FOLDING SYSTEM - PrintFinishing.com
Contents
1. W EF O FOLDING SYSTEM SERVICE MANUAL Morgana Systems Limited Snowdon Drive WinterHill Milton Keynes Buckinghamshire MK6 IAP United Kingdom Telephone 0908 608888 Facsimile ISSUE 2 MARCH 2002 625 030 INTRODUCTION SERVICE WL GJ FOLDING SYSTEMS Introduction The purpose of this manual is to explain the procedure for dis mantling and re assembly of the major assemblies on both the Folding and Cross Folding 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on the machines use dog point screws which engage in holes in the shafts to ensure reliable drive They must be fully withdrawn prior to dismantling All threaded fasteners are isometric amp all nuts are isometric hexagon All screws are hardened high tensile steel Cap head Button head Socket countersunk Shoulder bolts and Grubscrews have internal hexagon drives which require isometric hexagon wrenches allen2. 5 Replace the jumper at LK1 onto the two pins nearest to the potentiometer connector Note An alternative method instead of performing steps 3 4 amp 5 above is to leave the jumper in its original position and to press the On button while carefully shorting out the two pins of LK1 furthest from the poten tiometer connector with a small electrical screwdriver 6 Insert the Calibration plate 90 034 01 with its inserts set at 225 and move the deflector up to the plate 7 Press the Micro button when the display shows 225 the display will now change to read 160 8 Insert the Calibration plate with its inserts set at 160 and move the deflector up to the plate press the Micro button the display will now change to read 105 PAGE 36 FOLDING d 10 11 MANUAL FOLD PLATES Section 12 Insert the Calibration plate with its inserts set at 105 and move the deflector up to the plate press the Micro button the display will now change to read 50 Insert the Calibration plate with its inserts set at 50 and move the deflector up to the plate press the Micro button the calibration is now complete Replace the lower fold plate cover Note The above procedure is only necessary if either the PCB or the potentiometer is replaced 12 7 Digital Fold Plate Adjusting Accuracy If the display is inaccurate amp needs adjusting
3. Control Box The control box contains the printed circuit board relay and switches that are required to operate the machine and may be removed as follows Switch off the power supply at the isolator on the rear panel of the main unit and dis connect the crossfold cable plug from the 8 way socket which is also on the rear panel of the main unit On 16 page units you will also need to remove the 8 page units 8 way plug from the socket on the rear of the control box Remove the operator side cover and dis connect the guard and motor plugs from the rear of the control box Also remove the grounding earth cable fixing nut Remove the four screws located at the corners of the control box front panel and carefully slide the box out of the machine Access to the PCB relay and switches can now be gained by open the lid after slackening off the two retaining screws Replacement is a reversal of the above procedure 18 2 Motor Speed Control Board and Relay The motor speed control board PCB is mounted on four supports within the control box 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 circuit diagram on the previous page will help you to re connect the cables correctly The relay may be removed by dis connecting all the cables from the tab terminals and removing the two M3 nuts and bolts from the relay cover Min
4. sssssssssnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnaa Fig 5 21 5 3 Feed Belt Adjustment The feed belt must be correctly tensioned for correct operation If under tensioned the belt will track oft the rollers and if over tensioned the sidelay will be difficult to position across the feed bed when changing paper size The adjustment must be set equal on each side gauged by checking the gap in each bracket as indicated in fig 5 21 The feed belt tension is checked by raising the feed bed on the gas strut and measuring the distance from the middle of the belt to the bed which when correctly tensioned is typically 41mm To adjust the tension use a 10mm wrench on the adjusting nuts but ensure that each side is adjusted equal amounts as the gap in the adjusting brackets as indicated by the arrows in fig 5 21 must be equal both sides of the machine PAGE 14 FOLDING MANUAL FEED DRIVE BELT Section 6 M4 Fixing Screws a Feed Bed Belt Cover Motor Mounting a V Gas Strut Bracket 4 M5 Nuts amp Bolts HA oe Drive Pulley Motor Bracket tile Motor Drive Motor Drive Belt Toothed Torque Disc Gear Box Belt Cover Feed Driv Belkin FL 6 1 Feed Drive Belt Access The feed drive belt which takes the drive from the motor to the gearbox is accessed by removing the six screws securing the belt cover and sliding the cover over the pulleys The feed drive belt must be correctly tensioned as in
5. clamp Note After replacing the belts it will be neccessary to adjust the deflector as described in section 12 13 PAGE 34 FOLDING MANUAL FOLD PLATES Section 12 12 6 Digital Fold Plate Calibration 1 2 i ii iii iv v Remove the lower fold plate cover The following process is only necessary if the potentiometer has been replaced move onto step 3 if this is not the case To set up the Potentiometer for the Upper or the Lower Fold plate see Fig 12 15 amp Fig 12 16 and proceed as follows Move the Fold Plate fine adjuster knob so that itis in its central position 10 mm of thread showing Loosen the gear shown in Fig 12 15 By rotating the loose gear perform the following potentiometer adjustment Turn the potentiometer fully anti clockwise and then 5 turns clockwise Re tighten the loose gear Move the Fold Plate Deflector or Stop so that it measures 220 mm from the fold plate nose to the front of the deflector see Fig 12 16 Loosen gear Fig 12 15 SYSTEMS PAGE 35 Section 12 FOLD PLATES SERVICE 3 Move the jumper at LK1 onto the two pins furthest from the potentiometer connector see Fig 12 17 POSITIONAL DISPLAY PCB VIEWED ON NON COMPONENT SIDE Potentiometer Connector Fig 12 17 4 Switch on the display by pressing the On button The display will show Cal for four seconds and then toggle between tSt 225 and 8 8
6. Calliper Clamp Screws Linear Bearings Linear Bearing LH Bearing Plate BIEN FIG re Al 8 2 Linear bearings Continued Each moving calliper has two linear bearings which should be set one ata time as follows 1 The right hand linear bearing should be positioned clear of the moving calliper and both screws tightened 2 Push the left hand linear bearing against the bearing plate as indicated and lightly tighten both screws 3 Check for lateral movement at both the top amp bottom of the moving calliper and if it is excessive go to step 4 If there is no lateral movement go to step 5 PAGE 20 FOLDING MANUAL OUTER FOLD ROLLERS Section 8 Note Permissible lateral movement is less than 0 025mm 0 001 and can be felt either at the top or the bottom of the calliper 4 Using a Suitable punch lightly tap towards the calliper the end of the left hand linear bearing that is allowing sideways movement and repeat check 3 5 Check the moving calliper for movement and if it will not slide up and down go to step 6 If it will slide up and down go to step 7 6 Using a suitable punch give both of the screw heads a light tap and repeat checks 3 and 5 after each tap 7 Fully tighten the clamp screws for the left hand linear bearing repeat checks 3 and 5 and carry out the above procedure as often as is necessary to obtain the correct setting 8 Push the right hand linear bearing after slac
7. i e A4 81 2 x 11 does not fold accurately in half when the display reads 148 5 51 2 the following procedure should be followed 1 Remove the upper fold plate cover and disconnect the potentiometer connector from the PCB see Fig 12 17 on Page 36 Slacken off the potentiometer gear on the shaft Next to the timing belt pulley Slightly tighten the gear so that it can be turned but is not loose on the shaft Place the fold plate into the machine without its lower cover Run the machine and adjust the deflector position on the fold plate until A4 81 2 x 11 sheet folds exactly in half Re connect the potentiometer connector to the PCB press the On button amp rotate the loosened gear until the display reads 148 5 51 2 tighten the gear Replace the lower fold plate cover SYSTEMS PAGE 37 CONTROL SYSTEM SERVICE Section 13 3OV4H3LNI SOA RON HIM TYNOLLdO HOLS ALIMINONd HAA0I NYHI 932 94X H3UJANAN ap 05 Moassoyd D p me m ES HIN gett SH 3578 Q1 NG On H1871 Ol N IL FNN S wata S325 290IW ZOfzt TOYZ FO 9 JLVII NTIR ZEZ A AN JAA ILFSIONI CC SAHL SHEI SILON MOLIAS ALIMIXOdd an t Ira is TI YOLON Wie ADT NB g st HUN se a IMS ES sk ME JIM YOLOW Eli 105 JATrA Doop po v ig 13 11 Harness EE T n iring Folder W ircuit Diagram C FOLDING PAGE 38 MANUAL CONTROL SYS
8. intact remove drive side cover and check the main pulley If the rollers turn when the handwheel is turned check the fuse for motor 1 FS4 3 15 amp on the main control box If the fuse blows again disconnect the motor terminals and replace the fuse If the fuse blows repeatedly replace the control box Check connections on the motor and choke and connections at the back of the control box Set motor speed to 12 o clock and check voltage at motor which should read approx l00v If no voltage re check connections on control box If ok change control box 19 8 Counter Not Working The counter operates by means of a sensor housed under the feed bed in front of the paper gate and a reflector that is attached to the paper gate tie bar The counter sees reflects the gaps between the sheets so therefore accurate counting cannot be achieved on stream feed If the counter is erratic or fails to function when feeding in auto check the following 1 Look to see if the green light under the counter display is SYSTEMS PAGE 57 Section 20 TROUBLE SHOOTING SERVICE illuminated If not raise the feed bed and clean the reflector and the eyes on the sensor with a brush If the reflector and sensor eyes are very dirty use a cloth moistened with water 2 Check the sensor connector at the rear of the control box is secure 3 Check that the sensor alignment by referring to section 7 4 4 If the green light und
9. 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 PAGE 2 FOLDING MANUAL INTRODUCTION Pan head and Cross head countersunk screws all have 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 IN URY lil 1dentification For general identification of areas of the machines the following terms are used Operator side Drive side opposite operator side Feeder end on your left Swing up end on your right V aas New Machine Preparation Remove all packaging materials All metal parts including the folding rollers have a protective coating and any excess should be removed Connect the power cable to the mains supply The machine requires 220 240V 50Hz 11 Amps or 200 220V 60Hz 13 Amps Fit the fold plates to the machine and tighten securely Turn the fold rollers by using the hand wheel on the drive side of the machine to ensure it rotates freely Switch on the machine and check that all functions operate Set up the machine to fold paper and check tha
10. not rotate the problem will be either a transmission failure or the vacuum roller has seized See section 3 1 for vacuum roller replacement To check transmission inspect the drive through the universal joints ie grub screws in coupling hubs If the universal joint is sound start the motors and look to see if the gearbox handwheel located under the feed bed is turning If the handwheel is turning the gearbox belt drive 100XL inside the gearbox may have snapped See section 7 for details of how to remove the belt drive guard cover and the gearbox Replace the belt in the gearbox by following the drawing in the parts manual and referring to section 7 SYSTEMS PAGE 53 Section 19 TROUBLE SHOOTING SERVICE NOTE Be careful to keep the shafts and bearings housed near the sensor in place at all times to prevent damaging the sensor 5 Check motor brushes on feed bed motor Slide the delivery roller to one end of the delivery and lift the feed bed Remove the gas strut from the side frame lift the feed bed right up and rest the gas strut on the conveyor roller Take off the motor by removing the four screws in the motor bracket Hold the motor as you remove the screws and when all screws are removed twist the drive end of the motor downwards slightly This will allow you to remove the drive belt and remove the motor There is no need to remove the belt drive cover as a Suitable tool may be used to hook the belt over the
11. roller over the bottom roller and upwards back under the top roller around the cam once more and underneath the other side of the clamp screw and washer 4 Pass the cable over the bottom roller and forwards between the perforator shafts The cable should now be as shown in fig 11 11 with 1 1 2 turns around the cam 5 Rotate the stub shaft clockwise counter clockwise on the drive side Pass the upper length of the calliper cable through the hole in the stub shaft until it is sticking out 25mm or 1 inch Rotate the stub shaft to it s normal position 6 Pass the lower length of the cable around the stub shaft and down the hole it may be necessary to use pliers to achieve this 7 Pull both ends to remove all slack from the cable and fully tighten the cable clamp grub screw in the end of the stub shaft Note This screw must be very tight 8 Ensure that the stub shaft is in it s central position with the cable hole vertical 9 Tighten the cable clamp screw in the cam on the centre roller 10 Check the operation of the callipers and cut the ends of the cable to a reasonable length SYSTEMS PAGE 29 Section 12 FOLD PLATES SERVICE Locking Screw AA Adjusting Screw Upper Rail ey ER J acking Screw an we i Se ki Fold Plate Lower Rail Adiustment sx akRR RER ass Fig 12 11 Lower Rail Plate Shown Up side Down 12 1 Fold Plate Lower Rail Adjustment The fold plate lower rail on ea
12. 1 2 Calliper Cable Replacement 29 Section an 12 FOld Plates DEN Le 30 12 1 Fold Plate Lower Rail Adjustment 30 12 2 Lower Rail Initial Set up 31 12 3 Deflector 32 12 4 Deflector Stop 33 12 5 Toothed Belts 34 12 6 Digital Fold Plate Calibration 35 12 7 Digital Fold Plate Adjusting Accuracy 37 Section 13 CONtrOl System 2 Page 38 13 1 Control Box 39 13 2 Motor Speeds 40 Section 14 COMPIeSSOP sscssssessssessseeseeeess PAGE 41 14 1 Compressor 41 14 2 Filters 42 14 3 Compressor Removal 42 Section 15 Suction Control Valve Page 43 15 1 Suction Control Valve 43 15 2 Valve Dismantling 43 Section 16 Electric Delivery 0002 Page 45 16 1 Electric Delivery Motor Speed 45 Section 17 Swing up Perforator Page 45 17 1 Removal 45 17 2 Dismantling 46 Section 18 CrOSS FOLd Unit sssssssssssess21s PAGE 47 18 1 Control Box 48 18 2 Motor Speed Control Board amp Relay 48 18 3 Cross fold Bed Adjustment amp Removal 50 18 4 Cross fold Bed Transfer Gear Assembly 51 18 5 Cross fold Bed Feed Rollers 52 18 6 Cross fold Bed Roller Drive Shaft 52 Section 19 Trouble Shooting Folding Unit 53 Section 20 Trouble Shooting Auxilliary Units 58 20 1 Electric Delivery 58 20 2 Cross fold Unit 59 SYSTEMS PAGE 5 Section 1 COVERS SERVICE M6 Fixing Bolts 4 Each Side Tee Handle Side Cover Op Side Shown Si KONTER e
13. ERVICE M5 Fixing Screw 6 Positions ee Vacuum Roller Suction Choke Spigot Support Block Connecting Tube Connecting Tube Support Blocks Adjusting Knob VACUUM EUR 311 3 1 Vacuum Roller Removal The vacuum roller assembly is located on the underside of the feed bed see fig 5 11 and is removed by releasing the six screws securing the three support blocks to the feed bed using a No 2 pozi driv screw driver To disconnect the vacuum hose from the roller fully remove the grub screw as shown in Fig 3 11 slide the connecting tube over the hose and twist the hose off the spigot on the vacuum roller assembly Take care not to lose the spacer On re assembly ensure that the hole in the spacer is opposite the suction choke and lined up with the grub screw hole in the connecting tube PAGE 10 FOLDING MANUAL SIDE LAY Section 4 3 2 Vacuum Roller Adjustment The grub screw should initially be lightly tightened opposite the suction choke see fig 3 11 However with the vacuum roller assembly fitted to the machine the grub screw should be fully tightened so that the suction choke is in it s normal operating position at the top with the adjusting knob accessible and without the vacuum hose trying to rotate the suction choke out of position 4 1 Side Lay Removal The side lay is removed as follows Remove all the paper transport balls from their holders Move the side lay
14. LD PLATES Section 12 Stop Screws Deflector Deflector Fingers Upper Front Rail Blades Fingers amp Blades Flush Fold Plate Deflector Stop Position 2 FIG 12 13 12 4 Fold Plate Deflector Stop The deflector must stop in the correct position when moved fully forward to deflect This position is controlled by the deflector stop screws which should be adjusted so that the most forward edges of the deflector fingers and the upper front rail blades are flush Note The deflector must first be set parallel to the upper rail as described in the previous section 12 3 SYSTEMS PAGE 33 Section 12 FOLD PLATES SERVICE Carriage Plate Toothed Belt Op Side B4 33 32 31 30 29 28 27 26 Belt Clamps 342 or 13 On Scale Metric Belt Shown Imperial version is similar Fold Plate Toothed Belts sscsssssssssseessessesseseesessesesFlQ 12 14 12 5 FOld Plate Toothed Belts If the fold plate toothed belts are removed for any reason they must always be replaced with new belts which must be cut before fitting An unprinted belt may be cut in any position but a printed scale belt should be cut 25mm 1 inch from the end of the scale and clamped to the carriage plate in the exact position shown in Fig 12 14 The loose end is then passed around the pulleys through the hole in the carriage plate and the clamp is fitted loosely Tension the belt using a pair of pliers and then tighten the belt
15. Screw MANS FIG 2 10 2 1 Manifolds Removal Each manifold may be removed from the machine by twisting the hose off it s elbow connector unscrewing the rear clamp screw and unscrewing amp removing the front clamp assembly The front end of the manifold may now be lifted clear of the paper gate shaft and slid backwards to release it from the loading table Note Look out for the clamp spring located on each spigot PAGE 8 FOLDING MANUAL MANIFOLDS Section 2 2 2 Manifolds Adjustment The manifolds are a sealed assembly and do not have any serviceable parts or internal adjustments however the height to which the front clamp assembly tightens up is adjustable The clamp assembly is set so that the manifolds are not tight against the loading table and thus do not push down on the feed bed and affect the height of the vacuum roller The clamp assembly is set so that when tight the manifold has 0 5mm of vertical movement when pushed down ward against the clamp spring at the front end This adjustment is obtained by altering the length of the front clamp assembly which consists of two socket set screws tightened together within the knob The short clamp screw inside the knob is released using a 3mm allen key through the hole in the end of the knob Adjust the long protruding clamp screw as required and re tighten the short clamp screw inside the knob SYSTEMS PAGE 9 Section 3 VACUUM ROLLER S
16. TEM Section 13 Fuse 1 T 100 ma i Fuse 6 F 10 amp Fuse 5 F 200 ma Fuse 4 F3 15 amp Fuse 3 F 2 0amp Fuse 2 F 2 0 amp Main PCB Test Point TP3 Test Point TP7 Low Speed 3 High Speed High Speed Current Limit Test Point TP1 Feed Motor Settings Roller Motor Settings Control BOX EE Ae 13 12 13 1 Control Box The control box contains all the printed circuit boards that operate the machine The box is removed as follows Switch off the power supply Remove the operator side cover Dis connect the plugs from the rear of the control box Remove the two screws located at SYSTEMS PAGE 39 Section 13 CONTROL SYSTEM SERVICE the top corners of the control box front panel Slide the box out of the machine Lift off the lid after slackening off the four screws 13 2 Control Box Motor Speeds The motor speeds must be synchronised so that when the operator sets each speed control to the same position the sheets pass from the feeder section to the roller section without snatching or buckling Remove the lid of the control box and replace the box in the machine 1 Connect a volt meter Set to read 220v dc across the roller motor terminals 2 With the motor 1 speed control on the front panel set at it s minimum adjust the roller motor low speed pre set on the main PCB to obtain 20 volts at the roller motor 3 With the motor 1 speed control on the front panel set at it s maximum adjust the rol
17. aliper may now be withdrawn to the drive side 9 2 Centre Fold Roller Re Assembly Assemble in reverse sequence but before proceding check the condition of the perforator drive tyres as outlined in section 10 and note the following Ensure that the cable clamp screw holes in the cam are in the correct position as the roller is replaced by rotating the cams to obtain the correct position Push the fixed calliper firmly against the machined appeture in the side frame towards the feed end of the machine before tightening the nine bolts around the fixed calliper See fig 10 2 The linear bearings on the bottom roller must be set before fitting the pressure springs Note eu New calliper cables and nylon inserts Spacers MUST be used See Section 11 2 SYSTEMS PAGE 25 Section 10 PERFORATOR SHAFTS SERVICE Fixed Calliper S Moving Callipers Plate Outer Upper Perforator zb H Fixed Calliper Shaft Fixing Screws Fixed Callipers Fold Rollers Shaft Linear Bearings Lower Perforator Shaft Main Roller Centre Calliper J aws Perforator Shafts ccscscscscssssseesessesenseesessessessssssssesessF g 10 11 10 1 Perforator Shafts Removal The perforator shafts are located in the machine using the same bearing housings fixed callipers as the centre roller Owing to the extent of dismantling required consideration should always be given to replacing the drive tyres on the perforator shafts when
18. apen Check that all connections inside the control box are intact Check that the rotation sensor housed inside the gear box is operating correctly Refer to section 7 3 for details 19 4 Air On Motors Not Running GREEN MOTOR LIGHT DOES NOT ILLUMINATE 1 2 Check Fold Aux switch on rear panel is in folder mode Check the guard circuit by disconnecting the Din plug nearest to the multi pin connector on the rear of the control box and inserting Din test plug part no 613 049 if available If the motors then run check the magnetic reed switch on the side frame located on the drive side under the feed bed for continuity Make sure the bed is down Remove the side cover on the drive side and check the swinging top guard micro switch If the switch is intact and the machine runs with the cover off but fails with the cover on Check that the micro switch actuator arm is not fouling on the side cover or set too close to the micro switch WARNING YOU MUST REMOVE THE DIN TEST PLUG BEFORE RETURNING THE MACHINE TO THE OPERATOR GREEN MOTOR LIGHT DOES ILLUMINATE SYSTEMS PAGE 55 Section 19 TROUBLE SHOOTING SERVICE 1 Check both motor fuses F 3 2 0 Amp amp F 4 3 15 Amp 2 Replace control box 19 5 NO Air Motors Running 1 Check compressor control fuse F 5 on control box 200mA 2 Check the mains supply to the compressor The compressor start contactor is housed inside the rear ele
19. ch fold plate may be adjusted to reduce the gap between the upper and lower rails or may be moved closer to or further away from the fold rollers If heavy stock sticks in the fold plate without folding providing the rollers are set correctly this may indicate that the lower rail has been set too close to the fold rollers If light stock does not enter the fold plate has a very small fold or damage to the lead edge this may indicate that the lower rail has been set too far away from the fold rollers PAGE 30 FOLDING MANUAL FOLD PLATES Section 12 12 2 Lower Rail Initial Set up With all screws loose turn the adjusting screw using a 4mm ball ended allen key until the slot in the lower rail is central beneath the head of the locking screw For heavy stocks the slot should be showing at the back of the locking screw see last paragraph Lightly tighten the locking screw whilst watching the lower rail and stop tightening when the lower rail starts closing the gap Light stocks may need the gap closer see last but one paragraph Screw in the jacking screw until it lightly touches the lower rail as before stop turning the jacking screw as soon as the lower rail starts to open up and fully tighten the locking screw Check the gap between upper and lower rails at the centre The gap should be 2mm 5 64 Check by using a 2mm allen key as a gauge Adjust the jacking and locking screws to obtain the requ
20. chine as a unit by releasing the two M10 nuts Both shoulder bushes are then pulled inwards and removed The M10 bolt on the operator side is then pulled outwards and the swing up unit is removed SYSTEMS PAGE 45 Section 17 SWING UP PERFORATOR SERVICE Mounting Spindle Shoulder Bushes ac M 10 Nuts Hye J Flats Wrench Solid Hubs Lower Tyred Hubs Upper Drive Gears Lower Perforator Shaft Upper Perforator Shaft Swing up Perforating Unit cscscscscsssssessesesssesesseeeeees FIG 17 11 17 2 Swing up Perforating Unit Dismantling Once the unit is off the machine the perforator shafts can be removed from the unit The shafts are removed by releasing the M8 nut whilst stopping the shafts rotating by using a 13mm wrench on the flats With the M8 nuts removed the shafts are passed through the unit sliding off all the hubs in the process Upon re assembly fit the hubs correctly with the solid hubs on the lower shaft with their grub screws facing the drive side and the tyred hubs on the upper shaft with their grub screws facing the operator side PAGE 46 FOLDING Section 18 CROSS FOLD UNIT MANUAL eCl SICHI OGN a s oO D Lk i enen T 7 3200 S 5 29 20 com st Hi NS 18 11 Ig H x lt D Son J E QO Ss Ww Ww oO Sen QO ircuit Diagram C PAGE 47 SYSTEMS Section 18 CROSS FOLD UNIT SERVICE 18 1
21. ctrical panel Check across pins 1LI and 5L3 which should be at mains supply voltage 3 Check that the pins in the connector inside the roof of the base unit are clean and there are no signs of sparking or replace as required 4 Unbolt the compressor and remove it from the machine Inspect and replace the complete unit if necessary 19 6 Loss of Power when Starting Compressor 1 Ensure that an extension cable is not being used causing a drop in voltage Due to the relatively high current required to start the compressor the mains cable supplied should not be extended in any way 2 Check the main fuse in the plug or distribution board 3 Check the main isolator switch on the rear panel 4 Check filters are not clogged and change them frequently Cleaning has only a short term effect WARNING EXPENSIVE DAMAGE WILL OCCUR IF THE COMPRESSOR IS ALLOWED TO RUN WITHOUT ITS FILTERS 5 Check customers supply voltage and if necessary fit a Voltage Boosting Transformer of sufficient output level PAGE 56 FOLDING MANUAL TROUBLE SHOOTING Section 19 6 Check all wiring connections especially on the mains cables Note Always let the compressor reach full speed Before starting the motors 19 7 Rollers Not Turning Feed Working 1 Turn the handwheel on the drive side of machine If the rollers will not turn remove operator side cover and check the transmission If all the gears and their grub screws are
22. d to it must now be removed by releasing their screws in the top amp bottom flanges Finally remove all the screws securing the drive shaft bearing housings to the drive side rail and draw the shaft assembly out of the rail Re assembly is a reverse of the above procedure but leave the drive side support bracket screws loose until the assembly is complete On completion of the assembly including the front rail and short roller adjust each drive side support bracket to ensure that all the roller drive plugs make contact with their corresponding drive hubs on the drive shaft in exactly the same position to ensure consistent roller surface speed PAGE 52 FOLDING MANUAL TROUBLE SHOOTING Section 19 19 1 Machine Dead 1 Check main switch on rear panel is illuminated and if not check main fuse at mains supply If there is power supply to the machine replace the main switch If the main switch is illuminated check the logic fuse F 1 on back of control box See Note Check connections at back of control box Replace control box Note Fast blow fuse 315MA has been replaced with a 100MA Time Delay fuse from machine serial No 013640WDAC 19 2 Air On but Paper Not Feeding CHECK TO SEE IF VACUUM ROLLER IS ROTATING IF NOT 1 Check that the paper gate is not set too low and jamming the vacuum roller Place your hand under the feed bed hold the belt and move it manually If the drum does
23. drive pulley upon re assembly 6 Check the voltage to feed bed motor at the four way connector which should read 220VDC across the orange P and brown N and 50 170VDC depending on speed control setting across the red P and black N If no voltage check all cables back to the control box and if intact replace control box Replace brushes if they are shorter than 3 8 8mm 7 If brushes and voltages are sound replace the motor 19 3 No Suction Air On amp Motors Running IF GREEN FEED LIGHT IS FLASHING WITH FEED SWITCH ON 1 Check fuse FS6 1 0A on control box 2 Remove end panel at the loading table end of the machine and without disconnecting the fan which should have enough flex to allow you to rest the panel at the side of the machine see section 1 check that vibration has not caused the large nut on the coil and valve assembly to shake loose 3 Remove the valve assembly and refer to section 15 for servicing details PAGE 54 FOLDING MANUAL TROUBLE SHOOTING Section 19 4 5 Replace the solenoid coil Check the power supply to the coil which should Read 6v dc when the feed is switched to Stream IF GREEN FEED LIGHT DOES NOT FLASH WITH FEED SWITCH ON 1 Check the multi pin connector and din plugs at the rear of the control box are secure Remove the cover on the operator side and remove the control box from machine Check that no pins on the multi pin connector are bent or missh
24. er the counter display fails to illuminate after realignment change the control box or counter board if available 20 1 Electric Delivery Not Running 1 Check that the lead is plugged into the socket on the rear panel 2 Check the fuse by removing the electric delivery control box 3 Check the fuse FS2 2 0 amp on the main control box 4 Check the electric delivery motor brushes 5 If fuse keeps blowing check that the catch plate at the end of the delivery is not fouling on the cord roller 6 Make sure that the screws which hold the catch plates are not loose and preventing the cord roller from rotating 7 Check the voltage at the motor plug on the underside of the delivery bed It should be 20 to 200 VDC depending on the position of the speed control knob If its incorrect replace the PCB if available or the electric delivery control box 8 Finally replace the motor PAGE 58 FOLDING MANUAL TROUBLE SHOOTING Section 20 20 2 Crossfold Right angle Unit NO POWER AND NO GREEN LIGHT ON RIGHT ANGLE UNIT 1 Check fold aux switch on main unit is set to auxiliary This will complete the guard circuit and make sure all guards are in place on both the folder and cross fold unit 2 Check auxiliary plug and socket on main unit If broken caused by operator not unplugging before wheeling the unit away replace You will need an extractor tool Morgana special tool no 620 023 to do this easily Tr
25. ers are set correctly but note that the bottom roller is set with a slightly wider gap than the top and back rollers A Cut some 70gsm 14lb bond into strips 10mm 3 8 wide and insert a piece between the calliper jaws on each side of the machine and wind two strips of the same paper one at each side between the fold roller being set and the centre roller For the top and back rollers wind the strips between the safety rings For the bottom roller wind the strips between one of the polyu inserts and a grooved section PAGE 22 FOLDING MANUAL OUTER FOLD ROLLERS Section 8 B Stop the rollers rotating by holding either the gear or the pulley on the centre roller Do not hold the outer fold rollers and do not use any kind of wrench C Pull the strips of paper from the roller The pull should be 1 2kg or 2 6lb If the pull is less go to F If the pull is more go to G If the pull is correct and more importantly equal on each side of the roller go to H If you have no means of measuring the pull the paper strip should just slide out from between the rollers without tearing D If the pull is less than specified slacken the lock nut and turn the adjusting screw anti clockwise a small amount using a L shape 2 5mm allen key Tighten the lock nut open the calliper using the tee handle and reposition the piece of paper between the calliper jaws Repeat check E E If the pull is more than specified slacken the lock
26. ever the centre roller is removed The instructions that follow are assuming that only the perforator shafts require dismantling The perforator shafts should be removed as follows PAGE 26 FOLDING MANUAL PERFORATOR SHAFTS Section 10 On the operator side Remove the two large gears the two gears on the perforator shafts the large idler gear the lower roller gear and the primary conveyor gear Remove the calliper cable See Section 11 Remove the nine bolts securing the fixed calliper plate and remove the outer plates The inner plate remains in position Remove the lower roller calliper jaw and the lower roller left hand linear bearing On the drive side Remove the drive belt and the large pulley Remove the nine bolts securing the fixed calliper plates and remove the outer plate The inner plate may remain in position Remove the lower roller calliper jaw and the right hand linear bearing The perforator shafts and their bearings may now be carefully pushed out of the fixed calipers towards the drive side of the machine Retrieve the fixed caliper inner plates as the shafts are released from their bearing housings The M8 nuts and bearings may now be removed and the shafts drawn towards the operator side and out of the machine 10 2 Perforator Shafts Re Assembly Re assemble in the reverse sequence but note the following Ensure that the fixed calliper plates inner are in position whilst inserting
27. ged ee e EENS ENER E Eggs LL 1 1 Side Covers Removal In order to remove the Side Covers the Tee Handles must be removed from both sides of the Machine and on the Drive side the handwheel must also be removed using a 2 5mm allen key The tee handles are removed using a 13mm wrench spanner to hold the nut behind each handle whilst unscrewing the handle Once loosened fully unscrew the handle but leave the nut on the spindle Each side cover is secured by four bolts as shown in the drawing and using a 4mm allen key for ease of task preferably a ball ended type release the screws PAGE 6 FOLDING MANUAL COVERS Section 1 Pozi driv Screws Base Unit Electric Delivery Base Unit Base Access Panel Base ACCESS Panel siss Fig 1 21 1 2 Base Access Panel The base of the machine contains the compressor for the air and vacuum systems Access to the compressor is achieved by removing the electric delivery and releasing the two pozidriv screws on top of the base at the fan end below the delivery Pull the top of the panel forwards and when clear drop down to release the bottom from the base unit Take care of the cable to the fan See Section 14 for details of the compressor SYSTEMS PAGE 7 Section 2 MANIFOLDS SERVICE Front Clamp Assembly Short Clamp Screw Long Clamp Screw Manifold Assembly Op Side Shown Elbow Spigot Paper Gate Shaft Rear Clamp
28. housing Remove the screw that secures the other delivery bed to the bearing housing and withdraw the gear and bearing housing assembly in the direction shown by the arrow When replacing the transfer gear assembly ensure that the bearing housing is correctly adjusted to minimise but not eliminate back lash between the mating bevel gears SYSTEMS PAGE 51 Section 18 CROSSFOLD UNIT SERVICE 18 5 Crossfold Bed Feed Rollers The feed rollers are removed by first removing the transfer gear assembly as described in the previous section Remove the front rail and spacers from the side rails The first roller is shorter than the rest and will be removed with the front rail Each of the remaining full length rollers may now be removed by releasing the two screws which secure each of the support brackets to the top amp bottom flanges of the non drive side rail and easing the shaft of each feed roller assembly out of the support bracket on the drive side of the bed 18 6 Crossfold Bed Roller Drive Shaft The roller drive shaft is situated inside the drive side rail and to remove it the rail must be removed from the rest of the cross fold bed assembly The roller support brackets as described in the previous section are not fixed to the roller shafts but are a slide fit and only support them so the rollers remain attached to the non drive side rail With the drive side rail removed all the roller support brackets fixe
29. imum and maximum motor speeds may be set by adjusting the pre sets on the PCB but the IR compensation and current limit controls should not require altering from their factory settings PAGE 48 FOLDING MANUAL CROSS FOLD UNIT Section 18 18 2 Motor Speed Board Continued To set the minimum motor speed turn the front panel speed control to minimum and connect a volt meter set to read up to 50V dc across the red and black supply cables to the motor Adjust the Low speed pre set to read 25V dc To set the maximum motor speed turn the front panel speed control to maximum and connect a volt meter set to read up to 200V dc across the red and black supply cables to the motor Adjust the High speed pre set to read 170V dc Note Take care when working with high voltages Current Limit Setto 2 0 amps with Motor Maximum Speed Setto 170 V dc IR Compensation Setto Min Anti Clockwise Minimum Speed Setto 25 V dc PCB Supports Terminal Block See Circuit Diagram for Connection Details Control Box Circuit Board Motor Speed 110asssssnnns 18 21 SYSTEMS PAGE 49 Section 18 CROSSFOLD UNIT SERVICE Transfer Gear Side Frame Location Pad Fixed Location Pad Adjustable Drive Gear Crossfold Bed Drive scsscssscscssesseesessessnseesessessesesseeees FIG 18 31 18 3 Crossfold Bed Adjustment amp Removal The crossfold bed is installed between the sideframes supported on four location
30. ired setting and re tighten the locking screws Light stocks may require the gap between lower and upper rails to be reduced and this can be achieved by loosening the jacking screws and tightening the locking screws until the gap is as required before re tightening the jacking screws Heavy stocks may require the lower rail to be moved back away from the fold rollers but this can only be achieved by loosening all the screws first and following the instructions at the beginning of this section WARNING DO NOT EXCEED 2mm GAP OTHERWISE THE FOLD ROLLERS WILL BE DAMAGED SYSTEMS PAGE 31 Section 12 FOLD PLATES SERVICE Stop Upper Rail Screws Handwheel SSS NY Grub Screw Timing Pulley Tilt Control Set to Zero E KA Timing Pulley Drive Side Fold Plate Deflector Alignment sscssssssseseeseseseeeesFIQ 12 12 12 3 FOld Plate Deflector When the operator sets the tilt adjustment on the fold plate handwheel to zero the deflector should be perfectly parallel to the front rail and this can be checked by winding the deflector towards the upper rail and comparing the position of the deflector fingers with the rail They must line up exactly and if they do not the deflector can be adjusted by releasing the grub screws on the drive side pulley which is mounted on a sleeve to facilitate small adjustments and rotating it slightly on it s shaft until it is set correctly PAGE 32 FOLDING MANUAL FO
31. kening both screws against the bearing plate as indicated and lightly tighten both screws 9 Carry out the above procedure from step 5 for the right hand linear bearing going back to step 3 as required Note All the screws must be fully tightened on completion 8 3 Outer Fold Rollers Pressure Springs The pressure springs should be adjusted so that the 2mm dimension as shown in fig 8 41 is obtained between the pressure pad and the calliper Carry out the adjustment using a 2 5mm allen key in the adjusting screw it may be easier if the allen key is shortened enough to pass over the fold roller Note An excessive gap will limit how wide the callipers will open to accept paper but must be equal both sides SYSTEMS PAGE 21 Section 8 OUTER FOLD ROLLERS SERVICE Adjusting Screw amp Locknut Spring Roller Pressure Spring Pad a 2mm Se A 4 Ree Screw amp Locknut Spring Pressure Outer Fold Roller Moving Grooved Section SI mI Calliper Bue Paper Calliper Pad Calliper J aw S a Ar d Polyurethane Insert Main Roller Centre Paper Strips Safety Rings Pressure Spring amp Gap Setting csccsssecssseeeseeessesesseees Fig 8 41 8 4 Outer Fold Rollers Gap Setting The fold roller gap setting often called roller pressure is the most important adjustment on the machine and great care should be taken to ensure that the fold roll
32. ler motor high speed pre set on the main PCB to obtain 175 volts at the roller motor 4 Because the speeds interact repeat checks 2 and 3 and re adjust the PCB pre sets to obtain the correct voltages 5 Set up the machine to run A4 or 8 1 4 x 11 paper with the sheet spacing control on the front panel set at position 2 6 Run a few sheets with both motor speeds set at minimum on the front panel control and watch for any speed difference as the sheets are transported from feeder to roller section Adjust the feed motor low speed pre set on the main PCB until the speeds are matched 7 Run a few sheets with both operator speeds set at 2 o clock on the front panel control and watch for any speed difference as the sheets are transported from feeder to roller section Adjust the feed motor high speed pre set on the main PCB until the speeds are matched 8 Because the speeds interact repeat checks 6 amp 7 and re adjust accordingly The speeds should now be synchronised over the range of front panel adjustments PAGE 40 FOLDING MANUAL COMPRESSOR Section 14 In line Filter Housing Valve Lead Compressor Power Lead Vacuum Control Valve Wing e wa Inlet Filter Valve Connector Housing Vacuum Hose Filter Elements Exhaust Hose Silencer Assembly Manifold Hoses Behind Compressor Note Although Shown Vertically the Compressor is Actually Installed Horizontally Within the Base Cabinet Compressor Ins
33. ng brackets or the torque disc from the coupling when removing the shafts See Fig 6 11 Remove the counter sensor and it s bracket from the drive end stiffener and remove the six screws securing both stiffeners to the feed bed do not remove the screws which secure the insert to the stiffeners then carefully draw the insert and stiffeners from the machine and remove the feed belt Note On re assembly fit the new belt according to the direction arrow on the reverse side of the belt 5 2 2211 COunter Sensor The counter sensor is located beneath the feed bed as shown in fig 5 11 and its alignment is checked as follows Remove the control box lid see section 13 and set a volt meter to read 5 Volts DC Connect the positive lead to TP3 and the negative lead to TP1 on the counter PCB see fig 13 12 The signal should rise to 5 0 Volts DC when the detector is not reflecting ie when covered by a sheet of paper and drop to less than 0 5 Volts DC when reflecting no paper The detector and reflector must be cleaned and the reflector adjusted to obtain the lowest value when reflecting typically 0 2 Volts SYSTEMS PAGE 13 Section 5 FEED BED ASSEMBLY SERVICE Idler Shaft Bracket Adjusting Nuts Feed Belt Tension in Each Bracket This Gap Equal d Roller Retainer V Roller Feed Belt Conveyor 4 Conveyor Drive Shaft Feed Belt Idler Shaft Feed Belt Adjustment
34. ng housing on to the shafts ensuring that the disc springs are correctly installed Replace the gearbox cover and adjust the idler pulley to remove any slack in the belt Note Do not over tension the belt as this will cause premature failure and overload the motor SYSTEMS PAGE 17 Section 8 OUTER FOLD ROLLERS SERVICE Machine Side Frame Operator Side Spring Block Spring Adjusting Screw amp Locknut Roller Pressure Spring Pad H C Calliper i Sr Adjusting Screw amp Locknut Spring Pressure Calliper 4 _ Calliper aw H a me a a I hn Ba a ow Grub Screws Fold Roller Drive Gears Moving Linear Bearings Calliper Plate Inner Main Roller Centre FO Roller S anana FIG Oe 8 1 Outer Fold Rollers Removal Each of the fold rollers are removed to the operator side so the following instructions apply to the operator side calliper assemblies only Remove the pressure spring lock nut using a shortened 2 5mm allen key and unscrew the pressure screw enough to clear the spring pad PAGE 18 FOLDING MANUAL OUTER FOLD ROLLERS Section 8 Remove the nut and washer securing the spring block and remove the block taking care to hold the spring to avoid losing it and the spring pad Release both grub screws in both the large gear and the drive gear five full turns to clear the shaft and remove the gear Remove the calliper jaw by removing the tw
35. nut and turn the adjusting screw clockwise a small amount using a L shape 2 5mm allen key Tighten the lock nut open the calliper using the tee handle and re position the piece of paper between the calliper jaws Repeat check E Note Each time the adjusting screw is altered it is imperative to open the calliper using the tee handle and re position or replace the piece of paper between the calliper jaws Failure to do this will give misleading results F Repeat check E using new pieces of paper between the calliper jaws and new strips for checking the pull Because of the importance of this adjustment this will serve as a double check Also the paper after repeated use will squash and give a misleading setting G As a final check carry out the following procedure Wind two strips of the same paper one at each side into the roller being checked between the knurling on each roller In this position there should be no pull on the paper When checking the bottom roller there should be no pull on the paper strips wound between the safety rings SYSTEMS PAGE 23 Section 9 CENTRE FOLD ROLLER SERVICE Calliper Cable Tee Handle Grub Screw Cable Clamp CH Fixed Calliper Plate Inner Pac 5 P Fold Roller Top p f NR a Main Roller Centre i yes CH Drive Pulley t T Main Roller rr Drive Belt Cable Clamp Screw Cam ites Toothed m Fold Rolle
36. o socket head cap screws Remove the two bolts securing the linear bearings to the back plate and remove both bearings and back plate The calliper and roller may now be released from the side frames and the calliper can be pulled off the roller bearing The drive side bearing and calliper remain undisturbed Note Take care of the circular shims that are fitted between the calliper and the bearing They should be kept safe and used when replacing the roller The roller is replaced in the reverse sequence However before fitting and setting the pressure spring the linear bearings must be correctly adjusted see the following sections for the procedures 8 2 Outer Fold Rollers Linear Bearings The fold rollers are located in moving callipers which must move freely up and down without any lateral movement This is achieved by setting the linear bearings very carefully which is carried out at the factory and will require no further attention unless the rollers are removed Before any attempt is made to set the linear bearings the pressure spring must be removed as in section 8 1 above This is so that it is easier to feel the tightness or slackness in the moving calliper SYSTEMS PAGE 19 Section 8 OUTER FOLD ROLLERS SERVICE Spring Max Lateral Movement 0 025mm Spring Pad de Adjusting Screw amp WK Locknut Roller Pressure Adjusting Screw amp Locknut e Spring Pressure Calliper Pad Moving
37. or may now be lifted out of the machine Don t try to remove the compressor on your own the unit is very heavy FOLDING MANUAL SUCTION CONTROL VALVE Section 15 15 1 Suction 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 15 2 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 i
38. pads two each side and held in place by two socket head shoulder bolts which also act as pivots allowing the bed to be lifted for access to the perforator shafts and delivery The front pair of location supports are mounted in inclined slots which allows for adjustment of the mesh between the drive gear and the transfer gear assembly It is important that the drive gears mesh correctly so the location pads should be adjusted until the backlash between the gears is minimised but not eliminated as this will result in excessive vibration and premature wear The entire bed assembly may be removed from the machine by un screwing the two pivots Shoulder bolts one each side and lifting it clear of the side frames The side lay may remain in place When replacing the bed back between the side frames it should be lowered carefully onto the location pads and slid into position so that the pivots can be inserted and tightened securely PAGE 50 FOLDING MANUAL CROSSFOLD UNIT Section 18 Bearing Housing Drive Shaft Drive Shaft Feed Rollers Fixing Screws eg Delivery Bed Transfer Gear Assembly E Side Rail Drive Shaft Front Rail Spacers 2 each side Fixing Screws Bearing Housing Bearing Housing Transfer Gear Crossfold Beg EE A 16 21 18 4 Crossfold Bed Transfer Gear Assembly The transfer gear assembly is replaced by first removing one of the delivery beds and the two screws into the end of the bearing
39. r Bottom Centre ROlEF gees e Eege FIG OLLI 9 1 Centre Fold Roller Removal Having removed the fold rollers the centre roller is removed to the operator side as follows Remove the drive belt and large pulley from the drive side Remove all cable clamp screws and remove both cables from machine On the operator side remove all the gears and the nine bolts securing the fixed calliper plates See fig 10 11 The fixed calliper on the operator side together with the centre roller may then be carefully removed from the machine leaving both upper and lower perforator shafts in position PAGE 24 FOLDING MANUAL CENTRE FOLD ROLLER Section 9 Note sass Take care of the circular shims on the centre roller as they are vital to the elimination of roller end play Also take care of the spacer and disc springs on each perforator shaft If removing the centre roller without removing the outer fold rollers remove the roller to the drive side as follows Only remove the large gear and the small drive gear from the centre roller and then remove all cable clamp screws and both cables from the machine From the drive side remove the drive belt and the drive pulley and then remove the nine bolts securing the fixed caliper plates Remove the pressure spring from the bottom roller on the drive side and dismantle the bottom roller caliper plate and linear bearins also from the drive side The centre roller and fixed c
40. sufficient or excessive tension will cause vibration Slacken the four nuts securing the motor bracket to the feed bed Adjust the bracket as required to obtain the correct tension When correctly tensioned the belt will deflect approximately 5mm 3 16 when a force of 1 2Kg 2 6lb is applied to the mid point of it s run between the pulley s Note eu Take care to keep the motor parallel to the gearbox SYSTEMS PAGE 15 Section 7 FEED DRIVE GEARBOX SERVICE Gear Box Belt Toothed Idler Belt Tensioner Gear Box Cover Cover Fixing S BE Screws EN SA Bearing Housing Idler Side Feed Drive GearboOX s ssssssssnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnna IG 7s L1 7 1 Feed Drive Gearbox Removal The gearbox is removed from the underside of the feed bed as follows Remove the motor drive belt cover see section 6 Release all the cable ties securing the rotation sensor cable Remove the four screws securing the gearbox to the feedbed Note Take care not to lose the torque discs from the couplings See Fig 6 11 PAGE 16 FOLDING MANUAL FEED DRIVE GEARBOX Section 7 7 2 Gearbox Drive Belt With the gearbox removed from the machine remove the four screws securing the gearbox cover Ease off the idler side bearing housing from the shafts Note Take care of disc springs on disassembly Slacken off the idler pulley place a new belt over the pulleys and replace the beari
41. t the machine feeds and folds correctly SYSTEMS PAGE 3 INDEX SERVICE INE OGUCTION E PL i Introduction 2 ii Fasteners 2 iii Identification 3 iv New Machine Preparation 3 Section LE 1 COVErsS EN e 6 1 1 Side Covers Removal 6 1 2 Base access Panel 7 Section an 2 aana Manifolds E age 8 2 1 Manifolds Removal 8 2 2 Manifolds Adjustment 9 Section an 3 0 Vacuum Roller PAGE 10 3 1 Vacuum Roller Removal 10 3 2 Vacuum Roller Adjustment 11 Section an dinn Side Lay E age 11 4 1 Side Lay Removal 11 Section 5 Feed Bed Assembly nsss Page 12 5 1 Feed Belt Removal 13 5 2 Counter Sensor 13 5 3 Feed Belt Adjustment 14 Section an Dn EG Drive Belt DEE 06 15 6 1 Feed Drive Belt Access 15 Section 7 Feed Drive Gearbox sss Page 16 7 1 Feed Drive Gearbox Removal 16 7 2 Gearbox Drive Belt 17 Section amp 0uter Fold Rollers 0 2 Page 18 8 1 Outer Fold Rollers Removal 18 8 2 Outer Fold Rollers Linear Bearings 19 8 3 Outer Fold Rollers Pressure Springs 21 8 4 Outer Fold Rollers Gap Setting 22 Section 9 Centre Fold Roller ssassn Page 24 9 1 Centre Fold Roller Removal 24 9 2 Centre Fold Roller Re assembly 25 Section 10 Perforator Shafts 0101 Page 26 10 1 Perforator Shafts Removal 26 10 2 Perforator Shafts Re assembly 27 PAGE 4 FOLDING MANUAL INDEX Section 11 Calliper Cable 1012 Page 28 11 1 Calliper Cable Removal 28 1
42. tallation 2 Fig 14 11 14 1 Compressor Note The compressor is a very reliable unit and rarely gives any trouble but if you do suspect a problem be sure to check all electrical connections and hoses including the suction valve see section 15 before removing it SYSTEMS PAGE 41 Section 15 COMPRESSOR SERVICE 14 2 Filters 14 3 PAGE 42 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 three 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 See Section 1 2 for details on access to the compressor Remove the compressor power lead from inside the base roof 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 bolts through the base floor Remove the silencer hose from the exhaust port The compress
43. the shafts and that the disc springs are correctly fitted The pressure spring on the bottom callipers will have to be removed in order to set the linear bearings See Section xxx When replacing the gears be sure to locate the dog point screw into it s locating hole in the shaft Fit the hubs correctly with the solid hubs on the lower shaft with their grub screws facing the operator side and the tyred hubs on SYSTEMS PAGE 27 Section 11 CALLIPER CABLE SERVICE Clamp Screw amp Washer Cam Nylon Spacer Cam Main Roller Stub Shaft Calliper Cable A ae Main Roller Centre Grub Screw Cable Clamp Calliper Cable Operator Side Shown s ssssssssssssss Fig 11 11 11 1 Calliper Cable Removal The cable is removed as follows Remove the bale arm assembly from machine Release the cable clamp screw in the end of the stub shaft Pull the cable away Inside the cable hole in the stub shaft is a nylon spacer knock out the spacer using a suitable punch Note sass When replacing a calliper cable always fit a new cable and a new spacer PAGE 28 FOLDING MANUAL CALLIPER CABLE Section 11 11 2 Calliper Cable Replacement Before fitting a new cable insert a new nylon spacer into the stub shaft and set the clamp screw and washer on the cam so that the calliper cable will just pass beneath 1 Pass the cable under the top fold roller around the cam under the clamp screw and washer behind the back
44. to the third position from the outside and tighten the screws Raise the feed bed disconnect the gas strut from the side frame raise the feed bed further and support the strut on the conveyor roller Remove the two fixing screws see fig 5 21 which secure each of the two roller retainer brackets Lower the feed bed and release the two locating knobs on the top of the side lay The side lay can now be lifted off the feed bed With the side lay indicators set to zero 0 the gap between the floating and fixed side lays should be 10mm and the stop screws should have the underside of their heads set 5mm from the face of the floating side lay SYSTEMS PAGE 11 Section 5 FEED BED ASSEMBLY SERVICE Roller Retainer Brackets Conveyor Idler Shaft Assembly Roller Feed Belt Idler Shaft Brackets Feed Belt Stiffener Conveyor Drive Shaft Vacuum Roller Assembly Couplings Gas Strut Drive Shaft Bearing Housings Torque Discs Coupling Feed Bed Underside sssssssssssnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnan FIG 5 11 PAGE 12 FOLDING MANUAL FEED BED ASSEMBLY Section 5 5 1 Feed Belt Removal Remove the sidelay as described in section 4 remove the four screws securing the conveyor idler shaft brackets and remove the idler shaft assembly Remove the four screws securing the conveyor drive shaft bearing housings and remove the drive shaft as an assembly Note Take care not to lose the roller retaini
45. ts two fixing nuts Note Do not lubricate any part of the valve as this will lead to premature failure The armature is PTFE coated to resist wear Note Do not over tighten the coil fixing nut or the connector fixing screw Note The length and rating of the compression spring is critical to the performance of the machine Don t use substitutes SYSTEMS PAGE 43 Section15 SUCTION CONTROL VALVE SERVICE Pa Coil Mounting Tube Hose To Pressure Side of Compressor adaptor Coil Fixing Nut RE Solenoid Coil Hose To Vacuum Roller via suction control valve Valve Body Compression Spring Plunger Assembly Bottom Port Re inforced Hose To Vacuum Side of Compressor via in line filter Suction Control Valve 2201 FIG 15 11 PAGE 44 FOLDING MANUAL ELECTRIC DELIVERY Section 16 Low Speed Pre set Motor Speed PCB amp KL 2 SN Gei RS High Speed Pre set Terminal Block Electric Delivery Control Box Fig 16 11 16 1 Electric Delivery Speed The electric delivery speed range should be set to suitable levels by adjusting the high and low pre sets on the PCB This speed range is voltage dependant and will therefore vary according to the supply voltage WARNING HIGH VOLTAGE ON THESE PRE SETS GIVING RISK OF ELECTRIC SHOCK USE INSULATED TOOL OR DISCONNECT FROM MAINS BEFORE ADJ USTING 17 1 Swing up Perforating Unit Removal The swing up unit is removed from the ma
46. y to replace one wire at a time when fitting the new connector Do not mix the two brown wires as this will damage the control box 3 Check all electrical connections NO POWER BUT GREEN LIGHT SHOWING ON CROSS FOLD UNIT 1 Make sure on off switch on the unit is switched on 2 Check motor brushes 3 Check the white plug for the motor and the fuse at the rear of the crossfold control box 5 Remove operators side cover and the control box and check all internal connections 6 Check voltage in to PCB at live amp neutral mains AC 7 Check voltage to motor socket Should be 70 to 160 VDC Red positive Black negative 8 If no voltage change PCB or cross fold control box 9 If voltage correct change motor INPUT CONVEYOR ROLLER SPEED FLUCTUATES 1 Check thatthe transfer gear is not worn 2 Check motor brushes SYSTEMS PAGE 59 SERVICE PAGE 60 FOLDING
Download Pdf Manuals
Related Search