Machine Areas
24
Plockmatic PowerSquare™ 224 - Service Training Workbook
Locate the following:
Stitch Axis Home Position Sensor
Stitcher Wire-feed Cam Sensor
Stitch Sensor. Ferrous Metal Sensor.
Stitch Head Jam. Proximity Sensor
Stitch Clutch
Stitch-wire Feed Toggle Clutch
Stitcher Control PCB (900-274)
Stitch Axis Stepper Motor
Perform the following:
4.14.1.1(Remove the Stitch Head)
Disassemble, clean and assemble the G8 Stitch Head.
Refer to the document “G8 Stitch Head Maintenance Kit, Issue 2c”
4.14.1.2 (Fit the Existing Stitch Head)
ADJ 4.6.8 (Check the Stitch Head Alignment Central to the Endlays)
ADJ 4.6.10 (Check and Adjust the Clincher Alignment. Side-to-side.)
ADJ 4.6.11 (Check and Adjust the Clincher Alignment. Front-to-back.)
ADJ 4.6.1 (Check the Stitch Head Axis Calibration)
ADJ 4.6.12 (Set the Clincher Height)
ADJ 4.6.2 (Check the Stitch Head Wire Draw)
ADJ 4.6.4 (Check and Adjust the Wire Straightness)
ADJ 4.6.5 (Adjust the Position of the Cutter Box Assembly)
ADJ 4.6.7 (Check and Adjust the Position of the Wire Holder)
ADJ 4.6.14 (Check and Adjust the Height of the Stitch Sensor)
7.9.1 (Test the Wire-feed Clutch)
Use the RAPs to diagnose and repair the problem created by the trainer.
Machine Areas
Plockmatic PowerSquare™ 224 - Service Training Workbook
25
8.7
Fold and Form
When the shuttle stops in the park position, the folder blade is operated. The
folder blade pushes against the centre line of the book - located by the stitches
- and folds the book in half. The folder blade pushes the book to a calculated
depth between a pair of feed-rollers and into the form clamp.
On each face of the form clamp there is a horizontal, polyurethane strip that
gives a cushioned grip. The polyurethane strip is important for thin books
because the soft surface prevents the stitch cutting through the front and back
covers of the book. Drive for the fold blade is transferred from the main motor by
chain and clutch. The drive is changed from rotary to linear movement by a
crank and connecting rod.
Drive for the spine form clamp is provided by the main motor and transferred to
a drive shaft by a chain and clutch. Adjustment of the fold blade position for
different set thicknesses is made with a 24V DC motor. The fold blade retracts
and the clamp closes on the book.
The form roller rolls along the spine of the book to create the SquareBack book.
The number of spine forms and the pressure applied is calculated by the PSQ
or can be overridden on the touch screen by the operator.
While the book is held by the form clamp, a solenoid operates lifters that raise
the front and back of the book clear of the shuttle. The shuttle can then return to
the gathering area to collect the next book.
The form roller is transported on a carriage that runs along the carriage guide.
The carriage drive is from the main electric motor by a clutch and chain system.
When the carriage reaches the end of the carriage guide, either the LH or RH
limit sensor is operated. If the carriage stops before either of the limit sensors is
reached, a jam is indicated. The form roller is turned by a gear wheel that
engages with a rack. When the spine is formed, the carriage stops at one end of
the carriage guide and the spine form clamp is released. A solenoid is operated
that moves the eject rollers into contact with the book. The eject rollers rotate
and move the book towards the trimmer infeed.
