Plockmatic CF5030 User manual

25 November 2011
Subject to change
COVER FEEDER CF5030
SERVICE MANUAL

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I
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
3.2.10 PAPER POSITIONING SENSOR Q32 .................................... CF-3-14
3.2.11 UPPER AND LOWER PAPER PATHS .................................... CF-3-15
3.2.12 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

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CF-1-1
25 November 2011
Installation
1 INSTALLATION PROCEDURE
1.1 INSTALLATION PROCEDURE
Cover Feeder INSTALLATION PROCEDURE is located in the Booklet Maker
BK5030 Service Manual ( 1.4)

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CF-2-1
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Preventive
Maintenance
2 PREVENTIVE MAINTENANCE SCHEDULE
2.1 PREVENTIVE MAINTENANCE SCHEDULE
Cover Feeder PREVENTIVE MAINTENANCE SCHEDULE is located in the Book-
let Maker BK5030 Service Manual ( 2)

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25 November 2011
3. REPLACEMENT AND ADJUSTMENT
3.1 COVER FEEDER
3.1.1 REMOVE COMPLETE UNIT
Replacement
Adjustment
CF-3-1
1. Remove Top Cover ( BK5030 Service Manual 3.3.5 ).
2. Disconnect motor harness [A] ( x 2).
3. Disconnect sensor harness [B] ( x 1).
4. Disconnect fan harness [C] ( x 1).
[A][B] [C]
Cover Feeder,
viewed from Booklet
Maker outfeed
Cover Feeder, viewed from
Booklet Maker front side

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CF-3-2
6. Remove screws [D] ( x 2).
[D]
Cover Feeder, viewed from
Booklet Maker rear side
Cover Feeder, viewed from
Booklet Maker front side
COVER FEEDER

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Replacement
Adjustment
CF-3-3
8. Note the position of the brackets [F] and [G].
9. Lift the rear end of Cover Feeder and carefully remove the complete unit so
that the shaft [F] comes loose from brackets [F] and [G].
NOTE: The shaft [E] must exit the cut-outs in the brackets [F] and [G] in the
Top Cover before it can be removed.
[E][F] [G]
COVER FEEDER

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25 November 2011
Replacement
Adjustment
CF-3-5
AREA F
3.2 AREA F
3.2.1 EMPTY BIN SENSOR Q31
1. Remove screw [A] ( x1).
2. Gently lift out Sensor Q31 [B] and disconnect connector [C] ( x1).
2. Remove Sensor Q31 [B] ( x1).
[A]
[B][C]

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CF-3-6
1. Remove screw [A] ( x1).
2. Gently lift out Sensor Q38 [B] and disconnect connector [C] ( x1).
2. Remove Sensor Q38 [B] ( x1).
[A]
[B]
3.2.2 PAPER WIDTH SENSOR Q38
[C]
AREA F

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Replacement
Adjustment
CF-3-7
AREA F
3.2.3 FEED ROLLER ASSY AND PAPER SEPARATOR PAD
1. Remove the Feed roller assembly [A] by pressing it to the front side according
to gure [B].
2. Lift out the rear side [C] of the Feed roller assembly.
3. Remove the Paper separator pad [D] by lifting it out (with a small screwdriver)
from the holder.
[B]
[A]
[C]
[D]

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CF-3-8
AREA F
3.2.4 FEED MOTOR M15
Removal
1. Remove Rear Top Cover ( Booklet Maker Service Manual 3.3.6).
2. Remove Feed roller assembly ( 3.2.3).
3. Disconnect Connector [A] ( x1).
4. Remove screws [B] ( x3).
5. Remove Feed motor M15.
Replacement
1. Reverse the removal procedure.
2. Enter Service mode ( 5.1.1 in BK5030 Service Manual).
3. Perform Cover Feeder motor calibration ( 5.5 in BK5030 Service Manual).
[A] [B]

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Replacement
Adjustment
CF-3-9
AREA F
3.2.5 PAPER BIN LOW SENSOR Q33
[B]
[A] [C]
1. Remove Rear Top Cover ( Booklet Maker Service Manual 3.3.6).
2. Disconnect Connector [A] ( x1).
4. Remove screws [B] ( x2).
5. Remove Paper Bin Low Sensor Q33 [C.

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CF-3-10
3.2.6 DRIVE MOTOR M16 ASSEMBLY
[A]
0.4 ± 0.3 mm play between
the coupling and the clutch
Removal
1. Remove complete Cover Feeder unit ( 1.1.1).
2. Disconnect Connector [A] ( 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 (
3.2.9).
4. Loosen the allen screw [C] to Drive clutch assembly ( x1).
5. Remove the motor bracket by removing screws [D] ( x3).
[B]
[C]
[D]
Replacement
1. Reverse the removal procedure.
2. Enter Service mode ( 5.1.1 in BK5030 Service Manual).
3. Perform Cover Feeder motor calibration ( 5.5 in BK5030 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].
AREA F
[C]

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Replacement
Adjustment
CF-3-11
3.2.7 DRIVE SHAFT ASSEMBLY
Removal
1. Remove Drive motor M16 assembly ( 3.2.6).
2. Remove the Drive shaft assembly, by sliding it out through the rear frame.
Replacement
1. Reverse the removal procedure.
Adjustment
Adjust the Drive clutch assembly ( 3.2.6).
AREA F

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CF-3-12
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.
AREA F