Fellowes Standard Horizon SRN-9x Service Manual Download

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Instruction Manual

Summary of Contents for Standard Horizon SRN-9x

Page 1: ...Standard Horizon SRN 9x Suction Feed Rotary Numbering Machine Instruction Manual ...

Page 2: ...SERVICE MANUAL Standard Morgana FRN 6 and SRN 9x Read this manual and thoroughly familiarize yourself with its contents before operating or servicing this equipment ...

Page 3: ......

Page 4: ...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 ii Fasteners Most of the pulleys on the machines use dog point screws which engage in holes in the shafts to ensure reliable driv...

Page 5: ...ubstitute 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 above and No 1 Point Drivers for M3 below WARNING DO NOT USE PHILLIPS DRIVERS THESE WILL DAMAGE THE SCREWS MAY SLIP CAUSING DAMAGE OR INJURY iii Ident...

Page 6: ... 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 Inking Page 22 7 1 Ink Transfer Rollers Shaft Removal 22 7 2 Ink Transfer Roller Pressure Adjustment 23 Section 8 Registration Page 24 8 1 Numbering Registration 24 8 2 Opera...

Page 7: ...ition 44 13 2 Strippers 45 Section 14 Compressor 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 Troub...

Page 8: ...leasing the operator side cover but before removing it completely you will need to dis connect the 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 Two M6 Nuts Each Side Two M4 Screws Each S...

Page 9: ...low 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 M6 Nut Washer Hand Wheel Two M6 Nu...

Page 10: ...ousing 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 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 componen...

Page 11: ...ys Drive Shaft Fig 2 21 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 waved was...

Page 12: ...sembly 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 Feed Clutch Fig 2 31 13mm A F Spanner Wrench Upper Input Roller Clutch Spindle Assembly Feed Clutch Drive Pin Drive Slots input Anchor Pin Flats Tang Side Frame Clutch Side Integ...

Page 13: ... 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 two on the clutch side an...

Page 14: ...r to identify this problem use the following procedure Vacuum Roller Assembly Fig 3 11 Section 3 SUCTION FEED Clutch Side Manifold Operator Side Manifold Vacuum Roller Feed Drive Timing Belt Bed Stiffener Loading Table Paper Gate Shaft 1 Hose Elbow Hose Support Beam 2 4 5 6 Paper Gate Large Timing Pulley Feed Drive Shaft 7 8 Feed Bed Slot 3 Manifold Mounting Bracket Mounting Link 6 ...

Page 15: ...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 ...

Page 16: ...o achieve this an alignment tool a piece of dia Ø6 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 th...

Page 17: ...sioned 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 ADJUST THE BELT BY MOVING THE BED STIFFENER...

Page 18: ...lows 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 Remove Bolts Completely Before Attempting to Remove Bel...

Page 19: ...t note that an under tensioned belt will cause poor Section 4 DRIVE BELTS Motor Drive Belt Fig 4 31 Motor Drive Belt Adjust Motor to Tension Belt Motor Fixing Bolts 4 2 Adjustment Twin Grip and Clutch Drive Belts registration 4 3 Adjustment Motor Drive Belt The motor drive belts are tensioned by adjusting the motor position after slackening the motor fixing bolts which all run in slots in the side...

Page 20: ...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 Input Rollers Friction Machine Fig 5 11 Upper Input Roller Input Roller Lower M8 Nut Flats for 13mm A F Wrench M6 Bolts Clamp Washer Wav...

Page 21: ...ller 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 Input Rollers Suction Machine Fig 5 12 Upper Input Roller Lower Input Roller M8 Nuts ...

Page 22: ...he 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 Output Shafts Fig 6 11 M8 Nuts Flats for 13mm A F Wrench Waved Washers See Note 1 Page 21 Bear...

Page 23: ... to move sideways under the control of their springs waved washers or disc springs Note 1 Check this by holding each shaft or input roller in turn 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 chec...

Page 24: ...ator side only using a 10mm spanner wrench Remove the tie bar screw from operator side only using a 2mm Allen key Slide the inking shaft 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 Inking Fig 7 11 Tie Bar Screw Pivot Bolt Inking Stop Screw Polycord Belt Circlip Suppo...

Page 25: ...h side bearing which remained in it s support arm during dismantling use a 6mm cap head bolt large washer to draw the shaft into the bearing DO NOT USE A HAMMER 7 2 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 set a numbering collar below each transfer roller Set a numbering head loosel...

Page 26: ...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 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 num...

Page 27: ... 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 inpu...

Page 28: ...icro 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 29: ... 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...

Page 30: ...t 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 To Reduce Overtravel Move Tangs in This Direction Brake Spring Tang Clutch Spring Tan...

Page 31: ...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 manufacture...

Page 32: ...ROTARY PAGE 30 SERVICE Section 9 CLUTCH ASSEMBLY Over travel Adjustment New Style Clutch Fig 9 32 Actuator Inner Control Ring Inner Collar Control Collar Clip Input Hub ...

Page 33: ...ntrol ring and the inner collar as indicated until they stop and re engage both 6 Check that the over travel is minimised without the clutch binding Re adjust if required 7 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 8 Replace clip WARNING THE INTERNAL CLEARANCES WITHIN T...

Page 34: ...nd is measured as follows Remove the clutch from the 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 it is well clear of the actuator Press the solenoid armature as indicated Not the actuator and measure the clearance as shown in Fig 9 41 Actuator Measurement Fig 9...

Page 35: ...d is operated 9 6 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 ...

Page 36: ... 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 wh...

Page 37: ...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 Ω...

Page 38: ...e four bearing retainer plates 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...

Page 39: ...d 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 tightened to press the bearing into position Remove the special tool and finally replace the circlip the b...

Page 40: ...ft 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 Platen Mechanism Fig 11 11 Platen Eccentric Fixing Bolts Platen Adjustment Lock Shaft Spacers Behind Adjust...

Page 41: ...cs 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 The Narrow ...

Page 42: ...en 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 Platen Adjustment Fig 11 31 Decrease Pressure Increase Pressure Eccentric Fixing Bolts Adjuster Plate Platen Lock Platen Adjustment Cam Edge of Principle B...

Page 43: ...ator 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 se...

Page 44: ...you suspect misalignment 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 Frame Clutch Side Upper ...

Page 45: ...lignment 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 Side Frame Operator Side Upper Tie Bar Lowe...

Page 46: ...d 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 housin...

Page 47: ... 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 Stripper Fig 13 21 0 75mm 0 030 Friction Machine Front Guard Input Strip...

Page 48: ...unlikely to need removing from the machine If you do suspect a problem be sure to check all electrical connections and hoses including the suction valve before removing it Compressor Power Lead Control Box Valve Connector and Lead Vacuum Hose Transit Bolt Assembly End Panel Screws Inlet Filter Housing In line Filter Housing Filter Elements Manifold Hoses Compressor Support Bridge Wing Nut ...

Page 49: ...op 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 14 3 Compressor Removal Remove the compressor power lead from the control box Remove the valve connector from the valve Remove the two manifold hoses from the compressor adaptor Remove the vacuum hose fro...

Page 50: ...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 ...

Page 51: ...5 11 Coil Fixing Nut Coil Mounting Tube Solenoid Coil Valve Body Compression Spring Plunger Assembly Armature Sealing Washer Bottom Port Hose To Pressure Side of Compressor adaptor Hose To Vacuum Roller via suction control valve Re inforced Hose To Vacuum Side of Compressor via in line filter ...

Page 52: ...ISOLATOR SYSTEM SWITCH MAINS INLET GROUNDING POINT CAPACITOR MOTOR FEED CLUTCH NUMBERING CLUTCH ROTATION SENSOR TRIDENT SOCKET TRIDENT PLUG OUTPUT GUARD SWITCH FEED BED GUARD SWITCH SENSOR RECEIVER SENSOR TRANSMITTER SNUBBER 1 2 3 SNUBBER SNUBBER 43 17 1 2 1 2 CONTROL FUSE MOTOR FUSE 6 5 E T R C C E L N 3 2 1 X 5 4 3 2 1 X 5 4 52 53 50 51 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 7 6 5 4 3 2 1...

Page 53: ...w 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 holdi...

Page 54: ...ctive 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 numb...

Page 55: ...Sheets feed but will not number 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 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 7 on the PCB and check that these wires ar...

Page 56: ... SUCTION VALVE C8 GUARD SWITCH C7 STOP SWITCH C6 CHOKE C5 MOTOR C4 FAN C3 COMPRESSOR SOCKET C1 MAINS INLET C2 X DENOTES POLARIZING PIN X X X X 3 2 1 X 5 4 1 3 1 2 1 2 1 2 4 2 4 1 2 3 N L E L N E 24 25 26 7 6 5 4 P1 P2 P4 P3 ROTATION SENSOR SENSOR RECEIVER SENSOR TRANSMITTER MOTOR STOP SWITCH SUCTION VALVE ISOLATOR FAN NUMBERING CLUTCH OUTPUT GAURD SWITCH ENTRY GAURD SWITCH GROUNDING POINT REAR PAN...

Page 57: ...lugs 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 Control Box Fig 17 12 Control PCB Fixing Screws Control Panel Control Fuse 1 amp Motor Fuse 3 15 amp Cooling Fan Fuse 1 amp Bracket Fixing Screws Compressor Socket Mains Power Socket Lid Fan 4 Way Motor 4 Way Choke ...

Page 58: ...4 1 2 3 N L E L N E DIRECT CONNECTION TO TRANSMITTER CABLE RED DIRECT CONNECTION TO TRANSMITTER CABLE SCREEN DIRECT CONNECTION TO RECEIVER CABLE SCREEN DIRECT CONNECTION TO RECEIVER CABLE WHITE 6 20 21 22 23 24 22 23 21 42 41 41 18 1 2 11 12 7 39 2 3 4 5 9 10 14 19 37 10 8 17 29 30 8 30 47 49 54 46 50 56 45 52 51 53 19 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 7 6 5 4 3 2 1 L N A A C C F F H S...

Page 59: ...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 ...

Page 60: ...with re installation of the PCB the following table together with the circuit diagram on the previous page will help you to re connect 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 S Blue 37 L IR Compensation Set to Min Anti Clockwise Current Limit Set to 1 5 amps with Motor Maximum Speed Set to 170 V dc Minimum Speed Set to...

Page 61: ...mpressor 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 WARNING DON T DO THIS WITH THE POWER ON System switch will not latch Check that the guards are correctly...

Page 62: ...ockets 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 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 If output volt...

Page 63: ... 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 securit...

Page 64: ...ower 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 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 o...

Page 65: ...N U M B E R E R PAGE 63 MANUAL ...

Page 66: ......

Page 67: ...Standard Business Systems 10 Connector Road Andover MA 01810 978 470 1920 978 470 2771 SM_FRN6 SRN9x Issue 3 August 2004 ...

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Fellowes Standard Horizon SRN-9x, Service Manual

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