Plockmatic BM 60/61

2006 Bookletmaker

Service Manual

Provided By

http://www.MyBinding.com http://www.MyBindingBlog.com
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 BOOKLET MAKER BM 60/61

SERVICE MANUAL

3 October 2006
Part no. 60243

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 TABLE OF CONTENTS

1. INTRODUCTION
1.1 GENERAL INFORMATION............................................................................ 4
1.2 PLOCKMATIC CHISEL POINT STAPLES..................................................... 4
1.3 SPECIAL TOOLS........................................................................................... 4
2. COVER REMOVAL INSTRUCTION (CRI)
CRI 2.1 FRONT AND REAR COVER ................................................................. 5
CRI 2.2 INFEED AND OUTFEED COVER ......................................................... 6
3. REPAIRS/ADJUSTMENTS (REP)
REP 3.1 PARALLELISM FOLD KNIFE - ANVIL BAR.......................................... 7
REP 3.2 ADJUSTMENT OF SIDE GUIDES BM 60 ............................................ 8
REP 3.3 ADJUSTMENT OF SIDE GUIDES BM 61............................................. 9
REP 3.4 ADJUSTMENT OF SIDE JOGGER MOVEMENT BM 61.................... 10
REP 3.5 PARALLELISM STAPLE STOP - ANVILS ...........................................11
REP 3.6 PARALLELISM FOLD STOP - FOLD KNIFE...................................... 12
REP 3.7 POSITIONING STAPLES ON FOLD .................................................. 13
REP 3.8 ADJUSTMENT STAPLER POSITION TO ANVIL ............................... 14
REP 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 STAPLER HEAD ...................................................... 24
REP 3.19 PCB MD6DC..................................................................................... 25
4. ELECTRONIC DETAIL INFORMATION (EDI)
EDI 4.1 SOFTWARE DOWNLOAD................................................................... 27
EDI 4.2 LEDS.................................................................................................... 28
EDI 4.3 TEST POINTS...................................................................................... 29
EDI 4.4 CONTROLLER MD6DC....................................................................... 30
5. FAULT ISOLATION PROCEDURE (FIP)
FIP 5.1 FAULT ISOLATION PROCEDURE....................................................... 31
6. PREVENTIVE MAINTENANCE (MAI)
MAI 6.1 PREVENTIVE MAINTENANCE BOOKLET MAKER BM 60/61........... 33
7. WIRING DIAGRAMS
7.1 WIRING DIAGRAM BM 60.......................................................................... 34
7.2 WIRING DIAGRAM BM 61.......................................................................... 35

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 1. INTRODUCTION
1.1 GENERAL INFORMATION
This service manual describes both the BM 60 and the BM 61.
Also available is conversion kit instruction BM 60 to BM 61, installation instruction
BM 61 and a spare parts list BM 60/61.

1.2 PLOCKMATIC CHISEL POINT STAPLES

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 B Tool C

To be able to download software to the PCB a download cable is required,

part number 770010.

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 2. COVER REMOVAL INSTRUCTION (CRI)
CRI 2.1 FRONT AND REAR COVER
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.

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.


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 CRI 2.2 INFEED AND OUTFEED COVER
Infeed Cover
Removal
1. Remove the two screws (1).
2. Pull out the upper end of Infeed cover and open cover to horizontal position.

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.

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 3. REPAIRS/ADJUSTMENTS (REP)
REP 3.1 PARALLELISM FOLD KNIFE - ANVIL BAR
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 according to CRI 2.1 and 2.2.
3. Move the Fold knife to top position by turning the shaft on rear side of Fold
knife Motor manually.
4. Move the Side guides to outer position.
5. 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.

Tool A

Loosen screw
on this side

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 REP 3.2 ADJUSTMENT OF SIDE GUIDES BM 60
Purpose
The 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 Infeed cover, according to CRI 2.2.
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 the Side guide’s inner point is flush to tool.

VIEW FROM TOP SIDE

Fold knife

0.25-0.50 mm 0.25-0.50 mm

Tool A

Side guide flush to tool

Adjust on these screws

Adjustment
1. Loosen screws holding Side guides and adjust so that the guides are parallel to
tool.

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 REP 3.3 ADJUSTMENT OF SIDE GUIDES BM 61
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 Infeed cover, according to CRI 2.2.
3. Empty the Stapler 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.

VIEW FROM TOP SIDE Fold knife

Side guide flush to tool

Tool A

Side guide flush to tool

Adjust on these screws

Adjustment
1. Loosen the screws holding the Side guides, adjust until the Side guides are
flush along the side of tool A.

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 REP 3.4 ADJUSTMENT OF SIDE JOGGER MOVEMENT
BM 61
Purpose
On the BM 61 the side jogging is performed with the rear jogging rail. The jogging
stroke is essential to the jogging performance and the transport of sets to the fold
area.
1. Switch off the main power switch and disconnect the power cord.
2. Remove Infeed cover, according to CRI 2.2.
3. 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.

VIEW FROM TOP

Push here

Adjustment
1. Locate the Jogger arm assembly close to the Stapler motor.
2. Adjust on screw (1) to obtain 3.5 +/- 0.5 mm jogging movement.

Jogger arm assy

Stapler motor

10

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 REP 3.5 PARALLELISM STAPLE STOP - ANVILS
Purpose
The purpose is to obtain the correct staple position.
1. Switch off the main power switch and disconnect the power cord.
2. Empty Stapler 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

1

Staple stop

Tool B
2

3
Anvil bar

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).

NOTE: If further adjustment is necessary to align tool B with the anvils, also loosen
screw (3).

11

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 REP 3.6 PARALLELISM FOLD STOP - FOLD KNIFE
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, according to CRI 2.2.
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.

Fold knife

Tool C Turn here

M2

Adjustment
1. 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 adjusted.

Fold knife

Tool C

M2

12

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 REP 3.7 POSITIONING STAPLES ON FOLD
Purpose
The distance between the fold stop and the fold knife should be equal to the dis-
tance 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 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 3.5 for adjustment.

90º

2
3

Fold plate

NOTE: If the angle is larger than 90° the stapler position will vary and the book
quality will be poor.

13

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 REP 3.8 ADJUSTMENT STAPLER POSITION TO ANVIL
Purpose
By checking the staples on a stapled set you can easily 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, according to CRI 2.1.
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.
Move stapler head in this direction

Top view of misformed staples

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.

Stapler heads

Stapler head
Stapler bar

Anvil

14

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 REP 3.9 ADJUSTMENT STAPLER PRESSURE
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, according to CRI 2.2.
3. Empty the Stapler 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

Plastic crank arm

Stapler motor

Motor crank

Adjustment
1. Loosen the screws (1).
2. Position the stapler yoke bracket to obtain the 9 mm and tighten the screws.
Press here
Stapler bar

Stapler yoke
bracket

1 1

Stapler motor
Stapling bracket

15

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 REP 3.10 HOME POSITION STAPLER MOTOR M1
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, according to CRI 2.1 and 2.2.
3. Empty the Stapler magazines.
4. Turn the Stapler motor crank manually until the motor crank arm is aligned with
the plastic crank arm.

Plastic crank arm

Stapler motor
Motor crank

Adjustment
Locate Switch SW7 positioned on side frame operator side.
1. Loosen the screws (1).
2. Position SW7 so that the gap is 0.5 - 2.0 mm and tighten the screws (1).

1
SW7

0.5-2.0 mm

16

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 REP 3.11 HOME POSITION KNIFE MOTOR M2
Purpose
Switch SW8 stops the Knife motor at home position.
1. Remove Front and Infeed cover, according to CRI 2.1 and 2.2.
2. Select folding on front panel.
3. Run one set of paper trough and check that the Fold knife stops below the pa-
per path according to the drawing.
WARNING: This adjustment is performed with power ON, make sure to stay
clear from moving parts.
Paper path middle section

Paper path lower section

Fold knife motor M2

Fold knife

Adjustment
Locate Switch SW8 positioned on side frame operator side.
1. Manually turn the shaft of the folding knife motor until the folding knife is in the
lowest position.
2. Loosen the two screws (1).
3. 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 from moving parts.

Fold knife Fold knife motor M2

SW8

1
17

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 REP 3.12 ALIGNING EJECT ROLLERS
Purpose
This adjustment is more essential on the BM 61, when the set is fed to the Fold
stop on a BM 61 the inner Side jogger rail will not guide the set as on a BM 60.
1. Switch off the main power switch and disconnect the power cord.
2. Remove Infeed cover, according to CRI 2.2.
3. Run a few sets and check that they are fed straight down to the Fold stop.

Upper Idler roller

Paper path 1

Feed wheel

Feed wheel 4

Adjustment
1. Loosen screw (1) and align bracket (2) with cradle (3).
2. Position the Feed wheel in the centre of the paper path opening, according to
picture above, by positioning the set collars (4).

18

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 REP 3.13 ADJUSTMENT OF EJECT IDLER ROLLER
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
using an 4 mm allen key.

3.5 - 4.0 mm
Idler roller

Fold knife motor M2

S1

Adjustment
1. Adjust by carefully bending the bracket for Idler roller according to the drawing
below.
3.5 - 4.0 mm

Bend here

S1

19

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 REP 3.14 ADJUSTMENT OF EJECT MOTOR M4
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, according to CRI 2.2.
3. 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.

3 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.

3 mm

SOL1

20

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 REP 3.15 REMOVAL OF LOWER FOLD ROLLERS
Removal
1. Switch off the main power switch and disconnect the power cord.
2. Remove Front cover, according to CRI 2.1.
3. Remove the springs (1), use a screwdriver to compress the springs when
removing.
4. Remove the sprockets (2) and the drive chain (3).
5. Loosen the sheet metal screws (4) on one side of the fold roller shaft. This will
open up a space between the brackets (5).
6. 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.

5 4 1 3

Installation
1. Installation is an exact reversed procedure of removal.
NOTE: When installing run the machine for a few revolution to let the sprockets
“settle” before tightening.

21

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 REP 3.16 FOLD PRESSURE, TOP FOLD ROLLERS
Purpose
There are two springs on each side of the top Fold rollers, one is stiff and the oth-
er is softer. When running two to five sheets the Fold rollers will only use the soft
springs, when running up to twenty sheets all of the springs will be compressed.
1. Switch off the main power switch and disconnect the power cord.
2. Remove Front and Rear cover, according to CRI 2.1.
3. Check that there is a 35 +/- 0.5 mm space between the fold bracket and the
fold roller arm at the upper spring.
4. Check that there is 35.5 +/- 0.5 mm space between the fold bracket and the
fold roller arm at the lower spring.
5. Use a feeler gauge to check that there is a 2 +/- 0.5 mm space between the
screw (1) and the fold roller arm.

35 +/- 0.5 mm

35.5 +/- 0.5 mm

1

2.5 +/- 0.5 mm

Adjustment
1. Start with adjusting screw (1) to a distance of 33 mm.
2. Adjust the space between the fold bracket and the fold roller arm to 35 +/- 0.5
mm on the upper screw.
3. Loosen the screws (2) and position the fold pressure assembly until the Fold
rollers are in a straight line with the fold pressure assembly and the distance at
the lower spring is 35.5 +/- 0.5 mm.
Fold bracket 2

Fold rollers

33 mm

1
Fold roller arm

22

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 REP 3.17 REMOVAL OF INFEED MOTOR M6 ASSEMBLY,
BM 61
Purpose
By removing the infeed motor assembly you will have an easy access to the infeed
motor and infeed roller.
1. Switch off the main power switch and disconnect the power cord.
2. Remove Infeed cover, according to CRI 2.2
3. Disconnect the Infeed Motor M6 from the wire harness.
4. Remove the stud (1).
5. Push down the Infeed Motor assembly to bypass mode.
6. Push on the Infeed Motor assemble indicated in the drawing until it passes over
the edge (2).
7. Move the Infeed Motor assembly left/right and lift out.

VIEW FROM TOP

VIEW FROM INFEED SIDE 2

Infeed motor
assembly

Push here

Installation
1. Installation is an exact reversed procedure of removal.

23

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 REP 3.18 REMOVAL OF STAPLER HEAD
Removal
1. Switch off the main power switch and disconnect the power cord.
2. Remove the Stapler head by removing the pin (1) trough the hole (2).

Stapler bracket

Installation
1. Installation is an exact reversed procedure of removal.

24

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 REP 3.19 PCB MD6DC
P4 P5

P12 ON

P11

P3 P13

P2 P14

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. Failure to use ESD protection is
likely to result in a PCB failure.

Removal
1. Remove Infeed cover according to CRI 2.2.
2. Remove all connectors from the PCB.
3. Squeeze the barbs of the pins and remove PCB.

Replacement
1. Reinstall PCB.
2. Reconnect all connectors to the PCB.
3. Make sure all DIP-switches are set to OFF according to picture.
NOTE: Make sure to download the latest software, according to EDI 4.1.
4. Reinstall Infeed cover.

25

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 26

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 4. ELECTRONIC DETAIL INFORMATION (EDI)
EDI 4.1 SOFTWARE DOWNLOAD

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. Failure to use ESD protection is
likely to result in a PCB failure.

NOTE: To be able to download software to the PCB a download cable is required,

part number 770010.

1. Switch Off the Main Power Switch.

2. Remove Infeed Cover according to CRI 2.2.
3. Make sure all DIP-switches 1 - 4 is set to OFF (down) position.
4. Run the most recent software file and follow the instruction in the program.

NOTE: A red LED on the board will flash while downloading. When download is
complete LED goes out.

ON

27

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 EDI 4.2 LEDS

D15 D1 D2

D1: Yellow LED flashes when power is on. The flashing indicates that a program is
present 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.

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 EDI 4.3 TEST POINTS

+UNREG

GND/
PGND

VCC

+UNREG: Outgoing unregulated 36 V, after interlock relay. Measure between Test

Point +UNREG and Test Point GND/PGND using a voltmeter.

- Voltage should 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).

29

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 EDI 4.4 CONTROLLER MD6DC

The xCAN portion on MD6DC is not used.

The Counter portion on MD6DC is not used.

30

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 5. FAULT ISOLATION PROCEDURE (FIP)
FIP 5.1 FAULT ISOLATION PROCEDURE
OBSERVED POSSIBLE CAUSE FAULT ISOLATION/REPAIR
FAULT
No machine Power supply not connected. Check voltage in power cord.
initialisation.
Main fuse F1 defective. Check fuse at power receptacle.
Secondary fuses F2 and F3 Check fuses at transformer
defective.
1. Transformer defective. Check voltage at primary side of
transformer, according to label on
transformer. If OK go to step 2.
Main switch SW1 defective. Check function of main switch
SW1.
Interlock switch SW6 or SW14 Check function of Interlock switch
defective. SW6 and SW14.
2. Transformer defective. Check voltage on secondary side
of transformer.
Rectifier/Capacitor defective. Check voltage between Red and
Black for 36 V DC ± 10 %
P4 connector defective. 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 Check voltage according to EDI 4.3
defective.
Infeed motor M6 Fuse F2 defective. Check fuse F2 at transformer.
inoperative. Main circuit board PCB MD6DC Check for app. 24 V DC at
defective. Connector J2 pin 3 and 10.
Interface cable/wire harness Check for app. 30 V DC at
defective. connector J1 on Addon PCB
between pin 1 and 2.
Infeed motor M6 defective. Check for app. 24 V DC at motor
M6.
Stapler motor M1 Fuse F2 defective. Check fuse F2 at transformer.
inoperative. Main circuit board PCB MD6DC Check for app. 24 V DC at
defective. Connector J3 pin 6 and 7.
Staple mode switch SW2 on Check function of SW2.
front panel defective.
Stapler motor M1 defective. Check for app. 24 V DC at motor
M6.

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 OBSERVED POSSIBLE CAUSE FAULT ISOLATION/REPAIR
FAULT
Eject solenoid S1 Eject solenoid S1 defective. Check for app. 34 V DC at solenoid
inoperative. S1
Main circuit board PCB MD6DC Replace PCB MD6DC.
defective.
Eject motor M4 Eject motor M4 defective. Check for app. 24 V DC at motor
inoperative. M4.
Main circuit board PCB MD6DC Check for app. 24 V DC at
defective. connector J2 between pin 2 and 9.
Fold knife motor Main circuit board PCB MD6DC Check for app. 24 V DC at
M2 inoperative. defective. connector J2 between pin 1 and 8.
Fold mode switch SW 3 on front Check function of SW3.
panel defective.
Knife motor M2 defective. Check for app. 24 V DC at motor
M2.
Fold roller motor Main circuit board PCB MD6DC Check for app. 24 V DC at
M3 inoperative. defective. connector J3 between pin 2 and 3.
Fold mode switch SW 3 on front Check function of SW3.
panel defective.
Fold motor M3 defective. Check for app. 24 V DC at motor
M3.
Belt stacker Cable to stacker. Check that cable is connected and
motor M5 all leads have continuity.
inoperative. Main circuit board PCB 60 Check for 24 V DC at connector J2
defective. between pin 4 and 11.
Belt stacker motor M5 Check for 24 V DC at belt stacker
defective. motor.
Staple position Staple stop not parallel See REP 3.5.
not on fold. compared to anvils.
Fold plate not in correct See REP 3.7.
position.
Fold not straight. Fold stop not in correct position. See REP 3.6.
Side guides not straight. See REP 3.2 or 3.3.
Eject Idler rollers not aligned. See REP 3.12.
Eject Idler roller not in correct See REP 3.13.
position.
Eject motor not in correct See REP 3.14.
position.
Staples Staple position to anvils not See REP 3.8.
deformed. correct.
Staple pressure not correct. See REP 3.9.

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 6. PREVENTIVE MAINTENANCE (MAI)
MAI 6.1 PREVENTIVE MAINTENANCE BOOKLET MAKER
BM 60/61
Service interval: 80 000
NOTE: All INSTRUCTIONS are referring to the Booklet Maker BM 60/61 Service
Manual.
The REFERENCE column is referring to the Spare Parts Manual of
BM 60/61.

IMPORTANT: If any of the checkpoints show indication of wear at any point,

replace the part.
When lubricating, clean the surface before applying new lubricant.
CHECK POINT INSTRUCTION REFER- 80 000 160 000 240 000
ENCE
All Machine, Use a vacuum cleaner, towels Clean Clean Clean
Paper paths and brushes to clean the ma-
etc. chine from paper dust. Use
an alcohol to clean from ink.
Stapler head Clean stapler heads from Clean/ Clean/ Check/
(2 pcs.) glue and apply ball bearing Grease Grease Replace
grease on drive bar. Check
adjustment REP 3.8 - 3.10
O-ring on Eject Use a rubber reactivator Page 13 Clean Replace Clean
feed wheel. alcohol fluid. Check for wear. Item 5
If worn replace. Always
replace at 160 000.
Staple motor Apply silicon grease between Page 12 Check/ Check/ Check/
and Staple Motor crank and plastic Item 7 and 8 Adjust Adjust Adjust
motor Home crank arm. Check adjustment
position. according to REP 3.10.
Lifting clamp. Apply silicon grease between Page 10 Grease Grease Grease
Stapler head and Lifting Item 1
clamp.
Chain. Apply chain oil. Check for Oil Oil Oil
wear, if worn replace.
Chain idler Apply chain oil and check for Page 16 Oil/ Oil/ Check/
wheel wear, if worn replace. Item 3 and 10 Check Check Replace
Rubber rings Use a rubber reactivator Page 15 Clean Clean/ Check/
on Lower old alcohol fluid. Check for wear. Item 11 Check Replace
rollers. If worn replace.
Lower Fold Under the top cover, use oil Page 15 Check/
roller Flanged between the Flanged bush- Item 8 Oil
bushing. ings and shaft. Check for
wear, if worn replace.
Upper fold Use a rubber reactivator Clean Clean Clean
rollers. alcohol fluid.
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 CHECK POINT INSTRUCTION REFER- 80 000 160 000 240 000
ENCE
Bushing on Under the top cover, use Page 15 Grease Grease Grease
Upper fold grease between the bushing Item 6
rollers. and shaft. Apply grease
between bushings and side
frame. Replace at 160 000.
Fold knife Apply grease on vertical rods. Page 14 Grease
guides (2 pcs.) Item 1
Side jogger Inside the infeed cover, apply Page 14 Grease Grease Grease
movement grease on screw between Item 6
(Only BM 61) jogger linkage and lower
stapler bracket.
V-belt on Belt Check for wear. If worn Page 1.24 Check Check Check/
stacker motor. replace. Item 4 Replace
Transport belts Use a rubber reactivator Page 17 Clean Clean Replace
on Belt stacker. alcohol fluid. Check for wear. Item 2
If worn replace.

CHECK POINT INSTRUCTION REFER- 80 000 160 000 240 000

ENCE
INFEED MODULE BM 61
Infeed wheel Use a rubber reactivator Page 25 Clean Clean Check/
alcohol fluid. Check for wear. Item 8 Replace
If worn replace.
Plastic guide Apply grease between the Page 25 Check Grease Check
included in oblong hole and the metal Item 5
Back jogger pivot pin (4x).
Back jogger Apply a thin layer of silicon Page 25 Check Grease Check
adjustment grease between the Rear Item 3
bracket. jogger bracket and the
bottom frame.

FINAL CHECK POINTS

Side guide Check that the side guides Check/ Check/ Check/
parallelism are parallel according to Adjust Adjust Adjust
REP 3.2 or 3.3.
Booklet quality Check the booklet quality Check/ Check/ Check/
and adjust according to Adjust Adjust Adjust
REP 3.5 - 3.9.

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