Muller 6609d Operating instructions

Service Instructions
AutomaticFormsCutter
Modell 6609d-6612d
Stand:31.05.2006

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Contents
Toollist................................................................................3
EG-Konformitätserklärung..................................................................4
Subassemblies..........................................................................5
1.Adjusting tractor shaft.................................................................6
2.Removing the sprocket beltsofthe tractors.................................................6
3.Tightening the sprocket belts............................................................7
4.Removing the plate cover on the tractor...................................................7
5.Adjusting the magnetic hall-sensor on the plexiglass cover.....................................7
6.Adjusting the pneumatic spring on the plexiglass cover........................................7
7.Adjusting the paper guide (on the pneumatic spring)..........................................8
8.Adjusting the fibre-optic sensor for determining paper end......................................8
9.Removing the tractor shaft..............................................................8
10.Removing scannerson the tractor and cross cutter...........................................9
11.Cleaning, installing and adjusting scannerson the tractor shaft.................................10
12.Cleaning, installing and adjusting scannerson the cross cutter.................................10
13.Removing the cross cutter.............................................................11
14.Removing and adjusting the cross cutter blade.............................................12
15.Adjusting spring pressure ofthe lower blade on the cross cutter.................................13
16.Removing the blade bar...............................................................13
17.Removing and adjusting the blade guide bar...............................................14
18.checking and adjusting the angle ofthe cross cutter.........................................14
19.Removing the driving gear on the cross cutter..............................................15
20.Removing the deflector cylinder and ejector cylinders........................................15
21.Removing the ejector and deflector......................................................15
22.Removing the bladesofthe edge cutters..................................................16
23.Removing the terminalboard and replacing the eprom.......................................17
24.Replacing the fuse..................................................................17
25.Changing the mainsvoltage...........................................................17
26.Main PC-Board connections............................................................18
27.Removing the main board ............................................................18
Main PC-Board installation................................................................19
Listing ofall Automatic FormsCutter PCB, being produced since 1988...............................20
Measurement-Points-PC-Board..........................................................21/22
OMR.................................................................................23

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Tool list
A toolcase isavailable which containsall the toolslisted below:
Part no.Decription SizeNo. each
10580Cable tie 3
10893*Pin (for installing the pulley ofthe cross cutter)1
10897Feeler gauge61
10899*Open-ended spanner121
10961*Toolfor adjusting tractor shaft2
11077*Tachometer generator, complete1
11096*Holder complete for measuring unit1
11099*Measuring device for dialindicator 1
11101*Adjusting toolfor mounting cross cutter2
11102*Dialindicator 5/401
11103Plastic hammer221
11104Open-end ring wrench 101
11105Socket spanner101
11106Hexagon screwdriver with T-handle51
11107Open-end wrench5,51
11110Screwdriver for Philipsscrews21
11111Screwdriver for Philipsscrews11
11112*Plastic oiler11
11113Externalsnap ring pliersA01
11114Screwdriver3,5 x901
11115Screwdriver5,5 x2501
11116Open-end wrench71
11117Hexagon offset screwdriver31
11119*Magnet1
11121*High-speed grease1
11122*Triboelectric grease1
11123*Thermaltransfer compound1
11124Cable tie20
11158Toolcase1
11167*Adjusting toolfor potentiometer 1
12678Hexagon offset screwdriver51
13119Hexagon ball-head screwdriver31
13572*Lever (to change knives)1
14130Bit handle equipped with2
14131Bit (head 4 mm) for hexagon socket 21
14132Bit (head 4 mm) for hexagon socket 1,51
15336*Lever (to remove hexagon shaft) 1
15368Hexagon offset screwdriver2,51
15369Bit (head 4 mm) for hexagon socket 2,51
15667*Extension cord (for cross cutter motor) 2
15729*Holder complete for measuring unit1
15731*Measuring device for dialindicator 1
17597Brush2
17688*Extension cord (for cross cutter motor) 40 cm1
18182Open-ended ring spanner71
18853Hexagon screwdriver with T-handle41
19574Hexagon offset screwdriver81
21317Hexagon socket key with long handle1
23872Bit handle equipped with1/4"2
24939Bit (head 1/4" mm) for hexagon socket 2,51
24940Bit (head 1/4" mm) for hexagon socket 3,01
29890Hexagon offset screwdriver1,51
29891Hexagon offset screwdriver21
29892Hexagon offset screwdriver41
35211 Bit (head 1/4") for TorxTX10 1
35212 Bit (head 4mm) for TorxTX10 1
35286 TorxOffset Screwdriver TX10 1
29894Order-no. for hexagon screwdriver set complete consisting ofno.:1
11117, 12678, 14130 (2x), 14131, 14132, 23872 (2x), 24939, 24940,
29890, 29891, 29892
13570Order-no. for toolcase complete1
* Müller special tool
Release: 31.05.2006

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Mod. 6609-12d: Automatic FormsCutter31.05.2006
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Subassemblies
Housing and cover sheets
Frame
Driving shafts
Frame - motorsand fan
Safety cover
Cross cutter - blade bar
Cross cutter - ejector
Cross cutter - drive
Tractor unit
Tractor right and left
Edge cutter unit
Edge cutter right and left
Terminal
Power switch unit
Electronic and optoelectronic systems

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Caution: When performing servicing work on the cutter, alwaysmake sure it
isdisconnected fromthe mainspower supply.
1. Adjustingtractorshaft
The tractor shaft isdivided in the middle.
Usethe twoadjusting tools(toolno. 10961) to rotate the
tractor shaft and adjust the angle ofthe cross cutter.
2. Removingthe sprocket belts of the tractors
Remove the tractor shaft asdescribed in 9.
Removelower paper guide .Press the plate inthe
direction ofthe arrowand removethe tie-bar and tractor.
Unscrewand take off the cover plate .
Removethe sprocket belt. When re-installing the sprocket
belts,make sure that the gear teethofthe left and right 
tractorsareinthe sameposition with regard to the hexagon
socket ofthe toothed gear.
Thisiseasier, ifyou firstposition thesprocket belton the
toothed gear .

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3.Tighteningthe sprocket belts
Tightening the sprocket beltsisdone by pushing the rear cap
bolt. To do so, firsttake off the cover plate and unscrewthe
plate .
Do not overtighten the sprocket belts(test by hand to make sure
they move easily).
4. Removingthe plate coveronthe tractor
Unscrewthe plate .Removeboth pinswith apermanent
magnet (toolno. 11119, ). Whenremoving the pinswith the
magnet, alsopress downon the plate cover to compensate for
spring resistance. Otherwise the pinswill not come out.
5.Adjustingthemagnetic hall-sensoron the
plexiglass cover
To adjustthe magneticsensor, turn the screwon theleftside
wall.The automaticcutter shouldcometoastop when the
plexiglass cover islifted approx. 20 mm.
6.Adjustingthepneumatic springonthe
plexiglass cover
To adjust the pneumatic spring , push the connecting piece 
in a verticaldirection. To do so, first remove the screw .
Mounting position of the pneumatic spring:
The thinpiston shouldpoint towardsthe handleofthe plexiglass
cover.
Normal position
Pushthe connecting piece up asfar asitgoesand fasten it
with the screw .
After adjusting the spring, make sure that the cover staysopen
and closed.

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7.Adjustingthepaperguide(onthepneumatic
spring)
When the plexiglass cover isclosed, the paper guide should
be about 1to 1.5 mm fromthe center bearing block. Removethe
screw to move the device for holding down paper onto the
gascylinder .Be verycarefulwhen making thisadjustment
since this directlyaffects the correct positioning ofthe paper on
the edge ofthe cross cutter.
Be sure not to accidentallycover the fibre-opticsensor for
determining paper end with the device for holding downpaper.
Otherwise, the automaticcutter will continue to run once the end
ofthe paper hasbeen reachedand run inreversewhen the
machine isstarted.
8. Adjustingthefibre-opticsensorfor
determiningpaperend
Removethe tie-bar and tractor according to the instructionsin2.
Unscrewthe tie-bar holder . Remove the screwon the side
and vertically movethe sensor head .The sensor head should
have a clearance of0.3 mm.
9.Removingthe tractorshaft
Take out the flat belt. Insert the lever tool-nr. 15336 inthe belt
pulley .Liftthe lockingpin and, at the sametime, pull out the
tractor shaft in an axialdirection.
When reinstalling the tractor shaft, make sure that the locking pin
"clicks" into place in the shaft.

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10.Removing scannersonthetractorandcross
cutter
Toremovethe scanner on the cross cutter, firsttake out the
entire cross cutter (see 13).
The fibre-opticheadson the shaftsofthe tractor and cross cutter
are screwed into a holder.
Caution: Do notunscrewthe scanning headsfromthis
holder and do not removethe screws .
Otherwise, you may ruinthe positioning ofthe
scannerswhichwaspreciselyset at the factory.
Ifthishappens,you
will have to order a entire newscanner with
the correct factory set-up.
Remove the screws on the mainboard and pull itforward about
5cm. Disconnect both plugson the LED block .Usethe lever
(toolno. 15336 - )to disconnect the fibreplug - do not
disconnect it by pulling on the cable .
Releasethe spring at pos. .Open the setting collar and
remove the scanner.
Scannerscan onlybe exchanged asentire units(see listof
exchangeable parts).
See 11. for instructions on howto install and adjustthe scanner.

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11.Cleaning,installingandadjusting scanners
onthe tractorshaft
Removethe tractor shaftasdescribed in9. Clean the encoder
disc and scanner head with asoftlint-free cloth. Do not use
any cleansing agents.
Important: Do not use compressed air. Thiswould
distribute the paper dustthroughout the entire
machine and wouldparticularlydamage the
opticalscanning systemsand ball bearings.
Reassemle using the following sequence:
1. Mount the tractor shaft and encoder disc (see 9.)
2. Mount and adjust the scanner.
Insert the compression spring and scanner on the pin.Insert the
feeler gauge (0.3 mm)between thesetting collar and the
scanner. Whilethe feeler gauge isinplace, pushthe setting
collar towardsthe encoder discuntil the scanner isflush
against the encoder disc.
Tighten the setting collar and pull out the feeler gauge. Attach the
spring .
The twoscrews are protected frombeing removed with loctite
and shouldnot beunscrewed. Ifthishappens,you will haveto
order a entirelynewscanner with the correct factory positioning.
Usethe sameprocedure for adjustingthe scanner on the cross
cutter.
Adjusting the phase angle:
Use the grub screw to adjustthe phaseangle. See Operating
Instructionsfor information on settings.
12.Cleaning,installingandadjustingscannerson
the cross cutter
Removethe entire cross cutter asdescribed in13. Removethe
driving gear as described in19. and clean the scanner according
to the directionsprovided in 11. Usethe extension cord (toolno.
15667) to attach both motorsto the bushingsofthe cross cutter.
Carefullymovethe lower blade bar awayfromthe block .
Fromthe side, insert the cableclamp(toolno. 10580 - )
between the screw and lower blade bar. When making
adjustments,the cabletieprevents the blade frombeing
damaged while the machine isrunning without paper.
See 11. for instructionson how to adjustthe scanner on the cross
cutter.