Ricoh Plockmatic PBM350/PBM500 Production Booklet Maker Service Manual


Accurate, clear and concise text, combined with detailed illustrations, lists of error code, instruction and diagrams, guide you through procedure of repair, remediate, maintenance and adjustments your copier, printer or scanner.
Present service manual Ricoh Plockmatic PBM350/PBM500 Production Booklet Maker contain clear instructions and procedures on how to fix the problems occurring in your equipment.
The information contained in this repair manual is necessary for the repair, but also prevention, resulting in a longer life of your equipment.
Format of the manual: PDF, makes it easy to navigate, instant download and print. English language.
Table of contents:

1) INSTALLATION PROCEDURE
1.1 Unpacking Instruction
1.1.1 PBM Rotate Crease Trim Module
1.1.2 PBM500 Upgrade kit
1.1.3 Plockmatic Cover Feeder
1.1.4 PBM350 + PBM500 Production Booklet Maker
1.1.5 PBM Book Fold Module
1.1.6 PBM Trim Module
1.1.7 BST 4000-1 Belt Stacker Module
1.2 Installation Requirements
1.2.1 Minimum Space Requirements
1.2.2 Power Requirements
1.2.3 Pre Installation Information
1.2.4 Tools
1.3 Installation Precautions
1.4 Rotate Crease Trim Module (RCT)
1.4.1 Accessory Check
1.4.2 Installation procedure
1.5 PBM500 Upgrade kit
1.5.1 Accessory Check
1.5.2 Installation procedure
1.6 Plockmatic Cover Feeder
1.6.1 Accessory Check
1.6.2 Installation procedure
1.7 PBM350/500 Production Booklet Maker
1.7.1 Accessory Check
1.7.2 Installation procedure
1.8 PBM Book Fold Module
1.8.1 Accessory Check
1.8.2 Installation procedure
1.9 PBM Trim Module to PBM Book Fold Module
1.9.1 Accessory Check
1.9.2 Installation procedure, Trimmer to Book Folder
1.10 PBM Trim Module to PBM350/500 Booklet Maker
1.10.1 Accessory Check
1.10.2 Installation procedure, Trimmer to Booklet Maker
1.11 BST4000-1 Belt Stacker Module
1.11.1 Installation procedure
1.12 Cables, plugs and jumpers
1.12.1 Configurations with RCT, viewed from back side
1.12.2 Configurations without RCT, viewed from back side
1.12.3 BST4000-1 Belt Stacker Module
1.12.4 Main Power cord, PBM350/500 Booklet Maker
1.12.5 Main Power cord, Rotate Crease Trim Module
1.12.6 Main Power cord, BST4000-1 Belt Stacker Module
1.13 After switching on the power
1.13.1 Enabling the Cover Feeder & calibrating the DSD sensor.1-75
1.13.2 Setting NVM value for the Trimmer
1.13.3 Checking software versions
1.13.4 Perform a self diagnostic
1.14 Checking the installation
1.14.1 System alignment
1.14.2 Adjusting/checking the RCT bleed trim
1.14.3 Checking the RCT crease
1.14.4 Checking the Booklet Maker
1.14.5 Checking the Book Folder
1.14.6 Checking the Trimmer
1.14.7 Checking the Cover Feeder
(M7) PCB “C”, (M4) PCB “D”, (M1) PCB “E”, (M6) PCB “H”,
(M3) PCB “J” LEDs
(M7) PCB “C”, (M4) PCB “D”, (M1) PCB “E”, (M6) PCB “H”,
(M3) PCB “J” Test Points
Set Size Guide

2) PREVENTIVE MAINTENANCE (PM)

3) REPAIRS AND ADJUSTMENTS (REP and ADJ)
General cautions
Recommended tools
Booklet Maker REPs
REP 1.0 Undocking BM / TR / BF
REP 1.1 Front and Rear Cover
REP 1.2 Lower and Upper Infeed Cover and Infeeder
REP 1.3 Upper and Lower Exit Cover
REP 1.4 Top Cover
REP 1.5 Top Cover Assembly
REP 1.6 Interlock Switch Assembly
REP 3.0 Infeed Module
REP 3.1 BK-Q1 Paper Infeed Sensor
REP 3.2 Paper / Side Guides
REP 3.3 BK-M3 Side Jogger Motor &
BK-Q12 Side Jogger Motor Sensor
REP 3.4 Side Guide Transmission &
BK-Q13 Side Jogger home position sensor
REP 3.5 Side Guide Transmission Belt
REP 3.6 Back Jogger Module &
BK-Q3 Back Jogger Home Position Sensor
REP 3.7 Back Jogger Assembly
REP 3.8 Back Jogger Fingers
REP 3.9 BK-M2 Back Jogger Motor &
BK-Q45 Back Jogger Motor Sensor
REP 3.10 Infeed Transport Module
REP 3.11 Infeed Transport Wheel
REP 3.12 BK-M1 Infeed Motor &
BK-Q2 Infeed Motor Sensor
REP 4.0 Stapler Heads, Stapler Assy and Clincher
REP 4.1 Staple Quality (forming)
REP 4.2 BK-Q47 Stapler Home Position Sensor Right &
BK-Q50 Stapler Home Position Sensor Left
REP 4.3 BK-M5 Set Transport Motor &
BK-Q40 Set Transport Motor Sensor
REP 4.4 BK-M22 Stop Gate Stapler Motor
REP 4.5 BK-Q41 Stop Gate (M22) Motor Sensor
REP 4.6 BK-Q42 Home Position Stop Gate Stapler (M22) sensor
REP 5.0 BK-Q4 Start Sensor Saddle Stapling Sensor
REP 5.1 BK-M9 Staple Fold Positioning Motor &
BK-Q10 Stapler Fold Positioning Motor Sensor
REP 6.0 Length Transmission Shaft &
BK-Q11 Staple Fold Home positioning Sensor
REP 6.1 BK-M8 Stop Gate Folder Motor,
BK-Q7 Stop Gate Folder Sensor &
BK- Q48 Clinch Trigger Sensor Right
REP 6.2 Fold Stop Gate
REP 6.3 BK-M7 Fold Knife Motor &
BK-Q15 Fold Knife Home Position Sensor
REP 6.4 Fold Transmission Module, BK-M6 Fold Roller Motor,
BK-Q9 Fold roller sensor & fold transmission chain.
REP 6.5 Spring Support
REP 6.6 Upper Fold Rollers
REP 6.7 Lower Fold Rollers
REP 6.8 BK-Q44 Home Position Stop Gate Folder Sensor
REP 6.10 BK-Q8 Exit Sensor
REP 7.0 MD6DC PCB “H” (upper)
REP 7.1 MD6DC PCB “B” (middle)
REP 7.2 MD6DC PCB “C” (lower)
REP 7.3 PCB Controller, PCB “A”
REP 7.4 Addon PCB “F” 3-54
REP 7.5 Expansion PCB “J” 4 In 4 Out
REP 7.6 User Interface assembly
REP 7.7 BK-M23 Thick Sensor Motor
BK-Q37 Thick Set Motor Sensor &
BK-Q36 Thick Set Motor Home Sensor
REP 7.8 Removing Power Supply unit
REP 7.9 Accessing Rear Side of Connection Bracket
REP 7.10 Printer Interface PCB “E”
Belt Stacker REP’s
REP 8.0 Stacker Module
REP 8.1 ST-M1 Stacker Motor
Cover Feeder REPs
REP 9.0 Cover Feeder
REP 9.1 CF-Q31 Empty Bin Sensor
REP 9.2 CF-Q38 Paper Width Sensor
REP 9.3 Feed Roller Assy & Paper Separator Pad
REP 9.4 CF-M15 Cover Feed Motor
REP 9.5 CF-Q33 Paper Bin Low Sensor
REP 9.6 CF-M16 Cover Drive Motor Assembly
REP 9.7 Drive Shaft Assembly
REP 9.8 Pinch Roll Shaft Assembly
REP 9.9 CF-Q30 Paper Path / DSD Sensor
REP 9.10 CF-Q32 Paper Positioning Sensor
REP 9.11 Upper and Lower Paper Path
REP 9.12 CF-M17 / M18 Blower Motor
Trimmer REPs
REP 10.0 Front and Rear Cover
REP 10.1 Top Cover
REP 10.2 Infeed Cover
REP 10.3 TR-M5 / M6 Blower Motor (Blower Assembly)
REP 10.4 Upper Exit Cover
REP 10.5 TR-SW10 Interlock Switch & TR-Q1 Interlock sensor
REP 10.6 Repair deleted
REP 10.7 Protection Cover
REP 10.8 TR-Q8 Trim Bin Full Sensor
REP 10.9 TR-Q13 Infeed Sensor
REP 10.10 TR-Q2 Infeed Shaft Sensor
REP 10.11 TR-Q3 Exit Belt Sensor
REP 10.12 TR-M1 Transport / Knife Motor
REP 10.13 TR-Q4 Transport Belt Sensor
REP 10.14 TR-M2 Trim Knife Motor
REP 10.15 TR-Q5 Trim Knife Home Position Sensor
REP 10.16 Knife guard
REP 10.17 Repair deleted
REP 10.18 Upper Trim Knife
REP 10.19 Lower Trim Knife
REP 10.20 TR-Q14 Paper Path & TR-Q6 Exit Sensor
REP 10.21 Stop Gate Carriage
REP 10.22 TR-M3 Stop Gate Motor,
TR-Q7 Stop Gate Home Position sensor &
TR-Q11 length adjustment home position sensor
REP 10.23 TR-M4 Length Adjustment Motor &
TR-Q12 (M4) Motor Encoder
REP 10.24 Lower Exit Belts and foam rollers
REP 10.25 Upper Exit Belts and foam rollers
REP 10.26 Transmission Chain
REP 10.27 Knife Support Chain
REP 10.28 Knife Chain
REP 10.29 Infeed Belts
REP 10.30 MD6DC PCB “A”
REP 10.31 Latch, Docking
REP 10.32 TR-M8 Lifter Motor &
TR-Q15 Lift Motor Home Pos. Sensor
REP 10.33 Plunger, upper knife beam
Book Folder REPs
REP 11.0 Front and Rear Cover
REP 11.1 Infeed Cover
REP 11.2 Exit Cover Assembly
REP 11.3 Top Cover
REP 11.4 Tilt the Machine
REP 11.5 Antistatic Brushes
REP 11.6 BF-M1Transport Belt Motor
REP 11.7 BF-M2 Stop Gate Motor
REP 11.8 BF-M3 Clamp Motor
REP 11.9 BF-M4 Roll Motor
REP 11.10 BF-Q1 (M2) Stop Gate Sensor
REP 11.11 BF-M4 Roll Motor, BF-Q2 (M4) Right sensor &
BF-Q3 (M4) Left Sensor
REP 11.12 BF-Q4 Clamp Motor (M3) Encoder
REP 11.13 BF-Q5 Infeed Sensors
REP 11.14 BF-Q7 Exit Sensors
REP 11.15 BF-Q6 Clamp Sensor
REP 11.16 BF-M4 Roll Motor & BF-Q8 (M4) Motor Sensor
REP 11.17 Upper Transport Belt Assembly
REP 11.18 BF-SW2 Interlock Switches
REP 11.19 Upper Transport Belt, BF-SOL1/3 Clutches & Foam Rollers
REP 11.20 Lower Transport Belt, BF-SOL2/4 Clutches & Foam rollers
REP 11.21 Teflon Tape Lower Transport Belt
REP 11.22 Set Clamps
REP 11.23 Stop Gate
REP 11.24 MD6DC PCB “D”
REP 11.25 Accessing Rear Side of Connection Bracket
REP 12.0 Undocking RCT
Rotator Creaser Trimmer REP’s
REP 12.1 Front and Rear Cover
REP 12.2 Infeed and Exit Cover
REP 12.3 Top Cover
REP 12.4 Top Cover Assembly
REP 12.5 Interlock Switch Assy Top Cover CT-SW3 (CT-Q9)
& Main power switch CT-SW1
REP 12.6 Interlock Switch Slide Door CT-SW2 (CT-Q8)
REP 12.7 Entrance Sensor (CT-Q1)
REP 12.8 Exit Sensor (CT-Q7)
REP 12.9 Drive Motor (CT-M1)
REP 12.10 Drive Motor (CT-M1) Primary Timing Belt
REP 12.11 Drive Motor (M1) Secondary Timing Belt
REP 12.12 Docking Bracket, Infeed
REP 12.13 Docking Bracket, Exit
REP 12.14 Infeed Drive Shaft
REP 12.15 Infeed Idler Roller
REP 12.16 Infeed Baffle
REP 12.17 Exit Drive Shaft
REP 12.18 Exit Idler Roller
REP 12.19 Exit Baffle
REP 12.20 Pre Trimmer Fixing Roller
REP 12.21 Post Trimmer Fixing Roller
REP 12.22 Transmission Shaft
REP 12.23 Lower Drive Shaft
REP 12.24 Chassie Counter
REP 12.25 Waste Transport Belt
REP 12.26 Waste Bin Full Sensor (CT-Q11)
REP 12.27 Waste Transport Sensor (CT-Q14)
REP 12.28 Upper Drive Shaft
REP 12.29 Rotator Sensor (CT-Q2)
REP 12.30 Rotator Timing Belt
REP 12.31 Rotator Disengage Solenoid (CT-SOL1)
REP 12.32 Rotator Disengage Solenoid (CT-SOL1) Idler Shaft
REP 12.33 Rotator Disengage Solenoid (CT-SOL1) Mechanism
REP 12.34 Rotator Disengage Solenoid (CT-SOL2)
REP 12.35 Rotator Disengage Solenoid (CT-SOL2) Idler Shaft
REP 12.36 Rotator Disengage Solenoid (CT-SOL2) Mechanism
REP 12.37 Rotator Upper Drive Shaft
REP 12.38 Rotator Lower Drive Shaft
REP 12.39 Rotator Motor (CT-M3)
REP 12.40 Rotator Motor (CT-M3) Drive Shaft
REP 12.41 Registration Lead Screw
REP 12.42 Registration Width Adjustment Motor (CT-M4)
REP 12.43 Registration M4 Home Sensor (CT-Q3)
REP 12.44 Registration Cross Rolls Drive Shaft
REP 12.45 Registration Cross Rollers Timing Belt
REP 12.46 Registration Cross Rollers
REP 12.47 Registration Cross Rollers Idler Rollers
REP 12.48 Registration Primary Alignment Rail
REP 12.49 Registration Secondary Alignment Rail
REP 12.50 Registration Disengage Solenoid (CT-SOL5)
REP 12.51 Registration Disengage Solenoid (SOL5) Linkage
REP 12.52 Creaser Assembly
REP 12.53 Creaser Trigger Sensor (CT-Q4) LED
REP 12.54 Creaser Trigger Sensor (CT-Q4) Phototransistor
REP 12.55 Creaser Tools Home Sensor (CT-Q5)
REP 12.56 Creaser Timing Belt
REP 12.57 Creaser Tools
REP 12.58 Creaser Motor (CT-M6)
REP 12.59 Creaser Baffle
REP 13.0 Bleed Trimmer Drive Shaft
REP 13.1 Bleed Trimmer Upper Knives
REP 13.2 Bleed Trimmer Lower Knives
REP 13.3 Bleed Trimmer CT-M7 Home Sensor (CT-Q6)
REP 13.4 Bleed Trimmer Width Adjustment Motor (CT-M7)
REP 13.5 Bleed Trimmer Disengage Solenoid (CT-SOL3)
REP 13.6 Bleed Trimmer Disengage Shaft
REP 13.7 Bleed Trimmer Gratings Upper
REP 13.8 Bleed Trimmer Gratings Lower
REP 13.9 Slide Guide
REP 13.10 Slide Drive Shaft Transportation
REP 13.11 Transportation Disengage Solenoid (CT-SOL4)
REP 13.12 Transportation Disengage Solenoid (CT-SOL4) Idler Shaft
REP 13.13 Transportation Disengage Solenoid (SOL4) Mechanism
REP 13.14 Slide Latch Mechanism
REP 13.15 Slide Fixing Roller
REP 13.16 Slide “B” Baffle
REP 13.17 Slide “B” Paper Path
REP 13.18 Slide “C” Baffle
REP 13.19 Slide “C” Paper Path
REP 13.20 Slide L/H Lower (CT-SOL4) Baffle
REP 13.21 Slide R/H Lower Baffle
REP 13.22 Registration Solenoid SOL5 Trigger Sensor (CT-Q10)
REP 13.23 CPU / Controller PCB “A”
REP 13.24 Solenoid Driver PCB “B”
REP 13.25 Stepper Motor Driver (M7) PCB “C”
REP 13.26 Stepper Motor Driver (M4) PCB “D”
REP 13.27 Stepper Motor Driver (M1) PCB “E”
REP 13.28 PCB Printer Interface PCB “F”
REP 13.29 I/O Extension PCB “G”
REP 13.30 Stepper Motor Driver (M6) PCB “H”
REP 13.31 Stepper Motor Driver (M3) PCB “J”
REP 13.32 SCP (Short Circuit Protection) PCB “K”
REP 13.33 SCP (Short Circuit Protection) PCB “L”
REP 13.34 SCP (Short Circuit Protection) PCB “M”
REP 13.35 SCP (Short Circuit Protection) PCB “N”
REP 13.36 12V Power Supply Unit
REP 13.37 24V Power Supply Unit (1)
REP 13.38 24V (48V) Power Supply Unit (2)
REP 13.39 High Voltage Power Supply Unit (Optional, For Antistatic Bars)
REP 13.40 Interlock Relay (CT-REL1)
REP 13.41 Temp Sensor (CT-Q13)
REP 13.42 Cooling Fan (CT-FAN1)
REP 13.43 Docking sensor (CT-Q12)
Booklet Maker ADJs
ADJ 1.4 Top Cover Height
ADJ 1.6 Interlock Switch Assembly
ADJ 4.1 Staple Quality
ADJ 4.2 Set Transport Calibration
ADJ 4.3 Set Transport Drive
ADJ 6.1 BK-M8 Stop Gate Folder Motor,
BK-Q7Stop Gate Folder sensor &
BK-Q48 Clinch Trigger Sensor Right
ADJ 6.4 Fold Transmission Chain
ADJ 6.6 Upper Fold Roller
ADJ 6.7 Lower Fold Roller
Stacker Module ADJs
ADJ 8.0 Stacker Exit Module
Cover Feeder ADJs
ADJ 9.5 CF-Q33 Paper bin low sensor
ADJ 9.6 CF-M16 Cover Drive Motor Assembly
ADJ 9.9 DSD Calibration
Trimmer ADJs
ADJ 10.1 Top Cover
ADJ 10.5 TR-SW10 Interlock Switch & TR-Q1 Interlock Sensor
ADJ 10.13 TR-Q4 Transport Belt Sensor
ADJ 10.19 Lower Trim Knife
ADJ 10.21 TR-Q11 Length Adjustment Home Position Sensor
Book Folder ADJs
ADJ 11.3 Top Cover
ADJ 11.9 BF-M4 Roll Motor Assembly
ADJ 11.18 BF-SW1 Interlock Switch
Rotator Creaser Trimmer ADJs
ADJ 12.6 Interlock Switch Slide Door
ADJ 12.10 Drive Motor (M1) Primary Timing Belt
ADJ 12.11 Drive Motor (CT-M1) Secondary Timing Belt
ADJ 12.12 Docking Bracket, Infeed
ADJ 12.13 Docking Bracket, Exit
ADJ 12.23 Lower Drive Shaft
ADJ 12.28 Upper Drive Shaft
ADJ 12.31 Rotator Disengage Solenoid (CT-SOL1)
ADJ 12.34 Rotator Disengage Solenoid (CT-SOL2)
ADJ 12.43 Registration M4 Home Sensor (CT-Q3)
ADJ 12.44 Registration Cross Rollers Drive Shaft
ADJ 12.47 Registration Cross Rollers Idler Roller
ADJ 12.48 Registration Primary Alignment Rail
ADJ 12.49 Registration Secondary Alignment Rail
ADJ 12.50 Registration Disengage Solenoid (CT-SOL5)
ADJ 12.52 Creaser Assembly
ADJ 12.54 Creaser Trigger Sensor (CT-Q4) Phototransistor
ADJ 12.55 Creaser Tools M6 Home Sensor (CT-Q5)
ADJ 12.56 Creaser Timing Belt
ADJ 12.57 Creaser Tools
ADJ 12.59 Creaser Baffle
ADJ 13.4 Bleed Trimmer Home Sensor (CT-Q6)
ADJ 13.6 Bleed Trimmer Disengage Solenoid (CT-SOL3)
ADJ 13.7 Bleed Trimmer Disengage Shaft
ADJ 13.12 Transportation Disengage Solenoid (CT-SOL 4)
ADJ 13.15 Slide Latch Mechanism
ADJ 13.21 Slide R/H Lower Baffle
ADJ 13.36 12V Power Supply Unit
ADJ 13.37 24V Power Supply Unit (1)
ADJ 13.38 24V (48V) Power Supply Unit (2)

4) TROUBLESHOOTING
Common procedures
Entry RAP
Blown Fuse Conditions
Rotator Creaser Trimer (RCT)
RCT Entry RAP
CT-001 Registration M4 Home Sensor CT-Q3
Not activated in time after start of M4
CT-002 Registration M4 Home Sensor CT-Q3
Not deactivated in time after start of M4
CT-003 Bleed Trimmer M7 Home Sensor CT-Q6
Not activated in time after start of M7
CT-004 Bleed Trimmer M7 Home Sensor CT-Q6
Not deactivated in time after start of M7
CT-005 Creaser Tools M6 Home Sensor CT-Q5
Not activated in time after start of M6
CT-109 Entrance Sensor CT-Q1 blocked without a preceding Sheet Exit Signal
CT-111 Stepper Motor Driver CT-M1 PCB “E” No CAN communication
CT-113 Stepper Motor Driver CT-M3 PCB “J” No CAN communication
CT-114 Stepper Motor Driver CT-M4 PCB “D” no CAN communication
CT-116 Stepper Motor Driver CT-M6 PCB “H” No CAN communication
CT-117 Stepper Motor Driver CT-M7 PCB “C” No CAN communication
CT-119 PCB Printer Interface PCB “F” No Internal communication
CT-120 Solenoid Driver PCB “B” No CAN communication
CT-121 Stepper Motor Driver PCB “E” Voltage too low
CT-123 Stepper Motor Driver PCB “J” Voltage too low
CT-124 Stepper Motor Driver PCB “D” Voltage too low
CT-126 Stepper Motor Driver (M6) PCB “H” Voltage too low
CT-127 Stepper Motor Driver (M7) PCB “C” Voltage too low
CT-130 Solenoid Driver PCB “B” Voltage too low
CT-140 Interlock circuit Mismatch CT-Q8, CT-Q9 state with voltage
CT-141 Bad EEPROM
CT-150 CAN communication with Booklet Maker interrupted
CT-170 Temp Sensor CT-Q13 Failed RAP
CT-171 Temp Sensor CT-Q13 overheated RAP
CT-201 Entrance Sensor CT-Q1 Not activated in time
CT-202 Entrance Sensor CT-Q1 Activated too long
CT-203 Rotator Sensor CT-Q2 not activated in time
CT-204 Rotator Sensor CT-Q2 activated too long
CT-205 Registration Solenoid SOL5 Trigger Sensor CT-Q10 not activated in time
CT-206 Registration Solenoid SOL5 Trigger Sensor CT-Q10 activated too long
CT-207 Creaser Trigger Sensor CT-Q4 not activated in time
CT-208 Creaser Trigger Sensor Q4 Activated too long
CT-209 Exit Sensor CT-Q7 Not activated in time
CT-210 Exit Sensor CT-Q7 Activated too long
CT-211 Creaser Tools M6 Home Sensor CT-Q5 Not activated in time
CT-212 Waste Transport Sensor CT-Q14 Activated too long
CT-503 Waste Bin Full Sensor CT-Q11 activated
Drive Motor CT-M1 RAP
Rotator Motor CT-M3 RAP
Registration Width Adjustment Motor CT-M4 RAP
Creaser Motor CT-M6 RAP
Bleed Trimmer Width Adjustment Motor CT-M7 RAP
Rotator Disengage Solenoid CT-SOL1 RAP
Rotator Disengage Solenoid CT-SOL2 RAP
Bleed Trimmer Disengage Solenoid CT-SOL3 RAP
Transportation Disengage Solenoid CT-SOL4 RAP
Registration Disengage Solenoid CT-SOL5 RAP
Entrance Sensor CT-Q1 RAP
Rotator Sensor CT-Q2 RAP
Registration M4 Home Sensor CT-Q3 RAP
Creaser M6 Trigger Sensor CT-Q4 RAP
Creaser Tools M6 Home Sensor CT-Q5 RAP
Bleed Trimmer M7 Home Sensor CT-Q6 RAP
Exit Sensor CT-Q7 RAP
“Close Cover(s)”. Slide Door Interlock Switch CT-Q8/SW2 and/or Top Cover
Interlock Switch CT-Q9/SW3 Not activated
Slide Door Interlock Switch CT-Q8 RAP
Top Cover Interlock Switch (Q9/SW3) RAP
Registration Solenoid SOL5 Trigger Sensor CT-Q10 RAP
Waste Transport Sensor CT-Q14 RAP
CPU / Controller PCB “A” RAP
Solenoid Driver PCB “B” RAP
Stepper Motor (M7) Driver PCB “C” RAP
Stepper Motor Driver (M4) PCB “D” RAP
Stepper Motor Driver (M1) PCB “E” RAP
I/O Extension PCB “G” RAP
Stepper Motor Driver (M6) PCB “H” RAP
Stepper Motor Driver (M3) PCB “J” RAP
SCP (Short Circuit Protection) PCB “K” RAP
SCP (Short Circuit Protection) PCB “L” RAP
12V Power Supply Unit RAP
Printer Communication RAP
24V Power Supply Unit (1) RAP
24V (48V) Power Supply Unit (2) RAP
Interlock Relay Circuit (REL1) RAP
F1 Blown Fuse RAP
Antistatic Bars Waste Transport (optional) RAP
Antistatic Bars Exit (optional) RAP
Cooling Fan (FAN1) RAP
Counter RAP, CT
Bleed Trimmer Knives noisy RAP
Drive Motor (M1) Transmission RAP
Rotator Motor (M3) Transmission RAP
Registration Width Adjustment Motor (M4) Transmission RAP
Creaser Motor (M6) Transmission RAP
Bleed Trimmer Width Adjustment Motor (M7) Transmission RAP
Booklet Maker (BK)
BK-001 Infeed Motor BK-M1 No Displacement Pulses
BK-002 Infeed Motor M1 Short Circuit
BK-003 Infeed Motor BK-M1 Open Circuit
BK-004 Back Jogger Motor sensor BK-Q45 No displacement pulses
BK-005 Back Jogger Motor (M2) Cycle Timeout
BK-006 Back Jogger Motor BK-M2 Short circuit
BK-007 Back Jogger Motor BK-M2 Open Circuit
BK-008 Side Jogger Motor BK-M3 no displacement pulses
BK-009 Side Jogger Motor BK-M3 cycle timeout
BK-010 Side Jogger Motor BK-M3 Short Circuit
BK-011 Side Jogger Motor BK-M3 Open Circuit
BK-012 Set Transport Motor BK-M5 Motor Sensor BK-Q40
No displacement pulses
BK-013 Set Transport Motor BK-M5 Short Circuit
BK-014 Set Transport Motor M5 Open Circuit
BK-015 Fold Roller Motor BK-M6 No Displacement Pulses
BK-016 Fold Roller Motor BK-M6 Short Circuit
BK-017 Fold Roller Motor BK-M6 Open Circuit
BK-018 Fold Knife Motor BK-M7 Cycle Timeout
BK-019 Fold Knife Motor BK-M7 Short Circuit
BK-020 Fold Knife Motor BK-M7 Open Circuit
BK-021 Stop Gate Folder Motor BK-M8 Sensor BK-Q43
No displacement pulses
BK-022 Stop Gate Folder Motor BK-M8 Sensor BK-Q44 Cycle Timeout
BK-023 Stop Gate Folder Motor BK-M8 Short Circuit
BK-024 Stop Gate Folder Motor BK-M8 Open Circuit
BK-026 Staple/Fold Positioning Motor(M9) Sensor BK-Q10
No displacement pulses
BK-027 Staple/Fold Pos. Motor (M9) Sensor BK-Q11 Cycle Timeout
BK-028 Staple/Fold Positioning Motor BK-M9 Short Circuit
BK-029 Staple/Fold Positioning Motor BK-M9 Open Circuit
BK-045 Stapler Home Position Left Sensor BK-Q50 Cycle Timeout
BK-046 Clinch Trig Sensor Left, BK-Q51, Cycle timeout
BK-047 Stapler Left Motor BK-M20 Short Circuit
BK-048 Stapler Left Motor BK-M20 Open Circuit
BK-049 Stapler Home Pos Right Sensor BK-Q47 Cycle Timeout
BK-050 Clinch Trig Sensor Right BK-Q48 Cycle timeout
BK-051 Stapler Right Motor BK-M21 Short Circuit
BK-052 Stapler Right Motor BK-M21 Open Circuit
BK-053 Stop Gate BK-M22 Motor Sensor BK-Q41 no displacement pulses
BK-054 Home Pos. Stop Gate Stapler BK-M22 Sensor BK-Q42 Timeout
BK-055 Stop Gate Stapler Motor BK-M22 Short Circuit
BK-056 Stop Gate Stapler Motor BK-M22 Open Circuit
BK-057 Thick Set Motor BK-M23 Sensor BK-Q37 no displacement pulses
BK-058 Thick Set Motor BK-M23 home sensor BK-Q36 Cycle Timeout
BK-059 Thick Set Motor BK-M23 Short Circuit
BK-060 Thick Set Motor BK-M23 Open Circuit
BK-062 Paper infeed sensor BK-Q1 Faulty
BK-063 Start sensor Saddle stapling BK-Q4 Faulty
BK-064 Stop Gate Folder sensor BK-Q7 Faulty
BK-065 Exit Sensor BK-Q8 Faulty
BK-069 Staple Detection Clinch Left Sensor BK-Q19 Short Circuit
BK-070 Staple Detection Clinch Right Sensor BK-Q20 Short Circuit
BK-071 Docking Sensor BK-Q35 faulty
BK-150 30VDC low at Lower MD6DC PCB “C”
BK-151 30VDC very low at Lower MD6DC PCB “C”
BK-152 30VDC High at Lower MD6DC PCB “C”
BK-153 30VDC low at Middle MD6DC PCB “B”
BK-154 30VDC low at Upper MD6DC PCB “H”
BK-156 Relay off Timeout RAP (BK)
BK-157 Trimmer Communication Lost
BK-158 Book Folder Communication Lost
BK-159 PCB MD6DC “B” Not Connected
BK-160 PCB MD6DC “C” Not Connected
BK-161 PCB MD6DC “H” Not Connected
PCB MD3DC “O” Not Connected (Option)
BK-163 PCB Printer Interface, PCB “E” No Internal communication
BK-164 Addon PCB “F”Not connected
BK-168 Stacker Motor ST-M1 Short Circuit
BK-169 Stacker Motor ST-M1 Open Circuit
BK-170 Incompatible RCT Software
BK-201 Sensor BK-Q1 Not activated in time
BK-202 Sensor BK-Q1 Activated too long
BK-203 Sensor BK-Q4 Not activated in time
BK-204 Sensor BK-Q4 Activated too long
BK-205 Sensor BK-Q7 Not activated in time
BK-206 Sensor BK-Q7 Activated too long
BK-207 Sensor BK-Q8 not activated in time
BK-208 Sensor BK-Q8 Activated too long
BK-401 Staple Miss Right Stapler (BK-Q20)
BK-402 Staple Miss Left Stapler (BK-Q19)
BK-403 Staple Miss Both Staplers (BK-Q19, BK-Q20)
BK-404 Set too thick
BK-405 Remove Purged Set
BK-407 Too many sheets
BK-501 Staples, Low Stapler Right BK-Q46
BK-502 Staples, Low Stapler Left, BK-Q49
BK-503 Staples, Low both stapler (BK-Q46, BK-Q49)
BK-504 Stacker Full/Empty Stacker
Booklet Maker Communication Lost (UI: “No Com”)
Blank UI (no backlight)
Compiler RAP
Stapler RAP
Pre Fold Transport RAP
Length adjustment Unit RAP
Folding Unit RAP
MD6DC PCB RAP
Counter RAP, Booklet Maker
RS232 Program Loading Chassis 9-P, D-sub RAP
F1 Blown Up RAP
No 30VDC from SCP PCB “D” RAP
Mains Voltage connectivity check RAP
BK-SW1 Interlock circuit (SW16) RAP
SW1 Software signal SW17 RAP
Interlock Relay REL-1 RAP
No 12VDC, machine not starting RAP
User Interface (Display) not working RAP
Booklet Maker, Top Cover LED Lamp Faulty
Power Save Mode RAP
Close Cover/s RAP
Cover Feeder (CF)
Cover Feeder RAP
CF-001 Cover Feed Motor CF-M15 no displacement pulses
CF-002 Cover Feed Motor CF-M15 Short Circuit
CF-206 DSD Sensor CF-Q30 Mis- / Double Feed
CF-207 DSD Sensor CF-Q30 not activated when paper position sensor and bin
sensor are activated
CF-003 Cover Feed Motor CF-M15 Open Circuit
CF-004 Cover Drive Motor CF-M16 no displacement pulses
CF-005 Cover Drive Motor CF-M16 Short Circuit
CF-006 Cover Drive Motor CF-M16 Open Circuit
CF-007 Blower Motors CF-M17 / CF-M18 Open Circuit
CF-008 Empty Bin Sensor CF-Q31 faulty
CF-009 Paper path / DSD Sensor CF-Q30 Faulty
CF-010 Paper Positioning Sensor CF-Q32 Faulty
CF-011 Paper Low Bin Sensor CF-Q33 Faulty
CF-012 Paper Width Sensor CF-Q38 faulty
CF-201 Empty Bin Sensor CF-Q31 procedure
CF-202 Paper path/DSD Sensor CF-Q30 not activated in time
CF-204 Paper Positioning Sensor CF-Q32 not activated in time
CF-205 Paper Position Sensor CF-Q32 activated too long
CF-501 Paper Low Bin sensor CF-Q33
CF-502 Paper Width Sensor CF-Q38 Wrong Cover/Format
CF-503 Empty Bin sensor CF-Q31
STACKER (ST)
Belt Stacker RAP
ST-001 Stacker Motor ST-M1 Short circuit
ST-001 Stacker Motor ST-M1 Short circuit
ST-002 Stacker Motor ST-M1 Open Circuit
ST-002 Stacker Motor ST-M1 Open Circuit
Book Folder (BF)
BF-001 Transport Belt Motor BF-M1 Short circuit
BF-002 Transport Belt Motor BF-M1 Open circuit
BF-003 Stop Gate Motor BF-M2 Pulse timeout
BF-004 Stop Gate Motor BF-M2 Cycle timeout
BF-005 Stop Gate Motor BF-M2 Short Circuit
BF-006 Stop Gate Motor BF-M2 Open Circuit
BF-007 Clamp Motor BF-M3 Short circuit
BF-008 Clamp Motor BF-M3 Open circuit
BF-009 Clamp Motor BF-M3 Pulse Timeout
BF-010 Roll Motor BF-M4 Short circuit
BF-011 Roll Motor BF-M4 Open circuit
BF-012 Roll Motor BF-M4 cycle timeout
BF-013 Roll Motor BF-M4 Pulse timeout
BF-014 Infeed Sensor BF-Q5 Faulty
BF-015 Clamp Sensor BF-Q6 Faulty
BF-016 Exit Sensor BF-Q7 Faulty
BF-017 SOL1 / 3 Open circuit
BF-018 SOL2 / 4 Open circuit
BF-150 30V Input low
BF-151 30V Input high
BF-201 Infeed Sensor BF-Q5 Not activated in time
BF-202 Infeed Sensor BF-Q5 Activated to long
BF-203 Clamp Sensor BF-Q6 Not activated in time
BF-204 Clamp Sensor (BF-Q6) Activated too long
BF-205 Exit Sensor BF-Q7 not activated in time
BF-206 Exit Sensor BF-Q7 activated too long
BF-501 Stacker Full
Clamp RAP
Book Folder Stop Gate RAP
Book Folder Transport RAP
BF-SW1 Interlock circuit BF-SW3 RAP
BF-SW1 Software signal BF-SW2 RAP
RS232 Program Loading Chassis 9-P D-sub RAP
Book Folder does not square form a 4 sheet booklet RAP
Book Folder, LED Lamp PCB “L”Faulty
No 12Vdc RAP
Counter RAP, BF
Trimmer (TR)
TR-001 Transport knife Motor TR-M1 pulse timeout TR-Q4
TR-002 Transport Knife Motor TR-M1 timeout TR-Q5
TR-003 Transport Knife Motor TR-M1 short circuit
TR-004 Transport Knife Motor TR-M1 open circuit
TR-005 Trim Knife Motor TR-M2 short circuit
TR-006 Trim Knife Motor TR-M2 open circuit
TR-007 Trim Knife Motor TR-M2 Cycle timeout Q5
TR-008 Stop Gate Motor TR-M3 cycle timeout TR-Q7
TR-009 Stop Gate Motor TR-M3 short circuit
TR-010 Stop Gate Motor TR-M3 open circuit
TR-011 Length Adjustment Motor TR-M4 pulse timeout
TR-012 Length Adjustment Motor TR-M4 cycle timeout
TR-013 Length Adjustment Motor TR-M4 short circuit
TR-014 Length Adjustment Motor TR-M4 open circuit
TR-015 Blower Motors Motor TR-M5/TR-M6 open circuit
TR-016 Lift Motor TR-M8 cycle timeout
TR-017 Lift Motor TR-M8 short circuit
TR-018 Lift Motor TR-M8 open circuit
TR-019 Infeed Sensor TR-Q13 faulty
TR-020 Control Sensor Infeed TR-Q2 faulty
TR-021 Control Sensor Exit TR-Q3 faulty
TR-022 Exit Sensor TR-Q6 faulty
TR-023 Trim Bin Full Sensor TR-Q8 faulty
TR-024 Paper Path Sensor TR-Q14 Faulty
TR-025 Lift Motor Sensor TR-Q15 Faulty
TR-150 30V Input low
TR-151 30V Input high
TR-152 TR-SW1 Software signal TR-SW10 RAP
TR-153 Interlock Sensor Faulty TR-Q1
TR-201 Infeed Sensor TR-Q13 not activated in time
TR-202 Infeed Sensor TR-Q13 activated too long
TR-203 Paper Path Sensor TR-Q14 not activated in time
TR-204 Paper Path Sensor TR-Q14 activated too long
TR-205 Exit Sensor TR-Q6 not activated in time
TR-206 Exit Sensor TR-Q6 activated too long
TR-501 Waste Bin Full
TR-502 Stacker Full
TR-503 Close Trimmer Infeed Belts
TR-504 Close Trimmer Exit Belts
TR-505 Close Trimmer Infeed and Exit Belts
Trim Knife RAP
Trimmer Blower RAP
Trimmer Transport RAP
No 12VDC RAP
TR-SW1 Interlock circuit (TR-SW9,TR-SW10) RAP
Trimmer, LED Lamp Faulty RAP

5) SERVICE TABLES (General Procedures GP)
GP 1 Entering Service Mode
GP 2 Resetting / Changing the Service Mode Password
GP 3 Diagnostics
GP 4 Check Motors / Solenoids / Sensors
GP 5 Service Program Mode Tables
GP 6 Voltmeter
GP 7 Dead Cycle
GP 8 Printer / Changing NVM Values
GP 9 Check Interface
GP 10 NVM Values
GP 11 Fold Delay
GP 13 Trimmer Service (Trimmer Module)
GP 14 Enabling CF (Cover Feeder Module)
GP 15 BF Service Adjust stop gate (Book Folder Module)
GP 16 Counters
GP 17 Fault code Structure
GP 18 Checking Versions of Installed Software
GP 19 Update Software
GP 20 NVM Reset
GP 21 Printer Interface Check
GP 22 Calibrate Transport Pressure
GP 23 Cheat Trimmer cover 15min
GP 24 Adjust Mode
GP 25 Adjustment, compressor air stream trim waste kit
GP 26 30Vdc PSU (Power Supply SP-750-27) LED
GP 27 12 VDC PSU (Power Supply RS-35-12) LED
GP 28 PCB Printer Interface PCB “E” LEDs
GP 29 MD6DC PCB LEDs
GP 30 Controller PCB “A” LEDs and Test Points
GP 31 MD6DC PCB Test points
GP 32 4IN 4OUT PCB “J” LEDs
GP 35 Addon PCB “F” Testpoints
GP 35 Set Size Guide
GP 36 Tag Matrix and Serial Plate Location BK
GP 37 Tag Matrix and Serial Plate Location CF
GP 38 Tag Matrix and Serial Plate Location Trimmer
GP 39 Tag Matrix and Serial Plate Location Book Folder
GP 40 Tag Matrix and Serial Plate Location CT
GP 41 Tool Location
GP 42 Interlock cheater location
GP 43 RCT CPU / Controller PCB “A” LEDs
GP 44 RCT Solenoid Driver PCB “B” LEDs
GP 45 CT Stepper Motor Driver
GP 46 RCT PCB Printer Interface, PCB “F” LEDs
GP 47 RCT I/O 4IN4OUT PCB “G”
GP 48 RCT CPU / Controller PCB “A” Test points
GP 49 RCT MD3DC Solenoid Driver PCB “B” Test points
GP 50 CT Stepper Motor Driver 5-41

6) DETAILED DESCRIPTION SECTION

7) SPECIFICATIONS

8) WIRING
8.1 PBM350/500 Booklet Maker including Cover Feeder
8.2 PBM-BF Book Folder
8.3 PBM-TR Trimmer
8.4 PBM-RCT Rotator Creaser Trimmer
8.5 BST4000-1 High Capacity Stacker

9) BOOKLET QUALITY (BQ)
BQ Entry RAP
BQ 1 Paper Size Reset
BQ 2 Staple Stop Gate Parallelism
BQ 3 Paper / Side Guide Parallelism (staple skew)
BQ 4 Staple Position
BQ 4.1 Staple/s not Clinched
BQ 5 Fold Position
BQ 6 Back Jogger Adjust
BQ 7 Staple and Fold Position
BQ 8 Fold Skew
BQ 9 Transport Feed Force
BQ 10 Square Fold Stop Gate Adjustment A
BQ 11 Square Fold Stop Gate Adjustment B
BQ 12 Bleed Trimmer not Parallel to OB Registration edge (Skew cut)
BQ 13 Bleed Trimmer Sheet Width (Mismatch)
BQ 14 Bleed Trimmer Image Offset (Mismatch)
BQ 15 Bleed Trimmer Cutting Quality (Dull or damaged Knives)
BQ 16 Crease not Perpendicular to Registration Edge (Skew Crease)
BQ 17 Crease position in Process Direction (Mismatch)
BQ 18 Crease Insufficient Quality (Spine Cracking despite Crease)
BQ 19 Stop Gate Carriage
BQ 20 TR-M4 Length Adjustment Motor & TR-Q12 Motor Sensor

Ricoh Plockmatic PBM350 PBM500 PMB pbm