Instruction Manual Champion 990 - Promotional Printing Machinery

Instruction Manual
Champion 990
Rollem Patent Products Ltd
82 The Common
Ecclesfield
Sheffield
South Yorkshire
S35 9WN
ENGLAND
Tel: +44 (0) 114 246 8981
Fax: +44 (0) 114 246 5487
www.rollem.co.uk
Instruction Information Sheet
Machine:
Champion 990
Serial No:
………………………..
Instructions Reference:
91P-1121
Issue Number:
00
Operator Competence
It is assumed throughout these instructions that the operator will be a
competent one, having worked with similar machines for at least 2 years
previously.
Training can be obtained from qualified Rollem staff upon request, it is
recommended that operators attend a brief training session given by the Rollem
installation and service engineer upon installation of the machine.
If in any doubt at all about the setting or operation of this machine –
please contact Rollem for assistance.
-i-
Equipment Safety
General Safety
If you are unfamiliar with this equipment, read the manual thoroughly before
proceeding.
If there is any doubt at any stage, do not proceed but seek clarification.
Before installing, maintaining, cleaning or removing any covers from a machine,
switch off and isolate the machine either by disconnecting the plug from the
socket, or ensuring that the isolator is switched off and has disconnected all the
supply conductors (all lives and neutral).
There is no reason to work inside this equipment before it is correctly isolated.
Besides all procedures listed in this manual, reference must be made to local
procedures for safe working practices, particularly the dangers of working with
electricity.
Only competent persons trained on the equipment may service, maintain, repair
or adjust the machine, or for any other reason remove any covers or part of the
machines with a tool (a key is not a tool).
All Rollem manufactured machines are class 1 (to be earthed).
WARNING - THIS APPLIANCE MUST BE EARTHED
Although the machine has circuits at mains voltages and also at lower AC & DC
voltages, the electrical safety and insulation of the machine are designed,
constructed and are to be maintained at, the higher mains voltage.
• If the machine is rated 13A:
The wires in the mains lead are coloured according to the following code:
Green-and-yellow:
Earth
Blue:
Neutral
Brown:
Live
As the colours of the wires in the mains lead may not correspond with the
coloured markings identifying the terminals in your plug/isolator unit, proceed as
follows:
The wire that is coloured green-and-yellow must be connected to the terminal in
the plug that is marked with the letter E or by the earth symbol:
or coloured green, or coloured green-and-yellow.
- ii -
The wire that is coloured blue must be connected to the terminal that is marked
with the letter N or coloured black.
The wire that is coloured brown must be connected to the terminal that is
marked with the letter L or coloured red.
If the mains cord requires replacing, only cords supplied by Rollem must be
used.
• If the machine is single phase and rated above 13A:
The wires in the mains lead are coloured according to the following code:
Green-and-yellow:
Earth
Blue:
Neutral
Brown:
Live
The machine must not be connected to the electricity supply via a 13A (BS
1363) plug and socket; the machine must only be connected to a suitable
supply point rated greater than the machine and must only be connected by a
suitably qualified person. As the colours of the wires in the mains lead may not
correspond with the coloured markings identifying the terminals in the isolator
unit, proceed as follows:
The wire that is coloured green-and-yellow must be connected to the terminal,
which is marked with the letter E, or by the earth symbol, or coloured green, or
coloured green-and-yellow.
The wire that is coloured blue must be connected to the terminal that is marked
with the letter N or coloured black.
The wire that is coloured brown must be connected to the terminal that is
marked with the letter L or coloured red.
If the mains cord requires replacing, only cords supplied by Rollem must be
used.
It should be remembered that the mains cord can cause a significant trip hazard
if not secured safely.
• If the machine is rated for 3-phase electricity supply:
The machine must be connected to a 3-phase electricity supply point, a 13A
(BS 1363) plug and socket is not suitable. The machine must only be connected
by a suitably qualified person. Note, wire colours for 3-phase supplies may vary;
if there is any doubt, do not proceed but seek further clarification.
If the mains cord requires replacing, only cords supplied by Rollem must be
used.
- iii -
If the machine is rated differently from the above, reference must be made to
Rollem before proceeding.
All machines must be connected to the mains electrical supply by either a
suitable plug and socket (e.g. using a plug to BS4343 / EN60309-2), or by a
suitable isolator unit, which can securely disconnect all supply conductors (all
lives and neutral).
If left unattended for any time, the machines must be switched off and isolated.
Children must not operate Rollem machines.
Where machines are supplied for “bench use”, the machines must be sited on a
work surface, capable of securely supporting them, avoiding positions where
the legs or bases of the machines are near an edge and the machines could be
inadvertently knocked and fall over; if there is any doubt, the machines must be
bolted to a fixed, secure structure.
Attention must be paid to the recommended electrical safety maintenance
procedure detailed within this manual.
The machines must not be used outdoors or in any situation where they are
likely to be splashed or exposed to excessive damp.
When moving the machines, ensure that suitable facilities, or help, is available
to lift or move the machines; particularly into or from awkward locations where
overreaching may occur.
Do not block any of the ventilation holes on the equipment, either to the sides or
on the top.
Adequate lighting must be provided for the operation of the machine.
Any paper dust should be cleared from the machine on a regular basis with the
machine isolated from the electricity supply.
- iv -
Safe Working Procedure (Electrical)
UNDER NO CIRCUMSTANCES MUST SERVICING WORK OF ANY NATURE
BE CARRIED OUT WITHIN A LIVE MACHINE. THERE IS ABSOLUTELY NO
REASON FOR ANY PERSON TO EITHER TOUCH INSIDE A LIVE MACHINE
OR APPROACH THE VICINITY OF LIVE PARTS.
This procedure must be read together with, and does not take the place of, local
procedures and Health and Safety Policies.
Before any work commences, people in the vicinity, or likely to approach the
machine must be warned that the machine is about to be serviced.
Due regard must be made to site regulations such as permission/permit to work
rules.
The electrical supply must be switched off and isolated, either by removing a
plug or switching an isolator unit to off and ensuring that the live(s) and neutral
are disconnected.
Precautions must be taken to prevent the isolator being turned accidentally
back on, either:
• lock it off with a personal padlock.
• instruct a person to prevent the equipment being reconnected.
• if the isolator or plug and socket are in visual sight, attach a notice/sign to the
isolation point warning that the connection is not to be remade and keep a
visual check to prevent any person approaching the isolation point.
Covers may now be removed.
Before going further, a test must be made to ensure that the machine is isolated
from the electrical supply. Particular care must be taken if a switch on an
isolator unit disconnects the machine.
If it is necessary to run the machine with a cover removed, suitable precautions
must be made to prevent any person approaching the machine and being
exposed to danger.
Never leave a machine unattended with covers removed or in an unsafe
condition.
Hand held devices for making electrical tests, which rely on the human body to
complete a test circuit (such as neon-type screwdrivers) are not to be used;
devices with insulated test probes are particularly recommended. Follow this
procedure:
• isolate the machine
• check the points to be tested
-v-
• reconnect the machine
• take the required readings
• isolate the machine
Every time a machine is serviced, the following minimum checks must be made
as a matter of routine:
• Correct wiring of the mains cord into a plug or isolator unit.
• Physical inspection of the mains cord for damage.
• Physical check of the cord grips at both ends of the mains cord.
• Physical inspection of the earth bonding.
• Physical check of cables inside and outside
discolouration/other signs of overheating or damage.
the
machine
for
• Any sharp edges in accessible areas.
• The earth bond and insulation tests for any machine connected by a plug and
socket, and where practical to machines connected by other means)
- vi -
Routine Electrical Maintenance Procedure
This procedure covers the minimum tests required to be performed on ROLLEM
equipment, to comply with the UK Electricity at Work Regulations 1989. The
meaning of words and phrases used in this procedure is to be interpreted
according to the definitions within the regulations.
As a minimum, the maintenance procedure should be carried out at least
annually, but consideration must be given locally to more frequent maintenance
programs if there is a likelihood of the machines becoming dangerous within an
annual maintenance period.
Always do the tests in the correct order, if a machine does not pass a test, do
not pass onto the next test without rectifying the reason for the failure (a fault
indicates danger and the next test may not be safe), if a machine cannot be
rectified to pass one of the tests, the machine must not be reconnected and
must not be left in a state where it could be used.
BEFORE TESTING
• Check the operating voltage, current and power of the machine and the
supply; compare all sources of information (test sheet, serial plate etc.) and
correct if necessary.
• Check the environment for hazards: flammable vapours, dusts etc.
• Warn people that tests are about to be carried out, and ensure that
precautions are taken to keep a 3m (10’) safety area around the machine
during the periods when the machine is energised.
• Disconnect any additional equipment from the machine.
• Ensure that the supply for the test equipment is properly earthed.
• Physically isolate the machine from the supply; either by unplugging or by
disconnecting and removing the mains cord from its supply point.
• Ensure that the machine on/off switch is in its normal ON operating position.
PHYSICAL EXAMINATION
• Check equipment casing for signs of damage/loose parts that may give rise
to a source of danger, e.g. a breakdown of insulation or user access to live
parts.
• Check the mains plug (if fitted) for cracks or damage, open it up and check
the terminals, fuse and fuse rating; check that the cord grip is effective in
preventing the cord being pulled out, pushed in or twisted.
• Check the mains cord for damage to the insulation or other dangerous
conditions such as kinking.
- vii -
Portable Appliance Test
Portable Appliance Test to be carried out in accordance with the testing
equipments instructions.
- viii -
Safe Working Procedures (Blades and Other Sharp Areas)
1. When handling any sharp items, for example slitting blades, suitable
protection must be worn that will protect the hands and wrists from any risk of
injury.
2. When removing or adjusting shaft assemblies, to avoid the risk of damage to
the machine and the risk of personal injury, the shaft must be supported and
must only be moved with the assistance of a suitably rated, approved and
maintained mechanical hoist or equivalent.
- ix -
Contents
Operator Competence ...................................................................................... i
Equipment Safety .............................................................................................ii
General Safety ..............................................................................................ii
Safe Working Procedure (Electrical)............................................................ v
Routine Electrical Maintenance Procedure.................................................vii
Portable Appliance Test ......................................................................... viii
Safe Working Procedures (Blades and Other Sharp Areas) .......................ix
Contents........................................................................................................... x
Introduction ...................................................................................................... 1
The Rollem Champion 990 .......................................................................... 1
Technical Specification ................................................................................ 2
Installation and Maintenance........................................................................... 3
Setting up the Machine .................................................................................... 4
Setting of the Feeder Unit ............................................................................ 4
Relative Positions of Separating Tongue and Clamping Plates .............. 6
Setting up for Perforation ............................................................................. 7
Setting up for Creasing and Slitting ........................................................... 12
Replacing Perforating Blades .................................................................... 13
Fitting or Removing Perforating, Creasing and Slitting Units .................... 14
Variable Speed Drive..................................................................................... 16
Maintenance .................................................................................................. 17
Replacing Rubber Feed Sleeve ................................................................. 17
Steady Bearings......................................................................................... 19
Spare Parts .................................................................................................... 20
Automatic Feed Assembly ......................................................................... 21
Perforating Units ........................................................................................ 22
Troubleshooting ............................................................................................. 23
Checklist..................................................................................................... 24
Blade Sample Sheets…………………………………………………………….25
-x-
Introduction
The Rollem Champion 990
The Champion 990 can perform precision perf, score or slit with razor sharp
accuracy at up to 15,000 sheets per hour.
It can perform 23 styles of perf, 14 styles of scoring and precision slitting.
There is no excess wear on moving parts and no alignment problems as the
Champion is set on an indestructible base.
The Champion can be set up in minutes and will perf, score or slit any type of
stock – from 45 gsm stock to a 750 micron board; from tissue paper to a credit
card; traditionally printed to digitally printed stock.
Issue 00
Page 1
Issue 00
690
690
840
840
840
810
810
970
970
970
Machine Size
24”
(600mm)
30”
(750mm)
36”
(900mm)
42”
(1050mm)
18”
(450mm)
24”
(600mm)
30”
(750mm)
36”
(900mm)
42”
(1050mm)
Champion
Friction Feed
Double Head
Single Head
Width (mm)
1430
1300
1150
990
840
1400
1250
1090
Height (mm)
Friction Feed
560
560
560
510
510
440
440
440
Weight (kg)
190
156
134
111
90
111
98
84
72
Min Sheet Width
(mm)
390
125
125
125
125
125
125
125
125
125
Max Sheet Width
(mm
940
1040
890
735
580
430
1040
890
735
580
Min Sheet Length
(mm)
125
125
125
125
125
125
125
125
125
125
1060
910
760
610
450
1060
910
760
610
450
Max Sheet Length
(mm)
430
40
40
40
40
40
40
40
40
40
40
Min Sheet Weight
(g/sm)
125
700
700
700
700
700
700
700
700
700
700
Max Sheet Weight
(g/sm)
60
25
25
25
25
25
25
25
25
25
25
Max Pile Height
390
110/230
110/230
110/230
110/230
110/230
110/230
110/230
110/230
110/230
110/230
Power Supply (volts)
840
15,000
15,000
15,000
15,000
15,000
15,000
15,000
15,000
15,000
15,000
Max Speed A5 (s/hr)
Champion
Length (mm)
18”
(450mm)
Model
Technical Specification
Page 2
Installation and Maintenance
When the machine is delivered carefully remove all dust and anti-rust grease
with blanket wash or a similar solution.
Clean and lightly oil the cutter spindles, this enables the units to be moved
along the cutter spindles easily when setting.
Note:
There are no oiling points on the cutter spindle bearings as these are fitted with
oil impregnated bushes. An occasional drop of thin oil should be applied
between the stripper blades in the perforating units and between the bottom
cutter blades in the bottom perforating units.
This allows for smooth running of the units and reduces the possibility of any
squeaking noises due to dry components rubbing together.
Issue 00
Page 3
Setting up the Machine
Setting of the Feeder Unit
The cutters and lay bars should be set to give the required result so that the
paper is centrally disposed on the machine. The two lay bars should be set so
that the paper will slide easily between them and locked in place by the two
thumb screws underneath the front bar on which they slide. The wooden rails
are used for support of the paper between the lay bars.
Wing Nuts
Thumb Screws
The centre adjusting screw on the bracket carrying the rubber separating
tongue should be adjusted until a piece of paper placed under it will be gently
contacted between the rubber tongue and the rubber facer roller. The two
screws adjusting the two spring driving strips should be adjusted until the strips
lightly contact the rubber covered feed roller.
Adjusting screw for
separator tongue
Adjusting screws for driving springs
Issue 00
Page 4
A stack of paper, between 10 –15 mm thick, should be placed between the
aluminium lays and fanned out slightly so that the bottom sheet is in contact
with the feed roller.
Start the machine and gently push the stack towards the feed roller.
If double feeding results then slightly more pressure should be placed on the
rubber tongue by turning the adjustment screw.
If the paper does not feed without gentle pressure from the rear of the paper
stack then more pressure should be placed on the two drive springs with their
adjusting screws.
It should be quite easy to get the correct combination of pressures to suit all
classes of paper or card. Fine adjustment for the position of perforation can be
accomplished by turning the knurled knob on the right of the feed table.
Knurled Knob
Angular misalignment of the perforations can be corrected by appropriate
movement of the lay bars. By loosening the wing nuts, the lay bars can be slid
sideways to compensate for the misalignment, and then retightened.
Issue 00
Page 5
Relative Positions of Separating Tongue and Clamping Plates
Backing Plate
Tongue
Pressure Plate
The rubber Tongue should be 3mm shorter than the Backing Plate.
Separator Plate
Tongue
Sleeve
Adjust Separator Plate to make Tongue square to sleeve.
Issue 00
Page 6
Setting up for Perforation
1. Isolate the machine from the power supply.
2. Prepare a sample of work to be perforated – mark out the positions of the
perforations on the front edge of the sample.
3. Position the right and left hand aluminium lays so that they form a guide
down the length of each side of the material and at the same time centralise
the material in relation to the automatic feeder assembly.
4. Both aluminium lays are held in position by individual thumb screws, which
lock them onto the adjuster bar as shown on the diagram below:
RH Aluminium Lay
LH Aluminium Lay
Knurled Adjuster
Collar
Wing Nut
Adjuster Bar
Wing Nut
Thumb Screw
Paper Support Boards
Thumb Screw
RH Aluminium Lay
LH Aluminium Lay
Paper Width
Knurled Adjuster
Collar
Adjuster Bar
Wing Nut
Thumb Screw
Issue 00
Wing Nut
Paper Support
Board
Thumb Screw
Page 7
5. It is advisable, before locating the aluminium lays, to turn the knurled
adjuster collar so that there is an equal amount of screwed thread on either
side of it. This will allow the operator to make fine sideways adjustment of
the aluminium lays, once they are locked in position.
6. The wooden paper support boards can now be placed in position to fill up
the space between the right and left hand aluminium lays.
7. The smoother guard should now be removed in order to set the positions of
the perforating units.
8. Place the work sample in position between the aluminium lays and with the
marked out positions of the perforations as the leading edge.
9. Put the engagement lever in the out of engagement position.
Engagement Lever
(Disengaged Position)
Locking Fork
Stop Pin
Engagement
Lever
Engagement Lever
(Engaged Position)
Engagement Lever in Engaged Position
Stop Pin
Locking Fork
10. Slide the bottom perforating units into position. This is achieved by lining
the gap between the two steel bottom cutter blades in each of the bottom
units directly in line with the marked out position on the sample sheet.
Bottom Perforating Unit
Spare Unit
Sample sheet with perforating
positions marked on leading
edge
Issue 00
Page 8
11. Once in position the units should be locked onto the bottom shaft by
tightening the cutter retainer screw with the allen key provided.
12. Any spare bottom units should be spaced out along the bottom cutter shaft
to help support the paper as it passes through the machine.
13. At this stage it is important to ensure that all the top perforating units are
completely offset from the bottom units, as damage can occur at the
perforating blades whilst the top and bottom units are being brought into
engagement.
14. The top perforating units should now be mated, one at a time, with their
corresponding bottom units, by lowering the engagement lever down to the
stop pin.
15. Extreme care should be taken to ensure that the perforating blade is located
into the gap between the two steel bottom cutter blades.
16. Once in position the top units should be locked in position in the same
manner as the bottom units.
17. Any spare top perforating units should be parked to the side of the machine,
out of line with the work being perforated and fastened onto the shaft.
18. Where the work requires only one line of perforation near one edge of the
sheet it is essential to ensure that a minimum of three rubber control rings
are in contact with the sheet.
19. A perforating unit with the blade removed, or disengaged scoring head
should be positioned at the opposite edge of the perforation so that the
rubber ring is in contact with the sheet, giving additional control.
Perf Unit with
Blade removed
Control Ring only in
contact with sheet
Sheet to be perforated down
left hand side only
Issue 00
Page 9
20. When a perforation is required down the centre of the sheet only, additional
control should be applied to each edge of the sheet in the same manner as
below.
Control Rings only in contact with sheet
Sheet to be perforated down
centre only
21. The curl collars, situated on the delivery roller, should now be set in line
with the outer edges of the sheet and the burr-flattener wheels placed
directly at the back of each of the top perforating units. In addition to acting
as a burr-flattener agent, this positioning forms the paper into a shallow
trough shape and eliminates the tendency for some sheets to roll over in the
delivery tray instead of laying flat.
Delivery Roller
Stripper Retainer Bar
Burr Flattener Wheel
& Spring
Stripper Retainer Bar
Curl Collar
Paper Width
Delivery Roller
Issue 00
Retainer Screw
Page 10
22. After removing the keepers from the magnets, the back stops should now
be placed on the delivery table to form a box for the finished work to fall
into. The magnetism can be easily broken by lifting the back stop directly
from the table, thus allowing the positioning to be easily changed.
Note: The base section of the back stops should be placed to the inside
where the sheet will be supported by the bases at the outer edges, this will
give full table coverage.
23. The smoother guard can now be replaced back onto the machine and
locked in place with the two thumb screws.
24. With the machine switched on, present a sample sheet into the feeder and
gently turn the centre adjusting screw on the separator plate until a gentle
pulling of the sheet can be felt. The sheet can then be withdrawn and
presented, in turn, to each of the drive springs in the same manner.
25. A stack of paper approximately ½” (12mm) thick should now be placed
between the aluminium lays and fanned out slightly so that the bottom sheet
is in contact with the feed roller.
26. Start the machine and gently push the stack towards the feed roller. If
double feeding occurs then slightly more pressure should be placed on the
rubber tongue by turning the adjuster screw. If the paper does not feed
without gentle pressure from the rear of the paper stack then more pressure
should be placed on the two drive springs with their adjuster screws.
27. Fine adjustment for the position of the perforation can be accomplished by
turning the knurled adjuster collar on the right hand side of the feed table.
28. Angular misalignment of the perforations can be corrected by appropriate
movement of the lay bars. By loosening the wing nuts, the lay bars can be
slid sideways to compensate for the misalignment and then re-tighten.
Issue 00
Page 11
Setting up for Creasing and Slitting
The setting up procedure for creasing and slitting is the same as described
above for perforating.
In the case of creasing however, it will be necessary to run the machine with the
engagement lever slightly disengaged.
The position of the engagement lever will depend on the depth of crease
required. Once the appropriate position has been selected, the lever should be
locked in place by tightening the securing screw in the locking fork.
Note: Do not run the machine with the engagement lever too far out of
engagement, otherwise the rubber control rings will fail to grip the sheet
resulting in an inaccurate crease.
Care should also be taken to ensure that the male scoring blade is centred in
the female groove to prevent cracking or splitting along one edge of the crease.
Issue 00
Page 12
Replacing Perforating Blades
1. Replacement perforating blades can be fitted without taking the top and
bottom cutter out of the machine.
2. With the two ‘C’ spanners provided loosen off the top perforating unit nut.
3. Remove the stripper and distance piece.
4. The perforating blade, which is split, can now be removed by threading it
over the cutter shaft.
5. After fitting the replacement perforating blade, replace the distance piece and
stripper and tighten the nut, making sure that the stripper is riding on the top
distance piece. If not, the unit will jam, making rotary movement almost
impossible.
Issue 00
Page 13
Fitting or Removing Perforating, Creasing and Slitting Units
1. Isolate machinery from power supply.
2. Raise engagement lever to fully disengaged (‘out of engagement’ position).
3. Release smoother guard with the thumbscrews and remove.
Smoother Guard
Thumbscrews
4. Remove handwheel, belt guard cover and drive pulley.
Handwheel and
Belt Guard Cover
5. Slacken cap head screw in roller drive gear.
6. Slacken allen screw in sprocket.
7. Slacken allen screw in clamp collar.
8. Slacken top and bottom perforating units and then slide them to the left
hand side of the machine.
Issue 00
Page 14
9. Withdraw bottom cutter shaft from belt guard end, leaving sufficient space
between open end of shaft and right hand bearing block to enable bottom
units to be removed or fitted.
10. Withdraw top cutter shaft in same manner.
11. Reverse steps 1-10 to reassemble machine.
Note: Before tightening up sprocket and clamp collar, ensure that they are
pushed hard up to left hand bearing blocks.
LH Bearing
Blocks
Handwheel
RH Bearing
Blocks
Clamp Collar
Sprocket
Belt Guard
Cover
Issue 00
Roller Drive Gear
Engagement
Lever
Page 15
Variable Speed Drive
The machine is fitted with variable speed control.
This allows the operator to select a running speed of the machine appropriate to
the size and type of work at hand.
To alter the speed:
1. Switch the machine on and slacken the locking knob.
Belt Guard
A34 Drive Belt
24 Tooth Gear
Expanding Pulley
Speed Adjustment
Handle
25 Tooth Gear
Final Drive Pulley
Locking Knob
Motor Base
Speed Adjustment
Handle
Locking Knob
2. The speed adjustment handle can now be lifted or lowered to a position
where the required speed is obtained.
3. The locking knob should now be re-tightened to hold the speed adjustment
handle in position.
Issue 00
Page 16
Maintenance
Replacing Rubber Feed Sleeve
1. Isolate the machine from power supply.
2. Release smoother guard with thumbscrews and remove.
Smoother Guard
Thumbscrews
3. Remove paper support boards.
Rubber Sleeve
RH Lay
LH Lay
Knurled Adjuster
Collar
Wing Nut
Adjuster Bar
Wing Nut
Thumb Screw
Paper Support Boards
Thumb Screw
4. Slacken off feed lay thumb screw and lift lays over adjuster bar.
Issue 00
Page 17
5. Slacken off gear guard retainer screw and lift guard to vertical position.
Retainer Screw
Friction Feed
Roller Shaft
Rubber Sleeve
Friction Feed Roller
Gear Guard
Gear Guard
Retainer Screw
Flat Milled Face
6. Slacken off retainer screw in right hand bottom bearing block.
RH Bottom
Bearing Block
Plastic Knob
7. Completely withdraw friction feed roller shaft from right hand side of
machine.
8. Lift friction feed roller out of machine and replace rubber sleeve. Make sure
that the replacement sleeve is not put on inside out – the outside has a
ground finish.
9. Reverse steps 1-8 to reassemble machine. Before tightening retainer
screw, ensure that the flat, milled face on the friction feed roller shaft is face
onto it.
10. Finally, clean the outside face of the rubber sleeve with blanket wash.
Issue 00
Page 18
Steady Bearings
All machines size 24 inch (60cm) and above are fitted with steady bearings as
standard.
Retainer Screw with Brass
Pad
Top Steady Bar
Spacer Block
Top Steady
Top Shaft
Lubricating Point
Bottom Shaft
Bottom Steady
Eccentric Bar
In certain cases, where heavy-duty work is involved, heavy-duty steady
bearings are fitted to the machine.
Retainer Screw
with Brass Pad
Top Steady
Top Steady Bar
Stripper Retaining
Bar
Top Shaft
FHR205-16
Bearing
Bottom Shaft
Bottom Steady
Locking Collar
Eccentric Bar
Always position top and bottom steadies as near to the centre of the
machine as possible
Issue 00
Page 19
Spare Parts
It is not necessary to carry a wide range of spare parts in stock as these are
usually available from Rollem direct from stores. However, it is recommended
that a small quantity of the following components be held in your stock for
immediate use:
Part
Rollem Partcode
Rubber Feed tongue
85P-0004
Rubber Feed Sleeve
85P-0040
Rubber Control Ring
85P-0081
Bottom Cutter Blade
57P-0030
Perforating Blade (Blade 1)
57P-0006
Perforating Blade (Blade 2)
57P-0007
Perforating Blade (Blade 3)
57P-0008
Perforating Blade (Blade 4)
57P-0009
Perforating Blade (Blade 5)
57P-0010
Perforating Blade (Blade 6)
57P-0011
Perforating Blade (Blade 7)
57P-0012
Perforating Blade (Blade 8)
57P-0013
Perforating Blade (Blade 9)
57P-0014
Perforating Blade (Blade 10)
57P-0015
Perforating Blade (Blade 11)
57P-0016
Perforating Blade (Blade 12)
57P-0017
Perforating Blade (Blade 13)
57P-0018
(See back of instruction manual for Blade Sample Sheets).
Issue 00
Page 20
Automatic Feed Assembly
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
Issue 03
Description
Knoblet
¼” BSW x 1 ¼” Hex Socket
Head Cap Screw
¼” BSW Hex Nut
3/16” BSW Dome Nut
3/16” HG Washer
Separator Plate
Drive Spring
Backing Plate (Long)
Rubber Feed Tongue
Spacer Washer
Backing Plate (Short)
3/16” BSW x 3/8” Round
Head Machine Screw
3/16” BSW x 1/2” Round
Head Machine Screw
Qty
3
3
3
6
6
1
2
1
1
2
1
4
2
Page 21
Perforating Units
Exploded Diagram of Top Perforating Unit
RUBBER CONTROL RING
NUT
•018” DISTANCE PIECE
STRIPPER
PERFORATING BLADE
BODY
NB NUT & BODY MUST
BE ORDERED AS
ONE UNIT
STRIPPER
•018” DISTANCE PIECE
RETAINER SCREW WITH BRASS PAD
Exploded Diagram of Bottom Perforating Unit
NUT
BOTTOM CUTTER BLADE
•015” DISTANCE PIECE
BODY
NB NUT & BODY MUST
BE ORDERED AS
ONE UNIT
CLEANER
BOTTOM CUTTER BLADE
RETAINER SCREW WITH BRASS PAD
Issue 03
Page 22
Troubleshooting
Problem
Possible Solution
Machine will not start
No power input (incoming power off or circuit
breaker tripped)
Bad on/off switch or potentiometer
Fuse blown
Loose connection
Feeder not on
Stock does not register
Machine not level (tilted away from side guide)
Stock too far from side guide
Number of ball bearings wrong (too many, too
few or wrong type)
Stock catching on side
Not enough control rings
Far end of stock not riding on belt
Machine running too fast (especially very small
or very wavy stock)
Stock Cracking
Incorrect width of score
Incorrect depth of score
Incorrect score configuration
Score not centred
Heads or shafts loose
Double scoring may be necessary on some
stock
Steady bearings loose
If stock cracks on folder but not by hand:
(a) not folding on score
(b) pressure too great
(c) register off (see ‘stock does not register’)
Issue 03
Page 23
Problem
Possible Solution
Stock marring or scratching
Deflector panels down too low (scratching)
Deflector panels up too high (lead edge nicks)
Burr flattener has too much pressure (marring)
Score slits stock
Male scoring head not centred in female
Scoring head(s) loose
Shaft(s) loose
Handle too deep (mesh lever)
Uneven depth of score
Bad head (flattened score)
Change steady bearing position
Score not centred
Checklist
1. All lock collars tight
2. No movement in shafts
3. All scoring heads are tight.
4. All scoring heads are staggered or seated when handle is lowered (to avoid
flattening scores).
5. Deflector panels are down.
6. When perforating engagement handle should be down and locked.
7. All shafts are turning.
Issue 03
Page 24