BK5010 SERVICE MANUAL

BK5010 SERVICE MANUAL
BK5010
SERVICE MANUAL
002715MIU
BK5010
SERVICE MANUAL
BK5010
SERVICE MANUAL
002715MIU
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interest of Ricoh Corporation and its member companies.
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PERMISSION OF RICOH CORPORATION.
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any trade name, or web site is intended to convey endorsement or other
affiliation with Ricoh products.
© 2006 RICOH Corporation. All rights reserved.
WARNING
The Service Manual contains information
regarding service techniques, procedures,
processes and spare parts of office equipment
distributed by Ricoh Corporation. Users of this
manual should be either service trained or
certified by successfully completing a Ricoh
Technical Training Program.
Untrained and uncertified users utilizing
information contained in this service manual to
repair or modify Ricoh equipment risk personal
injury, damage to property or loss of warranty
protection.
Ricoh Corporation
LEGEND
PRODUCT CODE
GESTETNER
N/A
N/A
N/A
N/A
COMPANY
LANIER
RICOH
BK5010 Booklet Maker
CF5010 Cover Feeder
TR5010 Trimmer
BF5010 Book Folder
SAVIN
DOCUMENTATION HISTORY
REV. NO.
*
DATE
05/2006
COMMENTS
Original Printing
IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
Always connect the equipment to a
properly grounded power source. In doubt, have
the power source checked by a qualified
electrician.
Never use a ground adapter plug to
connect the equipment to a power source that
lacks a ground connection terminal.
Never attempt any maintenance function
that is not specifically described in this
documentation.
WARNING: Improper connection of the
equipment grounding conductor can result
in electrical shock.
Never remove the covers or guards that
are fastened with screws, unless you are a
trained Service representative.
Always follow all warnings marked on, or
supplied with, the equipment.
Always locate the equipment on a solid
support surface with adequate strength for
the weight of the machine.
Always exercise care in moving or
locating the equipment.
Never install the unit near a radiator or any
other heat source.
Never override or “cheat” electrical or mechanical interlock devices.
re-
Never operate the equipment if you notice
unusual noises or odors. Disconnect the
power cord from the power source and call
your customer service engineer to correct
the problem.
Always keep magnets and all devices with
strong magnetic field away from the
machine.
1. Before disassembling or assembling parts of the Booklet maker and peripherals.
make sure that the Booklet maker power cord is unplugged,
2. The wall outlet should be near the Booklet maker and easily accessible.
3. Note that some components of the Booklet maker and peripherals are supplied
with electrical voltage even if the main power switch is turned off.
4. If any adjustment or operation check has to be made with exterior covers off or
open while the main switch is turned on, keep hands away from electrical or mechanically driven components.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS
1. The Booklet maker and its peripherals must be installed and maintained by a
customer service representative who has completed the training course on those
models.
SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL
1.
Dispose of replaced parts in accordance with local regulations.
III
TABLE OF CONTENTS
1 INSTALLATION PROCEDURE
1.1 INSTALLATION REQUIREMENTS........................................................... 1-1
1.1.1 MINIMUM SPACE REQUIREMENTS.............................................. 1-1
1.1.2 POWER REQUIREMENTS.............................................................. 1-2
1.2 INSTALLATION FLOW CHART................................................................ 1-3
1.3 BOOKLET MAKER INSTALLATION......................................................... 1-5
1.3.1 ACCESSORY CHECK..................................................................... 1-5
1.3.2 INSTALLATION PROCEDURE........................................................ 1-6
1.3.3 ADJUSTMENTS............................................................................. 1-13
1.3.4 CONNECTORS.............................................................................. 1-20
1.3.5 CHECK THE INSTALLATION........................................................ 1-21
1.4 COVER FEEDER INSTALLATION......................................................... 1-22
1.4.1 ACCESSORY CHECK................................................................... 1-22
1.4.2 INSTALLATION PROCEDURE...................................................... 1-23
1.4.3 ENABLING THE COVER FEEDER................................................ 1-36
1.4.4 CHECK THE INSTALLATION........................................................ 1-37
1.5 TRIMMER INSTALLATION..................................................................... 1-39
1.5.1 ACCESSORY CHECK................................................................... 1-39
1.5.2 INSTALLATION PROCEDURE...................................................... 1-40
1.5.3 ADJUSTMENTS............................................................................. 1-43
1.5.4 DOCKING........................................................................................ 1-46
1.5.5 CONNECTORS.............................................................................. 1-49
1.5.6 CHECK THE INSTALLATION........................................................ 1-52
1.6 BOOK FOLDER INSTALLATION............................................................ 1-55
1.6.1 ACCESSORY CHECK................................................................... 1-55
1.6.2 INSTALLATION PROCEDURE...................................................... 1-56
1.6.3 ADJUSTMENTS............................................................................. 1-60
1.6.4 DOCKING........................................................................................ 1-63
1.6.5 CONNECTORS.............................................................................. 1-65
1.6.6 AUTO SET THICKNESS BRACKET.............................................. 1-66
1.6.7 CHECK THE INSTALLATION........................................................ 1-68
2.PREVENTIVE MAINTENANCE SCHEDULE
2.1 PM TABLE................................................................................................ 2-1
3.REPLACEMENT AND ADJUSTMENT
3.1 GENERAL CAUTIONS............................................................................. 3-1
3.2 SPECIAL TOOLS AND LUBRICANTS..................................................... 3-3
3.2.1 SPECIAL TOOLS............................................................................. 3-3
3.2.2 REQUIRED TOOLS......................................................................... 3-5
3.2.3 LUBRICANTS.................................................................................. 3-5
3.2.4 SYMBOLS USED IN TEXT.............................................................. 3-5
3.3 COVERS................................................................................................... 3-7
3.3.1 FRONT AND REAR COVER............................................................ 3-7
3.3.2 INFEED COVER.............................................................................. 3-8
3.3.3 INFEEDER....................................................................................... 3-9
3.3.4 OUTFEED COVER........................................................................ 3-10
3.3.5 UPPER TOP COVER..................................................................... 3-11
3.3.6 REAR TOP COVER....................................................................... 3-12
3.3.7 TOP COVER ASSEMBLY.............................................................. 3-13
3.3.8 INTERLOCK SWITCH S16 &S17.................................................. 3-16
3.4 AREA A................................................................................................... 3-17
3.4.1 INFEED MODULE.......................................................................... 3-17
3.4.2 PAPER INFEED SENSOR............................................................. 3-18
3.4.3 INFEED TRANSPORT MODULE................................................... 3-19
3.4.4 INFEED TRANSPORT WHEEL..................................................... 3-20
3.4.5 INFEED MOTOR M1 & SENSOR Q2............................................ 3-21
3.4.6 SIDE GUIDES................................................................................ 3-22
3.4.7 SIDE JOGGER MOTOR M3 & SENSOR Q12............................... 3-23
3.4.8 SIDE GUIDE TRANSMISSION &SENSOR Q13............................ 3-24
3.4.9 BACK JOGGER MODULE & SENSOR Q3................................... 3-26
3.4.10 BACK JOGGER FINGERS............................................................ 3-28
3.4.11 BACK JOGGER MOTOR M2......................................................... 3-30
3.4.12 STAPLER HEAD............................................................................ 3-31
3.4.13 STAPLER HEAD RETRACTION DISTANCE................................. 3-34
3.4.14 STAPLER MOTOR M4................................................................... 3-35
3.4.15 STAPLER ASSY DRIVE BAR & SENSOR Q14............................. 3-36
3.4.16 CLINCHER BAR ASSEMBLY......................................................... 3-37
3.4.17 CLEANING CLINCHER POINTS................................................... 3-38
3.4.18 SET TRANSPORT DRIVE ALIGNMENT........................................ 3-39
3.4.19 PRESSURE ROLLER.................................................................... 3-41
3.4.20 SET TRANSPORT MOTOR M5..................................................... 3-42
3.4.21 THICK SET SENSOR Q36............................................................. 3-43
3.5 AREA B................................................................................................... 3-45
3.5.1 STAPLE STOP GATE SOLENOID SOL1....................................... 3-45
3.5.2 STAPLE STOP GATE RELEASE SOLENOID SOL2..................... 3-46
3.5.3 SADDLE STAPLING START SENSOR Q4.................................... 3-48
3.6 AREA C................................................................................................... 3-49
3.6.1 STAPLE / FOLD POSITION MOTOR M9 & SENSOR Q10........... 3-49
3.6.2 LENGTH TRANSMISSION SHAFT & SENSOR Q11.................... 3-50
3.6.3 FOLD STOP GATE MOTOR M8 & SENSOR Q7........................... 3-52
3.6.4 FOLD STOP GATE........................................................................ 3-53
3.6.5 FOLD KNIFE MOTOR M7 & SENSOR Q15.................................. 3-54
3.6.6 FOLD TRANSMISSION MODULE................................................. 3-56
3.6.7 FOLD TRANSMISSION BELT & SENSOR Q9.............................. 3-57
3.6.8 FOLD ROLLER MOTOR M6.......................................................... 3-59
3.6.9 FOLD TRANSMISSION GEAR ASSEMBLYS................................ 3-61
3.6.10 FOLD DISTANCE BRACKET......................................................... 3-62
3.6.11 UPPER FOLDER ROLLER............................................................ 3-63
3.6.12 LOWER FOLDER ROLLER........................................................... 3-65
3.6.13 OUTFEED SENSOR...................................................................... 3-67
3.7 PCB........................................................................................................ 3-69
3.7.1 MD3DC PCB “H”............................................................................ 3-69
3.7.2 UPPER MD6DC PCB ”B”............................................................... 3-70
3.7.3 LOWER MD6DC PCB ”C”.............................................................. 3-71
VI
3.7.4 INTERLOCK PCB ”D”.................................................................... 3-72
3.7.5 CPU PCB AND COPIER INTERFACE PCB ”A”............................. 3-73
3.7.6 ADDON PCB ”F”............................................................................ 3-75
3.7.7 LCD PANEL.................................................................................... 3-76
3.8 STACKER............................................................................................... 3-77
3.8.1 STACKER MODULE...................................................................... 3-77
3.8.2 STACKER MOTOR M1.................................................................. 3-78
3.9 BOOKLET QUALITY ADJUSTMENT...................................................... 3-79
3.9.1 STAPLE STOP GATE PARALLELISM........................................... 3-79
3.9.2 SIDE GUIDE PARALLELISM......................................................... 3-81
3.9.3 STAPLE POSITION TO CLINCHER.............................................. 3-82
3.9.4 STAPLER PRESSURE.................................................................. 3-85
3.9.5 CLINCHER POINTS HEIGHT........................................................ 3-86
3.9.6 CLINCHER PRESSURE................................................................ 3-87
3.9.7 STAPLE AND FOLD POSITION..................................................... 3-89
3.9.8 FOLD SKEW.................................................................................. 3-91
3.9.9 STAPLE POSITION ON SQUARE FORMED SPINE..................... 3-92
3.10POWER REQUIREMENTS.................................................................... 3-93
3.10.1 TAPPING THE TRANSFORMER................................................... 3-93
4.TROUBLESHOOTING
4.1
4.2
4.3
4.4
FAULT CODE DESCRIPITIONS.............................................................. 4-1
BLOWN FUSE CONDITIONS................................................................ 4-33
LEDS...................................................................................................... 4-35
TEST POINTS........................................................................................ 4-41
5.SERVICE TABLES
5.1 SERVICE PROGRAM MODE................................................................... 5-1
5.1.1 SERVICE PROGRAM MODE OPERATIONS.................................. 5-1
5.1.2 SERVICE PROGRAM MODE TABLES............................................ 5-4
Check Motors and function.......................................................................... 5-4
5.1.3 EEPROM RESET........................................................................... 5-12
5.2 SOFTWARE DOWNLOAD..................................................................... 5-13
5.2.1 Downloading to upper PCB MD6DC B in Booklet maker............... 5-13
5.2.2 Downloading to lower PCB MD6DC C in the Booklet maker......... 5-14
5.2.3 Downloading to PCB CPU in Booklet maker.................................. 5-15
5.2.4 Downloading to lower PCB MD3DC H in the Booklet maker......... 5-16
5.2.5 Downloading to PCB MD6DC A in Trimmer................................... 5-17
5.2.6 Downloading to PCB MD6DC D in Book Folder............................. 5-18
5.3 SELF-DIAGNOSTIC MODE................................................................... 5-19
5.3.1 RUN TIME DIAGNOSTICS............................................................ 5-19
5.3.2 POWER ON SELF TEST............................................................... 5-19
5.3.3 DETAILED SELF-DIAGNOSTIC MODE......................................... 5-20
5.4
PAPER SIZE RESET..................................................................... 5-21
5.5 CF SERVICE.......................................................................................... 5-25
5.6 BF SERVICE.......................................................................................... 5-27
6.DETAILED SECTION DESCRIPTIONS
6.1 ELECTRICAL COMPONENT LIST........................................................... 6-1
6.1.1 FRONT VIEW................................................................................... 6-3
6.1.2 REAR VIEW..................................................................................... 6-4
VII
6.1.3 CONNECTOR VIEW........................................................................ 6-5
6.1.4 OUTFEED UPPER VIEW................................................................ 6-6
6.1.5 OUTFEED LOWER VIEW................................................................ 6-7
6.1.6 INFEED UPPER VIEW.................................................................... 6-8
6.1.7 INFEED LOWER VIEW.................................................................... 6-9
6.1.8 INFEED MODULE VIEW............................................................... 6-10
6.1.9 STACKER MODULE VIEW............................................................ 6-11
6.2 BOARD STRUCTURE............................................................................ 6-13
6.2.1 BLOCK DIAGRAM......................................................................... 6-13
6.2.2 CONTROLLER CPU...................................................................... 6-14
6.2.3 CONTROLLER MD6DC................................................................. 6-15
6.2.4 CONTROLLER MD3DC................................................................. 6-17
6.2.4 CONTROLLER MD3DC, CONTINUES.......................................... 6-18
6.3 BOOKLET MAKING PROCESS............................................................. 6-19
6.3.1 PRINCIPLE OF OPERATION........................................................ 6-19
6.3.2 SIZE ADJUSTMENT...................................................................... 6-23
SPECIFICATIONS
MAJOR SPECIFICATIONS........................................................................Spec-1
QUALITY SPECIFICATIONS......................................................................Spec-1
ATTACHEMENT TO BELLINI.....................................................................Spec-2
PERIPHERALS SPECIFICATION..............................................................Spec-3
COVER FEEDER CF5010.....................................................................Spec-3
TRIMMER TR5010................................................................................Spec-3
BOOK FOLDER BF5010.......................................................................Spec-4
WIRING
Booklet Maker................................................................................................Wir-1
Cover Feeder.................................................................................................Wir-1
Trimmer..........................................................................................................Wir-1
Book Folder...................................................................................................Wir-1
VIII
PERIPHERALS
COVER FEEDER CF5010
1 INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE........................................................... CF-1-1
2 PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE..................................... CF-2-1
3.REPLACEMENT AND ADJUSTMENT
3.1 COVER FEEDER............................................................................... CF-3-1
3.1.1 REMOVE COMPLETE UNIT...................................................... CF-3-1
3.2 AREA F............................................................................................... CF-3-5
3.2.1 EMPTY BIN SENSOR Q31........................................................ CF-3-5
3.2.2 PAPER WIDTH SENSOR Q38................................................... CF-3-6
3.2.3 FEED ROLLER ASSY AND PAPER SEPARATOR PAD............ CF-3-7
3.2.4 FEED MOTOR M15................................................................... CF-3-8
3.2.5 PAPER BIN LOW SENSOR Q33............................................... CF-3-9
3.2.6 DRIVE MOTOR M16 ASSEMBLY............................................ CF-3-10
3.2.7 DRIVE SHAFT ASSEMBLY...................................................... CF-3-11
3.2.8 PINCH ROLL SHAFT ASSEMBLY........................................... CF-3-12
3.2.9 PAPER PATH / DSD DETECTION SENSOR Q30................... CF-3-13
3.2.9 PAPER POSITIONING SENSOR Q32..................................... CF-3-14
3.2.10 UPPER PAPER PATH.............................................................. CF-3-15
3.2.11 BLOWER MOTOR M17 / M18................................................. CF-3-16
4.TROUBLESHOOTING
4.1 FAULT CODE DESCRIPTIONS......................................................... CF-4-1
5 SERVICE TABLES
5.1 SERVICE TABLES.............................................................................. CF-5-1
6.DETAILED SECTION DESCRIPTIONS
6.1 ELECTRICAL COMPONENT LIST..................................................... CF-6-1
6.1.1 REAR VIEW............................................................................... CF-6-2
6.1.2 OUTFEED VIEW........................................................................ CF-6-3
6.2 COVER FEEDING PROCESS........................................................... CF-6-5
6.2.1 PRINCIPLE OF OPERATION.................................................... CF-6-5
SPECIFICATIONS
SPECIFICATIONS................................................................................CF-Spec-1
WIRING
Cover Feeder...........................................................................................CF-Wir-1
IX
PERIPHERALS
TRIMMER TR5010
1 INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE........................................................... TR-1-1
2 PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE..................................... TR-2-1
3.REPLACEMENT AND ADJUSTMENT
3.1 COVERS............................................................................................. TR-3-1
3.1.1 FRONT AND REAR COVER...................................................... TR-3-1
3.1.2 TOP COVER.............................................................................. TR-3-2
3.1.3 BLOWER MOTOR M5 / M6....................................................... TR-3-3
3.1.4 INFEED COVER........................................................................ TR-3-4
3.1.5 LOCKING BRACKET................................................................. TR-3-5
3.1.6 UPPER OUTFEED COVER....................................................... TR-3-6
3.1.7 INTERLOCK SWITCH S9 &S10................................................ TR-3-7
3.1.8 LOWER OUTFEED COVER...................................................... TR-3-8
3.1.9 PROTECTION COVER.............................................................. TR-3-9
3.2 AREA C............................................................................................. TR-3-11
3.2.1 INFEED SENSOR Q13............................................................ TR-3-11
3.2.2 CONTROL SWITCH S2........................................................... TR-3-12
3.2.3 CONTROL SWITCH S3........................................................... TR-3-13
3.2.4 TRANSPORT MOTOR M1....................................................... TR-3-14
3.2.5 TRANSPORT BELT SENSOR Q4............................................ TR-3-15
3.2.6 TRIM KNIFE MOTOR M2......................................................... TR-3-16
3.2.7 TRIM KNIFE HOME POSTITON SENSOR Q5........................ TR-3-17
3.2.8 TRIM KNIFE............................................................................. TR-3-18
3.2.9 PAPER PATH & OUTFEED SENSOR Q6................................ TR-3-22
3.2.10 STOP GATE CARRIAGE......................................................... TR-3-23
3.2.11 STOP GATE MOTOR M3 & SENSOR Q7................................ TR-3-24
3.2.12 LENGTH ADJUSTMENT MOTOR M4 & SENSOR Q12.......... TR-3-25
3.2.13 LENGTH ADJUSTMENT HOME POSITION SWITCH S11..... TR-3-26
3.2.14 LOWER OUTFEED BELTS...................................................... TR-3-27
3.2.15 UPPER OUTFEED BELTS....................................................... TR-3-28
3.2.16 TRIM BIN FULL SENSOR Q8.................................................. TR-3-29
3.2.17 TRANSMISSION CHAIN.......................................................... TR-3-30
3.2.18 KNIFE SUPPORT CHAIN........................................................ TR-3-31
3.2.19 KNIFE CHAIN.......................................................................... TR-3-32
3.2.20 INFEED BELTS........................................................................ TR-3-33
3.3 PCB.................................................................................................. TR-3-35
3.3.1 MD6DC PCB ”A”...................................................................... TR-3-35
4.TROUBLESHOOTING
4.1 FAULT CODE DESCRIPTIONS......................................................... TR-4-1
5 SERVICE TABLES
5.1 SERVICE TABLES.............................................................................. TR-5-1
PERIPHERALS
6.DETAILED SECTION DESCRIPTIONS
6.1 ELECTRICAL COMPONENT LIST..................................................... TR-6-1
6.1.1 REAR VIEW............................................................................... TR-6-2
6.1.2 INFEED VIEW............................................................................ TR-6-3
6.1.3 OUTFEED VIEW........................................................................ TR-6-4
6.1.4 STOP CARRIAGE VIEW............................................................ TR-6-5
6.2 BOARD STRUCTURE........................................................................ TR-6-7
6.2.1 BLOCK DIAGRAM..................................................................... TR-6-7
6.2.2 CONTROLLER MD6DC............................................................. TR-6-8
6.2.2 CONTROLLER MD6DC, CONTINUES...................................... TR-6-9
6.3 TRIMMING PROCESS..................................................................... TR-6-11
6.3.1 PRINCIPLE OF OPERATION.................................................. TR-6-11
6.3.2 SIZE ADJUSTMENT................................................................ TR-6-13
6.3.2 SIZE ADJUSTMENT................................................................ TR-6-14
SPECIFICATIONS
SPECIFICATIONS................................................................................TR-Spec-1
WIRING
XI
PERIPHERALS
BOOK FOLDER BF5010
Trimmer....................................................................................................TR-Wir-1
1 INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE........................................................... BF-1-1
2 PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE..................................... BF-2-1
3 REPLACEMENT AND ADJUSTMENT
3.1 COVERS............................................................................................. BF-3-1
3.1.1 FRONT COVER......................................................................... BF-3-1
3.1.2 REAR COVER........................................................................... BF-3-2
3.1.3 INFEED COVER........................................................................ BF-3-3
3.1.4 OUTFEED COVER.................................................................... BF-3-4
3.1.5 TOP COVER.............................................................................. BF-3-6
3.1.6 TILT THE MACHINE.................................................................. BF-3-7
3.2 MOTORS............................................................................................ BF-3-9
3.2.1 TRANSPORT BELT MOTOR (M1)............................................. BF-3-9
3.2.2 STOP GATE MOTOR (M2)...................................................... BF-3-10
3.2.3 CLAMP MOTOR (M3)...............................................................BF-3-11
3.2.4 ROLLER MOTOR (M4) AND PRESSURE ROLLER................ BF-3-12
3.3 SENSORS AND SWITCHES............................................................ BF-3-15
3.3.1 STOP GATE SENSOR (Q1)..................................................... BF-3-15
3.3.2 ROLLER MOTOR FRONT / REAR SENSORS (Q2 AND Q3) BF-3-16
3.3.3 CLAMP MOTOR HOME POSITON SENSOR (Q4)................. BF-3-17
3.3.4 INFEED / OUTFEED SENSORS (Q5 AND Q7)....................... BF-3-18
3.3.5 CLAMP SENSOR (Q6)............................................................. BF-3-20
3.3.6 MOTOR M4 ENCODER SENSOR (Q8)................................... BF-3-21
3.3.7 TOP COVER INTERLOCK SWITCHES (S2 & S4).................. BF-3-22
3.3.8 UPPER TRANSPORT BELT CLUTCHES (SOL1 & SOL3)...... BF-3-23
3.3.9 LOWER TRANSPORT BELT CLUTCHES (SOL2 & SOL4)..... BF-3-24
3.4 BELTS............................................................................................... BF-3-25
3.4.1 UPPER TRANSPORT BELT.................................................... BF-3-25
3.4.2 LOWER TRANSPORT BELT................................................... BF-3-26
3.4.3 TEFLON TAPE LOWER TRANSPORT BELT ....................... BF-3-29
3.5 MECHANICS.................................................................................... BF-3-31
3.5.1 SET CLAMPS........................................................................... BF-3-31
3.5.2 STOP GATE............................................................................. BF-3-34
3.6 PCB.................................................................................................. BF-3-37
3.6.1 PCB MD6DC “D”...................................................................... BF-3-37
3.7 POWER REQUIREMENTS.............................................................. BF-3-39
3.7.1 TAPPING THE TRANSFORMER............................................. BF-3-39
4.TROUBLESHOOTING
4.1 FAULT CODE DESCRIPTIONS......................................................... BF-4-1
4.2 BLOWN FUSE CONDITION............................................................. BF-4-13
XII
PERIPHERALS
4.3 LED’S................................................................................................ BF-4-15
4.4 TEST POINTS.................................................................................. BF-4-17
5 SERVICE TABLES
5.1 SERVICE TABLES.............................................................................. BF-5-1
6.DETAILED SECTION DESCRIPTION
6.1 ELECTRICAL COMPONENT LIST..................................................... BF-6-1
6.1.1 COMPONENT LAYOUT............................................................. BF-6-2
6.2 BOARD STRUCTURE
. ...................................................... BF-6-5
6.2.1 CONTROLLER MD6DC “D”....................................................... BF-6-5
6.3 PRINCIPLE OF OPERATION............................................................. BF-6-7
SPECIFICATIONS
SPECIFICATIONS................................................................................ BF-Spec-1
WIRING
Book Folder.............................................................................................BF-Wir-1
XIII
BOOKLET MAKER BK5010
04 October 2007
INSTALLATION PROCEDURE
Installation
1
INSTALLATION REQUIREMENTS
1.1 INSTALLATION REQUIREMENTS
1.1.1 MINIMUM SPACE REQUIREMENTS
Stacker
625 mm
24 3/8 ”
BF5010
TR5010
360 mm
13 3/4 ”
360 mm
13 3/4 ”
2140 mm
84 1/4 ”
1-1
BK5010
795 mm
31 5/16”
555 mm
21 7/8”
400 mm
15 3/4 ”
CF5010
715 mm
28 1/8”
Rail
INSTALLATION REQUIREMENTS
04 October 2007
1.1.2 POWER REQUIREMENTS
WARNING
1.Make sure that the wall outlet is near the main machine and easily
accessible. Make sure the plug is firmly inserted in the outlet.
2.Avoid multi-wiring.
3.Be sure to ground the machine.
1.
2.
3.
Input voltage level:
North America 120V AC, 50-60Hz: More than 4 A.
Europe/Asia 230V AC, 50-60Hz: More than 2 A.
Permissible voltage fluctuation: ± 10%
Never place anything on the power cord.
1-2
INSTALLATION REQUIREMENTS
04 October 2007
The following flow chart shows how to install the optional units more efficiently.
Install the Booklet maker BK5010
Does the user require a Cover Feeder?
No
Yes
Install the Cover Feeder CF5010
Does the user require a Trimmer?
No
Yes
Install the Trimmer TR5010
Does the user require a Book Folder?
Yes
No
Is a Trimmer installed?
Yes
No
Install Trimmer
Install the Book Folder BF5010
Install the Belt Stacker
Check the Installation
TR5010 Trimmer:
Enables On-line trimming. Especially thicker sets ( > 4
sheets) look unprofessional because of ”creep”.TR5010
will trim those edges ( up to 16 mm / 5/8”).
CF5010 Cover Feeder: Enables the possibility to add colour covers to the boolets.
BF5010 Book Folder: Enables the possibility to give the booklets the perfect bound look.
1-3
Installation
1.2 INSTALLATION FLOW CHART
Page intentionally blank
BOOKLET MAKER INSTALLATION
04 October 2007
Installation
1.3 BOOKLET MAKER INSTALLATION
1.3.1 ACCESSORY CHECK
[A]
[B]
[G]
[L]
[C]
[H]
[I]
[M]
[D]
[E]
[J]
[F]
[K]
[N]
Check the quantity and condition of the accessories in the box against the following list:
Description
Q’ty
A. Exit arm Catcher................................................................... 1
B. Communication Cable to SR5000 finisher............................ 1
C. Communication Cable to SR841 finisher.............................. 1
D. Docking assembly................................................................. 1
E. Shift tray plate....................................................................... 1
F. Exit tray plate........................................................................ 1
G.Powercord............................................................................. 1
H. Terminator plug, will always be installed onto BK5010......... 1
I. Terminator plug TR5010........................................................ 1
J. Interlock Jumper, will always be installed onto BK5010 . ..... 1
K. Interlock Jumper TR5010...................................................... 1
L. Cable protector...................................................................... 1
M.Cable protector sticker ......................................................... 1
N. Cable holder.......................................................................... 1
1-5
BOOKLET MAKER INSTALLATION
04 October 2007
1.3.2 INSTALLATION PROCEDURE
Unpacking
[A]
1. Remove all parts from the pallet.
2. Slide the Booklet maker off the pallet by pulling the two cardboard handles [A]
underneath the Booklet maker straight out.
WARNING
2 persons are required to slide the Booklet Maker off the pallet.
1-6
BOOKLET MAKER INSTALLATION
04 October 2007
Installation
Exit arm catcher
[A]
1. Remove the adhesive backing from the Exit arm catcher.
2. Install the Exit arm catcher on the finisher so that it will hold the Exit paper arm
as high as possible. The nut on the Exit arm catcher should be centered over
the Exit paper arm, according to figure.
3. Lift up the Exit paper arm, and set it onto the Exit arm catcher [A].
1-7
BOOKLET MAKER INSTALLATION
04 October 2007
Copier exit tray
[A]
[B]
[C]
1. Make sure that the Exit paper arm is in the upper position [A].
2. Remove the finisher exit tray by removing screws [B] (
3. Remove the plastic deflector [C], on the finisher exit tray.
1-8
x 4).
BOOKLET MAKER INSTALLATION
Installation
04 October 2007
[D]
[E]
[F]
4. Remove the plastic deflector [D] from the shift tray.
5. Install the Shift tray plate [E] on to the finisher (
installation kit)
x 4 counter screws from
6. Install the Exit tray plate [F] on to the finisher exit tray (
kit).
1-9
x 4 from installation
BOOKLET MAKER INSTALLATION
04 October 2007
[F]
Docking assembly
[A]
[B]
[C]
[E]
[G]
Finisher seen from above
[D]
Finisher seen from front side
1. Remove the finisher rear cover (
x 2).
2. Open the finisher door and pull out the stapling tray.
3. Remove black plastic covers [A] at the bottom of the finisher (
x 2).
4. Install the docking assembly [B] in the holes under the black plastic covers [A].
NOTE: Both nuts [C], installed on the docking assembly, have different
diameters on each side of the nut. A big diameter [D] on one side,
and a smaller diameter [E] on the other.
5. Secure the docking assembly with the two nuts [C], using the multi tool.
Mounted correctly, there shall be less than 1mm play in the Docking assembly.
NOTE: The Multi tool (
3.2 ) is located behind the rear cover of the Booklet maker ( x 5).
NOTE: Make sure to fit the nuts in the correct position. The bigger diameter should fit in the hole nearest the rear side [F] of the finisher.
The smaller diameter should fit in the hole nearest the front side
[G] of the finisher.
1-10
BOOKLET MAKER INSTALLATION
04 October 2007
Installation
Interface to SR5000 Finisher
Finisher Main PCB
[C]
[B]
[A]
Finisher with rear cover installed
Interface between SR5000 Finisher and BK5010
1. Install the Communication cable from the installation kit, to connector
CN138H [A] (
x1) on the finisher main board.
NOTE:Make sure to use the communication cable for SR5000 Finisher.
2. Guide the Communication cable through the cable holder [B] and secure it in
the finisher [C], with two tie wraps from the installation kit.
1-11
BOOKLET MAKER INSTALLATION
04 October 2007
Interface to SR841 Finisher
[A]
Finisher Main PCB
[B]
Interface between SR841 Finisher and BK5010
1. Install the Communication cable from the installation kit, to connector
CN132 [A] (
x1) on the finisher main board.
NOTE:Make sure to use the communication cable for SR841 Finisher.
2. Secure the Communication cable in the finisher [B], with a tie wrap from the
installation kit.
1-12
BOOKLET MAKER INSTALLATION
04 October 2007
Installation
1.3.3 ADJUSTMENTS
[A]
[B]
[C]
1. Remove screws [A] and remove the Bookler maker front cover (
x5).
2. Remove screws [B], loosen screw [C] and remove the Bookler maker rear
cover ( x5).
1-13
BOOKLET MAKER INSTALLATION
04 October 2007
Booklet Maker, front view
[C]
[A]
[B]
[D]
1. If installing a Rail unit, install it now.
NOTE: If the Rail unit is installed later the height adjustment of the Booklet
maker will be incorrect.
2. Dock the Booklet Maker to the Docking assembly.
CAUTION
Before docking, make sure the Jogger Fence [A] is in the upper position. If
not, with copier powered on - open and close finisher door.
3. Unhook the Exit paper arm [B].
4. To align the Booklet Maker side to side, turn both front adjustment nuts [C] until
the Exit paper arm [B] fits in the cut-out [D] on the Booklet Maker.
NOTE: Turn both screws equal amount of turns.
NOTE: Do not adjust the machine sideways by moving the docking pins on the docking bracket.
5. Hook up the Exit arm catcher to it’s upper position.
1-14
04 October 2007
Installation
BOOKLET MAKER INSTALLATION
Booklet Maker, outfeed view
[D]
[E]
6. Turn both outfeed side adjustment nuts [D] until the gap [E] between the Booklet maker and the Finisher is parallell ± 2mm.
NOTE: Turn both screws equal amount of turns.
1-15
04 October 2007
BOOKLET MAKER INSTALLATION
[F]
7. Place the Multi tool outside the hand feeding paper guides as illustrated [F].
1-16
BOOKLET MAKER INSTALLATION
Installation
04 October 2007
[G]
8. The height adjustment of the Booklet Maker is correct when the lower edge of
the Finisher top cover is level with the cut-out [G] in the Multi tool.
1-17
BOOKLET MAKER INSTALLATION
04 October 2007
Booklet Maker, rear view
[I]
Booklet Maker, front view
9. To adjust the height of the Booklet Maker, turn all four adjustment nuts [I].
One revolution equals 2 mm difference in height.
10. Undock the Booklet maker.
11. Reinstall the Booklet maker front and rear covers (
1-18
x 10).
BOOKLET MAKER INSTALLATION
04 October 2007
Installation
Top Cover over Cover Feeder dummy
[A]
[B]
1. If installting a Cover Feeder CF5010, skip step 2.
2. Insert the two screws mounted on the rear side of the UpperTop Cover into the
grommets [A] at the rear side of the Cover Feeder dummy and secure at the
front side [B] with screws in plastic bag taped to the inside of the Upper Top
Cover( x 2).
1-19
BOOKLET MAKER INSTALLATION
04 October 2007
1.3.4 CONNECTORS
1. Connect the communication cable [A] from the finisher (
let maker.
x1), to the Book-
x1).
2. Connect the Belt Stacker cable [B] (
NOTE: Unless Trimmer TR5010 and/or Book Folder BF5010 will be installed.
If so, Belt Stacker cable will be connected to the last module in the system.
3. Install the Terminator plug [C] and the Interlock jumper [G].
NOTE: The Terminators and Interlock jumpers are stored in the installation kit.
4. Install the Terminator plug [D] and the Interlock jumper [F].
NOTE:Unless Trimmer TR5010 will be installed. If so, communication cable
and power cord between BK5010 and TR5010 will be connected.
5. Connect the powercord [E] to the Booklet maker (
x1).
6. Mount the cable protector [H] positioned as shown with two screws in the
holes [I] and route the cables inside the cable protector ( x 2).
7. Attach the sticker “Do not lift here” [J] on the cable protector.
8. Install the cable holders on the rear side of the Booklet Maker and route the
cables through them.
[A] [B]
[G]
[C]
[F]
[D]
[E]
Only Booklet Maker installed
[H]
[I]
[J]
1-20
BOOKLET MAKER INSTALLATION
04 October 2007
1. If installing a Cover Feeder CF5010 or Trimmer TR5010, continue to that section (
1.4 or 1.5 ) otherwise continue with step 2.
2. Power on the Booklet maker.
NOTE: Make sure that the finisher connector is connected to the copier.
3. Remove the two Stapler heads, according to section (
4. Perform a Detailed self-diagnostic, according to section (
5. Reinstall the two Stapler heads, according to section (
3.4.12 ).
5.3.3 )
3.4.12 ).
6. Power on the Copier.
NOTE: Make sure that the Booklet maker is powered ON before the Copier.
7. Set up the Booklet maker to Auto paper size.
8. Send one A4/8.5 x 11” job to the Booklet maker.
9. Check for the correct feeding of the paper.
NOTE: If paper is not fed correctly, check adjustment of the Booklet maker according to section (
1.3.3 ).
10. Send one A3/11 x 17” job to the Booklet maker.
11. Check for the correct feeding of the paper.
NOTE:If paper is not fed correctly, check adjustment of the Booklet maker according to section (
1.3.3 ).
1-21
Installation
1.3.5 CHECK THE INSTALLATION
COVER FEEDER INSTALLATION
04 October 2007
1.4 COVER FEEDER INSTALLATION
1.4.1 ACCESSORY CHECK
[C ]
[A]
[B]
Check the quantity and condition of the accessories in the box against the following list:
Description
Q’ty
A. Cover Feeder module, CF5010............................................. 1
B. Feeder roller . ....................................................................... 1
C. DSD Calibration strip............................................................. 1
1-22
COVER FEEDER INSTALLATION
04 October 2007
Installation
1.4.2 INSTALLATION PROCEDURE
Unpacking
[A]
[B]
[C]
1. Remove all parts from the box.
2. Cut the cable tie [A] to release the paper bin and DSD Calibration strip [B].
3. Place the DSD Calibration strip on the cable holder [C] behind the Booklet
Maker rear cover.
1-23
COVER FEEDER INSTALLATION
04 October 2007
Removal of the Upper Top Cover
[A]
[B]
1. If installed, remove the Upper Top Cover by removing the screws [A] and [B] (
x 4).
1-24
COVER FEEDER INSTALLATION
04 October 2007
Installation
Removal of the Rear Top Cover
[A]
1. Open the Booklet Maker Top Cover.
2. Remove the screw [A] (
x 1).
1-25
COVER FEEDER INSTALLATION
04 October 2007
[B]
[C]
[B]
3. Remove the screws [B] and remove the Rear Cover of the Top Cover [C]
( x 3).
1-26
COVER FEEDER INSTALLATION
04 October 2007
Installation
Removal of cover Feeder dummy
[A]
[B]
1. Remove the nut [A] ( x 1).
NOTE: Nut will be used later when installing the Cover Feeder.
2. Remove the screws [B] ( x 2).
NOTE: Screws will be used later when installing the Cover Feeder.
1-27
COVER FEEDER INSTALLATION
04 October 2007
[C]
[D]
3. Loosen nuts [C] (
x 2).
4. Remove the Cover Feeder dummy [D] by sliding it out.
1-28
COVER FEEDER INSTALLATION
04 October 2007
Installation
Installing the Cover Feeder
[B]
Cover Feeder, outer side view
[C]
[A]
[B]
Cover Feeder, inner side view
[A]
[C]
1. Install the Cover Feeder in the exact same position as the Cover Feeder
dummy was installed.
NOTE: The shaft [A] must be positioned in the cut-out of the bracket [B] in the
Top Cover.
NOTE:The frame of the Cover Feeder [C] must be on the outside of the
bracket [B] in the Top Cover.
1-29
04 October 2007
COVER FEEDER INSTALLATION
[D]
[E]
Cover Feeder, viewed from
Booklet Maker rear side
2. Secure the Cover Feeder with the nut [D] and the screws [E] (
1-30
x 1,
x 2).
04 October 2007
COVER FEEDER INSTALLATION
Installation
Installation of the Cover Feeder connectors
[B]
[C]
[A]
Cover Feeder, viewed from
Booklet Maker outfeed
Cover Feeder, viewed from
Booklet Maker front side
1. Install motor harness [A] (
2. Install sensor harness [B] (
3. Install fan harness [C] (
x 2).
x 1).
x 1).
1-31
04 October 2007
COVER FEEDER INSTALLATION
Installation of Feed roller
[B]
[A]
[C]
[D]
1. Install Feed Roller by inserting the bushing [A] in the hole in the Cover Feeder
front side frame [B].
2. Press the feed roller against the Cover Feeder front side frame and insert the
one-way clutch [C] into the drive clutch [D].
NOTE: Make sure that the one-way clutch [C] fully enters the drive clutch [D].
1-32
COVER FEEDER INSTALLATION
04 October 2007
Installation
Installation of the Rear Top Cover
[B]
[A]
[C]
[D]
1. Install the Rear Top Cover [A] of the Top Cover [B] and secure the the screws
[C] ( x 3).
NOTE: Lift the Jam clearance baffle [D] to get better access to the screw.
1-33
COVER FEEDER INSTALLATION
04 October 2007
[E]
2. Secure the screw [E] (
x 1).
1-34
04 October 2007
COVER FEEDER INSTALLATION
Installation
Installation of the Upper Top Cover
[A]
[B]
[C]
1. Install the Top Cover by inserting the studs [A] into the grommets [B].
2. Secure the Top Cover with screws [C] (
1-35
x 2).
COVER FEEDER INSTALLATION
04 October 2007
1.4.3 ENABLING THE COVER FEEDER
1. Power on the Booklet Maker.
2. Enter the service mode on the Booklet Maker by pressing and holding the
leftmost menu button while powering on the Booklet Maker.
NOTE: Do not enter the service mode through the Tools menu.
3. Key in the password.
4. Scroll down to CF5010 Service and press the OK button.
5. Press the CHG button, so the “Installed:” is set to YES.
6. Press the OK button.
7. Perform a Cover Feeder motors Calibration according to section (
8. Perform a Cover Feeder DSD sensor Calibration according to section (
5.5 ).
9. Make sure that the stapler heads are removed, according to section
(
Service Manual BK5010 3.4.12 ).
10. Perform a self diagnosis.
- Scroll up to Diagnostic and press the OK button.
- Press the RUN button.
- If the Diagnostic is OK, continue.
11. Power off the Booklet Maker.
12. Reinstall the stapler heads according to section (
BK5010 3.4.12 ).
1-36
Service manual
5.5 ).
COVER FEEDER INSTALLATION
04 October 2007
1. If installing a Trimmer TR5010 continue to section (
tinue with step 2.
1.5 ) otherwise con-
2. Power on the Booklet maker.
NOTE: Make sure that the finisher connector is connected to the copier.
3. Power on the Copier.
NOTE: Make sure that the Booklet maker is powered ON before the Copier.
4. Prepare a 15mm high stack of A4/8.5 x 11” covers.
5. Make sure that the ink has dried out well, to avoid smearing.
6. Make sure that the covers are well fanned to avoid misfeeds or double-feeds.
7. Align the covers well to achieve a reliable collating operation and good finishing result.
8. Press down the green marks on Paper bin and load the covers.
9. Move the adjustable side guides up against the covers, until there is no clearance.
10. Set up the Cover Feeder to Cover ON, the fan will start and the Cover Feeder
will prefeed the first cover to be ready for the set from the copier.
11. Set up the Booklet maker to A4/8.5 x 11” paper size.
12. Send one A4/8.5 x 11” job to the Booklet maker system.
13. Check for the correct feeding of the set from the finisher.
NOTE: The paper should enter in the middle of the infeeder. If not, adjust the
Booklet maker according to section (
1.3.3 ).
14. Check that the covers are correctly fed into the Booklet maker.
15. Set up the Cover Feeder to Cover OFF and remove all covers from the bin.
Use the Purge mode to completely empty the Cover Feeder from covers.
16. Prepare a 15mm high stack of A3/11 x 17” covers.
17. Repeat step 5 to 10.
18. Set up the Booklet maker to A3/11 x 17” paper size.
19. Send one A3/11 x 17” job to the Booklet maker system.
20. Check for the correct feeding of the set from the finisher.
NOTE: The paper should enter in the middle of the infeeder. If not, adjust the
Booklet maker according to section (
1.3.3 ).
21. Check that the covers are correctly fed into the Booklet maker.
1-37
Installation
1.4.4 CHECK THE INSTALLATION
Page intentionally blank
TRIMMER INSTALLATION
04 October 2007
Installation
1.5 TRIMMER INSTALLATION
1.5.1 ACCESSORY CHECK
[A]
[B]
[E]
[C]
[F]
[G]
[D]
Check the quantity and condition of the accessories in the box against the following list:
NOTE: - The Installation Box is located in the trim bin on the Trimmer.
- The trim bin is tie wraped on the rear side.
- Trimmer fan is bubble wrapped and located inside the Trimmer.
- The Rail Extension is located in the packing material
Description
Q’ty
A. Communication cable between the Booklet maker............... 1
and the Trimmer
B. Powercord between the Booklet maker and Trimmer........... 1
C. Trimmer fan assy ................................................................. 1
D. Rail extension ...................................................................... 1
Plugs and screws ................................................................. 4
E. Cable protector...................................................................... 1
F. Cable protector sticker.......................................................... 1
G.Cable holder.......................................................................... 1
1-39
TRIMMER INSTALLATION
04 October 2007
1.5.2 INSTALLATION PROCEDURE
Unpacking
1. Remove all parts from the pallets.
2. Ensure all of the packing material is removed from the outside of the Trimmer.
3. Tilt the Trimmer to upright position.
WARNING
2 persons are required to tilt the Trimmer to the upright position.
1-40
TRIMMER INSTALLATION
04 October 2007
Installation
Remove the belt stacker
Booklet Maker
[A]
1. Loosen screws [A] on the Booklet Maker (
2. Disconnect the Belt stacker cable (
x 2 ).
x 1).
3. Remove belt stacker from the Booklet maker.
4. Secure screws [A] (
x 2 ).
1-41
TRIMMER INSTALLATION
04 October 2007
Install Rail Extension
[C]
[A]
[D]
[B]
[E]
1. Remove the Rail stop from the Rail under the Boklet Maker.
2. Insert the Rail extension [A] into the Rail under the Booklet Maker [B].
3. Press the plugs [C] into the holes in the Rail under the Trimmer and press/
hammer down the plugs ( x 4).
4. Insert the Rail stop [D] into the Rail extension.
5. Secure the Rail stop with the screws [E] (
1-42
x 4).
TRIMMER INSTALLATION
04 October 2007
Installation
1.5.3 ADJUSTMENTS
Height adjustment
[A]
1. Remove the Trimmer front cover by removing the screws [A] (
2. Move the Trimmer up to the Booklet maker.
1-43
x 5).
TRIMMER INSTALLATION
04 October 2007
Height adjustment
[B]
[C]
[D]
3. Adjust the height of the Trimmer, so that the docking bracket [B] on the Trimmer fits in the docking hole [C] on the Booklet maker (one revolution on the
nuts is 1.5mm / 1/16” in height). Adjust by turning the four nuts [D] on the Trimmer with the Multi tool.
NOTE: Make sure that the Ground plate on the docking bracket [B], is grounded correctly.
1-44
TRIMMER INSTALLATION
Installation
04 October 2007
[F]
[E]
4. Looking from behind the system, make sure that the Trimmer is parallel with
the Booklet Maker [E] ± 2mm. If necessary, adjust by turning the two nuts [F]
on the outfeed side of the Trimmer.
1-45
TRIMMER INSTALLATION
04 October 2007
1.5.4 DOCKING
Docking procedure
[B]
[D]
[A]
Trimmer interior towards
Booklet Maker
[D]
[C]
1. Loosen nuts [A] to the Locking bracket [B] (
x 2).
2. Dock the Trimmer to the Booklet maker.
3. Secure the Trimmer by lifting the Locking bracket [B] and tightening nuts [A]
(
x 2).
NOTE:Make sure that the Trimmer locking bracket [B] locks in the outer slot
[C] on the positioning pin.
1-46
TRIMMER INSTALLATION
04 October 2007
Installation
Install Trimmer fan
[A]
Trimmer interior towards Booklet Maker
[B]
1. Install Trimmer fan [A] by hanging it onto the position pins [B] inside the
Trimmer.
1-47
TRIMMER INSTALLATION
04 October 2007
Install Belt stacker
Trimmer
[A]
1. Loosen screws [A] ( x 2) on the Trimmer.
NOTE:Unless the Book folder BF5010 will be installed. If so, the Belt stacker
will be installed on to the Book folder instead.
2. Install the Belt stacker on to the Trimmer.
3. Secure the Belt stacker with the screws [A] (
1-48
x 2).
TRIMMER INSTALLATION
04 October 2007
Installation
1.5.5 CONNECTORS
1. Connect the Belt stacker cable [A] to the Trimmer (
x1).
NOTE:Unless a Book folder BF5010 also will be installed. If so, the Belt
stacker cable will connected to the Book folder instead.
2. Remove the Trimmer Terminator plug from the Booklet maker [B] (
3. Connect the Trimmer Terminator plug on the Trimmer [C] (
x1).
4. Remove the Interlock jumper [D] from the Booklet maker (
x1).
x1).
x1) (see
5. Connect the Interlock jumper to the Booklet maker frame [E] (
next spread). This jumper will be stored in this area, it will be needed at a later
date to allow the Booklet maker to function while the Trimmer is serviced.
x1).
6. Connect the communication cable to the Trimmer [F] (
NOTE: The communication cable you received with the Trimmer.
7. Connect, the other end of the communication cable, to the Booklet maker [G]
(
x1). (see next page)
8. Connect the powercord to the Trimmer [H] (
x1).
x1)
9. Connect, the other end of the powercord, to the Booklet maker [ I ] (
(see next spread).
10. Mount the cable protector [J] positioned as shown with two screws in the holes
[K] and route the cables inside the cable protector ( x 2).
11. Attach the sticker “Do not lift here” [L] on the cable protector.
12. Install the cable holder on the rear side of the Trimmer.
13. Route cables through the cable holders on the rear side of the Booklet Maker
and Trimmer.
[B]
[D]
Booklet Maker without Trimmer installed
Continued on next page....
1-49
TRIMMER INSTALLATION
04 October 2007
[A]
COM BK5010
[C]
[H]
[F]
[K]
[J]
COM
BK501
0
Trimmer with cable protector installed
Continued on next page....
1-50
[L]
Installation
TRIMMER INSTALLATION
04 October 2007
[G]
Booklet Maker with Trimmer installed
[I]
[E]
Booklet Maker, rear side
1-51
TRIMMER INSTALLATION
04 October 2007
1.5.6 CHECK THE INSTALLATION
1. If installing a Book Folder BF5010, continue to section (
continue with step 2.
1.6 ) otherwise
2. Power on the Booklet maker.
NOTE: Make sure that the finisher connector is connected to the copier.
[A]
Trimmer interior towards Booklet Maker
3. In the Trimmer, check the Index 16 value [A].
4. Press the Tools button.
5. Scroll down to Service and press the OK button.
6. Key in the Password.
7. Scroll down to EEPROM Values and press the OK button.
8. Scroll to INDEX 16, TR5010.Knife Zero, and press the CHG button.
9. Key in the value you have in the trimmer.
10. Go down to Store and press the OK button.
11. Perform a Detailed self-diagnostic, according to section (
5.3.3 ).
12. Restart the system.
13. Power on the Copier.
NOTE: Make sure that the Booklet maker is powered ON before the Copier.
14. Set up the Booklet maker to Auto paper size.
15. Check that the Booklet maker is set to Staple ON.
16. Set up the Trimmer to Trimmer ON.
1-52
17. If a Cover Feeder CF5010 is installed:
A. Prepare a 15mm high stack of A4/8.5 x 11” covers.
B. Make sure that the ink has dried out well, to avoid smearing.
C. Make sure that the covers are well fanned to avoid misfeeds or double-feeds.
D. Align the covers well to achieve a reliable collating operation and good
finishing result.
E. Press down the green marks on Paper bin and load the covers.
F. Move the adjustable side guides up against the covers, until there is no
clearance.
G. Set up the Cover Feeder to Cover ON, the fan will start and the Cover
Feeder will prefeed the first cover to be ready for the set from the copier.
18. Set up the Booklet maker to Auto paper size.
19. Send one A4/8.5 x 11” job to the Booklet maker system.
20. Check for the correct feeding of the set from the finisher.
NOTE: The paper should enter in the middle of the infeeder. If not, adjust the
Booklet maker according to section (
1.3.3 ).
21. If a Cover Feeder CF5010 is installed, check that the covers are correctly fed
into the Booklet maker.
22. Check if the set has been trimmed correctly.
23. If a Cover Feeder CF5010 is installed:
A. Set up the Cover Feeder to Cover OFF and remove all covers from the bin.
Use the Purge mode to completely emtpy the Cover Feeder from covers.
B. Prepare a 15mm high stack of A3/11 x 17” covers.
C. Repeat step 18 B to 18 G.
24. Send one A3/11 x 17” job to the Booklet maker system.
25. Check for the correct feeding of the set from the finisher.
NOTE: The paper should enter in the middle of the infeeder. If not, adjust the
Booklet maker according to section (
1.3.3 ).
26. If a Cover Feeder CF5010 is installed, check that the covers are correctly fed
into the Booklet maker.
27. Check if the set has been trimmed correctly.
1-53
Installation
TRIMMER INSTALLATION
04 October 2007
Page intentionally blank
BOOK FOLDER INSTALLATION
04 October 2007
Installation
1.6 BOOK FOLDER INSTALLATION
1.6.1 ACCESSORY CHECK
[A]
[B]
[C]
[D]
COM. BF5010
[E]
[J]
[I]
[H]
[G]
[F]
[K]
[L]
[M]
Check the quantity and condition of the accessories in the box against the following list:
Description
Q’ty
A. Communication cable .......................................................... 1
B. Power cord ........................................................................... 1
C. Auto set thickness bracket, with spring ................................ 1
D. Sensor bracket, with sensor . ............................................... 1
E. Spacer pin and screw .......................................................... 2
F. 25 mm washer and screw .................................................... 2
G.Extended trim bin (two parts) ............................................... 1
Screw and nut ...................................................................... 4
H. COM. BF5010 sticker . ......................................................... 1
I. Ground strap and screw . ..................................................... 1
J. Rail extension ...................................................................... 1
Plugs and screws ................................................................. 4
K. Cable protector...................................................................... 1
L. Cable protector sticker.......................................................... 1
M.Cable holder.......................................................................... 1
1-55
BOOK FOLDER INSTALLATION
04 October 2007
1.6.2 INSTALLATION PROCEDURE
Unpacking
1. Remove all parts from the pallets.
2. Ensure all of the packing material is removed from the outside of the Book
Folder.
3. Tilt the Book Folder to upright position.
WARNING
2 persons are required to tilt the Book Folder to the upright position.
1-56
04 October 2007
BOOK FOLDER INSTALLATION
Installation
Remove the belt stacker
Trimmer
[A]
Trimmer
[D]
[B]
[E]
[C]
Trimmer, inside view
1. Disconnect the Power cord to the Booklet Maker (
2. Loosen screws [A] (
x 1).
x 2 ) securing the Belt Stacker on the Trimmer.
x 1) from the Trimmer.
3. Disconnect the Belt stacker cable (
4. Remove the Belt stacker from the Trimmer.
5. Secure screws [A] on the Trimmer.
6. Remove the positioning pins from the upper holes [B], used for the belt stacker (
x 2).
7. Using the lower hole [C], install the Ground strap to the inside of the positioning pin [E] using the 25 mm washer and screw provided, (
x 1, x 1).
8. Install the other end of the ground strap to the rear frame [D] (
x 1 torx).
9. Using the second lower hole, install the other positioning pin, using the 25 mm
washer and screw provided (
x 1, x 1).
1-57
BOOK FOLDER INSTALLATION
04 October 2007
Extended trim bin
[A]
1. Remove the existing trim bin from the Trimmer. This trim bin can not be used
together with the Book Folder.
2. Assemble the new extended trim bin [A] with the four screws and nuts
from the installation kit ( x 4,
x 4).
1-58
BOOK FOLDER INSTALLATION
04 October 2007
Installation
Install Rail Extension
[C]
[A]
[D]
[B]
[E]
1. Remove the Rail stop from the Rail under the Trimmer.
2. Insert the Rail extension [A] into the Rail under the Trimmer [B].
3. Press the plugs [C] into the holes in the Rail under the Trimmer and press/
hammer down the plugs ( x 4).
4. Insert the Rail stop [D] into the Rail extension.
5. Secure the Rail stop with the screws [E] (
1-59
x 4).
BOOK FOLDER INSTALLATION
04 October 2007
1.6.3 ADJUSTMENTS
Height adjustment
[A]
1. Remove the front cover of the Book Folder by removiing the screws [A] (
2. Move the Book Folder up to the Trimmer.
1-60
x 5).
BOOK FOLDER INSTALLATION
Installation
04 October 2007
[C]
[B]
Book Folder
Trimmer
[D]
Book Folder, front view
Book Folder, rear view
3. Adjust the height of the Book Folder, so that the positioning pins [B] on the Trimmer fits in the docking holes [C] on the Book Folder. Adjust by turning the
four nuts [D] on the Book Folder with the Multi tool (one revolution on the nuts
is 1.5mm in height). Adjust on the front and rear side.
NOTE: The Multi Tool is located behind the rear cover of the BK5010 ( x 5).
1-61
BOOK FOLDER INSTALLATION
04 October 2007
Parallellity adjustment
[F]
[E]
4. Looking from behind the system, make sure that the Book Folder is parallell
with the Trimmer [E] ± 2mm. If necessary, adjust by turning the two nuts [F] on
the outfeed side of the Book Folder .
1-62
BOOK FOLDER INSTALLATION
04 October 2007
Docking procedure
[D]
Installation
1.6.4 DOCKING
[B]
[A]
[D]
Book Folder interior, view
towards Belt Stacker
[C]
1. Loosen nuts [A] to the Locking bracket [B].
2. Dock the Book folder to the Trimmer.
3. Secure the Book folder by lifting the Locking bracket [B] and tightening nuts
[A] (
x 2).
NOTE: Make sure that the Book Folder locking bracket [B] locks in the outer
slot [C] on the positioning pin [D].
4. Install the new Extended trim bin.
1-63
BOOK FOLDER INSTALLATION
04 October 2007
Installing Belt stacker
Book Folder
[A]
1. Loosen screws [A] (
x 2) on the Book Folder.
2. Install the Belt stacker on to the Book Folder.
3. Secure the Belt stacker by tightening screws [A] (
1-64
x 2) on the Book Folder.
BOOK FOLDER INSTALLATION
04 October 2007
COM
Installation
1.6.5 CONNECTORS
[A]
BK5010
[B]
Trimmer without Book Folder installed
[D]
[C]
[F]
COM
BK5010
Book Folder
COM
BF501
0
[E]
[G]
Trimmer with Book Folder installed
x 1).
1. Move the Belt stacker cable [A] to the Book Folder (
NOTE: Do not connect the Belt stacker cable [A] to the Trimmer.
2. Move the Terminator plug [B] from the Trimmer to the Book Folder (
x 1).
3. Install the COM. BF5010 sticker [C], from the installation kit, over the “Terminator” sticker on the Trimmer.
4. Install the Communication cable [D] between the Trimmer and the Book Folder
(
x 1).
5. Connect the power cord from the BK5010 to the BF5010
6. Mount the cable protector [E] positioned as shown with two screws in the
holes [F] and route the cables inside the cable protector ( x 2).
7. Attach the sticker “Do not lift here” [G] on the cable protector.
8. Install the cable holder on the rear side of the Book Folder.
9. Route cables through the cable holders on the rear side of the Booklet Maker,
Trimmer and Book Folder.
1-65
BOOK FOLDER INSTALLATION
04 October 2007
1.6.6 AUTO SET THICKNESS BRACKET
Auto set thickness bracket
[B]
[A]
[C]
Booklet Maker, rear side view
1. Unplug BK 5010 power cord.
2. Remove the rear cover on the Booklet maker (
BK5010 3.3.1) ( x 5 ).
Service Manual 3. Install the Spacer pin [A], with the collar out.
NOTE: Install the Spacer pin’s on the rear side of the Booklet maker.
4. Install the Auto set thickness bracket [B], and tighten it with the other
Spacer pin [C] with the collar in.
CAUTION
ONLY install spacer pin [A] and [C] finger tight.
Over tightening may break loose the screw from the Fold roller plate.
1-66
BOOK FOLDER INSTALLATION
04 October 2007
Installation
Sensor bracket
[A]
Booklet Maker, rear side view
[D]
Booklet Maker, rear side view
[B]
[C]
[E]
Booklet Maker, rear side view
1. Place the spring [A] on the screw on the Sensor bracket.
2. Secure the Sensor bracket by tightening it with the screws [B] & [C] (
torx).
NOTE: Make sure that the Actuator runs in the sensor slot!
3. Connect the sensor harness [D] to the sensor on bracket [E] (
1-67
x 1).
x2
BOOK FOLDER INSTALLATION
04 October 2007
1.6.7 CHECK THE INSTALLATION
1. Power on the Booklet maker.
NOTE: Make sure that the finisher connector is connected to the copier.
[A]
Trimmer interior, view
towards Booklet Maker
2. In the Trimmer, check the Index 16 value [A].
3. Press the Tools button.
4. Scroll down to Service and press the OK button.
5. Key in the Password.
6. Scroll down to EEPROM Values and press the OK button.
7. Scroll to INDEX 16, TR5010.Knife Zero, and press the CHG button.
8. Key in the value you have in the trimmer.
9. Go down to Store and press the OK button.
10. Remove the two Stapler heads, according to section (
11. Perform a detailed self-diagnostic, according to section (
12. Reinstall the two Stapler heads, according to section (
3.4.12 ).
5.3.3 ).
3.4.12 ).
13. Power on the Copier.
NOTE: Make sure that the Booklet maker is powered ON before the Copier.
14. Set up the Booklet maker to Auto paper size.
15. Check that the Booklet maker is set to Staple ON.
16. Set up the Trimmer to Trimmer ON.
1-68
17. If a Cover Feeder CF5010 is installed:
A. Prepare a 15mm/ high stack of A4/8.5 x 11” covers.
B. Make sure that the ink has dried out well, to avoid smearing.
C. Make sure that the covers are well fanned to avoid misfeeds or double-feeds.
D. Align the covers well to achieve a reliable collating operation and good
finishing result.
E. Press down the green marks on Paper bin and load the covers.
F. Move the adjustable side guides up against the covers, until there is no clearance.
G. Set up the Cover Feeder to Cover ON, the fan will start and the Cover
Feeder will prefeed the first cover to be ready for the set from the copier.
18. Set up the Booklet Maker to Auto paper size.
19. Send five 2 sheet booklets of A4/8.5 x 11” (8 pages of A5/8.5 x 5.5 = a booklet
containing 2 sheets of A4/8.5 x 11”) to the Booklet maker system.
20. Check for the correct feeding of the set from the finisher.
NOTE: The paper should enter in the middle of the infeeder. If not, adjust the
Booklet maker according to section (
1.3.3 ).
21. If a Cover Feeder CF5010 is installed - check that the covers are correctly fed
into the Booklet maker.
22. Check if the sets have been trimmed correctly.
23. Check that the booklet not has a Book folded spine.
24. If a Cover Feeder CF5010 is installed:
A. Set up the Cover Feeder to Cover OFF and remove all covers from the bin.
Use the Purge mode to completely empty the Cover Feeder from covers.
B. Prepare a 15mm high stack of A3/11 x 17” covers.
C. Repeat step 17 B to 18 G.
25. Send five 10 sheet booklets of A3 / 11x17” (40 pages of A4/8.5 x 11 = a booklet containing 10 sheets of A3 / 11x17”) to the Booklet maker system.
26. Check for the correct feeding of the set from the finisher.
NOTE: The paper should enter in the middle of the infeeder. If not, adjust the
Booklet maker according to section (
1.3.3 ).
27. If a Cover Feeder CF5010 is installed - check that the covers are correctly fed
into the Booklet maker.
28. Check if the sets have been trimmed correctly.
29. Check that the booklet has a square formed spine.
1-69
Installation
BOOK FOLDER INSTALLATION
04 October 2007
Page intentionally blank
19 April 2006
PM TABLE
2.
PREVENTIVE MAINTENANCE SCHEDULE
2.1
PM TABLE
CAUTION
If any of the checkpoints or other parts show indication of wear at any
point, replace the part. When lubricating, clean the surface if necessary
before applying new lubricant.
Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect
BK5010
125K
250K
375K
500K
NOTE
REFERENCE
Paper paths
C
C
C
C
Blower Brush
Sensors
C
C
C
C
Blower Brush
Booklet quality
I
I
I
I
Inspect
Section 3.9
L
L
L
L
Oil, Every 20K
3.4.17
L
Grease 501
3.4.16
Stapler assembly
Clinchers (2x)
Drive bars (2x)
L
Stapler heads (2x)
I
R
I
R
Inspect, Replace if
needed
3.4.12
Stapler Drive Bar
I
L
I
L
Grease 501
3.4.15
Folder assembly
Fold knife drive bars
(2x)
L
L
Grease 501
Fold stop bars (2x)
L
L
Grease 501
Length adjustment
shaft
L
L
Grease 501
3.6.2
Fold roller bearings
(x6, x2 bracket)
L
L
Grease: KS660: SHI
3.6.10
Cams to Upper fold
rollers (2x)
L
L
L
L
Grease: KS660: SHI
3.6.11 Item [J]
Driving belt / Fold
transmission
I
I
I
R
Inspect, Replace if
needed
3.6.7
Fold transmission
coupling assy.
I
I/R
I
I/R
Inspect. Replace if
needed.
3.6.9
Drive
CF5010
125K
250K
375K
500K
Paper paths
C
C
C
C
Blower brush
Sensors
C
C
C
C
Blower brush
Feed rollers (5x)
C
C/R
C
C/R
Alcohol
CF 3.2.3
Paper seperator pad
C
C/R
C
C/R
Alcohol
CF 3.2.3
Drive shaft tires (3x)
C
C
C
R
Alcohol
CF 3.2.7, 3.2.8
2-1
NOTE
REFERENCE
Preventive
Maintenance
NOTE: Amounts mentioned as the PM interval indicate the number of sets.
PM TABLE
TR5010
19 April 2006
125K
250K
375K
500K
Paper paths
C
C
C
C
Blower Brush
NOTE
REFERENCE
Sensors
C
C
C
C
Blower Brush
C
C
C
R
Alcohol
3.2.20
Upper outfeed belts
(2x)
C
C/ I
C
C/ I
Alcohol
3.2.15
Lower outfeed belts
(2x)
C
C/ I
C
C/ I
Alcohol
3.2.14
I
I
I
I
Inspect
3.2.8
Knife chain
L
L
L
L
Launa Oil 40
3.2.19
Knife support chain
L
L
L
L
Launa Oil 40
3.2.18
Transmission chain /
Chain sprockets
L
L/ I
L
L/ I
Launa Oil 40
3.2.17
L
Grease 501
3.2.10
Infeed module
Infeed belts (4x)
Outfeed module
Trim Knife
Trim knife
Drive
Gear rack
BF5010
L
250K
500K
All machine, paper
path etc.
C
C
Blower brush.
Sensors.
C
C
Blower brush.
Transport belt.
C/I/R
C/I/R
Pressure roller.
I/R
I/R
Inspect O-rings and
3.2.4
pressure roller*.
Change position of
wear point of pressure
roller. Replace Complete assy if needed.
Link Arms for
Clamps.
I/R
I/R
Inspect Link Arms
for wear. Replace if
needed.
3.5.1
Lower Clamp
L
L
Check that the lower
Clamp moves, when
pressed by upper
Clamp. Grease 501.
3.5.1
Upper Clamp
L
L
Grease 501.
3.5.1
Brass Guides
L
L
Grease 501.
3.5.1
Teflon Tape
I/R
I/R
Inspect, Replace if
needed.
3.4.3
Dampers
R
R
Replace dampers.
Adjust stop gage
3.5.2
* To prevent flatness of pressure roller.
2-2
NOTE
Alcohol.
REFERENCE
3.4.1 & 3.4.2
21 August 2006
GENERAL CAUTIONS
3.
REPLACEMENT AND ADJUSTMENT
3.1
GENERAL CAUTIONS
WARNING
Turn off the main power switch and unplug the machine before attempting
any of the procedures in this section.
Purpose
The purpose of the ESD (Electrostatic Discharge) ground strap is to preserve the
inherent reliability and quality of electronic components handled by the Service
Representative. The strap should be used whenever handling the circuit boards or
any other ESD sensitive components.
Procedure
NOTE: All procedures requiring use of the ESD ground strap will contain a caution
referring to this procedure.
1 Switch off the main power switch.
2.Make sure the power cord connects the machine to the wall outlet. The power
cord and wall outlet must have ground.
3.Connect the claw end of the grounding cord to a chassis ground, such as earth
wires screwed to chassis ground, unpainted frame or an unpainted bracket
secured to the frame.
4.Connect the snap end of the blue cord to the snap on the adjustable wrist strap.
5.Place the adjustable wrist strap securely on the wrist. Wait for one minute to let
the electrostatic be discharged from your body.
6.ESD sensitive components can now be handled without causing any ESD related damage.
7.New replacement PCBs and ESD sensitive components, as well as old defective PCBs should be handled during unpacking and repacking using the ESD
ground strap. During the transfer from or to the packaging material, the PCB
should be placed on the ESD bag the replacement PCB came in.
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs). ESD
problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards/ sensors, refer to this
procedure 3.1.
- Use ESD protection when working near PCBs. Failure to use ESD protection is likely to result in a PCB failure.
3-1
Replacement
Adjustment
Using the ESD Ground Strap
Page intentionally blank
21 August 2006
3.2
SPECIAL TOOLS AND LUBRICANTS
SPECIAL TOOLS AND LUBRICANTS
3.2.1 SPECIAL TOOLS
Replacement
Adjustment
In order to facilitate the service of the BK5010 Booklet Making system there are a
few special tools needed. Where part number is written it can be purchased from
your supplier.
Multi tool (Included in BK5010, Part No. SR781032
Interlock cheater
(Included in BK5010 and
BF5010, Part No. SR103101565)
USB converter
(Not included in BK5010,
purchase locally)
Software loading cable
(Not included in
BK5010. Part No.
SR770010)
Cheater
location
BF5010, infeed side view
BK5010, infeed side view
Two Cheaters (one for BK5010 and one for TR5010) are stored inside the panels
between copier and BK5010. The BF5010 Cheater is stored on the inside of the
front side machine frame.
3-3
21 August 2006
For the BK5010 Booklet Making system not to be interlocked (interlocked=36V
interrupted), the Interlock switch must be activated and the Interlock magnet must
be blocked with a metal. Use the Cheater to override the interlock for running the
system with open top covers.
On the BK5010 and TR5010
1. Hold the Cheater above the interlock so the arrows meet.
2. Put in the right end in the slot so it hooks under the bracket.
3. Push the Cheater down and to the left so it latches in place.
BK5010, view towards user interface
TR5010, view from outfeed side
On the BF5010
1. Make sure that the belt stacker is in its normal operating position.
2. Press down on the lever [A] that prevents opening the cover [B] of the belt stacker.
3. Hold the Cheater above the with the interlock with the arrow pointing upwards.
4. Put in the left end in the slot so it hooks under the bracket.
5. Push the Cheater down and to the right so it latches in place.
[A]
BF5010, view from outfeed side
[B]
3-4
21 August 2006
SPECIAL TOOLS AND LUBRICANTS
3.2.2 REQUIRED TOOLS
Open wrenches:
5.5, 7, 8, 10, 13, 17, 19 mm
Allen keys:
1.5, 2, 2.5, 3, 4, 5 mm
Torx T-20
Circlip pliers
Metric Feeler gauge set
Replacement
Adjustment
Metric Sliding calliper
3.2.3 LUBRICANTS
Grease:
Part number:
Grease : KS660 : SHI
G004-9668
Grease 501
5203-9502
Recomended
IBM Equvivalent P/N
29F0362, Rheolube 7236R
1165927, Mobilgrease 28
Oil:
Launa oil 40
57X0040, Mobil BTE 24
(IBM oil, No.6)
5442-9103
3.2.4 SYMBOLS USED IN TEXT
Go to section:
Screw:
Nut:
Connector:
Allen screw:
E-clip:
Spring:
Washer:
Use a Screwdriver:
3-5
Page intentionally blank
21 August 2006
3.3
COVERS
COVERS
Replacement
Adjustment
3.3.1 FRONT AND REAR COVER
[A]
1. Open top cover.
[B]
[C]
2. Remove screws [A] to Front cover (
x5 ).
3. Remove screws [B] to Rear cover (
x4 ).
4. Loosen screw [C] ( x1 ).
NOTE: Unhook the Rear cover.
3-7
COVERS
21 August 2006
3.3.2 INFEED COVER
[A]
[B]
1. Remove Front and Rear cover (
2. Remove screws [A] (
3.3.1 ).
2 ).
3. Support Infeed Cover.
4. Remove screws [B] to remove Infeed Cover.
NOTE: Remove screws in this order to avoid bending front frame part.
WARNING
Infeed cover is very heavy and could cause injury if it falls down.
3-8
21 August 2006
COVERS
[B]
[A]
[A]
1. Open the Top Cover.
2. Remove screws [A] (
x4 ).
3. Disconnect connector [B].
4. Lift out the Infeeder.
3-9
Replacement
Adjustment
3.3.3 INFEEDER
COVERS
21 August 2006
3.3.4 OUTFEED COVER
[B]
[A]
[C]
[E]
[D]
1. Set the machine to A4.
2. Remove Stacker module (
3. Remove Front and Rear cover (
4. Remove screws [A] (
x2 ).
5. Remove screws [B] (
x2 ).
6. Remove screws [C] (
x2 ).
3.8.1 ).
3.3.1 ).
7. Turn Fold Gate [D] halfway to its downmost position.
8. Pull out lower end of the Outfeed Cover and lift it up enough to clear the Outfeed Sensor [E].
10. Pull out upper end of the Outfeed Cover and lower it until it touches the Fold
Gate.
11. Turn Fold Gate to its uppermost position and remove Outfeed cover.
3-10
COVERS
21 August 2006
3.3.5 UPPER TOP COVER
Replacement
Adjustment
[D]
[A]
[B]
[C]
1. Open the Top Cover.
2. Remove screws [A] (
x2 ).
3. Lift front end of upper Top Cover and pull so that the studs [B] exits the rubber
bushings [C] at the rear side of the Cover Feeder or Cover Feeder Dummy.
4. Lift off the Upper Top Cover [D].
3-11
COVERS
21 August 2006
3.3.6 REAR TOP COVER
[A]
[B]
[C]
[D]
1. Remove the nut [A] (
x 1).
2. Remove the screw [B] ( x 1).
NOTE: Lift the Jam clearance baffle [C] to get better acces to the screw.
3. Remove the screws [D] (
x 2).
4. Remove the Rear Top Cover.
3-12
21 August 2006
COVERS
Replacement
Adjustment
3.3.7 TOP COVER ASSEMBLY
[A]
[B]
Removal
1. Remove Front and Rear cover (
3.3.1 ).
2. If a Cover Feeder is installed - disconnect connectors [A].
3. Squeeze the barbs on the sides and remove connectors [B] from Top cover.
3-13
COVERS
21 August 2006
[C]
[C]
[F]
[G]
[D]
4. Remove nuts [C] (
x4 ).
5. Remove screw [D] (
x1 ) and [E] (
[E]
[F]
x1 ).
6. Move Top cover towards the front side.
7. Remove screws [F](
x2 ) and adjustment plates [G] ( x2 ).
8. Lift off the Top cover.
Replacement
1. Reverse the removal procedure.
3-14
[G]
COVERS
Replacement
Adjustment
21 August 2006
[J]
[H]
[I]
[J]
[K]
Adjustment
1. Loosen screw [D] ( x1 ) and screws [F] ( x2 ). Adjust so that the Top cover
rests on the rubber supports [H] ( x3 ) when closed.
x4 ) and adjust so that the plate [I] holding the upper part
2. Loosen nuts [C] (
of the Top cover lock enters the cut-out in the front frame centered.
3. Check that the Top cover lock works without binding. Loosen screws and nuts
[J] ( x2 ) (
x2 ) to adjust upper part in/out. Loosen nuts [K] (
x2 ) to
adjust lower part up/down.
4. Check that the Top cover Interlock switch is correctly adjusted (
3-15
3.3.8 ).
COVERS
21 August 2006
3.3.8 INTERLOCK SWITCH S16 &S17
[A]
[C]
Removal
[B]
1. Remove Front cover (
3.3.1 ).
2. Remove connector [A] (
x1 ).
x2 ).
3. Remove nuts [B] to Interlock box (
4. Remove screws [C] to Switch PCB (
x2 ).
Replacement
1. Reverse the removal procedure.
Adjustment
1. Check that the Top cover is correctly adjusted (
2. Loosen nuts [B] to Interlock box (
3.3.5 ).
x2 ).
3. Adjust the Interlock box, so that Top cover activates interlock switch 2 mm /
5/64” before closing.
4. Tighten nuts [B] to Interlock box (
x2 ).
5. Recheck step 3.
WARNING
Overriding or cheating the interlock allows the BK5010 system to operate
with the top cover open which can result in personal injury. Never give
the operator access to the cheater or show how overriding the interlock
system is carried out.
3-16
21 August 2006
3.4
AREA A
AREA A
3.4.1 INFEED MODULE
[A]
Replacement
Adjustment
[B]
[D]
[C]
1. Remove Front and Rear cover (
2. Remove Infeed cover (
3.3.1 ).
3.3.2 ).
3. Remove connectors [A] (
x2 ).
4. Unhook of the length adjustment strap [B].
5. Remove screws [C] on the Front side of the Booklet maker (
6. Remove screws [D] on the Rear side of the Booklet maker (
x2 ).
x2 ).
7. Pull out the Infeeder carefully.
NOTE: Make sure that the Side jogger motor M3 is not catching the frame of the
Booklet maker.
3-17
AREA A
21 August 2006
3.4.2 PAPER INFEED SENSOR
[B]
[A]
1. Remove Infeed Module (
3.4.1 ).
2. Remove screw [A] ( x1 ).
NOTE: You do not have to remove the Infeed module to reach the screw, you
are able to reach the screw through the hole in the Infeed module.
3. Remove connector [B] (
x1 ).
3-18
21 August 2006
AREA A
3.4.3 INFEED TRANSPORT MODULE
Replacement
Adjustment
[B]
[A]
1. Remove connectors [A] (
[C]
x2 ).
2. Cut tie wrap [B] .
3. Remove E-clip [C] (
x1 ).
4. Remove pin to the Infeed transport module.
3-19
AREA A
21 August 2006
3.4.4 INFEED TRANSPORT WHEEL
[B]
[A]
1. Remove Infeed transport module (
2. Remove nuts [A] (
3. Remove E-clip [B] (
3.4.3 ).
x3 ).
x1 ).
3-20
21 August 2006
AREA A
Replacement
Adjustment
3.4.5 INFEED MOTOR M1 & SENSOR Q2
[A]
1. Remove Infeed transport wheel (
2. Remove screws [A] (
3.4.4 ).
x3 ).
3. Pull out the Infeed motor M1 & sensor Q2.
NOTE: The sensor Q2 is located on the motor.
3-21
AREA A
21 August 2006
3.4.6 SIDE GUIDES
[C]
[D]
[A]
[B]
Removal Front
1. Remove Infeed module (
3.4.1 ).
2. Remove screw [A] and [B] to the Front side guide [C] (
x2 ).
3. Same procedure on the Rear side guide [D].
Replacement
1. Reverse the removal procedure.
NOTE: Make sure that you are using the correct screws (M4 x 8mm) when
reinstalling the side guides. If you are using longer screws, you may damage
the side guide shaft.
Adjustment
1. Adjust Side guide parallelism (
3.9.2 ).
3-22
21 August 2006
AREA A
3.4.7 SIDE JOGGER MOTOR M3 & SENSOR Q12
Replacement
Adjustment
[A]
[C]
[B]
Removal
1. Remove Infeed module (
2. Remove connectors [A] (
[D]
3.4.1 ).
x2 ).
3. Loosen allen screw [B] to pulley (
x1 ).
4. Remove screws [C] to motor bracket (
x2 ).
5. Remove Side jogger motor M3 & sensor Q12.
NOTE: The sensor Q12 is located on the motor.
Replacement
1. Push the pulley down, to make sure that it is in the right position.
2. When installing the motor, make sure that the allen screw is positioned against
the flat [D] of the motor shaft.
3. Reverse the rest of the removal procedure.
3-23
AREA A
21 August 2006
3.4.8 SIDE GUIDE TRANSMISSION &SENSOR Q13
[A]
[I]
[E]
[G]
[D]
[F]
Continued on next page....
3-24
[H]
[B]
[C]
21 August 2006
AREA A
Removal Sensor Q13
3.4.1 ).
1. Remove Infeed module (
x1 ).
2. Disconnect connector [A] to sensor Q13 (
NOTE: Make sure that the side guides are in there most inner position and move
the Back jogger module by hand, to make it easier to get to the sensor.
Replacement
Replacement
Adjustment
1. Reverse the removal procedure.
Removal Side guide transmission
3.4.7 ).
1. Remove Side jogger motor (
2. Loosen nuts [B] (
x2 ).
3. Use a screwdriver [C] to press the springs [D] together, to slack the drive belt
( x2,
x1).
4. Tighten nuts [B] again (
5. Remove screwdriver [C] (
6. Remove connector [A] (
x2 ).
x1).
x1 ).
7. Remove Side jogger home position sensor Q13 [E].
8. Use a flat plier to lift up the drive belt from the side guide brackets [F].
9. Remove the pulley [G] and the dive belt [H].
Replacement
1. Place the side guides in there outermost position [I].
2. Take the pulley [G], and press the drive belt into the left side guide bracket [F]. Continue and press the drive belt into the right side guide bracket [F].
3. Loosen nuts [B], and let the springs [D] tensioning the drive belt (
4. Tighten nuts [B] again (
x2 ).
5. Reverse the rest of the removal procedure.
3-25
x2,
x2 ).
AREA A
21 August 2006
3.4.9 BACK JOGGER MODULE & SENSOR Q3
[D]
[F]
[A]
[B]
[G]
[C]
[H]
Continued on next page....
3-26
[E]
[C]
21 August 2006
AREA A
Removal Sensor Q3
3.3.2 ).
1. Remove Infeed cover (
NOTE:Picture shows Infeed module removed for clarity. It is not necessary to
remove Infeed module to replace Sensor Q3.
x1 ).
2. Disconnect connector [A] to Sensor Q3 (
3. Remove sensor Q3 [B].
Replacement Sensor Q3
Replacement
Adjustment
1. Reverse the removal procedure.
Removal Back jogger module
1. Remove Infeed module (
3.4.1 ).
3.4.3 ).
2. Remove Infeed transport module (
3. Remove the screw to plastic distance [C] (
x1 ).
4. Unhook the Length adjustment strap wheel [D].
NOTE: DO NOT TURN THE ADJUSTMENT SCREW.
5. Insert a screwdriver [E] in the shaft and unscrew the shaft [F] to the Back jogger module (
x1 ).
NOTE: Rotate the screwdriver counterclockwise to unscrew the shaft.
6. Remove the shaft [F].
7. Remove the Back jogger module.
NOTE: If removing the Back jogger module completely, remove three cable
ties to the Infeed sensor Q1 harness.
Replacement Back jogger module
NOTE: When replacing the Back jogger module, make sure that the Back jogger
fingers [G] and the Infeed bearing bracket [H] is in its right position.
1. Reverse the removal procedure.
3-27
AREA A
21 August 2006
3.4.10 BACK JOGGER FINGERS
[C]
[B]
[A]
[D]
[O]
[F]
[E]
[G]
[E]
[H]
[K]
[L]
Continued on next page....
[P]
3-28
[I]
[J]
[O]
21 August 2006
AREA A
[M]
[N]
1. Remove Back jogger module (
3.4.9 )
2. Loosen spring [A] with a screwdriver [B], by pulling the screwdriver straight out
according to the arrows [C] (
x1 ).
3. Remove screws [D] (
x2 ).
4. Remove E-clips [E] (
x4 ).
5. Pull out the Back jogger arm shaft [F].
NOTE: Make sure to notice the orientation of the Back jogger fingers [G], [H],
[I] and [J], and the brass bracket [K].
x1 ).
6. Remove nut [L] and dismount the Back jogger finger (
NOTE: There is two different kind of Back jogger fingers. One type with a
bearing [M] and one type without a bearing [N].
Replacement
x1 ).
1. Remount the Back jogger finger and tighten the nut [L] (
NOTE: Tighten the nut finger tight, then tighten the nut ½ revolution with a 19
mm open wrench.
2. Reinstall correct Back jogger finger [G], [H], [ I ] and [J], Bras bracket and the
two bushings [O] on correct place.
NOTE: Make sure to turn the Brass bracket correctly, according to the circles
in the picture.
3. Slide Back jogger arm shaft [F] in place.
NOTE: Make sure to turn the shaft the correct way [ P].
4. Reinstall E-clips [E] (
x4 ).
5. Reinstall Back jogger arm module in place, and tighten screws [D] (
6. Push the spring [A] back with your thumb.
NOTE: Make sure that the bearing is in the slot on the feather spring.
7. Reverse the rest of the removal procedure.
3-29
x2 ).
Replacement
Adjustment
Removal
AREA A
21 August 2006
3.4.11 BACK JOGGER MOTOR M2
[E]
[C]
[F]
[B]
[A]
[D]
Removal
1. Remove Back jogger module (
2. Remove screw [A] and nut [B] (
3.4.9 ).
x1,
x1 ).
3. Remove the Bracket [C] from the motor axel.
4. Remove connector [D] (
x1).
5. Remove screws [E] to the motor (
x3 ).
Replacement
1. Reinstall screws [E] to the motor (
2. Reinstall connector [D] (
x3 ).
x1).
x1 ).
3. Reinstall screw [A] and nut [B] ( x1,
NOTE: Make sure that the screw [A] is positioned against flat of the motor
shaft. And that the motor shaft is level [F] with the Bracket [C].
4. Reverse the rest of the removal procedure.
3-30
21 August 2006
AREA A
3.4.12 STAPLER HEAD
Replacement
Adjustment
[B]
[A]
Replacement of staple cartridge
[C]
1. Open the booklet maker top cover.
2. Raise the handle (A) on the staple cartridge locking lever.
3. Remove the staple cartridge [B] from the stapler head by sliding it away from
the stapler head.
4. Renewing or reinstalling the staple cartridge, pull 25 mm / 1 inch of staples out
of the cartridge and tear the staples downward against the staple tear line [C].
The staple tear line is indicated by an arrow on the side of the cartridge.
5. Insert the cartridge into the stapler head with the end of the staples facing
toward the head of the stapler mechanism. Push it firmly ahead.
NOTE: Hold the staple cartridge firmly in place and push down the cartridge locking lever [A].
6. Close the top cover. Hand feed a four sheet set of paper. The booklet maker
will automatically cycle and advance staples until both staple heads are driving staples. If not and/or if error message persists, repeat procedure.
Continued on next page....
3-31
AREA A
21 August 2006
[E]
[D]
Removal of stapler head
1. Open the booklet maker top cover.
2. Disconnect the staple indication lead [D] from the socket.
3. Hold the stapler head in place, press the release lever [E] to release the rear
end of the stapler head and lift up this end.
4. Lift out the head, allowing it to rotate around the front end. The stapler assembly is spring loaded and will follow the rotation of the stapler.
4. Remove staple cartridge. Look inside stapler head to locate jammed staples
by eject point. Remove staples if any.
5. Position the stapler head on the edge of a firm surface (for example the top of
a table).
6. While securely holding the head, actuate the stapler up and down through full
travel. Perform this operation first without staple cartridge, then with staple
cartridge. Repeat this a few times to ensure that the staples are ejected at
each down movement.
3-32
21 August 2006
AREA A
[G]
[F]
Maintenance of stapler head
The stapler head drive post on each stapler head should be lubricated every 20 00
cycles.
1. Put a couple of drops of oil [F] on each side of the drive post [G].
2. Cycle the stapler head a few times before installing it again.
[H]
Replacement of stapler head
1. Reinstall the stapler head by inserting the pin at the top of the stapler head
into the stapler retraction swing arm [H].
2. While rotating the stapler head, insert the pin located at the rear end of the
stapler head into the slots in the frame of the stapler head assembly. Press
down the rear end of the stapler head until the release lever snaps into place,
locking the stapler head in position.
3. Press down the front end of the stapler head until it snaps in position under
the frame assembly.
4. Reconnect the staple indication lead [D].
5. Close the top cover and switch on the booklet maker. The booklet maker will
automatically cycle and advance staples until both staple heads are driving
staples. If an error message occors, repeat procedure.
3-33
Replacement
Adjustment
[F]
AREA A
21 August 2006
3.4.13 STAPLER HEAD RETRACTION DISTANCE
[A]
[D]
[C]
[B]
1,0 - 2,0 mm
Purpose
The purpose is to ensure the staple feed.
Removal
3.3.2 ).
1. Remove Infeed cover(
2. Make sure that the Stapler motor linkage is in the top dead center.
Adjustment
1. Push down the stapler head [A].
2. Check that the gap [B] is 1,0 - 2,0 mm. If not, go to step 3.
3. Loosen screws [C] (
x3 ).
4. Adjust screws [D] according to step 2 (
5. Tighten screws [C] (
x1 ).
x3 ).
5. Perform the same check on the Rear side [E], adjust if needed.
Replacement
1. Reverse the removal procedure.
3-34
21 August 2006
AREA A
3.4.14 STAPLER MOTOR M4
[H]
[A]
[G]
[F]
[B]
[D]
[C]
Replacement
Adjustment
[I]
[E]
Removal
3.3.2 ).
1. Remove Infeed cover(
2. Disconnect connector [A] (
x1 ).
3. Remove nut [B], brass spacer [C] and screw [D] (
x1,
x1 ).
4. Remove Crank journal [E] with an 17 mm open wrench.
5. Remove screw and washer [F] (
x1,
x1 ).
6. Remove the Crank wheel [G].
7. Remove screws [H] to the motor (
x3 ).
Replacement
1. Reinstall screws [H] to the motor ( x3 ).
NOTE: DO NOT TIGHTEN THE SCREWS.
2. Reinstall the Crank wheel [G].
3. Reinstall screw and washer [F] (
4. Tighten screws [H] (
x1,
x1 ).
x3 ).
5. Reinstall Crank journal [E] with an 17 mm open wrench.
NOTE: Make sure to install the grater end [ I ] of the Crank journal.
6. Reverse the rest of the removal procedure.
3-35
AREA A
21 August 2006
3.4.15 STAPLER ASSY DRIVE BAR & SENSOR Q14
[A]
0,05 to 0,15 mm
[B]
[C]
[D]
[C]
[D]
Purpose
The purpose is to limit the front-to-rear movement of the Stapler assembly drive
bars, without causing them to bind.
Removal
3.3.1 ).
1. Remove Front and Rear cover (
2. Remove Infeed cover(
3.3.2 ).
Adjustment
1. Push the Drive bar [A] toward the Rear of the Booklet maker.
2. Insert a feeler gauge to Check the gap [B]. The distance should be 0.05 - 0.15
mm. If not, go to step 3.
3. Loosen locknuts [C] (
x2 ).
4. Adjust screws [D] according to step 2 (
5. Tighten locknuts [C] (
x2 ).
x2 ).
6. Perform the same check on the Rear side [E], adjust if needed.
Replacement
1. Reverse the removal procedure.
3-36
21 August 2006
AREA A
3.4.16 CLINCHER BAR ASSEMBLY
[D]
[A]
Replacement
Adjustment
Incorrect, with gap
[B]
[C]
Correct, no gap
Removal
1. Set the machine to A3 / 11x17”.
2. Remove Infeed module (
3.4.1 ).
3. Remove screws and nuts [A] on both sides of the Booklet maker (
x2,
x2 ).
4. Remove the screws [B] fastening the clincher beam, on both sides of the
Booklet maker ( x2 ).
5. Lift out the Clincher bar assembly.
Replacement
1. Reinstall the Clincher bar assembly.
NOTE:Make sure that the spring [C] is positioned on top of the Stapler assy
drive bar ( x2 ).
2. Before tightening the screws [B], make sure that the Clincher bar assembly is
firmly seated [D].
NOTE: There should be no space [D], If you look at the clincher bar through
the positioning holes in the Front and Rear frame.
3. While pressing the Clincher bar assembly, tighten the screws [B] (
4. Reverse the rest of the removal procedure.
3-37
x2 ).
AREA A
21 August 2006
3.4.17 CLEANING CLINCHER POINTS
[B]
[A]
[D]
[C]
Removal
1. Remove Clincher bar assembly [A] (
3.4.16 ).
2. Remove screws [B] to clincher plate [C] (
x3 ).
3. Remove clincher plate [C].
NOTE: The clincher points [D] are not interchangeable. They must be refitted
on their original position.
4. Clean clincher bar [A], clincher plate [C] and clincher points [D].
NOTE: Check for wear, replace if needed.
5. Apply oil on moving surfaces.
Replacement
1. Reverse the removal procedure.
2. Before refitting the clincher bar assembly, check/adjust the Clincher points
height (
3.9.5 ).
3-38
21 August 2006
AREA A
3.4.18 SET TRANSPORT DRIVE ALIGNMENT
[C]
[A]
[B]
Replacement
Adjustment
[D]
[D]
[C]
[I]
Continued on next page....
3-39
[H]
[G]
[F]
[E]
AREA A
21 August 2006
Purpose
The purpose is to horizontally align the Set transport drive rollers with the Idler
wheels, to ensure the correct set transportation into the fold area.
1. Set the machine to A4 / 8.5x11”.
2. Ensure that the tires [A] are centered on the hubs [B] of the drive rollers.
3. Manually move the Drive rollers [C] up against the Pressure rollers [D], by
pushing the Staple stop gate down.
4. Visually check that the Drive rollers [C] are centered on the Pressure rollers [D].
Removal
1. Remove Infeed cover (
3.3.2 ).
Adjustment
1. Insert a 0.3 mm feeler gauge [E] to ensure 0,3 ± 0,2 mm endplay.
If not, go to step 2.
NOTE: The endplay 0.3 mm is to prevent the Staple stop gate shaft from binding.
2. Loosen allen screw [F] (
x 1 ).
3. Push the shaft [G] toward the Front of the Booklet maker.
4. Adjust distance according to step 1.
5. Tighten allen screw [F] (
6. Loosen allen screws [H] (
x 1 ).
x 2 ).
7. Move the assembly [ I ], so that the tires [A] are centered on the Pressure rollers [D].
8. Tighten allen screws [H] (
x 2 ).
Replacement
1. Reverse the removal procedure.
3-40
21 August 2006
AREA A
3.4.19 PRESSURE ROLLER
[C]
[A]
Replacement
Adjustment
7-10 mm
[B]
[A]
[C]
7-10 mm
Purpose
The purpose is to position the Pressure rollers for the correct engagement with the
Drive rollers. This adjustment interacts with 3.5.1.
Adjustment
1. Set the machine to A3 / 11x17”.
2. Check that the distance [A] is 24.5 mm.
NOTE: Use a sliding caliper to measure the distance from paper path to the
top of the pressure rollers. Make sure not to push down the rollers as
the measurement in that case will not be correct.
x2 ).
3. Adjust Press roller height [A] on the two nuts [B] (
NOTE:If you want to make the Distance [A] grater, turn the two nuts [B] CW.
If you want to make the Distance [A] smaller, turn the two nuts [B] CCW.
4. Make sure that the distance from the paper path to the top of the
paper guides [C] is 7-10 mm.
5. If paper guides [C] is deformed, form paper guides to obtain adjustment.
6. Check/Adjust the Staple Stop Gate Solenoid (
3-41
3.5.1 ).
AREA A
21 August 2006
3.4.20 SET TRANSPORT MOTOR M5
[B]
[A]
[C]
[D]
1. Remove Infeed cover (
3.3.2 ).
2. Remove screw [A] to ground strap (
x1 ).
3. Remove O-ring [B].
4. Loosen the allen screw underneath the O-ring (
5. Loosen screws [C] and remove the motor (
6. Disconnect connector [D] (
x1 ).
3-42
x2 ).
x1 ).
AREA A
21 August 2006
3.4.21 THICK SET SENSOR Q36
[A]
View from infeed
[D]
[E]
View from outfeed
[F]
[B]
Removal
1. Remove the outermost stapler head [A] (
3.4.12 ).
x1 ).
2. Remove nut [B] (
NOTE: In order to maintain distance [C], do not loosen screws [D] or [E].
3. Disconnect connector [F] (
Continued on next page....
x1 ).
3-43
Replacement
Adjustment
[C]
AREA A
21 August 2006
Replacement
1. Reverse the removal procedure.
Check
1. Install interlock cheater in order to operate BK5010 with Top Cover open.
2. Set trimming to off.
2. Check sensor Q36 adjustment by hand feeding sets of 80 gsm sheets. A set of
32 sheets should pass but a set of 35 sheets should be stopped in the stapling
area with the display showing the message “Set to thick”.
NOTE: If a 35 sheet should pass, quickly switch off the power in order to avoid
jam clearence.
3. If not OK, perform adjustment.
Adjustment
1. Ensure trimming is set to off.
2. Feed a set of 32 sheets of 80 gsm.
If set passes - go to item 6.
If set is stopped - proceed with item 3.
3. Loosen screw [D].
4. Turn screw [E] 1/8 turn counterclockwise.
5. Thighten screw [D]. Go to item 2.
6. Feed a set of 35 sheets of 80 gsm.
NOTE: If a 35 sheet should pass, quickly switch off the power in order to avoid
jam clearence.
If set passes - go to item 7.
If set is stopped, adjustment is concluded.
7. Loosen screw [D].
8. Turn screw [E] slightly clockwise.
9. Thighten screw [D]. Go to item 6.
3-44
21 August 2006
3.5
AREA B
AREA B
3.5.1 STAPLE STOP GATE SOLENOID SOL1
[A]
Replacement
Adjustment
[C]
[A]
Purpose
The purpose is to ensure adequate engagement of the pressure rollers.
NOTE: This adjustment interacts with 3.4.19. Perform adjustment 3.4.19 before
this adjustment 3.5.1.
Removal
3.4.19 ).
1. Check/Adjust the Pressure roller (
2. Set the machine to A3 / 11x17”.
3.3.2 ).
3. Remove Infeed cover (
Adjustment
5.1.1, 5.1.2 ).
1. Enter service mode and activate the SOL1, in check solenoids (
NOTE: The solenoid will be activated for approximately 30 seconds.
2. Check that distance [A] is 26 mm.
NOTE: Use a sliding caliper to measure the distance from paper path to the top
of the pressure roller. When SOL1 is activated. If not, go to step 3. Make
sure that the right and left Drive roller, contacts the Pressure roller at the
same time. If not, form the Drive rollers to obtain adjustment.
3. Loosen screws [C] (
x2 ).
4. Activate the SOL1 again, and adjust according to step 2.
5. Tighten screws [C] (
x2 ).
Replacement
1. Reverse the removal procedure.
3-45
AREA B
21 August 2006
3.5.2 STAPLE STOP GATE RELEASE SOLENOID SOL2
[A]
[B]
Continued on next page....
3-46
21 August 2006
AREA B
Removal
1. Start Staple / Fold positioning motor M9, in Check motors (
5.1.1 ).
2. Engage the motor until you can see the screws [A].
3. Remove Infeed cover (
3.3.2 ).
4. Cut the tie wrap, securing the cable.
5. Disconnect connector to SOL2 (
x2 ).
Adjustment
1. When the Stapled stop gate is in it’s upper position, the play in the solenoid
plate [B] should be 0.1-0.5 mm. If not, go to step 2.
2. Loosen screws [A] (
x2 ).
3. Adjust according to step 1.
4. Tighten screws [A] (
x2 ).
Replacement
1. Reverse the removal procedure.
3-47
Replacement
Adjustment
6. Loosen screws [A] (
x1 ).
AREA B
21 August 2006
3.5.3 SADDLE STAPLING START SENSOR Q4
[B]
[A]
Removal
1. Remove nut [A] (
x1 ).
2. Disconnect connector [B] (
x1 ).
Replacement
1. Reverse the removal procedure.
NOTE: Make sure that the sleeve of the wire, do not interfere with the paper path.
3-48
21 August 2006
3.6
AREA C
AREA C
Replacement
Adjustment
3.6.1 STAPLE / FOLD POSITION MOTOR M9 & SENSOR Q10
[B]
[A]
1. Set the machine to A4 / 8.5x11”.
2. Remove Outfeed cover (
3. Disconnect connectors [A] (
3.3.4 ).
x2 ).
4. Remove screws [B] to the motor bracket (
NOTE: The sensor Q10 is located on the motor.
5. Remove Joint.
3-49
x3 ).
AREA C
21 August 2006
[C]
Grea
se
3.6.2 LENGTH TRANSMISSION SHAFT & SENSOR Q11
[B]
[A]
View inside Booklet maker with
Infeed cover removed
G
re
a
[C se
]
View on Length adjustment shaft with Rear cover removed
Continued on next page....
3-50
21 August 2006
AREA C
Removal Sensor Q11
1. Remove Rear cover (
2. Remove Infeed cover (
3. Disconnect connector [A] (
3.3.1 ).
3.3.2 ).
x1 ).
4. Remove sensor Q11 [B].
Replacement Sensor Q11
Replacement
Adjustment
1. Reverse the removal procedure.
Lubricate Length transmission shaft
1. Remove Rear cover (
2. Remove Infeed cover (
3.3.1 ).
3.3.2 ).
3. Lubricate with grease on the Length transmission shaft [C], and the nut to the
Length transmission shaft.
NOTE: You should be able to turn the length adjustment shaft by hand.
3-51
AREA C
21 August 2006
3.6.3 FOLD STOP GATE MOTOR M8 & SENSOR Q7
[A]
[B]
[C]
[D]
Removal
1. Set the machine to A3 / 11x17”.
2. Disconnect connector [A] (
x1 ).
3. Loosen allen screw [B] and remove the linkage (
4. Remove screws [C] to the motor (
x1 ).
x3 ).
5. Remove screw and washer [D] to the ground strap (
x1,
x1 ).
x1,
x1 ).
Replacement
1. Reinstall screw and washer [D] to the ground strap (
2. Reinstall screws [C] to the motor (
x3 ).
3. Reinstall linkage and tighten allen screw [B] ( x1 ).
NOTE: Make sure that allen screw [B] is positioned against the D-surface.
4. Reverse the rest of the removal procedure.
3-52
21 August 2006
AREA C
Replacement
Adjustment
3.6.4 FOLD STOP GATE
[A]
[B]
Removal
1. Set the machine to A3 / 11x17”.
2. Loosen locknut [A] (
3. Remove screw [B] (
x1 ).
x1 ).
4. Remove the Fold stop gate.
Replacement
1. Reinstall the Fold stop gate.
NOTE: Make sure that the shaft on the Fold stop gate, is positioned in the linkage.
2. Reverse the rest of the removal procedure.
3-53
AREA C
21 August 2006
3.6.5 FOLD KNIFE MOTOR M7 & SENSOR Q15
[D]
[E]
Continued on next page....
[B]
[H]
[I]
[G]
[C]
[J]
3-54
[A]
[F]
21 August 2006
AREA C
Removal
1. Set the machine to A4 / 8.5x11”.
3.3.1 ).
2. Remove Front and Rear cover (
3.3.2 ).
x1 ).
4. Disconnect connector [A] to motor M7 (
x1 ).
5. Disconnect connector [B] to sensor Q15 (
6. Loosen allen screw [C] and remove the stop ring (
x1 ).
7. Remove screws [D] on front side of the Booklet maker (
x2 ).
8. Remove the same screws on the rear side of the Booklet maker (
9. Remove the Fold knife motor M7 module.
10. Remove sensor Q15 [E].
11. Remove Crank journal [F] with an 17 mm open wrench.
12. Remove screw and washer [G] (
x1,
x1 ).
13. Remove the Crank wheel [H].
14. Remove screws [ I ] to the motor (
x3 ).
Replacement
1. Reinstall screws [ I ] to the motor ( x3 ).
NOTE: DO NOT TIGHTEN THE SCREWS.
2. Reinstall the Crank wheel [H].
3. Reinstall screw and washer [G] (
x1,
4. Tighten screws [ I ] to the motor (
x3 ).
x1 ).
5. Reinstall Crank journal [F] with an 17 mm open wrench.
NOTE: Make sure to install the smaller end [J] of the Crank journal.
6. Reverse the rest of the removal procedure.
3-55
x2 ).
Replacement
Adjustment
3. Remove Infeed cover (
AREA C
21 August 2006
3.6.6 FOLD TRANSMISSION MODULE
[C]
[B]
1. Remove Front cover (
[A]
3.3.1 ).
2. Disconnect connector [A] to Fold roller motor M6 (
x1 ).
3. Disconnect connector [B] to Fold roller sensor Q9 (
x1 ).
4. Remove nuts [C] to the Fold transmission module (
x3 ).
3-56
21 August 2006
AREA C
3.6.7 FOLD TRANSMISSION BELT & SENSOR Q9
[B]
[A]
[E]
[C]
[G]
[F]
[H]
Continued on next page....
3-57
Replacement
Adjustment
[D]
AREA C
21 August 2006
Removal
1. Remove Fold transmission module (
3.6.6 ).
2. Remove screws [A], [B] and [C] to Fold transmission plate (
x3 ).
3. Remove the Fold transmission plate and Fold roller sensor Q9 plate [D].
3. Loosen screw [E] (
x1 ).
4. Remove the Fold transmission belt [F].
Replacement
1. Reinstall Fold transmission belt.
2. Reinstall Fold roller sensor Q9 plate [D).
NOTE: make sure that the sensor plate is correctly installed.
3. Reinstall the Fold transmission plate.
NOTE: Make sure that the flat of the flange bushing, correspond to the flat on
the Fold transmission plate.
4. Reinstall screws [A], [B] and [C] ( x3 ).
NOTE: Check/adjust the Fold transmission belt tension by tightening screws
[C] and [E], so you have 1mm of deflection on the middle of the belt
[F], between pully [G] and [H] ( x2 ).
5. Reverse the rest of the removal procedure.
3-58
21 August 2006
AREA C
3.6.8 FOLD ROLLER MOTOR M6
Replacement
Adjustment
[C]
[B]
[A]
[D]
Continued on next page....
3-59
AREA C
21 August 2006
Removal
3.6.7 ).
1. Remove Fold transmission belt (
2. Remove screw and washer [A] (
x1,
x1 ).
3. Remove bearing [B].
4. Remove the Motor transmission pulley [C].
5. Remove screws [D] (
x3 ).
Replacement
1. Reinstall screws [D] ( x3 ).
NOTE: DO NOT TIGHTEN THE SCREWS.
2. Reinstall the Motor transmission pulley [C].
3. Reinstall screw and washer [A] (
x1,
x1 ).
4. Reinstall Fold transmission belt.
5. Reinstall Fold roller sensor Q9 plate.
NOTE: make sure that the sensor plate is correctly installed.
6. Reinstall the Fold transmission plate.
NOTE: Make sure that the flat of the flange bushing, correspond to the flat on
the Fold transmission plate.
7. Reinstall screws to the Fold transmission plate ( x3 ).
NOTE: Tighten the Fold transmission belt before tightening the screws to the
tensioner, then tighten the last screw ( x3 ).
8. Tighten screws [D] (
x3 ).
9. Reverse the rest of the removal procedure.
3-60
21 August 2006
AREA C
Replacement
Adjustment
3.6.9 FOLD TRANSMISSION GEAR ASSEMBLYS
[A]
[B]
[C]
[D]
[E]
1. Remove Fold transmission belt (
2. Remove E-clips (
3.6.7 ).
).
3. Remove transmission gears.
4. It is the same Fold transmission coupling assembly [E] on all of the Fold transmission gear assembly’s.
3-61
AREA C
21 August 2006
3.6.10 FOLD DISTANCE BRACKET
[D]
[A]
[C]
[B]
Removal
1. Remove Fold transmission module (
3.6.6 ).
2. Remove nut [A] to the middle bearing bracket (
x1 ).
3. Remove the bearing bracket [B].
4. Remove Fold distance bracket [C].
NOTE: DO NOT LOOSEN OR REMOVE THE NUT [D] TO THE EXCENTER.
Replacement
1. Reverse the removal procedure.
NOTE: DO NOT LOOSEN OR REMOVE THE NUT [D] TO THE EXCENTER.
Lubricate Fold distance brackets and Fold roller bearings
1. Lubricate with Molybdenum grease, behind the Fold distance bracket and on the places marked with red.
2. Perform the same lubrication on the rear side of the Booklet maker.
3-62
21 August 2006
AREA C
3.6.11 UPPER FOLDER ROLLER
Replacement
Adjustment
[A]
[G]
[J]
[J]
[B]
[B]
[F]
[I]
[H]
[E]
[D]
[C]
Continued on next page....
3-63
AREA C
21 August 2006
Removal
1. Remove outfeed cover (
3.3.4 ).
2. Remove the paper guide [A] by pressing it against the rear side of the Booklet
maker.
3. Loosen springs [B] to the Cams to the Upper folder rollers (
4. Remove Fold distance bracket (
x2 ).
3.6.10 ).
5. Remove nuts [C] and bearing brackets [D] on the front and rear side of the
booklet maker (
x2 ).
6. Remove springs [E] on the front and rear side of the Booklet maker (
x2 ).
7. Remove bearings [F] ( x2 ) on the rear side of the Booklet maker.
NOTE: Bearings on the rear side are secured with screws and washers
( x2,
x2 ). At the front side of the folder rollers there is a transverse hole through the axle journal in which an allen key can be inserted to facilitate removal of the screws.
8. Gently remove the Upper folder rollers.
Adjustment
1. Insert a 0,2 mm feeler gauge between the Upper folder rollers [G], to ensure
0,2 ± 0,05 mm gap [G] between the Upper folder rollers. If not, go to step 2.
2. Loosen nuts [H] on the front and rear side of the booklet maker (
x2 ).
3. Adjust eccenter [ I ] on the front and rear side of the Booklet maker, according
to step 1.
4. Tighten nuts [H] (
x2 ).
5. After tightening nuts [H], recheck the distance between the Upper folder rollers [G].
6. Lubricate with Molybdenum grease, on the upper side [J] of the Cams to the
upper folder rollers.
Replacement
1. Reverse the removal procedure.
NOTE: Screws securing the bearings to the folder rollers on the rear side must
be thightened with 10 Nm.
NOTE: Make sure to lubricate, with Molybdenum grease, according to
(
3.6.10).
3-64
21 August 2006
AREA C
3.6.12 LOWER FOLDER ROLLER
Replacement
Adjustment
[A]
[E]
[F]
[G]
[D]
[C]
[B]
Continued on next page....
3-65
AREA C
21 August 2006
Removal
1. Remove outfeed cover (
3.3.4 ).
2. Remove the paper guide [A] by pressing it against the rear side of the Booklet
maker.
3. Remove Fold distance bracket (
3.6.10 ).
4. Remove nuts [B] and bearing brackets [C] on the front and rear side of the
booklet maker (
x2 ).
5. Loosen nuts [D] on the front and rear side of the Booklet maker (
x4 ).
6. Remove springs [E] on the front and rear side of the Booklet maker ( x4 ).
NOTE: Use the Caster tool to remove the springs.
NOTE: Bearings [F] ( x2 ) are pressed on to the axle journals from factory and
can therefore not be removed.
7. Gently remove the Lower folder rollers.
Replacement
1. Reinstall the Lower folder rollers.
2. Reinstall the bearings [F] ( x2 ) on the rear side of the Booklet maker.
NOTE: On the newer type of folder rollers, the bearings are allready pressed
on to the axle journals from factory.
NOTE: Make sure to lubricate, with Molybdenum grease, according to
(
3.6.10).
3. Reinstall springs [E] on the front and rear side of the Booklet maker (
4. Insert the Caster tool, with the pointed end, in the hole [G].
NOTE: Insert the Caster the whole way.
5. When the Caster tool is in it’s most inner position, tighten the nut [D].
NOTE: Repeat step 4 and 5 for all four of the springs.
6. Reverse the rest of the removal procedure.
NOTE: Make sure to lubricate, with Molybdenum grease, according to
(
3.6.10).
3-66
x4 ).
21 August 2006
AREA C
3.6.13 OUTFEED SENSOR
[B]
Replacement
Adjustment
[A]
1. Remove outfeed cover (
2. Remove nut [A] (
x1 ).
3. Disconnect connector [B] (
3.3.4 ).
x1 ).
3-67
Page intentionally blank
PCB
21 August 2006
3.7
PCB
3.7.1 MD3DC PCB “H”
H.P14
H.P2
Replacement
Adjustment
H.P5
H.P4
H.P11
ON
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
Removal
1. Remove Rear cover (
3.3.1 ).
2. Remove all connectors from the PCB (
x5 ).
3. Squeeze the barbs of the pins and remove PCB ”H”.
Replacement
1. Reinstall PCB.
2. Reconnect all connectors to the PCB (
x5 ).
3. Make sure all DIP-switch 2 are set to ON according to picture.
4. Reinstall Rear cover (
3.3.1 ).
3-69
PCB
21 August 2006
3.7.2 UPPER MD6DC PCB ”B”
B.P4
B.P5
ON
B.P12
B.P11
B.P3
B.P13
B.P2
B.P14
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
Removal
1. Remove Rear cover (
3.3.1 ).
2. Remove all connectors from the PCB ”B” (
x8 ).
3. Squeeze the barbs of the pins and remove PCB ”B”.
Replacement
1. Reinstall PCB ”B”.
2. Reconnect all connectors to the PCB ”B” (
x8 ).
3. Make sure all DIP-switches are set to OFF according to picture.
NOTE: Make sure replaced PCB has matched software with the system, referring to the latest Technical Bulletin.
4. Reinstall Rear cover (
3.3.1 ).
3-70
21 August 2006
PCB
3.7.3 LOWER MD6DC PCB ”C”
C.P4
C.P5
ON
C.P12
C.P11
C.P3
C.P2
C.P14
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
Removal
1. Remove Rear cover (
3.3.1 ).
2. Remove all connectors from the PCB ”C” (
x8 ).
3. Squeeze the barbs of the pins and remove PCB ”C”.
Replacement
1. Reinstall PCB ”C”.
2. Reconnect all connectors to the PCB ”C” (
x8 ).
3. Make sure DIP-switches 1 and 4 is set to ON according to picture.
NOTE: Make sure replaced PCB has matched software with the system, referring to the latest Technical Bulletin.
4. Reinstall Rear cover (
3.3.1 ).
3-71
Replacement
Adjustment
C.P13
PCB
21 August 2006
3.7.4 INTERLOCK PCB ”D”
D.P5
D.P6
D.P8
[A]
D.P9 D.P13
D.P10
D.P11
[A]
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
1. Remove Rear cover (
3.3.1 ).
2. Remove all connectors from the Interlock PCB “D” (
3. Remove screws [A] (
x2 ).
3-72
x7 ).
21 August 2006
PCB
3.7.5 CPU PCB AND COPIER INTERFACE PCB ”A”
A.P5
A.P4
A.P3
A.P2
A.P9
Replacement
Adjustment
A.P1
A.P13
A.P10
A.P8
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
1. Remove Front cover (
3.3.1 ).
2. Remove all connectors from the PCB ”A” (
x9 ).
3. Squeeze the barbs of the pins and remove PCB ”A”.
Continued on next page....
3-73
PCB
21 August 2006
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
Removal
1. Enter service mode (
5.1.1 ).
2. Note all EEPROM values (Index 1-26) (
3. Remove Front cover (
5.1.2 EEPROM values ).
3.3.1 ).
4. Remove all connectors from the CPU and Copier Interface PCB (
x9 ).
5. Squeeze the barbs of the pins and remove CPU and Copier Interface PCB.
Replacement
1. Install the EEPROM [C] on the new CPU PCB.
NOTE: If the EEPROM is changed or broken, you have to manually type in the
EEPROM values you previously noted (
5.1.1 Changing EEPROM values ).
2. Reinstall the CPU PCB.
3. Reconnect all connectors to the CPU PCB (
x9 ).
4. Reinstall Protection plate and tighten screws [A] (
5. Reinstall Front cover (
x2 ).
3.3.1 ).
Adjustment
1. If you do not have the EEPROM values or EEPROM is corrupted, perform the EEPROM reset followed by Paper size reset (
5.1.3, 5.4 ).
3-74
PCB
21 August 2006
3.7.6 ADDON PCB ”F”
F.P1
F.P2
F.P3
F.P6
Replacement
Adjustment
F.P4
F.P5
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
1. Remove Front cover (
3.3.1 ).
2. Remove all connectors from the PCB ”F” (
x6 ).
3. Squeeze the barbs of the pins and remove PCB ”F”.
3-75
PCB
21 August 2006
3.7.7 LCD PANEL
[B]
[A]
[C]
[C]
[D]
[D]
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
1. Remove Front cover (
2. Disconnect connector [A] (
4. Remove nuts [B] (
3.3.1 ).
x2 ).
x 2 ).
5. Remove nuts and plastic washers [C] (
x4,
x4 ).
6. Remove plastic washers [D] between the button PCB and display (
3-76
x4 ).
21 August 2006
3.8
STACKER
STACKER
Replacement
Adjustment
3.8.1 STACKER MODULE
[A]
1. Loosen screws [A] to the Stacker Module (
x2 ).
2. Disconnect the connector to the Stacker Module (
3. Lift off the Stacker Module.
3-77
x1).
STACKER
21 August 2006
3.8.2 STACKER MOTOR M1
[B]
[A]
[C]
[D]
Removal
1. Remove Stacker Module (
2. Loosen nuts [A] (
3.8.1 ).
x3 ).
3. Slide the motor bracket [B] and remove.
4. Disconnect connector [C] (
5. Remove screws [D] (
x1 ).
x3 ).
Replacement
1. Reverse the removal procedure.
NOTE:Stacker motor pulley is D-shaped.
3-78
21 August 2006
3.9
BOOKLET QUALITY ADJUSTMENT
BOOKLET QUALITY ADJUSTMENT
3.9.1 STAPLE STOP GATE PARALLELISM
Replacement
Adjustment
[B]
[A]
[D]
Continued on next page....
3-79
[C]
BOOKLET QUALITY ADJUSTMENT
21 August 2006
Purpose
The purpose is to ensure that the staples are parallel to the edge of the sets.
Removal
1. Set the machine to A3 / 11x17”.
2. Open Top cover.
3. Remove the rear stapler head (
3.4.12 ).
4. Fold an A4 / 8.5x11” paper lengthwise by hand, and feed the paper down between the side guides (LEF).
5. Feed the paper so that the straight edge [A] is positioned against the Staple
stop gate.
6. Enter the Service program (
5.1.1 ).
7. Start the Staple / Fold positioning motor M9.
8. Step the motor to align the straight edge [A] with the locating holes [B] in the
paper path.
9. The straight edge [A] must align with the locating holes on both sides.
Adjustment
1. Loosen screw [C] (
x1 ).
2. Insert a screwdriver in the notches [D], rotate to align the locating holes [B]
with the straight edge [A] (
x1 ).
3. Tighten the screw [C] (
x1 ).
4. Check according to step 9 in Removal section.
Replacement
1. Reverse the removal procedure.
3-80
21 August 2006
BOOKLET QUALITY ADJUSTMENT
3.9.2 SIDE GUIDE PARALLELISM
[A]
[B]
[D]
[C]
[E]
Stapler area seen from above, with the
stapler heads removed.
Removal Front
1. Check/adjust Staple stop gate parallelism (
2. Remove Infeed cover (
3.9.1).
3.3.2 ).
3. Remove screw [A] and [B] to the Front side guide [C] (
NOTE: The nut plate may fall down into the machine.
x2 ).
4. Same procedure on the Rear side guide [D].
Adjustment
1. Move the side guide [C] to the two holes [E] and [F] in the paper path.
2. Check the distance between the two holes and the side guide. The distance
should be equal ± 0.3 mm between the lower hole [E] and the side guide [C],
and the upper hole [F] and the side guide [C]. If not, go to step 3.
3. Loosen screw [A], also loosen screw [B] a little. Adjust the side guide [C] according to step 2 ( x2 ).
4. Perform the same check on the Rear side guide [D], adjust if needed.
Replacement
1. Reverse the removal procedure.
3-81
Replacement
Adjustment
[F]
BOOKLET QUALITY ADJUSTMENT
21 August 2006
3.9.3 STAPLE POSITION TO CLINCHER
CAUTION
Alignment of the stapler head to clincher is carried out at factory. Screws are
sealed with red paint to ensure that alignment is maintained and also to indicate if
it has been moved.
Alignment will not change over time and will therefore not need further adjustment. However, if the adjustment has been tampered with (i.e if red seal is broken)
it is very important to strictly follow the described procedure below. The alignment of the stapler head to anvil is crucial and will determine the staple result as
well as the lifetime of the stapler head.
The procedure requires 2 brand new stapler heads.
If, at any time during the procedure the new stapler heads were cycled, when
adjustment were off (staple legs not hitting the slot in the anvil/clincher), stapler
heads are ruined and must be replaced.
The Stapler heads must be adjusted very precisely in order to achieve proper
staple result.
Checking Adjustment
1. Open the Top cover and disconnect a staple detection lead, close the Top cover.
2. Hand feed a two sheet set of paper.
NOTE: Open and close the Top cover and the Booklet maker will automatically cycle
and advance staples.
3. Check that the staples are formed properly, according to Figures below.
4. If a bad staple result is achieved, first perform step 1-20, then proceed from step 21.
5. If a good staple result is achieved on two sheets of paper,
double check the adjustment by running a 20 sheet set.
Bad
View from
above
View from
side
Good
Good
Bad
Deformed
Lengthwise
Bad
Deformed
Lengthwise
Adjustment
1. Check/adjust Stapler Assembly Drive Bar (
2. Check/adjust Stapler Pressure (
3.9.4).
4. Check/adjust Clincher points height (
5. Check/adjust Clincher pressure (
Continued on next page....
Deformed
Incorrect
Sidewise
pressure
(
3.9.4)
3.4.15).
3. Check/adjust Stapler Head Retraction distance (
3.9.5).
3.9.6).
3-82
Bad
3.4.13).
21 August 2006
[A]
BOOKLET QUALITY ADJUSTMENT
[B]
[C]
[D]
[E]
[F]
[H]
6. Remove Infeeder (
3.3.3).
7. Disconnect the Staple detection lead [G].
8. Push down latch [E] and lift the Stapler head out.
9. Push the plunger [C] slowly so that the legs of the staple comes out about
1-2 mm.
[I]
[J]
10. Insert the Multi Tool [ I ] so lever [J] becomes pressed down.
11. Reinstall Stapler head only on the pivot pin side. Not in the retraction swing
arm [D].
NOTE: Install the Stapler head gently so the staple legs are not touched.
Continued on next page....
3-83
Replacement
Adjustment
[G]
BOOKLET QUALITY ADJUSTMENT
21 August 2006
12. Push gently on plunger [C] and check if the staple legs are positioned in the
center of the clincher points [K]. Check both sidewise and lengthwise.
NOTE: Use a flash light to clearer see the alignment.
13. Loosens screws [B] and [F] (
x2).
14. For lengthwise adjustment, turn adjustment screw [H].
For sidewise adjustment, turn adjustment screw [A].
NOTE: Push Stapler head bracket against adjustment screw [A] while adjusting sidewise. Push Stapler head bracket upwards while adjusting
lengthwise.
15. When correct position is obtained, tighten screws [F] and [B] ( x2).
NOTE: First tighten screw [F] while pushing Stapler head bracket upwards.
Secondly tighten screw [B] while pushing Stapler head bracket against
screw [A].
16. Repeat procedure for the other Stapler head.
17. Remove Tool [I].
18. Reinstall Infeeder (
3.3.3).
19. Install new stapler heads.
20. Repeat Checking Adjustment.
Staple deformed Lengthwise
21. Loosens screws [B] and [F] (
x2).
[K]
22. Turn Screw [H] maximum 1/8 of a revolution (45°).
NOTE: Turn clockwise if adjusting stapler assembly downwards and vice
versa.
23. Tighten screws [F] and [B] ( x2).
NOTE: First tighten screw [F] while pushing Stapler head bracket upwards.
Secondly tighten screw [B] while pushing Stapler head bracket against
screw [A].
24. Repeat Checking Adjustment.
NOTE: This procedure may need to be performed several times before a good
staple result is achieved.
Staple deformed Sidewise
25. Repeat step 6-20 regarding the sidewise adjustment.
NOTE: Do not loosen screw [F] this time.
3-84
21 August 2006
BOOKLET QUALITY ADJUSTMENT
3.9.4 STAPLER PRESSURE
[C]
70 ± 0,3 mm
[B]
[A]
Removal Front
1. Remove Infeed cover (
2. Remove Stapler heads (
3.3.2 ).
3.4.12 ).
3. Check/adjust the Clincher Pressure (
3.9.6 ).
4. Rotate the motor linkage [A] to the down dead center.
NOTE: Use a 17 mm open wrench.
Adjustment
1. Use a sliding calliper, and check that the distance between the upper side of the clincher
bar, and the upper side of the sheet plate is 70 mm ± 0,3 mm. If not, go to step 2.
NOTE: Check both front and rear side.
2. Loosen screws [B] (
x4 ).
3. Adjust the sheet plate [C] according to step 1.
4. Tighten screws [B] (
x4 ).
5. Check/adjust the Stapler assy drive bar (
6. Check/adjust Stapler head retraction distance (
Replacement
1. Reverse the removal procedure.
3-85
3.4.15 ).
3.4.13).
Replacement
Adjustment
[B]
BOOKLET QUALITY ADJUSTMENT
21 August 2006
3.9.5 CLINCHER POINTS HEIGHT
[A] [B]
Purpose
The purpose is to achieve the correct, flat form of the staples and to maintain lifetime of the clincher points and stapler heads.
NOTE: Adjustment of clincher points can be performed with clincher beam installed. However, if Clincher bar assembly is already removed, perform
Clincher bar assembly adjustment (
3.4.16 ).
Removal Front
1. Remove Stapler heads (
3.4.12 ).
Adjustment
1. Press on the clincher arm where the arrow indicates.
2. Press down the clincher points [A] to make sure that they are resting on the
clincher arm.
3. Check that the clincher points are flush with the upper side of the clincher
beam when actuated. If not, go to step 4.
4. Rotate allen screws [B] to adjust the clincher points ( x2 ).
NOTE: Rotate the allen screw clockwise if the clincher points are located to high. Rotate the allen screw counterclockwise if the clincher points are located to low.
5. Repeat the above procedure until theclincher points are flush with the upper
side of the clincher bar.
Replacement
1. Reverse the removal procedure.
3-86
21 August 2006
BOOKLET QUALITY ADJUSTMENT
3.9.6 CLINCHER PRESSURE
[A]
Replacement
Adjustment
[B]
[C]
[D]
Continued on next page....
3-87
BOOKLET QUALITY ADJUSTMENT
21 August 2006
Purpose
The purpose is to achieve the correct, flat form of the staples.
Removal Front
3.9.5 ).
1. Check/adjust Clincher points height (
2. Remove Infeed cover (
3. Remove Stapler heads (
3.3.2 ).
3.4.12 ).
4. Rotate the motor linkage (see Removal step 4, (
dead center.
3.9.4) to the down
Adjustment
1. Insert the Multi Tool [A] so lever [B] becomes pressed down.
2. Loosen the nut [C] until the bushing [D] can just barely be rotated by hand
(
x1 ).
x1 ).
3. Tighten nut [A] 2 revolutions more (
4. Repeat the procedure on the Rear side of the Booklet maker.
5. Check/adjust Stapler pressure (
6. Reinstall Stapler heads (
3.9.4 ).
3.4.12 ).
7. Run a set of 22 sheets, 80 gsm. Check that the staples are flat. If not, go to
step 8.
8. Tighten the nut [A] ¼ revolutions more (
to step 5.
NOTE: Check/adjust Stapler pressure (
Replacement
1. Reverse the removal procedure.
3-88
x1 ). Check adjustment according
3.9.4 ).
21 August 2006
BOOKLET QUALITY ADJUSTMENT
3.9.7 STAPLE AND FOLD POSITION
Purpose
The purpose is to ensure that the set is folded in the center of the set, and that the
staple is positioned in the center of the set.
Replacement
Adjustment
[A]
[B]
Shown in tipped position for clarity
Initial Action
1. Check/adjust Side Guide Parallelism (
3.9.2 ).
2. Make sure that the value ”Index 3, Rear jogger offset” in EEPROM values, is
the same value as the value on the label in the back of the machine.
3. If not, Change the value in EEPROM values to the value on the label.
4. Set up the Booklet maker for 297x420 mm / 11x17” in Custom size.
NOTE: Do NOT use the preset A3 or 11x17” paper sizes.
5. Hand feed a 2-sheet set, using 297x420 mm / 11x17” paper.
6. Run a few sets.
7. Check that the staples are aligned with fold, and that the fold is in the middle
of the set. If not, go to Adjustment.
Continued on next page....
3-89
BOOKLET QUALITY ADJUSTMENT
21 August 2006
Staple Adjustment:
1. Check/adjust Paper size reset (
5.4 ).
2. Set up the Booklet maker for 297x420 mm / 11x17” in Custom size.
NOTE: Do NOT use the preset A3 or 11x17” paper sizes.
3. Hand feed a 2-sheet set, using 297x420 mm / 11x17” paper.
4. Run a few sets.
5. Check that the staples are in the middle of the set (½ of the input paper size,
210 mm / 8.5”)
6. If the staple position is incorrect, fine adjust by changing ”Index3, Rear jogger
offset” in EEPROM values.
Fold Adjustment:
1. Staple Adjustment must be performed before performing the Fold Adjustment.
2. Loosen screws [A], and rotate screws [B] to adjust the staples to the fold
( x2, x2 ).
NOTE: Rotate both screws [B], same amount of turns, clockwise if the staples are located on the bottom side of the set. Rotate both screws [B],
same amount of turns, counterclockwise if the staples are located on
the top side of the set.
3. Tighten screws [A].
4. Hand feed a 2-sheet set, using 297x420 mm / 11x17” paper.
5. Run a few sets.
6. Check that the staples are aligned with fold. If not, go to step 2.
3-90
21 August 2006
BOOKLET QUALITY ADJUSTMENT
3.9.8 FOLD SKEW
Replacement
Adjustment
[A]
[B]
Shown in tipped position for clarity
Purpose
The purpose is to ensure that the fold is parallel to the edge of the sets.
Adjustment
1. Hand feed a 2-sheet set, using A3/ 11x17” paper.
2. Run a few sets.
3. Check that the fold is parallel to the edge of the set. If not, go to step 4.
x2 ).
4. Loosen screws [A] (
5. Rotate the two screws [B] to adjust the fold pocket (
NOTE: Adjust according to the picture.
[B]
[B]
or
L
x2 ).
or
R
L
R
6. Tighten screws [A] ( x2 ).
NOTE: Push in the fold stop assembly, when tightening the screws.
7. Retrieve a new job, then retrieve the job you where working with.
8. Go to step 1.
3-91
BOOKLET QUALITY ADJUSTMENT
21 August 2006
3.9.9 STAPLE POSITION ON SQUARE FORMED SPINE
Purpose
The purpose is to position the staples on the square formed spine according to
customer preferences. Factory default is within the spine.
[B]
[A]
Shown in tipped position for clarity
[C]
[D]
Adjustment
NOTE: This adjustment will affect all types of booklets!
If the staple position is adjusted on a 20 sheet booklet with Square formed
spine, a big difference will be seen. Staple position will then be “miss
aligned” also on a 2 sheet booklet but the difference will not be as noticeable.
1. Disconnect the Trimmer from the Booklet maker.
2. Loosen lock nut [A] on the fold pocket (
x1 ).
3. Adjust by turning allen screw [B] ( x1 ).
Turn allen screw CW if the staples are on the top edge [C] of the spine.
Turn allen screw CCW if the staples are on the lower side [D] of the spine.
4. Tighten lock nut [A] on the fold pocket (
3-92
x1 ).
21 August 2006
POWER REQUIREMENTS
3.10 POWER REQUIREMENTS
3.10.1 TAPPING THE TRANSFORMER
[D]
[C]
[B]
Transformer in picture tapped for 230V
Purpose
To be able to change the Transformer setting.
Removal
1. Remove screw [A] and renove Transformer cover [B] (
2. Remove Front Cover (
x1 ).
3.3.1 ).
Adjustment
1. Measure the wall outlet voltage.
2. Tap the Transformer to the appropriate setting according to the label on the
Transformer by moving cable [C].
NOTE: Do not move cable [D].
Replacement
1. Reverse the removal procedure.
3-93
Replacement
Adjustment
[A]
Page intentionally blank
19 April 2006
FAULT CODE DESCRIPTIONS
4.
TROUBLESHOOTING
4.1
FAULT CODE DESCRIPITIONS
Item
Fault description
No.
Page
No.
BK-001 BK-M1
Infeed motor No displacement pulses................................................... 4 - 3
BK-002 BK-M1
Infeed motor Short circuit....................................................................... 4 - 3
BK-003 BK-M1
Infeed motor Open circuit....................................................................... 4 - 3
BK-004 BK-M2
Back jogger motor Cycle time out......................................................... 4 - 4
BK-005 BK-M2
Back jogger motor Short circuit............................................................. 4 - 4
BK-006 BK-M2
Back jogger motor Open circuit............................................................. 4 - 5
BK-007 BK-M3
Side jogger motor No displacement pulses.......................................... 4 - 5
BK-008 BK-M3
Side jogger motor Cycle time out.......................................................... 4 - 6
BK-009 BK-M3
Side jogger motor Short circuit.............................................................. 4 - 6
BK-010 BK-M3
Side jogger motor Open circuit.............................................................. 4 - 7
BK-011 BK-M4
Stapler motor Cycle time out.................................................................. 4 - 8
BK-012 BK-M4
Stapler motor Short circuit..................................................................... 4 - 9
BK-013 BK-M4
Stapler motor Open circuit..................................................................... 4 - 9
BK-014 BK-M5
Set transport motor Short circuit........................................................... 4 - 9
BK-015 BK-M5
Set transport motor Open circuit......................................................... 4 - 10
BK-016 BK-M6
Fold roller motor No displacement pulses........................................... 4 -10
BK-017 BK-M6
Fold roller motor Short circuit...............................................................4 - 11
BK-018 BK-M6
Fold roller motor Open circuit...............................................................4 - 11
BK-019 BK-M7
Fold knife motor Cycle time out........................................................... 4 - 12
BK-020 BK-M7
Fold knife motor Short circuit.............................................................. 4 - 12
BK-021 BK-M7
Fold knife motor Open circuit............................................................... 4 - 13
BK-022 BK-M8
Fold stop gate motor Short circuit....................................................... 4 - 13
BK-023 BK-M8
Fold stop gate motor Open circuit....................................................... 4 - 13
BK-024 BK-M9
Staple/Fold positioning motor No displacement pulses.................... 4 - 14
BK-025 BK-M9
Staple/Fold positioning motor Cycle time out.................................... 4 - 15
BK-026 BK-M9
Staple/Fold positioning Short circuit................................................... 4 - 15
BK-027 BK-M9
Staple/Fold positioning Open circuit................................................... 4 - 16
BK-031 BK-SOL1
Stop gate solenoid Open circuit........................................................... 4 - 16
BK-033 BK-SOL2
Stop gate release solenoid Open circuit............................................. 4 - 17
BK-034 BK-Q1
Paper infeed sensor is Faulty............................................................... 4 - 17
BK-035 BK-Q4
Start sensor Saddle stapling is Faulty................................................. 4 - 18
BK-038 BK-Q7
Fold stop sensor is Faulty.................................................................... 4 - 18
BK-039 BK-Q8
Outfeed sensor booklet maker is Faulty............................................. 4 - 19
4-1
Troubleshooting
Fault
code
FAULT CODE DESCRIPTIONS
Fault
code
19 April 2006
Item
Fault description
No.
Page
No.
BK-040 BK-M19/Q34Pre-Infeed Motor No displacement pulses.......................................... 4 - 19
BK-041 BK-M19
Pre-Infeed Motor Short circuit.............................................................. 4 - 20
BK-042 BK-M19
Pre-Infeed Motor Open circuit.............................................................. 4 - 20
BK-043 BK-Q35
Docking Position Sensor Faulty........................................................... 4 - 21
BK-044 BK-Q36
Thick Set Sensor Faulty........................................................................ 4 - 21
BK-045 BK-Q37
Fold Gap Sensor Faulty........................................................................ 4 - 22
BK-150 36V Input
36V Input High........................................................................................ 4 - 22
BK-151 36V Input
36V Input Low........................................................................................ 4 - 23
BK-152 36V Output 36V Output High..................................................................................... 4 - 23
BK-153 36V Output 36V Output Low..................................................................................... 4 - 24
BK-154 24V Output 24V High................................................................................................. 4 - 24
BK-155 24V Output 24V Low ................................................................................................. 4 - 25
BK-156 BK-S16/S17Interlock switch Booklet maker is Faulty............................................ 4 - 25
BK-157 36V Output 36V Output relay faulty.......................................................................... 4 - 26
BK-158 Com
Communication lost.............................................................................. 4 - 26
BK-159 PCB
PCB MD6DC “B” Not connected.......................................................... 4 - 27
BK-160 PCB
PCB MD6DC “C” Not connected.......................................................... 4 - 27
BK-161 PCB
PCB MD3DC “H” Not connected.......................................................... 4 - 27
BK-201 BK-Q1
Paper infeed sensor was Not blocked within timeout........................ 4 - 28
BK-202 BK-Q1
Paper infeed sensor was Blocked exceeding timeout....................... 4 - 28
BK-203 BK-Q4
Start sensor Saddle stapling was Not blocked within timeout......... 4 - 28
BK-204 BK-Q4
Start sensor Saddle stapling was Blocked exceeding timeout......... 4 - 29
BK-207 BK-Q7
Fold stop sensor was Not blocked within timeout............................. 4 - 29
BK-208 BK-Q7
Fold stop sensor was Blocked exceeding timeout............................ 4 - 29
BK-209 BK-Q8
Outfeed sensor was Not blocked within timeout................................ 4 - 30
BK-210 BK-Q8
Outfeed sensor was Blocked exceeding timeout............................... 4 - 30
BK-401
No staples............................................................................................... 4 - 31
ST-001 ST-M1
Stacker motor Short circuit.................................................................. 4 - 32
ST-002 ST-M1
Stacker motor Open circuit................................................................... 4 - 32
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all
machine ground connections, ensuring the proper handling of circuit boards/ sensors
- Use ESD protection when working near PCBs. Failure to use ESD protection is likely to
result in a PCB failure (
3.1 ).
4-2
19 April 2006
FAULT CODE DESCRIPTIONS
BK-001
Fault Code BK-001, indicates that the Infeed motor (BK-M1) does not receive any displacement
pulses.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select Infeed motor (BK-M1) in check motors.
Procedure
Disconnect the sensor plug Q2 to motor BK-M1. Measure between the red wire Q2 and the black wire Q2 (5V and Signal
ground). The voltage is approximately 5 VDC?
Y
N
Disconnect plug B.P14 from PCB “B”. Measure between the J14-13 and J14-15 (5V and Signal ground). The
voltage is approximately 5 VDC?
Y
N
Replace PCB “B”.
Replace wire harness.
Disconnect plug B.P14 from PCB “B”. Check wires for Continuity / Short circuit from the white wire Q2 to B.P14-14,
the black wire Q2 to B.P14-13, the red wire Q2 to B.P14-15. Is there Continuity and no Short circuit?
Y
N
Replace wire harness.
BK-002
Fault Code BK-002, indicates that the Infeed motor (BK-M1) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M1. Run the Diagnostics again. Fault code BK-003 (Open circuit) is displayed?
Y
N
Disconnect plug B.P2 from PCB “B”. Check wires for Short circuit across leads, the orange wire M1 to B.P2-8
(violet) and the violet wire M1 to B.P2-1 (orange). Is there a Short circuit?
Y
N
Replace PCB ”B”.
Replace wire Harness.
Replace motor BK-M1.
BK-003
Fault Code BK-003, indicates that the Infeed motor (BK-M1) has an Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M1. Enter Service mode and start Infeed motor (BK-M1) in check motors. Measure between the
orange wire M1 and the violet wire M1 (PWM 36V and ground). The voltage is approximately 36 VDC?
Y
N
Disconnect plug B.P2 from PCB “B”. Measure between J2-1 and J2-8 (PWM 36V and ground). The voltage is
approximately 36 VDC?
Y
N
Replace PCB “B”.
Replace wire Harness.
Replace motor BK-M1.
4-3
Troubleshooting
1. Replace motor BK-M1.
2. Replace PCB “B”.
FAULT CODE DESCRIPTIONS
19 April 2006
BK-004
Fault Code BK-004, indicates that the Back jogger motor (BK-M2) had a Cycle time out.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select Back jogger motor (BK-M2) in check motors.
Make sure that the Back jogger home position sensor (BK-Q3) is installed correctly.
Procedure
Enter the Service mode and select Back jogger home position sensor (BK-Q3) in check sensors. The back jogger home
position sensor indicates :1 when the sensor is blocked, and :0 when the sensor is unblocked?
Y
N
1. Replace sensor BK-Q3.
2. Disconnect plug C.P13 from PCB “C”. Measure between J13-1 and J13-3 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “C”.
Disconnect plug from sensor BK-Q3. Check wire for Continuity / Short circuit from, the white wire Q3 to C.P13-2. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug C.P13 to PCB “C”. Measure between the red wire Q3 and the black wire Q3 (5V and ground). The
voltage is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “C”.
Turn motor BK-M2 one and a half turn in both directions by hand. You should be able to use about the same amount of force
throughout the turn. Are you able to turn the motor without using a lot of force?
Y
N
Are the two outer back joggers finger in their right position (
3.4.9 Item H)?
Y
N
Position the two outer back jogger fingers in their correct position (
3.4.9).
1. Lubricate were needed.
2. Replace motor BK-M2.
Replace motor BK-M2.
BK-005
Fault Code BK-005, indicates that the Back jogger motor (BK-M2) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M2. Run the Diagnostics again. Fault code BK-006 (Open circuit) is displayed?
Y N
Disconnect plug C.P2 from PCB “C”. Check wires for Short circuit across leads, the orange wire M2 to C.P2-8
(violet) and the violet wire M2 to C.P2-1 (orange). Is there Short circuit?
Y
N
Replace PCB “C”.
Replace wire Harness.
Replace motor BK-M2.
4-4
19 April 2006
FAULT CODE DESCRIPTIONS
BK-006
Fault Code BK-006, indicates that the Back jogger motor (BK-M2) has an Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M2. Enter Service mode and start Back jogger motor (BK-M2) in check motors. Measure between
the orange wire M2 and the violet wire M2 (PWM 36V and ground). The voltage is approximately 36 VDC?
Y
N
Disconnect plug C.P2 from PCB “C”. Start Back jogger motor (BK-M2) in check motors again. Measure between
J2-1 and J2-8 (PWM 36V and ground). The voltage is approximately 36 VDC?
Y
N
Replace PCB “C”.
Replace wire Harness.
Replace motor BK-M2.
Fault Code BK-007, indicates that the Side jogger motor (BK-M3) does not receive any displacement
pulses.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select Side jogger motor (BK-M3) in check motors.
Procedure
Disconnect the sensor plug Q12 to motor BK-M3. Measure between the red wire Q12 and the black wire Q12 (5V and Signal
ground). The voltage is approximately 5 VDC?
Y
N
Disconnect plug C.P14 from PCB “C”. Measure between the J14-6 and J14-8 (5V and Signal ground). The voltage is approximately 5 VDC.
Y
N
Replace PCB “C”.
Replace wire harness.
Disconnect plug C.P14 from PCB “C”. Check wires for Continuity / Short circuit from the gray wire Q12 to C.P14-4,
the white wire Q12 to C.P14-7, the black wire Q12 to C.P14-6, the red wire Q12 to C.P14-8. Is there Continuity and no
Short circuit?
Y
N
Replace wire harness.
1. Replace motor BK-M3.
2. Replace PCB “C”.
4-5
Troubleshooting
BK-007
FAULT CODE DESCRIPTIONS
19 April 2006
BK-008
Fault Code BK-008, indicates that the Side jogger motor (BK-M3) had a Cycle time out.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select Side jogger motor (BK-M3) in check motors.
Make sure that the Side jogger home position sensor (BK-Q13) is installed correctly.
Procedure
Enter the Service mode and select Side jogger home position sensor (BK-Q13) in check sensors. The Side jogger home
position sensor indicates :1 when the sensor is blocked, and :0 when the sensor is unblocked?
Y
N
1. Replace sensor BK-Q13.
2. Disconnect plug C.P13 from PCB “C”. Measure between J13-4 and J13-6 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “C”.
Disconnect plug from sensor BK-Q13. Check wire for Continuity / Short circuit from, the white wire Q13 to
C.P13-5. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug C.P13 to PCB “C”. Measure between the red wire Q13 and the black wire Q13 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “C”.
Is the two outer back jogger fingers in it’s right position (
3.4.9 Item H)?
Y
N
Position the two outer back jogger fingers in their correct position (
3.4.9).
1. Lubricate were needed.
2. Replace motor BK-M3.
BK-009
Fault Code BK-009, indicates that the Side jogger motor (BK-M3) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M3. Run the Diagnostics again. Fault code BK-010 (Open circuit) is displayed?
Y
N
Disconnect plug C.P2 from PCB “C”. Check wires for Short circuit across leads, the orange wire M3 to C.P2-9
(violet) and the violet wire M3 to C.P2-2 (orange). Is there Short circuit?
YN
Replace PCB ”C”.
Replace wire Harness.
Replace motor BK-M3.
4-6
19 April 2006
FAULT CODE DESCRIPTIONS
BK-010
Fault Code BK-010, indicates that the Side jogger motor (BK-M3) has an Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M3. Enter Service mode and start Side jogger motor (BK-M3) in check motors. Measure between
the orange wire M3 and the violet wire M3 (PWM 36V and ground). The voltage is approximately 36 VDC?
Y
N
Disconnect plug C.P2 from PCB “C”. Measure between J2-2 and J2-9 (PWM 36V and ground). The voltage is
approximately 36 VDC?
Y
N
Replace PCB “C”.
Replace wire Harness.
Troubleshooting
Replace motor BK-M3.
4-7
FAULT CODE DESCRIPTIONS
19 April 2006
BK-011
Fault Code BK-011, indicates that the Stapler motor (BK-M4) had a Cycle time out.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select Stapler motor (BK-M4) in check motors.
Make sure that the Stapler home position sensor (BK-Q14) is installed correctly.
Procedure
Enter the Service mode and select Stapler home position sensor (BK-Q14) in check sensors. The Stapler home position
sensor indicates :1 when the sensor is blocked, and :0 when the sensor is unblocked?
Y
N
1. Replace sensor BK-Q14.
2. Disconnect plug C.P13 from PCB “C”. Measure between J13-7 and J13-9 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “C”.
Disconnect plug from sensor BK-Q14. Check wire for Continuity / Short circuit from, the white wire Q14 to
C.P13-8. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug C.P13 to PCB “C”. Measure between the red wire Q14 and the black wire Q14 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “C”.
Is the crank journal correctly mounted (
Y
N
Mount the crank journal correctly (
3.4.14 Item I )?
3.4.14 Item I ).
Remove the stapler heads (
3.4.12.) Does the stapler heads run as they should?
Y
N
1. Make sure that there is no jammed staples in the stapler head.
2. Lubricate the stapler head.
3. Replace stapler head.
Move the right and left Clinch arm up and down. Do they run as they should (
Y
N
1. Remove any jammed staples.
2. Lubricate the Clinch.
3.9.5)?
Remove the link arms to the crank journal. Move the Lower stapler bracket, by hand, up and down. Does it run as it
should?
Y
N
1. Make sure that nothing interferes with the movement.
2. Adjust the stapler assy drive bar (
3.4.15).
Replace motor BK-M4.
4-8
19 April 2006
FAULT CODE DESCRIPTIONS
BK-012
Fault Code BK-012, indicates that the Stapler motor (BK-M4) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M4. Run the Diagnostics again. Fault code BK-013 (Open circuit) is displayed?
Y
N
Disconnect plug C.P3 from PCB “C”. Check wires for Short circuit across leads, the orange wire M4 to
C.P3-7 (violet) and the violet wire M4 to C.P3-6 (orange). Is there Short circuit?
Y
N
Replace PCB “C”.
Replace wire Harness.
Replace motor BK-M4.
BK-013
Procedure
Disconnect the motor plug M4. Enter Service mode and start Stapler motor (BK-M4) in check motors. Measure between the
orange wire M4 and the violet wire M4 (PWM 36V and ground). The voltage is approximately 24 VDC?
Y
N
Disconnect plug C.P3 from PCB “C”. Measure between J3-6 and J3-7 (PWM 36V and ground). The voltage is
approximately 24 VDC?
Y
N
Replace PCB “C”.
Replace wire Harness.
Replace motor BK-M4.
BK-014
Fault Code BK-014, indicates that the Set transport motor (BK-M5) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M5. Run the Diagnostics again. Fault code BK-015 (Open circuit) is displayed?
Y
N
Disconnect plug C.P2 from PCB “C”. Check wires for Short circuit across leads, the orange wire M5 to
C.P2-10 (violet) and the violet wire M5 to P2-3 (orange). Is there Short circuit?
Y
N
Replace PCB “C”.
Replace wire Harness.
Replace motor BK-M5.
4-9
Troubleshooting
Fault Code BK-013, indicates that the Stapler motor (BK-M4) has a Open circuit.
Initial Actions
Check fuse F2 on Transformer.
FAULT CODE DESCRIPTIONS
19 April 2006
BK-015
Fault Code BK-015, indicates that the Set transport motor (BK-M5) has an Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M5. Enter Service mode and Set transport motor (BK-M5) in check motors. Measure between the
orange wire M5 and the violet wire M5 (PWM 36V and ground). The voltage is approximately 36 VDC?
Y
N
Disconnect plug C.P2 from PCB “C”. Measure between J2-3 and J2-10 (PWM 36V and ground). The voltage is
approximately 36 VDC?
Y
N
Replace PCB “C”.
Replace wire Harness.
Replace motor BK-M5.
BK-016
Fault Code BK-016, indicates that the Fold roller motor (BK-M6) does not receive any displacement
pulses.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Fold roller sensor (BK-Q9) is installed correctly (
3.6.7).
Procedure
Enter the Service mode and select Fold roller motor (BK-M6) in check motors. Does the encoder run properly, Parts Catalog
page 24 Item 10
Y
N
1. Check fold transmission (
3.6.7).
2. Replace motor BK-M6.
1. Replace sensor BK-Q9.
2. Disconnect plug C.P14 from PCB “C”. Measure between J14-10 and J14-12 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “B”.
Disconnect plug from sensor Q9. Check wire for Continuity / Short circuit from the white wire Q9 to C.P14-11. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug C.P14 to PCB “C”. Measure between the red wire Q9 and the black wire Q9 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “C”.
4-10
19 April 2006
FAULT CODE DESCRIPTIONS
BK-017
Fault Code BK-017, indicates that the Fold roller motor (BK-M6) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M6. Run the Diagnostics again. Fault code BK-018 (Open circuit) is displayed?
Y
N
Disconnect plug C.P3 from PCB “C”. Check wires for Short circuit across leads the orange wire M6 to
C.P3-3 (violet) and the violet wire M6 to C.P3-2 (orange). Is there Short circuit?
Y
N
Replace PCB “C”.
Replace wire Harness.
Replace motor BK-M6.
BK-018
Procedure
Disconnect the motor plug M6. Enter Service mode and start Fold roller motor (BK-M6) in check motors. Measure between the
orange wire M6 and the violet wire M6 (PWM 36V and ground). The voltage is approximately 19 VDC?
Y
N
Disconnect plug C.P3 from PCB “C”. Measure between J3-2 and J3-3 (PWM 36V and ground). The voltage is
approximately 19 VDC?
Y
N
Replace PCB “C”.
Replace wire Harness.
Replace motor BK-M6.
4-11
Troubleshooting
Fault Code BK-018, indicates that the Fold roller motor (BK-M6) has a Open circuit.
Initial Actions
Check fuse F2 on Transformer.
FAULT CODE DESCRIPTIONS
19 April 2006
BK-019
Fault Code BK-019, indicates that the Fold knife motor (BK-M7) had a Cycle time out.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select Fold knife motor (BK-M7) in check motors.
Make sure that the Fold knife home position sensor (BK-Q15) is installed correctly.
Procedure
Enter the Service mode and select Fold knife home position sensor (BK-Q15) in check sensors. The Fold knife home position
sensor indicates :1 when the sensor is blocked, and :0 when the sensor is unblocked?
Y
N
1. Replace sensor BK-Q15.
2. Disconnect plug B.P13 from PCB “B”. Measure between J13-7 and J13-9 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “B”.
Disconnect plug from sensor BK-Q15. Check wire for Continuity / Short circuit from the white wire Q15 to
B.P13-8. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug B.P13 to PCB “B”. Measure between the red wire Q15 and the black wire Q15 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “B”.
Replace motor BK-M7.
BK-020
Fault Code BK-020, indicates that the Fold knife motor (BK-M7) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M7. Run the Diagnostics again. Fault code BK-021 (Open circuit) is displayed?
Y
N
Disconnect plug B.P3 from PCB “B”. Check wires for Short circuit across leads, the orange wire M7 to B.P3-7
(violet) and the violet wire M7 to B.P3-6 (orange). Is there Short circuit?
Y
N
Replace PCB “B”.
Replace wire Harness.
Replace motor BK-M7.
4-12
19 April 2006
FAULT CODE DESCRIPTIONS
BK-021
Fault Code BK-021, indicates that the Fold knife motor (BK-M7) has an Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M7. Enter Service mode and start Fold knife motor (BK-M7) in check motors. Measure between the orange wire M7 and the violet wire M7 (PWM 36V and ground). The voltage is approximately
19 VDC?
Y
N
Disconnect plug B.P3 from PCB “B”. Measure between J3-6 and J3-7 (PWM 36V and ground). The voltage is
approximately 19 VDC?
Y
N
Replace PCB “B”.
Replace wire Harness.
Replace motor BK-M7.
Fault Code BK-022, indicates that the Fold stop gate motor (BK-M8) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M8. Run the Diagnostics again. Fault code BK-023 (Open circuit) is displayed?
Y
N
Disconnect plug B.P2 from PCB “B”. Check wires for Short circuit across leads, the orange wire M8 to
B.P2-9 (violet) and the violet wire M8 to B.P2-2 (orange). Is there Short circuit?
Y
N
Replace PCB “B”.
Replace wire Harness.
Replace motor BK-M8.
BK-023
Fault Code BK-023, indicates that the Fold stop gate motor (BK-M8) has an Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M8. Enter Service mode and start Fold stop gate motor (BK-M8) in check motors. Measure between
the orange wire M8 and the violet wire M8 (PWM 36V and ground). The voltage is approximately 12 VDC?
Y
N
Disconnect plug P2 from PCB “B”. Measure between J2-2 and J2-9 (PWM 36V and ground). The voltage is
approximately 12 VDC?
Y
N
Replace PCB “B”.
Replace wire Harness.
Replace motor BK-M8.
4-13
Troubleshooting
BK-022
FAULT CODE DESCRIPTIONS
19 April 2006
BK-024
Fault Code BK-024, indicates that the Staple / Fold positioning motor (BK-M9) does not receive any
displacement pulses.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select Staple / Fold positioning motor (BK-M9) in check motors.
Procedure
Disconnect the sensor plug Q10 to motor BK-M9. Measure between the red wire Q10 and the black wire Q10 (5V and Signal
ground). The voltage is approximately 5 VDC?
Y
N
Disconnect plug B.P14 from PCB “B”. Measure between the J14-6 and J14-8 (5V and Signal ground).
The voltage is approximately 5 VDC?
Y
N
Replace PCB “B”.
Replace wire harness.
Disconnect plug B.P14 from PCB “B”. Check wires for Continuity / Short circuit from the gray wire Q10 to B.P14-7,
the white wire Q10 to B.P14-4, the black wire Q10 to B.P14-6, the red wire Q10 to B.P14-8. Is there Continuity and no Short
circuit?
Y
N
Replace wire harness.
1. Replace motor BK-M9.
2. Replace PCB “B”.
4-14
19 April 2006
FAULT CODE DESCRIPTIONS
BK-025
Fault Code BK-025, indicates that the Staple / Fold positioning motor (BK-M9) had a Cycle time
out.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select Staple / Fold positioning motor (BK-M9) in check motors.
Make sure that the Staple / Fold home position sensor (BK-Q11) is installed correctly.
Procedure
Enter the Service mode and select Staple / Fold home position sensor (BK-Q11) in check sensors. The Staple / Fold home
position sensor indicates :1 when the sensor is blocked, and :0 when the sensor is unblocked?
Y
N
1. Replace sensor BK-Q11.
2. Disconnect plug B.P13 from PCB “B”. Measure between J13-4 and J13-6 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “B”.
Connect plug B.P13 to PCB “B”. Measure between the red wire Q11 and the black wire Q11 (5V and ground). The
voltage is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “B”.
Turn the length transmission shaft by hand. Are you able to turn the shaft?
Y
N
Lubricate shaft (
3.6.2).
Pull the length adjustment strap (
3.4.1 Item B) down towards Stapler motor BK-M4. Does it move easily?
Y
N
1. Make sure that nothing interferes with the movement.
2. Lubricate where needed.
1. Lubricate where needed.
2. Replace motor BK-M9.
BK-026
Fault Code BK-026, indicates that the Staple / Fold positioning motor (BK-M9) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M9. Run the Diagnostics again. Fault code BK-027 (Open circuit) is displayed?
Y
N
Disconnect plug B.P2 from PCB “B”. Check wires for Short circuit across leads, the orange wire M9 to B.P2-10
(violet) and the violet wire M9 to B.P2-3 (orange). Is there Short circuit?
Y
N
Replace PCB “B”.
Replace wire Harness.
Replace motor BK-M9.
4-15
Troubleshooting
Disconnect plug from sensor BK-Q11. Check wires for Continuity / Short circuit from the white wire Q11 to
B.P13-5. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
FAULT CODE DESCRIPTIONS
19 April 2006
BK-027
Fault Code BK-027, indicates that the Staple / Fold positioning motor (BK-M9) has an Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M9. Enter Service mode and start Staple / Fold positioning motor (BK-M9) in check motors. Measure
between the orange wire M9 and the violet wire M9 (PWM 36V and ground). The voltage is approximately 36 VDC?
Y
N
Disconnect plug B.P2 from PCB “B”. Measure between J2-3 and J2-10 (PWM 36V and ground). The voltage is
approximately 36 VDC?
Y
N
Replace PCB “B”.
Replace wire Harness.
Replace motor BK-M9.
BK-031
Fault Code BK-031, indicates that the stopgate solenoid has an Open circuit
Initial Actions
Make sure that the connectors are properly connected to the Solenoid.
Check fuse F3 on Transformer
Procedure
Power off the machine. Remove connectors from solenoid SOL1. Measure on the contacts on the Solenoid. Is there an
open circuit?
Y
N
Reinstall connectors. Measure between the violet connector on the solenoid and P2-12 on PCB MD6DC C.
Is there continuity?
Y
N
Replace wire harness.
Measure between the orange connector on the solenoid and P11-1om the interlock PCB. Is there continuity?
Y
N
Replace wire Harness.
Replace PCB MD6DC C.
Replace Solenoid SOL1.
4-16
19 April 2006
FAULT CODE DESCRIPTIONS
BK-033
Fault Code BK-033, indicates that the stopgate release solenoid has an Open circuit
Initial Actions
Make sure that the connectors are properly connected to the Solenoid.
Check fuse F3
Procedure
Power off the machine. Remove connectors from solenoid SOL2. Measure on the contacts on the Solenoid. Is there an
open circuit?
Y
N
Reinstall connectors. Measure between the violet connector on the solenoid and P2-13 on PCB MD6DC C.
Is there continuity?
Y
N
Replace wire harness.
Measure between the orange connector on the solenoid and P11-2 on the interlock PCB. Is there continuity?
Y
N
Replace wire Harness.
Replace PCB MD6DC C.
Troubleshooting
Replace Solenoid SOL2.
BK-034
Fault Code BK-034, indicates that the Paper Infeed sensor (BK-Q1) is faulty.
Initial Actions
Make sure that the Paper Infeed sensor (BK-Q1) is installed correctly.
Procedure
1. Replace sensor BK-Q1.
2. Disconnect plug A.P1 from CPU PCB. Measure between J1-7 and J1-9 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace CPU PCB.
Disconnect plug from sensor BK-Q1. Check wire for Continuity / Short circuit from the white wire Q1 to A.P1-8. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug A.P1 to CPU PCB. Measure between the red wire Q1 and the black wire Q1 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace wire Harness.
Replace CPU PCB.
4-17
FAULT CODE DESCRIPTIONS
19 April 2006
BK-035
Fault Code BK-035, indicates that the Start sensor, Saddle stapling sensor (BK-Q4) is faulty.
Initial Actions
Make sure that the Start sensor, Saddle stapling sensor (BK-Q4) is installed correctly.
Procedure
1. Replace sensor BK-Q4.
2. Disconnect plug A.P1 from CPU PCB. Measure between J1-4 and J1-6 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace CPU PCB.
Disconnect plug from sensor BK-Q4. Check wire for Continuity / Short circuit from the white wire Q4 to A.P1-5. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug A.P1 to CPU PCB. Measure between the red wire Q4 and the black wire Q4 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace wire Harness.
Replace CPU PCB.
BK-038
Fault Code BK-038, indicates that the Fold stop sensor (BK-Q7) is faulty.
Initial Actions
Make sure that the Fold stop sensor (BK-Q7) is installed correctly.
Procedure
1. Replace sensor BK-Q7.
2. Disconnect plug A.P1 from CPU PCB. Measure between J1-10 and J1-12 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace CPU PCB.
Disconnect plug from sensor BK-Q7. Check wire for Continuity / Short circuit from the white wire Q7 to A.P1-11. Is there
Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug A.P1 to CPU PCB. Measure between the red wire Q7 and the black wire Q7 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace wire Harness.
Replace CPU PCB.
4-18
19 April 2006
FAULT CODE DESCRIPTIONS
BK-039
Fault Code BK-039, indicates that the Outfeed sensor Booklet maker (BK-Q8) is faulty.
Initial Actions
Make sure that the Outfeed sensor Booklet maker (BK-Q8) is installed correctly.
Procedure
1. Replace sensor BK-Q8.
2. Disconnect plug A.P1 from CPU PCB. Measure between J1-17 and J1-19 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace CPU PCB.
Disconnect plug from sensor BK-Q8. Check wire for Continuity / Short circuit from the white wire Q8 to A.P1-18. Is there
Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug A.P1 to CPU PCB. Measure between the red wire Q8 and the black wire Q8 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace wire Harness.
BK-040
Fault Code BK-040, indicates that the Pre-Infeed Motor (BK-M19) does not receive any displacement
pulses.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select Pre-Infeed Motor (BK-M19) in check motors.
Procedure
Disconnect the sensor plug Q34 to motor BK-M19. Measure between the red wire Q34 and the black wire Q34 (5V and Signal
ground). The voltage is approximately 5 VDC?
Y
N
Disconnect plug H.P14 from PCB “H”. Measure between the J14-15 and J14-13 (5V and Signal ground). The voltage is approximately 5 VDC.
YN
Replace PCB “H”.
Replace wire harness.
Disconnect plug H.P14 from PCB “H”. Check wires for Continuity / Short circuit from the white wire Q34 to H.P14-14,
the black wire Q34 to H.P14-13, the red wire Q34 to H.P14-15. Is there Continuity and no Short circuit?
Y
N
Replace wire harness.
1. Replace motor BK-M19.
2. Replace PCB “H”.
4-19
Troubleshooting
Replace PCB.
FAULT CODE DESCRIPTIONS
19 April 2006
BK-041
Fault Code BK-041, indicates that the Pre-Infeed Motor (BK-M19) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M19. Run the Diagnostics again. Fault code BK-042 (Open circuit) is displayed?
Y N
Disconnect plug H.P2 from PCB “H”. Check wires for Short circuit across leads the orange wire M19 to H.P2-1
and the violet wire M19 to H.P2-8. Is there Short circuit?
Y
N
Replace PCB “H”.
Replace wire Harness.
Replace motor BK-M19.
BK-042
Fault Code BK-042, indicates that the Pre-Infeed Motor (BK-M19) has an Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M19. Enter Service mode and start Pre-Infeed Motor (BK-M19) in check motors. Measure between
the orange wire M19 and the violet wire M19 (PWM 36V and ground). The voltage is approximately 36 VDC?
Y
N
Disconnect plug H.P2 from PCB “H”. Start Pre-Infeed Motor (BK-M19) in check motors again. Measure between
J2-1 and J2-8 (PWM 36V and ground). The voltage is approximately 36 VDC?
Y
N
Replace PCB “H”.
Replace wire Harness.
Replace motor BK-M19.
4-20
19 April 2006
FAULT CODE DESCRIPTIONS
BK-043
Fault Code BK-043, indicates that the Docking Position Sensor (BK-Q35) is faulty.
Initial Actions
Make sure that the Docking Position Sensor (BK-Q35) is installed correctly.
Procedure
1. Replace sensor BK-Q35.
2. Disconnect plug F.P6 from Addon PCB. Measure between J6-1 and J6-3 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace Addon PCB.
Disconnect plug from sensor BK-Q35. Check wire for Continuity / Short circuit from the white wire Q35 to F.P6-2. Is there
Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug F.P6 to Addon PCB. Measure between the red wire Q35 and the black wire Q35 (5V and ground). The voltage
is approximately 5 VDC?
Y
N
Replace wire Harness.
Troubleshooting
Replace Addon PCB.
BK-044
Fault Code BK-044, indicates that the Thick Set Sensor (BK-Q36) is faulty.
Initial Actions
Make sure that the Thick Set Sensor (BK-Q36) is installed correctly.
Procedure
1. Replace sensor BK-Q36.
2. Disconnect plug F.P2 from Addon PCB. Measure between J2-1 and J2-4 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace Addon PCB.
Disconnect plug from sensor BK-Q36. Check wire for Continuity / Short circuit from the white wire Q36 to F.P2-3. Is there
Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug F.P2 to Addon PCB. Measure between the red wire Q36 and the black wire Q36 (5V and ground). The voltage
is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace Addon PCB.
4-21
FAULT CODE DESCRIPTIONS
19 April 2006
BK-045
Fault Code BK-045, indicates that the Fold Gap Sensor (BK-Q37) is faulty.
Initial Actions
Make sure that the Fold Gap Sensor (BK-Q37) is installed correctly.
Procedure
1. Replace sensor BK-Q37.
2. Disconnect plug F.P3 from Addon PCB. Measure between J3-2 and J3-4 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace Addon PCB.
Disconnect plug from sensor BK-Q37. Check wire for Continuity / Short circuit from the white wire Q37 to F.P3-3. Is there
Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug F.P3 to Addon PCB. Measure between the red wire Q37 and the black wire Q37 (5V and ground). The voltage
is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace Addon PCB.
BK-150
Fault Code BK-150, indicates that the 36V input is high
Initial Actions
Make sure that contact P8 on interlock PCB is correctly installed.
Make sure that contact P12 on controller PCB is correctly installed
Make sure that the transformer in the machine is wired correcly.
Procedure
Power on machine. Measure incoming voltage on Rectifier (White and Blue). The voltage is approximately 26V?
Y
N
Replace transformer
Measure outgoing voltage on rectifier (Red and Black). The voltage is approximately 36V?
Y
N
Replace Rectifier.
Power off the machine. Measure between the black connector on the Rectifier and P6-3 on interlock PCB. Is there continuity?
Y
N
Replace wire Harness.
Measure between the red connector on the Rectifier and P6-1 on interlock PCB. Is there continuity?
Y
N
Replace wire harness.
Replace interlock PCB.
4-22
19 April 2006
FAULT CODE DESCRIPTIONS
BK-151
Fault Code BK-151, indicates that the 36V input is low.
Initial Actions
Check fuse F3.
Check the Voltage protection plug P7 on the interlock PCB. The resistance must be grater than MOhm.
Make sure that contact P8 on interlock PCB is correctly installed.
Make sure that contact P12 on controller PCB is correctly installed
Make sure that the transformer in the machine is wired correctly.
Procedure
Measure incoming voltage on Rectifier (White and Blue). The voltage is approximately 26V?
Y
N
Replace transformer
Measure outgoing voltage on rectifier (Red and Black). The voltage is approximately 36V?
Y
N
Replace Rectifier.
Measure between the red connector on the Rectifier and P6-1 on interlock PCB. Is there continuity?
Y
N
Replace wire harness.
Replace interlock PCB.
BK-152
Fault Code BK-152, indicates that the 36V output is high.
Procedure
Power on machine and close covers. Measure between P6-1 and P6-3 on the interlock PCB.
The voltage is approximately 36V.
Y
N
The voltage is more than 43V?
Y
N
The voltage is less than 26V?
Y
N
Replace the interlock PCB.
Go to 36V output low Fault code description BK153.
Go to 36V input high Fault code description BK150.
Measure between P4-1 and P4-2 on the interlock PCB. The voltage is more than 43V?
Y
N
The voltage is less than 26V?
Y
N
Replace the interlock PCB.
Go to 36V output low Fault code description BK153.
Replace the interlock PCB.
4-23
Troubleshooting
Power off the machine. Measure between the black connector on the Rectifier and P6-3 on interlock PCB.
Is there continuity?
Y
N
Replace wire Harness.
FAULT CODE DESCRIPTIONS
19 April 2006
BK-153
Fault Code BK-153, indicates that the 36V output is low.
Initial Actions
Make sure that all the connectors are properly installed on the interlock PCB
Procedure
Power on machine and close covers. Measure between P6-1 and P6-3 on the interlock PCB. The voltage is approximately 36V.
Y
N
The voltage is less than26V?
Y
N
The voltage is more than 43V?
Y
N
Replace the interlock PCB.
Go to 36V output high Fault code description BK150.
Go to 36V input low Fault code description BK151.
Measure between P4-1 and P4-2 on the interlock PCB. The voltage is less than 26V?
Y
N
The voltage is more than 43V?
Y
N
Replace the interlock PCB.
Go to 36V output high Fault code description BK152.
Replace the interlock PCB.
BK-154
Fault Code BK-154, indicates that the 24V output is high.
Initial Actions
Make sure that all the connectors are properly installed on the BK5010 interlock PCB.
Enter Service mode, and run Trimmer motors M5/6, make sure that they run correctly.
Procedure
Power on machine and close covers. Measure between J14-11 and J14-8 and between J12-11 and J12-8 on the interlock
PCB. The voltage is approximately 24V at both measurements.
Y
N
Measure between J6-1 and J6-3 on the interlock PCB. The voltage is approximately 36V.
Y
N
The voltage is more than 43V.
Y
N
The voltage is less than 26V.
Y
N
Replace the interlock PCB.
Go to 36 V input low Fault code description BK151.
Go to 36 V input high Fault code description BK150.
Replace the interlock PCB.
Replace the interlock PCB.
4-24
19 April 2006
FAULT CODE DESCRIPTIONS
BK-155
Fault Code BK-155, indicates that the 24V output is low.
Initial Actions
Make sure that all the connectors are properly installed on the BK5010 interlock PCB.
Enter Service mode, and run Trimmer motors M5/6, make sure that they run correctly.
Procedure
Power on machine and close covers. Measure between J14-11 and J14-8 on the interlock PCB. The voltage is approximately 24V.
Y
N
Measure between J6-1 and J6-3 on the interlock PCB. The voltage is approximately 36V.
Y
N
The voltage is more than 43V.
Y
N
The voltage is less than 26V.
Y
N
Replace the interlock PCB.
Go to 36 V input low Fault code description BK151.
Go to 36 V input high Fault code description BK150.
Replace the interlock PCB.
Troubleshooting
Replace the interlock PCB.
BK-156
Fault Code BK-156, indicates that one of the interlock switches in the system is faulty.
Initial Actions
Check that the Transformer is tapped to the correct voltage (
3.10.1 ).
If a trimmer is not installed, make sure that the interlock jumper (Parts Catalog page 8, Item 7) is
installed in the BK5010.
If a trimmer is installed, make sure that the interlock jumper (Parts Catalog page 8, Item 7) is installed
in the TR5010.
Make sure that all the connectors to the interlock switches are properly installed.
Procedure
Use interlock cheaters to close all covers. Measure between P1-1 and P1-2 on the BK5010 Interlock PCB. Is there continuity?
Y
N
Replace the BK5010 interlock switch.
Measure between P1-4 and P1-5 on the BK5010 interlock. Is there an open circuit?
Y
N
Replace the BK5010 interlock switch.
Measure between P1-1 and P1-2 on the TR5010 interlock. Is there continuity?
Y
N
Replace the TR5010 interlock switch.
Measure between P1-4 and P1-5 on the TR5010 interlock. Is there an open circuit?
Y
N
Replace the TR5010 interlock switch.
Replace the interlock PCB.
4-25
FAULT CODE DESCRIPTIONS
19 April 2006
BK-157
Fault Code BK-157, indicates that the 36V output relay is faulty.
Initial Actions
Check fuse F2.
Procedure
Power on machine. Measure between P6-1 and P6-3 on the Interlock PCB. The voltage is approximately 36VDC.
Y
N
The voltage is less than 26VDC.
Y
N
The voltage is more than 43V.
Y
N
Replace Interlock PCB.
Go to 36V input high Fault code description BK150.
Go to 36V input low Fault code description BK151.
Measure between J5-1 and J5-2. The voltage is approximately 36VDC.
Y
N
The voltage is less than 26VDC.
Y
N
The voltage is more than 43V.
Y
N
Replace Interlock PCB.
Go to 36V output high Fault code description BK152.
Go to 36V output low Fault code description BK153.
Replace Interlock PCB.
BK-158
Fault Code BK-158, indicates that there is a communication lost problem.
Initial Actions
Make sure that the communication cable between the BK5010 and the TR5010 is properly connected.
Make sure that the communication cable between the BK5010 and the CF5010 is properly connected.
Procedure
Power off the machine. Remove all connectors to the TR5010. Power on the machine. Is there still communication lost?
Y
N
Replace the communication cable between the BK5010 and the TR5010.
Power off the machine. Remove all connectors to the CF5010. Power on the machine. Is there still communication lost?
Y
N
Replace the communication cable between the BK5010 and the CF5010.
Replace the Interlock PCB.
4-26
19 April 2006
FAULT CODE DESCRIPTIONS
BK-159
Fault Code BK-159, indicates that the PCB MD6DC B is not connected.
Initial Actions
Make sure that all connectors are properly connected to PCB MD6DC B.
Make sure that the dipswitches on the PCB are set correctly (
Procedure
5.2.1).
Power off the machine. Measure for continuity between P4-1 on MD6DC B PCB and P5-1 on MD6DC C PCB. Is there continuity?
Y
N
Replace wire harness.
Measure for continuity between P4-2 on MD6DC B PCB and P5-2 on MD6DC C PCB. Is there continuity?
Y
N
Replace wire harness.
Replace MD6DC B PCB.
Fault Code BK-160, indicates that the PCB MD6DC C is not connected.
Initial Actions
Make sure that all connectors are properly connected to PCB MD6DC C.
Make sure that the dipswitches on the PCB are set correctly (
Procedure
5.2.2).
Power off the machine. Measure for continuity between P4-1 on MD6DC C PCB and P2-1 on Controller PCB. Is there continuity?
Y
N
Replace wire harness.
Measure for continuity between P4-2 on MD6DC C PCB and P2-2 on Controller PCB. Is there continuity?
Y
N
Replace wire harness.
Replace MD6DC B PCB. BK-161
Fault Code BK-161, indicates that the PCB MD3DC H is not connected.
Initial Actions
Make sure that all connectors are properly connected to PCB MD3DC H.
Make sure that the dipswitches on the PCB are set correctly (
Procedure
5.2.4).
Power off the machine. Measure for continuity between P4-1 on MD3DC H PCB and P5-1 on MD6DC B PCB. Is there continuity?
Y
N
Replace wire harness.
Measure for continuity between P4-2 on MD6DC C PCB and P5-2 on MD6DC B PCB. Is there continuity?
Y
N
Replace wire harness.
Replace MD6DC B PCB. 4-27
Troubleshooting
BK-160
FAULT CODE DESCRIPTIONS
19 April 2006
BK-201
Fault Code BK-201, indicates that during a run, the Paper infeed sensor (BK-Q1), was not blocked
within timeout after the start signal from the copier was detected.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Paper infeed sensor (BK-Q1) is installed correctly.
Ensure that the Paper infeed sensor (BK-Q1) is clean.
Procedure
Enter the Service mode and select Paper infeed sensor (BK-Q1) in check sensors. Block, then unblock, the BK-Q1 with
a sheet of paper. The Paper infeed sensor (BK-Q1) sensor indicates :0 when the sensor is blocked, and :1 when
the sensor is not blocked.
Y
N
Go to BK-034 fault code.
1. Make sure that nothing interferes with the paper coming out from the copier and going in to the Booklet maker.
2. Make sure that nothing interferes with the paper path in the Booklet maker.
3. Make sure that the Booklet maker is correctly installed.
BK-202
Fault Code BK-202, indicates that at “initialization” or during a run, the Paper infeed sensor (BK-Q1),
was blocked exceeding timeout.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Paper infeed sensor (BK-Q1) is installed correctly.
Ensure that the Paper infeed sensor (BK-Q1) is clean.
Procedure
Enter the Service mode and select Paper infeed sensor (BK-Q1) in check sensors. Block, then unblock, the BK-Q1 with a
sheet of paper. The Paper infeed sensor (BK-Q1) sensor indicates :0 when the sensor is blocked, and :1 when the
sensor is not blocked.
Y
N
Go to BK-034 fault code.
Make sure that nothing interferes with the paper path.
BK-203
Fault Code BK-203, indicates that during a run, the Start sensor Saddle stapling (BK-Q4), was not
blocked within timeout.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Start sensor Saddle stapling (BK-Q4) is installed correctly.
Ensure that the Start sensor Saddle stapling (BK-Q4) is clean.
Procedure
Enter the Service mode and select Start sensor Saddle stapling (BK-Q4) in check sensors. Block, then unblock, the BKQ4 with a sheet of paper. The Start sensor Saddle stapling (BK-Q4) sensor indicates :0 when the sensor is blocked,
and :1 when the sensor is not blocked.
Y
N
Go to BK-035 fault code.
Make sure that nothing interferes with the paper path.
4-28
19 April 2006
FAULT CODE DESCRIPTIONS
BK-204
Fault Code BK-204, indicates that at “initialization” or during a run, the Start sensor Saddle stapling
(BK-Q4), was blocked, exceeding timeout.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Start sensor Saddle stapling (BK-Q4) is installed correctly.
Ensure that the Start sensor Saddle stapling (BK-Q4) is clean.
Procedure
Enter the Service mode and select Start sensor Saddle stapling (BK-Q4) in check sensors. Block, then unblock, the BKQ4 with a sheet of paper. The Start sensor Saddle stapling (BK-Q4) sensor indicates :0 when the sensor is blocked,
and :1 when the sensor is not blocked.
Y
N
Go to BK-035 fault code.
Make sure that nothing interferes with the paper path.
Fault Code BK-207, indicates that during a run, the Fold stop sensor (BK-Q7), was not blocked
within timeout.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Fold stop sensor (BK-Q7) is installed correctly.
Ensure that the Fold stop sensor (BK-Q7) is clean.
Procedure
Enter the Service mode and select Fold stop sensor (BK-Q7) in check sensors. Block, then unblock, the BK-Q7 with a sheet
of paper. The Fold stop sensor (BK-Q7) sensor indicates :0 when the sensor is blocked, and :1 when the sensor is
not blocked.
Y
N
Go to BK-038 fault code.
Make sure that nothing interferes with the paper path.
BK-208
Fault Code BK-208, indicates that at “initialization” or during a run, the Fold stop sensor (BK-Q7),
was blocked exceeding timeout.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Fold stop sensor (BK-Q7) is installed correctly.
Ensure that the Fold stop sensor (BK-Q7) is clean.
Procedure
Enter the Service mode and select Fold stop sensor (BK-Q7) in check sensors. Block, then unblock, the BK-Q7 with a sheet
of paper. The Fold stop sensor (BK-Q7) sensor indicates :0 when the sensor is blocked, and :1 when the sensor is
not blocked.
Y
N
Go to BK-038 fault code.
Make sure that nothing interferes with the paper path.
4-29
Troubleshooting
BK-207
FAULT CODE DESCRIPTIONS
19 April 2006
BK-209
Fault Code BK-209, indicates that during a run, the Outfeed sensor Booklet maker (BK-Q8), was not
blocked within timeout.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Outfeed sensor Booklet maker (BK-Q8) is installed correctly.
Ensure that the Outfeed sensor Booklet maker (BK-Q8) is clean.
Procedure
Enter the Service mode and select Outfeed sensor Booklet maker (BK-Q8) in check sensors. Block, then unblock, the BK-Q8
with a sheet of paper. The Outfeed sensor Booklet maker (BK-Q8) sensor indicates :0 when the sensor is blocked,
and :1 when the sensor is not blocked.
Y
N
Go to BK-039 fault code.
Make sure that nothing interferes with the paper path.
BK-210
Fault Code BK-210, indicates that at “initialization” or during a run, the Outfeed sensor Booklet maker
(BK-Q8), was blocked exceeding timeout.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Outfeed sensor Booklet maker (BK-Q8) is installed correctly.
Ensure that the Outfeed sensor Booklet maker (BK-Q8) is clean.
Procedure
Enter the Service mode and select Outfeed sensor Booklet maker (BK-Q8) in check sensors. Block, then unblock, the BK-Q8
with a sheet of paper. The Outfeed sensor Booklet maker (BK-Q8) sensor indicates :0 when the sensor is blocked,
and :1 when the sensor is not blocked.
Y
N
Go to BK-039 fault code.
Make sure that nothing interferes with the paper path.
4-30
19 April 2006
FAULT CODE DESCRIPTIONS
BK-401
Fault Code BK-401, indicates that the stapler head is faulty.
Initial Actions
3.4.12 ).
Check stapler head (
Procedure
Disconnect the connectors to the stapler heads. Disconnect plug A.P1 from CPU PCB. Check wire for Continuity / Short circuit
from the rear stapler head lead to the A.P1-24 and the front stapler head lead to the A.P1-15. Is there Continuity and no Short
circuit?
Y
N
Replace wire Harness.
Troubleshooting
Replace CPU PCB.
4-31
FAULT CODE DESCRIPTIONS
19 April 2006
ST-001
Fault Code ST-001, indicates that the Stacker motor (ST-M1) has a Short circuit.
Initial Actions
Make sure that the connectors are properly installed on the stacker motor.
Procedure
Disconnect the motor plug M1. Run the Diagnostics again. Fault code ST-002 (Open circuit) is displayed?
Y
N
Disconnect plug P2 from PCB “B”. Check wires for Short circuit across leads the red wire M1 to P2-11 (violet) and
the black wire M1 to P2-4 (orange). Is there Short circuit?
Y
N
Replace PCB “B”.
Replace wire Harness.
Replace motor ST-M1.
ST-002
Fault Code ST-002, indicates that the Stacker motor (ST-M1) has an Open circuit.
Initial Actions
Make sure that the connectors are properly installed on the stacker motor.
Procedure
Disconnect the motor plug M1. Enter Service mode and start Stacker motor (ST-M1) in check motors. Measure between the
red wire M1 and the black wire M1 (24V and ground). The voltage is approximately 24? VDC?
Y
N
Disconnect plug P2 from PCB “B”. Measure between J2-4 and J2-11 (24V and ground). The voltage is
approximately 24? VDC?
Y
N
Replace PCB “B”.
Replace wire Harness.
Replace motor ST-M1.
4-32
19 April 2006
4.2
BLOWN FUSE CONDITIONS
BLOWN FUSE CONDITIONS
WARNING
ONLY USE SLOW BLOW FUSES.
Fuse Sec.
Symptom at power on
5A
No response
F1
6.1.3
F2 6.1.1
16A
Normal display function but no operations in
the machine are possible
F3
6.1.1
2A
No response
F4
6.1.1
2A
Not in use
4-33
Troubleshooting
Rating
Page intentionally blank
19 April 2006
4.3
LEDS
LEDS
Motor Drive PCB (MD6DC) in Booklet Maker & Trimmer
D1
D2
D1: Yellow LED flashes when power is on. The flashing indicates that a program is
present and functioning. Should a download fail or the 5V is missing, LED would be
OFF.
D2: Red LED flashes whenever information is sent or received on the Internal CAN.
If power is switched on but no operations are performed, LED is OFF.
D15: Green LED permanently OFF. It has no direct function in this configuration.
4-35
Troubleshooting
D15
LEDS
19 April 2006
Motor Drive PCB (MD3DC) in Booklet Maker
D26
D1 (B)
D2 (A)
D1: Red LED flashes when power is on. The flashing indicates that a program is
present and functioning. Should a download fail or the 5V is missing, LED would be
OFF.
D2: Yellow LED flashes whenever information is sent or received on the Internal CAN.
If power is switched on but no operations are performed, LED is OFF.
D26: Red LED lights to indicate that power to sensors is present.
4-36
19 April 2006
LEDS
CPU PCB in Booklet Maker
D5: Yellow LED flashes when power is on. The flashing indicates that a program is
present and functioning. Should a download fail or the 5V is missing, Yellow LED
would be OFF.
4-37
Troubleshooting
D5
LEDS
19 April 2006
Interlock PCB in Booklet Maker
Green By
PGND
(TP2)
D9
D6
+UNREG
TP1
+24V
D7
D6: Red LED is ON when unregulated 36V is present. If machine is interlocked (i.e.
the top cover is open and 36V is cut off) or 36V is missing, LED is OFF.
The unregulated 36V can be measured between +UNREG Test Point and PGND
Test Point.
D7: Red LED is ON when 24V is present. If machine is interlocked (i.e. the top cover
is open) LED will still be ON.
It will also be ON if 36V is present but not 24V. In such a case the 24V stabilizing circuit on the Interlock PCB would be defective. To establish that actual 24V is present,
measure between +24V Test Point and PGND Test Point.
D9: At power up, input power is checked to be within allowed range. If input voltage is too high or too low a fault is presented to the operator and machine will be
inoperable. If the input voltage is within allowed range the interlock relay is activated. When interlock relay is activated the LED D9 is ON. If an interlock relay
fault is detected, that is presented to the operator and machine will be inoperable.
During normal operation the LED D9 is ON when covers are closed. If a cover is open
LED D9 is OFF. Note that the fault codes are only visable in operator mode.
4-38
19 April 2006
LEDS
Copier Interface PCB in Booket Maker
D8 D7 D6 D5 D4 D3 D2 D1
D9 D10 D11 D12 D13 D14 D15 D16
D1 - D8 are signals from BK5010
D9 - D16 are signals from Copier
D2, D3, D6-D8, D13-D16: Not used.
D1: Connection detect. Power on BK5010 is switched on. Docking sensor is activated (machines are docked). BK5010 indicates connection to Copier. Icon on
Copier UI pops up.
D4: Hard stop from BK5010. Copier stops immediately (such as when top cover
opens).
D5: Soft stop from BK5010. Copier cycles out (such as when stacker is full).
D9: Start signal from copier. Papers are exiting Copier entering BK5010
D10-D12: Paper size indicators. A binary pattern between the three LEDs shows the
paper size sent from the copier.
A3
A4
11x17”
8.5x11”
8.5x14”
JIS B4
D10
ON
ON
ON
ON
D11
ON
ON
ON
Note: The LED illuminates throughout the duration of the signal.
4-39
D12
ON
ON
Troubleshooting
Green B
Page intentionally blank
TEST POINTS
19 April 2006
4.4
TEST POINTS
Motor Drive PCB (MD6DC) in Booklet Maker & Trimmer
+UNREG
GND/
PGND
Troubleshooting
VCC
+UNREG: Outgoing unregulated 36V, after interlock relay. Measure between Test
Point +UNREG and Test Point GND/PGND using a voltmeter. The voltage will be
shown on the voltmeter unless:
- Voltage is outside allowed range 29-43V. Voltage will be 0V.
- Machine is interlocked (i.e. the top cover is open). Voltage will be 0V.
VCC: Stabilised and rectified 5V made from incoming 10V AC from transformer.
- Measure between Test Point VCC and Test Point GND/PGND using a voltmeter.
The voltage will be shown on the voltmeter. Range 4.9-5.1V.
GND / PGND: Ground /Power Ground is the minus when measuring either unregulated 36V (+UNREG) or 5V (VCC).
4-41
TEST POINTS
19 April 2006
Motor Drive PCB (MD3DC) in Booklet Maker
GND/
PGND
VCC
VCC: Stabilized and rectified 5V made from incoming 10V AC from transformer.
Measure between Test Point VCC and Test Point GND/PGND using a voltmeter. The
voltage will be shown on the voltmeter. Range 4.9-5.1V.
GND / PGND: Ground /Power Ground is the minus when measuring 5V (VCC).
4-42
TEST POINTS
19 April 2006
CPU PCB in Booklet Maker
GND /
PGND
VCC
Troubleshooting
R41
VCC: Stabilized and rectified 5V made from incoming 10V AC from transformer.
Measure between Test Point VCC and Test Point GND/PGND using a voltmeter. The
voltage will be shown on the voltmeter. Range 4.9-5.1V.
GND: Ground is the minus when measuring 5V (VCC).
R41: Trim Potentiometer for Contrast setting of the LCD.
4-43
TEST POINTS
19 April 2006
Interlock PCB in Booklet Maker
TP1
PGND (TP2)
Green By
+UNREG
+24V
TP1: Incoming unregulated 36V, before interlock relay. Measure between Test Point
TP1 and Test Point PGND using a voltmeter. The voltage will be shown on the voltmeter regardless of the voltage being outside allowed range 29-43V.
+UNREG: Outgoing unregulated 36V, after interlock relay. Measure between Test
Point +UNREG and Test Point PGND using a voltmeter. The voltage will be shown
on the voltmeter unless:
- Voltage is outside allowed range 29-43V. Voltage will be 0V.
- Machine is interlocked (i.e. the top cover is open). Voltage will be 0V.
+24V: Stabilised 24V made from incoming unregulated 36V, before interlock relay.
Measure between Test Point +24V and Test Point PGND using a voltmeter. The voltage will be shown on the voltmeter. Range 23-25V.
PGND (TP2): Power Ground is the minus when measuring either unregulated 36V
(+UNREG) or 24V (+24V).
4-44
TEST POINTS
19 April 2006
GND
GND / PGND: Ground /Power Ground is the minus
4-45
Troubleshooting
Addon PCB in Booklet Maker
Page intentionally blank
21 August 2006
5.
SERVICE PROGRAM MODE
SERVICE TABLES
CAUTION
Never turn off the main power when motors are cycling. To avoid damaging
the circuitry, stop the motor/motors running under the Check Motors menu,
and then switch the main power off.
5.1
SERVICE PROGRAM MODE
5.1.1 SERVICE PROGRAM MODE OPERATIONS
The Service Program (SP) mode is used to check electrical data, check electrical
components and adjust values. One service program mode is provided and controlled
from the UI (User Interface) on the booklet maker. Peripheral units are embedded
in this service program. Where applicable, a sub menu appears after a function is
selected listing the peripherals.
Entering and Exiting the SP mode
Exit
Exit
)
1. Press the Tools button.
NOTE: Insert interlock cheater if +UNREG (voltage for motors) is needed.
2. With the Arrow key, select Service access and press the OK
button.
3. Key in password: 107 (using the Arrow and Change button).
4. Press the OK button.
5. Switch off the main power to exit the Service mode or press
the ESC button to exit the Service mode and enter the operator mode.
1. Make sure the main power is switched off.
NOTE: Insert interlock cheater if +UNREG (voltage for motors) is needed.
2. Press and hold the left hand button on the Control Panel.
3. Switch on the main power switch.
4. Release the button on the Control Panel.
NOTE: When entering the SP mode this way, the machine will reset the password to the default value 107.
5. Key in password: 107 (using the Arrow and Change button)
6. Press the OK button.
7. Switch off the main power to exit the Service mode or press
the ESC button to exit the Service mode and enter the operator mode.
5-1
Service
Tables
There are two ways to enter the service mode either from the operator mode (
or directly from switched off machine ( ).
SERVICE PROGRAM MODE
21 August 2006
Checking Motors and Solenoids
1. Go to Check Motors or Check Solenoids. Press OK.
2. Go to the unit in which the motor/solenoid to be checked is
located. Press OK.
3. Go to the motor/solenoid to be checked. Press OK.
4. Press Arrow (two arrows appear if motor is bi-directional) to start
the motor (symbol appears if motor is off).
Press Cycle button (motors with defined positions only) to let the
motor perform one working cycle.
NOTE: Motors with defined positions also shows status (H:1 or H:0)
of corresponding sensor.
5. Press Stop to stop the motor (symbol appears if motor is running).
Press ESC to exit that motor check, which leaves it running.
NOTE: When checking BM-M9, you have to press the cycle button before
being able to press the Arrow buttons (To get the position of the motor).
NOTE: For safety reasons you have to press the unlock button to be able to
start TR-M2. You have to press the unlock button between every cycle.
Checking Sensors
All sensors can individually be checked by blocking/unblocking sensors. While
blocking/unblocking, view the display for response. Displayed is the state by :1 or
:0. Which state corresponding to blocked/unblocked is depending on whether the
sensor has inverted function or not.
For status definition, see Service Program Mode Tables 5.1.2.
Running Dead Cycling (free run)
Dead cycling is a modified machine cycle. All functions in the machine are run such
as motors and solenoids. The program is basically made for factory testing, but can
be of some use when trouble shooting.
1. Remove the two stapler heads.
2. Go to Dead Cycling. Press OK.
3. Press Arrow to go to the unit in which to perform the dead cycling.
4. Press On to start the dead cycling.
5. Press Off to stop the dead cycling.
5-2
21 August 2006
SERVICE PROGRAM MODE
Interface
Under Interface you adapt the BK5010 interface to the correct host machine.
1. Go to Interface. Press OK.
2. Press Arrow to select correct host machine. Press OK.
Changing EEPROM Values
1. Go to EEPROM values. Press OK.
2. Press Arrow to go to the Index to be changed.
3. Press Change.
4. Key in New value (using the Arrow and Change button).
5. Go to Store. Press OK.
Using Fold Delay
Fold delay is default On. The fold delay indicates that the booklet is stopped between
the second pair of fold rollers by the spine, to make the booklet flatter. It sits in that
position up to about 15 seconds depending on the interval between sets. If the time
interval between the sets from the Copier is less, the booklet is fed out sooner, when
the next booklet enters the booklet maker.
Counters
Under Counters the total amount of cycles are displayed for the stapler heads, Fold
knife, trimmer knives and cover feeder. When stapler heads or the trimmer knives
have been replaced, the counter for the corresponding function should be reset to
zero. That is done under EEPROM Values.
Jam History
The last 40 error messages are listed here. The most resent error at the top. This is a
very helpful tool when troubleshooting as all events are logged consecutive. Displayed
are the total count for the event and the fault code. It is also logged when the service
program mode has been entered. It is indicated by a wrench symbol in front of the
total count. To remedy errors listed, go to Fault Code Descriptions (
4.1).
5-3
Service
Tables
IMPORTANT
Changing EEPROM values can jeopardize the way the machine operates
considerably. Be sure that changing the EEPROM value is the correct solution before doing so. If changes are made which cause the unit to operate
incorrectly, perform the EEPROM reset procedure (
5.1.3).
SERVICE PROGRAM MODE
21 August 2006
5.1.2 SERVICE PROGRAM MODE TABLES
Check Motors and function
Booklet Maker
Motor
Normal Reading
Function
BK-M1
14V ±2V, ≈0.90m/s
Infeed Motor transports the set to the stapling
section.
BK-M2
9V ±2V
Back Jogger Motor jogs the sheets together
lengthwise.
BK-M3
200mm - 325mm
Side Jogger Motor adjusts the position of the
side guides for different paper sizes. It also
jogs the sheets together sidewise and guides
the set through the machine.
BK-M4
15V ±2V
Stapler Motor drives the staples into the set
and drives the clinchers that clinches the staple
legs flat.
BK-M5
24V ±2V
Set Transport Motor transports the set from the
stapling area to the folding area.
BK-M6
18V ±2V, 0.25m/s
Fold Roller Motor folds and compresses the set
and transport it out of the Booklet Maker.
BK-M7
19V ±2V
Fold Knife Motor pushes the set up through the
fold rollers.
BK-M8
12V ±2V
Fold Stop Gate Motor makes a slight jog to ensure set is straightened up before folding.
BK-M9
≈269mm - ≈460mm
Staple/Fold Position Motor adjusts the position
of the staple stop, fold stop and back jogger for
different paper sizes.
BK-M19
14V ±2V, 0.4m/s
Pre Infeed Motor transports the set to the stapling section.
Cover Feeder
Motor
Normal Reading
Function
CF-M15
12V ±2V, 0.4 m/s
Feed Motor separates the top sheet from the stack
and transports the sheet towards the Drive Motor.
CF-M16
4V ±2V, 0.3 m/s
Drive Motor, together with Feed Motor, transports
the sheet into the Booklet Maker.
CF-M17/
M18
20V
Blower Motor blows air between the sheets in the
Cover Feeder as a pre-separation.
5-4
21 August 2006
SERVICE PROGRAM MODE
Trimmer
Motor
Normal Reading
Function
TR-M1
22V ±2V, ≈0.70m/s
Transport/Knife Motor transports the booklet in
and out ≈0.70m/s of the Trimmer unit. It also
functions as a second Trim Knife Motor when
reversed. In Service mode, only transport direction can be run.
TR-M2
28V ±2V
Trim Knife Motor cycles knife to cut the booklet.
TR-M3
28V ±2V
Stop Gate Motor moves the stop gate up to
stop the booklet to be trimmed and down when
transporting it out.
TR-M4
21V ±2V,
≈120-220mm
Length Adjustment Motor adjusts the position of
the stop gate for different booklet sizes.
TR-M5/M6 24V
Blower Motor blows the trimmed shingle (cut
paper edge) down to the scrap bin.
Motor
Normal Reading
Function
BF-M1
17,5V ±2V
Transport Belt motor transports the booklet in and out of the Book Folder.
BF-M2
N.A.
Stop gate motor moves the stop gate up and
down to stop the booklet in correct position.
BF-M3
N.A.
Clamp motor opens and closes the Set clamp,
holding the booklet in place when the Roller
motor are performing the book folding action.
BF-M4
12V ±2V,
≈0.35 m/s
Roller motor performs the book folding action.
Motor
Normal Reading
Function
ST-M1
15V ±2V or
29V ±2V
Stacker Motor transports the set on the belt
stacker.
Stacker
5-5
Service
Tables
Book Folder
SERVICE PROGRAM MODE
21 August 2006
Check Solenoids and function
Booklet Maker
Solenoid
Normal Reading
Function
BK-SOL1
Will be actuated Stop Gate Solenoid moves the staple stop down
for appr. 30 sec.
and the set transport rollers up/down.
BK-SOL2
Will be actuated Stop Gate Release Solenoid releases the staple
for appr. 5 sec.
stop when latched in down position.
Book Folder
Solenoid
Normal Reading
Function
BF-SOL1
Will be actuated
until sensor BFQ6 is actuated
Will be actuated
until sensor BFQ6 is actuated
Belt drive engagement solenoid
BF-SOL2
BF-SOL3
BF-SOL4
5-6
21 August 2006
SERVICE PROGRAM MODE
Check Sensors/Switches and function
Booklet Maker
Normal State
Function
BK-Q1
0 = Unblocked
Paper Infeed Sensor
BK-Q3
0 = Unblocked
Back Jogger Home Position Sensor
BK-Q4
0 = Unblocked
Start Sensor, Saddle Stapling
BK-Q7
0 = Unblocked
Fold Stop Sensor
BK-Q8
0 = Unblocked
Outfeed Sensor
BK-Q11
0 = Unblocked
Staple/Fold Home Position Sensor
BK-Q13
0 = Unblocked
Side Jogger Home Position Sensor
BK-Q14
1 = Blocked
Stapler Home Position Sensor
BK-Q15
1 = Blocked
Fold Knife Home Position Sensor
BK-Q19
0 = No signal
Staple Detection
BK-Q20
0 = No signal
Staple Detection
BK-Q35
1 = Blocked
Docking position sensor
BK-Q36
0 = Unblocked
Thick set sensor
BK-Q37
0 or 1
Foldgap sensor
Service
Tables
Sensor
Cover Feeder
Sensor
Normal State
Function
CF-Q31
1 = Unblocked
Empty Bin Sensor
CF-Q30
1 = Unblocked
Paper Path Sensor / DSD detection
CF-Q32
1 = Unblocked
Paper Positioning Sensor
CF-Q33
1 = Unblocked
Paper Low Sensor, Bin
CF-Q38
0 = Unblocked
Paper width sensor
5-7
SERVICE PROGRAM MODE
21 August 2006
Trimmer
Sensor
Normal State
Function
TR-S2/S3
0 = Unactuated
Infeed Switch / Control Switch Infeed / Control
Switch Out feed
TR-Q5
1 = Blocked
Trim Knife Home Position Sensor
TR-Q6
1 = Unblocked
Outfeed Sensor
TR-Q7
0 = Blocked
Stop Gate Home Position Sensor
TR-Q8
0 = Unblocked
Trim Bin Full Sensor
TR-Q13
0 = Unblocked
Infeed sensor
TR-S9/S10
1 = Unactuated
Interlock switches (S9 -switch, S10 -magnet)
TR-S11
1 = Unactuated
Length Adjustment Home Position Switch
Book Folder
Sensor
Normal State
BF-Q1
0 = Unblocked
BF-Q2
1 = Blocked*
BF-Q3
0 = Unblocked*
BF-Q4
0 = Unblocked
BF-Q5
0 = Unblocked
BF-Q6
0 = Unblocked
BF-Q7
0 = Unblocked
BF-S1
1 = Blocked
BF-S2
1 = Blocked
BF-S3
1 = Blocked
BF-S4
1 = Blocked
Function
Stop Gate sensor
Rear sensor
Front sensor
Home position sensor
Infeed sensor
Clamp sensor
Outfeed sensor
External interlock device Interlock switch
Top cover Interlock switch
External interlock device Interlock switch
Top cover Interlock switch
NOTE: *BF-Q2 and BF-Q3 are home position sensors for the Roller motor. If one
is blocked, the other must be unblocked and vice versa.
5-8
21 August 2006
SERVICE PROGRAM MODE
Voltage at
Range
MD3DC (H)
29-43V
Unregulated 36V (after interlock relay) distributed from
Interlock PCB in Booklet maker.
Voltage supplies: BK-M19
Pre Infeed motor
CF-M15
Feed motor
CF-M17/18 Blower motors
MD6DC (B)
29-43V
Unregulated 36V (after interlock relay) distributed from
Interlock PCB in Booklet maker.
Voltage supplies: BK-M1
Infeed motor
BK-M7
Fold knife motor
BK-M8
Fold stop gate motor
BK-M9
Staple/fold pos. mot.
ST-M10
Stacker motor
MD6DC (C)
29-43V
Unregulated 36V (after interlock relay) distributed from
Interlock PCB in Booklet maker.
Voltage supplies: BK-M2
Back jogger motor
BK-M3
Side jogger motor
BK-M4
Stapler motor
BK-M5
Set transport motor
BK-M6
Fold roller motor
CF-M16
Drive Motor
Ground only to: BK-SOL1 Stop gate sol.
BK-SOL2 Stop gate rel. sol.
BK Set counter
TR5010
29-43V
Unregulated 36V (after interlock relay) distributed from
Interlock PCB in Booklet maker.
Voltage supplies: TR-M1
Transport/knife motor
TR-M2
Knife motor
TR-M3
Stop gate motor
TR-M4
Length adjust. motor
TR Set counter
Ground only to: TR-M5
Blower motor
TR-M6
Blower motor
BF5010
29-43V
Unregulated 36V (after interlock relay) distributed from
Interlock PCB in Booklet maker.
Voltage supplies: BF-M1
Transport belt motor
BF-M2
Stop Gate motor
BF-M3
Clamp motor
BF-M4
Roller motor
ST-M1
Belt stacker motor
BF Set counter
5-9
Service
Tables
Voltmeter
SERVICE PROGRAM MODE
21 August 2006
EEPROM Values
Index
Default
Function
0
Password
107
The password to enter service mode can
be changed here.
1
STD Trim
004.50
Standard trim margin that is default presented in the user menu. Value reflects how
many millimetres that will be trimmed off from
the longest sheet (centre fold) in the booklet.
2
Side Jog Offset
≈321 mm
Reference regarding position for paper
size adjustment. Value reflects paper size
width at home position.
3
Rear Offset
≈270 mm
Reference regarding position for paper
size adjustment. Value reflects paper size
length at home position.
4
Staple
0-
The counter for the stapler. Value reflects
the count of how much the stapler heads
have cycled.
5
Fold
0-
The counter for the folder. Value reflects the
count of how much the fold knife has cycled.
6
Trim knife
0-
The counter for the trimmer. Value reflects
the count of how much the trimmer knife
has cycled.
7
Cover feed
0-
The counter for the cover feeder. Value
reflects the count of how many sheets the
cover feeder has delivered.
8
Book Folder
0-
The counter for the Book Folder. Value
reflects the count of how many Books the
Book Folder has delivered.
9
BK-M1 Speed
Low
≈01000
10
M1 Speed High
≈01400
The values reflect calibration of Infeed motor
BK-M1, Pre Infeed motor BK-M19 and Fold
roller motor BK-M6 at power on.
11
BK-M19 Speed
Low
≈01900
12
BK-M19 Speed
High
≈02700
13
BK-M6 Speed
≈01900
14
CF-M15 Speed
Low
≈01300
15
CF-M15 Speed
High
≈01900
The values reflect calibration of Feed motor
CF-M15 at service.
5-10
21 August 2006
SERVICE PROGRAM MODE
EEPROM Values
Default
Function
16
Zero Trim Offset
≈3.0
Fine tuning of trim margin. Value reflects
deviation from real trim margin and STD trim
margin.
17
TR-M1 Speed
≈01800
The value reflect calibration of Transport
motor M1.
18
CF-M16 Speed
Low
≈00500
The values reflect calibration of Drive motor
CF-M15 at service.
19
CF-M16 Speed
High
≈00800
20
Service Timeout
010
21
Size A4
B=209.4 x H=296.5
22
Size A3
B=296.4 x H=418.5
23
Size 8,5x11
B=215.2 x H=279.2
24
Size 8,5x14
B=215.2 x H=354.6
25
Size 11x17
B=279.2 x H=431.0
26
Size B4
B=256.3 x H=363.0
27
UI Control reg
0-
The value reflects the time that you can
be logged in to service mode without
touching any buttons before the machine
closes the service mode.
Factory use only.
5-11
Service
Tables
Index
Rev.
10/2007
19 April
2006
SERVICE PROGRAM MODE
5.1.3
EEPROM RESET
If minor logic problems arise the EEPROM reset procedure can be initiated. All data
in the EEPROM will be cleared including jobs, jam history etc. The only data not
cleared are:
Counters:
- Staple
- Fold
- Trim knife
- Cover feed
1.
Access the service menu and note the following EEPROM
values:
Index 1, 2, 3, 16 and 20 to 26.
2. Make sure the main power to the Booklet maker is switched
OFF.
3. Press and hold the leftmost and rightmost button on the Control
Panel.
4. Switch ON the main power switch.
5. Release the buttons on the Control Panel when the text CLEARING EEPROM is shown on the LCD. This will be followed by
text DONE on the LCD.
6. Key in the password, press the OK button.
7. Press the ESC button.
8. Switch OFF the main power to the Booklet maker.
9. Switch ON the main power switch.
- Default EEPROM values are restored.
­ Followed by this procedure it is advised to perform the Paper Size Reset in order to
also reset the paper size parameters that have a great importance in the operation
of the machine (
BK5010 SM Section 5.4 for instructions).
­ Followed by this procedure it is advised to set INDEX 16, TR5010.Knife Zero, in
order to make sure that this specific Trimmer is set up correctly for this specific
Booklet maker (
BK5010 SM Section 1.5.6 for instructions).
5-12
21 August 2006
5.2
SERVICE PROGRAM MODE
SOFTWARE DOWNLOAD
5.2.1 Downloading to upper PCB MD6DC B in Booklet maker.
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
1. Switch Off the Main Power Switch.
2. Remove Rear Cover (
3.3.1).
3. Make sure all DIP-switches 1 - 4 is set to OFF (down) position.
4. Run the BK5010 MD6DC v1.00.exe* file (* v1.00 is an example - use latest
version) and follow the instruction in the program, or according to the latest
bulletin.
ON
5-13
Service
Tables
NOTE: A red LED on the board will flash while downloading. When download is
complete LED goes out.
SERVICE PROGRAM MODE
21 August 2006
5.2.2 Downloading to lower PCB MD6DC C in the Booklet maker.
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
1. Switch Off the Main Power Switch.
2. Remove Rear Cover (
3.3.1).
3. Make sure DIP-switches 1 and 4 is set to ON (up) position.
Make sure DIP-switches 2 and 3 is set to OFF (down) position.
4. Run the BK5010 MD6DC v1.00.exe* file (* v1.00 is an example - use latest
version) and follow the instruction in the program, or according to the latest
bulletin.
NOTE: A red LED on the board will flash while downloading. When download is
complete LED goes out.
ON
5-14
21 August 2006
SERVICE PROGRAM MODE
5.2.3 Downloading to PCB CPU in Booklet maker.
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
1. Switch Off the Main Power Switch on the BK5010.
2. Remove the Front Cover on the BK5010 (
3.3.1).
3. Run the BK5010 CPU v1.00.exe* file (* v1.00 is an example - use latest version)
and follow the instruction in the program, or according to the latest bulletin.
4. When the download is complete, set the contrast of the LCD by turning the potentiometer R 41 (
4.4).
5. Perform a EEPROM RESET (
5.1.3).
5.4) or use the values previously Service
Tables
6. Either perform a Paper Size Reset (
noted in step 5.
R41
5-15
SERVICE PROGRAM MODE
21 August 2006
5.2.4 Downloading to lower PCB MD3DC H in the Booklet maker.
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
1. Switch Off the Main Power Switch.
2. Remove Rear Cover (
3.3.1).
3. Make sure DIP-switches 2 is set to ON (down) position.
Make sure DIP-switches 1, 3 and 4 is set to OFF (up) position.
4. Run the BK5010 MD3DC v1.00.exe* file (* v1.00 is an example - use latest
version) and follow the instruction in the program, or according to the latest
bulletin.
NOTE: A red LED on the board will flash while downloading. When download is
complete LED goes out.
ON
5-16
21 August 2006
SERVICE PROGRAM MODE
5.2.5 Downloading to PCB MD6DC A in Trimmer.
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
1. Switch Off the Main Power Switch.
ON
5-17
Service
Tables
TR5010 Service Manual 1.1.1).
2. Remove Rear Cover (
3. Make sure all DIP-switches 1 - 4 is set to OFF (down) position.
4. Run the TR5010 MD6DC v1.00.exe* file (* v1.00 is an example - use latest
version) and follow the instruction in the program, or according to the latest
bulletin.
SERVICE PROGRAM MODE
21 August 2006
5.2.6 Downloading to PCB MD6DC D in Book Folder.
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure (
3.1 ).
1. Switch Off the Main Power Switch.
2. Remove rear cover (
3.3.1 ).
3. Run the BF5010 MD6DC v1.00.exe* file (* v1.00 is an example - use latest version) and follow the instruction in the program, or according to the latest bulletin.
OFF
NOTE: The DIP switches must be in the off position.
5-18
21 August 2006
5.3
SELF-DIAGNOSTIC MODE
SELF-DIAGNOSTIC MODE
5.3.1 RUN TIME DIAGNOSTICS
Throughout the operation of the machine all functions and components are monitored. Should an error occur, a fault code is displayed. Many faults can simply be
corrected by the operator. In that case a picture shows the location of the fault with
a text message, such as ”Clear Misfeed(s)”. If the fault can not be corrected by the
operator, the text message ”Fault in area” is displayed. All messages regardless of
nature are always accompanied by a fault code. The operator manual lists the fault
codes that the operator can solve. This manual lists all fault codes. To correct the
fault, go to Fault Code Descriptions (
4.1) .
5.3.2 POWER ON SELF TEST
At power on the program checks the EEPROM. It checks that it is present and not
corrupt. If not present or corrupt, the machine will lock-up. If present and not corrupt
the machine will enter normal operation mode unless:
The service mode is entered.
B.
EEPROM reset is entered.
Service
Tables
A.
Power on
Operation
mode
Service mode
(
5.1.1)
EEPROM
reset
(
5.1.3)
5-19
Machine
lock-up
SELF-DIAGNOSTIC MODE
21 August 2006
5.3.3 DETAILED SELF-DIAGNOSTIC MODE
The main self-diagnostic mode, Diagnostics, is available from the service program
mode. Diagnostics checks the EEPROM, the sensors and the motors. If a fault is found
it will be displayed as a fault code. To remedy the fault, go to Fault Code Description
(
4.1).
IMPORTANT
Reflecting paper path sensors can be faulty although not detected by the
diagnostics. If they have a failure state equal to constantly unblocked, it will
not be detected as it is the correct home position state. Should this failure
occur it will be detected by the run time diagnostics.
Executing Diagnostics
Follow this procedure to execute the diagnostics.
1. Undock the BK5010 from the copier.
2. Enter the service program mode (
3. Remove the two stapler heads (
5.1.1).
3.4.12).
4. Close the top cover.
5. If a Cover Feeder is installed, make sure the adjustable side guides
are in their innermost position.
6. Go to Diagnostics. Press OK.
7. Press Run.
8. If a fault code is displayed, go to Fault Code Descriptions.
(
4.1). Locate the fault code and follow the procedure .
9. When the fault has been remedied, go through this procedure
again until no faults are found
NOTE: Look through Jam History in the Service mode to locate other faults or to establish a pattern of repeated faults (
5.1.1).
10.IMPORTANT:
ALWAYS POWER OFF THE SYSTEM WHEN EXITING THE DIAGNOSTIC MODE.
5-20
21 August 2006
5.4
PAPER SIZE RESET
PAPER SIZE RESET
If any mechanical adjustments have been carried out that effects the positioning of side guides, staple stop or fold stop, this procedure must be performed.
If the EEPROM or the CPU PCB has been replaced, this procedure must be
performed.
During the procedure, the side jogger motor and staple/fold positioning motor moves
between given positions to calculate this specific motors characteristics in conjunction with this specific machines mechanics. The paper size reset procedure results
in variables used when calculating the different positions for different paper sizes.
Service
Tables
Should the procedure fail or not be carried out after an EEPROM reset or CPU
PCB exchange:
The side guides will stop in the wrong position, resulting in booklets not properly
jogged or sets jamming between the side guides.
The staple and fold stop will stop in the wrong position, resulting in booklets not
folded in the centre, booklets not properly jogged or sets jamming between the
side guides.
5-21
PAPER SIZE RESET
21 August 2006
Executing Paper Size Reset
The side guides and stop gate must be parallel and square before this procedure
is carried out (
3.8.1, 3.8.2 ).
1. Remove the two stapler heads (
3.4.12 ).
2. Insert a Interlock cheater.
3. Enter the Service Program Mode.
4. Go to Paper Size Reset. Press OK.
5. The text READY will be shown on the LCD display. Press Run.
The text SIDE JOGGERS will be shown.
The side joggers moves in and out.
NOTE: If this fails, switch OFF and ON the main power switch and go to
step 1.
6. The text INSERT TOOL will be shown.
7. Insert the Multi tool [A], according to picture below.
Push the Multi tool gently up against the side guide to make sure it is in contact.
8. Press OK.
The text FOLD POSITION will be shown on the LCD.
The stop gate moves the Multi tool upwards [B] so the top of the Multi tool
catches the clincher bar.
IMPORTANT: If this fails, the procedure must be done all over again!
The text REMOVE TOOL will be shown.
9. Remove the tool. Press OK.
[B]
[A]
5-22
21 August 2006
PAPER SIZE RESET
If the purpose of performing the paper size reset procedure is strictly a result of an
electronical or logical operation, such as replacement of CPU PCB, the procedure
can be ended her by pressing ESC.
If any changes has been made that effects the geometry regarding the paper size,
such as mechanically adjusted stop gate, back jogger or replaced/moved home
position sensor, the procedure must be continued to the end.
9. The text BACK JOGGER will be shown on the LCD. Press RUN.
10.The text INSERT TOOL will be shown.
11.Insert the tool according to pictures below.
12. Press OK.
The sharp end of the tool on the 3rd stop finger.
The other end of the tool by the 3rd
back jogger finger.
13.The text Adjust B. Jogger will be shown.
14.Turn the adjustment screw to move the back jogger fingers so the finger just
touches the tool slightly.
Wrong!
Adjustment screw below
infeed module.
15.Press OK.
The text REMOVE TOOL will be shown.
16.Remove the tool. Press OK.
The text IS TOOL REMOVED will be shown.
17.Press OK.
5-23
Correct!
No tension,
no play.
Service
Tables
Page intentionally blank
21 August 2006
5.5
CF SERVICE
CF SERVICE
In the Cover Feeder Service you are able to Enable the Cover Feeder and calibrate
the motors and DSD (Double sheet detection) sensor in the Cover Feeder.
If any mechanical adjustments have been carried out in the Cover Feeder. If the Cover
Feeder is displaying false double feeds, or if the Cover Feeder HAS problems with the
feeding of the covers, the Calibration procedure can be performed. If the Addon PCB
has been replaced in the Booklet Maker, this procedure must also be performed.
Enable the Cover Feeder
At installation of the Cover Feeder you have to Enable the Cover Feeder, other
wise the BK5010 system do not recognise the machine.
1. Enter the Service Program mode.
2. Go to CF5010 Service. Press the OK button.
3. Scroll to Installed: Press the CHG button, so it says YES in the UI
(User Interface).
Service
Tables
4. Press the OK button.
Executing Cover Feeder motors Calibration
1. Enter the Service Program Mode.
2. Go to CF5010 SERVICE. Press OK.
3. Select Calibrations. Press OK.
4. Select Motors. Press OK.
5. Press the bin downwards as when loading cover sheets and hold it down.
6. Press the RUN button. The Cover Feeder will start by calibrating the CF-M1
Feed motor.
7. Press the OK button when the message Successful is displayed.
5-25
CF SERVICE
21 August 2006
Executing Cover Feeder DSD sensor Calibration
1. Enter the Service Program Mode.
2. Go to CF5010 SERVICE. Press OK.
3. Select Calibrations. Press OK.
4. Select Double Sheet Det. Press OK.
5. Place the DSD calibration strip, located behind the rear cover of the Booklet
Maker, as illustrated [A]. The calibration strip must be positioned between the
CF-Q30 (DSD sensor) LED and phototransistor [B] (
Service Manual
CF5010 6.1.2 ).
6. The value should be +4.7 ± 0.05. If not, go to step 7.
7. Remove Booklet Maker Front Cover (
3.3.1).
8. Turn the potentiometer [C] on the Addon PCB until you reach the value in step 6.
9. Press the OK button.
[B]
[A]
Upper Top Cover removed for clarity
[C]
5-26
BF SERVICE
21 August 2006
5.6
BF SERVICE
In the Book Folder Service menu, you are able to set up the Book folder to Adjustment mode. Use the Adjustment mode when adjusting the Square folding quality.
When the Adjustment mode is set to ON, the Home position of the Stop gate is
changed. So you will be able to adjust the Stop gate during run.
Adjustment mode
Set the Adjustment mode to ON when performing Stop gate adjustment A
(
BF5010 Service Manual 3.5.2).
NOTE: When you are done with the adjustment, remember to set the Adjustment mode to OFF.
1. Enter the Service Program mode.
2. Go to BF5010 Service. Press the OK button.
3. Scroll to Adjust mode: Press the CHG button, so it says ON in the UI.
Service
Tables
4. Press the OK button.
5-27
Page intentionally blank
5 May 2006
ELECTRICAL COMPONENT LIST
6.
DETAILED SECTION DESCRIPTIONS
6.1
ELECTRICAL COMPONENT LIST
Page
BK-M1
BK-M2
BK-M3
BK-M4
BK-M5
BK-M6
BK-M7
BK-M8
BK-M9
BK-M19
Grid code
Infeed motor................................................................................................. 6-8........... E2
Back Jogger motor.................................................................................... 6-10........... D2
Side jogger motor...................................................................................... 6-10........... F2
Stapler motor................................................................................................ 6-9......... H20
Set transport motor...................................................................................... 6-9......... E20
Fold roller motor.......................................................................................... 6-3......... H20
Fold knife motor................................................................................... 6-3 / 6-9......... E13
Fold stop gate motor................................................................................... 6-7......... E16
Staple / Fold positioning motor.................................................................. 6-7......... C19
Pre-Infeed motor.......................................................................................... 6-4...........G7
BK-Q1
BK-Q2
BK-Q3
BK-Q4
BK-Q7
BK-Q8
BK-Q9
BK-Q10
BK-Q11
BK-Q12
BK-Q13
BK-Q14
BK-Q15
BK-S16
BK-S17
BK-Q19
BK-Q20
BK-Q35
BK-Q36
BK-Q37
Paper Infeed sensor..................................................................................... 6-8........... H2
Infeed motor sensor (located on motor M1).............................................. 6-8........... E2
Back jogger home position sensor.......................................................... 6-10...........G2
Saddle stapling start sensor....................................................................... 6-6........... N2
Fold stop sensor.......................................................................................... 6-7......... D16
Outfeed sensor..................................................................................... 6-6 / 6-7........... N2
Fold roller sensor......................................................................................... 6-3......... F13
Staple / Fold positioning motor sensor (loc. on mot M9 )........................ 6-7......... D19
Staple / Fold home position sensor........................................................... 6-4...........G7
Side jogger motor sensor (located on motor M3)................................... 6-10...........G2
Side jogger home position sensor........................................................... 6-10........... H2
Stapler home position sensor..................................................................... 6-9.........G13
Fold knife home position sensor................................................................ 6-9...........G7
Interlock switch............................................................................................ 6-6............J2
Interlock magnet.......................................................................................... 6-6............J2
Staple detection lead (rear side)................................................................. 6-6............J4
Staple detection lead (front side)............................................................... 6-6............J4
Docking position sensor............................................................................. 6-6.........M16
Thick Set sensor.......................................................................................... 6-6......... S17
Fold Gap sensor........................................................................................... 6-4......... R16
BK-SOL1 Stop gate solenoid....................................................................................... 6-9......... F20
BK-SOL2 Stop gate release solenoid.......................................................................... 6-9......... F20
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
PCB
CPU ”A”........................................................................................................ 6-3........... L6
Copier Interface ”E”..................................................................................... 6-3........... L8
Interlock ”D”................................................................................................. 6-4......... L17
MD6DC ”B”................................................................................................... 6-4........... E9
MD6DC ”C”................................................................................................... 6-4.........G16
MD3DC ”H”................................................................................................... 6-4.............I5
Addon ”F”..................................................................................................... 6-3.........O17
Soft start....................................................................................................... 6-3......... N10
Interlock switch............................................................................................ 6-3............J3
6-1
Detailed
Description
ST-M1 Stacker motor............................................................................................. 6-11......... A20
ELECTRICAL COMPONENT LIST
5 May 2006
Page
Grid code
Communication Copier.................................................................................................. 6-5......... L10
Stacker Receptacle........................................................................................................ 6-5......... A18
Terminator....................................................................................................................... 6-5........... N5
Interlock jumper............................................................................................................. 6-5.........M15
Terminator / Communication Trimmer.......................................................................... 6-5........... N4
Interlock jumper / Power supply Trimmer.................................................................... 6-5.........M18
Power supply Book Folder............................................................................................ 6-5......... T26
Fuse F1........................................................................................................................... 6-5...........O8
Power Receptacle / Line Filter...................................................................................... 6-5...........O7
Set Counter............................................................................................................. 6-3 / 6-6.........G20
LCD.................................................................................................................................. 6-3........... N6
Panel Switches............................................................................................................... 6-3...........O6
Main power Switch......................................................................................................... 6-3...........O9
Rectifier........................................................................................................................... 6-3.........O12
Transformer.................................................................................................................... 6-3.........O10
Fuse F2 16A.................................................................................................................... 6-3......... O11
Fuse F3 2A...................................................................................................................... 6-3......... O11
Fuse F4 2A...................................................................................................................... 6-3......... O11
Capacitor......................................................................................................................... 6-3.........O13
6-2
5 May 2006
ELECTRICAL COMPONENT LIST
6.1.1 FRONT VIEW
Main Power SW
LCD
Panel Switches
Addon PCB
Interlock switch PCB
Set Counter
Softstart PCB
Detailed
Description
CPU PCB
BK-Q9
BK-M6
BK-M4
Rectifier
Transformer
6-3
F2
F3
F4
Capacitor
ELECTRICAL COMPONENT LIST
5 May 2006
6.1.2 REAR VIEW
BK-M19
MD3DC PCB “H”
MD6DC PCB “B”
BK-Q11
MD6DC PCB “C”
BK-Q35
Copier Interface PCB
6-4
Interlock PCB
BK-Q37
5 May 2006
ELECTRICAL COMPONENT LIST
6.1.3 CONNECTOR VIEW
Terminator
Terminator/
COM. TR5010
Power Receptacle /
Line Filter
Detailed
Description
Stacker
Receptacle
COM
Copier
F1
Interlock jumper
Interlock jumper/
Power Supply Trimmer
6-5
Power Supply
Book Folder
ELECTRICAL COMPONENT LIST
5 May 2006
6.1.4 OUTFEED UPPER VIEW
Staple Detection Lead
BK-Q19 / BK-Q20
BK-Q36
Interlock Switch
BK-S16 / S17
Set Counter
Outfeed cover removed
BK-Q4
BK-Q8
6-6
5 May 2006
ELECTRICAL COMPONENT LIST
6.1.5 OUTFEED LOWER VIEW
Detailed
Description
BK-Q8
Outfeed cover removed
BK-M9 /
BK-Q10
BK-Q7
6-7
BK-M8
ELECTRICAL COMPONENT LIST
5 May 2006
6.1.6 INFEED UPPER VIEW
BK-M1/
BK-Q2
BK-Q1
6-8
5 May 2006
ELECTRICAL COMPONENT LIST
6.1.7 INFEED LOWER VIEW
BM-M5
BM-SOL1
BM-Q14
Detailed
Description
BM-SOL2
BK-Q15
BK-M4
BK-M7
6-9
ELECTRICAL COMPONENT LIST
5 May 2006
6.1.8 INFEED MODULE VIEW
Bottom view
BK-M3 /
BK-Q12
BK-Q13
BK-Q3
6-10
BK-M2
5 May 2006
ELECTRICAL COMPONENT LIST
6.1.9 STACKER MODULE VIEW
Detailed
Description
ST-M1
6-11
Page intentionally blank
19 April 2006
6.2
BOARD STRUCTURE
BOARD STRUCTURE
6.2.1 BLOCK DIAGRAM
xCAN
Bookfold
Trimmer
CIM
Bookletmaker
Ricoh finisher
iCan
CPU
Addon PCB
Ricoh Comm.
MD3DC
MD6DC
SPI
electrical
signals
MD6DC
Optocouplers
UI
Interlock
The electronics in the BK5010 is distributed and divided in four different PCBs,
one CPU board (CPU PCB PL76) and three motor drive boards (two PCB MD6DC
and one MD3DC) . Each PCB has their own processor, they are communicating
via internal CAN (iCAN). The system also has many support PCBs, such as one
interlock PCB and one copier interface PCB.
The CPU board is equipped with a 32 bit ARM processor which has two CAN
channels, iCAN and xCAN. iCAN to communicate with the motor drive boards and
xCAN to communicate with other external units, such as the Trimmer.
The power supply to the Trimmer is taken from the Booklet Maker. The Booklet
Maker also controls the interlock system. An interlock lead connects the interlock
PCB and the Trimmer. The interlock lead goes through a cover switch on the
Booklet Maker and Trimmer.
6-13
Detailed Description
Interlock Lead
BOARD STRUCTURE
19 April 2006
6.2.2 CONTROLLER CPU
xCAN
CAN2
Start/Exit
iCAN
CAN1
Flash download
Debug
Sensors/
Staplers
UART0
UART1
IO-0 IO-7
LPC2292
ARM CPU
16 KB / 256 KB
128KB
Atmega48
RAM
Support
2 MB Data
CPU
storage
EEProm 2 KB
UI
Expansion
6-14
GPIO / AD
Expansion 1
Interlock
GPIO
Expansion 2
GPIO
Expansion
external
SPI Ch 1
Addon
SPI Ch 2
Copier
interface
19 April 2006
BOARD STRUCTURE
The MD6DC PCB is present in Booklet maker (x2), Trimmer (x1) and Book Folder
(x1).
The xCAN portion on MD6DC is not used in the Booklet maker as the external
communication is handled by the xCAN portion on the CPU PCB.
In the Trimmer and the Book Folder the xCAN portion on MD6DC is used for external communication.
6-15
Detailed Description
6.2.3 CONTROLLER MD6DC
BOARD STRUCTURE
19 April 2006
6.2.3 CONTROLLER MD6DC, CONTINUES
BK-M1
BK-M8
BK-M7
BK-M9
ST-M1
BK-M6
BK-M4
BK-M2
BK-SOL1
BK-M3
BK-SOL2
Booklet maker
Set counter
CF-M16
6-16
BK-M5
19 April 2006
The MD3DC PCB is present in Booklet maker (x1).
6-17
Detailed Description
6.2.4 CONTROLLER MD3DC
19 April 2006
6.2.4 CONTROLLER MD3DC, CONTINUES
BK-M19
CF-M17, CF-M18
CF-M15
6-18
19 April 2006
6.3
BOOKLET MAKING PROCESS
BOOKLET MAKING PROCESS
6.3.1 PRINCIPLE OF OPERATION
M1
Q1
Q4
M3
Compiling
Copier sends a start signal. The pre infeed motor (BK-M19) and infeed motor (BKM1) start. The set enters the infeed module. Infeed sensor (BK-Q1) activates. Side
guides moves half way in (BK-M3). The infeed wheel transports the set down to
the staple stop. The set stops at the staple stop. The start sensor (BK-Q4), by the
staple stop, activates. The infeed wheel keeps on running for a period of time set
by the paper size, after the trail edge of the last sheet has passed the infeed sensor (BK-Q1).
M19
Q1
M3
Q4
6-19
Detailed Description
M1
BOOKLET MAKING PROCESS
19 April 2006
Q4
Q1
M2
M3 & Q12
M4
Q14
M4
Jogging and Stapling
When start sensor (BK-Q4) is activated and infeed sensor (BK-Q1) deactivated
back jogger motor (BK-M2) moves the back jogger up to knock the trail edge of
the set. At the same time the side jogger motor (BK-M3) moves the side guides
against the paper plus a few millimeters to over jog the set by about 5mm, depending on the set stiffness. The side guides then moves outwards to the paper width
plus about one millimetre. The position is set by the paper width that has been entered and found by encoder (BK-Q12) on side jogger motor. At the same time the
stapler motor (BK-M4) cycles, putting staples through the center of the set. When
the staples contact the clinchers a closed circuit is established (BK-Q19/Q20 - see
page 6-21) by current running from stapler head through staple contacting the
clincher. The closed circuit created, indicates that staples are present. If out of
staples the paper will insulate the stapler head from the clincher, which will result
in an open circuit. The open circuit at this time will indicate, out of staples. The stapler motor (BK-M4) will complete its cycle and stop in upper position as the stapler
home position sensor (BK-Q14) activates.
6-20
19 April 2006
BOOKLET MAKING PROCESS
Pre-fold transport
M5
M3
SOL1
Q19/Q20
SOL2
Q4
Q7
6-21
Detailed Description
When staples are detected (BK-Q19/Q20) the back jogger motor (BK-M2 - see
page 6-20) moves the back jogger down to release the trail edge of the set. The
side guides (BK-M3) move out slightly. Just enough to release the grip of the set
but still to guide the set straight to the fold stop. The stop gate solenoid (BK-SOL1)
moves the transport rollers upwards, gripping the set between the transport roller
below and idler roller on top of the set. The staple stop gate is pulled down by the
same solenoid and latched below the paper path. The set transport motor (BK-M5)
starts and transports the set down to the fold stop. Fold stop sensor (BK-Q7) near
the fold stop, activates. Side guides (BK-M3) move out to their initial position.
In case the sheet length is shorter than the distance between staple stop and fold
stop (i.e. A4), the staple stop will unlatch as soon as the set has cleared the start
sensor. The staple stop is unlatched by the stop gate release solenoid (BK-SOL2).
In case the sheet length is longer than the distance between staple stop and fold
stop (i.e. A3), the staple stop will remain latched during folding until the set has
cleared the start sensor (BK-Q4).
The stop gate solenoid (BK-SOL1) releases and the set transport motor (BK-M5)
stops when the fold stop sensor (BK-Q7) is activated or start sensor (BK-Q4) is
clear, whatever comes first.
BOOKLET MAKING PROCESS
19 April 2006
Q4
Q8
Q1
M8
Q7
M8
M4
Q15
M7
Folding
Folder roller motor (BK-M6) that drives the first and second pair of fold rollers
starts about the time when the start sensor (BK-Q4) is activated. Also the fold stop
gate motor (BK-M8) moves the fold stop away a bit at that time. Slightly after the
fold stop sensor (BK-Q7) is activated, the fold stop gate motor (BK-M8) jogs the
set upwards into position. Slightly after that the fold knife motor (BK-M7) cycles. The
fold knife pushes the center of the set up through the first pair of fold rollers. The fold
knife motor will complete its cycle and stop in the lower position when the fold knife
home position sensor (BK-Q15) activates. A booklet is now formed. When the booklets leading edge (the spine) is about to enter the second pair of fold rollers, the
fold roller motor (BK-M6) stops for a short time* and then starts again. The time
the booklet sits between the second pair of fold rollers depends on the speed (the
delay between each set) of the copier. The longer it sits the more compressed the
spine becomes, resulting in a flatter booklet. When the set is exiting the second
pair of fold rollers the outfeed sensor (BK-Q8) activates. When the trail edge of the
set exits the booklet maker the outfeed sensor (BK-Q8) becomes clear.
Belt stacker
If the belt stacker is installed directly on the booklet maker (no trimmer installed) the
stacker motor (ST-M1 - not shown in picture) starts when the outfeed sensor (BKQ8) activates and runs for a short while to separate the booklets on the stacker belt.
* If fold delay is set to On the booklet sits between the second pair of fold rollers up to
about 15 seconds depending on the interval between sets. If the time interval between
the sets from the Copier is less, the booklet is fed out sooner. When the next booklet
activates the infeed sensor (BK-Q1) the fold roller motor (BK-M6) starts again.
6-22
19 April 2006
BOOKLET MAKING PROCESS
6.3.2 SIZE ADJUSTMENT
Initialization cycle
Main power is switched on
Staple/fold positioning motor (BK-M9) and side jogger motor (BK-M3) starts.
Staple/fold positioning motor (BK-M9) moves staple stop and fold stop to the shortest sheets size.
Side jogger motor (BK-M3) moves side guides to the widest paper size.
Staple/fold positioning motor (BK-M9) stops when staple/fold home position sensor
(BK-Q11) is activated.
Side jogger motor (BK-M3) stops when side jogger home position sensor (BKQ13) is activated.
Detailed Description
When both sensors (BK-Q11 & Q13) have been activated, a counter for each motor starts and both motors (BK-M9 & M3) reverse.
Staple/fold positioning motor (BK-M9) runs until staple/fold positioning sensor (BKQ10) has counted the preset amount of pulses set by the paper size. Staple stop
and fold stop are now in the correct position, corresponding to the paper size selected.
Side jogger motor (BK-M3) runs until side jogger motor sensor (BK-Q12) has
counted the preset amount of pulses set by the paper size. Side guides are now in
correct position corresponding to the paper size selected.
Q13
Q11
M4
M9 &
Q10
6-23
BOOKLET MAKING PROCESS
19 April 2006
Changing paper size
New paper size is selected on the UI.
Staple/fold positioning motor (BK-M9) and side jogger motor (BK-M3) starts.
Side jogger motor (BK-M3) runs in the direction towards the new paper size. Side
jogger motor sensor (BK-Q12) counts pulses from the previous paper size to the
new paper size and stops the motor (BK-M3) when the correct amount of pulses
are received. Side guides are now in correct position corresponding to the new paper size selected.
The staple/fold positioning motor (BK-M9) movement depends on the change in
paper size (to take out mechanical play):
- If changing to a longer paper size where the total length is 30 mm longer or more,
staple/fold positioning motor (BK-M9) runs in the direction towards the new paper
size. Staple/fold positioning sensor (BK-Q10) counts pulses from the previous paper size to the new paper size and stops the motor (BK-M9) when correct amount
of pulses are received. Staple stop and fold stop are now in correct position corresponding to the new paper size selected.
- If changing to a longer paper size where the total length is longer, but less than
30 mm, staple/fold positioning motor (BK-M9) runs opposite the direction of the
new paper size for a bit. Then the motor (BK-M9) reverses and runs in the direction towards the new paper size. Staple/fold positioning sensor (BK-Q10) counts
pulses from the previous paper size to the new paper size and stops the motor
(BK-M9) when correct amount of pulses are received. Staple stop and fold stop
are now in correct position corresponding to the new paper size selected.
- If changing to a shorter paper size,
staple/fold positioning motor (BK-M9) runs in the direction towards the new paper
size. The motor (BK-M9) passes new selected paper size. Then the motor (BK-M9)
reverses and runs in the direction towards the new paper size. Staple/fold positioning sensor (BK-Q10) counts pulses from the previous paper size to the new paper
size and stops the motor (BK-M9) when correct amount of pulses are received.
Staple stop and fold stop are now in correct position corresponding to the new paper size selected.
If paper jam occurs
If jam occurs, side jogger motor (BK-M3) starts.
Side jogger motor (BK-M3) moves side guides to the widest paper size (to ease
the removal of jammed papers).
Side jogger motor (BK-M3) stops when side jogger home position sensor (BKQ13) is activated.
When top cover has been opened, jammed papers removed and top cover closed,
a counter for the motor (BK-M3) starts and motor the (BK-M3) reverses.
Side jogger motor (BK-M3) runs until side jogger motor sensor (BK-Q12) has
counted the preset amount of pulses set by the paper size. Side guides are now
back in position corresponding to the paper size.
6-24
18 April 2006
SPECIFICATIONS
SPECIFICATIONS
MAJOR SPECIFICATIONS
Specifications
Remarks
Speed (Online usage)
Maintain engine speed (actual depends if
engine is 90, 110 or 135 ppm version).
Actual speed in number of
booklets (per min / hour)
depends on number of sheets
per booklet.
Maximum Speed
1800 booklets / hour (A4 / 8.5x11”)
1800 booklets / Hour (A3 / 11x17”)
Standard Paper Sizes
A4, A3, B4, 8.5x11”, 8.5x14”, 11x17
Paper Size (Minimum)
Width 206mm / 8.1”
Length 275mm / 10.8”
Paper Size (Maximum)
Width 320mm / 12.6”
Length 457.2mm / 18”
Paper Weight (Minimum)
64gsm/16 lb. Bond
Paper Weight (Maximum)
300gsm/172 lb. Index/ 115 lb. Cover
Engine Duplex: 216 gsm
Input / Output Sheets
1 – 30 Sheets (80 gsm / 20 lb. Bond, equivalent)
Stapled
Input / Output Sheets
1 – 2 Sheets
Non Stapled Folding
Off-line Use
Possible
Stitch/ Fold (2 staples)
Weight
130 kg / 286.6 lb
Dimensions (L x H x D)
1420 x 970 x 700 mm / 55.9 x 38.2 x 27.6”
Incl. Base and Stacker
Power Source
100/110/115/127/220/230 50-60Hz
+ - 10%
Power consumption
200 W or less
Continuous Operations
Custom sizes are available
QUALITY SPECIFICATIONS
Target shut down*
1 / 600 booklets or less
Fold Skew
0.7 mm (A4), 1.0 mm (A3)
Fold Variation
0.5 mm
Fold Quality
Less than 17 mm (A3, 80gsm, 4 sheets
Stapled Set Registration
0.7 mm Maximum
Staple Line Position
variation
Less than 0.5 mm
*Shut down: Finisher stops by paper jam, staple jam.
Spec-1
Remarks
1 / 4800 Copies
Maximum height per set (also
depends on paper quality
Specification
Specifications
SPECIFICATIONS
18 April 2006
ATTACHEMENT TO BELLINI
Specifications
Remarks
Physical Connection
Attached after Victoria.E (detachable)
Attached by bracket (docking unit)
Released by foot release
Bracket is standard accessory
Electrical Connection
Jam signal to stop Bellini (Soft stop)
Jam signal to stop Bellini (Hard stop)
Start Signal from Bellini to start BK5010
Paper size information from Bellini
Connection detect BK5010
Seven types of paper size
information: A3SEF / A4SEF /
DLTSEF / LTSEF / LGSEF /
B4SEF
Spec-2
18 April 2006
SPECIFICATIONS
PERIPHERALS SPECIFICATION
COVER FEEDER CF5010
Specifications
Maximum Speed
Same as BK5010
Standard Paper Sizes
Same as BK5010
Paper Weight (Minimum)
70 gsm/ 18 lb. Bond
Paper Weight (Maximum)
Same as BK5010
Cover Feeder Capacity
20 mm (approx 200 sheets of 80gr/m2 paper)
Off-line Use
Possible
Weight
7 kg / 15.4 lb or less
Dimensions (L x H x D)
310 x 190 x 530 mm / 12.2 x 7.5 x 20.9”
Power Source
From BK5010
Remarks
(Together with Booklet maker)
TRIMMER TR5010
Specifications
Remarks
Speed
Same as BK5010
Standard Paper Sizes
Same as BK5010
Custom sizes are available
Default trim length
4,5 mm / (11/64”)
Adjustable in 0.5 mm steps
Minimum trimming
1 mm / (0.0394 in)*
Adjustable in 0.5 mm steps
Maximum trimming
16 mm / (0.63”)
Adjustable in 0.5 mm steps
Paper Weight (Minimum)
Same as BK5010
Paper Weight (Maximum)
Same as BK5010
Input / Output Sheets
Same as BK5010
Input / Output Sheets
Same as BK5010
Off-line Use
Possible
Weight
65 kg / 143.3 lb or less
Dimensions (L x H x D)
360 x 900 x 620 mm / 14.2 x 35.4 x 24.4”
Power Source
From BK5010
Engine Duplex: 216 gsm
* When trimming SRA3 (450 mm) Booklets minimum trimming is 5 mm, when trimming 18” Booklets minimum trimming is 9 mm.
Spec-3
Specification
(Together with Booklet maker)
SPECIFICATIONS
18 April 2006
BOOK FOLDER BF5010
Specifications
Remarks
Speed
Same as BK5010
Standard Paper Sizes
Same as BK5010
Paper Weight (Minimum)
Same as BK5010
Paper Weight (Maximum)
Same as BK5010
Input / Output Sheets
Same as BK5010
Input / Output Sheets
Same as BK5010
Off-line Use
Possible
Weight
52 kg / 114.6 lb
Dimensions (L x H x D)
360 x 900 x 620 mm / 14.2 x 35.4 x 24.4”
Power Source
From BK5010
Custom sizes are available
(Together with Booklet maker
& Trimmer)
Spec-4
19 April 2006
WIRING
Booklet Maker
See pocket at rear of manual for wiring diagrams.
Cover Feeder
See pocket at rear of manual for wiring diagrams.
Trimmer
See pocket at rear of manual for wiring diagrams.
Book Folder
Wiring
See pocket at rear of manual for wiring diagrams.
Wir-1
Page intentionally blank
COVER FEEDER CF5010
SERVICE MANUAL
19 April 2006
Subject to change
Page intentionally blank
TABLE OF CONTENTS
1 INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE............................................................ CF-1-1
2 PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE...................................... CF-2-1
3.REPLACEMENT AND ADJUSTMENT
3.1 COVER FEEDER................................................................................ CF-3-1
3.1.1 REMOVE COMPLETE UNIT...................................................... CF-3-1
3.2 AREA F................................................................................................ CF-3-5
3.2.1 EMPTY BIN SENSOR Q31........................................................ CF-3-5
3.2.2 PAPER WIDTH SENSOR Q38................................................... CF-3-6
3.2.3 FEED ROLLER ASSY AND PAPER SEPARATOR PAD............ CF-3-7
3.2.4 FEED MOTOR M15.................................................................... CF-3-8
3.2.5 PAPER BIN LOW SENSOR Q33............................................... CF-3-9
3.2.6 DRIVE MOTOR M16 ASSEMBLY............................................ CF-3-10
3.2.7 DRIVE SHAFT ASSEMBLY...................................................... CF-3-11
3.2.8 PINCH ROLL SHAFT ASSEMBLY........................................... CF-3-12
3.2.9 PAPER PATH / DSD DETECTION SENSOR Q30................... CF-3-13
3.2.9 PAPER POSITIONING SENSOR Q32..................................... CF-3-14
3.2.10UPPER PAPER PATH.............................................................. CF-3-15
3.2.11 BLOWER MOTOR M17 / M18.................................................. CF-3-16
4.TROUBLESHOOTING
4.1 FAULT CODE DESCRIPTIONS........................................................... CF-4-1
5 SERVICE TABLES
5.1 SERVICE TABLES............................................................................... CF-5-1
6.DETAILED SECTION DESCRIPTIONS
6.1 ELECTRICAL COMPONENT LIST...................................................... CF-6-1
6.1.1 REAR VIEW............................................................................... CF-6-2
6.1.2 OUTFEED VIEW........................................................................ CF-6-3
6.2 COVER FEEDING PROCESS............................................................ CF-6-5
6.2.1 PRINCIPLE OF OPERATION..................................................... CF-6-5
SPECIFICATIONS
SPECIFICATIONS................................................................................CF-Spec-1
WIRING
Cover Feeder...........................................................................................CF-Wir-1
I
Page intentionally blank
1
INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE
Cover Feeder INSTALLATION PROCEDURE is located in the Booklet Maker
BK5010 Service Manual (
1.4)
CF-1-1
Installation
19 April 2006
Page intentionally blank
19 April 2006
2
PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE
Preventive
Maintenance
Cover Feeder PREVENTIVE MAINTENANCE SCHEDULE is located in the Booklet Maker BK5010 Service Manual (
2)
CF-2-1
Page intentionally blank
19 April 2006
3.
REPLACEMENT AND ADJUSTMENT
3.1 COVER FEEDER
Replacement
Adjustment
3.1.1 REMOVE COMPLETE UNIT
[B]
[C]
[A]
Cover Feeder, viewed from
Booklet Maker outfeed
Cover Feeder, viewed from
Booklet Maker front side
1. Remove Upper Top Cover (
2. Remove Rear Top Cover (
3. Disconnect motor harness [A] (
4. Disconnect sensor harness [B] (
5. Disconnect fan harness [C] (
BK5010 Service Manual 3.3.5 ).
BK5010 Service Manual 3.3.6 ).
x 2).
x 1).
x 1).
CF-3-1
COVER FEEDER
19 April 2006
[D]
[E]
Cover Feeder, viewed from
Booklet Maker rear side
6. Loosen nut [D] (
x 1).
7. Remove screws [E] (
x 2).
CF-3-2
19 April 2006
COVER FEEDER
Cover Feeder, outer side view
[H]
[F]
[G]
Cover Feeder, inner side view
[F]
[H]
8. Note the position of the brackets [G] and [H].
9. Lift the rear end of Cover Feeder and carefully remove the complete unit so
that the shaft [F] comes loose from brackets [G] and [H].
NOTE: The shaft [F] must exit the cut-outs in the brackets [G] and [H] in the
Top Cover before it can be removed.
CF-3-3
Replacement
Adjustment
[G]
Page intentionally blank
19 April 2006
AREA F
3.2 AREA F
[A]
[C]
1. Remove screw [A] (
[B]
x1).
2. Gently lift out Sensor Q31 [B] and disconnect connector [C] (
2. Remove Sensor Q31 [B] (
x1).
CF-3-5
x1).
Replacement
Adjustment
3.2.1 EMPTY BIN SENSOR Q31
AREA F
19 April 2006
3.2.2 PAPER WIDTH SENSOR Q38
[A]
[C]
1. Remove screw [A] (
[B]
x1).
2. Gently lift out Sensor Q38 [B] and disconnect connector [C] (
2. Remove Sensor Q38 [B] (
x1).
CF-3-6
x1).
AREA F
19 April 2006
3.2.3 FEED ROLLER ASSY AND PAPER SEPARATOR PAD
[D]
Replacement
Adjustment
[B]
[C]
[A]
1. Remove the Fold roller assembly [A] by pressing it to the front side according
to figure [B].
2. Lift out the rear side [C] of the Fold roller assembly.
3. Remove the Paper separator pad [D] by lifting it out (with a small screwdriver)
from the holder.
CF-3-7
AREA F
19 April 2006
3.2.4 FEED MOTOR M15
[A]
[B]
Removal
Booklet Maker Service Manual 3.3.6).
1. Remove Rear Top Cover (
3.2.3).
2. Remove Feed roller assembly (
3. Disconnect Connector [A] (
4. Remove screws [B] (
x1).
x3).
5. Remove Feed motor M15.
Replacement
1. Reverse the removal procedure.
2. Enter Service mode (
5.1.1 in BK5010 Service Manual).
3. Perform Cover Feeder motor calibration (
CF-3-8
5.5 in BK5010 Service Manual).
19 April 2006
AREA F
3.2.5 PAPER BIN LOW SENSOR Q33
Replacement
Adjustment
[B]
[A]
1. Remove Rear Top Cover (
2. Disconnect Connector [A] (
4. Remove screws [B] (
Booklet Maker Service Manual 3.3.6).
x1).
x2).
5. Remove Paper Bin Low Sensor Q33.
CF-3-9
AREA F
19 April 2006
3.2.6 DRIVE MOTOR M16 ASSEMBLY
[A]
[D]
[B]
[C]
Removal
1. Remove complete Cover Feeder unit (
2. Disconnect Connector [A] (
1.1.1).
x1).
3. Remove Drive motor M16 assembly by removing screws [B] (
x2).
NOTE: Be careful when removing the Drive motor M16 assembly, so that the
Drive Shaft Assembly will not damage the LED sensor CF-Q30 (
3.1.2).
4. Loosen the allen screw [C] to Drive clutch assembly ( x1).
5. Remove the motor bracket by removing screws [D] (
x3).
Replacement
1. Reverse the removal procedure.
2. Enter Service mode (
5.1.1 in BK5010 Service Manual).
3. Perform Cover Feeder motor calibration (
5.5 in BK5010 Service Manual).
Adjustment
Adjust the Drive clutch assembly, so that there is play between the coupling on the
Drive shaft and the Clutch. The play should be 0.4 ± 0.3 mm. Adjust by loosening
screw [C].
0.4 ± 0.3 mm play between
the coupling and the clutch
CF-3-10
19 April 2006
AREA F
Replacement
Adjustment
3.2.7 DRIVE SHAFT ASSEMBLY
Removal
1. Remove Drive motor M16 assembly (
3.2.6).
2. Remove the Drive motor M16 assembly, by sliding it out through the rear
frame.
Replacement
1. Reverse the removal procedure.
Adjustment
Adjust the Drive clutch assembly (
3.2.6).
CF-3-11
AREA F
19 April 2006
3.2.8 PINCH ROLL SHAFT ASSEMBLY
1. Remove the Pinch roll shaft assembly by pressing it to the rear side of the
Cover Feeder.
CF-3-12
19 April 2006
AREA F
3.2.9 PAPER PATH / DSD DETECTION SENSOR Q30
[A]
[C]
[D]
Removal
1. Remove nut [A] (
x1).
2. Disconnect Photo transistor connector [B] (
3. Remove Drive shaft assembly (
4. Disconnect LED connector [C] (
x1).
3.2.7).
x1).
5. Loosen the LED nut [D] and slide off the connector (
x1).
Replacement
NOTE: Make sure to install the LED connector [C] correctly, so it will not interfere
with the Drive shaft assembly.
1. Reverse the removal procedure.
2. Enter Service mode (
5.1.1 in BK5010 Service Manual).
3. Perform Cover Feeder DSD sensor calibration (
Manual).
CF-3-13
5.5 in BK5010 Service
Replacement
Adjustment
[B]
AREA F
19 April 2006
3.2.9 PAPER POSITIONING SENSOR Q32
[A]
1. Remove screw [A] (
[B]
x1).
2. Disconnect connector [B] (
x1).
CF-3-14
19 April 2006
AREA F
3.2.10UPPER PAPER PATH
[B]
Replacement
Adjustment
[A]
[A]
[B]
1. Open the Top Cover.
2. Remove Rear Top Cover (
Booklet Maker Service Manual 3.3.6).
3. Remove Spring [A] on the Front and Rear side of the Cover Feeder (
4. Remove screws [B] to Upper paper path (
CF-3-15
x2).
x2).
BIN EXTENSION PLATE
19 April 2006
3.2.11BLOWER MOTOR M17 / M18
[C]
[C]
[A]
[B]
[B]
1. Remove complete Cover Feeder unit (
2. Cut cable tie [A].
3. Remove screws [B] (
x4).
4. Remove Blower motors M17/M18 [C].
CF-3-16
3.1.1).
19 April 2006
4.
FAULT CODE DESCRIPTIONS
TROUBLESHOOTING
4.1 FAULT CODE DESCRIPTIONS
CF-001 CF-M15
Feed motor short circuit..................................................................... CF-4-2
CF-002 CF-M15
Feed motor open circuit...................................................................... CF-4-2
CF-003 CF-M15
Feed motor no displacement pulses................................................. CF-4-2
CF-004 CF-M16
Drive motor short circuit..................................................................... CF-4-3
CF-005 CF-M16
Drive motor open circuit..................................................................... CF-4-3
CF-006 CF-M16
Drive motor no displacement pulses................................................. CF-4-3
CF-008 CF-Q31
Empty bin sensor is faulty.................................................................. CF-4-4
CF-009 CF-Q30
Paper path / DSD sensor is faulty...................................................... CF-4-5
CF-010 CF-Q32
Paper positioning sensor is faulty..................................................... CF-4-5
CF-011 CF-Q33
Paper bin low sensor is faulty............................................................ CF-4-6
CF-012 CF-Q38
Paper format sensor is faulty............................................................. CF-4-6
CF-201 CF-Q30
Paper path / DSD sensor was Not blocked within timeout.............. CF-4-7
CF-202 CF-Q30
Paper path / DSD sensor was Blocked exceeding timeout............. CF-4-7
CF-203 CF-Q32
Paper positioning sensor was Not blocked within timeout............. CF-4-7
CF-204 CF-Q32
Paper positioning sensor was Blocked exceeding timeout............ CF-4-7
CF-205 CF-Q30
Double feed / Misfeed sensor............................................................. CF-4-8
CF-401 CF-Q31
Load covers, Empty bin sensor......................................................... CF-4-8
CF-501 CF-Q33
Load covers, Paper bin low sensor................................................... CF-4-8
CF-502 CF-Q38
Wrong cover format, Paper width sensor......................................... CF-4-8
CF-4-1
Troubleshooting
CF-007 CF-M17/18 Blower motors open circuit................................................................ CF-4-4
FAULT CODE DESCRIPTIONS
19 April 2006
CF-001
Fault Code CF-001, indicates that the feed motor (CF-M15) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M15. Run the SDS again. Fault code CF-002 (Open circuit) is displayed?
Y
N
Disconnect plug H.P2 from PCB “H”. Check wires for Short circuit across leads, the orange wire M15 to H.P2-10
(violet) and the violet wire M15 to H.P2-3 (orange). Is there Short circuit?
Y
N
Replace PCB ”H”.
Replace wire Harness.
Replace motor CF-M15.
CF-002
Fault Code CF-002, indicates that the feed motor (CF-M15) has an Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M15. Enter Service mode and start feed motor (CF-M15) in check motors. Measure between the
orange wire M15 and the violet wire M15 (PWM 36V and ground). The voltage is approximately 36 VDC?
Y
N
Disconnect plug H.P2 from PCB “H”. Measure between J2-3 and J2-10 (PWM 36V and ground). The voltage is
approximately 36 VDC?
Y
N
Replace PCB “H”.
Replace wire Harness.
Replace motor CF-M15.
CF-003
Fault Code CF-003, indicates that the feed motor (CF-M15) do not receive any displacement pulses.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select feed motor (CF-M15) in check motors.
Procedure
Disconnect the sensor plug Q28 to motor CF-M15. Measure between the red wire Q28 and the black wire Q28 (5V and Signal
ground). The voltage is approximately 5 VDC?
Y
N
Disconnect plug F.P6 from PCB “F”. Measure between the J6-18 and J6-19 (5V and Signal ground). The
voltage is approximately 5 VDC?
Y
N
Replace PCB “F”.
Replace wire harness.
Disconnect plug F.P6 from PCB “F”. Check wires for Continuity / Short circuit from the white wire Q28 to F.P18-18,
the black wire Q28 to F.P18-19, the red wire Q28 to F.P18-4. Is there Continuity and no Short circuit?
Y
N
Replace wire harness.
1. Replace motor CF-M15.
2. Replace PCB “B”.
CF-4-2
19 April 2006
FAULT CODE DESCRIPTIONS
CF-004
Fault Code CF-001, indicates that the drive motor (CF-M16) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M16. Run the SDS again. Fault code CF-005 (Open circuit) is displayed?
Y
N
Disconnect plug C.P2 from PCB “C”. Check wires for Short circuit across leads, the orange wire M16 to C.P2-11
(violet) and the violet wire M16 to C.P2-4 (orange). Is there Short circuit?
Y
N
Replace PCB ”C”.
Replace wire Harness.
Replace motor CF-M16.
CF-005
Procedure
Disconnect the motor plug M16. Enter Service mode and start feed motor (CF-M16) in check motors. Measure between the
orange wire M16 and the violet wire M16 (PWM 36V and ground). The voltage is approximately 36 VDC?
Y
N
Disconnect plug C.P2 from PCB “C”. Measure between J2-4 and J2-11 (PWM 36V and ground). The voltage is
approximately 36 VDC?
Y
N
Replace PCB “C”.
Replace wire Harness.
Replace motor CF-M16.
CF-006
Fault Code CF-006, indicates that the drive motor (CF-M16) do not receive any displacement pulses.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select feed motor (CF-M16) in check motors.
Procedure
Disconnect the sensor plug Q29 to motor CF-M16. Measure between the red wire Q29 and the black wire Q29 (5V and Signal
ground). The voltage is approximately 5 VDC?
Y
N
Disconnect plug F.P6 from PCB “F”. Measure between the J6-13 and J6-22 (5V and Signal ground). The
voltage is approximately 5 VDC?
Y
N
Replace PCB “F”.
Replace wire harness.
Disconnect plug F.P6 from PCB “F”. Check wires for Continuity / Short circuit from the white wire Q29 to F.P21-21,
the black wire Q29 to F.P22-21, the red wire Q29 to F.P13-21. Is there Continuity and no Short circuit?
Y
N
Replace wire harness.
1. Replace motor CF-M16.
2. Replace PCB “B”.
CF-4-3
Troubleshooting
Fault Code CF-005, indicates that the drive motor (CF-M16) has an Open circuit.
Initial Actions
Check fuse F2 on Transformer.
FAULT CODE DESCRIPTIONS
19 April 2006
CF-007
Fault Code CF-007, indicates that the blowers (CF-M17 CF-M18) has an Open circuit.
Initial Actions
Check correctly mounted.
Procedure
Disconnect the motor plug M17/18. Enter Service mode and start blowers (CF-M17 CF-M18) in check motors. Measure between
the orange wire M17/18 and the violet wire M17/18 (PWM 36V and ground). The voltage is approximately 36 VDC?
Y
N
Disconnect plug H.P2 from PCB “H”. Measure between J2-2 and J2-9 (PWM 36V and ground). The voltage is
approximately 36 VDC?
Y
N
Replace PCB “H”.
Replace wire Harness.
Replace motor CF-M17/18.
CF-008
Fault Code CF-008, indicates that the Empty bin sensor (CF-Q31) is faulty.
Initial Actions
Make sure that the Paper Infeed sensor (CF-Q31) is installed correctly.
Procedure
1. Replace sensor CF-Q31.
2. Disconnect plug F.P2 from PCB “F”. Measure between J2-7 and J2-9 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “F”.
Disconnect plug from sensor CF-Q31. Check wire for Continuity / Short circuit from the white wire Q31 to F:P2-8. Is there
Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug F.P2 to PCB “F”. Measure between the red wire Q31 and the black wire Q31 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “F”.
CF-4-4
19 April 2006
FAULT CODE DESCRIPTIONS
CF-009
Fault Code CF-009, indicates that the DSD/paper path sensor (CF-Q30) is faulty.
Initial Actions
Check correctly mounted.
Procedure
Disconnect plug P1 at PCB “F”. Measure between P1-2 and P1-4 (5V and ground) in the P1 plug. The voltage is approximately 5 VDC.
Y
N
Replace PCB “F”
Connect plug P1. Measure between pin 2 (black) and pin 3 (red) at DSD sensor. The voltage is approximately 5 VDC?
Y
N
Check wires for open or short circuit. Is there an open or short circuit?
Y
N
Replace DSD sensor
Replace harness to sensor.
CF-010
Fault Code CF-010, indicates that the Paper postioning sensor (CF-Q32) is faulty.
Initial Actions
Make sure that the Paper positioning sensor (CF-Q32) is installed correctly.
Procedure
1. Replace sensor CF-Q32.
2. Disconnect plug F.P6 from PCB “F”. Measure between J6-10 and J6-12 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “F”.
Disconnect plug from sensor CF-Q32. Check wire for Continuity / Short circuit from the white wire Q32 to F:P2-11. Is there
Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug F.P6 to PCB “F”. Measure between the red wire Q32 and the black wire Q32 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “F”.
CF-4-5
Troubleshooting
Replace DSD sensor
FAULT CODE DESCRIPTIONS
19 April 2006
CF-011
Fault Code CF-011, indicates that the Paper low sensor bin (CF-Q33) is faulty.
Initial Actions
Make sure that the Paper low sensor bin (CF-Q33) is installed correctly.
Procedure
1. Replace sensor CF-Q33.
2. Disconnect plug F.P6 from PCB “F”. Measure between J6-23 and J6-25 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “F”.
Disconnect plug from sensor CF-Q33. Check wire for Continuity / Short circuit from, the white wire Q33 to F:P2-24. Is there
Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug F.P6 to PCB “F”. Measure between the red wire Q33 and the black wire Q33 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “F”.
CF-012
Fault Code CF-012, indicates that the Paper format sensor (CF-Q38) is faulty.
Initial Actions
Make sure that the Paper format sensor (CF-Q38) is installed correctly.
Procedure
1. Replace sensor CF-Q38.
2. Disconnect plug F.P4 and F.P6 from PCB “F”. Measure between J6-7 and J6-9 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “F”.
Disconnect plug from sensor CF-Q38. Check wire for Continuity / Short circuit from the white wire Q38 to F:P4-3. Is there
Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug F.P6 and F.P4 to PCB “F”. Measure between the red wire Q38 and the black wire Q38 (5V and ground). The
voltage is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “F”.
CF-4-6
19 April 2006
FAULT CODE DESCRIPTIONS
CF-201
Fault Code CF-201, indicates that during Run, the Paper path / DSD sensor (CF-Q30), was not
blocked in time.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Paper path / DSD photo transistor sensor, and the Paper path / DSD LED sensor (CF-Q30) is installed correctly.
Ensure that the Paper path / DSD sensor (CF-Q30) is clean.
Procedure
Enter the Service mode and select Paper path / DSD sensor (CF-Q30) in check sensors. Block, then unblock, the CF-Q30
with a sheet of paper. The Paper path / DSD sensor (CF-Q30) sensor indicates D:0 when the sensor is blocked and D:1
when the sensor is not blocked.
Y
N
Go to CF-009
1. Clean the feed rollers.
2. Make sure that the Jam clearance baffle is installed correctly.
3. Make sure that nothing interferes with the paper path in the Cover feeder.
CF-202
CF-203
Fault Code CF-203, indicates that during Run, the Paper positioning sensor (CF-Q32), was not
blocked within timeout.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Paper positioning sensor (CF-Q32) is installed correctly.
Ensure that the Paper positioning sensor (CF-Q32) is clean.
Procedure
Enter the Service mode and select Paper positioning sensor (CF-Q32) in check sensors. Block, then unblock, the CF-Q32
with a sheet of paper. The Paper positioning sensor (CF-Q32) sensor indicates D:0 when the sensor is blocked and D:1
when the sensor is not blocked.
Y
N
Go to CF-010
1. Clean the feed rollers.
2. Make sure that the Jam clearance baffle is installed correctly.
3. Make sure that nothing interferes with the paper path in the Cover feeder.
CF-204
Fault Code CF-204, indicates that during Run, the Paper positioning sensor (CF-Q32), was blocked
exceeding timeout.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Paper positioning sensor (CF-Q32) is installed correctly.
Ensure that the Paper positioning sensor (CF-Q32) is clean.
Procedure
Enter the Service mode and select Paper positioning sensor (CF-Q32) in check sensors. Block, then unblock, the CF-Q32
with a sheet of paper. The Paper positioning sensor (CF-Q32) sensor indicates D:0 when the sensor is blocked and D:1
when the sensor is not blocked.
Y
N
Go to CF-010
1. Clean the feed rollers.
2. Make sure that the Jam clearance baffle is installed correctly.
3. Make sure that nothing interferes with the paper path in the Cover feeder.
CF-4-7
Troubleshooting
Go to CF-009 Paper path / DSD sensor is faulty
FAULT CODE DESCRIPTIONS
19 April 2006
CF-205
Fault Code CF-205, indicates that during Run, the DSD sensor (CF-Q30), stopped the system due
to double feed.
Initial Actions
Same kind of paper is loaded in bin
Ensure that the DSD sensor (CF-Q32) is clean.
Procedure
Go to CF service
(
5.5).
CF-401
Fault Code CF-401, indicates that during Run, the Empty bin sensor (CF-Q31), was not blocked.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Empty bin sensor (CF-Q31) is installed correctly.
Ensure that the Empty bin sensor (CF-Q31) is clean.
Replace sensor.
Procedure
Enter the Service mode and select Empty bin sensor (CF-Q31) in check sensors. Block, then unblock, the CF-Q31 with a
sheet of paper. The Empty bin sensor (CF-Q31) sensor indicates D:0 when the sensor is blocked and D:1 when the
sensor is not blocked.
Y
N
Go to CF-008
1. Make sure that nothing interferes with the paper path in the Cover feeder.
CF-4-8
19 April 2006
5
SERVICE TABLES
5.1 SERVICE TABLES
Service
Tables
Cover Feeder SERVICE TABLES is located in the Booklet Maker BK5010 Service
Manual (
5)
CF-5-1
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19 April 2006
6.
ELECTRICAL COMPONENT LIST
DETAILED SECTION DESCRIPTIONS
6.1 ELECTRICAL COMPONENT LIST
Page
Grid code
CF-M15 Feed motor.............................................................................................. CF-6-2
CF-M16 Drive motor............................................................................................. CF-6-2
CF-M17/
M18 Blower motors........................................................................................ CF-6-3
Empty bin sensor................................................................................... CF-6-3
Paper path / DSD detection sensor (Phototransistor)........................ CF-6-3
Paper path / DSD detection sensor (LED)............................................ CF-6-3
Paper positioning sensor...................................................................... CF-6-3
Paper bin low sensor............................................................................. CF-6-2
Paper width sensor................................................................................ CF-6-2
Detalied description
CF-Q31
CF-Q30
CF-Q30
CF-Q32
CF-Q33
CF-Q38
CF-6-1
ELECTRICAL COMPONENT LIST
19 April 2006
6.1.1 REAR VIEW
CF-Q33
CF-M16
CF-M15
CF-6-2
19 April 2006
ELECTRICAL COMPONENT LIST
6.1.2 OUTFEED VIEW
CF-Q38
CF-Q32
Detalied description
CF-Q30
Phototransistor
CF-Q31
CF-Q30
LED
CF-M17/
M18
CF-6-3
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19 April 2006
COVER FEEDING PROCESS
6.2 COVER FEEDING PROCESS
6.2.1 PRINCIPLE OF OPERATION
Inserting covers
M15
Q30
M17 M18
M16
Q31
Q32
During automatic operation the copier sends a start signal, a manually fed set
needs to insert a cover or the single feed mode is selected.
Feed motor (CF-M15) and drive motor (CF-M16) starts. This drives the cover into
the booklet maker. The feed motor (CF-M15) uses an encoder and the current
format to determine when the trailing edge leaves the feed motor rollers. When
this happens the feed motor stops. The drive motor monitors the paper positioning
sensor (CF-Q32) and when the trailing edge of the cover leaves this sensor, the
drive motor (CF-M16) lowers its speed (unless already running at low speed as
when running an A3 job). When the speed of the drive motor (CF-M16) is lowered
the feed motor starts and repeats the initial cycle.
CF-6-5
Detalied description
Cover On is selected in the booklet maker UI (operation panel).
Empty bin sensor (CF-Q31) detects that sheets are loaded. The operator must
press down the bin to load covers. The bin automatically positions the covers
against the feed roller. Blower CF-M17 / M18 blows separation air into the stack.
If sheets have been run previously, the cover feeder is now in ready mode.
If sheets have just been loaded, feed motor (CF-M15) and drive motor (CF-M16)
start and transport the first sheet past sensor (CF-Q30). When paper positioning
sensor (CF-Q32) is activated the feed and drive motors runs a short distance longer and then stops. The cover feeder is now in ready mode.
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19 April 2006
SPECIFICATIONS
SPECIFICATIONS
Specification
Cover Feeder SPECIFICATIONS is located in the Booklet Maker BK5010 Service
Manual (
SPECIFICATIONS)
CF-Spec-1
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19 April 2006
WIRING
Cover Feeder
Wiring
See pocket at rear of manual for wiring diagrams.
CF-Wir-1
Page intentionally blank
TRIMMER TR5010
SERVICE MANUAL
19 April 2006
Subject to change
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19 April 2006
TABLE OF CONTENTS
1 INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE............................................................ TR-1-1
2 PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE...................................... TR-2-1
3.REPLACEMENT AND ADJUSTMENT
3.1 COVERS.............................................................................................. TR-3-1
3.1.1 FRONT AND REAR COVER...................................................... TR-3-1
3.1.2 TOP COVER.............................................................................. TR-3-2
3.1.3 BLOWER MOTOR M5 / M6........................................................ TR-3-3
3.1.4 INFEED COVER......................................................................... TR-3-4
3.1.5 LOCKING BRACKET................................................................. TR-3-5
3.1.6 UPPER OUTFEED COVER....................................................... TR-3-6
3.1.7 INTERLOCK SWITCH S9 &S10................................................. TR-3-7
3.1.8 LOWER OUTFEED COVER...................................................... TR-3-8
3.1.9 PROTECTION COVER.............................................................. TR-3-9
3.2 AREA C.............................................................................................. TR-3-11
3.2.1 INFEED SENSOR Q13............................................................ TR-3-11
3.2.2 CONTROL SWITCH S2........................................................... TR-3-12
3.2.3 CONTROL SWITCH S3........................................................... TR-3-13
3.2.4 TRANSPORT MOTOR M1....................................................... TR-3-14
3.2.5 TRANSPORT BELT SENSOR Q4............................................ TR-3-15
3.2.6 TRIM KNIFE MOTOR M2......................................................... TR-3-16
3.2.7 TRIM KNIFE HOME POSTITON SENSOR Q5........................ TR-3-17
3.2.8 TRIM KNIFE............................................................................. TR-3-18
3.2.9 PAPER PATH & OUTFEED SENSOR Q6................................ TR-3-22
3.2.10STOP GATE CARRIAGE.......................................................... TR-3-23
3.2.11 STOP GATE MOTOR M3 & SENSOR Q7................................ TR-3-24
3.2.12LENGTH ADJUSTMENT MOTOR M4 & SENSOR Q12.......... TR-3-25
3.2.13LENGTH ADJUSTMENT HOME POSITION SWITCH S11...... TR-3-26
3.2.14LOWER OUTFEED BELTS...................................................... TR-3-27
3.2.15 UPPER OUTFEED BELTS....................................................... TR-3-28
3.2.16TRIM BIN FULL SENSOR Q8.................................................. TR-3-29
3.2.17TRANSMISSION CHAIN.......................................................... TR-3-30
3.2.18KNIFE SUPPORT CHAIN........................................................ TR-3-31
3.2.19KNIFE CHAIN........................................................................... TR-3-32
3.2.20INFEED BELTS........................................................................ TR-3-33
3.3 PCB................................................................................................... TR-3-35
3.3.1 MD6DC PCB ”A”....................................................................... TR-3-35
4.TROUBLESHOOTING
4.1 FAULT CODE DESCRIPTIONS........................................................... TR-4-1
5 SERVICE TABLES
5.1 SERVICE TABLES............................................................................... TR-5-1
19 April 2006
6.DETAILED SECTION DESCRIPTIONS
6.1 ELECTRICAL COMPONENT LIST...................................................... TR-6-1
6.1.1 REAR VIEW............................................................................... TR-6-2
6.1.2 INFEED VIEW............................................................................ TR-6-3
6.1.3 OUTFEED VIEW........................................................................ TR-6-4
6.1.4 STOP CARRIAGE VIEW............................................................ TR-6-5
6.2 BOARD STRUCTURE......................................................................... TR-6-7
6.2.1 BLOCK DIAGRAM...................................................................... TR-6-7
6.2.2 CONTROLLER MD6DC............................................................. TR-6-8
6.2.2 CONTROLLER MD6DC, CONTINUES...................................... TR-6-9
6.3 TRIMMING PROCESS...................................................................... TR-6-11
6.3.1 PRINCIPLE OF OPERATION................................................... TR-6-11
6.3.2 SIZE ADJUSTMENT................................................................. TR-6-12
SPECIFICATIONS
SPECIFICATIONS................................................................................TR-Spec-1
WIRING
Trimmer....................................................................................................TR-Wir-1
VI
1
INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE
Trimmer INSTALLATION PROCEDURE is located in the Booklet Maker BK5010
Service Manual (
1.5)
TR-1-1
Installation
19 April 2006
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19 April 2006
2
PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE
Preventive
Maintenance
Trimmer PREVENTIVE MAINTENANCE SCHEDULE is located in the Booklet
Maker BK5010 Service Manual (
2)
TR-2-1
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19 April 2006
3.
COVERS
REPLACEMENT AND ADJUSTMENT
3.1 COVERS
3.1.1 FRONT AND REAR COVER
Replacement
Adjustment
Front Cover
1. Open the Top Cover.
2. Remove screws [A] (
3. Loosen screws [B] (
x3)
x2)
[A]
[B]
Rear Cover
1. Loosen screws [C] (
[C]
TR-3-1
x3)
19 April 2006
COVERS
3.1.2 TOP COVER
[A]
[B]
[B]
[C]
[D]
Bad
Top cover too low
Good
Bad
Top cover too high
Removal
1. Pry off the Gas spring [A] using a screw driver.
x4,
2. Remove screws and nuts [B] (
x4).
Replacement
1. Reverse the removal procedure.
Adjustment
1. Loosen screws and nuts [C] (
x4,
x4).
2. Adjust Top cover so frame edge [C] is aligned with top of the hinge [D].
See drawings above.
3. Tighten screws and nuts [C] (
x4,
x4).
TR-3-2
19 April 2006
COVERS
Replacement
Adjustment
3.1.3 BLOWER MOTOR M5 / M6
[A]
Removal
1. Remove blower assy by lifting it straight up [A].
Replacement
1. Reverse the removal procedure.
TR-3-3
19 April 2006
COVERS
3.1.4 INFEED COVER
[A]
[B]
[C]
1. Open the Top Cover.
3.1.3).
2. Remove Blower assy (
2. Disconnect connectors [A] (
3. Remove Front and Rear cover (
4. Remove screws [B] (
x5).
5. Remove screws [C] (
x5).
x2).
3.1.1).
TR-3-4
19 April 2006
COVERS
Replacement
Adjustment
3.1.5 LOCKING BRACKET
[B]
[B]
[A]
Removal
1. Loosen nuts [A] (
x2).
2. Locking bracket will fall down.
Replacement
1. Push Trimmer against Bookletmaker.
2. Push up Locking bracket so it latches studs [B].
3. Tighten nuts [A] (
x2).
TR-3-5
19 April 2006
COVERS
3.1.6 UPPER OUTFEED COVER
[A]
[B]
[C]
[D]
[E]
1. Remove Belt stacker.
2. Remove Front and Rear cover (
3.1.1).
3. Open the Top Cover.
4. Remove the Gas spring [A] by prying it off using a screw driver.
x1).
5. Remove connector [B] (
6. Cut cable ties [C] inside cover.
7. Remove screws [D] (
x5).
8. Remove screws [E] (
x5).
TR-3-6
19 April 2006
COVERS
3.1.7 INTERLOCK SWITCH S9 &S10
[B]
Replacement
Adjustment
[A]
Removal
1. Remove connector [B](
2. Remove nuts [A] (
x1).
x2).
Replacement
1. Reverse the removal procedure.
Adjustment
1. Loosen nuts [A] (
x2).
2. Adjust the interlock so that Top cover actuates interlock switch 2 mm before
closed.
NOTE: Make sure both rubber dampers contact the front cover when closed.
3. Tighten nuts [A] (
x2).
WARNING
Overriding or cheating the interlock allows the TR5010 system to operate
with the top cover open which can result in personal injury. Never give the
operator access to the cheater or show how ovverriding the interlock system is carried out.
TR-3-7
19 April 2006
COVERS
3.1.8 LOWER OUTFEED COVER
[A]
[B]
[B]
1. Remove Belt stacker.
2. Remove Front and Rear cover (
3. Remove Protection Cover (
4. Loosen screws [A] (
5. Remove screws [B] (
3.1.1).
3.1.9).
x2).
x4).
TR-3-8
19 April 2006
COVERS
Replacement
Adjustment
3.1.9 PROTECTION COVER
[B]
[C]
[A]
Replacement Step 1.
Replacement Step 2.
Removal
1. Lift out scrap paper bin [B].
2. Remove screws [A] (
x4).
Replacement
1. Place the front end of the cover up against the lower knife beam [C].
2. Push in cover so it hooks onto the screws [D].
3. Mount screws [A] (
x4).
TR-3-9
[D]
Page intentionally blank
19 April 2006
AREA C
3.2 AREA C
Replacement
Adjustment
3.2.1 INFEED SENSOR Q13
[B]
[A]
1. Undock the Trimmer.
2. Remove nuts [A] inside bracket holding the Sensor bracket (
3. Remove connector from the Sensor (
4. Remove sensor [B].
TR-3-11
x1).
x2).
19 April 2006
AREA C
3.2.2 CONTROL SWITCH S2
[A]
[B]
Removal
1. Remove Rear cover (
3.1.1).
2. Remove connectors [A] (
3. Remove screws [B] (
x2).
x2 ).
Replacement
1. Reverse the removal procedure.
Adjustment
1. Lift the Infeed shaft.
2. Make sure the Switch activates slightly before the shaft latches in upper position.
3. To adjust, loosen screws [B] (
x2 ).
4. Reposition switch to obtain adjustment.
5. Tighten screws [B] (
x2 ).
TR-3-12
19 April 2006
AREA C
3.2.3 CONTROL SWITCH S3
Replacement
Adjustment
[A]
[B]
Removal
1. Remove Rear cover (
3.1.1).
2. Remove connector [B] (
X2).
3. Remove screw [A] (
x2).
Replacement
1. Reverse the removal procedure.
Adjustment
1. Lift the compressing bracket.
2. Make sure the Switch activates approximately 10 mm from where the compressing bracket latches in the upper position.
3. To adjust, loosen screws [A] (
x2 ).
4. Reposition switch to obtain adjustment.
5. Tighten screws [A] (
x2 ).
TR-3-13
19 April 2006
AREA C
3.2.4 TRANSPORT MOTOR M1
[B]
[C]
[A]
1. Remove Transmission chain (
3.2.17).
2. Remove Knife support chain (
3.2.18).
3. Remove connector [A] (
x1).
4. Grab the inner sprocket to pull out the whole sprocket assembly [B].
5. Remove screws [C] holding the motor ( x3).
NOTE: Hold the spacers between motor and frame when removing screws.
TR-3-14
19 April 2006
AREA C
Replacement
Adjustment
3.2.5 TRANSPORT BELT SENSOR Q4
[C]
[A]
[B]
Removal
1. Remove Rear cover (
3.1.1).
x1).
2. Remove connector [A] (
3. Remove nut and screw [B] (
x1,
x1).
4. Remove bracket [C].
5. Squeeze the barbs of the sensor to remove.
Replacement
1. Reverse the removal procedure
NOTE: When tightening nut/screw make sure there is a space between encoder disc and sensor.
2. Enter service program mode and start the belts (motor M1). Check speed (m/
s) is registered (
Service Manual BK5010: 5.1.1, 5.1.2).
3. If no, or erratic speed, loosen screw/nut [B] (
x1,
4. Reposition sensor to obtain correct speed registration.
5. Tighten screw/nut [B] (
x1,
x1).
TR-3-15
x1).
19 April 2006
AREA C
3.2.6 TRIM KNIFE MOTOR M2
WARNING
Place the safety block [D] between lower knife and upper knife beam. When
removing the chain nothing holds upper knife beam and knife in position.
[B]
[A]
[C]
[F]
[E]
[D]
Removal
1. Remove Rear cover (
2. Remove connector [E] (
3.1.1).
x1).
3. Remove circlip [C] using a circlip plier.
4. Loosen screws [A] holding the motor (
x3).
5. Remove sprocket [F].
6. Remove screws [A] holding the motor (
x3).
Replacement
1. If it is difficult to mount sprocket [F] remove master link [B].
2. Reverse the removal procedure.
3. Tension the chain so there is no slack when tightening screws [A] (
TR-3-16
x3).
19 April 2006
AREA C
3.2.7 TRIM KNIFE HOME POSTITON SENSOR Q5
[D]
[A]
[B]
Removal
1. Remove Rear cover (
2. Remove connector [A] (
3.1.1).
x1).
3. Squeze the barbs of the sensor to remove.
NOTE: Gently pull bracket [B] to remove.
WARNING
Stay clear from upper knife. The knife edge may cause serious injuries.
Replacement
1. Reverse the removal procedure.
2. Enter service program mode to check that sensor Q5 changes state when
blocked/unblocked (
Service Manual BK5010: 5.1.1, 5.1.2).
NOTE: Do not cheat the interlock.
3. Move the Upper knife by turning crank [C] using a 13 mm wrench.
4. Check on the LCD that sensor Q5 changes state when blocked/unblocked by
actuators [D].
TR-3-17
Replacement
Adjustment
[C]
19 April 2006
AREA C
3.2.8 TRIM KNIFE
WARNING
Stay clear from upper knife. The knife edge may cause serious injuries.
Place the safety block [A] between lower knife and upper knife beam. Keep
the safety block in that position as much time as possible throughout this
procedure.
[A]
[D]
[B]
[G]
Removal
1. Remove the belt stacker.
[E]
2. Undock the Trimmer.
3. Latch the compressing bracket in upper position.
[F]
4. Remove the infeed cover (
3.1.4).
5. Remove protection cover (
3.1.9).
[C]
Removal Upper knife
Upper knife
1. Remove screws [B] ( x3).
Lower knife
2. Remove knife protection plate [C].
3. Move transport protection from the new to the old knife or use the transport
protection attached behind the front cover.
4. Remove the e-clip [D] from the middle plunger, to release the Set clamp (
x1).
5. Remove screws [E] and cup spring washers ( x6).
NOTE: When removing screws [E] the nuts [G] will fall down through the cutout in bottom of knife beam.
Removal Lower knife
1. Remove screws [H] ( x4).
2. Remove screws [I] and cup spring washers (
TR-3-18
x2).
Replacement Upper knife
1. Move transport protection from the old to the new knife.
2. Clean and apply grease on guide bars [J] and side guides [K].
3. Fit upper knife onto guide bars [J].
Apply grease on the cup spring washers [F] closest to the knife.
Mount screws [E] with nuts [G] ( x6,
x6).
NOTE: Make sure each screw has 7 cup spring washers placed according to figure.
4. Remove transport protection and mount [D]
it on the old knife.
[O]
5. Mount knife protection plate [C].
[B]
6. Mount the set clamp in position with
[K]
e-clip [D] (
x1) .
[G]
Replacement Lower knife
[E]
1. Place the lower knife onto the lower knife
beam.
[F]
2. Apply grease on both washers.
3. Mount screws [I] ( x2) and cup spring [J]
washers.
[C]
4. Mount screws [H] ( x4).
[N] [L] [M]
[I]
[H]
5
1
3
4
2
6
[L]
[M]
[N]
Adjustment
1. Turn screws [E] so there is no tension and no play between cup spring washers and upper knife.
2. Then turn screws [E] one revolution clockwise each.
3. Loosen nuts [L] (
x3)
4. Turn screws [M] ( x3) counter clockwise until they passes edge [N].
5. Loosen screws [I] & [H] ( x6).
6. Push the Lower knife against the bracket [N].
TR-3-19
Replacement
Adjustment
AREA C
19 April 2006
AREA C
19 April 2006
7. Use a feeler gauge and check that the space [Q] between upper knife and the
two red marked reference screws in the middle [P] is 0.50 mm.
NOTE: Never touch the red painted reference screws [P].
8. Adjust the space if necessary with screws [O] ( x2).
[O]
[P]
0.50 mm
[Q]
[R]
9. Bring the Upper knife down to the bottom position by turning crank [R] using a
13 mm wrench.
NOTE: When bringing the Upper knife down, make sure it does not touch the
Lower knife.
10. Gently push in the Lower knife against the Upper knife.
NOTE: Listen that it touches on both sides.
11. Raise the upper knife to the top position by turning crank [R].
12. Tighten screws [I] & [H] ( x6).
NOTE: Tighten a little at first according to the sequence 1-6. Then tighten a little harder to finally fully tighten the screws. Always according to the sequence
1-6.
13. Turn screws [M] ( x3) so they touch the lower knife.
TR-3-20
13. Slowly and carefully without paper lower the upper knife by turning crank [R].
Check that the upper knife does not contact the lower knife. In that case, back
up the upper knife and start over from step 3. If no contact proceed to the bottom position.
NOTE: Look through the cut out in the side frames while turning crank.
14. Make 5 different booklets in the BK5010 required for the adjustment. The
booklets should have 2, 15, 20 & 25 sheets A3 (11“x17“) 80 gsm (20# bond).
15. Place the 2 sheet booklet in cutting position.
Trim the set by turning crank [R].
Inspect the trim result. Check if the lowest sheet of the booklet is cut clean
throughout the length.
If good, trim and inspect the 15 sheet booklet the same way.
If good, trim and inspect the 20 sheet booklet the same way.
If the set is not correctly cut on one of the ends, loosen the five screws [I] & [H]
on the bad end and keep the one screw [I] tightened at the good end.
Turn screw [M] on the bad end 1/36 revolution or 10° clockwise ( x1).
16. Repeat from step 11 until trim result is perfect.
NOTE: As guidance, trim the over spec. 30 sheet booklet to clearer see if and
where it does not cut clean.
17. If not correctly cut in the middle, loosen the four screws [H] and keep the
screws [I] tightened.
Turn screw [M] in the middle 1/72 revolution or 5°clockwise ( x1).
Repeat from step 11.
NOTE: If the knife/knives has been damaged, they have to be replaced or
resharpened even if a correct result is obtained, due to shortened life time.
18. Tighten the lock nuts [L] without turning screws [M] (
x3).
19. Reverse removal procedure step 1-5.
NOTE: When the knives become dull it is possible to resharpen them.
The upper knife can be resharpened until it is 70 mm (2”3/4) wide at the shorter end. Resharpen at a 25° angle.
The lower knife can be resharpened until it is 38 mm (1”½) wide.
Resharpen at a 1° angle.
TR-3-21
Replacement
Adjustment
AREA C
19 April 2006
19 April 2006
AREA C
3.2.9 PAPER PATH & OUTFEED SENSOR Q6
[A]
[B]
[C]
[D]
1. Remove connector [D] (
x1).
2. Lift up and latch compressing bracket [B].
3. Remove screws [A] (
x2).
4. Remove screws [C] (
x2).
5. Pull Paper path out through the outfeed.
6. To remove sensor, remove screw [E] (
x1).
TR-3-22
[E]
19 April 2006
AREA C
3.2.10STOP GATE CARRIAGE
[B]
[C]
Replacement
Adjustment
[D]
[A]
Removal
1. Before switching off the power,
set the Trimmer (Paper size) to A4 / 8.5x11” and Trimming to off.
2. Remove Lower outfeed cover (
3.1.8).
3. Remove connectors [A] (
x2).
4. Remove connectors [B] (
x2).
5. Remove connector [C] (
x1).
6. Pull out the Carriage gently.
CAUTION
When removing the Carriage, watch out so the motor connectors [B] & [C]
do not get damaged by the side frame cut-outs.
Replacement
1. When positioning the carriage in place, make sure the two sliding rods and the
gear rack enters their holes and slot.
2. Reverse the removal procedure.
TR-3-23
19 April 2006
AREA C
3.2.11 STOP GATE MOTOR M3 & SENSOR Q7
[E]
[B]
[D]
[C]
[A]
Removal
1. Remove Stop gate carriage (
2. Remove nut [A] (
1.2.10).
x1).
3. Remove Crank arm [B].
4. Remove screws [C] holding the motor (
5. Loosen set screw [D] (
x4).
x1).
Replacement
1. Mount the Crank pulley [E] without tightening the set screw [D] (
2. Mount motor with screws [C] (
x4).
3. Mount Crank arm [B].
x1).
4. Tightening nut [A] (
NOTE: Make sure play for Crank arm [B] is maintained.
5. Position the Crank pulley [E] so it is aligned with Crank arm [B].
6. Tighten set screw [D] (
x1) on the flat of the shaft..
7. Reinstall Stop gate carriage (
3.2.10).
TR-3-24
x1).
19 April 2006
AREA C
3.2.12LENGTH ADJUSTMENT MOTOR M4 & SENSOR Q12
Replacement
Adjustment
[B]
[A]
1. Remove Stop gate carriage (
3.2.10).
2. Unhook spring [A].
3. Remove screws [B] holding the motor (
TR-3-25
x4).
19 April 2006
AREA C
3.2.13LENGTH ADJUSTMENT HOME POSITION SWITCH S11
[B]
[Picture 1]
[A]
[Picture 2]
Removal
1. Remove Stop gate carriage (
2. Remove screws [B] (
3.2.10).
x2).
3. Remove connectors [A] (
x2).
Replacement
1. Reverse the removal procedure.
Adjustment
1. Place a ruler across the slide rods and up against the flange bushings
[Picture 1].
2. Position the switch so it is activated by the ruler and
so there is a 0.5 mm ± 0.2 mm gap between switch body and ruler [Picture 2].
3. Tighten screws [B] (
x2).
TR-3-26
19 April 2006
AREA C
3.2.14LOWER OUTFEED BELTS
[B]
[D]
Replacement
Adjustment
[B]
[C] [A]
Removal
1. Remove Stop gate carriage (
2. Remove Paper path (
3.2.9).
3. Remove Transmission chain (
4. Remove screws [B] (
5. Remove e-clip [C] (
3.2.10).
3.2.17).
x2).
x1).
6. Slide Flange bushing [C] towards the center of the shaft and tilt the shaft out
through the cut-out in the side frame.
Replacement
1. Reverse the removal procedure.
Adjustment
1. Loosen screws [B] (
x2).
2. The belts should be adjusted so they have no slack and even tension.
3. Pull shaft [D] to obtain adjustment and tighten screws [B] (
TR-3-27
x2).
19 April 2006
AREA C
3.2.15 UPPER OUTFEED BELTS
[I]
[H]
[E]
[F]
Removal
1. Remove Belt stacker.
2. Remove Front and Rear cover (
3. Remove Transmission chain (
4. Unhook springs [A] (x2).
3.1.1).
3.2.17).
5. Remove screws [B] ( x6).
NOTE: Leave the screw at the top on each side
for the outfeed cover to pivot around.
x2).
6. Remove e-clip [C] (
Remove nylon washer [C] (x2).
Unhook link arm [D] (x2).
Remove needle bearing [C] (x2).
x2).
7. Remove e-clip [E] (
8. Pull out shaft [F].
9. Remove e-clips [G] (
x2) inside frames.
10. Slide Flange bushings [G] towards the center of
the shaft and pull out the whole assembly through the outfeed.
11. Loosen screws [H] (
x4) and remove belts.
Adjustment
1. The belts should be adjusted so they have no
slack and even tension.
2. Pull runner pulleys [I] to obtain adjustment and
tighten screws [H] ( x4).
Replacement
1. Reverse the removal procedure.
TR-3-28
[A]
[D]
[C]
[G]
[B]
[A]
[D]
[C]
[G]
19 April 2006
AREA C
[A]
[B]
1. Undock the Trimmer.
2. Remove connector [A] (
3. Remove screw [B] (
x1).
x1).
TR-3-29
Replacement
Adjustment
3.2.16TRIM BIN FULL SENSOR Q8
19 April 2006
AREA C
3.2.17TRANSMISSION CHAIN
WARNING
Place the safety block [D] between lower knife and upper knife beam. When
removing the chain nothing holds upper knife beam and knife in position.
[D]
[A]
[C]
[B]
1. Remove Front cover (
2. Remove screws [A] (
3.1.1).
x3).
3. Remove bracket [B].
4. Pull Tensioner [C] to release tension when removing chain.
TR-3-30
19 April 2006
AREA C
3.2.18KNIFE SUPPORT CHAIN
[A]
Replacement
Adjustment
[B]
1. Remove Front cover (
3.1.1).
2. Remove Transmission chain (
3. Loosen screws [A] (
3.2.17).
x3).
4. Remove chain from sprocket [B].
Replacement
1. Reverse the removal procedure.
2. Tension the chain so there is no slack when tightening screws [A] (
TR-3-31
x3).
19 April 2006
AREA C
3.2.19KNIFE CHAIN
WARNING
Place the safety block [D] between lower knife and upper knife beam. When
removing the chain nothing holds upper knife beam and knife in position.
[E]
[B]
[A]
[C]
[D]
Removal
1. Remove Rear cover (
3.1.1).
2. Remove retaining ring [A].
3. Loosen screws [B] holding the motor (
x3).
4. Remove sprocket [C].
Replacement
1. If it is difficult to mount sprocket [C] remove master link [E].
2. Reverse the removal procedure.
3. Tension the chain so there is no slack when tightening screws [B] (
TR-3-32
x3).
AREA C
19 April 2006
[E] [B]
[A]
[F]
[H]
[G] [D]
Replacement
Adjustment
3.2.20INFEED BELTS
[C]
Removal
1. Undock the Trimmer.
2. Remove Infeed cover (
3.1.4).
3. Remove Front and Rear cover (
3.1.1).
4. Unhook Transmission chain [E] from sprocket [F].
NOTE: Unhooking chain from outfeed shaft sprockets first to gain more slack.
5. Unhook Springs [A] on both ends of the shaft (x2).
6. Remove screws [B] on both ends of the shaft (
x2) .
7. Remove Plastic retaining clips [G] (x8).
8. Remove Belts [D] (x4) from Lever shaft [H].
NOTE: Move the belts to one end and the lever shaft to the opposite end.
9. Remove e-clip [C] and slide flange bushing towards the center of the shaft.
(
x1)
10. Tilt the shaft out through the cut-out in the side frame on that end to
remove the Belts [D] (x4).
Replacement
1. Reverse the removal procedure.
Adjustment
1. Loosen nuts [B] (
x2) slightly.
2. Place a piece of paper (80 gsm) between the two center belts and the ball
bearings.
3. Pull the sheet a little, by each of the center belts to verify even pressure.
4. Unskew shaft until even pressure is obtained and tighten nuts [B] (
TR-3-33
x2).
Page intentionally blank
19 April 2006
PCB
3.3 PCB
3.3.1 MD6DC PCB ”A”
ON
A.P4
A.P7
A.P6
A.P11
A.P13
A.P3
A.P14
A.P2
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes, data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs). ESD problems can be minimized by maintaining all
machine ground connections, ensuring the proper handling of circuit boards/ sensors
- Use ESD protection when working near PCBs. Failure to use ESD protection is likely to
result in a PCB failure (
Service Manual BK5010 3.1 ).
Removal
1. Remove Rear cover (
3.1.1 ).
2. Remove all connectors from the PCB (
x8 ).
3. Squeeze the barbs of the four pins [A] and lift out the PCB.
Replacement
1. Position the PCB on the pins [A] and snap it in place.
2. Connect all plugs to PCB according to picture (
x8 ).
3. Make sure all DIP-switches are set to OFF according to picture.
NOTE: Make sure replacement PCB has matched software with the system
refering to the latest Technical Bulletin.
Download software if needed (
Service Manual BK5010 5.2 ).
4. Reinstall Rear cover (
3.1.1 ).
TR-3-35
Replacement
Adjustment
[A]
Page intentionally blank
19 April 2006
4.
FAULT CODE DESCRIPTIONS
TROUBLESHOOTING
4.1 FAULT CODE DESCRIPTIONS
Fault
code
Item
Fault description
No.
TR-001 TR-M1
Page
No.
Transport motor No displacement pulses......................................... TR-4-2
TR-003 TR-M1
Transport motor Short circuit............................................................. TR-4-4
TR-004 TR-M1
Transport motor Open circuit............................................................. TR-4-4
TR-005 TR-M2
Trim knife motor Short circuit............................................................ TR-4-4
TR-006 TR-M2
Trim knife motor Open circuit............................................................. TR-4-5
TR-007 TR-M3
Stop gate motor Cycle time out.......................................................... TR-4-5
TR-008 TR-M3
Stop gate motor Short circuit............................................................. TR-4-6
TR-009 TR-M3
Stop gate motor Open circuit............................................................. TR-4-6
TR-010 TR-M4
Stop gate positioning motor No displacement pulses..................... TR-4-6
TR-011 TR-M4
Stop gate positioning motor Cycle time out..................................... TR-4-7
TR-012 TR-M4
Stop gate positioning motor Short circuit......................................... TR-4-7
TR-013 TR-M4
Stop gate positioning motor Open circuit......................................... TR-4-8
TR-014 TR-M5/M6 Blower motor(s) Open circuit............................................................. TR-4-8
TR-015 TR-Q13
Infeed sensor is Faulty........................................................................ TR-4-8
TR-016 TR-S2/S3
Control switch infeed or out feed Faulty........................................... TR-4-9
TR-017 TR-Q6
Outfeed sensor Trimmer is Faulty...................................................... TR-4-9
TR-018 TR-Q8
Trim bin full sensor is Faulty............................................................ TR-4-10
TR-150
36V Input low .................................................................................... TR-4-10
TR-151
36V Input high.................................................................................... TR-4-10
TR-152 TR-S9/S10 Interlock switch faulty........................................................................TR-4-11
TR-201 TR-Q13
Infeed sensor was Not blocked within timeout................................TR-4-11
TR-202 TR-Q13
Infeed sensor was Blocked exceeding timeout...............................TR-4-11
TR-203 TR-Q6
Outfeed sensor Trimmer was Not blocked within timeout............ TR-4-12
TR-204 TR-Q6
Outfeed sensor Trimmer was Blocked exceeding timeout............ TR-4-12
TR-205 TR-S2/S3
Infeed shaft or Outfeed compressing bracket
not in lower position.......................................................................... TR-4-12
TR-401
Trim bin full........................................................................................ TR-4-12
TR-501
Trim bin full........................................................................................ TR-4-12
TR-502
Trimmer fan missing.......................................................................... TR-4-13
TR-4-1
Troubleshooting
TR-002 TR-M1/M2 Transport motor and Trim knife motor Cycle time out..................... TR-4-3
FAULT CODE DESCRIPTIONS
19 April 2006
TR-001
Fault Code TR-001, indicates that the Transport motor (TR-M1) does not receive any displacement
pulses.
Initial Actions
Check fuse F2 on Transformer.
TR 3.2.5).
Make sure that the Transport belt sensor (TR-Q4) is installed correctly (
Procedure
Enter the Service mode and select Transport motor (TR-M1) in check motors. Does the encoder run properly, Parts catalog
page 13, Item 17?
Y
N
1. Check transmission (
3.2.17).
2. Replace motor TR-M1.
1. Replace sensor TR-Q4.
2. Disconnect plug B.P14 from PCB “A”. Measure between J14-13 and J14-15? (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “A”.
Disconnect plug from sensor TR-Q4. Check wires for Continuity / Short circuit from the white wire Q4 to B.P14-14. Is there
Continuity and no Short circuit?
Y
N
Replace Wire Harness
Connect plug B.P14 to PCB “A”. Measure between the red wire Q4 and the black wire Q4 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “A”.
TR-4-2
19 April 2006
FAULT CODE DESCRIPTIONS
TR-002
Fault Code TR-002, indicates that either the Transport motor (TR-M1) or the Trim Knife motor
(TR-M2) had a Cycle time out.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Trimmer knife home position sensor (TR-Q5) is installed correctly.
Procedure
Enter the Service mode and select Trimmer knife home position sensor (TR-Q5) in check sensors. The Trimmer knife home
position sensor indicates :1 when the sensor is blocked, and :0 when the sensor is unblocked?
Y
N
1. Replace sensor TR-Q5.
2. Disconnect plug B.P13 from PCB “A”. Measure between J13-23 and J13-25 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “A”.
Connect plug B.P13 to PCB “A”. Measure between the red wire Q5 and the black wire Q5 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “A”.
Enter the Service mode and select Transport motor (TR-M1) and Trim Knife motor (TR-M2) in check motors. Both motors
energizes?
Y
N
Disconnect the motor plug M1 to Transport / Knife motor (TR-M1). Enter the Service mode and start Transport motor
(TR-M1) in check motors. Measure between the orange wire M1 and the violet wire M1 (PWM 36V and ground).
The voltage is approximately 22 VDC?
Y
N
Disconnect plug B.P3 from PCB “A”. Measure between J3-2 and J3-3 (PWM 36 and ground). The
voltage is approximately 22 VDC?
Y
N
Replace PCB “A”.
Replace wire Harness.
Disconnect the motor plug M2 to Trim Knife motor (TR-M2). Enter the Service mode and start Trim Knife motor
(TR-M2) in check motors. Measure between the orange wire M2 and the violet M2 (PWM 36 and ground). The
voltage is approximately 28 VDC?
Y
N
Disconnect plug B.P3 from PCB “A”. Measure between J3-6 and J3-7 (PWM 36 and ground). The
voltage is approximately 28 VDC?
Y
N
Replace PCB “A”.
Replace wire Harness.
1. Make sure that nothing interferes with the mechanical movement.
2. Lubricate where needed.
1. Make sure that nothing interferes with the mechanical movement.
2. Lubricate where needed.
TR-4-3
Troubleshooting
Disconnect plug from sensor TR-Q5. Check wires for Continuity / Short circuit from the white wire Q5 to
B.P13-24. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
19 April 2006
FAULT CODE DESCRIPTIONS
TR-003
Fault Code TR-003, indicates that the Transport motor (TR-M1) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M1. Run the Diagnostics again. Fault code TR-004 (Open circuit) is displayed?
Y
N
Disconnect plug B.P3 from PCB “A”. Check wires for Short circuit across leads the orange wire M1 to B.P3-3
(violet) and the violet wire M1 to B.P3-2 (orange). Is there Short circuit?
Y
N
Replace PCB “A”.
Replace wire Harness.
Replace motor TR-M1.
TR-004
Fault Code TR-004, indicates that the Transport motor (TR-M1) has a Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M1. Enter Service mode and start Transport motor (TR-M1) in check motors. Measure between the
orange wire M1 and the violet wire M1 (PWM 36 and ground). The voltage is approximately 22 VDC?
Y
N
Disconnect plug B.P3 from PCB “A”. Measure between J3-2 and J3-3 (PWM 36 and ground). The voltage is
approximately 22 VDC?
Y
N
Replace PCB “A”.
Replace wire Harness.
Replace motor TR-M1.
TR-005
Fault Code TR-005, indicates that the Trim knife motor (TR-M2) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M2. Run the Diagnostics again. Fault code TR-006 (Open circuit) is displayed?
Y
N
Disconnect plug B.P3 from PCB “A”. Check wires for Short circuit across leads the orange wire M2 to B.P3-6
(violet) and the violet wire M2 to B.P3-7 (orange). Is there Short circuit?
Y
N
Replace PCB “A”.
Replace wire Harness.
Replace motor TR-M2.
TR-4-4
19 April 2006
FAULT CODE DESCRIPTIONS
TR-006
Fault Code TR-006, indicates that the Trim knife motor (TR-M2) has a Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M2. Enter Service mode and start Trim knife motor (TR-M2) in check motors. Measure between the
orange wire M2 and the violet wire M2 (PWM 36 and ground). The voltage is approximately 22 VDC?
Y
N
Disconnect plug B.P3 from PCB “A”. Measure between J3-6 and J3-7 (PWM 36 and ground). The voltage is
approximately 22 VDC?
Y
N
Replace PCB “A”.
Replace wire Harness.
Replace motor TR-M2.
Fault Code TR-007, indicates that the Stop gate motor (TR-M3) had a Cycle time out.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select Stop gate motor (TR-M3) in check motors.
Make sure that the Paper stop gate home position sensor (TR-Q7) is installed correctly.
Procedure
Enter the Service mode and select Paper stop gate home position sensor (TR-Q7) in check sensors. The Paper stop gate
home position sensor indicates :1 when the sensor is blocked, and :0 when the sensor is unblocked?
Y
N
1. Replace sensor TR-Q7.
2. Disconnect plug B.P13 from PCB “A”. Measure between J13-7 and J13-9 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “A”.
Disconnect plug from sensor TR-Q7. Check wires for Continuity / Short circuit from the white wire Q7 to
B:P13-8. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug B.P13 to PCB “A”. Measure between the red wire Q7 and the black wire Q7 (5V and ground). The
voltage is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “A”.
Are you able to move the Stop gate up and down without it interfering with anything?
Y
N
Make sure that the Stop gate does not interferes with the “Deck plate”. Adjust if necessary (
1. Check the allen screw on the “cam” to TR-M3.
2. Replace motor TR-M3.
TR-4-5
TR 3.2.10).
Troubleshooting
TR-007
19 April 2006
FAULT CODE DESCRIPTIONS
TR-008
Fault Code TR-008, indicates that the Stop gate motor (TR-M3) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M3. Run the Diagnostics again. Fault code TR-009 (Open circuit) is displayed?
Y
N
Disconnect plug B.P2 from PCB “A”. Check wires for Short circuit across leads the orange wire M3 to B.P2-11
(violet) and the violet wire M3 to B.P2-4 (orange). Is there Short circuit?
Y
N
Replace PCB “A”.
Replace wire Harness.
Replace motor TR-M3.
TR-009
Fault Code TR-009, indicates that the Stop gate motor (TR-M3) has a Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M3. Enter Service mode and start Stop gate motor (TR-M3) in check motors. Measure between the
orange wire M3 and the violet wire M3 (PWM 36V and ground). The voltage is approximately 36 VDC?
Y
N
Disconnect plug B.P2 from PCB “A”. Measure between J2-4 and J2-11 (PWM 36V and ground). The voltage is
approximately 36 VDC?
Y
N
Replace PCB “A”.
Replace wire Harness.
Replace motor TR-M3.
TR-010
Fault Code TR-010, indicates that the Length adjustment motor (TR-M4) do not receive any displacement pulses.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select Length adjustment motor (TR-M4) in check motors.
Procedure
Disconnect the sensor plug Q12 to motor M4. Measure between the red wire Q12 and the black wire Q12 (5V and Signal
ground). The voltage is approximately 5 VDC?
Y
N
Disconnect plug B.P14 from PCB “A”. Measure between the J14-3 and J14-5 (5V and Signal ground). The volt
age is approximately 5 VDC.
Y
N
Replace PCB “A”.
Replace wire harness.
Disconnect plug B.P14 from PCB “A”. Check wires for Continuity / Short circuit from the grey wire Q12 to B.P14-7, the white wire
Q12 to B.P14-4, the black wire Q12 to B.P14-3, the red wire Q12 to B.P14-5. Is there Continuity and no Short circuit?
Y
N
Replace wire harness.
1. Replace motor TR-M4.
2. Replace PCB “A”.
TR-4-6
19 April 2006
FAULT CODE DESCRIPTIONS
TR-011
Fault Code TR-011, indicates that the Length adjustment motor (TR-M4) had a Cycle time out.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and select Length adjustment motor (TR-M4) in check motors.
Make sure that the Length adjustment home position switch (TR-Q131) is installed correctly.
Procedure
Enter the Service mode and select Length adjustment home position switch (TR-Q131) in check switches. The Length adjustment home position switch indicates :1 activated, and :0 deactivated?
Y
N
Disconnect plug B.P13 from PCB “A”. Measure between J13-2 and J13-3 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “A”.
Connect plug B.P13 to PCB “A”. Measure between the white wire Q131 and the black wire Q131 (5V and ground).
The voltage is approximately 5 VDC?
Y
N
Replace wire Harness.
1.Replace switch TR-Q131
2.Replace PCB “A.
Enter the Service mode and select Length adjustment motor (TR-M4) in check motors. The motor energizes?
Y
N
Replace motor TR-M4.
2. Check the allen screw on the “cam” to the “Stop gate push rod”.
1. Lubricate were needed.
TR-012
Fault Code TR-012, indicates that the Length adjustment motor (TR-M4) has a Short circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M4. Run the Diagnostics again. Fault code TR-013 (Open circuit) is displayed?
Y
N
Disconnect plug B.P2 from PCB “A”. Check wires for Short circuit across leads the orange wire M4 to
B.P2-9 (violet) and the violet wire M4 to B.P2-2 (orange). Is there Short circuit?
Y
N
Replace PCB “A”.
Replace wire Harness.
Replace motor TR-M4.
TR-4-7
Troubleshooting
19 April 2006
FAULT CODE DESCRIPTIONS
TR-013
Fault Code TR-013, indicates that the Length adjustment motor (TR-M4) has an Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Procedure
Disconnect the motor plug M4. Enter Service mode and start Length adjustment motor (TR-M4) in check motors. Measure
between the orange wire M4 and the violet wire M4 (PWM 36V and ground). The voltage is approximately 36 VDC?
Y
N
Disconnect plug B.P2 from PCB “A”. Measure between J2-2 and J2-9 (PWM 36V and ground). The voltage is
approximately 36 VDC?
Y
N
Replace PCB “A”.
Replace wire Harness.
Replace motor TR-M4.
TR-014
Fault Code TR-014, indicates that the Blowers (TR-M5/M6) have an Open circuit.
Initial Actions
Check fuse F2 on Transformer.
Check placement of blowers.
Procedure
Disconnect the blowers. Enter Service mode and start blowers (TR-M5/M6) in check motors. Measure between the orange
wire M5/M6 and the violet wire M5/M6 (24V and ground). The voltage is approximately 24 VDC?
Y
N
Replace PCB.
Replace blowers TR-M5/M6.
TR-015
Fault Code TR-015, indicates that the Infeed sensor (TR-Q13) is faulty.
Procedure
Enter the Service mode and select Infeed sensor (TR-Q13) in check sensors. The Infeed sensor indicates :1 activated,
and :0 deactivated?
Y
N
Disconnect the connector to sensor Q13. Measure between the wires to sensor Q13 (5V and
ground). The voltage is approximately 5 VDC?
Y
N
1. Replace PCB “A”.
2. Replace wire harness.
Replace Infeed sensor (TR-Q13).
Replace PCB “A”.
TR-4-8
19 April 2006
FAULT CODE DESCRIPTIONS
TR-016
Fault Code TR-016, indicates that the Control switch infeed (TR-S2) or Control switch outfeed (TRS3) is faulty.
Initial Actions
Make sure that the Infeed shaft and the Outfeed compressing bracket is in it’s lower position.
Procedure
Enter the Service mode and select Infeed switch (TR-S2/S3) in check switches. The Infeed switch indicates D:1 activated,
and D:0 deactivated?
Y
N
Disconnect the two connectors to switch S2/S3. Measure between the two connectors to switch S2/S3 (5V and
ground). The voltage is approximately 5 VDC?
Y
N
Replace PCB “A”.
Replace switch S2/S3.
TR-017
Fault Code TR-017, indicates that the Outfeed sensor Trimmer (TR-Q6) is faulty.
Initial Actions
Make sure that the Outfeed sensor Trimmer (TR-Q6) is installed correctly.
Procedure
1. Replace sensor TR-Q6.
2. Disconnect plug B.P13 from PCB “A”. Measure between J13-4 and J13-6 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “A”.
Disconnect plug from sensor TR-Q6. Check wires for Continuity / Short circuit from, the white wire Q6 to
B.P13-5. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug B.P13 to PCB “A”. Measure between the red wire Q6 and the black wire Q6 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “A”.
TR-4-9
Troubleshooting
Replace PCB “A”.
19 April 2006
FAULT CODE DESCRIPTIONS
TR-018
Fault Code TR-018, indicates that the Trim bin full sensor (TR-Q8) is faulty.
Initial Actions
Make sure that the Trim bin full sensor (TR-Q8) is installed correctly.
Procedure
1. Replace sensor TR-Q8.
2. Disconnect plug B.P13 from PCB “A”. Measure between J13-10 and J13-12 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB “A”.
Disconnect plug from sensor TR-Q8. Check wires for Continuity / Short circuit from, the white wire Q8 to
B.P13-11. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug B.P13 to PCB “A”. Measure between the red wire Q8 and the black wire Q8 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB “A”.
TR-150 / 151
Fault Code TR-150, indicates that the Unreg is low/high.
Procedure
Measure between D.P14-1 and D.P14-2in the BK5010. The voltage is approximately 36V?
Y
N
Replace the BK5010 Interlock PCB “D”.
Measure between D.P14-7 and D.P14-8 in the BK5010. The voltage is approximately 36V?
Y
N
Replace the BK5010 Interlock PCB “D”.
Power OFF the Booklet Maker. Remove the power cable between the booklet maker and the trimmer. Measure for continuity
in the wires between Pin 1, 2, 7 and 8 on both ends of the cable. Is there continuity between all cables?
Y
N
Replace the power cable between the BK5010 and TR5010.
Power ON the Booklet Maker. Measure between A.J12-1 and A.J12-2 in the TR5010. The voltage is approximately 36V?
Y
N
Replace the TR5010 wire harness.
Replace PCB “A”.
TR-4-10
19 April 2006
FAULT CODE DESCRIPTIONS
TR-152
Fault Code TR-151, indicates that the Interlock switch is faulty.
Initial Actions
Check fuse F2 on Transformer.
Enter the Service mode and check the Trimmer voltmeter.
Power ON and Power OFF the Trimmer (make sure that the Top cover interlock, and the External Interlock Device interlock is interlocked).
Procedure
Measure the Interlock switch S9 and S10, and make sure that they are OK. Are all two switches OK?
Y
N
Replace faulty switch.
Measure for continuity between J14-18 and J14-19, between J25-3 and J25-4. Is there continuity in both cables?
Y
N
Replace wire harness.
Replace PCB.
Fault Code TR-201, indicates that during Run, the Infeed sensor (TR-Q13), was not blocked within
timeout.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Infeed sensor (TR-Q13) is installed correctly.
Procedure
Enter the Service mode and select Infeed sensor (TR-Q13) in check sensors. Activate, then deactivate, the TR-Q13. The Infeed
sensor (TR-Q13) indicates :1 when the sensor is activated and :0 when the sensor is deactivated.
Y
N
Go to TR-016 fault code.
1. Make sure that the Exit guide bracket is installed as high as possible.
2. Make sure that nothing interferes with the paper path.
TR-202
Fault Code TR-202, indicates that at “initialization” or during Run, the Infeed sensor (TR-Q13), was
blocked exceeding timeout.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Infeed sensor (TR-Q13) is installed correctly.
Procedure
Enter the Service mode and select Infeed sensor (TR-Q13) in check sensors. Activate, then deactivate, the TR-Q13. The Infeed
sensor (TR-Q13) indicates :1 when the sensor is activated and :0 when the sensor is deactivated.
Y
N
Go to TR-016 fault code.
Make sure that nothing interferes with the paper path.
TR-4-11
Troubleshooting
TR-201
19 April 2006
FAULT CODE DESCRIPTIONS
TR-203
Fault Code TR-203, indicates that during Run, the Outfeed sensor trimmer (TR-Q6), was not blocked
within timeout.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Outfeed sensor trimmer (TR-Q6) is installed correctly.
Ensure that the Outfeed sensor trimmer (TR-Q6) is clean.
Procedure
Enter the Service mode and select Outfeed sensor trimmer (TR-Q6) in check sensors. Block, then unblock, the TR-Q6 with a
sheet of paper. The Outfeed sensor trimmer (TR-Q6) sensor indicates :1 when the sensor is blocked and :0 when the
sensor is not blocked.
Y
N
Go to TR-017 fault code.
Make sure that nothing interferes with the paper path.
TR-204
Fault Code TR-204, indicates that at “initialization” or during Run, the Outfeed sensor Trimmer (TRQ6), was blocked exceeding timeout.
Initial Actions
Check fuse F2 on Transformer.
Make sure that the Outfeed sensor Trimmer (TR-Q6) is installed correctly.
Ensure that the Outfeed sensor Trimmer (TR-Q6) is clean.
Procedure
Enter the Service mode and select Outfeed sensor Trimmer (TR-Q6) in check sensors. Block, then unblock, the TR-Q6 with
a sheet of paper. The Outfeed sensor Trimmer (TR-Q6) sensor indicates :1 when the sensor is blocked and :0 when
the sensor is not blocked.
Y
N
Go to TR-017 fault code.
Make sure that nothing interferes with the paper path.
TR-205
Fault Code TR-205, indicates that the Infeed shaft or the Outfeed compressing bracket not is in it’s
lower position or that control switch S2 or S3 is faulty.
Procedure
Is the Infeed shaft or the Outfeed compressing bracket lifted from it’s lower position?
Y
N
Go to TR-016 fault code.
Lift Infeed/outfeed latch and make sure that the Infeed shaft and the Outfeed compressing bracket is in it’s lower position.
TR-401
Fault Code TR-401, indicates that the Trim bin is full, or that the Trim bin full sensor TR-Q8 is faulty.
Procedure
Is there something blocking the Trim bin full sensor TR-Q8?
Y
N
Go to TR-018 fault code.
Remove the object and empty the Trim bin.
TR-501
Fault Code TR-501, indicates that the Trim bin is full, or that the Trim bin full sensor TR-Q8 is faulty.
Procedure
Is there something blocking the Trim bin full sensor TR-Q8?
Y
N
Go to TR-018 fault code.
Remove the object and empty the Trim bin.
TR-4-12
19 April 2006
TR-502
Fault Code TR-502, indicates that the blowers (TR-M5/M6) do not respond.
Initial Actions
Check placement of blowers.
Make sure blowers are installed correctly.
Procedure
Enter the Service mode and select blowers Trimmer (TR-M5/M6) in check motors. Do the blowers work?
Y
N
Go to TR-014 fault code.
Troubleshooting
Replace PCB.
TR-4-13
Page intentionally blank
TR-4-14
19 April 2006
5
SERVICE TABLES
5.1 SERVICE TABLES
Service
Tables
Trimmer SERVICE TABLES is located in the Booklet Maker BK5010 Service Manual (
5)
TR-5-1
Page intentionally blank
19 April 2006
6.
ELECTRICAL COMPONENT LIST
DETAILED SECTION DESCRIPTIONS
6.1 ELECTRICAL COMPONENT LIST
Page
Grid code
TR-M1 Transport motor....................................................................... TR-6-3 / TR-6-4................
TR-M2 Trim knife motor....................................................................... TR-6-3 / TR-6-4................
TR-M3 Stop gate motor...................................................................................... TR-6-5................
TR-M4 Length adjustment motor...................................................................... TR-6-5................
TR-M5/M6Blower motor.......................................................................................... TR-6-3................
TR-Q13
TR-S2
TR-S3
TR-Q4
TR-Q5
TR-Q6
TR-Q7
TR-Q8
TR-S9
TR-Q130
TR-S11
TR-Q12
Infeed sensor.......................................................................................... TR-6-3................
Control switch infeed............................................................................. TR-6-2................
Control switch outfeed.......................................................................... TR-6-2................
Transport belt sensor............................................................................ TR-6-2................
Trim knife home position sensor.......................................................... TR-6-2................
Outfeed sensor....................................................................................... TR-6-2................
Paper stop gate home position sensor................................................ TR-6-5................
Trim bin full sensor................................................................................ TR-6-3................
Interlock switch...................................................................................... TR-6-3................
Interlock magnet.................................................................................... TR-6-3................
Length adjustment home position switch........................................... TR-6-5................
Length adj. motor sensor (loc. on mot M4)......................................... TR-6-5................
PCB MD6DC PCB ”A”..................................................................................... TR-6-2................
Safety block for knife............................................................................................... TR-6-2................
TR-6-1
Detailed
description
Stacker Receptacle.................................................................................................. TR-6-2................
Communication Booklet Maker BK5010................................................................ TR-6-2................
Power supply Trimmer TR5010............................................................................... TR-6-2................
Terminator / Communication Book Folder BF5010............................................... TR-6-2................
Counter...................................................................................................................... TR-6-2................
19 April 2006
ELECTRICAL COMPONENT LIST
6.1.1 REAR VIEW
Counter
Safety
block
TR-S3
TR-S2
TR-Q5
TR-Q4
MD6DC
PCB “A”
Stacker
Receptacle
COM BK5010
Terminator / COM BF5010
Power Supply
Trimmer
TR-6-2
19 April 2006
ELECTRICAL COMPONENT LIST
6.1.2 INFEED VIEW
TR-M5 / M6
TR-M2
Detailed
description
TR-M1
Interlock Switch
TR-S9 / Q130
TR-Q13
TR-Q8
TR-6-3
19 April 2006
ELECTRICAL COMPONENT LIST
6.1.3 OUTFEED VIEW
TR-M2
TR-Q6
TR-6-4
TR-M1
19 April 2006
ELECTRICAL COMPONENT LIST
TR-M4 /
TR-Q12
TR-S11
TR-Q7
TR-6-5
TR-M3
Detailed
description
6.1.4 STOP CARRIAGE VIEW
Page intentionally blank
19 April 2006
6.2 BOARD STRUCTURE
Detailed
description
Interlock
magnet
6.2.1 BLOCK DIAGRAM
TR-6-7
19 April 2006
6.2.2 CONTROLLER MD6DC
The motor drives:
MA-MD are for bi-directional motors with lower current
ME is for bi-directional motor with higher current.
MF is for one-directional motor with higher current.
As the TR5010 does not have any solenoids, one of the solenoid drives is used for
the electro-mechanical counter.
TR-6-8
19 April 2006
6.2.2 CONTROLLER MD6DC, CONTINUES
TR-M2
TR-M1
TR-M4
Set counter
TR-M3
ST-M1
TR-6-9
Detailed
description
TR-M5
&
TR-M6
Page intentionally blank
19 April 2006
TRIMMING PROCESS
6.3 TRIMMING PROCESS
6.3.1 PRINCIPLE OF OPERATION
M2
S11
Q13
Q6
Trimming
Booklet maker sends a start signal. The transport motor (TR-M1) starts and transports the booklet into the machine. The infeed sensor (TR-Q13) is activated by the
booklet. The booklet passes and deactivates the infeed sensor (TR-Q13). When
the booklet hits the stop gate, the transport motor (TR-M1) stops. The timing is
controlled by transport motor sensor (TR-Q4) and set by the paper size.
Trim knife motor (TR-M2) starts moving the knife down. After a while when the
knife is about to cut the sheets, transport motor (TR-M1) is triggered by knife position sensor (TR-Q5) to reverse and helps knife motor (TR-M2) during the cutting
stroke. About the time when the knife has cut through the sheets, the stop gate
motor (TR-M3) moves the stop gate down and the transport motor (TR-M1) reverses again to transport the set out of the machine. The knife motor completes its
cycle and stops at the trim knife home position sensor (TR-Q5).
The stacker motor (ST-M1) starts when the outfeed sensor (TR-Q6) activates and
runs for a short while to separate the booklets on the stacker belt. When outfeed
sensor (TR-Q6) activates, stop gate motor (TR-M3) moves the stop gate to up position and is stopped when the stop gate home position sensor (TR-Q7) activates.
TR-6-11
Detailed
description
M1
19 April 2006
TRIMMING PROCESS
6.3.2 SIZE ADJUSTMENT
Initialization cycle
Main power is switched on.
Length adjustment motor (TR-M4) starts. The motor (TR-M4) moves the stop gate
to the smallest booklet size.
The motor (TR-M4) stops when length adjustment home position switch (TR-S11)
is activated.
When the switch(TR-S11) is activated, a counter for the motor (TR-M4) starts and
the motor (TR-M4) reverses.
The motor (TR-M4) runs until* length adjustment motor sensor (TR-Q12) has
counted the preset amount of pulses set by the paper size and trim length. The
stop gate is now in correct position corresponding to the paper size and trim length
selected.
Changing paper size
New paper size and or trim length is selected on the UI.
Length adjustment motor (TR-M4) starts. The motor (TR-M4) runs in the direction
towards the new paper size. Length adjustment motor sensor (TR-Q12) counts
pulses from the previous paper size to the new paper size and stops motor (TRM4) when correct amount of pulses are received*. Stop gate is now in correct position corresponding to the new paper size selected.
If paper jam occurs
If top cover is opened and closed:
Stop gate motor (TR-M3) moves the stop gate down. Length adjustment motor
(TR-M4) moves the stop gate to the smallest booklet size.
The motor (TR-M4) stops when length adjustment home position switch (TR-S11)
is activated. Transport motor (TR-M1) starts to purge sets out of the machine and
stops after a while.
Length adjustment motor (TR-M4) reverses and start counting pulses from home
position switch (TR-S11.
The motor (TR-M4) runs until* length adjustment motor sensor (TR-Q12) has
counted the preset amount of pulses set by the paper size and trim length. The
stop gate is now back in correct position corresponding to the paper size and trim
length selected. Stop gate motor (TR-M3) moves the stop gate up and stops by
stop gate home position sensor (TR-Q7).
* Length adjustment motor (TR-M4) actually passes the stop position slightly,
reverses slightly pass the point and reverses again for the last time to stop at the
exact position, to take out any play.
TR-6-12
19 April 2006
SPECIFICATIONS
SPECIFICATIONS
Specification
Trimmer SPECIFICATIONS is located in the Booklet Maker BK5010 Service Manual (
SPECIFICATIONS)
TR-Spec-1
Page intentionally blank
19 April 2006
WIRING
Trimmer
Wiring
See pocket at rear of manual for wiring diagrams.
TR-Wir-1
Page intentionally blank
BOOK FOLDER BF5010
SERVICE MANUAL
19 April 2006
Subject to change
Page intentionally blank
19 April 2006
TABLE OF CONTENTS
1 INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE........................................................... BF-1-1
2 PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE..................................... BF-2-1
3 REPLACEMENT AND ADJUSTMENT
3.1 COVERS............................................................................................. BF-3-1
3.1.1 FRONT COVER......................................................................... BF-3-1
3.1.2 REAR COVER........................................................................... BF-3-2
3.1.3 INFEED COVER........................................................................ BF-3-3
3.1.4 OUTFEED COVER.................................................................... BF-3-4
3.1.5 TOP COVER.............................................................................. BF-3-5
3.1.6 TILT THE MACHINE.................................................................. BF-3-6
3.2 MOTORS............................................................................................ BF-3-9
3.2.1 TRANSPORT BELT MOTOR (M1)............................................. BF-3-9
3.2.2 STOP GATE MOTOR (M2)...................................................... BF-3-10
3.2.3 CLAMP MOTOR (M3)...............................................................BF-3-11
3.2.4 ROLLER MOTOR (M4) AND PRESSURE ROLLER................ BF-3-12
3.3 SENSORS AND SWITCHES............................................................ BF-3-15
3.3.1 STOP GATE SENSOR (Q1)..................................................... BF-3-15
3.3.2 ROLLER MOTOR FRONT / REAR SENSORS (Q2 AND Q3) BF-3-16
3.3.3 CLAMP MOTOR HOME POSITON SENSOR (Q4)................. BF-3-17
3.3.4 INFEED / OUTFEED SENSORS (Q5 AND Q7)....................... BF-3-18
3.3.5 CLAMP SENSOR (Q6)............................................................. BF-3-20
3.3.6 MOTOR M4 ENCODER SENSOR (Q8)................................... BF-3-21
3.3.7 TOP COVER INTERLOCK SWITCHES (S2 & S4).................. BF-3-22
3.3.8 UPPER TRANSPORT BELT CLUTCHES (SOL1 & SOL3)...... BF-3-23
3.4 BELTS............................................................................................... BF-3-25
3.4.1 UPPER TRANSPORT BELT.................................................... BF-3-25
3.4.2 LOWER TRANSPORT BELT................................................... BF-3-26
3.4.3 TEFLON TAPE LOWER TRANSPORT BELT ....................... BF-3-29
3.5 MECHANICS.................................................................................... BF-3-31
3.5.1 SET CLAMPS........................................................................... BF-3-31
3.5.2 STOP GATE............................................................................. BF-3-34
3.6 PCB.................................................................................................. BF-3-37
3.6.1 PCB MD6DC “D”...................................................................... BF-3-37
3.7 POWER REQUIREMENTS.............................................................. BF-3-39
3.7.1 TAPPING THE TRANSFORMER............................................. BF-3-39
4.TROUBLESHOOTING
4.1
4.2
4.3
4.4
FAULT CODE DESCRIPTIONS......................................................... BF-4-1
BLOWN FUSE CONDITION............................................................. BF-4-13
LED’S................................................................................................ BF-4-15
TEST POINTS.................................................................................. BF-4-17
19 April 2006
5 SERVICE TABLES
5.1 SERVICE TABLES.............................................................................. BF-5-1
6.DETAILED SECTION DESCRIPTION
6.1 ELECTRICAL COMPONENT LIST..................................................... BF-6-1
6.1.1 COMPONENT LAYOUT............................................................. BF-6-2
6.2 BOARD STRUCTURE
. ...................................................... BF-6-5
6.2.1 CONTROLLER MD6DC “D”....................................................... BF-6-5
6.3 PRINCIPLE OF OPERATION............................................................. BF-6-7
SPECIFICATIONS
SPECIFICATIONS................................................................................ BF-Spec-1
WIRING
Book Folder.............................................................................................BF-Wir-1
VI
1
INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE
Book Folder INSTALLATION PROCEDURE is located in the Booklet Maker
BK5010 Service Manual (
1.6)
BF-1-1
Installation
19 April 2006
Page intentionally blank
19 April 2006
2
PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE
Preventive
Maintenance
Book Folder PREVENTIVE MAINTENANCE SCHEDULE is located in the Booklet
Maker BK5010 Service Manual (
2)
BF-2-1
Page intentionally blank
19 April 2006
3
COVERS
REPLACEMENT AND ADJUSTMENT
3.1 COVERS
Replacement
Adjustment
3.1.1 FRONT COVER
[A]
[A]
[B]
Removal
1. Open top cover.
2. Remove screws [A] (
x 3 ).
3. Remove screws [B] (
x2)
BF-3-1
COVERS
19 April 2006
3.1.2 REAR COVER
[A]
[A]
Removal
1. Loosen screws [A] ( x 2 ).
NOTE: Lift out lower part and unhook the Rear cover.
BF-3-2
19 April 2006
COVERS
3.1.3 INFEED COVER
[B]
[A]
Replacement
Adjustment
[A]
Bottom view
[C]
Removal
1. Open Top cover.
2. Remove nuts [A] (
x 4 ).
3. Remove nuts [B] and remove locking bracket (
4. Tilt machine (
5. Remove nuts [C] (
x 2 ).
3.1.6 ).
x 2 ).
Replacement
4. Reverse the removal procedure.
NOTE: Make sure that the springs to the Upper Transport Belts are in correct
position.
BF-3-3
COVERS
19 April 2006
3.1.4 OUTFEED COVER
[B]
Rear view
Outfeed view
[A]
[C]
[D]
Removal
1. Remove Front and Rear cover (
3.3.1, 3.3.2 ).
2. Remove Top cover gas spring lower end from joint [B].
NOTE: Press plastic stud from pivot point.
3. Remove screws [A] (
4. Tilt machine (
x 4)
3.1.6 ).
5. Remove screws [C] (
x 2)
6. Lift Out feed cover carefully and disconnect wiring to sensor Q7 Phototransistor
[F] (
x 1).
BF-3-4
COVERS
19 April 2006
Replacement
Adjustment
3.1.5 TOP COVER
[B]
[A]
Bad
Top cover too low
Good
Bad
Top cover too high
Removal
1. Open Top cover.
2. Remove Top cover gas spring lower end from joint [A].
NOTE: Press plastic stud from pivot point.
3. Remove screws [B] (
x 4).
BF-3-5
COVERS
19 April 2006
3.1.6 TILT THE MACHINE
[G]
[C]
[D]
[B]
[A]
WARNING
Book Folder may Tip. Install Service bracket before separating the Book
Folder from the Trimmer.
Removal
1.
2.
3.
4.
5.
Remove Belt stacker ( Service manual BK5010
3.8.1).
Remove the Trim bin.
Remove the Service bracket [A] from the Book folder base [B].
Place the Service bracket in the Book folder base [C].
Turn screw [D] on the Service bracket, until the Service bracket firmly contacts
the floor.
6. Remove the screw [G] securing the machine with the base.
NOTE: The screw is only used at the factory.
7. Remove the External Interlock Device ( x 2).
8. Remove Front cover (
3.3.1).
9. Remove screw [E] ( x 1).
NOTE: Keep the screw. It will be used later.
10.Remove Rear cover (
3.3.2).
11.Remove screw [F] ( x 1).
NOTE: Keep the screw. It will be used later.
12.Tilt machine by lifting infeed cover.
CAUTION
When lowering or raising the machine, lift in infeed area only.
BF-3-6
Front view
Rear view
[E]
[F]
Front view,
machine tilted
Rear view,
machine tilted
11.Secure machine with the screw [E] removed earlier (
x1).
12.Secure machine with the screw [F] removed earlier (
x1).
BF-3-7
Replacement
Adjustment
COVERS
19 April 2006
Page intentionally blank
MOTORS
19 April 2006
3.2 MOTORS
3.2.1 TRANSPORT BELT MOTOR (M1)
Replacement
Adjustment
M1
[A]
[B]
[C]
Removal
1. Tilt machine (
3.1.6).
2. Remove R-pin [A] (
x 1).
3. Remove sprocket [B].
4. Disconnect the motor connectors (
5. Remove screws [C] (
x 2) .
x 4).
6. Remove Motor.
Replacement
1. Reinstall the motor, and secure it by tighten screws [C] (
2. Connect the motor connectors (
x 2) .
NOTE: The Orange wire on ”+”, and the Violet wire on ”-”.
3. Reverse the rest of the removal procedure.
BF-3-9
x 4).
MOTORS
19 April 2006
3.2.2 STOP GATE MOTOR (M2)
M2
[A]
[B]
Removal
1. Tilt machine (
3.1.6).
3. Remove cam by loosening allen screw [A] (
4. Remove screws [B] (
5. Disconnect the Motor (
x 1).
x4).
x 2).
6. Remove Motor.
Replacement
1. Reinstall the motor, but do not tighten screws [B] (
x 4).
2. Connect the motor connectors (
x 2) .
NOTE: The Orange wire on ”+”, and the Violet wire on ”-”.
3. Reverse the rest of the removal procedure.
4. Perform Stop Gate adjustment B (
BF-3-10
3.5.2).
MOTORS
19 April 2006
3.2.3 CLAMP MOTOR (M3)
M3
[C]
[A]
[B]
[C]
Replacement
Adjustment
[BF-Q4]
[C]
CAUTION
Be careful not to damage sensor BF-Q4
Removal
1. Remove Outfeed Cover (
3.1.4 ).
2. Remove the E-Clips and Washers [A] (
x 2,
x 2).
3. Remove the driving disc [B] by loosening allen screw (
4. Disconnect the motor connectors (
x 1).
x 2).
5. Remove screws [C] holding Motor bracket (
6. Remove screws holding Motor bracket (
x 4).
x 3).
Replacement
1. Mount Motor to Motor bracket (
x 3).
2. Reinstall motor, by tighten screw [C] (
x 4).
3. Connect the motor connectors (
x 2) .
NOTE: The Orange wire on ”1”, and the Violet wire on ”2”.
4. Reverse the rest of the removal procedure.
BF-3-11
MOTORS
19 April 2006
3.2.4 ROLLER MOTOR (M4) AND PRESSURE ROLLER
M4
Changing of wear point
The wear point is the area on the roller that strikes the Booklet first, as the roller
moves from the home position (left and right).
1. Remove outfeed cover (
3.1.4).
2. Move Roller Motor Assembly towards center of clamps.
3. Stop Pressure Roller from moving by pressing with your fingers towards the
Pressure Roller and out from the Clamps.
4. Move Roll Motor Assembly 20 to 30 mm’s (1”) sideways.
BF-3-12
MOTORS
19 April 2006
M4
Replacement
Adjustment
[A]
Rear view
[C]
O-rings
[B]
Outfeed view
[D]
Removal
1. Remove Outfeed cover (
3.1.4).
2. Disconnect Motor plug M4, and sensor plug J26 [A] from wire harness (
x 2).
3. Move Roller Motor assembly towards centre of the clamps.
4. Remove E-Clips [B] (
x 2).
5. Lift out Motor and Pressure Roller [C] upwards.
6. Cut cable ties [D] all the way to connectors, when removing complete Motor.
BF-3-13
Page intentionally blank
SENSORS AND SWITCHES
19 April 2006
3.3 SENSORS AND SWITCHES
Replacement
Adjustment
3.3.1 STOP GATE SENSOR (Q1)
Front view,
machine tilted
[B] [A]
[C]
[B]
[E]
Removal
1. Tilt machine (
3.1.6).
2. Disconnect connector [A] (
3. Remove screws [B] (
3. Loosen screw [C] (
x 1).
x 2).
x 1).
4. Remove screw [D] and sensor [E].
BF-3-15
[D]
SENSORS AND SWITCHES
19 April 2006
3.3.2 ROLLER MOTOR FRONT / REAR SENSORS (Q2 AND Q3)
Sensor Q3
Sensor Q2
[B]
[B]
[A]
[A]
Removal
1. Remove Outfeed Cover (
3.1.4).
2. Move Roller Motor assembly towards center of the clamps.
3. Disconnect connector [A] (
4. Remove screw [B] (
x 1).
x 1).
BF-3-16
SENSORS AND SWITCHES
19 April 2006
3.3.3 CLAMP MOTOR HOME POSITON SENSOR (Q4)
[B]
Replacement
Adjustment
[A]
Removal
1. Remove Outfeed Cover (
3.1.4).
2. Disconnect connector [A] (
x1 ).
3. Remove screw [B] (
x1).
BF-3-17
SENSORS AND SWITCHES
19 April 2006
3.3.4 INFEED / OUTFEED SENSORS (Q5 AND Q7)
Infeed Sensor Q5)
[A]
[B]
[C]
[F]
[E]
[D]
Removal Q5, LED
1. Open Top Cover.
2. Disconnect connector [A] (
3. Remove nut [B] (
x 1).
Phototransistor
LED
x 1).
4. Remove LED [C].
Removal Q5, phototransistor
1. Tilt machine (
3.1.6).
2. Disconnect connector [D] (
3. Remove nut [E] (
White
x 1).
x 1).
4. Remove Phototransistor [F].
BF-3-18
Red
SENSORS AND SWITCHES
19 April 2006
Outfeed Sensor (Q7)
[A]
[B]
[C]
Replacement
Adjustment
[F]
[E]
[D]
Removal Q7, LED
1. Remove Outfeed Cover (
3.1.4).
2. Disconnect connector [A] (
x 1).
3. Remove nut [B] (
Phototransistor
LED
x 1).
4. Remove LED [C].
White
Removal Q7, phototransistor
1. Tilt machine (
3.3.6).
2. Disconnect connector [D] (
3. Remove nut [E] (
x 1).
x 1).
4. Remove Phototransistor [F].
BF-3-19
Red
SENSORS AND SWITCHES
19 April 2006
3.3.5 CLAMP SENSOR (Q6)
Bottom view
[B]
[C]
Removal
1. Tilt machine (
3.1.6).
2. Disconnect connector [A] (
3. Remove screw [B] (
x 1).
x 1).
4. Remove sensor [C].
BF-3-20
[A]
SENSORS AND SWITCHES
19 April 2006
3.3.6 MOTOR M4 ENCODER SENSOR (Q8)
[B]
Replacement
Adjustment
[E]
[A]
[D]
[C]
Removal
1. Remove Outfeed Cover (
3.1.4).
2. Loosen allen screw [A] and remove Tacho Disc [B] (
2. Disconnect connector [C] (
x 1).
x 1).
3. Remove sensor [D].
Replacement
1. Reverse the removal procedure.
NOTE: Install Encoder Disc in centre [E] of slot in sensor.
BF-3-21
[D]
SENSORS AND SWITCHES
19 April 2006
3.3.7 TOP COVER INTERLOCK SWITCHES (S2 & S4)
[A]
[B]
[B]
[E]
[F]
Red
White
Black
[C]
Red
BF-S4
BF-S2
Removal
1. Remove Outfeed Cover (
3.1.4).
2. Remove nuts [A] and remove switch bracket [B] (
3. Disconnect connectors [C] (
4. Remove nuts and screws [D] (
x 2).
x 4).
x 2,
x 2).
5. Remove switches BF-S4 [E] and BF-S2 [F].
Replacement
1. Connect connectors [C] (
x 4).
NOTE: Connect the connectors according to figures.
2. Reinstall switches BF-S4 [E] and BF-S2 [F].
3. Reinstall the nuts and screws [D] ( x 2,
x 2).
NOTE: Do not tighten the nuts to hard, that will result in broken switches.
4. Reverse the removal procedure.
NOTE: When opening the Top Cover, make sure the soft interlock switch [F]
breaks before the hard interlock switch [E].
BF-3-22
SENSORS AND SWITCHES
19 April 2006
Replacement
Adjustment
3.3.8 UPPER TRANSPORT BELT CLUTCHES (SOL1 & SOL3)
[A]
[B]
Removal
1. Remove Upper Transport Belt (
2. Remove belt [B].
3. Remove screw [A] ( x 1)
3.4.1).
BF-3-23
SENSORS AND SWITCHES
19 April 2006
[C]
[A]
[B]
Removal
1.
2.
3.
4.
5.
Tilt machine (
3.1.6).
Pulley [A].
Remove E-Clips [B] (
x2).
Lift out shaft.
Remove screw [C] ( x 1)
BF-3-24
BELTS
19 April 2006
3.4 BELTS
Front view
[B]
Front view
[A]
[C]
[D]
Rear view
[E]
Top view
[F]
[G]
[H]
Removal
1. Remove Front and Rear cover (
3.1.1, 3.1.2 ).
2. Remove R-pin [A] and remove upper gear [B] (
3. Remove E-Clip [C] and bushing [D] (
x1).
4. Remove E-Clip [E] and bushing [F] (
x1).
x 1).
5. Disconnect clutches [H].
6. Move the shaft towards the transformer. Lift up rear end of shaft [G] and
remove shaft.
BF-3-25
Replacement
Adjustment
3.4.1 UPPER TRANSPORT BELT
BELTS
19 April 2006
3.4.2 LOWER TRANSPORT BELT
[C]
[D]
Top view
[A]
Front view
[B]
Front view
[C]
[D]
Removal
1. Remove Upper Transport Belt (
2. Remove Infeed cover (
3.4.1).
3.1.3).
3. Loosen nut [A] to transformer (
x 1).
4. Rotate the Fuse plate CW [B].
5. Tilt machine (
3.1.6).
6. Remove R-pin [C] and remove middle gear [D] (
7. Remove E-Clip [E], and bushing [F] (
x 1) .
BF-3-26
x 1).
Rear view,
machine tilted
Front view,
machine tilted
[G]
8. Remove Screw [G] (
[H]
[I]
x 1).
9. Remove E-Clips [H], and bushings [ I ] (
x 2).
Bottom view
[J]
10.Cut cable ties [J] ( x 5).
BF-3-27
Replacement
Adjustment
BELTS
19 April 2006
BELTS
19 April 2006
3.4.2 LOWER TRANSPORT BELT, CONTINUES
[K]
[K]
[L]
Bottom view
11.Disconnect connectors Q5, Q6, Q7, P20 and P21 [K] (
x 5).
12.Remove connectors J20 and J21 [L] from machine frame (
[P]
x 2).
[O]
[M]
Bottom view
[N]
13.Remove shafts [M] ( x 2).
14.Remove nuts [N] holding the Sliding plate [O] (
15.Gently lift the Sliding plate.
16.Gently slide off the belts [P] to rear-side.
BF-3-28
x 4).
BELTS
19 April 2006
Replacement
Adjustment
3.4.3 TEFLON TAPE LOWER TRANSPORT BELT Removal
1. Open the Top cover.
2. Lift the upper Feed belt assembly.
3. Lift the lower Feed belt and remove Teflon tape.
Replacement
1. Mount the new teflon tape straps between the cut-outs for the rollers and on
each side of the cut-outs for the cable ties.
BF-3-29
Page intentionally blank
MECHANICS
19 April 2006
3.5 MECHANICS
Replacement
Adjustment
3.5.1 SET CLAMPS
Outfeed view
[A]
[C]
[B]
Rear view
[D]
Removal
1. Remove Outfeed cover (
3.1.4).
2. Remove allen screws [A] for upper and lower Paper Guides (
x 8).
3. Remove the upper and lower paper guide.
4. Tilt machine (
3.1.6).
5. Remove linkage shafts [B] holding the upper clamp on front side, by removing
E-clip [C] on the side of the linkage shafts which has a chamfered end (
x 1).
6. Remove linkage shafts holding the upper clamp on rear side, by removing
E-clip on the side of the linkage shafts which has a chamfered end (
x 1).
7. Remove the two brass guides [D] on the PCB side of the machine (
BF-3-31
x 6).
MECHANICS
19 April 2006
[E]
8. Remove upper clamp.
9. Grab the roller cage [E] (not the motor) and remove the ball bearings from the
rail, (downwards).
[H]
[F]
[G]
10.Loosen the lower clamp [F] by tapping gently, using a plastic hammer [G], on
lower clamp front side until the spring pressure is relieved.
11.Hold the roller cage down and remove the lower set clamp.
BF-3-32
MECHANICS
19 April 2006
[ J]
Replacement
Adjustment
[H]
[I]
Replacement
1. Insert lower clamp [ I ], roller assembly, and springs in the machine.
2. Mount pins [H] centerd in the lower clamp.
3. Apply grease on each end of the lower clamp, by the pins.
4. Insert upper clamp [J].
5. Apply grease on clamp, by brass guides.
NOTE: Make sure no grease gets in contact with the roll.
6. Grease the upper clamp on the infeed side by the roll assembly’s home
position / turning points.
7. Mount the linkage shafts [B], to the upper clamp, and the E-clips on both front
and rear side (
x 2).
NOTE: Make sure flat end corresponds to flat on linkage.
8. Turn linkage to press down the lower clamp [ I ].
9. Push lower clamp in position.
10.Mount brass guides without tightening the screws (
NOTE: Grease the brass guides.
x 6).
11.Press the brass guides together and tighten the screws. There should be no
play between guides and clamps ( x 6).
CAUTION: The clamps must be centerd in the cut-outs.
12.Turn linkage afterwards to make sure that clamps moves without binding.
13.Clean clamps on outfeed side and press area with alcohol fluid.
14.Mount lower paper guide (
x4).
15.Mount upper paper guide (
x4).
16.Check Set Stop Gate adjustment (
17.Reverse the removal procedure.
3.5.2).
BF-3-33
MECHANICS
19 April 2006
3.5.2 STOP GATE
[B]
[A]
[D]
[C]
Not Good
Not Good
Good
Tighten Adjustment Nut
Loosen Adjustment Nut
Stop Gate Adjustment A
NOTE: Procedure adjusts appearance of Book folded spine of booklet.
1. Enter Service mode ( Service manual BK5010
5.1).
2. In BF5010 Service, set ”Adjust mode” to ON ( Service manual BK5010
5.6 ).
3. Set up the Book Folder to Mode 1.
4. Run 6 sheet booklets of 80 gsm (20lb bond), from the Copier.
5. Check appearance of booklets according to pictures above.
6. Turn Adjustment Nuts [A] to obtain correct result.
NOTE: Adjustment Nuts can be reached through outfeed cover.
7. In BF5010 Service, set ”Adjust mode” to OFF ( Service manual BK5010
5.6 ).
8. Run 6 sheet booklets of 80 gsm (20lb bond), from the Copier.
9. Check appearance of booklets according to pictures above.
BF-3-34
MECHANICS
19 April 2006
Stop Gate Adjustment B
NOTE: This procedure must be performed if any mechanics in the stopgate have
been altered, or if the stop gate motor or stop gate has been replaced.
1. Tilt machine (
3.1.6).
3. Measure between Lower Clamp [B] and Stop Gate [C] on one side only (which
side does not matter). Distance [D] should be 7.5 ± 0.2 mm.
4. Loosen Stop Gate Motor M2 mounting screws and move Stop Gate Motor to
obtain measurement ( x 4).
5. Perform Stop Gate Adjustment A.
BF-3-35
Replacement
Adjustment
2. Turn Stop Gate Cam using the Stop Gate Motor so that Stop Gate is in upper
position.
Page intentionally blank
PCB
19 April 2006
3.6 PCB
3.6.1 PCB MD6DC “D”
[B]
Replacement
Adjustment
ON
[A]
[C]
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure ( 3.1 ).
Removal
1. Remove Rear Cover (
3.1.2).
2. Remove all connectors from PCB [A] (
x 8).
3. Remove PCB by squeezing barbs [B] on the standoffs ( x4) securing PCB.
REPLACEMENT
1. Reverse the removal procedure.
NOTE: Make sure all DIP switches are in off position [C].
NOTE: Make sure correct software version is loaded in the PCB.
BF-3-37
Page intentionally blank
POWER REQUIREMENTS
19 April 2006
3.7 POWER REQUIREMENTS
3.7.1 TAPPING THE TRANSFORMER
[B]
Replacement
Adjustment
[A]
Transformer in picture tapped for 230V
Purpose
To be able to change the Transformer setting.
Removal
1. Remove Front Cover (
3.1.1 ).
Adjustment
1. Measure the wall outlet voltage.
2. Tap the Transformer to the appropriate setting according to the label on the
Transformer by moving cable [A].
NOTE: Do not move cable [B].
Replacement
1. Reverse the removal procedure.
BF-3-39
Page intentionally blank
19 April 2006
4.
FAULT CODE DESCRIPTION
TROUBLESHOOTING
BF-001 BF-M1
Transport belt motor Short circuit................................................ BF-4-2
BF-002 BF-M1
Transport belt motor Open circuit................................................ BF-4-2
BF-003 BF-M2
Stop gate motor No displacement pulses.................................... BF-4-2
BF-004 BF-M2
Stop gate motor Short circuit........................................................ BF-4-3
BF-005 BF-M2
Stop gate motor Open circuit........................................................ BF-4-3
BF-006 BF-M2
Stop gate motor Cycle time out.................................................... BF-4-3
BF-007 BF-M3
Clamp motor Short circuit............................................................. BF-4-4
BF-008 BF-M3
Clamp motor Open circuit............................................................. BF-4-4
BF-009 BF-M3
Clamp motor Cycle time out.......................................................... BF-4-4
BF-010 BF-M4
Roller motor Short circuit.............................................................. BF-4-5
BF-011 BF-M4
Roller motor Open circuit.............................................................. BF-4-5
BF-012 BF-M4
Roller motor Cycle time out........................................................... BF-4-6
BF-013 BF-M4
Roller motor No displacement pulses.......................................... BF-4-7
BF-014 BF-Q5
Infeed sensor is Faulty................................................................... BF-4-7
BF-015 BF-Q6
Clamp sensor is Faulty.................................................................. BF-4-8 BF-016 BF-Q7
Outfeed sensor is Faulty................................................................ BF-4-8
BF-150 36V input low.................................................................................. BF-4-9 BF-151 36V input high................................................................................. BF-4-9 BF-152 BF-SW1,
2, 3 or 4
Interlock switch Book folder is Faulty.......................................... BF-4-9 BF-201 BF-Q5
Infeed sensor was Not blocked within timeout......................... BF-4-10 BF-202 BF-Q5
Infeed sensor was Blocked exceeding timeout......................... BF-4-10
BF-203 BF-Q6
Clamp sensor was Not blocked within timeout......................... BF-4-10 BF-204 BF-Q6
Clamp sensor was Blocked exceeding timeout.........................BF-4-11 BF-206 BF-Q7
Outfeed sensor was Not Blocked exceeding timeout................BF-4-11
No Square folding action
Book folder does not Square fold a 4 sheet booklet..........BF-4-11
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
likely to result in a PCB failure ( 3.1 ).
BF-4-1
Trouble-
shooting
4.1 FAULT CODE DESCRIPTIONS
FAULT CODE DESCRIPTION
19 April 2006
BF-001
Fault code BF-001, indicates that the Transport Belt motor (BF-M1) has a short circuit.
Initial Actions
Check Fuse F2 on the Book Folder Transformer.
Procedure
Disconnect the motor plug M1. Run the Diagnostics again. Fault code BF-002 (Open circuit) is displayed?
Y
N
Disconnect plug D.P3 from PCB ”D”. Check wires for Short circuit across leads, the Orange wire M1 to D.P3-6 (violet) and the Violet wire M1 to D.P3-7 (orange). Is there Short circuit?
Y
N
Replace PCB ”D”.
Replace wire Harness.
Replace motor BF-M1.
BF-002
Fault code BF-002, indicates that the Transport belt motor (BF-M1) has an Open circuit.
Initial Actions
Check Fuse F2 on the Book Folder Transformer.
Procedure
Disconnect the motor plug M1. Enter Service mode and start Transport Belt motor (BF-M1) in check motors. Measure between the Orange wire M1 and the violet wire M1 (PWM 36V and ground). The voltage is approximately 18 VDC?
Y
N
Disconnect plug D.P3 from PCB ”D”. Measure between J3-6 and J3-7 (PWM 36V and ground). The voltage is approximately 18 VDC?
Y
N
Replace PCB ”D”.
Replace wire Harness.
Replace motor BF-M1.
BF-003
Fault code BF-003, indicates that the Stop gate motor (BF-M2) does not receive any displacement
pulses.
Initial Actions
Check Fuse F2 on the Book Folder Transformer.
Check Fuse F3 on the Book Folder Transformer.
Enter the Service mode and select Stop gate motor (BF-M2) in check motors.
Make sure that the Stop gate sensor (BF-Q1) is installed correctly.
Procedure
Disconnect the sensor plug Q10 to motor M2. Measure between the red wire Q10 and the black wire Q10 (5V and Signal
ground). The voltage is approximately 5 VDC?
Y
N
Disconnect plug B.P14 from PCB “D”. Measure between the J14-9 and J14-3 (5V and Signal ground). The volt age is approximately 5 VDC.
Y
N
Replace PCB “D”.
Replace wire harness.
Disconnect plug B.P14 from PCB “D”. Check wires for Continuity / Short circuit from the grey wire Q10 to B.P14-4, the white wire
Q10 to B.P14-7, the black wire Q10 to B.P14-3, the red wire Q10 to B.P14-9. Is there Continuity and no Short circuit?
Y
N
Replace wire harness.
1. Replace motor BF-M2.
2. Replace PCB “D”.
BF-4-2
19 April 2006
FAULT CODE DESCRIPTION
BF-004
Fault code BF-004, indicates that the Stop gate motor (BF-M2) has a short circuit.
Initial Actions
Check Fuse F2 on the Book Folder Transformer.
Procedure
Disconnect the motor plug M2. Run the Diagnostics again. Fault code BF-005 (Open circuit) is displayed?
Y
N
Disconnect plug D.P2 from PCB ”D”. Check wires for Short circuit across leads, the Orange wire M2 to D.P2-9 (violet) and the Violet wire M1 to D.P2-2 (orange). Is there Short circuit?
Y
N
Replace PCB ”D”.
Replace wire Harness.
Replace motor BF-M2.
Fault code BF-005, indicates that the Stop gate motor (BF-M2) has an Open circuit.
Initial Actions
Check Fuse F2 on the Book Folder Transformer.
Make sure that the allen screw to the white cam is tighten against the flat on the motor shaft.
Procedure
Disconnect the motor plug M2. Disconnect plug D.P2. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
1. Replace motor BF-M2.
2. Replace PCB ”D”.
BF-006
Fault code BF-006, indicates that the Stop gate motor (BF-M2) had a Cycle time out.
Initial Actions
Check Fuse F2 on the Book Folder Transformer.
Check Fuse F3 on the Book Folder Transformer.
Enter the Service mode and select Stop gate motor (BF-M2) in check motors.
Make sure that the Stop gate motor Home position sensor (BF-Q1) is installed correctly.
Procedure
Enter the Service mode and select Stop gate motor Home position sensor (BF-Q1) in check sensors. The Stop gate motor
Home position sensor indicates :1 when the sensor is blocked, and :0 when the sensor is unblocked?
Y
N
1.Replace sensor BF-Q1.
2.Disconnect plug D.P13 from PCB ”D”. Measure between J13-1 and J13-3 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace PCB ”D”.
Disconnect plug from sensor BF-Q1. Check wire for Continuity / Short circuit from the white wire Q1 to D.P13-3. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug D.P13 to PCB ”D”. Measure between the red wire Q1 and the black wire Q1 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB ”D”.
Replace the BF-M2.
BF-4-3
Trouble-
shooting
BF-005
FAULT CODE DESCRIPTION
19 April 2006
BF-007
Fault code BF-007, indicates that the Clamp motor (BF-M3) has a short circuit.
Initial Actions
Check Fuse F2 on the Book Folder Transformer.
Procedure
Disconnect the motor plug M3. Run the Diagnostics again. Fault code BF-008 (Open circuit) is displayed?
Y
N
Disconnect plug D.P3 from PCB ”D”. Check wires for Short circuit across leads. Check the Orange wire M3 to D.P3-3 (violet) and the Violet wire M3 to D.P3-2 (orange). Is there Short circuit?
Y
N
Replace PCB ”D”.
Replace wire Harness.
Replace motor BF-M3.
BF-008
Fault code BF-008, indicates that the Clamp motor (BF-M3) has an Open circuit.
Initial Actions
Check Fuse F2 on the Book Folder Transformer.
Procedure
Disconnect the motor plug M3. Disconnect plug D.P3. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
1. Replace motor BF-M3.
2. Replace PCB ”D”.
BF-009
Fault code BF-009, indicates that the Clamp motor (BF-M3) had a Cycle time out.
Initial Actions
Check Fuse F2 on the Book Folder Transformer.
Check Fuse F3 on the Book Folder Transformer.
Enter the Service mode and select Clamp motor (BF-M3) in check motors.
Make sure that the Clamp motor Home position sensor (BF-Q4) is installed correctly.
Procedure
Enter the Service mode and select Clamp motor Home position sensor (BF-Q4) in check sensors. The Clamp motor Home
position sensor indicates :1 when the sensor is blocked, and :0 when the sensor is unblocked?
Y
N
1.Replace sensor BF-Q4.
2.Disconnect plug D.P13 and D.P14 from PCB ”D”. Measure between J14-1 and J13-12 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace PCB ”D”.
Disconnect plug from sensor BF-Q4. Check wire for Continuity / Short circuit from the white wire Q4 to D.P13-11. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug D.P13 and D.P14 to PCB ”D”. Measure between the red wire Q4 and the black wire Q4 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB ”D”.
Replace the BF-M3.
BF-4-4
19 April 2006
FAULT CODE DESCRIPTION
BF-010
Fault code BF-010, indicates that the Roller motor (BF-M4) has a short circuit.
Initial Actions
Check Fuse F2 on the Book Folder Transformer.
Procedure
Disconnect the motor plug M4. Run the Diagnostics again. Fault code BF-012 (Open circuit) is displayed?
Y
N
Disconnect plug D.P2 from PCB ”D”. Check wires for Short circuit across the leads of the Orange wire M4 to D.P2-12 (violet) and the Violet wire M4 to D.P2-3 (orange). Is there Short circuit?
Y
N
Replace PCB ”D”.
Replace wire Harness.
Replace motor BF-M4.
BF-011
Disconnect the motor plug M4. Disconnect plug D.P2. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
1. Replace motor BF-M4.
2. Replace PCB ”D”.
BF-4-5
Trouble-
shooting
Fault code BF-011, indicates that the Roller motor (BF-M4) has an Open circuit.
Initial Actions
Check Fuse F2 on the Book Folder Transformer.
Procedure
FAULT CODE DESCRIPTION
19 April 2006
BF-012
Fault code BF-012, indicates that the Roller motor (BF-M4) had a Cycle time out.
Initial Actions
Check Fuse F2 on the Book Folder Transformer.
Check Fuse F3 on the Book Folder Transformer.
Enter the Service mode and select Roller motor (BF-M4) in check motors.
Make sure that the Roller motor Rear Home position sensor (BF-Q2) is installed correctly.
Make sure that the Roller motor Front Home position sensor (BF-Q3) is installed correctly.
Procedure
Enter the Service mode and select Roller motor Front Home position sensor (BF-Q3) in check sensors. The Roller motor
Front Home position sensor indicates :1 when the sensor is blocked, and :0 when the sensor is unblocked?
Y
N
1.Replace sensor BF-Q3.
2.Disconnect plug D.P13 and D.P14 from PCB ”D”. Measure between J14-2 and J13-6 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace PCB ”D”.
Disconnect plug from sensor BF-Q3. Check wire for Continuity / Short circuit from the white wire Q3 to D.P13-8. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug D.P13 and D.P14 to PCB ”D”. Measure between the red wire Q3 and the black wire Q3 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB ”D”.
Enter the Service mode and select Roller motor Rear Home position sensor (BF-Q2) in check sensors. The Roller motor
Rear Home position sensor indicates :1 when the sensor is blocked, and :0 when the sensor is unblocked?
Y
N
1.Replace sensor BF-Q2.
2.Disconnect plug D.P13 from PCB ”D”. Measure between J13-13 and J13-9 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace PCB ”D”.
Disconnect plug from sensor BF-Q2. Check wire for Continuity / Short circuit from the white wire Q2 to D.P13-5. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Connect plug D.P13 to PCB ”D”. Measure between the red wire Q2 and the black wire Q2 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace wire Harness.
Replace PCB ”D”.
Pull the motor gently by hand. Are you able to pull the motor back and forth without using a lot of force?
Y
N
Lubricate where needed.
Replace motor BF-M4.
BF-4-6
19 April 2006
FAULT CODE DESCRIPTION
BF-013
Fault code BF-013, indicates that the Roller motor (BF-M4) do not receive any displacement pulses.
Initial Actions
Check Fuse F2 on the Book Folder Transformer.
Enter the Service mode and select Roller motor (BF-M4) in check motors.
Make sure that the Roller motor sensor (BF-Q8) is installed correctly.
Procedure
Disconnect the sensor plug Q8 to motor BF-M4. Measure between the yellow wire Q8 and the grey wire Q8 (5V and
ground). The voltage is approximately 5 VDC?
Y
N
Disconnect plug D.P14 from PCB ”D”. Measure between the J14-15 and J14-13 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace PCB ”D”.
Replace wire Harness.
Disconnect plug D.P14 from PCB ”D”. Check wires for Continuity / Short circuit from the white wire Q8 to D.P14-14, the grey
wire Q8 to D.P14-13, and the yellow wire Q8 to D.P14-15. Is there Continuity and no Short circuit?
Y
N
Replace wire Harness.
Trouble-
shooting
1. Replace motor BF-M4.
2. Replace PCB ”D”.
BF-014
Fault code BF-014, indicates that the Infeed sensor (BF-Q5) is faulty.
Initial Actions
Make sure that the sensor Is clean.
Make sure that the Infeed photo transistor sensor, and the Infeed LED sensor (BF-Q5) is installed correctly.
Check fuse F3 on the Book folder Transformer.
Procedure
Disconnect plug D.P13 from PCB ”D”. Measure between J13-23 and J13-16 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace PCB ”D”.
Disconnect plug from Infeed LED sensor BF- Q5. Check wire for Continuity / Short circuit from black wire Q5 to D.P13-16,
the red wire Q5 to D.P13-23. Is there continuity and no Short circuit?
Y
N
Replace wire Harness.
1. Replace Infeed LED sensor Q5.
2. Connect plug D.P13 to PCB ”D”. Disconnect plug from Infeed photo transistor sensor BF-Q5. Measure between black
wire Q5 and white wire Q5 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Disconnect plug J20. Measure between P20-2 and P20-3 (5V and ground) in the plug J20. The voltage is approximately 5 VDC?
Y
N
Disconnect plug D.P13 from PCB ”D”. Measure between J13-24 and J13-25 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace PCB ”D”.
Replace wire Harness.
Replace wire Harness to Infeed photo transistor sensor Q5.
Replace Infeed photo transistor sensor Q5.
BF-4-7
FAULT CODE DESCRIPTION
19 April 2006
BF-015
Fault code BF-015, indicates that the Clamp sensor (BF-Q6) is faulty.
Initial Actions
Make sure that the Clamp sensor (BF-Q6) is installed correctly.
Make sure that the sensor is clean.
Make sure that the Feeding belts are moving smoothly by running Motor M1 according to section 5, Service tables.
Check fuse F3 on the Book folder Transformer.
Procedure
Disconnect plug to Clamp sensor BF-Q6. measure between black wire Q6 and red wire Q6. The voltage is approximately
5 VDC?
Y
N
Disconnect plug J20. Measure between P20-4 and P20-6 (5V and ground) on plug J20. The voltage is approximately 5 VDC?
Y
N
Disconnect plug D.P13 from PCB ”D”. Measure between J13-20 and J13-22. The voltage is approximately 5 VDC?
Y
N
Replace PCB ”D”.
Replace wire Harness.
Replace wire Harness to Clamp sensor Q6.
Replace Clamp sensor Q6.
BF-016
Fault code BF-016, indicates that the Outfeed sensor (BF-Q7) is faulty.
Initial Actions
Make sure that the sensor Is clean.
Make sure that the Outfeed photo transistor sensor, and the Outfeed LED sensor (BF-Q7) is installed correctly.
Check fuse F3 on the Book folder Transformer.
Procedure
Disconnect plug D.P13 and D.P14 from PCB ”D”. Measure between J13-17 and J14-10 (5V and ground). The voltage is
approximately 5 VDC?
Y
N
Replace PCB ”D”.
Disconnect plug from Outfeed LED sensor BF- Q7. Check wire for Continuity / Short circuit from black wire Q7 to D.P14-10,
the red wire Q7 to D.P13-17. Is there continuity and no Short circuit?
Y
N
Replace wire Harness.
1. Replace Outfeed LED sensor Q7.
2. Connect plug D.P13 and D.P14 to PCB ”D”. Disconnect plug from Outfeed photo transistor sensor BF-Q7. Measure between black wire Q7 and white wire Q7 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Disconnect plug D.P13 from PCB ”D”. Measure between J13-18 and J13-19 (5V and ground). The voltage is approximately 5 VDC?
Y
N
Replace PCB ”D”.
Replace wire Harness.
Replace Outfeed photo transistor sensor Q7.
BF-4-8
19 April 2006
FAULT CODE DESCRIPTION
BF-150 / 151
WARNING
Warning this measurement involves live conductors. Use caution not to
short circuit any conductors.
Fault Code BF-150, indicates that the Unreg is low/high.
Procedure
Measure the voltage across the rectifier capacitor. The voltage is approximately >0V?
Y
N
Replace fuse F2.
Measure the voltage across the rectifier capacitor. The voltage is approximately 36V? Y
N
Check transformer tappings (
3.7.1 ).
Go to BF-152 fault code.
Fault code BF-152, indicates that one of the interlock switches in the Book folder is faulty.
Initial Actions
Power OFF the Booklet Maker and make sure the Book Folder is powered off.
Check Fuse F2 on the Book Folder Transformer.
3.7.1 ).
Check that the Transformer is tapped to the correct voltage according to (
Procedure
Measure the Interlock switches SW1, SW2, SW3 and SW4 and make sure that they are OK. Are all switches OK?
Y
N
Replace the faulty switch.
Make sure Switch SW1, SW2, SW3 and SW4 is interlocked. Power ON the Booklet Maker. Disconnect plug D.P13 and
D.P15. Measure J15-2 and J13-14 . Is there 5V?
Y
N
Replace PCB ”D”.
Measure J12-1 and J12-2 on PCB ”D”. The voltage is approximately 36V DC?
Y
N
Replace wire Harness.
Replace PCB ”D”.
BF-4-9
Trouble-
shooting
BF-152
FAULT CODE DESCRIPTION
19 April 2006
BF-201
Fault code BF-201, indicates that during Run (Operation) the Infeed sensor (BF-Q5), was not
blocked within timeout after the exit signal from the Trimmer, was detected.
Initial Actions
Make sure that the sensor Is clean.
Make sure that the Infeed sensor (BF-Q5), is installed correctly.
Check fuse F3 on the Book folder Transformer.
Procedure
Enter the Service mode and select Infeed sensor (BF-Q5) in check sensors. Block, then unblock, the Q5 sensor with a sheet
of paper. The Infeed sensor (BF-Q5) sensor indicates :0 when the sensor is blocked, and :1 when the sensor is not
blocked?
Y
N
Go to BF-013 fault code.
Make sure that nothing interferes with the paper coming out from the Trimmer, and going into the Book folder.
BF-202
Fault code BF-202, indicates that at ”initialization” or during Run the Infeed sensor (BF-Q5), was
blocked exceeding timeout.
Initial Actions
Make sure that the sensor Is clean.
Make sure that the Infeed sensor (BF-Q5), is installed correctly.
Check fuse F3 on the Book folder Transformer.
Procedure
Enter the Service mode and select Infeed sensor (BF-Q5) in check sensors. Block, then unblock, the Q5 sensor with a sheet
of paper. The Infeed sensor (BF-Q5) sensor indicates :0 when the sensor is blocked, and :1 when the sensor is not
blocked?
Y
N
Go to BF-013 fault code.
1. Make sure that nothing interferes with the paper path.
2. Make sure that the Feeding belts are moving as they should.
3. Clean the Feeding belts.
BF-203
Fault code BF-203, indicates that during Run the Clamp sensor (BF-Q6), was not blocked within
timeout.
Initial Actions
Make sure that the sensor Is clean.
Make sure that the Clamp sensor (BF-Q6), is installed correctly.
Check fuse F3 on the Book folder Transformer.
Procedure
Enter the Service mode and select Clamp sensor (BF-Q6) in check sensors. Block, then unblock, the Q6 sensor with a
sheet of paper. The Clamp sensor (BF-Q6) sensor indicates :0 when the sensor is blocked, and :1 when the sensor
is not blocked?
Y
N
Go to BF-014 fault code.
1. Make sure that nothing interferes with the paper path.
2. Make sure that the Feeding belts are moving as they should.
3. Clean the Feeding belts.
BF-4-10
19 April 2006
FAULT CODE DESCRIPTION
BF-204
Fault code BF-204, indicates that at ”initialization” or during Run the Clamp sensor (BF-Q6), was
blocked exceeding timeout.
Initial Actions
Make sure that the sensor Is clean.
Make sure that the Clamp sensor (BF-Q6), is installed correctly.
Check fuse F3 on the Book folder Transformer.
Procedure
Enter the Service mode and select Clamp sensor (BF-Q6) in check sensors. Block, then unblock, the Q6 sensor with a
sheet of paper. The Clamp sensor (BF-Q6) sensor indicates :0 when the sensor is blocked, and :1 when the sensor
is not blocked?
Y
N
Go to BF-014 fault code.
1. Make sure that nothing interferes with the paper path.
2. Make sure that the Feeding belts are moving as they should.
3. Clean the Feeding belts.
Fault code BF-206, indicates that at ”initialization” or during Run the Outfeed sensor (BF-Q7), was
not blocked exceeding timeout.
Initial Actions
Make sure that the sensor Is clean.
Make sure that the Outfeed sensor (BF-Q7), is installed correctly.
Check fuse F3 on the Book folder Transformer.
Procedure
Enter the Service mode and select Outfeed sensor (BF-Q7) in check sensors. Block, then unblock, the Q7 sensor with a
sheet of paper. The Outfeed sensor (BF-Q7) sensor indicates :0 when the sensor is blocked, and :1 when the sensor
is not blocked?
Y
N
Go to BF-015 fault code.
1. Make sure that nothing interferes with the paper path.
2. Make sure that the Stacker belts are moving as they should.
3. Clean the Stacker belts.
Book folder does not Square fold a 4 sheet booklet
Initial Actions
Make sure that the Book folder is set up to Mode 1.
Procedure
The Specification for the Book Folder BF5010 is to perform the Square folding action on booklets
with approximately 6 sheets/booklet, up to 30 sheet/booklet.
In [Auto] mode, the Booklet maker detects how may sheets there are in the booklet, and automatically set the Book folder to the correct mode.
NOTE: When the Book folder is set to [Auto] and the booklet has less than approximately 6 sheets/
booklet, the Book folder will bypass the Square folding action, transporting the booklet out to the
Belt stacker.
To be able to Square fold a booklet with approximately 5 sheet/booklet or less, the Book folder
must be set to [Mode 1].
BF-4-11
Trouble-
shooting
BF-206
Page intentionally blank
19 April 2006
BLOWN FUSE CONDITION
4.2 BLOWN FUSE CONDITION
Fuse
Rating 115V 210-230V
Symptom at power on
F1
6.3A 3.15A
Power on the BF5010, on UI
F2
10A
10A
Fault in Area E BF-150
F3
2A
2A
Power on the BF5010, on UI
F4
Not in use in the BF5010 configuration
F1
F2
F3
F4
BF-4-13
Trouble-
shooting
WARNING
ONLY USE SLOW BLOW FUSES.
Page intentionally blank
19 April 2006
LED’S
4.3 LED’S
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
3.1 ).
likely to result in a PCB failure ( D2: Red LED flashes whenever information is sent or received on the Internal CAN
(Central area network). If power is switched on but no operations are performed,
LED is OFF.
D15: Green LED permanently OFF. It has no direct function in this configuration.
D2
D1
D15
BF-4-15
Trouble-
shooting
D1: Yellow LED flashes when power is on. The flashing indicates that a program is
present and functioning. Should a download fail or the 5V be missing, LED would
be OFF.
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19 April 2006
TEST POINTS
4.4 TEST POINTS
CAUTION
ESD Hazard! ESD (Electrostatic Discharge) can cause software crashes,
data and/or communications problems. Failure to use proper ESD procedures will cause damage to electronic components (example: PCBs).
ESD problems can be minimized by maintaining all machine ground connections, ensuring the proper handling of circuit boards and sensors. Use
ESD protection when working near PCBs. Failure to use ESD protection is
3.1 ).
likely to result in a PCB failure ( VCC
+UNREG
+UNREG: Outgoing unregulated 36V, after interlock. Measure between Test Point
+UNREG and Test Point GND/PGND using a voltmeter. The voltage will be shown
on the voltmeter unless:
- Voltage is outside allowed range 29-43V. Voltage will be 0V.
- Machine is interlocked (i.e the top cover is open). Voltage will be 0V.
VCC: Stabilized and rectified 5V made from incoming 10V AC from transformer.
Measure between Test Point VCC and Test Point GND/PGND using a voltmeter.
The voltage will be shown on the voltmeter. Range 4.9-5.1V.
GND / PGND: Ground /Power Ground is the negative reference when measuring
either unregulated 36V (+UNREG) or 5V (VCC).
BF-4-17
Trouble-
shooting
GND/
PGND
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19 April 2006
5
SERVICE TABLES
5.1 SERVICE TABLES
Service
Tables
Book Folder SERVICE TABLES is located in the Booklet Maker BK5010 Service
Manual (
5)
BF-5-1
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19 April 2006
6.
ELECTRICAL COMPONENT LIST
DETAILED SECTION DESCRIPTION
6.1 ELECTRICAL COMPONENT LIST
Page
Grid
code
BF-M1
Transport belt motor.............................................................................6 - 2................
BF-M2
Stop gate motor ...................................................................................6 - 2................
BF-M3
Clamp motor .........................................................................................6 - 2 ...............
BF-M4
Roller motor . ........................................................................................6 - 2 ...............
BF-SOL1
BF-Q1
BF-Q2
BF-Q3
BF-Q4
BF-Q5
BF-Q5
BF-Q6
BF-Q7
BF-Q7
BF-Q8
Stop gate sensor...................................................................................6 - 2 ...............
Roller motor Rear Home position sensor ..........................................6 - 2 ...............
Roller motor Front Home position sensor . .......................................6 - 2 ...............
Clamp motor Home position sensor ..................................................6 - 2 ...............
Infeed sensor (Phototransistor)...........................................................6 - 2 ...............
Infeed sensor (LED)..............................................................................6 - 2 ...............
Clamp sensor .......................................................................................6 - 2 ..............
Outfeed sensor (Phototransistor)........................................................6 - 2 ...............
Outfeed sensor (LED) ..........................................................................6 - 2 ...............
Roller motor sensor .............................................................................6 - 2 ...............
BF-SW1, External interlock device, interlock switches.....................................6 - 4................
SW3
BF-SW2 Top cover interlock switches...............................................................6 - 4................
SW4
Stacker Receptacle.................................................................................................6 - 4................
Communication Book folder..................................................................................6 - 4................
Fuse F1 6.3A on 115V machines, 3.15A on 230V machines................................6 - 4................
Power Receptacle / Line Filter...............................................................................6 - 4................
Terminator................................................................................................................6 - 4................
Set Counter..............................................................................................................6 - 5................
Main power Switch..................................................................................................6 - 4................
Rectifier ................................................................................................................6 - 5................
Transformer.............................................................................................................6 - 5................
Fuse F2 10A.............................................................................................................6 - 5................
Fuse F3 2A...............................................................................................................6 - 5................
Capacitor ................................................................................................................6 - 5................
BF-6-1
Detailed Description
PCB MD6DC “D” .....................................................................................................6 - 5................
COMPONENT LAYOUT
19 April 2006
6.1.1 COMPONENT LAYOUT
BF-M3
BF-Q10
BF-M2
BF-M1
Top view
BF-Q8
BF-M4
BF-Q7
BF-Q6
BF-SOL2&4
BF-SOL1&3
Front view
BF-Q1
BF-Q2
BF-Q4
BF-Q3
Set Clamp view,
seen from Outfeed view
BF-6-2
BF-Q5
19 April 2006
COMPONENT LAYOUT
Rear view
Top cover Interlock
switches
S2 & S4
Stacker receptacle
COM. BF5010
Terminator
F1
Power receptacle / Line Filter
BF-6-3
Detailed Description
Main Power
Switch S5
COMPONENT LAYOUT
19 April 2006
Rear view
Top view,
Inside machine
Set counter
PCB MD6DC “D”
Rectifier
Capacitor
F3
F2
Transformer
Front view
BF-6-4
19 April 2006
BOARD STRUCTURE
6.2 BOARD STRUCTURE The motor drives:
MA-MD are for bi-directional motors with lower current
ME is for bi-directional motor with higher current.
MF is for one-directional motor with higher current.
One of three solenoid drives is used for the electro-mechanical counter.
BF-6-5
Detailed Description
6.2.1 CONTROLLER MD6DC “D”
BOARD STRUCTURE
19 April 2006
6.2.1 CONTROLLER MD6DC “D”, CONTINUES
BF-M2
BF-M4
BF-M3
ST-M1
Set
counter
BF-M1
SOL
1&2
SOL
3&4
BF-6-6
19 April 2006
PRINCIPLE OF OPERATION
6.3 PRINCIPLE OF OPERATION
Square folding sequence:
Detailed Description
The stapled and folded booklet, and trimmed if selected, is transported up against
the Stop gate in the Book folder. The booklet is then compressed by the Set
Clamps, holding the booklet in place.
First the Stop gate moves downward and the Set Clamps compresses the Booklet.
The Roller motor moves (rolling) over the spine of the Booklet, pressing it up
against the Set clamps, producing the Square fold look.
When the Square folding sequence is completed, the Set Clamp moves up and
releases its grip on the booklet. The booklet is finally transported out on to the Belt
stacker.
BF-6-7
PRINCIPLE OF OPERATION
19 April 2006
Initialization Cycle:
Top view
BF-Q7
BF-Q6
Front view
BF-M3
BF-M1
BF-M4
BF-Q1
BF-M2
BF-Q2
BF-Q4
BF-Q5
BF-Q3
Set Clamp view,
seen from Outfeed view
The BF5010 performs an initialization-check at power on or when one of the
interlocks has been opened and closed.
Clamp motor BF-M3 runs until the Clamp motor Home position sensor BF-Q4 is
activated / deactivated, and reverses until sensor BF-Q4 is activated / deactivated.
This is done to open up the gap between the Clamps. Stop Gate motor BF-M2
runs until the Stop gate sensor BF-Q1 is activated / deactivated. All the paper
path sensors are checked BF-Q5, BF-Q6 and BF-Q7 to make sure that there is no
paper in the machine. The Book Folder is now in Ready mode.
BF-6-8
19 April 2006
PRINCIPLE OF OPERATION
In OFF mode:
This mode is for booklets that cannot be Book folded:
BF-SOL1&3 BF-SOL2&4
Front view
BF-Q5
BF-M1
BF-Q6
When Outfeed sensor BF-Q7 is activated and deactivated, Transport Belt motor
BF-M1, Solenoids SOL1-SOL4 and Stacker motor ST-M1 stops.
Front view
BF-Q7
BF-M1
BF-6-9
Detailed Description
When Infeed sensor BF-Q5 is activated, the Transport belt Motor BF-M1 and
Solenoids BF-SOL1-BF-SOL4 are energized. When Clamp sensor BF-Q6 is
activated, Belt Stacker motor ST-M1 continues to feed out the set.
PRINCIPLE OF OPERATION
19 April 2006
In Mode 1:
This mode is for booklets with approximately 6 to 11 sheets of paper that are being
Book folded.
BF-SOL2&4 BF-SOL1&3
Front view
Top view
BF-Q6
BF-Q5
BF-M3
BF-M1
Front view
Set Clamp view,
seen from Outfeed view
BF-Q2
BF-Q4
BF-Q3
BF-M2
BF-Q1
When Infeed sensor BF-Q5 is activated, the Transport belt Motor BF-M1,
Solenoids BF-SOL1-BF-SOL4 and Stop gate motor BF-M2 are energized, moving
the Stop gate upwards. Motor BF-M2 runs until Stop gate sensor BF-Q1 becomes
active, plus a certain amount of milliseconds. Motor BF-M1 runs until Clamp
sensor BF-Q6 is activated, plus a certain amount of milliseconds. Solenoids BFSOL1-SOL4 deactivate immediately when Clamp sensor BF-Q6 is activated.
When Transport belt motor BF-M1 has stopped, Clamp motor BF-M3 is energized,
moving the Clamps downwards. When Clamp motor Home position sensor BFQ4 is activated / deactivated, Motor BF-M3 is denergized. When motor BF-M3 is
denergized, motor BF-M2 is energized, moving the Stop gate downwards. Motor
BF-M2 will run until sensor BF-Q1 becomes deactivated. Now the Clamps are
holding the booklet, and Stop gate is down.
BF-6-10
19 April 2006
PRINCIPLE OF OPERATION
BF-Q2
BF-M3
BF-Q8
BF-Q3
Top view
When Sensor BF-Q1 is deactivated, The Roller motor BF-M4 is energized, and
moves over the spine of the Booklet, pressing it up against the Set clamps,
producing the Square fold look. The Encoder Sensor Q8 starts counting pulses by
reading the Encoder Disc. When the correct number of pulses have been counted,
motor BF-M4 slows down. When Sensor BF-Q2 or BF-Q3 is activated, motor BFM4 stops.
When Roller motor BF-M4 has reached it’s home position (BF-Q2 or BF-Q3),
Clamp motor BF-M3 is energized, moving the Clamps upwards. Motor BF-M3 runs
until Clamp motor Home position Sensor BF-Q4 is activated / deactivated. The
Clamps are now in their upper position.
When sensor BF-Q4 is deactivated, Transport Belt motor BF-M1 and Belt Stacker
motor ST-M1 together with Solenoids BF-SOL1-BF-SOL4 are energized to feed
out the set. When Outfeed sensor BF-Q7 is Activated / Deactivated, Transport
Belt motor BF-M1 and Stacker motor ST-M1 stop, Solenoids BF-SOL1-BF-SOL4
deactivate.
BF-6-11
Detailed Description
BF-M4
PRINCIPLE OF OPERATION
19 April 2006
In Mode 2:
This mode is for booklets with approximately 12 to 16 sheets of paper that are
being Book folded.
The difference between Mode 1 and Mode 2 is, that the Stop gate motor BF-M2 is
stopped a little bit further out from the clamps according to number of pulses from
the BF-M2 motor encoder. The result of this will be that the booklet will be pushed
out a little, when being compressed by the Set Clamps, compared to Mode 1.
In Mode 3:
This mode is for booklets with approximately 17 to 23 sheets of paper that are
being Book folded.
The difference between Mode 2 and Mode 3 is, that Stop gate Motor BF-M2 is
stopped according to pulses from it´s encoder a certain distance from the clamps.
Also when Roller motor BF-M4 has reached it’s home position, the motor BF-M4
reverses and starts moving in the opposite direction. The result of this is that the
spine becomes flatter, compared to Mode 2.
In Mode 4:
This mode is for booklets with approximately 24 to 30 sheets of paper that are
being Book folded.
The difference between Mode 3 and Mode 4 is, that Stop gate Motor BF-M2 is
stopped according to pulses from it´s encoder a certain further distance from the
clamps.
In Mode AUTO:
When a set passes the fold rollers in the BK5010, and forces them apart, sensor
BK-Q37 starts counting pulses by reading the movement of the cam. Based on
that information, the BK5010 decides which mode is the most appropriate. That
decision is then communicated to the BF5010.
In all other respects the principle of operation is as already described.
NOTE: The Specification for the Book Folder BF5010 is to perform the Square
folding action on booklets from approximately 6 sheets and up.
NOTE: When the Book folder is set to [Auto] and the booklet has less than approximately 6 sheets/booklet, the Book folder will bypass the Square folding action,
transporting the booklet out to the Belt stacker.
BF-6-12
19 April 2006
SPECIFICATIONS
SPECIFICATIONS
Specification
Book Folder SPECIFICATIONS is located in the Booklet Maker BK5010 Service
Manual (
SPECIFICATIONS)
BF-Spec-1
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19 April 2006
WIRING
Book Folder
Wiring
See pocket at rear of manual for wiring diagrams.
BF-Wir-1
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