Transpak GENESIS HORI TP-502MH Operation, Safety & Spare Parts Manual Download

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Original Instruction

TP-502MH

PALLET

TP-502MH

TP-502MHB

(with battery)

SEMI-AUTO

GENESIS HORI

/201

Summary of Contents for GENESIS HORI TP-502MH

Page 1: ...Original Instruction TP 502MH PALLET TP 502MH TP 502MHB with battery SEMI AUTO GENESIS HORI 04 2018...

Page 2: ......

Page 3: ...l Safety Instructions A1 2 Construction and Units A4 3 General Safety Remarks A6 4 Machine Information A9 5 Operating the Machine A20 6 Adjustment A23 7 Maintenance A25 8 Troubleshooting Guide A30 PAR...

Page 4: ...PART III 1 Strapping Head Unit C1 2 Base Group C33 3 Reel Control Group C39 4 Body Frame Group C43 5 Electric Control Unit C47 6 Battery Group C57...

Page 5: ...PART I...

Page 6: ...machine must be properly grounded to avoid a shock hazard All wiring must be in accordance with local wiring standards c The strapping machine can only be operated with polypropylene P P strapping do...

Page 7: ...s will result in severe injury or death Warning for hot surface Welding area is approximately 270o C 520 Allow sufficient time for the heater to cool down before any work in welding area Warning for d...

Page 8: ...ronment c Place the machine on an even floor in order to avoid any distortion 7 Other Reminders a An operation manual must remain attached to the machine at all times b Do not alter the equipment or c...

Page 9: ...ontrol group Holds the strap coil If the reel core size is 280mm you can take off the center drum to have core size 200mm 1 Strapping head unit This unit is the most important part of the machine for...

Page 10: ...trol unit 6 Battery unit 3 Reel control group Holds the strap coil If the reel core size is 280mm you can take off the center drum to have core size 200mm 1 Strapping head unit This unit is the most i...

Page 11: ...ys complete and perfectly legible Always make certain that persons being trained and instructed in working on or with the machine are permanently supervised by an experienced person Work on the electr...

Page 12: ...ified current Any electrical work performed on the equipment must be conducted by a skilled electrician or under the supervision of a skilled electrician All work must be observed good electrical engi...

Page 13: ...of the cord or plug is necessary connect the ground wire to the ground terminal of the plug The wire with green insulation with or without yellow stripes is the grounding wire Check with a qualified...

Page 14: ...eel it is easy to move around Control Panel on Both Sides The strapping position could be moved up and down between 175mm 2200mm from ground Environment Information The strapping machine shall be inst...

Page 15: ...ion Power Switch QS1 This switch is lockable for safety Danger of burns near the heating unit 1 Dangerous points in the machine are covered by the screwed table top Please keep hands away from this da...

Page 16: ...5 8 Strap reel diameter 200 mm 8 Width 1130 mm 44 5 Depth 891 mm 35 1 Height 2822 mm 111 1 Electrical Requirement AC110V 220V 230V 240V 50 60Hz Single phase Weight 242 kg 535 5 lbs Noise emission 72d...

Page 17: ...p reel diameter 200 mm 8 Width 1130 mm 44 5 Depth 1031 mm 40 6 Height 2822 mm 111 1 Electrical Requirement AC110V 220V 230V 240V 50 60Hz Single phase Weight 342 kg 917 1 lbs Noise emission 72dB A Mini...

Page 18: ...A13 5 How to Remove Handle the Machine from the Pallet Safely remove the machine with a forklift...

Page 19: ...passed through this guide 10 Movement Handle Strap position can be changed by both side handles The operator can use this handle to lift and pull down the strapping height between 175mm 2200mm from g...

Page 20: ...ndle Strap position can be changed by both side handles The operator can use this handle to lift and pull down the strapping height between 175mm 2200mm from ground easily 11 Support Handle This Suppo...

Page 21: ...ndition and all kinds of warnings will be displayed on this panel Status LED Represents current operating status LED Color Green Orange Red Status Normal Saving mode Abnormal Note Refer to page 31 for...

Page 22: ...rt C 2 Make sure screws firmly tightened Step 2 1 Place Part D close to part C and get an 800mm tall object to keep Part D stays 800mm from the ground 2 Push Part D into Part C and place E secured int...

Page 23: ...t please go back to the step 2 for adjustments Step 4 1 Place Part J and Part K onto the main body from both side and fix them by 20 sets of No 4 screws 2 Slide Part L onto the main body and fix it by...

Page 24: ...d fix it by Key 4 Use screw driver to lose 4 screws 2 to open the UPS panel 5 Plug in the power wire X4 inside of UPS for Battery power LED indicator We unplug this wire X4 before we ship the machine...

Page 25: ...reel nut handle 3 refer to following drawing B Step 2 Pull out some strap to thread it through the roller 4 on the Break Arm Also thread strap through two rollers 5 6 Step 3 Turn on the power switch T...

Page 26: ...kage the strapping head should be close to the corner of the package or will cause not easy to threading the strap into the strap inlet pull strap and pass the strap around the package and insert the...

Page 27: ...activate the strapping cycle Then the strapping cycle is completed 5 Move the strapping head up and down to the next strapping position and repeat the strapping process until the last strapping is fi...

Page 28: ...as smoother surface or different thickness some adjustments for higher tension might be necessary When insufficient strapping tension occurs while tension adjustment knob is on MAX position please tur...

Page 29: ...to the scale indicated refer to fig 6 c Change RH Strap Guide 5MH 1 100100 5MH 1 100110 5MH 1 100120 according to the strap width refer to fig 7 Fig 6 Strap Guide Cover T5 1 24143 Strap Guide Cover T...

Page 30: ...the capacity of the battery drop dramatically It will be dangerous if doing the charging process on an old dead battery because the temperature of the battery will rise while charging f When the batt...

Page 31: ...n which means battery charge is completed and it is under floating charge mode Please unplug power cord and the machine is ready for use f It takes around 4 hours for charging Note the following point...

Page 32: ...burns with this area 1 Cleaning and Lubrication The high reliability and long service life of the strapping machine will depend on regular cleaning and maintenance ATTENTION All the important strap tr...

Page 33: ...if necessary Monthly or 3 000 strapping cycles Clean both sides of heater plate and polish with fine sandpaper if necessary ATTENTION Make sure the welding plate is cool first Check cam rollers of sea...

Page 34: ...Replace deflection roller if it shows visible changes In case of loud noise at bearings locate them replace the bearings Get machine ready for operation again strap one bundle manually several times p...

Page 35: ...he correct melting position e If you find the jointed surface is smaller than the standard size check if the position of the Strap Guide B T5 1 10152 is according to your requested strapping width Or...

Page 36: ...too high Please de rating the output usage or reduce the ambient temperature Overload protection Make sure the output load does not exceed the rated value or the instantaneous start up current is not...

Page 37: ...ith one longer PCB can t received signal form SQ2 Check wire connection and function of SQ2 Make sure the SQ2 is not broken and wire is connecting well One shorter with one longer PCB can t received s...

Page 38: ...PART II...

Page 39: ...B1 1 Wiring Diagram a TP 502MH...

Page 40: ...B2...

Page 41: ...B3...

Page 42: ...B4...

Page 43: ...B5...

Page 44: ...B6 b TP 502MHB...

Page 45: ...B7...

Page 46: ...B8...

Page 47: ...B9...

Page 48: ...B10...

Page 49: ...B11...

Page 50: ...B12...

Page 51: ...B13...

Page 52: ...B14...

Page 53: ......

Page 54: ......

Page 55: ...PART III...

Page 56: ...PART III...

Page 57: ...1 2 3 STRAPPING HEAD UNIT C1 1 5MH 1 900000 5MH 1 900010...

Page 58: ...d Unit For 9mm 1 5MH 1 900010 Strapping Head Unit For 12mm 1 5MH 1 900020 Strapping Head Unit For 15 5mm 1 1 5MH 1 100000 Cam Group For 9mm 1 SEE PAGE C3 5MH 1 100010 Cam Group For 12mm 1 5MH 1 100020...

Page 59: ...5 67 73 28 27 13 85 85 72 80 80 42 65 58 34 84 55 49 37 30 21 45 7 6 35 47 61 29 20 48 1 62 72 63 72 79 71 84 60 71 24 23 63 33 32 63 31 58 34 22 66 36 64 38 39 38 39 26 86 74 86 12 11 10 53 70 78 70...

Page 60: ...y 1 SEE PAGE C13 11 T5 1 14000 Press Bar Ass y 1 SEE PAGE C15 12 5MH 1 130000 Front Bar Ass y 1 SEE PAGE C17 13 T5 1 30000 Transmission Group 1 SEE PAGE C19 20 T5 1 10110 Main Body Block 1 21 T5 1 101...

Page 61: ...PMS M4 20 1 58 HSS0606G HSS M6 6 G 2 60 HBS0425 HBS M4 25 1 61 HBS0505 2 HBS M5 5 2 1 62 HBS0510 HBS M5 10 2 63 HBS0512 HBS M5 12 6 64 HBS0516 HBS M5 16 1 65 HBS0525 HBS M5 25 1 66 HBS0525H HBS M5 25...

Page 62: ...C6 C6...

Page 63: ...CAM ASS Y C7 1 1 1 5MH 1 110000 25 1 30 37 36 24 36 31 43 43 11 2 3 4 13 20 12 8 14 35 43 13 13 7 20 10 9 30 43 23 30 30 30 30 36 43...

Page 64: ...0 Tension Cam 1 9 T5 1 11141 Limit Switch Contactor 1 10 TA 008 2 Bearing Support L 1 11 TA 015B Heater Cam 1 12 TA 017 2 Bearing Support R 1 13 TA 241 Spacer 3 14 TB 223 Washer 1 20 BR6003ZZ Bearing...

Page 65: ...FAN ASS Y C9 1 1 2 5MV 1 110000 15 7 14 11 1 10 3 11 2 8 9 14 7 15 12...

Page 66: ...CRIPTION Q TY REMARKS 1 5MV 1 100100 Fan Support 1 2 T5 1 12370 Fan 1 3 5MV 1 100300 Fan Cover 1 7 SW04 SW M4 4 8 SW06 SW M6 2 9 PW06A PW M6 A 2 10 HBS0616 HBS M6 16 2 11 TMS0412 TMS M4 12 4 12 LA 400...

Page 67: ...15 20 19 3 5 12 8 38 HEATER ASS Y C11 1 1 3 T5 1 12004 7 11 10 9 13 14 16 4 37 6 11...

Page 68: ...ide Plate 1 6 TB 114 Return Spring 1 7 TB 115 Spring 1 8 HBS0440H HBS M4 40 H 2 9 PW04 PW M4 2 10 SW04 SW M4 2 11 HN04 HN M4 3 12 HBS0516 HBS M5 16 1 13 BR635ZZ Bearing 635ZZ 1 14 PW05 PW M5 1 15 HN05...

Page 69: ...1 5 8 2 4 7 6 REAR BAR ASS Y C13 1 1 4 5MH 1 120000 3 9...

Page 70: ...O PART NO DESCRIPTION Q TY REMARKS 1 SP0318 Spring Pin 3 18 1 2 TA 071 Return Spring 1 3 TA 073 Spring Hook 1 4 TA 074 Rear Bar 1 5 TA 075 Plunger 1 6 BR635ZZ Bearing 635ZZ 1 7 SP0514 Spring Pin 5 14...

Page 71: ...8 5 2 4 3 7 6 1 PRESS BAR ASS Y C15 1 1 5 T5 1 14000...

Page 72: ...0 REF NO PART NO DESCRIPTION Q TY REMARKS 1 TA 069 Press Par 1 2 SP0318 Spring Pin 3 18 1 3 TA 071 Return Spring 1 4 TA 073 Spring Hook 1 5 TA 075 Plunger 1 6 BR635ZZ Bearing 635ZZ 1 7 SP0514 Spring P...

Page 73: ...8 7 4 6 5 1 3 2 FRONT BAR ASS Y C17 1 1 6 5MH 1 130000 9...

Page 74: ...O PART NO DESCRIPTION Q TY REMARKS 1 SP0318 Spring Pin 3 18 1 2 TA 071 Return Spring 1 3 TA 073 Spring Hook 1 4 TA 075 Plunger 1 5 BR635ZZ Bearing 635ZZ 1 6 SP0514 Spring Pin 5 14 1 7 TA 078 Spring 1...

Page 75: ...12 11 M1 6 10 3 7 17 6 1 9 17 5 14 13 TRANSMISSION GROUP C19 1 1 7 T5 1 30000 15 16...

Page 76: ...0130 Motor M1 1 5 HBS0625 HBS M6 25 3 6 SW06 SW M6 6 7 KYC0310 Key 3 10 1 9 PW06A PW M6 A 3 10 PW06C PW M6 C 3 11 HBS0616 HBS M6 16 3 12 T5 1 30220 Worm Gear for M1 Motor 1 13 T5 1 30230 Flexible Coup...

Page 77: ...FEED GROUP C21 1 2 5MH 1 200000 17 11 12 31 28 1 14 13 30 34 40 40 41 39 32 3 41 33 41 51 2 39 29...

Page 78: ...1 220000 Roller Arm Ass y 1 SEE PAGE C25 13 5MH 1 230000 Main Roller Ass y 1 SEE PAGE C27 14 5MH 1 240000 Strap Guide Ass y 1 SEE PAGE C29 17 5MH 1 200400 Motor M2 1 28 HBS0420 HBS M4 20 4 29 HBS0416...

Page 79: ...FEED SHOOTER ASS Y C23 1 2 1 5MH 1 210000 13 24 13 1 20 28 19 23 23 19 15 25 8 2 8 25 15 29 29 14 24...

Page 80: ...5MH 1 210100 Feed Shooter 1 2 5MH 1 210200 Roller 2 8 BR686ZZ Bearing 686ZZ 4 13 HBS0512 HBS M5 12 2 14 HBS0616 HBS M6 16 2 15 HBS0660HN HBS M6 60 H N 2 19 SW05 SW M5 2 20 SW06 SW M6 2 23 PW05 PW M5 2...

Page 81: ...ROLLER ARM ASS Y C25 1 2 2 5MH 1 220000 8 33 38 12 1 35 25 28 20 47 42 53 47 47 53 42 53 7 25 28 37 43 14 43 48 19 54 54 11 54 43 36 43 49 33 9 2 13 3 18 4 18 10 29...

Page 82: ...1 TC 025 Spring 1 12 T7 1 22200 Spring 1 13 TB 133 Nut 1 14 TB 223 Washer 1 18 BR6001ZZ Bearing 6001ZZ 2 19 BR636 2RS Bearing 636 2RS 1 20 BR635ZZ Bearing 635ZZ 1 25 MB0808 Metal Bushing 0808 2 28 ER0...

Page 83: ...MAIN ROLLER ASS Y C27 1 2 3 5MH 1 230000 6 7 5 6 13 1 18 8 27 22 15 26 21 33...

Page 84: ...n Roller Shaft 1 5 T5 1 21122 Main Roller 1 6 T5 1 21130 Side Plate 2 7 T5 1 21160 Gear 1 8 TB 223 Washer 1 13 BR6004 2RS Bearing 6004 2RS 1 15 KYA050532 Key 5 5 32 1 18 SR20 Snap Ring S 20 1 21 HBS04...

Page 85: ...STRAP GUIDE ASS Y C29 1 2 4 5MH 1 240000 17 3 17 21 21 4 28 21 30 25 6 9 7 15 20 16 21 8 2 1 10 5 17 21...

Page 86: ...Guide B 1 4 T5 1 24144 Strap Guide Cover 1 5 T5 1 24152 Strap Guide C 1 6 T5 1 24183 Spring 1 7 T5 1 24191 Spring Shaft 1 8 T5 1 24260 Tension Socket 1 9 T5 1 24270 Spring Bushing 1 10 TF 006 Micro Sw...

Page 87: ...BASE PLATE GROUP C31 1 3 5MH 1 300000 8 26 1 48 10 20 21 54 43 49 49 43 54 54 54 38 9 41 47 7 2 3 42 35 48 42 35 18 42 53 36 30 30 37 43 50 37 43 50 37 43 50...

Page 88: ...9 TF 015 Terminal Bracket 1 10 TF 016 Cover 1 18 FMS0410 FMS M4 10 4 20 PMS03 515 PMS M3 5 15 2 21 PMS0408 PMS M4 8 2 26 TMS0408N TMS M4 8 N 2 30 HSS0506G HSS M5 6 G 2 35 HBS0510 HBS M5 10 2 36 HBS051...

Page 89: ...BASE GROUP C33 2 5MH 2 100000...

Page 90: ...2 BASE GROUP 5MH 2 100000 REF NO PART NO DESCRIPTION Q TY REMARKS 5MH 2 100000 Base Group 1 C34...

Page 91: ...00 90 80 1 26 66 3 21 98 88 78 35 59 59 56 50 66 77 88 98 66 66 42 25 2 SEE PAGE 98 88 76 88 43 37 99 89 108 49 34 98 88 98 107 107 28 98 88 78 22 72 73 86 94 85 105 5 98 88 107 23 30 42 98 88 107 4 5...

Page 92: ...160 Caster 2 20 TE 079 Rubber 8 21 T2 2 10170 Rubber 1 22 T2 3 10111 T Support 1 23 5MH 2 101300 Suspension Bracket Ass y 2 24 T2 3 10210 Troy Weight Roller Pin 4 25 T2 3 10220 Support Handle 1 26 T2...

Page 93: ...0 N 8 HBS M6 20 N Option 11 76 HBS0820N HBS M8 20 N 22 77 HBS0825N HBS M8 25 N 4 78 HBS0830N HBS M8 30 N 6 79 HBS0816N HBS M8 16 N 4 80 HBS0512N HBS M5 12 N 2 81 HBS0660HN HBS M6 60 H N 2 85 SW03 SW M...

Page 94: ...C38 C38...

Page 95: ...REEL CONTROL GROUP C39 3 5MH 3 100000...

Page 96: ...3 REEL CONTROL GROUP 5MH 3 100000 REF NO PART NO DESCRIPTION Q TY REMARKS 5MH 3 100000 Reel Control Group 1 C40...

Page 97: ...REEL CONTROL GROUP C41 3 1 5MH 3 100000 21 5 17 20 4 8 7 16 3 14 29 19 37 32 23 10 1 31 11 36 12 28 15 34 18 38 33 13 37 2 30 24 22 35 50 45 46 45 50 28 34 26 27 39 25...

Page 98: ...Reel Shaft 1 17 TD 016 Reel Nut Handle LH 1 18 TD 024 Spring Hook 1 19 TD 046 1 Arm 1 20 LA 30200 Label 2 21 LA 30210 Label 1 22 T2 3 10160 Reel Support 1 23 T2 4 20015 Brake Belt 1 24 T6 4 20031 Lini...

Page 99: ...BODY FRAME GROUP C43 4 5MH 4 100000...

Page 100: ...4 BODY FRAME GROUP 5MH 4 100000 REF NO PART NO DESCRIPTION Q TY REMARKS 5MH 4 100000 Body Frame Group 1 C44...

Page 101: ...8 65 57 48 65 57 48 71 65 57 65 57 48 65 57 48 65 57 48 40 65 57 48 40 17 65 57 71 43 65 57 30 13 16 15 30 57 43 65 30 16 13 15 30 48 57 65 30 16 13 14 30 48 57 65 30 16 13 30 14 63 55 46 63 55 46 25...

Page 102: ...Roller Cover R 1 19 T2 5 10180 Knob 1 20 T2 5 10190 Knob Bracket 1 21 5MH 4 100600 Side Cover 1 22 T6 2 11140 RH Bandway Flap Pin Rear 2 23 T6 2 11150 RH Bandway Flap Spring 2 24 T6 5 11150 Table Han...

Page 103: ...ELECTRIC CONTROL UNIT C47 5 5MH 5 900000 5MH 5 900010 2 1...

Page 104: ...T NO DESCRIPTION Q TY REMARKS 5MH 5 900000 Electric Control Unit For 220V 240V 1 5MH 5 900010 Electric Control Unit For 110V 1 1 5MH 5 100000 Electric Control Group For 220V 240V 1 5MH 5 100010 Electr...

Page 105: ...ELECTRIC CONTROL GROUP C49 5 1 5MH 5 100000 5MH 5 100010 52 45 38 1 30 30 30 38 45 52 38 45 52 12 18 24 24 24 30 11 30 30 30 51 44 37 2 30 30 30 4 37 44 51 3 17 27 38 45 52 20 20...

Page 106: ...ter Transformer For 220V 240V 1 5MH 5 100410 Heater Transformer For 110V 1 11 5MH 5 110000 Electrical Box Ass y For 220V 240V 1 SEE PAGE C51 5MH 5 110010 Electrical Box Ass y For 110V 1 12 5MH 5 12000...

Page 107: ...ELECTRICAL BOX ASS Y C51 5 1 1 5MH 5 110000 5MH 5 110010 41 41 41 2 3 20 49 23 21 1 41 19 19 55 65 65 36 37 22 22 22 18 18 17 35 40 40 40 40 40 4 27 25 24 26...

Page 108: ...witch 1 18 T5 4 10221 Knob Hole 3 2 2 19 T5 4 10231 Variable Resistor 5K 3 2 2 20 T6 6 10250 Earth Plate 1 21 T6 6 10980 Cable Gland PG11 1 22 TG 013 Fuse Holder 3 23 TK 001 Main Power Switch 1 24 FU3...

Page 109: ...CONTROL PANEL ASS Y C53 5 1 2 5MH 5 120000 31 32 31 3131 2 32 10 9 9 38 1 38 19 8 4 3 11 12...

Page 110: ...Box Cover 1 3 5MH 5 120300 Green Lamp Indicator 1 4 5MH 5 120400 Amber Lamp Indicator 1 8 T5 4 10222 Knob Hole 6 0 2 9 T5 4 10232 Variable Resistor 5K 6 0 2 10 T5 4 10580 Grommet 1 11 TG 004 Reset Pus...

Page 111: ...WIRES GROUP C55 5 2 5MH 5 200001 X1 X3 X9 X41 X4 X8 X2 X5 X7 X6 10 9 1 3 4 5 8 6 7 2...

Page 112: ...el 1 3 EW52H0000X09 Wire Ass y X9 For LED Indicator 1 4 EW52H0000X03 Wire Ass y X3 For SQ1 SQ2 SQ3 1 5 EW52H0000X41 Wire Ass y X41 For SQ4 1 6 EW52H0000X05 Wire Ass y X5 For M1 M2 1 7 EW52H0000X08 Wir...

Page 113: ...BATTERY GROUP C57 6 5MH 6 100000 5MH 6 100010 For TP 502MHB...

Page 114: ...6 BATTERY GROUP 5MH 6 100000 For TP 502MHB 5MH 6 100010 REF NO PART NO DESCRIPTION Q TY REMARKS 5MH 6 100000 Battery Group For 220V 230V 240V 1 5MH 6 100010 Battery Group For 110V 1 C58...

Page 115: ...63 73 79 63 73 79 33 32 29 66 66 81 81 6 18 17 16 27 28 40 31 10 9 15 73 79 79 73 62 14 53 53 53 53 1 6 77 70 85 3 77 70 85 26 25 55 55 55 55 55 55 7 80 73 63 51 35 5 15 73 79 79 73 62 53 53 53 30 11...

Page 116: ...Battery Voltage Indicator 1 13 5MH 6 101400 Battery 2 14 5MH 6 101500 Power Supply Fixing Plate 1 15 5MH 6 101600 Support Rod 4 16 5MH 6 101700 Charger Wire Connector 1 17 5MH 6 101800 Inverter Wire...

Page 117: ...TMS M4 8 N 1 52 TMS0412N TMS M4 12 N 2 53 TMS0508N TMS M5 8 N 18 55 TMS0612N TMS M6 12 N 6 61 HBS0512N HBS M5 12 N 4 62 HBS0612N HBS M6 12 N 4 63 HBS0616N HBS M6 16 N 8 66 HB08200 HB M8 200 2 70 SW03...

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