREW 3X10 184 RB11775 BINDING HEAD SCREW 185 RB11776 MAGAZINE LEAF SPRING 187 RB81108 MAGAZINE COVER KIT 188 FF31559 PIN 1559 189 FF51656 PIN 1656 191 JJ10510 RETAINING RING 2 3 10 192 RB70217 MAGNET HOLDER UNIT 193 RB11666 ARM COVER 201 RB70349 TWISTING MOTOR TD5046 UNIT 202 RB70351 FEEDING MOTOR RS 55VC UNIT 5 203 RB70222 FEED GEAR SHAFT 205 RB70113 MAIN SWITCH BASE ASSY 207 RB70284 TWISTER ASSY 208 RB70033 FINGER BASE ASSY 209 RB70281 A ASSY 210 RB70285 ARM B ASSY 211 RB70283 TWISTER A ASSY 2 84 TIGHTENING TORQUE CHART TORQUE cN m 200 250 200 220 150 200 100 150 80 100
11. PG 662 Grease Ensure that the Cutter lever is free of Epoxy glue when adhering and drying it TORQUE ADHESIVE 200 250 cN m Epoxy glue 42 Arm Assy Continued RB10749 CUTTER GREASE OR FF41730 RB10748 STEP PIN 1730 FIXED CUTTER p RB10747 ARM C Temporary fixing bolt ECT 0 BOLT 3 x 16 ASSEMBLY PROCEDURE Apply Molykote PG 662 Grease to the perimeter of a Fixed Cutter Put the Fixed Cutter through a hole in a Cutter and align it with a hole in an Arm B to assemble Apply Molykote PG 662 Grease to a Step Pin 1730 Align a hole in the Cutter with the one in a Cutter Connecting Rod to insert the Step Pin 1730 Put an Arm C over the fixed Cutter put a Temporary Fixing Bolt through it and then tighten with a Bolt 3 x 16 Tightening torque 180 220 cN m Remove the Temporary Fixing Bolt TORQUE ADHESIVE 180 220 cN m Not required CHECK PROCEDURE 1 Make sure that the Cutter Lever is free of epoxy glue 2 Move the Cutter Lever in the arrow direction to make sure that the Cutter Lever and Cutter are smoothly interlocked with each other 3 Make sure that the E Retaining Ring has been firmly fit into the groove in the Cutter Lever Pin 43 Arm Assy IMPORTANT NOTE Degrease the Arm A unit with dipping it in a solvent Also use a spray for degreasing to additionally degrease the tapped AA22102 FLAT SCREW 3 x 6 holes 1
12. RB10748 RB70351 RB11762 RB11763 RB81102 RB81103 CUTTER FIXED CUTTER Maintenance of the area around the HOOKS FEEDING MOTOR The maintenance for FEEDING MOTOR HOOK L HOOK R MAGAZINE ASSY MAGAZINE COVER ASSY The edge of the Cutter is worn out Phenomenon the cutting load becomes higher then the tool can not to cut the wire The overcurrent beep sound may be heard when cutting load is too high and the cutting action is prevented The edge of the Cutter is worn out the cutting load becomes higher then the tool can not to cut the wire The overcurrent beep sound may be heard when cutting load is too high and the cutting action is prevented The dust metal powder around the Hooks makes movement of the Hooks not smooth and the load on the Twisting Motor to open and close the Hooks becomes higher It the load becomes too high the wire cannot be cut The overcurrent beep sound may be heard when cutting load is too high and the cutting action is prevented The tool can not feed the wire because the brush of the Feeding Motor is worn out At initializing action feeding error beep sound may be heard The Twisting Motor is brushless motor and does not have wearing part Due to the dust on Feeding Gears the feed sensor may not sence all of the magnets around the gear then the tool may feed more wire than required When the Hooks are worn out the space between Center Hook and Hook
13. SPRING 54 RB10743 WIRE GUIDE BASE 120 RB10537 JOINT DIAL 187 RB81108 MAGAZINE COVER KIT 55 RB70039 ARM B UNIT 121 RB10853 TORQUE DIAL 188 FF31559 PIN 1559 56 BB40425 BOLT 3X10 122 RB81102 MAGAZINE ASSY 189 FF51656 PIN 1656 57 BB40810 BOLT 3X16 123 RB10783 PROTECTOR 191 JJ10510 RING 2 3 58 CC41103 HEX NUT 1 4 124 RB10785 BUSHA 192 RB70217 MAGNET HOLDER UNIT 59 FF41730 STEP PIN 1730 125 RB10786 BUSH B 193 RB11666 ARM COVER 60 JJ10509 E RING 4CF 126 RB10787 SENSOR COVER 201 RB70349 TWISTING MOTOR TD5046 UNIT 61 RB10746 WIRE GUIDE B 127 RB10791 SENSOR COVER PLATE 202 RB70351 FEEDING MOTOR RS 55VC UNIT 62 RB10747 ARMC 128 RB10792 RETAINING RING 203 RB70222 FEED GEAR SHAFT 63 RB10748 FIXED CUTTER 129 RB70082 SENSOR BOARD F UNIT 205 RB70113 MAIN SWITCH BASE ASSY 64 RB10749 CUTTER 130 AA32708 SCREW 2 6X6 207 RB70284 TWISTER ASSY 65 RB10750 CUTTER CONNERCTING ROD 131 RB81103 MAGAZINE COVER ASSY 208 RB70033 FINGER BASE ASSY 66 RB70277 CUTTER LEVER UNIT 132 RB11774 MAGAZINE COVER LOCK 209 RB70281 ARM A ASSY 67 RB11767 CUTTER SHAFT 133 RB10806 ADJUST RING 210 RB70285 ARM B ASSY 69 RB10754 CURL GUIDE A 134 BB40405 BOLT 5X25 211 RB70283 TWISTER A ASSY 70 RB10755 CURL GUIDE B 135 EE32104 WASHER 2 3 71 RB70041 COVER L UNIT 136 EE39172 WASHER 5 1X12X1 2 72 RB70042 MAGNET HOLDER L UNIT 137 EE39602 WASH
14. a Temporary Fixing Bolt through the Wire Guide B and tighten with a Hex bolt 3 x 5 Tightening torque 200 220 cN m 3 Remove the Temporary Fixing Bolt TORQUE ADHESIVE 200 220 cN m Not required 41 Arm Assy Continued CC41103 HEX NUT 1 4 RB10751 CUTTER LEVER Put it through the holes S JJ10101 in the Cutter lever and Downward Arm B and then apply ERETAINING RING 4 epoxy glue Dry epoxy glue as shown in the figure T GREASE MOLYKOTE PG 662 EE etum PG 662 0752 E CUTTER SHAFT E RETAINING RING 4 RB10753 CUTTER LEVER CUTTER CONNECTING ROD ASSEMBLY PROCEDURE Apply Molykote PG 662 Grease to a Cutter Lever Pin Put the Cutter Lever Pin through a smaller hole in a Cutter Lever and secure with an E Retaining Ring 4 Put the other end of the Cutter Lever Pin through a Cutter Connecting Rod and secure with an E Retaining Ring 4 Degrease a Cutter Shaft and apply Molykote PG 662 Grease only to the slideway with a Cutter Lever Put the Cutter Shaft through the Cutter Lever and an Arm B Unit Apply epoxy glue only to the threaded part of the Cutter Shaft and tighten a Hex nut 1 4 Tightening torque 200 250 cN m Place the nut facing downward to dry Epoxy glue Note Make sure that the E Retaining Ring is firmly fit into a groove in the Cutter Lever Pin Ensure that the threaded part of the Cutter Shaft is free of Molykote
15. a Wire Guide Unit 2 Align a hole in a Wire Guide Base with the one in the Wire Guide Unit 3 Apply Molykote PG 662 Grease to a Step Pin 1729 put it through the holes in the Wire Guide Base and Wire Guide Unit and secure it with an E Retaining Ring 2 5 Note Make sure that both ends of the Compression Spring are in the dowel holes in the Arm A Unit and Wire Guide Unit respectively 46 Arm A Assy Continued IMPORTANT AT 408 HEX SCREW 3 3 IMPORTANT NOTE Degrease before applying IMPORTANT NOTE Loctite HEX BOLT 3 x 5 Tighten further in order to 52 Tighten further and ARM A UNIT RB10740 WIRE GUIDE LEVER ASSEMBLY PROCEDURE 1 Apply Molykote PG 662 Grease to a Wire Guide Lever 2 Put the Wire Guide Lever in between an Arm A Unit and a Wire Guide 3 After degreasing a Hex Screw 3 x 3 apply Loctite Blue to it to tighten to a Wire Guide Base Tightening torque 20 30 cN m 4 Tighten further a Hex bolt 3 x 5 temporarily secured to the Wire Guide Base Tightening torque 150 200 cN m Note Wipe off overflowing adhesive agent TORQUE ADHESIVE 20 30 cN m Loctite Blue 150 200 cN m Not required 47 Arm Assy Continued IMPORTANT lt Open position gt Push in the Wire guide lever as deeply as possible Make sure that the Wire guide is opened by about 0 14 lt IMPORTANT NOTE At the closed position the
16. clearance between silver pin and Arm A must be less than 0 8mm Use TW897 wire Silver pin 0 8mm and confirm that the wire does not pass through the clearance NOTE TW1525 wire can not be used for this check Clearance between silver A pin and Arm A ASSEMBLY PROCEDURE 1 Make sure that a Wire Guide Lever can be manually slided smoothly 2 Make sure that when the Wire Guide Lever is pushed in deeply a Wire Guide is opened by about 0 14 at its nose 3 Lower the Wire Guide lever to the rear end of the Wire Guide Unit to close the Wire Guide Unit 4 Check the clearance between silver pin and Arm A If it is more than 0 8mm which is diameter of TW897 wire an adjustment is required see next page 48 ADJUSTMENT OF WIRE GUIDE UNIT ISTEP 1 Unscrew the set screw 3x3 AA71408 then slide the Wire Guide Lever and set the Wire Guide Unit in its open position Put Loctite Blue on the set screw 3x3 and tighten it again Slide the Wire Guide Lever Unscrew the set screw and set the Wire Guide Unit Apply Loctite and tighten in its open position the set screw again ISTEP 2 Connect an object which weighs 9 to 10 oz Ex Twisting Motor to Wire Guide Lever with tie wire and lift the Arm Then unscrew the set screw 3x3 71408 slowly until the Twister Assy falls sure to stop unscrewing when the Twister Assy falls ISTEP 3 Assemble the Wire Guide Lever an
17. is not connected firmly 1 Connect the connectors firmly beep or the connector is broken 2 3 Replace the broken part with a new one 2 Sensor board D unit or Sensor board E unit is broken 3 Magnet holder L unit or Magnet holder R unit is broken Bip bip bip bip bip Is the tool body very hot No PC board has problem Replace PC board with a new one Five beep Yes Tooi is overheated Turn the main switch off and keep the tool in cool place for a while When the No beep Do the Feeding Gears hold the tidNo V shape groove of the Feeding Gear is worn out Replace the Feeding Gear with a new one Twister is in wire firmly bearing of the Feeding Gear is broken its home position Feed gears Yes 1 Cut end of the wire or foreign obstacle blocks the Wire Guide 1 Remove the cut end of the wire or foreign obstacle from the Wire Guide feed tie wire 2 Spring at the Feeding Gear is worn out B Hooks are 2 Replace the spring with a new one in horizontal Tip of the tie wire does not No beep Is the Wire Guide Unit closed Yes The Cutter Ring steel plate on the Twister is not assembled between the ssemble the Wire Guide Lever correctly position come out from the Arm A when the Twister is in its home legs of the Wire Guide Lever osition deformed and the gap between the Replace the Wire G and Arm A is too large length of tie wire fed is too No beep Is the tie wire deformed inside of No 1 V shape groove of the Feeding Ge
18. its backlash and turn it in the counterclockwise direction with a finger tip to stop it at the 37 step Shift from the 1 to the 274 and 3 step while confirming Only when it is not easy to turn the Adjust Ring in shifting to the 3 stage return it in the clockwise direction holding the Magazine Stopper and stop it where the tapped screw is aligned 27 step 6 Tighten tapped screws 2 6 x 6 Tightening torque 15 20 Note Control torque after confirming that the screws have been fully seated TORQUE ADHESIVE 15 20 cN m Not required 27 Sensor Base Assy TAPPED SCREW 2 4 RB70081 SENSOR BOARD E UNIT After degreasing Apply Loctite Purple RB10765 SENSOR BASE RB70080 SENSOR BOARD D UNIT avi T TAPPED SCREW 2 x 4 If properly assembled the topside will be flush ASSEMBLY PROCEDURE 1 Apply Loctite Purple to a degreased Tapped Screw 2 x 4 to secure a Sensor Board D Unit toa Sensor Base 2 Similarly secure a Sensor Board E unit to the Sensor Base Tightening torque 10 20 cN m Note Be careful not to assemble the Sensor Boards the other way around Torque should be controlled after confirming that a Screw Head has seated on the board TORQUE ADHESIVE 10 20 cN m Loctite Purple 38 Jaw Base Assy KK33249 TORSION COIL SPRING 3249 RB10779 Hook a longer spring JAW A leg onto the lower side of the Jaw A
19. legs onto the Twist Guide 2 Put the Twist Guide Shaft through the Twist Guide and Torsion Coil Spring 3330 Note Do not confuse the Torsion Coil Springs 3330 and 3328 with each other 56 Cover Assy Continued 40481 HEX BOLT 3 5 Hook the longer spring leg onto the cover as shown in the figure ASSEMBLY PROCEDURE 1 Put the Twist Guide R Assy into the front end of the Cover R Unit and hook the longer spring leg onto the Cover R Position 2 Tighten the hex bolts 3 x 5 2 pcs Tightening torque 150 200 cN m 3 Confirm that opening closing the Cover moves the Magnet Holder R Unit back and forth TORQUE ADHESIVE 150 200 cN m Not required 57 Twisting Motor Assy g y Assemble into a Motor Housing L from the arrow indicating the air blow direction marked side of a Fan Unit Ensure that the name label air blow direction Arrow Marked Surface indicating arrow of the Fan Unit is directed to the opening side of the Motor Housing as shown in the figure EN gt RB11886 FAN PROTECTOR RB70354 FAN UNIT MOTOR HOUSING L Assemble the cut surface side in the direction shown in the figure U Wiring of Fan Unit Harness ASSEMBLY PROCEDURE 1 Assemble a Fan Protector into a Motor Housing in the direction shown in the figure Note that it has directionality 2 Assemble a Fan Unit into the Fan Protector from the arrow indicating the air blow directio
20. 027 PLANET GEAR RB10726 SUN GEAR UNIT 3 PCS PLANET GEAR 3 PCS RB10776 GEAR RETAINER B GREASE MOLYKOTE PG 662 Punched 2 Surface Assemble the Planet Gear so that its grooves can be seen RB70284 TWISTER ASSY Apply Molykote PG 662 to the inner teeth of an internal Gear and the pins of a Planet Cage B unit Apply Molykote PG 662 to Planet Gears B 3 pcs and fit them onto the pins of the Planet Cage B unit Assemble them so that you can see the grooves in the top surface of the Planet Gears Apply Molykote PG 662 to the gear and pins of a Sun Gear Unit to assemble it Apply Molykote PG 662 to the Planet Gears B 3 pcs to assemble them in such a manner that you can see the grooves in their top surface Assemble a Gear Retainer B directing its punched surface inside Note Confirm that the internal gear is smoothly turned when it is turned with the Planet Cage held Feed Assy The side with a cross rib should face upward RB70054 FEEDING GEAR B UNIT JJ10113 E RETAINING RING 2 5 ee HSn D IMPORTANT NOTE RB10775 Beware of the mounting direction RELEASE LEVER 12 Direction of the step pin Obverse and reverse of the Feeding gear B unit FF41728 STEP PIN 1728 ASSEMBLY PROCEDURE 1 Put a Step Pin 1728 into a Release Lever and Feeding Gear B unit and secure with an E Retaining Ring 2 5 2 Make sure that
21. 2 through St RB70036 WIRE GUIDE A2 UNIT RB10737 WIRE GUIDE A1 RB70026 ARM A UNIT ASSEMBLY PROCEDURE 1 Degrease the Arm A Unit and the Flat Screws 3 x 6 2 Align a Wire Guide A1 and a Wire Guide A2 unit with an Arm A unit and tighten with the Loctite applied Flat Screws 3 x 6 Tightening torque 80 100 cN m Note Wipe off overflowing adhesive agent TORQUE ADHESIVE 547 80 100 cN m Loctite Blue 44 Magazine Assy Continued IMPORTANT YY HEX BOLT 3 x 5 Secure temporarily amp WARNING Assemble temporarily in order of i and 2 EE31127 PLAIN WASHER 3 2 x 7 WARNING RB10743 bolt seat side WIRE GUIDE BASE should be in the return direction IMPORTANT NOTE RB70026 ARM A UNIT Make sure to degrease ASSEMBLY PROCEDURE 1 Align the dowels of a Wire Guide Base with the holes in an Arm A Unit to assemble temporarily 2 Put a Hex bolt 3 x 5 through a Plain Washer 3 2 x 7 and secure it to the Wire Guide Base temporarily Tightening torque Approx 10 cN m EN TORQUE ADHESIVE Approx 10 cN m YY Temporal Not required tightening 45 Arm Assy Continued FF41729 STEP PIN 1729 1 i t GREASE MOLYKOTE PG 662 KK23849 COMPRESSION SPRING 3849 RB70026 ARM A UNIT RB70037 WIRE GUIDE UNIT ASSEMBLY PROCEDURE 1 Place a Compression Spring 3849 on an Arm A unit and retain it with
22. 4 PLAIN WASHER 2 3 CENTER COVER R ASSY EE32104 PLAIN WASHER 2 3 Set Plain Washers 2 3 in the frame L and then tighten bolts BB40425 BOLT 3 x 10 ASSEMBLY PROCEDURE Fix the Frames R and L with two x 16 012 53 three 3 x 10 2 6 7 and three 3 x 25 bolts The bolt gt should be put through the Plain Washer 2 3 Assemble the Arm Cover R Assy to the Frame L and fix them with two x 10 bolts amp 97 The bolts amp 8 should be put through the Plain Washer 2 3 Tightening torque 2 b E 100 150 cN m 7 40 60 cN m Others 50 100 cN m Note Tighten the bolts in order of 512 to Bs Tomaue ADHESWE 73 MERE 3 all CH 3 b I brown Important Note Confirm that the connector has been fully inserted Fit onto the rib Sensor board ofthe Frame R Harness green Harness purple Harness blown 8570354 G S FEEDING MOTOR RS 550VF ASSY Internal gear Feed gear base ASSEMBLY PROCEDURE 1 Connect the harnesses green and brown of a Feeding motor RS 550VF unit to those green and brown coming out of a Frame L respectively 2 Connect the harness 3P red coming out of the Frame L to a Sensor Board C Unit 3 Apply Molykote PG 662 Grease to the gear of the Feeding RS 550VF unit and assemble it to an Internal Gear and th
23. 76 GEAR RETAINER 102 FF51628 HOLLOW PIN 1628 168 RB70085 HARNESS 7P UNIT 36 BB40481 BOLT 3X5 103 JJ10514 E RING 3 CF 169 RB70086 HARNESS 3P UNIT 38 FF41822 STEP PIN 1822 104 KK23851 COMP SPRING 3851 170 RB70339 FAN UNIT 39 JJ10113 E RING 2 5 105 1111181 WHEEL 6704 171 RB11884 FILTERA 40 KK33249 TORSION SPRING 3249 106 RB10043 STEP PIN 172 RB11885 FILER B 41 RB10370 JAW BASE 107 RB10338 INTERNAL GEAR 173 RB11004 PROTECTOR 42 RB10735 JAW B 108 RB10341 PLANET GEAR 174 EE39830 WASHER 5 1X 9 43 RB10779 JAW A 109 RB10484 GEAR PRESS WHEEL 175 RB11777 STOPPER PLATE 44 RB70056 MOTOR GEAR B UNIT 110 RB10770 FEED GEAR A 176 RB10718 SLEEVE GUIDE 45 RB70026 ARM A UNIT 111 RB10774 WIRE GUIDE C 177 RB11762 HOOK L 46 RB70036 WIRE GUIDE A2 UNIT 112 RB10852 RELEASE STOPPER 178 RB11763 HOOK R 47 RB70276 WIRE GUIDE UNIT 113 RB70079 SENSOR BOARD C UNIT 179 RB11886 FAN PROTECTOR 48 AA22415 SCREW 3X8 114 RB70087 WARNING LED UNIT 180 RB11883 FILTER COVER 49 AA71408 SCREW 3X3 115 RB70341 MAIN SWITCH UNIT 181 RB10724 SLEEVE COVER 50 EE31801 WASHER 3 2 7 116 AA31721 SCREW 3X6 182 RB11003 PROTECTOR B 51 FF41729 SETP PIN 1729 117 AA74410 SCREW 3X6 183 CK10198 SCREW 3X10 52 KK23849 COMP SPRING 3849 118 RB10400 LEAF SPRING 184 RB11775 BINDING HEAD SCREW 53 RB10737 WIRE GUIDE A1 119 RB10536 MAIN SWITCH BASE 185 RB11776 MAGAZINE LEAF
24. AL RB10537 Part Accompanying DIAL JOINT Positioning Range of Warning LED Unit Torque Dial Projection RB10400 i TORQUE DIAL SPRING AA31714 TAPPED SCREW 2 x 4 Put a Warning LED Unit through a Main Switch Base apply Loctite Purple to a threaded part and fix with an accompanying washer and hex nut from below 2 Fit a Main Switch Unit into the Main Switch Base Note Shift to the ON side 3 Insert a Dial Joint into the D cut part of a Torque Dial until as deeply as possible and fix with a Hex screw 3 x 6 Tightening torque 10 20 cN m 4 Put the Torque Dial through the Main Switch Base from below and fix a Torque Dial Spring with a Tapped Screw 2 x 4 Tightening torque 20 30 cN m Note The projection of the Torque Dial should be positioned as shown in the figure below TORQUE ADHESIVE Y 20 30 Not required 27 10 20 cN m RB70087 Loctite Purple 21 Main Switch Base Assy Continued RB70367 BOARD RB655 UNIT a AA31721 TAPPED SCREW 3 x6 Position of the Torque dial as shown in the figure Dial position 2 Plug the connector Posto of the LED unit osition the concave part of the Rotary Switch to 1 ASSEMBLY PROCEDURE 1 Position a Torque Dial to the position 2 as shown in the figure 2 Position the concave part of a Rotary Switch shaft to 1 Note Improper positioning of the Torque Dial and R
25. B Section A A RB10785 BUSH A Apply silicone grease Place the Magazine s Sensor Cover side facing upward apply silicone grease to a Bush B and fit it into an upper hole in the Magazine fit it in until it becomes flush with the bottom surface of the Magazine Apply silicone grease to a Bush A and fit it into a lower hole fit it in until it is positioned to the middle RB10785 BUSH A and RB10786 BUSH B come with RB81102 MAGAZINE ASSY 32 Magazine Assy Continued Confirm that the L cm um STOPPER PLATE shape has been fit into the concave part of the 1 Insert into the Stopper Plate 2 Press the magazine s boss ASSEMBLY PROCEDURE 1 Insert the nose of a Stopper Plate into the boss of the Magazine 2 Push the U Shape of the Stopper Plate to fit its L Shape into the concave part of the Magazine RB11777 STOPPER PLATE comes with RB81102 MAGAZINE ASSY 33 Magazine Assy Continued AA31504 TAPPED SCREWS 3 X 6 RB11776 MAGAZINE COVER SPRING ASSEMBLY PROCEDURE 1 Align a center hole in a Magazine Cover Spring with the projection of a Magazine Cover 2 Fix the Magazine Cover Spring to the Magazine Cover with Tapped Screws 3 x 6 2 pcs Control torque after confirming that the Tapped Screws have been fully seated Tightening torque 40 50 cN m TORQUE ADHESIVE 40 50 cN m Loctite Pu
26. BLY PROCEDURE 1 Set a Special Rubber Washer 7 in the position shown in the figure 2 Align the hinge of the Magazine with that of the Magazine Cover 3 Put a Torsion Coil Spring in between the hinges and place its legs on the Magazine and the Magazine Cover 4 Put a Parallel Pin 1289 through the Magazine Magazine Cover and Torsion Coil Spring and push it in until the Special Rubber Washer is fit into a groove Note Confirm that the Magazine Cover is opened by a spring force 36 Magazine Assy Continued RB10806 ADJUST RING RB11774 MAGAZINE STOPPER Turning Projection Turning Direction for 11 Direction for 3 Turning Direction for 2 Adjust Ring Height Adjustment Process 4 Step Direction 18 Step ond rd 2 Step 3 Step Tightest Loosest Counterclockwise Clockwise n Only when hard to shift to the 3 step Adjust at the 3 or 2 step Not at 1 or 4 step ASSEMBLY PROCEDURE Turn the Magazine Stopper until it hits the projection of the Magazine Cover followed by the Adjust Ring in the clockwise direction until it also comes to stop 1 Close the Magazine Cover Assy Align the Magazine Stopper with CLOSE to prevent the Magazine Cover from being opened Holding the Magazine Stopper turn the Adjust Ring in the clockwise direction until you feel a strike 15 step the slackest position Make the Magazine Stopper float by
27. CONFIDENTIAL SERVICE MANUAL REBAR TYING TOOL Model RB655 Specifications and parts may be changed for improvement MAXA MAX USA CORP 257 East 2 Street Mineola NY 11501 Phone 800 223 4293 Fax 516 741 3272 1 2 P4 P8 11 12 13 17 20 21 24 P30 P38 P39 P40 P49 P50 P58 P62 P77 P78 P81 P83 P85 CONTENTS EXPLODED VIEW AND SPARE PARTS LIST PARTS LIST DIFFERENCES OF THE TOOL PERFORMANCE BETWEEN THE RB655 AND RB650A DIFFERENT PARTS BETWEEN RB650A AND RB655 RB655 TYING TIMES INDICATION MODE RB650 RB650A RB655 TOOL CHECKER TOOLS AND ADHESIVE REQUIRED FOR RB655 TOOL REPAIR MUST DO MAINTENANCE BEFORE THE TOOL REACHES 500 000 TIES HOW TO CLEAN UP THE FEEDING GEAR AREA HOW TO CLEAN UP THE CUTTERAREA SELF WARM UP PROGRAM HOW TO ASSEMBLE THE TOOL 1 MAIN SWITCH BASE ASSY 2 TWISTER ASSY FEED ASSY 3 MAGAZINE ASSY 4 SENSOR BASE ASSY 5 JAW BASE ASSY 6 ARM ASSY ADJUSTMENT OF WIRE GUIDE UNIT 7 COVER ASSY 8 MOTOR ASSY HOW TO ATTACH THE EACH ASSEMBLY TO THE FRAME BEEP SOUND REFERENCE TROUBLE SHOOTING OF RB655 PROCESS OF TYING ACTION RECOMMENDED INITIAL STOCK PARTS LIST TIGHTENING TORQUE CHART EXPLODED VIEW AND SPARE PARTS LIST 191 173 SS C e 127 128 BODY R ASSY Parts marked are included in the BODY R ASSY RB655 Parts list
28. EEDING GEAR B UNIT Feed Gear Shaft A L7 5 BG ASSEMBLY PROCEDURE 1 Put a Feed Gear A and a Special Plain Washer 5 onto a Feeding Gear Shaft A in that order and secure with an E Retaining Ring 2 5 2 Put a Feeding Gear B Unit and a Special Plain Washer 4 2 x 13 x 1 onto the Feeding Gear Shaft B of the Feeding Gear Base unit and secure with an E Retaining Ring 3 3 Secure a Wire Guide C onto a Wire Guide Base Unit with Hex bolts 3 x 5 Tightening torque 100 150 cN m Note Assemble the Feeding Gear B Unit so that the cross rib side will face upward TORQUE ADHESIVE 100 150 cN m Not required 28 Feed Assy Continued RB10341 PLANET GEAR Sagging Surface Correct Wrong 22222774 no groove Hd CE ie Planet gears HLA fi D P x V RB10484 GEAR RETAINER MOLYKOTE PG 662 ASSEMBLY PROCEDURE 1 Apply Molykote PG 662 Grease to the gear portion of an Internal gear and the pins of a Planet Cage A Unit 2 Apply Molykote PG 662 Grease to side and gear portion of Planet Gears 4 pcs 3 Fit the Planet Gears 4 pcs onto the pins of the Planet Cage A Unit 4 Apply Molykote PG 662 Grease to the Planet Gears and the slideway of a Gear Retainer and set the Gear Retainer with its sagging surface on the Internal Gear side Note Make sure that the Planet Gears have no grooves in their sides To prevent wrong assembly with the Planet Gears B Bring
29. ER 7 73 KK23850 COMP SPRING 3850 138 FF31289 PIN 1289 74 KK33328 TORSION SPRING 3328 139 KK33327 TORSION SPRING 3327 75 RB70369 TWIST GUIDE COVER L 140 RB81106 FRAME L ASSY USA 76 RB10759 TWIST GUIDE SHAFT 141 RB81107 FRAME R ASSY USA 77 RB11667 SENSOR ROD 142 BB40410 BOLT 3X8 78 RB70044 COVER R UNIT 143 BB40811 BOLT 3X25 79 RB70045 MAGNET HOLDER R UNIT 144 RB10970 ELECTRODE BLOCK 80 KK33330 TORSION SPRING 3330 145 KK23656 COMPRESSION SPRING 3656 81 RB70370 TWIST GUIDE COVER R 146 RB10213 WINDOW 82 RB10765 SENSOR BASE 147 RB81034 MOTOR COVER ASSY 83 RB70080 SENSOR BOARD D UNIT 148 RB11769 ELECTRODE PLATE You can get most updated list at www maxusacorp com Differences of the tool performance between the RB655 and RB650A Difference RB650A RB655 Tying times per charge was increased by about 40 This was 430 to 530 600 to 700 achieved by following factors ties ties 30 more 1 Improvement of the work efficiency of the Twisting motor and f Feeding motor Tying times per charge 2 The PC board has new program which reduces required electric current Thanks to the increase of tying times per charge the total tying times per battery life is also increased by about 40 These numbers are when the tool is used with a brand new battery Twisting motor of 655 is
30. VERL 5 140 RB81106 FRAME L ASSY USA 76 RB10759 TWIST GUIDE SHAFT 141 RB81107 FRAME R ASSY USA 77 RB11667 SENSOR ROD 142 40410 BOLT 3X8 5 78 RB70044 COVER R UNIT 5 143 BB40811 BOLT 3X25 10 79 RB70045 HOLDER R UNIT 144 RB10970 ELECTRODE BLOCK 80 KK33330 TORSION SPRING 3330 10 145 KK23656 COMPRESSION SPRING 3656 81 RB70370 TWIST GUIDE COVER R 5 146 RB10213 WINDOW 5 82 RB10765 SENSOR BASE 147 RB81034 MOTOR COVER ASSY 83 RB70080 SENSOR BOARD D UNIT 148 RB11769 ELECTRODE PLATE 10 83 RB655 Recommended initial stock parts list For 20 tools IND Code Description Q ty 149 RB10795 GRIP COVER L 150 RB10796 GRIP COVER R 153 RB10854 TRIGGER 154 RB10855 TRIGGER LOCK 155 RB70367 BOARD UNIT 5 157 RB70101 TRIGGER SWITCH 5 160 RB10423 LABEL MAIN SWITCH 161 RB10421 LABEL FCC USA 162 10799 TORQUE ADJUSTMENT LABEL 163 RB11921 LABEL USA 164 RB10846 WIRE LOADING LABEL 165 RB10847 WIRE SETTING LABEL 166 RB10962 ARM CAUTION LABEL 167 RB70084 HARNESS 11P UNIT 5 168 RB70085 HARNESS 7P UNIT 5 169 RB70086 HARNESS 3P UNIT 5 170 RB70339 FAN UNIT 171 RB11884 FILTER A 172 RB11885 FILER B 173 RB11004 PROTECTOR 174 EE39830 WASHER 5 1X 9 175 RB11777 STOPPER PLATE 176 RB10718 SLEEVE GUIDE 177 RB11762 HOOKL 178 RB11763
31. X3 10 115 RB70341 MAIN SWITCH UNIT 50 EE31801 WASHER 3 2X7 10 116 AA31721 SCREW 3X6 51 FF41729 SETP PIN 1729 117 AA74410 SCREW 3X6 52 KK23849 COMP SPRING 3849 20 118 RB10400 LEAF SPRING 53 RB10737 WIRE GUIDE A1 119 RB10536 MAIN SWITCH BASE 54 RB10743 WIRE GUIDE BASE 120 RB10537 JOINT DIAL 55 RB70039 ARM B UNIT 121 RB10853 TORQUE DIAL 56 BB40425 BOLT 3X10 10 122 RB81102 MAGAZINE ASSY 57 BB40810 BOLT 3X16 10 123 RB10783 PROTECTOR 58 CC41103 HEX NUT 1 4 20 124 RB10785 BUSHA 59 FF41730 STEP PIN 1730 125 RB10786 BUSH B 60 JJ10509 E RING 4CF 10 126 RB10787 SENSOR COVER 61 RB10746 WIRE GUIDE B 127 RB10791 SENSOR COVER PLATE 62 RB10747 ARMC 128 RB10792 RETAINING RING 63 RB10748 FIXED CUTTER 5 129 RB70082 SENSOR BOARD F UNIT 64 RB10749 CUTTER 5 130 AA32708 SCREW 2 6X6 5 65 RB10750 CUTTER CONNERCTING ROD 131 RB81103 MAGAZINE COVER ASSY 66 RB70277 CUTTER LEVER UNIT 10 132 RB11774 MAGAZINE COVER LOCK 5 67 RB11767 CUTTER SHAFT 133 RB10806 ADJUST RING 69 RB10754 CURL GUIDE A 134 40405 BOLT 5X25 5 70 RB10755 CURL GUIDE B 135 EE32104 WASHER 2 3 20 71 RB70041 COVER L UNIT 5 136 EE39172 WASHER 5 1 12 1 2 72 RB70042 MAGNET HOLDER L UNIT 137 EE39602 WASHER 7 73 23850 COMP SPRING 3850 5 138 FF31289 1289 74 KK33328 TORSION SPRING 3328 10 139 KK33327 TORSION SPRING 3327 75 RB70369 TWIST GUIDE CO
32. ack of the Main Board Unit as shown in the figure 65 Step 5 Harness 7 Terminals connected in How to Expose m PROCESS MAIN harness 11P Hamess of a SWITCH BASE ASSY 4 and 7P Units Trigger switch AE n Bunkered Harness 11P CIL LL nf fo LILY Sq bs tb c3 ToN m Harness 7P c S k To Notch lt LE Cy Irl y TTA Wiring Notch 0 Notch O Fitting Parts of Main Fitting Parts of Main Switch Board and Frame L Base and Frame L HARNESS 11P UNIT 3P TO SENSOR BOARD E UNIT Fitting Parts of Sub Board and Frame L Harness red 4P Expose the harness 11P and 7P units from the back of the main board unit Fit the Main Board Unit and the Main Switch Base Assy into the grooves in the Frame L Assemble the bunkered as shown in the figure As shown in the figure route the harness 7P unit between the rib of the Frame L and the Main Board Unit and between the bunkered and the Frame L to put it through a notch 2 Then divide it into and 4P 48 to wire them as shown the figure Route the harness of the Trigger Switch as with the harness 7P unit 59 0 and fit the Trigger Switch into the boss of the Frame L Put the harness 11P unit coming from the Main Board unit through a notch 1 66 Step 8 Wire the yellow blue white black brown RB70086 Sensor board and purple harnesses coming from the sub board unit t
33. ar is worn out 1 Replace the Feeding Gear Pull the short and the Hooks can not the Magazine 2 The spring at Feeding Gear is worn out 2 Replace the spring Trigger catch the tip of the tie wire E 99 Yes The play between the Magazine and Magazine Cover is too big Turn the Adjust Ring to tighter position and reduce the play The tie wire fed is too long No beep Does the Magnet Holder Unit No Due to the missing magnet the feeding length of the wire becomes the Magnet Holder Unit with a new one have 4 pcs of the magnet than regulated Yes The dust or iron powder on the magnet prevents the sensor from With compressed air remove the iron powder or dust from magnet detecting magnetic power Bip bip bip bip bip bip Is the connector on Sensor Board No The sensor at Feeding Gear does not work Connect the connectors firmly Triple repetitive beep C connected firmly Yes Sensor Board C unit is broken Replace Sensor Board C or Harness 7P unit with a new one lt Feeding action error gt Harness 7P Unit is cut Twister does not go back to Bip Slow Does the connector on Twisting No The PC boards can not detect the rotation of the Twisting Motor Connect the connector and wire harnesses firmly home position Nia movement error Motoris connected to Sub board Yes Twisting Motor is locked Or Twister is locked Remove foreigh substances which lock the motor or Twister eep gt irmly
34. art with a new one No beep Do the Feeding Gears hold the tie wire firmly V shape groove of the Feeding Gear is worn out bearing of the Feeding Gear is broken Replace the Feeding Gear with a new one 1 Cut end of the wire or foreign obstacle blocks the Wire Guide B 2 Spring at the Feeding Gear is worn out 1 Remove the cut end of the wire or foreign obstacle from the Wire Guide B 2 Replace the spring with a new one Tip of the tie wire does not come out from the Arm A Is the Wire Guide Unit closed when the Twister is in its home position Cutter Ring steel plate on the Twister is not assembled between the legs of the Wire Guide Lever Assemble the Wire Guide Lever correctly Wire Guide Unit is deformed and the gap between the silver pin on the Wire Guide Unit and Arm A is too large Replace the Wire Guide Unit with a new one tie wire fed is too long Does the Magnet Holder Unit have 4 pcs of the magnet Due to the missing magnet the feeding length of the wire becomes longer than regulated Replace the Magnet Holder Unit with a new one dust or iron powder on the magnet prevents the sensor from detecting magnetic power With compressed air remove the iron powder or dust from magnet After feeding the tie wire the Twister does not move Bip bip bip bip bip bip Triple repetitive beep Feeding action error gt Is the connector
35. ation of the Twisting Motor Connect the connector and wire harnesses firmly tip of e T ing Motor error beep gt Motor is connected to Sub board i irmly Twister does not move Now beep sound from firmly Yes 1 Twisting Motor is locked Or Twister is locked 1 Remove foreigh substances which lock the motor or Twister Hooks catch the tip of tie wire 2 After catching the wire Twister stops RB655 Do the three wire harnesses Yellow Bule White connected same color wire of the Main Board firmly 2 Connector on the Twisting Motor is cut 2 Replace Twisting Motor with a new one 79 lt TROUBLE SHOOTING RB655 3 3 gt User Normal tool Operation operation Problem Beep sound What to check Cause of the problem How to fix the problem Not Pulling wire Bip Is the Feeding gear rotating No Feeding Motor end its life Brush is worn out Replace Feeding Motor with a new one Fast single beep Foreign substance entered into the Feeding Motor and lock up the motor lt Overcurrent error gt Foreign substance prevents rotation of the Feeding Gear Remove the foreign substance Yes During the pulling action the tip No beep Does the Hook L grabs the tie wire No Hook L is broken Replace Hook L with a new one of the tie wire is off from the firmly Yes L or
36. closes Hook L closes and catch the tip of the tie The tip of the tie wire is now caught by Hook L firmly At the same time Twister pushes Wire Guide Lever and it opens the Wire Guide Base Then the Feeding Motor starts pulling the tie wire and automatically stops when the wire tension becomes high Wire Guide Lever 81 3 CUTTING The Twister keeps moving forward and the Hook R also closes to catch the tie wire The Twister pushes the Cutter Lever and the Connecting Rod makes the Cutter rotates to cut the tie wire 4 TWISTING Just after the Cutter cuts the wire the Hook L R starts rotating action and the wire is kept twisted 5 RELEASING When the Main PC board senses the tightness is good enough the Twister stops twisting action and moves backward opening Hook L R and releasing the tie wire When the Twister goes back to home position the tying action is finished and the tie is completed Cutter Lever we t RB655 Recommended initial stock parts list For 20 tools IND Code Description Q ty IND Code Description Q ty 1 RB70025 PLANET CAGE B UNIT 84 RB70081 SENSOR BOAD E UNIT 2 40427 T BOLT 4 X8 85 KK33329 TORSION SPRING 3329 3 KK23847 COMP SPRING 3847 86
37. d confirm that the Lever moves smoothly Also make the Wire guide unit in its closed position and confirm that the gap between silver pin of Wire Guide Unit and Arm A is less than 0 8mm which is diameter of TW897 wire If the TW897 wire does not pass through the clearance it means the adjustment is correctly done 49 Cover L Assy RB11667 EE32104 SLIDE GUIDE SENSOR ROD PLAIN WASHER 2 3 SSS ee KK23850 COMPRESSION SPRING 3850 ASSEMBLY PROCEDURE RB70041 COVER L UNIT 1 Put the slotted end of the Sensor Rod through the Plain Washer Compression Spring and Slide Guide in that order 2 Put the unslotted end of the Sensor Rod through the upper hole in the Cover L Unit Note Watch out for the Sensor Rod direction 50 Cover L Assy Continued JJ10510 E RETAINING RING 2 5 RB70042 MAGNET HOLDER L UNIT Position the Sensor Rod so that its two slots will be projected from the Slide Guide and set the E Retaining Ring 1 Put the slotted end of the Sensor Rod into the Magnet Holder L Unit in the direction shown in the figure Set the E Retaining Ring 2 Push the Compression Spring in between the Slide Guide and the remaining slots of the Sensor Rod via the Plain Washer and set the E Retaining Ring 232 Note Confirm that the Magnet Holder L Unit is marked with L Confirm that the E Retaining Rings are firmly fit into the slots in the Sensor Rod Confirm that t
38. e 1 Twister goes back to its home position When the Twister is not in its home position 2 Feed Gear feeds wire Hooks are not in horizontal position 3 Cutting wire 4 Open the Hooks Twister does not go back to home position Slow Tsister movement error gt Does the connector on Twisting Motor is connected to Sub board firmly Do the three wire harnesses Yellow Bule White connected same color wire of the Main Board firmly PC boards can not detect the rotation of the Connect the connector and wire harnesses firmly Twisting Motor is locked Or Twister is locked Remove foreigh substances which lock the motor or Twister position then stops lt Tsister movement error gt Does the Connector of Harness 11P unit 3P connected firmly to the Sensor board A unit Main PC board can not detect the home position Connect the connectors firmly 1 Hamess 11P unit is cut or Sensor board A unit is broken 2 Twister is locked 1 Replace Harness 11P unit with a new one 2 Remove foreign substances which lock Twister ster goes back to home n and feeds wire but of the tie wire does not come out from the Arm No beep Are the Hooks are in horizontal ion Tie wire got entangled around the Hooks Remove the tie wire from the Hooks 1 The Cutter Ring steel plate on the Twister is not assembled between the leg
39. e Release Stopper and Feeding Gear Base Apply Loctite Purple to the threaded part projecting from the Feeding Gear Base of the Step Pin and tighten with a Hex nut 1 3 Tightening torque 50 80 cN m Put a Compression Spring 3851 in between a Release Lever and the dowel of the Feeding Gear Base Put a Hollow Pin 1628 into a Release Lever Assy and tighten with a Special Plain Washer 5 and a Hex bolt 4 x 16 Tightening torque 100 150 cN m Note Make sure that the Release stopper is free of adhesive agent TORQUE ADHESIVE 50 80 cN m Loctite Purple 100 150 cN m Not required 26 Feed Assy Continued RB70217 MAGNET HOLDER UNIT AA21102 PAN HEAD SCREW 3 x 4 ASSEMBLY PROCEDURE 1 Fit the Magnet Holder unit into the D cut section of the Feeding Gear Shaft 2 Using a Pan Head Screw 3 x 4 with Loctite Purple applied to it assemble a Sensor Board to a Feeding Gear Base Unit Tightening torque 50 80 cN m 3 Put a Feeding Gear Shaft A into the bearing of the Feeding Gear Base Unit TORQUE ADHESIVE 50 80 cN m Loctite Purple a2 Feed Assy Continued Assemble the Feeding gear B unit so that the cross rib side will face upward JJ10113 E RETAINING RING 2 5 EE39121 JJ10112 SPECIAL PLAIN WASHER 5 1 E RETAINING RING 3 RB10770 Mm mc EE39168 FEED GEAR A SPECIAL PLAIN WASHER 40481 Feed Gear Shaft 4 2 x 13x 1 HEX BOLT 3 x 5 RB70054 F
40. en to the Frame Assemble a Motor stopper and the Internal Gear to the rib of the Frame L and a Feed Gear Base to the rib of a Frame R 74 Step 27 40810 BOLT 3 x 16 Locate the terminals as shown in the figure RB10213 WINDOW EE32104 PLAIN WASHER 2 3 P RB80134 MOTOR COVER ASSY use BB40425 G BOLT 3 x 10 ASSEMBLY PROCEDURE Insert a window into a hole in a Frame R Bundle the connected harness green and brown as shown in the figure and put a Motor Cover over them Fix the Motor Cover with Bolts x 10 422 43 on the Frame L side and 1 Bolt x 16 4 on the Frame R side Put the Bolt lt through a Plain Washer 2 3 Tightening torque 2 100 150 cN m Others 50 100 cN m Note Tighten the Bolts in order of 1 to 44 TORQUE ADHESIVE 2 100 150 cN m Not required Others 50 100 cN m Not required 75 Step 1 Note Ensure that the harness is not caught EE39172 SPECIAL PLAIN WASHER 5 1 x 12x 1 2 Assemble with the punched surface facing upward BB40405 L Harness 4P Passage BOLT 5 x 25 BB10787 Sensor Cover GP Sensor Board F Unit ASSEMBLY PROCEDURE 1 Assemble a Magazine Assy to a Frame 2 Fix it with a Bolt 5 x 25 Set a Special plain Washer 5 1 x 12 x 1 2 with its sagging surface held the direction shown in the figure Tightening torque 200 250 cN m Note A
41. er Put the L bent section in between the two levers of the Cutter Lever After assembling make sure that the harnesses are not caught between the cylindrical section of the Internal Gear B and the ribs of the Frame L and that the front angular form of the Internal Gear B is firmly fit into the ribs of the Frame L Connect the Harness 3P unit to the Sensor Board B Unit Make sure that the Sleeve Guide of the Arm Shaft Assy Arm Shaft Guide Internal Gear B and Motor Gear B Unit are fit into the ribs of the Frame and that the Cutter Ring is fit into the Wire Guide Lever 69 MOTOR SENSOR CONNECTOR 6 FAN UNIT CONNECTOR SUB BOARD MOTOR HARNESS WHITE SUB BOARD FN UNIT CONNECTING TERMINAL on MOTOR GEAR B TWISTING MOTOR ASSY HARNESS RED Locate the fan and the motor sensor harness between the sub board and the motor housing J E ng ES l j PEE 6 EX Wr ge T I 7f ALA N M NE E Socr A ZW w A COLI IE A eis li E AL Route under the harness red and through a notch in the sub board to connect to the sub board Lay out the terminals in order of yellow blue and white from the bottom 70 ASSEMBLY PROCEDURE Connect the three harnesses of the twisting motor TD5046 unit to the terminals of the Sub board in order of yellow blue and white Insert the Motor Shaft into a hexagona
42. er Hook is worn out Replace Hook R or Center Hook with a new one Bip beee Bip beee Does the connector on Twisting Motor The PC boards can not detect the rotation of the Twisting Motor Connect the connector and wire harnesses firmly lt Twisting Motor error beep gt New beep sound from RB655 is connected to Sub board firmly Do the three wire harnesses Yellow Bule White connected same color wire of the Main Board firmly 1 Twisting Motor is locked Or Twister is locked 2 Connector on the Twisting Motor is cut h substances which lock the motor or Twister g Motor with a new one Releasing the wire The Hooks release the tie wire and then stops with beep sound After three ties are made Is the wire used TW1525 series tie No Tie wire used is not correct Use TW1525 Bip bip bip bip bip bip bip e Yes 1 The Connector of Harness 7P unit is not connected to the Sensor 1 Connect the connectors firmly t Board F unit Reel sensor firmly 2 Clean up the photo sensor inside of the reel magazine with cotton swab 4 repetitive beep 2 The photo sensor of Sensor Board F unit Reel sensor is dirty and 3 Replace the Harness 7P unit or Sensor Board F unit with a new one can not sense the projections of the wire reel Reel sensor error gt 3 Harness 7P unit is cut or Sensor board F unit is broken After one Is the connector of Cooling Fan No Cooling Fan can not work Co
43. er parts Apply Molykote grease on Fixed Cutter and reassemble them 8 HOW TO CLEAN UP THE CUTTER AREA 3 3 BB40810 150 200cN m BB40425 100 150cN m 19 Self warm up program When the RB650 RB655 tool is used under cold temperature below 0 C 30F you may find the following phenomenon A The part that catches the tie wire does not fully open after the tying action is completed and it is hard to pull out the tool from the tied wire B The tie wire is not cut The self warm up program is installed to the RB650 and RB655 Running the self warm up program helps to solve the phenomenon above How to run the self warm up program Step 1 Turn the main switch off and remove the tie wire from the tool Step 2 Set the Torque dial at position 8 maximum position Step 3 Keep pulling the Trigger and turn the Power switch on The twisting part of the RB650 RB655 automatically starts 50 times of twisting action then stops TURN THE POWER 20 Main Switch Base Assy RB70113 RB70341 MAIN SWITCH RB655 UNIT MAIN SWITCH BASE WARNING If the Power switch is mounted in the opposite direction the tool will be activated with the switch being at the OFF position endangering you Shift to the ON side RB70087 WARNING LED UNIT Apply Loctite Purple YY 74410 HEX SCREW 3 x 6 RB10853 TORQUE DI
44. g it Set a Plain Bearing B F3 1 onto a cylindrical part at the nose of the Arm A Setscrew from above a Wire Guide Lever and secure with an E Retaining Ring 2 5 Put an Arm B Assy on the Frame L and assemble it with an Arm Setscrew and a Bolt 3 x 10 Degrease the Bolt 3 x 10 and apply an adhesive agent Loctite Blue Tightening torque 100 150 cN m Set the coiled part of a Torsion Coil Spring 3329 onto the cylindrical part of a Cutter Shaft and hook the straight part of a spring leg onto the Arm Setscrew and its arc part into a groove in a Cutter Lever pin After assembling check movements Turn a Cutter Lever and confirm that it is returned to its previous position by a spring load TORQUE ADHESIVE 100 150 Loctile 242 100 150 cN m Not required 529 100 150cN m Loctite 242 47 100 150 cN m Not required 64 Step 4 70085 HARNESS 7P UNIT RB70075 RB70084 MAIN BOARD UNIT HARNESS 11P UNIT MAIN SWITCH BASE ASSY 4 70101 TRIGGER SWITCH UNIT RB70084 RB70085 HARNESS HARNESS 7P UNIT 11P UNIT How to Expose Harness 11P and 7P Units For preparation before assembling to the frame ASSEMBLY PROCEDURE 1 Plug a Harness 11P Unit Harness 7P Unit and Trigger Switch Unit into the relevant connectors of the Main Board Unit RB655 as shown in the figure 2 Expose the Harness 11P Unit and the Harness 7P Unit from the b
45. has better efficiency and requires less electricity NOT interchangeable with Feeding Motor of RB650A Board Unit RB70367 Red Black Purple Brown Yellow Blue White Main board and Sub board is not supplied individualy White color wire is added for running Brushless motor Main Board 155 Sub Board 156 Bunkered RB70195 RB70196 RB10833 lt Different parts between RB650A and RB655 1 4 RB70091 RB70341 The length of wire harness is different The longer wire is placed on the groove of Twisting Motor housing RB650A RB655 RB70119 USA RB70120 Picture CE RB81104 USA RB81106 Picture The amount of glass fiber in plastic material is increased and protect rubber is removed CE RB81069 USA RB81068 CE RB81105 USA RB81107 The amount of glass fiber in plastic material is increased and protect rubber is removed RB81032 RB70354 lt Different parts between RB650A and RB655 2 4 RB81033 RB11882 RB650A RB655 Fan Unit RB81031 Picture RB70339 Picture Connector on Fan Unit is directly connected to the PC board Without connection cable Fan Protector RB11886 Same as the sponge part of RB650A these two parts protect Fan unit RB11883 This part holds Filter A and Filter B in place Fi
46. he Sensor Rod and the Magnet Holder L Unit are activated interlockingly by a spring force 51 Cover L Assy Continued RB10759 TWIST GUIDE SHAFT Hook the spring legs as shown in the figure RB70369 TWIST GUIDE COVER L oO KK33328 TORSION COIL SPRING 3328 Hook the spring legs as shown in the figure ASSEMBLY PROCEDURE 1 Assemble the Torsion Coil Spring 3328 to the Twist Guide Cover L as shown in the figure and hook the Torsion Coil Spring legs onto the Twist Guide Cover L 2 Put the Twist Guide Shaft into the Twist Guide Cover L and Torsion Coil Spring 3328 Note Do not confuse the Torsion Coil Springs 3328 and 3330 with each other 52 Cover L Assy Continued BB40481 HEX BOLT 3 x 5 Hook the longer spring leg onto the Arm Cover as shown in the figure position ASSEMBLY PROCEDURE 1 Put the Twist Guide L Assy into the front end of the Cover L Unit and hook the longer spring leg onto the Cover L Position 284 2 Tighten the hex bolts 3 x 5 2 pcs Tightening torque 150 200 cN m 3 Confirm that opening closing the cover moves the Magnet Holder L Unit back and forth TORQUE ADHESIVE 150 200 cN m Not required 53 Cover R Assy EE32104 RB11667 PLAIN WASHER 2 3 SENSOR ROD pu e e SLIDE GUIDE KK23850 BB70044 COMPRESSION SPRING 3850 COVER R UNIT ASSEMBLY PROCEDURE 1 Put the slot
47. ip bip bip Sextet repetitive sound Problem happens on Cooling Fan TT lt TROUBLE SHOOTING OF RB655 1 3 gt User Operation Normal tool operation 1 Feed Gear feeds wire 2 Cutting wire Hooks are in horizontal 3 Open the Hooks Wire is not fed Beep sound Bip bip bip bip Fast single beep lt Overcurrent error beep gt What to check Is Feeding Gear on the Feeding Motor is rotating Cause of the problem Feeding Motor end its life Brush is worn out Foreign substance entered into the Feeding Motor and lock up the motor How to fix the problem Replace Feeding Motor with a new one Foreign substance prevents rotation of the Feeding Gear Remove the foreign substance Movement of the cutter parts is not smooth and the Cutter blocks the hole of the Fixed Cutter Clean up the Cutter and Fixed Cutter and apply Molykote grease Beee Continuous beep Twist Guide Cover open gt Do Twist Guide Covers close perfectly Twist Guide Cover is deformed Torsion spring on the Twist Guide Cover is deformed Replace Twist Guide Covers and torsion springs 1 Connector of the sensor at Twist Guide Cover is not connected firmly or the connector is broken 2 Sensor board D unit or Sensor board E uni 3 Magnet holder L unit or Magnet holder R is broken 5 broken 1 Connect the connectors firmly 2 3 Replace the broken p
48. l hole in the Motor Gear B With the Motor Assy tilted as shown in the figure When this is done pass the Motor Housing Sssy under the harness red of the main switch After inserting the Motor Shaft confirm that the Motor Assy is properly fit into the Frame L Pass the Fan Unit connector under the harness red of the Main Switch to connect it to the Fan connecting terminal of the Sub board Pass the Motor Sensor Connector under the harness red of the Main Switch to connect it to the Motor Sensor Connecting Terminal of the Sub Board Lay out the motor terminals in the grip as shown in the figure Lay out the harness red of the Main Switch in the wiring grooves in the Motor Housing R as shown in the figure 71 Setting the Trigger lock onto this rib RB10854 5 TRIGGER set the Trigger onto this rib b KK23656 2 22 COMPRESSION ZO RB70353 SPRING 3656 A FRAME R ASSY 655CE RB10855 TRIGGER LOCK ncs EE39830 SPECIAL PLAIN WASHER 5 1 X 9 ASSEMBLY PROCEDURE 1 Assemble a Trigger Trigger Lock and Compression Spring 3656 and assemble them onto the rib of a Frame L 2 Set a Special Plain Washer 5 1 x 9 onto the boss of the Frame L as shown in the figure 1 place 3 Assemble a Frame R assy to the Frame L 72 Step 20 40810 40810 BOLT 3 x 16 BB40425 BOLT 3x16 BB40811 BOR eae HEX BOLT 3 x 25 Assemble and fix a Cover R Assy to the frame L EE3210
49. lter A 1 wire mesh 71 RB11002 RB11884 Filter B Sponge lt Different parts between RB650A and RB655 3 4 RB11885 To prevent dust from getting inside this sponge was added RB650A RB655 Motor Housing Assy Picture Picture Twist Guide Cover L RB70178 RB70179 RB70369 RB70370 To improve wire pulling action the shape of the Twisg Guide Cover L and R were changed rotation sensor and fan unit to PC board Placement of red wire harness of Main Switch lt Different parts betw Wire harness on Main Switch is placed on the groove of Motor housing RB655 Tying times indication mode With the beep sound and LED blinks total tying times can be read without opening tool frame Readable tying times Minimum 1 000 ties Maximum 999 000 ties How to go to the Tying times indication mode 1 Turn the Main Switch off and remove battery 4 With using a screw driver keep the Twist Guide Cover open 2 Remove Tie wire from Magazine as the picture below shows 3 Set the Torque adjust dial to the position 1 5 Set the battery to the tool 6 Keep pulling the trigger and turn the Main Switch on Then the tool start showing how many ties has been made with LED blinks and beep sound How to read the tying times Tool shows each digit indication first LED blinks only followed by number indicatio
50. n LED and beep Example of ties is 16 300 ties Digit indication LED blinks only No beep Number indication LED blinks and beep sound Note No indication Digit of 100 000 LED blinks EE because of ties does not reach 100 000 Number indication is LED blinks one time which Digit of 10 000 ENS means 10 000 ties Number indication is TA ime Ea aes LED blinks Sum 1 2 and 3 16 000 ties 300 ties can not be read with this program It can be read by Checker box After the rapid 2 time blink 4 tool repeats indication from 1 MAXI MAXCD LTD RB650 RB650A RB655 tool checker ee 2 LIND 2345 1 3 05984 No Name Function 1 AC CODE 2 Not for use 3 POWER SWITCH Power switch 4 DISPLAY Display the information of the tool status 5 CONNECTOR Connector to Main Board inside of the tool 6 BINDS BUTTON Press to see total number of ties made by a tool 7 POWER BUTTON Press to see how many times a tool is powered on Press to see total number of each error happened on a tool 8 ERR BUTTON With pressing the button each error number will be shown in turn 1 MOTOR LOCK ERROR 2 TWISTING ACTION ERROR 3 TWIST GUIDE COVER OPEN ERROR 4 FEEDING FUNCTION ERROR 5 REEL SENSOR ERROR 6 CPU OVERHEAT 7 OVERHEAT 9 LAST ERR BUTTON Press to see the last error 10 VERSION BUTTON Press to see the version of the program in Main Board
51. n marked side Ensure that the name label air blow direction indicating arrow of the Fan Unit is directed to the opening side of the Motor Housing as shown in the figure 3 Wire the Fan Unit harness 58 Twisting Motor Assy Continued IAE ae ess RB11884 RB11885 FILTER A FILTER B RB11883 FILTER COVER em ois Toth HERE 210 6 59 Twisting Motor Assy Continued Wiring of Yellow Blue and White Harnesses ASSEMBLY PROCEDURE 1 Assemble a Twisting Motor TD5046 Unit to the motor housing L as shown in the figure 2 Wire a Motor Sensor Harness coming from the Twisting Motor and three yellow blue and white harnesses as shown in the figure 3 After assembling confirm that the Twisting Motor is properly fit into the Motor Housing 60 Twisting Motor Assy Continued RB11886 Assemble the C surface FAN PROTECTOR side in the direction shown in the figure RB11882 577 40811 MOTOR HOUSING R HEX BOLT 3 X 25 Wiring of Fan Unit Harness Wiring of Yellow Blue and White Harnesses Assemble a Fan Protector into a Motor Housing R in the direction shown in the figure Note that it has directionality Attach the Motor Housing R with the assembled Fan Protector to the Motor Housing L There should be no gap allowed between the Motor Housing L and the Motor Housing R C
52. nnect the connectors firmly connected to the Sub board firmly Yes Wire harnesses at Cooling Fan are cut Replace the Cooling Fan with a new one bip bip bip bip 6 repetitive beep Cooling fan error beep gt Cooling Fan is broken Bip beee Bip beee lt Twisting Motor error beep gt New beep sound from RB655 Does the connector on Twisting Motor is connected to Sub board firmly Do the three wire harnesses Yellow Bule White connected same color wire of the Main Board firmly The PC boards can not detect the rotation of the Twisting Motor Connect the connector and wire harnesses firmly 1 Twisting Motor is locked Or Twister is locked 2 Connector on the Twisting Motor is cut 1 Remove foreigh substances which lock the motor or Twister 2 Replace Twisting Motor with a new one 80 Process of Tying Action 1 FEEDING When the Trigger is pulled the Feeding Motor starts feeding tie wire toward the Arm through the room between the Hook R and Center Hook The Arm makes the tie wire into arc shape The wire is kept feeding and the tip of the wire reaches the room between the Hook L and the Center Hook The Sensor at the Feeding Motor stops feeding action when approx 12 13 of wire is fed 2 PULLING The Twister moves forward and the Hook L
53. o the frame one by one in that HARNESS 3P UNIT D unit Red order Wire a red harness from the main switch as Sensor Purple hown in the fi Sensor base assy board E unit ala Ub Ead Black 1 Eat 4 Route the harness under the projection of the jaw base Ensure that the harness is not exposed from the rib of the frame OS iy Harness blue Notch in Electrode Block ASSEMBLY PROCEDURE Connect the 3P of a Harness 11P unit to a Sensor Board E Unit Connect a Harness 3P Unit to a Sensor Board D Unit Assemble a Sensor Base Assy to a Frame L When this is done pass the 3P Harness under a Finger Base through a notch 1 Route the yellow blue and white harnesses coming from the sub board one by one in that order between the frame L and the Sub board through a notch 525 followed by Area B to wire them as shown in the figure Route the brown and purple harnesses coming from the sub board one by one in that order between the frame L and the sub board and through the notch 2 to expose them from the back of the Frame L as shown in the figure Route a black harness coming from the Sub board between the frame L and the sub board through the notch 2 followed by Area B to wire it as shown in the figure Wire a red harness coming from the Main Switch Unit as shown in the figure Assemble the electrode block with its notch facing upward Confirm that the red harness is on the upper
54. on Sensor Board C connected firmly The sensor at Feeding Gear does not work Connect the connectors firmly Sensor Board C unit is broken Harness 7P Unit is cut Replace Sensor Board C or Harness 7P unit with a new one Bip beee Bip beee lt Twisting Motor error gt New beep sound from RB655 Does the connector on Twisting Motor is connected to Sub board firmly Do the three wire harnesses Yellow Bule White connected same color wire of the Main Board firmly PC boards can not detect the rotation of the Twisting Motor Connect the connector and wire harnesses firmly 1 Twisting Motor is locked Or Twister is locked 2 Connector on the ing Motor is cut 1 Remove foreigh substances which lock the motor or Twister 2 Replace ing Motor with a new one After feeding tie wire Twister moves but can not cut the tie wire Bip bip bip bip Fast single beep lt Overcurrent error beep gt load to cut the tiw wire is too high 1 Cutter is worn out 2 Hook parts are too dirty 1 Replace the Cutter with a new one 2 Clean up the Hooks with Paslode Degreaser Cleaner and then apply Molykote grease No beep Is the tool repeating initializing action Cutter Lever is worn out Cutter Shaft is broken Replace Cutter Lever or Cutter Shaft Battery is discharged or ends its life Charge the battery or replace it with a brand new on
55. onfirm that no harness is caught between them Fix with a Hex Bolt 3 x 25 Tightening torque 50 100 cN m TORQUE ADHESIVE 50 100 cN m Not required 61 HOW ATTACH THE EACH ASSEMBLY THE FRAME Step 1 Y BB40410 HEX BOLT 3 x 8 EE32104 PLAIN WASHER 2 3 RB70120 FRAME L ASSY RB70033 JAW BASE ASSY ASSEMBLY PROCEDURE 1 Assemble a JAW Base Assy to the Frame L with Hex Bolts 3 x 8 Tightening torque 100 150 cN m TORQUE ADHESIVE 100 150 cN m Not required 62 Step 2 Y giua BOLT 3 x 10 EE32104 PLAIN WASHER 2 3 COVER L ASSY ASSEMBLY PROCEDURE 1 Assemble a Cover L Assy to a Frame L upper tapped hole with a Bolt 3 x 10 2 For the side where a Hollow pin has been press fit into the Frame L set a Plain Washer 2 3 and fix with a Bolt 3 x 10 Tightening torque 100 150 TORQUE ADHESIVE 100 150 cN m Not required 63 Step X Vestre ARM A SETSCREW ARM ASSY fi JJ10113 E RETAINING RING 2 5 BB40810 BOLT 3 x 16 ARM B ASSY 11768 ARM SETSCREW KK33 329 After degreasing TORSION COIL SPRING 3329 apply Loctite 242 BB40425 BOLT 3 x 10 ASSEMBLY PROCEDURE Assemble Arm A Assy to Frame L with Bolt 3 x 16 and Arm A Setscrew Tightening torque 100 150 cN m Apply Loctite 242 to a Bolt 3 x 16 after degreasin
56. otary Switch dislocate them from each other 3 Insert a LED unit connector into a Sub board Unit 4 Connect the harness of a Main Switch Unit to the one red coming from the Sub board Unit 5 Insert the Rotary Switch into a Dial joint and fix the Main Switch Base and Sub board Unit with Tapped Screw 3 x 6 Tightening torque 40 50 cN m 6 After assembling turn the Torque Dial to confirm that it is changed over in 8 steps TORQUE ADHESIVE 40 50 cN m Not required 22 Main Switch Base Assy Continued RB10970 ELECTRODE BLOCK Locate the terminals as shown in the figure CC41104 HARNESS HEX NUT 1 3 HARNESS RED BLACK MAIN SUB BOARD SWITCH ELECTRODE PLATE BB40410 HEX BOLT 3 X 8 RB11769 ASSEMBLY PROCEDURE 1 Put Hex Nuts 1 3 in an Electrode Block and fix a harness red coming from the Main Switch Unit and an Electrode Plate to the notched side with a Hex Bolt 3 x 8 Likewise fix a harness black coming from a Sub board and an Electrode Plate to the non notched side with a Hex Bolt 3 x 8 Tightening torque 80 100 cN m Pay heed to the position of the notch in the Electrode Block and the relevant wire color If the wire is connected to the other side the Main Board Unit will be broken 2 Locate the terminals connected as shown in the figure TORQUE ADHESIVE 80 100 cN m Not required 23 Twister Assy RB10726 RB70
57. r Lever or Cutter Shaft action Cutter Shaft is broken Battery is discharged or ends its life Charge the battery or replace it with a brand new one Not twisting wire No beep Does the Hook L grabs the tie wire Hook L is broken Replace Hook L with a new one firmly Hook L or Center Hook is worn out Replace Hook L or Center Hook with a new one Bip beee Bip beee Does the connector on Twisting Motor The PC boards can not detect the rotation of the Twisting Motor Connect the connector and wire hamesses firmly lt Twisting Motor error beep gt New beep sound from RB655 is connected to Sub board firmly Do the three wire harnesses Yellow Bule White connected same color wire of the Main Board firmly 1 Twisting Motor is locked Or Twister is locked 2 Connector on the Twisting Motor is cut 1 Remove foreigh substances which lock the motor or Twister 2 Replace Twisting Motor with a new one Twisting wire Twister twists wire but the No beep Does the Hook L grabs the tie wire No Hook L is broken Replace Hook L with a new one length of the one side of firmly Yes HookL or Center Hook is worn out Replace Hook L or Center Hook with a new one straight part of the tie is short Or the Twister does not t onece in several The Hooks do not release the No beep Does the Hook R releases the tie wire No R is broken Replace Hook R with a new one tie wire Hook R or Cent
58. rple RB11776 MAGAZINE COVER SPRING and AA 31504 TAPPED SCREW 3 x 6 come with RB81103 MAGAZINE COVER 34 Magazine Assy Continued RB11775 STOPPER HEAD RB81103 MAGAZINE COVER RB10806 ADJUST RING RB11774 MAGAZINE STOPPER 577 10198 A 9172 SPECIAL PLAIN WASHER 5 1 X 12 1 2 SPECIAL BIND SCREW 3 X 10 Direct the punched surface to the Magazine Cover Aligning with the D cut part of the Magazine Stopper insert the Stopper Head Put a Magazine Stopper through an Adjust Ring to fit it into a Magazine Cover Assemble the Adjust Ring directing its knurling to the Magazine Stopper side Put a Stopper Head through a Special Plain Washer 5 1 x 12 x 1 2 to fit it into the Magazine Stopper Align the D cut part of the Stopper Head with that of the Magazine Stopper Assemble the Special Plain Washer 5 1 x 12 x 1 2 directing its punched surface to the Magazine Cover side as shown in the figure Assemble the Magazine Stopper and the Stopper Head with a Special Bind Screw 3 x 10 Tightening torque 80 100 cN m TORQUE ADHESIVE 80 100 cN m Not required 35 Magazine Assy Continued EE39602 SPECIAL RUBBER WASHER 7 KK33327 TORSION COIL SPRING 3327 NI X N S FF31289 2 PARALLEL PIN 1289 The special rubber washer is fit into the groove Place the legs of the Torsion Coil Spring ASSEM
59. s of the Wire Guide Lever 2 Wire Guide Unit is deformed and the gap between the silver pin on the Wire Guide Unit and Arm A is too large 1 Assemble the Wire Guide Lever correctly 2 Replace the Wire Guide Unit with a new one Other problems are same as the case of Twister is in its home position lt TROUBLE SHOOTING RB655 2 3 gt User Operation Normal tool operation Problem Beep sound What to check Cause of the problem How to fix the problem Wire is not fed Bip bip bip bip Is Feeding Gear on the Feeding Feeding Motor end its life Brush is worn out Replace Feeding Motor with a new one Fast single beep Motor is rotating Foreign substance entered into the Feeding Motor and lock up the motor lt Overcurrent error beep gt Foreign substance prevents rotation of the Feeding Gear Remove the foreign substance Movement of the cutter parts is not smooth and the Cutter blocks the holeClean up the Cutter and Fixed Cutter and apply Molykote grease of the Fixed Cutter Yes Beee Do Twist Guide Covers close No Twisti Guide Cover is deformed Replace Twist Guide Covers and torsion springs Continuous beep perfectly spring on the Twist Guide Cover is deformed Twist Guide Cover open Yes 1 Connector of the sensor at Twist Guide Cover
60. side 67 Step 7 Wire Guide Lever GP P 3P Sensor Board E Unit Sensor Base Assy Pawl Base Putting Harness 11P Unit through Notch of Arm Shaft Guide Sensor Board G Unit GREASE MOLYKOTE PG 662 RB70056 MOTOR GEAR B UNIT Sleeve Suide Cutter Ring Arm Shaft Internal Guide Gear B Confirm that the cutter ring is properly fit onto the wire guide lever Ge 2 AUTE G TIE L7 mE EI ao iE Apply Molykote PG 662 to the contact surface of the cutter lever and the cutter ring 68 ASSEMBLY PROCEDURE Apply Molykote PG 662 to the Sleeve B and Cutter Ring of the Arm Shaft Assy and the Cutter Lever of the Arm B Assy as shown in the figure Apply Molykote PG 662 to the gear section of the Motor Gear B unit and put it in between the Planetary Gears B Connect the 3P of the Harness 11P unit to the Sensor Board A unit and the 5P to the Sensor Board B unit As shown in the figure put the 3P and 5P of the harnesses through the Arm Shaft Guide and the notch 12 of the Frame L When assembling the Arm Shaft Guide to the Frame L block the notch 1 with the Arm Shaft Guide so that the harnesses will not float Assemble the Arm Shaft Assy to the Frame L Fit the Sleeve Guide Arm Shaft Guide Internal Gear B and Motor Gear B unit into the ribs of the Frame L Fit the straight section of the Cutter Ring into the groove in the Wire Guide Lev
61. ssemble the Magazine making sure that a Harness 4P has been set in a groove in the Frame L as shown in the figure 3 Connect the connector of the Harness 4P coming from the frame to the sensor Board F Unit 4 Fit the pawl of the Sensor Cover into the square hole in the Magazine TORQUE ADHESIVE 200 250 cN m Not required T6 BEEP SOUND REFERENCE Type of beep Beep meaning Bee Single continuous sound Twist guide cover safety is opened during tying action Or problem happens on sensor at the Twist guide cover bip bip bip Single repetitive sound SLOW Problem happens on twisting action Bip bip bip bip bip bip Double repetitive soun The battery almost runs out Bip bip bip bip bip bip bip bip Triple repetitive sound Problem happens on wire feeding action Or problem happens on sensor at the Feeding gear Bip bip bip bip bip bip bip bip Quadruple repetitive sound Sensor in the Magazine can not sense the notches on the wire reel Orthe sensor itself has problem Bip bip bip bip bip Quintuple sound The Twisting motor is too hot Bip bee bip bee bip bee Short and long beep combination New beep from RB655 sProblem happens on the Twisting Motor rotation Bip bip bip bip bip Single repetitive sound FAST Electrical overload happens Bip bip bip bip bip bip bip bip bip b
62. ted end of the Sensor Rod through the Compression Spring 3850 and Slide Guide in that order 2 Put the unslotted end of the Sensor Rod through the upper hole in the Cover R Unit Note Watch out for the Sensor Rod direction 54 Cover R Assy Continued JJ10510 E RETAINING RING 2 3 RB70045 MAGNET HOLDER R UNIT SLIDE GUIDE ASSEMBLY PROCEDURE Position the Sensor Rod so that its two slots will be projected from the Slide Guide and set the E Retaining Ring 512 Put the slotted end of the Sensor Rod into the Magnet Holder R unit in the direction shown in the figure Set the E Retaining Ring 2 Push the Plain Washer and Compression Spring in between the Slide Guide and the remaining slots of the Sensor Rod and set the E Retaining Ring 2 Note Confirm that the Magnet Holder R Unit is marked with R Confirm that the E Retaining Rings are firmly fit into the slots in the Sensor Rod Confirm that the Sensor Rod and the Magnet Holder R Unit are activated interlockingly by a spring force 55 Cover R Assy Continued 7 10759 Hook the spring legs as shown the figure TWIST GUIDE SHAFT RB70370 TWIST GUIDE R UNIT WANE KK33330 TORSION COIL SPRING 3330 T Hook the spring legs as shown in the figure ASSEMBLY PROCEDURE 1 Assemble the Torsion Coil Spring 3330 to the Twist Guide R as shown in the figure and hook the Torsion Coil Spring
63. the Feeding Gear B unit turns smoothly 24 Feed Assy Continued GREASE MOLYKOTE PG 662 Groove where the JJ21603 RB10338 LL11181 retainina ri C RETAINING RING FOR SHAFT 20 INTERNAL GEAR BEARING 6704 CTetaining nng for D Shielded Surface Bearing Open Surface R FEED GEAR SHAFT If opened too much at the time of assembling the C retaining ring 222222 Beware of the bearing direction will be deformed causing faulty operation Use snap ring pliers with stopper The opening limit dimension should be 20 2 Adjust at the stopper position ASSEMBLY PROCEDURE 1 Apply Molykote PG 662 Grease to the side of a Bearing 6704 2 Set the Bearing with its shielded surface on the Internal Gear Side put a Feeding Gear Shaft A Unit and secure with a C Retaining Ring for Shaft 20 25 Feed Assy Continued RB70055 BB40420 FF51628 RELEASE LEVER ASSY HEX BOLT 4 x 16 HOLLOW PIN 1628 KK23851 COMPRESSION SPRING 3851 EE39121 MU EO ME SPECIAL PLAIN RB70053 FEEDING GEAR BASE UNIT Rc RB10852 CC41104 RELEASE STOPPER rex HEX NUT 1 3 After 23850 degreasing hae 0043 z COMPRESSION SPRING 3850 5 STEP Apply Loctite Purple ASSEMBLY PROCEDURE Put a Compression Spring 3850 in between a Feeding Gear Base and a Release Stopper and put a degreased Step Pin into the holes in th
64. the sagging surface of the Gear Retainer to the Planet Gear side 29 Magazine Assy RB81102 MAGAZINE ASSY RB10792 RETAINING RING The sagging direction should face upward RB10791 SENSOR COVER PLATE RB10791 SENSOR COVER PLATE RB10792 RETAINING RING Section A A Profile after Assembly ASSEMBLY PROCEDURE 1 Set a Sensor Cover into a Magazine with its larger flange facing upward 2 Set a Retaining Ring into a groove in the Magazine in the direction shown in the figure with its sagging direction facing upward 3 Make sure that the Retaining Ring is fit into the groove and that the Sensor Cover turns 30 Magazine Assy Continued RB70082 SENSOR BOARD F UNIT AA31714 TAPPED SCREW 2 x 4 2 75522 Apply Loctite purple after degreasing ASSEMBLY PROCEDURE 1 Set a Sensor Board F unit into the Magazine with its connector side facing upward 2 Apply Loctite Purple to a degreased Tapped Screw 2 x 4 to tighten it Tightening torque 10 20 cN m Note For torque control confirm that a Screw Head has seated on a board and then tighten with a Torque Screwdriver TORQUE ADHESIVE 10 20 cN m Loctite Purple 31 Magazine Assy Continued Make the Bush B flush with the bottom surface of the Magazine Section B B RB10786 BUSH B NS Apply silicone grease Fit the Bush A until it is positioned to the middle

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