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Manual Tok 2

heidelberg

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Jorge Díaz Búquez
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2K views107 pages

Manual Tok 2

heidelberg

Uploaded by

Jorge Díaz Búquez
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
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T-OFFSET . TOK/TOM Maintenance and Repairs o-2 PREFACE TO THE MECHANIC. We have compiled for you the most important check-ups/ adjustments on T-Offset presses in this concise repair manual. These hints shall be a help for the Heidelberg service technician to enable him to localize and eliminate any malfunctions fast. The electrical part of the press, including the electronic system, is explained in detail in the "MANUAL - ELECTRONICS TOK/TOM" (HDM no. 22.100,0022), which is supplied with every press delivered. Wie are entrusting this important information to you on loan, commending it to your special care. Please note the property clause on the cover sheet. The present manual should remain usable for a long time to come. This is why we have put it in a loose-leaf binder. Individual sheets may easily be exchanged as per our instructions. Supplemental sheets may be inserted at any time in the order of the table of contents (subject index). Each sheet has its own classification number in the upper corner, This refers to the table of contents (subject index) and indicates successively - main chapter (letter) ~ subchapter i (number), and - page number within the subchapter (number) « Example: 2 - 3/4 = IMPRESSION/BLANKET/PLATE CYLINDER Adjusting the printing pressure Setting blanket cylinder - plate cylinder page 4 Supplemental sheets should be inserted according to the classification number in the upper corner. Maintenance and Repairs NUMBERING AND ORDERING L Kaj a Display before adjustment Display after adjustment Maintenance and Repairs 5. Retighten the screws @) and remove the shin. 5. Malfunction of the pile height scanning méchanism: Information display Pulse generator adjusted too high: The press stops printing when the feed pile is trans- ported subsequently. the symbol "feed pile" appears in the information display. Pulse generator adjusted too lo: ‘the symbol “feed pile" does not appear in the information display or is on only shortly (flickering) - The press tries to pick up a sheet although the pile has not reached its working height. Maintenance and Repairs Adjusting the sucker bar Pa ., Coarse adjistment: 3) eccentric mark Basic adjustment: eccentric down 1. Vertical adjustment of the sucker bar 1.1 Set the sucker bar to the lowest position of the feed board. 1.2 To obtain the basic adjustment, the eccentric bolt (@) should be turned down (roller at lowest position) as shown Yh the illustration. Then the sucker bar should be adjusted exactly vertical} to the feed board (90°) by means of the eccentric bolt (A). The sucker bar must not touch the shaft of the lower tra¥is- port roller. 2. Height adjustment of the sucker bar 2.1 Set the swing lever for the sucker bar adjustment to the upper end position (blower bar is positioned exactly vertically). 2.2 For the coarse adjustment turn the eccentric bolt until the eccentric mark is in the shown position (see ilT.). 2.3 Switch on compressor, pick up a sheet (80 gsm. offset paper) and crank the press manually in direction of rotation until the leading edge of the sheet is seized by the upper and lower transport roller, The sheet must be in- serted exactly between the two rollers: by no means should the leading edge contact the lower one. Corrections can be made via the eccentric bolt (8). Maintenance and Repairs Adjusting the suction air control ee DS. G a ® Ce oo 7 oF 1 i ‘i \@®- Most the high section of the cam (3/2-way valve mast not be blocked). Magnet ¥9 must be dIsenergized. 1. Crank the press until the mor @) is positioned on 2, The distance between the stop lever ©) and the valve cut-off lever must_be 0.2 mm (see i1l.). For corrections, the bearing-bolt ® on the side frame should be slackened and adjusted accordingly within the bore hole. 3. The stop lever ©) (inner edge_of the angle) must be in line with the valve ciit-off lever as shgwn in the illustration. For an adjustment slacken the Screws and adjust the height of the magnet support with the magnet ¥9. Then check whether in position “paper run" (magnet energi the valve cut-off lever (0) swings past the stop lever (¢) until the end position. od} Maintenance and Repairs Adjusting the blower bar to the lower transport roller = ‘Swing lever end position “up” 1. Set the swing lever for the blower bar adjustment to the upper end position. 2. Before adjusting the blower bar, the partition (G) must be aligned to the lower transport rolley The distance between the lower transport roller fouter edge) and the partition (face of feed pile) must_be 7.5 0.3 mm equally on D.S.-and o Slacken screws (E) and adjust the cross bar () accordingly. 3. The distance between lover transport roller and blower bar (@) must also be set to 7.5 + 0.3 mn equally on D. and 0-S., as shown in the illustration. Corrections may be made via the small bearing brackets Slacken the screws © and adjust the bearing brackets on the cross bar Adjusting the upper transport roller Crank the press in direction of rotation until the upper transport roller “6 the lowest section to the lower transport roller (B). For this adjustment, insert one punched steel tape of 0.1 mm thickness each on D.S. and 0.8. (outer rings) between the upper and lower trans- port roller. For these adjustments upper and lower transport roller must be cleaned and grease~free (use alcohol) . It must be possible to remove the steel tape on both sides D.S. and 0.8. evenly with a force of 200 g to 250 g. For this exact adjustment we recommend to use a spring scale 0.5 kg (part no. 00.894.0630) which should be applied alternately on D.S. and 0.8. on the punched steel tape to measure the applied force (see ill.). For corrections slacken the locking screws © and adjust the eccentrics ® (slacken the screws as well) accordingly. Take care that the eccentrics on D.S. and 0.S. are aligned in the same direction. Check the pressure of the upper transport roller once more with tissue paper. It must be possible to remove the tissue paper evenly on both sides, D.S. and 0.S., on the outer rings. In case of differences, always readjust on the weaker side. Maintenance and Repairs Adjusting the skeet guide plates to the impression cylinder 1, There must be a distance of 0.9 to 1.1 mm on D.S. and 0.8., i.e. over the entire width, between the upper sheet guide plate (A) and the impression cylinder surface (see ill.) . 2. For this adjustment, the soxews (B) should be slackenea aad the sheet guide’ plate @) agjiated via the: supports © to the impression cylinder surface. 3. Check whether there is some clearance between the lower sheet guide plate and the impression cylinder surface (sheet guide plate must not touch the impression cyl- inder surface) . Maintenance and Repairs IMPRESSION/BLANKET/PLATE CYLINDER Axial adjustment of the impression cylinder —— Impression cylinder bearing 0.8. D.S. ZTE SN Mm 4263/1 .0056 0.03 mm pressure 00,894.05 Mm 4447 (0) |-—T 00.894.0058 1. First adjust the impression cylinder without axial play, however, without any pretension, by tightening the lock nut accordingly by means of the special wrench Vim 4263/1 Part no. 00,894.0056 (see ill.). 2. Pix the plate for the magnetic stand vam 4447 part no. 00.894.0058 at a suitable place on the side frame D (see ill.). Attach the clock indicator with magnetic stand as shown in above illustration and set the clock indicator at the measuring point (see ill.) to with some pretension. 3. Tighten the lock nut until the clock indicator shows -0.05 mm. Then the lock nut should be released (clock indicator “ie To obtain the correct adjustment, re-tighten the lock nut until the clock indicator shows 0.03 mm = 0.03 mm axial pressure in the cylinder bearing. Maintenance and Repairs xing the shaft of the plate cylinder j H i | Plate cylinder i U The shaft of the plate cylinder should be fixed with the nuts (A),as shown in the illustration, on the side frame D.S. and 0.8. Then it should by no means be possible to move the cylinder sahft. Maintenance and Repairs Axial adjustment of the blanket cylinder to the plate cylinder JI" Plate cylinder Ory In alignment me if O. + + Blanket cylinder 1, The front sides of bearer (B) (blanket cylinder) and bearer ® (plate cylinder) must be if alignment as shown in above illustration. To obtain this setting, the blanket cylinder must be aligned to the plate cylinder. 2. For this adjustment, the locking nuts © should be lackened and the blanket cylinder should be pushed axially in the respective direction_over the sliding Pieces by means of the screws 3. Then the blanket cylinder must be adjusted without axial play but without clamping and locked. Maintenance and Repairs. Adjusting the printing pressure 1. Setting blanket cylinder - plate cylinder vMm 4019/1 item 2 ee 000.894.0064 fee Eccentric bearing sleeve oN : VMm 4019/1 i 00.894.0047 Blanket cylinder | Maintenance and Repairs KANO CLEAN Hf MEEBED THe Gc AR 1 crt whores. macs mekese ADSuStae HITS. cil beer RE PLATE AND GLALKET 1.1 Loosen the locking dise (@) via the self-locking nut (see ill, 2). 1,2 Bring the blanket cylinder to position “IMPRESSION ON" in relation to the plate cylinder. Keep magnet y 12 pushed and turn the press manually in direction of rotation until the blanket cylinder is in position "IMPRESSION ON" in relation to the plate cylinder. he roller ©) (see ill. 2) must be positioned om the highest point of the inner cam, and the roller must be ina perfect lock-in position. The press mist remain in this position during the entire adjusting procedure. @ Fest RELEASE. ge ADS OTT pivot Ped cere wnt matey B) 2 Of TEC WALD I. 2 Maintenance and Repairs Demount the clamping rings for the eccentric bearing sleeve D.S. and 0.8, Slacken the nut (4) on D.S. and 0.8. (see ill. 1). Adjust the eccentric bearing sleeves by means of the wrench insert VMm 4019/1 part no. 00.894.0047 in circumferential direction towards the feeder until a light gap becomes visible between the bearers on D.S. ard 0.8. Insert a steel tape of 0.03 mm thickness between the bearers on D.S. and 0.8, (see ill. 1). Adjust the eccentric bearing sleeves alternately on D.S. and 0.8. in circumferential direction towards the delivery until the steel tapes can be removed evenly on both sides with slight resistance. * After this adjustment, the steel tapes should be removed completely. Clamp a gauge vin 4019/1 item 2 part no. 00.894.0064 on each eccentric bearing sleeve D.S, and 0.S. (see ill. 1). Measure 12 mm from upper edge of the gauge towards the delivery and make a mark (see ill. 1). Turn the eccentric bearing sleeve on D.S. and 0.8, in circumferential direction by means of the wrench insert VM 4019/1 item 1 part no. 00.894.0047 towards the delivery until the tip of the gauge side meets with the previously made mark (see ill. 1). Remove the gauges. Reassemble the clamping rings and clamp the eccentric bearing sleeves in the set position. Re-tighten the self-locking nut (@) (see ill. 2). Tighten the nut () D.S. and 0.8, (see ill. 1). Maintenance and Repairs 2. Setting blanket cylinder - impression cylinder Maintenance and Repairs 2.1 Mount a test plate with line division onto the plate cyl- inder (e.g. positioning foil). : 2.2 Pack the blanket to the correct height (choose the underlay sheet accordingly) . 2.3 Set the pressure between blanket Perfect and impression cylinder to f printed image position "-0.1" of the scale (see ill. 2). es Printed image fainty evenly m2 Print a few sheets of 80 gsm. offset paper. The printed image should be evenly fainty over the entire width. Cor- rections are made by means of the stop screw (6) on D.S- and 0.8. of the press (see ill. 1). unscrew the stop screws = more impression Screw in the stop screws = less impression -6 Set the pressure between blanket and impression cylinder to position "0" of the scale (see ill. 2). Again print a few sheets. Now the printed image must: be perfect (printed image not fainty). -7 For a new adjustment of the spring pressure of the com- 1, In position "IMPRESSION OFF" the adjusting spindle (A) (see ill, 1)"D.S. and 0.5. should be turned in until the stop, 2, Then the adjusting spindles should be turned back by one revolution. Maintenance and Repairs Setting the adjusting lever for the pressure between blanket and impression cylinder 0.s. Tighten the self-locking nut ® so that a self-adjustment of the entire lever mechanism, i.e. of the desired pressure between blanket and imoression cylinder, is impossible. The adjusting power of the adjusting lever (@) by means of the T-handie socket wrench (€) should be approx. 4 kg. Maintenance and Renairs Adjusting the on-off mechanism blanket cylinder to plate cylinder D.S. Position impression “off” approx. 0.2 mm + Operate the press at minimum speed in position "IMPRESSTON OFF". llere, the lever (A) must contact the stop pin when it is in its starting position (must not vibrate). For corrections the stop pin (@) should be adjusted (aligned) accordingly. Maintenance and Repairs D.S. Position impression “on” m2 Push the armature on the magnet Y 12 by hand while the press is in operation (minimum speed) = position "IMPRESSION ON" blanket cylinder to plate cylinder. In this position "IMPRESSTON ON" the lever (@) (sce ill. 2) must as well remain in its starting position™(must not Vibrate) when the press is in operation. Should a correction be necessary, the screws G) should be Slackened and the magnet support’ (F) should be-adjusted accordingly. Then set the press to position “IMPRESSION OFF". In this position there must be a clearance of approx. 0.?_mm (sec i11. 1) between the armature and the stop plate @).Slacken screws and adjust the height of the stop plate ©) {see i1ly 1). Maintenance and Repairs Adjusting the on-off mechanism blanket cylinder to impression cylinder adjusting lever for the pressure between blanket and impression cy&inder must be in position "+0.1" during the entire adjusting procedure. 1. Eor a first coarse adjustment the eccentric bolts (©) and must be adjusted in a way that the mark (notch) is pointing upwards (see ill.). 1.1 Crank the press in direction of rotation with the magnet Y3 pushed = magnet energized, until the cam follqwer is positioned in the lowest section of the cam (B)(seeill.). 1.2 In this position (magnet ¥3 and Y4 disenergized) there must be a clearance of 0.7 ma between the pawl and the stop lever © (see ill.). 1.2 corrections can be made via the eccentric bolt © 2.2 Maintenance and Repairs. In this cam section, the stop lever ©) engages with the blocking plate @) eG ere plate must be 0.2 mm, as shown in the illustration. Corrections can be made via the eccentric bolt (). Maintenance and Repairs ith the magnet ¥3 pushed = magnet energized, orank’ the press manually in direction of rotation by one press Povolution until the eam followeg. (A) is again positioned inthe high section of the can’ ()- With the magnet ¥3 pushed = magnet energized, there must be a digtance of 0.5 - 0.8 mm (see ill.) between the stop lever ® and the pawl (&). This distance (0.5 ~ 0.8 mm) can be adjusted via magnet ¥3. For this purpose slacken the screws and adjust the magnet support with the magnet Y3 accordingl¥ (see ill.). 4 Maintenance and Repairs follower is again positioned in the lowest section of Crank the press in direction of rotation until the cam a the cam & magnet energized, the pawl entirely engage with 4.1 In this position and with tps magnet Y4 pushed = my the cam part on the stop lever (@) until the stop {sce ill.). 4.2 For corrections slacken the screws and adjust the magnet_support with the magnet Y4 acSordingly to the pawl Magnet “energized” itenance and Repairs %. Retease the magnet ¥4 = magnet disenergized. The tension spring pulls the armature towards the ad- justing screw @ (see i21.). Push thesmagnet Y3 manually = magnet energized. In this position, a distance of 0.3 mm, as shown in the illustration, between the pawl and‘the armature {magnet Y4) should be adjusted afd fixed by means of the adjusting screw Maintenance and Repairs With the magnet ¥3 pushed = magnet energized, crank the press in direction of rotation until the cam follower is positioned in the high section of cam (B) (sec ill. Release magnet_¥3 = magnet disenergized. Now the pawl contacts the cam part of the stop lever i at IW this position there_must be a distance of 0.5 tween the stop lever @) and the blocking plate daisy Corrections can be made via the stop pin (Q) by adjusting (aligning) it accordingly (sec ill.}). wn be- (see Now the_distance between stop lever and blocking plate should be 1 to 2 mm. Again push the magnet ¥3 manually = en energized. Magnet “disenergized” Maintenance and Repairs Adjusting the roller lever and grippers on the impression cylinder 1. Adjusting the roller lever with the impression cylinder denouitee ~ The distance between the trunnion and the roller be 86.85 mm as shown in the illustration. We recommend to use a slide gauge for measuring this distance, as shown in illustration 1. must - Corrections can be made by means of the grub screw on D.S. and 0.8. of the impression cylinder. For thi purpose the grub screws hould be adjusted evenly on hoth sides to the stops) (see tll. i) NQ ASX O <> H Y/ Y) £) W.1 Maintenance and Repairs 2. Adjusting the roller lever with the impression cylinder mounted - Crank the press until the “0-position" is reached and sett the graduated disc to "0". ~ Crank the press in direction of rotation until the 40° mark is reached, - Inthis position, adjust a distance_of 0.45 mm between the ‘cam’ (K) and’ the cam follower For this purpose we recommend to use a slide gauge as shown in illustration 2. ~ Corrections can be made as described under paragraph 1 by means of the grub screws (A) - Machine positiot 40° after “O-position’ Maintenance and Repairs 3, Adjusting the impression cylinder grippers i These adjustments can be made with the impression cylinder mounted or demounted. - Bring the press to a position in which the gripper bar is accessible from the delivery side with the impression cylinder mounted and in which the cam follower @ is not in contact with cam © See all 2). = Slacken the locking screws @. =,Now a distance of 4 mm (see ill. 3) between the gripper holdexs and the clamping pieces shoula be adjusted via the adjusting screw; : ~ Then the individual grippers THI, 3 should be pushed onto the gripper : pads and the locking screws ®) tightened (see ill. 3). For the following adjustment of the individual grippers At is necegsary to clamp a shim of 0.4 my_thickness between the stud ® D. sand O-S. and the stop (B) D.S. and 0.5. (see i2]. purpose, adjust each gripper via the adjusting screw so that the inserted tissue paper can just be removed From the gripper with a slight pull (see ill. 4). jugee ye yuh) ha) eel out, EcPiAd MARA AOS apeessiab) VLIMOER 19 racine ROUND Te LF mis Mie va Adjust each individual gripper with tissue paper. For é° PING Assembling/adjusting the planetary gear unit for the circumferential register adjustment Before the planetary gear unit is assembled, the impression cylintier must be demounted. Furthermore, all gears must be greased, 1, Insert gear (@) into gear (®) (with gasket and retainer ring). Mount both gears (A) and ® ‘on the impression cylinder (Zace 0.5.). Take Sare that the mark () (sce ill. 7) is pointing towards the impression cylinder gap. Fasten gear (A) on the impression cylinder by means of the screws (O) (lock the screws with LOCTITE St) - 2. Remove the grease nipple on gear (8) and insert a locking screw instead (see ill. 1)T For a coarse ad- justment, adjust gear in circumferential direction to gear @ so that the mark is in alignment with the threaded hole (locking scréw) as shown in illustra- tion 1, Fix this adjustment by means of the locking screw. Important! Before the impression cylinder is demounted, we recommend to fix the setting of the planetary gear unit to prevent it from turning, as described under paragraph 2. | Locking screw M 5x10 Maintenance and Repairs The marks and ee 2. Loel 3. Mount gear & on gi Brak BUSE be in alignment as shown in gear by means of the screws 4. Por the fine adjustment the inner meshes of teeth of gear @)tand gear (B) must be exactly in alignnent. SlackeW the locking screw and adjust the gears accordingly in circumferential direction. Pix the adjustment by means of the locking screw. {n alignment 0. S., Locking screw Maintenance and Repairs @ 0.8. 0. S. [ a I Locking screw Locking screw The teeth of the two gears ® aTign- and must be exactly in ment. At the same time the marked tooth spaces and (see ill. 3) mist be in alignment. Pix this adjustment by means of a locking screw (sce ill. 3) Il. 3 Slide the_pre-mounted gear support ontg the two gears @ and (H) (see i114). Insert the bearing sleeve with gear support {0} into the gear block on the im- pression cylinder. Mount the tapered roller bearing, retainer plate, lock nut etc. Then the locking screw (see ill. 3 and 4) should be removed. Important! The locking screw on Gear () (sce ill. 1 and 2) may only be slackened after the impression cylinder is mounted into the press. Ui. 4 Maintenance and Repairs Adjusting the circumferential register adjustment Locating bolt VMm 4306 Planetary gear unit 4 00.894.0626 Side frame O. S..~ 1. align roa @) through the sige erame Va boring 0,S.~-by means of the locating bolt’ Uiim 4306 part no, 00.894.0626 | POSES EEARCEeaeeaeee gee Cc 2. Insert adjusting knob into the square-shaped bolt (8),adjust it free from play via nit (C) and lock it. d 3. Screw spindle (B) into roa until | there is a distance of 46 4 T mm to the adjusting knob as shown in B the illustration and~until the flat part for the scale is positioned on top. Lock the spindle with nut ®. In this position, the print-free margin is 8 mm, 4. Then use a marking tog] to make a mark on the spindle (b), flush with ry the frgnt side of the-adjusting 4 knob (A) (see illustration, ‘0 distance 46 * 1 mm). a8 : i 46 +1mm |e Remove Locating bolt Vim 4306, 3ha un- a screw the cpiaae with the'ad- | . t= un justing knob ‘il the stop, In this position, paste the scale onto thé spindle, with the "-1" of the scale being exactly flush with the previously made mark. With position "0", the print-free margin is 7 mm. Maintenance and Repairs D DELIVERY Adjustments/che -ups on the chain delivery Adjusting the delivery grippers : iad 1, refRSS" all grippers and the tension piece 6 Set the distance mn as shown in TIT. T and clamp one gripper accordingly on the shaft. > : Torsion springs released 2. Tensioning the torsion springs Set. the torsion springs slightly against the grippe: bar via the tension piece’ (B). -turn the tension piece (8) on eee 120° ‘ang clamp it by means of screw (see ill. 2). Then the spring tension is 2.5 kg. Torsion springs tensioned mM. 2 3, Adjust the individual grippers evenly. It should be possible to remove a strip of tissue paper with a slight pull. Maintenance and Repairs ioning the delivery chains If it becomes necessary to remove and to mount the delivery chains again on the chain sprockets, e.g. in case of repairs, it is espeoially important to position the chains correctly. As shown in the illustration, the Sth space before and angle support of the gripper bar should be positioned at the marked booth, i.e, first on D.S.. The mesh of teeth is not marked for positioning the chain on 0.. should be aligned accordingly to Therefore, this chain + and positioned. Mark 5 43 210 Maintenance and Repairs Setting the delivery chain tension The best method to set the delivery chain tension is to use the spring scale 00.894.0631. For this purpose insert the spring scale as shown in the illustration. With 4 kg lifting capacity, the distance between chain and shaft 22.015.006F must be 43 mm on D.S. and 0.8. (see ill.). Release_the lock nut (8) and tension the chain by means of screw (A) as shown in the illustration. Maintenance and Repairs Adjusting the closing time of the chain gripper at sheet transfer An exact adjustment can be made by means of the graduated disc (for thet procedure refer to part "Adjustments of the press by means of the graduated disc"). The chain gripper closing point is at 198° to 199°, i.e. i® to 2° before the actual cylinder gripper opening point. Check the opening and closing times by means of tissue paper. ror corrections release the screws © and adjust the can 22.014,042 accordingly (see ill.). Gripper closing point 198° to 199° Maintenance and Repairs Adjusting the gripper margin on the chain gripper The chain gripper bar must be aligned to the impression cylinger so that there is a gripper bite of 2.5 - 3 mm in the chain grippers after sheet transfer. For an adjustment release screws (6) on the chain sprocket 22.014.018 (see i11.) and align thé chain gripper bar to the impression cylinder accordingly. 25-3 m, —_ Tip, ‘ D.S. Per bite ele 7 ee @ e its O i] 7 22.014.018 | 1 | \ Maintenance and Repairs Adjusting the overshooting control on the chain delivery 1, The switch plates 22,014,034 $ must be adjusted so that they are jin alignment with the paper stops 22,015.241/242 (see ill.) . This adjustment should be made by means of the adj sleeve 22.014.050 (see ill.). sting 2. In this position the switch S 11 must be actuated. adjust switch S 11 to the lever 22.014.037 S accordingly. 3. Tension the spring 22.040.146 so that the switch plates 22.014.034 $ are just pulled to their end position, i.e. the switch S$ 11 is actuated = press ready to run. Check whether the press stops at an overshooting sheet (check it with tissue paper). Switch § 11 not actuated = press stops. Maintenance and Repairs Adjusting the transport mechanism of the pile board on TOK presses 0s) — 22.015.003F 22.015.001S - 2 \O S7 aa lo ~~~ 22.015,029_ Lg —— 22,015.004 — l 22.015.033 = SS 0: 22.108.1731 Maintenance and Repairs When installing the transport mechanism of the pile board, you must observe the marked mesh of teeth of the bevel gear 22.015.008 and 22.015.004 D The mesh, of teeth of the bevel gear 22.015.008 and 22.015.004 0.5. should be chosen so that the delivery pile board Ties level on the pile board support 22.015.001 S D.S. and 0.8. Release the stop plate 22.015.030 and carefully lower the pile board support until the spindle nut 22.015.026 slightly contacts the slide ring 22.015.005. Turn the pile board support up by one turn of the spindle (spindle for lowering the pile board 22.015.003 F). In this position adjust the stop plate 22.015.030 so that the spring dowel sleeve 00,530.0244 is positioned in the middle of the stop (see ill.). Turn the spindle by one turn more. During this turn it must be possible to move the spring dowel sleeve 00.530.0244 without contact below the stop plate 22,015,030. Attention + In this position the switch $ 7 must be actuated = pile limitation. For corrections release the plate 22.015.033 and adjust the switch S 7 to the switch element 22.015.029 accordingly. It is important that the transport mechanism for the pile board stops before the spring dowel sleeve 00.530.0244 contacts the stop 22.015.030. Maintenance and Repairs Adjustments/check-ups on the chute delivery 1, The two grooved ball bearings 00.520.1020 must be aligned equally with slight contact to the impression cylinder surface. Adjustments can be made via the nuts on the studs 00.520.1744 (see ill.). 2, The master removing rail 22.014,525 must be adjusted to the smallest possible distance (without contact) to the impression cylinder surface (see ill.). For an adjustment release the fixing bolts. 00.520.1020 Impression cyli 22.014.525, Maintenance and Repairs E INKING UNIT Inking roller engaging and disengaging 1. Bring the drive cam 22.019.0298 and the stop lever 22.019.021 to the position shown in ill. 1. - In this position the cam follower 22.019.023 must definitely be at the lowest section of the cam. If a correction is necessary, the bearing bolt 22.019.032 on the side frame should be released (including the mounting support of the roller washing device) and the drive cam 22.019.0298 should be adjusted accordingly. - Then realign the mounting support 22.204.011 (on the side frame D.S. inside) for the roller washing device. - Release the stop 22.019.051 on the stop lever 22.019.0528, push it against the screws in direction of the arrow (see ill. 2) and fix it in this position. 22.019.021 © 22.019.023 a 22.019.029S 22.019.032 iia Maintenance and Repairs 2. Bring the drive cam 22.019.029S and the stop lever 22,019,021 to the position shown in illustration 2. - Crank the press by hand until the lever 22.019.0828 is on the bottom dead centre (see ill. 2). - The stop 22,019,051 must engage with the locking pin 22,019,049 by 3 mm as shown in illustration 2. For corrections adjust the stop 22.203.005 to the stop lever 22.019.0525 accordingly. - Align the grooved dowel pin 00.530.0753 so that there is a play of 1 mm between the connecting rod 22.019.050 and the shouldered screw 22.019.085 (see ill. 2). 2.019.021 Ss : oe © 22019049 222.019.0298, 22.019.05: 00.530.01 2.190688 a Bottom dead centre \ 2.919.050. ~~ ve 22.019.085, WM. 2 Maintenance and Repairs. 3. The lever 22.019,082S remains at the bottom dead centre (see ill. 3). - Push the stop lever 22.019,0525 to the right; in this position (sec ill. 3) the stop 22.019.051 contacts the locking pin 22.019.049. ~ There must be a backlash of 0.05 mm between the connecting rod 22.019.050 and the shouldered screw 22.019.085 as shown in illustration 3. For corrections release the hexagon nut 00.520.0838 on the stop lever 22.019.021 and adjust the connecting rod 22.019.050 to the shouldered screw 22.019.085 accordingly. - Release the connecting angle 22.019.047 at the link to the connecting rod 22.019.046 and adjust the length so that the cam follower 22.019.040 slightly contacts the drive cam 22.019.029S, and the trigger 227.019.0653 slightly contacts the stop pin 22.019.071 (see arrows in ill. 3). 22.019.021 22.019.049 22.019.052S 22.019.051_ Bottom dead centre 22.019.082S 5 mm i. 3 Maintenance and Repairs 4. Bring the drive cam 22,019.029S and the stop lever 22.019.021 to the position shown in illustration 4. - Crank the press by hand until the lever 22.019.0825 is on the upper dead centre (see ill. 4). - Check whether the stop lever 22.019.0528 contacts the stop 22.203.005 (see ill. 4 item (A)). ~ The latch 22.019.058 must be flush with the incised mark on the driver 22,019.083 as indicated by the arrows in the illustration. For corrections release the screw 00.520.0884 and ad- just the driver 22,019,083 accordingly. - Push the stop lever 22.019.0528 slightly to the right and let it spring back to the locking pin 22.019.049. During this procedure, the stop 22.019.051 should engage with the locking_pin 22.019.049 only approx. i_mm (see ill. 4 item (@)). Corrections can be made by a height adjustment Sf the stop 22.019.051. When fastening the stop, it must always be completely pushed to the right towards the screws. - With the press running, check whether after the first fow revolutions the stop lever 22.019.021 comes to a complete stop in the shown position. If necessary, align the stop 22.019.051 to the locking bolt 22.019.049 accordingly. 22.019.021 22.019.029 S dead conte] | 019.082 S~ 00.520.0884 Maintenance and Repairs 5, The press should remain in the position as described under paragraph 4. - The distance between the angle piece © on the stop 22.019.061 and the stop lever 22.019.0525 must be 9.2 mm (see ill. 5). Release the stop 22.019.061 and adjust it accordingly. ~ There must be a distance of 4 mm between the angle piece on the stop 22.019.061 and the casing on the magriet Y 10, as shown in illustration 5. For corrections, the angle piece (0) should be re~ aligned (bent). tenance and Repairs 6. Bring the drive cam 22.019.0295 and the stop lever 22.019.021 to the position shown in illustration 6. The lever 22.019,0823 must be at the upper dead centre (see ill. 6). - Push the magnet ¥ 11 to the stop = magnet energized. ‘There must be some backlash between the connecting rod 22.019.050, the pin screw 00.510.0067 and the shouldered screw 22.019,085 (see arrow in ill. 6). Release the angle plate for the magnet 22.019.103 and adjust the backlash accordingly. - The distance between the driver 22.019.083 and the latch 22.019.0585 must be 0.2 - 0.3 mm as shown in ill. 6 For corrections release the pin 22.019.060 and adjust the latch 22,019,058S accordingly (see ill. 6). 2.019.103, 22.019.060 2.019.021 feet © MW. 6 Maintenance and Repairs Axial adjustment of the plate inking roller 2.010.020 F 1, The plate inking roller 22,010.020 F should be centred axially to the plate cylinder by means of the adjusting scréws 22.030.032 S D.S, and 0.8. (see ill. 1). - When making the adjustment take care that the inking roller has no lateral play and that it can be moved easily up and down between the adjusting screws 22.030.032 S D.S, and 0.8. (see ill. 1). Side frame Side frame 1D. Sj pm 10. S.i i 1 ‘ t I 1 1 t 1 I ie n Il ' i i 1 i 22.030.082 $_ Maintenance and Repairs + The adjusting screws 22.030.032 S on the side frame 0.8. can only be adjusted when the bearing plate 22.040.101 F/02 is completely demounted together with the auxiliary drive for the automatic master injection. Attention! When fitting the bearing plate 22.040.101 F/02 with the auxiliary drive, the marks on the gears (side frame 0.5. inside) must be aligned as shown in the illustration 2 (see arrows). Maintenance and Repairs The bearing plate 22.040.101 F/02 with the auxiliary drive must be mounted on the side frame 0.S. outside in a way that the marked teeth and tooth spaces mesh as shown in illustration 3 (see arrows). When fastening the bearing plate take care that there is some gear backlash. F DAMPING UNIT Aligning the damping unit in the press The damping unit must be aligned horizontally in the press. For a check-up place a spirit level onto the water pan roller. For corrections release the bearing 22.030.005 0.8. (spare parts book page 30-1, item 14) and 22.030 ,004 D.S. (spare parts book page 30-2, item 13) and align the damping unit accordingly; take care that there is a gear backlash in the mesh of teeth 0.S. on the water pan roller. Check the alignment of the press before that. Adjusting the damping solution transfer roller 22.03 (oscillating) 0.048F/01 - The plastic sliding block (@) on the longer bolt must be inserted into the groove of the damping distributor 22.030.055F/a when the bearing bracket 22.030.090/K01 is mounted (see ill. 1). 22.030.090/K0 Bearing bracket 22.012.006 Cross bar 22.019.001F 22,030,040 F/03' Metering roller 22.030.020 F103 22,030,048 F/01 Water pan roller Damping solution Damping distibutor 4 transfer roller Maintenance and Repairs - Centre the damping solution transfer roller axially to the water pan roller by shifting the bearing bracket 22.030.090/KO1 on the cross bar 22.012.006 (see ill. 2). Attention! Take care not to jam the control shaft 22.019.001F. The damping solution transfer roller should be centred by shitting the bearing bracket Bearing bracket F'22.012.006. E ross bar —|_| 2019001 stl femeaet 22.030.048 F/01 Damping solution transfer roller ML 2 Maintenance and Repairs Aligning the inking/damping rollers and the inking/damping enie unk Wink stripe Plate cylinder m4 The following rollers must be aligned: Item no. Designation Part number 1 Plate inking roller 22.010.020 2 Ink distributor 22.010.042 3 Ink transfer roller 22.010.050 9 Damping distributor 2.030.055 10 Damping solution trans- | 22.030.048 fer roller W Water pan roller 22.030.020 12 Metering roller 22.030.040 Maintenance and Repairs Maintenance and Repairs When aligning the inking/damping rollers and the inking/ damping unit, proceed according to the following sequence: 1, Rompve set of rollers (ill. i items 8, 7a, 7b, 6a, Gb), plate inking roller (ill. 1 item 1), damping solution transfer roller (ill. 1 item 10) and metering roller (Gill. 1 item 12) from the press. 2, Set the ink distributor (ill. 1 item 2) parallel to the damping distributor (ill, 7 item 9) according to the following instructions: from the adjusting screw 22.010.036 (ill. 2 item (a)) D.S. and 0.5. and release the Jocking nut 00.909.2271 (11, 2 item ()) Des. and 0.8. ~ Remove retaining ring 00.540.0384 (ill. 2 item ao) - Insert the plate inking roller (ill. 1 item 1) into the press, Apply a thin, even layer of ink on the rollers. - Set the damping distributor (ill. 1 item 9) with the hexagon nuts 00.520.0413 (ill, 3 item (F)) D.S. and 0.S. to the plate inking roller so that ther® is an ink stripe of 4 mm over the entire width between plate inking roller and ink distributor (ill. 1 item 2), as well as between plate inking roller and damping distributor (ill. 1 item 9). Check both ink stripes on the plate inking roller. ~ Turn the adjusting screw 22.010.036 (ill. 2 item ® D.S. and 0.8. in or out on the block 22.010.035 (iT1. 2 item ®) so that the screw head has slight contact and the re¥aining ring 00.540.0384 (ill. 2 item (©)) can be inserted again. Lock the adjusking screws with the hexagon nut 00.909,2271 (111, 2 item ()) D.s. and 0.8. 3. Check the axial adjustment of the plate inking roller (ill. 1 item 1); align it if necessary between the side frames without play so that it turns freely (see page E - 2/1). ‘Take care that the swash plate 22.010.024 (inking roller down) does not contact the plate cylinder bearer. Maintenance and Repairs WL 4 Maintenance and Repairs 4, Aligning the plate inking roller (ill. 1 item 1) to the plate cylinder. - Mount a metal plate on the plate cylinder and ink if up without damping. - Lower the plate inking roller manually on the plate cylinder and lift it again. - Check the ink stripe on the metal plate. The ink stripe must be equally wide over the entire length and should be 4 to 6 mm depending on the kind and thickness of the plate. - Corrections can be made by means of the grub screw 090.520.0012 (i11. 4 item ()) on D.S. and 0.8. of the press, 5. Align water pan roller (ill. 1 item 11) and damping distributor (ill, 1 item 9) parallel as described below. ~ Release the bearing of the damping system 22.030.004 D.S. (QUI. 3 item ® and 22,030,005 0.8. (ill. 5 item (K)) on the side frame. - Adjust some gear backlash in the mesh of teeth of the water pan roller 0.8. (ill. 5 item @)). ror this Purposay the bearing of the damping System 0.s. (ill. 5 item ® should be adjusted accordingly and fixed on the side frame. - By means of a spirit level (measuring accuracy 0:04 to 0.05 mm per metre) align the water pan roller (11. 1 item 11). However, a prerequisite is that the levelling of the press is absolutely exact, which must be checked in this case on the plate cylinder before the alignment of the water pan roller. For this purpose take the plate inking roller (ill, 1 item 1) out of the press. The parallel setting of the water pan roller (ill. 1 item 11) to the damping distributor (ill. 1 item 9) should be made_via the damping unit bearing 0.3. (11. 3 item ©). Maintenance and Repairs. Aligning the damping solution transfer roller (ill. 1 item 10) to the damping distributor (ill. 1 item 9) and water pan roller (iil. 1 item 11). ~ Insert the damping solution transfer roller into the press. , - Align the damping solution transfer roller to the damping distributor by means of the grub screw 00.520.0038 ) on D.S. and 0.8. so that the ink stripe 2 GL. 3 item is parallel ani As a@ result there is an ink stripe of 2 mm as well to the water pan roller. The ink stripe must be equally wide over the entixe length, If it is not, the water pan roller and the damping distributor are not exactly parallel to each other. m wide. Aligning the metering roller (ill. 1 item 12) to the water pan roller (ill, 1 item 11). - Insert the metering roller into the press. - Feed damping solution. Set the lever for adjusting the amount of damping solution to position 6 (ill. 5 item (L)). - With the press running, align the metering roller to the water pan roller so that on the outer area of approx. 2 cma damping film is just visible. screw 22.030.032 (411. 3 and 5 item @)) on D.S. and 0.8. of the press. The adjusting screws can be turned through the slot in the guard by means of a fork wrench (10 mm). Then lock the adjusting screws with the hexagon nuts. - The adjustment should be made by mean of the adjusting Aligning the ink transfer roller (ill. 1 item 3) to the ink distributor (i11. 1 item 2). ~ The ink stripe must be parallel and 3 to 4 mm wide. - If a correction must be made, the clamp on the latch 22.010.049 (ill. 2 item (M)) D.S. and 0.8. should be re-aligned accordingly. Attention! All distributor grooves must be free of dirt @ greased extensively. Maintenance and Repairs G ETCHING DEVICE Adjusting the etching roller to the plate cyli i, Turn in the adjusting screws 22.203.105 D.S. and 0.8. (sce i114 1) until the stop. 2. Place the etching device into the press and fasten it with the screws 22.203.104 (see ill. 1). ention! During the following adjustments take care that S some gear backlash between the gear 22.203.141 F (spare parts book page 203-2 item 8 etching device) and the gear 22.030.082 (spare parts book page 30-2 item 17 damping unit) when the etching device is engaged. Tf necessary, adjust gear backlash by means of adjusting plate 22.020.080F (spare parts book page 30-2 item 18). With the etching device disengaged, the two gears must be completely out of mesh. This check-up must also be made with extreme pressure between etching roller and plate cylinder (unscrew adjusting serews 22.203.105 until the end position). Plate cylinder surface 2.203.104 3.105, Etching roller with sleeve 22.2 6. Maintenance and Repairs With the magnet ¥ 15 pushed, turn the press until the etching roller is engaged at its end position to the plate cylinder surface. Adjust pregsure of the etching roller (with new sleeve) to the plate cylinder surface so that a steel tape 0.1 mm can be removed at the narrowest point with slight re- sistance. Adjust the stop screw 00.520.0361 accordingly and lock it {see ill. 2). Release fixing bolts 22.203.104 D.S. and 0.8. (see ill. Align the etching roller by means of the two adjusting serews 22.203,105 (see ill. 1) parallel to the plate cyl- inder surface, using a steel tape 0.1 mm. With the etching device fastened, it must be possible to remove the steel tape 0.1 mm evenly and with slight resistance. With the magnet Y 15 disenergized, there must be an over- 1). lap of 1 mm in the shown position (see ill. 2) between the lever 22.019,082 and the latch 22.203.030. Corrections can be made by means of screw 00.520.0351. shown in illustration 2 + There must be a distance of 13 mm between the spring rod guide 22.203.054 and the stretching bolt 22.203.055 as (spring tension). Maintenance and Repairs H_ MASTER INJECTION AND EJECTION Manual master injection Basic adjusti tof the manual master injection 0,3mm Adjusting the distance 0.3 mm between guide plate and juide roller (see ill. 1). Unscrew guide (@) 22.040.325. Release screwing ©) and set the stepped lever ® 22.040.309 to the_eentre of the elongated hole of the connecting link (Q) 22.040.3035; re-tighten the screwing). Insert the master feed table into the press and screw it down. Release screws @) and, by means 2f the feeler gauge, set the es Between guide plate @) 22.080 310 end guine roller 22.040.324 to 0.3 mm paFallel (see ill. 1); tighten The screws (E). If the guide plate (©) cannot be adjusted far ecnough_to obtain the measurement 0.3 mm, release the screwing ©) and Set the distance 0.3 mg via the connecting link (D). Tighten the screwing (C). Screw down the guide (a). Maintenance and Repairs 2. Positioning run of the plate cylinder (see ill. 2) 2.1 Set the hinged lever 22.040.001 F upwards. (Plate cyl- inder moves into positYon, clamping bar 22,007.030 § is open.) 2.2 Place a master onto the master feed table and slide it into the open clamping bar (a). 2.3 Set the hinged lever @) down to its original position (master is clamped) . 2.4 With a correct setting, the clamping mazgin must be parallel and 5 - 6 mm wide. 3. Correction of the plate cylinder position 3.1 If the plate cylinder stops too early or too so that, it is not possible to slide the master into the open clamping bar, the timing of the synchronous discs PZ and TS must be checked and readjusted. (See Manual Electronics TOK/TOM 3.16 and 3.17). 3.2 For checking the correct adjustment pull out the handwhee1 and turn it into direction of paper travel. The displays P4 and TS must change in this sequence from "1" to "0" one after the other. (Synchronous disc TS approx. 1° after synchronous disc Pz). Mainienance and Repairs Automatic master injection Basic adjustment of the automatic master injection Me 4 Adjusting the distance 0.3 mm between guide plate and Sonact pressure pressure roller (see Vit} 1 Unscrew guide (8) 22.040.326. Release screws ©) and, by means of thg feeler gauge, set the distance between guide plate (€) 22.040.310 and contact pressure roller © 22.040.430 to 0.3 mu parallel (see ill. 1). ‘Tighten screws Insert the master feed table into the press and screw it down. Maintenance and Repairs I. 2 2, Adjusting the distance” 1.3 mm between rubber rol and contact pressure roller (see i 2.1 Release the screwing (©) (ill. 2) and set the distance between rubber roller (©) 22.040.427 S (ill. 1) and contact pressure roller 22,040,430 (i114) to 1.3 mm (see ill. 1) by adjustingthe forked lever 22.040.477 {i11, 2) and the intermediate leyer © 22.0%0.412 $ (ill. 2). Tighten the screwing (PT2) 2.2 Screw down guide 22,040,326 (ill. 1). Adjusting the master transport 1. Basic adjustment on the automatic master injection 1,1 With the master feed table inserted, release the stop 22,040,445 (see i11. 2) and set it to contact the segment 22.040.435 S (see_ill. 2). (The stop ® should just gontact the segment (&), however without play.) 1.2 Align a master, push the magnet ¥7 (see ill. 4) and crank the press manually in direction of rotation until the master is transported to the plate cylinder. 1.3 Check the transfer of the master into the clamping bar. With the correct adjustment, the master should slightly touch the front edge of the open clamping bar with manual operation. Adjusting the control mechanism for the automa injection ‘auxiliary drive Maintenance and Repairs ¢ master ul. 3 tl. 4 Manet Y7 is disenergized (see ill. 3) With the magnet disenergized, the clutch is out of operation. The lever’ (@).22.040.112 8 must overlap the square nipple by approx. 2.5 mm (see ill. 3). Corrections can be made by bending the stop pin (B). To ensure smooth enyaging and disengaging of the clutch, it, is necessary that the magnet Y7 easily actuates_ the lever Corrections can be made on the eccentric bolt) 22-010,157, Magnet Y7 is energized (see ill. 4). With the magnet energized, the clutch is engaged, There must be a distance of approx. 1 mm between the lever 22.040.112 S$ and the squaré nipple ® (see ill. 1). For corrections adjust the magnet support plate ©) 22.040.144 accordingly. Maintenance and Repairs 1. Correction of the master transfer up to serial no! 492/434 and on presses which have not been equipped Subsequently with the Umproved automatic master in= jection (see Service Information of May 14, 1985). fh eeepc i933 j= Stop forward: | Stop backwards: master arrives master arrives later earlier I. 5 1.1 When the master is not seized by the clamping bar (the master arrives too late), the stop (@) 22.040.445 (ZIT. 5) must be set backwards (see ill. 5). 1.2 When the master is transported beyond the clamping bar (the master arrives too carly), the stop (A) 22.040.445 (GIT. 5) must be set forward (see ill. 5). 1.3 When the stop (A) (ill. 5) cannot be adjusted far enough, so that the optimum master transfer timing cannot be ob- tained, the mesh of teeth of spur gear 8 22.040.143 (il. 6) and spur gear 22.040.129 (iT1. 6) must be shifted additionally 244 Maintenance and Repairs Correction of the master transfer_as of serial no. 492 435 and on presses which have beén equipped sub- Bequéntly with the improved automatic master injection {see Service Information of May 14, 1985). when the master is not seized by the clamping bar (the master arrives too late), the cam 22.040.124 (iTT. 6) must be adjusted clockwise. When the master is transported beyond the clamping bar {the master arrives too early), the cam (€) (i11. 6) must be adj unter=clockwise. Put the press into operation and check the master in- jection. With the correct adjustment, the clamping margin must be parallel and 5 - 6 mm wide. Maintenance and Repairs Stack-load master feed table 3. inserting the stack-load master feed table Push in the two retention bolts (see ill.) on the automatic master injection and slide in the stack-load master feed table until the retention bolts snap in and the stack-load master feed table is fixed. Adjusting the master feed and the pressure Throw over lever (G) 22.040.532 § towards the press. Insert master stack. Set the lever ©) back to its original position. Position the rollers (®) 22.040.592 to the left and right with thin masters and to the middle with thick masters. Adjust the pressure of the master stack to the rollers on the adjusting knob ® 22.040.567. D&crease the pressure with Thin masters, increase the pressure with thick masters (see ill. indicator (@)). Put the press into operation. The masters must be fed Maintenance and Repairs Automatic mi aster ejection Inserting the master ejection 1.1 Insert the master ejection into the press. Let the snap_lever D.s. 22.050.211 S and the snap lever 0.8. (©) 22.050.210-(ill. 1) snap in. With the master ejection inserted, the microswitch (i11. 2) must not be actuated. when the suites Gist is not inserted into the press, the microswitch (ill, 2) is actuated by the control lever (@) 22.050.764 § (ill. 2). Maintenance and Repairs i. 2 Adjusting parallelism and correct distance between master ejection and plate cylinder Actuate magnet Y8 (ill. 3) or connecting rod 22.050.134 5 (ill. 3). Crank the press manually in direction of rota- tion, (Swivel part of the master ejection moves into nm position.) In this position, the master removing rail () 22.050.255 (ill. 1) must by no means touch the plate Cylinder surface. Insert one thin strip of paper each on drive side and operator's side of the master ejection between roller 22.050.233 F (ill. 1) and plate cylinder. Remove the strips of paper. it must be possible to remove them evenly with slight resistance. Corrections of oe and parallelism can be made on the eccentric bolts 22.050.215 (ill. 1). Adjusting the control mechanism for the master ejection Maintenance and Repairs 2.5mm I. 3 Magnet _¥8 is disenergiz With the magnet disenergized, the clutch is out of operation. The lever 22.050.123 S must overlap the square nipple by approx. 2.5 mm (see ill. 3). Corrections can be made by bending the stop pin ©) zed (see ill. 3) To ensure smooth engaging and disengaging of the clutch, it is necessary that the magnet ¥8 easily actuates the lever (D). Corrections can be made on the eccentric bolt (A) 22.040.151. 2. Maintenance and Repairs Ul. 4 Magnet Y8 is energized (see ill. 4) 2.1 With the magnet energized, the clutch is engac- sees. lever 2.2 For corrections, adjust the magnet support pl must be a distance of approx. 1 mm between th: 22.050.123 S and the square nipple (see i=2. 4). © 22.040.144 accordingly. 2.3 By adjusting the angle support 22,050.127, set the 3. microswitch so that it is not completely =::ressed. Put the press into operation and check the mazz2r ejection. Maintenance and Repairs 1 BLANKET WASHING DEVICE 1. Mounting and demounting of the blanket washing device 1.1 Press the key @) "pla inking" and then key "start" (The press automatically moves into position, the sucker bar has reached the lowest point above the feed board pile.) 1.2 Now the blanket washing device can be mounted or demounted. the shaft (A) (B) ©. 2. Centerin 0,.05mm © O WL 2 2.1 Mount the blanket washing device. 2.2 Via the stops @) center the shaft @) 22.205.138 F to the side frames. 2.3 Via the stops (A) 22.205,023 adjust a play of approx. 0.05 mm on both sides (see ill. 2). 2.4 Tighten nuts ©). 2.5 Demount the blanket washing device and check whether the distance between stops (A) and the side frames is equal on both sides. Maintenance and Repairs djusting the locking and unlocking mechanism of the planket washing device (see ill. 3). Centre Ws sowest point 3.1 Insert the blanket washing device into the press. 3.2 Crank the press_manually into direction of operation until the cam lever (6) 22.205.001 S is positioned at the lowest point of the cam 22.011.044 (see ill. 3). 3.3 Slacken screws (@). 3.4 Set the nose of the clamping lever © 22.205.005 § to the centre of the cam lever {see ill, 3). Hold the clamping lever in this position until the cam follower support (8) 22.205.013 is adjusted. 3.5 Set the cam follower support (B) so that there is no play between lever (C)22.205.115 Sand can follower support. @). 3.6 Tighten screws (@). Crank the press manually until the caj lever is positioned at the highest point of the cam o. Check pYay 0.5 - 1 mm (see ill. 3). 3.7 When the magnet ¥14 is energized or disenergized, it must be adjusted in a way that it Lifts the clamping lever G) far enough off the cam lever Corrections should be made on the magnet support plate (F) 22.205.024. Maintenance and Repairs 4. Adjusting parallelism between wash-up roller and nenccarnin a4 14 4.1 Press the key ©) “blanket washup" (sce ill. 1). (the press starts, the washing device engages on the blanket cylinder.) 4.2 Open the guard in front of the washing device. (The press stops, the washing device remains engaged.) 4.3 Insert a steel tape (A) (thickness 0.1 mm) between wash-up roller (8) 22,205,136 F and blanket cylinder (see ill. 4). 4.4 Release threaded nipple (0) and by means of the stop eccentrics 22,205,123 adjust the parallelism between wash-up rollér (®) and blanket cylinder. It should be posSible to remove the steel tape (A) evenly and with slight resistance. 4.5 Tighten the threaded nipple @). Maintenance and Repairs K TROUBLESHOOTING HINTS. Paper run 1. Sheet is not picked up - Pile positioned too low - Suckers worn ~ 3/2-way valve 00,580.1780 jammed - Magnet 9 not energized ~ Dust filter on compressor clogged - Compressor defective 2. Sheet creasing - Suckers not at equal height - Sheet guide plate dirty - Upper sheet guide plate is aligned too high to the impression cylinder (distance 0.9 to 1.1 mm) - Transfer from suckers to transport roller not okay (check degree values) - Pressure of transport roller too high - Ejectors on gripper segment disturbing (TOK: shorten them slightly, if necessary) 3. Bdges bending - Pile positioned too low - Lateral sheet separating springs reach too far into the pile ~ Sheet transfer from suckers to transport roller ad- justed too low 4. Sheet jam in the feeder = Guide plates dirty ~ Sheet not lying flat - Light barrier defective or dirty - Transport rollers dirty 5. Sheet jam in the delivery (chain delivery) - Check chain grippers for easy motion ~ Check impression cylinder grippers for easy motion - Chain tension too low ~ Uransfer impression cylinder to chain grippers not okay - Check opening of chain grippers 6. Sheet jam in the chute delivery - Contact between grooved ball bearings 00.520.1020 and impression cylinder surface either too tight, too weak or uneven. Maintenance and Repairs 7. Sheet torn at leading edge ~ Sheet arrives too early Check for correct position of the blower bar (slanted/upright) Check tHe degree value at which the sheet arrives at the gripper sheet stop ~ Check the distance between upper guide plate and cylinder (0.9 ~ 1.1 mm) Blanket _wash-up 1, No wash-up = Wash-up device does not engage Check function of magnets Y13 and ¥14 - Replace spring dowel sleeve on lever 22.205.008 F by tapered pin ~ Check locking mechanism 2, Insufficient wash-up = Unsuited wash-up solution - Damping felt dirty Wash-up roller not moving easily on shaft Insufficient contact between wash-up roller and blanket Wash-up device not sufficiently engaged - Blanket cylinder not unlockea (check impression mechanism blanket cylinder to impression cylinder) 3. Continuous wash-up - Check function of magnets ¥13 and y14 = No spring tension applied on wash-up device > Cardigan cam lever 22.205.1278 does not engage Replace spring dowel sleeve on lever 22.205.008 F by tapered pin Etching 1. No etching (sheet completely inked) > Check function of magnet 15 - Check control mechanism 2. Partly etching (sheet partly inked) ~ Check whether etching roller and plate cylinder surface are parallel ~ Check pressure between etching roller and plate cylinder surface Maintenance and Repairs 3. Insufficient etching (ink marks showing) = Check pressure between etching roller and plate cylinder ~ Roller sleeve dirty or dry - Unsuited roller sleeve = Not enough etching solution in etching trough ~ Etching roller not locked 4, Insufficient etching by the continuous-flow etching device, master tinting Check etching solution level Check speed of master passage (set it slower) Check pressure of squeeze roller The master must be dry when arriving at the contiuous- flow etching device Master injection (manual) : 1, Plate cylinder does not stop at correct position - Correct the position of the plate cylinder by means of the synchronous disc 22.004.040 2. Actuation of hinged lever 22.040.001 not possible - Previous master not ejected ~ Magnet Y6 blocks the hinged lever (does not release) - Mechanical jam Master injection (automatic) 1. Creasing in the middle of the master during injection - Lever for actuation of the microswitch pushes the master up (adjust the microswitch $14 correctly) 2. Master positioned diagonally on cylinder ~ Align guide plate to contact pressure roller (distance 0.3 mm parallel) ~ Rubber roller soiled - Check injection time of master injection (clamping margin of the master 5 ~ 6 mm parallel) 3. Master cannot be inserted manually far enough ~ Distance between rubber roller and contact pressure roller too small (distance 1.3 mm parallel) Maintenance and Repairs Master is not injected - Lever for actuation of the microswitch $14 inhibits master - Check microswitch $14 (not actuated; defective) ~ Clutch of auxiliary drive not actuated ~ Magnet ¥7 not energized Magnet ¥7 incorrectly adjusted Clutch of auxiliary drive jammed Master arrives at the cylinder clamping at the wrong time ~ Rubber and contact pressure roller dirty ~ Master arrives too early or too late Incorrect adjustment of the stop 22.040.445 on master injection Incorrect adjustment of cam 2.040.124 on auxiliary drive . Check meshes of teeth of the individual gears (observe the marks) ~ Check overrunning clutches on rubber roller drive + Marks on the contact pressure roller in image = Overrunning clutches on rubber roller drive blocking ~ Rubber and contact pressure roller dirty ~ Master gets caught during injection = Remove U-clip 00,580.2103 on the guide plate ~ Lever for actuation of the microswitch S14 slows down rubber roller (grease contact point) Marks of the separator rollers of the stack-load master feed table ~ Insufficient fixation of the image on the master - Separator rollers dirty ~ Master does not leave the separators (separator rollers chafing) ~ Pressure between separating rollers and master pile too high or too low Plate cylinder 1 Master (plate) tearing in the perforation holes - Master too short ~ Hookbars bent - Blanket packed too high - Inking roller engaged too much Maintenance and Repairs Master ejection 1 Master not ejected ~ Check clamp margin of the master (correct injection parallel 5 ~ 6 mu) > Ejector dirty (rubber rollers, skids, master removing rail) - Tight motion on the engaging part (toothed belt gear, stretching roller, rubber rollers) ~ Guides for insertion of master ejection not parallel = Magnet ¥8 not energized ~ Check ejector on cylinder gripper segments (correct @istance 8.5 mm above impression cylinder surface) Press d ejectia: § not start, information display “master "is on ~ Master ejection not inserted ~ Switch $12 not actuated ~ Switch S12 defective Plate cylinder surface is inked at approx. 240 mm; as a result, the master sticks to the cylinder ~ Plate inking roller lifts off too late (check control mechanism) Inking/damping unit Damping solution splashing off ~ Check adjustment of inking/damping rollers ~ Bridge of ink between water pan roller core and edge of trough ~ Severe lateral ink piling on water pan roller and metering roller ~ Emulsification of ink in damping unit (ink/water emulsion), incorrect ink/water balance, unsuitable ink, unsuitable damping solution, damping solution very dirty > Check journal box of water pan roller and metering roller - Damping solution level too high (check valve) . Standard of printed image le Parts of image missing ~ Blanket not properly packed to suit plate or master ~ Hole in blanket ~ Pressure between blanket cylinder and impression cylinder too low = Check bearer pressure plate cylinder ~ blanket cylinder - Unsuitable ink Maintenance and Repairs Faint image = Too little ink on inking roller - Too much damping solution ~ Check adjustment of inking/damping rollers - Unsuitable solvents ~ Blanket not properly packed ~ Blanket dirty Scumming Too little damping solution ~ Too much ink ~ Unsuitable solvents, ink, plate not okay - Too little ink, resulting in not enough damping solution being applied ~ Check adjustment of inking/damping rollers Ink build-up at the edges of the plate cylinder outside the plate format ~ Clean plate cylinder with appropriate cleaning agent ("Stahl£ix") Streaks of ink in printed image when using straight-edgea masters ~ When it is fed, the master is hitting the drip tray, etching trough, damping solution trough, guide plate of the master injection (clean parts), insufficient preforming - Etching roller sleeve dirty - Etching roller sleeve too dry - Insufficient pressure between etching roller and plate cylinder Ink starts to build up on the front edge of the plate or master ~ Too little damping solution = Speed too low ~ Unsuitable solvents ~ Incorrect pressure between blanket cylinder and plate cylinder ~ Check adjustment of damping rollers Scumming streaks approx. 14 cm after leading edge of image ~ Blanket insufficiently tensioned. Maintenance and Repairs Rear side of sheet printed in the first third = Mechanism for locking the impression on the blanket cylinder faulty (see Service Information of Jan. 16, 86) 9. Firbt sheet is printed only in the second half - Check adjustment of the impression on-off mechanism blanket cylinder -~ impression cylinder +55" | pal ac 725" “o-Positionl" GAUGE Fok SEMI 2Ro-Position! ol A HELE Bu TOK Fi Wom Bog PART Me 0628 8 Gauge WLm 4305 Port no, 00.894.0628 s+] aur MAREING pAANO2&L Fok THE AD\OMTMUNT of Tr STNCHRONODS DISK "PLATE CYUIMEEIL” oN A HEICLLGERG Tor PeeSS Vim 4852 * Torys honcutesl unl te plate cinder ip she macing position, he. the centre of the holes are congruent ( () @ Mark the plate cylinder using the marking mandrel (HDM-No. 0.894.045), FEEDER CAM PIN FoR HEIDELGERG TDK PRESS, a) ® € VM 4262, D PALT NE 00. 44.0627 1) \ yen 4262 (00.894.0627 J Impression cylinder 4135". Le LOCATING GotT Fok ADJUSTING a ADUSTMENT ON A HEIDCLQERG @ 3,637". THE CIRCUMFERENTIAL REGISTER TOL PRESS VMm 4306 PART HE 00.394. 0636 007) 9290'P68'00 90EP HINA 1109 6 2 § le 8 Enb scbtw 2 Lies J-—c1s'—+| pos pees 1.398 ine’ : WRENCH FOR ADJUSTING PRINTING PRESSURE ON HEIDELBERG Tok PRESS Mn 40l9/i (EMI PART N28 009.894.0047 ‘vam 4019/1 item 2 5 6 [00.884.0064 7 ae Eccentric bearing sleeve Ae [aarp ‘vin 4019/1 item 4 fooss4.0087 Bearer Impression “on” a) feed rah“ Far Adon GhvGé Fok ADSTINE TRUTIRLG PEESSUE BUANeeT CLMIDLR PLATE CYLINDER, hen ft PABT ALL 00.8%, 006 Dees TAP Hoves FoR Sum Beets \ Impressi Leck Nur whiNCil Fok AKIAL ADJUSTMENT oF IMPRESSION CYCLINOER oN A steIOEL! sTOK PRESS VMun 4263/1 PART NE 06.874. as, MAGNETIC STAND PLATE Yor THe MEASORIG AND ADSOSIMENET o¢ Tee waPRessiaN CYLIMOLe Vin 4269/1 aseii aes 00.84.0056 FSEtSEtSEtSEORSSRESPESEEDEEES GWIEE sane + Sow/ ° ct 5 }»~ 2.57 ial 1 Lock nut Vian 44a | PART N2 00.894.0958 | 8 Yin 4487 | 00.894.0058 i a a rie FoR tOwys our 1. Impression cylinder (2.011.001) 1) Remove the impression cylinder cover plate (2.011.039). 2) Remove any remaining tension springs (22.011.034), pay 3) Loosen 6mm grub screw (00.520.1371, item 3) on the clamping © piece (22.01 1.031, item 3) of all six gripper assemblies allowing them to rotate freely around the shaft (22.011.025, item 5). 3. Stop (22.011.027) —o- . i 5. Clamping piece 5. Gripper operating shat © (22.011.031) ¢ Ss) 3. Grub screw HEIDELBERG TOK SPARE PARTS BOOK SECTION 11-1 Center punch mark 4) Swing the gripper operating shaft (22.011.025, item 5) around until the grooved pins (00.530,0740, item 6) hit the inside of the impression cylinder. i 6mm / .2362" 5) Mark the centerline where both | | ‘grooved pins (00.530.0740, item 6) 1 + touch the impression cylinder. TrelP* NCO © ©) Use center punch on the centerline 6mm up from the edge of the impression. oO cylinder, t cae © %. Close tolerance grooved pin (00.530.0740) HEIDELBERG TOK SPARE PARTS BOOK SECTION 11-1 2. 5mm / 1968" Dia. hole 7 z 7) Drill one hole Smm dia, thru per grooved pin (00.530.0740, item 6). 8) Use a saw to cut Iwo slots that meet each hole, M _— = © HEIDELBERG TOK SPARE PARTS BOOK SECTION 11-1 6. Close tolerance grooved pin (00.530.0740) 9) Clean-up the opening with a Sle until the grooved pins (00,530.0740, item 6) can pass through. 1 = — —. c HEIDELBERG TOK SPARE PARTS BOOK SECTION 11-1 MS-0,08 thread die Hose tolerance | ‘grooved pin 00.530.0740) 3. Stop (22.011 10) Use a Sm thread die to cut threads ‘on the grooved pins (00.530.0740, item 6) 11) Stack-up MS washers around the ‘grooved pins (00.530,0740, item 6), then use an M5 nut to remove the pins from the stops (22.011.027, item 6) 12) Use an MG tap to cut threads inside the holes of the stops (2.011.027, item 6). 13) Make two new grooved pins Screwdriver flat anu ‘M6-1.0 threads CT S 6mm / 2362" 10mm / sssr—al | | [fpr 0591" Tm / 2756" =*) 20mm /.7874" }— ‘HEIDELBERG TOK SPARE PARTS BOOK SECTION 11-1 5.

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