Standard FRN-6 & SRN-9x Numbering Machines
Contents
1. S9 340HO 99 HOLIMS dOLS Control 19 HOLIMS quvno ION 80 TATWA NOILOnS DDDDDDDDDDDDDDDO Suct ngados 318Vv9 H3 LLINSNVH L OL NOLLO3NNOO 19341A 8 v8 HOLIMS 340 NO N33HOS 318vO H3AI3O3H OL NOLLO3NNOO 193410 SNIH3SITIN Od OL On NYHL SS399v ELIHM 318VO H3AI3O3H OL NOLLO3NNOO 193410 019 HOLO3NNOO HOSN3S v 60 HOSN3S NOILVLOY SS HOLIMS vy 8 HILMO NV OLNY ov Ww oF Sr ev SIHOLIMS SYOLOANNOO iagram D iring W ROTARY Section 17 CONTROL SYSTEM SUCTION SERVICE PAGE 56 MANUAL CONTROL SYSTEM SUCTION Section 17 17 2 Control System Access Access to the control box is by removing the base access panel under the loading table To remove the unit you will also need to remove the operator side cover see section 1 2 and disconnect all the plugs from their sockets on the rear panel and from the side of the enclosure Also disconnect the sensor connector from the lid If a replacement control box is fitted it may be necessary to adjust the alignment of the front panel to suit the aperture in the side cover This can be achieved by loosening the four screws which fix the mounting brackets to the2. On the suction machine the print position is greatly affected by the machine speed so should be set with the speed control at posn 3 Adjustment of the stop collar position is always necessary after adjusting the over travel or fitting a new clutch and is achieved with the machine fully assembled See section 9 7 on page 32 PAGE 33 Section 9 CLUTCH ASSEMBLY SERVICE Clutch Pulley Retaining Ring Clutch Backplate Stop Collar Control Collar Splines Slots for Brake Spring Tang Collar Position 9 d oss Collar Position Adjustment Locate the stop collar and lever the retaining ring out of it s groove in the control collar using a small screwdriver under the shaped end of the ring Slide the stop collar in towards the pulley until it comes off the splines rotate the collar enough to adjust the numbering position and then slide the collar back on to the control collar splines The effect on the numbering position is approximately double the movement of the stop collar on it s splines 1 spline 2mm 0 080 Run the machine briefly and check that the head position corresponds to the distance from the top of the sheet to the top of the printed number Replace the retaining ring into the groove in the control collar when the correct position is obtained PAGE 34 ROTARY MANUAL CLUTCH ASSEMBLY Section 9 Reaction Plate On Clutch Backplate Micro Switch Fixing Screws Micro Switch Rotation Sensor Mic
3. M Cable Ties l 3 Print Position Shaft Lower Sensor LAN S Mounting nr i Cable Passes Lower ve Upper amp Lower Over Print Position Shaft Sensor Cable Sensor Cables Lower Tie Bar Sensor Installation Suction Machine Fig 12 12 NUMBERER PAGE 43 Section 13 GUARDS SERVICE Kaff Guard Position Both the main guard and the exit guard are held in place by magnets which are adjustable to allow the guards to close correctly Lateral height adjustment is achieved by screwing the magnets in or out of their mounting blocks as required A large thick blade screwdriver may be used to turn the magnets if they cannot be moved by hand but take care not to force them The gap between the two guards should be 3mm 1 8 Angular adjustment is achieved by loosening the two M3 screws which hold each magnet housing It is important that the magnets sit squarely on their keep plates particularly on the exit guard and this is best achieved by setting the height first as in the previous paragraph and then loosening the housing screws and closing the guard The magnets should now self align allowing the housings to be held whilst the screws are tightened in the correct position Main upper Lift Up to Open Guard Counter Plate Guard Safety Switch 7 Actuator pur Housing Screws Le v Under Side Cover Magnet Housings Exit lower E Drop Down Guard Guard positioning Fig 13 11 PAGE 44 ROTARY MAN
4. WARNING DON T DO THIS WITH THE POWER ON System switch will notlatch Check that the guards are correctly closed and the emergency stop switch is released by turning it counter clockwise Check the security of both 2 way plugs at the rear of the control box and check both motor and control fuses Check the continuity through each 2 way plug and if not sound trace the fault to defective connection or switch If continuity is sound check the security of connections between both 2 way sockets and terminals 18 amp 19 on the suction control board PCB 1 Also check the blue wires at terminals 22 and 23 on PCB 1 NUMBERER PAGE 59 Section 17 ELECTRICAL SUCTION SERVICE If the PCB clicks when a guard is opened or closed replace the system switch If there is no audible click then replace the PCB Motor will not run Check the motor fuse is intact and rated at 3 15 amps Check the security of the choke and motor 4 way plugs and check the connections to the choke amp motor Check the connections inside the control box to the 4 way sockets and system switch and check all connections to the motor speed PCB Check the input voltage to the motor speed PCB mains AC voltage across orange amp grey If not correct trace the fault to a switch or connector Check the output voltage from the motor speed PCB 170 V DC across Red and Black at the max speed setting on the front panel If output voltage is incorrect replace motor PCB
5. inaccurate paper cutting and sets with a very wavy lead edge can cause registration problems Again ignore any problems with such stocks and ascertain this by numbering flat well cut stock twice If the numbering head is not fully secured on it s collar or the numbering collar is not fully secured to the shaft registration errors will occur If the nip wheel on friction machines or the papergate on suction machines is set too loose double sheet feeding may result and cause registration problems Machine Problems If the twin grip or clutch drive belts are slack or there is a loose drive pulley especially on the main drive shaft registration errors are likely to occur ROTARY MANUAL REGISTRATION Section 8 The small pulley that drives the clutch belt under the cover next to the handwheel has it s grub screw outside the cover and can be released by the operator so must therefore be carefully checked Loose pulleys may be detected by holding the large clutch pulley whilst carefully trying to turn the machine backwards and forwards by hand Insufficient drive on the paper between the input rollers will also cause registration errors so wind a sheet between the rollers while holding the paper tight to see if this is the case Check for a complete revolution of the rollers to check for any low spots on the rollers Due to the input rollers manufacturing tolerances some eccentricity maximum of 0 03mm 0 12 is
6. is then twisted off the vacuum roller spigot After replacing the hose amp connecting tube the grub screw in the tube MUST be locked up so that the suction choke control knob is in vertical alignment with the suction slot inside the vacuum roller To achieve this an alignment tool a piece of Ya dia 06 35mm bar at least 2 50mm long will do may be carefully inserted through one of the holes in the vacuum roller and into the suction slot The suction choke control knob may now be temporarily screwed into it s tapped hole in the connecting tube and brought into vertical alignment with the alignment tool in the vacuum roller before finally locking the grub screw tight PAGE 14 ROTARY MANUAL SUCTION FEED Section 3 Note Remove the tool and the knob before continuing assembly 3 4 Vacuum Belt Adjustment The vacuum drive belt takes the drive from the lower input roller to the feed drive shaft and is tensioned by adjusting the bearing blocks Release the two screws in each bearing block and move the screws in their slots until the belt is tensioned Care must be taken to ensure that the vacuum drive shaft remains parallel to the input shafts When the feed drive shaft is parallel all the adjusting screws will be in similar positions in their slots Failure to set the feed drive shaft correctly will result in the toothed belt tracking badly and may result in premature belt failure WARNING DO NOT ADJ
7. If output voltage is correct check voltage at the motor and if okay replace motor brushes If this fails replace the motor Note Voltage checks need to be carried out with all connections intact as the motor load will affect the PAGE 60 ROTARY MANUAL ELECTRICAL SUCTION Section 17 voltage drop 17 6 Trouble Shooting Machine Will Not Feed Suction Valve Will Not Operate Check the security of the 3 way plug at the rear of the Control Box and the valve connector on the valve coil Check the wiring to the valve connector the 3 way plug amp socket and to terminals 12 amp 13 at the control PCB inside the Control Box Check the wiring between the feed On Off switch on the front panel and terminals 20 amp 21 on the control PCB Check the voltage at the valve with the feed switch on it should be 4VDC If the Voltage is incorrect replace the control PCB If the Voltage is correct check the coil resistance it should be 10 Ohms If it s incorrect replace the coil If the coil resistance is correct dismantle the valve See Section 15 and inspect the plunger assembly for failure or sticking If the valve is okay then replace the control PCB Machine feeds one sheet and fails to feed thereafter Check the security of the 6 way connector at the rear of the Control Box Check that the rotation sensor micro switch which is located on the main clutch back plate is operated by the clu
8. UST THE BELT BY MOVING THE BED STIFFENER AS THE RESULTING MISALIGNMENT WILL CAUSE FEEDING PROBLEMS Bearing Blocks Are Adjustable Bed Stiffener Vacuum Belt Adjustment NUMBERER PAGE 15 Section 4 DRIVE BELTS SERVICE Remove Bolts Completely Before Attempting to Remove Belt Bearing Housing Twin Grip Drive Belt 4 1 Twin Grip Drive Belt Remove the operator side cover to gain access to this belt which is removed only after taking out the bearing housing bolts This allows the bearing housing more travel to give extra slack on the belt which may then be wound off the pulleys in the direction shown See fig 4 11 When replacing the belt wind it back on to the pulleys in the same direction being careful not to strain the belt WARNING DO NOT ATTEMPT TO REMOVE OR REPLACE THE BELT WITHOUT FIRST REMOVING THE BOLTS PAGE 16 ROTARY MANUAL DRIVE BELTS Section 4 4 2 Adjustment Twin Grip and Clutch Drive Belts These belts are tensioned by adjusting the bearing housings after slackening their fixing bolts see note below Bearing Housing Fixing Bolts The fixing bolt nearest to the feeder end of the machine acts as a pivot whilst the delivery end bolt runs in a slot in the side frame and allows adjustment to be made The belts should not be over tensioned but note that an under tensioned belt will cause poor registration 4 3 Adjustment Motor Drive Belt The motor drive belts are
9. cover and terminals 16 amp 17 on the PCB NUMBERER PAGE 53 Section 17 CONTROL SYSTEM SUCTION SERVICE 19 13490S zo LAINI HOSSIHANOID SNIVIN 0 NVA Nid SNIZIHV1Od SALONA Gi 9 HOLOW 80 SHOHO 99 HOLIMS dOlS 29 HOLIMS quvno 89 3A1VA NOILONS 60 HOSNIS NOILLV LOH 8 HOLNTO an NYHL ss399v 010 HOSN3S H3dVd HOLIMS dOLS YOSSAYdNOO JAVA NOILONS HOLVIOSI O E e B O E 090 SHOLOANNOO INIT k Le WALSAS TOHLNOD Houws qunvo AH 9 9c H3 LLINSNVH L HOSN3S TL Ts H3AI3O3H HOSN3S cd Houms J Oe INdLNO E 8 8j HOSN3S NOILV LOY e TANVd HV3H 1NIOd SNIGNNOYD q18vo AlddNs SNIVIN 17 11 Ig F LOOM AEN iagram D iring W ROTARY PAGE 54 MANUAL CONTROL SYSTEM SUCTION Section 17 Cooling Fan Fuse 1 amp Sensor Socket Lid Control Panel Motor Fuse 3 15 amp EA Control Fuse 1 amp Control aS Rear Panel Fixing SE NY Bracket Fixing Screws Mounting Bracket Motor 4 Way
10. inking stop screw until a slight contact is made between the numbering head and the transfer roller Repeat for the opposite side and double check the adjustments as adjusting one side may affect the opposite side Move the inking assembly to the secondary position or primary position see operators guide for details and repeat the steps above Finally increase the pressure at each inking stop screw by 1 turns counter clockwise viewed from head end of screw NUMBERER PAGE 23 Section 8 REGISTRATION SERVICE PAGE 24 Numbering Registration The main clutch installed in all machines is an incremental control unit and contains four wrap springs Like all precision components it has to work to a tolerance which is and this will allow for a maximum registration error of 1 2mm 0 048 Whilst a faulty clutch or an incorrectly adjusted clutch will cause registration problems there may be other causes which should be investigated before dismantling the clutch Points to check that will cause registration problems are divided into three sections as follows Operational Problems The feeder should be set so that the paper feeds regularly and reliably and the job should have been printed accurately so feed paper through twice to ascertain such stock errors and remember that the machine speed affects the printing position and should not be adjusted whilst running a job Badly curled sheets poor printing registration
11. not rotate freely when the clutch is idling increase the over travel by moving the clutch and brake springs back one position The opposite direction to that shown in Fig 9 31 If the position of the tangs is lost or the over travel wildly excessive the clutch manufacturers setting marks may be utilised to restore the tangs to the default position The tangs are generally factory set three notches past the manufacturers setting marks Note Using the clutch manufacturers default setting marks is likely to impair performance so should only be used as a starting point before using the above procedure to adjust the over travel WARNING THE INTERNAL CLEARANCES WITHIN THE CLUTCH BRAKE UNIT ARE PRACTICALLY ZERO ANY INGRESS OF DIRT OR OTHER CONTAMINATES WILL SERIOUSLY AFFECT THE PERFORMANCE OF THIS UNIT EXTREME CARE SHOULD BE TAKEN TO PROTECT ALL COMPONENTS DURING DISMANTLING amp RE ASSEMBLY DO NOT USE LUBRICANTS NUMBERER PAGE 29 Section 9 CLUTCH ASSEMBLY SERVICE Inner Control Ring Inner Collar Control Collar Clip Input Hub Actuator Over travel Adjustment New Style Clutch PAGE 30 ROTARY MANUAL CLUTCH ASSEMBLY Section 9 9 3B Over travel Adjustment New Syle Clutch kel N LA Ui N The over travel adjustment on the new style clutch can be done without removing the clutch from the machine as follows See Fig 9 32 Remove the clip from its groove Operate the actuato
12. tensioned by adjusting the motor position after slackening the motor fixing bolts which all run in slots in the side frame Note On the friction machine the clutch side bearing housing is on the outside of the side frame and the clutch drive Motor Fixing Bolts Motor Drive Belt NUMBERER PAGE 17 Section 5 INPUT ROLLERS SERVICE Dili Input Rollers Dismantling Before dismantling the input rollers remove the twin grip belt Section 4 and on the friction machine the feed clutch Section 2 Remove the M8 nuts from the ends of the input rollers clutch side and on the suction machine the feed drive belt and pulley from the lower input roller Work on one roller at a time starting with the top roller Remove the pulley from the operator end of the roller by releasing the M6 bolt in the end of the roller shaft and the M4 grub screws in the pulley Note In order to stop the rollers turning use a 13mm spanner wrench on their flats Side Frame Clutch Side Timing Pulley Flanged Upper Input Roller Side Frame Operator Side Roller Bearing Waved Washers See Note 1 Page 21 Flats for 13mm A F Wrench Grub Screws M8 Nut Input Roller Lower Timing Pulley Un Flanged Friction Clutch Ball Bearings M6 Bolts amp Clamp Washer Input Rollers Friction Machine PAGE 18 ROTARY MANUAL INPUT ROLLERS Section 5 Slide the roller assembly out of it s clutch side bear
13. the rotation sensing micro switch and the feed clutch on the friction machine and release all cable ties securing the cables to the clutch back plate Remove the two screws securing the spring bracket to the side frame and slacken the grub screw in the clutch hub using a 2 5mm Allen key Grasp the clutch firmly by it s back plate and pulley it s fairly heavy and slide it off the main shaft taking care not to lose the key PAGE 26 ROTARY MANUAL CLUTCH ASSEMBLY Section 9 9 2 Over travel Measurement The clutch and brake springs have a combined adjustment to ensure that when the brake spring engages the clutch spring is released Note This adjustment is critical to the accuracy of the numbering machine and is measured by the over travel which is checked as follows Rotate the output hub Fig 9 31 until the brake spring is fully engaged This is the normal stopping position of the clutch Operate the actuator without rotating any parts The stop collar will spring forward the distance shown in Fig 9 21 as over travel This adjustment may be checked with the clutch on the machine by marking the stop collar after completing the two steps above The over travel should be 3mm or 1 8 maximum Actuator 3 mm 1 8 Over travel _ _ _ Stop Collar Over travel Measurement NUMBERER PAGE 27 Section 9 CLUTCH ASSEMBLY SERVICE To Reduce Overtravel Move Tangs in This Directio
14. Choke 4 Way Compressor Socket Guard Loop 2 Way Emergency Stop 2 Way Mains Power Socket Suction Control Valve 3 Way Clutch amp Rotation Sensor 6 Way Control Box Control Box Fig 17 12 17 1 Control Box The suction machine s control system is housed in an enclosure which has a front panel accessible to the operator and can be removed from the machine as a complete unit It is connected to the machine by a wiring loom whose individual circuits are terminated by Trident plugs which mate with corresponding sockets at the rear of the control box The fuses are also housed at the rear of the box The sensors are connected directly to the PCB through the lid NUMBERER PAGE 55 13 Lead INOHI AYNSOTONA NIVIN TANVd a R I H388nNS 10 LIMOOS HOSS3HdWOO 20 LA INI SN Nid DNIZIHWTOd SALONAG Q ig 17 F L3 LNIOd ONIGNNOYD 14 asna 9 NVA IS HOLIMS YOSSAYdNOO 23 ASN HOLON 70 HOLOW ZS HOLIMS H WALSAS OF eg asnd YOLVOICNI TOHINOI NO H3MOd e ec L oo0Q0Q0o02202000 Se TOHLNOI el daadS 1 S H d 4 00 VHVN 1 8L 1 god auvoa 4 z god CUVOA LINOHIO HOLOW LINOHIO TOHLNOD 9 Si vL ei es HOLIMS si a333 T OL 034 318v9 H3LLINSNVH L OL NOLLO3NNOO 193uld 6
15. N FEED Section 3 Sel ses Vacuum Roller Assembly See Fig 3 11 Overleaf The vacuum roller is mounted on the bed stiffener beneath the loading table To replace the vacuum roller the loading table manifolds and papergate must be removed See Fig 3 11 Remove the side covers and the base access panel See fig 1 21 Remove the two M8 bolts item 1 which secure the papergate shaft and disconnect the hoses fromthe manifold elbows Remove the four M6 Hex Head screws item 2 which secure each manifold mounting bracket to it s mounting link Remove the hose support beam by releasing it s two fixing screws item 3 and the three nuts item 4 below the loading table Remove the two M4 nuts item 5 which secure the underside of the loading table to the bed stiffener Remove the six M8 bolts item 6 which secure the loading table to the side frames and lift the loading table manifolds and papergate off the machine as one unit Remove the feed drive timing belt by winding it carefully off the larger of the two timing pulleys Remove the five screws item 7 from the bed stiffener three on operator side amp two on the clutch side and the two screws item 8 from the feed bed Cut all cable ties taking care not to damage the cables and lift the vacuum roller assembly and feed bed from the machine Remove the vacuum roller from the subframe by removing the hose amp connecting tube and then releasing the 4 screw
16. PLATEN SURFACE IS EASILY DAMAGED TAKE EXTRA CARE DURING REMOVAL AND REPLACEMENT NOT TO DAMAGE THE SURFACE OF THE PLATEN The Narrow Side of the Eccentric without a fixing hole Must Face the Feeder End of the Machine on Both Sides This View is of the Operator Side Eccentric Clutch Side Should Be Mirror Image Platen Eccentric Fig 11 21 11 2 Platen Re assembly Re assemble with both eccentrics facing as shown in Fig 11 21 ensuring that any shims that were removed are replaced Replace the adjustment lock shaft with it s associated parts and set the adjusting plates so that their slots are clear of and do not stick on the lock shaft Replace the pulley after the platen pressure has been set as in section 11 3 Once again be very careful with the platen as it is easily damaged NUMBERER PAGE 39 Section 11 PLATEN SERVICE a RS ener Platen Adjustment Set the operator adjuster cam shaft to the position shown in Fig 11 31 and tighten the lock Set the numbering head mounting collars towards the sides of the machine and lay a piece of 80gsm 20lb paper over the platen on each side Hold a numbering head loosely on the collar and holding it firmly seated to the base of the collar check the contact with the paper on each side of the machine If adjustment is required on either side use the following procedure Decrease Pressure Increase Pressure Adjuster Plate AC y he Eccentric S
17. Standard FRN 6 amp SRN 9x Numbering Machines Service Manual g P Provided By MyGinding When Image Matters SERVICE MANUAL Standard Morgana FRN 6 and SRN 9x ao STANDARD MuyBindingj When Image Matters INTRODUCTION SERVICE _ Clergurie FF ES RY LF INGI ROTARY NUMBERING MACHINES SERVICE MANUAL I Introduction The purpose of this Manual is to explain the procedure for dis mantling and re assembly of the major assemblies on both the Friction Feed and Suction Feed Rotary Numbering Machines All the engineering adjustments are shown at the end of each relevant section Operator s adjustments and routine maintenance are explained in the appropriate Operators Guide which should always be used in conjunction with this manual It is always a good idea to have a copy of the machines Illustrated Parts Manual available when servicing as its illustrations provide an invaluable reference to the construction of the individual assemblies used to build the machine li Fasteners Most of the pulleys on the machines use dog point screws which engage in holes in the shafts to ensure reliable drive They must be fully withdrawn prior to dismantling All threaded fasteners are ISO Metric amp all nuts are ISO Metric Hexagon All screws are hardened high tensile steel PAGE2 ROTARY MANUAL INTRODUCTION Cap Head Button Head Socket Countersunk Shoulder Bolts and Grub Screws hav
18. UAL GUARDS Section 13 13 2 Stripper The guard at the feed end supports the stripper plate which has been designed to minimize the risk of damaged stock wrapping around the input rollers It is important that the stripper is correctly adjusted and this can be achieved by releasing its three fixing screws to obtain a clearance of 0 75mm or 0 030 between the edge of the stripper and the upper input roller Note It is important to check this with the guard closed WARNING DO NOT OPEN THE GUARDS WHILST THE MACHINE IS RUNNING AS YOU COULD INADVERTENTLY FORCE THE STRIPPER INTO THE ROLLER BEFORE THE SAFETY SWITCH HAS STOPPED THE MACHINE Front Guard Entry Guard Input Stripper Input Stripper 0 75mm 0 030 0 75mm 0 030 Upper Input Upper Input Roller Roller Lower Input Lower Input Roller Roller Friction Machine Suction Machine Stripper Fig 13 21 NUMBERER PAGE 45 Section 14 COMPRESSOR SERVICE In line Filter Housing Wing Nut Inlet Filter Valve Connector Housing ala d IER and Lead Manifold Hoses Vacuum Hose Filter Elements SIA ARE SS y im End Panel a x xr Screws Compressor p Transit Bolt Support Bridge Assembly Fig 14 11 14 1 Compressor Suction Machine Note The compressor is a very reliable unit and rarely gives any trouble so is unlikely to need removing from the machine If you do suspect a problem be sure to check all electrical connections a
19. e has 0 2mm or 0 008 of sideways movement end float so tighten the grub screw so that it is radially well clear of the hole in the shaft Note If the grub screw is positioned too close to the hole in the shaft it may be impossible to achieve the correct amount of clearance for the support tube Note Take care to make sure the one way clutch within the friction tyre operates in the correct direction amp waved washers have been replaced in their correct positions NUMBERER PAGE 9 Section 2 FRICTION FEED SERVICE Sleeve Gear Assembly 13mm A F Spanner Wrench Drive Slots Output Feed Clutch Drive Slots input Drive Pin Upper Input Roller Clutch Spindle 4 Anchor Pin Side Frame Assembly DS Clutch Side Integral Flying Lead In Line Connectors Un Plug Clutch Cable to control system Feed Clutch Note It s worth consulting the relevant section in the appropriate illustrated parts manual to ensure that this assembly is correctly re constructed 2 3 ws Feed Clutch The feed clutch is removed from the machine by unplugging it s wires taking care not to strain them and using a 5mm allen key to unscrew the clutch spindle assembly Hold the input roller using a 13mm spanner wrench on the flats while releasing the spindle Upon re assembly ensure that the tang on the clutch back plate engages with the anchor pin the drive dog on the sleeve gear PAGE 10 ROTARY MANUAL SUCTIO
20. e internal hexagon drives which require ISO Metric Hexagon Wrenches Allen Keys Ball Drivers may be used but care should be taken particularly when releasing screws for dismantling to avoid breaking the driver as they cannot cope with full tightening torques Do not substitute fasteners with low grade alternatives which may fail or become irremovable Pan Head and Cross Head Countersunk Screws all have ISO Metric Taptite Threads and Pozi Drive Recesses Use No 2 Point Pozidriv or Supadriv Drivers for all screws M4 amp above and No 1 Point Drivers for M3 amp below WARNING DO NOT USE PHILLIPS DRIVERS THESE WILL DAMAGE THE SCREWS amp MAY SLIP CAUSING DAMAGE OR INJ URY Identification For general identification of areas of the machines the following terms are used Operator Side Clutch Side opposite Operator Side Feeder End on your Left Delivery End on your Right NUMBERER PAGE 3 INDEX SERVICE INEFOGUCHON canoa Page 2 i Introduction 2 ii Fasteners 2 iii Identification 3 Section 1 Gu e Page 6 1 1 Side Covers Friction Machine 6 1 2 Covers Suction Machine 7 Section 2 Friction Feed Page 8 2 1 Friction Feed Drive Shaft 8 2 2 Drive Shaft Adjustment 9 2 3 Feed Clutch 10 Section 3 SUCTION Feed Page 11 S Vacuum Roller 11 3 2 Vacuum Roller Adjustment 12 3 3 Vacuum Hose 14 3 4 Vacuum Belt Adjustment 15 Sec
21. e wires from the socket to terminals 9 10 11 14 15 amp 16 on the control PCB Check the connections to the main clutch coil red amp black wires Check the main clutch coil resistance which should be 10 Ohms and replace the coil if this is incorrect otherwise replace the PCB If the clutch does not operate in manual mode check the wiring between the numbering auto man switch on the control panel and terminals 16 amp 17 on the PCB PAGE 62 ROTARY MANUAL NUMBERER PAGE 63 MuyBindingj When Image Matters Standard Business Systems SM_FRN6 SRN9x 10 Connector Road Andover MA 01810 a Issue 3 August 2004 978 470 1920 978 470 2771 STANDARD Our Standards Are Simply Better
22. enclosure and adjusting the position of the entire box The control system enclosure houses all of the switches fuses sockets and other components including the suction control circuit board PCB 1 and the motor speed control circuit board PCB 2 which are mounted on the underside of the lid To gain access to these items after removing the control box from the machine simply lift the lid and hinge it right back 17 3 Suction Control Board Removal To remove the control PCB disconnect the four remaining wiring plugs by easing them out of their headers The main header has three separate plugs but unlike the friction control PCB they are mounted on a vertical header like the mains in plug Cut any cable securing ties that are on the PCB taking care not to damage any of the cables and partly release the PCB from it s two Supports by depressing their tangs Firmly support the PCB by holding the large transformer remove the two fixing screws from the outside of the lid and withdraw the board See Fig 16 12 on page 49 NUMBERER PAGE 57 Section 17 ELECTRICAL SUCTION SERVICE 17 4 Motor Speed Control Board The motor speed control board PCB 2 is mounted on four supports and may be removed by depressing their tangs after disconnecting all the cables from the terminal block To help with re installation of the PCB the following table together with the circuit diagram on the previous page will help you to re c
23. es located on the inside of the frame plates both sides using a 3mm Allen key See Fig 10 11 The main shaft may now be partly withdrawn to the clutch side of the machine allowing the room between the side frames to be used to remove the operator side bearing using a suitable hub puller Remove the thrust washer and the numbering head collars make a note of the orientation of their scales to ensure correct re assy whilst withdrawing the main shaft through the clutch side frame Collars for Numbering Heads Circlip Bearing Thrust Washer K Grub Screw for Collar Bearing Retainer Plates M6 Tapped Hole for Ink Drive Idler amp Bearing Tool Main Print Shaft Fig 10 11 PAGE 36 ROTARY MANUAL MAIN PRINT SHAFT Section 10 Note Always support the shaft and use a hub puller to remove the operator side bearing from the shaft and take care not to lose the keys from the collars 10 2 Main Print Shaft Re assembly The main print shaft is replaced in reverse sequence but make sure the collars are the right way round or you won t be able to set the numbering heads Also make sure that the thrust washer is placed over the shoulder on the main shaft before replacing the bearing To fit the operator side bearing without damage special tool T040 should be used as shown in fig 10 21 below The tool is fitted over an M6 bolt which is screwed into the tapped hole in the end of the main shaft The nut is then tighte
24. et Camto 30 Platen Fixing Bolts Platen Lock Adjustment Cam PAGE 40 Operator Side Shown See Fig 11 11 for Clutch Side Fig 11 31 ROTARY MANUAL PLATEN Section 11 Loosen the eccentric fixing bolts and use the bolts to rotate the eccentric behind the adjusting plate until the numbering head makes light contact with the paper Note This adjustment can be difficult to do but please persevere it is important To increase pressure rotate the operator side eccentric clockwise and the clutch side eccentric counter clockwise Adjusting one side affects the other so always double check the adjustment and tighten the bolts securely On a machine that appears to have unequal pressures the platen may be levelled off by adjusting only the clutch side eccentric Finally if the platen has been replaced re fit the drive pulley and twin grip belt See section 4 Tip s212 The illustrated parts manuals and operators guides for each machine are an invaluable reference when using this manual NUMBERER PAGE 41 Section 12 SENSOR SERVICE 12 1 Sensor All Machines Sensor maintenance is dealt with in the operators manual and only involves careful cleaning of both units and their lenses The sensors are mounted so that they are exactly aligned without any adjustment so no provision is made to adjust them Sensor alignment can only be measured using an oscilloscope but if you suspect mi
25. he 6 way Trident plug which connects the switches on the facia plate to the control system from it s socket on the side frame under the cover Note Do not allow dirt to enter the handwheel bore as it contains a one way clutch which operates directly on the shaft PAGE 6 ROTARY MANUAL COVERS Section 1 M6 Nut amp Washer Two M6 Nuts Each Side Hand Wheel Base Access Panel Screws A Five M4 Screws Two Each Side Each Side 1 2 Suction Machine Each side cover is secured by five screws and two nuts as shown in Fig 1 21 Before removing the clutch side cover remove the handwheel using a 10mm socket wrench Note Do not allow dirt to enter the handwheel bore as it contains a one way clutch which operates directly on the shaft The base access panel is removed by releasing the four screws two through each side frame pulling the panel out and then upwards Take care not to pull the fan lead which may be easily unplugged from the control box inside the machine See section 17 on page 53 NUMBERER PAGE 7 Section 2 FRICTION FEED SERVICE Gears Inside Housing Pull Housings Together To Release Pins LZ 8 Screw s Two Cap Head Bolts Each Side Friction Feed GEN RA Friction Feed Drive Shaft The friction feed drive shaft is removed after unscrewing the four cap head bolts as shown in Fig 2 11 The bearing housings are located on dowel pins and must be pulled inwards as shown t
26. inevitable but it s effects can often be minimised by adjusting the relative radial position of the upper and lower rollers To carry out radial re positioning of the input rollers remove the twin grip belt see section 4 and turn each input roller in turn until the highest point is at the top Hold the rollers in this position and replace the belt Note This procedure is only likely to be necessary if the input rollers are worn and can only be considered as a temporary measure Also check for loose or rough parts that may impede the paper travel including a sticking wheel on the hold down wheels Lift hold down wheels clear of the platen and spin them to ensure there are no tight spots 8 4 Clutch Problems Registration errors caused by clutch problems such as a loose securing screw or the over travel or actuator requiring adjustment are described fully in section 9 but don t forget that the clutch unit does have a working tolerance as stated at the beginning of this section NUMBERER PAGE 25 Section 9 CLUTCH ASSEMBLY SERVICE Clutch Drive Belt ia aN Main Shaft Grub Screw Micro Switch It Spring Bracket Solenoid Coil bon Cables Bellcrank Assembly Clutch Assembly Dillo Removal of the Clutch Assembly Remove all numbering heads from the machine to avoid them swinging down and damaging the platen and remove the clutch drive belt from the clutch pulley Remove the wiring from the solenoid coil
27. ing towards the operator side of the machine and remove the operator side bearing and waved washers see Note 1 on page 21 from the end of the Shaft Finally swing the clutch side of the roller forward amp clear of the sideframe and withdraw the operator side of the roller from the machine The same procedure may now be used for removing the bottom roller Re assembly is carried out in reverse order but take care not to force anything Note Ensure that all parts are clean and free from damage before re assembly particularly the clutch end of the top roller shaft on the friction machine as it is hardened and runs directly in the sleeve gear needle roller bearing M8 Nuts Upper Input Roller Timing Pulley Flanged Side Frame Clutch Side Side Frame Operator Side Bearings Waved Washers See Note 1 Page 21 A Flats for 13mm A F Wrench Bearings Grub Screws M8 Washers Two Off Behind Pulley Timing Pulley Un Flanged Feed Drive Pulley Lower Input Roller M6 Bolts amp Clamp Washer Input Rollers Suction Machine NUMBERER PAGE 19 Section 6 OUTPUT SHAFTS SERVICE Timing Pulley Flanged Side Frame Clutch Side Side Frame Operator Side Output Shaft Upper Waved Washers Drive Hub Upper See Note 1 Page 21 Bearings Flats for 13mm A F Wrench Grub Screws Drive Wheel Lower Bearings Timing Pulley Un Flanged Output Shaft Lower M8 Nuts Output Shafts 6 1 Out
28. ion is on and then runs straight whilst the suction is off listen to the sound of the suction while watching the edge of the sheets the vacuum roller will require adjusting The vacuum roller assembly is set at the factory with it s adjustment as far forward as possible to the delivery end of the machine This means that if the sheet edge runs towards the operator side the clutch side of the vacuum roller assembly must be adjusted rearwards towards the feeder end Conversely if the sheet runs away from the operator side the operator side of the vacuum roller assembly must be adjusted rearwards towards the feeder end The vacuum roller assembly is adjusted by re positioning the screws item 7 in the slots in the side frames The M4 nuts item 5 under the loading table will also have to be released before adjusting the vacuum roller assembly Ensure they are re tightened after adjustment is completed The feed drive timing belt may also require adjustment See section 3 4 Note Don t attempt to stretch the drive belt over pulley flanges NUMBERER PAGE 13 Section 3 SUCTION FEED SERVICE Suction Slot Inside Vacuum Roller Alignment Tool Drive Shaft Suction Choke Control Vacuum Roller Spigot X Grub Screw Bed Stiffener Sub Frame Vacuum Hose S5 MM Vacuum Hose To disconnect the vacuum hose remove the grub screw as shown in Fig 3 31 and slide the connecting tube over the hose The hose
29. irmly installed Lower the control panel see section 16 1 and check the security of the two blue wires to terminals 22 and 23 and the two white wires to terminals 18 and 19 Check the continuity through white wires to terminals 18 and 19 remove wires from PCB first If there is no continuity trace the fault to a defective switch connection or a defective switch If the PCB clicks when a guard is opened or closed replace the system switch If there is no audible click then replace the PCB System Switch Latches Is the machine jammed It should rotate freely by using the handwheel To minimise starting loads ensure that the Feed switch is Off and that the main clutch is not still engaged This can happen if the machine was switched off during a numbering cycle before the heads had stopped Turn the machine by hand to position the heads in their starting position Check the mains voltage to the motor and the connections to the capacitor If all else fails replace the motor 16 3 Trouble Shooting Machine Will Not Feed Friction Feed Tyres do not rotate Check the wiring between the feed on off switch on the side cover and terminals 20 amp 21 on the PCB and check the wiring between the feed clutch and terminals 12 amp 13 on the PCB PAGE 52 ROTARY MANUAL CONTROL SYSTEM FRN Section 16 Check the coil resistance of the feed clutch which should be between 206 ohms and 248 Ohms and replace the clu
30. lacement 43 Section 13 UA E Page 44 13 1 Guard Position 44 13 2 Strippers 45 Section 14 COBIDIGSSOL uices s oii daro bs Page 46 14 1 Compressor Suction Machine 46 14 3 Filters 47 14 4 Compressor Removal 47 Section 15 Suction Control Valve Page 48 15 1 Suction Control Valve 48 15 2 Valve Dismantling 49 Section 16 Control System Friction Page 50 16 1 Control System Access 51 16 2 Troubleshooting Machine Won t Run 52 16 3 Troubleshooting Machine Won t Feed 52 16 4 Troubleshooting Machine Won t Number 53 Section 17 Control System Suction Page 54 17 1 Control Box 55 17 2 Control System Access 57 17 3 Suction Control Board 57 17 4 Motor Speed Control Board 58 17 5 Troubleshooting Machine Won t Run 59 17 6 Troubleshooting Machine Won t Feed 61 17 7 Troubleshooting Machine Won t Number 62 NUMBERER PAGE 5 Section 1 SIDE COVERS SERVICE Operator Side Cover Clutch Side Cover Facia Plate Two M6 Nuts Each Side r M6 Nut amp Washer i cor aja SE DELE M d d S l Two M4 Screws Each Side Handwheel Side Covers Friction Machine Lili Friction Machine Each of the side covers is secured by two screws and two nuts as shown in Fig 1 11 Before removing the clutch cover remove the handwheel using a 10mm socket wrench After releasing the operator side cover but before removing it completely you will need to dis connect t
31. n Clutch Spring Tang Brake Spring Tang Input Hub Output Hub Input Hub Circlip Stop Collar E Control Collar Clutch Manufacturers Actuator Default Setting Marks Over travel Adjustment Old Style Clutch 9 3A Over travel Adjustment Old Style Clutch Remove the clutch from the machine See Fig 9 11 Remove the large pulley from the clutch using a 4mm Allen key to release the three countersunk screws and then remove the input hub circlip Ensure that the clutch is in it s normal stopping position with the output hub turned hard against the stop collar and remove the input hub by rotating counter clockwise Operate the actuator see section 9 2 to release the drive springs and rotate the output hub to locate the tang of the brake spring PAGE 28 ROTARY MANUAL CLUTCH ASSEMBLY Section 9 Carefully dis engage the control collar from the tang of the brake spring and replace the tang in the next slot as shown in Fig 9 31 Move the tang of the clutch spring into the next slot in the control collar as shown in Fig 9 31 Rotate the output hub sharply against the actuator stop and replace the input hub by rotating anti clockwise and pushing in at the same time Check the over travel and repeat the procedure until the over travel is minimised Note a If the over travel is reduced too much it will not be possible to replace the input hub If the over travel is reduced to the point where the input hub does
32. nd hoses including the suction valve before removing it PAGE 46 ROTARY MANUAL COMPRESSOR Section 14 14 2 Filters 14 3 It is important that the filter cartridges are replaced when necessary as they can have a dramatic affect on performance DO NOT TRY TO CLEAN THEM Knocking dust out of them only gives a short term improvement they re clog very quickly NEVER RUN WITHOUT THEM the internal clearances are small and any foreign particles entering the chamber can cause the impeller to seize an expensive mistake The inlet filter may be removed by releasing the wing nut from the top of it s fixing bolt The in line filter housing is secured by two spring clips which can be released by hand The filter cartridges are of the same type and should normally be replaced as a pair Compressor Removal Remove the compressor power lead from the control bok Remove the valve connector from the valve Remove the two manifold hoses from the compressor adaptor Remove the vacuum hose from the valve port Remove the three screws through the end panel Remove the two transit bolts one each side through the side plates taking care not to lose the spacer and washer The compressor and it s support bridge may now be lifted out of the machine Don t try to remove the compressor on your own the unit is very heavy NUMBERER PAGE 47 Section 15 SUCTION CONTROL VALVE SERVICE dolio PAGE 48 Sucti
33. ned to press the bearing into position Remove the special tool and finally replace the circlip the bearing plates and all the other items removed not forgetting the ink drive Special Tool Bearing Thrust Washer M6 Tapped Hole in End of Print Shaft M6 Nut amp Set Screw Principle Bearing Housing Operator Side Bearing Replacement Print Shaft Fig 10 21 NUMBERER PAGE 37 Section 11 PLATEN SERVICE Platen Eccentric Fixing Bolts Adjuster Plate Platen Adjustment Lock Shaft Spacers Behind Clutch Side Shown See Fig 11 31 for Operator Side W Cam Return Spring i Le Bolt Adjuster Plate Tension Spring Platen Mechanism Fig 11 11 Llano PAGE 38 Platen Removal Remove the twin drive belt see section 4 and remove the leg of the cam return spring from the retaining bolt Remove the lock shaft by releasing the two M8 lock nuts and unscrewing the lock shaft fully from the machine Beware of the spacers falling as the lock shaft is withdrawn Remove the tension springs from the adjusting plates each side and using a 7mm spanner wrench remove the three platen eccentric fixing screws from the CLUTCH SIDE ONLY and remove the adjusting plate Some machines will have a shim fitted behind the adjusting plate Keep it safe ROTARY MANUAL PLATEN Section 11 The platen may now be withdrawn through the operator side frame with the pulley and eccentric housings in place WARNING THE
34. o release them but take care not to lose the idler gear and washer from inside the clutch side housing To replace the friction feed tyre the friction feed shaft is dismantled as follows See Fig 2 21 Remove the grub screw from the drive hub and rotate the drive hub to align the holes in both hub amp shaft so that a 2 5mm hexagon wrench allen key will pass through both This will enable you to hold the shaft whilst releasing the M6 nut at the end using a 10mm socket wrench and withdraw all components from the shaft Note During dismantling and certainly before re assembly ensure that all components are kept clean and handled carefully to avoid damage The drive has to be sensitive to all stocks particularly lightweight NCR amp it s sensitivity will be impaired if the components are PAGE 8 ROTARY MANUAL FRICTION FEED Section 2 0 2mm 0 008 End Float Grub Screw HA 4 Idler Gear Drive Hub ee Tube Tube Location Dowel Pin Waved Washers M6 Nut Holes Through Hub amp Shaft Friction Tyre amp Clutch Assembly Drive Shaft contaminated or damaged PAP Drive Shaft Adjustment Re assemble the shaft in reverse order but set the position of the drive hub only after the assembly has been fitted into the machine and the four cap head bolts fully tightened See Fig 2 11 It is important that the drive hub is positioned laterally on the shaft so that the support tub
35. ol system circuit board PCB is mounted on the inside of the control panel which is under the feed bed and also houses the mains power inlet socket isolator system switch amp fuses To gain access to these items carefully lower the panel onto it s Support strap by removing the two upper screws The right hand side of the panel has an additional screw below the panel fixing screw which retains the support strap and should not be removed To remove the PCB disconnect all five wiring plugs by easing them out of their headers The main header is mounted horizontally and has three separate plugs Cut any cable securing ties that are on the PCB and partly release the PCB from it s two supports by depressing their tangs Firmly support the PCB by holding the large transformer remove the two fixing screws from the outside of the panel and withdraw the board Horizontal Header with Three Plugs e Transformer Suction PCB has Vertical Header CH Mains In Plug iG a Spacers ba ES Control Panel ae Lid on Suction M e eI E E Sensor Plug bise Fixing Screws Fig 16 12 NUMBERER PAGE 51 Section 16 CONTROL SYSTEM FRN SERVICE The following sections should be used in conjunction with the troubleshooting section in the operators guide 16 2 Trouble Shooting Machine Will Not Run System Switch does notlatch Check that the guards and feed bed are correctly fitted and that both fuses are intact and f
36. on Control Valve The Suction Control Valve is mounted on the Compressor Filter Vacuum port by a short piece of reinforced hose which protects it to some extent from heat and vibration Although generally reliable these valves operate in a relatively harsh environment at speeds of up to 150 Hz Dust ingress is likely to be the most likely cause of trouble but before dismantling the unit check all electrical connections and fuses Suction Control Valve Dismantling Remove the electrical connection by releasing the small fixing screw on the top of the connector and pulling it off the coil Release all three hose clips and remove the valve from its hoses To ease re assembly it s worth making a note of which ports the hoses are connected to Hold the valve body securely preferably in a vice and remove the coil if necessary Its held in place by a thin nut Unscrew the bottom port this is the vacuum port and remove it carefully followed by the plunger assembly taking care not to lose the spring All the valve s components may now be cleaned examined and replaced as required before re assembling in reverse order but be sure to check that the plunger assembly is fully intact and that the rubber washer is properly secured between its two fixing nuts Do not lubricate any part of the valve as this will lead to premature failure The plunger is PTFE coated to resist wear Do not over tighten the coil fixing nut or the connecto
37. onnect the cables correctly Wire colour Wire Number Terminal Ident Orange 30 L Grey 18 N Red 31 A Black 32 C Red 35 H White 36 Blue 37 L Current Limit Set to 1 5 amps with Motor Maximum Speed Set to 170 V d IR Compensation Set to Min Anti Clockwise SCH ids Minimum Speed Set to 70 V dc Tangs Terminal Block E See Table above for Connection Details i Control Box Lid Circuit Board Motor Speed Fig 17 41 PAGE 58 ROTARY MANUAL ELECTRICAL SUCTION Section 17 The following sections should be used in conjuction with the troubleshooting section in the operators guide 17 5 Trouble Shooting Machine Will Not Run Mains Power on Does Not Illuminate Check that mains power of the correct voltage is reaching the machine and rear isolator Check that the mains input lead is securely plugged into it s socket in the side of the control box remove base access panel to check Compressor Does Not Run If the Switch does not illuminate check the connections from the mains inlet socket to the switch and if sound replace the switch If the switch does illuminate remove the base access panel and check the compressor lead is securely plugged into it s socket in the side of the control box Check the connections between the switch and the socket and check the mains voltage at the compressor motor Finally check that compressor is not seized by rotating the fan on top of motor before replacing the unit
38. put Shafts Removal Remove the twin grip drive belt See section 4 1 and any perforating slitting or scoring blades and anvils from the shafts Slacken all the upper and lower drive hubs by using a 2mm allen key in the grub screws amp remove the M8 nuts from the ends of the shafts Note To stop the shafts turning use a 13mm spanner wrench on the flats Slide the lower output shaft out of its clutch side bearing towards the operator side and remove the lower drive hubs while doing so See following note Unlike the input rollers the output shafts are drawn through the operator side frame completely Repeat this procedure for the upper output shaft PAGE 20 ROTARY MANUAL OUTPUT SHAFTS Section 6 Note Before removing the upper amp lower hubs from their shafts study the hubs and note the orientation of the tapped holes in the hub faces It is important that the orientation is maintained during re assembly as it will be impossible to follow the setting instructions for perforating amp slitting See the operators guide if the hubs are incorrectly installed Re assemble in reverse order see Note above but note that bearings are a Slide fit in their housings so if ANY force is required something is wrong and should be investigated before proceeding There are no adjustments for the input rollers or output shafts but you should ensure that the shafts are free to move sideways under the control of their sp
39. r fixing screw ROTARY MANUAL SUCTION CONTROL VALVE Section 15 Coil Fixing Nut o gp AC Mounting Tube Hose To Pressure Side of i NG Compressor adaptor Solenoid Coil Hose To Vacuum Roller via suction control valve Plunger Assembly Bottom Port Re inforced Hose To Vacuum Side of Compressor via in line filter Suction Control Valve Fig 15 11 NUMBERER PAGE 49 SERVICE CONTROL SYSTEM FRN Section 16 3SNH TOHLNOO HOLVIOSI vd d ISNA HOLON cal YaganNns a dl ze es SYS 1 god quvoa LINDYHIO TOHINOO EZ ZZ Lo OC 6L BL ZL OL SE VL EL CL LL OL 6 8 HIAANNS HIAANNS HOLN19 1334 HOLIMS QHVf19 das qaad ONIGNNOWD LNIOd e 8 6 HOLIMS TWANVW OLNY 9N7d INIOIHL 133908 INIOIHL HOLIOVdvo HOLIMS CHYN9 LAdLNO YALLINSNVYL HOSN3S Dx 15 05 Ces S cS 65 H3AI3O3H HOSN3S HOSN3S NOILVLOH 6c HOI SNIH3SIACN 16 11 Ig Control F ION Frict iagram D iring W ROTARY PAGE 50 MANUAL CONTROL SYSTEM FRN Section 16 16 1 Control System Access The contr
40. r to release the control collar Slide the control collar at least 5mm outwards Slide the inner collar off the inner control ring Turn the inner control ring and the inner collar as indicated until they stop and re engage both Check that the over travel is minimised without the clutch binding Re adjust if required Adjust control collar by sliding off of its splines to obtain the stopping position shown in Fig 9 21 on page 27 so that the machine prints accurately to scales on collars Replace clip WARNING THE INTERNAL CLEARANCES WITHIN THE CLUTCH BRAKE UNIT ARE PRACTICALLY ZERO ANY INGRESS OF DIRT OR OTHER CONTAMINATES WILL SERIOUSLY AFFECT THE PERFORMANCE OF THIS UNIT EXTREME CARE SHOULD BE TAKEN TO PROTECT ALL COMPONENTS DURING DISMANTLING amp RE ASSEMBLY DO NOT USE LUBRICANTS NUMBERER PAGE 31 Section 9 CLUTCH ASSEMBLY SERVICE 9 4 Actuator Measurement The actuator controls the stopping and starting position of the numbering heads If the actuator is adjusted too far away from the stop collar the solenoid will not have enough power to operate the clutch consistently The adjustment is therefore critical and is measured as follows Remove the clutch fromthe machine See Section 9 1 Remove the large drive pulley using a 4mm Allen key to release the three countersunk screws Slacken the actuator stop which is eccentric and rotate it so that itis well clear of the actuator P
41. ress the solenoid armature as indicated Not the actuator and measure the clearance as shown in Fig 9 41 Actuator Actuator Stop Actuator Clearance Max 0 2mm 0 008 Armature Solenoid Clutch Backplate Solenoid Fixing Screws Stop Collar Actuator Measurement PAGE 32 ROTARY NUMBERER MANUAL CLUTCH ASSEMBLY Section 9 Actuator Adjustment The actuator should only be adjusted after the over travel has been checked and if necessary adjusted see sections 9 2 and 9 3 Slacken the two solenoid fixing screws using a 4mm allen key and move the solenoid body up to reduce the actuator clearance and down to increase the actuator clearance Tighten the screws and check the actuator clearance Re adjust if the clearance is not correct and ensure that the solenoid screws are fully tightened after adjustment Finally adjust the actuator stop so that it just touches the actuator when the solenoid is operated Collar Position Measurement The machine should print the top of a number at the required distance from the top of the sheet and this distance corresponds to the scale on the numbering head collars The scale is read off the back edge of the numbering head and is affected by the print position adjustment so the print position control must be in it s mid point which is with the end of the knob 75mm 3 away from the side frame of the machine Print Position Control Machine Side Frame 75mm 3
42. rings waved washers or disc springs Note 1 Check this by holding each shaft or input roller in turn amp pulling it against it s springs The shafts should return to their operating positions upon release See Note 3 below Note 1 Some machines may have their control springs waved washers or disc springs on the clutch side Note 2 Before carrying out this check you should ensure that any perforating slitting or scoring units are separated Note 3 Input rollers may not return to their operating position immediately due to the friction between them so rotate the machine by hand and they should move back within a few turns Note 4 The operator side bearings on the output shafts are a press fit and do not normally need replacing but if they do they should be pressed off and on to the shaft using a proper bearing press and following the bearing manufacturers guide lines NUMBERER PAGE 21 Section 7 INKING SERVICE Tie Bar Tie Bar Screw Laa di P4 EN Inking Shaft O Se DX a Ze Ze Som 4 Inking Stop Screw Support Arm Operator Side JL is Removal of Ink Transfer Rollers amp Shaft Release the transfer roller clamp screws using a 2mm Allen key Remove the green polycord drive belt from the operator side Remove the pivot bolt from the operator side only using a 10mm spanner wrench Remove the tie bar screw from operator side only using a 2mm Allen key Slide the inking shaf
43. ro Switch Operating Arm Operating Arm Pivot Switch Operating Point 3mm or 1 8 CON From Tip of Stop Collar Clutch Position Switch 9 8 Clutch Position Switch The clutch position switch controls the feed so that only one sheet ata time is numbered It is adjusted as shown in Fig 9 81 Using a 5 5mm wrench or spanner loosen the two micro switch fixing screws and move the switch up or down so that the tip of the stop collar operates the micro switch 2 to 3mm 3 32 to 1 8 before the end of the lever The clutch must be operated and the machine turned by hand to check this adjustment You will hear a click as the switch operates or if this is not possible a meter may be used between the common and one of the other terminals on the switch Note Before using a meter switch the power off at the mains and set the meter to read resistance Q NUMBERER PAGE 35 Section 11 MAIN PRINT SHAFT SERVICE 10 1 Main Print Shaft Removal The main print shaft may be removed with the clutch assembly in place but you should remove any numbering heads and loosen the grub screws in the collars Remove the clutch drive belt the spring and it s retainer bracket and all the wiring See Fig 9 11 On the friction machine also remove the ink drive idler pulley from the operator end of the main Shaft by un screwing it s shoulder bolt using a 4mm Allen Key Remove the circlip and the four bearing retainer plat
44. s holding the two roller support blocks See fig 3 31 on page 14 Replacing the assembly is a reversal of the above but care should be taken to align all fixing holes BEFORE attempting to replace the fasteners as damage to the threads will result from mis aligned components NUMBERER PAGE 11 Section 3 SUCTION FEED SERVICE Paper Gate Shaft Paper Gate Feed Drive Shaft Operator Side Manifold Large Timing Pulley Feed Drive Timing Belt Clutch Side Manifold Feed Bed Vacuum Roller Manifold Mounting Bracket Mounting Link Loading Table Hose Support Beam Vacuum Roller Assembly Dili plana Vacuum Roller Adjustment If the vacuum roller is not set parallel to the input rollers paper will always be driven to one side whilst it is feeding In order to identify this problem use the following procedure PAGE 12 ROTARY MANUAL SUCTION FEED Section 3 The op side manifold must be set accurately by measuring it s position on the loading table Do not rely on the printed scales because they may not be accurate enough due to limitations of the printing process Load some paper and set the clutch side manifold so that there is no side ways movement of the paper Run a few sheets with the numbering ON and watch carefully the edge of the sheet whilst it is feeding The edge should always run straight as this indicates that the vacuum roller is correctly adjusted If the edge runs off to one side while the suct
45. salignment first check that all fixing screws are secure and that none of the relevant components are damaged When swinging the upper sensor assembly away from its mounting take great care not to strain or trap it s cable and if you are clearing a paper jam avoid bending the input bed as this may result in an excessive gap between upper and lower sensors Side iig i Side Upper Tie Bar A Upper Sensor Mounting Upper Sensor ped S Cable ee Bed Lower Sensor Cable Ties Mounting Lower PE Upper amp Lower Lower Cable Passes Sensor Cable Sensor Cables Tie Bar Over Print Position Shaft Sensor Installation Friction Machine Fig 12 11 PAGE 42 ROTARY MANUAL SENSOR Section 12 12 2 Sensor Replacement If you need to replace the sensors the diagrams in this section will help you as although all machines use the same arrangement the wiring to the sensor assemblies follows different routes You are advised to replace the sensors as an assembly with their mounting hardware to ensure correct alignment NEVER REPLACE UPPER OR LOWER UNITS INDIVIDUALLY AS THEY ARE SUPPLIED AS A MATCHED PAIR Take great care when routing the sensor cables as they are fragile and any damage normally results in failure Ensure that the cables are clear of moving parts particularly around the input rollers and that they do not get trapped when fitting covers or closing Upper Tie Bar Upper Sensor Mounting Upper Sensor Cable
46. t together with the support arm towards the operator side The shaft should slide out of the clutch side bearing which is retained in the clutch side support arm by the side frame PAGE 22 ROTARY MANUAL INKING Section 7 Care should be taken to guide the circlip through the radial slot in the sideframe The operator side support arm will slide off the tie bar which will remain in the machine Remove the circlip and continue to draw the support arm and shaft out of the machine from the operator side whilst sliding the transfer rollers off the shaft Care should be taken not to damage the shaft on the side frame Slots as this will cause the transfer rollers to jam on the shaft Re assembly is a reverse of the above but don t forget to replace the circlip after re installing the transfer rollers as it retains the Shaft laterally between it s bearings If you experience any difficulty in sliding the shaft into the clutch side bearing which remained in it s support arm during dismantling use a 6mm cap head bolt amp large washer to draw the shaft into the bearing DO NOT USE A HAMMER rM E Adjustment Transfer Roller Pressure Remove the green polycord drive belt from the operator side Position one transfer roller near each of the two side frames amp set a numbering collar below each transfer roller Set a numbering head loosely on a collar and holding it firmly seated to the base of the collar with your hand adjust the
47. tch if this is incorrect Check the voltage to the feed clutch which should be 24VDC and replace PCB if this is incorrect Feed wheels operate for one sheet and fail to operate thereafter Check that the rotation sensor micro switch which is located on the main clutch back plate is operated by the clutch stop collar when the clutch rotates and when the clutch stops Check the wiring to the micro switch and to terminals 9 10 11 20 amp 21 on the PCB If all else fails replace the PCB 16 4 Trouble Shooting Machine Will Not Number Sheets feed but will notnumber Release the upper sensor and clean both lenses Check that the LED on the control PCB is not illuminated This indicator should only illuminate when paper is between the upper amp lower sensors but it will also illuminate if the sensors or their cables are damaged If the LED is illuminated check the connections to terminals 4 5 6 amp 7 on the PCB and check that these wires are not shorting Replace the PCB and or the sensors If the LED is not illuminated Check the security of the wires to terminals 9 10 11 14 15 amp 16 on the control PCB and check the connections to the main clutch coil red amp black wires Check the main clutch coil resistance which should be 10 Ohms and replace the coil if this is incorrect otherwise replace the PCB If the clutch does not operate in manual mode check the wiring between the auto man switch on the side
48. tch stop collar when the clutch rotates and when the clutch stops Check the wiring to the micro switch the 6 way plug and socket on the rear of the control box and to terminals 9 10 11 on the control PCB NUMBERER PAGE 61 Section 17 ELECTRICAL SUCTION SERVICE If all else fails replace the control PCB 17 7 Trouble Shooting Machine Will Not Number Sheets feed but will not number Check that the numbering on off switch on the control panel is down to the on position Check that the sensor cables are properly installed and clamped into the correct positions in their 4 way plug and that there are no stray strands of wire which could short out on the lid Also ensure that the 4 way sensor plug is firmly installed into its mating header on the control PCB Release the upper sensor and clean both sensor lenses Check that the LED on the control PCB is not illuminated This indicator should only illuminate when paper is between the upper amp lower sensors but it will also illuminate if the sensors or their cables are damaged If the LED is illuminated check the connections to terminals 4 5 6 amp 7 on the PCB and check that these wires are not shorting Also check the soldered connections to the phono plugs and sockets to ensure they are not shorting Finally replace the PCB and or the sensors If the LED is not illuminated Check the security of the 6 way socket on the rear of the control box and th
49. tion 4 Drive Belts Page 16 4 1 Twin Grip Drive Belt 16 4 2 Adjustment Twin Grip Belt 17 4 3 Motor Drive Belt Adjustment 17 Section 5 Input Rollers Page 18 5 1 Input Rollers Removal 18 Section 6 Output ShaftS Page 20 6 1 Output Shaft Removal 20 Section 7 ING E Page 22 7 1 Ink Transfer Rollers amp Shaft Removal 22 7 2 Ink Transfer Roller Pressure Adjustment 23 Section 8 Registration sss Page 24 8 1 Numbering Registration 24 8 2 Operational Problems 24 8 3 Machine Problems 24 8 4 Clutch Problems 25 Section 9 Clutch Assembly Page 26 9 1 Clutch Assembly Removal 26 9 2 Over travel Measurement 27 9 3A Over travel Adjustment Old Style Clutch 28 9 3B Over travel Adjustment New Style Clutch 30 PAGE 4 ROTARY MANUAL INDEX 9 4 Actuator Measurement 32 9 5 Actuator Adjustment 33 9 6 Collar Position Measurement 33 9 7 Collar Position Adjustment 34 9 8 Clutch Position Switch 35 Section 10 Main Print Shaft Page 36 10 1 Main Print Shaft Removal 36 10 2 Main Print Shaft Re assembly 37 Section 11 CT NOE Page 38 11 1 Platen Removal 38 11 2 Platen Re assembly 39 11 3 Platen Adjustment 40 Section 12 DESO ge okan aa aia anaa kaanan Page 42 12 1 Sensor All Machines 42 12 2 Sensor Rep
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