Doc.

ID #:
NORCOM INC. STANDARD OPERATING PROCEDURE
Operation Name: Wire Head Setup Written by: Rev. Date:

C.T.:

Equip No. / Line: Machine #8, #17 Part No. / Name:

# Main Step Operation Analysis Photo Q S E Key Point

1 Get a quality Inspect for punch dots, slip ✓ Having a known
book sheets, punch holes lined up, good book to
and smooth, even cuts start with is
throughout the book. critical to all the
steps that
follow.

2 Set infeed Jog drum around till drum ✓ Make sure the
plate height stops and verify that infeed infeed plate is
plate and bottom pocket plate level with the
are aligned with each other. pocket plate all
the way across.

If the infeed plate is NOT level

with the pocket, loosen lock
collar and turn handle to
position infeed plate level with
pocket plate. Tighten lock
collar.

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# Main Step Operation Analysis Photo Q S E Key Point
If the infeed plate is not level
with the pocket all the way
across, adjust the infeed
leveling control arms until the
plate is level.

3 Set infeed Jog machine till infeed pins are ✓ Pins need to be
pin height all the way down and all the straight and
way forward (toward drum) perpendicular
and check that the infeed pins to the infeed
are level with the infeed plate. plate.

If pins are not straight, either

bend them or replace them.

4 Set infeed Verify that infeed control arm Make sure

drive is touching the stop collar. infeed is all the
position way down and
forward.
If not, loosen control arm bolt
and move control arm to lock
collar, then tighten bolt.

Verify that the distance

between the infeed carriage
and front frame piece is the
same.

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# Main Step Operation Analysis Photo Q S E Key Point
Verify cam follower is touching Make sure
the drive cam. If not, loosen infeed is all the
the cam follower control arm way down and
bolt and set the cam follower forward.
on the cam, then tighten the
bolt.

Ensure lift rod bearings are Make sure

touching the lift rails on both 5mm gap
infeed is all the
sides, and there’s a 5mm gap way down and
between the infeed carriage forward.
and crossbar.

If not, place 5mm allen wrench

between infeed carriage and
crossbar, loosen 10mm bolt
and push cam follower down
till it touches the lift rail, then
tighten 10mm bolt.

Adjust cover pressure plate so

front side is 1/16th of an inch Pressure
above infeed plate. plate

5 Verify Place a book against infeed The operator

alignment of pushers to check alignment side rails should
infeed and verify book slides stay in place
pushers and between rails with little to no and any
rails resistance. adjustment
should be made
on gear side.

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# Main Step Operation Analysis Photo Q S E Key Point

6 Set infeed Jog machine till infeed is all

position the way down and forward.

Ensure infeed pins are aligning If pushers are

to enter the center of the wire too tight, it may
holes. rip the wire
holes on the
back stroke.
Check that the brass pushers
are just touching the back of
the book. If not, adjust brass
pushers.

Jog infeed all the way down

and forward and set infeed
fingers so they just touch
cover.

7 Pocket Jog the machine forward till ✓ Infeed pins

clamp timing the pocket clamp closes. should not pull
on the wire
holes in the
Continue to jog and verify that
book on the
the infeed pins raise and the
return stroke of
infeed carriage backs out.
the infeed
assembly.

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# Main Step Operation Analysis Photo Q S E Key Point
8 Align hooks Loosen the two 13mm bolts If hooks align
on the hook mount bar with hole of
located on the gear side of notebook
machine and slide the hook proceed to step
mount bar side to side to align 11.
the hooks with the holes of
the book. Tighten bolts.
If hooks will
not align with
the holes in the
notebook then
proceed to step
9.

9 Setting up Jog machine till the hooks are Hook Mount Bar
hook down and closed. Remove
assemblies hook mount bars then bolt
into the hook alignment jig
Loosen all the hook mounts
before installing into the
alignment jig.

Hook Alignment Jig

Align hooks into the slots of jig

and tighten all the holders,
then reinstall the hook mount
bar into the wire head. Repeat
this step for the other hook
mount bar.

10 Align hooks If needed, loosen the two

13mm bolts on the hook
mount bar located on the gear
side of machine and side the
hook mount bar side to side to
align the hooks with the holes
of the book. Tighten bolts.

11 Setting the Set the former depth so that

formers they just touch the book at
their lowest point by adjusting
the linkage rod.

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# Main Step Operation Analysis Photo Q S E Key Point
12 Align book Jog machine around till the If the hooks
to the coiling book is in the coiling section need to be
tool and the guides are fully closed. raised or
The book needs to be level lowered, go
with the top of the back back and verify
guides. To reposition the book the infeed
to the guides, raise or lower position. Adjust
the hooks as needed. as needed.
13 Adjust hook Place tool in adjustment shaft You must hold
height and hold while loosening the adjustment
lock bolts on both sides of the shaft in place.
hook assembly and rotate
adjustment shaft to position
the hooks to the needed
height.

Tighten lock bolts while

holding adjustment shaft in
position.

14 Position the Jog machine till a book is at

front and the coiling station and the
back wire guides are closed. Raise top
guides to the guide about an inch. Lift front
book guide and verify the back
guide slots are aligned with
the book holes. If needed,
loosen guide mount bolts and
move guide till properly
aligned. Repeat this step for
the front guide by lifting the
back guide.

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# Main Step Operation Analysis Photo Q S E Key Point
15 Setup the Loosen lock down bolt and Make sure wire
pre-cut knife slide back wire motor. motor stop
collar is
touching wire
CHECK THIS…. What about the
motor mount
wire guide bearing assy?
before moving
wire motor.

Check pre-cut knife position ✓ Wire must be in

verifying wire is centered in the center of
the pre-cut knife hole. the pre-cut
knife hole.
Otherwise the
What if it needs to be
wire will rub
adjusted?
against the pre-
cut knife,
causing metal
dust buildup,
and pitch
variation which
will lead to mis-
wired books.
Slide wire motor back in till it
touches the stop and tighten
the lock down bolt.

PUT WIRE GUIDE BEARING

ASSY BACK

16 Check wire Jog machine around till the The reason for
pitch guides are all the way open. feeding 3 to 4
Using spiral motor, jog to feed feet of wire is
out 3 to 4 feet of coiled wire, to simulate
cut off. Then feed out another operating
coiled wire long enough to conditions for
check the pitch against a pitch.
notebook cover.

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# Main Step Operation Analysis Photo Q S E Key Point
The pitch of the wire should
be smaller than the hole
pattern of the notebook.
Measure the pitch by placing
the coil on a cover of a book.
The coil should be 1 to 2 holes
smaller than the book.
The pitch is adjustable by
loosening the 1st handle and
turning the knob located
1st
above the wire motor. To Handle
make the pitch smaller, turn
the knob clockwise. Turning
the knob counterclockwise will
make the pitch larger.

Check wire Hand turn the wire motor

motor drive belt to verify the wire
position does not rub the pre-cut knife
and that the second coil aligns
with the center of the first
hole of the book. Continue
manually feeding wire to
verify the wire feeds through
at least 5 holes.

If needed, loosen wire motor

stop collar and move motor
until wire aligns with the first
hole of the book.

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# Main Step Operation Analysis Photo Q S E Key Point
17 Position the Shoot wire through a book,
top wire then lower the top wire guide
guide till it just touches the wire coil.
Adjust the top guide side to
side so the pins are centered
between the coil loops.

18 Set wire Set wire motor speed and

length counter so that the book is
wired fully and three coils
extend past the end of the
book.

19 Verify the Place a coil in the coil lock and

coil lock is activate by hand to check if
working coil lock is working.

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# Main Step Operation Analysis Photo Q S E Key Point
20 Check coil Jog a coiled book around to
lock the coil lock station until the
alignment coil locks are within ½ an inch
of the wire coil.

Push coil locks towards book

by hand and verify alignment
with coil of the book.

21 Set If needed, loosen bolts and

alignment of slide coil lock fixture to align
coil locks coil lock with wire in book.

Retighten bolts.

22 Set coil lock Jog machine till coil lock

depth touches the book.

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# Main Step Operation Analysis Photo Q S E Key Point
Place coil lock stop mount on Coil lock stop
Washer
coil lock shaft, ensuring the bolt should not
shaft is fully in the stop Coil lock move the coil
mount, touching the washer, stop mount lock, but just
then tighten mount bolt. Then touch the
turn coil lock stop bolt by hand frame.
till it touches machine frame.

Perform this step on one coil Coil lock stop

bolt touching
lock only. Only when that coil the machine
lock is setup correctly, should frame
you setup the second coil lock.

23 Pull out Jog machine till pull out

wheel setup wheels are closed with no
book in them.

Verify bottom pull out wheels

align with the cut outs of
pockets, then verify top pull
out wheels line up with
bottom pull out wheels.
Loosen front pull out wheels ✓ Check books
and set them on the back pull after pull out
out wheels evenly then for marks.
tighten mount bolts.

ADD BOTTOM PULL OUT

WHEEL ADJUSTMENT FOR
TIGHTNESS.

24 Verify wire Run machine and check the

head setup quality.

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