Routine Maintenance
30
Plockmatic PowerSquare™ 224 - Service Training Workbook
9.
Routine Maintenance
9.1
Operator Maintenance
Operator maintenance is documented in Chapter 6 of the user manual and in
Section 6.17 of the PSQ Service Manual.
Operator Maintenance Plan
Perform these tasks:
Lubricate the stitch head (operator lubrication).
Clean the former roller.
Clean the trimmings-removal fingers.
Clean excess grease from the stitch head.
9.2
Technical Maintenance
Technical Maintenance is documented in the Service Manual (see 1.5 “Routine
Maintenance”).
The recommended service interval is every 6 months.
In addition, after 1 million stitches or 3 spools of stitch-wire the stitch head must
be disassembled and inspected for wear. There is a kit of replacement parts for
this procedure:
• G8 Stitch Head Maintenance Kit, Part No. 914-880
9.3
Care Pack
The PowerSquare is shipped with a care pack of essential spare parts.
If spare parts are used, the care pack must be replenished. Order forms are
included in the care pack.
Interval
Task
• Every week
Clean the machine.
• Every month
or
• When a new stitch-wire is installed
if this interval is shorter
or
• When the message
OPERATOR
MAINTENANCE
is displayed on the
screen.
Lubricate the stitch head.
Clean the former roller.
Clean the polyurethane strips in the form
clamp.
Clean the trimmings-removal fingers.
Clean excess grease from the stitch head
Machine Areas
Plockmatic PowerSquare™ 224 - Service Training Workbook
19
8.
Machine Areas
8.1
Introduction
During this section of the training, we review the different areas of the machine,
and the key set up procedures for each area. See Section 7.4 in the Service
Manual for the location of components.
The Axis Calibration of the PSQ is critical to the quality of the books it will
produce. Performing these procedures ensures all of the sub-assemblies are in
correct alignment to each other.
Note:
Areas marked with red paint are Factory Settings only. You must not
change this setting unless instructed to do so as part of a Call Escalation.
8.2
Connecting Bridge
The paper transport belts are driven by a brushless 3-phase motor with dedi-
cated controller. The rotate axis is adjusted by a 24V DC Axis Motor.
The Bridge Drive motor runs when the PSQ starts.
The sheets are transported under 2 Optical Sensors. The first Optical Sensor is
located at the Bridge Infeed, and the second Optical Sensor is located at the
entrance to the Gathering Area.
If the time between the sheets passing under the Bridge Infeed Sensor to the
Gathering Area Flow Sensor is more than a pre-calculated time, a jam will be
indicated.
Locate the following in the Connecting Bridge (Top):
Uplift cover switch
DFA Interface PCB (900-218)
Rotate Axis Motor Control PCB (900-212)
DFA Connect PCB (900-284)
Locate the following in the Connecting Bridge (Bottom):
Bridge Infeed Optical Sensor
Rotate Axis Home Switch
Rotate Axis Motor
Bridge Drive Motor
Minas bridge Motor I/F PCB (900-270)
Minas motor controller
Perform the following tasks:
ADJ 4.4.1 (Calibrate the Rotate Axis)
6.19.2 (Manual Operation of Machine Axes from Axis Control PCBs)
