Fromm P324.0001.01 User manual

1-1
SERVICE MANUAL
BATTERY - POWERED
PLASTIC STRAPPING TOOL
MODEL P324.0001.01
Manual for authorized dealers and service points
P324.0001.01.sen/MAS/© 12.08

1-2
INDEX PAGE
1.1 ACCESSORIES 1-3
1.1.1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.1.2 Battery chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.1.3 Battery tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.1.4 Charger for car batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.1.5 Battery light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2 TECHNICAL DETAILS 1-4
1.2.1 Electric schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2.2 Connecting plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2.3 Strap tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3 CONVERSION PARTS P324 1-5
1.3.1 Conversion parts: strap width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3.2 Conversion parts: strap thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.4 PERIODIC MAINTENANCE AND CONTROL 1-6
1.4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4.2 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.4.3 Battery test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.4.4 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.4.5 Glueing rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.4.6 Lubrication rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.4.7 Assembly informations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.4.8 Repair kit for electronic P32.2043 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.5 RECOMMENDED SPARE PARTS 1-15
1.6 ACCESSORY TOOLS 1-16
1.7 USE OF ACCESSORY TOOLS 1-17
1.8 ORDERING SPARE PARTS 1-21
1.8.1 Ordering manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.8.2 Ordering address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.8.3 Finding out of the tool type (item number),
the serial number and the version number:. . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.9 SERVICE ADDRESS 1-22
1.10 CHART OF TYPES 1-22

1-3
1.1 ACCESSORIES
1.1.1 Battery
Use only original Fromm batteries N5.4309 (NiCd) or N5.4316 (NiMH) for the P324 tool.
In case of a damaged battery housing, it can be ordered separately under item no. N5.4318.
1.1.2 Battery chargers
The battery charger must be ordered separately according to the table mentioned below.
Standard charger
Turbo charger
1.1.3 Battery tester
For testing the batteries order battery tester N7.5127.
1.1.4 Charger for car batteries
The charger N5.4407 must be ordered for connection to a car battery with 12 or 24V.
Can only charge NiCd-Batteries!
1.1.5 Battery light
For completely discharging of the battery the battery light N5.4313 can be used.
Item-No. Voltage / frequency Admitted for country
N5.4414 220 - 240V / 50 - 60Hz A, B, BG, BIH, BOL, BR, BY, CH, CL, CZ, D, DK, DZ, E, EAS, EST, ET, F,
FIN, GE, GR, H, HK, HR, I, IL, IND, IR, IRQ, IS, JOR, KSA, KWT, L, LAR, LT,
LV, MA, MC, MK, MOC, N, NL, P, PK, PE, PL, PRC, PY, RA, RCH, RI, RL,
RO, ROK, ROU, RP, RUS, S, SK, SLO, SYR, THA, TN, TR, UA, UAE, YU,
YV, (Z), (ZA), (ZW)
N5.4416 220 - 240V / 50 - 60Hz BRN, BRU, CY, EAK, EAT, GB, IRL, M, MAL, OM, SGP, Y
N5.4418 220 - 240V / 50 - 60Hz AUS, NZ
N5.4420 220V / 60Hz ROK
Item-No. Voltage / frequency Admitted for country
N5.4422 220 - 240V / 50 - 60Hz A, B, BG, BIH, BOL, BR, BY, CH, CL, CZ, D, DK, DZ, E, EAS, EST, ET, F,
FIN, GE, GR, H, HK, HR, I, IL, IND, IR, IRQ, IS, JOR, KSA, KWT, L, LAR, LT,
LV, MA, MC, MK, MOC, N, NL, P, PK, PE, PL, PRC, PY, RA, RCH, RI, RL,
RO, ROK, ROU, RP, RUS, S, SK, SLO, SYR, THA, TN, TR, UA, UAE, YU,
YV, (Z), (ZA), (ZW)
N5.4424 120V / 50-60Hz BR, C, CDN, CO, CR, DOM, EC, GCA, J, JA, KSA, LB, MEX, NIC, PA,
Puerto Rico, RC, RP, USA, YV
N5.4426 110V / 50 - 60Hz GB
N5.4428 220 - 240V / 50 - 60Hz BRN, BRU, CY, EAK, EAT, GB, IRL, M, MAL, OM, SGP, Y
N5.4430 220 - 240V / 50 - 60Hz AUS, NZ

1-4
1.2 TECHNICAL DETAILS
1.2.1 Electric schematic
1.2.2 Connecting plan
1.2.3 Strap tension
The tension force values mentioned in the P324 operation manual (300-2400N) are not achievable with each
strap. They depend on following factors:
• Hardness of the package,
the maximum tension force values are achievable with hard packages.
• Elongation and creep properties of the plastic strap,
the maximum tension force values are achievable by using plastic straps with a low elongation.
• Surface quality of the plastic strap,
the maximum tension force values are achievable with waxed and embossed straps.
• Strap width, strap thickness,
the maximum tension force values are achievable with thick and wide straps.
14,4VDC
-
+
M
+
-
black
red
red
white
black (-)
red (+)
red (+)
white (-)
N5.2359
N5.2322

1-5
1.3 CONVERSION PARTS P324
When changing strap thickness or strap width the following parts must be exchanged.
1.3.1 Conversion parts: strap width
1.3.2 Conversion parts: strap thickness
10mm 11.1mm 12mm 12.7mm 13mm 15mm 15.5mm 16mm
Guide
pin P30.1156 P30.1158 P30.1156 P30.1157 P30.1158 P30.1159 P30.1160 P30.1161
Guide
pin P30.1162 P30.1164 P30.1162 P30.1163 P30.1164 P30.1165 P30.1166 P30.1167
Guide
case P32.1205 P32.1205 P32.1206 P32.1206 P32.1206 P32.1206 P32.1206 P32.1206
Strap
stop P32.1230 P32.1231 P32.1232 P32.1233 P32.1234 P32.1235 P32.1236 P32.1237
Strap
guide P32.1239 P32.1240 P32.1241 P32.1242 P32.1243 P32.1244 P32.1245 P32.1246
0.4-0.64mm 0.65-1.05mm
Tensioning wheel P32.1219 P32.1220
Gripper P32.1222 P32.1225
Gripper P32.1223 P32.1226
Gripper P32.1224 P32.1227
Attention!
When converting tools always change the item number on the type label
Replace following parts:
Type label N43.9142
2 x hammer head bolts N2.4902
Enclose the suitable operation manual with the tool after each
conversion
(see paragraph 1.8.1 Ordering manuals)

1-6
1.4 PERIODIC MAINTENANCE AND CONTROL
(Carry out 12- months cycles doing one shift work. Doing more shift work respectively more often.)
1.4.1 Procedure
Before using check tool for following possible faults:
• Visual test of the tool for loose, lost or damaged parts
• Clean all dirty parts of the tool, especially strap abrasion in the tensioning or the welding unit by
using compressed air. (Never use any hard tools like a wire brush or a screw driver for cleaning)
Carry out a test strapping and check following:
• Insertion of the strap
• Strap feed and strap tensioning
• Tensioning force adjustment (see operation manual P324)
• Cutting of the upper strap
• Welding time adjustment (see operation manual P324)
• Seal quality (see operation manual P324)
• Function of the LED - display
Proceed according to paragraph 1.4.2 after a fault appears.
Attention!
Remove battery from tool before each maintenance work.
For exchange of wearing parts see operation Manual P324.
Never use water or solvents for cleaning the tool’s surface.

1-7
1.4.2 Troubleshooting
Ensure before each tool repair that the battery is charged and
the tool’s specific strap is used
SYMPTOM CAUSE REMEDY
Tool doesn’t work at all Battery is empty or defective Charge or replace battery
Contact problems caused by a broken
battery housing N5.4318.
Replace battery housing
Contact problems caused by a
damaged cover P32.2010, insertation
part P32.2011 or damaged motor
housings P32.2040 and P32.2042
Replace cover insertation part or
motor housing
Contact problem of the internal wires Check contacts and fix them if required
or change defective parts
Defective circuit board Replace circuit board
Tool doesn’t tension Tensioning wheel is dirty or worn Clean tensioning wheel or replace it,
don’t use any hard objects for this
(see operation manual P324)
P32.1051 is not meshing with
P32.1048, because spring N2.5822 is
defective or parts are dirty
Replace spring N2.5822,
clean dirty parts
Faulty tensioning wheel or tensioning
wheel is assembled reversed
Correct assembling
(see operation manual P324)
Grippers are dirty, worn or wrongly
assembled
Replace grippers, clean them or
assemble correct,
don’t use any hard objects for this
(see operation manual P324)
Gearing parts from the tensioning gear
are defective
Check tensioning gear and replace
defective parts
Defective motor P32.2065 Replace motor
Defective circuit board Replace circuit board
Micro switch N5.2359 for tensioning
is defective
Replace micro switch
Contact problem of the internal wires Check contacts and fix them if
required, change defective parts or
solder on motor wires
Defective gear bearings Replace bearings
Defective tensioning body Replace tensioning body
Needle free wheeling in gear wheel
P32.0156 or in conical gear wheel
P32.0151 assembled reversed
or defective
Assemble the needle free wheeling
correct or replace it

1-8
Tensioning wheel turns
back immediately after the
tensioning cycle
Defective needle free wheeling
N3.4509 in P32.0156
Check parts and replace if necessary
Tool doesn’t weld Welding gripper P32.1053 is dirty or
worn
Replace or clean welding gripper,
don’t use any hard objects for this
(see operation manual P324)
Welding stop gripper P32.1203 is dirty
or worn
Replace or clean welding stop gripper,
don’t use any hard objects for this
(see operation manual P324)
Damaged housing parts Replace housing parts
Defective circuit board Replace circuit board
Defective motor P32.2065 Replace motor
Pressure spring N2.5294 defective Replace pressure spring
Needle free wheeling N3.4509 in
P32.0150 defective or assembled
reversed
Assemble the needle free wheeling
correct or replace it
Gearing parts of the welding gear are
defective
Check welding gear and replace
defective parts
Micro switch N5.2322 for welding is
defective
Replace micro switch
Contact problem of the internal wires Check contacts and fix them if
required, change defective parts or
solder on motor wires
Defective gear bearing Replace bearing
Tool badly cuts the strap or
doesn’t cut at all
Cutter is worn or damaged Replace cutter
(see operation manual P324)
Wrong adjustment of the coupler
P32.1250
Check adjustment and readjust if
necessary
(see operation manual P324)
Welding gripper is worn Replace welding gripper
(see operation manual P324)
Welding time too short Change adjustment
(see operation manual P324)
Defective pressure spring N2.5237 Replace pressure spring
Tool switches off after a few
strappings
(Displaying empty battery)
Battery defective or empty Check the battery and change
defective batteries
Gear noise Tensioning or welding gear is worn Check component parts and replace
defective ones
SYMPTOM CAUSE REMEDY

1-9
1.4.3 Battery test
The battery should be checked while each maintenance by using the battery tester N7.5127.
The use is described in the instruction manual of the battery tester.
• NiCd-Batteries 14,4V / (2,4Ah) must be replaced at a capacity less than 70% (1,7 Ah).
• NiMH-Batteries 14,4V / (3Ah) must be replaced at a capacity less than 70% (2,1Ah).
1.4.4 Checklist
Carry out some test strappings and check following tool components.
• Inserting of the strap
• Insert battery in the tool and check function of the LED-display (see operation manual P324)
• Strap feed and strap tension
• Tension force adjustment (see operation manual P324)
• Cutting of the upper strap
• Welding time adjustment (see operation manual P324)
• Seal quality (see operation manual P324)
• Function of the LED-display (see operation manual P324)
• Correct type label
1.4.5 Glueing rules
Following parts have to be glued with LOCTITE 603:
N2.2188
P32.2017
P32.2001
Planet shaft P32.1044
with the parallel pins N2.2145.
Tensioning body P32.1254
with the parallel pins N2.2189
Body P32.2001 with
swivel shaft P32.2017
and parallel pins N2.2188
N2.2145
P32.1044
N2.2189
P32.1254

1-10
Additional the screws N1.2112 have to be glued with the
idler step P32.0118 using LOCTITE 222.
Don’t clamp the planet shaft on the pinion while loosening or
tightening the screws N1.2112.
1.4.6 Lubrication rules
All gear parts have to be lubricated with MOLYKOTE BR 2 PLUS grease.
Lubrication interval: While each maintenance or after 12 months at the latest.
All bearing parts of the welding unit have to be cleaned and
lubricated with Klüber Isoflex Alltime SL2 grease while
each maintenance.
Lubrication interval: While each maintenance or after 12
months at the latest.
All other parts have to be greased due to the explosion drawing.
Lubrication interval: While each maintenance
1.4.7 Assembly informations
By installing the grippers into the tensioning
body P32.1254 it must be observed the
direction of the teeths.(look at the picture)
P32.0118
N1.2112
clamp
here
P32.1029
N3.1702 (6X)
P32.1027
P32.1053
Bearing
welding unit
P32.1254
Grippers

1-11
Like imaged the connections of the motor P32.2065 must be adjusted 90° to the sheet P32.2064.
The mounting of the sheet happens by fixation of the disk P32.2063 with the screws N1.2216.
To adjust the sheet the motor could be placed into the housing.
Pay attention to the mounting position of the needle free wheelings N3.4509 and N3.4520.
The rolling direction is stamped in at the front side of the free wheelings.
P32.2065
P32.2064
P32.2063
N1.2216
90°
P32.2064
(+)
(-)
X
view X
N3.4509
P32.2036
P32.2018
N3.4520
N3.4509
P32.2015

1-12
Pay attention to the mounting position of the eccentric (P32.2034).
Adjustment of the lever P32.1414
If the handle lever after welding and cooling of the strap can be pulled up difficult or not at all, the adjustment
of the lever P32.1414 must be checked.
It can be done as follows:
- Loose lock nut N1.5120
- Screw in the socket set screw N1.3150, until it touches the coupler P32.1410
- Tighten lock nut N1.5120
Test without battery and strap:
- Press welding lever down until it locks
- Pull handle lever up
The welding lever must move up before the tension body swings forward.
Swings the tension body forward first, the strap blocks the welding jaw and the handle lever can be pulled up
difficult or not at all.
Afterwards do a test strapping and readjust if necessary.
(P324) Eccentric at the top
Welding lever
Tension body
P32.1410
N1.3150
N1.5120
P32.1414
Handle lever

1-13
Connection of the electronic to the motor
In order to prevent a cracking of the terminals on the motor, the connection cables of the electronic are laid
with a light bend before soldered to the motor.
This method is used for all battery powered plastic strapping tools.

1-14
1.4.8 Repair kit for electronic P32.2043
The repair kit can be ordered with the article number P32.2075.
With the repair kit defective plugs on the connection cables of the electronic can be changed.
Procedure:
• Cut the cables to a length of 126 mm (see drawing).
• Strip wire ends 6mm,
• tin plate wire ends,
• push insulating hose N5.3420 above the cables.
• Overlap the cables and solder them together,
• push the insulating hoses over the solder joint X.
The cable length after soldering must be between 240 and 248mm (see drawing).
red
white
black
red
6
126240+8
P32.2043
N5.3420
P32.2071
P32.2073
X
X

1-15
1.5 RECOMMENDED SPARE PARTS
Following spare parts are recommended for stock keeping:
Besides should be stocked the wearing parts of the different Types.
Stock only parts from tools that are in sale.
Item-No. Description Pieces per tool
N1.1305 Screw 2
N1.1904 Screw 5
N1.1909 Flat head screw 2
N1.1927 Flat head screw 1
N1.1929 Screw 1
N1.1934 Flat head screw 4
N1.6503 Safety washer 6
N1.6504 Safety washer 12
N1.6505 Safety washer 3
N1.7206 PT-screw 1
N1.7211 PT-screw 7
N2.1118 Security ring 1
N2.1121 Security ring 5
N2.1606 Spring ring 1
N2.1805 Tensioning ring 1
N3.1702 Ball 6
N3.4509 Free wheeling 2
N3.4520 Free wheeling 1
N5.2322 Micro switch 1
N5.2359 Micro switch 1
N5.4318 Housing 1
P32.0153 Body 1
P32.1238 End cover 1
P32.2010 Cover 1
P32.2011 Insertation part 1
P32.2026 Lever 1
P32.2040 Motor housing 1
P32.2042 Motor housing 1
P32.2043 Circuit board 1
P32.2065 Electric motor 1

1-16
1.6 ACCESSORY TOOLS
* a) These tools are also included in the P320 tool set.
b) These tools are also included in the P321 tool set.
c) These tools are also included in the P322 tool set.
d) These tools are also included in the P323 tool set.
e) These tools are also included in the P355 tool set.
f) These tools are also included in the P356 tool set.
g) These tools are also included in the P325 tool set.
Item
number
Description Application
N71.3235 *a,b,c,d,e,f,g Press in and press out arbor N3.4509/P32.2036;
N3.4509/P32.2015
N71.3237 *a,b,c,d,e,f,g Press in and press out arbor N3.1159/P32.2016
N71.3239 *a,b,c,d,e,f,g Press in arbor N3.2347/P32.1024
N71.3240 *a,b,c,d,e,f,g Press out arbor N3.2347/P32.1024
N71.3241 *a,b,c,d,e,f,g Press in and press out pressure pad N3.2347/P32.1024
N71.3242 *a,c,e Press in and press out arbor N3.2346/P32.1238
N71.3243 *a,b,c,d,e,f,g Press in arbor N3.1134, P32.1023/P32.1022
N71.3244 *a,b,c,d,e,f,g Press out arbor N3.1134, P32.1023/P32.1022
N71.3245 *a,b,c,d,e,f,g Pressure pad N3.1134, P32.1023/P32.1022;
N3.2346/P32.1238
N71.3246 *a,c,e Press in and press out arbor N3.1157/P32.1044
N71.3247 *a,d,e,f,g Press in and press out pressure pad N3.1157/P32.1044
N71.3248 *a,b,c,d,e,f,g Press in arbor N3.3172/P32.1254
N71.3249 *a,c,e Press out pressure pad N3.3172/P32.1254
N71.3250 *a,c,e,f,g Press in and press out arbor N3.3172/P32.2001; N3.3172/
P32.1254
N71.3282 g Press in and press out pressure pad N3.4509/P32.2015; N3.4520/
P32.2018; N3.4509/P32.2036
N71.3283 g Press in and press out pressure pad N3.1159/P32.2016
N71.3284 g Press out arbor N3.4520/P32.2018
N71.3285 g Press in pressure pad N3.1137/P32.2015
N71.3286 g Press out arbor N3.1137/P32.2015

1-17
1.7 USE OF ACCESSORY TOOLS
Accessory tools should only be used with the suitable arbor press
N7.5108 to prevent a jam of the parts have to be pressed in.
Additional a retainer (N7.3215) is necessary.
Part Disassembly Assembly
N3.1157/
P32.1044
N3.2346/
P32.1238
N7.5108
N7.3215
N71.3246
N71.3247
N3.1157
P32.1044
N71.3242
N71.3245
N3.2346
P32.1238

1-18
N3.2347/
P32.1024
N3.3172/
P32.2001
N3.4509/
P32.2036
Part Disassembly Assembly
N71.3240
N71.3241
N71.3239
P32.1024
N3.2347
The seal of the
needle bushing
(N3.2347) has
to face to the
outside.
N71.3250
N3.3172 P32.2001
N71.3235
N71.3282
*Pay attention to the
assembling direction
see assembly informations
N3.4509*
P32.2036

1-19
N3.3172/
P32.1254
P32.1023/
N3.1134/
P32.1022
P32.2016/
N3.1159
Part Disassembly Assembly
N71.3250
N71.3249
N71.3248
N3.3172
P32.1254
N71.3244
N71.3245
N71.3243
P32.1022
N3.1134
P32.1023
N71.3237
P32.2016
N3.1159
N71.3283

1-20
P32.2015/
N3.1137
P32.2018/
N3.4520
P32.2015/
N3.4509
Part Disassembly Assembly
N3.1137
P32.2015
N71.3286
N71.3285
N71.3284
N3.4520
P32.2018
N71.3282
N71.3235
N71.3282
N3.4509
P32.2015