430 Manual - 2006

April 2006

Operation, Maintenance andIllustrated Parts Breakdown Manual

DGM - 430 Printing Press

DAUPHIN GRAPHIC MACHINES, INC.BOX 573

ELIZABETHVILLE, PA 17023

Introductionfor

Pressroom Personnel

1. The most important part of presswork is proper training. Therefore, the necessity for safe press andmaintenance procedures can not be overstated. DGM, Inc. will not be responsible or held liable foraccidents or injuries to press operators. This is the responsibility of the purchaser, not the manufacturer.The purchaser must be sure its’ press operators are properly trained and familiar with the characteristics ofthe DGM - 430 unit.

2. If you have any questions concerning the DGM - 430 unit, special product requirements, or unusualequipment conditions, contact a representative from DGM, Inc., toll free at 800 - 346-6119. Let thefriendly experts and staff at Dauphin Graphic Machines, Inc. serve you.

3. Before operating the unit, carefully read the entire operations manual. Take extra time to becomefamiliar with specific procedures to obtain efficient operation and maximize quality. NOTE: Section XI ofthis manual can be treated as a “stand alone”, Illustrated Parts Breakdown section. Reference to figurenumbers indicated in this section, are solely within Section XI.

4. Establish a preventive maintenance program. Make periodic inspections of the unit for wear andcleanliness. Good housekeeping maintains the unit’s performance and quality; it pays dividends in the longrun.

5. A complete selection of parts, optional equipment, service and training is available through our person-nel at Dauphin Graphic Machines, Inc. We can be contacted 24 hours a day at our emergency servicenumber (717) 657-6089.

6. NOTICE! This manual may show some safety devices removed or out of position for illustrativepurposes only.

7. Never work alone.

8. KEEP THIS MANUAL WITH THE UNIT AT ALL TIMES.

Because of specific customer and manufacturing requirements, features and op-tional equipment described or illustrated in this publication, may not apply to all

situations and products.

Dauphin Graphic Machines, Inc.

TABLE OF CONTENTSSECTION I - Safety And PrecautionsGeneral ---------------------------------------------------------------------------------------- I-2Unit Safety Controls ----------------------------------------------------------------------------------- I-2

INCH/STOP Station-------------------------------------------------------------------------- I-2INCH Button ----------------------------------------------------------------------------- I-3STOP Button ----------------------------------------------------------------------------- I-3

Continuous Run ------------------------------------------------------------------------------- I-3Interlocks and Guards ------------------------------------------------------------------------ I-4Unit ---------------------------------------------------------------------------------------- I-4Press (Units and Folders)--------------------------------------------------------------------- I-4Lockout/Tagout ------------------------------------------------------------------------------- I-5Steps and Platforms --------------------------------------------------------------------------- I-6Electrical Equipment -------------------------------------------------------------------------- I-6Terms ---------------------------------------------------------------------------------------- I-6

Operator Side ---------------------------------------------------------------------------- I-6Drive Side -------------------------------------------------------------------------------- I-610-Side ----------------------------------------------------------------------------------- I-613-Side ----------------------------------------------------------------------------------- I-6

Specifications ---------------------------------------------------------------------------------------- I-621 1/2” Cutoff Specifications----------------------------------------------------------------- I-722” Cutoff Specifications --------------------------------------------------------------------- I-722 3/4” Cutoff Specifications----------------------------------------------------------------- I-7

SECTION II -Unit Operating ControlsUnit Overview ---------------------------------------------------------------------------------------- II-3

Compensator Handwheel--------------------------------------------------------------------- II-3Ink Fountain Locking Handwheel ------------------------------------------------------------ II-3Ink Fountain Levers --------------------------------------------------------------------------- II-3Dampener Fountain --------------------------------------------------------------------------- II-3Ink Feed Throwoff Levers ------------------------------------------------------------------- II-3Ink Form Throwoff Levers ------------------------------------------------------------------- II-3Plate Cylinder Running Sidelay Handwheel ------------------------------------------------- II-3Dampener Form Throwoff Levers ----------------------------------------------------------- II-3Unit Water/Dampener Control Panel -------------------------------------------------------- II-3Running Circumferential Register Handwheel ----------------------------------------------- II-3

Unit Roll Stand ---------------------------------------------------------------------------------------- II-3Lead-In Rollers-------------------------------------------------------------------------------- II-3Paper Roll Sidelay Handwheel --------------------------------------------------------------- II-3Paper Roll Spindle Shaft ---------------------------------------------------------------------- II-4Brake Shoe Handwheel ---------------------------------------------------------------------- II-4Tension Nut ------------------------------------------------------------------------------------ II-4

Tower Units ---------------------------------------------------------------------------------------- II-4

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Page

Page B


Unit Control Panel ------------------------------------------------------------------------------------- II-4Unit Control Panel ---------------------------------------------------------------------------- II-4

Pneumatic On/Off Toggle Switch ------------------------------------------------------- II-4Dampener Fuses ------------------------------------------------------------------------- II-4Dampener Motor Switch ---------------------------------------------------------------- II-4Dampener Speed Control Dials --------------------------------------------------------- II-5Stop-Safe Button ------------------------------------------------------------------------- II-5Inch (Jogging) Button -------------------------------------------------------------------- II-5

Optional Tower Unit Control Panels -------------------------------------------------------- II-5Affected Side Indicator ------------------------------------------------------------------ II-5Ink Motor Toggle Switch ---------------------------------------------------------------- II-5Ink Motor Selector Switch -------------------------------------------------------------- II-5Ink Motor Speed Dial ------------------------------------------------------------------- II-6Pneumatic Toggle Switch ---------------------------------------------------------------- II-6Dampener Motor Toggle Switch -------------------------------------------------------- II-6Dampener Speed Control Dial ---------------------------------------------------------- II-6Stop-Safe Button ------------------------------------------------------------------------- II-6Inch (Jogging) Button -------------------------------------------------------------------- II-6

SECTION III - Press Make-ReadyIntroduction ---------------------------------------------------------------------------------------- III-3Unit Drive ---------------------------------------------------------------------------------------- III-3

Engaging a Unit -------------------------------------------------------------------------------- III-3Disengaging a Unit ---------------------------------------------------------------------------- III-4Horizontal Drive Clutch ----------------------------------------------------------------------- III-4Engaging a Clutch ----------------------------------------------------------------------------- III-4Disengaging a Clutch -------------------------------------------------------------------------- III-5

Roll Stand ---------------------------------------------------------------------------------------- III-5Unloading The Roll Stand -------------------------------------------------------------------- III-5Loading The Roll Stand----------------------------------------------------------------------- III-5

Plates ---------------------------------------------------------------------------------------- III-6Plate Care ------------------------------------------------------------------------------------- III-6Plate Bending ---------------------------------------------------------------------------------- III-7Plate Packing ---------------------------------------------------------------------------------- III-7Plate Installation ------------------------------------------------------------------------------- III-7Plate Removal --------------------------------------------------------------------------------- III-8Plate Cylinders -------------------------------------------------------------------------------- III-8

Blankets ---------------------------------------------------------------------------------------- III-8Blanket Care ---------------------------------------------------------------------------------- III-8Blanket Packing ------------------------------------------------------------------------------- III-8Blanket Installation ---------------------------------------------------------------------------- III-9

Lock-Up Procedures - “T”-Bar -------------------------------------------------------- III-9Removal ------------------------------------------------------------------------------ III-9Installation ---------------------------------------------------------------------------- III-10

Lock-Up Procedures - Reel Rod ------------------------------------------------------- III-11

Table Of Contents (Continued) Page

Page C


Installation ---------------------------------------------------------------------------- III-11Removal ------------------------------------------------------------------------------ III-12

Ink System ---------------------------------------------------------------------------------------- III-12Ink Fountain Cleaning ------------------------------------------------------------------------- III-13Ink Stripe -------------------------------------------------------------------------------------- III-13Making Ink Stripes ---------------------------------------------------------------------------- III-13

Dampening System ------------------------------------------------------------------------------------ III-13Water Stops ----------------------------------------------------------------------------------- III-13

Webbing The Unit -------------------------------------------------------------------------------------- III-14Setting Web Tension -------------------------------------------------------------------------- III-14Splicing ---------------------------------------------------------------------------------------- III-15

Make-Ready Checklist -------------------------------------------------------------------------------- III-15

SECTION IV - Running ProcedureIntroduction ---------------------------------------------------------------------------------------- IV-2Startup ---------------------------------------------------------------------------------------- IV-2Running ---------------------------------------------------------------------------------------- IV-2Shutdown ---------------------------------------------------------------------------------------- IV-3Wash-Up ---------------------------------------------------------------------------------------- IV-3

Rollers ---------------------------------------------------------------------------------------- IV-3Cylinders --------------------------------------------------------------------------------------- IV-3Safety ---------------------------------------------------------------------------------------- IV-3

SECTION V - Page Imposition Or Plate PositioningIntroduction ---------------------------------------------------------------------------------------- V-2Plate Positioning ---------------------------------------------------------------------------------------- V-2Page Patterns ---------------------------------------------------------------------------------------- V-2Some “Set Up” Questions ----------------------------------------------------------------------------- V-2Terminology ---------------------------------------------------------------------------------------- V-3

Broadsheet ------------------------------------------------------------------------------------ V-3Tabloid ---------------------------------------------------------------------------------------- V-3Mini-Tab Or Signature ------------------------------------------------------------------------ V-3Former ---------------------------------------------------------------------------------------- V-3Upper Former --------------------------------------------------------------------------------- V-3Center Spread --------------------------------------------------------------------------------- V-3

Unit Configurations ------------------------------------------------------------------------------------ V-3Page Impositions --------------------------------------------------------------------------------------- V-4

SECTION VI - Roller AdjustmentsRoller Pressure ---------------------------------------------------------------------------------------- VI-2Roller Adjustments - Ink ------------------------------------------------------------------------------ VI-2

Ink Fountain Roller A ------------------------------------------------------------------------- VI-2Ink Feed Roller B to Fountain Roller A ----------------------------------------------------- VI-3Ink Transfer Rollers C and E ----------------------------------------------------------------- VI-4Ink Form Rollers G and H-------------------------------------------------------------------- VI-5



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Roller Adjustments - Dampener ---------------------------------------------------------------------- VI-6Dampener Fountain Roller I ------------------------------------------------------------------ VI-6Sock Feed Roller J --------------------------------------------------------------------------- VI-6Dampener Form Roller L --------------------------------------------------------------------- VI-7

Gap Adjustments --------------------------------------------------------------------------------------- VI-8Setting Cylinder Gaps - Timing --------------------------------------------------------------- VI-8Spiral Brush Dampening Adjustment--------------------------------------------------------- VI-9

Iron-To-Iron Setting ----------------------------------------------------------------------------------- VI-10Setting The Plate And Impression Cylinders ------------------------------------------------ VI-10To Check The Settings------------------------------------------------------------------------ VI-10To Adjust The Settings ------------------------------------------------------------------------ VI-11

13 Cylinder Set --------------------------------------------------------------------------- VI-1113 - 12 Cylinder Set --------------------------------------------------------------------- VI-1112 - 11 Cylinder Set --------------------------------------------------------------------- VI-1211 - 10 Cylinder Set --------------------------------------------------------------------- VI-12

SECTION VII - MaintenanceIntroduction ---------------------------------------------------------------------------------------- VII-2Corrosion Control ------------------------------------------------------------------------------------- VII-2

Procedure-------------------------------------------------------------------------------------- VII-2Plate Cylinders --------------------------------------------------------------------------- VII-5Blanket Cylinders ------------------------------------------------------------------------ VII-5

Reference -------------------------------------------------------------------------------------- VII-6Corrosion Develops--------------------------------------------------------------------------- VII-6

Lubrication ---------------------------------------------------------------------------------------- VII-6Oil Level ---------------------------------------------------------------------------------------- VII-6Oil Changing ---------------------------------------------------------------------------------------- VII-6Oil Strainer ---------------------------------------------------------------------------------------- VII-7Grease Fittings ---------------------------------------------------------------------------------------- VII-7

Lubrication Panel ------------------------------------------------------------------------------ VII-7Ink System ---------------------------------------------------------------------------------------- VII-9

Ink Fountain Cleaning ------------------------------------------------------------------------- VII-9Cleaning Rollers ------------------------------------------------------------------------------- VII-9Cleaning Cylinders ---------------------------------------------------------------------------- VII-10

Dampener System ------------------------------------------------------------------------------------- VII-10General ---------------------------------------------------------------------------------------- VII-10Feed Roller Sock Installation----------------------------------------------------------------- VII-11

Roll Stand Brake Blocks ------------------------------------------------------------------------------ VII-11

SECTION VIII - Direct PrintingThe Method ---------------------------------------------------------------------------------------- VIII-2The Reverse Image ------------------------------------------------------------------------------------ VIII-2The Impression ---------------------------------------------------------------------------------------- VIII-2The Registration ---------------------------------------------------------------------------------------- VIII-2The Conversion ---------------------------------------------------------------------------------------- VIII-2




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Governor Roller To Compensator Conversion --------------------------------------------- VIII-2Compensator to Governor Roller Conversion ---------------------------------------------- VIII-2

SECTION IX - TroubleshootingScumming ---------------------------------------------------------------------------------------- IX-2Tinting ---------------------------------------------------------------------------------------- IX-2Graininess ---------------------------------------------------------------------------------------- IX-2Hickies ---------------------------------------------------------------------------------------- IX-2Stripping ---------------------------------------------------------------------------------------- IX-2Fill-In ---------------------------------------------------------------------------------------- IX-2Slurring ---------------------------------------------------------------------------------------- IX-2Streaking ---------------------------------------------------------------------------------------- IX-2Catch-Up ---------------------------------------------------------------------------------------- IX-3Blinding ---------------------------------------------------------------------------------------- IX-3Loose Web ---------------------------------------------------------------------------------------- IX-3Web Breaks ---------------------------------------------------------------------------------------- IX-3

SECTION X - GlossaryA - C ---------------------------------------------------------------------------------------- X-2D - E ---------------------------------------------------------------------------------------- X-3F - H ---------------------------------------------------------------------------------------- X-4I - M ---------------------------------------------------------------------------------------- X-5N - R ---------------------------------------------------------------------------------------- X-6S - V ---------------------------------------------------------------------------------------- X-7W - Z ---------------------------------------------------------------------------------------- X-8

SECTION XI - Illustrated Parts BreakdownIllustrated Parts Breakdown--------------------------------------------------------------------------- XI-3

General ---------------------------------------------------------------------------------------- XI-3Group Assembly Parts List (GAPL) --------------------------------------------------------- XI-3Index Number --------------------------------------------------------------------------------- XI-3Part Number----------------------------------------------------------------------------------- XI-3Description ------------------------------------------------------------------------------------ XI-3Vendor Codes --------------------------------------------------------------------------------- XI-3Units per Assembly --------------------------------------------------------------------------- XI-3

Abbreviations Used Throughout the ManualANSI - American National Standards InstituteAR - As RequiredDGM - Dauphin Graphic MachinesDP - Double ParallelFig. - Figureft. - Feet (length measure)

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in. - Inches (length measure)IPB - Illustrated Parts Breakdowniph - inch per hour (length measure)lb(s) - Pound(s) (weight measure)kPa - Kilo Pascalsmm - Millimeter (length measure)NS - Not Shown (within IPB)OP - Operator (i.e., OP Side = Operator’s Side)OSHA - Occupational Safety and Health AdministrationP/N - Part Numberperf - Perforator (i.e., Trolley Perf.= Trolley Perforator)PPH - Papers per HourR-P-F - Rollers-Point-Of-FormerR-T-F - Roller-Top-Of-FormerREF - Referencesec - Second (time measure)TYP - Type

Illustrations ListFigure Nr. Title Page

1-1 INCH/STOP Station or Safe Operation Panel (STOP/SAFE) ............... I-31-2 Locked and Inter-Locked Guards ......................................................... I-41-3 Cylinder Locations - Operator Side ...................................................... I-62-1 DGM-430 Floor Unit - Operator Side .................................................. II-32-2 DGM-430 Roll Stand ........................................................................... II-42-3 430 4-High Tower Unit ......................................................................... II-42-4 Standard Floor Unit Control Panel ........................................................ II-52-5 Optional Tower Unit Control Panels ...................................................... II-63-1 Pinion and Ring Gears ........................................................................... III-33-2 Clutch Rims .......................................................................................... III-43-3 Roll Stand ............................................................................................ III-53-4 Plate Lockup ........................................................................................ III-63-5 Blanket Cylinder (T-Bar) ...................................................................... III-93-6 Blanket Cylinder Reel Rod System ........................................................ III-103-7 Blanket Cylinder Torque Wrench .......................................................... III-103-8 Ink Fountain Assembly .......................................................................... III-113-9 Water Stop ........................................................................................... III-123-10 Water Stops In Place ............................................................................ III-123-11 Diagram of Web Lead - Unit ................................................................. III-133-12 Tension System Diagram ....................................................................... III-135-1 Mark-Up Example ............................................................................... V-25-2 Placement ............................................................................................. V-3

Illustrations List (con’t)

Figure Nr. Title Page

Page G


5-3 Using a “Balloon” Former ..................................................................... V-35-4 Broadsheet Page Imposition .................................................................. V-55-5 Tabloid Page Imposition ........................................................................ V-65-6 Mini-Tab Page Imposition ..................................................................... V-76-1 Roller Identification Chart ..................................................................... VI-26-2 Ink Feed Throwoff ............................................................................... VI-46-3 Ink Transfer Roller ................................................................................ VI-46-4 Ink Form and Transfer Rollers ............................................................... VI-56-5 Dampener Feed Roller Adjustments ...................................................... VI-66-6 Dampener Form Roller ......................................................................... VI-76-7 Gap Gauges ......................................................................................... VI-86-8 Cylinder Slip Bolts ................................................................................ VI-86-9 Gap Gauge - Reel Rod to Slot .............................................................. VI-96-10 Gap Gauge - Reel Rod Blanket to Blanket ............................................ VI-96-11 Spiral Brush Gauge ............................................................................... VI-106-12 Spiral Brush Dampener Adjustment ....................................................... VI-106-13 Iron-To-Iron Setting ............................................................................. VI-117-1 Gear Side View .................................................................................... VII-67-2 Oil Pump and Strainer ........................................................................... VII-77-3 Lubrication Panel .................................................................................. VII-77-4 Independent Lubrication Points ............................................................. VII-87-5 Ink Fountain in “Up” Position ................................................................ VII-97-6 Wash-Up Tray ...................................................................................... VII-107-7 Dampener Feed Roller Bracket ............................................................. VII-117-8 Roll Stand Break Block Assembly ......................................................... VII-128-1 Compensator Hardware ....................................................................... VIII-38-2 Direct Printing Web Leads .................................................................... VIII-411-1 DGM-430 Press Unit (Floor Model) .................................................... XI-511-2 Frame Sub-Assembly (Floor Unit) ........................................................ XI-811-3 Frame Sub-Assembly (Base Unit) ......................................................... XI-1111-4 Frame Sub-Assembly (Stack Unit) ........................................................ XI-1411-5 Ink and Dampener Form Roller Throwoff Assembly .............................. XI-1711-6 Ink Ball Assembly - Operator Side ........................................................ XI-2011-7 Ink Ball Assembly - Gear Side .............................................................. XI-2311-8 Ink Fountain Assembly .......................................................................... XI-2611-9 Swing Down Ink Fountain Assembly ..................................................... XI-2911-10 Blanket Cylinder Throw-Off Linkage Assembly - Manual Operation ...... XI-3211-11 Circ Shaft Assembly ............................................................................. XI-3511-12 Governor Roller, Tension Control and Lead-In Assembly - Floor Unit .... XI-3811-13 Blanket Cylinder Assembly ................................................................... XI-4111-14 #10 Side Narrow Gap Lock-Up Assembly ........................................... XI-4511-15 Narrow Gap Lock-Up ......................................................................... XI-4811-16 #13 Side Narrow Gap Lock-Up Assembly ........................................... XI-5111-17 #10 Side Wide Gap Lock-Up Assembly ............................................... XI-54




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11-18 Wide Gap Lock-Up ............................................................................. XI-5711-19 #13 Side Wide Gap Lock-Up Assembly ............................................... XI-6011-20 #10 Cylinder Assembly - Gear Side ...................................................... XI-6311-21 #10 Cylinder Assembly - Operator Side ................................................ XI-6611-22 #10/#13 Sidelay ................................................................................... XI-6911-23 #13 Cylinder Assembly - Gear Side ...................................................... XI-7211-24 #13 Cylinder Assembly - Operator Side ................................................ XI-7511-25 Lower Copper Assembly ...................................................................... XI-7811-26 Upper Copper Assembly ...................................................................... XI-8111-27 Water Pan Roller Assembly ................................................................... XI-8411-28 Water Vibrator Assembly ...................................................................... XI-8711-29 Water Vibrator Idler ............................................................................. XI-9011-30 Micro Roller Assembly ......................................................................... XI-9311-31 Micro Shaft .......................................................................................... XI-9611-32 #10 Side Ink Vibrator ........................................................................... XI-9911-33 #13 Side Ink Vibrator ........................................................................... XI-10211-34 Ink Vibrator Assembly .......................................................................... XI-10511-35 #10 Side Water Vibrator ....................................................................... XI-10811-36 #13 Side Water Vibrator ....................................................................... XI-11111-37 Circ. Assembly ..................................................................................... XI-11411-38 Drive Shaft ........................................................................................... XI-11811-39 Oil Pump Assembly .............................................................................. XI-12111-40 Gear Side Cover .................................................................................. XI-12411-41 Paper Roll Sidelay ................................................................................ XI-12711-42 Paper Roll Brake .................................................................................. XI-13011-43 Paper Roll Sidelay and Brake Assembly ................................................ XI-13311-44 Belt Register ......................................................................................... XI-13611-45 Optional Pneumatic Assembly ............................................................... XI-13911-46 Blanket Cylinder Throwoff Linkage - Optional Pneumatics .................... XI-14211-47 Rubber Rollers ..................................................................................... XI-14511-48 Nip Guards .......................................................................................... XI-14711-49 Roller Guards ....................................................................................... XI-15011-50 Upper Roller Guard .............................................................................. XI-15311-51 Outer Roller Guard ............................................................................... XI-15611-52 Operator Side Cover ............................................................................ XI-15911-53 Color Drop Roller ................................................................................ XI-16211-54 Lead-In Roller - Base Unit .................................................................... XI-16511-55 Lead-In Roller and Under Unit Compensator Assembly - Stack Unit ..... XI-16811-56 B1 Swing Compensator ........................................................................ XI-17111-57A Full Page Motorized Compensator - Pre-2001 ...................................... XI-17411-57B Full Page Motorized Compensator - Post-2001 .................................... XI-18011-58 Belt Drive/Covers - Stack ..................................................................... XI-18611-59 Belt Drive/Covers - 2 High ................................................................... XI-189



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11-60 Belt Drive/Covers - 3 High - #10 Side .................................................. XI-19211-61 Belt Drive/Covers - 3 High - #13 Side .................................................. XI-19511-62 Belt Drive/Covers - 4 High - #10 Side .................................................. XI-19811-63 Belt Drive/Covers - 4 High - #13 Side .................................................. XI-201

ChartsTables ListChart/Table Nr. Title Page

1 Roller Specification Chart VI-3 2 Lubrication Chart VII-2 3 Maintenance Chart VII-3

This page left intentionally blank.

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SECTION I

SAFETY AND PRECAUTIONS

SECTION I - Safety And PrecautionsGeneral ---------------------------------------------------------------------------------------- I-2Unit Safety Controls ----------------------------------------------------------------------------------- I-2

INCH/STOP Station-------------------------------------------------------------------------- I-2INCH Button ----------------------------------------------------------------------------- I-3STOP Button ----------------------------------------------------------------------------- I-3

Continuous Run ------------------------------------------------------------------------------- I-3Interlocks and Guards ------------------------------------------------------------------------ I-4Unit ---------------------------------------------------------------------------------------- I-4Press (Units and Folders)--------------------------------------------------------------------- I-4Lockout/Tagout ------------------------------------------------------------------------------- I-5Steps and Platforms --------------------------------------------------------------------------- I-6Electrical Equipment -------------------------------------------------------------------------- I-6Terms ---------------------------------------------------------------------------------------- I-6

Operator Side ---------------------------------------------------------------------------- I-6Drive Side -------------------------------------------------------------------------------- I-610-Side ----------------------------------------------------------------------------------- I-613-Side ----------------------------------------------------------------------------------- I-6

Specifications ---------------------------------------------------------------------------------------- I-621 1/2” Cutoff Specifications----------------------------------------------------------------- I-722” Cutoff Specifications --------------------------------------------------------------------- I-722 3/4” Cutoff Specifications----------------------------------------------------------------- I-7


I-2

1. GENERAL

a. Safety requires a proper attitude. If aperson is careless, anything can happen. Properlyplan ahead and use safe procedures to avoidserious injuries.

b. Never operate or perform maintenanceon this unit without proper training. By operatingand maintaining this unit, you may expose yourselfto a hazardous situation. Hazardous situationsmay lead to an accident or injury. Therefore, westress the importance of proper training andoperational practices.

c. Safety must be practiced as part of yourcompany’s Standard Operating Procedures. Failureto follow safety practices and precautions can leadto accidents and injury. Printing plants need tomaintain a regular program of safety to assurecompliance to proper operating and maintenancepractices.

d. While working on this unit, some operat-ing and maintenance procedures may exposeoperators to hazardous situations. These areasand situations can be identified in this manual, oron equipment, by the words DANGER, WARNING,or CAUTION. These situations/hazards are definedas:

DANGER

STOP

Hazards that are readily available andare capable of causing seriouspersonal injury or death.

WARNING

WARNING

Hazards that are not immediatelyavailable but are capable of causingserious personal injury or death.

CAUTION

CAUTION

Hazards that are not immediatelyavailable but can cause less seriousinjury. (Also used to describe safeoperating procedures.)

e. Wear appropriate clothing. No loosesleeves or shirt-tails. Remove neckties andnecklaces.

f. Do not wear any jewelry. Jewelry maycause additional injury to personnel.

g. Cover or tie back long hair. This helps toprevent entanglement in the unit or other equip-ment.

h. Keep floors clean and dry to preventslips and falls. Maintain good housekeepingpractices. Good housekeeping promotes produc-tivity and reduces waste while improving quality.

i. Report safety hazards to supervisors.

j. Use caution and wear proper protectiveclothing and equipment when using solvents in thepressroom. Refer to the solvent manufacturer’sMSDS sheets for specific precautions.

k. Locate and familiarize yourself with theinter-locks and web break detector safetyswitches.

l. STAY ALERT - Remember, SAFETY ISAN ATTITUDE!

2. UNIT SAFETY CONTROLS.

a. INCH/STOP Station. The INCH/STOPStation; or, Safe Operation Panel, (See Figure 1-1)contains both a STOP Button and an INCH Button.As a minimum, one (1) of these panels is locatedon each side of the unit.

WARNING

WARNING

Avoid injury. Be careful when inchingthe press. Keep hands away fromNip and Pinch points!


I-3

Figure 1-1. INCH/STOP Station or

Safe Operation Panel

(STOP/SAFE)

(1) INCH Button (Gray). The INCHbutton, also known as the “jogging” button, is usedto initiate operation of the unit. When the INCHbutton is depressed, a warning bell or alarm willring/sound for approximately two (2) seconds thenthe press will begin to physically cycle the drives,thus causing the machinery to begin to function.The cylinders will rotate at a very low speed aslong as ONLY the INCH button is held down. If thebutton is released and depressed within a four (4)second period after disengaging, NO ALARM WILLSOUND UNLESS the STOP Button is depressed.Once the STOP button is depressed, the cycle will“restart” and alarms will reinitiate.

DANGER

STOP

The STOP button, when engaged,prevents the press from operating.Releasing or disengaging the button,by any person other than the personwho engaged the STOP button, couldresult in personal injury and orequipment malfunction. The STOPbutton is primarily used to performminor adjustments, various align-ments, etc. Ensure the reason forengaging the STOP button has beendetermined and that all personnel areclear of the unit prior to disengagingthe STOP button.

(3) STOP Button (“Mushroom” shaped,Red and Silver). The STOP Button, better knownas the STOP/SAFE Button, is the standardpractice for makeready and some maintenance

around the press. The minimum physical require-ments for the STOP Button are outlined in ANSIB65.1-1985, Safety Specifications for PrintingPress Control Drives. This button has two primaryfunctions: 1) for emergency stops; and, 2) to putthe press on SAFE.

(a) Activation is done by pressingdown on the STOP button. When this is done, theoperation of the unit should stop within 10 sec-onds. When the press is used with additionalpress and folder units in a press line, depressingthe STOP button on ANY unit within the press lineshould stop ALL units within that pressline. Be-cause its primary function is a SAFETY FEATURE- to provide for EMERGENCY STOPS - activationof the STOP button should be taken very seri-ously. When purposefully activated, such as formaintenance, or setting up the press for a run, thisaction is called “placing the press in SAFE mode”.

(b) Disengaging the button to allownormal operation, requires the operator to “pull” theSTOP-SAFE button straight out until the buttonstops. As a safety precaution, disengaging thebutton should be completed ONLY by the individualwho engaged, or activated, the STOP button.

b. Continuous Run. When the INCH, orjogging, button AND the faster button are de-pressed together during an existing INCH (or jog)function, a continuous run condition will be initi-ated. The unit will remain at the speed set at thispoint. The continuous run can be terminated by aSTOP button being depressed, a web break, clutchfault, an open interlock or by a drive/motor fault.

Note

If any switch is left in “Manual” mode,when the press is locked into acontinuous run, all manual settingswill turn off. The result will be noimprint or impressions. The impres-sion cylinders, form, micrometric, inkand water cylinders will have disen-gaged. It is recommended that thepressline be stopped and all switchesbe verified/returned to auto mode.Upon completion of verification, restartthe pressline.

Caution

CAUTION

SAFE and READY lights are UNIT


I-4

SPECIFIC. When a unit is placed inMANUAL mode and is in a “stacked”configuration, that specific unit mayindicate READY or SAFE. Prior toengaging the press line, the operatorshould verify the condition of eachunit.

Note

While in automatic mode, and using amaster console, if ANY unit within thepressline individually falls into, or isplaced in a SAFE condition, theMaster console indicator lights wouldfunction, as well as the affected unitsindividual lights.

c. Interlocks & Guards.

10 and 13-Side Outside Guards

10 and 13-Side Inside Guards

Gear Side Guard

Figure 1-2. Locked and Inter-Locked Guards

(1) Interlocks and guards are designedfor the protection of press operators. Therefore,DO NOT circumvent these devices. Safetydevices should be maintained and functional. DONOT open or remove guards while the press is

running. All safety devices must be in place beforeoperating the press.

d. UNIT.

(1) Use proper techniques for the safehandling of rags around the unit.

(2) Wear gloves sparingly, only whennecessary. Be sure that the gloves fit tightly.

(3) Do not clean cylinders, rollers,drums, or other moving parts while the press is inmotion.

(4) Be careful working around sharpobjects, such as, the fountain blade, worn gears,and plate edges.

(5) Do not try to web the unit while thepress is in motion.

(6) Avoid standing between units whilethe press is in motion.

e. Press (Units and Folders).

(1) Always have the press STOPPEDand on SAFE before any cleaning or maintenanceis performed on the press. Follow this procedure:

(a) Have the press stopped andon SAFE.

(b) Complete the task in thatposition.

(c) Remove rags, tools, supplies,etc. from the operating area of the press.

(d) Remove the SAFE and inchthe press to the next work area.

(e) Stop the press, engage theSAFE.

(f) Repeat as necessary.

(2) Do not disengage a SAFE buttonthat you have not personally engaged.

(3) If performing procedures whichplace personnel in a hazardous location, followLOCKOUT procedures (see paragraph “e” below)..

(4) Do not operate the press at unsafespeeds.

(5) The press alarm warns that thepress will start moving; be sure you are clear of thepress.


I-5

(6) Keep your hands clear of thecylinder and roller nips.

(7) Do not apply lubricants to the presswhile it is in motion.

(8) Remove all rags, tools, cans,supplies, etc. from the press frame, platforms, andaisles immediately after using them.

(9) Inspect equipment and tools on aregular basis.

(10) HOUSEKEEPING - Keep the pressarea clean. It is best to Pick-up and Clean-up.

f. Lockout/Tagout.

(1) The Occupational Safety andHealth Administration (OSHA) published for generalindustry the Lockout/Tagout Standard; it went intoeffect January 2, 1990. Because this standardapplied to servicing or make-ready procedures,confusion arose as to how it applied to cleaning thecylinders and rollers, plate changes, lubrication,paper jams, and make-ready procedures.

(2) The proper use of the STOP-SAFEbutton system provides equivalent protection. TheSTOP-SAFE button system is published throughthe American National Standards Institute (ANSI):Safety Specifications for Printing Press ControlDrives (B65. 1-1985).

(3) The following is a brief of theLockout/Tagout procedures. These procedures DONOT override or replace the requirements asspecified in ANSI Lockout/Tagout procedures orthose procedures established at your facility.

(a) Sequence of lockout ortagout;

1 - After determining the exactwork required and all energy sources involved, theauthorized employee should notify all affectedemployees about the lockout/tagout that is going tobe implemented. There may be multiple energysources and possibly secondary energy paths toaddress for any one energy source. Some specificwork on a unit, for example, may require certainelectrical circuits, drive line clutches plus hydraulicand air lines to be locked or tagged out. Determinewhere the various pertinent disconnects are locatedbefore starting the work.

2 - If the specific equipment is

operating, stop or shut it down by the normalstopping procedures.

3 - Operate the switch, valve,or other energy isolating device(s) to isolate thespecific equipment from its energy source(s). Allelectrical loads must be off or at a minimum beforethe main disconnect is switched.

4 - The authorized employeethen locks out and/or tags out the energy isolatingdevice(s) with his/her assigned lock and/or tag.With a grease type pencil, note on the back of thetag the work location and, if necessary, the circuitsde-energized.

5 - After ensuring that nopersonnel are exposed and as a check on havingdisconnected all energy sources/paths, the autho-rized employee shall operate these normal operat-ing controls to make certain that the equipment willnot move. Make sure these normal operatingcontrols are returned to their neutral or off positionafter this test. For electrical lockout/tagout, testcircuit voltage to assure de-activation. First, checkvoltage tester on a known energized circuit. Then,test the de-energized circuit on the load side andon the de-energized side. Finally, recheck thevoltage tester.

6 - The specific equipment isnow locked or tagged out and servicing or mainte-nance may proceed.

(b) Procedure for transfer orremoval of locks/tags.

1 - When work covered by thisprocedure is carried over from one shift to another,the authorized employee working on the endingshift shall remove his/her lock only after the personstarting the next shift has installed theirs. Thestatus of the work in progress must be totallydiscussed.

2 - When the authorizedemployee who applied the lockout or tagout deviceis not available to remove it, the device may beremoved by his/her supervisor or a person sodesignated. This person must be familiar with theapplicable machinery and follow the steps torestore the equipment to normal operation. Thisperson is required to inform the authorized em-ployee that the lock or tag has been removedbefore the authorized employee resumes work.

(c) When locks and tags must


I-6

temporarily be removed to test or position themachine, the following sequence should be fol-lowed.

1 - Clear the machine of alltools or equipment.

2 - Remove all employeesfrom the area around the machine. If testing isrequired under these circumstances, only properlytrained personnel are allowed to perform thesetests and all affected employees must be properlynotified of this testing.

3 - Remove the lockout ortagout devices.

4 - Energize the machine andproceed with testing or positioning.

5 - De-energize all systemsand reapply all locks/tags before continued servic-ing and/or maintenance.

(d) When restoring the equipmentto normal operation, the following procedures aresuggested.

1 - After the servicing andmaintenance is complete and the equipment isready for normal production operations, check thearea to ensure that no one is exposed. Notifyaffected employees that the lockout/tagout is beingremoved, and that the energy is being restored tothe equipment.

2 - After all tools, loose parts,etc., have been removed from the equipment, andthe guards, signaling systems, and other safetydevices have been reinstalled, and employees arein the clear, remove all lockout and tagout devices,and restore energy to the system.

3 - Test the equipment forproper operation.

g. Steps And Platforms.

(1) To insure safe footing, keep stepsand platforms free of rags, tools, paper, grease, oil,etc.

(2) Where available, always usehandrails or hand grips on steps and platforms.

(3) Use railings for their intendedpurpose as a hand assist or safety barrier. Do notlean, sit, or climb on railings.

h. Electrical Equipment.

(1) You must be a qualified, licensedelectrician, or a properly trained DGM ServiceTechnician, to inspect, test, adjust, or repairelectrical components or equipment.

(2) Follow Lockout/Tagout procedures.

(3) Wear insulated footwear and useinsulated tools.

(4) Remove all jewelry.

(5) Do not stand on a wet floor.

(6) Do not allow fluids, of any kind, toenter into circuits or electrical hand tools.

i. Terms. When describing locations on theDGM - 430 unit, the following terms are used:

(1) Operator Side - the side of the unitwhere the controls are located.

(2) Drive Side - the side of the unitwhere the drive shaft is located.

(3) 10-Side - when facing the operatorside of the unit, the 10-Side is on your left. Theplate cylinder on the left side is called the 10-Cylinder.

(4) 13-Side - when facing the operatorside of the unit, the 13-Side is on your right. Theplate cylinder on that side is called the 13-Cylinder.

10

11 12

13

Figure 1-3. Cylinder Locations - Operator Side

3. SPECIFICATIONS.

Web Width .................. 35” Max.

Undercuts - Standard Plate Cylinder... .014” Blanket Cylinder .081”

Rubber Roller DurometerInk Rollers ......... 26Water Rollers ..... 20


I-7

Max. Speed ................ 30,000 iph

Registration Adjustments -Plate Cylinder Sidelay +/- .125”Running Circumferential +/- .060”

Weight (Gross)Floor Unit ........... 5,500 lbsStack Unit .......... 5,250 lbsBase Unit .......... 6,000 lbs

21 1/2” Cutoff Specifications

Max. Image LengthReel Rod Blanket Lockup w/Standard Slot Gap Plate Lockup 20 15/16”Narrow Gap Blanket Lockup with “On The Nose” Plate Lockup 20 11/16”Narrow Gap Blanket Lockup w/Standard Slot Gap Plate Lockup 20 11/16”

Plate Thickness ......... 0.008-0.012” Total Thickness (Plate plus Packing) 0.014”

Blanket Thickness ..... 0.064-0.066” Total Thickness (Blanket plus Packing 0.085”

.................. (0.083” After Compression)

22” Cutoff Specifications





22 3/4” Cutoff Specifications






I-8

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II-1

SECTION II - Unit Operating ControlsUnit Overview ---------------------------------------------------------------------------------------- II-3

Compensator Handwheel--------------------------------------------------------------------- II-3Ink Fountain Locking Handwheel ------------------------------------------------------------ II-3Ink Fountain Levers --------------------------------------------------------------------------- II-3Dampener Fountain --------------------------------------------------------------------------- II-3Ink Feed Throwoff Levers ------------------------------------------------------------------- II-3Ink Form Throwoff Levers ------------------------------------------------------------------- II-3Plate Cylinder Running Sidelay Handwheel ------------------------------------------------- II-3Dampener Form Throwoff Levers ----------------------------------------------------------- II-3Unit Water/Dampener Control Panel -------------------------------------------------------- II-3Running Circumferential Register Handwheel ----------------------------------------------- II-3

Unit Roll Stand ---------------------------------------------------------------------------------------- II-3Lead-In Rollers-------------------------------------------------------------------------------- II-3Paper Roll Sidelay Handwheel --------------------------------------------------------------- II-3Paper Roll Spindle Shaft ---------------------------------------------------------------------- II-4Brake Shoe Handwheel ---------------------------------------------------------------------- II-4Tension Nut ------------------------------------------------------------------------------------ II-4

Tower Units ---------------------------------------------------------------------------------------- II-4Unit Control Panel ------------------------------------------------------------------------------------- II-4

Unit Control Panel ---------------------------------------------------------------------------- II-4Pneumatic On/Off Toggle Switch ------------------------------------------------------- II-4Dampener Fuses ------------------------------------------------------------------------- II-4Dampener Motor Switch ---------------------------------------------------------------- II-4Dampener Speed Control Dials --------------------------------------------------------- II-5Stop-Safe Button ------------------------------------------------------------------------- II-5Inch (Jogging) Button -------------------------------------------------------------------- II-5

Optional Tower Unit Control Panels -------------------------------------------------------- II-5Affected Side Indicator ------------------------------------------------------------------ II-5Ink Motor Toggle Switch ---------------------------------------------------------------- II-5Ink Motor Selector Switch -------------------------------------------------------------- II-5Ink Motor Speed Dial ------------------------------------------------------------------- II-6Pneumatic Toggle Switch ---------------------------------------------------------------- II-6Dampener Motor Toggle Switch -------------------------------------------------------- II-6Dampener Speed Control Dial ---------------------------------------------------------- II-6Stop-Safe Button ------------------------------------------------------------------------- II-6Inch (Jogging) Button -------------------------------------------------------------------- II-6

SECTION II

UNIT OPERATING CONTROLS


II-2


II-3

1. UNIT OVERVIEW

Figure 2-1. DGM 430 Floor Unit - Operator Side

C

A - Compensator Handwheel

B - Ink Fountain Locking Knob

C - Ink Fountain Levers

D - Dampener Fountain

E - Ink Feed Throwoff Levers

F - Ink Form Throwoff Levers

G - Plate Cylinder Running Sidelay Handwheel

H - Dampener Form Throwoff Levers

I - Unit Water/Dampener Control Panel

J - Running Circumferential Register Handwheel

K - Impression Throw Lever

D J

H

G

F

E

AB

E

G

H

I

K

F

a. Compensator Handwheel. Controls unit-to-unit registration or cutoff registration.

b. Ink Fountain Locking Handwheel.Secures the ink fountain in its operational positionor allows the fountains to be tilted down for clean-ing and color changes.

c. Ink Fountain Levers. Controls theamount of ink exiting the fountain and it’s distribu-tion throughout the ink train. On units with levers,move the levers down to increase the flow of ink.

On units with ink keys, increase the ink flow byturning the ink keys counterclockwise.

d. Dampener Fountain. A pan that holdsdampener solution which is being picked up by aset of rollers and delivered to the plate surface.

e. Ink Feed Throw-off Levers. Engagesand disengages the ink feed roller with the inkfountain roller. When the ball of the handle ispointing towards the CENTER of the unit, the rolleris OFF (disengaged). When the ball of the handleis pointing away from the center, the roller is ON(engaged).

f. Ink Form Throw-off Levers. Engagesand disengages the ink form rollers with the platecylinder surface. When the ball of the handle ispointing towards the CENTER of the unit, the rolleris OFF (disengaged). When the ball of the handleis pointing away from the center, the roller is ON(engaged).

g. Plate Cylinder Running Sidelay Hand-wheel. Used to adjust registration across the webwidth. The maximum travel from operator side todrive side of the plate cylinder is 0.250” (Ref. +/-0.125”). A knurled locking handle, located in themiddle of the handwheel, holds the setting.

h. Dampener Form Throw-off Levers.Engages and disengages the dampener form rollerswith the plate cylinder surface. When the ball ofthe handle is pointing towards the TOP of the unit,the roller is OFF (disengaged). When the ball ofthe handle is pointing towards the OUTSIDE of theunit, the roller is ON (engaged).

i. Unit Water/Dampener Control Panel.Houses some operating controls for a particularunit. A detailed look at the unit control panel isdiscussed in paragraph 4 of this section.

j. Running Circumferential RegisterHandwheel. Used to adjust the back-to-backregistration lengthwise within the unit. The 10cylinder is rotated in relation to the 13 cylinder.The maximum image travel is 0.120” (Ref. +/-0.060”).

2. UNIT ROLL STAND.

a. Lead-In Rollers. Directs the web into theunit.

b. Paper Roll Sidelay Handwheel. Ad-justs the side-to-side position of the paper roll when


II-4

it is in the roll stand. To move the paper rolltowards the drive side of the press, turn thehandwheel clockwise.

Figure 2-2. DGM 430 - Roll Stand

A - Lead-In Roller (Not Shown)

B - Paper Roll Sidelay Handwheel

C - Paper Roll Spindle Shaft

D - Brake Shoe Handwheel

E - Tension Nut

F - Governor Roller

BC

E

A

DF

c. Paper Roll Spindle Shaft. Supports thepaper roll when mounted in the roll stand. The hubat the end of the spindle shaft helps to control webtension as well as being part of the braking systemof the paper roll. Loading the paper roll is dis-cussed in section 3, paragraph 3.b of this manual.

d. Brake Shoe Handwheel. Controls webtension by working with the governor roller. Byturning the handwheel clockwise, you increase theweb tension.

e. Tension Nut. Controls the amount ofpressure being applied to the governor roller (F).Adjustment should be made by a trained servicerepresentative.

3. TOWER UNITS.

a. Tower Units are comprised of two (2) ormore printing units. Each tower has a “Base” unitand subsequent “tower” unit(s), which is/are placedon top of the “base” unit. Figure 2-3 illustrates a 4-High Tower Unit with optional doors.

Figure 2-3. 430 4-High Tower Unit

b. The tower unit utilizes the same printingelectro-mechanical principals as the floor unit - lessthe roll stand. As an option, the operator side ofthe tower may be enclosed by door panels toprovide additional safety considerations. Theprimary differences between the 430 Floor Unit anda 430 Tower Unit, besides the roll stand, is that theunit controls are located on both the 10-side and13-sides, vice the operator side.

4. UNIT CONTROL PANELS.

a. Unit Control Panel. The Unit ControlPanel is located on the Operator side of each unit,as shown in Figure 2-1. Refer to figure 2-4.

(1) Pneumatic On/Off Toggle Switch.Toggle switch used to turn on either the 10-side or13-side pneumatics.

(2) Dampener Fuses. 1 1/2 amp fusesused to protect the dampener motors. To remove,turn fuse holder knob counterclockwise and pull.

(3) Dampener Motor Switch. A toggleswitch used to turn on both the 10- and 13-Sidedampener motors.


II-5

Figure 2-4. Standard Floot Unit Control Panel

6

3

4

2

1

5

1 - Pneumatic On/Off Switchs

2 - Dampener Fuses

3 - Dampener Motor Switch

4 - Dampener Speed Control Dials

5 - STOP-SAFE Button (Red)

6 - Inch (or Jogging) Button (Gray)

(4) Dampener Speed Control Dials.Adjusts the speed of rotation of the dampenermotor; one for the 10-Side and one for the 13-Side.The faster the motor speed, the more solution isbeing delivered to the plate surface.

(5) STOP-SAFE Button.

DANGER

STOP

The STOP-SAFE button,when engaged, preventsthe press from operating.Releasing or disengagingthe button, by any personother then the person whoengaged the STOP-SAFEbutton, could result inpersonal injury and orequipment malfunction.The STOP-SAFE button isprimarily used to performminor adjustments,various alignments, etc.Ensure the reason forengaging the STOP-SAFEbutton has been deter-mined and that all person-nel are clear of the unitprior to disengaging the

STOP-SAFE button.

This button has two functions:

1. For emergency stops.

2. To put the press on SAFE.

The Stop-Safe button, when depressed, preventsthe press from operating. To disengage the buttonand allow normal operation, it will be necessary to“pull” the STOP-SAFE button straight out until thebutton stops.

(6) Inch (Jogging) Button.

WARNING

WARNING

Avoid injury. Be careful when inchingthe press. Keep hands away from Nipand Pinch points!

The Inch, or Jogging, button allows the press torotate as long as you hold in the button. Theinching speed is adjustable at the press controlpanel. When depressing the inch button, a warningbell or alarm will ring for approximately two (2)seconds. The press will begin to move after thiswarning is sounded. There is a four (4) secondperiod after disengaging the inch button in whichthe inch will work, unless the STOP is depressed,then the cycle will “restart”.

b. Optional Tower Unit Control Panels.Optional Control Panels are available as shown infigure 2-5.

(1) Affected Side Indicator. Theshaded portion identifies which side the control(s)will affect.

(2) Ink Motor Toggle Switch. Toggleswitch used to turn on (engage) or off the ink ballmotor.

(3) Ink Motor Selector Switch. Used toplace the unit in either AUTOMATIC or MANUALMode. AUTOMATIC allows the unit to be con-trolled through the use of a console unit. Whenplaced MANUAL mode, the unit is disengaged fromthe rest of the press line. This is used primarilyduring set-up or for various maintenance functions.


II-6

10-Side Control Panel

13-Side Control Panel

2

2

3

3

4

4

5

5

6

6

7

7

8

9

9

8

1

1

1 - Affected Side Indicator

2 - Ink Motor Toggle Switch (Engage/Off)

3 - Ink Motor Selector Switch (Auto/Manual)

4 - Ink Motor Speed Dial

5 - Pneumatic Toggle Switch (Engage/Off)

6 - Dampener Motor Toggle Switch (Engage/Off)

7 - Dampener Speed Control Dial

8 - STOP-SAFE Button (Red)

9 - Inch (or Jogging) Button (Gray)

Figure 2-5. Optional Tower Unit Control Panels

(4) Ink Motor Speed Dial. Adjusts thespeed of rotation of the Ink motor. The faster themotor speed, the more ink is being delivered to theplate surface.

(5) Pneumatic Toggle Switch. Toggleswitch used to turn on the pneumatics.

(6) Dampener Motor Toggle Switch. Atoggle switch used to turn on (engage) or off, thedampener motors.

(7) Dampener Speed Control Dial.Adjusts the speed of rotation of the dampenermotor. The faster the motor speed, the moresolution is being delivered to the plate surface.

(8) STOP-SAFE Button.

DANGER

STOP

The STOP-SAFE button,when engaged, preventsthe press from operating.Releasing or disengagingthe button, by any personother then the person whoengaged the STOP-SAFEbutton, could result inpersonal injury and orequipment malfunction.The STOP-SAFE button isprimarily used to performminor adjustments,various alignments, etc.Ensure the reason forengaging the STOP-SAFEbutton has been deter-mined and that all person-nel are clear of the unitprior to disengaging theSTOP-SAFE button.

This button has two functions:

1. For emergency stops.

2. To put the press on SAFE.

The Stop-Safe button, when depressed, preventsthe press from operating. To disengage the buttonand allow normal operation, it will be necessary to“pull” the STOP-SAFE button straight out until thebutton stops.

(9) Inch (Jogging) Button.

WARNING

WARNING

Avoid injury. Be careful when inching


II-7

the press. Keep hands away from Nipand Pinch points!

The Inch, or Jogging, button allows the press torotate as long as you hold in the button. Theinching speed is adjustable at the press controlpanel. When depressing the inch button, a warning

bell or alarm will ring for approximately two (2)seconds. The press will begin to move after thiswarning is sounded. There is a four (4) secondperiod after disengaging the inch button in whichthe inch will work, unless the STOP is depressed,then the cycle will “restart”.


II-8



III-1

SECTION III - Press Make-ReadyIntroduction ---------------------------------------------------------------------------------------- III-3Unit Drive ---------------------------------------------------------------------------------------- III-3

Engaging a Unit -------------------------------------------------------------------------------- III-3Disengaging a Unit ---------------------------------------------------------------------------- III-4Horizontal Drive Clutch ----------------------------------------------------------------------- III-4Engaging a Clutch ----------------------------------------------------------------------------- III-4Disengaging a Clutch -------------------------------------------------------------------------- III-5

Roll Stand ---------------------------------------------------------------------------------------- III-5Unloading The Roll Stand -------------------------------------------------------------------- III-5Loading The Roll Stand----------------------------------------------------------------------- III-5

Plates ---------------------------------------------------------------------------------------- III-6Plate Care ------------------------------------------------------------------------------------- III-6Plate Bending ---------------------------------------------------------------------------------- III-7Plate Packing ---------------------------------------------------------------------------------- III-7Plate Installation ------------------------------------------------------------------------------- III-7Plate Removal --------------------------------------------------------------------------------- III-8Plate Cylinders -------------------------------------------------------------------------------- III-8

Blankets ---------------------------------------------------------------------------------------- III-8Blanket Care ---------------------------------------------------------------------------------- III-8Blanket Packing ------------------------------------------------------------------------------- III-8Blanket Installation ---------------------------------------------------------------------------- III-9

Lock-Up Procedures - “T”-Bar -------------------------------------------------------- III-9Removal ------------------------------------------------------------------------------ III-9Installation ---------------------------------------------------------------------------- III-10

Lock-Up Procedures - Reel Rod ------------------------------------------------------- III-11Installation ---------------------------------------------------------------------------- III-11Removal ------------------------------------------------------------------------------ III-12

Ink System ---------------------------------------------------------------------------------------- III-12Ink Fountain Cleaning ------------------------------------------------------------------------- III-13Ink Stripe -------------------------------------------------------------------------------------- III-13Making Ink Stripes ---------------------------------------------------------------------------- III-13

Dampening System ------------------------------------------------------------------------------------ III-13Water Stops ----------------------------------------------------------------------------------- III-13

Webbing The Unit -------------------------------------------------------------------------------------- III-14Setting Web Tension -------------------------------------------------------------------------- III-14Splicing ---------------------------------------------------------------------------------------- III-15

Make-Ready Checklist -------------------------------------------------------------------------------- III-15

SECTION III

PRESS MAKE-READY


III-2

1. INTRODUCTION.

a. If the press requires prolonged mainte-nance, the use of the Lockout/Tagout proceduresshould be done. The STOP-SAFE button systemis the standard safety practice for make-ready andsome maintenance procedures around the press.The physical requirements for the STOP-SAFEbutton system is outlined in ANSI B65. 1-1985,Safety Specifications for Printing Press ControlDrives and should not be over-ridden. The follow-ing is a summary of this practice:

(1) Inch the press to the desired workposition and put the press on SAFE.

(2) Do the necessary cleaning, make-ready, or maintenance. Remove tools and acces-sories.

(3) Take the press off of SAFE by pullingthe button out until the button stops and inch thepress to the next desired work position then, putthe press on SAFE.

(4) Repeat this procedure until the re-quired cleaning, make-ready, or maintenance iscompleted.

WARNING

WARNING

The LEAD PRESS OPERATOR isresponsible for making sure allpersonnel are clear of the pressbefore inching the press. All person-nel are responsible for proper use ofthe STOP-SAFE button.

WARNING

WARNING

NIP POINTS between cylinders androllers can cause permanent injury.Fold and hold rags properly; neverattempt to clean cylinders or rollerswhile the press is moving. Neverattempt to remove “hickeys” with yourfingers or hand-held objects while thepress is moving.

2. UNIT DRIVE.

WARNING

WARNING

Printing Units are supplied withcovers, doors, and guards for yourprotection. Some of these items mayhave interlocks which will prohibit thepress from operating if left open. Besure that when cleaning, performingmaintenance, or make-ready proce-dures that the press is on SAFEbefore any of these items are openedor removed.

a. Engaging A Unit.

NOTE

Upon installation, timing marks shouldbe indicated on the unit so that thedrive shaft and the unit are in timingwith the complete press line, includingfolder unit.

(1) Inch the press so that the timingmarks indicated on the drive shaft and the unitalign by using the Inch Button.

(2) Put the press on SAFE.

(3) By opening the left access door on thedrive side (13-side) of the unit, you have access tothe Ring and Pinion Gears (see figure 3-1). De-pending on the type of runs the unit is used for, thegeneral practice has been found that color codesare used to identify different web color inking,number of webs used, etc. These codes haveusually been placed on the inside of the accessdoor. Depending on the type of press run andconfiguration of the web, further refinement of theRing and Pinion Gears may be necessary.

(4) Loosen the locknut (B) and remove, orclearly back off, the tapered setscrew (spottingbolt) from the pinion gear collar.

(5) Place the shifting lever (E) under thepivot stud (C) while at the same time placing theshifting lever pin into the groove around the piniongear collar. The pinion gear (A) should slide intomesh with the bevel gear (D) easily. DO NOT


III-3

FORCE THE PINION GEAR. IF NECESSARY,BAR THE UNIT SLIGHTLY TO MESH GEARS.

Figure 3-1. Pinion and Ring Gears

B

C

D

A

A - Pinion Gear

B - Locknut and Tapered Setscrew

C - Pivot Stud

D - Ring Gear (13 Cylinder)

E - Shifting Lever (Not Shown)

Pinion Gear Collar

Groove

(6) If removed in item (4) above, return thetapered setscrew and locknut (B) into the samehole of the pinion gear collar. Be sure the set-screw is “bottomed out”. At this point, the locknutshould move freely. Now tighten the locknut.

(7) Check oil level in the gear housing.Be sure there is adequate oil.

(8) Close the access door.

b. Disengaging A Unit.

(1) Using the procedures outlined inparagraph 2.a(1) above, inch the press so that theappropriate timing marks are aligned by using theInch Button.


(3) By opening the left access door on thedrive side (13-side) of the unit, you have access tothe Ring and Pinion Gears (see figure 3-1).

(4) Loosen the locknut (B) and remove thetapered setscrew (spotting bolt) completely fromthe pinion gear collar.

(5) Place the shifting lever (E) under thepivot stud (C) while at the same time placing theshifting lever pin into the groove around the piniongear collar. The pinion gear (A) should slide out ofmesh of the ring gear (D). Slide the pinion gear asfar as it will go until the tapered setscrew (spottingbolt) hole in the pinion gear collar aligns with thehole in the horizontal drive shaft.

(6) Replace or tighten the tapered set-screw (spotting bolt) and locknut into the samehole of the pinion gear collar. Be sure the set-screw is “bottomed out”. At this point, the locknutshould move freely. Now tighten the locknut.

(7) Close the access door.

c. Horizontal Drive Clutch.

(1) Because of various press and productrequirements, it may be necessary to disengagethe horizontal drive shaft. A manual drive shaftclutch can be supplied. Disengaging the clutch willprevent all equipment from running beyond thepoint of the clutch.

d. Engaging A Clutch.

(1) Inch the press so that the timingmarks on the driveshaft and the unit align by usingthe Inch button.


(3) Remove the clutch cover on the unitby loosening the two clutch cover thumbscrews.

(4) Refer to figure 3-2. Loosen or removethe setscrew (B) on the rim.

(5) Slide the clutch rim (A) on the driveshaft until the setscrew hole aligns with theengagement hole position (C) in the drive shaftgear. Reinsert and tighten the setscrew.

(6) Replace the clutch cover and retightenthe two clutch cover thumbscrews.


III-4

BA

C

D

Driveshaft

Gear

Disengaged

Engaged

Figure 3-2. Clutch Rims

A - Clutch Rim

B - Setscrew

C - Setscrew Hole for Engaged Position

D - Setscrew Hole for Disengaged Position

e. Disengaging A Clutch.

(1) Inch the press so that the timingmarks on the driveshaft and the unit align by usingthe Inch button.


(3) Remove the clutch cover on the unitby loosening the two clutch cover thumbscrews.

(4) Loosen or remove the setscrew (B) onthe rim.

(5) Slide clutch rim (A) backwards on thedrive shaft until the setscrew hole realigns with thedisengagement hole position (D) in the drive shaftgear. Reinsert and tighten the setscrew.

(6) Replace the clutch cover and retightenthe two clutch cover thumbscrews.

3. ROLL STAND.

a. Unloading The Roll Stand (See figure 3-3).


CAUTION

CAUTION

Burns may result fromcontacting the brake hub orspindle shaft when removingor changing paper rolls. Donot touch the brake hub orspindle shaft until they havecooled down.

(2) Unlock the paper roll brake assemblysafety guard (H) by turning the T-handle (I) andswinging the guard outward.

(3) Loosen the brake shoe handwheel (G)and separate the wooden shoe blocks (A) and (F)from the brake hub (B).

(4) Depending on the size of the paper rollon the spindle shaft (E), remove the paper rolleither by hand or with the aid of the lifting levers.If possible, remove the paper roll onto a dolly forease of transporting the roll.

(5) Remove the paper roll spindle shaft(E) according to the particular design of the spindleshaft.

b. Loading The Roll Stand.


(2) Load a roll of paper onto a paper rolldolly. Be aware of the proper direction of rotationnecessary for the run.

(3) Place lifting levers onto pivot stud andleave the handles resting on the floor.

(4) Place paper roll spindle shaft (E)through the core of the roll. NOTE: paper rollspindle shafts come in different designs. If youneed assistance, contact a DGM, Inc. CustomerService representative.

(5) Position the paper roll spindle shaft (E)so that there is proper distance between thespindle shaft brake hub (B) and the paper roll.

(6) Once you have the desired distance,tighten the devices (depending on design) on thespindle shaft (E) to lock the paper roll in position.You can then use the paper roll sidelay handwheel(C) to make slight adjustments of the webs posi-tion.


III-5

(7) Align the brake hub (B) with the brakeshoes (A) and (F). Push the dolly and paper rollinto the roll stand, keeping the brake hub alignedwith the brake shoes.

(8) With a crewperson on each side ofthe unit, they should lift up on the lifting levers atthe same time to load the paper roll.

WARNING

WARNING

You must control the lifting levers.The weight of the paper roll will shiftto the front of the lifting levers. Thiscauses the levers to spring upquickly, therefore, it is recommendedthat you stand to the side of the liftinglevers when using them.

(9) Connect the brake shoes (A) (F) to thebrake hub (B) by placing the brake shoe handwheel

(G) into the bracket on the upper brake shoe andblock assembly (A). Then lightly tighten thehandwheel (G).

(10) The paper roll is now ready for web-bing or splicing.

4. PLATES.

a. Plate Care.

(1) Plates should be handled carefully toavoid damage to either the plate itself or the imagearea. Keep plates stored flat, out of the light, in acool and dry area. Handle plates by their edges.

WARNING

WARNING

Plate edges and corners are sharp.Severe cuts can occur from plateedges. Handle with care.

Figure 3-3. Roll Stand

G

H I

A

B

F

C

D

E

A - Upper Brake Shoe and Block

B - Brake Hub

C - Paper Roll Sidelay Handwheel

D - Paper Roll Spindle Chuck

E - Paper Roll Spindle Shaft

F - Lower Brake Shoe and Block

G - Brake Shoe Handwheel

H - Safety Guard

I - Tee Handle


III-6

(2) It should be standard operatingprocedure to remove the plates after each pressrun. Preserve and store the used plate accordingto the manufacturer’s recommendations.

b. Plate Bending.

Each specific lockup requires precise bending ofthe printing plate to maintain register control andproper attachment to the plate cylinder. Dependingon the type of lockup, cylinder undercut and pressmodel purchased, specific training has beenprovided upon installation of the equipment.

c. Plate Packing.

(1) DGM provides plate cylinders withmany different customer specified undercuts.Those undercuts requiring packing can be packedusing either mylar or special “Printing Press Paper”packing. These products can be purchased fromyour local pressroom supply dealers. The followingare two recommended methods of packing plates.In both methods, when placing the packing mate-rial on the back of the printing plate, ensure thematerial is smoothed out to eliminate air pockets.

(2) Printing Press Paper Packing. Thistype of packing should be purchased in a thick-ness that will require only one sheet of paper tomake up the proper packing height. The sheetsshould be trimmed so that they are approximately1/2 inch narrower than the printing plate. Attachthe packing to the back of the plate with a lightcoat of spray glue along the lead edge of the plate.Be careful to only cover the area between the twoinside bends with the packing. DO NOT allow thepacking to hang down into the plate lockup oraround the gap edges of the cylinder. A light coatof greaseless lube, sprayed on the back of thepaper packing will aid in removing the plate afterthe printing run.

(3) Mylar Packing. This type of packingshould be purchased in the proper thickness sothat only one sheet is required to achieve thedesired packing height. When purchasing, ensurethat the mylar is specifically for use as platepacking. This packing should be the grained typeand installed on the cylinder with the direction ofthe grain against and around the cylinder. Beforeapplying the mylar to the cylinder, it is recom-mended the grained side be lightly roughened andcleaned to provide better adhesion. Use a thin filmof spray adhesive to secure the mylar to thecylinder. Any excess mylar should be trimmed offto keep the lockup area clear. Mylar packing

should cover the entire width of the plate cylinderwhich is covered by the printing plate.

d. Plate Installation.

Because various models of presses may havespecific lockup requirements, training will beprovided upon installation of the equipment.

The following is a general procedure for installing aplate.

Figure 3-4. Plate Lock-Up

A - Plate Lock-Up Spring

B - Lock-Up Shaft

C - Packing

D - Plate

E - Lock-Up Slot

F - Tail Edge of Plate

A

B

C D

E

F

(1) Have the plate cylinder lockup (orcylinder gap) accessible by using the inch button.


(3) Depending upon design, open or alignthe plate cylinder lockup mechanism.

WARNING

WARNING

Keep hands away from Nip Points.

(4) Place the lead edge of the plate overthe lead edge of the cylinder. Align the plateaccording to your standard operating procedure.Be sure that the leading plate edge is completelyseated across the entire width of the plate cylinder.


III-7

(5) With the unit not webbed, engage theimpression lever and disengage the SAFE.

(6) While securely holding onto the tailedge of the printing plate, inch the press slowlyuntil the plate cylinder lockup is accessible onceagain. Put the press on SAFE.

(7) Depending upon design, open or alignthe plate cylinder tail clamp mechanism.

(8) Insert the tail edge of the plate into thegap of the plate cylinder. Close the clamp onNarrow-Gap design.

(9) Disengage the SAFE, and disengagethe impression lever.

(10) With the inch button, make the pressmove one revolution.


(12) Inspect the plate to be sure it is on thecylinder squarely and securely. Any loosenessmay cause a plate to come off while running, orresult in poor reproduction quality.

e. Plate Removal.

(1) Have the plate cylinder lockup (orcylinder gap) accessible by using the inch button.

(2) Put the press on SAFE and verify theimpression lever has been disengaged.

(3) Depending upon the design, open theplate cylinder lockup mechanism. The tail edge ofthe plate should come off, or out, of the lockupmechanism.

(4) While using the heals of both hands onthe lead edge of the plate, push up, to separate thelead edge of the plate from the cylinder edge.

(5) Disengage the SAFE and keep theimpression lever in the disengaged position.

(6) Hold the lead edge of the plate se-curely while inching the press slowly for onerevolution. This will allow the plate to come off thecylinder by the time the one revolution is com-pleted.

f. Plate Cylinders.

Moisture left on the cylinder surfaces can cause

rust and corrosion. Therefore, it is good preventa-tive maintenance to clean the plate cylinders aftereach press run or at least after each eight hourshift. Simply clean the cylinder with a rag andsolvent, using the STOP-SAFE system. Then,apply a thin film of oil to the cylinder surface.

5. BLANKETS.

a. Blanket Care.

(1) New blankets may have a protectivecoating put on by the manufacturer. Check withyour blanket manufacturer for the proper cleaningsolution to clean the blanket before installation.

(2) Blankets should be cleaned with ablanket wash and perhaps water at the end of eachpress run. The water will help remove paper fiberand dust from the blanket surface.

(3) Check the tightness of the blanketevery week; tighten if necessary. (Refer toparagraph 5.c “Blanket Installation”.) A looseblanket will cause print quality problems.

(4) If the blanket packing becomes wet,wrinkled, or torn, remove it immediately. Cleanand dry the blanket cylinder before installing newpacking material.

(5) Because the blanket is the final pointbetween ink and substrate, print quality can bemaintained through proper blanket handling.Consult your blanket manufacturer. Do not mixcompressible and non-compressible blankets onthe same press.

b. Blanket Packing.

NOTE

It may be easier to manage theblankets when starting by making asharp crease or bend on the leadedge of the packing.

(1) It is a good practice to use a deadweight micrometer to measure the thickness of ablanket supplied by the manufacturer. Do not relyon the written thickness on the back of the blanket.

(2) The thickness of the blanket pluspacking, off the press, should be approximately0.087 inches. The thickness may need to beadjusted based upon the type of materials usedand the current condition of the press. After the


III-8

blanket and packing have been installed and“rolled-in”, the thickness, on the cylinder, shouldmeasure no less then 0.083 and no more than .085inches when measured with a blanket gauge.Blanket gauges are manufactured by variouscompanies. Use the one that suits personnel andgives you the most accurate measurement.

(3) It is recommended that you use thefewest number of packing sheets as possible; but,no more than three sheets.

(a) The blanket packing materialshould be cut slightly narrower than the blanketwidth and approximately one inch longer in length.

(b) Packing Installation One (1)Sheet:

1- Adhere a one inch long by 1/2inch wide piece of transparent tape lengthwise atthe center of the width of the packing material.The tape should be positioned so that approxi-mately 3/8 of an inch extends past the edge of thepacking material while 1/8 of an inch is on thepacking material itself.

2- Place two more pieces of tapein a similar manner at the packing materials’ width,one at each end.

3- Place the packing materialalong the edge of the cylinder gap toward theblanket cylinders nip. Center the packing materialacross the cylinder.

4- Bend the tape over the edgeof the cylinder gap and press the tape to thecylinder gap wall.

(c) Packing Installation MultipleSheets:

1- Lay the packing material on aflat table; a light table works very well.

2- Tape the first packing sheetsquarely to the table with the lead edge closest toyou.

3- Place the second piece ofpacking material on top of the first leaving approxi-mately 1/64 of an inch gap between leading edges.

4- Place the third piece ofpacking material on top of the second in likemanner.

5- While holding the packingmaterial in this position, adhere a one inch long by1/2 inch wide piece of transparent tape length wiseat the center of the width of the packing material.The tape should be positioned so that approxi-mately 3/8 of an inch extends past the edge of thepacking material while 1/8 of an inch is on thepacking material itself.

6- Place two more pieces of tapein a similar manner at the packing materials’ width,one at each end.

7- Place the packing materialalong the edge of the cylinder gap toward theblanket cylinders nip. Center the packing materialacross the cylinder.

8- Bend the tape over the edgeof the cylinder gap and press the tape to thecylinder gap wall

(4) While securely holding the packingmaterial, bar or inch the unit one revolution whilesmoothing the packing material around the cylin-der. Stop the unit when the cylinder gap is onceagain accessible.

(5) Trim the excess packing material evenwith the cylinder gap.

(6) While holding the packing material inthis position, adhere a one inch long by 1/2 inchwide piece of transparent tape lengthwise at thecenter of the width of the packing material and ateach outside edge. Bend the tape over into thecylinder gap.

c. Blanket Installation.

NOTE

Various models of presses may havespecific lockup requirements. There-fore, depending upon the model ofpress, training will be provided uponinstallation of the equipment. The twomost frequently used on the DGM 430Press (“T”-Bar and Reel-Rod) arediscussed below.

(1) Lock-Up Procedures - “T” Bar. Thefollowing is a general lockup procedure for blanketcylinders equipped with a T-bar design. (Refer tofigure 3-5.)

(a) Removal.


III-9

1 - Inch the press until theblanket cylinder gaps are accessible by using theinch button.

2 - Put the press on SAFE.

3 - Remove the six socket headcap screws (D) from the T-bar (C) located in theblanket cylinder gap. Remove the T-bar (C).

4 - After noting the direction thecylinder will rotate, remove the lead edge of theblanket (A) from the cylinder gap.

A - Blanket

B - Blanket Packing

C - T-Bar

D - Socket Head Cap Screw

Figure 3-5. Blanket Cylinder (T-Bar Design)

C

A

B D

5 - Replace two socket head capscrews (D), one at each end of the cylinder gap, tohold the tail edge of the blanket in the gap. Makesure the tops of the screws are well below thecylinder surface.

6 - Disengage the SAFE.

7 - While securely holding thelead edge of the blanket, inch the unit one revolu-tion so that the cylinder gap is accessible again.


9 - Remove the two socket headcap screws from the cylinder gap; remove theblanket and packing.

(b) Installation.

1 - Using the STOP-SAFEsystem, clean the blanket cylinder and especiallythe cylinder gap. Remove dirt, oil, and old tape.



4 - Install the blanket packingaccording to the directions given in the paragraph5.b, “Blanket Packing”.

5 - After noting the direction thecylinder will rotate, insert the lead edge of theblanket into the blanket cylinder gap. (The under-side of the blanket should face the oppositeblanket cylinder.)

6 - Replace two socket head capscrews (D), one at each end of the cylinder gap, tohold the lead edge of the blanket in the gap.Again, make sure the screws of the bolts are wellbelow the cylinder surface.


8 - While securely holding theopposite edge of the blanket (tail edge), inch theunit one revolution so that the cylinder gap isaccessible again. Be sure the blanket wrapsaround the cylinder squarely and tight.

9 - Remove the two socket headcap screws (D) from the cylinder gap and insert thetail edge of the blanket into the gap.

10 - Install the T-bar (C) along withthe six socket head cap screws (D) into thecylinder gap. Starting with the center screws andworking to the outside, slightly tighten the sockethead cap screws.

11 - Starting with the center sockethead cap screws and working to the outside,tighten the socket head cap screws using ablanket T-wrench set for 35 inch-pounds.

12 - After both blankets areinstalled, engage the impression lever and run theunit for approximately one-hundred revolutions to“roll in” the blankets.

13 - Stop the press.




III-10

16 - Disengage the impressionlever.

17 - Retighten the socket head capscrews in the same manner as previously de-scribed.

18 - After 1,000 and 10,000impressions, check the hex-head bolts again. It isa good idea to periodically check the tightness ofthe blanket and hex-head bolts until the blanketsare changed again.

(2) Lock-Up Procedures - Reel Rod.The following is a general lockup procedure forReel-Rod Blanket cylinders. (Refer to Figure 3-6.)

1

4

3

2

5

Blanket Cylinder

Figure 3-6. Blanket Cylinder

Reel Rod System

Cylinder Gap

Head of bolt is

recessed in block

1 - Clamp

2 - Socket Head Cap Screw

3 - "Lead Edge" Gap

4 - 7/8" Hex Head Reel Rod Shaft

5 - "Tail Edge" Gap

(a) Installation. Because thetightening of the reel rod is necessary at both endsof the blanket cylinder, it is highly recommendedthat installation procedures be performed by two (2)personnel.

1 - Using the STOP-SAFEsystem, clean the blanket cylinder and especiallythe cylinder gap. Remove dirt, oil, and old tape.



4 - Loosen the socket head capscrews (2) from the clamp (1) located at the endsof the blanket cylinder.

5 - Install the blanket packingaccording to the directions given in the paragraph5.b, Blanket Packing.

6 - After noting the direction thecylinder will rotate, insert the lead edge of theblanket into the lead edge gap (3) of the blanketcylinder gap. (The underside of the blanket shouldface the opposite blanket cylinder.)


8 - While securely holding theopposite edge of the blanket (tail edge), inch theunit one revolution so that the cylinder gap isaccessible again. Be sure the blanket wrapsaround the cylinder squarely and tightly.

9 - Insert the tail edge of theblanket into the tail edge gap (5).

Figure 3-7. Blanket Cylinder Torque Wrench

10 - Set the blanket lock-up torquewrenches to 45 ft. lbs.

11 - Using a blanket lock-up torquewrench at each end of the blanket cylinder, turn thereel rod shaft (4) OPPOSITE THE ROTATION ofthe cylinder. As the shaft is turning, the tail edgeof the blanket will wrap around the shaft, tighteningthe blanket on the blanket cylinder.

12 - At each end of the blanketcylinder, retighten the socket head cap screws (2)into the clamp (1).

13 - After both blankets areinstalled, engage the impression lever and run theunit for approximately one-hundred revolutions to“roll in” the blankets.


III-11

14 - Stop the press.



17 - Disengage the impressionlever.

18 - Retighten the reel rod (4) inthe same manner as previously described.

19 - After 1,000 and 10,000impressions, check the reel rod (4) and the sockethead cap screws (2) in the clamps (1) again. It is agood idea to periodically check the tightness of theblanket and clamp screws until the blankets arechanged again.

(b) Removal.



3 - Refer to figure 3-6. Loosenthe socket head cap screw (2) from the clamp (1)located at the ends of the blanket cylinder.

4 - After noting the direction thecylinder will rotate, using a 7/8 inch open-end boxwrench at each end, turn the reel rod shaft (4) INTHE DIRECTION of the rotation of the cylinder.

NOTE

When the reel rod has been loosened,using the palm of your hand againstthe blanket and pushing upwards, willhelp in loosening the blanket.

5 - Remove the leading edge ofthe blanket away from the slot. Remove the tailedge of the blanket from the tail edge gap (5) onthe reel rod (4) but leave this edge in the slot.

6 - Retighten the socket head capscrew (2), at each end of the blanket cylinder.Make sure the tops of the screws are well belowthe cylinder surface.


8 - While securely holding thelead edge of the blanket, place a slight “pull” on theblanket and inch the unit one revolution so that thecylinder gap is accessible again. The blanketshould “peel” off the cylinder during the rotation.


6. INK SYSTEM.

a. The DGM - 430 unit is equipped with aswing-down ink fountain (see figure 3-8) for com-plete and easy cleaning. The ink from the fountainto the ink feed roller is controlled by either inkfountain screws or levers. Ink is transferred fromfountain to plate by the ink train, consisting of theink feed roller, the rubber transfer rollers, the metalrollers or drums, and the form rollers. The ink formand feed roller Throw-offs are controlled manuallyor pneumatically.

A - Ink Fountain Levers

B - Cross Brace

C - Handknob

D - Ink Fountain Seal

E - Ink Fountain Roller

F - Ink Fountain Blade

Figure 3-8. Ink Fountain Assembly

B

C

A

FE

D

CAUTION

CAUTION

Do not close the ink fountain lever orscrews so that the ink fountain bladecomes into contact with the inkfountain roller. This will causedamage to both the blade and roller.

b. The gap between the ink fountain bladeand the ink fountain roller determines the amount


III-12

of ink leaving the ink fountain. The gap betweenthe blade and roller is adjusted by either a lever ora thumbscrew (ink key).

c. With lever up, ink flow is shut off. As thelever is adjusted down, the ink flow increases.

d. With thumbscrews, turning clockwisedecreases the ink flow while turning counterclock-wise increases the ink flow.

e. Ink Fountain Cleaning.

(1) If it is necessary to clean the InkFountain, follow the procedures outlined in SectionVII, Maintenance, paragraph 8.a.

f. Ink Stripe.

(1) The pressure between a soft rubberroller and a harder metal drum causes the rubberroller to flatten and squeeze the ink film out frombetween the two. Thus, this area of the rollersappear as a long stripe, the length of the rollers.This is called an ink stripe, but in fact, there is verylittle ink at all. Another term which can be used isan ink flat. In any case, this “No Ink”, ink stripe isused to measure the ink roller settings throughoutthe ink train. The ink stripe width should beuniform the entire length of the roller.

(2) If equipped with a pneumatic throw-offsystem, the air cylinders must be operative inorder to make your measurements. Measurementsmade with air cylinders inoperative will not staymaintained.

g. Making Ink Stripes.

(1) With the ink train properly inked, runthe unit until all of the previous ink stripes havedisappeared. Check to make sure that the inkrollers have inked up evenly.

(2) Stop the unit and engage, thendisengage, the ink rollers.

(3) Inch the unit until the desired stripeyou are checking becomes accessible.


(5) Inspect the ink stripe.

7. DAMPENING SYSTEM.

a. A sock type continuous feed dampening

system is standard. An optional spiral brush orspray-bar dampening system is also available. Amanual or pneumatic dampener form roller throw-offis used.

b. The speed of the dampener fountain panroller regulates the amount of dampener solutionbeing fed into the dampener roller train. The fasterthe pan roller rotates, the greater the amount ofsolution is being applied to the plate surface. Thespeed of the pan roller is adjusted by the dampenerfeed motor speed control dial on the unit controlpanel or by the dampener motor speed switch onthe press console, if so equipped. From a slowstart to production speed, adjustments will benecessary to maintain proper ink and water bal-ance.

c. The fountain pans and dampener circula-tion system should be cleaned weekly. Follow thedirections of the circulation system manufacturerto clean the system.

d. Water Stops.

(1) Water stops are used for shutting offor greatly reducing the amount of dampeningsolution to a particular part of the dampening train.When the product calls for the use of less than full

Figure 3-9. Water Stop

Water Stop

webs or for adjusting the demand on certainforms, then a water stop is placed in the fountainpan to squeegee off dampening solution from thefountain pan roller.

Figure 3-10. Water Stops In Place

CAUTION

CAUTION

Do not place water stops in the


III-13

fountain pan unless the press iscompletely stopped.

8. WEBBING THE UNIT.

a. Web lead patterns will vary dependingupon the requirements of the end product. There-fore, the following are general procedures that canbe followed when webbing a press (refer to figure 3-11).


A - Compensator Rollers

B - Blanket Nip

C - Web Tension Rollers

Figure 3-11. Diagram of Web Lead - Unit

C

B

A

To

Folder

(2) Disengage impression levers andloosen the brake shoe handwheels.

(3) Produce a tapered edge at the lead-end of the web by tearing the paper at an anglefrom the operator side to the drive side of the web.The tapered edge permits the web to pass throughthe unit and press freely and evenly.

CAUTION

CAUTION

You will encounter variousnip points during thisoperation which can causebodily harm. Care should beobserved in webbing thepress to ensure personalsafety.

(4) While an operator unrolls the paper rollto create slack in the web, another operator pullsthe tapered lead-end of the web through the webtension rollers (C), between the blankets (B) in theunit, and around the compensator rollers (A).

(5) When all of the webs are brought tothe folder, consult the folder operator’s manual forprocedures to web the folder.

b. Setting Web Tension.

Figure 3-12. Tension System Diagram

D

C

B

A

E

F

A - Brake Drum

B - Brake Shoe

C - Brake shoe Handwheel

D - Knurled Tension Spring Nut

E - Tension Spring

F - Governor Roller

(1) Refer to figure 3-12. The initial tensionspring (E) setting is made upon installation of theunit. When the setting is complete, the length ofthe spring will be 16 to 17 1/2 inches.

(2) The unit farthest from the folder hasthe lowest spring tension setting while the unitclosest to the folder has the highest. This gradualincrease in spring tension from farthest to nearestinsures an even web feed to the folder.


III-14

(3) As the press runs and the paper rollreduces, brake shoe (B) adjustments are neces-sary to keep the governor roller (F) perpendicular tothe floor to maintain proper web tension.

(4) When the press is started, tighten thebrake shoe handwheel (C) so that the governorroller arm (F) just comes off of the nylon bushingsthat they rest on when there is no web tension.

(5) As press speed increases, tighten thebrake shoe handwheel (C) to pull the governor roller(F). By production speed, the governor roller andarm should be vertical to the floor.

(6) When running multiple webs, thebottom web has the greatest amount of webtension. The web tension is progressively lesswith each successive web.

c. Splicing.


(2) Loosen and disengage the brake shoehandwheel (C).

(3) Remove the expired webs’ core,leaving a long tail for splicing, and install the newpaper roll according to the procedures outlined inparagraph 3.b above, “Loading The Roll Stand”.

WARNING

WARNING

Contact with the spindle shaft orbrake hub of an expired paper roll cancause serious burns. Wait until theshaft and brake hub have cooledbefore touching.

(4) Inspect the new paper roll for anydamage or defects.

(5) Fold and tear off the lead-end of thenew roll square across the width of the web.

(6) Lay the tail of the expired web over thenew paper roll, being sure it extents past the lead-end of the new roll; fold and tear the tail of the oldweb off square with the width of the web.

(7) Place double-sided tape or an adhe-sive along the entire width of the expired webs’ tail.

Try to keep the tape or adhesive parallel to the tailedge.

(8) Remove the lead-end of the new rollout from under the expired webs’ tail and attach itto the tape or adhesive. Tear off the excess paperfrom the lead-end of the new roll.

(9) With the impression levers engaged,run the press at a slow speed until the splice(s)enter the folder. If the splice(s) are passingthrough more than one unit, you may want todisengage the impression levers while the splicepasses through those units; then re-engage theimpression levers.

9. MAKE-READY CHECKLIST. (RECOM-MENDED PROCEDURES TO BE COMPLETEDPRIOR TO ENGAGING THE PRESS DRIVE.)

a. ___ If the press is supplied with pneumaticcontrols, turn on the air supply to the press.

b. ___ Engage units to be used, disengageunits not to be used. Disengage the folder.

c. ___ Load the unit roll stands to be used,with the proper kind and size of paper.

d. ___ Fill appropriate ink fountains.

e. ___ Center register controls.

f. ___ Install plates in proper position.

g. ___ Web the press.

h. ___Turn on and adjust dampening systemand controls.

i. ___Check the level of the dampeningsolution and its pH/conductivity.

j. ___ Engage the folder, web the folder, andadjust for the product requirements.

k. ___Engage the impression levers on theunits being used.

l. ___ You are now ready to slowly start upthe press. As you do, adjust web tension asneeded. The webs may wander side-to-side for ashort time. Once the press is running, applydampening solution to the plate from the dampenerform rollers, apply ink from the ink form rollers andstart registering the webs, images, and cutoff whilecontrolling ink and water balance.


IV-1

SECTION IV - Running ProcedureIntroduction ---------------------------------------------------------------------------------------- IV-2Startup ---------------------------------------------------------------------------------------- IV-2Running ---------------------------------------------------------------------------------------- IV-2Shutdown ---------------------------------------------------------------------------------------- IV-3Wash-Up ---------------------------------------------------------------------------------------- IV-3

Rollers ---------------------------------------------------------------------------------------- IV-3Cylinders --------------------------------------------------------------------------------------- IV-3Safety ---------------------------------------------------------------------------------------- IV-3

SECTION IV

RUNNING PROCEDURE


IV-2

1. INTRODUCTION.

a. The following is a procedure outline forsetting and adjusting the operation controls of theDGM - 430 unit for a press run. Each procedure initself is complete. However, the skill of thepressroom personnel and local conditions mayrequire some minor changes for best quality andperformance.

WARNING

WARNING

The DGM - 430 unit is equipped withguards, doors and covers which mayhave interlock safety devices for yourprotection. Never by-pass any safetydevice. Be sure that the press is onSAFE before opening any of thesedevices.

2. STARTUP.

a. Have all ink feed, ink form, dampenerform, and impression throw-off levers disengaged.

b. Set the master dampener motor toggleswitch to the ON position at the unit; the dampenermotors will be turned off at the control panel/console. Set the dampener motor speed controldials at the unit to approximately 3.

c. Engage the folder. Engage the impressionthrow-off levers.

d. Startup the press and run between 3000and 4000 iph. Be sure that the web(s) are runningthrough the press and delivering properly.

e. Turn on the master dampening motorsfrom the control panel/console.

f. Engage the dampener form rollers. Ob-serve the plate; it should reflect light from themoisture and look shiny.

g. Engage the ink form rollers and the inkfeed throw-off levers; observe the plate. The non-image areas should remain clean while the imageareas become inked.

(1) A “roll up” procedure can be used to

pre-ink the plates, before the press run, by follow-ing these steps:

(a) Disengage the folder.

(b) Run the unit at approximately3000 iph.

(c) Engage the ink feed throw-offlever.

(d) Start the dampener motors at boththe unit and the control panel/console.

(e) When the ink form rollers areevenly inked, disengage the ink feed throw-offlever.

(f) When the dampener form rollersare moist, engage the dampener form throw-offlever.

(g) When the plate looks wet or shiny,engage the ink form throw-off lever to ink theimage on the plate.

(h) When the plate is evenly inked,disengage the ink form throw-off lever, then thedampener form throw-off lever.

(i) Shut off the unit and engage thefolder while the press is on “SAFE”.

h. While bringing the press up to productionspeed, observe the webs and images. Makeadjustments for web tension, ink and water bal-ance, ink coverage and registration.

i. Never adjust an ink or water feed rollerwhile the press is in motion. Always place thepress on “SAFE” before adjusting rollers.

j. At the delivery, check the product for pageimposition, cutoff, and ink coverage.

k. Make fine adjustments as necessary.

3. RUNNING.

WARNING

WARNING

Never attempt to clean or make


IV-3

adjustments while the press isrunning. Severe injury may occur.Beware of nip points.

a. Establish proper ink and water balance assoon as possible.

b. Inspect the running web for ink coverageand dampener changes.

c. As soon as there is image on the web,make the necessary register adjustments. Suchas: side margin register, back-to-back register,color register, cutoff register, and web-to-webregister.

d. Adjust the folder delivery as necessary.

4. SHUTDOWN.

a. Slow the press to a walking or inchingspeed.

b. Disengage the ink feed roller, the ink formroller, and the dampener form roller throw-offlevers.

c. Turn off the dampener motors at the unit orat the control panel/console.

d. Allow the press to rotate a few revolutionsto remove excess ink from the blankets.

e. Stop the press. Inch the press to align thetiming marks located on the driveshaft and theunit.

f. Loosen the brake shoe handwheels.

g. Disengage the impression levers.

h. Disengage the folder.

i. Remove and preserve the plates if neces-sary.

5. WASH-UP.

a. Rollers.

Refer to Section VII, Maintenance, paragraph 8.bfor procedures applicable to cleaning rollers.

b. Cylinders.

By the use of the STOP-SAFE system:

(1) Clean the blankets used for the runwith two rags and solvent. Break down the ink filmwith a solvent soaked rag and then wipe dry with adry rag.

(2) After removal of the plates, wipe theplate cylinder surface dry. Then apply a thin filmof oil to the cylinder surface.

c, Safety.

Wash-up procedures, as well as any work on thepress, should always be done with a helper, or at aminimum, another person observing, who mayassist in cases of emergencies.


IV-4



V-1

SECTION V - Page Imposition Or Plate PositioningIntroduction ---------------------------------------------------------------------------------------- V-2Plate Positioning ---------------------------------------------------------------------------------------- V-2Page Patterns ---------------------------------------------------------------------------------------- V-2Some “Set Up” Questions ----------------------------------------------------------------------------- V-2Terminology ---------------------------------------------------------------------------------------- V-3

Broadsheet ------------------------------------------------------------------------------------ V-3Tabloid ---------------------------------------------------------------------------------------- V-3Mini-Tab Or Signature ------------------------------------------------------------------------ V-3Former ---------------------------------------------------------------------------------------- V-3Upper Former --------------------------------------------------------------------------------- V-3Center Spread --------------------------------------------------------------------------------- V-3

Unit Configurations ------------------------------------------------------------------------------------ V-3Page Impositions --------------------------------------------------------------------------------------- V-4

SECTION V

PAGE IMPOSITION OR PLATE POSITIONING


V-2

1. INTRODUCTION.

a. Page imposition is the process of deter-mining where on the press the plates are to bepositioned to have the page sequence in properorder in the finished product.

2. PLATE POSITIONING.

a. The physical arrangement of the press willdictate the web lead. However, the following“Helps” can be used to determine the proper platepositioning.

Help #1 - The first and last page of a section arelocated on the same plate. On a Broadsheet, theyare next to each other.

Help #2 - The page numbering will form a “U”-shaped pattern.

Help #3 - Page 1 will be located on the farthest unitbeing used, away from the folder.

Help #4 - The inside pages will be located on thenearest unit being used, from the folder.

Help #5 - The pages with the lowest numbers willbe located on the drive side of the press.

Help #6 - The pages with the highest numbers willbe located on the operator side of the press.

Help #7 - One DGM - 430 unit can produce 4 pagesin a broadsheet format; 8 pages in a tabloid format;16 pages in a mini-tab or magazine (signature)format.

Help #8 - If the pages are in their proper location,then by adding the page numbers on companionpages (pages next to each other), you should get asum equal to one more than the number of pagesin that section.

Example: A 12 page section plus 1 = 13

Pages 1 plus 12 = 13Pages 2 plus 11 = 13Pages 5 plus 8 = 13Pages 6 plus 7 = 13

b. The procedure to follow for positioning theplates is based on the arrangement of the printingunits and the characteristics of the folder. On mostpresses, when facing the former, page 1 is on thetop of the uppermost web and is on the right handside (drive side) of the former.

3. PAGE PATTERNS.

a. A study of figure 5-1 will reveal a pattern fornumbering the pages. Page 1 is on the drive sideof the unit farthest from the folder. The pagenumbers forma “U” - shapedpattern fromthe farthestunit to thenearest unitand back tothe farthestunit. The firstand last pageswill be printedon the printingcouple farthestfrom the folder,while theinside pageswill be printedon the printingcouple nearestthe folder.Lower pagenumbers areon the driveside and thehigher num-bers are onthe operatorsside. The sumof the compan-ion pagesequals thenumber ofpages in thesection plusone.

4. SOME“SET-UP” QUESTIONS.

a. A list of questions which need to beanswered, before marking up the page imposition,may be as follows:

(1) What type of format? Broadsheet?Tabloid? Mini-Tab?

(2) How many pages?

(3) Is there any color? Spot? Process?Location?

(4) How many sections?

10 7

12 5

14 3

16 1

Drive

Side

Op.

Side

16 Page Markup for a

Broadsheet Product

Figure 5-1. Markup Example

2 15

4 13

6 11

8 9

Folder


V-3

(5) Size and location of paper rolls?

(6)Press and foldercapacity?

(7) Theremay be othersdepending uponyour situation.

5. TERMINOL-OGY.

a. Broad-sheet - a stan-dard newspapersheet whichcontains 4numbered pages.2 pages on oneside of the sheet(single-width web)and 2 pages onthe other side.The head or top ofthe page image islocated on thetrailing edge ofthe plate.

b. Tabloid -the tabloid pageis half the size ofthe standardnewspaper page;each broadsheetpage areabecomes 2tabloid pages.Tabloid pages runhead-to-head; allheads are locatedtoward the verticalcenterline of thepress. Tabloidsizes can varydepending on thewidth of the web.

c. Mini-tabor Signature - ishalf the size ofthe tabloid page.Each newspaperpage areabecomes 4 mini-

tab pages. The mini-tab pages run head-to-headacross the width of each plate. A Quarter-Foldassembly on the folding unit, is normally needed forthis product.

d. Former - forms the first longitudinal fold ofthe web. The web passes over and down a smoothtriangular plate located towards the top of thefolder. This triangular plate is called the formerboard or pan.

e. Upper Former - is sometimes calledballoon former. This is a second former panlocated above the first to allow for the running of anadditional section.

f. Center Spread - It is a carryover termfrom letterpress days and means a two-page centerspread in the center of each section.

6. UNIT CONFIGURATIONS.

a. As shown in figure 5-2, when using units infront of the folder, it will be necessary to visuallyplace that units’ run behind the folder and thennumbered. This would essentially place the firstand last pages farthest from the folder.

b. If your press is equipped with a secondformer located above the former on the folder, thenyou have what is called a Balloon former. Eachadditional former increases the number of sectionsthat can be ran.

8A

1

A

6A

3

A

2A

7A

6 3

4 5

8 1

2 7

4A

5A

Figure 5-3. Using a "Balloon" Former

c. The upper former can only be fed withwebs from the farthest units that are being used orfrom units in front of the folder using an over-the-topweb lead.

d. One set of eight pages is run over theballoon former while another set of eight pages isrun over the lower former.

e. The web lead from the balloon former can

4 17

18 3

2 19

20 1

10 11

12 9

8 13

14 7

6 15

16 5

4 17

18 3

2 19

20 1

20 - Page

Figure 5-2. Placement

Folder


V-4

be brought down on either side of the lower former.When the web lead from the balloon former isbrought down on the operator’s side of the lowerformer, it will become the inside section. When theweb lead from the balloon former is brought downon the drive side of the lower former, it will becomethe outside section.

7. PAGE IMPOSITIONS.

a. Figures 5-4, 5-4 and 5-6 show “Broad-sheet”, “Tabloid” and “Mini-Tab” page impositionsand is provided for reference purposes.


V-5

2 3

4 1

8 9

10 7

2 5

6 1

6-Page4-Page 8-Page 10-Page 12-Page 16-Page

18-Page

20-Page

24-Page

24-Page

Folder

4

3

Folder

2 7

8 1

2 9

10 1

4 5

6 3

Folder

4

3

6 7

8 5

Folder

2 11

12 1

4 9

10 3

6 7

8 5

Folder

2 23

24 1

2 19

20 1

4 17

18 3

2 23

24 1

4 21

22 3

2 15

16 1

4 13

14 3

6 11

12 5

Folder

12 13

14 11

6 19

20 5

8 17

18 7

10 15

16 9

Folder

8 9

10 7

4 15

16 3

2 17 18 1

13

14

6 11

12 5

Folder

12 13

14 11

6 19

20 5

4 21 22 3

8 17

18 7

10 15

16 9

Folder

6 15

16 5

8 13

14 7

10 11

12 9

Folder

Figure 5-4. Broadsheet Page Impositions

Count Left to Right.

Start on the Drive side.

End on the Op side.

StartStop

Op

Side

Drive

Side


V-6

8-Page 12-Page2 7

8 14

5 6

3

2 1

1 12 1

6 7

8 5

Folder

10 2

7 2

8 9

Folder

4 9

10 3

Folder

16-Page 32-Page 36-Page 40-Page 44-Page

2 1

5 16 1

4 1

3 14 3

8 9

10

76 1

1 1

2 5

Folder

10 31 32 9

12

29

30

11

Folder

Folder

6 2

7 28 5

8 2

5 2

6 7

12 2

1 2

2 1

11

0 2

3 2

4 9

Folder

31

13

3

2 1

4 2

9 30 3

8 2

9 30 7

16

17

18

15

14

19

20

13

4 4

1 4

2 3

20

25

26

19

2 4

3 4

4 1

22

23

24

214

3

7 3

8 3

18

23

24

17

2 3

9 4

0 1

14

19

20

13

4 3

3 3

4 3

16

21

22

15

2 3

5 3

6 1

18

19

20

17

6 3

1 32 5

14

23

24

13

12 2

5 2

6 1

1

12

33

34

11

10

3

5 3

6 9

14

31

32

13

6 3

5 36 5

8 3

3 3

4 7

16

25

26

15

14

27

28

13

6 1

5 1

6 5

Folder

20-Page 24-Page

6 1

9 2

0 5

8 1

7 1

8 7

Folder

4 1

7 1

8 3

2 1

9 2

0 1

10 1

1 1

2 9

8 1

3 1

4 7

2 2

3 2

4 1

4 2

1 2

2 3

12

13

14

11

10

15

16

9

6 3

9 40 5

8 3

7 38 7

18

27

28

17

16

29

30

15

Figure 5-5. Tabloid Page Imposition


End on the Drive side.

Sta

rt

Sto

p

Op

Side

Drive

Side


V-7

16-Page

16 1 4 13

12 5 8 9

10 7 6 11

14 3 2 15

56 1 14 43

42 15 28 29

30 27 16 41

44 13 2 55

64 1 16 49

48 17 32 33

34 31 18 47

50 15 2 63

24-Page

24 1 6 19

18 7 12 13

14 11 8 17

20 5 2 23

32-Page

32 1 8 25

24 9 16 17

18 15 10 23

26 7 2 31

40-Page

40 1 10 31

30 11 20 21

22 19 12 29

32 9 2 39

Folder

4 21

16 9

10 15

22 3

Folder

30 3 6 27

22 11 14 19

20 13 1 21

28 5 4 29

38 3 8 33

28 13 18 23

24 17 14 27

34 7 4 38

Folder

6 35

26 15

16 25

36 5

Folder

48-Page 56-Page 64-Page

48 1 12 37

36 13 24 25

26 23 14 35

38 11 2 47

46 3 10 39

34 15 22 27

28 21 16 33

40 9 4 45

44 5 8 41

32 17 20 29

30 19 18 31

42 7 6 43

Folder

54 3 12 45

40 17 26 31

32 25 18 39

46 11 4 53

52 5 10 47

38 19 24 33

34 23 20 37

48 9 6 51

8 49

36 21

22 35

50 7

Folder

62 3 14 51

46 19 30 35

36 29 20 45

52 13 4 61

60 5 12 53

44 21 28 37

38 27 22 43

54 11 6 59

58 7 10 55

42 23 26 39

40 25 24 41

56 9 8 57

Folder

Figure 5-6. Mini-Tab Page Imposition


End on the Drive side.

Sta

rt

Sto

p

Op

SideDrive

Side


V-8



VI-1

SECTION VI - Roller AdjustmentsRoller Pressure ---------------------------------------------------------------------------------------- VI-2Roller Adjustments - Ink ------------------------------------------------------------------------------ VI-2

Ink Fountain Roller A ------------------------------------------------------------------------- VI-2Ink Feed Roller B to Fountain Roller A ----------------------------------------------------- VI-3Ink Transfer Rollers C and E ----------------------------------------------------------------- VI-4Ink Form Rollers G and H-------------------------------------------------------------------- VI-5

Roller Adjustments - Dampener ---------------------------------------------------------------------- VI-6Dampener Fountain Roller I ------------------------------------------------------------------ VI-6Sock Feed Roller J --------------------------------------------------------------------------- VI-6Dampener Form Roller L --------------------------------------------------------------------- VI-7

Gap Adjustments --------------------------------------------------------------------------------------- VI-8Setting Cylinder Gaps - Timing --------------------------------------------------------------- VI-8Spiral Brush Dampening Adjustment--------------------------------------------------------- VI-9

Iron-To-Iron Setting ----------------------------------------------------------------------------------- VI-10Setting The Plate And Impression Cylinders ------------------------------------------------ VI-10To Check The Settings------------------------------------------------------------------------ VI-10To Adjust The Settings ------------------------------------------------------------------------ VI-11

13 Cylinder Set --------------------------------------------------------------------------- VI-1113 - 12 Cylinder Set --------------------------------------------------------------------- VI-1112 - 11 Cylinder Set --------------------------------------------------------------------- VI-1211 - 10 Cylinder Set --------------------------------------------------------------------- VI-12

SECTION VI

ROLLER ADJUSTMENTS


VI-2

CAUTION

STOP

Avoid personal injury,observe nip points betweencylinders and rollers. Keepguards closed when runningthe press. Do not defeat theinterlock devices affixed tothe guards (if available).

1. ROLLER PRESSURE.

a. To obtain maximum efficiency from therollers, pressure settings between rollers should beset as lightly as possible without affecting thequality of the product. It is very important that thepressure be uniform the entire length of the roller. Ifeven ink and dampener distribution can not beachieved, inspect the rollers for uneven wear orroller swell. Replace if necessary. Figure 6-1 isprovided to aid in roller identification.

A B

CE

D

GF

H

L

J K

I

PLATE

(13-Side)PLATE

(10-Side)

A - Ink Fountain Roller

B - Ink Feed Roller

C - Ink Transfer Roller

D - Vibrator Ink Drum

E - Ink Transfer Roller

F - Vibrator Ink Drum

G - Outside Ink Form Roller

H - Inside Ink Form Roller

I - Dampener Fountain

Roller

J - Dampener Feed (Sock)

Roller

K - Water Vibrator Drum

L - Dampener Form Roller

Figure 6-1. Roller Identification Chart

AB

DE

F

H

G

L

K

I

J

C

Blanket Blanket

b. There are two methods of checking rollerpressure settings; the slip sheet method and theink stripe method. The dampener rollers use theslip sheet method and the ink rollers use the inkstripe method.

c. Slip Sheet: The slip sheet method providesa quick and accurate check of dampener rollersettings. (If units are equipped with a pneumaticsystem, air cylinders must be operative.)

(1) Cut two pieces of scrap film approxi-mately 12 inches long and 1 inch wide.

(2) Insert the slip sheets between the tworollers to be checked, about 3 inches in from eachend of the rollers. (This may have to be done byinching the press.)

(3) Pull on the two slip sheets at thesame time. The tension or drag should be even onboth sides.

d. Ink Stripe: The ink stripe method relies onthe pressure of the ink rollers to form an ink stripethe length of the roller; then measure the width ofthe ink stripe. This is not actually an ink stripe butrather an area with very little ink. The softertransfer rollers flatten slightly when they restagainst a solid drum roller. As the transfer rollerflattens out, it pushes the film of ink out frombetween the two rollers and leaves a stripe of noink. The stripe width must be uniform the length ofthe roller. (If units are equipped with a pneumaticsystem, air cylinders must be operative.)

(1) Engage the ink feed roller and run theunit until the ink rollers are evenly inked. Be surethe ink form rollers are in the off position.

(2) Stop the press for a moment, engagethen disengage the ink roller so that a line of ink ismade. Inch the press to observe the ink stripe onthe desired roller to be measured.


(4) Measure the ink stripe and see if it isuniform the entire length of the roller.

2. ROLLER ADJUSTMENTS - INK.

a. Ink Fountain Roller A.

No adjustment should be necessary. For thoseunits which are equipped with ink fountain levers,those levers should be set in the “O” or closedposition. If the ink fountain is equipped with inkfountain keys, the fountain blade should be set tothe fountain roller with a feeler gauge. In bothinstances, use a 0.002-in. (0.10mm) feeler gaugeand the ink levers/keys so that there is a slightdrag on the feeler gauge between the fountain rollerand the fountain blade.

b. Ink Feed Roller B to Fountain Roller A.


VI-3

(1) With clean rollers, turn the eccentricsat both ends of the roller until they are parallel toeach other, the ink feed throw-off lever engaged,and using a feeler gauge, a 0.003-in. (0.08mm)

gauge will go between the rollers. A 0.004-in.(0.10mm) gauge will not.

(a) To adjust (refer to figure 6-2) andafter both rollers are parallel to each other, performthe following action.

LETTER ROLLER DIA. In./mm TYPE SET TO... ADJUSTMENT SETTING

A Ink Fountain 4 / 102mm Fountain No AdjustmentBlade

B Ink Feed 3 / 76mm Steel Using a feeler gauge:Plastic A 0.003 in./0.08mm GO

Covering 0.004 in./0.1mm NO GO

DC Ink Transfer 2 3/4 / 70mm Rubber Then to Ink Stripe Method

B 1/8 to 3/16 in./3mm to 5mm

Vibrator InkD Drum 3 1/4 / 83mm Copper No Adjustment

DE Ink Transfer 2 3/4 / 70mm Rubber Then to Ink Stripe Method

F 1/8 to 3/16 in. /3mm to 5mm

Vibrator InkF Drum 3 1/4 / 83mm Copper No Adjustment

FG Ink Form 2 7/8 / 73mm Rubber Then to Ink Stripe Method

Plate 1/8 to 3/16 in. / 3mm to 5mm

FH Ink Form 2 3/4 / 70 mm Rubber Then to Same as G above.

Plate

DampenerI Fountain 3 1/4 / 83mm No Adjustment

Slip Sheet MethodK Snug, steady pull

J Dampener 2 3/4 / 70mm Rubber Then toFeed (Sock) I Slip Sheet Method

Light pull/contact

VibratorK Drum 3 1/4 / 83mm No Adjustment

Slip Sheet MethodK Snug, steady pull

L Dampener 2 3/4 / 70mm Rubber Then toForm Plate Slip Sheet Method

Slight, steady pull

Table 1. Roller Specification Chart


VI-4

Figure 6-2. Ink Feed Throwoff

CB

A

A - Throwoff Lever

B - Locknut

C - Stopscrew


2 - Remove operator’s side cover.

3 - Place the ink feed throw-offlever (A) in the on position.

(b) To decrease the gap (ensure therollers are parallel to each other).

1 - Loosen locknut (B).

2 - Insert feeler gauge betweenrollers.

3 - Turn stopscrew (C) clockwiseto decrease the gap.

4 - When the gap is correct,tighten locknut (B). IMPORTANT. The ink feedroller must not come into contact with the inkfountain roller.

(c) To increase the gap.

1 - Loosen locknut (B) .

2 - Turn stopscrew (C) counter-clockwise to push on the throw-off lever (A) stoppin.

3 - Turn stopscrew (C) until the0.003 in. feeler gauge fits between the rollers.IMPORTANT. The ink feed roller must not comeinto contact with the ink fountain roller.

4 - Tighten locknut (B).

c. Ink Transfer Rollers C and E.

Figure 6-3. Ink Transfer Roller

A

BC

D Transfer Eyebolt

Adjuster

A - Locknut

B - Locknut

C - Lockbolt

D - Adjusting Bolt

(1) IMPORTANT. It is necessary to firstadjust the ink transfer rollers C and E to drum D offigure 6-1, as follows (refer to figure 6-3).

(a) Put the press on SAFE.

(b) Loosen the locking bolts (C)located at the ends of the rollers.

(c) To decrease the ink stripe.

1 - Turn the adjustment bolt (D)counterclockwise.

(d) To increase the ink stripe.

1 - Turn the adjustment bolt (D)clockwise.

(2) When the adjustment is correct,tighten the locking bolts (C).

(3) It is very important that the ink stripe isrechecked after tightening the locking bolts.


VI-5

(4) IMPORTANT - After the adjustmentperformed in item 2(c) above has been accom-plished, it is necessary to secondly, adjust thetransfer rollers (C to B and E to F as indicated infigure 6-1) after rollers C and E have been set to theink drum D (refer to figure 6-3). This is done asfollows.


(b) To decrease the ink stripe.

1 - Loosen locknut (B) and tightenlocknut (A) against the frame stud.

(c) To increase the ink stripe.

2 - Loosen locknut (A) and tightenlocknut (B) against the frame stud.

(d) After the rollers have been ad-justed, tighten locknuts not in contact with theframe studs.

(e) It is very important that the inkstripe is re-checked after tightening the locknuts.

d. Ink Form Rollers G and H.

(1) IMPORTANT - It is necessary to first,adjust rollers G and H to ink drum F. (Refer tofigure 6-4).


(b) Loosen the lockbolt (B) located inthe form roller bracket at both ends of the roller.

(c) To decrease the ink stripe.

1 - Turn the adjusting bolt (A)counterclockwise.

(2) After completing the above adjust-ments at both ends of the roller, tighten the lockingbolt(s) (B).

(d) To increase the ink stripe.

1 - Turn the adjusting bolt (A)clockwise.

(3) It is very important that the ink stripe isrechecked after tightening the lockbolt(s) (B).

(4) IMPORTANT - After the adjustmentperformed in item 2.d previously has been accom-

plished, it is necessary to secondly, adjust rollersG and H to the plate cylinder after rollers G and Hhave been set to ink drum F.

Ink Transfer Roller

Vibrator Ink Drum

Ink Transfer Roller

Ink Form Roller

Roller Nip Guard

10-Cylinder

Vibrator Ink Drum

Ink Transfer Roller

Ink Form Roller

10-Cylinder

Figure 6-4. Ink Form and Transfer Rollers

(Guard Removed for Clarity Purposes)

No Guard

With Guard

A - Adjusting Bolt (In and Out Adjustments)

B - Lockbolt

C - Roller-To-Plate Adjusting Bolt (Up and

Down Adjustments)

D - Anti-Bounce Bolt

(a) A properly packed plate must bemounted on the plate cylinder and the ink trainevenly inked.

(b) Put the press on SAFE.

(c) Being sure that the ink form rollerswill not fall into the plate cylinder gap, engage theink form rollers.

(d) After several seconds, disengagethe ink form rollers.


VI-6

(e) Take the press off SAFE and inchthe unit to where the rollers contacted the plate.

(f) The result should be an ink stripethe width of the plate with a uniform thickness.

(g) To adjust.

1 - With the form rollers disen-gaged, back off the Anti-bounce bolts about 3 fullturns counterclockwise.

(h) To decrease the ink stripe.

1 - Turn the roller to plate adjust-ing bolt counterclockwise.

(i) To increase the ink stripe.

1 - Turn the roller to plate adjust-ing bolt clockwise.

(j) After completing adjustments atboth ends of the roller, engage the form rollers.

(k) Turn the anti-bounce bolts in,clockwise, until they touch the stop plate. Turningthe anti-bounce bolt too far will decrease the rollerstripe.

3. ROLLER ADJUSTMENTS - DAMPENER.

a. Dampener Fountain Roller I.

(1) No adjustment should be necessary.

b. Sock Feed Roller J.

(1) IMPORTANT- It is necessary to first,adjust sock feed roller J to the vibrator drum K offigure 6-1. Setting should be checked and madewith the sock material wet. (Refer to figure 6-5.)

(a) Insert slip sheets between roller Jand vibrator drum K.


(c) Loosen the lockbolt (D).

(2) To decrease the pull on the slipsheets.

(a) Turn the adjusting bolt (E) counter-clockwise.

(3) To increase the pull on the slip sheets.

(a) Turn the adjusting bolt (E) clock-wise.

Figure 6-5. Dampener Feed Roller Adjustments

C

A

B

D

E

A - Locknut

B - Frame Stud

C - Locknut

D - Lockbolt

E - Adjusting Bolt: Roller to Vibrator Drum

(4) After achieving a snug steady pull onthe slip sheets, tighten the lockbolt (D).

(5) IMPORTANT - After the adjustmentperformed in item 3.b above has been accom-plished, it is necessary to secondly, adjust thesock feed roller J to the dampener fountain roller Iafter roller J has been set to vibrator drum K.Setting should be checked and made with the sockmaterial wet.

(a) Insert the slip sheets betweenroller J and the dampener fountain roller I.


(6) To decrease the pull on the slip sheet.

(a) Loosen locknut (C) and tightenlocknut (A) against the frame stud (B).

(7) To increase the pull on the slip sheet.

(a) Loosen locknut (A) and tightenlocknut (C) against the frame stud (B).


VI-7

(8) After achieving a slight steady pull onthe slip sheets, tighten locknuts (A) or (C) not incontact with the frame studs.

c. Dampener Form Roller L.

(1) IMPORTANT - It is necessary to first,adjust form roller L to the vibrator drum K of figure6-1.

Figure 6-6. Dampener Form Roller

I

H

G E

D

B

C

A

F

A - Vibrator Drum Roller

B - Lockbolt - Roller To

Vibrator Drum

C - Adjusting Bolt

D - Locknut

E - Nip Guard

F - Dampener Form Roller

G - Adjusting Bolt - Roller To

Vibrator Drum

H - Anti-Bounce Bolt

I - Stop Plate

(a) (Refer to figure 6-6.) Insert slipsheets between the form roller L and the vibratordrum K.


(c) Loosen the lockbolt (B) located inthe form roller bracket at both ends of the roller.

(d) To decrease the pull on the slipsheets.

(1) Turn the adjusting bolts (G)counterclockwise.

(e) To increase the pull on the slipsheets.

(1) Turn the adjusting bolts (G)clockwise.

(f) After achieving a snug steady pullon the slip sheets, tighten the lockbolt (B).

(g) It is very important that theadjustment is rechecked after tightening thelockbolt.

(h) IMPORTANT - After the adjust-ment performed in item 3.c above has been accom-plished, it is necessary to secondly, adjust roller Lto the plate cylinder after roller L has been set tovibrator drum K. (Refer to figure 6-6.)

(1) A properly packed plate mustbe mounted on the plate cylinder.

(2) Insert slip sheets between theform roller L and the plate being sure that the formroller will not fall into the cylinder gap.

(3) Engage the dampener formroller. Check for a steady pull on the slip sheets.

(i) To adjust.

(1) With the form rollers disen-gaged, back off the anti-bounce bolts (H) about 3full turns counterclockwise.

(2) Engage the dampener formroller with slip sheets in place.

(j) To decrease the pull on the slipsheet.

(1) Turn the roller to plate adjust-ing bolt (C) counterclockwise.

(k) To increase the pull on the slipsheet.

(1) Turn the roller to plate adjust-ing bolt (C) clockwise.

(l) After achieving a steady pull onthe slip sheets, disengage the dampener formroller.

(m) Remove the slip sheets andengage the form roller.

(n) Turn the anti-bounce bolts (H) inclockwise, until they touch the stop plate. Turningthe anti-bounce bolt too far will decrease the rollerpressure.


VI-8

4. GAP ADJUSTMENTS.

a. Setting Cylinder Gaps - Timing.

(1) During the course of normal usage, itis recommended that the gaps between the #10,#11, #12 and #13 cylinders be periodically checkedand reset if necessary. The particular gap gauge tobe used is dependent upon the type of cylindersand cutoffs of the unit. (See Figure 6-7 for ex-amples of gap gauges.) The order used in settingthe gap is as follows:

(a) #12 Cylinder to the #13 Cylinder.

(b) #11 Cylinder to the #12 Cylinder.

(c) #10 Cylinder to the #11 Cylinder.

(2) The following procedures should beutilized to adjust the gap timing between thecylinders and will require access to the drive side

gears. During the setting of the gaps, it will benecessary to place the unit off impression mode,loosen the slip bolts, place the unit into impressionmode, make the adjustment and tighten the bolts.It may be necessary to perform this procedure anumber of times until the cylinder gaps are ad-equately set.

(a) Place the unit off-line and ensurethe SAFE button is engaged.

(b) Remove the drive side cover fromthe unit.

(c) Loosen the slipbolts (see Figure 6-8) on the cylinder to be set. (Loosening all of theslip bolts on that cylinder will allow free turning ofthe particular cylinder.)

(d) Install the appropriate gap gaugewithin the slot of the cylinder.

(e) Using your hand, turn the cylinder

Figure 6-7. Gap Gauges

AB

C

GFED

A - Narrow Gap Blanket to On-The-Nose Lockup (DGM111NN-1)

B - Narrow Gap Blanket to Slot Gap Plate (DGM111TG)

C - Reel Rod Blanket to Blanket Gap Gauge (M-M-G-0002)

D - Reel Rod to Slot Gap Plate (DGM111SR-1)

E - Narrow Gap Blanket to Blanket Gauge (DGM111NN-2)

F - Narrow Gap Plate to Narrow Gap Blanket Gauge (DGM111NN-3)

G - Wide Gap Plate Standard T-Bar to Blanket Gap Gauge (DGM111WN-1)

Figure 6-8. Cylinder Slip Bolts

Slip Bolts


VI-9

until the gap gauge is seated within the slots ofboth the cylinders to be set.

(f) Retighten the slip bolts on thecylinder. Torque all slip bolts to 30 ft.lbs. Removethe gap gauge.

Figure 6-9. Gap Gauge

#11

Cylinder

#10

Cylinder

Reel Rod to

Slot Gap Gauge

(g) Loosen the slip bolts on the nextcylinder.

(h) Install the appropriate gap gaugewithin the slot of the cylinder.

(i) Using your hand, turn the loos-ened cylinder until the gap gauge is seated withinthe slots of both the corresponding cylinders.

(j) Retighten the slip bolts. Torque allslip bolts to 30 ft.lbs. Remove the gap gauge.

(k) CRITICAL. The running circumfer-ential assembly must be on-center to ensuresmooth operation and alignment of the unit. Usingthe handle on the #10 cylinder, turn the handlecounterclockwise until it stops completely. Count-ing the number of complete turns, turn the handleclockwise until it stops again. Divide the number ofturns by two (2). This establishes the centerposition.

(l) Turn the handle the number ofturns established in (k) above to place the runningcircumferential assembly on center.

(m) Loosen the four (4) bolts on the#10 cylinder. Install the appropriate gauge on the

slot of the #11 cylinder and turn the #10 cylinder byhand to align the slot so that the gauge sets intoboth slots.

(n) Tighten and retorque the #10cylinder slip bolts to 30 ft. lbs., and remove thegauge.

Figure 6-10. Gap Gauge

#11

Cylinder

#12

Cylinder

Reel Rod Blanket to

Blanket Gap Gauge

(o) Visually inspect all four cylindersto ensure no gauges are between the cylinders.

(p) Reinstall the drive side cover.

(q) Disengage the SAFE button oncethe unit is ready for normal operation.

b. Spiral Brush Dampening Adjustment.

(1) For those units utilizing a spiral brush,adjustment of the dampening system, is completedas follows.

(a) Put the press on SAFE and theMaster Water on AUTO.

(b) Remove the spiral brush cover toallow access to the spiral brush assembly.

(c) Insert the spiral brush gaugebetween the water pan roller and the spiral brushaluminum body. The gauge should be insertedbetween the rows of brush material towards bothends of the spiral brush.


VI-10

(d) Adjust the spiral brush using thetransfer eye bolt located at the dampener bracket.

Figure 6-11. Spiral Brush Gauge

(4353-0162)

(e) To change the distance settings:

1- Refer to figure 6-12. Toincrease the distance loosen the locknut (B) on theeyebolt and tighten the locknut (A) located on thetop of the eyebolt against the transfer poppet.

Figure 6-12. Spiral Brush Dampener Adjustment

Locknut "B"

Locknut "A"

Transfer Eye Bolt

Transfer Poppet

2- To decrease the distanceloosen the locknut (A) located on top of the transfereyebolt and tighten locknut (B) on the transfereyebolt, against the transfer poppet.

(f) Perform the adjustments aboveuntil no drag or pressure can be felt when movingthe gauge with minimal clearance between the panroller and the brush body. The settings should beuniform at both ends of the spiral brush.

(g) After a uniform setting is com-pleted, tighten the locknuts that are not in contactwith the transfer poppet.

5. IRON-TO-IRON SETTING

a. Setting The Plate And ImpressionCylinders.

(1) The iron-to-iron distance between theplate and impression cylinders is set when thepress is installed and rarely, if ever, needs to beadjusted.

b. To Check The Settings

(1) To check the settings, use the gaugesfurnished with the press. The settings between allof the cylinders are shown below. Plates andblankets must be removed from the cylinders tocheck the iron-to-iron distances.

(2) Distances are based on an undercut of.081” which is considered the “standard” undercut.

Blanket - to - Blanket -- .158” GO, .159” NO-GO.Plate - to - Blanket -- .091” GO, .092 NO-GO.

(3) The Plate-to-Blanket distance mayvary for the following undercuts:

.012 - .089-.090

.010 - .087-.088

.008 - .085-.086

(4) The following procedures should beused in checking the settings. Refer to figure 6-13.

(a) Remove the plates and blanketsfrom the cylinders.

(b) Throw the blanket cylinder impres-sions ON.

(c) Check the iron-to-iron distancebetween each of the cylinders. Check at bothsides, about two or three inches from the ends.

(5) The GO gauge must fit between thecylinders, and the NO-GO gauge must not fit. If


VI-11

the settings are not within these limits, adjustthem.

c. To Adjust The Settings.

A

B

B

5

5

6

10

11

12

8

2

7

1

13

14

3

4

9

Figure 6-13. Iron-To-Iron Setting

A

13 Cylinder 10 Cylinder

10 Cylinder 11 Cylinder 12 Cylinder

12 Cylinder 11 Cylinder

13 Cylinder

(1) To adjust the settings, make thefollowing adjustments on both the operating anddrive side of the unit simultaneously. It is best tohave two persons, one on each side workingtogether.

(2) The following procedures should beused in adjusting the settings.

(a) Remove the housings from boththe operating and drive side of the unit. Ensure theimpression is ON and no packing, plates orblankets are on the cylinders. Figure 6-13 showsthe linkage arrangement on the operating side. Thelinkage on the drive side is identical.

(b) On turnbuckles (A) and (B), loosenthe locknuts (1 thru 4).

(c) Loosen the stop screw bolts (5)and (6).

(d) 13 Cylinder Set - Verify andensure the bolt (7) is wrench tight. This holds the13 cylinder in place.

(e) At turnbuckle (B), turn the stopscrew (8) to allow the impression lever assembly tomove slightly so that the pin (9) is slightly to theleft of the zerk (10).

(f) Retighten nut (6) until the nut issitting against the stop.

NOTE

Adjusting the tightness of turnbuckle(B) will “push” the eccentric for the#11 cylinder upward. This will causethe #12 cylinder eccentric to bepushed downward, which in turn willlower the eccentric ear down againstthe stop. The tightness of turn-buckle (B) is essential for properiron-to-iron setting.

(g) 13 - 12 Cylinder Set - Simulta-neously turn turnbuckle (B) and stop bolt (11) untilthe specified iron-to-iron distance is obtainedbetween cylinders #12 and #13. During thisprocedure, always keep the eccentric ear contain-ing the pin (12) on the #12 cylinder tight against thestop bolt (11). When the proper distance isobtained, retighten the locknut (5) on the stop bolt(11).


VI-12

(h) 12 - 11 Cylinder Set - Simulta-neously turn turnbuckles (A) and (B) until thespecified iron-to-iron distance is obtained betweencylinders #11 and #12. During this procedure,ensure the ear pin (12) remains against the stopbolt (11) and turnbuckle (B) is moderately snug.This will be evident in the sound (“snap”) heardwhen the impression is thrown on and off.

(i) On turnbuckles (A) and (B),retighten the locknuts (1 thru 4) ensuring turnbuck-les (A) and (B) do not move. Movement of eitherof these turnbuckles will give false iron-to-ironsetting.

(j) 11 - 10 Cylinder Set - After theiron is set on the #11 to #12 cylinders, loosen bolt(13) inside the “ear” of the eccentric on the #10cylinder on the Op side; and, loosen bolt (14)located at top right of the circumferential assembly.

(k) Pivot the eccentric until the propersetting is obtained.

(l) Retighten bolts (13) and (14).

(m) Throw the cylinders off impressionand then on. Recheck all the iron-to-iron distancesusing the procedures previously described inparagraph 5.b “To Check The Settings”.


VII-1

SECTION VII - MaintenanceIntroduction ---------------------------------------------------------------------------------------- VII-2Corrosion Control ------------------------------------------------------------------------------------- VII-2

Procedure-------------------------------------------------------------------------------------- VII-2Plate Cylinders --------------------------------------------------------------------------- VII-5Blanket Cylinders ------------------------------------------------------------------------ VII-5

Reference -------------------------------------------------------------------------------------- VII-6Corrosion Develops--------------------------------------------------------------------------- VII-6

Lubrication ---------------------------------------------------------------------------------------- VII-6Oil Level ---------------------------------------------------------------------------------------- VII-6Oil Changing ---------------------------------------------------------------------------------------- VII-6Oil Strainer ---------------------------------------------------------------------------------------- VII-7Grease Fittings ---------------------------------------------------------------------------------------- VII-7

Lubrication Panel ------------------------------------------------------------------------------ VII-7Ink System ---------------------------------------------------------------------------------------- VII-9

Ink Fountain Cleaning ------------------------------------------------------------------------- VII-9Cleaning Rollers ------------------------------------------------------------------------------- VII-9Cleaning Cylinders ---------------------------------------------------------------------------- VII-10

Dampener System ------------------------------------------------------------------------------------- VII-10General ---------------------------------------------------------------------------------------- VII-10Feed Roller Sock Installation----------------------------------------------------------------- VII-11

Roll Stand Brake Blocks ------------------------------------------------------------------------------ VII-11

SECTION VII

MAINTENANCE


VII-2

Interval Part Lubricant Method

Daily

Weekly

Annually oras usagerequires

Table 2. Lubrication Chart

Circulating Syst. - check sight window of unit Oil Pour in

Ink and Dampener Drum Bushings (Operator Side) Grease Grease Fitting

Dampener Fountain Roller Bushings (Op. and Grease Grease FittingDrive Side)

Roll Sidelay Screw and Brake Linkages Oil Oil Can

Brake Linkage Eccentric Grease Grease Fitting

Plate and Blanket Cylinder Bearings (Operator Side) Grease Grease Fitting

Blanket Cylinder Impression Throw-off (Operator Grease Grease FittingSide)

Horizontal Drive Clutch Grease Grease Fitting

Unit Housing (Drive Side) Oil Drain and Refill

Oil Screen Remove, clean, replace

1. INTRODUCTION.

a. A routine maintenance schedule is criticalfor the production of a quality product plus addingto the longevity of your press. Maintenance is thesystematic inspection of your press and theperforming of maintenance activities on a sched-uled basis. A maintenance schedule may varydepending upon the degree of usage of the press.

b. In this section, there are no instructions asto the opening or lifting of doors, guards andcovers. When working on this unit, it will beobvious as to which of these items must be movedor removed to access areas of the unit.

CAUTION

CAUTION

To avoid personal injury,

proper training is required toperform maintenance oradjustments. Work on thepress only if it is on safe orlocked out. Practice theSTOP-SAFE-READYmethod for safety. Refer tosafety practices and precau-tions at the beginning of thismanual.

c. IMPORTANT - All grease fittings should becleaned before applying grease to prevent contami-nants from entering the bearings .

2. CORROSION CONTROL.

a. Procedure. In order to help preventcorrosion from initiating in the cylinders, thefollowing procedures should be adhered to.

Recommended Lubricants:Oil - Mobile Vactra #4, Exxon Mobile Corp., Fairfax, VAGrease - Mobilith SHC 100, Exxon Mobil Corp., Fairfax, VA


VII-3

Table 3. Maintenance Chart

Interval Item Method

Daily Lubrication Perform all daily lubrication proceduresfrom Lubrication Chart under Daily.

Guards and All guards are closed before each press run;Interlocks Do not circumvent interlocks.

Plate Cylinders At the end of each 8 hour shift, remove theplates and packing. Clean cylinders. Coatwith a light film of oil.

Dampener Rollers At the beginning of each 8 hour shift, in-spect the sock covered roller; replace as nec-essary.

Clean rubber rollers with a solvent recom-mended by the roller manufacturer.

Blankets Inspect surface for damage or wear. Cleanwith recommended solvent. Replace asnecessary.

Ink Fountain, Clean with recommended solvent as necess-Form, and ary.

Transfer Rollers

Dampener At the beginning of each 8 hour shift, in-Fountains spect, clean as necessary.

Lead Rollers Inspect, clean as necessary.and Water Pan

Web Scanners At the beginning of each 8 hour shift, clean(if equipped) with a soft, lint free cloth.

Dampener At the beginning of each 8 hour shift, in-Circulation spect, clean as necessary. Check for proper

System pH or Conductivity of the solution.

Pneumatic At the beginning of each 8 hour shift, in-System spect the filters and sediment bowls.

(if equipped) Clean as necessary according to manufactur-ers instructions.

General Good housekeeping promotes high quality,minimal waste, high efficiency, and safety.

Weekly Lubrication Perform all weekly lubrication proceduresfrom Lubrication Chart under Weekly

Ink and Dampener Check roller settings as necessary to main- Roller Settings and tain quality. Refer to Roller Adjustment

Cleaning section of the manual. Clean with recom-mended solvent as necessary.


VII-4


Table 3. Maintenance Chart (Con’t.)

Dampener Drain and clean according to manufacturers Circulation instructions. See Dampener System in this

System section.

Wash-up Attachment Inspect, clean as necessary. Replace scraperblade if badly nicked.

Dampener Form Inspect, clean with recommended solventRollers to remove gum, ink, lint buildup.

Dampener Drums Inspect, clean as necessary. Treat rollersthat are not water receptive with a con-centrated fountain etch and 14 baume gumarabic.

Blankets Inspect surface and wash with a recom-mended deglazer. Replace if necessary.

Bi-Monthly Blankets Measure blanket height with chosenPacking Gauge. Repack or replace asnecessary.

All Form and Check settings and make necessary ad- Transfer Rollers justments. Refer to Roller Adjustment

section of this manual.

Monthly Lubrication Perform all monthly lubrication proceduresfrom Lubrication Chart under Monthly.

All Rollers Inspect bearing and bracket conditions.

Controls Check the operation of all switches andpushbuttons.

Drive Belts Inspect for wear, replace as necessary.

Guards Inspect for loose, broken, or guards that havebeen removed. Clean or replace as neces-sary.

Ink Fountain Blade Inspect fountain blade for wear; replace asnecessary.

Every 3 Months Dampener Motor Inspect; replace as necessary.

Ink Feed Roller to Check the setting; adjust as necessary.Ink Fountain Roller

Setting

Iron Check settings on plates and blankets.to Adjust as necessary.

Iron


VII-5


Table 3. Maintenance Chart (Con’t.)

All Form and Transfer Check roller durometer and roller bearings.Rollers

Dampening System Flush and clean dampening system accordingto the manufacturer’s instructions.

Every 6 Months Web Break Detectors Inspect and check for proper operation.

Press Drive Motor Inspect and maintain according toand Drive Belts manufacturer’s instructions. Check and adjust

drive belts as necessary.

Annually or Lubrication Perform all annual lubrication procedures as usage from Lubrication Chart under Annual. requires

CAUTION

CAUTION

Known corrosive elements to thecylinders include, but are not limitedto – chlorine, fluorine, and ammonia.These elements may be present invarious cleaners or solvents in someform. (Products with ingredientslisting “chloro” in their formula descrip-tion are made with chlorine or chlo-rides). Water solutions should alsobe checked for these elements.Blankets may be manufactured withone or more of these elements, andcould be released during use whencombined with fluids used in theprinting operation.

Prolonged contact of dissimilarmetals, such as aluminum (plates) ona bare cylinder, may also have atendency to cause corrosion.

(1) Plate Cylinders. After each produc-tion run:

(a) Remove plates and any packingmaterial.

(b) Wipe plate cylinders with solvent.(See “Caution” above.)

(c) Wipe cylinders dry with a cleancloth.

(d) Wipe plates and packing materialdry if re-using.

(e) Coat the cylinders with a light filmof oil or grease.

(f) Avoid applying lubricants in areaswhere adhesive needs to stick to the cylinder.

(g) Re-install any packing and plate:

(1) On cylinders designed for useof plates with no packing, it is important to applylubricants between the plate and cylinder. (See“Caution” above.)

(2) on cylinders that have mylarpacking attached with adhesive, the entire innersurface of the mylar, or the entire body of thecylinder, should be coated with a continuous layerof adhesive or grease. In this case, the timebetween cylinder cleaning may be extended to amaximum of 3 months.

(2) Blanket Cylinders. When changingblankets, or a minimum of 1 time every 3 months:

(a) Remove blanket and any packingmaterial.

(b) Wipe blanket cylinders withsolvent. (See “Caution” above.)


VII-6

(c) Wipe cylinders dry with a cleancloth.

(d) Coat the cylinders with a light filmof oil or grease.

(e) Avoid applying lubricants in areaswhere adhesive needs to stick to the cylinder.

(f) Re-install packing and blanket.

b. Reference. Lubricants are used to repelthe elements listed in the “Caution”, and to deterthe formation of corrosion. Areas of the cylinderthat are not open to air and that tend to trapmoisture and fluids against the cylinder surface,such as underneath plates and blankets, are mostsusceptible to corrosion. Recommended lubricantsinclude:

Product Description Manufacturer

Rust Veto Heavy Grease Houghton International, Inc.LPS 1 Greaseless Lubricant LPS Laboratories, Inc.

c. Corrosion Develops. If corrosion is seenon the cylinders, the following procedures shouldbe used to correct:

(1) Check all solutions, solvents, andprinting materials for corrosive elements. (See“Caution” above.)

(2) Mechanically remove as much of thecorrosion as possible, using polishes, compounds,or cleaners that do not contain the known corrosiveelements listed in the “Caution” above.

(3) Apply a “rust converter” to neutralizethe remaining corrosion.

(4) Recommended products include:

Product Description ManufacturerExtend Permatex for Balcamp, Inc.

(5) Wipe cylinders clean and dry, and re-apply lubricants to the cylinders as describedabove.

3. LUBRICATION.

a. Dauphin Graphic Machines, Inc. does notendorse any one brand of lubricant, but relies uponindustry testing and standards for proper ratings.Except under abnormal conditions, lubricants withproper service ratings should be used. If other

lubricants are used, your supplier needs to knowthe application in order to supply you with theappropriate equivalent.

b. When shipped within the U.S., each unitis filled using Mobil VACTRA Oil Number 4 andMobilith SHC-100 grease, or equivalent products.

4. OIL LEVEL.

Figure 7-1. Gear Side View

AB

C

A - Access Doors

B - Oil Inspection Window

C - Oil Drain Plug

CAUTION

CAUTION

Excessive skin contact withoil may cause skin irritationand be harmful. MaterialSafety Data Sheets providesafety precautions to befollowed.

a. (Refer to figure 7-1.) On a daily basis,while the unit is running, check the oil level throughthe inspection window (B) on the drive side of theunit. The following instructions are provided if oil isneeded.


(2) Open either access door (A) and addan appropriate weight gear oil (see paragraph 3)until the oil level is up in the inspection window (B)(approximately 3.5 gallons).

5. OIL CHANGING.

a. (Refer to figure 7-1.) Depending upon theusage of the press, change the oil and clean the


VII-7

strainer approximately every 2500 hours of runningtime or annually, whichever comes first. If the oil isto be changed, wait until after a press run when theoil is warm. To accomplish an oil change:


(2) With a 5 gallon bucket under the drainplug (C), remove the drain plug and open bothaccess doors (A).

(3) Remove and clean the oil strainer byfollowing the instructions provided in paragraph 6below.

(4) Wipe out the inside of the unit toremove any sediment which might have settled inthe bottom. Replace the drain plug (C).

(5) Refill the unit with the recommendedoil lubricant or its equivalent gear oil until the levelis in the inspection window (B) (approx. 3.5 gal.).

(6) Close the access doors (A) and runthe unit.

(7) Check the oil level while the unit isrunning. Add additional oil if necessary.

6. OIL STRAINER.

a. Each time the unit oil is changed, the oilstrainer should be cleaned or replaced (Refer tofigure 7-2.).

Figure 7-2. Oil Pump and Strainer

A

C

B

D

A - Oil Pump

B - Tube Nut

C - Oil Tube

D - Oil Strainer


(2) Drain the unit oil according to theinstructions contained in paragraph 5 above.

(3) Open the left access door (figure 7-1,item A) and locate the Oil Pump (A).

(4) After loosening the oil tube nut (B),remove the oil strainer (D) and oil tube (C) assem-bly.

(5) To remove contaminants, rinse thestrainer (D) in a solvent. The use of a soft brush isadvised to help clean the strainer. If compressedair is used, do not exceed 30 psi (207 kPa).

(6) Reattach the oil tube (C) and oilstrainer (D) assembly and tighten the tube nut (B).

7. GREASE FITTINGS.

a. Lubrication Panel. As shown in figure 7-3, two (2) lubrication panels are located on theOperator side.

Figure 7-3. Lubrication Panel

B

CA

PL CYKBRG

A - Lubrication Panel

B - Lubricate every 8 hours

C - Lubricate every 40 hours

b. Utilizing the lubrication panels provides aconvenient method of lubricating primary compo-nents on either the 10-side and 13-side. Depen-dent on the model type, 5 or 6 additional single


VII-8

Figure 7-4. Independent Lubrication Points

Lube

Lube

LubeLube

Lube Lube

Lube

Lube


VII-9

entry lubrication points are located on the unit.(Refer to figure 7-4.) These additional lubricationpoints are located as follows:

(1) One on each side of the Ink Fountaintray, located on the frame of the unit.

(2) One on each end of the turnbuckleattached to the number 11 and 12 Blanket Rollers.

(3) Two located on the operator side, justunder the number 10 Plate Roller and above theimpression lever linkage.

(4) For Floor Models, one additionallubrication point is located on the upper portion ofthe Roll Stand Brake Assembly.

c. When lubricating the unit via the installedgrease fittings, use an appropriate grease for theintended application. The grease should beabsolutely free of contaminants. Fittings should becleaned before application of grease. Do notovergrease. Wipe off excess grease from fittings,bearings, and sleeves.

d. A hand operated, low pressure, grease guncan be used or an air operated grease gun with nomore than 35 psi (241 kPa) can be used.

8. INK SYSTEM.

a Ink Fountain Cleaning.


(2) Refer to figure 7-5. Being careful notto damage the ink fountain roller (A) or blade (B),remove the ink from the fountain.

(3) If the fountain has ink keys, turn thekeys counterclockwise at least 4 full turns. If thefountain has levers (C), no adjustment is neces-sary.

(4) Turn the handknobs (D) counterclock-wise until the fountain can be lowered. DO NOT letthe fountain drop.

NOTE

Some units are equipped with afountain roller override handle. Withan override handle, the unit does nothave to be operated in order to rotatethe fountain roller. Moving the override

handle up and down will rotate thefountain roller in its normal direction.

(5) Using a recommended ink solvent andrags, clean the fountain and fountain roller.

(6) Once the fountain and fountain rollerare clean, again check to see that the ink keys arebacked off at least 4 full turns.

Figure 7-5. Ink Fountain in "Up" Position

D

C

B

A

A - Ink Roller

B - Ink Blade

C - Ink Fountain Levers

D - Handknob

(7) Swing the fountain back up intoposition and tighten handknobs.

b. Cleaning Rollers.

(1) When two people work as a team,roller cleaning is accomplished safely, easily, andquickly. When using two wash-up trays, bothsides of the unit can be cleaned at the same time.Follow the same steps, at the same time, on theboth sides of the unit.

WARNING

WARNING

Solvents used in the pressroom may


VII-10

emit vapors which are highly volatile.Obtain the Material Safety DataSheets for your solvents and followthe procedures for proper storage andhandling.

WARNING

WARNING

Nip Points - keep hands away fromthe cylinder and roller nip points.Severe injury can occur. Use theSTOP-SAFE system to clean thecylinders and rollers.

(2) Remove the web from the unit.

(3) Disengage the folder.


Figure 7-6. Washup Tray

A

B

A

A - Attachment Bolt

B - Washup Tray

(5) Refer to figure 7-6. Open the guardsabove the ink rollers and locate the attachmentbolts (A). The wash-up tray (B) should be placedsuch that they hangs on the attachment bolts.

(6) Hang the wash-up tray.

(7) Position the roller guards on top of thewash-up tray.

(8) Remove the SAFE and start up theunit.

(9) With the unit running about 4,000 iph,use a squeeze bottle to apply a recommendedsolvent to the ink rollers. Apply the solvent throughthe mesh of the guard.

(10) Continue to apply solvent to the rollers

until the rollers are clean. Remember, too muchsolvent will drip down onto the plate cylinder andthe dampening rollers. Wait until the rollers appeardry before adding more solvent to the rollers.

(11) Stop and put the press on SAFE.

(12) Open the guard and place twisted ragsinto the wash-up tray. This should absorb most ofthe ink solvent from the tray.

(13) Remove the wash-up tray being surenot to spill the contents.

(14) Clean the wash-up tray being sure toput used rags in a safety approved container.

(15) Wipe the line of ink left by the wash-uptray from the ink vibrator drum roller.

(16) Using the STOP-SAFE method, checkall of the roller ends for ink buildup. Clean asnecessary.

c. Cleaning Cylinders.


(2) Clean all blankets used for the run witha recommended ink solvent. Use one solventsoaked rag and one dry rag. The solvent soakedrag is used to break down the ink and buildup onthe blankets, then the dry rag is used to wipe theblanket dry.

(3) After removing the plate and packing,clean the plate cylinder with an ink solvent. Thenapply a thin film of oil to the cylinder surface.

9. DAMPENER SYSTEM.

a. General. The dampening system is acritical part of the printing process. Good house-keeping will assure consistent dampening chemis-try. Dampening solution chemistry affects printquality. A dirty system breaks down the chemistrythus producing poor quality. Use themanufacturer’s instructions for cleaning the damp-ener circulation system. The following is a shortoutline for cleaning.


(2) Drain the circulation system whichincludes the fountains, reservoir, and filtrationsystem if applicable

(3) Fill the reservoir with hot water and


VII-11

circulate for approximately 30 minutes.

(4) Remove the fountain pans and cleanthoroughly.

(5) Drain the circulation system again andclean the reservoir and filter system. Replace thefountains.

(6) Refill the circulation system with a newdampener solution.

b. Feed Roller Sock Installation.


(2) Remove sock roller J from its mountingbracket (refer to figure 7-7) as follows:

a. Put the press on SAFE.

Figure 7-7. Dampener Feed Roller Bracket

A

B

C

A - Bracket

B - Adjustment Bolt

C - Locking Bolt

b. Remove the adjustment bolts (B)from each end of the dampener feed roller.

c. Loosen the locking bolt (C) ateach end of the dampener feed roller.

d. Remove the dampener feed rollerfrom the brackets (A) at each end.

(3) Remove the old covering with a razorblade being careful not to damage the rubber roller.

(4) Clean the roller with a recommended

ink solvent or blanket wash.

(5) Measure and cut a length of sockmaterial approximately four inches longer than thelength of the roller.

(6) Slide the sock material over the fibertube supplied with the unit. Place the tube over theroller.

(7) While standing the roller on end, holdonto the sock and one end of the roller togetherand pull the tube off of the roller; leaving the sockon the roller.

(8) Place the tube over the roller and workthe sock back onto the tube for about 2/3 thelength of the roller.

(9) While holding the sock tightly onto thetube, push the tube down to stretch the sock overthe roller.

(10) Remove the tube and tie the overlap ofsock material with a plastic tie. Be sure the sockmaterial is not twisted. Roll the remaining over-lap over the roller shaft, up to the plastic tie.

(11) Repeat steps 8 through 10 from theother end of the roller.

(12) After completing the feed roller sockinstallation, replace the feed roller into its mountingbrackets and adjust according to roller settingprocedure in this section of the manual.

10. ROLL STAND BRAKE BLOCKS.

a. Floor units with roll stands require addi-tional application of lubricants. Refer to figure 7-4for locations of independent grease fittings.

b. The following information is provided whenchanging brake blocks is necessary (refer to figure7-8). Prior to changing the brake blocks, allow thebrake blocks to “cool-down” after the press run.


(2) With the brake shoe assembly open,remove the cotter pin (C) and clevis pin (D) from thebrake block assembly (A).


VII-12

Figure 7-8. Roll Stand Break Block Assembly

D

C

C

A

B

BC

A

A - Brake Block

B - Brake Shoes (Wooden)

C - Clevis Pin

D - Cotter Pin

Opened Brake Shoe Assembly

Rear View - Closed Brake Shoe Assembly

(3) Remove the old brake blocks (A) bysliding them off the bracket that supports the brakeblock assembly.

(4) If you are choosing to replace just thewooden brake shoes (B), the shoes will attach tothe block mount by either 4 wood screws (throughthe base of the block mount) or by 2 bolt and nutsets which pass through the block mount and shoelaterally.

(5) Install the new brake shoes by slidingthem onto the brake block (A) bracket. Make sure

that the 1 - 1/2 inch (38mm) face of the block isfacing the brake tension handwheel (or as you arefacing the operators side of the unit, the 10-side). Ifthe brake blocks are improperly positioned, loss oftension control will result.

(6) After aligning the hole of the brakeblock assembly (A) with the hole of the brake blockbracket, replace the clevis pin (C) and cotter pin(D).


VIII-1

SECTION VIII - Direct PrintingThe Method ---------------------------------------------------------------------------------------- VIII-2The Reverse Image ------------------------------------------------------------------------------------ VIII-2The Impression ---------------------------------------------------------------------------------------- VIII-2The Registration ---------------------------------------------------------------------------------------- VIII-2The Conversion ---------------------------------------------------------------------------------------- VIII-2

Governor Roller To Compensator Conversion --------------------------------------------- VIII-2Compensator to Governor Roller Conversion ---------------------------------------------- VIII-2

SECTION VIII

DIRECT PRINTING


VIII-2

1. THE METHOD.

a. Depending upon the configuration of theprinting job, in direct printing, one unit is used toprint two colors, on one side of the web.

b. The web passes between the blanketcylinders in its normal travel, but then wrapsaround the 13 side blanket cylinder and proceedsout from between the blanket and plate cylinder.

c. The first color comes from the 10 sideblanket and the second color comes from the 13side plate.

d. The 13 side blanket functions as a com-mon-impression-cylinder.

e. The plate on the 13 side prints directlyonto the web, therefore the image must be inreverse. The plate must be underpacked tocompensate for the thickness of the web and aconversion apparatus is needed to change thegovernor roller assembly to a compensator adjust-ment. (Figure 8-1)

2. THE REVERSE IMAGE.

a. The direct printing plate prints directly ontothe web. Therefore, it is necessary to have areversed image on that plate in order to produce aright-reading image on the web. There are 3methods to produce the reverse image.

(1) Assemble the negative so that thebase side is against the plate by simply flippingover the film. This works well for coarse line workbut not for high quality.

(2) Use a duplicating contact film toproduce a negative from a negative but in theprocess causing the emulsion side of the film tochange from the wrong reading side to the rightreading side. Consult your film customer servicerepresentative.

(3) Place the film on the film board of yourprocess camera with the emulsion facing the filmboard. This method may have an adverse filteringand/or flaring affect because of the exposurethrough the film base.

3. THE IMPRESSION.

a. To obtain proper impression squeezebetween the 13 cylinder plate and the web, mea-sure the thickness of the web with a graphic arts

micrometer. Subtract the thickness of the webfrom your normal amount of plate packing.

b. If the normal press run uses no packing,have on hand thinner plates so that packing sheetscan be used to control the amount of impressionsqueeze.

4. THE REGISTRATION.

a. Use the plate sidelay handwheel to adjustfor image registration across the web.

b. Circumferential register between the first(offset) color and the second (direct) color isadjusted by the circumferential register handwheellocated on the operator’s side of the unit.

5. THE CONVERSION.

a. To register the image between the unitprinting direct and the subsequent unit that the webtravels through requires a conversion of thegovernor roller assembly to a compensator assem-bly. (Refer to figure 8-1.)

b. Governor Roller to CompensatorConversion.


(2) Remove the cotter key and clevis pinwhich holds the brake linkage to the roller lever.

(3) See Figure 8-1. Position the adjustingstud (B) on the compensator shaft (A) so that itcan be inserted into the compensator bracket (D).

(4) Insert the swivel stud (C) into the rollerlever and the adjusting stud (B) into the compensa-tor bracket (D).

(5) Secure the compensator assembly byreplacing the cotter key through the swivel stud.

c. Compensator to Governor RollerConversion.


(2) Remove the cotter key from the swivelstud (C).

(3) Remove the swivel stud (C) from theroller lever and remove the adjusting stud (B) fromthe compensator bracket (D).


VIII-3

(4) Reattach the brake linkage to the rollerlever using the clevis pin and cotter key.

Figure 8-1. Direct Print

Compensator Hardware

D

C

B

A

A - Compensator Shaft and Handle

B - Adjusting Nut

C - Swivel Stud

D - Compensator Bracket


VIII-4

Three Colors

on Top of Web - 2 Units

Direct Printing on End Unit

Four Colors


Direct Printing on End Unit

Four Colors


Direct Printing on Middle Unit

Four Colors

on Bottom of Web - 3 Units

Direct Printing on Middle Unit

Figure 8-2. Direct Printing Web Leads


IX-1

SECTION IX - TroubleshootingScumming ---------------------------------------------------------------------------------------- IX-2Tinting ---------------------------------------------------------------------------------------- IX-2Graininess ---------------------------------------------------------------------------------------- IX-2Hickies ---------------------------------------------------------------------------------------- IX-2Stripping ---------------------------------------------------------------------------------------- IX-2Fill-In ---------------------------------------------------------------------------------------- IX-2Slurring ---------------------------------------------------------------------------------------- IX-2Streaking ---------------------------------------------------------------------------------------- IX-2Catch-Up ---------------------------------------------------------------------------------------- IX-3Blinding ---------------------------------------------------------------------------------------- IX-3Loose Web ---------------------------------------------------------------------------------------- IX-3Web Breaks ---------------------------------------------------------------------------------------- IX-3

SECTION IX

TROUBLESHOOTING


IX-2

Problem: SCUMMING - the printing plate ispicking up ink in the non-image area.

Causes: 1. Too much ink2. Insufficient dampening3. Dampener rollers dirty4. Improperly set form rollers5. Improper dampener solution

mixture6. Improperly packed cylinders7. Flattened form rollers8. Blanket damaged or loose9. Improperly processed plates10. Incoming water supply too hard

Problem: TINTING - an overall color tint onthe press sheet.

Causes: 1. Too much dampening solution2. Improper dampener solution

mixture3. Improperly formulated ink

Problem: GRAININESS - a gray or weak im-age characterized by unevenness, particularly inhalftones.

Causes: 1. Dampener motor speed is too fast.2. Insufficient ink3. Insufficient impression4. Blanket is glazed or dirty5. Worn image6. Improperly formulated ink

Problem: HICKIES - White or black spots withrings around them in solid image areas.

Causes: 1. Foreign particles in ink2. Unclean ink and/or dampener

rollers3. Unclean blankets4. Too much lint from paper5. Tacky blanket6. Tacky ink

Problem: STRIPPING - uneven ink distribu-tion in ink train; vibrator drum rollers do not ac-cept ink..

Causes: 1. Dampener solution too acidic2. Rollers are glazed3. Improper roller settings4. Copper plating is worn or desens-

itized on vibrator drums.5. Improperly formulated ink

Problem: FILL-IN - areas around and betweentype, screen tints, and halftone dots accepts inkand plugs up.

Causes: 1. Too much ink2. Improperly set form rollers3. Insufficient dampening4. Overpacked cylinders5. Improperly formulated ink6. Worn plate

Problem: SLURRING - areas of blurred imageacross the web; noticed as an elongation in half-tone and screen tint dots.

Causes: 1. Improper dampener solutionmixture

2. Improperly set form rollers3. Over packed cylinders4. Ink dried on plate5. Worn image area6. Lint build-up on form rollers or

blanket7. Worn roller bearings, eccentrics and/

or sockets

Problem: STREAKING - ink in the non-imagearea running parallel to the cylinders; appears asstreaks across the web.

Causes: 1. Roller bounce caused by heavy formroller settings

2. Improper ink /water balance


IX-3

Problem: CATCH UP - ink in the non-image arearunning circumferentially around the cylinder.

Causes: 1. Insufficient dampening2. Improperly set dampener form roller3. Unclean or badly covered dampener

rollers.

Problem: BLINDING - an image that has lostits ink-receptivity; parts of the image will not print.

Causes: 1. Form rollers set too heavy2. Improper dampener solution3. Improperly processed plate4. Dried ink on image5. Over packed cylinders

Problem: LOOSE WEB - loose or baggy web

between units or between unit and folder.

Causes: 1. Low roll tension2. Improperly set trolley wheels3. Improperly set nipping rollers4. Tacky blankets5. Lint build-up on blankets6. Overpacked blankets

Problem: WEB BREAKS -

Causes: 1. Too much dampener solution2. Improper web tension3. Paper problem


IX-4



X-1

SECTION X - GlossaryA - C ---------------------------------------------------------------------------------------- X-2D - E ---------------------------------------------------------------------------------------- X-3F - H ---------------------------------------------------------------------------------------- X-4I - M ---------------------------------------------------------------------------------------- X-5N - R ---------------------------------------------------------------------------------------- X-6S - V ---------------------------------------------------------------------------------------- X-7W - Z ---------------------------------------------------------------------------------------- X-8

SECTION X

GLOSSARY


X-2

A

Adjustable Idler. An idling roller that moves,or can be adjusted, to control the web.

Angle Bars. A pair of turning bars used totransfer the web from one side of thepress to the other.

Anti-Friction. 1) A machine in which themajority of rotating parts are mounted ina ball or roller bearing. 2) A newspaperpress in which the plate and impressioncylinders, inking roller, and web leadrollers are mounted in roller or ballbearings.

Artificial Tension. The amount of brakingforce which must be applied to a paperroll by mechanical means.

Associate. 1) To bring together. 2) To bringthe folded web from one former togetherwith the folded web from another former.3) To “cross-associate”; to transfer a webfrom one side of the press to the otherside.

Automatic Lead Device. A mechanicaldevice for leading a web from a paperroll to a printing couple.

Automatic Paster. 1) by means of specialequipment, attaching a new roll of paperto an expiring web without stopping thepress. 2) The equipment used for attach-ing a new roll of paper to the expiringweb without stopping the press.

B

Backlash. 1) Machinery : the recoil or playdue to loose fitting or worn parts. 2)Printing presses: the play which results inout-of-register print because of loosefitting or worn parts.

Back Pressure. The squeeze pressure be-tween the blanket and impression cylin-ders.

Balloon Former. Former pan located abovethe regular former pan on a folder deliv-

ery.Bar. 1) to turn a shaft or cylinder manually. 2)

Transferring the web from one side of thepress to the other with angle bars. 3) Tochange the direction of the web with aturning bar. 4) An angle bar or turningbar.

Bay Window. An idling roller, or series ofrollers, mounted on the side of the presssuperstructure and set at right angles tothe RTF, and a pair of turning bars set atan angle of 45 degrees. Bay windowsare used to turn the web over.

Blanket Creep. The slight forward move-ment of that part of the blanket surfacethat is in contact with the plate or paper.

Blanket Thickness Gauge. A special mi-crometer for measuring the offset blanketand packing while on the press.

Broadsheet. A full size newspaper page.Actual size depends on the size of thepaper used and the cutoff of the press.

Butt. A roll of paper that has been partiallyused.

C

Catching Up. A term which indicates that thenon-image areas of the plate are begin-ning to take ink.

Chalking. The improper drying of ink; thepigment dusts off due to lack of bindingvehicle.

Cheekwoods. Blocks of wood, fibre orplastic mounted on both sides of a knifein a folder cutting cylinder, usually springloaded.

Chopper. 1) A reciprocating folding blade ora folder using such a blade. 2) The knifeassembly that severs the web during thepaster cycle. 3) A web severing device.

Chuck. A device for fastening a paper roll toa spindle shaft or for holding a rollbetween the spider arms of a reel.

Circumferential Register. 1) The position of


X-3

one plate in relation to another platearound a plate cylinder. 2) The movingor adjusting of a plate or cylinder so thatthe printed design is moved along theweb length.

Cocking Roller. An adjustable idling rollerthat is fixed on one end and adjustable onthe other. Located between the paper rolland the printing couple to even orsmooth the web.

Collect Cylinder. On a 2:1 folder, the sectionto be collected travels around the cuttingcylinder while the next section is broughtinto the folder.

Color Hump. A common-impression-cylinderunit that allows three colors to be appliedto one side of the web at one passthrough the unit.

Compensator. An adjustable idler rollerwhich is moved to vary the length of theweb path; adjusting color register orcutoff position.

Copy. The manuscript or text furnished toprinters.

Copyfitting. Calculations made in order todetermine the proper size of type andwidth of line to fit the copy into a givenarea of space.

Core. A cardboard, wood or metal tube onwhich the rolls of paper are wound.

Core Tension. A tension system that exertsthe braking or restraining action throughthe cores of the roll of paper.

Cross Associate. On a double-wide pressfolder, bringing one web across the pressfrom one former to the folder under theadjacent former.

Cutting Cylinder. A cylinder in a folder thatholds cutting knives which cut the webinto sheets.

Cutting Rubber. In a folding cylinder, arubber bar, inset in the cylinder, whichthe cutting cylinder knife cuts against.

Cutoff. The length of the sheets between

successive cuts in a folder or sheeterdelivery.

D

Dampener. 1) The form rollers which applydampening solution to the plate. 2) Theentire dampening system.

Dampeners. The cloth-covered rollers thatdistribute the dampening solution.

Dampening Solution. A water mixture usedfor wetting the non-image areas of theplate to prevent them for accepting ink.

Dinky. 1) A quarter roll of newsprint. 2) Anewsprint web that is one page wide.

Direct Printing. A method of printing bydirect transfer of the ink from the plate tothe paper.

Double Deck. Color printing equipmentconsisting of two extra printing couplesmounted above a press unit.

Double Truck. A design printed across thecenter pages of a newspaper section sothere is no center margin.

Drive Side. The side of a press on which thedrive shafts and most of the gearing islocated.

Dry-Back. The change in color or finish of anink film as it dries.

Dummy. A set of blank pages made up inadvance to show the size, shape, form,and general style and plan of a printingjob.

E

Emulsification. The breaking down of ink inthe ink train due to excessive dampeningsolution.

Emulsify. To allow to mix. Absorption ofwater by ink.

Expiring Roll. A roll of paper which isapproaching its end and is about to bereplaced by a new roll.


X-4

F

Fan. In a folder, an arrangement of curvedmetal fingers that receives the productfrom the folding rollers and places it onthe delivery conveyor belt.

Fly. 1) In a folder, an arrangement of severalfans on the same shaft. 2) The act ofmanually removing papers, in groups orbundles, from a folder delivery or con-veyor belt.

Folder. A machine which folds and cuts theweb into sheets or signatures.

Folding Blade. In a folding cylinder, a bladewhich raises the product from the cylin-der surface and inserts it between foldingrollers or into folding jaws. (Also knownas a “Tucker Blade”.

Folding Cylinder. 1) In a folder, a cylinderthat holds the cutting rubbers and thetucker blade(s) for making the secondfold. 2) In a folder, any cylinder thatincludes a blade or blades which areinvolved in folding the product.

Folding Rollers. A pair of driven rollersbetween which a sheet is tucked to forma fold.

Form Rollers. The ink and dampening rollerswhich contact the plate surface.

Former. A triangular metal plate over which aweb passes to receive the first fold,parallel to the web travel.

Fountain Blade. The blade in an ink fountainthat is supported under the fountain rollerto control the amount of ink fed to theink train.

Fountain Keys. Thumbscrews used forcontrolling the amount of ink fed into anink train and consequently to the plate.

Fountain Solution. “The water”; solution ofwater, gum arabic, and other chemicalsused to dampen the offset plate and keepthe non-image areas from accepting ink.

Fountain Stops. Movable strips of materialplaced to rest on the dampener fountain

roller to cut down on the amount ofwater to a particular area of the plate.

Full Roll. 1) A roll of newsprint which is fourbroadsheet newspaper pages wide. 2) Aroll of paper which is approximately aswide as the maximum web width of thepress. 3) A new roll of paper.

G

Gear Side. Same as Drive Side.Gear Streaks. Parallel streaks appearing

across printed sheet at same interval asgear teeth on cylinder.

Ghosting. A process in which heavy removalof ink, by a solid or other heavily inkedareas, results in ink starvation to anotherarea.

Governor Roller. A movable idling rollerlocated between the paper roll and theprinting couple; it is either spring loadedor pneumatically loaded. It absorbs theshock of sudden changes in demand forpaper.

Gumming. 1) The treating of surfaces with athin coating of gum arabic as a protectionagainst oxidation and ink-receptivecoatings for image. 2) An aid to desensi-tize an offset plate.

Gum Streaks. Streaks produced by theuneven gumming of plates; most notice-able in halftones.

H

Half Deck. An extra printing couple mountedabove a unit.

Half Roll. A roll of newsprint which is twonewspaper pages wide. This is thewidest roll that can be used on a single-wide press.

Hand Paster. 1) The method of manuallyattaching a new roll of paper to anexpiring web. 2) The splice made bysuch a method.


X-5

Head. 1) The top of a page. 2) The edge of aplate nearest the top of the page. 3) Aheadline.

Hickeys. An imperfection in the printed imagedue to several causes such as ink con-taminated with dry ink, which works itsway onto the plate or blanket.

Horizontal Drive Shaft. 1) The main driveshaft on a unit style press. 2) Anydriving shaft whose axis is parallel to thefloor.

Hydrometer. A generic term for variousinstruments designed to determine thespecific gravity of liquids.

Hydrophilic. Water-receptive.Hydrophobic. Water-repellent.Hygrometer. An instrument for measuring

atmospheric moisture.

I

Idling Roller. A free-turning roller used toguide and control a web through a press.

Image. The area of a plate which is intendedto print.

Imposition. The arranging and fastening ofnegatives or positives to a flat for use inoff-set platemaking.

Impression. 1) The amount of pressure on thepaper needed to print. 2) The place atwhich the printing takes place, i.e. thefirst or second impression. 3) Theprinted image on the paper.

Inch. To run the press slowly by pressing theinch button. The press will stop whenthe button is released.

Ink Train. A series of bare metal cylindersand rubber covered rollers which workthe ink to a thin uniform film and apply itto the printing plate.

Ink Drum. A metal roller, either solid orhollow, that oscillates back and forth toaid in ink distribution.

Ink Fountain. The reservoir that stores andsupplies the ink to the ink train.

Ink Receptive. Having a surface which willrepel water and attract ink.

Ink Repellent. Having a surface which willattract water and repel ink.

J

K

Kicker. In the delivery of a folder, a devicewhich displaces a newspaper in thestream of the delivery to facilitate manualcounting.

Knife. 1) The knife blade(s) on an automaticpaster device that severs the web after thepaste has been made. 2) The knife bladein the cutting cylinder of a folder thatcuts the web into the finished product. 3)The knife in a web severing device thatcuts the web just below the unit.

L

Lead. 1) Lead and web are often used inter-changeably. A lead is usually used tomean the beginning of the web or thebeginning of the roll of paper that isbeing threaded through the press.

2) Also used to mean the web or theweb pattern in the press.

Line Copy. Any copy suitable for reproduc-tion without using a screen; opposite ofcontinuous tone.

M

Make-ready. The proper adjusting of alldevices and assemblies in order toprepare the press for a press run.

Margin. The unprinted area surrounding theprinted image.

Masking Paper. Opaque paper to whichnegatives are attached in image assemblyto produce a flat.

Misting. A mist or fog of tiny ink droplets


X-6

being thrown off a press by the rollers.Flying.

Mottle. Spots, usually in printed solids, due tovariations in ink absorption or paperfinish.

N

Newsprint. A paper made mostly fromgroundwood pulp. Used for printingnewspapers.

Nipping Rollers or Nips. Driven rollers in afolder that guide the folded web from theformer pan to the cutting and foldingcylinders.

O

Operator Side. The side of the press onwhich most of the controls are located.

Overpacking. Packing the plate or blanket toa level that is excessive; above the levelfor proper cylinder pressure.

P

Packing. The paper or plastic used to under-lay a blanket or plate to bring the surfaceto the desired height to establish propercylinder pressures.

Packing Gauge. An instrument used on thepress to measure the difference betweenthe cylinder body and the height of theplate or blanket surface.

Paste. 1) A web splice to join the end of oneroll of paper to a second roll, made in thepressroom.

Paster. 1) The mechanism used to make asplice.

Perfecting Press. A printing press of any kindthat prints both sides of paper in oneoperation or pass through the press.

pH. A scale used for expressing the acidity oralkalinity of solutions.

Picking. The removal of part of the surface of

paper during printing. Picking occurswhen the ink tac is greater than thesurface strength of the paper.

Piling. The sticking or caking of ink pigmenton the plate or blanket.

Pin Holes. The holes made by the pins of thefolding cylinder along one edge of thepage.

Pins. 1) The pins that pull the paper aroundthe folding cylinder. 2) The pins thathold the sections to a cutting or foldingcylinder during a collect run. 3) Any setof pins that are used on the press.

Plate Cylinder. The cylinder on a press towhich the printing plates are attached.

Pre-drive. The device on an automatic pastersystem that brings the new roll of news-print up to the speed of the expiring web.

Printing Couple. The combination of platecylinders and its accompanying blanketcylinders in a 4 cylinder, perfecting unit.

Q

R

Reel. A roll stand that has the capacity to hold3 rolls of newsprint. Automatic pastersare usually equipped on reels.

Register. The placement of the image inrelation to its margins. This placementneeds to be in an identical location onevery sheet that passes through thedelivery.

Rider Rollers. Metal or rigid plastic rollers inthe ink train which serves to break down,transfer, and distribute the ink.

Roller Setting. 1) The degree of contactbetween rollers in inking or dampeningsystems. 2) The act of adjusting roller tovary the contact.

Roller Striping. The ink does not adhere tothe metal rollers in the ink train.

R-T-F. Abbreviation for roller-top-of-former.


X-7

The driven roller directly behind the topof the former on a folder.

R-P-F. Abbreviation for roller-point-of-former. The rollers that begin to fold theweb lengthwise over the nose.

Run. 1) The printing of a product from thetime the press starts until the requirednumber of products have been produced.2) The number of products produced fora given job.

S

Safe. A control pushbutton when actuated willprevent the press from starting.

Scumming. The non-image areas of the platepicks up ink.

Severing Device. A cutting device whichautomatically cuts the web when a webbreak occurs to prevent a wrap up. Thedevice is located between the roll ofpaper and the printing couple.

Sheeter. A device attached to a web press tocut the web and deliver sheets rather thana folded product.

Side Lay. 1) Controls which move the webfrom side to side for side margin adjust-ment. 2) The lateral movement of theplate and cylinder for registration.

Signature. 1) The folded product of a webpress. 2) A printed sheet consisting of anumber of pages that is correctly foldedto form a section of a book or magazine.

Silenced. Not operating; disengaged.Single Wide. A press that prints a web two

newspaper pages wide.Slitter. 1) A circular blade for cutting a web

into ribbons of a desired width. 2) Anycutting device that makes a longitudinalcut.

Spider. The three arm arrangement that holdsthe paper rolls on a reel.

Spot Color. An area printed with a singleadditional color.

Static Neutralizer. A press attachment de-

signed to remove the static electricityfrom the paper .

Striping. 1) The positioning of negatives orpositives on a flat for imposition. 2) Thecondition under which metal rollers failto take up ink in an ink train.

T

Tabloid. A newspaper or newspaper pagewhose dimensions are 1/2 that of abroadsheet.

Tack. The force necessary to split a film ofink.

10-Side. When facing the operator side of theunit, the 10-side is the left-hand side.

Tension. The amount of pull applied to theweb in the direction of travel.

13-Side. When facing the operator side of theunit, the 13-side is the right-hand side.

Tinting. An all-over color tint on the presssheet due to various reasons.

Trapping. The printing of one ink film onanother. Proper trapping depends on therelative tack and thickness of theinkfilms.

Trolley. A narrow roller or wheel whichpresses webs against a driven roller (R-T-F) to control the web and tension.

Tucker Blade. See Folding Blade.Turning Bar. A non-rotating shaft used to

change the direction of travel of a webby 90 degrees and to turn the web over.

U

Undercut. The measured difference betweenthe surface of a cylinder and the height ofthe bearers.

Upper Former. See Balloon Former.

V

Vibrating Roller. A drum or roller thatoscillates back and forth for properdistribution of water or ink.


X-8

W

Wash. A special solvent or solvent mixtureused to clean ink and lint from blanketsand/or rollers.

Wash-up. The process of cleaning rollers,cylinders, plates, and fountains of apress.

Water Fountain. The metal reservoir on apress which holds the dampening solu-tion.

Web. Paper fed from a roll and threadedthrough a press.

Web Break Detector. A device which bringsthe press to a stop whenever a web breakoccurs.

Web Severing Device. See Severing Device.Wrap. Paper wrapped around a press cylinder

or inking rollers as a result of a web break.

X-Y-ZNo vocabulary words that start with X, Y or Z.


XI- 1

SECTION XI - Illustrated Parts BreakdownIllustrated Parts Breakdown--------------------------------------------------------------------------- XI-3

General ---------------------------------------------------------------------------------------- XI-3Group Assembly Parts List (GAPL) --------------------------------------------------------- XI-3Index Number --------------------------------------------------------------------------------- XI-3Part Number----------------------------------------------------------------------------------- XI-3Description ------------------------------------------------------------------------------------ XI-3Vendor Codes --------------------------------------------------------------------------------- XI-3Units per Assembly --------------------------------------------------------------------------- XI-3

Illustrations List


11-1 DGM-430 Press Unit (Floor Model) .................................................... XI-511-2 Frame Sub-Assembly (Floor Unit) ........................................................ XI-811-3 Frame Sub-Assembly (Base Unit) ......................................................... XI-1111-4 Frame Sub-Assembly (Stack Unit) ........................................................ XI-1411-5 Ink and Dampener Form Roller Throwoff Assembly .............................. XI-1711-6 Ink Ball Assembly - Operator Side ........................................................ XI-2011-7 Ink Ball Assembly - Gear Side .............................................................. XI-2311-8 Ink Fountain Assembly .......................................................................... XI-2611-9 Swing Down Ink Fountain Assembly ..................................................... XI-2911-10 Blanket Cylinder Throw-Off Linkage Assembly - Manual Operation ...... XI-3211-11 Circ Shaft Assembly ............................................................................. XI-3511-12 Governor Roller, Tension Control and Lead-In Assembly - Floor Unit .... XI-3811-13 Blanket Cylinder Assembly ................................................................... XI-4111-14 #10 Side Narrow Gap Lock-Up Assembly ........................................... XI-4511-15 Narrow Gap Lock-Up ......................................................................... XI-4811-16 #13 Side Narrow Gap Lock-Up Assembly ........................................... XI-5111-17 #10 Side Wide Gap Lock-Up Assembly ............................................... XI-5411-18 Wide Gap Lock-Up ............................................................................. XI-5711-19 #13 Side Wide Gap Lock-Up Assembly ............................................... XI-6011-20 #10 Cylinder Assembly - Gear Side ...................................................... XI-6311-21 #10 Cylinder Assembly - Operator Side ................................................ XI-6611-22 #10/#13 Sidelay ................................................................................... XI-6911-23 #13 Cylinder Assembly - Gear Side ...................................................... XI-7211-24 #13 Cylinder Assembly - Operator Side ................................................ XI-7511-25 Lower Copper Assembly ...................................................................... XI-7811-26 Upper Copper Assembly ...................................................................... XI-81

SECTION XI

ILLUSTRATED PARTS BREAKDOWN


XI- 2

11-27 Water Pan Roller Assembly ................................................................... XI-8411-28 Water Vibrator Assembly ...................................................................... XI-8711-29 Water Vibrator Idler ............................................................................. XI-9011-30 Micro Roller Assembly ......................................................................... XI-9311-31 Micro Shaft .......................................................................................... XI-9611-32 #10 Side Ink Vibrator ........................................................................... XI-9911-33 #13 Side Ink Vibrator ........................................................................... XI-10211-34 Ink Vibrator Assembly .......................................................................... XI-10511-35 #10 Side Water Vibrator ....................................................................... XI-10811-36 #13 Side Water Vibrator ....................................................................... XI-11111-37 Circ. Assembly ..................................................................................... XI-11411-38 Drive Shaft ........................................................................................... XI-11811-39 Oil Pump Assembly .............................................................................. XI-12111-40 Gear Side Cover .................................................................................. XI-12411-41 Paper Roll Sidelay ................................................................................ XI-12711-42 Paper Roll Brake .................................................................................. XI-13011-43 Paper Roll Sidelay and Brake Assembly ................................................ XI-13311-44 Belt Register ......................................................................................... XI-13611-45 Optional Pneumatic Assembly ............................................................... XI-13911-46 Blanket Cylinder Throwoff Linkage - Optional Pneumatics .................... XI-14211-47 Rubber Rollers ..................................................................................... XI-14511-48 Nip Guards .......................................................................................... XI-14711-49 Roller Guards ....................................................................................... XI-15011-50 Upper Roller Guard .............................................................................. XI-15311-51 Outer Roller Guard ............................................................................... XI-15611-52 Operator Side Cover ............................................................................ XI-15911-53 Color Drop Roller ................................................................................ XI-16211-54 Lead-In Roller - Base Unit .................................................................... XI-16511-55 Lead-In Roller and Under Unit Compensator Assembly - Stack Unit ..... XI-16811-56 B1 Swing Compensator ........................................................................ XI-17111-57A Full Page Motorized Compensator - Pre-2001 ...................................... XI-17411-57B Full Page Motorized Compensator - Post-2001 .................................... XI-18011-58 Belt Drive/Covers - Stack ..................................................................... XI-18611-59 Belt Drive/Covers - 2 High ................................................................... XI-18911-60 Belt Drive/Covers - 3 High - #10 Side .................................................. XI-19211-61 Belt Drive/Covers - 3 High - #13 Side .................................................. XI-19511-62 Belt Drive/Covers - 4 High - #10 Side .................................................. XI-19811-63 Belt Drive/Covers - 4 High - #13 Side .................................................. XI-201


XI- 3

1. ILLUSTRATED PARTS BREAKDOWN.

a. GENERAL. The complete Illustrated PartsBreakdown (IPB) contains information applicable tothe Dauphin Graphic Machines DGM-430 PressUnit. It lists and describes the parts necessary forequipment support and is used for requisitioning,identifying parts and for illustrating disassemblyand assembly relationships. When using the IPB,keep in mind that the press is “cutoff specific”.When ordering parts, inform the Customer Service/Parts Department personnel of your cutoff of yourunit.

b. GROUP ASSEMBLY PARTS LIST(GAPL). The GAPL consists of a breakdown of thecomplete unit into subassemblies and detail parts.Attaching parts are generally identified immediatelyfollowing the item they attach. The GAPL is a fourcolumn format. Standard symbols and abbrevia-tions for use on drawings and in technical typepublications are used in the GAPL.

c. INDEX NUMBER. In this column the indexnumbers are assigned in numerical sequence andare essentially in disassembly sequence. After theindex numbers are assigned in this column, theyare then added to the line art exploded view of theequipment / repairable. Exception to the disas-sembly procedure are those items identified as“HARDWARE” which consists of standard nuts,bolts, screws, etc.

d. PART NUMBER. This column lists theDGM prime part number. Because vendor partnumbers change from item to item, the termHARDWARE is utilized to denote common, generalitems used throughout the unit.

e. DESCRIPTION. This column lists the itemnomenclature plus those modifiers necessary toidentify the item. The assemblies, subassemblies,detail parts and attaching parts properly identified(named or indented) to show their relationship tothe assembly. Attaching parts are listed immedi-ately after the part they attach and preceding anydetails of the assembly. All measurements areindicated using English vice Metric measurements(except where specifically identified).

f. VENDOR CODES. Part numbers, otherthan those of the manufacturer, are designated byvendor names in // following the nomenclature ofthe part. Dauphin Graphic Machines, Inc., doesnot endorse any particular supplier/vendor; how-ever it should be noted that standard hardware (i.e,nuts, bolts, screws, etc.) used are of a grade 5 orbetter ASTM standard. The individual vendor partnumbers and vendor names have been excludedfor ease of understanding.

g. UNITS PER ASSEMBLY. This column willlist the total number of each part required perassembly or subassembly and are not necessarilythe total number used in the end item of equip-ment. The letters "AR" (As Required) are used toidentify bulk items. The abbreviation "REF"(Reference) as used, indicates the part has beenlisted and illustrated elsewhere in the IPB and isincluded in the present listing for reference only.

NOTE: Hardware items (i.e., bolts, washers,nuts, pins, etc.) will not be shown in pictureformat; however, they are provided an IndexNumber for reference purposes.


XI- 4

ILLUSTRATIONS AND PARTS


XI- 5

Figure 11-1. DGM-430 Press Unit (Floor Model)

51 (Location

shown only)

38

44

52

53

54

55

56

57

50

35

36

37

17

21

31

32

33

34

1

45

5

6

23

24

25

26

27

28

29

30

7

2

3

4

39

40

46

47

41

42

43

8

9

10

11

12

13

14

15

16

18

19

20

22

48

49


XI- 6

INDEX PART DESCRIPTION

NO. NUMBER 1 2 3 4 5 6 7

UNITS

PER

ASSY

DGM-430 PRESS, DAUPHIN GRAPHIC MACHINES, INC / 430 MODEL 11 SAF2150 • FRAME / FLOOR UNIT / 21 1/2” ............................................ 1

SAF2200 • FRAME / FLOOR UNIT / 22” .................................................. 1

SAF2275 • FRAME / FLOOR UNIT / 22 3/4” ............................................ 1

SAB2150 • FRAME / BASE UNIT / 21 1/2” .............................................. 1

SAB2200 • FRAME / BASE UNIT / 22” ..................................................... 1

SAB2275 • FRAME / BASE UNIT / 22 3/4” .............................................. 1

SAS2150 • FRAME / STACK UNIT / 21 1/2” ............................................ 1

SAS2200 • FRAME / STACK UNIT / 22” ................................................... 1

SA2275 • FRAME / STACK UNIT / 22 3/4” ............................................ 1

2 ASSEMBLY • • INK AND DAMPENER FORM ROLLER THROW-OFF ..... 1

3 ASSEMBLY • • INK BALL - OPERATOR SIDE ........................................... 1

4 ASSEMBLY • • INK BALL - GEAR SIDE ..................................................... 1

5 ASSEMBLY • • INK FOUNTAIN ................................................................... 1

6 SADGM890-2 • • • INK SWING DOWN FOUNTAIN ..................................... 2

7 ASSEMBLY • • BLANKET CYLINDER THROW-OFF LINKAGE ................ 1

8 ASSEMBLY • • CIRC SHAFT ....................................................................... 1

9 ASSEMBLY • • GOVERNOR ROLLER, TENSION CTRL, AND LEAD-IN .. 1

10 ASSEMBLY • • BLANKET CYLINDER......................................................... 1

11 ASSEMBLY • • #10 SIDE NARROW GAP LOCK-UP ................................. 1

12 SA100029 • • • NARROW GAP LOCK-UP ............................................. 2

13 ASSEMBLY • • #13 SIDE NARROW GAP LOCK-UP ................................. 1

14 ASSEMBLY • • #10 SIDE WIDE GAP LOCK-UP ........................................ 1

15 SA91835 • • • WIDE GAP LOCK-UP .................................................... 2

16 ASSEMBLY • • #13 SIDE WIDE GAP LOCK-UP ........................................ 1

17 ASSEMBLY • • #10 CYLINDER - GEAR SIDE ............................................ 1

18 SA51945 • • • CIRC ASSEMBLY .......................................................... 1

19 ASSEMBLY • • #10 CYLINDER - OPERATOR SIDE .................................. 1

20 SA48879 • • • #10 AND #13 SIDELAY .................................................. 2

21 ASSEMBLY • • #13 CYLINDER - GEAR SIDE ............................................ 1

22 ASSEMBLY • • #13 CYLINDER - OPERATOR SIDE .................................. 1

23 ASSEMBLY • • LOWER COPPERS ............................................................ 2

24 ASSEMBLY • • UPPER COPPERS............................................................. 2

25 ASSEMBLY • • WATER PAN ROLLER ....................................................... 1

26 ASSEMBLY • • WATER VIBRATOR ............................................................ 1

27 SA22141-10 • • • #10-SIDE WATER VIBRATOR ....................................... 1

SA22141-13 • • • #13-SIDE WATER VIBRATOR ....................................... 1

28 SA70170 • • • WATER VIBRATOR IDLER ............................................ 2

29 ASSEMBLY • • MICRO ROLLER ................................................................. 2

30 SA108643-3 • • • MICRO SHAFT ............................................................... 2


XI- 7


NO. NUMBER 1 2 3 4 5 6 7

UNITS

PER

ASSY

31 ASSEMBLY • • INK VIBRATOR/INK FOUNTAIN DRIVE ............................. 1

32 SA16366 • • • #10-SIDE INK VIBRATOR .............................................. 1

SA16367 • • • #13-SIDE INK VIBRATOR .............................................. 1

33 ASSEMBLY • • DRIVE SHAFT..................................................................... 1

34 ASSEMBLY • • GEAR SIDE COVER .......................................................... 1

35 ASSEMBLY • • PAPER ROLL SIDELAY AND BRAKE .............................. 1

36 SA71624 • • PAPER ROLL SIDELAY ..................................................... 1

37 SA94282-3 • • PAPER ROLL BRAKE........................................................ 1

38 SADG89706 • • • BELT REGISTER ............................................................ 1

39 ASSEMBLY • • PNEUMATICS (OPTIONAL) ............................................... 1

40 ASSEMBLY • • BLANKET CYLINDER THROW-OFF LINKAGE / .............. 1OPTIONAL PNEUMATICS /

41 ASSEMBLY • • RUBBER ROLLERS ........................................................... 2

42 ASSEMBLY • • NIP GUARDS ...................................................................... 1

43 ASSEMBLY • • ROLLER GUARDS ............................................................. 1

44 ASSEMBLY • • UPPER ROLLER GUARD .................................................. 1

45 ASSEMBLY • • OUTER ROLLER GUARD .................................................. 1

46 ASSEMBLY • • OPERATOR SIDE COVER ................................................ 1

47 ASSEMBLY • • COLOR DROP ROLLER ..................................................... 1

48 ASSEMBLY • • LEAD-IN ROLLER - BASE UNIT ........................................ 1

49 ASSEMBLY • • LEAD-IN ROLLER & SWING COMP - STACK UNIT ......... 1

50 ASSEMBLY • • B1 SWING COMPENSATOR ............................................. 1

51 ASSEMBLY • • FULL PAGE MOTORIZED COMPENSATOR .................... 1

52 ASSEMBLY • • BELT DRIVE/COVERS (STACK UNIT ONLY) ................... 1

53 ASSEMBLY • • BELT DRIVE/COVERS (2 HIGH ONLY) ............................ 1

54 ASSEMBLY • • BELT DRIVE/COVERS (3 HIGH - 10 SIDE) ...................... 1





XI-8

Figure 11-2. Frame Sub-Assembly (Floor Unit) (1 of 2)

3

911

13

11

129

4

9

2

7

88

6

5

6

1

8

7


XI-9

Figure 11-2. Frame Sub-Assembly (Floor Unit) (2 of 2)

6

12

3

4

5

7

89


XI-10

1 2C2789 • OPERATOR SIDE FRAME 21 1/2” ........................................ 1

2C2889 • OPERATOR SIDE FRAME 22” .............................................. A/R

2C2989 • OPERATOR SIDE FRAME 22 3/4” ........................................ A/R

2 1C2789 • GEAR SIDE FRAME 21 1/2” .................................................. 1

1C2889 • GEAR SIDE FRAME 22” ........................................................ A/R

1C2989 • GEAR SIDE FRAME 22 3/4” .................................................. A/R

3 4C2989FCF • • CROSS FRAME (FLOOR) .................................................. 1

4 3C2989FCF • • CROSS FRAME (#13 SIDE) .............................................. 1

5 5C2989FCF • • CROSS FRAME (#10 SIDE) .............................................. 1

6 DGM890-1 • • INK FOUNTAIN SUPPORT ................................................. 2

7 HARDWARE • • • 1/2 - 13 X 3 HEX HEAD BOLT ........................................ 8

8 HARDWARE • • • #7 X 2 1/2 TAPER PIN W/THREADS (NOT SHOWN) .. 8

9 HARDWARE • • • 5/8 LOCK WASHER ....................................................... 16

10 HARDWARE • • • 5/8 -11 X 1 1/2 HEX HEAD BOLT................................... 8

11 HARDWARE • • • 5/8 -11 X 2 HEX HEAD BOLT ......................................... 12

12 HARDWARE • • • 5/8 -11 X 2 SOCKET HEAD CAP SCREW .................... 4

13 HARDWARE • • • 7/8 - 9 X 4 LEVELING BOLTS ........................................ 4

14 HARDWARE • • • 7/8 - 9 JAM NUT (OPTIONAL - NOT SHOWN) .............. 4

15 D1230-2 • • STEP, OPERATOR EXTENDED (NOT SHOWN) .............. 1

16 E1234-1 • • • BRACKET, RIGHT SIDE STEP (NOT SHOWN) ............ 1

17 E1234-2 • • • BRACKET, LEFT SIDE STEP (NOT SHOWN) .............. 1


NO. NUMBER 1 2 3 4 5 6 7 UNITS

PER

ASSY


XI-11

Figure 11-3. Frame Sub-Assembly (Base Unit) (1 of 2)

10

12 6

6

10

10

9

8

107

10

63

610

10

6

1

5

11

2

4

5

2


XI-12

Figure 11-3. Frame Sub-Assembly (Base Unit) (2 of 2)

1

3

2

4


XI-13

1 2C3789 • OPERATOR SIDE FRAME, 21 1/2” ....................................... 1

2C3889 • OPERATOR SIDE FRAME, 22” ............................................. A/R

2C3989 • OPERATOR SIDE FRAME, 22 3/4” ....................................... A/R

2 DGM890-1 • INK FOUNTAIN SUPPORT ..................................................... 2

3 DG897BP • BASE PLATE (BASE UNIT) ................................................... 1

4 1C3789 • GEAR SIDE FRAME, 21 1/2” ................................................. 1

1C3889 • GEAR SIDE FRAME, 22" ....................................................... A/R

1C3989 • GEAR SIDE FRAME, 22 3/4" ................................................. A/R

5 HARDWARE • • 1/2 - 13 X 3 HEX HEAD BOLT ............................................ 8

6 HARDWARE • • 1/2 - 13 X 1 3/4 HEX HEAD BOLT ...................................... 20

7 HARDWARE • • 7/8 - 9 X 4 LEVELING BOLT .............................................. 4


9 HARDWARE • • 1/2 - 13 X 1 1/2 SOCKET HEAD CAP SCREW ................ 2

10 HARDWARE • • 1/2 LOCK WASHER ........................................................... 24

11 HARDWARE • • #7 X 2 1/2 TAPER PIN W/THREAD (NOT SHOWN) ......... 8

12 HARDWARE • • #7 X 3 TAPER PIN W/THREAD (NOT SHOWN) ............... 4



PER

ASSY


XI-14

Figure 11-4. Frame Sub-Assembly (Stack Unit) (1 of 2)

8

7

1

2

3

4

7

56


XI-15

Figure 11-4. Frame Sub-Assembly (Stack Unit) (2 of 2)

3

21

4


XI-16

1 2C4789 OPERATOR SIDE FRAME, 21 1/2” ........................................... 12C4889 OPERATOR SIDE FRAME, 22” .................................................. A/R2C4989 OPERATOR SIDE FRAME, 22 3/4” ........................................... A/R

2 5C4989FCF • CROSS BRACE ...................................................................... 2

3 DGM890-1 • INK FOUNTAIN SUPPORT ..................................................... 2

4 1C4789 • GEAR SIDE FRAME, 21 1/2” ................................................. 1

1C4889 • GEAR SIDE FRAME, 22” ....................................................... A/R

1C4989 • GEAR SIDE FRAME, 22 3/4” ................................................. A/R




8 HARDWARE • • #7 X 2 1/2 TAPER PIN W/THREAD (NOT SHOWN) ......... 8



PER

ASSY


XI-17

Figure 11-5. Ink and Dampener Form Roller Throw-Off Assembly (1 of 2)

15

7 45

6

7

64

5 43 2

1

23

4

65

4

2

1

34

6

5 8

14

16

10

12

8

11

16

12

10

913

14

15

109

11


XI-18

Figure 11-5. Ink and Dampener Roller Throwoff Assembly (2 of 2)

1

3 45 7

89

11

16


XI-19

ASSEMBLY INK AND DAMPENER FORM ROLLER THROW-OFF.............. REF(See Fig 11-1, Item 2 for NHA)

1 119953 • 3/4 X 46" THROW-OFF SHAFT .............................................. 4

2 HARDWARE • • 3/4 STEEL SET COLLAR ................................................... 6

3 ST 2450-3 • • BRONZE WASHER ............................................................ 6

4 119950 • • THROW-OFF LINK ............................................................. 12

5 119951 • • CAM ................................................................................ 8

6 HARDWARE • • • 3/16 X 1 1/4 ROLL PIN ................................................... 8

7 40064-1610 • • 3/4 ID SPACER - 1" LONG ................................................ 4

8 12DU16 • • BUSHING ............................................................................ 8

9 94996-2 • • THROW-OFF HUB .............................................................. 4

94996-2-2 • • THROW-OFF HUB// PNEUMATICS OPTION // ................ 4


11 145026 • • THROW-OFF STOP ROD .................................................. 4

12 HARDWARE • • 3/8 X 2 ROLL PIN STOPS .................................................. 4

13 HARDWARE • • • 1/4 - 20 X 1/2 KNURLED POINT SOCKET .................... 4HEAD SET SCREW

14 HARDWARE • • • 1/4 - 20 JAM NUT ........................................................... 4

15 HARDWARE • • • 1/4 - 20 X 1 3/4 SQUARE HEAD SET SCREW ............ 4

16 140765 • • POPPET STOP................................................................... 4

(#13 SIDE SHOWN)(#10 SIDE NOT SHOWN)

(TOTAL OF 4 SETS UTILIZED)



PER

ASSY


XI-20

Figure 11-6. Ink Ball Assembly - Operator Side (1 of 2)

11

4

56

7

8

10

9

3

11

2

1

12


XI-21

Figure 11-6. Ink Ball Assembly - Operator Side (2 of 2)

2

1

4

5

6

7

3

10


XI-22

ASSEMBLY INK BALL, OP SIDE (See Fig 11-1, Item 3 for NHA) ................ REF1 119418-3 • INK BALL ROLLER - 37 1/2 BODY ........................................ 1

119418-4 MOTORIZED INK BALL (OPTIONAL) ................................... 12 62062RS • • BEARING ............................................................................ 1

3 40070D • • .562 ID X 1 1/2 OD X 1/4 MACHINE WASHER ................. 1

4 152549 • • STUD WITH PIN .................................................................. 1

5 HFL-2026 • • BEARING ............................................................................ 1

6 600130-3 • • RATCHET INK BALL ROD END ......................................... 1

7 41440070-2 • • MACHINE WASHER W/COUNTER SINK - OP STUD ...... 1

8 HARDWARE • • • 1/4 - 20 X 3/4 FLAT HEAD SOCKET CAP SCREW ..... 1

9 HARDWARE • • • 1/2 -13 JAM NUT ............................................................ 1

10 B-8 • • • • BLACK BALL - HANDLE END ................................... 1

11 HARDWARE • • • 3/8 X 2 1/2 ROLL PIN - HANDLE POSITIVE STOP ...... 2

12 HARDWARE • • • 3/16 X 1 1/2 ROLL PIN - STUD TO INK BALL ............... 1

(#10 SIDE SHOWN)



PER

ASSY


XI-23

Figure 11-7. Ink Ball Assembly - Gear Side (1 of 2)

18

1614

12

10

8

6

4

3

5

7

5

2

4

6

1

7

9

11

13

1517


XI-24

Figure 11-7. Ink Ball Assembly - Gear Side (2 of 2)

213

4

510

16

1112

13

Photo Not

Available

Item 8

W-06

Photo Not

Available

Item 9

N-06

Photo Not

Available

Item 15

CMRTH-1

Photo Not

Available

Item 14

CMRTH-2


XI-25

ASSEMBLY INK BALL, GEAR SIDE (See Fig 11-1, Item 4 for NHA) ........... REF1 119418-3 • INK BALL ROLLER - 37 1/2 BODY ........................................ 1

119418-4 • INK BALL ROLLER (OPTIONAL MOTORIZED) ..................... 1

2 62062RS • • BEARING ............................................................................ 1

3 40066-2127 • • BEARING SPACER ............................................................ 1

4 108701 (SUP.) • • • SHIM SET ....................................................................... 2

5 108290 • • END CAP ............................................................................ 2


7 HARDWARE • • • 1/4 - 20 X 3/4 HEX HEAD BOLT..................................... 8

8 W-06 (SUP.) • • BEARING LOCK WASHER................................................ 1

9 N-06 (SUP.) • • BEARING NUT .................................................................... 1

10 40072 • • • .752 ID X 1 1/2 OD X 3/16 MACHINE WASHER ........... 1

11 IR1220OH • • HARDENED SLEEVE - CLUTCH BEARING ..................... 1

12 RCB162117 • • TORRINGTON BEARING.................................................... 1

13 99704-2 • • GEAR ................................................................................ 1

14 CMRTH-2 • • • PLASTIC SHIM SET ....................................................... 1

15 CMRTH-1 • • • METAL SHIM .................................................................. 1

16 153568 • • WASHER W/STEP............................................................. 1


18 HARDWARE • • • 3/8 - 16 X 1 HEX HEAD BOLT ........................................ 1

(#10 SIDE SHOWN)



PER

ASSY


XI-26

Figure 11-8. Ink Fountain Assembly (1 of 2)

11

10

9

5

3

2

3

4

6

12

12

87

4

5


XI-27

Figure 11-8. Ink Fountain Assembly (2 of 2)

2

1

4

3a3b

11a 11b


XI-28

ASSEMBLY INK FOUNTAIN ASSEMBLY (See Fig 11-1, Item 5 for NHA) ... REF1 SADGM890-2 SWING DOWN INK FOUNTAIN ASSEMBLY ........................... 12 SA119765 • SWING DOWN INK BLADE ASSEMBLY .............................. 1

3 DG127-1 • LEFT HAND SIDE MOLDED SEAL ........................................ 1

DG127-2 • RIGHT HAND SIDE MOLDED SEAL ...................................... 1

4 160493 • BRACKET - INK FOUNTAIN SEAL ........................................ 2

5 HARDWARE • • 5/16 - 18 X 2 SOCKET HEAD CAP SCREW ..................... 4

6 HARDWARE • • 1/4 - 20 X 3/4 SET SCREW................................................ 2

7 HARDWARE • • 3/8 FLAT WASHER ............................................................ 6



10 HARDWARE • • 1/4 - 28 X 3/8 BUTTON HEAD ALLEN SCREW ................ 5

11 DG9018-3, -4 • COVER ................................................................................ 1

12 HARDWARE • • 1/4 X 3/4 ROLL PIN ............................................................. 2



PER

ASSY


XI-29

Figure 11-9. Swing Down Ink Fountain Assembly (1 of 2)

14

12

1511

10

13

10

13

15

11

5

1

8

7

2

3

4

8

7

6

5

64

9

9

Ink Fountain

Ink Fountain Levers


XI-30

Figure 11-9. Swing Down Ink Fountain Assembly (2 of 2)

4 5

6

1 2

3

7

89

10

15

11


XI-31

SADGM890-2 SWING DOWN INK FOUNTAIN ASSEMBLY (See Fig 11-1, ... REFItem 6 for NHA)

1 DGM890-2 • INK FOUNTAIN SWINGDOWN IRON..................................... 1

2 DGM891S-2 • SHAFT - LEVER ..................................................................... 1

3 DGM891SBP • SUPPORT POST .................................................................... 7

4 DGM891P • ALUMINUM SPACER, PLASTIC ............................................ 18

5 DGM891LV • LEVER EYE ............................................................................ 24

6 DGM891LIN-3 • LEVER ................................................................................ 24

7 DGM891SPR • SPRING ................................................................................ 24

8 DGM891SP • LEVER POST .......................................................................... 24

9 147620 • HANDLE ................................................................................ 2

10 RC3A • • KNOB ................................................................................ 2

11 S100-37 • • SNAP RING ........................................................................ 2

12 HARDWARE • • 5/16 - 18 X 3 3/4" SOCKET HEAD CAP SCREW ............. 7

13 HARDWARE • • 1/8 X 1 1/4 DOWEL PIN ..................................................... 2

14 HARDWARE • • SPRING WASHER ............................................................. 6

15 DGM890-5S • • PIVOT PIN W/FLAT - 1/4 - 20 THREADS .......................... 2



PER

ASSY


XI-32

Fig

ure

11

-10. B

lan

ket

Cylin

der

Th

row

-Off

Lin

kag

e A

ssem

bly

- M

an

ual O

pera

tio

n (

1 o

d 2

)

18

15

10

4

1

2

2

27

27

212

22

01

81

51

3 16

18 2

0

21

22

18

7

27

27

25

26

18

18

27

6

5

81

6

1417

3

18

20

21

22

19

12

14 1

62

6

23 30

24

29

15 13 16 11

1827

27

18

20

21

22

282

7

9


XI-33

Figure 11-10. Blanket Cylinder Throw-Off Linkage Assembly - Manual Operation (2 of 2)

3

56

8

7

9

1

10

11

12

13 18

19

24

2529

1417

20


XI-34

ASSEMBLY BLANKET CYLINDER THROW-OFF LINKAGE ......................... REF(See Fig 11-1, Item 7 for NHA)

1 119420 • IMPRESSION SHAFT ............................................................. 1

2 HARDWARE • • 3/8 X 1 1/2 KEY .................................................................. 2

3 Q4-125 • QUAD SEAL ............................................................................ 1

4 HARDWARE • • 1/8 - 27 NPT STRAIGHT GREASE FITTING ...................... 1

5 TRE-8 • • 1/2 ROD END - 1 1/8 THD. RH THREAD, FULL LENGTH 1

6 TRE-8S • • 1/2 ROD END - 1 1/8 THD. RH THREAD, SHORT LENGTH 1

7 TREL-8 • • 1/2 ROD END - LH THREAD - 1 1/8 THD. FULL LENGTH 1

8 TREL-8S • • 1/2 ROD END - LH THREAD - 1 1/8 THD. SHORT LENGTH 1

9 TRE-8N • • 1/2 ROD END - 1 5/8 THD. RH THREAD, FULL LENGTH 1W/ZERK

10 TRE8NS • • 1/2 ROD END - 1 5/8 THD. RH THREAD, SHORT LENGTH 1W/ZERK

11 TREL-8N • • 1/2 ROD END - LH THREAD - 1 5/8 THD. FULL LENGTH 1W/ZERK

12 TREL-8NS • • 1/2 ROD END - LH THREAD - 1 5/8 THD. SHORT LENGTH 1W/ZERK

13 156765 • • 2 5/8 COUPLING NUT ........................................................ 2

14 108416-2 • • 1 3/8 COUPLING NUT ........................................................ 2

15 HARDWARE • • 1/2 - 20 LOCK NUT ............................................................. 3

16 HARDWARE • • 1/2 - 20 LOCK NUT - LH THREAD ..................................... 4

17 116103 • • 3/4 DIA. - 1/2 - 20 LOCK NUT ............................................ 1

18 156136-3 • • 1/2 X 1 3/8 LINKAGE PIN ................................................... 9

19 156136-4 • • 1/2 X 1 13/16 LINKAGE PIN ............................................... 1

20 108418-2 • • POPPET.............................................................................. 4

21 HARDWARE • • 3/8 - 16 JAM NUT ............................................................... 4

22 HARDWARE • • 3/8 - 16 X 2 SQUARE HEAD SET SCREW ....................... 4

23 HARDWARE • • 3/8 X 2 1/2 ROLL PIN ......................................................... 1

24 52288 • THROW-OFF LEVER - OP SIDE - MANUAL/PNEUMATIC .. 1

25 118306 • THROW-OFF LEVER - GEAR SIDE ...................................... 1

26 HARDWARE • • 1/4 - 20 X 3/8 KNURLED POINT SOCKET ........................ 1HEAD SET SCREW

27 HARDWARE • • 10-24 X 3/8 SOCKET HEAD SET SCREW W/NYLOCK... 10

28 HARDWARE • • 1/4 - 20 X 3/8 SOCKET HEAD SET SCREW .................... 1

29 108643-8 • • 3/4 X 14 IMPRESSION HANDLE - FLOOR UNIT .............. 1

108419-2 • • 3/4 X 18 IMPRESSION HANDLE - BASE UNIT ................. A/R

108419-3 • • 3/4 X 14 IMPRESSION HANDLE - STACK UNIT ............... A/R

30 HARDWARE • • 5/16 - 18 X 3/8 KNURLED POINT SOCKET ...................... 1HEAD SET SCREW



PER

ASSY


XI-35

Fig

ure

11

-11. C

irc S

haft

Assem

bly

(1 o

f 2)

78

6

2

1

9

10

11

10

5

4

3


XI-36

Figure 11-11. Circ Shaft Assembly (2 of 2)

4a4b

5

8

6

1

9

11


XI-37

ASSEMBLY CIRC SHAFT ASSEMBLY (See Fig 11-1, Item 8 for NHA) ...... REF1 159748 • CIRC SHAFT ........................................................................... 1

2 HARDWARE • • 1/4 X 1/2 KEY ..................................................................... 1

3 HARDWARE • • 1/4 - 20 X 3/4 FLAT HEAD SOCKET HEAD SCREWS..... 3

4a 159765 • PLATE - CIRC SHAFT ............................................................ 1

b 159765-2 • PLATE - BLANK (USED W/O SHAFT) .................................. 1

5 Q4-116 • QUAD SEAL - CIRC SHAFT ................................................... 1

6 CIRCORK • • CORK GASKET .................................................................. 1

7 HARDWARE • 3/4 STEEL SET COLLAR ....................................................... 1

8 ST2450-3 • • BRASS WASHER - CIRC SHAFT ..................................... 1

9 16DU16 • BUSHING ................................................................................ 1

10 HARDWARE • • 10-24 X 3/8 SOCKET HEAD DOG POINT SET SCREW .. 2

11 M41HP50H • • CIRC DIAL GAGE ............................................................... 1



PER

ASSY


XI-38

Fig

ure

11

-12

. G

ov

ern

or

Ro

lle

r, T

en

sio

n C

on

tro

l a

nd

Le

ad

-In

As

se

mb

ly -

Flo

or

Un

it (

1 o

f 2

)

26

27

28

29

31

31

32

31

30

25

24

13

11

12

16

20

21

22

23

16

10151

515

16

16

16

10

11

19

14

18

17

4

4

7

5

1

2

4

4

5

5

6

6

24

25

3

9

5

29

6

6


XI-39

Figure 11-12. Governor Roller, Tension Control and Lead-In Assembly - Floor Unit (2 of 2)

1

2 4

5

3

16

18 20 26

27

28

30

29

1917

14

13

32

11

12

15


XI-40

ASSEMBLY GOVERNOR ROLLER TENSION CONTROL LEAD-IN .............. REFROLLER ASSEMBLY (FLOOR UNIT ONLY) (See Fig 11-1, Item 9 for

NHA)1 53429-3 • 3" PIPE ROLLER - 36 LONG.................................................. 1

2 ERX20XLOA • BEARING ................................................................................ 2

3 96343-2 • 1 1/4 TGP GOVERNOR SHAFT - 47 1/2 LONG .................... 1

4 108467 • BUMPER ................................................................................ 4

5 HARDWARE • • 5/8 SAE FLAT WASHER ................................................... 4


7 89812 • LEVER ARM - OPERATOR SIDE .......................................... 1

8 HARDWARE • • 1/4 - 20 X 3/8 SET SCREW................................................ 1

9 HARDWARE • • 3/8 - 16 X 5/8 KNURLED POINT SOCKET ........................ 4HEAD SET SCREW

10 HARDWARE • • #7 X 2 1/2 TAPER PIN ........................................................ 2

11 SS4048-28 • • 1 1/4 ID X 1 1 /2 OD X 1 3/4 BRONZE BUSHING .............. 2

12 AR6216-2 • • 5/8 X 1 3/8 CLEVIS PIN W/FLAT ....................................... 1

13 108469-2 • BRAKE LINKAGE ................................................................... 1

14 90065 • LEVER ARM - GEAR SIDE .................................................... 1

15 108425 • • 1 7/8 LEAD-IN PIPE ROLLER ............................................ 3

16 RAL012NPP • BEARING/COLLAR SET / FAFNIR, COLFS450 .................... 6

17 108643-2 • • 3/4 TGP ROLLER SHAFT - 44 1/2 LONG.......................... 1

18 108642-1 • • 3/4 TGP ROLLER SHAFT W/THREADS - 41 LONG......... 1


20 141745 • ROLLER MOUNTING BLOCK ................................................ 1


22 HARDWARE • • 1/4 20 X 1 SOCKET HEAD CAP SCREW ......................... 1

23 HARDWARE • • 5/16 - 18 X 3/8 SOCKET HEAD CAP SCREW.................. 1

24 HARDWARE • • 1/2 SAE FLAT WASHER ................................................... 2


26 108729 • LEVER - SPRING SHAFT ...................................................... 1

27 97542 • GOVERNOR TENSION BALL ................................................ 1

28 140856 • TENSION CONTROL SPRING................................................ 1

29 108892 • TENSION CONTROL ROD...................................................... 1

30 109657 • KNURLED NUT ....................................................................... 1

31 HARDWARE • • 5/8 - 11 JAM NUT ............................................................... 3

32 97543 • POPPET - TENSION CONTROL ............................................ 1



PER

ASSY


XI-41

Fig

ure

11

-13. B

lan

ket

Cylin

der

Assem

bly

(1 o

f 3)

16

27

24

22

20

8

6

7

7

4

21

21

31

4

15

17

19

11

10

16

18

1

35

21

23

262

5

17

9


XI-42

Figure 11-13. Blanket Cylinder Assembly (2 of 3)

7

48

20

15

1113

2122

Photo Not

Available

Item 1

38877-1SS

Photo Not

Available

Item 16

108369

Photo Not

Available

Item 19

EP-40


XI-43

Figure 11-13. Blanket Cylinder Assembly (3 of 3)

23

24

27


XI-44

ASSEMBLY BLANKET CYLINDER ASSEMBLY (See Fig 11-1, Item 10 ...... REFfor NHA)

1 38877-1SS • BLANKET CYLINDER, STANDARD, 21 1/2” ......................... 1

28877-1SS • BLANKET CYLINDER, STANDARD, 22” ............................... A/R

18877-1SS • BLANKET CYLINDER, STANDARD, 22 3/4” ......................... A/R

2 HARDWARE • • 1/4 - 20 X 1 SOCKET HEAD CAP SCREW ....................... 4

3 HARDWARE • • 1/4 HI COLLAR LOCK WASHER ....................................... 4

4 46456-3 • CAP - GEAR SIDE .................................................................. 1

5 HARDWARE • • PLASTIC SHIM SET - GEAR SIDE .................................... 1

6 HARDWARE • • BRASS SHIM SET - GEAR SIDE ...................................... 1

7 368-902A5 • TIMKEN ROLLER BEARING SET W/RACE AND SPACER . 2

8 149045 • SPACER - GEAR SIDE JOURNAL ........................................ 1


10 HARDWARE • • 5/16 LOCK WASHER ......................................................... 3

11 48643-2 • CAP - OPERATOR SIDE ........................................................ 1

12 HARDWARE • • 7/16 X 2 KEY....................................................................... 1

13 100741 • BLANKET BAR ....................................................................... 1

14 HARDWARE • • 1/4 - 20 X 2 SOCKET HEAD CAP SCREW W/NYLOCK .. 6

15 ACO-56008 • ECCENTRIC - #11 OPERATOR SIDE .................................... 1

ACP-56007 • ECCENTRIC - #12 OPERATOR SIDE (NOT SHOWN) .......... 1

16 108639 • • LOAD WASHER - OPERATOR SIDE ................................ 1



19 EP-40 • CAP PLUG .............................................................................. 1

20 Q4-246 • QUAD SEAL ............................................................................ 1

21 16973 • ECCENTRIC - #11 GEAR SIDE.............................................. 1

13851 • ECCENTRIC - #12 GEAR SIDE (NOT SHOWN) .................... 1

22 104795 • • GEAR HUB (22 3/4”) ........................................................... 1

104795-2 • • GEAR HUB (22, 21 1/2”) .................................................... 1

23 118310-2 • RING GEAR (21 1/2”) .............................................................. 1106562-2 RING GEAR (22”) ........................................................................ A/R118308 RING GEAR (22 3/4”) .................................................................. A/R

24 3424-3 • • SLIP WASHER (21 1/2” AND 22” ONLY) .......................... 4

3424 • • SLIP WASHER (22 3/4” ONLY) ......................................... 6

25 HARDWARE • • 1/2 LOCK WASHER (22 3/4” ONLY) ................................. 4

• • 3/8 HI COLLAR LOCK WASHER (21 1/2” AND 22” ONLY) 6

26 HARDWARE • • 1/2 - 13 X 1 1/2 SOCKET HEAD CAP SCREW ................ 4(22 3/4” ONLY)

HARDWARE • • 3/8 - 16 X 1 SOCKET HEAD CAP SCREW (21 1/2” AND 6(22” ONLY)

27 148639-1 • • LOAD WASHER - GEAR SIDE .......................................... 1

(#11 SIDE SHOWN - 22 3/4 CUTOFF)



PER

ASSY


XI-45

Figure 11-14. #10 Side Narrow Gap Lock-Up Assembly (1 of 2)

7

3

42

5

5

6

8

9

1

3 4

87

10

11

12

10


XI-46


4

2

1

5

11

10


XI-47

ASSEMBLY #10-SIDE NARROW GAP LOCK-UP (See Fig 11-1, ................ REFItem 11 for NHA)

1 18880-3SS PLATE CYLINDER (NARROW GAP - 22 3/4” CUTOFF) .......... 128880-3SS PLATE CYLINDER (NARROW GAP - 22” CUTOFF) ................ 138880-3SS PLATE CYLINDER (NARROW GAP - 21 1/2” CUTOFF) .......... 1

2 149800 • LEVER - AUTOMATIC PLATE LOCK-UP .............................. 1


4 99441 • • THROW-OFF LOCK-UP NUT ............................................. 2

5 SA100029 • NARROW GAP LOCK-UP SUBASSEMBLY ......................... REF

6 HARDWARE • • 8 - 32 X 3/4 SOCKET HEAD CAP SCREW W/NYLOCK .. 4

7 HARDWARE • • 1/4 - 20 X 3/4 HEX HEAD BOLT ......................................... 4


9 HARDWARE • • 1/4 X 1 1/4 DOWEL PIN (REGISTER BLOCK) .................. 1

10 148071 • LOCK-UP REGISTER BLOCK/N.G. ....................................... REF

11 104488-1 • STRIKER PLATE - #10 SIDE.................................................. 1

12 HARDWARE • • 3/8 - 16 X 1/2 SOCKET HEAD CAP SCREW.................... 2



PER

ASSY


XI-48

Figure 11-15. Narrow Gap Lock-Up (1 of 2)

6

1

4

5

3

2


XI-49

Figure 11-15. Narrow Gap Lock-Up (2 of 2)

1

3

4

5

6


XI-50

SA100029 NARROW GAP LOCK-UP (See Fig 11-1, Item 12 for NHA) ..... REF1 99787 • LOCK-UP SHAFT/N.G. ........................................................... 1

2 HARDWARE • • 8 - 32 X 3/8 FLAT HEAD SOCKET HEAD SCREW .......... 16

3 148072 • • LOCK-UP SPRING CLAMP PLATE ................................... 4

4 35044 • • LOCK-UP SPRING/N.G. ..................................................... 8

5 150241 • • ANTI-RATTLE SPRING/N.G. .............................................. 1

6 100029 • • LOCK-UP BAR/N.G. ........................................................... 1



PER

ASSY


XI-51


7

8

9 104

3

2

5

11

12

1

10

8

7

3

4

6

5


XI-52

Figure 11-16. #13 Side Narow Gap Lock-Up Assembly (2 of 2)

4

2

1

5

1110


XI-53

ASSEMBLY #13-SIDE NARROW GAP LOCK-UP (See Fig 11-1, ................ REFItem 13 for NHA)

1 18878-3SS PLATE CYLINDER (NARROW GAP - 22 3/4” CUTOFF) .......... 128878-3SS PLATE CYLINDER (NARROW GAP - 22” CUTOFF) ................ 138878-3SS PLATE CYLINDER (NARROW GAP - 21 1/2” CUTOFF) .......... 1

2 149800 • LEVER - AUTOMATIC PLATE LOCK-UP .............................. 1


4 99441 • THROW-OFF LOCK-UP NUT ................................................. 2

5 SA100029 • NARROW GAP LOCK-UP SUBASSEMBLY ......................... REF

6 HARDWARE • • 8 - 32 X 3/4 SOCKET HEAD CAP SCREW W/NYLOCK .. 4



9 HARDWARE • • 1/4 X 1 1/4 DOWEL PIN (REGISTER BLOCK) .................. 1

10 148071 • LOCK-UP REGISTER BLOCK/N.G. ....................................... REF

11 104488-2 • STRIKER PLATE - #13 SIDE.................................................. 1




PER

ASSY


XI-54

Figure 11-17. #10 Side Wide Gap Lock-Up Assembly (1 of 2)

6 78

10 4

11

12

1

2

7

64

3

4

56

9

35

12

11

4


XI-55

Figure 11-17. #10 Side Wide Gap Lock Up Assembly (2 of 2)

7

23

8 1112

Photo Not

Available

Item 1

18880-2SS


XI-56

ASSEMBLY #10-SIDE WIDE GAP LOCK-UP (See Fig 11-1, ....................... REFItem 14 for NHA)

1 18880-2SS PLATE CYLINDER (WIDE GAP) ................................................ 12 SA91835 • WIDE GAP LOCK-UP ASSEMBLY ....................................... REF

3 104917 • REGISTER BLOCK/W.G. ....................................................... 2

4 HARDWARE • • 5/16 - 18 X 1/2 SHOULDER BOLT ..................................... 4

5 HARDWARE • • 3/16 X 1 1/4 DOWEL PIN ................................................... 4



8 94775 • LOCK-UP CLOSER/W.G. ....................................................... 1

9 HARDWARE • • 1/4 - 20 JAM NUT ............................................................... 1

10 HARDWARE • • 1/4 - 20 X 1/2 BUTTON HEAD CAP SCREW .................... 1

11 94778 • WIDE-GAP U-BOLT ADJUSTING SCREW ............................ 2

12 119471 • • WIDE-GAP U-BOLT BRACKET ......................................... 2



PER

ASSY


XI-57

Figure 11-18. Wide Gap Lock-Up (1 of 2)

1

2

3

4

5

6


XI-58

Figure 11-18. Wide Gap Lock-Up (2 of 2)

6

3

1

2


XI-59

SA91835 WIDE GAP LOCK-UP (See Fig 11-1, Item 15 for NHA) ............ REF1 91835 • LOCK-UP L-BAR/W.G. ........................................................... 1

2 91836 • • LOCK-UP SHAFT/W.G. ...................................................... 1

3 25709 • • LOCK-UP SPRING/W.G. .................................................... 6

4 HARDWARE • • #6 LOCK WASHER ............................................................ 12

5 HARDWARE • • 6 -32 X 1/4 ROUND HEAD MACHINE SCREW ................. 12

6 118873 • • MYLAR SCREW W/NYLOCK ............................................ 2



PER

ASSY


XI-60

Figure 11-19. #13 Side Wide Gap Lock-Up Assembly (1 of 2)

7 6

84 11

3

2

1

12

4

56

10

9

11

12

3

4

6

74

5


XI-61

Figure 11-19. #13 Side Wide Gap Lock Up Assembly (2 of 2)

73

2

811

12

Photo Not

Available

Item 1

18878-2SS


XI-62

ASSEMBLY #13-SIDE WIDE GAP LOCK-UP(See Fig 11-1, ....................... REFItem 16 for NHA)

1 18878-2SS PLATE CYLINDER (WIDE GAP)................................................ 12 SA91835 • WIDE GAP LOCK-UP ASSEMBLY ....................................... REF

3 104917 • REGISTER BLOCK/W.G. ....................................................... 2

4 HARDWARE • • 5/16 - 18 X 1/2 SHOULDER BOLT ..................................... 4




8 94775 • LOCK-UP CLOSER/W.G. ....................................................... 1

9 HARDWARE • • 1/4 - 20 JAM NUT ............................................................... 1


11 94778 • WIDE-GAP U-BOLT ADJUSTING SCREW ............................ 2

12 119471 • WIDE-GAP U-BOLT BRACKET.............................................. 2



PER

ASSY


XI-63

Figure 11-20. #10 Cylinder Assembly - Gear Side (1 of 2)

23

22

14

18

1716

15

14

1213

9

8

1

34

6

2

5

11

12

192021

7

10


XI-64


18

24

7

98

1

5

10

14

15

17

Photo Not

Available

Item 6

116327G


XI-65

ASSEMBLY #10 CYLINDER GEAR SIDE (See Fig 11-1, Item 17 for NHA) . REF1 18880-3SS #10 CYLINDER (NARROW GAP - 22 3/4” CUTOFF) ................ 1

28880-3SS #10 CYLINDER (NARROW GAP - 22” CUTOFF) ...................... 138880-3SS #10 CYLINDER (NARROW GAP - 21 1/2” CUTOFF) ................ 1

2 HARDWARE • • 7/16 x 2 KEY....................................................................... 1

3 HARDWARE • • • 1/4 - 20 X 1 1/4 SOCKET HEAD CAP SCREW ............ 4


5 116327 • CAP - GEAR SIDE .................................................................. 1

6 116327G • CORK GASKET ...................................................................... 1

7 368-902A5 • TIMKEN BEARING SET ......................................................... 1

8 Q4-243 • QUAD SEAL............................................................................ 1

9 16972 • ECCENTRIC .......................................................................... 1

10 17269 • CIRC PLATE............................................................................ 1

11 HARDWARE • • 5/16 HI COLLAR LOCK WASHER ..................................... 3

12 HARDWARE • • 5/16 - 18 X 3/4 BUTTON HEAD CAP SCREW .................. 3

13 HARDWARE • • 5/16 DOWEL PIN ................................................................ 2

14 SA51945 • CIRC SUBASSEMBLY (22 3/4”) ............................................ REF

SA51945-2 • CIRC SUBASSEMBLY (22”) ................................................... REF

SA51945-3 • CIRC SUBASSEMBLY (21 1/2”) ............................................ REF

15 148639-1 • LOAD WASHER ..................................................................... 1

16 HARDWARE • • 5/8 - 11 X 1 1/4 BUTTON HEAD CAP SCREW ................. 1

17 157092-3 • • .531 X .781 X 1.188 SLEEVE ............................................. 1

18 100935 • STUD - CIRC PLATE............................................................... 3





23 HARDWARE • • 1/2 - 13 X 1 1 /4 HEX HEAD BOLT..................................... 324 SA51945-M CIRC SUB-ASSEMBLY (NOT SHOWN)

// USED WITH QUAD TECH MOTORIZATION OPTION //SA51945-2M CIRC SUB-ASSEMBLY (NOT SHOWN)

// USED WITH QUAD TECH MOTORIZATION OPTION //SA51945-3M CIRC SUB-ASSEMBLY (NOT SHOWN)

// USED WITH QUAD TECH MOTORIZATION OPTION //



PER

ASSY


XI-66

Figure 11-21. #10 Cylinder Assembly - Operator Side (1 of 2)

1

2

3

4

2022

23

2424

10

11

12

21

5

6

789

1314

15

16

14

17

18

19


XI-67

Figure 11-21. #10 Cylinder Assembly - Operator Sider (2 of 2)

4

1

5

3

6

20

18

19

1013

16

Photo Not

Available

Item 21

88-LB-03X02

Photo Not

Available

Item 22

89-LB-03X02

Photo Not

Available

Item 24

4638K511


XI-68

ASSEMBLY #10 CYLINDER - OPERATOR SIDE (See Fig 11-1, .................. REFItem 19 for NHA)

1 18880-3SS #10 CYLINDER (NARROW GAP - 22 3/4” CUTOFF) ................ REF28880-3SS #10 CYLINDER (NARROW GAP - 22” CUTOFF) ...................... REF38880-3SS #10 CYLINDER (NARROW GAP - 21 1/2” CUTOFF) ................ REF

2 HARDWARE • • 5/16 - 18 X 1 HEX HEAD BOLT .......................................... 3

3 123472 • OPERATOR SIDE CAP .......................................................... 1


5 25351 • OPERATOR SIDE ECCENTRIC ............................................. 1

6 157092-3 • • .531 X .781 X 1.188 SLEEVE ............................................. 1




10 108639 • LOAD WASHER - OPERATOR SIDE .................................... 1



13 118344 • SIDELAY PLATE..................................................................... 1



16 SA48879 • SIDELAY ................................................................................ REF


18 1084BW • BEVEL WASHER ................................................................... 1

19 108440-2 • SIDELAY LOCKING KNOB .................................................... 1

20 DG155GF • ELBOW BODY ........................................................................ 1

21 88-LB-03X02 • STRAIGHT PIPE FITTING ....................................................... 1

22 89-LB-03X02 • RIGHT ANGLE PIPE FITTING ................................................ 1

23 HARDWARE • • 3/16 OD HIGH PRESSURE GREASE LINE ...................... 1

24 4638K511 • • 1/8 PIPE PLUG ................................................................... 2



PER

ASSY


XI-69

Figure 11-22. #10/#13 Sidelay (1 of 2)

1

2

3

4


XI-70

Figure 11-22. #10/#13 Sidelay (2 of 2)

12

4

3


XI-71

SA48879 #10 and #13 SIDELAY (See Fig 11-1, Item 20 for NHA) .......... REF1 94683 • SIDELAY HANDWHEEL HUB ................................................ 1

2 48879 • SIDELAY BRACKET ............................................................... 1

3 5IDE • ARBOR SHIM .......................................................................... 1

4 5100-262 • • 2 5/8 EXTERNAL SNAP RING ........................................... 1



PER

ASSY


XI-72


13

1015

17

14

15

16

9

8

7

6

5

4

3

2

1

12

11


XI-73


8

9

5

1

1311 12

14

Photo Not

Available

Item 2

1688-B


XI-74

ASSEMBLY #13 CYLINDER, GEAR SIDE (See Fig 11-1, Item 21 for NHA) . REF1 18878-3SS • #13 CYLINDER (NARROW GAP - 22 3/4” CUTOFF) ............ 1

28878-3SS • #13 CYLINDER (NARROW GAP - 22” CUTOFF) .................. 1

38878-3SS • #13 CYLINDER (NARROW GAP - 21 1/2” CUTOFF) ............ 1

2 1688-B • GREASE FITTING - 45 DEGREE ........................................... 2

3 HARDWARE • • 5/16 - 18 X 1 1/4 SOCKET HEAD CAP SCREW .............. 4


5 123348 • RACE END PLATE ................................................................. 1

6 HARDWARE • CORK GASKET ...................................................................... 1


8 149090 • BEARING END PLATE ........................................................... 1


10 HARDWARE • • 3/8 - 16 X 2 1/2 SOCKET HEAD CAP SCREW W/ HI LOCK 3

11 Q4-258 • QUAD SEAL - GEAR SIDE .................................................... 1

12 49001 • SLEEVE - PUMPKIN .............................................................. 1

13 104484 • DRIVE SIDE GEAR HUB, 21 1/2” .......................................... 1

106586-2 • DRIVE SIDE GEAR HUB, 22” ................................................ A/R

70179 • DRIVE SIDE GEAR HUB, 22 3/4” .......................................... A/R

14 142024 • SHIFT LEVER BRACKET ....................................................... 1



17 HARDWARE • • 3/8 X 3/8 SHOULDER BOLT .............................................. 1



PER

ASSY


XI-75


1

2

3

4

20

10

1112

13

14

1516

18

19

98

76

5

24

14

17

2122

23


XI-76

6

5


4

1

3

20

18

10

1316

19

Photo Not

Available

Item 21

88-LB-03X02

Photo Not

Available

Item 22

89-LB-03X02

Photo Not

Available

Item 24

4638K511


XI-77

ASSEMBLY #13 CYLINDER, OPERATOR SIDE (See Fig 11-1, .................. REFItem 22 for NHA)

1 18878-3SS • #13 CYLINDER (NARROW GAP - 22 3/4” CUTOFF) ............ REF

28878-3SS • #13 CYLINDER (NARROW GAP - 22” CUTOFF) .................. REF

38878-3SS • #13 CYLINDER (NARROW GAP - 21 1/2” CUTOFF) ............ REF

2 HARDWARE • • 5/16 - 18 X 1 HEX HEAD BOLT .......................................... 3

3 125527 • OPERATOR SIDE CAP .......................................................... 1


5 16700 • OPERATOR SIDE ECCENTRIC ............................................. 1

6 157092-3 • • .531 X .781 X 1.188 SLEEVE ............................................. 1




10 108639 • LOAD WASHER - OPERATOR SIDE .................................... 1



13 118344 • SIDELAY PLATE..................................................................... 1



16 SA48879 • SIDELAY ................................................................................ REF


18 1084BW • BEVEL WASHER ................................................................... 1

19 108440-2 • SIDELAY LOCKING KNOB .................................................... 1

20 DG155GF • ELBOW BODY ........................................................................ 1

21 88-LB-03X02 • STRAIGHT PIPE FITTING ....................................................... 1

22 89-LB-03X02 • RIGHT ANGLE PIPE FITTING ................................................ 1

23 HARDWARE • • 3/16 OD HIGH PRESSURE GREASE LINE ...................... 1

24 4638K511 • • 1/8 PIPE PLUG ................................................................... 2



PER

ASSY


XI-78

Figure 11-25. Lower Copper Assembly (1 of 2)

22

20

18

16

15

1

29 10

11

13

12

1312

8

14

15

24

107

6

7 986

3

23

24

6

10

7

86 9

7

10

24

14

17

19

21

12

11

1312

13

59

11


XI-79

Figure 11-25. Lower Copper Assembly (2 of 2)

3

1

4

5

8

9

11 1210

16

14

17

1819

20


XI-80

ASSEMBLY LOWER COPPER (See Fig 11-1, Item 23 for NHA) .................. REF1 94492 • COPPER ROLLER .................................................................. 1

2 HARDWARE • • 1 7/8 EXTERNAL SNAP RING ........................................... 2

3 130983 • OPERATOR SIDE BUSHING ................................................. 1

4 95421-3 • GEAR SIDE BUSHING ........................................................... 1

5 123199 • WIPER - GEAR SIDE BUSHING............................................ 1

6 HARDWARE • • 5/16 - 24 X 1 1/2 SOCKET HEAD CAP SCREW W/NYLOCK 4

7 HARDWARE • • 10-24 X 1/4 SOCKET HEAD SET SCREW W/NYLOCK... 4

8 122710 • FORM ROLLER BRACKETS.................................................. 4

9 119954 • POPPET ................................................................................ 4

10 120115 • ANTI-BOUNCE SCREW -1 3/4”.............................................. 4

120115-1 • ANTI-BOUNCE SCREW -1 1/4” // 21 1/2” CUTOFF ONLY // 4

120115-2 • ANTI-BOUNCE SCREW -1 1/2” //22” & 22 3/4” CUTOFFS // 4

11 122810 • ANTI-BOUNCE SPRING ......................................................... 4

12 119975 • L BRACKET (NOT USED ON #13 DRIVE SIDE) ................... 6

13 HARDWARE • • 1/4 - 20 X 1/2 BUTTON HEAD BOLT (ALLEN) .................. 8

14 DGM144 • WIDGET ................................................................................ 2

15 HARDWARE • • 1/4 - 20 X 1/2 FLAT HEAD BOLT (ALLEN) ........................ 2

16 70168 • GEAR ................................................................................ 1

17 113908-2 • BEVEL SPACER .................................................................... 1

18 113906-2 • BEARING HOUSING............................................................... 1

19 5203ATN9 • BEARING ................................................................................ 1

20 113433 • • MACHINE WASHER W/PIN .............................................. 1


22 HARDWARE • • 5/16 - 18 X 3/4 HEX HEAD BOLT ....................................... 1

23 HARDWARE • • 1/4 X 1/4 X .600 KEY .......................................................... 1

24 HARDWARE • • SHIM ................................................................................ 2

(#10 SIDE SHOWN)



PER

ASSY


XI-81

Figure 11-26. Upper Copper Assembly (1 of 2)

21

19

17

15

9

11

10

65

42

1

2

3

76

6

99

10

11

14

13

23

7

89

10

8

9

229

10

9

8

78

7

96

12

13

14

16

18

20


XI-82

Figure 11-26. Upper Copper Assembly (2 of 2)

3

6

4

1

5

1312

15

16

17

11

10

18

19


XI-83

ASSEMBLY UPPER COPPER (See Fig 11-1, Item 24 for NHA) .................. REF1 94492 • COPPER ROLLER .................................................................. 1


3 130983 • OPERATOR SIDE BUSHING ................................................. 1


5 123199 • WIPER - GEAR SIDE BUSHING ............................................ 1

6 759000-6 • EYE BOLTS ............................................................................ 4

7 HARDWARE • • 3/8 X 1 1/2 PIN (TRANSFER BRACKET) W/HOLE ........... 4

8 HARDWARE • • 1/6 X 3/4 COTTER PIN........................................................ 4

9 HARDWARE • • 3/8 - 16 JAM NUT ............................................................... 8

10 108532 • POPPET ................................................................................ 4

11 65996-2 • TRANSFER ROLLER BRACKET ........................................... 2

12 65996-1 • TRANSFER ROLLER BRACKET ........................................... 2

13 DGM144 • WIDGET ................................................................................ 2

14 HARDWARE • • 1/4 - 20 X 1/2 FLAT HEAD BOLT (ALLEN) ........................ 2

15 70168 • GEAR ................................................................................ 1

16 113908-2 • BEVEL SPACER .................................................................... 1

17 113906-2 • BEARING HOUSING............................................................... 1

18 5203ATN9 • BEARING ................................................................................ 1

19 113433 • • MACHINE WASHER W/PIN .............................................. 1



22 HARDWARE • • 1/4 X 1/4 X .600 KEY .......................................................... 1

23 HARDWARE • • SHIM ................................................................................ 2

(#10 SIDE SHOWN)



PER

ASSY


XI-84

Figure 11-27. Water Pan Roller Assembly (1 of 2)

17

16

15

1413

12

56

7

4

19

2

9

10

11

8

6

18

5

87

3

2

1

8

8


XI-85

Figure 11-27. Water Pan Roller Assembly (2 of 2)

1

32

4

5

6

9a9b

15a15b

18

1210


XI-86

ASSEMBLY WATER PAN ROLLER ASSEMBLY(See Fig 11-1, Item 25 ..... REFfor NHA)

1 93547 WATER PAN ROLLER ............................................................... 22 5100-187 • 1 7/8 EXTERNAL SNAP RING................................................ 4


4 143805-2 • OPERATOR SIDE BUSHING ................................................. 2

5 157119-P • WATER PAN BRACKET ........................................................ 4

6 148175 • CLIP ................................................................................ 4


8 HARDWARE • • 3/8 - 16 X 3.4 HEX HEAD BOLT ......................................... 8

9 114016-1 • #10 SIDE WATER PAN .......................................................... 1

114016-2 • #13 SIDE WATER PAN .......................................................... 1

10 750-OD • BRONZE WATER LEVELER.................................................. 2

11 HARDWARE • • 1/4 - 28 STRAIGHT GREASE FITTING (1641B) ................ 2

12 108487 • COUPLING .............................................................................. 2


14 HARDWARE • • 1/8 X 1/8 X 1 KEY ............................................................... 2

15a 02-99193A • #10 SIDE WATER MOTOR .................................................... 1

b 02-99194A • #13 SIDE WATER MOTOR (SHOWN) ................................... 1



18 935PLG • GEAR SIDE BUSHING PLUG ................................................ 2



PER

ASSY


XI-87

Figure 11-28. Water Vibrator Assembly (1 of 2)19

21

24

26

25

20

27 22

8

16

1514

13

12 12

6 5 79

10

42

1

23

5

810

97

11

1212

13

16

11

1514

6

26

2425

23

17

18


XI-88

Figure 11-28. Water Vibrator Assembly (2 of 2)

3 46

7

1

8

9

15

16

11

17

14

1920

21

22

23 25 27


XI-89

ASSEMBLY WATER VIBRATOR (See Fig 11-1, Item 26 for NHA) ................ REF1 103678-1 • 3/4 - 10 RIGHT HAND ROLLER - #13 SIDE ........................... 1

103678-2 • 3/4 - 10 LEFT HAND ROLLER - #10 SIDE ............................. 1


3 130983 • • OPERATOR SIDE BUSHINGS .......................................... 2

4 95421 • • GEAR SIDE BUSHING - #10 SIDE .................................... 1

95422 • • GEAR SIDE BUSHING - #13 SIDE .................................... 1

5 HARDWARE • • • 5/16 -24 X 1 1/2 SOCKET HEAD BOLT W/NYLOCK .... 4

6 119954 • • POPPET - FORM ROLLER ADJUSTMENT ....................... 4

7 73460 • • SOCK ROLLER BRACKET ................................................ 4

8 122710 • • FORM ROLLER BRACKET ................................................ 4

9 157426 • • TRANSFER ROLLER EYE BOLT ...................................... 4

10 HARDWARE • • • 1/2 X 1/2 SHOULDER BOLT .......................................... 4

12011S-2 • • • ANTI-BOUNCE SCREW 1 1/2” // NOT SHOWN - 21 1/2”CUTOFF ONLY //

11 108532 • • POPPET - TRANSFER ROLLER ADJUSTMENT .............. 4

12 HARDWARE • • • 3/8 - 16 JAM NUT ........................................................... 8

13 HARDWARE • • • 10 - 24 X 1/4 SET SCREW W/NYLOCK........................ 4

14 120115 • • ANTI-BOUNCE SCREW 1 3/4 ............................................ 4

15 122810 • • ANTI-BOUNCE SPRING ..................................................... 4

16 119975 • • L-BRACKET (ANTI - BOUNCE) .......................................... 3

17 157943 • • OSCILLATOR ARM BOLT W/1 X 8 THREAD .................... 2

18 HARDWARE • • • 1" LOCK WASHER ........................................................ 2

19 34625 • • GUIDE ROD - 3/4 X 7 DOWEL ........................................... 2

20 SA22141-10 • • WATER VIBRATOR ASSEMBLY - #10 SIDE (SHOWN) .. REF

SA22141-13 • • WATER VIBRATOR ASSEMBLY - #13 SIDE ................... REF

21 SA70170 • • IDLER SUB-ASSEMBLY .................................................... 2

22 141206 • • PIVOT ARM - OSCILLATOR .............................................. 2

23 3424 • • • SLIP WASHER ............................................................... 2

24 HARDWARE • • • 1/4 - 20 FLAT HEAD BOLT (ALLEN HEAD) .................. 4

25 DGM144 • • • WIDGET .......................................................................... 4

26 HARDWARE • • • SHIM ............................................................................... 4

27 SS1620-10 • • • 1/2 X 5/8 X 5/8 BUSHING ............................................... 4



PER

ASSY


XI-90

Figure 11-29. Water Vibrator Idler (1 of 2)

3

1

2

3


XI-91

Figure 11-29. Water Vibrator Idler (2 of 2)

1

32


XI-92

SA70170 WATER VIBRATOR IDLER ASSEMBLY (See Fig 11-1, ........... REF Item 28 for NHA)

1 70170 • IDLER GEAR ........................................................................... 1

2 WK2587 • BEARING ................................................................................ 1

3 5000-150 • • 1 1/2 I.D. INTERNAL SNAP RING ...................................... 2



PER

ASSY


XI-93

Figure 11-30. Micro Roller Assembly (1 of 2)

811

6

3

13

1

2

3

9

5

4

4

45

5

10

12

7


XI-94

Figure 11-30. Micro Roller Assembly (2 of 2)

23

7

10

13

9

1

A

A


XI-95

ASSEMBLY MICRO ROLLER ASSEMBLY (See Fig 11-1, Item 29, for NHA)REF

1 95891N MICRO ROLLER - PLASTIC COATED ...................................... 22 62062RS • 6206 BEARING ....................................................................... 4

3 148137 • SPLIT ECCENTRICS............................................................... 4


5 HARDWARE • • 1/4 - 20 X 3/4 SOCKET HEAD CAP SCREW .................... 8

6 HARDWARE • • 3/4 SPLIT COLLAR ............................................................. 2

7 144600 • MICRO BUSHING ................................................................... 2

8 HARDWARE • 1 1/4 EXTERNAL SNAP RING................................................ 2

9 12DU16 • BUSHING ................................................................................ 2

10 148127 • STOP POPPET ....................................................................... 2

11 HARDWARE • • 1/4 - 20 X 2 SQUARE HEAD BOLT ................................... 2

12 HARDWARE • • 1/4 - 20 JAM NUT ............................................................... 2

13 SA108643-3 • MICRO SHAFT ASSEMBLY .................................................. REF



PER

ASSY


XI-96

Figure 11-31. Micro Shaft (1 of 2)

7

73

4

8

96

10

5

1

2


XI-97

Figure 11-31. Micro Shaft (2 of 2)

2a

3

1

5

4

6

2b


XI-98

SA108643-3 MICRO SHAFT (See Fig 11-1, Item 30 for NHA) ........................ REF1 108643-3 3/4 OD X 46 7/8 SHAFT .............................................................. 12a 95444-2 • LONG THROW-OFF HUB // NON-PNEUMATIC // ................ 1

b 95444-2-2 • THROW-OFF HUB // PNEUMATICS OPTION ONLY// .......... 1

3 145029 • POPPET // NON-PNEUMATIC // ............................................ 1

4 127712 • COMPRESSION SPRING/SOCK ROLLER SPRING// NON- 1 PNEUMATIC //

5 2528 • 3/4 OD X 4 3/4 THROW-OFF STOP ROD ............................. 1

6 145028 • SPRING SHAFT // NON-PNEUMATIC // ................................ 1

7 HARDWARE • • 3/8 - 16 JAM NUT ............................................................... 2


9 HARDWARE • • 1/8 X 3/4 SPRING PIN ........................................................ 1




PER

ASSY


XI-99

Figure 11-32. #10 Side Ink Vibrator (1 of 2)

19

20

6

8

4

5

23 13

24

2612

16

15

12

1614

1122

21

19

27

20

6

98

10

4

51

2

18

3

30

10

9

8

7

20

19

30

17

25

29

28

26

17

27

25


XI-100


21

3

45

6 7 9

25 3013

14

12

16

1011

1517


XI-101

SA16366 #10-SIDE, INK VIBRATOR ASSEMBLY (See Fig 11-1, Item 32,REF

for NHA)1 16366 • #10 HOUSING ......................................................................... 1

2 123676 • #10 COPPER OSCILLATOR GEAR ....................................... 1

3 48756-1 • COPPER OSC. WORM PINION SHAFT ............................... 1

4 L44610 • TIMKEN BEARING RACE ...................................................... 2

5 L44649 • TIMKEN ROLLER BEARING .................................................. 2

6 95332-1 • END CAP ................................................................................ 2

7 95332-2 • END CAP ................................................................................ 1

8 HARDWARE • SHIM SET................................................................................ 3

9 1328 • TIMKEN BEARING RACE ...................................................... 2

10 1380 • TIMKEN BEARING .................................................................. 2

11 40070-310 • LOAD WASHER - INK VIBRATOR WORM GEAR................ 1

12 108429 • ECCENTRIC CAM ................................................................... 2

13 122821 • SHAFT ................................................................................ 1

14 99704-1 • WORM PINION - COPPER OSC. ASSEMBLY ..................... 1

15 48756-2 • WORM GEAR ......................................................................... 1

16 108427 • LINK - BRONZE ...................................................................... 2

17 113907 • CONNECTORS - CAST .......................................................... 2

18 HARDWARE • • 5/16 X 1 3/4 KEY (705-020-020-148) .................................. 1





23 HARDWARE • • 1/4 X 2 1/4 KEY (705-016-016-216) .................................... 1

24 HARDWARE • • 1/4 X 5/8 KEY ..................................................................... 1

25 108387-2 • • 1/2 X 7/16 ROLL PIN ........................................................... 2



28 HARDWARE • • 5/16 - 18 X 3/4 SOCKET HEAD SET SCREW .................. 1

29 HARDWARE • • 5/16 - 18 JAM NUT ............................................................. 1

30 40064-2102 • • SPACER ............................................................................. 2



PER

ASSY


XI-102


2

3

184

5

1

30

10

9

8

6

20

19

13

23

24

12

2625

27

17

2829

2725

17

21

22

11

14

16 26

12

15

16

19

20

6

4

8

5

30

10

9

8

7

20

19


XI-103


9

76

4

5

3

2

1

3025

17

13

161514

1110

12


XI-104

SA16367 #13-SIDE, INK VIBRATOR ASSEMBLY (See Fig 11-1, ............ REFItem #32, for NHA)

1 16367 • #13 HOUSING ......................................................................... 1

2 70177 • #13 COPPER OSCILLATOR GEAR ....................................... 1

3 48756-1 • COPPER OSC. WORM PINION SHAFT ............................... 1

4 L44610 • TIMKEN BEARING RACE ...................................................... 2

5 L44649 • TIMKEN ROLLER BEARING .................................................. 2

6 95332-1 • END CAP ................................................................................ 2

7 95332-2 • END CAP ................................................................................ 1

8 HARDWARE • SHIM SET................................................................................ 3

9 1328 • TIMKEN BEARING RACE ...................................................... 2

10 1380 • TIMKEN BEARING .................................................................. 2

11 40070-310 • LOAD WASHER - INK VIBRATOR WORM GEAR................ 1

12 108429 • ECCENTRIC CAM ................................................................... 2

13 122821 • SHAFT ................................................................................ 1

14 99704-1 • WORM PINION - COPPER OSC. ASSEMBLY ..................... 1

15 48756-2 • WORM GEAR ......................................................................... 1

16 108427 • LINK - BRONZE ...................................................................... 2

17 113907 • CONNECTORS - CAST .......................................................... 2

18 HARDWARE • • 5/16 X 1 3/4 KEY (705-020-020-148) .................................. 1





23 HARDWARE • • 1/4 X 2 1/4 KEY (705-016-016-216) .................................... 1

24 HARDWARE • • 1/4 X 5/8 KEY ..................................................................... 1

25 108387-2 • • 1/2 X 7/16 ROLL PIN........................................................... 2




29 HARDWARE • • 5/16 - 18 JAM NUT ............................................................. 1

30 40064-2102 • • SPACER ............................................................................. 2



PER

ASSY


XI-105

Figure 11-34. Ink Vibrator Assembly (1 of 2)

3

2

5

5

14

4


XI-106

Figure 11-34. Ink Vibrator Assembly (2 of 2)

1a

1b


XI-107

ASSEMBLY INK VIBRATOR/INK FOUNTAIN DRIVE ASSEMBLY (See ....... REFFig 11-1, Item 37, for NHA)

1 SA16366 • #10 SIDE INK VIBRATOR....................................................... REF

SA16367 • #13 SIDE INK VIBRATOR....................................................... REF




5 HARDWARE • • 1/4 - 20 X 1 1/4 SOCKET HEAD CAP SCREW //NS// ...... 8

6 HARDWARE • • 1/4 HI COLLAR LOCK WASHER //NS// ............................ 8



PER

ASSY


XI-108

Figure 11-35. #10 Side Water Vibrator (1 of 2)

10

17

18

14

8

9 11

6

5

3

16

15

1

7

4

2

13

1219

13

12

6

5

316

15


XI-109


9

8

76

31

2

17

1911

10


XI-110

SA22141-10 #10 SIDE, WATER VIBRATOR ASSEMBLY (See Fig 11-1, ..... REFItem 27, for NHA)

1 22141-1 • CASTING - OSC BOX ............................................................. 1

2 110697 • END PLATE - 4 HOLE ............................................................ 1

3 119885 • END PLATE - 3 HOLE ............................................................ 2

4 HARDWARE • • SHIM SET - 4 HOLE ........................................................... 1


6 62062RS • BEARING //SKF // .................................................................. 2

7 5203ATN9 • BEARING //MRC // ................................................................. 1

8 60072RS • BEARING // SKF // ................................................................. 1

9 103676-2 • WORM SHAFT W/RIGHT HAND THREADS - #10 SIDE ...... 1

10 70188 • GEAR - WATER OSCILLATOR .............................................. 1

11 127371 • WORM GEAR SHAFT - WATER OSCILLATOR.................... 1

12 HARDWARE • • 1/4 - 20 x 5/8 BUTTON HEAD CAP SCREW .................... 5


14 HARDWARE • • 5/16 X 1 3/4 KEY (705-020-020-148) .................................. 1



17 105603-3 • • SPOTTING BOLT ................................................................ 1

18 HARDWARE • • JAM NUT ............................................................................. 1

19 40070A-207 • • MACHINE WASHER .......................................................... 1



PER

ASSY


XI-111


10

8

9

11

6

5

3

16

15

12

131912

13

2

4

76

5

316

15

14

18

17

1


XI-112


23

6 7

8

1

9

171110

19


XI-113

SA22141-13 #13-SIDE WATER VIBRATOR ASSEMBLY (See Fig 11-1, ...... REFItem 27, for NHA)

1 22141-1 • CASTING - OSC BOX ............................................................. 1

2 110697 • END PLATE - 4 HOLE ............................................................ 1

3 119885 • END PLATE - 3 HOLE ............................................................ 2



6 62062RS • BEARING //SKF // .................................................................. 2

7 5203ATN9 • BEARING //MRC // ................................................................. 1

8 60072RS • BEARING // SKF // ................................................................. 1

9 103676-1 • WORM SHAFT W/RIGHT HAND THREADS - #13 SIDE ...... 1

10 70188 • GEAR - WATER OSCILLATOR .............................................. 1

11 127371 • WORM GEAR SHAFT - WATER OSCILLATOR.................... 1

12 HARDWARE • • 1/4 - 20 x 5/8 BUTTON HEAD CAP SCREW .................... 5


14 HARDWARE • • 5/16 X 1 3/4 KEY (705-020-020-148) .................................. 1



17 105603-3 • • SPOTTING BOLT ................................................................ 1

18 HARDWARE • • JAM NUT ............................................................................. 1

19 40070A-207 • • MACHINE WASHER .......................................................... 1



PER

ASSY


XI-114

Figure 11-37. Circ Assembly (1 of 3)

3221

1619

1520

39

242333369

25

3537

17

143313

353438

2627 3 2

421 (Set)

440

41

1 (Set)

5

6729288

3130

36

1812

10

11


XI-115

Figure 11-37. Circ. Assembly (2 of 3)

1

2

4

5

7

89

3

12

10

1314

1516

17

1819

20


XI-116

Figure 11-37. Circ. Assembly (3 of 3)

33

2122

41 42

Photo Not

Available

Item 23

W-00

Photo Not

Available

Item 24

N-00


XI-117

SA51945 CIRC ASSEMBLY - 22 3/4” CUTOFF ............................................... REF(See Fig 11-1, Item 18, for NHA)

SA51945-M CIRC ASSEMBLY - 22 3/4” CUTOFF - MOTORIZED ........................ REFSA51945-2 CIRC ASSEMBLY - 22” CUTOFF ...................................................... REFSA51945-2M CIRC ASSEMBLY - 22” CUTOFF - MOTORIZED .............................. REFSA51945-3 CIRC ASSEMBLY - 21 1/2” CUTOFF ................................................ REFSA51945-3M CIRC ASSEMBLY - 21 1/2” CUTOFF - MOTORIZED ........................ REF

1 49203-2 • GEAR HUB.................................................................................... 12 123610 • GEAR, 21 1/2” CUTOFF ................................................................ 1

106563-2 • GEAR, 22” CUTOFF ...................................................................... A/R123939 • GEAR, 22 3/4” CUTOFF ................................................................ A/R

3 158497 • • SLIP WASHER - BRASS W/FLAT ............................................. 44 158456 • PLATE - INNER BEARING RETAINER ......................................... 15 1209ETN • SKF BEARING .............................................................................. 16 HARDWARE • • SHIM SET ................................................................................. 17 123590 • BEARING CAP - #10 GEAR INNER SPLINE ................................ 18 30475-1 • CIRC BEARING SUPPORT CASTING - A .................................... 19 30475-2 • CIRC BEARING SUPPORT CASTING - B .................................... 110 W6N • • 3/8 - 16 X 3/4 BALL PLUNGER // NOT MOTORIZED // ............ 111 HARDWARE • • 3/8 - 16 JAM NUT ..................................................................... 112 155726 • CIRC LOCATOR W/THREADED CENTER HOLE........................ 113 128109 • CIRC ADJ SCREW ....................................................................... 114 SS4048-10 • 1 1/4 ID. X 1 1/2 OD. X 5/8 BUSHING ........................................... 115 SS2432-8 • 3/4 ID. X 1 OD. X 1/2 BUSHING// NOT MOTORIZED // ................. 116 SF2432-8 • 3/4 ID. X 1 OD. X .545 BUSHING W/FLANGE// NOT..................... 1

MOTORIZED //17 51945 • CIRC PLATE ................................................................................. 118 150279 • NEW CIRC ADJ - TOP GEAR// NOT MOTORIZED // ..................... 119 127766 • CIRC PLATE// NOT MOTORIZED // .............................................. 120 159749 • STUD - CIRC PLATE// NOT MOTORIZED // ................................. 121 127820 • NEW CIRC ADJ - LARGE GEAR// NOT MOTORIZED // ................ 122 159764 • NEW CIRC ADJ - LOWER GEAR // NOT SHOWN // NOT ............ 1

MOTORIZED //23 W-00 • • WASHER .................................................................................. 124 N-00 • • NUT .................................................................................... 125 HARDWARE • • 5/16 X 1.450 DOWEL PIN ........................................................ 126 HARDWARE • • 1/2 - 13 X 1 1/2 SOCKET HEAD CAP SCREWS ...................... 427 HARDWARE • • 1/2 HI COLLAR LOCK WASHERS ........................................... 428 HARDWARE • • 1/4 - 20 X 3/4 SOCKET HEAD CAP SCREWS ......................... 429 HARDWARE • • 1/4 HI COLLAR LOCK WASHERS ........................................... 430 HARDWARE • • 10 - 24 X 5/8 SOCKET HEAD CAP SCREWS .......................... 431 HARDWARE • • #10 HI COLLAR LOCK WASHERS .......................................... 432 HARDWARE • • 3/4 EXTERNAL SNAP RING ..................................................... 133 DG58062 • • BRASS WASHER ..................................................................... 234 HARDWARE • • 5/16 - 18 X 7/8 SOCKET HEAD CAP SCREW ......................... 435 HARDWARE • • 5/16 HI COLLAR LOCK WASHERS ......................................... 636 HARDWARE • • 1/4 X 1 DOWEL PIN .................................................................. 237 HARDWARE • • 5/16 - 18 X 1 SOCKET HEAD CAP SCREW ............................ 238 HARDWARE • • 1/4 - 20 SOCKET HEAD SET SCREW - KNURLED POINT .... 139 HARDWARE • • 3/8 - 16 X 1 1/4 HEX HEAD BOLT ............................................ 240 HARDWARE • • 5/8 - 11 X 1 1/4 BUTTON HEAD CAP SCREW ........................ 141 148639-1 • BEARING LOAD WASHER - #10 GEAR SIDE .............................. REF42 158414 • CIRC SPACER.............................................................................. 1

NOTE: CIRC SUB-ASSEMBLY IS STRICTLY DEPENDENT ON CUTOFF SIZEAND MOTORIZED OPTION.



PER

ASSY


XI-118

Fig

ure

11

-38. D

rive S

haft

(1 o

f 2)

13

12

11

10

98

74

42

1

35

68

9

10

11

12

13

14

14

15

18

19

20

21

18

22

23

1617


XI-119

Figure 11-38. Drive Shaft (2 of 2)

5

2 3 4

6

21

11

22

18

Photo Not

Available

Item 1

95833-K

Photo Not

Available

Item 7

CDSS

Photo Not

Available

Item 8

W-09

Photo Not

Available

Item 23

COMR+P

Photo Not

Available

Item 9

N-09


XI-120

ASSEMBLY DRIVE SHAFT (See Fig 11-1, Item 33, for NHA) ....................... REF1 95833-K • DRIVE SHAFT - FLOOR UNIT/STACK................................... 1

94097-2 • DRIVE SHAFT - BASE UNIT 4 HIGH ..................................... A/R

116720-2 • DRIVE SHAFT - 2ND UNIT 4 HIGH ........................................ A/R

101902-2 • DRIVE SHAFT - 3RD UNIT 4 HIGH ........................................ A/R

101903-2 • DRIVE SHAFT - 4TH UNIT 4 HIGH ......................................... A/R

94097-2 • DRIVE SHAFT - SINGLE STACK ........................................... A/R

2 123347-1 • OIL SLINGER - #13 SIDE ....................................................... 1

3 123347-2 • OIL SLINGER - #10 SIDE ....................................................... 1

4 63092RS • BEARING ................................................................................ 2

5 40065-4003 • • #10 SIDE SPACER............................................................. 1

6 62092RS • BEARING ................................................................................ 1

7 CDSS • • .020 PLASTIC SHIM ........................................................... 1

8 W-09 • • BEARING LOCK WASHER................................................ 2

9 N-09 • • BEARING NUT .................................................................... 2

10 HARDWARE • • DRIVE SHAFT CAP SHIMS - 1 SET ................................. 1

11 158762-2 • • DRIVE SHAFT CAP ............................................................ 2

12 HARDWARE • • • 3/8 HI COLLAR LOCK WASHER................................... 8

13 HARDWARE • • • 3/8 - 16 X 1 1/4 SOCKET HEAD CAP SCREWS .......... 8

14 HARDWARE • • • 3/8 X 2 KEY .................................................................... 2

15 HARDWARE • • • 5/16 X 2 3/4 ..................................................................... 1

16 HARDWARE • • • 3/8 - 16 X 1 SPOTTING BOLT ........................................ 1

17 HARDWARE • • • 3/8 - 16 JAM NUT ........................................................... 1

18 70178 • • • RING AND PINION SET ................................................. 1

19 HARDWARE • • • 1/2 - 13 X 2 SOCKET HEAD CAP SCREW .................. 6

20 HARDWARE • • • 1/2 HI COLLAR LOCK WASHER................................... 6

21 3424-2 • • • SLIP WASHER - BRONZE ............................................ 6

22 108384 • • • SLIP HUB ........................................................................ 1

23 COMR+P • • • RING AND PINION SHIMS - 1 SET ............................... 1



PER

ASSY


XI-121

18

18

17

3

1

5

6

4

16

14 16

197

8

9

10

14

13

12

11

(Located on pump shaft)2

Figure 11-39. Oil Pump Assembly (1 of 2)


XI-122

Figure 11-39. Oil Pump Assembly (2 of 2)

31

4

5

11

10

Photo Not

Available

Item 6

89CO492


XI-123

ASSEMBLY OIL PUMP ASSEMBLY .............................................................. REF1 116628 • OIL PUMP GEAR .................................................................... 1

2 HARDWARE • WOODRUFF KEY (12574) ..................................................... 1

3 1AC • OIL PPUMP // TUTHIL // ......................................................... 1

4 762948-46 • OIL FILTER .............................................................................. 1

5 B5631 • OIL SIGHT GLASS .................................................................. 1

6 89CO492 • 1/2 PIPE PLUG (OIL DRAIN) / NS / ....................................... 1




10 116616 • • OIL PUMP BRACKET ......................................................... 1

11 119966 • • HOLDER CLIPS .................................................................. 4


13 HARDWARE • • • 1/4 - 20 X 1/2 ROUND HEAD MACHINE SCREW ........ 4

14 HARDWARE • • 95 - LB - 04 X 04 FITTING ................................................... 1




18 HARDWARE • • • 1/4 OD SOFT COPPER TUBING ................................... 10 FT

19 HARDWARE • • • 1/2 OD SOFT COPPER TUBING ................................... 2 FT



PER

ASSY


XI-124

Fig

ure

11

-40. G

ear

Sid

e C

over

(1 o

f 2)

3

1

4

5

8

9

10

2

9

7

10

7

8

7

6


XI-125

Figure 11-40. Gear Side Cover (2 of 2)

1

4

4

8

Photo Not

Available

Item 9

95801


XI-126

ASSEMBLY GEAR SIDE COVER (See Fig 11-1, Item 34, for NHA) ............. REF1 16431-2 • COVER W/DOORS AND HANDLES ..................................... 1

16431-4 • COVER W/DOORS AND HANDLES // MOTORIZED OPTION// 1

2 HARDWARE • • • CAUTION LABEL ............................................................ 1


4 DG006 • MYLAR ................................................................................ AR

5 HARDWARE • • CORK GASKET MATERIAL - 13 FT .................................. 1

6 145211-2 • PLATE - TOP .......................................................................... 2


8 DG897PLT • INSIDE LEG COVER (STACK UNIT) ...................................... 2

9 95801 • OUTSIDE LEG COVER (STACK UNIT) .................................. 2




PER

ASSY


XI-127

Figure 11-41. Paper Roll Sidelay (1 of 2)

1

6 2

3

5

4


XI-128

Figure 11-41. Paper Roll Sidelay (2 of 2)

2

5

1


XI-129

SA71624 PAPER ROLL SIDELAY ASSEMBLY (See Fig 11-1, Item 36, . REFfor NHA)

1 71624 • SIDELAY HANDWHEEL......................................................... 1

2 144371 • BRACKET, BRAKE SIDELAY ................................................ 1



5 108466-1 • • SIDELAY SCREW 9 1/4 ..................................................... 1


NOTE: ASSEMBLY SA71624 IS MAINTAINED IN THIS MANUAL FOR RECORD PURPOSES ONLY.



PER

ASSY


XI-130

Figure 11-42. Paper Roll Brake (1 of 2)

81

3

4

7

1

8

9

3

9

4

5

2

2

5

6


XI-131

Figure 11-42. Paper Roll Brake (2 of 2)

2

3

1

6

7


XI-132

SA94282-3 PAPER ROLL BRAKE (See Fig 11-1, Item 37, fro NHA) .......... REF1 94282-3 • UPPER/LOWER BRAKE SHOE LEVER............................... 2

2 97326 • • BRAKE SHOE (NEW STYLE 1 PC) .................................. 2

3 97325 • • BRAKE BLOCK WOODEN ................................................ 2

4 HARDWARE • • 3/4 X 2 1/2 WORKING DISTANCE CLEVIS PIN................ 2

5 HARDWARE • • #10 X 1 PHILLIPS HEAD WOOD SCREW ........................ 8

6 106700 • • BRAKE SHOE KNOB......................................................... 1

7 119892-2 • • BRAKE TENSION SCREW ................................................ 1


9 HARDWARE • • 1/8 X 1 1/2 COTTER PIN .................................................... 2



PER

ASSY


XI-133

Figure 11-43. Paper Roll Sidelay and Brake Assembly (1 of 2)

1

2122

23

30

2

29

43

16

17

20

19

15

28

27

25

24

26

18

56

7

8 910

11

1413

12


XI-134

Figure 11-43. Paper Roll Sidelay and Brake Assembly (2 of 2)

21

5 78

31

20

15

1821

32 3334

35

42

45

11

25

29

30

3638

39

40

41

43

44

37


XI-135

ASSEMBLY PAPER ROLL SIDELAY AND BRAKE (See Fig 11-1, .............. REFItem 35 for NHA)

1 SA94282-3 • BRAKE ASSEMBLY............................................................... 12 144371 • BRACKET, BRAKE SIDELAY ................................................ 13 HARDWARE • • 3/8 - 16 X 1 SOCKET HEAD SET SCREW ....................... 14 HARDWARE • • 3/8 - 16 JAM NUT ............................................................... 15 54484 • BRAKE DRUM (OPTIONAL) ................................................... 16 HARDWARE • • 1 1/2 EXTERNAL SNAP RING ........................................... 17 144365 • ECCENTRIC SHAFT ............................................................... 18 140764 • ROLL LIFTING STUD .............................................................. 29 HARDWARE • • 1/4 - 20 X 1 SOCKET HEAD CAP SCREW ....................... 210 HARDWARE • • 1/4 HI COLLAR LOCK WASHER ....................................... 211 122916 • ECCENTRIC SHAFT BUSHING.............................................. 112 HARDWARE • • 1/8 - 27 NPT GREAST FITTING - 90 DEG. ........................ 113 HARDWARE • • 7/8 - 14 JAM NUT ............................................................... 414 HARDWARE • • 7/8 LOCK WASHER ........................................................... 415 897322-3 • SIDELAY BAR ........................................................................ 116 HARDWARE • • 3/8 - 16 X 2 SQUARE HEAD SET SCREW ....................... 217 HARDWARE • • 3/8 - 16 JAM NUT ............................................................... 218 108418-3 • POPPET - SIDELAY LEVER STOP....................................... 219 HARDWARE • • 1/4 - 20 X 1/2 MACHINE SCREW ...................................... 420 149042 • PLATE - POPPET KEEPER .................................................. 221 CF 2 1/4 S • 2 1/4 MCGILL CAM FOLLOWER ........................................... 422 HARDWARE • • 1/4 PRESS FIT GREASE FITTING .................................... 423 HARDWARE • • 1/2 - 13 NUT ........................................................................ 124 HARDWARE • • 1/2 LOCK WASHER ........................................................... 125 94291 • ECCENTRIC BRAKE LEVER ................................................. 126 HARDWARE • • 1/8 X 1 COTTER PIN ........................................................... 127 HARDWARE • • 1/2 - 13 X 3 HEX HEAD BOLT ............................................ 128 HARDWARE • • 5/8 X 1 1/2 WORKING DISTANCE CLEVIS PIN ................ 129 108466-1 • SCREW, SIDLAY 7” BRAKE DRUM ...................................... 130 77214 • KNOB, SIDELAY ADJUSTMENT ........................................... 131 68-10-101-20 LATCH, GUARD // NS // ............................................................. 132 77213-2 PLATE, MOUNTING BRACKET GUARD // NS // ...................... 133 77211-2 BRACKET, GUARD COVER LOWER // NS // ........................... 134 77212-2 BRACKET, GUARD COVER UPPER // NS // ........................... 135 77210-2 GUARD, PAPER ROLL BRAKE // NS // .................................... 136 77215 BRACKET, BRAKE GUARD HANDLE //NS // ........................... 137 TV8S-335-02Z SWITCH, INTERLOCK // NS // ................................................... 138 97543 TENSION SCREW THREADED POPPET // NS // .................... 139 97542 BALL, TENSION CONTROL // NS // .......................................... 140 140856 SPRING, TENSION SCREW ROD // NS // ................................ 141 109657 KNOB, TENSION SCREW ROD KNURL // NS // ...................... 142 108892 ROD, LINKAGE TENSION SCREW // NS // .............................. 143 77216 PLATE, SWITCH COVER // NS // .............................................. 144 77217 BRACKET, COVER SUPPORT // NS // ..................................... 145 ACP-77001 HANDWHEEL WITH SOCKET, PAPER ROLL SIDELAY // NS // 1



PER

ASSY


XI-136

Figure 11-44. Belt Register (1 of 2)

76

5

5

43

2

1

14

13

76

11

102

8

98

12

43


XI-137

Figure 11-44. Belt Register (2 of 2)

1

2

5

6

9

14

10

11


XI-138

SADG89706 BELT REGISTER ASSEMBLY (See Fig 11-1, Item 38 for NHA)REF

1 DG89701 • BACKING PLATE .................................................................... 1

2 DG89704 • • ADJUSTING STUD BRACKET ........................................... 2


4 HARDWARE • • • 1/4 - 20 X 3/4 HEX HEAD BOLT..................................... 6

5 DG89702-3 • • IDLER PULLEY MOUNTING BLOCK ................................. 1

6 DG89707 • • IDLER PULLEY ................................................................... 2

7 HARDWARE • • SNAP RING (5100-37) ........................................................ 2

8 HARDWARE • • 1/2 STEEL THREADED COLLAR ...................................... 2

9 DG89706 • • BELT REGISTER SUPPORT ............................................. 1

10 DG89710 • • HANDLE STUD ................................................................... 1

11 RC - 4A • • HANDLE .............................................................................. 1

12 HARDWARE • • 1/8 X 1 1/4 SPRING PIN ..................................................... 1

13 HARDWARE • • 1/2 X 3/4 SPRING PIN ........................................................ 1

14 DG89711 • • SPACER (4 HIGH ONLY) ................................................... 4



PER

ASSY


XI-139

Fig

ure

11

-45

. O

pti

on

al P

ne

um

ati

c A

ss

em

bly

(1

of

2)

10

95

10

95

10

95

4

6

16

13

141

09

78 7

8

7

3

4

59

1

12

8

23

34

5

6

4

10

7

8

91

0

11

12

8

7

10

87

2

4

5

15


XI-140

Figure 11-45. Optional Pneumatic Assembly (2 of 2)

5 6

7

11

16

12a 12b

Photo Not

Available

Item 2

172DP

Photo Not

Available

Item 13

I34

Photo Not

Available

Item 18

SCHRADER430KIT


XI-141

ASSEMBLY PNEUMATICS (OPTIONAL) (See Fig 11-1, Item 39, for NHA) .. REF1 HARDWARE • • 3/8 EXTERNAL SNAP RING .............................................. 6

2 172DP • BIMBA SMALL PNEUMATIC CYLINDER .............................. 6

3 HARDWARE • • 90 DEG. MALE ELBOW (CAMOZZI) ................................. 12

4 HARDWARE • • 7/16-20 JAM NUT ................................................................ 6

5 CFF7 • ROD END - SMALL CYLINDER ............................................. 6

6 157606 • PNEUMATIC STUD - THROW-OFF ....................................... 6

7 94997 • THROW-OFF COLLAR ........................................................... 6



10 HARDWARE • • 7/16 - 14 SOCKET HEAD CAP SCREW ........................... 6

11 156136-5 • • 1/2 X 2 LINKAGE PIN ......................................................... REF

12a 157601-3 • PNEUMATIC IMPRESSION COUPLING - 21 1/2” ONLY ...... REF

b 157601-2 • PNEUMATIC IMPRESSION COUPLING - 22 3/4” ................. REF

13 I34 • PNEUMATIC IMPRESSION CYLINDER W/JAM NUT ........... REF

14 HARDWARE • • 7/16 EXTERNAL SNAP RING ............................................ REF

15 HARDWARE • • 10 - 24 X 3/8 SOCKET HEAD SET SCREW W/NYLOCK REF

16 157605 • PNEUMATIC STUD - IMPRESSION....................................... REF

17 HARDWARE • • 1/4 0D AIR LINE // NS // ..................................................... 32 FT.

18 SCHRADER430KIT • 430 PNEUMATIC KIT .............................................................. 1



PER

ASSY


XI-142

Figure 11-46. Blanket Cylinder Throw-Off Linkage - Optional Pneumatics (1 of 2)

6

5

4

3

2

1


XI-143

Figure 11-46. Blanket Cylinder Throwoff Linkage - Optional Pneumatics (2 of 2)

2

5a 5b

6

Photo Not

Available

Item 4

I34


XI-144

ASSEMBLY BLANKET CYLINDER THROW-OFF LINKAGE - OPTIONAL ... REFPNEUMATICS (See Fig 11-1, Item 40 for NHA)

1 HARDWARE • 10-24 X 3/8 SOCKET HEAD SET SCREW W/NYLOCK ....... 1

2 157605 • PNEUMATIC STUD - IMPRESSION....................................... 1

3 HARDWARE • • 7/16 EXTERNAL SNAP RING ............................................ 1

4 I34 • PNEUMATIC IMPRESSION CYLINDER W/JAM NUT ........... 1

5a 157601-3 • • PNEUMATIC IMPRESSION COUPLING - 21 1/2” ONLY .. 1

b 157601-2 • • PNEUMATIC IMPRESSION COUPLING - 22” AND .......... A/R22 3/4” ONLY

6 156136-5 • • • 1/2 X 2 LINKAGE PIN ..................................................... 1



PER

ASSY


XI-145

Fig

ure

11

-47

. R

ub

be

r R

oll

ers

4

A

32

4

3

2

7 W

ate

r P

ick-U

p R

olle

r

12

In

sid

e I

nk F

orm

Ro

ller

8 W

ate

r F

orm

Ro

ller

9 O

uts

ide

In

k F

orm

Ro

ller

10

In

k T

ran

sfe

r R

olle

r

11

In

k T

ran

sfe

r R

olle

r

15

65

A


XI-146

ASSEMBLY RUBBER ROLLERS (See Fig 37, Item 41, for NHA) ................. REF1 126209 • FORM ROLLER SHAFT ......................................................... 6


HARDWARE • • 1/4 - 20 X 2 HEX HEAD BOLT (FORM ROLLER BRACKET) 6

3 HARDWARE • • 1/4 ZIP WASHER ............................................................... 12

4 HARDWARE • • 1/4 - 20 X 1 1/2 SOCKET HEAD CAP SCREW W/NYLOCK 12

5 HARDWARE • • BEARING ............................................................................ 12

6 HARDWARE • • RUBBER ROLLER .............................................................. 6

Roller Positions7 WATER PICKUP ROLLER (1 7/8” x 2.750” x 35 1/2” x 36 1/2”) .............................. 28 WATER FORM ROLLER (1 7/8” x 2.750” x 35 1/2” x 36 1/2”) ................................. 29 OUTSIDE INK FORM ROLLER (1 7/8” x 2.875” x 35 3/8” x 36 1/2”) ...................... 210 INK TRANSFER ROLLER (1 7/8” x 2.750” x 35 1/2” x 36 1/2”) ............................... 111 INK TRANSFER ROLLER (1 7/8” x 2.750” x 35 1/2” x 36 1/2”) ............................... 112 INSIDE INK FORM ROLLER (1 7/8” x 2.750” x 35 3/8” x 36 1/2”) .......................... 2

(#10 SIDE SHOWN)



PER

ASSY


XI-147

Fig

ure

11

-48

. N

ip G

ua

rds

(1

of

2)

5

33

3

3

2

5

15

4

5


XI-148

Figure 11-48. Nip Guards (2 of 2)

1

2

3


XI-149

ASSEMBLY NIP GUARDS (10-SIDE SHOWN) (See Fig 11-1, Item 42, ....... REFfor NHA)

1 888IF-1 • GUARD - INK FORM - INSIDE ............................................... 2

2 93258 • GUARD - INK FORM - OUTSIDE ........................................... 2


4 888WF-1 • GUARD - WATER FORM - OUTSIDE .................................... 2

5 HARDWARE • • 1/4-20 x 1 1/2 SOCKET HEAD CAP SCREW ................... 4



PER

ASSY


XI-150

Figure 11-49. Roller Guards (1 of 2)

1

1

10

15

2

4

13

12

11

57

68 12

13

11

12

13

7

11

9

8 65

41

1

1410

3

9


XI-151

Figure 11-49. Roller Guards (2 of 2)

1 1

17

59

11

11 11


XI-152

ASSEMBLY ROLLER GUARDS (See Fig 11-1, Item 43, for NHA) ................ REF1 68-10-101-20 • HANDLE - DOOR LOCK ......................................................... 4

2 SA888OG • ASSEMBLY - OPERATOR SIDE ROLLER GUARD ............. 1

3 SA888GG-2 • ASSEMBLY - GEAR SIDE ROLLER GUARD ....................... 1

4 HARDWARE • • 5/16 X 3/4 SHOULDER BOLT ............................................ 2

5 ST14-RA-B1 • INTERLOCK KEY - RIGHT ANGLE ........................................ 2

6 HARDWARE • • 8-32 X 1/2 SOCKET HEAD MACHINE SCREW ................ 4

7 ST14-20K • INTERLOCK SWITCH W/O KEY ............................................ 2

8 HARDWARE • • 1/4 - 20 X 3/4 FLAT HEAD ALLEN HEAD SCREW........... 4

9 888SB • SPACER BLOCK - SWITCH .................................................. 2

10 HARDWARE • • 5/16 X 1/2 SHOULDER BOLT ............................................ 4

11 888LP • LATCH PLATE - ROLLER GUARD ........................................ 4



14 888GM-3 • MOUNT - ROLLER GUARD - GEAR SIDE ............................ 1

15 888GM-4 • MOUNT - ROLLER GUARD - OPERATOR SIDE .................. 1



PER

ASSY


XI-153

Figure 11-50. Upper Roller Guard (1 of 2)

2

1

2

3

3

3

3

3

2

2

33

3


XI-154

Figure 11-50. Upper Roller Guard (2 of 2)

1

1


XI-155

ASSEMBLY UPPER ROLLER GUARD // 10-SIDE SHOWN // ...................... REF(See Fig 11-1, Item 44, for NHA)

1 888RG-4 • ROLLER GUARD .................................................................... 2

2 888GM-2 • MOUNT - ROLLER GUARD .................................................... 8




PER

ASSY


XI-156

Figure 11-51. Outer Roller Guard (1 of 2)

3

1

3

2

645

Inside of frame


XI-157

Figure 11-51. Outer Roller Guard (2 of 2)

2

3

5 6

1


XI-158

ASSEMBLY OUTER ROLLER GUARD // 13-SIDE SHOWN // (See Fig ....... REF11-1, Item 45, for HNA)

1 888RG-5-1 • ROLLER GUARD, 22 3/4” CUTOFF ....................................... 2

888RG-5-2 • ROLLER GUARD, 22” CUTOFF ............................................. 2

888RG-5-3 • ROLLER GUARD, 21 1/2” CUTOFF ....................................... 2

888RG-5-1GMI • ROLLER BUARD // FOR USE WITH GMI PACKAGE .......... 2

2 ST14-20K • INTERLOCK SWITCH W/KEY................................................ 2

3 19-14-10 • HANDLE, SWELL LATCH ...................................................... 4


5 888SB • SPACER BLOCK - SWITCH .................................................. 2

6 ST14-B • KEY, CLOSE RADIUS ............................................................ 2



PER

ASSY


XI-159

Fig

ure

11

-52. O

pera

tor

Sid

e C

over

(1 o

f 2)

9

8

1

23

54

67

6


XI-160

Figure 11-52. Operator Side Cover (2 of 2)

3

1

77


XI-161

ASSEMBLY OPERATOR SIDE COVER (See Fig 11-1, Item 46, for NHA) ... REF1 16418-3 • OPERATOR SIDE COVER - 21 1/2" ...................................... 1

16418-2 • OPERATOR SIDE COVER - 22" ............................................ A/R

16418 • OPERATOR SIDE COVER - 22 3/4" ...................................... A/R

16418-1-2 • OPERATOR SIDE COVER - 22 3/4" // PNEUMATIC ............ A/ROPTION//

16418-2-2 • OPERATOR SIDE COVER - 22" // PNEUMATIC OPTION //A/R

16418-3-2 • OPERATOR SIDE COVER - 21 1/2" // PNEUMATIC ............ A/ROPTION//

16418-1-4 • OPERATOR SIDE COVER - 22 3/4” // PNEUMATIC AND ... A/RMOTORIZATION OPTION //


3 108703 • COVER MOUNTING BLOCK .................................................. 7


5 HARDWARE • • 5/16 FLAT WASHER .......................................................... 7

6 144608-1 • THROW-OFF RODS - 5" // NOT USED WITH PNEUMATICS // 10

7 B-8 • • BLACK BALL // NOT USED WITH PNEUMATICS // ......... 10

8 HARDWARE • • • CAUTION STICKER ........................................................ 1

9 HARDWARE • • • DGM-430 NAME PLATE ................................................ 1



PER

ASSY


XI-162

Figure 11-53. Color Drop Roller (1 of 2)

4

2

1

2

56

7

5

67

3

4


XI-163

Figure 11-53. Color Drop Roller (2 of 2)

2

3

5

1


XI-164

ASSEMBLY COLOR DROP ROLLER // 13 SIDE SHOWN// (See Fig 11-1, . REFItem 47, for NHA)

1 108425 • 1 7/8 PIPE ROLLER ............................................................... 1


3 108642-6 • 3/4 ROLLER SHAFT W/THREADS - 42 1/2 .......................... 1


5 161384 • COLOR DROP BRACKET ...................................................... 2





PER

ASSY


XI-165

Fig

ure

11

-54

. L

ea

d-I

n R

oll

er

- B

as

e U

nit

(1

of

2)

47

65

2

3

2

1


XI-166

Figure 11-54. Lead-In Roller - Base Unit (2 of 2)

2

1

4

3


XI-167

ASSEMBLY LEAD-IN ROLLER (BASE UNIT ONLY) (See Fig 11-1, ............. REFItem 48, for NHA)

1 108643-2 • 3/4 TGP ROLLER SHAFT - 44 1/2 LONG .............................. 3


3 108425 • • 1 7/8 LEAD-IN PIPE ROLLER ............................................ 3




7 HARDWARE • • 5/16 - 18 X 3/8 SOCKET HEAD CAP SCREW .................. 3

NOTE: CENTER ROLLER MAY BE REPLACED WITH A FAN-OUT ROLLER, P/N LTC100103.



PER

ASSY


XI-168

Fig

ure

11

-55. L

ead

-In

Ro

ller

an

d U

nd

er

Un

it C

om

pen

sato

r A

ssem

bly

- S

tack U

nit

(1 o

f 2)

11

10

13

12

20

19

17

16

15

11

10

14

3

2

33

1

8

9

12

7

13

65

4

2

18

21

23


XI-169

Figure 11-55. Lead-In Roller and Under Unit Compensator Assembly - Stack Unit (2 of 2)

26

10

15

17

16

2022

3

18

9


XI-170

ASSEMBLY LEAD-IN ROLLER AND SWING COMP (STACK UNIT ONLY) . REF(See Fig 11-1, Item 49, for NHA)

1 108643-2 • 3/4 TGP ROLLER SHAFT - 44 1/2 LONG .............................. 1


3 108425 • 1 7/8 LEAD-IN PIPE ROLLER ................................................ 3




7 HARDWARE • • 5/16 - 18 X 3/8 SOCKET HEAD CAP SCREW.................. 1



10 145225 • COMP BRACKET ................................................................... 2


12 HARDWARE • • 5/16 - 18 X 1 1/4 SOCKET HEAD CAP SCREW .............. 2


14 HARDWARE • • 1/2 X 3/8 SHOULDER BOLT .............................................. 1

15 145227 • COMP SCREW ....................................................................... 1

16 145228 • COMP ROD ............................................................................. 1

17 145229 • COMP BLOCK W/ 3/8 STUD ................................................. 1

18 HARDWARE • • 1/4 - 20 THUMB SCREW ................................................... 1

19 HARDWARE • • 1/2 SET COLLAR ................................................................ 1

20 145228-2 • COMP ROD EXTENSION ....................................................... 1

21 HARDWARE • • 1/8 X 3/4 ROLL PIN............................................................. 1

22 RC3A • HANDLE ................................................................................ 1

23 HARDWARE • • 1/8 X 1 ROLL PIN ................................................................ 1



PER

ASSY


XI-171

Fig

ure

11

-56. B

1 S

win

g C

om

pen

sato

r (1

of

2)

9

10

18

17

22

12

21

9

8

7

6

7

5

3

12

10

9

11

13

14

26

26

24

23

24

25

4

3

2

1

1

5

11

15

13

16

19

10

20


XI-172

Figure 11-56. B1 Swing Compensator (2 of 2)

13

42

6

7

811 14

15

16

25

18

2023

24


XI-173

ASSEMBLY B1 SWING COMPENSATOR (See Fig 11-1, Item 50, for NHA) REF1 E5064-SET • B1 TOP IRON - PAIR .............................................................. 1

2 53429-3 • 3 X 36 PIPE ROLLER ............................................................. 1

3 ERX20XLOA • BEARING ................................................................................ 2

4 96343-1 • 1 1/4 ROLLER SHAFT - 42 1/4 .............................................. 1

5 HARDWARE • 1/2 X 2 1/2 ROLL PIN .............................................................. 4

6 108425 • 1 7/8 PIPE ROLLER ............................................................... 1


8 108643-4 • 3/4 ROLLER SHAFT - 39 1/2.................................................. 1



11 B108747-3 • BRACKET - 1 1/4 COMP ........................................................ 2


13 HARDWARE • • 5/8 - 11 JAM NUT ............................................................... 4

14 148582 • COMP SWIVEL PIN ............................................................... 1

15 148403 • COMP SCREW ....................................................................... 1

16 148489 • SCREW POPPET ................................................................... 1


18 RC3A • HANDLE ................................................................................ 1

19 HARDWARE • • 1/8 X 7/8 ROLL PIN ............................................................. 1

20 148406-3 • COMP HANDWHEEL BRACKET ........................................... 1

21 HARDWARE • • 1/4 - 20 JAM NUT ............................................................... 1

22 HARDWARE • • 1/4 - 20 X 3/8 SOCKET HEAD SET SCREW .................... 1// SA108642-2 PIPE ROLLER (WITH SHAFT) ASSEMBLY) //

23 108425 • PIPE ROLLER - 1 7/8 ............................................................. 3


25 108642-2 • SHAFT - PIPE ROLLER - 39 3/4 W/THREADED ENDS ....... 3




PER

ASSY


XI-174

Fig

ure

11

-57

A. F

ull

Mo

tori

ze

d C

om

pe

ns

ato

r (P

re-2

00

1)

(1 o

f 4

)

40

2

8

34

05

246

43 4

47

47

50 19

53

2 42

41 8

31

45

6

5 32

473

3

61

0

47

38

501

74

82

04

817

57

29

28

28

29

29

26

27

38

343

5

3247

33

7

5

4

1

310

45

94

1

42

47

48

20

18

50

38

48

48

19

48

18

50

55

37

36

29

24

29 5

4

39

53

22

23

22

40

47

11

16

56

48 4

8

48

51 21

48

14

56

47

12

49

16

15

404

7 52

46

434

4

43

13

57

24

25

29

28

54

53

39


XI-175

Figure 11-57A. Full Page Motorized Compensator - Pre-2001 (2 of 4)

1

34

5

2

6

7

89

10

13 14 15

16

Photo Not

Available

Item 11

BGFM-15-25-S60

12b

12a


XI-176

29 3031

32 33

3435

17

1819 20

21

22

23

24

2625

27

28



XI-177

58

59 60

61

62 63

64

65


3638

37b37a


XI-178

ASSEMBLY FULL PAGE MOTORIZED COMPENSATOR // PRE-2001 // .... REF(See Fig 11-1, Item 51, for NHA)

1 DG895-RH • RIGHT HAND SUPPORT PLATE ........................................... 1

2 DG895-LH • LEFT HAND SUPPORT PLATE ............................................. 1

3 DG895-1 • SUPPORT LEG ....................................................................... 2

4 DG895-2 • SUPPORT LEG ....................................................................... 2

5 DG895-3 • SUPPORT BLOCK .................................................................. 4

6 DG895-4L • LEFT HAND ADJUSTING SCREW BLOCK ........................... 1

7 DG895-4R • RIGHT HAND ADJUSTING SCREW BLOCK ......................... 1

8 DG895-5L • COMP SCREW - LEFT HAND THREAD ............................... 1

9 DG895-5R • COMP SCREW - RIGHT HAND THREAD ............................. 1

10 DG895-6 • SUPPORT ROD ...................................................................... 2

11 BGFM-15-25-S60 • MOTOR ................................................................................ 1

12a DG895MP-R • • MOTOR MOUNT - RIGHT (13 SIDE MOUNT) .................... 1

b DG895MP-L • • MOTOR MOUNT - LEFT (10 SIDE MOUNT) ...................... 1

13 DG895MPS • • MOTOR MOUNT SPACER ................................................. 1

14 DG1236 • BEVEL GEAR ......................................................................... 1

15 DG1218-1 • BEVEL GEAR ......................................................................... 1

16 DG895MC-1, -2 • • MOTOR GEAR COVER - 2 PC .......................................... 1

17 DG895LHC • • LEFT HAND GEAR COVER - 2 PC ................................... 1

18 DG895RHC • • RIGHT HAND GEAR COVER - 2 PC ................................. 1

19 DG1224-50 • BEVEL GEAR - 1/2 BORE ..................................................... 2


21 HT11R • • HANDLE .............................................................................. 1

22 108643-18 • • 24 X 3/4 SHAFT .................................................................. 2

23 ISCC-075-075 • COUPLING .............................................................................. 1

24 E5064-SET • B-1 TOP IRON - PAIR ............................................................. 1

25 108642-2 • SHAFT - PIPE ROLLER - 39 3/4 W/THREADED ENDS ....... 3

26 108643-4 • SHAFT - PIPE ROLLER - 39 1/2 ............................................ 1

27 108643-5 • SHAFT - PIPE ROLLER - 42 .................................................. 1

28 108425 • PIPE ROLLER - 1 7/8 ............................................................. 5

29 RAL012NPP • BEARING/COLLAR SET / FAFNIR, COLFS450 .................... 1030 SS2432-20 BUSHING - HANDLE SHAFT - MOTOR SIDE .......................... 131 SS2432-8 • BUSHING - HANDLE SHAFT - NON - MOTOR SIDE............ 1

32 SS1620-12 • BUSHING - COMP SCREW ................................................... 4

33 SS3240-24 • BUSHING - SUPPORT ROD .................................................. 2

34 80MXL025 • BELT - COUNTER ................................................................... 1

35 72MXL025 • COUNTER GEAR - COMP SHAFT ........................................ 1

36 10MXL025 • • COUNTER GEAR - COUNTER .......................................... 1

37a 5X71LAC101 • • COUNTER - LEFT HAND.................................................... 1

b 5X71RAC101 • • COUNTER - RIGHT HAND.................................................. 1



PER

ASSY


Page 179

38 DG895-7 • • BUSHING - B1 TOP IRON .................................................. 2

39 HARDWARE • • • 1/2 X 2 1/2 ROLL PIN ..................................................... 4

40 HARDWARE • • • 5/15 - 18 X 1 FLAT HEAD SOCKET HEAD SCREW .... 16

41 HARDWARE • • • 1/2 E-CLIPS .................................................................... 2

42 HARDWARE • • • 1/2 FLAT WASHER ........................................................ 2

43 HARDWARE • • • 5/16 LOCK WASHER ..................................................... 6

44 HARDWARE • • • 5/16 - 18 X 1 SOCKET HEAD CAP SCREW ................ 2

45 HARDWARE • • • 5/16 - 18 X 1 1/4 SOCKET HEAD CAP SCREW .......... 4

46 HARDWARE • • • 5/16 - 18 X 1 1/4 HEX HEAD BOLT ............................... 4

47 HARDWARE • • • 5/16 - 18 X 3/8 SOCKET HEAD SET SCREW .............. 8

48 HARDWARE • • • 1/4 - 20 X 3/8 SOCKET HEAD SET SCREW ................ 12

49 HARDWARE • • • 10 - 32 X 1/2 MACHINE SCREW ................................... 3



52 HARDWARE • • • 3/4 X 1 SHOULDER BOLT ............................................. 2


54 HARDWARE • • • 5/8 - 11 JAM NUT ........................................................... 2

55 HARDWARE • • • 6 - 32 X 1/4 MACHINE SCREW ..................................... 4


57 HARDWARE • • • 1/2 - 13 X 1 3/4 HEX HEAD BOLT ................................. 2

58 COMP-BOX • • ELECTRICAL BOX //NS// ................................................... 1

59 T3043 • • SWITCH SELECT SPRING RETURN //NS// ...................... 1

60 T2 • • BLOCK, CONTACT, 2 NORMALLY OPEN //NS// ............. 1

61 TM50 • • LEGEND PLATE, OFF/REVERSE //NS// .......................... 1

62 E-1PB • • ONE HOLE STATION BOX - HOFFMAN (STACKED UNITS 1AND 3 AND 4 HIGHS ONLY) //NS//

63 COMP-BOX-C • • COVER, ELECTRICAL BOX // NS // .................................. 1

64 2W938 • • SWITCH, ELECTRICAL // NS // ......................................... 2

65 DG895-9 • • BRACKET // NS // .............................................................. 1



PER

ASSY


Page 180

Fig

ure

11

-57

B. F

ull

Mo

tori

ze

d C

om

pe

ns

ato

r (P

os

t-2

00

1)

(1 o

f 4

)

34

34

464

03

7

41

41

44 14

12

7 36

35 4

26

39

2

1 27

412

8

26

41

441

24

21

54

212

51

28

24

22

293

0

2741

28

3

16

39

53

5

36

41

42

15

13

44

38

42

42

14

42

13

44

49

32

31

24

19

24 4

8

33

47

17

18

17

34

41

711

50

42 4

2

42

45 16

42

95

0

25

84

3

11

10

344

1 46

40

373

8

37

51

19

20

24

23

48

47

33


Page 181

Figure 11-57B. Full Page Motorized Compensator - Post 2001 (2 of 4)

1

3

45 6

78b

8a

9

2

10

1112


Page 182

20

21 22

23

24 2526 27

28

29

30

31

13

14 15 16

17

18

19


32b32a

52


Page 183

5354

55

56

57

58

59

60



Page 184

ASSEMBLY FULL PAGE MOTORIZED COMPENSATOR // POST-2001 // .. REF(See Fig 11-1, Item 51, for NHA)

1 DG895-3 • SUPPORT BLOCK .................................................................. 4

2 DG895-4L • LEFT HAND ADJUSTING SCREW BLOCK ........................... 1

3 DG895-4R • RIGHT HAND ADJUSTING SCREW BLOCK ......................... 1

4 DG895-5L • COMP SCREW - LEFT HAND THREAD ............................... 1

5 DG895-5R • COMP SCREW - RIGHT HAND THREAD ............................. 1

6 DG895-6 • SUPPORT ROD ...................................................................... 2

7 BGFM15-040SFICX • MOTOR ................................................................................ 1

8a DG895MP-R • • MOTOR MOUNT - RIGHT (13 SIDE MOUNT) .................... 1

b DG895MP-L • • MOTOR MOUNT - LEFT (10 SIDE MOUNT) ...................... 1

9 DG1236 • BEVEL GEAR ......................................................................... 1

10 DG1218-1 • BEVEL GEAR ......................................................................... 1

11 DG895MC-1, -2 • • MOTOR GEAR COVER - 2 PC .......................................... 1

12 DG895LHC • • LEFT HAND GEAR COVER - 2 PC ................................... 1

13 DG895RHC • • RIGHT HAND GEAR COVER - 2 PC ................................. 1



16 HT11R • • HANDLE .............................................................................. 1

17 108643-18 • • 24 X 3/4 SHAFT .................................................................. 2

18 ISCC-075-075 • COUPLING .............................................................................. 1

19 E5064-3-SET • B-1 TOP IRON - PAIR ............................................................. 1

20 SA108642-2 • SHAFT - PIPE ROLLER - 39 3/4 W/THREADED ENDS ....... 5

21 108643-4 • SHAFT - PIPE ROLLER - 39 1/2 ............................................ 1

22 108643-5 • SHAFT - PIPE ROLLER - 42 .................................................. 1

23 108425 • PIPE ROLLER - 1 7/8 ............................................................. 1

24 RAL012NPP • BEARING/COLLAR SET / FAFNIR, COLFS450 .................... 225 SS2432-12 BUSHING - HANDLE SHAFT - MOTOR SIDE .......................... 126 SS2432-10 • BUSHING - HANDLE SHAFT - NON - MOTOR SIDE............ 1

27 SS1620-12 • BUSHING - COMP SCREW ................................................... 4

28 SS3240-24 • BUSHING - SUPPORT ROD .................................................. 2

29 80MXL025 • BELT - COUNTER ................................................................... 1

30 72MXL025 • COUNTER GEAR - COMP SHAFT ........................................ 1

31 10MXL025 • • COUNTER GEAR - COUNTER .......................................... 1

32a 5X71LAC101 • • COUNTER - LEFT HAND.................................................... 1

b 5X71RAC101 • • COUNTER - RIGHT HAND.................................................. 1

33 HARDWARE • • • 1/2 X 2 1/2 ROLL PIN ..................................................... 4

34 HARDWARE • • • 5/15 - 18 X 1 FLAT HEAD SOCKET HEAD SCREW .... 16

35 HARDWARE • • • 1/2 E-CLIPS .................................................................... 2

36 HARDWARE • • • 1/2 FLAT WASHER ........................................................ 2

37 HARDWARE • • • 5/16 LOCK WASHER ..................................................... 6


NO. NUMBER 1 2 3 4 5 6 7

UNITS

PER

ASSY

Page 184


Page 185

38 HARDWARE • • • 5/16 - 18 X 1 SOCKET HEAD CAP SCREW ................ 2

39 HARDWARE • • • 5/16 - 18 X 1 1/4 SOCKET HEAD CAP SCREW .......... 4

40 HARDWARE • • • 5/16 - 18 X 1 1/4 HEX HEAD BOLT ............................... 4

41 HARDWARE • • • 5/16 - 18 X 3/8 SOCKET HEAD SET SCREW .............. 8

42 HARDWARE • • • 1/4 - 20 X 3/8 SOCKET HEAD SET SCREW ................ 12




46 HARDWARE • • • 3/4 X 1 SHOULDER BOLT ............................................. 2


48 HARDWARE • • • 5/8 - 11 JAM NUT ........................................................... 2



51 HARDWARE • • • 1/2 - 13 X 1 3/4 HEX HEAD BOLT ................................. 2

52 COMP-BOX • • ELECTRICAL BOX //NS// ................................................... 1

53 T3043 • • SWITCH SELECT SPRING RETURN //NS// ...................... 1

54 T2CP • • BLOCK, CONTACT, 2 NORMALLY OPEN //NS// ............. 1

55 TM50 • • LEGEND PLATE, OFF/REVERSE //NS// .......................... 1

56 E-1PB • • ONE HOLE STATION BOX - HOFFMAN (STACKED UNITS 1AND 3 AND 4 HIGHS ONLY) //NS//

57 COMP-BOX-C • • COVER, ELECTRICAL BOX // NS // .................................. 1

58 2W938 • • SWITCH, ELECTRICAL // NS // ......................................... 2

59 DG895-9 • • BRACKET, LIMIT SWITCH MOUNTING // NS // ................ 1

60 DG895-10 • CONDUIT SUPPORT BRACKET ............................................ 1


NO. NUMBER 1 2 3 4 5 6 7

UNITS

PER

ASSY

Page 185


XI-186

Figure 11-58. Belt Drive/Covers - Stack (1 of 2)

67

1011

1011

676

7

12

4

10

11

10

11

7 6

76

8

11

10

13 76

6

7

97

61011


XI-187

Figure 11-58. Belt Drive/Covers - Stack (2 of 2)

9

1

3

45

8

2

12

13


XI-188

ASSEMBLY BELT DRIVE/COVERS (STACK UNIT ONLY) (See Fig 11-1, ... REFItem 52, for NHA)

1 P34 14M40 • PULLEY ................................................................................ 2

SK1 11/16 • • BUSHING ............................................................................ 2

2 2450 14M40 • DRIVE BELT............................................................................ 1

3 SADG89706 • BELT REGISTER ASSEMBLY ............................................... 1

4 40669-22 • COVER - TOP SECTION - 2 PC. ........................................... 1


6 HARDWARE • • 1/4 - 20 X 1/2 BUTTON HEAD SOCKET ............................ 8HEAD CAP SCREW


8 109957-6 • COVER - CENTER SECTION ................................................. 1

9 12170-6 • COVER - BOTTOM SECTION ................................................ 1

10 HARDWARE • • 5/16 - 18 X 3/4 BUTTON HEAD SOCKET .......................... 6HEAD CAP SCREW


12 DG213-1 • DRIVE SHAFT END COVER - 2" DEEP ................................ 1

13 109957-3 • CENTER ACCESS PLATE ..................................................... 1

***** ITEMS 4,5,8,and 9 CAN BE COMBINED UNDER P/N SA12170-3



PER

ASSY


XI-189

Figure 11-59. Belt Drive Covers - 2 High (1 of 2)

56

9 10

10

5

5612

4

65

8

56

65

8

10

10

9

9

6

9

11

5

66

5


XI-190

Figure 11-59. Belt Drive/Covers - 2 High (2 of 2)

8

7

3

1

4

2

12

11


XI-191

ASSEMBLY BELT/DRIVE/COVERS (2 HIGH ONLY) (See Fig 11-1, ............ REFItem 53, for NHA)

1 P34 14M40 • PULLEY ................................................................................ 2

SK1 11/16 • BUSHING ................................................................................ 2

2 2450 14M40 • DRIVE BELT............................................................................ 1


4 40669-3 • COVER - TOP SECTION ........................................................ 1









***** ITEMS 4,7,and 8 CAN BE COMBINED UNDER P/N SA12170-4



PER

ASSY


XI-192

Figure 11-60. Belt Drive/Covers - 3 High - #10 Side (1 of 2)

56 1

6 5

34

43

34

43

56

2

65

5

6

5

6


XI-193


1

2


XI-194

ASSEMBLY BELT DRIVE/COVER - 10 SIDE (3 HIGH ONLY) (See .............. REFFig 11-1, Item 54, for NHA)









PER

ASSY


XI-195


1

3

2

1

3

2

1

4

9

10

11

65

65

65

65

87

8

7

78

87

12

78

78


XI-196


2

1

3

4

9

13

10

11

12


XI-197

ASSEMBLY BELT DRIVE/COVERS - 13 SIDE (3 HIGH ONLY) (See Figure REF11-1, Item 55, for NHA)

1 P34 14M40 • PULLEY ................................................................................ 4

SK1 11/16 • BUSHING ................................................................................ 4

2 2450 14M40 • DRIVE BELT............................................................................ 2











13 DG89711 • SPACER, BELT REGISTER ................................................... 4

***** ITEMS 4,9,10,and 11 CAN BE COMBINED UNDER P/N SA12170-2



PER

ASSY


XI-198


78

11

12

87

16

11

12

78

1211

11 12

11 12

11 12

88

7

11

12

12

11

87

12

11

11

8

12

14

13

610

5

4

3

9

2

1

7

15


XI-199


12

3

5

6

9

4

10

13

14

15

16


XI-200


1 24 x H200QD • PULLEY ................................................................................ 1

SF1 11/16 • BUSHING ................................................................................ 1

2 980 x H200 • DRIVE BELT............................................................................ 1

3 DG89709 • IDLER PULLEY ASSEMBLY.................................................. 1

4 2450 14M40 • DRIVE BELT............................................................................ 1


6 P34 14M40 • PULLEY ................................................................................ 1

SK1 11/16 • BUSHING ................................................................................ 1



9 101988-2 • COVER - TOP SECTION ........................................................ 1




13 40670-4-1 • COVER - BOTTOM SECTION - 3 PC. ................................... 1




***** ITEMS 9,10,13,14,and 15 CAN BE COMBINED UNDER P/N SA40670



PER

ASSY


XI-201

Figure 11-63. Belt/Covers - 4 High - #13 Side (1 of 2)

5

1

3

2

1

3

2

1

8

7

11

10

14

9

4

65

6

78

56

5

87

87

138 7

78

8

7

8

12

7

14

6

5

6

56

8

7


XI-202


2

1

3

4

9

14

10

11

13

12


XI-203


1 P34 14M40 • PULLEY ................................................................................ 4

SK1 11/16 • BUSHING ................................................................................ 4

2 2450 14M40 • DRIVE BELT............................................................................ 2












14 DG89711 • SPACER, BELT REGISTER ................................................... 4

***** ITEMS 4, 9,10, and 11 CAN BE COMBINED UNDER P/N SA12170-2



PER

ASSY


XI-204


Documents

430 Manual - 2006