Plockmatic BM 60 User manual

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Plockmatic BM 60/61
Bookletmaker
Service Manual

Stapler/Folder Model 60/61
Service manual
OCTOBER 1994

i Contents T08011 TJ
PAGE
INTRODUCTION i i OCTOBER -94
COVER REMOVE INSTRUCTION (CRI)
CRI 1.1 Front and rear cover 1.1 OCTOBER -94
CRI 1.2 Infeed and outfeed covers 1.2 OCTOBER -94
REPAIRS/ADJUSTMENTS (REP)
REP 2.1 Parallelity Fold knife - Anvil bar 2.1 OCTOBER -94
REP 2.2 Adjustment of Side guides Model 60 2.2 OCTOBER -94
REP 2.3 Adjustment of Side guides Model 61 2.3 OCTOBER -94
REP 2.4 Adjustment of Side jogger movement Model 61 2.4 OCTOBER -94
REP 2.5 Parallelity Staple stop - Anvils 2.5 OCTOBER -94
REP 2.6 Parallelity Fold stop - Fold knife 2.6 OCTOBER -94
REP 2.7 Positioning staples on fold 2.7 OCTOBER -94
REP 2.8 Adjustment of stapler position to anvils 2.8 OCTOBER -94
REP 2.9 Adjustment of stapler pressure 2.9 OCTOBER -94
REP 2.10 Home position Stapler motor M1 2.10 OCTOBER -94
REP 2.11 Home position Fold knife motor M2 2.11 OCTOBER -94
REP 2.12 Adjustment of Eject Idler roller 2.12 OCTOBER -94
REP 2.13 Adjustment of Eject motor M4 2.13 OCTOBER -94
REP 2.14 Aligning Eject rollers 2.14 OCTOBER -94
REP 2.15 Removal of lower Fold rollers 2.15 OCTOBER -94
REP 2.16 Fold pressure, top Fold rollers 2.16 OCTOBER -94
REP 2.17 Removal of Infeed motor M6 assembly Model 61 2.17 OCTOBER -94
REP 2.18 Removal of Stapler head 2.18 OCTOBER -94
ELECTRONIC DETAIL INFORMATION (EDI)
EDI 3.1 Trimming of circuit board PCB 60-1 3.1 OCTOBER -94
EDI 3.2 Wiring/circuit diagram Model 61 3.2 OCTOBER -94
EDI 3.3 Wiring/circuit diagram Model 60 3.3 OCTOBER -94
EDI 3.4 PCB PL60 layout 3.4 OCTOBER -94
EDI 3.5 PCB PL61 layout 3.5 OCTOBER -94
FAULT ISOLATING PROCEDURE (FIP)
FIP 4.1 Fault isolating procedure Model 61 4.1-4.4 OCTOBER -94
FIP 4.2 Fault isolating procedure Model 60 4.5-4.7 OCTOBER -94
FIP 5. . 1 P reventive Maintenance 5.1-5.2 MAY -02
STAPLER FOLDER MODEL 60/61 PAGE i OCTOBER -94

ii Introduction T08011 TJ
GENERAL INFORMATION
This service manual describes both the Model 60 and the Model 61.
Also available is conversion kit instruction Model 60 to Model 61, installation instruction Model 61 and a spare
parts list Model 60/61.
PLOCKMATIC CHISEL POINT STAPLES
The staples that should be used in the Model 60/61 are PLOCKMATIC chisel point staples, part number 800001.
When using PLOCKMATIC staples functional disorders are avoided and the life length of the stapler heads are
radically increased.
SPECIAL TOOLS
There is a tool set available, part number 600007, in order to facilitate adjustments on Model 60/61.
Tool A Tool B Tool C
STAPLER FOLDER MODEL 60/61 PAGE ii OCTOBER-94

CRI 1.1 Front and rear cover T08010 TJ
FRONT COVER
REMOVAL
1. Loosen the two screws (1).
2. Pull out the lower end and lift up to remove.
CAUTION: Lift carefully when removing front cover to prevent damaging the wire harness to front
panel.
1
INSTALLATION
1. Installation is an exact reversed procedure of removal.
REAR COVER
REMOVAL
1. Loosen the two screws (1).
2. Pull out the lower end and lift up to remove.
1
INSTALLATION
1. Installation is an exact reversed procedure of removal.
STAPLER FOLDER MODEL 60/61 PAGE 1.1 OCTOBER-94

CRI 1.2 Infeed and outfeed cover T08010 TJ
UPPER/LOWER INFEED COVER
REMOVAL
1. Remove the two screws (1).
2. Pull out the upper end of Lower infeed cover and open cover to horizontal position.
3. Remove the screws (2) and remove the upper infeed cover.
1
2
INSTALLATION
1. Installation is an exact reversed procedure of removal.
OUTFEED COVER
REMOVAL
1. Loosen the two screws (1).
2. Pull out the upper end of cover and open to horizontal position.
1
INSTALLATION
1. Installation is an exact reversed procedure of removal.
STAPLER FOLDER MODEL 60/61 PAGE 1.2 OCTOBER-94

REP 2.1 Parallelity Fold knife - Anvil bar T08008 TJ
PURPOSE
The purpose is to align the Anvil bar with the Fold knife to obtain a correct staple position.
1. Switch off the main power switch and disconnect the power cord.
2. Remove front, Rear and Infeed cover CRI.1.1 and 1.2.
3. Empty the stapler magazines.
4. Move the Fold knife to top position by turning the shaft on rear side of Fold knife Motor manually.
5. Move the Side guides to outer position.
6. Insert tool A and check that the Anvils are aligned with the edge of tool A.
Tool A
ADJUSTMENT
1. Loosen the screw holding the Anvil bar a fraction on the rear side of machine.
2. Tap carefully on the screw with a hammer to position the Anvil bar.
3. Tighten the screw.
CAUTION: Do not move the Anvil bar up or down, that could cause the stapling pressure to be
uneven.
LOOSEN SCREW
ON THIS SIDE
Tool A
STAPLER FOLDER MODEL 60/61 PAGE 2.1 OCTOBER-94

REP 2.2 Adjustment of Side guides Model 60 T08008 TJ
PURPOSE
Side guides needs to have the correct position in order to transport the set straight to the fold stop.
1. Switch off the main power switch and disconnect the power cord.
2. Remove lower Infeed cover, CRI 1.2.
3. Empty Stapler magazines.
4. Move Fold knife to top position by turning the shaft on rear side of fold knife manually.
5. Tighten the Side guides in the outer most position and insert tool A.
6. Move tool A until Side guide inner point is flush to tool.
VEIW FROM TOP SIDE
1mm
1mm
Side guide flush to tool
Adjust on these screws
Fold knife
Tool A
ADJUSTMENT
1. Loosen screws holding Side guides and adjust so that there is a 1mm gap at the lower end of Side
guides according to the figure.
STAPLER FOLDER MODEL 60/61 PAGE 2.2 OCTOBER-94

REP 2.3 Adjustment of Side guides Model 61 T08009 TJ
PURPOSE
The Side guides needs to be exactly parallel in order to transport the set straight to the Fold stop.
1. Switch off the main power switch and disconnect the power cord.
2. Remove lower Infeed cover, CRI 1.2.
3. Empty the Staple magazines.
4. Move the Fold knife to top position by turning the shaft on the rear side of Fold knife motor
manually.
5. Move the Side guides to the outer most position and insert tool A.
6. Check that the Side guides are flush to tool.
VEIW FROM TOP SIDE
Adjust on these screws
Side guide flush to tool
Fold knife
Side guide flush to tool
Tool A
ADJUSTMENT
1. Loosen the screws holding the Side guides, adjust until the Side guides are flush along the side of
tool A.
STAPLER FOLDER MODEL 60/61 PAGE 2.3 OCTOBER-94

REP 2.4 Adjustment of side jogger movement Model 61 T08009 TJ
PURPOSE
On the Model 61 the side jogging is performed with the rear jogging rail. The jogging stroke is
essential
to the jogging performance and the transport of stets to the fold area.
1. Switch off the main power switch and disconnect the power cord.
2. Remove lower Infeed cover, CRI 1.2.
3. Push the jogging rail in manually and make a mark with a pen, release the jogging rail and measure
the distance from the mark to the jogging rail. The jogging movement should be 3.5 +/- 0.5mm.
VIEW FROM TOP
Push here
ADJUSTMENT
1. Locate the Jogger arm assembly close to the Stapler motor.
2. Adjust on screw (1) to obtain the 3.5 +/- 0.5mm.
1
Stapler motor
Jogger arm assy
STAPLER FOLDER MODEL 60/61 PAGE 2.4 OCTOBER-94

REP 2.5 Parallelity Staple stop - Anvils T08009 TJ
PURPOSE
The purpose is to obtain the correct staple position.
1. Switch off the main power switch and disconnect the power cord.
2. Empty Staple magazines.
3. Insert tool B according to the drawing and crank hand wheel to position upper edge of tool at
Anvils.
CAUTION. The clear Indicator switch could be damaged when inserting tool B.
VIEW FROM TOP SIDE
Tool B
1
2
Anvil bar
Staple stop
ADJUSTMENT
1. Loosen one of the screws at position (1) and two of the screws at position (2).
2. Adjust by skewing the staple stop carriage until tool B is aligned with the anvils.
3. Tighten the screws at position (1) and (2).
STAPLER FOLDER MODEL 60/61 PAGE 2.5 OCTOBER-94

REP 2.6 Parallelity Fold stop - Fold knife T08009 TJ
PURPOSE
The purpose is to obtain the correct folding position.
1. Switch off the main power switch and disconnect the power cord.
2. Remove Outfeed cover, CRI 1.2.
3. Move Fold knife to top position by turning the shaft on rear side of fold knife motor manually.
4. Turn the hand wheel to fit tool C between the Fold stop and the Fold knife.
5. Check that the Fold stop is parallel with the Fold knife.
Tool C
Fold knife
Turn here
M2
ADJUSTMENT
1. Loosen the screws 1 and position the Fold stop parallel compared to the Fold knife.
NOTE. Loosen only the screws on one side of Fold stop, if loosen screws on both sides, staple
position on fold may have to be adjusted.
Fold knife
1
Tool C
M2
STAPLER FOLDER MODEL 60/61 PAGE 2.6 OCTOBER-94

REP 2.7 Positioning staples on fold T08009 TJ
PURPOSE
The distance between the fold stop and the fold knife should be equal to the distance between the fold
knife and the staple outlet. Regardless of where the fold is positioned the staples should always be on
the fold.
1. Run a few sets of two sheets and check the position of the staples.
OK
ADJUSTMENT
1. Remove the nut (1).
2. Position the Fold plate by turning the set screw (2), clockwise will increase the length between
the Fold stop and the Fold knife.
NOTE. The Fold plate should be in an approximately 90oangle compared to the fixed part of the
Fold stop. It is not recommended to do a large adjustment on the set screw. If a large adjustment is
needed, loosen the screws (3) on both sides of Fold stop and go to REP. 2.5 for adjustment.
3
2
1
90
Fold plate
STAPLER FOLDER MODEL 60/61 PAGE 2.7 OCTOBER-94

REP 2.8 Adjustment stapler position to Anvil T08009 TJ
PURPOSE
By checking the staples on a stapled set you can easely determine if the staple outlet on the stapler
head is positioned on top of the slot in the anvil.
1. Remove front and rear cover, CRI 1.1.
2. Make a few staples on a set of two sheets (do not fold), the ends of the staple are always pointing
at the slot in the anvil.
Top view of misformed staples
Move stapler head in this direction
ADJUSTMENT
1. Loosen the screw (1).
2. Loosen the screws (2) a fraction, holding the Stapler bar to the side frame.
3. Use a 17 mm wrench to turn the Stapler bar until the staples are formed correctly.
WARNING: This adjustment is performed with the power ON, make sure to stay clear from moving
parts.
1
2
Staper heads
Stapler bar
Stapler head
Anvil
STAPLER FOLDER MODEL 60/61 PAGE 2.8 OCTOBER-94

REP 2.9 Adjustment stapler pressure T08009 TJ
PURPOSE
It is possible to staple through 22 sheets of paper without adjusting the stapler pressure.
The stapler pressure should increase when thick sets are stapled.
To make this possible a piece of spring steel is mounted underneath the stapling bracket. If stapler
pressure is incorrect adjusted, staples will be loose when stapling two sheets.
To check do the following steps.
1. Switch off the main power switch and disconnect the power cord.
2. Remove Infeed cover, CRI 1.2.
3. Empty the Staple magazines.
4. Press on top of the Stapler bar until the Stapler heads are fully compressed.
5. Check that the distance is 9 mm from the stapler Motor crank to the plastic Crank arm.
9 mm
Stapler motor
Plastic crank
Motor crank
arm
ADJUSTMENT
1. Loosen the screws (1).
2. Position the stapler yoke bracket to obtain the 9 mm and tighten the screws.
Press here
Stapler motor
Stapler yoke
bracket
1
1
Stapler bar
stapling bracket
STAPLER FOLDER MODEL 60/61 PAGE 2.9 OCTOBER-94

REP 2.10 Home position Stapler motor M1 T08009 TJ
PURPOSE
Switch SW7 stops the Stapler motor at home position.
There are two springs that holds the Stapler yoke in top position when Stapler motor is in home
position.
1. Switch off the main power switch and disconnect the power cord.
2. Remove Front and Infeed cover, CRI 1.1 and 1.2.
3. Empty the Staple magazines.
4. Turn the Stapler motor crank manually and check that Switch SW7 activates 0-1mm before motor
crank arm is aligned with plastic crank arm.
0 -1mm
Stapler motor
Plastic crank
Motor crank
arm
Turn motor in this direction
ADJUSTMENT
Locate Switch SW7 positioned on side frame operator side.
1. Loosen the screws (1).
2. Turn Stapler motor manually and stop when the plastic crank arm on the motor is 1mm
(5 degrees) before top dead centre.
3. Position SW7 so that it activates and tighten the screws (1).
1
SW7
STAPLER FOLDER MODEL 60/61 PAGE 2.10 OCTOBER-94

REP 2.11 Home position Knife motor M2 T08009 TJ
PURPOSE
Switch SW8 stops the Knife motor at home position.
1. Remove Front and Infeed cover, CRI 1.1 and 1.2.
2. Select folding on front panel.
3. Run one set of paper trough and check that the Fold knife stops below the paper path according to
the drawing.
WARNING: This adjustment is performed with power ON, make sure to stay clear from moving
parts.
Fold knife
Fold knife motor M2
Paper path middle section
Paper path lower section
ADJUSTMENT
Locate Switch SW8 positioned on side frame operator side.
1. Loosen the screws (1).
2. Position SW8 to obtain the correct home position for the Fold knife.
WARNING: This adjustment is performed with power ON, make sure to stay clear from moving
parts.
SW8
1
Fold knife motor M2
Fold knife
STAPLER FOLDER MODEL 60/61 PAGE 2.11 OCTOBER-94

REP 2.12 Adjustment of Eject Idler roller T08009 TJ
PURPOSE
The upper Idler roller has to be positioned at the correct height in order for the Eject motor feed
wheel to feed the set to the Fold stop.
1. Switch off the main power switch and disconnect the power cord.
2. Measure the distance from the paper path to the lower end of the Idler roller.
5 mm
S1
Idler roller
Eject motor feed wheel
Paper path
Ruler
ADJUSTMENT
1. Adjust by carefully bending the bracket for Idler roller according to the drawing below.
5 mm
Bend here
S1
STAPLER FOLDER MODEL 60/61 PAGE 2.12 OCTOBER-94

REP 2.13 Adjustment of Eject motor M4 T08009 TJ
PURPOSE
There should be a clearance between the Idler roller and the Eject feed wheel when Solenoid SOL1
is activated. If Idler roller and Feed wheel are touching there could be a problem to feed sets with
large sizes (A3/11"x17").
1. Switch off the main power switch and disconnect the power cord.
2. Remove Infeed cover, CRI 1.2.
3. Press on the plunger for Solenoid SOL1 and view from the infeed side, the rollers will appear to
be
flush when there is a 2mm space in between them.
2 mm
SOL1
ADJUSTMENT
1. Loosen the screw on the rear side of Solenoid SOL1 and position the solenoid to obtain the correct
distance between the rollers.
2 mm
SOL1
STAPLER FOLDER MODEL 60/61 PAGE 2.13 OCTOBER-94

REP 2.14 Aligning Eject rollers T08009 TJ
PURPOSE
This adjustment is more essential on the Model 61, when the set is fed to the Fold stop on a Model
61
the inner Side jogger rail will not guide the set as on a Model 60.
1. Switch off the main power switch and disconnect the power cord.
2. Remove lower Infeed cover, CRI 1.2.
3. Run a few sets and check that they are fed straight down to the Fold stop.
SOL1
M4
Upper idler roller
Feed wheel
1
2
Push here
ADJUSTMENT
1. Adjust the skewing of Feed wheel by loosening the screw (1) and turn the Feed motor assembly.
2. Align the Feed wheel with the upper Idler roller by positioning the set collars (2).
STAPLER FOLDER MODEL 60/61 PAGE 2.14 OCTOBER-94