BM 2000

Plockmatic BM 2000
Booklet Maker
Service Manual 1
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BOOKLET MAKER BM 2000
SERVICE MANUAL
This manual applies to the BM 2000 both in left and right version.
Within this document, all references to right version also apply to the left version
unless specially mentioned.
The difference is basically that the two models are mirrored. All pictures within this manual are of
the right version.
Due to the mirroring, typical Front and Rear designations which normally is viewed from the opera-
tor location has been replaced by Left and Right. Left and Right is viewed from the paper direction.
Clearification:
Left = Rear for right version & Front for left version
Right = Front for right & Rear for left
20 September 2006, Rev 0.01

Subject to change

Page intentionally blank

IMPORTANT SAFETY NOTICES
PREVENTION OF PHYSICAL INJURY
Always connect the equipment to a prop- Never use a ground adapter plug to con-
erly grounded power source. In doubt, have nect the equipment to a power source that
the power source checked by a qualified lacks a ground connection terminal.
electrician.
Never attempt any maintenance function
WARNING: Improper connection of the that is not specifically described in this
equipment grounding conductor can result documentation.
in electrical shock.
Never remove the covers or guards that
Always follow all warnings marked on, or are fastened with screws, unless you are a
supplied with, the equipment. trained Service representative.
Always locate the equipment on a solid Never install the unit near a radiator or any
support surface with adequate strength for other heat source.
the weight of the machine.
Never override or “cheat” electrical or me-
Always exercise care in moving or re- chanical interlock devices.
locating the equipment.
Never operate the equipment if you notice
Always keep magnets and all devices with unusual noises or odors. Disconnect the
strong magnetic field away from the ma- power cord from the power source and call
chine. your customer service engineer to correct
the problem.
1. Before disassembling or assembling parts of the Booklet maker and peripherals.

make sure that the Booklet maker power cord is unplugged,
2. The wall outlet should be near the Booklet maker and easily accessible.
3. Note that some components of the Booklet maker and peripherals are supplied
with electrical voltage even if the main power switch is turned off.
4. If any adjustment or operation check has to be made with exterior covers off or
open while the main switch is turned on, keep hands away from electrical or
mechanically driven components.
OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

1. The Booklet maker and its peripherals must be installed and maintained by a
customer service representative who has completed the training course on those
models.
SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

1. Dispose of replaced parts in accordance with local regulations.
III


TABLE OF CONTENTS
1 INSTALLATION PROCEDURE
BOOKLET MAKER BM 2000BOOKLET TRIMMER FTR 2000SQUARE
FOLDER MODULE SQF 2000.................................................................... 1-1
1.1 INSTALLATION REQUIREMENTS........................................................... 1-1
1.1.1 MINIMUM SPACE REQUIREMENTS.............................................. 1-1
1.1.2 POWER REQUIREMENTS.............................................................. 1-2
1.2 INSTALLATION FLOW CHART................................................................ 1-3
1.2.1 INSTALLATION OF BM 2000............................................................. 1-3
1.2.2 INSTALLATION OF BM 2000 AND FTR 2000.................................... 1-4
1.2.3 INSTALLATION OF BM 2000, FTR 2000 ANDSQF 2000.................. 1-5
1.3 BOOKLET MAKER INSTALLATION......................................................... 1-7
1.3.1 ACCESSORY CHECK..................................................................... 1-7
1.3.2 INSTALLATION PROCEDURE........................................................ 1-8
1.3.3 ADJUSTMENTS............................................................................. 1-17
1.3.4 CONNECTORS.............................................................................. 1-19
1.3.5 CHECK THE INSTALLATION........................................................ 1-20
1.3.6 SYSTEM SETUP.............................................................................. 1-21
1.4 BOOKLET TRIMMER INSTALLATION.................................................. 1-23
1.4.1 ACCESSORY CHECK................................................................... 1-23
1.4.2 INSTALLATION PROCEDURE...................................................... 1-24
1.4.3 ADJUSTMENTS............................................................................. 1-26
1.4.4 DOCKING........................................................................................ 1-28
1.4.5 CONNECTORS.............................................................................. 1-30
1.5 SQUARE FOLDER MODULE INSTALLATION...................................... 1-33
1.5.1 ACCESSORY CHECK................................................................... 1-33
1.5.2 INSTALLATION PROCEDURE...................................................... 1-34
1.5.2.2 Belt Stacker................................................................................... 1-35
1.5.3 ADJUSTMENTS............................................................................. 1-37
1.5.4 DOCKING........................................................................................ 1-39
1.5.5 CONNECTORS.............................................................................. 1-40
2. PREVENTIVE MAINTENANCE SCHEDULE
2.1 PM TABLE................................................................................................ 2-1
3. REPLACEMENT AND ADJUSTMENT
3.1 GENERAL CAUTIONS............................................................................. 3-1
3.2 SPECIAL TOOLS AND LUBRICANTS..................................................... 3-3
3.2.1 SPECIAL TOOLS............................................................................. 3-3
3.2.2 REQUIRED TOOLS......................................................................... 3-4
3.2.3 SYMBOLS USED IN TEXT.............................................................. 3-4
3.3 COVERS................................................................................................... 3-5
3.3.1 FRONT COVER............................................................................... 3-5
3.3.2 REAR COVER................................................................................. 3-6
3.3.3 INFEED COVER.............................................................................. 3-7
3.3.4 OUTFEED COVER.......................................................................... 3-8


3.3.5 BELT STACKER............................................................................... 3-9
3.3.6 PAPER PATH................................................................................. 3-10
3.4 MAIN ASSEMBLIES............................................................................... 3-11
3.4.1 INFEED MODULE.......................................................................... 3-11
3.4.2 INFEED BELT................................................................................ 3-12
3.4.3 INFEED ROLLER SHAFT.............................................................. 3-13
3.4.4 INFEED IDLER ARM ASSEMBLY.................................................. 3-14
3.4.5 IDLER ARM STAPLER AREA........................................................ 3-15
3.4.6 STAPLER CARTRIDGE AND STAPLER HEAD............................ 3-16
3.4.7 STAPLER ASSEMBLY................................................................... 3-20
3.4.8 STAPLER DRIVE, STAPLING POSITION (LOWER)..................... 3-21
3.4.9 STAPLER DRIVE, HOME POSITION (UPPER)............................ 3-22
3.4.10 CLINCHER TIMING....................................................................... 3-23
3.4.11 CLINCHER HEIGHT...................................................................... 3-24
3.4.12 CLINCHER ASSEMBLY................................................................. 3-25
3.4.13 SIDE JOGGER DRIVE................................................................... 3-27
3.4.14 SIDE JOGGER CHANNELS.......................................................... 3-28
3.4.15 REAR JOGGER FINGERS............................................................ 3-31
3.4.16 REAR JOGGER ALIGNMENT....................................................... 3-32
3.4.17 FOLD ROLLER, LOWER............................................................... 3-33
3.4.18 FOLD ROLLER, UPPER................................................................ 3-34
3.4.19 STOP GATE................................................................................... 3-35
3.4.20 FOLD STOP................................................................................... 3-36
3.4.21 PRE-FOLD TRANSPORT BELTS.................................................. 3-38
3.5 SENSORS AND SWITCHES.................................................................. 3-39
3.5.1 Q1 INFEED PAPER PATH............................................................. 3-39
3.5.2 Q2 MANUAL FEEDING START SENSOR..................................... 3-40
3.5.3 Q3 INFEED MOTOR ENCODER (M1)........................................... 3-41
3.5.4 Q4 BACK JOGGER MOTOR HOME SWITCH (M2)...................... 3-42
3.5.5 Q5 BACK JOGGER POSITIONING MOTOR ENCODER (M3)..... 3-43
3.5.6 Q6 SIDE JOGGER MOTOR ENCODER (M4)............................... 3-44
3.5.7 Q7 EDGE STAPLING START CYCLE SENSOR........................... 3-45
3.5.8 Q8 SIDE STAPLING START CYCLE SENSOR............................. 3-46
3.5.9 Q9 STAPLE/FOLD POSITIONING MOTOR ENCODER (M6)....... 3-47
3.5.10 Q10 PRE-FOLD TRANSPORT MOTOR ENCODER (M8)............. 3-48
3.5.11 Q11 FOLD ROLLER MOTOR ENCODER (M9)............................. 3-49
3.5.12 Q12 FOLD SENSOR...................................................................... 3-50
3.5.13 Q13 FOLD STOP POSITIONING MOTOR ENCODER (M11)....... 3-51
3.5.14 Q14 EXIT SENSOR....................................................................... 3-52
3.5.15 Q15 COVER OPEN SENSOR....................................................... 3-53
3.5.16 SW1 BACK JOGGER MOTOR (M11) HOME POS. SWITCH....... 3-54
3.5.17 SW2 STAPLER MOTOR (M5) HOME POS. SWITCH................... 3-55
3.5.18 SW4 STAPLE/FOLD POS. MOTOR (M6) HOME POS. SWITCH....3-56
3.5.19 SW5 FOLD KNIFE MOTOR (M10) HOME POS. SWITCH............ 3-57
3.5.20 SW6 INTERLOCK CIRCUIT..............................................................3-58
3.6 MOTORS................................................................................................ 3-59
3.6.1 INFEED MOTOR M1...................................................................... 3-59
3.6.2 BACK JOGGER MOTOR M2......................................................... 3-60
VI

3.6.3 BACK JOGGER POSITIONING MOTOR M3................................ 3-61
3.6.4 SIDE JOGGER MOTOR M4.......................................................... 3-62
3.6.5 STAPLER MOTOR M5................................................................... 3-63
3.6.6 STAPLE / FOLD POSITIONING MOTOR M6................................ 3-64
3.6.7 STAPLED SET TRANSPORT MOTOR M7.................................... 3-65
3.6.8 PRE-FOLD TRANSPORT MOTOR M8.......................................... 3-66
3.6.9 FOLD ROLLER MOTOR M9.......................................................... 3-67
3.6.10 FOLD KNIFE MOTOR M10............................................................ 3-68
3.6.11 FOLD STOP GATE MOTOR M11.................................................. 3-70
3.6.12 BELT STACKER MOTOR ST-M1................................................... 3-71
3.7 SOLENOIDS........................................................................................... 3-73
3.7.1 SOL1 EDGE STAPLING TRANSPORT SOLENOID...................... 3-73
3.7.2 SOL2/SOL3 STAPLE STOP GATE SOLENOIDS.......................... 3-74
3.7.3 SOL4 STOP GATE SOLENOID..................................................... 3-75
4. TROUBLESHOOTING
4.1 FAULT CODE DESCRIPITIONS.............................................................. 4-1
4.2 BLOWN FUSE CONDITIONS................................................................ 4-33
4.3 LEDS...................................................................................................... 4-35
4.4 TEST POINTS........................................................................................ 4-41
5. SERVICE TABLES
5.1 SERVICE PROGRAM MODE................................................................... 5-1
5.1.1 SERVICE PROGRAM MODE OPERATIONS.................................. 5-1
5.1.2 SERVICE PROGRAM MODE TABLES............................................ 5-4
Check Motors and function.......................................................................... 5-4
5.1.3 NVM RESET.................................................................................. 5-12
5.2 SOFTWARE DOWNLOAD..................................................................... 5-13
5.2.1 Downloading to upper PCB MD6DC B in Booklet maker............... 5-13
5.2.2 Downloading to lower PCB MD6DC C in the Booklet maker......... 5-14
5.2.3 Downloading to PCB CPU in Booklet maker.................................. 5-15
5.2.4 Downloading to PCB UI in the Booklet maker................................ 5-16
5.2.5 Downloading to PCB MD6DC in Trimmer...................................... 5-17
5.2.6 Downloading to PCB MD6DC in Square Fold................................ 5-18
5.3 SELF-DIAGNOSTIC MODE................................................................... 5-19
5.3.1 RUN TIME DIAGNOSTICS............................................................ 5-19
5.3.2 DETAILED SELF-DIAGNOSTIC MODE......................................... 5-19
5.4 PAPER SIZE RESET..................................................................... 5-21
5.5 SQF SERVICE........................................................................................ 5-25
6. DETAILED SECTION DESCRIPTIONS
6.1 ELECTRICAL COMPONENT LIST........................................................... 6-1
6.1.1 CONNECTOR VIEW........................................................................ 6-3
6.1.2 RIGHT VIEW.................................................................................... 6-4
6.1.3 LEFT VIEW...................................................................................... 6-5
6.1.4 OUTFEED VIEW, INNER AND LOWER.......................................... 6-6
6.1.5 PREFOLD TRANSPORT VIEW....................................................... 6-7
6.1.6 CLINCHER AREA VIEW.................................................................. 6-8
6.1.7 INNER VIEW.................................................................................... 6-9
6.1.8 INFEED MODULE VIEW............................................................... 6-10
6.1.9 STACKER MODULE VIEW............................................................ 6-11
VII

6.2 BOARD STRUCTURE............................................................................ 6-13
6.2.1 BLOCK DIAGRAM......................................................................... 6-13
6.2.2 CONTROLLER CPU...................................................................... 6-14
6.2.3 CONTROLLER MD6DC................................................................. 6-15
6.3 BOOKLET MAKING PROCESS............................................................. 6-17
6.3.1 PRINCIPLE OF OPERATION........................................................ 6-17
6.3.2 SIZE ADJUSTMENT...................................................................... 6-19
SPECIFICATIONS
MAJOR SPECIFICATIONS........................................................................Spec-1
QUALITY SPECIFICATIONS......................................................................Spec-1
WIRING
Booklet Maker................................................................................................Wir-1
VIII

20 September 2006, Rev 0.01 INSTALLATION REQUIREMENTS
1 INSTALLATION PROCEDURE
Installation
BOOKLET MAKER BM 2000
TRIMMER FTR 2000
SQUARE FOLDER SQF 2000
1.1 INSTALLATION REQUIREMENTS
1.1.1 MINIMUM SPACE REQUIREMENTS
892 mm 360 mm 360 mm 645 mm

35 1/8” 13 3/4 ” 13 3/4 ” 25 13/32 ”
680 mm
26 25/32”
400 mm
Stacker 15 3/4 ”
BM 2000 FTR 2000 SQF 2000
555 mm
21 7/8”
2257 mm
88 7/8 ”
1-1

INSTALLATION REQUIREMENTS 20 September 2006, Rev 0.01
1.1.2 POWER REQUIREMENTS
WARNING
1. Make sure that the wall outlet is near the main machine and easily
accessible. Make sure the plug is firmly inserted in the outlet.
2. Avoid multi-wiring.
3. Be sure to ground the machine.
1. The input voltage level and the permissible voltage fluctuation are as follows:

100 V AC ± 10 %
110 V AC ± 10 %
6 %
120 V AC + - 13 %
8 A 50-60 Hz

127 V AC ± 10 %
220 V AC ± 10 %
4 A 50-60 Hz
230 V AC ± 10 %
2. Never place anything on the power cord.
1-2

20 September 2006, Rev 0.01 INSTALLATION FLOW CHART
1.2 INSTALLATION FLOW CHART
Installation
The following flow charts show how to make the installation more efficient.
1.2.1 INSTALLATION OF BM 2000
Unpack BM 2000 according to unpacking procedure

Step 1
Unpacking
Make the accessory check for BM 2000 ( 1.3.1)
Step 2
Removing Remove covers from BM 2000 ( 1.3.2.1)
covers
Step 3 Install User Interface ( 1.3.2.2)

Mechanical
adjustments.
Adjust the BM 2000´s height ( 1.3.3)
Step 4 Connect the cables of the BM 2000 ( 1.3.4)

Electrical
connections
Make sure to connect the Beltstacker cable to the FTR 2000
Step 5
Complete Check the Installation
installation
FTR 2000 Trimmer: Enables On-line trimming. Especially thicker sets

( > 4 sheets) look unprofessional because of ”creep”.
FTR 2000 will trim those edges (up to 16 mm / 5/8”).
SQF 2000 Square Folder: Enables the possibility to give the booklets the
perfect bound look.
1-3

INSTALLATION FLOW CHART 20 September 2006, Rev 0.01
1.2.2 INSTALLATION OF BM 2000 AND FTR 2000
Unpack BM 2000 and FTR 2000

Step 1
Unpacking
Make the accessory check for BM 2000 ( 1.3.1) and FTR
2000 ( 1.4.1)
Step 2 Remove covers from BM 2000 ( 1.3.2.1)

Removing
covers
Remove covers from FTR 2000 ( 1.4.2.1)
Install User Interface ( 1.3.2.2)
Adjust the height of the FTR 2000 ( 1.4.3)

Step 3
Mechanical
adjustments Make sure the FTR 2000 is parallel to the BM 2000
Dock the FTR 2000 to the BM 2000 ( 1.4.4)
Install the Beltstacker on FTR 2000
Connect the cables of the BM 2000 ( 1.3.4) and the FTR

Step 4
2000 ( 1.4.5)
Electrical
connections
Make sure to connect the Beltstacker cable to the FTR 2000
Step 5
installation
1-4

20 September 2006, Rev 0.01 INSTALLATION FLOW CHART
1.2.3 INSTALLATION OF BM 2000, FTR 2000 ANDSQF 2000
Installation
Unpack BM 2000, FTR 2000 andSQF 2000 according to
Step 1 unpacking procedure
Unpacking
Make the accessory check for BM 2000 ( 1.3.1), FTR
2000 ( 1.4.1) andSQF 2000 ( 1.5.1)
Remove covers from BM 2000 ( 1.3.2.1)
Step 2
Removing Remove covers from FTR 2000 ( 1.4.2.1)
covers
Remove covers fromSQF 2000 ( 1.5.2.1)
Install User Interface ( 1.3.2.2)
Adjust the height of the FTR 2000 ( 1.4.3)
Make sure the FTR 2000 is parallel to the BM 2000
Step 3
Mechanical Dock the FTR 2000 to the BM 2000 ( 1.4.4)
adjustments
Adjust the height of theSQF 2000
Make sure the FTR 2000 is parallel to theSQF 2000
Dock theSQF 2000 to the FTR 2000 ( 1.5.4)
Install the Beltstacker onSQF 2000
Step 4 Connect the cables of the BM 2000 ( 1.3.4),

Electrical FTR 2000 ( 1.4.5) and theSQF 2000 ( 1.5.5)
connections
Make sure to connect the Beltstacker cable to theSQF 2000
Step 5
installation
1-5


20 September 2006, Rev 0.01 BOOKLET MAKER INSTALLATION
1.3 BOOKLET MAKER INSTALLATION
Installation
1.3.1 ACCESSORY CHECK
[A] [B] [C] [D] [E]
Check the quantity and condition of the accessories in the box against the following list:
Description Q’ty
A. Power cord EUR and US...................................................... 2
B. Terminator plug, will always be installed onto BM 2000........ 1
C. Terminator plug FTR 2000.................................................... 1
D. Interlock Jumper, will always be installed onto BM 2000 ..... 1
E. Interlock Jumper FTR 2000................................................... 1
1-7

BOOKLET MAKER INSTALLATION 20 September 2006, Rev 0.01
1.3.2 INSTALLATION PROCEDURE

1.3.2.1 Removal of covers
Front cover
[B]
[A]
Removal
1. Open the top cover.
2. Lift up the front cover according to arrow [A] and slide it out according to arrow
[B].
Replacement
1. Reverse the removal procedure.
NOTE: Please note that the front castors might need to be turned inwards to allow
the cover to be fitted.
WARNING
Cover is very heavy and could cause injury if it falls down.
1-8

Rear cover
Installation
[A]
Removal
1. Open the top cover.
2. Loosen the screw [A] ( x 1) for the rear cover.
3. Lift up about 10 mm and remove the rear cover.
Replacement
WARNING
Cover is very heavy and could cause injury if it falls down.
1-9

In-feed cover
[B]
[D] [C]
Removal
NOTE: The in-feed cover only has to be removed if the input voltage level has to
be changed, the default value is 230 V.
1. Remove front cover and rear cover.
2. Loosen the screws [B] ( x 2) a few turns.
3. Remove screw [C] ( x 1) and place it in the other hole [D].
4. Remove the cover.
Replacement
1-10

1.3.2.2 Installation of User Interface (UI)
Installation
[B]
[A]
1. Unpack the UI.

2. Connect cables [A] and [B] according to picture above.
1-11

[C]
3. Assemble the UI to the Booklet Maker.

4. Tighten the screws [C] ( x 2).
1-12

1.3.4 CONNECTORS
Installation
1. Connect the Belt Stacker cable to the connector [B] ( x 1).
NOTE: Unless Trimmer FTR 2000 and/or Square Folder SQF 2000 will be
installed. If so, the Belt Stacker cable will be connected to the last
module in the system.
[B]
2. Install the Terminator plug [C] and the Interlock jumper [G].
3. Install the Terminator plug [D] and the Interlock jumper [F].
4. Connect the power cord to the connector [E] on the Booklet Maker ( x 1).
[A] [G] [C] [F] [D] [E]
[C], [D] [F], [G]
1-13

1.3.5 CHECK THE INSTALLATION
1. Power on the Booklet Maker.

2. Do the system setup according to section ( 1.3.6 ).
3. Remove the two Stapler heads, according to section ( 3.4.6 ) in the
Service manual.
4. Perform a Detailed self-diagnostic, according to section ( 5.3.2 ) in the
Service manual.
5. Reinstall the two Stapler heads, according to section ( 3.4.6 ) in the
Service manual.
6. Set up the Booklet Maker to A4/8.5 x 11”.
7. Feed a A4/8.5 x 11” set to the Booklet Maker.
8. Check for the correct feeding of the paper.
NOTE: If paper is not fed correctly, check adjustment of the Booklet Maker ac-
cording to section ( 1.3.3 ).
9. Feed a A3/11 x 17” set to the Booklet Maker.
10. Check for the correct feeding of the paper.
NOTE: If paper is not fed correctly, check adjustment of the Booklet Maker ac-
cording to section ( 1.3.3 ).
1-14

1.3.6 SYSTEM SETUP
Installation
NOTE: If software is installed for the first time the system setup screen (step 5) is
shown when power on.
1. Enter admin mode by

pressing Admin button.
2. Enter Service mode by

scrolling down to Serv-
ice using arrow down
and then press enter.
3. Enter the service code

and press enter.
1-15

4. Enter the system setup

by pressing the system
setup button
5. Choose system setup.
NOTE: do not change

the address between
the “()”.
Press enter to save and

exit system setup.
6. Enter the admin mode,

scroll down to Standard
Paper Size and press
enter to change the pa-
per size standard.
7. Set the correct region.
Press enter to save and

exit.
Press the button
to return to the main
screen
1-16

20 September 2006, Rev 0.01 TRIMMER INSTALLATION
1.4 TRIMMER INSTALLATION
Installation
[A] [B]
Check the quantity and condition of the accessories in the box against the follow-
ing list:
NOTE: - The Installation Box is located in the trim bin on the Trimmer.
- The trim bin is tie wrapped on the rear side.
Description Q’ty
A. Communication cable between the Booklet Maker..................... 1
and the Trimmer (1.6 m/63”)
B. Power cord between the Booklet Maker and Trimmer................ 1
1-17

TRIMMER INSTALLATION 20 September 2006, Rev 0.01

Front Cover
1. Open the Top Cover.
2. Remove screw [A] ( x 1)
3. Lift cover upwards to unhook [A]
cover at the lower end [B].
[B]
[C]
[D]
Rear Cover
2. Remove screw [C] ( x 1).
Similarly located as for the
Front Cover.
3. Lift cover upwards to unhook
cover at the lower end [D].
1-18

1.4.2.2 Removing the Belt Stacker
Installation
[A]
Booklet Maker
[B]
1. Disconnect the Belt Stacker cable [A] ( x 1).

2. Remove screws [B] ( x 2).
3. Lift the Belt Stacker according to arrow.
4. Remove Belt Stacker from the Booklet Maker.
1-19

1.4.3 ADJUSTMENTS
Height adjustment
[A] [B]
[C]
1. Adjust the height of the Trimmer, so that the docking bracket [A] on the Trim-
mer fits in the docking hole [B] on the Booklet Maker (one revolution on the
nuts is 1.5 mm / 1/16” in height). Adjust by turning the castors [C] on the Trim-
mer with the Castor Wrench.
NOTE: Make sure that the Ground plate on the docking bracket [A], is
grounded correctly.
1-20

Installation
[E]
[D]
2. Looking from behind the system, make sure that the Trimmer is parallel to the
Booklet Maker [D] ± 2 mm. If necessary, adjust by turning the two nuts [E] on
the outfeed side of the Trimmer.
1-21

1.4.4 DOCKING
Docking procedure
[B]
Trimmer interior towards

[D] [A] [D] Booklet Maker
[C]
1. Loosen nuts [A] to the Locking bracket [B] ( x 2).

2. Dock the Trimmer to the Booklet Maker.
3. Secure the Trimmer by lifting the Locking bracket [B] and tightening nuts [A] (
x 2).
NOTE: Make sure that the Trimmer locking bracket [B] locks in the outer slot
[C] on the positioning pin.
1-22

Install Belt Stacker
Installation
Trimmer
[A]
1. Loosen screws [A] ( x 2) on the Trimmer.

NOTE: Unless the Square folder SQF 2000 will be installed. If so, the Belt
Stacker will be installed on to the Square folder instead.
2. Install the Belt Stacker on to the Trimmer.
3. Secure the Belt Stacker with the screws [A] ( x 2).
1-23

1.4.5 CONNECTORS
1. Connect the Belt Stacker cable to the Trimmer connector [A] ( x1).
NOTE: Unless a Square folder SQF 2000 also will be installed. If so, the Belt
Stacker cable will connected to the Square Folder instead.
2. Move Terminator plug from connector [B] to connector [C] ( x 1).
3. Remove the Interlock jumper [D] from the Booklet Maker ( x 1).
4. Connect the communication cable to the Trimmer [F] ( x 1).
NOTE: The communication cable you received with the Trimmer.
5. Connect, the other end of the communication cable, to the Booklet Maker [B]
( x 1).
6. Connect the power cord to the Trimmer [E] ( x 1).
7. Connect, the other end of the power cord, to the Booklet Maker [D] ( x 1)
8. Route cables through the cable holders in the Booklet Maker and Trimmer.
[D] [B]
[E] [F] [C] [A]
[D]
1-24

Installation
1. If installing a Square Folder SQF 2000, continue to section
( 1.5 ) otherwise continue with step 2.
4. Press the Admin button.
5. Scroll down to Service and press the Enter button.
6. Key in the Password.
7. Select PL77000.
8. Scroll down to NVM Values and press the Enter button.
9. Scroll to Index 1, Trim Zero, and press the Change button.
10. Key in the Index 1 value [A] written on the sign in the Trimmer.
[A]
Trimmer interior towards Booklet Maker
11. Press the OK button.

Service manual.
13. Perform a Detailed self-diagnostic, according to section ( 5.3.2 ) in the
Service manual.
Service manual.
1-25

15. Check that the Booklet Maker is set to Staple ON.

16. Set up the Trimmer to Trimmer ON.
17. Set up the Booklet Maker to A4/8.5 x 11.
18. Feed a A4/8.5 x 11” set to the Booklet Maker system.
19. Check for the correct feeding of the set from the finisher.
NOTE: The paper should enter in the middle of the infeeder. If not, adjust the
Booklet Maker according to section ( 1.3.3 ).
20. Check if the set has been trimmed correctly.
21. Feed a A3/11 x 17” set to the Booklet Maker system.
23. Check if the set has been trimmed correctly.
1-26

20 September 2006, Rev 0.01 SQUARE FOLDER INSTALLATION
1.5 SQUARE FOLDER INSTALLATION
Installation
[A] [B] [C] [D]
Check the quantity and condition of the accessories in the box against the following list:
Description Q’ty
1
A. Communication cable (1.1 m / 43 /3”)................................... 1
B. Power cord ........................................................................... 1
C. Washer and screw ............................................................... 2
D. Ground strap and screw . ..................................................... 1
1-27

SQUARE FOLDER INSTALLATION 20 September 2006, Rev 0.01

Front Cover
2. Remove screw [A] ( x 1).
3. Lift and remove cover.
[A] [B]
Rear Cover
2. Loosen screw [B] ( x 1).
3. Close Top Cover.
4. Lift up and remove Rear
Cover.
1-28

1.5.2.2 Belt Stacker
Installation
Remove the Belt Stacker
Trimmer Trimmer
[C]
[A]
[D]
[B]
Trimmer, inside view
1. Disconnect the Power cord to the Booklet Maker ( x 1).

2. Disconnect the Belt Stacker cable ( x 1) from the Trimmer.
3. Lift the Belt Stacker according to arrow.
4. Remove the Belt Stacker from the Trimmer.
6. Remove the positioning pins from the upper holes [A], used for the Belt Stack-
er ( x 2).
7. Using the lower hole [B], install the Ground strap to the inside of the position-
ing pin [D] using the washer and screw provided, ( x 1, x 1).
8. Install the other end of the ground strap to the rear frame [C] ( x 1 torx).
9. Using the second lower hole, install the other positioning pin, using the washer
and screw provided ( x 1, x 1).
1-29

Installing Belt Stacker
Square Folder
[A]
1. Loosen screws [A] ( x 2) on the Square Folder.

2. Install the Belt Stacker on to the Square Folder.
3. Secure the Belt Stacker by tightening screws [A] ( x 2) on the Square Folder.
1-30

1.5.3 ADJUSTMENTS
Installation
Height adjustment
[B] [A]
Square Folder Trimmer
Square Folder, front view

[C]
1. Adjust the height of the Square Folder, so that the positioning pins [A] on the
Trimmer fits in the docking holes [B] on the Square Folder. Adjust by turning
the castors [C] on the Square Folder with the Castor Wrench (one revolution
on the nuts is 1.5 mm in height). Adjust on the front and rear side.
1-31

Parallellity adjustment
[E] [D]
2. Looking from behind the system, make sure that the Square Folder is parallel
to the Trimmer [D] ± 2 mm. If necessary, adjust by turning the two nuts [E] on
the outfeed side of the Square Folder .
1-32

1.5.4 DOCKING
Installation
Docking procedure [B]
Square Folder interior, view

towards Belt Stacker
[D] [A] [D]
[C]
1. Loosen nuts [A] to the Locking bracket [B].

2. Dock the Square Folder to the Trimmer.
3. Secure the Square Folder by lifting the Locking bracket [B] and tightening nuts
[A] ( x 2).
NOTE: Make sure that the Square Folder locking bracket [B] locks in the outer
slot [C] on the positioning pin [D].
1-33

1.5.5 CONNECTORS
[A]
[B]
[C]
Trimmer
Square Folder
1. Move the Belt Stacker cable [A] to the Square Folder ( x 1).
NOTE: Do not connect the Belt Stacker cable [A] to the Trimmer.
2. Move the Terminator plug from the Trimmer com port [C] to the Square Folder
com port [B] ( x 1).
3. Install the Communication cable [C] between the Trimmer and the Square
Folder ( x 1).
4. Route cables through the cable holders in the Booklet Maker, Trimmer and
Square Folder.
1-34

Installation
3. Press the Admin button.
4. Scroll down to Service and press the Enter button.
5. Key in the Password.
6. Scroll down to NVM Values and press the Enter button.
7. Scroll to Index 1, Trim Zero, and press the Change button.
8. Key in the Index 1 value [A] written on the sign in the Trimmer.
[A]
Trimmer interior, view towards

Booklet Maker
9. Press the OK button.

Service manual.
11. Perform a detailed self-diagnostic, according to section ( 5.3.2 ) in the
Service manual.
Service manual.
13. Check that the Booklet Maker is set to Staple ON.
14. Set up the Trimmer to Trimmer ON.
15. Set up the Square Folder to Auto mode.
1-35

16. Set up the Booklet Maker to A4/8.5 x 11”.

17. Feed a A4/8.5 x 11” set to the Booklet Maker system.
19. Check if the sets have been trimmed and square folded correctly.
20. Feed a A3/11 x 17” set to the Booklet Maker system.
22. Check if the sets have been trimmed and square folded correctly.
1-36

20 September 2006, Rev 0.01 PM TABLE
2. PREVENTIVE MAINTENANCE SCHEDULE

2.1 PM TABLE
NOTE: Amounts mentioned as the PM interval indicate the number of sets.
CAUTION
Maintenance
If any of the checkpoints or other parts show indication of wear at any
Preventive
point, replace the part. When lubricating, clean the surface if necessary
before applying new lubricant.
Symbol key: C: Clean, R: Replace, L: Lubricate, I: Inspect
BM 2000 250K 500K NOTE REFERENCE

Paper paths C C Blower Brush
Sensors C C Blower Brush
Stapler assembly
Clinchers (2x) L L Oil, Every 20K 3.4.12
Drive bars (2x) L L Grease 3.4.11
Stapler heads (2x) R R Inspect, Replace if 3.4.6
needed
Stapler Drive Bar L L Silicon grease 3.4.8
Stapler drive chain L L Oil
Folder assembly
Fold knife drive bars L L Silicon grease
(2x)
Fold stop bars (2x) L L Grease
Length adjustment L L Grease 3.6.20
shaft
Drive
Drive chains L L Oil 3.6.17, 3.6.20
Fold roller chains L L Oil 3.6.17, 3.6.20
2-1

PM TABLE 20 September 2006, Rev 0.01
FTR 2000 250K 500K NOTE REFERENCE

Paper paths C C Blower Brush
Sensors C C Blower Brush
Infeed module
Infeed belts (4x) C R Alcohol 3.2.20
Outfeed module
Upper outfeed belts C/ I C/ I Alcohol 3.2.15
(2x)
Lower outfeed belts C/ I C/ I Alcohol 3.2.14
(2x)
Trim Knife
Trim knife I I Inspect 3.2.8
Drive
Knife chain L L Oil 3.2.19
Knife support chain L L Oil 3.2.18
Transmission chain / L/ I L/ I Oil 3.2.17
Chain sprockets
Gear rack L L Grease 3.2.12
SQF 2000 250K 500K NOTE REFERENCE

All machine, paper C C Blower brush.
path etc.
Sensors. C C Blower brush.
Transport belt. C/I/R C/I/R Alcohol. 3.4.1 & 3.4.2
Pressure roller. I/R I/R Inspect O-rings and 3.2.4
pressure roller*.
Change position of
wear point of pressure
roller. Replace Com-
plete assy if needed.
Link Arms for I/R I/R Inspect Link Arms 3.5.1
Clamps. for wear. Replace if
needed.
Lower Clamp L L Check that the lower 3.5.1
Clamp moves, when
pressed by upper
Clamp. Ball bearing
grease
Upper Clamp L L Ball bearing grease 3.5.1
Brass Guides L L Ball bearing grease 3.5.1
Teflon Tape I/R I/R Inspect, Replace if 3.4.3
needed.
Dampers R R Replace dampers. 3.5.2
Adjust stop gate
* To prevent flatness of pressure roller.
2-2

BM 2000

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Plockmatic BM 2000

20 September 2006, Rev 0.01

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1. Before disassembling or assembling parts of the Booklet maker and peripherals.

OBSERVANCE OF ELECTRICAL SAFETY STANDARDS

SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL

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892 mm 360 mm 360 mm 645 mm

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1.1.2 POWER REQUIREMENTS

2. Never place anything on the power cord.

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1.2 INSTALLATION FLOW CHART

1.2.1 INSTALLATION OF BM 2000

Unpack BM 2000 according to unpacking procedure

Step 3 Install User Interface ( 1.3.2.2)

Step 4 Connect the cables of the BM 2000 ( 1.3.4)

FTR 2000 Trimmer: Enables On-line trimming. Especially thicker sets

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1.2.2 INSTALLATION OF BM 2000 AND FTR 2000

Unpack BM 2000 and FTR 2000

Step 2 Remove covers from BM 2000 ( 1.3.2.1)

Install User Interface ( 1.3.2.2)

Adjust the BM 2000´s height ( 1.3.3)

Adjust the height of the FTR 2000 ( 1.4.3)

Dock the FTR 2000 to the BM 2000 ( 1.4.4)

Install the Beltstacker on FTR 2000

Connect the cables of the BM 2000 ( 1.3.4) and the FTR

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1.2.3 INSTALLATION OF BM 2000, FTR 2000 ANDSQF 2000

Remove covers from BM 2000 ( 1.3.2.1)

Install User Interface ( 1.3.2.2)

Adjust the BM 2000´s height ( 1.3.3)

Adjust the height of the FTR 2000 ( 1.4.3)

Make sure the FTR 2000 is parallel to the BM 2000

Make sure the FTR 2000 is parallel to theSQF 2000

Dock theSQF 2000 to the FTR 2000 ( 1.5.4)

Install the Beltstacker onSQF 2000

Step 4 Connect the cables of the BM 2000 ( 1.3.4),

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1.3 BOOKLET MAKER INSTALLATION

[A] [B] [C] [D] [E]

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1.3.2 INSTALLATION PROCEDURE

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1.3.2.2 Installation of User Interface (UI)

1. Unpack the UI.

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3. Assemble the UI to the Booklet Maker.

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[A] [G] [C] [F] [D] [E]

[C], [D] [F], [G]

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