Plockmatic TR5010e Service Manual Download Page 59

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Trouble-

shooting

TR-4-13

28 May 2009

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?

Go to TR-014 fault code.

Replace PCB.

TR-503

Fault Code TR-503, indicates that the stacker is full.

Procedure

Empty stacker.

Fault still appears?

Go to TR-017 fault code.

Summary of Contents for TR5010e

Page 1: ...TRIMMER TR5010e SERVICE MANUAL 4 August 2009 Subject to change...

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Page 3: ...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 KN...

Page 4: ...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 PR...

Page 5: ...TR 1 1 28 May 2009 Installation 1 INSTALLATION PROCEDURE 1 1 INSTALLATION PROCEDURE Trimmer INSTALLATION PROCEDURE is located in the Booklet Maker BK5010e Service Manual 1 5...

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Page 7: ...1 28 May 2009 Preventive Maintenance 2 PREVENTIVE MAINTENANCE SCHEDULE 2 1 PREVENTIVE MAINTENANCE SCHEDULE Trimmer PREVENTIVE MAINTENANCE SCHEDULE is located in the Booklet Maker BK5010e Service Manu...

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Page 9: ...ustment 4 August 2009 TR 3 1 COVERS 3 REPLACEMENT AND ADJUSTMENT 3 1 COVERS 3 1 1 FRONT AND REAR COVER Rear Cover 1 Loosen screws C x3 Front Cover 1 Open the Top Cover 2 Remove screws A x3 3 Loosen sc...

Page 10: ...ver 2 Remove screws and nuts B x4 x4 Replacement 1 Reverse the removal procedure Adjustment 1 Loosen screws and nuts B x4 x4 2 Adjust Top cover so frame edge C is aligned with top of the hinge D See d...

Page 11: ...WER MOTOR M5 M6 COVERS Removal 1 Open the Top Cover 2 Cut tie wrap A 2 Disconnect connectors B x2 3 Remove Front and Rear cover 3 1 1 4 Remove Infeed cover 3 1 4 5 Remove screws C x2 6 Lift out Fan as...

Page 12: ...TR 3 4 4 August 2009 3 1 4 INFEED COVER COVERS 1 Open the Top Cover 2 Remove Front and Rear cover 3 1 1 3 Remove screws A x5 4 Remove screws B x5 A B...

Page 13: ...gust 2009 TR 3 5 3 1 5 LOCKING BRACKET COVERS A B 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 st...

Page 14: ...S 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 5 Remove connector B x1 6 Cut cable ties C inside cover...

Page 15: ...rocedure Note Mount the interlock box to its uppermost position Adjustment 1 Check adjustment according to 3 1 10 A B WARNING Overriding or cheating the interlock allows the TR5010e system to operate...

Page 16: ...TR 3 8 4 August 2009 3 1 8 LOWER OUTFEED COVER COVERS 1 Remove Belt stacker 3 8 1 2 Remove Front and Rear cover 3 1 1 3 Remove Protection Cover 3 1 9 4 Loosen screws A x2 5 Remove screws B x4 B A B...

Page 17: ...OVER COVERS 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 M...

Page 18: ...ent 1 Reverse the removal procedure Adjustment 1 Make sure interlock box is mounted correctly 3 1 7 2 Loosen nuts A x2 3 Adjust the interlock mechanism B so that it is parallel to the Top cover and so...

Page 19: ...justment 4 August 2009 TR 3 11 3 2 AREA C 3 2 1 INFEED SENSOR Q13 AREA C 1 Undock the Trimmer 2 Remove nuts A inside bracket holding the Sensor bracket x2 3 Remove connector from the Sensor x1 4 Remov...

Page 20: ...nnectors A x2 3 Remove screws B 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 posi tion...

Page 21: ...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 com pressing bracket...

Page 22: ...ve 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...

Page 23: ...the sensor to remove Replacement 1 Reverse the removal procedure NOTE When tightening nut screw make sure there is a space between en coder disc and sensor 2 Enter service program mode and start the...

Page 24: ...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 sl...

Page 25: ...e C D Replacement 1 Reverse the removal procedure 2 Enter service program mode to check that sensor Q5 changes state when blocked unblocked Service Manual BK5010e 5 1 1 5 1 2 NOTE Do not cheat the int...

Page 26: ...ove the infeed cover 3 1 4 5 Remove protection cover 3 1 9 Removal Upper knife 1 Remove screws B x3 2 Remove knife protection plate C 3 Move transport protection from the new to the old knife or use t...

Page 27: ...nt it on the old knife 5 Mount knife protection plate C 6 Mount the set clamp in position with e clip D x1 Replacement Lower knife 1 Place the lower knife onto the lower knife beam 2 Apply grease on b...

Page 28: ...ote Never touch the red painted reference screws P 8 Adjust the space if necessary with screws O x2 O Q 0 50 mm P AREA C 9 Check that there is a gap of 1 2 mm between the knife protection plate S and...

Page 29: ...he upper knife is lowered 12 Gently push in the Lower knife against the Upper knife NOTE Listen that it touches on both sides 13 Raise the upper knife to the top position by turning crank R 14 Tighten...

Page 30: ...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...

Page 31: ...Replacement Adjustment Page intentionally blank...

Page 32: ...PER PATH OUTFEED SENSOR Q6 AREA C 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 sens...

Page 33: ...ver 3 1 8 3 Remove connectors A x2 4 Remove connectors B x2 5 Remove connector C x1 6 Pull out the Carriage gently A B C D CAUTION When removing the Carriage watch out so the motor connectors B C do n...

Page 34: ...5 Loosen set screw D x1 Replacement 1 Mount the Crank pulley E without tightening the set screw D x1 2 Mount motor with screws C x4 3 Mount Crank arm B 4 Tightening nut A x1 NOTE Make sure play for Cr...

Page 35: ...Replacement Adjustment 4 August 2009 TR 3 27 3 2 12 LENGTH ADJUSTMENT MOTOR M4 SENSOR Q12 AREA C 1 Remove Stop gate carriage 3 2 10 2 Unhook spring A 3 Remove screws B holding the motor x4 A B...

Page 36: ...2 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 acti...

Page 37: ...17 4 Remove screws A x2 5 Remove e clip B 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 pr...

Page 38: ...ylon washer C x2 Unhook link arm D x2 Remove needle bearing C x2 7 Remove e clip E x2 8 Pull out shaft F 9 Remove e clips G x2 inside frames 10 Slide Flange bushings G towards the center of the shaft...

Page 39: ...Replacement Adjustment 4 August 2009 TR 3 31 3 2 16 TRIM BIN FULL SENSOR Q8 AREA C A B 1 Undock the Trimmer 2 Remove connector A x1 3 Remove screw B x1...

Page 40: ...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 B C 1 Remove Front cover 3 1 1 2 Remove screws A x3 3 Remov...

Page 41: ...FE SUPPORT CHAIN AREA C A B 1 Remove Front cover 3 1 1 2 Remove Transmission chain 3 2 17 3 Loosen screws A x3 4 Remove chain from sprocket B Replacement 1 Reverse the removal procedure 2 Tension the...

Page 42: ...move 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 x3 E B A C W...

Page 43: ...move 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 shaf...

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Page 45: ...system refering to the latest Technical Bulletin Download software if needed Service Manual BK5010e 5 2 4 Reinstall Rear cover 3 1 1 ON CAUTION ESD Hazard ESD Electrostatic Discharge can cause softwar...

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Page 47: ...tor 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 Co...

Page 48: ...m 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...

Page 49: ...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...

Page 50: ...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 lea...

Page 51: ...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 i...

Page 52: ...e motor TR M4 2 Replace PCB A 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 E...

Page 53: ...CB 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 mo...

Page 54: ...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 Disco...

Page 55: ...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 016 Fault Cod...

Page 56: ...ower 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 018 Fault Code TR 018 indicates that t...

Page 57: ...e 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 Interl...

Page 58: ...rim 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 203 Fault Code TR 203 i...

Page 59: ...lacement 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 Repla...

Page 60: ...TR 4 14 Page intentionally blank...

Page 61: ...Service Tables TR 5 1 28 May 2009 5 SERVICE TABLES 5 1 SERVICE TABLES Trimmer SERVICE TABLES is located in the Booklet Maker BK5010e Service Manual 5...

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Page 63: ...outfeed TR 6 2 F1 TR Q4 Transport belt sensor TR 6 2 C3 TR Q5 Trim knife home position sensor TR 6 2 F1 TR Q6 Outfeed sensor TR 6 2 D1 TR Q7 Paper stop gate home position sensor TR 6 5 E1 TR Q8 Trim...

Page 64: ...R 6 2 28 May 2009 6 1 1 REAR VIEW TR S2 TR S3 TR Q4 TR Q5 MD6DC PCB A Safety block for knife Stacker Receptacle Power Supply Trimmer COM BK5010e Terminator COM BF5010e ELECTRICAL COMPONENT LIST Counte...

Page 65: ...Detailed description TR 6 3 28 May 2009 6 1 2 INFEED VIEW TR M1 TR M2 TR Q13 TR Q8 Interlock Switch TR S9 Q130 TR M5 M6 ELECTRICAL COMPONENT LIST...

Page 66: ...TR 6 4 28 May 2009 6 1 3 OUTFEED VIEW TR Q6 TR M2 TR M1 ELECTRICAL COMPONENT LIST...

Page 67: ...Detailed description TR 6 5 28 May 2009 6 1 4 STOP CARRIAGE VIEW TR M3 TR M4 TR Q12 TR Q7 TR S11 ELECTRICAL COMPONENT LIST...

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Page 69: ...Detailed description TR 6 7 28 May 2009 6 2 BOARD STRUCTURE 6 2 1 BLOCK DIAGRAM Interlock magnet...

Page 70: ...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 TR5010e does not have any solenoids one o...

Page 71: ...Detailed description TR 6 9 28 May 2009 6 2 2 CONTROLLER MD6DC CONTINUES TR M2 TR M1 TR M4 TR M3 ST M1 Set counter TR M5 TR M6...

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Page 73: ...Detailed description TR 6 11 28 May 2009 6 3 TRIMMING PROCESS 6 3 1 PRINCIPLE OF OPERATION TRIMMING PROCESS TR M2 TR Q6 TR M1 TR Q13 TR Q4 TR Q5...

Page 74: ...r TR M1 is triggered by knife posi tion 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...

Page 75: ...arts 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 counte...

Page 76: ...TR Q12 counts pulses from the previous paper size to the new paper size and stops motor TR M4 when correct amount of pulses are received Stop gate is now in correct posi tion corresponding to the new...

Page 77: ...TR Spec 1 28 May 2009 Specification SPECIFICATIONS SPECIFICATIONS Trimmer SPECIFICATIONS is located in the Booklet Maker BK5010e Service Manual SPECIFICATIONS...

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Page 79: ...TR Wir 1 28 May 2009 Wiring WIRING Trimmer See pocket at rear of manual for wiring diagrams...

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