Fellowes Standard Morgana FRN-6 User manual

Standard Horizon SRN-9x
Suction Feed Rotary
Numbering Machine
Instruction Manual

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.

ROTARY
PAGE 2
SERVICE
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.
ii ......... 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fully withdrawn prior to dismantling.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 & all nuts are ISO-Metric
Hexagon. All screws are hardened high tensile steel.
SERVICE MANUAL
INTRODUCTION
ROTARY NUMBERING MACHINES

NUMBERER PAGE 3
MANUAL
INTRODUCTION
Cap Head, Button Head, Socket Countersunk, Shoulder Bolts and
Grub-Screws have 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.
NOTE...... 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 & 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 ........ 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 )

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PAGE 4
SERVICE
INDEX
Introduction ..... .................................................Page 2
¡Introduction 2
¡¡ Fasteners 2
¡¡¡ Identification 3
Section ..1.......Covers ......................................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
3.1 Vacuum Roller 11
3.2 Vacuum Roller Adjustment 12
3.3 Vacuum Hose 14
3.4 Vacuum Belt Adjustment 15
Section ..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.......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 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

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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 .....Platen .....................................Page 38
11.1 Platen Removal 38
11.2 Platen Re-assembly 39
11.3 Platen Adjustment 40
Section ..12 .....Sensor....................................Page 42
12.1 Sensor -All Machines 42
12.2 Sensor Replacement 43
Section ..13 .....Guards....................................Page 44
13.1 Guard Position 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 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

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PAGE 6
SERVICE
Side Covers -Friction Machine.................................... Fig 1.11
Section 1
SIDE COVERS
1.1 ...... 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 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 Side M6 Nut & WasherHandwheel
Operator Side Cover Clutch Side Cover
Facia Plate

NUMBERER PAGE 7
MANUAL
Covers -Suction Machine............................................Fig 1.21
Section 1
COVERS
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)
M6 Nut & Washer
Hand Wheel
Two M6 Nuts Each Side
Five M4 Screws
Each Side
Base Access
Panel Screws -
Two Each Side

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PAGE 8
SERVICE
Friction Feed.............................................................. Fig 2.11
Two Cap Head Bolts Each Side
Grub Screw
Gears Inside Housing Pull Housings Together To Release Pins
Section 2
FRICTION FEED
2.1 ...... 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 to
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 & 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 -& it's
sensitivity will be impaired if the components are