Morgana Plockmatic BM 60, Service Manual

Page 1: ...Provided By http www MyBinding com http www MyBindingBlog com Plockmatic BM 60 61 2006 Bookletmaker Service Manual ...

Page 2: ...BOOKLET MAKER BM 60 61 SERVICE MANUAL 3 October 2006 Part no 60243 ...

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Page 4: ... 3 9 ADJUSTMENT STAPLER PRESSURE 15 REP 3 10 HOME POSITION STAPLER MOTOR M1 16 REP 3 11 HOME POSITION KNIFE MOTOR M2 17 REP 3 12 ALIGNING EJECT ROLLERS 18 REP 3 13 ADJUSTMENT OF EJECT IDLER ROLLER 19 REP 3 14 ADJUSTMENT OF EJECT MOTOR M4 20 REP 3 15 REMOVAL OF LOWER FOLD ROLLERS 21 REP 3 16 FOLD PRESSURE TOP FOLD ROLLERS 22 REP 3 17 REMOVAL OF INFEED MOTOR M6 ASSEMBLY BM 61 23 REP 3 18 REMOVAL OF ...

Page 5: ...S The staples that should be used in the BM 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 1 3 SPECIAL TOOLS There is a tool set available part number 600007 in order to facilitate adjustments on BM 60 61 Tool A Tool C Tool B To be able to download software ...

Page 6: ...emove CAUTION Lift carefully when removing front cover to prevent damaging the wire harness to front panel 1 2 Installation Installation is an exact reversed procedure of removal Rear Cover Removal Loosen the two screws 1 Pull out the lower end and lift up to remove 1 1 2 Installation Installation is an exact reversed procedure of removal 1 1 1 ...

Page 7: ...ews 1 Pull out the upper end of Infeed cover and open cover to horizontal position 1 2 Installation Installation is an exact reversed procedure of removal Outfeed Cover Removal Loosen the two screws 1 Pull out the upper end of cover and open to horizontal position 1 1 2 1 1 ...

Page 8: ...o top position by turning the shaft on rear side of Fold knife Motor manually Move the Side guides to outer position Insert tool A and check that the Anvils are aligned with the edge of tool A 1 2 3 4 5 Adjustment Loosen the screw holding the Anvil bar a fraction on the rear side of machine Tap carefully on the screw with a hammer to position the Anvil bar Tighten the screw CAUTION Do not move the...

Page 9: ... top position by turning the shaft on rear side of fold knife manually Tighten the Side guides in the outer most position and insert tool A Move tool A until the Side guide s inner point is flush to tool 1 2 3 4 5 6 Adjustment Loosen screws holding Side guides and adjust so that the guides are parallel to tool 1 REP 3 2 ADJUSTMENT OF SIDE GUIDES BM 60 Tool A VIEW FROM TOP SIDE 0 25 0 50 mm Adjust ...

Page 10: ...pler magazines Move the Fold knife to top position by turning the shaft on the rear side of Fold knife motor manually Move the Side guides to the outer most position and insert tool A Check that the Side guides are flush to tool 1 2 3 4 5 6 Adjustment Loosen the screws holding the Side guides adjust until the Side guides are flush along the side of tool A 1 VIEW FROM TOP SIDE Fold knife Side guide...

Page 11: ... switch and disconnect the power cord Remove Infeed cover according to CRI 2 2 Push the jogging rail in manually and make a mark with a pen release the jog ging rail and measure the distance from the mark to the jogging rail The jog ging movement should be 3 5 0 5 mm 1 2 3 Adjustment Locate the Jogger arm assembly close to the Stapler motor Adjust on screw 1 to obtain 3 5 0 5 mm jogging movement 1...

Page 12: ...per edge of tool at Anvils CAUTION The clear Indicator switch could be damaged when inserting tool B 1 2 3 Adjustment Loosen one of the screws at position 1 and two of the screws at position 2 Adjust by skewing the staple stop carriage until tool B is aligned with the anvils Tighten the screws at position 1 and 2 NOTE If further adjustment is necessary to align tool B with the anvils also loosen s...

Page 13: ...haft on rear side of fold knife motor manually Turn the hand wheel to fit tool C between the Fold stop and the Fold knife Check that the Fold stop is parallel with the Fold knife 1 2 3 4 5 Adjustment Loosen the screws 1 and position the Fold stop parallel 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 adj...

Page 14: ...ove the nut 1 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 90 angle 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...

Page 15: ... sheets do not fold the ends of the staple are always pointing at the slot in the anvil 1 2 Adjustment Loosen the screw 1 Loosen the screws 2 a fraction holding the Stapler bar to the side frame 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 3 Top view of misforme...

Page 16: ...ets To check do the following steps Switch off the main power switch and disconnect the power cord Remove Infeed cover according to CRI 2 2 Empty the Stapler magazines Press on top of the Stapler bar until the Stapler heads are fully compressed Check that the distance is 9 mm from the stapler Motor crank to the plastic Crank arm 1 2 3 4 5 Adjustment Loosen the screws 1 Position the stapler yoke br...

Page 17: ...d disconnect the power cord Remove Front and Infeed cover according to CRI 2 1 and 2 2 Empty the Stapler magazines Turn the Stapler motor crank manually until the motor crank arm is aligned with the plastic crank arm 1 2 3 4 Adjustment Locate Switch SW7 positioned on side frame operator side Loosen the screws 1 Position SW7 so that the gap is 0 5 2 0 mm and tighten the screws 1 1 2 Stapler motor P...

Page 18: ...th power ON make sure to stay clear from moving parts 1 2 3 Adjustment Locate Switch SW8 positioned on side frame operator side Manually turn the shaft of the folding knife motor until the folding knife is in the lowest position Loosen the two screws 1 Position SW8 so that the gap is 0 5 2 0 mm and tighten the two screws WARNING This adjustment is performed with power ON make sure to stay clear fr...

Page 19: ... main power switch and disconnect the power cord Remove Infeed cover according to CRI 2 2 Run a few sets and check that they are fed straight down to the Fold stop 1 2 3 Adjustment Loosen screw 1 and align bracket 2 with cradle 3 Position the Feed wheel in the centre of the paper path opening according to picture above by positioning the set collars 4 1 2 1 3 2 Upper Idler roller Feed wheel Feed w...

Page 20: ...d the set to the Fold stop Switch off the main power switch and disconnect the power cord Measure the distance from the paper path to the lower end of the Idler roller using an 4 mm allen key 1 2 Adjustment Adjust by carefully bending the bracket for Idler roller according to the drawing below 1 S1 Fold knife motor M2 3 5 4 0 mm Idler roller S1 3 5 4 0 mm Bend here ...

Page 21: ...th large sizes A3 11 x17 Switch off the main power switch and disconnect the power cord Remove Infeed cover according to CRI 2 2 Press on the plunger for Solenoid SOL1 and view from the infeed side the roll ers will appear to be flush when there is a 3 mm space in between them 1 2 3 Adjustment Loosen the screw on the rear side of Solenoid SOL1 and position the solenoid to obtain the correct distan...

Page 22: ...open up a space between the brackets 5 Move the Fold roller shaft up down and push out the brackets 5 and shaft trough the cut out in the side frame CAUTION In order to compensate for variations between machines there could be shim washers placed on the inside of the bushing at the end of the Fold roller shafts Note the position of the washers when removing 1 2 3 4 5 6 Installation Installation is...

Page 23: ...ler arm at the upper spring Check that there is 35 5 0 5 mm space between the fold bracket and the fold roller arm at the lower spring Use a feeler gauge to check that there is a 2 0 5 mm space between the screw 1 and the fold roller arm 1 2 3 4 5 Adjustment Start with adjusting screw 1 to a distance of 33 mm Adjust the space between the fold bracket and the fold roller arm to 35 0 5 mm on the upp...

Page 24: ...ver according to CRI 2 2 Disconnect the Infeed Motor M6 from the wire harness Remove the stud 1 Push down the Infeed Motor assembly to bypass mode Push on the Infeed Motor assemble indicated in the drawing until it passes over the edge 2 Move the Infeed Motor assembly left right and lift out 1 2 3 4 5 6 7 Installation Installation is an exact reversed procedure of removal 1 VIEW FROM TOP 1 VIEW FR...

Page 25: ...HEAD Removal Switch off the main power switch and disconnect the power cord Remove the Stapler head by removing the pin 1 trough the hole 2 1 2 Installation Installation is an exact reversed procedure of removal 1 Stapler bracket 1 2 ...

Page 26: ...ing to EDI 4 1 Reinstall Infeed cover 1 2 3 1 2 3 4 P5 P4 P11 P3 P2 P13 P14 ON CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit ...

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Page 28: ...oes out 1 2 3 4 ON CAUTION ESD Hazard ESD Electrostatic Discharge can cause software crashes data and or communications problems Failure to use proper ESD pro cedures will cause damage to electronic components example PCBs ESD problems can be minimized by maintaining all machine ground con nections ensuring the proper handling of circuit boards and sensors Use ESD protection when working near PCBs...

Page 29: ...resent and functioning Should a download fail or the 5V is missing LED would be OFF D2 Red LED flashes whenever information is sent or received on the Internal CAN If power is switched on but no operations are performed LED is OFF D15 Green LED permanently OFF It has no direct function in this configuration ...

Page 30: ...ld be within 36 V 10 If the machine is interlocked i e the top cover is open voltage will be 0 V VCC Stabilised and rectified 5 V made from incoming 10 V AC from transformer Measure between Test Point VCC and Test Point GND PGND using a voltmeter GND PGND Ground Power Ground is the minus when measuring either unregu lated 36 V UNREG or 5 V VCC EDI 4 3 TEST POINTS ...

Page 31: ...30 EDI 4 4 CONTROLLER MD6DC The xCAN portion on MD6DC is not used The Counter portion on MD6DC is not used ...

Page 32: ...ective Check voltage between pin 4 and 5 for 14 V AC P11 connector defective Check voltage between pin 1 and 2 for 36 V DC Main circuit board PCB MD6DC defective Check voltage according to EDI 4 3 Infeed motor M6 inoperative Fuse F2 defective Check fuse F2 at transformer Main circuit board PCB MD6DC defective Check for app 24 V DC at Connector J2 pin 3 and 10 Interface cable wire harness defective...

Page 33: ... V DC at connector J3 between pin 2 and 3 Fold mode switch SW 3 on front panel defective Check function of SW3 Fold motor M3 defective Check for app 24 V DC at motor M3 Belt stacker motor M5 inoperative Cable to stacker Check that cable is connected and all leads have continuity Main circuit board PCB 60 defective Check for 24 V DC at connector J2 between pin 4 and 11 Belt stacker motor M5 defecti...

Page 34: ... Use a rubber reactivator alcohol fluid Check for wear If worn replace Always replace at 160 000 Page 13 Item 5 Clean Replace Clean Staple motor and Staple motor Home position Apply silicon grease between Motor crank and plastic crank arm Check adjustment according to REP 3 10 Page 12 Item 7 and 8 Check Adjust Check Adjust Check Adjust Lifting clamp Apply silicon grease between Stapler head and Li...

Page 35: ...the Rear jogger bracket and the bottom frame Page 25 Item 3 Check Grease Check INFEED MODULE BM 61 FINAL CHECK POINTS CHECK POINT INSTRUCTION REFER ENCE 80 000 160 000 240 000 Bushing on Upper fold rollers Under the top cover use grease between the bushing and shaft Apply grease between bushings and side frame Replace at 160 000 Page 15 Item 6 Grease Grease Grease Fold knife guides 2 pcs Apply gre...

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