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