MechanicsR300 Completo PDF

Product Training Sheetfed Presses
Service Manual Mechanics
ROLAND 300
C95A 6423 39 - 12.11.2004

Preface
Dear course participant
You are attending a training course at MAN Roland Druckmaschinen AG, to receive
information and instructions about our products.
Only the sucessful completion of MAN Roland training courses qualiﬁes you for maintenance
and repair on MAN Roland products. This Service Manual alone is not an authorisation for
maintenance and repair on MAN Roland products.
The Service Manual will help you to use the aquired knowledge in your daily practice.
Since the work on documentation is never complete, we always welcome suggestions,

corrections and contributions. Feel free to speak to your trainer or contact us directly.
[email protected]
We wish you a successful training session and thank you for your cooperation.
MAN Roland Druckmaschinen AG

Business Sector Sheetfed Presses
Product Training
Copyright 2003 - 2005 MAN Roland Druckmaschinen AG
The copyright for this technical documentation remains with

MAN Roland Druckmaschinen AG.
All rights, including reproduction and distribution rights as well
astranslation rights, are reserved. No part of the documentation
may be reproduced in any form (printing, photocopying,
microﬁlm or any other method) without written authorization
or be stored, processed, reproduced or distributed using
electronic systems. Every misuse is punishable and requires
restitution of damages.
C95A 6423 39 - 12.11.2004

Service Training Mechanics Roland 300
Contents
0
0 General information
Preface / customer service / locations
1 Modules
2 Technical data
3 Gripper settings
4 Transport of the machine
5 Installation of the press
6 Feeder till series 330

6A from series 331
7 Infeed
8 Printing units
8A S&W
9 Delivery
10 Inking unit
11 Dampening unit
12 Washing devices
13 Lubrication
14 Air supply / pneumatics
15 Electrical information
16 CPL
17 Coating unit
C 95A 6423 39 – 13. Nov. 2003 0-1

0 Contents
0-2 C 95A 6423 39 – 13. Nov. 2003

Modules
1
1 Modules
1.1 Machine .......................................................................................... 1-3
1.2 Aggregates..................................................................................... 1-3
1.3 Feeder............................................................................................. 1-4
1.4 Printing unit ................................................................................... 1-4
1.5 Delivery .......................................................................................... 1-5
1.6 Extended delivery with coating module ...................................... 1-5
1.7 Coating unit.................................................................................... 1-6
1.8 List of Assembly Groups .............................................................. 1-7
C 95A 6423 39 – 11. Nov. 2003 1-1

1 Modules
1-2 C 95A 6423 39 – 11. Nov. 2003

Modules
1
1.1 Machine
1 extended delivery 4 intermediate printing units

2 coating module 5 1. printing unit
3 delivery printing unit 6 feeder
1.2 Aggregates
1 2 3 4 5 6 7
8 9
1001.cdr
1 dry sprayer 6 washing agent reserve container

2 ink dryer 7 coolant refrigerator
3 coating pump 8 central control console
4 air-center 9 plate scanner
5 lubrication station
C 95A 6423 39 – 11. Nov. 2003 1-3

1 Modules
1.3 Feeder
1 suction tape feed board

2 suction tape - blower
3 double-sheet detection
4 suction head
5 non-stop
6 pile supporting plate
1.4 Printing unit
1 2nd transfer cylinder or

collecting drum
2 3rd transfer cylinder or
reversing drum
3 1sts transfer cylinder
4 impression cylinder
5 blanket cylinder
6 plate cylinder
7 inking unit
8 dampening unit
9 feed cylinder
(feed drum)
10 stop gripper
11 feed
1-4 C 95A 6423 39 – 11. Nov. 2003

Modules
1
1.5 Delivery
1 pile supporting plate 6 suction roller (sheet slow-down)

2 dry sprayer 7 sheet decurler
3 non-stop 8 air track
4 blowing pipes 9 ink dryer exhaust
5 blast frame 10 air track with water cooling
1.6 Extended delivery with coating module
C 95A 6423 39 – 11. Nov. 2003 1-5

1 Modules
1.7 Coating unit
1 bailing roller 6 3. transfer cylinder

2 ink form roller 7 delivery – sprocket wheel
3 form cylinder 8 2. transfer cylinder
4 wash-up device 9 take-off drum
Instead of 1+2 anilox roller and chamber blade
1-6 C 95A 6423 39 – 11. Nov. 2003

Modules
1
1.8 List of Assembly Groups
001 side frame 031 inking unit

002 drive 038 wash-up devices
003 plate cylinder 045 – 048 dampening unit
004 blanket cylinder 061 – 074 delivery
006 1. transfer cylinder 061 sprocket wheel shaft
007 2. transfer cylinder / collecting drum 062 sprocket wheels
008 impression cylinder 065 suction roller
009 3. transfer cylinder / reversing drum 080 feeder
011 – 013 feed 091 electrical equipment
014 feed cylinder 096 pneumatic control
017 register adjustment
026 – 028 stop grippers
The numbers correspond to those indicated in the catalogue of spare parts!
C 95A 6423 39 – 11. Nov. 2003 1-7

1 Modules
1-8 C 95A 6423 39 – 11. Nov. 2003

Reference values
2
2 Reference values
2.1 Machine Configurations................................................................ 2-3
2.2 Sizes ............................................................................................... 2-4
Paper – end sizes DIN 476.............................................................. 2-4
MAN Roland size identification ........................................................ 2-4
2.3 Abbreviations / Explanations ....................................................... 2-5
2.4 Degree dial ..................................................................................... 2-6
2.5 Gripper adjustment gauges .......................................................... 2-7
1. Printing unit.................................................................................. 2-7
Intermediate printing units without perfecting .................................. 2-7
Intermediate printing units with perfecting ....................................... 2-8
Last printing unit without perfecting ................................................. 2-8
2.6 Gripper opening and closing times ............................................. 2-9
Printing unit.................................................................................... 2-10
Intermediate printing unit with perfecting ....................................... 2-11
Intermediate printing unit without perfecting .................................. 2-11
Last printing unit with perfecting, Sprocket shaft or take-off drum . 2-12
Last printing unit without perfecting, Sprocket shaft or take-off
drum .............................................................................................. 2-12
2.7 Transfers in the 1. printing unit.................................................. 2-13
2.8 Perfecting and collecting drum .................................................. 2-14
2.9 Feeder timing, suction head movement sequence................... 2-15
Series 311 to 314 .......................................................................... 2-15
Series 315 to 319 .......................................................................... 2-16
From series 320 ............................................................................ 2-17
2.10 Feed, functional sequence from................................................. 2-18
Series 311 to 314 .......................................................................... 2-18
From series 315 to 316.................................................................. 2-19
From series 317 to 326.................................................................. 2-20
From series 327............................................................................. 2-21
C 95A 6423 39 – 08. Jul. 2004 2-1

2 Reference values
2.11 Inking units...................................................................................2-22

2.12 Cylinder specifications................................................................2-23
2.13 Stepper (SM) and potentiometer motors (PM)...........................2-24
2.14 Function and stripe test ..............................................................2-28
Setting up and function test from series 337 ..................................2-30
2.15 Maximum torque in Nm ...............................................................2-33
Screws DIN 912, 931 etc. with a control thread .............................2-33
Necked-down bolts ........................................................................2-33
Notes about special torque values for the R 300: ..........................2-34
2.16 Devices, gauges and tools ..........................................................2-35
2-2 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
2.1 Machine Configurations

Euro 530 x 740mm US 23“ x 29“ (590 x 740 mm) dimensions in
dimensions in mm inches
Sheet size max. 530 x 740 max. 23 1/4“ x 29 1/8“ / (590 x 740 mm)
min. 260 x 400 min. 10 1/4“ x 15 3/4“
max. S+W 530 x 740 max. S+W 23 1/4“ x 29 1/8“ / (590 x 740 mm)
Printing area, first side printing max. 510 x 735 max. 22 7/8“ x 28 15/16“ / (580 x 735 mm)
Printing area, printing and perfecting max. 510 x 735 max.22 15/32“ x 28 15/16“ / (570 x 735 mm)
Paper edge to leading edge of print 10 (9.5 – 10.5) .393“ (374“ - .4133“)
Substrate thickness 0.04 – 0.6 .0015“ - .023“
Performance in first side printing 15 000 S / h 15 000 S / h
from series 341 16 000 S / h 16 000 S / h
Performance in printing & perfecting mode, 15 000 S / h 15 000 S / h
according to the flexural stiffness
Plate cylinder standard:
Plate cylinder ø 235 9.291“
Plate cylinder - undercut 0.5 .019“
Leading edge of plate to - edge of print 52 / 53 1 11/16“ / 2.087“
Plate thickness max. 0.3 max. .012“
Printing plate (length x width) 605 x 740 26“ x 29 1/8“ / (660.4 x 739.8mm)
Register adjustment +/- 1.5 +/- .0590"
Plate cylinder CPL:
Plate cylinder ø 235.2 9.259“
Plate cylinder - undercut 0.4 .0157“
Leading edge of plate to - edge of print 43 1.692“
Plate thickness 0.3 .012“
Printing plate (length x width) 605 x 740 26 5/8“ x 29 1/8“ / (676.3 x 739.8mm)
Register adjustment +/- 1.25 +/- .0492
Blanket cylinder (refer to chapter 8)
Blanket, with bars (refer to the series) 770 x 750 30 5/16“ x 29 1/2“
Blanket thickness 1.9 .075“
Blanket cylinder - undercut 2 .078“
Blanket cylinder ø 232 9.133“
Impression cylinder:
Impression cylinder ø 236 9.291“
Coating module:
Take-off drum ø 472 18.5826"
2. Transfer cylinder ø 472 18.5826"
3. Transfer cylinder ø 236 9.291“
Impression cylinder ø 472 18.5826"
Form cylinder ø 230.8 18.1732"
Form cylinder - undercut 2.6 .1023"
Bailing rollers ø 143.4 5.6456"
Ink form rollers ø 143.2 5.6377"
Feeder pile height main pile 1050 41.338“
residual pile 150 5.905“
Delivery pile height main pile 1080 42.519“
residual pile 130 5.118“
— The Data can vary to the respective series —
C 95A 6423 39 – 08. Jul. 2004 2-3

2 Reference values
2.2 Sizes
Paper – end sizes DIN 476
DIN - sizes A0 A1 A2 A3 A4 A5 A6
Finished sheet in 841 x 1189 594 x 841 420 x 594 297 x 420 210 x 297 148 x 210 105 x 148
Paper sizes (DIN 476) can be extended upwards from 2A0 (1189 x 1682) to
4A0 (1682 x 2378) and downwards to A10 (26 x 37).
Maximal paper sizes for different size categories:
Size category 00 01 0B 1 2 2C
Finished sheet in mm 360 x 520 480 x 660 520 x 720 560 x 830 610 x 860 640 x 915
Size category 3B 5 5W 6 7 7B
Finished sheet in mm 720 x 1020 890 x 1260 920 x 1300 1000 x 1400 1100 x 1600 1200 x 1600
MAN Roland size identification
Size Max. paper Min. paper

Machine
identification size (mm) size (mm)
00 Roland Practica 360 x 520 160 x 180

01 Roland Practica 480 x 660 210 x 280
0B Roland 200 520 x 740 210 x 280
0B Roland 300 530 x 740 260 x 400
Option 590 x 740 210 x 280
0B Roland 500 530 x 740 260 x 400
Option 590 x 740
3B Roland 700 740 x 1040 340 x 480
4 Roland 900 820 x 1130 460 x 620
5 Roland 900 890 x 1260 500 x 700
5B1 Roland 900 940 x 1300 500 x 700
5B2 Roland 900 965 x 1300 500 x 700
6 Roland 900 1000 x 1400 600 x 850
6B1 Roland 900 1020 x 1420 500 x 700
6B2 Roland 900 1020 x 1420 600 x 850
7 Roland 900 XXL 1120 x 1620 600 x 920
7b Roland 900 XXL 1200 x 1620 600 x 920
8 Roland 900 XXL 1300 x 1850 700 x 1150
2-4 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
2.3 Abbreviations / Explanations

ABD Automatic Blanket Wash-Up Device automatische Gummituchwaschanlage
ACD Automatic Cylinder Setting Device automatische Plattenzylinderpositionierung
APD Automatic Printing Pressure Adjustment Device automatische Druckbeistellung
APL Automatic Plate Loading vollautomatisches Plattenwechselsystem
ARD Automatic Roller Washing Device automatische Farbwalzenwaschanlage
ASD Automatic Size Positioning Device automatische Formateinstellung An / Ausleger
AUPASYS Automatic Palette System automatisches Palettentransport-System
CBT Computer Based Training Training am Computer
CUA Computer Assisted Support (Computer unterstützte Anweisung)
CUL Computer Assisted Learning (Computer unterstütztes Lernen)
CCC Color Contamination Check Farbverschmutzungskontrolle
CCI Computer Controlled Inking densitometrische Farbregelanlage
Multi CCI Computer Controlled Inking Anschluß mehrerer Maschinen möglich
CCI-2D Computer Controlled Ink - 2 Dimension (XY) densitometrische Farbregelanlage, zwei-
dimensionale Messung, beliebige Position
CPL Cocking Plate Loading auto. Platteneinzug und Diagonalverstellung
EPS Electronic Plate Scanner Plattenleser für Farbschiebervoreinstellung
FDM Ink Density Measuring Device (Farb-Dichte-Meßanlage)
GTW Blanket Wash-Up Device (Gummituch Waschanlage)
LCS Low Coverage Stabilization Farbdosierung mit max. Heberstreifer, aber
nur jeder 2. Farbschieber auf
MDC Machine Data Collection Maschinendatenerfassung für Kon.
MIS Management Information Systems
PECOM Process Electronic Concept Prozeß-Elektronik-Konzept, Druckereivernetzung
PEC Process Electronic Control alle Steuer- und Regelfunktionen RCI, CCI, usw.
PEO Process Electronic Organization Organisationsebene im Drucksaal
PEM Process Electronic Management Management-Ebene, PMI, PEO und PEC
PBR PECOM Barcode Reader Strichkodeleser zur Betriebdaten-Erfassung,
nur bei PMI
PMI PECOM Management Interface Netzwerkanbindung für Management
Informations-System
PPI PECOM Pre-press Interface Übernahme von Daten aus der digitalen 'Druck-
vorstufe zur Farbvoreinstellung
PRI PECOM RCI Interface Anbindung Konv. RCI-Maschinen
PST PECOM Software Trainer
PPC PECOM Press Center Leitstand der Druckmaschine
PPL Power Plate Loading automatischer Platteneinzug / ausstoß
PPL2
PPS Product Planning System
RCI Remote Controlled Ink ferngesteuerte Farbregelung
RQM Register Quality Magnifier Videolupe
TPP Technical Press Preparation Pecom-Ebene, Auftragsvorbereitung
TQM Total Quality Management
Used abbreviations (Fitters’ training)

DW Druckwerk (printing unit) SM Schrittmotor (stepper motor)
DA Druckanfang (leading edge) PM potentiometer motor
DE Druckende (tail edge) LED Leuchtdiode (light emitting diode)
A-Seite Antrieb-Seite (drive side) LS Leitstand (central control)
B-Seite Bedienungs-Seite (operation side) DZW Druckzylinder-Waschvorrichtung
(impression cylinder wash-up device)
ANL Anlegerseite (feeder side) FWW Farbwalzen-Waschvorrichtung
(inking roller wash-up device)
AUSL Auslegerseite (delivery side) GTW Gummituch-Waschvorrichtung
(blanket wash-up device)
BMK Betriebsmittelkennzeichen S&W Schön- und Widerdruck (printing & perfecting)
(means of production identification)
C 95A 6423 39 – 08. Jul. 2004 2-5

2 Reference values
2.4 Degree dial

The degree dial is fixed to the printing units on the A-side of the impression cylinder.
To fix it replace the screw on the cover disk by a prepared hex screw (thread boring M6 in screw head).
Advance machine to “0°“ and clamp degree dial/pointer at “0°“.

A magnetic stand with dial gauge can be used as a pointer.
Now you can check all machine times, e.g. gripper opening and closing times.
The degree dial is fixed to the feeder on the air control roller B-side.
Set the degree dial/pointer to 300° while the forwarder sucker air is “OFF“.
New feeder starting from series 331: pointer to 9° while suction air is “OFF“.
Now you can check control times from the feeder. For feeder times see table.
10 0 350 3
4
20 5 0 10 2 0 3 3 0
3 0 34 0 3 0 3
0 0 3 20
40 0 33 40
32 e An
31 0 6
in leg
0 3 50
ch
5
10
30
29 0 0
er
as
0 2 70 80 90 100 110 240

1 0 1 0 270 280 70 6
0
30
90
280 270 260 250
00 90 80
26
1 2 0 2 50
1
12 23
4
0
0
13 0 2
13 0
23
0
0
14
22 0 1 0
0 50 0 22 0
21 160 21 14
0 2 17 0 1 9 0 2 00 1 50
00
190 180 170 160
2001.cdr
Maschine: Machine
Anleger: Feeder
The degree dial can be cut out and stuck on a board.
2-6 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
2.5 Gripper adjustment gauges
1. Printing unit
View from A-side
Gauge no.: Gauge size Adjustment at

in mm display DW 1
1 stop gripper 099 M 4902 40 4.155 130°
2a feed cylinder 099 M 4903 40 1.5 130°
2b feed cylinder 099 J 0773 30 11.7 130°
3a impression cylinder 099 A 3769 13 14.038 55°
3b impression cylinder 099 I 2606 30 Ø 36.85 340°
4 1. transfer cylinder 099 A 3769 13 14.038 167°
Intermediate printing units without perfecting
Gauge no.: Gauge size

in mm
1 2. transfer cylinder 013 A 0658 13 92.45
3 impression cylinder 099 I 2606 30 Ø 36.85
View from A-side
C 95A 6423 39 – 08. Jul. 2004 2-7

2 Reference values
Intermediate printing units with perfecting

in mm
2 reversing drum 099 B 4464 30 7.68
View from A-side
Last printing unit without perfecting

in mm
4 sprocket shaft 099 J 2608 30 2x 0.4
View from A-side
Gripper opening and closing times
- The grippers close or open always 1° before or after the transfer point.
Grippers, with the exception of stop grippers, close at 161°.
- 1° = 2 mm on the impression cylinder circumference, transfer travel = 4 mm.
– Angular displacement between printing units is 95°.
2-8 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
2.6 Gripper opening and closing times
View from A-side
Display:
Display DW 1
Use a feeler gauge of 0.1mm to

check gripper opening and closing
times.
The machine must be in straight

printing mode and rotating in paper
run direction (forward) when doing
so.
The correct setting of the grippers

is a condition.
If a correction has to be made,

adjust the corresponding cam
holders.
C 95A 6423 39 – 08. Jul. 2004 2-9

2 Reference values
1. Printing unit
View from A-side
Last printing unit with sprocket shaft or coating unit with take-off drum
(degree dial on impression cylinder A-side)
View from A-side
R 302 Gripper Gripper

closed open
4 sprocket shaft 140° -0.1° -------
4a take-off drum 140° -0.1° 257.5° +0.1°
R 304
4 sprocket shaft 310° -0.1° -------
4a take-off drum 310° -0.1° 67.5° +0.1°
R 305
4 sprocket shaft 215° -0.1° -------
4a take-off drum 215° -0.1° 332.5° +0.1°
R 306
4 sprocket shaft 120° -0.1° -------
4a take-off drum 120° -0.1° 237.5° +0.1°
R 308
4 sprocket shaft 290° -0.1° -------
4a take-off drum 290° -0.1° 47.5° +0.1°
2-10 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
Intermediate printing unit with perfecting

Intermediate printing unit without perfecting

C 95A 6423 39 – 08. Jul. 2004 2-11

2 Reference values
Gripper opening and closing times
Last printing unit with perfecting,

Sprocket shaft or take-off drum
Last printing unit without perfecting,

Sprocket shaft or take-off drum
2-12 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
2.7 Transfers in the 1. printing unit
Drive direction Display: Unit 1

161° -1° Stop gripper
Stop gripper
255° -0,1° Feed cylinder- gripper closed

256° Transfer point, both grippers closed 2° = 4 mm
257° +0,1° Stop gripper open
Feed cylinder
19° -0,1° Impression cylinder- gripper closed

21° +0,1° Feed cylinder- gripper open
Impression cylinder
DW 1
236° -0,1° 1.Transfer cylinder - gripper closed

238° +0,1° Impression cylinder - gripper open
1.Transfer cylinder
107,5° -0,2° 2.Transfer cylinder - gripper closed

108,5° Transfer point, both grippers closed 2° = 4 mm
109,5° +0,2° 1.Transfer cylinder - gripper closed
DW 2 2.Transfer cylinder 2011e.cdr
C 95A 6423 39 – 08. Jul. 2004 2-13

2 Reference values
2.8 Perfecting and collecting drum

Collecting drum = 2. transfer cylinder with sucker)
Indication on display DW 1
Machine in single-side Printing unit Printing unit Printing unit

printing mode 2 3 4
single-side printing – 240° 145° 50°
grippers open
single-side printing – 53.5° 318.5° 223.5°
grippers closed
Caution: The machine has to be “set to” a paper length of 500mm when checking the
perfecting gripper!
Machine in perfecting mode Printing unit Printing unit Printing unit

2 3 4
perfecting gripper closed 294.3° 199.3° 104.3°
Suction box in
collecting drum.
Caution: transfer 3°!
Suction air off / Blast air on 297.3° 202.3° 107.3°
Setting by eccentric bolt
B-side at air control valve
Collecting drum
Gripper open 296.3° 201.3° 106.3°
Can be checked only and not
adjusted!
(Display A-side at “50“!)
Checking the perfecting gripper in a separate printing unit
In this case a degree dial has to be mounted in the perfecting unit.

(Degree dial on impression cylinder A-side)
In single-side printing mode:

single-side printing – 335°
grippers open
single-side printing – 148.5°
grippers closed
In perfecting mode:
single-side printing – 335°
grippers open
perfecting - grippers closed 94°
2-14 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
2.9 Feeder timing, suction head movement sequence

Series 311 to 314
- Attach degree dial to suction head of the air distribution roller on B-side.
The pointer is fixed at 300° when forwarding sucker air is off.
– 1° equals 0.46 mm on the suction tape.
– sheet overlap 165 mm.
C 95A 6423 39 – 08. Jul. 2004 2-15

2 Reference values
Series 315 to 319
Air control Mechanic run
60° Seperating suckers highest position
80° pressure foot lowest position
Supporting air ON 100°
Forarder suckers air ON147° 145° Sheet flap start to move
Pick-up suckers air 170°

175° Forwarder suckers start to move
225° Pick-up suckers moves down
230° Forwarder rollers start to lift
Supporting air OFF 265°

270° pressure foot start to lift
Seperating air ON 280°
Forwarder suckers air OFF 300° 300° Forwarder rollers touching shaft
Seperating air ON 310° 310° Sheeet flap staight 90°
340° Forwarder suckers foremost position
Seperating air OFF 345° 342° Pick-up suckers lowest position

347° Pressure foot highest position
2013E.cdr 355° Pressure footmoves down
2-16 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
From series 320
C 95A 6423 39 – 08. Jul. 2004 2-17

2 Reference values
2.10 Feed, functional sequence from

Series 311 to 314
- Indications with * are generated automatically and need not be checked.

- Suction wheel ø 52.5mm.
2-18 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
From series 315 to 316

- Suction wheel ø 52.5mm.
C 95A 6423 39 – 08. Jul. 2004 2-19

2 Reference values

- Suction wheel ø 40mm.
2-20 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
From series 327

- Suction wheel ø 40mm.
C 95A 6423 39 – 08. Jul. 2004 2-21

2 Reference values
2.11 Inking units

Conditions:
- The printing units have been moved together in the marks during installation.
- All degree data refer to the display DW 1.
- The machine has to be always rotated in forward direction.
- The machine has to be in first-side printing mode!
- The device for the rough adjustment of the plate cylinder has to be latched (“0“ position).
- The pointer (hole) of distribution commencement has to be on “G“!
Series 311 to 315

DW Commence- Fountain Ductor roller
ment of roller starts contacts
distribution to rotate distributor
1 63° 198° 120°

2 328° 103° 25°
3 233° 8° 290°
4 138° 273° 195°
5 43° 178° 100°
6 308° 83° 5°
7 207° 348° 270°
8 118° 253° 175°
From series 316

DW Commence- Fountain Ductor roller
ment of roller starts contacts
distribution to rotate distributor
1 249° 198° 120°

2 154° 103° 25°
3 59° 8° 290°
4 324° 273° 195°
5 229° 178° 100°
6 134° 83° 5°
7 39° 348° 270°
8 304° 253° 175°
The degree data may vary by +/- 3 °.
2-22 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
2.12 Cylinder specifications
C 95A 6423 39 – 08. Jul. 2004 2-23

2 Reference values
2.13 Stepper (SM) and potentiometer motors (PM)
Hand terminal Machine

Name Pos. UNIT Menu 6 Menu 7 Bus max. Basic Leit- Ty- Slot
address move- position stand pe
ment
No. 1/2 in mm in mV No. in mm in mm No. SM/
PM
Feeder:
suction head height adj. 1 1 0.0 - 60 50 5 9 SM 4
suction head
to stop
Suction head size adj. 2 1 0.0 - 61 350 610 10 SM 5
(Option A4) paper stop
to sheet flap
(400)
Feeder timing 3 1 9 - 62 35 gearbox A-side 11 SM 6

horizontal
(17.5) (+/-17.5)
Side stop drive side 4 1 0.0 - 63 270 400 13 SM 7
stop to middle
of machine
Pile supporting plate 5 1 0.0 - 64 30 supporting plate 12 SM 8
in machine middle
(+/-15)
Side stop operating side 6 1 0.0 - 65 270 400 14 SM 9
stop to middle
of machine
Feeder as of series 331
Suction head height adj. 1 1 0,0 - 60 46 5 9 SM 4
Sensor to casting
Suction head size adj. 2 1 0,0 - 61 385 595 10 SM 5
paper stop
to sheet flap
RESERVE 3 62
Side stop drive side 4 1 0,0 - 63 265 46 13 SM 7
Sensor to casting
Side stop operating side 5 1 0,0 - 64 265 46 14 SM 8
Sensor to casting
Pile supporting plate 6 1 0,0 - 65 46 supporting plate 12 SM 9
(+/-23) in machine middle
Feeder timing 7 1 0,0 5000 66 36 11 PM 10
Index bore
(+/-18)
2-24 C 95A 6423 39 – 08. Jul. 2004

Reference values
2

Name Pos. UNIT Menu 6 Menu 7 Bus max. Basic Leit- Ty- Slot
address move- position stand pe
ment
PM
1. printing unit, Unit 1:
Circumference reg. 1 1 0.0 5000 60 +/-1.5 110 A-S 2 PM 4
(on CPL machines) outer tooth front
edge to side wall
(+/-1.25)
Side register 2 1 0.0 5000 61 +/-1.5 110 A-S 3 PM 5
(on CPL machines) inside bearer
to side frame
(+/-1.25)
Ductor roller strip width 3 1 0% 8996 62 100% ink fountain roller 6 PM 6
not moving
Pull-type side guide 4 1 0.0 - 63 195 115 26 SM 7
A-side (Option A4) CPL / 2 paper stop
to side frame
(245)
Pull-type side guide 5 1 0.0 - 64 195 115 27 SM 8
B-side (Option A4) CPL / 2 paper stop
to side frame
(245)
Cover guide height adj. 6 2 0.0 2150 65 2.85 0.15 24 PM 9
cover guides
to feed register
plate
Material thickness A-side 9 2 0.0 2854 60 0.70 2 20 PM 3*
CPL / 1 blanket cylinder
to impression
cylinder
(Leitstand 0.1)
Material thickness B-side 10 2 0.0 2854 61 0.70 2 21 PM 4*
CPL / 1 blanket cylinder
to impression
cylinder
(Leitstand 0.1)
Inking unit: Menu 3
Slides 1-24 1 0.000 1135 1-24 0.5 ink slides touch 1 PM -
ductor
1. printing unit, Unit 1: Menu 3
Front guide adj. 1-5 2 0.135 3320 1-5 +/-0.50 3 19 PM -
front guides to
feed register plate
* Extension rack
C 95A 6423 39 – 08. Jul. 2004 2-25

2 Reference values

Name Pos. UNIT Menu 6 Menu 7 Bus max. Basic Leit- Type Slot
address move- position stand
ment
PM
2-n printing unit (Intermediate units):
Circumference reg. 1 1 0.0 5000 60 +/-1.5 110 A-S 2 PM 4
(on CPL machines) outer tooth front
edge to side frame
(+/-1.25)
Side register 2 1 0.0 5000 61 +/-1.5 85 A-S 3 PM 5
(on CPL machines) inside bearer
to side wall
(+/-1.25)
Ductor roller strip width 3 1 0% 8996 62 100% ink fountain roller 6 PM 6
not moving
Material thickness A-side 4 1 0.0 2854 63 0.70 2 20 PM 7
blanket cylinder
to impression
cylinder
(Leitstand 0.1)
Material thickness B-side 5 1 0.0 2854 64 0.70 2 21 PM 8
blanket cylinder
to impression
cylinder
(Leitstand 0.1)
Gripper opening cam 6 1 0.0 (8924) 65 605 (old: Euro) 23 PM 9
new: Euro/USA
0.0 9440
Coating unit:
Circumference reg. 1 1 0.0 3641 60 +1.5 -0.5 drive gear wheels 2 PM 4
A-side flush
(on CPL machines) (3981)
(+1.25 -0.5)
Side register 2 1 0.0 5000 61 +/-1.5 form cylinder 3 PM 5
centered between
(on CPL machines) (+/-1.25)
side frames
Material thickness A-side 3 1 0.0 2383 62 0.80 2.6 20 PM 6
form cyl. to
impression cyl.
(Leitstand 0.1)
Material thickness B-side 4 1 0.0 2383 63 0.80 2.6 21 PM 7
form cyl. to
impression cyl.
(Leitstand 0.1)
Metering gap A-side 5 1 0.610 6525 64 2 marks above 28 PM 8
each other
Metering gap B-side 6 1 0.610 6525 65 2 marks above 29 PM 9
each other
2-26 C 95A 6423 39 – 08. Jul. 2004

Reference values
2

Name Pos. UNIT Menu 6 Menu 7 Bus max. Basic Leit- Type Slot
address move- position stand
ment
PM
Delivery:
Suction roller size 1 1 0.0 - 60 350 610 15 SM 4
(Option A4) sheet slow-down
to sheet stop
(400)
Sheet jogger A-side 2 1 0.0 - 61 230 147.5 16 SM 5
(Option A4) sheet stop
to wall frame
(235)
Sheet jogger B-side 3 1 0.0 - 62 230 147.5 17 SM 6
(Option A4) sheet stop
to wall frame
(235)
Gripper opening cam 4 1 27.4 8864 63 27.7 cam roller start 42 18 PM 7
C 95A 6423 39 – 08. Jul. 2004 2-27

2 Reference values
2.14 Function and stripe test

Dampening Stripe test till series 336
unit:
The stripe test is activated by pressing together once the two lowest keys of the membrane
keyboard +BA on the feeder side, +CA…+CF on the delivery side. The different functions are
selected by the same keys and activated by “+/-“ keys. (Function 03 is active as long as the “+” key
is pressed). Starting from PS 314XY all functions are activated and deactivated by the “+” key.
To exit the stripe test press once (at the same time) and hold the two lowest keys of the membrane
keyboard.
No. Function BMK Output, -A350 Input, A350

01 Water form roller to bailing roller (Y097) and bridge roller to Y097 Byte 19, Bit 1 ---
1. ink form roller (Y098) Y098 Byte 19, Bit 2 ---
02 Water form roller to bailing roller (Y097) and plate (Y096) Y096 Byte 19, Bit 0 ---
and bridge roller to 1. ink form roller (Y098) Y097 Byte 19, Bit 1 ---
Y098 Byte 19, Bit 2 ---
03 Inch “ahead” dampening unit motor M101 Byte 17, Bit 1 Byte 11, Bit 6
04 All “ON“: ink form rollers (Y014), bridge roller (Y098), water Y014 Byte 19, Bit 3 ---
form roller to bailing roller (Y097) Y098 Byte 19, Bit 2 ---
and to plate (Y096) Y097 Byte 19, Bit 1 ---
Y096 Byte 19, Bit 0 ---
Printing Function test till series 336

units:
The function test is activated by pressing twice (together) the two lowest keys of the membrane
keyboard (on the delivery side of the printing unit). The different functions are selected by the
same keys and activated by “+/-“ keys. (The functions are active as long as the “+” key is pressed).
To exit the function test press once (at the same time) and hold the two lowest keys of the
membrane keyboard
No. Function BMK Output, -A350 Input, -A350

01 Dampening unit motor “ahead“ M101 Byte 17, Bit 1 Byte 11, Bit 6
02 Brush roller GTW motor M015 Byte 17, Bit 2 B.B. 2.3 & 11.4
03 Solenoid valve GTW water Y031 Byte 17, Bit 5 ---
04 Solenoid valve WW water Y045 Byte 17, Bit 6 ---
05 Solenoid valve GTW washing agent Y030 Byte 18, Bit 0 ---
06 Solenoid valve WW washing agent Y044 Byte 18, Bit 1 ---
07 Water form roller to plate Y096 Byte 19, Bit 0 ---
08 Water form roller to bailing roller Y097 Byte 19, Bit 1 ---
09 Bridge roller to 1. ink form roller Y098 Byte 19, Bit 2 ---
10 Ink form rollers to plate Y014 Byte 19, Bit 3 ---
11 Inking unit separation Y012 Byte 19, Bit 4 ---
12 Auxiliary drive of the ink fountain roller Y099 Byte 19, Bit 5 ---
13 Washing blade On/Off Y108 Byte 19, Bit 6 ---
14 GTW On/Off Y107 Byte 19, Bit 7 ---
15 DZW On/Off Y406 Byte 20, Bit 4 ---
16 Solenoid valve DZW water Y407 Byte 18, Bit 4 ---
17 Solenoid valve DZW washing agent Y408 Byte 18, Bit 5 ---
18 DZW brush roller motor M409 Byte 17, Bit 3 B.B. 2.4 & 11.4
19 CPL pressure roller Y065 Byte 21, Bit 0 ---
20 Pneumatic brake S&W Y118 Byte 20 , Bit 5 ---
2-28 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
Coating Function test till series 336
unit:
membrane keyboard.

01 Solenoid valve coating roller On/Off Y063 Byte 18, Bit 5 ---
02 --- --- --- ---
03 GTW motor (right) K440 Byte 17, Bit 1 B.B. 4.1& 9.2
04 DZW motor (right) K406 Byte 17, Bit 2 Byte 4, Bit 3
06 Solenoid valve GTW-water Y401 Byte 20, Bit 3 ---
07 Solenoid valve DZW- water Y407 Byte 20, Bit 4 ---
08 Solenoid valve GTW-washing agent Y403 Byte 20, Bit 5 ---
09 Solenoid valve DZW- washing agent Y408 Byte 20, Bit 6 ---
10 SERA: suction pump on ZK3 Byte 19, Bit 1 Byte 9, Bit 4
11 SERA: Solenoid valve water shut-off Byte 19, Bit 0 ---
12 SERA: Solenoid valve spray bar 4Y5 Byte 19, Bit 3 ---
13 SERA: 3-way-valve varnish suction flow 5K2 Byte 19, Bit 4 Byte 12, Bit 1
14 SERA: 3- way-valve water suction flow 5K3 Byte 19, Bit 5 Byte 12, Bit 0
15 SERA: 3- way-valve varnish tank return flow 6K2 Byte 19, Bit 6 Byte 12, Bit 3
16 SERA: 3- way-valve water tank return flow 6K3 Byte 19, Bit 7 Byte 12, Bit 2
17 SERA: control release pump flow on Byte 19, Bit 2 ---
18 DZW On/Off Byte 18, Bit 6 Byte 4, Bit 6
Feeder: Feeder test till series 336
keyboard +BA (on the delivery side of the printing unit). The different functions are selected by the
To exit the function test press once and hold at the same time the two lowest keys of the membrane
keyboard.

01 Suction head clamping (only till series 330) Y115 Byte 18, Bit 0 ---
02 Solenoid valve side blower Y005 Byte 18, Bit 1 ---
03 Solenoid valve blast air to 10,000 sheets/h, 1. grade Y001 Byte 18, Bit 2 ---
04 Solenoid valve blast air over 10,000 B/h, 2. grade Y006 Byte 18, Bit 3 ---
05 Solenoid valve blast air at the detector B115 Y007 Byte 18, Bit 4 ---
C 95A 6423 39 – 08. Jul. 2004 2-29

2 Reference values
Setting up and function test from series 337

Program version 335C1 ,from MMS 10.11 also backwards compatible
Printing unit Function test
1
keyboard (on the feeder side of the printing unit). The different functions are selected by the same
keys and activated by “+/-“ keys. (The functions are active as long as the “+” key is pressed).
membrane keyboard

Feeder: Feeder test

11 Suction head clamping (only till series 330) Y115 Byte 18, Bit 0 ---
12 Solenoid valve side blower Y005 Byte 18, Bit 1 ---
13 Solenoid valve blast air to 10,000 sheets/h, 1. grade Y001 Byte 18, Bit 2 ---
14 Solenoid valve blast air over 10,000 B/h, 2. grade Y006 Byte 18, Bit 3 ---
15 Solenoid valve blast air at the detector B115 Y007 Byte 18, Bit 4 ---
Dampening Setting-up
unit
GTW:
The stripe test is activated by pressing together once the two lowest keys of the membrane
keyboard (feeder side). The different functions are selected by the same keys and activated by “+/-“
keys. (Function 03 is active as long as the “+” key is pressed). Starting from PS 314H1 all functions
are activated and deactivated by the “+” key, cover have to be closed.
To exit the stripe test press once (at the same time) and hold the two lowest keys of the membrane
keyboard.

01 Water form roller to bailing roller (Y097) Y097 Byte 19, Bit 1 ---
02 Water form roller to bailing roller (Y097) and plate (Y096), Y096 Byte 19, Bit 0 ---
(switches sequentially) Y097 Byte 19, Bit 1 ---
and to plate (Y096), (switches sequentially) Y097 Byte 19, Bit 1 ---
Y096 Byte 19, Bit 0 ---
05 GTW contact pressure, (switches sequentially) Y107 Byte 19, Bit 7 ---
The brush has to be wet, strip width approx. 20mm. M015 Byte 17, Bit 2 B.B. 2.3 & 11.4
.
2-30 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
Printing Function test
units:
membrane keyboard

11 Ink form rollers to plate Y014 Byte 19, Bit 3 ---

12 Inking unit separation Y012 Byte 19, Bit 4 ---
13 Auxiliary drive of the ink fountain roller Y099 Byte 19, Bit 5 ---
14 Washing blade On/Off Y108 Byte 19, Bit 6 ---
15 DZW On/Off Y406 Byte 20, Bit 4 ---
16 DZW brush roller motor M409 Byte 17, Bit 3 B.B. 2.4 & 11.4
17 Solenoid valve DZW water Y407 Byte 18, Bit 4 ---
18 Solenoid valve DZW washing agent Y408 Byte 18, Bit 5 ---
19 CPL pressure roller Y065 Byte 21, Bit 0 ---
20 Pneumatic brake S&W Y118 Byte 20, Bit 5 ---
Dampening Setting-up
unit
GTW/DZW:
The setting-up is activated by pressing together once the two lowest keys of the membrane
keyboard (delivery side). The different functions are selected by the same keys and activated by
“+/-“ keys. (Function 03 is active as long as the “+” key is pressed). Starting from PS 314H1 all
functions are activated and deactivated by the “+” key, cover have to be closed.
To exit the setting-up press once (at the same time) and hold the two lowest keys of the membrane
keyboard.

01 Water form roller to bailing roller (Y097) Y097 Byte 19, Bit 1 ---
02 Water form roller to bailing roller (Y097) and plate (Y096), Y096 Byte 19, Bit 0 ---
(switches sequentially) Y097 Byte 19, Bit 1 ---
and to plate (Y096), (switches sequentially) Y097 Byte 19, Bit 1 ---
Y096 Byte 19, Bit 0 ---
05 GTW contact pressure, (switches sequentially) Y107 Byte 19, Bit 7 ---
The brush has to be wet, strip width approx. 20mm. M015 Byte 17, Bit 2 B.B. 2.3 & 11.4
06 DZW contact pressure, (switches sequentially) M409 Byte 17, Bit 3 B.B. 2.4 & 11.4
The brush has to be wet, strip width approx. 20mm. Y406 Byte 20, Bit 4 ---
C 95A 6423 39 – 08. Jul. 2004 2-31

2 Reference values
Coating Function test

unit:
membrane keyboard.

01 DZW On/Off Y406 Byte 18, Bit 6 Byte 4, Bit 6
06 Chambered doctor blade

unit:
keyboard (on the feeder- side of the printing unit). The different functions are selected by the same
membrane keyboard.

Coating Setting-up
unit:
The setting-up is activated by pressing twice (together) the two lowest keys of the membrane
keyboard (on the feeder delivery side of the printing unit). The different functions are selected by
the same keys and activated by “+/-“ keys. (The functions are active as long as the “+” key is
pressed).
keyboard.

01 FZW - contact pressure, (switches sequentially) Y412 Byte 18, Bit 3 ---
feeder side K440 Byte 17, Bit 1 B.B. 4.1 & 9.2
02 DZW - contact pressure, (switches sequentially) Y406 Byte 18, Bit 6 Byte 4, Bit 6
delivery side K406 Byte 17, Bit 2 Byte 4, Bit 3
2-32 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
2.15 Maximum torque in Nm
Screws DIN 912, 931 etc. with a control thread
Maximum torque in Nm
Strength 8.8 10.9 12.9
category
Coefficient 0.10 0.14 0.20 0.10 0.14 0.20 0.10 0.14 0.20
of sliding
Dimension
M4 2,4 3 3,6 3,6 4,4 5,3 4,2 5,1 6,1
M5 4.8 5.9 7.1 7.1 8.7 10 8.3 10 12
M6 8,3 10 12 12 15 18 14 18 21
M8 20 25 30 30 36 44 35 43 52
M 10 40 49 60 59 72 87 69 84 100
M 12 69 85 105 100 125 151 120 145 177
M 14 110 135 165 160 200 240 190 235 285
M 16 170 210 260 250 310 380 290 365 445
M 18 245 300 365 345 430 520 405 500 610
M 20 340 425 520 490 610 740 570 710 870
M 22 470 580 710 660 830 1000 780 970 1200
M 24 590 730 890 840 1050 1250 980 1220 1500
M 27 870 1100 1350 1250 1550 1900 1450 1800 2200
M 30 1200 1450 1800 1700 2100 2550 1950 2450 3000
Coefficient of sliding: 0.10, very good surface, lubricated

0.14, good surface, lubricated or dry
0.20, surface black or phosphated, dry
Necked-down bolts
Maximum torque in Nm
Strength 8.8 10.9 12.9
category
Coefficient 0.10 0.14 0.20 0.10 0.14 0.20 0.10 0.14 0.20
of sliding
Dimension
M6 4.6 5.4 6.4 6.7 8 9.3 7.9 9.4 11
M8 12 14 17 17 21 24 20 24 28
M 10 23 28 32 34 40 47 40 47 56
M 12 41 49 58 60 72 85 70 85 100
M 14 67 81 95 98 120 140 115 140 165
M 20 225 135 330 325 200 470 375 230 550
M 22 305 370 440 430 530 630 500 620 740
M 24 390 480 570 560 680 810 650 800 950
C 95A 6423 39 – 08. Jul. 2004 2-33

2 Reference values
Notes about special torque values for the R 300:
– Feed drum, bearing A-side, shaft nut -------------------------------------------- 180 Nm

– Plate cylinder bearing A-side, shaft nut (KMTA 14 M70x1.5x26) --------- 160 Nm
– Plate cylinder Standard, hub –cylinder ------------------------------------------ 85 Nm
– Plate cylinder CPL, hub – cylinder ------------------------------------------ 65 Nm
– Back gear DW 1, A-side, shaft nut (KMTA 14 M70x2) ---------------------- 300 Nm
– Nut (spanner size 24) of the cam roller ---------------------------------------------- 80Nm
– Gripper on gripper shaft (M8x1) --------------------------------------------------- 25 Nm
– Gripper shaft bearing block (M10) ------------------------------------------------ 50 Nm
– 2. Transfer cylinder gear wheel, A-side (M10) --------------------------------- 85 Nm
– 2. Transfer cylinder, cover disk (M16) ------------------------------------------- 210 Nm
– Blanket cylinder, cover disk on bearing body (M6) --------------------------- 14 Nm
– Plate cylinder, B-side, gear wheel to inking unit (M16) ---------------------- 190 Nm
– Perfecting cylinder, clamping screw A-side (M20) ---------------------------- 180 Nm
from series 328 ------- 200 Nm
– Delivery, shoulder bolt (M10)------------------------------------------------------- 45 Nm
Screw-locking device from series 325
Screws smaller than M 6 = Loctite 932 (094 R8213 40)

Screws bigger than M 6 = Loctite 243 (094 R8209 40)
After tightening screws are to be sealed by a coat of safety paint!
Color marks:
Pre-assembly: green
Tact band: red
Final assembly: yellow
1 colour marking 2 screw-locking device
2-34 C 95A 6423 39 – 08. Jul. 2004

Reference values
2
2.16 Devices, gauges and tools

Transport of the printing units:
H- cross-bar
4 x suspension brackets No. 013 V 0154 30
4 x ring screw M 16 No. 099 I 3004 30
4 x ring screw M 20
The R700 transport box can also be used. No. J 28 W 0032 93
Alignment of the printing units:

1 x angle water balance No. 099 M 5225 40
1 x water balance No. 099 M 5341 40
1 x pipe water balance No. 099 M 5342 40
1 x prism No. 099 J 0879 30
1 x dial gauge holder No. 099 J 0626 30
1 x probing lever gauge, Tesatest, DIN 2270 No. 7.9103.2202
1 x special wrench, SW 17 No. 099 M 3759 50
1 x special wrench, SW 17 No. 099 M 3758 50
1 x standard wrench, SW 17
1 x straightedge, 1m long
1 x open-end wrench, SW 36
1 x oil bleed valve (oil lines in the printing units) Nr. 343 T 5608 13
Soldering wire “Massive“ ø 3 mm (co. Felder GmbH), L-Pb 99,94 DIN 1719
Gripper setting gauges on printing units:

1 x stop gripper, 4.15 mm No. 099 M 4902 40
1 x feed cylinder, 1.5 mm (old series) No. 099 M 4903 40
1 x feed cylinder, 11.7 mm (new series) No. 099 J 0773 30
1 x 1.- 2. impr. cyl. ø 36.85 mm No. 099 I 2606 30 *
1 x 1. impr -1. and 3. Transfer cyl. 14.038 mm No. 099 A 3769 13 *
1 x 2. transfer cyl., 92.45 mm No. 099 J 0625 30 *
1 x perfect. cyl. 7.68 mm No. 099 B 4464 30
2 x delivery gripper, 0.4 mm No. 099 J 2608 30
1 x wedge (brass) No. 343 T 4176 13
1 x back-off lever No. 013 A 0661 13
Gripper setting gauges on the coating module:

1 x take-off drum, closed cam, 17.63 mm No. 343 T 3805 13
1 x take-off drum, cam segments, 112.9 mm No. 099 B 4760 13
1 x 2. transfer cyl., closed cam, ø 36.85 mm No. 099 I 2606 30 *
1 x 2. transfer cyl., cam segments No. 099 J 0625 30 *
1 x 3. transfer cyl., 14.038 mm No. 099 A 3769 13 *
1 x impression cyl., closed cam,
cam roller ø 38.1 mm, gauge ø 36.7 mm No. 013 A 0688 30
1 x impression cyl, closed cam,
cam roller ø 40 mm, gauge ø 38,6 mm No. 013 A 0687 30
1 x impression cyl, cam segments,
cam roller ø 38,1 mm, gauge 106,5 mm No. 099 B 4876 30
1 x impression cyl, cam segments,
cam roller ø 40 mm, gauge 105,55 mm No. 099 B 4875 30
* The same slip gauges for printing units and coating module
Belt tension:
manual measuring device Type 3, 15–300 Hz. No. 037 X 2850 44
Pretensioning measuring device Nr. M41 C 2115 30
CONTITECH VSM-1, 10–500Hz
Double sheet - measuring device:
Leuze- Elektronik, Type KA 902 No. 037 U 3388 44
C 95A 6423 39 – 08. Jul. 2004 2-35

2 Reference values
Repair tools:
CPL:
2 x assembly devices No. M 099J513313
1 x Allen key (6mm with ball end) No. 013A067730
Printing units:
1 x system; pneumatic cyl. No. M 760 028- 2
2 x disassembly device system No. M 760.011-8
1 x plate cyl. lateral; 85 mm No. M 760 017- 2
1 x cutting point gauge, 1.6 mm No. 0 99 J 0774 13
1 x gripper margin adjustment, 6 mm No. 0 99 J 0156 50
1 x “0“ degree gauge printing units (4.75mm) No. 099 J 5132 30
1 x “0“ degree gauge coating unit (3mm) No. 353 T 3807 13
1 x index bolt (20/22), impression on/off (old series) No. M 760 015- 6
1 x index bolt (20/27), impression on/off (new series) No. 343 T 4149 13
1 x measuring bolt chain guide (16mm) No. 343 T 3803 13
1 x torque wrench 10 Nm - 100 Nm
1 x torque wrench 50 Nm - 200 Nm
1 x slip gauges 0.05mm - 1 mm
1 x set of long T Allen keys from 3 mm to 10 mm
1 x Seeger ring pliers, (sprocket shaft/stop gripper cam) Type: J41, outside 90°
1 x Seeger ring pliers, (plate cylinder) Type: J4, inside, straight
Dial gauges
1 x precision dial gauge ORION, DIN 878, D = 58 mm, 0.01 No. 7.9103.2301
1 x precision dial gauge ORION, DIN 878, D = 58 mm, 0.001 No. 7.9103.2302
1 x magnetic stand, height 285 mm, measuring arm 180 mm No. 7.9103.9906
1 x dial gauge magnetic holder, height 57 mm No. 7.9103.9907
1 x probing lever measuring gauge, Tesatest, DIN 2270 No. 7.9103.2202
Mounting and dismantling tools

1 x nut and disk No. M 970 00000- 15
1 x dismantling spindle M16/M24 No. M 870 00000- 65
1 x dismantling spindle M12/M24 No. M 870 00000- 75
1 x dismantling tool 260 mm No. M 980 00000- 18
1 x dismantling tool 190 mm No. M 980 00000- 16
1 x hexagon head collar screw No. M 980 00000- 18/1
1 x hexagon head collar screw No. M 980 00000- 16/1
2 x spacer bolt, M 10 No. M 460 00000- 40
2 x spacer bolt, M 8 No. M 460 00000- 41
2 x spacer bolt, M 6
1 x mounting socket No. M 769 003- 11/3
1 x bell No. M 769 003- 11/1+2
1 x mounting socket, 2. transfer cyl. No. M 980 00000- 70
1 x disk, 2. transfer cyl.
1 x disk, CPL (A-side) No. M 769 003- 8/4
1 x two-armed dismantling device, size 2 No. 55030 020 (788140021)
1 x two-armed dismantling device, size 4 No. 55030 040
1 x two-armed dismantling device, size 6 No. 55030 060
2 x special dismantling device, bearing 2. transfer cyl. B-side No. M 63020- 1
2-36 C 95A 6423 39 – 08. Jul. 2004

Gripper settings
3
3 Gripper settings
3 Gripper settings..............................................................3-1
3.1 Pregripper ...................................................................................... 3-3
3.2 Feed cylinder ................................................................................. 3-4
Version 1 ......................................................................................... 3-4
3.3 Impression cylinder in the first printing unit as well as
all 1st and 3rd transfer cylinders ............................................. 3-6
3.4 Impression cylinders in the intermediate and last
printing units ........................................................................... 3-7
Dismantling the cam roller ............................................................... 3-8
Exchanging the gripper shaft ........................................................... 3-9
3.5 2. Transfer cylinder and collecting drum................................... 3-10
Exchanging gripper shafts on the collecting drum ......................... 3-11
Exchanging gripper shafts on the 2nd transfer cylinder .................. 3-12
3.6 Perfecting cylinder ...................................................................... 3-13
3.7 Delivery gripper systems ............................................................ 3-14
C 95A 6423 39 – 11. Nov. 2003 3-1

3 Gripper settings
3-2 C 95A 6423 39 – 11. Nov. 2003

Gripper settings
3
3.1 Pregripper
– Remove guard in front of the water pan (4x screws).

– Advance press to 40° and dismantle cylinder-half from the feed drum.
– Advance press to 130° and block the STOP-Safe key!
– Use back-off lever device no. 013 A 0661 13 to carefully lift the roller lever
and place the 4.15 mm thick gauge no. 099 M 4902 40 between
the cam roller and cam.
– Use a 0.1 mm feeler gauge to check gap between gripper and gripper pad.
– If necessary change adjustment by turning setting screw (4).
– It is important that all grippers are set equally!
– Remove gauge and reassemble cylinder-half.
Caution: When setting the gripper it is necessary to extend the pneumatic

piston of the pregripper blocking device!
View from A-side
1 Gripper cam
2 Gauge no. 099 M 4902 40
3 Setting screw
4 Cam roller ø 38.1 mm
C 95A 6423 39 – 11. Nov. 2003 3-3

3 Gripper settings
3.2 Feed cylinder
Version 1

– Use back-off lever device no. 099 M 4902 40 to carefully lift the roller lever
and place the 1.5mm thick gauge no. 099 M 4903 40 between
the cam roller and gripper cam.
– Remove gauge
View from A-side
1 Gripper cam
3 Setting screw
4 Gauge no. 099 M 4903 40
3-4 C 95A 6423 39 – 11. Nov. 2003

Gripper settings
3
Version 2

– Use back-off lever device no. 099 M 4902 40 to carefully lift the roller lever and place
11.7mm thick gauge no. 099 J 0773 30 between the cam roller and gripper cam.
– Remove gauge
View from A-side
1 Gripper cam
3 Setting screw
4 Gauge no. 099 J 0773 30
C 95A 6423 39 – 11. Nov. 2003 3-5

3 Gripper settings
3.3 Impression cylinder in the first printing unit as well as all 1st and
3rd transfer cylinders
14.038mm thick gauge no. 099 A 3769 13 between the cam roller and gripper cam.
Caution: - When adjusting the grippers it may be necessary to advance the machine manually
(by a hand crank) to a more convenient position. “Follow with gauge”!!!
- Remove gauge after finishing!
1 Gripper cam
2 Gauge no. 099 M 4902 40
4 Setting screw
View from A–side
Example 1. Transfer cylinder
3-6 C 95A 6423 39 – 11. Nov. 2003

Gripper settings
3
3.4 Impression cylinders in the intermediate and last printing units

- Lock STOP-safe key and advance press only by means of the hand crank!
- Dismantle cam roller and use gauge no. 099 I 2606 30 ; Ø 36.85 mm
(for the dismantling of the cam roller see page 3/3.1)
- Use 0.1mm feeler gauge to check gap between gripper and gripper pad in position max. cam radius
- If necessary change adjustment by turning setting screw (3).
Caution: Reassemble cam roller after adjustment!
1 Setting screw
2 gauge no. 099 I 2606 30
3 Gripper opening cam
View from A-side
C 95A 6423 39 – 11. Nov. 2003 3-7

3 Gripper settings
Dismantling the cam roller
– Extract blanket wash-up device. Lock STOP-safe key and advance press only by means of the
hand crank!
– Advance machine so that nuts (SW 24) on the cam roller can be loosened.
– Loosen nuts. If necessary use Allen key to hold SW 8.
– Insert wedge between roller lever and cylinder edge as shown in drawing below.
– Reverse machine until the cam roller is free, remove nut and cam roller and
assemble gauge no. 099 I 2606 30.
– Advance machine until the gauge stands on the max. cam radius.
– Remove wedge and adjust grippers.
View from A-side
Wedge no. M 760 008-14
Assembling the cam roller
After the adjustment, place gripper wedge again between the roller lever and cylinder edge. Reverse
machine until the gauge can be freely removed. Assemble cam roller and nuts. Advance machine to
max. cam radius, remove wedge and tighten nuts.
3-8 C 95A 6423 39 – 11. Nov. 2003

Gripper settings
3
Exchanging the gripper shaft
The gripper shaft (16) is supplied with bushing (17). The bushing is glued in the correct position..
Setting:
– Mount gripper shaft (16) with torsion-bar spring (20), bearing (1, 3, 9), metal plates (13-15) and roller
lever (28) on to the cylinder.
– Bearings (1 and 9) are fixed by tapered pins.
– Screw all grippers to gripper shaft and tighten the cylinder screws (25) to 25 Nm.
– When tightening cylinder screws (50Nm) that hold the bearings, see that the gripper shaft can be still
be slightly moved.
– Pre-loading: Set dimension of 21 mm over the set screw (24).
– While turning the gripper shaft press grippers on the gripper pads (27). Find lowest gripper and clamp
0.1mm feeler gauge between gripper and gripper pad.
– Mount gauge (no. 099 I 2606 30, ∅ 36.85 mm) in roller lever and set on the max. cam radius.
– Set gripper shaft without lateral backlash, clamp roller lever and fix with pins. The tapered pin holds
the roller lever, gripper shaft and bushing in position. At the same time it functions as a stop for the
torsion-bar rod.
– Clamp torsion-bar rod by a lever (31),
adjust grippers, remove gauge and mount
cam roller (29).
C 95A 6423 39 – 11. Nov. 2003 3-9

3 Gripper settings
3.5 2. Transfer cylinder and collecting drum

– Use the STOP-Safe key to block the machine!
gauge no. 013 A 0658 13, length 92.45 mm, between the cam roller (3) and the cylinder axis (5).
Caution: Adjust 2nd gripper system in the same way!

It is important that all grippers are set equally!
Remove gauge after adjustment!
View from A-side
1 Cylinder screw, tightening torque 25 Nm

2 Setting screw
4 Gauge no. 013 A 0658 13
5 Cylinder axis
3-10 C 95A 6423 39 – 11. Nov. 2003

Gripper settings
3
Exchanging gripper shafts on the collecting drum
The gripper shaft (12) is supplied with bushing (13).

The bushing is already glued in the correct position.
Setting:
– Lock bushing by a cylinder pin DIN 7, ø 4 x 10 mm! See drawing * for the position of the pin.
– Mount gripper shaft with torsion-bar spring (16), bearing (1, 3, 5), stop (24), metal plates (7 - 10),
roller lever (25) and cam roller (26 + 27) on to the cylinder.
– The outermost bearings (1 and 5) are fixed by tapered pins.
– Screw all grippers to gripper shaft and tighten the cylinder screws (20) to 25 Nm.
– Pre-loading: Set dimension of 21 mm over the setting screw (22).
– When tightening the cylinder screws (50Nm) that hold the bearings, see that the gripper shaft can
be easily moved.
– While turning the gripper shaft press grippers on the gripper pads (11). Find lowest gripper and
clamp 0.1mm feeler gauge between gripper and gripper pad.
– Set, tighten and pin stop (24) at a distance of 0.4 mm from the pad (23).
– Place gauge 0.4 mm below the stop and clamp torsion-bar spring.
– Clamp gripper setting gauge (no. 013 A 0658 13, 92,45 mm) between the cylinder axis and cam
roller.
– Remove gripper setting gauge, gauges 0.1 and 0.4 mm.
– Use degree dial to measure cam roller height; advance machine by means of the hand crank and
check the 2nd gripper system. Both cam rollers have to be equally high. If necessary adjust and fix
them.
– Clamp gripper setting gauges (92.45 mm) between the cylinder axis and the cam roller.
Adjust grippers.
24 Pad
* Cylinder pin
13 Bushing
12 Gripper shaft
25 Gripper crank
C 95A 6423 39 – 11. Nov. 2003 3-11

3 Gripper settings
Exchanging gripper shafts on the 2nd transfer cylinder
The gripper shaft (15) is supplied with bushing (16).

The bushing is already glued in the correct position.
Setting:
– Lock bushing by a cylinder pin DIN 7, ø 4 x 10 mm! See drawing * for the position of the pin.
– Mount gripper shaft with torsion-bar spring (19), bearing (1, 4, 7), metal plates (9 - 13),
roller lever (27) and cam roller (28 + 29) on to the cylinder.
– The outermost bearings (1 and 7) are fixed by tapered pins.
– Screw all grippers to the gripper shaft and tighten cylinder screws (20) at 25 Nm.
– Pre-loading: Set dimension of 21 mm by setting screw (23).
– When tightening the cylinder screws (50Nm) that hold the bearings, see that the gripper shaft can
be easily moved.
– Dismantle outermost gripper A-side and screw on device no. M 760007-14.
– Clamp torsion-bar spring.
– Use device to turn gripper shaft until the grippers meet the gripper pads (14). Determine the lowest
gripper and set it so that a 0.1 mm feeler gauge only just moves between the gripper and gripper pad.
– Clamp gripper setting gauge (92.45mm) between the cylinder axis and cam roller,
press on from the side and tighten gripper crank.
– Turn eccentric disk (26) counterclockwise and set gap of 0.60 mm.
– Remove gripper setting gauge, gauge and device.
– Use degree dial to measure cam roller; use hand crank to
advance machine and check cam roller of the 2nd gripper
system. Both cam rollers have to be equally high, otherwise
adjust and pin into position.
– Clamp gripper setting gauge (92.45 mm) between cylinder axis
and cam roller. Adjust grippers.
26 Eccentric disk
27 Gripper crank
28 Cam roller
15 Gripper shaft
16 Bushing
* Cylinder pin
3-12 C 95A 6423 39 – 11. Nov. 2003

Gripper settings
3
3.6 Perfecting cylinder
- Machine has to be in single-side printing mode!

- Use STOP-Safe key to lock machine!
- Use device (see drawing) to lift roller lever and place 7.68 mm thick gauge no. 099 B 4464 30
between supporting roller (6) and min. radius of the first-side printing cam (10).
- Place 0.60 (12 x 0,05mm) and 0.75 mm (15 x 0,05mm) shims between the cam rollers (4) and gripper
cam (5) and set grippers to 0.1 mm clearance.
Caution: Both shim packages have to be inserted!

Always adjust both gripper systems!
Support roller
lifting device
1 shim packages
2 setting screw
3 stop
4 cam rollers
5 gripper cam (anchor)
6 support roller
7 eccentric bolt
8 gauge
9 perfecting gripper cam
10 first-side printing gripper cam
11 min. radius
C 95A 6423 39 – 11. Nov. 2003 3-13

3 Gripper settings
3.7 Delivery gripper systems
- Use STOP-Safe key to lock machine!

- Place 2 x gauge no. 099 J 2608 30, 0.4 mm thick, under stops on A- and B-side.
- Use 0.1mm feeler gauge to check gap between gripper and gripper pad.
- Turn setting screw to change adjustment.
- Or inch machine forward until the gripper is on the gripper opening cam.
set cam so that the stops have a clearance of 0.4 mm.
- Set gripper clearance to 0.1 mm.
Caution: Adjust all gripper system equally!
View from A-side
Set gripper pre-loading:
Loosen clamping screw and clamp gripper freely to the gripper shaft. Use a balance to check
pulling force of 40N on the gripper tip, if necessary use setting screw to adjust. After the
adjustment release gripper again and align laterally to the gripper pad. Clamp grippers and
adjust as described above.
3-14 C 95A 6423 39 – 11. Nov. 2003

Transport of the Machine

4
4 Transport of the Machine
4.1 Dimensions and weights, required size of openings in
buildings .................................................................................. 4-3
4.2 Transport........................................................................................ 4-4
Lifting device.................................................................................... 4-4
Transport by forklift truck ................................................................. 4-4
Hydraulic lifting device..................................................................... 4-5
Transport rollers: ............................................................................. 4-5
4.3 Fastening positions for eyebolts and lifting shackle ................. 4-6
4.4 Lifting devices ............................................................................... 4-7
C 95A 6423 39 – 11. Nov. 2003 4-1

4-2 C 95A 6423 39 – 11. Nov. 2003


4
4.1 Dimensions and weights, required size of openings in buildings
Printing unit width: 1,903 mm, control cabinet height: 1,974 mm.
C 95A 6423 39 – 11. Nov. 2003 4-3

4.2 Transport
Lifting device
Transport by forklift truck
4-4 C 95A 6423 39 – 11. Nov. 2003


4
Hydraulic lifting device
Caution: min. carrying capacity 5 tons
Transport rollers:
Caution: min. carrying capacity 5 tons
C 95A 6423 39 – 11. Nov. 2003 4-5

4.3 Fastening positions for eyebolts and lifting shackle
4-6 C 95A 6423 39 – 11. Nov. 2003


4
4.4 Lifting devices
Adjustable H – cross tie
Carrying capacity SWL: 8t

Length, adjustable: 500-2300 mm
Width, adjustable: 300-1100 mm
Weight: 280 kg
Lifting means for printing presses
2 wire ropes diameter 18 mm

length 630 mm
2 wire ropes diameter 18 mm
length 1070 mm
2 wire ropes - chain GK 8 with shortening
device ø 18 mm / 10 mm
length 1500 mm
Eyebolts and lifting shackle
Eyebolt DIN 850 / No. 890.97.45.1

Carrying capacity, straight 3000 kg
45 degrees 1575 kg
60 degrees 1125 kg
Lifting shackles No. 013 V 0154 30

Carrying capacity 2500 kg
Caution:
The load suspension devices must be approved and must comply

with VBG 9A and the lifting devices, winches, the lifting and drawing devices with VBG 8.
CAUTION: INSPECTION STAMP MUST BE VALID!
C 95A 6423 39 – 11. Nov. 2003 4-7

4-8 C 95A 6423 39 – 11. Nov. 2003

Installation
5
5 Installation
5.1 Hints for assembly ........................................................................ 5-3
Sequence of assembly at the customer’s plant ............................... 5-3
5.2 Layout: Example R 302 with Air- Center...................................... 5-4
5.3 Positioning of the oil pans............................................................ 5-5
Up to series 333 .............................................................................. 5-5
From series 334............................................................................... 5-6
5.4 Gear meshes .................................................................................. 5-7
Example R 304: Up to series 320 .................................................... 5-7
Example R304: From series 321 ..................................................... 5-8
Inking unit position........................................................................... 5-9
5.5 Alignment of the printing units .................................................. 5-10
Till series 319 ................................................................................ 5-10
From series 320............................................................................. 5-12
Attention when cardboard device .................................................. 5-13
Shim calculation ............................................................................ 5-14
5.6 Measuring protocol ..................................................................... 5-15
5.7 Main drive motor.......................................................................... 5-16
Position of the main drive motor on the R 302............................... 5-16
Position of the main drive motor on the R 304............................... 5-16
Position of the main drive motor on the R305R - 308 .................... 5-16
Console Main drive motor, R304 ................................................... 5-18
Alignement of motor on center drive.............................................. 5-19
5.8 V-belt tension............................................................................... 5-20
On machines with main drive motor in the 1st printing unit ............ 5-21
V-belt tension with middle drive ..................................................... 5-21
5.9 Feeder........................................................................................... 5-22
Till series 330 ................................................................................ 5-22
From series 331............................................................................. 5-24
C 95A 6423 39 – 08. Jul. 2004 5-1

5 Installation
5.10 Delivery .........................................................................................5-25

5.11 Connections .................................................................................5-26
GTW, WW, DZW,...........................................................................5-26
Central lubrication, example R 304 ................................................5-27
Bleeding oil lines ............................................................................5-28
5.12 Suction air / blast air pipeline dimensions ................................5-29
5.13 Hints for disassembly..................................................................5-31
5.14 Putting into operation and delivery of the machine..................5-32
5-2 C 95A 6423 39 – 08. Jul. 2004

Installation
5
5.1 Hints for assembly
Sequence of assembly at the customer’s plant
- Determine erecting place of the press precisely, co-ordinate with person responsible for the press
erection.
- Check if all supply lines are installed (electricity, water, etc.).
- Position oil drip pans and, if necessary, mark locations accordingly.
- Check floor (straight edge and spirit level).
Transport: Use prescribed means of transport!

- The transport operator will position the printing units on the oil drip pans, distance approx. 20 mm.
- Check completeness of delivery against the packing list and, if necessary, file complaint immediately.
Caution: Insert the levelling screws on delivery control cabinet and main control cabinet!
The erection of the press may start with either Unit 1 or the delivery.
If possible, start with delivery/last printing unit – heaviest part.
- Let the machine settle in its position (24h – in this time the floor will settle and the machine will reach
the ambient temperature).
- Align the printing units, check mesh of tooth!
Fill in measuring protocol, (position of spirit level) acceptance protocol page 2.
- Connect pneumatic grease and oil lines, B-side.
- Align and tighten main drive motor (not with 2-color machine).
- Mount cable duct on A- and B-side.
Interface for the electrician
- Assemble, align and fix the feeder

- Position main control cabinet on A-side
- Position the supply tanks for the washing devices
- Completely connect GTW, DZW and WW hoses
- Mount gearbox on A-side
- Set up pumps and blowers
- Mount air hoses on A-side after checking the direction of rotation
- Install dampening water pipes, B-side
- Install compressed air unit
- Position and connect water dampening unit as well as grease/oil supply devices
- Connect grease and oil lines to central container
- Assemble steps on A-side
Beginning of the electrical & mechanical start-up procedure

- Mount feeder drive chain, from series 331 cardan shaft
- Check tightness of pneumatic, grease, oil, dampening water, blanket washing and WW lines
Note: Keep dampening water additive to minimum (%)!
- Vent all GTW, DZW and WW lines
- Vent oil lines
- Vent grease lines if necessary
- Assemble B-side steps
- Check transfer on reversing unit, 2nd transfer drum to perfecting cylinder
- Provide tank for the return flow from the washing devices
The customer must place a container!!
C 95A 6423 39 – 08. Jul. 2004 5-3

5 Installation
5.2 Layout: Example R 302 with Air- Center

Layout no.: 014 F 3003 39
For repairs, the distance on A- or B-side between the machine side frame and the wall of the building
should be at least 1200 mm
5-4 C 95A 6423 39 – 08. Jul. 2004

Installation
5
5.3 Positioning of the oil pans

Up to series 333
C 95A 6423 39 – 08. Jul. 2004 5-5

5 Installation
From series 334
5-6 C 95A 6423 39 – 08. Jul. 2004

Installation
5
5.4 Gear meshes

Example R 304: Up to series 320
– At 0° (360°), shown on the display of DW 1, all gear meshes of the gears are marked on the drive side by
consecutive numbers.
– Furthermore, the meshing teeth are marked with red paint.
– The meaning of the digits printed on the front of the side parts, e.g. 4-1, 4-2, 4-3, 4-4 is:
first digit: number of printing units; second digit: printing unit number.
On the operating side, the gear meshes between the plate cylinder and inking unit (ink vibrator timing) and
distribution commencement are marked by red paint. Here, too, the press is at 0°.
1 Gear with ink

ductor cam
2 Gear for ink
distribution
3 Driving gear on the
plate cylinder
Caution: “All” marks on A- and B-side have to be matched before joining the printing units!
C 95A 6423 39 – 08. Jul. 2004 5-7

5 Installation
Example R304: From series 321

- The meshing teeth on gears of the 1st and 2nd transfer cylinders are marked by red paint at the transfer
point. Display DW 1 = 249°.
- The meaning of the digits printed on the front of the side parts, e.g. 4-1, 4-2, 4-3, 4-4 is:
first digit: number of printing units; second digit: printing unit number.
- The asterisk (*) is an auxiliary mark between the plate cylinder and the ink unit gear.
On the operating side, the gear meshes between the plate cylinder and inking unit (ink vibrator timing) and
distribution commencement are marked by red paint. Here, too, the press is at 249°.
1 Gear with ink

ductor cam
2 Gear for ink
distribution
3 Driving gear on
the plate cylinder
B-side
Printing units with a manual crank device can be advanced to the marks by hand.
On R 302 release the main motor brake by hand! On the intermediate printing units a ring wrench SW24 is
required. The ring wrench is applied to the hexagon cap screw of the cylinder cover disk on the A-side.
Turn wrench clockwise (tighten screws)!
Caution: “All” marks on A- and B-side have to be matched before joining the printing units!
5-8 C 95A 6423 39 – 08. Jul. 2004

Installation
5
Inking unit position
– The printing units are joined at the marks during erection.

– The machine has to be in straight printing mode!
– The plate cylinder rough adjustment has to be locked (in “0” position).
– The distribution commencement pointer (hole) has to be set to “G”!
The inking unit gears on B-side are in the following position when the machine is set at 249°:
Degree indication if a degree dial is mounted on the different printing units!

DW 1 249° DW 3 79.2° DW 5 269.3° DW 7 99.4°
DW 2 344.2° DW 4 174.3° DW 6 4.4° DW 8 194.5°
C 95A 6423 39 – 08. Jul. 2004 5-9

5 Installation
5.5 Alignment of the printing units

Till series 319
1 Shims only if the side frame is provided with a stamped-on number in 1/100mm.
2 Measuring points only on A-side for the lateral alignment of the printing units.
3 Holder for dial gauge with lever measuring gauge.
4 Stamped-on number in 1/100mm, only in case of a height difference between the printing units.
5 Slim, tubular water level.
6 Marking for placement of spirit level.
7 Distance between floor and base plate of 55 - 75 mm
Conditions:
– Printing units are first pre-aligned and then joined!

– It is necessary to maintain the distance of 55 - 75 mm between floor
and base plate.
– The printing units are positioned next to each other in the marks
on A- and B-side.
Printing unit alignment:
For alignment in longitudinal direction place slim tubular water level (5) on
the base frame, A- and B-side,
between the marks (6).
In transverse direction a prism water level is placed on the impression cylinder.

– Place prism (4) no. 099 J0879 30 in the middle of the impression cylinder.
– The blast pipe (1) may not touch the prism (!). If necessary loosen the holding and shift the blast pipe.
– To avoid measuring errors, the water level (3) has to lie on the stop (2)
1 Blast pipe 3 Prism water level
2 Stop 4 Prism
5-10 C 95A 6423 39 – 08. Jul. 2004

Installation
5
The height of the different printing units in relation to each other is checked by a measuring device (3).
The measuring device is positioned on the base frame on side A and B.
The mutual difference in height between the printing units is determined by shifting the measuring device.
The base frames on A-side should be equally high. Measuring result of 0.00 mm.
Exception:
If a number (4) is stamped on the base frame on B-side, then this printing unit has to be adjusted higher
(+ 0.XX) or lower (- 0.XX) in keeping with the number indicated.
Caution: Alignment on A-side has to be equal 0.00 mm.
The faces of the side frames are bolted together directly by three screws.
If a number (1) is stamped on near any of the screws then a shim has to be inserted in keeping with the
number indicated between the side frame faces at the location of this screw.
The lateral alignment of the printing units on A-side is checked by a measuring device (3) at the
measuring points (2). Measuring result has to equal “0.00mm“.
After the alignment of all the printing units it is necessary to check the whole machine by a water
level and the measuring result has to be entered in the machine acceptance protocol!
Check:
The gear backlash on A-side may not exceed the range of 0.05 mm to 0.11 mm.
The parallelism of the printing units is measured between the 1st and 2nd transfer cylinder.
a) use a lead wire between the cylinder bodies (possible with full-body cylinders only)
b) measure the gap between the gripper pads in the transfer point. Before that dismantle outermost
grippers on the 1st transfer cylinder. Screw off the two outermost gripper pads on the 2nd transfer cylinder
and bring them to a position directly opposite the gripper pads of the 1st transfer cylinder. Use a feeler
measuring gauge to measure the gap. See table in chapter 2.
Maximum deviation between A- and B-side = 0.025 mm.

Caution: None of the adjustments may change when the screws holding the printing units together are
tightened.
From series 314 to 319 bores for locating pins were drilled after the alignment of the printing units.
A-side 1 cylinder pin ∅ 12 mm x 32 mm, B-side 1 tapered pin ∅ 8 mm x 50 mm.
C 95A 6423 39 – 08. Jul. 2004 5-11

5 Installation
From series 320

Alignment procedure when starting from the 1st printing unit
DW 1 DW 2
X
23
1
XXX
3
4
5
6
5008.cdr
View from A-side
X Scribed line
1 Right-angled water level
2 Stamped-on number in 1/100mm units on A- and B-side
The values apply to all shims of a side frame (thickness ~ 2.7 - 3mm)
3 Measuring points on A-side for lateral alignment
4 Holder for dial gauge with lever gauge
5 Slim, tubular water level
6 Distance between floor and lower edge of the base plate, 55 - 75 mm
Alignment procedure when starting from

delivery
Conditions:
- The printing units have to be pre-aligned before actually

joining them!
– The distance of 55 - 75 mm between the floor and base 7
Ausleger
plate is maintained. delivery
– The printing units are positioned next to each other in
350
their marks at 249° A- and B-side.
7 The position of the right-angle water level in the last

printing unit, 5009.cdr
if alignment starts from delivery.
View from A-side
5-12 C 95A 6423 39 – 08. Jul. 2004

Installation
5
Attention when cardboard device
When aligning the DW`s, take off the blast pipe only, not the whole brackets.
The brackets are aligned to the cylinders!!!
Longitudinal alignment:
DW 1 is aligned by a right-angled water level (1). (See page before)
The right-angled water level (with magnet) is placed on the front of the side frame on A- and B-side.
The height of the right-angled water level in the 1st printing unit ~ 23mm from the top of the side frame and
~ 350mm from the base frame in the last printing unit.
The cross-sectional alignment is checked on the impression

cylinder.
– Place prism (4) no. 099 J0879 30 in the middle of the impression
cylinder.
– The blast pipe (1) may not get into the way of the prism!
Otherwise it is necessary to loosen the holder and move the blast
pipe.
– In order to avoid measuring errors it is necessary to place
the water level (3) on the stop (2)!
1 blast pipe 3 prism water level
2 stop 4 prism
The height of the printing units in relation to each other is checked by a measuring device (4).
The measuring device with measuring dial is placed on the base on A-side.
The difference in height between the printing units is checked by shifting the measuring device.
The measuring result equals 0.00 mm.
B-side ensues automatically from the cross direction.
The lateral alignment of the printing units is checked on A-side at the measuring points
by a measuring device. Measuring result has to equal “0.00mm“.
The appropriate shims (see stamped-on numbers (2)) are inserted on the front between the side frames.
In this way the distance between each two printing units is fixed.
When tightening the connecting screws all shims have to be clamped at the same time.
The indication of the tubular level (5) must not change!
The tubular level (5) is used only to determine the actual state.
Caution: The right-angle water level (1) overrides the tubular level (5)!
Note: It is recommended to use two tubular levels.

Example: Place one tubular direction level on A-side in DW1 and on the base frame in DW2.
Observe whether the bubble moves while tightening. If so, use adjustment screws to correct
the position of the printing unit.
Check:
The gear mesh on A-side has to be within the range of 0.05 mm to 0.11 mm.
Further checking possibilities in case of printing and paper run trouble:

The gear mesh on A-side has to be within the range of 0.05 mm to 0.11 mm.
The parallelism of the 1st and 2nd printing unit is checked on the transfer cylinder.
a) use a lead wire between the cylinder bodies (possible with full-body cylinders only)
b) measure the gap between the gripper pads in the transfer point. Before that, dismantle outermost
grippers on the 1st transfer cylinder. Screw off the two outermost gripper pads on the 2nd transfer cylinder
and bring them to a position directly opposite the gripper pads of the 1st transfer cylinder. Use a feeler
measuring gauge to measure the gap. See table in chapter 2.
Maximum deviation between A and B-side = 0.025 mm.
C 95A 6423 39 – 08. Jul. 2004 5-13

5 Installation
Shim calculation
From series 320
A min. = 156.929mm XXX = etched number A and B

A max. = 157.162mm
B min. = 193.173mm smallest overall dimension G min. = 353.087mm
B max. = 193.233mm biggest overall dimension G max. = 353.109mm
A+B (mm) C (mm)

over up to shim
350.1 350.135 3
350.135 350.185 2.95
350.185 350.235 2.9
350.235 350.285 2.85
350.285 350.335 2.8
350.335 350.385 2.75
350.385 350.41 2.7
5-14 C 95A 6423 39 – 08. Jul. 2004

Installation
5
5.6 Measuring protocol
The “measuring protocol” is in the manual

“Transport, Erection and Putting into Operation “.
The measuring results determined by the water level during the alignment of the printing units
are to be entered into this protocol.
Machine no.: __________ Date: __________

Type: __________ Signatures: __________
Measuring DW 1 DW 2 DW 3 DW 4 DW 5 DW 6 DW 7 DW 8 Lack
point
A
B
C
C 95A 6423 39 – 08. Jul. 2004 5-15

5 Installation
5.7 Main drive motor
Position of the main drive motor on the R 302
Position of the main drive motor on the R 304
Position of the main drive motor on the R305R - 308
5-16 C 95A 6423 39 – 08. Jul. 2004

Installation
5
Main drive motor alignment, R304
- Position console.
- Bolt tracks to main motor and place on console.
- Center tracks around the oblong hole and bolt to console.
- Mount two V-belts (in the outermost groove) and push motor together
with the console away until the belt is taut.
- Assemble the cable duct completely while ensuring that the cable duct
is not twisted by the console; if necessary move console.
- Use water level to align console in longitudinal and cross direction;
if necessary use underlay plates supplied with machine.
Further check: place water level on motor belt disk!
- Use straightedge to check the direction of both V-belt disks and align console.
- First drill the holes for the two front plugs, then shift motor and drill holes for the two rear plugs.
- When assembling a new machine use the supplied anchor rods M 16 x 190 mm, (drill ∅ 18 mm)
and glass tube containing chemical compound for M 16.
Clean the drilled hole well, place small glass tube and use power drill to drive the anchor rod
into the hole so that it assumes the correct height
Setting time of the chemical compound:
over 20° C = 20 min.

10° - 20° C = 30 min.
0° - 10° C = 1 h
-5° - 0° C = 5 h
- After fixing the console, mount all V-belts and tension them by the two setting screws after.
– Tighten belts correctly! See tables.
C 95A 6423 39 – 08. Jul. 2004 5-17

5 Installation
Console Main drive motor, R304
First adjustment possibility:
Use a straightedge (5) to check the

parallelism
of the two drive belt pulleys.
1 external ventilator
2 tacho-generator B 150
3 brake
4 water level
5 straightedge
6 V-belt
7 console
8 plugs
9 track
Second adjustment possibility:
Clamp a straightedge (5) to the A-side frame.

Measure the distance to motor belt pulley.
Side frame (60 mm) + dimension “X“ should be
the same
as the distance between the straightedge to
motor
drive belt pulley .
“X“ ~ 15 mm.
5-18 C 95A 6423 39 – 08. Jul. 2004

Installation
5
Alignement of motor on center drive
A
A Oil connection for
central lubrication
B Filler opening for:
Shell, Omala Oil 150
~209
(~1,5 l)
C Oil level check
A 1.......10 D...Filler opening for:
Shell, Vitrea 100
820
820
A
B C C D 1 Straightedge
2 V-belt, No. 1-10
3 Fastening dowel
4 Spirit level
5023.cdr
3
4
View from above
Alignment of motor and mounting plate
1. Mount motor on tracks and mounting plate.

2. Install v-belts (2) and shift motor until the v- belts are slightly tensioned.
3. Align mounting plate so that a distance of 820 mm between base and centre of fastening dowel is established .
(refer to figure)
4. Check mounting plate with spirit level(4), if necessary equalise with shims.
5. Using a straightedge (1) check the alignment of the two belt pulleys.
If necessary, shift motor with mounting plate sideways
6. Fasten mounting plate to floor, using the fastening dowels that were provided.
(Possible the motor mounting screws must be unscrewed again and the motor be shifted once more)
7. Once the motor and the plate is fastened, install all v-belts and tighten belts.
(belt tension meter No.: M41 C 2115 30)
8. Install v-belts guards and check function of the hand crank.
(Guard open, machine blocked and brake released)
Attention: Before putting press in operation, top up the oil in the gear box and connect oil lines of the
central lubrication system. Activate central lubrication system several times on Central Control
Console.
C 95A 6423 39 – 08. Jul. 2004 5-19

5 Installation
5.8 V-belt tension

The table shows the dimensions of the belts in use.
belt profile - upper belt width active width belt height standard diameter
abbreviation (nominal) of the appropriate
smallest allowed disk
b1 according to DIN 2211
b2 h d
open flange XPZ 9.7 8.5 8 50

teethed
open flange XPA 12.7 11 9 63
teethed
The correct V-belt tension is the main condition for constant and good machine registration!
The following 2 methods can be applied when checking the V-belt tension:
1. Use a balance spring to check the indentation depth “tee“ (see drawing)
or
2. use a suitable measuring device to check the frequency of the belts
E.g. Conti belt tensioning manual measuring device, type 2, measuring range 15–300Hz,
MRO item number: 037 X 2850 44,
or Pretensioning measuring device CONTITECH VSM-1, 10–500Hz

MRO item number M41 C 2115 30
5-20 C 95A 6423 39 – 08. Jul. 2004

Installation
5
On machines with main drive motor in the 1st printing unit
Machine Belt profile Active length Testing force Fe Indentation Frequency

(mm) (N) depth te (HZ)
(mm)
R 302 XPA 1400 50 10+/-0.5 78 +/-4
R 302 XPZ 1400 25 8+/-0.5 81 +/-4
R 304 XPA 2120 50 27+/-1.5 30 +/-2
R 304 XPZ 2120 25 17+/-1.0 37 +/-2
R 305 / R306 XPA 2120 50 23+/-1.0 35 +/-2
R 305 / R306 XPZ 2120 25 14+/-0.8 43 +/-2
R 307 / R308 XPA 2120 50 20+/-1.0 39 +/-2
R 307 / R308 XPZ 2420 25 12+/-1.0 46+/-2
Caution: Mount V-belts in correlated sets only!
V-belt tension with middle drive
Machine Belt profile Active length Testing force Fe Indentation depth Frequency
(mm) (N) te (HZ)
(mm)
R 305 XPA 2120 50 27+/-1 30 +/-2
R 306 and XPA 2120 50 25+/-1 32 +/-2
R 305 + LV
R 307 and XPA 2120 50 24+/-1 34 +/-2
R 306 + LV
R 308 XPA 2120 50 22+/-1 36 +/-2
Caution: Mount V-belts in correlated sets only!
C 95A 6423 39 – 08. Jul. 2004 5-21

5 Installation
5.9 Feeder
Till series 330
View from B-side
1 Water level 6 Alignment bolts, only inside B-side

2 Cross bar 7 Self-locking nuts SW 19
3 Guide rails from suction head 8 Levelling screw SW 17
4 Connecting rods A- and B-side 9 Fastening plugs
5 Straightedge
After alignment plugs (9) are used to fasten the

feeder to the floor.
Before that, an electric cabinet on A-side has to be

loosened.
Fastening plug from feeder–side wall

Drawing rotated by 90°
5-22 C 95A 6423 39 – 08. Jul. 2004

Installation
5
Conditions:
The printing units are aligned.
If the machine drive is at the front: Console and main drive motor are aligned, mounted and fixed.
Feeder - height: (see fig. 5017.cdr)

Use a straightedge (5) to measure distance to bolt (6) on B-side.
The surface of the base frame and the upper surface of the bolt (6) have to line up.
Loosen nuts (7) on the feeder side frame A- and B-side and adjust by levelling screw (8).
It may be necessary to cut the sheet stop rails of the feeder pile when
the 1st printing unit is aligned at 55 to 60 mm from the floor!
Transverse direction:
Place the water level (1) in the middle of the cross bars (2).
Longitudinal alignment:
Place the water level (1) on the suction head guide rails (3).
Lateral alignment
Use straightedge (5) to measure from inside of printing unit A-side frame to feeder side frame. The side
frames have to line up. See that the brackets of the suction tapes fit in the cutouts of the register plate and
rework the plate if necessary.
Parallelism with printing unit

The connecting bars (4) on A- and B-side were adjusted at the factory. They only have to be mounted.
C 95A 6423 39 – 08. Jul. 2004 5-23

5 Installation
From series 331
View from B-side
1 Fixing bolts
2 Levelling bolts
* Checking positions, A- and B-side
Alignment:
Condition: Printing unit 1 is aligned.

– Pre-align feeder.
The distance between the floor and the lower edge of the feeder side frame is between 35 mm (min.) and
75 mm (max.). (The height of the feeder ensues automatically from the height of the base frame of the
1st printing unit.)
– Place prism water level on the guide rails of the suction head and align.
– Move pre-aligned feeder to printing unit and complete levelling.
– You will have reached the final position when the checking positions (*) on A- and B-side
have the same contact between the side frames (check by feeler gauge 0.03 mm).
– The feeder is centered in relation to the inside side section of the printing unit (straightedge).
– Tighten fixing screws (1) A- and B-side.
When doing so, the air bubble of the water level on the base frame in the 1st printing unit may not move.
– Remove transport device from the pile supporting plate.
Caution: Pile guide rails on A- and B-side have to be 5 mm above the floor!
Check whether the guide rollers do not derail when in lowest position!
Check pile control: If necessary readjust control cams “Stop after contact with floor“
and 120 mm above the floor.
5-24 C 95A 6423 39 – 08. Jul. 2004

Installation
5
5.10 Delivery
For standard installations, delivery and last printing unit are already connected!
Should the delivery be disconnected from the last printing unit for some reason,
then align the last printing unit as follows:
Disassemble the front chain tracks and push the delivery up to the last printing unit. The stops (1) on A-
and B-side determine the lateral position to the side frame inside and to the height of the base frame.
The delivery is aligned by the levelling screws.
Check:
Use a 0.03 mm thick feeler gauge to check whether the stops contact the side frame and base frame.
1 Stops, A- and B-side, inside

2 Tubular water level, A- and B-side
3 Marks
Caution:
The indication of the tubular water level (2) in the last printing unit may not change while the fastening
screws are being tightened.
C 95A 6423 39 – 08. Jul. 2004 5-25

5 Installation
5.11 Connections
GTW, WW, DZW,
Functions test no. Solenoid Hose type BMK

old / new valve
04 05 1 WW, water, thin blue hose Y 045
03 03 2 GTW, water, thick blue hose Y 031
06 06 3 WW, washing agent, thin white hose Y 044
05 04 4 GTW, washing agent, thin white hose Y 030
16 17 5 DZW, water, thin blue hose Y 407
17 18 6 DZW, washing agent, thin white hose Y 408
5-26 C 95A 6423 39 – 08. Jul. 2004

Installation
5
Central lubrication, example R 304
M 219 Grease pump

B 098 Initiator for min. grease level
M 218 Oil circulation pump

S 861 Float switch for min. oil level
M 216 Oil pump delivery LA 8

– From series 325, LA 8 pump is
installed in delivery
S 862 Float switch for min. oil level
1 F 002, oil pressure switch (12 bar) 6 Grease distributor, line from distributor to given printing unit
2 B 078, initiator for chain lubrication LA 8 7 Forward run grease
3 Forward run LA8 8 Return flow grease
4 B 077, initiator for central greasing 9 Forward run oil
5 Oil lines from printing unit to printing unit
- No return flow (8) if the grease distributor (6) is completely connected!
C 95A 6423 39 – 08. Jul. 2004 5-27

5 Installation
Bleeding oil lines
Oil /Grease lines should be connected and bled!
I E: - Putting into operation, New- and Used machines

- Repairs
- Exchange of bearings / cylinder bearings
R3K13_01.jpg
Gauge No: 343 T 5608 13
In all printing units, A- and B-side (highest

position) the oil lines have to be bled
In the coating unit only on A-side.
Therefore unscrew the plug and put in gauge

No: 343 T 5608 13.
Than activate the oil pump at central control

console as long as no air is in the lines.
Afterwards unscrew gauge No: 343 T 5608 13

and mount the plug.
3K13_02
View A-side
3K13_03
View B-side
5-28 C 95A 6423 39 – 08. Jul. 2004

Installation
5
5.12 Suction air / blast air pipeline dimensions
- Pressure loss 'p remains smaller than 0.01 bar, if the hose lengths and diameters listed below
are observed.
- A volume current “Q“ corresponding to the condition of the hoses has to be always used.
– If the volume currents Qo in atmospheric state are known,

then they can be converted to “Q“ as follows:
Q = Qo X 1/p where p (bar) = absolute pressure in the pipeline
Volume Length of a straight pipeline in m

current 5 10 15 20 25 30 40 50 60 70 80 90 100
in m³/h Nominal length of the pipeline
10 ¾“
15 1“
20 ¼“
25
30 1½“
35
40 2“
50
60
70 2½“
80
90 3“
100
130 4“
For each sheet or angle the following substitute lengths are to be used with a straight pipeline length:
Pipeline (inch) ½“ ¾“ 1“ 1 ¼“ 1½“ 2“ 2 ½“ 3“ 4“

Sheet (m) 0.15 0.20 0.25 0.30 0.35 0.45 0.60 0.70 0.90
Angle (m) 0.25 0.35 0.45 0.60 0.70 1.00 1.35 1.60 2.20
Outside ∅ in mm 21.3 26.9 33.7 42.4 48.3 60.3 76.1 88.9 114.3
inner diameter (mm) 16.0 21.6 27.2 35.9 41.8 53.0 68.8 80.8 105.3
C 95A 6423 39 – 08. Jul. 2004 5-29

5 Installation
Remote installation of the compressor
The connection data indicated in the pressure/vacuum generators and side channel compressor
are required for the connection of the hose lines in the machine.
For pipeline cross sections between the compressors and the machine see table.
A return flow valve calculated on the basis of the cross section has to be attached
to the compressors before each blast air line.
The return flow valves should be mounted in horizontal position!
Moreover, with pipelines longer than 20m, a dust or condensate separator for each pipeline
has to be mounted on the side of the press.
The cross section of a pneumatic compressor has to have a min. inside diameter and
outside diameter of 13 mm and 16 mm respectively, and has to be designed for a rated
pressure of 10 bar.
The condensate separator should be mounted on the lowest position.
Caution: Before mounting the hoses, check the direction of rotation of the compressors!
5-30 C 95A 6423 39 – 08. Jul. 2004

Installation
5
5.13 Hints for disassembly
Only trained staff may assemble or disassemble the press!!!
Conditions:
The press has been cleaned completely (ink fountain, ink rollers, cylinders, etc.)
Advance press to correct position:
– Set all ink slides to “100“.

– Remove drive chain from feeder.
– Lower feeder pile to 120 mm above the floor.
– Lower delivery pallet and disassemble.
– Empty reserve tanks and containers for return cleaning agent liquids.
– Advance machine to marks on the gears on A- and B-side.
– Switch off machine and disconnect power supply
Caution: Observe safety directions!
- First bleed pressure tank before separating the pneumatic lines!

- Empty all feed and return hoses, WW, GTW and dampening unit pipes,
as well as waste containers and dispose! Caution – danger of slipping!
- Disassemble oil and grease lines, seal and package them well. Caution – danger of slipping!
- Disassemble feeder, main drive motor and printing units.
- Use only lifting devices as directed to transport the units!
(See section 4 “Machine Transport“)
- Place printing units, delivery and feeder on transport pallets and fasten securely!
- Preserve all parts subject to oxidation!
Caution: Collect in a suitable container and subsequently dispose of all

solvents!
Avoid open fire!
C 95A 6423 39 – 08. Jul. 2004 5-31

5 Installation
5.14 Putting into operation and delivery of the machine

Up to series 337 one document:
„Transport, Installation, Putting into operation“
3K5_01jpg
From series 338 separate documents

„Transport“ „ Putting into Operation“
3K5_02pg 3K5_03jpg
The Document „Installation“ is not applicable.
5-32 C 95A 6423 39 – 08. Jul. 2004

Installation
5
The electrical and mechanical systems must be put into operation in keeping with instructions.
Part 1: Commissioning for “Safety“

Part 2: Commissioning for “Function“
Confirm the commissioning procedure according to part 1 and part 2 on the transfer protocol point 2 and on the
last page of the manual “Transport, Installation, Putting into Operation”.
From series 338 only “Putting into Operation”
The transfer of the machine is to be confirmed by the customer and sales and service partner in point 3 of the
Transfer Protocol.
Transfer protocol:
Original for MAN Roland
1 photocopy (front/back) for sales and service partner
1 photocopy (front/back) stays with the customer.
Manual “Transport, Installation, Putting into Operation”.

From series 338 only “Putting into Operation”
1 copy (filled in) for MAN Roland
1 copy stays with the customer.
The sales and service partner is required to send the transfer protocol
and the filled in manual “Transport, Installation, Putting into Operation” to the address below:
MAN Roland Druckmaschinen AG

Service Bogenmaschinen
Mühlheimer Str. 341
D-63075 Offenbach
www.MAN-Roland.de
C 95A 6423 39 – 08. Jul. 2004 5-33

5 Installation
5-34 C 95A 6423 39 – 08. Jul. 2004

Feeder
6
6 Feeder till series 330
6.1 Overview......................................................................................... 6-3
6.2 Command boards .......................................................................... 6-4
A-side .............................................................................................. 6-4
B-side .............................................................................................. 6-4
6.3 Suction head .................................................................................. 6-5
Disassembly .................................................................................... 6-5
Assembly ......................................................................................... 6-6
Suction head height adjustment ...................................................... 6-7
Suction head size adjustment.......................................................... 6-8
Basic position of the sensors ........................................................... 6-9
Single parts.................................................................................... 6-10
Pick-up sucker ............................................................................... 6-12
Air supply connections in the suction head.................................... 6-13
Suction head, air control roller and control cams........................... 6-14
Suction head drive......................................................................... 6-16
6.4 Feeder drive ................................................................................. 6-18
6.5 Machine feeder ............................................................................ 6-19
Feeder drive via chain and register feeder drum ........................... 6-19
Feeder timing................................................................................. 6-21
Setting the machine to feeder:....................................................... 6-23
6.6 Sheet run ...................................................................................... 6-24
Setting notes.................................................................................. 6-24
6.7 Setting sheet hold down ............................................................ 6-27
6.8 Pile control ................................................................................... 6-28
Programmed switching device A 352/3 ......................................... 6-28
Pile supporting plate ...................................................................... 6-29
Setting the side stops .................................................................... 6-30
Side stop A/B - side ....................................................................... 6-32
6.9 Suction tape feed board.............................................................. 6-33
Sheet flap movement..................................................................... 6-33
Tape feeder roller .......................................................................... 6-34
Installation of the suction tapes ..................................................... 6-35
C 95A 6423 39 – 11. Nov. 2003 6-1

6 Feeder
6.10 Air control.....................................................................................6-37

Installation position for mechanical valves .....................................6-38
Double sheet detection ..................................................................6-39
6.11 Non-stop device (Option) ............................................................6-40
6-2 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
6.1 Overview
1 Blast air adjustment – suction head 8 Floor

2 Suction air adjustment – suction head 9 Control station B–side
3 Blast air, lateral pick-up jets 10 Suction head
4 Hand wheel 11 Control station A–side
5 Pile support board control 12 Non-stop device
6 Skew sheet adjustment 13 Pile support board
7 Suction air – suction tapes
C 95A 6423 39 – 11. Nov. 2003 6-3

6 Feeder
6.2 Command boards

A-side
2 Pile STOP (Halt-safe)

3 Automatic pile rise
4 Hand-held terminal
5 Normal pile UP
6 Non-stop pile UP
7 Free
8 Normal pile DOWN
9 Non-stop pile DOWN
10 Free
B-side
12 Suction head UP
13 Suction head DOWN
14 Suction head BACK
15 Suction head FORWARD
16 Free
17 Free
18 Pile stop B-side BACK
19 Pile stop B-side FORWARD
20 Pile stop A-side FORWARD
21 Pile stop A-side BACK
22 Move pile to B-side
23 Move pile to A-side
24 Free
25 Free
26 Feeder positioning motors
One step ON / OFF
27 Free
6-4 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
6.3 Suction head

Disassembly
1. Move suction head to sheet size and then to its lowest position,
if necessary use hand-held terminal.
2. Move pile support board carefully up and prop suction head for disassembly.
3. Switch off machine!
4. Remove all operating knobs from the front plate, screw out protection screws
and take off suction head protection cover.
5. Loosen all supply lines to the suction head (see drawing below).
6. Remove cardan shaft protection and knock out tapered pin in the cardan shaft.
7. Extract 2 tapered pins from the mounting plate and loosen 6 Allen screws.
8. Extract the suction head.
Supply lines to the suction head
B 086 Pile upper edge sensor B 026 Suction head height max. sensor
B 091 Pressure foot sensor Y 115 Brake pneumatic valve
B 134 Pressure foot sensor Y 059 Suction air to suction head
B 090 Pressure foot sensor Y 001 Blast air, 1. grade
M 340 Suction head height motor Y 006 Blast air, 2. grade
B 025 Suction head height zero sensor
C 95A 6423 39 – 11. Nov. 2003 6-5

6 Feeder
Assembly
1. Screw new suction head to mounting plate, use water level to align and finally fix by pins.
(Place water level on cross bar and check feeder.)
2. Connect all supply lines.
3. Attach suction head protection cover and operation knobs.
4. Insert cardan shaft driving the suction head and clamp setting screw.
5. Switch on machine (make-ready) and advance to 156°, display DW 1.
6. Set feeder timing to "50" and connect feeder.
7. Loosen setting screw on cardan shaft and turn suction head so that the marks
on the suction head and on the disk of the control roller are on top of each other.
8. Tighten setting screw and fix cardan joint by pins.
9. Mount cardan shaft protection.
Notes:
The cardan shaft has to be pushed into the marks!

Concentricity error max. 0.4mm.
If the marks on the suction head /

disk on the control roller cover each other,
then the forwarding sucker drops the
picked up sheet and the sheet guiding
rollers are engaged.
Further, it is necessary to check the sheet flap and,
if necessary, readjust the sheet flap eccentric cam.
Sheet flap eccentric cam no. 089 868-000
Setting values:
Forwarding sucker moves too soon 165° View: From the back of the suction head
Sheet flap tilts to one side : 165° 1 Allen screw
2 Tapered pin with inside thread
1 Cross bar
2 Water level
3 Cardan
Front view of the suction head
6-6 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
Suction head height adjustment
Stepper motor, Unit 1, drive no. 1, bus address no. 60
1 Drive no. 1, M 340

2 Upper stop
3 Zero detector B 025
4 Suction head
5 Max. detector B 026
6 Lower stop
Sensor holding has changed

since series 323.
Rear view of suction head
Using the hand-held terminal:
1. Plug hand-held terminal in feeder, membrane keyboard A-side.

2. Press reset switch in control cabinet on A-side (active mode). Electricians only!
3. Enter code and select Menu 8.
4. Select drive no. 1 and check sensors. Use metal strip to dampen sensor,
the indication of the zero and max. sensor has to change from “ON“ to “OFF“.
5. Select Menu 7, enter code and select bus address no. 60.
6. Use arrow keys to move suction head to a distance of 5 mm from the stop (2).
7. Exit Menu 7 via Exit and select Menu 8.
8. Call drive no. 1 and set zero sensor (from ON to OFF).
10. Select drive no. 1 and execute “AUTO CALIB.“
11. Move along the whole track of 50 mm and set max. sensor to a distance of 2 mm.
12. Move suction head back to 0 mm.
C 95A 6423 39 – 11. Nov. 2003 6-7

6 Feeder
Suction head size adjustment
Positioning motor , unit 1, drive no. 2, bus address no. 61
1 Max. sensor B 024

2 Suction head
3 Zero detector B 023
4 Drive no. 2
5 Sheet flap
6 Sheet stop
7 Pressure foot
Turn the feeder so that the sheet flap (5) is in the top
vertical position.
Check whether the sheet stop (6) is positioned at a
right angle.
View from B-side
The pressure foot is in bottom position (12 mm)

during automatic size adjustment.

1. Plug hand-held terminal in the feeder, membrane keyboard A-side.
2. Press reset switch in control cabinet, A-side (active mode) Electricians only!
Caution: Loosen pneumatic brake on suction head!
(Switch manual solenoid valve Y 115 or remove bolt)
6. Use arrow keys to move suction head to a distance of 610 mm between sheet flap (5) and sheet stop (6).
8. Call drive no. 2 and set zero sensor (from ON to OFF).
11. Move along the whole track of 350 mm (with A4, 400mm) and set max. sensor to a distance of 2 mm.
12. Move suction head back to 0 mm.
Caution: Reactivate the pneumatic brake function!
6-8 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
Basic position of the sensors
1 2 3 4 5 6 7
B090
B134
B091
0,5
4
2
1 Pressure foot
2 Switch flag
B086 3 Sensor B 091, suction head
4 Sensor B 134, pile rise

8 5 Sensor B 090, suction head
9
6 LED. orange, covered - ON,
10
7 LED. green, power supply

8 Sensor B 086
9 LED
(X)
X 75
1,5
0,5
6008.cdr
View from A-side
When the sheet flap sensor is activated from the Leitstand:

then sensors B091 and B090 are active,
the suction head adjusts itself to the sheet edge,
the sheet flap sensor controls the rise
of the pile supporting plate.
When the pressure foot is activated from the Leitstand:

the suction head is fixed in a top position and the sensors control
the rise of the pile supporting plate.
Setting the B 086 sensor (8)
The sensor can be adjusted when the suction head has reached the size and is in its top position. Push the sensor,
which is mounted on a holder, on to the rear holding rod of the sucker and clamp loosely. Then move pile to
working position. The detection distance of the sensor is to be set by a setting screw at 75mm from a white sheet
and sealed. Adjust the holder with the sensor so that the rear edge of the sheet pile is detected and the LED on the
sensor glows. Finally fasten the holder.
C 95A 6423 39 – 11. Nov. 2003 6-9

6 Feeder
Single parts
6-10 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
Pressure foot mount:
Pressure foot drive:
C 95A 6423 39 – 11. Nov. 2003 6-11

6 Feeder
Pick-up sucker
Front view
1 Suction head
2 Turning knob
3 Turning knob
4 Clamping bolts
5 Lead screw with spring
6 Pick-up sucker
7 Sheet pile
8 Stop
9 Self-locking nut
Setting: View from B-side

Remove suction head cover
Lateral movement of the pick-up sucker
Turn knob (2) clockwise to stop
Loosen clamping bolts (4) and set both pick-up suckers (6) at a right angle (90°)
Fasten clamping bolts (4)
Move pick-up sucker forward and back
Turn knob (3) clockwise to stop (8)
Use nut (9) to set pick-up sucker (6) at right angle (90°).
6-12 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
Air supply connections in the suction head
Suction air for pick-up suckers Pre-blower

Suction air for forwarding suckers Air cushion
Suction air from control valve

Blast air from control valve
Air cushion Air cushion

Pre-blower Pre-blower
Air cushion Pre-blower
1 Air cushion
2 Pre-blower
3 sucker
C 95A 6423 39 – 11. Nov. 2003 6-13

6 Feeder
Suction head, air control roller and control cams
B-side A-side
X Screw on degree dial here when checking the feeder timing.

1 Air control roller 5 Positioning holes 10 H7
2 Control socket 6 Eccentric cam for pick-up sucker (A5x35 DIN 1)
3 Balancer 7 Eccentric cam for pressure foot (A5x35 DIN 1)
4 Control cam (A5x30 DIN 1) 8 Drive shaft (A5x35 DIN 1)
♦ The eccentric cam/balancer (4, 6 and 7) in the suction head are adjusted to each other and fixed by a
connecting bolt in the borings (7), see drawing above.
Drive / Control cams
6-14 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
Air control roller design
♦ The control roller (1) has a cut of area that is fixed it in relation to the eccentric cam.
The control cam can be extracted for cleaning purposes.
C 95A 6423 39 – 11. Nov. 2003 6-15

6 Feeder
Suction head drive
Design and the suspension of the drive-side
6-16 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
Suction head drive, suspension on the drive-side
Series 311 to 328
From series 329
C 95A 6423 39 – 11. Nov. 2003 6-17

6 Feeder
6.4 Feeder drive
Design of the drive shaft including coupling and sprocket
6.5
6-18 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
Machine feeder
Feeder drive via chain and register feeder drum
Feeder Printing unit 1
View from A-side

1 Sprocket with coupling 4 Chain guide
2 Chain tensioner 5 Sprocket (to register feeder drum)
3 Chain
Caution: Realign the chain guide (4) after tightening the chain (3)
by means of the chain tensioner (2).
View from machine to feeder

1. Shaft 03-082 509-000 (register spring A4x4x15 DIN 6885, A5x5x20 DIN 6885)
2. Connection from the coupling 03-082 501-000 to bevel gearing
3. Bevel gearing 10-003 795-000
4. Sprocket, drive from suction head
5. Connection to tape roller
6. Chain tensioner
7. Drive chain from printing unit 1 to feeder
C 95A 6423 39 – 11. Nov. 2003 6-19

6 Feeder
Connection between coupling and bevel gearing
Series 311 to 321 Series 322 to 328
From series 329 and all retrofits
Connection no. 094 D2164 13
6-20 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
Feeder timing
Stepper motor, unit 1, drive no. 3, bus address no. 62
1 Zero - detector B 070

2 Max. - sensor B 071
3 Drive no. 3, M342
4 Water level
5 Bevel gearing
View from A-side
1. Plug hand-held terminal in the feeder

2. Press reset switch in control cabinet, A-side (active mode) Electricians only!
6. Use water level to align bevel gearing
7. Use sliding caliper to set zero detector to ~ 18mm
10. Move along the whole track of 35 mm (with A4, 400mm) and set max. sensor to a distance of 3 mm.
11. Move bevel gearing to middle (17.5 mm or 0 mm)
C 95A 6423 39 – 11. Nov. 2003 6-21

6 Feeder
Setting the machine feeder:
Series Machine position Sheet arrival

311 to 314 182 ° +/-2° ~ 35°
315 to 326 156 ° +/-2° ~ 9°
327 to 330 167 ° +/-2° ~ 20°
from 331 11° ~ 20°
Mount feeder drive chain:
Example: (Series 315 to 326)

1. Place feeder drive chain (3) over the sprocket on the feed cylinder (1. printing unit A-side)
and use hand crank to advance press until both ends of the chain hang out of the protection cover.
2. While doing so turn machine to 156 ° +/-2° (display DW 1, A-side).
3. Seven segment display (DW 1, A-side) set feeder timing to “50“.
4. Plug hand-held terminal in feeder, select Menu 6, drive no. 3,
the actual value should be 17.5 mm (0 mm), if necessary execute auto-calibration.
5. Loosen three screws on sprocket (5) of the feeder coupling and position the sprocket
in the middle of the oblong holes, tighten screws.
6. Switch on feeder, i.e. activate magnetic coupling from DW 1 while seeing that the teeth
are interlocked - this is possible in just one position per revolution!
7. Use hand wheel to turn feeder to the right until the marks on the suction head and disk (8)
on the air control roller are above each other. In this position the sheet feed rollers (6)
touch the forwarding roller (7) – if the sheet guiding rollers are properly set.
8. Finish the mounting and tightening of the drive chain (3) in this position.
9. Realign chain guide (4)!
Example: Series 315 to 326
1 Seven-segment display
2 Display - machine
3 Drive chain
4 Chain guide
5 Sprocket
6 Guiding roller
7 Forwarding roller
8 Disk
View from B-side
6-22 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
Setting the machine to feeder:
- Set sheet run with 115g/m2 at 10,000 sheets/h.

Required speed is over 10,000 sheets/h, so that the 2nd blast air degree is activated.
- Use the +/- key on the DW 1 to set feeder timing so that the trend display
on A- and B-side indicates “0 +/- 2“.
- If the seven-segment display is not yet on “50“ then proceed as follows:
1. Interrupt sheet run, allow sheets to run out of the press.

2. Activate feeder coupling and lock in by inching forward.
3. Inch press forward until the sheet feed rollers just touch the transport roller .
The sheet feed rollers are equally adjusted with a pre-loading of 0.2 mm.
4. Use the +/- key to move the seven-segment display to “50“.
5. Loosen screws on sprocket, use hand wheel to turn feeder around to the right until
the sheet feed rollers lift off in a straight position. Tighten the sprocket bolts.
Caution: The coupling has to be “ON“ during adjustment!
Repeat sheet run if necessary correct setting.
Display of printing unit 1
Sheet run
direction
Setting sheet guiding rollers:
Rotate feeder until the timing rollers

press fully against the forwarding roller.
Set stop screws to a distance
of 0.2 mm.
Check whether both rollers engage at the same time
or readjust stop screws.
Version 1 Sheet earlier at machine Middle Sheet later at machine

position
Seven-segment display “0“ “50“ “99“
Hand-held terminal 0 mm 17.5 mm 35 mm
Version 2
Hand-held terminal - 9 mm 0 mm + 9 mm
Version 3 / from series 331
Hand-held terminal - 18 mm 0 mm + 18 mm
C 95A 6423 39 – 11. Nov. 2003 6-23

6 Feeder
6.6 Sheet run

Setting notes
Important:
The rollers have to be lubricated by special printing press oil at a press speed of over 5000 sheets,
or if the press is running longer than 30 minutes.
1. Settings on the suction head

Blast air to the suction head
Substrate (g/m2) Blast air (bar)

Voluminous, 0.5 - 0.7
porous
< 70 0.3 - 0.5
> 70 0.5 - 0.7
Pre-blast air and air cushion:
Recommendation: The pre-blast jets should loosen the top 15-20 sheets.
For double sheets or difficult sheet guiding (sticky sheets)
increase pre-blast and air cushion slightly.
Separating jets: Substrate (g/m2) < 250 wave blower, > 250 case blower.
Flipper springs (4x) on rear sheet edge:
- Paper: all 4x sheet separators 5 mm in paper size with slight pressure on the sheet pile
- Carton: the same setting, though the two middle separators without pressure on the sheet pile
Sheet hold downs, weights:
Substrate (g/m2) Flipper springs

Voluminous, cancel function
porous
< 70 4 weights
70 – 150 2 weights
150 – 250 cancel function
> 250
Diagonal setting of the pick-up suckers (2x):
- Paper: Turn pick-up suckers slightly inward (adapted to sheet bending)

- Carton: Set pick-up suckers in parallel to pile
Distance between upper edge of the pile and upper edge of the sheet flap:
- Select sheet flap sensor: Distance of 5-8 mm fixed (upper edge of the pile)
– Select pressure foot: Distance of 5-8 mm adjustable via manual setting of suction head height
Suction air on the suction bar:
- Paper: open as far as possible (tap on air control valve)

- Carton: turn off
2. Lateral blasts
Set blasts so that the top 10-15 sheets are loosened, A- and B-side.
6-24 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
3. Double sheet detection
mechanical: Basic adjustment: Open guard in front of system and a display appears.
Turn the setting wheel on the double sheet detection device until the double sheet symbol is displayed.
Roller pressure: When printing on paper hook the pulling spring down, with carton hook pulling spring up
(more pressure).
- depending on sheet size, place sheet strips of the sheet that is being printed between the double sheet
setting wheel and the metal plate
- Paper size 210 to 340 mm 2x sheet strips

- Paper size 352 to 505 mm 3x sheet strips
- Paper size over 516 mm 4x sheet strips
- With intermediate sizes 341 - 351 mm, 506 – 515 mm x check sheet strips.
- Check: Star sheet run, hold 1x sheet strip under the roller, feeder has to shut itself off.
electrical: - place 1x white sheet of the material that is being printed between the sensors and adjust
on the membrane keyboard of printing unit 1.
Note: Electrical double sheet detection does not function with:

- thick and/or printed substrates
- foils
4. Foreign body guard:
- Set rail to double or tripple sheet thickness of .
5. Sheet hold downs

- Paper: Set height so that double sheet thickness can be easily inserted.
- Carton: Lock height accordingly (0.6 to 0.7 mm)
(Basic adjustment: see Appendix)
6. Side guide
Suction air:
g/m2 bar
30 – 100 – 0.1
100 – 170 – 0.3
Carton – 0.6 or max. value
Sheet guiding:
- The height of the mechanical guiding system should be set so that double sheet thickness can be easily inserted.
Pulling pads :
- Gummed paper, black pulling pads
- from 250g/m2 carton: smooth metal pulling pads
Setting of the acoustic signal:

Basic setting: Open guard in front of system and a display appears.
Place substrate on front and side stops.
Use setting screw to adjust so that the sensor display becomes “black”.
Check: Start sheet run (condition: pulling track, suction air and sheet stop have to be adjusted).
Use setting screw for fine adjustment. Adjustment is perfect as soon as the signal becomes inaudible.
C 95A 6423 39 – 11. Nov. 2003 6-25

6 Feeder
7. Adjustments on the Leitstand (select and acknowledge with “+/-“)
Menu DR-preselect
– set all printing, inking and damping units to minus (sheet run only)
Menu DR-preselect-substrate (F1):

– Sheet size: (move the delivery pile supporting plate to lowest position)
– Substrate thickness: (cover guides are set automatically 0.2 mm higher but can be adjusted if necessary)
Menu DR-preselect-feeder/delivery (F2):

– Select pull-type side guide A- or B-side suction air, switch lever on printing unit 1 mechanically!
– Pile control: Feeder: pressure foot or sensor in the sheet flap
Delivery: determine pile lift with 0.5 paper; correspondingly higher for carton
– Side edge detection: Recommendation: select “+“
– Front edge detection: Select small size < 450 mm or large size > 450 mm
– Suction tape blower: select “strong“ or “weak“.
Menu DR-register-front lays (F2):
Front lays positions, recommendation:
1 2 3 4 5
0 – 0.02 – 0.03 – 0.02 0
8. Settings on delivery
Sheet slow-down: (5x lever no.: 1,2,3,4,5 top left)

– Place sheet slow-down devices in the print-free area.
– Set max. suction air with S&W or possibly set to blast air.
Blast frame:
– Set ventilators to sheet size.
– Set revolutions so that the sheets float smoothly to the delivery (position 5 to 8)
Rule of thumb: The higher the machine speed the more air is required.
Blast rods: (3x lever no.: 1,2,3 top right)

– If necessary use hand-operated wheel for lateral setting of outer blast pipe to size.
– Normally not much blast air is required. It may be sufficient to activate just the middle blast rods.
Gripper opening cam:

– Set gripper opening cam before the paper run to 23%.
– Changes via Make ready key “+“ the sheet is dropped earlier
Make ready key “–“ the sheet is dropped later
– The gripper opening cam adjusts automatically to the machine speed..
Suction roller speed:

– Set suction roller speed before the paper run to 58%.
– Changes via Make ready key “–“ the sheet is dropped earlier
Make ready key “+“ the sheet is dropped later
Inspection sheet removal:

– The production or sheet run is interrupted if a tone comes on while the sheet flap is opened and not closed
immediately.
6-26 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
6.7 Setting sheet hold down

1. Distance from the front edge of the sheet:
– Open clamp handle (4).

– Swivel sheet hold down to desired position.
– Tighten clamp handle (4).
2. Distance to sheet:
– Open screws (1) and (3).

– Use screw (2) to adjust height.
– Tighten screw (3).
3. Swivel height:
– Screw (1) is still open.

– Lift sheet hold down to desired level and tighten
screw (1).
4. Spring pressure:
– Open screw (6).

– Use screw (7) to make adjustment.
(Increase or decrease the pressure of the sheet hold down by turning to the left or right respectively).
– Tighten screw (6).
5. Adjust rollers:
- Adjust rollers by shifting them sideways.
Note:
- Paper: Position the sheet hold down shaft as close to the feed as possible.
- Carton: Position the sheet hold down shaft as far back as possible to avoid frequent early sheets.
C 95A 6423 39 – 11. Nov. 2003 6-27

6 Feeder
6.8 Pile control

Programmed switching device A 352/3
1 Feeder side frame, A–side M003 Auxiliary pile motor

2 Base plate for main pile hoist motor M004 Main pile hoist motor
3 Sprocket for main pile movement A352/3 Programmed switching device
4 S 604, Pile supporting board up, stop at 140 mm to
upper edge of sheet flap (stationary cam disk)
5 S 602, Pile supporting board stops at 120 mm above the floor,
then at crawl speed down to the floor
6 S 601, Pile supporting board down, stops upon contact with the
floor
X Sheet flap
Caution:
Chain guides and pile guides have to be

installed before moving the pile.
Otherwise danger of breakage!
6-28 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
Pile supporting plate
Stepper switch motor, unit 1, drive no. 5, bus address no. 64
From series 311 to 313 From series 314 to 330
A-side B-side
1. Plug the hand-held terminal in the feeder.

2. Press reset switch in the control cabinet A-side (active mode). Electricians only!
4. Select drive no. 5 and check sensors, activate them by a metal strip,
zero - max.- sensor should alternate between “ON“ and “OFF“.
5. Enter code and select menu 7.
6. Enter code and select bus address no. 64.
7. Use arrow keys to move guide rail to 485 mm to B-side.
8. Leave menu 7 via Exit and select menu 8.
9. Call drive no. 5 and set zero sensor B 065 (from “ON“ to “OFF“)
11. Call drive no. 5 and execute “AUTO CALIB.“
12. Enter nominal value 0 mm and check middle position of 500 mm to A- and B-side.
13. Move nominal value +15 mm and set max. sensor B 064 to a distance of 3 mm.
14. Move back to middle position.
Caution: The pile supporting plate may not be moved to the side once it is in contact with the floor.
Danger of breakage!
C 95A 6423 39 – 11. Nov. 2003 6-29

6 Feeder
Setting the side stops
Condition:
- Initiators of the IS 3002-BNOG type (normally closed function) made by IFM are used.
- The distance between the initiators is 4.7 ± 0.2 mm.
- The distance between the switching surface and the initiators is 1 ± 0.2 mm.
1 Feeler gauge
2 Contact plate
3 Initiators with holder
4a Stop
4b Stop
5 Stop
6 Stop
7 Roller holder
8 Guiding roller
Setting:
Mechanical centring:
1. Use feeler gauge (1) to measure gap between stop plate and guiding rod of the roller holder.
Leave feeler gauge (0.8 to 1mm) inserted in gap!
2. Position roller holder (7) at a right angle (90°) to the guiding roller (8) over the stop 4a
(to series 324, from series 325 stop 4b).
3. Clamp contact plate (2) so that both LED’s of the initiators (3) glow.
The distance between the contact plate and the initiators 1 ± 0.2 mm.
Movement between switching points:

4. Hoist pile supporting plate and position auxiliary stop.
Align auxiliary stop at a distance of 1 mm to the switching roller (position 1).
5. Remove feeler gauge (1). The switching roll is now in contact with the auxiliary stop
(position 2).
6. In this position the LED on the left initiator has to go off.
If not, move the holders with the initiators (3) appropriately.
7. Set a distance of 2 mm (feeler gauge) to auxiliary stop (position 3).
The LED on the right initiator has to go off in this position.
If not, adjust the holders with the initiators (3) appropriately.
When doing so, do not exceed the range of 1 ± 0.2 mm!
8. Check: The feed path of the switching roller is ± 1 mm from the vertical position.
6-30 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
Stop B-side:
Mechanical feed path:

9. Remove auxiliary stop.
Set stop (5) so that the contact plate just covers the second outer ring (X) (position 4).
10. Set stop (6) in the same way in relation to the right initiator.
11. The settings for the lateral stop on A-side are identical.
C 95A 6423 39 – 11. Nov. 2003 6-31

6 Feeder
Side stop A/B - side

Positioning motor A-side, unit 1, drive no. 4, bus address no. 63
Positioning motor B-side, unit 1, drive no. 6, bus address no. 65
Mechanical centring:
Use feeler gauge (1) to measure gap between

stop plate and guiding rod of the roller holder.
Leave feeler gauge (0.8 to 1mm) inserted in
gap! (See drawing 6035.cdr)
Using the hand-held terminal: (Example B-side)

1. Plug hand-held terminal in feeder.
2. Press reset switch in control cabinet A-side (active mode). Electricians only!
4. Select drive no. 4 and check sensors, activate sensor by a metal strip,
zero - max.- sensors should alternate between ON and OFF.
5. Select menu 7, enter code and select bus address no. 63.
6. Move roller lever (at a right angle) to a distance of 100 mm from the inside of the side frame.
7. Leave menu 7 via Exit and select menu 8
8. Cal drive no. 4 and set zero-detector B 021 (from ON to OFF).
10. Select drive no. 4 and execute AUTO CALIB.
11. Move along the whole path of 270mm and set max. sensor B 022 to a distance of 7 mm.
12. Enter nominal value of 0 mm and move back to basic position.
13. Reset setting screw on the roller lever back to dimension “x“.
Set A-side in the same way (Min. size is limited to 400mm when setting from the Leitstand!)
B-side A-side
6-32 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
6.9 Suction tape feed board

Sheet flap movement
Series Sheet flap tilts away Sheet flap remains vertical
311 to 316 170° 340°
317 to 319 145° 310°
from 320 165° 295°
Check:
Mounting the degree dial:
- Forwarding sucker suction air “Off“, set pointer to 300° (series 311 to 330).
Forwarding sucker suction air “Off“, set pointer to 9° (from series 331).
- Use hand wheel to turn feeder until the sheet flap is in vertical position.
- Position measuring dial and set measuring dial pointer to “0“.
- Use hand wheel to turn feeder counterclockwise and check setting against table above.
- If the setting is wrong, readjust the sheet flap eccentric cam.
1 Sheet flap
eccentric
cam
2 Sheet flap
3 Measuring dial
4 Eccentric cam for
sheet guiding
rollers
A-side inside View from machine to feeder
Exchanging the sheet flap eccentric flap:

- Remove protection guards
- Extract tensioning pin from lead screw
- Remove Seeger ring
- Loosen clamping screw on middle bearing
- Move middle bearing in the direction of the
arrow
- Extract tapered pin from sheet flap eccentric
cam
- Remove sheet flap eccentric cam in arrow
direction from the shaft
- Mount new eccentric cam in reversed
sequence of steps
1 Sheet flap eccentric cam
2 Eccentric cam for sheet guiding roller
3 Clamping screw
4 Lead screw
5 Tensioning pin
6 Seeger ring
7 Middle bearing
C 95A 6423 39 – 11. Nov. 2003 6-33

6 Feeder
Tape feeder roller
View from printing unit 1 to feeder
1 Feeder roller A-side 7 Middle bearing

2 Tapered pins 8 Feeder roller B-side
3 Follower ring made of Febo-Preno Aclathan 9 Marking
4 Spur gear 10 Clamp screw M6x35
5 Dome nut 11 Joint shaft to setting knob
6 Lead screw M6x6 (secured by paint)
Settings:
- Turn back spur gear (4) in paper travel direction (i.e. negative range) so far
until the follower ring (3) becomes slack, dimension: 51.4 ± 0.02 mm.
- Turn spur ring against sheet travel direction (i.e. positive range) to the start of the tensioning range
- Set dome nut (5) gap to 0.2 mm, then tighten lead screw (6).
- Turn spur gear via the setting knob and joint shaft (11) to setting dimension of 51.8 + 0.08 mm and
tighten with clamping screw (10).
- Mark both spur gears with red paint.
Radial runout of the feeder roller A- and B-side max. 0.1 mm.
Presetting the feeder roller speed:

- Mark both suction tapes by a felt-tipped pen (fig. 1).
- Advance feeder by hand-operated wheel (see fig. 2)
- Check markings with straightedge.
The marks should be at the same level, if not set follower ring (3) appropriately.
Fig. 1 Fig. 2
6-34 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
Installation of the suction tapes
When installing the suction tapes observe the following points:
- Tape length = 1440 mm, tape thickness = 0.75mm, tape tension = 0.5 %
- Sheet travel direction = see arrow printed on the suction tape.
- Use tapes from a single consignment only.
- Tape underside = light green
- Tape upper side = dark green
Bonding the suction tapes:
1 and 2 = remove protecting foil from the surfaces.

Apply an even thin coat of FIXOL to the surface 1. Apply
to surface 2 and rub in adhesive only over the traction
layer without fabric, until the bonding agent begins to
set. Let the solvent evaporate for at least 5 minutes.
Place tapes in cold bonding press and align. Close

press and switch on, allow 20 minutes to vulcanize
and let cool off.
Time in press min. = 10 minutes

Temperature 100° - 120 °C
Mounting the suction tapes:
Mark the suction tape and feed board with a felt-tipped pen
as follows:
Distance between marks on the tape = 500 mm.

Distance between marks on the feed board = 502.5 mm.
(tape tension 0.5%)
Mount suction tapes over the tensioning rollers,
until the feed board and suction tape marks coincide.
C 95A 6423 39 – 11. Nov. 2003 6-35

6 Feeder
Suction tape feed board
1 Suction tape feed board with structured surface to prevent

static charges.
2 Ventilator, M 110, (2x step control).
3 Rotary magnet Y 114
4 Two perforated suction tapes
5 One suction box for each suction tape
Function of the flap control:
When paper travel is interrupted there are still some sheets on the register table.
The rotary magnet (3) is active on the arrival of X sheets.
The flap shuts off the opening for a short time.
This allows the last sheets to settle stress free.
The ventilator (2) can be set from to “strong“ to “weak“ on the Leitstand.
The suction of the suction tapes can be infinitely controlled by a rotating button on the feeder.
Basic adjustment of the sheet guiding rollers:
Use the hand-operated wheel to turn feeder until the sheet guiding rollers contact the forwarding roller.
Adjust stop screw (1) to 0.2 mm and tighten lock nut (2).
Caution: Uniform setting of the transport

rollers is absolutely necessary if skewed sheets
are to be prevented.
1 Stop screw
2 Lock nut
3 Feeler gauge 0.2 mm
6-36 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
6.10 Air control
View from B-side
1 Pneumatic piston, brake on the suction head 7 Solenoid valve Y 005

2 Suction head 8 Solenoid valve Y 007
3 Solenoid valve Y 115 9 Blast air lateral blowers
4 Air pressure 10 Blast air to suction head
5 Blast air lateral blowers A-side 11 Suction air to suction head
6 Blast air lateral blowers B-side 12 Sheet flap sensor B 115
No. Solenoid valve Function Function test

a Y 001 switches valve A 03
b Y 006 switches valve B 04
c Y 059 switches valve C --
4 Y 005 lateral blower 02
5 Y 007 cleaning B 115 05
6 Y 115 brake on suction head 01
Solenoid valve no. 6 : from series 310 to 314 = Y302

from series 315 to ... = Y115
C 95A 6423 39 – 11. Nov. 2003 6-37

6 Feeder
Installation position for mechanical valves
Situation shown:
- The feeder compressor is ON
- Valves a (Y001), b (Y006) and c (Y059) are inactive.
- The available blast air keeps switching pistons A, B and C in “CLOSED” position.
- When the valves (Y001, Y006, Y006) are activated, blast air changes to suction air.
The position of the switching pistons (A, B and C) changes from “CLOSED” to “OPEN”.
a Solenoid valve Y 001

b Solenoid valve Y 006
c Solenoid valve Y 059
A Switching valve, 1. stage blast air to suction head

B Switching valve, 2. stage blast air to suction head
C Switching valve, suction air to suction head
1 Air control from Y 001

6-38 C 95A 6423 39 – 11. Nov. 2003

Feeder
6
Double sheet detection
Basic adjustment:
- Open protection guard above the feeder, the sensor display appears on the display of the printing unit 1.
- Use hand-operated wheel to advance the feeder until the double sheet detection device is in the lowest
position in relation to the transport roller.
- Turn setting wheel (4) until the grooved ball bearing lifts off just before the transport roller (9).
The double sheet symbol is displayed (without a paper strip).
1 Paper strip
2 Metal plate
3 Switch S 812
4 Setting wheel
5 Pin (for cardboard)
6 Pin (for paper)
7 Grooved ball bearing
8 Paper strip
9 Transport roller
- Paper size 210 to 340 mm 2x sheet stripes

- Paper size 352 to 505 mm 3x sheet stripes
- Paper size over 516 mm 4x sheet stripes
- With intermediate sizes 341 - 351 mm, 506 – 515 mm x check sheet stripes.
- Check: Start sheet travel, hold 1x sheet stripes under the roller, feeder has to stop
Note:
The metal plate (2) has to be loose

do not tighten
C 95A 6423 39 – 11. Nov. 2003 6-39

6 Feeder
6.11 Non-stop device (Option)

Setting of the rest pile rails
- Transverse alignment: use water level to align rest pile rails.

- Longitudinal alignment: rail (A) 5 mm is “lower“ than rail (B).
Caution: The metal plate rail has to lie on (A) during alignment.
The purpose of this adjustment: when the rest pile moves under the main pile, the pile edge close to the register
mechanism reaches the rest pile before the pile edge under the suction head.
View from B-side
Non-Stop control
- Rest pile “Up“: upper edge rail (A) to upper edge sheet flap 80 mm.
Switch S 605 is contacted.
- Rest pile “Down“: total travelling distance = 305 mm from the upper edge of the sheet flap
to upper edge of the rail (A).
Switch S 603 is contacted.
- Caution: The metal plate rail has to lie on (A) during adjustment.
a Upper edge of the sheet flap

b Upper edge of the rail (A)
c Rest pile rails
d Main pile
6-40 C 95A 6423 39 – 11. Nov. 2003

Feeder from series 331

6A
6A Feeder from series 331
6.1 Modules .......................................................................................... 6-3
6.2 Control panels ............................................................................... 6-4
6.3 Parameters ..................................................................................... 6-6
Setting of the graduated disc ........................................................... 6-7
6.4 Placing of the switch gears and the control gears ..................... 6-8
6.5 Suction head ................................................................................ 6-12
Suction head – height adjustment ................................................. 6-12
Suction head – size adjustment..................................................... 6-13
Sensors / Pressure foot ................................................................. 6-14
6.6 Feeder to machine....................................................................... 6-15
6.7 Drive ............................................................................................. 6-16
Feeder timing................................................................................. 6-17
Feeder clutch................................................................................. 6-18
6.8 Pile control ................................................................................... 6-19
Pile supporting plate ...................................................................... 6-19
Pile control..................................................................................... 6-20
Switching device............................................................................ 6-22
Non Stop ....................................................................................... 6-23
Pile guiding .................................................................................... 6-24
6.9 Suction tapes feed board............................................................ 6-25
6.10 Air control .................................................................................... 6-26
C 95A 6423 39 – 11. Nov. 2003 6-1

6-2 C 95A 6423 39 – 11. Nov. 2003


6A
6.1 Modules
1 Pile supporting plate 13 Suction tape feed board
2 Residual pile hoist 14 Safety zone
3 Control panel fine adjustments 15 Safety pictographs
4 Control panel pile control 16 sheet guide roller
5 Air regulation infeed 17 Air regulation feeder
6 Air regulation suction tape feed board 18 Deposit for NON_STOP-device
7 Suction head 19 Pressure gauge
8 Lateral pick-up blower 20 Lateral blast nozzle (Option)
9 Crooked sheet correction
C 95A 6423 39 – 11. Nov. 2003 6-3

6.2 Control panels
1 Pile stop-secure
2 Main pile: raise
3 Main pile: lower
4 Automatic pile control
5 Residual pile. Raise
6 Residual pile: lower
7 Service socket
8 Speaker
9 EMERGENCY stop
Suction head:
10 lower
11 higher
12 to a smaller size
13 to a larger size
Lateral blower A-side:
15 to a larger size
Pile supporting plate/lateral blowers B-side:
16 to the B-side
17 to the A-side
18 Pre-setting step size for keys 10-15
LED on small steps
LED off motor will turn as long as
you press the key
19 feeder: clutch on / off
to get sheets out of the feeder
(only possible at base speed)
6-4 C 95A 6423 39 – 11. Nov. 2003


6A
1 Pressure gauge side guide
2 Pressure gauge suction rolls
3 Pressure gauge blast/suction device
4 Suction tapes 1st suction chamber (feeder)
5 Side blowers A-side
6 Suction air side guide A-/B-side
7 Suction air side guide
8 Suction air suction rolls
9 Blast/suction device
10 Suction tapes 2nd suction chamber
11 Side blowers B-side
C 95A 6423 39 – 11. Nov. 2003 6-5

6.3 Parameters
• Stream distance 196 mm
• Slowing-down from 40% to 60% of the average speed
• 1° ~ 0,33 mm on the suction tape feed board at minimum speed
• Sheet transfer from the forward suckers to the feed board table at minimum speed
• Sheet arriving at the front guides at minimum speed

theoretical sheet arriving time 20°, (degrees from the machine)
• Feeder timing adjustment ± 28° ⇒ ± 9,4 mm on the suction tape feed board at minimum speed
Settings on the feeder
• The feeder can be set out curves completely, except the forwarder rollers, they have to be set
• The feeder drive angle “0°” is set through the 4 marked off drill holes in the suctionhead,
the forwarder rollers and sheet flap cams found in the deceleration gears and the feeder timing
• The feeder timing is found through the marking off in the middle position (display ”50”)
• The deceleration gear is 9° before the minimum speed
6-6 C 95A 6423 39 – 11. Nov. 2003


6A
Setting of the graduated disc at the feeder
graduated disc mounted on the control drum
• Set out the feeder with the index bolt (see: feeder to the machine)
• Than adjust the graduated disc to zero degree
Air control: Control drum No.: 021F029130
Supporting air ON 173° ±4°

OFF 254° ±4°
Separating air ON 334° ±4°
OFF 53° ±4°
Pick-up suckers air ON 33° ±3°
OFF 198° ±3°
Forwarder suckers air ON 170° ±3°
OFF 9° ±3°
Mechanic: Cams: Forwarder rollers and sheet flap No.: 021B026930

Pressure foot No.: 021F022730
Pick-up suckers No.: 021F022830
Forwarder suckers No.: 021F022930
Forwarder rollers touching shaft 9°

lowermost pos. 17°
start to lift 258°
highest pos. 328°
Sheet flap straight 90° 13°

start to move 193°
Pressure foot start to lift 2°

highest pos. 67°
moves down 117°
lowest pos. 182°
Pick-up suckers lowest pos. 43°

highest pos. 180°
moves down 338°
Forwarder suckers backmost pos. 184°

start to move 194°
C 95A 6423 39 – 11. Nov. 2003 6-7

6.4 Placing of the switch gears and the control gears

M340
B025
M341
B021 B022 B020 B019
S609 B026
B157 B086 B156
B083
B085
B081
M345 B809 M343
front view
BMK function I/O -A352 slot

Byte.Bit in -A351
B019 min. sensor for M343 --- ---
B020 max. sensor for M343 --- ---
B021 min. sensor for m345 --- ---
B025 sensor for M340 (suction head up) --- ---
B026 sensor for M340 (suction head low) --- ---
B081 crawl speed on for main pile: raise 1.2 ---
B083 side stop, B-side moved to B-side 5.2 ---
B085 side stop, B-side moved to A-side 6.2 ---
B086 detector suction head horizontal adjustment 6.0 ---
B156 lateral stop, A-side, max. 6.6 ---
B157 lateral stop, B-side, max. 6.7 ---
B809 residual pile carrier rails 6.3 ---
M340 suction head height --- 4
M341 suction head size --- 5
M343 lateral stop, A-side, max. --- 7
M345 lateral stop, B-side, max. --- 8
S609 suction head: upper limit 1.0 ---
6-8 C 95A 6423 39 – 11. Nov. 2003


6A
M342
S500
FESTO M110
Y114
M003
Y323
S605
S603
B065
B064
M004 M344
Y322
S678
S601
S602
S604
M109
view from machine 1

Byte.Bit in -A351
Festo air distributor (see air control system) --- ---
M003 residual pile motor --- ---
M004 main pile motor --- ---
M109 blower: suction tapes feed board 18.0 ---
M110 ventilator suction tape feed board 17.1 & 17.2 ---
M342 feeder timing --- 10
M344 setting of the pile supporting plate --- 9
S500 limit switch: stopping device 2.7 ---
S601 l.s.: main pile: lower, stop 1.4 ---
S602 l.s.: main pile: lower (distance to floor < 120mm) 1.5 ---
S603 l.s.: residual pile: lower, stop 1.7 ---
S604 l.s.: main pile: raise stop 1.3 ---
S605 l.s.: residual pile: raise stop 1.6 ---
S678 l.s.: control: pile supporting plate off 1.1 ---
Y114 electro-magnet suction tape feed board 0.3 ---
Y322 brake: main pile motor +AX, p. 45 ---
Y323 brake: residual pile motor +AX, p. 45 ---
C 95A 6423 39 – 11. Nov. 2003 6-9

Roland
300
M345
-A478
B065
M344
B064
-A477
Y Y005
view from B-side

Byte.Bit in -A351
A477 programmed switching device main pile +AX, p. 46 ---
A478 programmed switching device residual pile +AX, p. 46 ---
M344 setting of the pile supporting plate --- 9
M345 side stop, B-side --- 8
Y005 solenoid valve blast air / side blowers 18.1 ---
6-10 C 95A 6423 39 – 11. Nov. 2003


6A
M341 B023 B024

Y244
Y059
Y001
Y006
B081
M343 M342
A332
A513
U102
Y113
3anl2010
View from A-side

Byte.Bit in -A351
A332 distributor feeder +AX, p. 46 ---
A513 additional distributor feeder +AX, p. 50 ---
B081 crawl speed on for main pile: raise 1.2 ---
M341 suction head size --- 5
M342 feeder timing --- 10
M343 side stop, A-side --- 7
U102 switching amplifier +AX, p. 56 ---
Y001 solenoid valve: blast air: ON/OFF 18.2 ---
Y006 solenoid valve: blast air 10000 sh/h 18.3 ---
Y059 solenoid valve: suction air: ON/OFF 0.2 ---
Y113 solenoid valve:pregripper stop
Y244 quick bleeding, suction air → feeder head, 0.7
from S341
C 95A 6423 39 – 11. Nov. 2003 6-11

6.5 Suction head

Suction head – height adjustment
View from machine 1 to feeder
M340 suction head adjustment motor
1 025, min sensor
2 elastically mounted switching element
3 B 026, max sensor
4 switching flag
5 S 609, safety sensor with LED
Display on hand terminal:
Suction head height adjustment

Stepper motor: Unit 1, drive no. 1, bus address no. 60
„0“ suction head in highest position

„46“suction head in lowest position
Setting: min and max sensor
Screw on min sensor 1 at 5 mm from surface.

Plug in hand terminal to feeder and auto-zero, during auto-zero motor shaft rotates to the right
(when viewing the motor from the back).
Move suction head gradually down to 46 mm (max nominal value).
Set max sensor 3 to 5.5 mm from switching element 2.
Setting: Safety sensor
Set safety sensor 5 at 1 mm from switching flag 4.

The safety sensor is high. It becomes active when the suction head is lifted by about 1 mm.
6-12 C 95A 6423 39 – 11. Nov. 2003


6A
Suction head – size adjustment
1 B024 max sensor
2 Threaded spindle
3 Follower
4 Suction head
5 B023 / min sensor
6 M341 suction head adjustment

motor
7 Sheet flap
8 Paper pile
9 Sheet stop
10 Pressure foot View from B-side
11 Screw
View from top

Display on hand terminal:
Suction head size adjustment
Stepper motor: Unit 1, drive no. 2, bus address no. 61
Setting:
- Check min-5 and max-1 sensors (min sensor = max sheet size).
- Screw on min sensor flush with nut.
- Set follower to 400 mm
- Set screw 11 so that min sensor switches straight
- Plug hand terminal to feeder and execute auto-zero; during auto-zero motor shaft rotates to the left
- Check dimension 595 mm from sheet flap 7 to sheet stop 9, both have to be in vertical position,
if necessary use screw 11 to adjust.
- Gradually move suction head to max nominal value of 385 mm which corresponds to smallest sheet size.
- Set max sensor to 1.5 mm to follower 3.
C 95A 6423 39 – 11. Nov. 2003 6-13

Sensors / Pressure foot
1 2 3 4 5
1 Pressure foot
B090 4
B134
2 Switching flag B091 2
0,5
3 B091 sensor, suction head „down“
4 B134 sensor, suction head „pile rise“
5 B090 sensor, suction head „up“ B086

8
8 B086 sensor, (paper identification)
9
9 Red LED
10
X detection range, 70mm
(X)
2
3 / 4 / 5/, LED at sensor ON when covered 1,5
0,5
6A004.cdr
If the sheet flap sensor is selected on the Leitstand,

i.e. suction head adjusts itself to the sheet edge.
The sheet flap sensor controls the pile rise of
the pile supporting plate.
If the pressure foot is selected on the Leitstand,

i.e. suction head is fixed in the top position.
The sensors control the pile rise of the pile supporting plate.
Setting: Sensor B086
The adjustment of the sensor takes place on the suction head in its uppermost position, when standing on the size.
The sensor, that is mounted on a holder, is to be pushed on to the rear sucker holding rod and loosely clamped .
Finally move pile to working position. Set and seal the sensor detection distance at 70 mm from a white piece of
material by a setting screw. Now move the holder with the sensor on it so far, until the last rear edge of the paper
pile is detected and the LED on the sensor glows. Then fix the holder.
6-14 C 95A 6423 39 – 11. Nov. 2003


6A
6.6 Feeder to machine
Assembly
1. Assemble the piston of the pregripper lock on the inside of the feeder wall A-side and check.
Pregripper gripper closed 161°.
2. Assemble protection frame on A-side of machine 1.
3. Turn machine to 11° (use hand crank).
4. Check whether the feeder timing (seven-segment display, B-side) is set to „50“. If necessary use
„+“ or „–“ key to set it to „50“.
5. Mark feeder with index bolt (∅ 8 mm) – see drawing below.

The sheet guide roller has borings on the B-side so that a drift pin can be used to rotate the feeder.
6. Dock in feeder (command board B-side) and turn by hand the drive mandrel on the feeder A-side until the
coupling locks in mechanically.
7. Place cardan shaft on to the feeder drive mandrel and assemble pin.
The cardan shaft is marked on both machine 1 and on the feeder, and connected with drive mandrel.
If the cardan shaft is out of the gearing then it is necessary to observe marks provided by the manufacturer
when sliding the shafts together.
8. Remove index bolt! (see drawing below)
9. Run sheets and check sheet arrival (display B-side, display „0±“ )
The sheet arrival time can be changed if necessary. Release coupling screws and turn feeder to machine, tighten
screws and repeat paper run.
Index pin no.: 3A069330/4
View of feeder A-side inside.
C 95A 6423 39 – 11. Nov. 2003 6-15

6.7 Drive
View from top A-side (Attention: in this drawing are all objects in one level)
1 Sheet flap
2 Sheet guide roller
3 Index bore
4 Compressed air supply: feeder clutch “ON – OFF” (to valve Y201)
5 Drive to the suction head
6 Feeder clutch
7 Compressed air supply: brake (to the valve Y302, not active at the moment)
8 Angle drive
9 Motor M342, (feeder timing)
10 Coupling
11 Cardan drive from machine 1
6-16 C 95A 6423 39 – 11. Nov. 2003


6A
Feeder timing
View from A-side
1 Sheet guide roller

2 Sheet slow down
3 Connection to motor M342, AEP (Feeder timing)
4 Marking borings for sheet slow down and AEP
5 Feeder coupling
6 Connecting splice piece
Overall adjustment range with minimal tape speed:
On the machine On the tape board

± 28,0° ± 9,4 mm
If the marking borings are flush with the borings in the side walls, then the seven-segment display
on machine 1 has to show the following values:
Machine angle AEP seven-segment display

„11°“ “50“
Hand terminal display:

Feeder timing
Stepper motor: unit 1, drive no. 7, bus address 66
7-segment display Hand terminal Sheet arrival

„0“ „- 18 mm“ Earlier
„50“ „0,0 mm“ Correct Boring can be
marked
„99“ „+18 mm“ Later
C 95A 6423 39 – 11. Nov. 2003 6-17

Feeder clutch
1 To the feeder
2 Compressed air supply: feeder clutch “ON – OFF” (to valve Y201)
3 Compressed air supply: brake (to the valve Y302, not active at the moment)
4 Cardan drive from machine 1
5 Coupling
With the coupling (5) it is possible to change the timing to the feeder
6-18 C 95A 6423 39 – 11. Nov. 2003


6A
6.8 Pile control

Pile supporting plate
1 Side frame B-side
2 Lateral pile guide
3 Middle of feeder / machine
4 Pile supporting plate
5 B064 min sensor
6 B065 max sensor
7 Connecting rod between switching flag and pile

supporting plate
8 Threaded pin
M344 Pile supporting plate adjustment motor
Before exchanging motor M344 it is necessary to release

a threaded pin that is accessed from below on the outer side
of B-side. Does not apply from series 332.
Display hand terminal:
Diagonal adjustment of the pile supporting plate

Stepper motor: unit 1, drive no. 6, bus address no. 65
Setting: Do not place the pile supporting plate on the floor – danger of breaking!
- Check min-5 and max-6 sensors (min sensor outside)

- Set min sensor to 24.5 mm from switching flag 7
The pile supporting plate has to be in the middle between the side frames!!
- Plug hand terminal to feeder and execute auto-zero, during auto-zero motor shaft rotates to the left
- Move to max nominal value of +23 mm, pile supporting plate max to A-side
- Set max sensor to 2 mm from switching flag
- Enter nominal value „0“, check whether pile supporting plate is in the middle between the side walls and adjust
sensors if necessary.
C 95A 6423 39 – 11. Nov. 2003 6-19

Pile control
Side stop A-side
1 B019 min sensor

2 B156 sensor switches when the side stop lift off from stop
3 B020 max sensor
4 Side stop and blast device
5 Paper pile
6 Side wall B-side
7 Connection to motor M343
Display on hand terminal
Side stop drive side

Setting:
- Check min-1 and max-3 sensors

- Screw min sensor at 46 mm on to side frame
- Plug hand terminal to feeder and execute auto-zero
- Motor shaft rotates to the left during auto-zero (viewing the motor from the back),
side stop moves to side wall A-side
- Move to max nominal value of +265 mm
- Set max sensor to 2 mm from side stop 4
6-20 C 95A 6423 39 – 11. Nov. 2003


6A
Side stop B-side
1 B021 min sensor

2 B157 sensor switches when the side stop lift off from stop
3 B022 max sensor
4 Side stop, blast device and holder for B083+B085
5 B083 infra-red sensor for pile control
6 B085 infra-red sensor for pile control
7 Paper pile
8 Side wall B-side
9 Connection to motor M345
Display on hand terminal
Side stop operating side

Setting
- Check min-1 and max-3 sensors

- Screw min sensor at 46 mm on to side frame
- Plug hand terminal to feeder and execute auto-zero
- Motor shaft rotates to the left (viewing the motor from the back),
side stop moves to side wall B-side
- Move to max nominal value of +265 mm
- Set max sensor to 2 mm from side stop 4
C 95A 6423 39 – 11. Nov. 2003 6-21

Switching device
Main pile
Drive side
1 Sheet flap
2 NON-STOP (option)
B809 Residual pile rail
M003 Residual pile motor
M004 Main pile motor
Setting the programming system
S601 The S601 switch is set so that it becomes activated as soon as the pile supporting plate touches the floor.
S602 The S602 switch is set so that it becomes activated as soon as the pile supporting plate reaches a level of
120 mm above the floor.
The descent of the pile supporting plate stops in this position and the pile supporting plate is centred. Then
its slow movement down can continue.
S604 Set the S604 switch so that it switches at a distance of 149 mm between the pile supporting plate and the
sheet flap upper edge (in vertical position).
S678 The S678 switch is used to deactivate the programming system of the pile supporting plate control. It is to
be set so that it becomes active when there is less than 20 mm of paper on the pile table.
6-22 C 95A 6423 39 – 11. Nov. 2003


6A
Non Stop
Drive side
1 Sheet flap
2 NON-STOP (option)
B809 Rest pile rail
M003 Rest pile motor
M004 Main pile motor
Setting the programming system
With NON-STOP only (option)
S603 The S603 switch is set so that it becomes active when the distance between the sheet flap upper edge
(in vertical position) and the pressed down NON-STOP rail is 479 mm.
S605 The S605 switch is set so that it becomes active when the distance between the sheet flap upper edge
(in vertical position) and the pressed down NON-STOP rail is 114.5 mm.
The NON-STOP rail behind the paper guide is 8.5 mm deeper than the suspended rail.
C 95A 6423 39 – 11. Nov. 2003 6-23

Pile guiding
Drive side inside
1 Pile supporting plate holding system

2 Chain
3 Guiding roller
4 Guide rail
5 Safety screw
6 Eccentric guiding roller
The pile supporting plate holding system (1) has to move freely and without backlash in the guiding rail (4).
The B-side and the pile guiding of the auxiliary pile (NON-STOP) are to be adjusted in the same way.
Chain tensioning mechanism
1 green marks
2 yellow marks
3 red marks
The chain tension is correct if only the green and not more than the yellow mark is visible.
6-24 C 95A 6423 39 – 11. Nov. 2003


6A
6.9 Suction tapes feed board
view from top
View from B-side
1 suction tapes feed board
2 suction tapes
3 adjustment of the suction tapes tension (suction tapes tension 0,5 %)
4 2nd suction box
5 1st suction box
M109 blower 2nd suction box (only active, when „PR ⇒ feeder ⇒ suction tapes blower⇒ is set on
strong in the central control console)
M110 blower 1st suction box
Y114 electro-magnet suction tapes feed board
C 95A 6423 39 – 11. Nov. 2003 6-25

6.10 Air control
B-side
1 air control A/B-side

2 air supply „blast air“
3 side stop B-side
4 lateral blower B-side
5 suction head
6 sheet flap detector
7 pressure gauge
8 side stop A- side
9 lateral blower A- side
10 blast air
11 suction air
12 air supply “compressed air“
13 valve block for air control: “blast / suction air“
14 feeder clutch
15 brake: feeder clutch
16 compressed-air supply
17 valve block for air control: “compressed air“
Y005 magnet valve blast air
6-26 C 95A 6423 39 – 11. Nov. 2003


6A
Valve block for air control: „blast air“
1 compressed-air supply (Ø 12 mm)

2 test pin
3 socket
4 compressed-air supply (Ø 6 mm),to the valve block
blast-/suction air
Y302 feeder clutch: brake (not active)

Y201 feeder clutch: „On / Off“
Y007 blast air: sheet flap detector
(The valve is active for ~5 sec when the pile reaches 120mm over floor, while lowering the pile)
Valve block for air control: blast / suction air
1 blast / suction air to the feeder head
2 stop screw, (blast air bore will be free for 4 mm)

for the 1st stage
3 compressed-air supply (Ø 6 mm)
4 Y059 suction air
5 Y001 blast air 1st stage
6 Y006 blast air 2nd stage at 10000 s/h
7 to the hand wheel
8 blast/suction air from the pump
9 to the pressure gauge
C 95A 6423 39 – 11. Nov. 2003 6-27

6-28 C 95A 6423 39 – 11. Nov. 2003

Infeed
7
7 Infeed
7.1 Design ............................................................................................ 7-3
Supply lines / electrical connections ................................................ 7-5
Supply lines / blast air, suction air and lubrication hoses................. 7-6
Disassembly of the infeed cross tie: ................................................ 7-6
Assembly of the infeed cross tie: ..................................................... 7-6
Sensors ........................................................................................... 7-9
7.2 Electrical double sheet detection............................................... 7-11
DB 12 till series 343....................................................................... 7-11
Error messages on the display: ..................................................... 7-12
DB 14 as of series 344 .................................................................. 7-13
7.3 Front lays ..................................................................................... 7-15
Basic position ................................................................................ 7-16
Checking front lay movement: ....................................................... 7-18
Front lay lock: ................................................................................ 7-18
7.4 Side guide / suction wheels........................................................ 7-19
Side guide design .......................................................................... 7-19
Suction wheels design ................................................................... 7-20
Motor ............................................................................................. 7-20
Drive .............................................................................................. 7-21
Sequence of adjustment steps for all series .................................. 7-22
Side guide basic position ............................................................... 7-23
7.5 Cover guide.................................................................................. 7-24
Design and arrangement ............................................................... 7-24
Drive .............................................................................................. 7-25
Adjustment to register plate .......................................................... 7-26
Check double cams: ...................................................................... 7-26
7.6 Air control .................................................................................... 7-28
Till series 330 ................................................................................ 7-28
Air distributor design...................................................................... 7-29
From series 331............................................................................. 7-29
C 95A 6423 39 – 23. Jul. 2004 7-1

7 Infeed
7.7 Pregripper bearings .....................................................................7-30

Design............................................................................................7-31
Drive ..............................................................................................7-32
Pregripper control and pregripper stop ..........................................7-33
Gripper opening cam .....................................................................7-34
Damping, from series 311 to 326 ...................................................7-34
Pneumatic cylinder from series 327 or upgrade.............................7-35
7.8 Infeed drum ..................................................................................7-36
Bearing, double cams, gripper opening cam and gear wheel ........7-36
Design............................................................................................7-36
Checking the gripper margin ..........................................................7-38
Auxiliary gear adjustment...............................................................7-39
Repair of gripper shaft bearings.....................................................7-40
7-2 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
7.1 Design
- The front lays and the cover guides are mounted on different shafts.
- The front lay movement is effected by a cam on the side lay drive on the B-side inside.
- The front lays can be adjusted individually – motor driven adjustment.
- The gripper margin is adjustable between 5.3 and 6.3 mm.
- The cover guides are firmly mounted on a shaft.
They are controlled by double cams on B-side.
- The height adjustment of the cover guides is motor-controlled within a
range of 0.15 mm to 3 mm to register plate.
- The infeed cross bar with front lay control and pneumatic side guide
is designed as a slide-in module.
- The infeed can be removed or mounted after the loosening of the connecting elements.
1 Pregripper 6 Size adjustment of the pull-type side guide

2 Cover guides 7 Infeed cross bar
3 Front lays 8 Potentiometer
4 Pull-type side guide 9 Motor
5 Suction wheel
C 95A 6423 39 – 23. Jul. 2004 7-3

7 Infeed
Infeed assembly procedure (on an assembly band)
- Assemble infeed drum with control cams on A- and B-side

- Align and pin supporting bearings B-side
- Assemble cover guide control lever B-side
- Adjust transfer point of infeed drum to impression cylinder
- Assemble and adjust gripper opening cams
- Assemble intermediate gear ( plastic ) A-side inside
- Shrink-fit bolt of pregripper lever A-side
- Assemble pregripper drive lever and cover plate
- Assemble stop gripper shaft together with gear and cam
- Adjust transfer point pregripper to infeed drum
- Assemble pregripper lock (pneumatic cylinder)
- Assemble damping device for pregripper lock
- Mount and adjust pregripper opening cam
- Assemble cover guide shaft with positioning motor B-side
- Clamp shaft so that the press may be advanced
- Assemble and pre-align front lay drive B-side
- Assemble and pre-align infeed cross bar
- Adjust position of infeed cross bar to impression cylinder to obtain correct gripper margin and pin
- Final adjustment of front lay drive and pin
- Adjust cover guide shaft
- Assemble front lay lock on inside of B-side
- Cover guides – adjust potentiometers
- Assemble side lay motors and detectors
- Assemble air distributors on B-side and connect air hoses
- Assemble sheet guides above infeed and mount guards
7-4 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
Supply lines / electrical connections
Caution: Switch off machine before disassembly!
Amplifier and level converter A 523
C 95A 6423 39 – 23. Jul. 2004 7-5

7 Infeed
Supply lines / blast air, suction air and lubrication hoses
1 Cam roller of the front lay control

2 Grease lines
3 Oil lines
4 Suction air B-side stop
5 Suction air suction wheels
6 Suction air A-side stop
7 Blast air to blast-suction device
Disassembly of the infeed cross tie:

- Dismantle protection covers as necessary.
- Move pull-type side guides to min. sheet size (holes M10 for suspension loops under the side stop).
- Dismantle drive shaft (Allen key) of the B-side stop:
Make marks: cam front lays / side stop / suction wheel / coupling to A-side stop.
Screw off coupling (clamping elements) on B-side, loosen set screw on front lay cam,
loosen coupling between A- and B-side stop and extract drive shaft in B-side direction.
- Extract sheet guide above the infeed.
- Dismantle double sheet detection with holder.
- Lift and secure feed board (screw off blower and take care when handling the pre-detector sensor).
- Use hand crank to advance the press until the pregripper and cover guides swing out.
- Switch off machine and secure against activation.
- Loosen all supply lines as shown in the drawings.
- Screw in suspension loops and suspend infeed cross tie (assembly block).
- Remove tapered pins and fixing bolts between the console and infeed cross tie.
- Carefully lift infeed cross tie while taking care of possible underlying pans.
Assembly of the infeed cross tie:

- Assembly takes place in the reversed sequence of steps.
- The function of all connections and feed times has to be checked.
For feed times see Section 2 “Reference Values“
- Use measuring gauge no. 037 U 3388 44 to readjust electrical double sheet detection.
7-6 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
Lateral alignment:
- The cut out areas in the register plate are centred in relation to the swing gripper stops.
Infeed cross tie height

- Use hand crank to advance machine until the pregripper reaches its top position in which the grippers are
still open (145° - 155°)
- Use a measuring device to check each gripper stop (1) in relation to register plate (2).
- The tolerance of the gripper stops to register plate: + 0.01 mm to – 0.03 mm;
Correction:
- Use packing shims (4) between the console (5) and the infeed cross tie (A- and B-side)
to equalize the height.
View of B-side
1 Gripper stop
2 Register plate
3 Setting screw
4 Packing shims
5 Console
C 95A 6423 39 – 23. Jul. 2004 7-7

7 Infeed
Setting the gripper margin
Conditions:
- The infeed cross tie is aligned in lateral and vertical direction.
- All front lays (mechanical and electrical) are in “middle position“ (Leitstand on “0“)
Check:
- Place a straight cut sheet on the front lays and the press
use hand crank to advance press forward until the sheet reaches
the grippers of the 1. impression cylinder.
- Check gripper margin, which should be 5.8 mm, by feeler gauge no. 099 J 0156 50.
Alternative:
- Take a sheet and draw a line 5.8 mm in parallel to the sheet front edge.
- Place the sheet in the machine as described.
The line should still be seen on the gripper tips!
Correction:
- Extract tapered pins (when drilled) and loosen fixing bolts.
Use the setting screws (3) to move infeed cross tie.
- Tighten fixing bolts and check setting.
- If the setting is correct pin infeed cross tie. Otherwise reream the holes.
- Caution: Realign front lay drive on B-side!
Top view
1 Gripper stop
2 Feeler gauge no. 099 J 0156 50
3 Gripper
4 Sheet front edge
5 Impression cylinder
7-8 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
Sensors
Checking the reflex light sensing heads:

- Advance press until front lays are in uppermost idle position.
- Advance front lays on the Leitstand to “middle position“.
- Open plastic guard over the register mechanism.
- The sensor display appears on the monitor.
Display: Printing unit 1

3
D C B A
7
sheet travel direction

5
4
3
6
7007.cdr/wmf
Register mechanism: Printing unit 1
2a
2b A B108, front edge detection

B B106, front edge detection
D C B A C B107, front edge detection
D B109, front edge detection
1 U100/U101, double sheet (DB, DBK)
2a large size
7 2b small size
3 B110, pull-type side guide A-side
1 3 B111, pull-type side guide B-side
3 3 4 B113, pre-detection
4 as of series 344 integrated in DB14
5 B115, sheet flap
6 B116, missing sheet detection
in the impression cylinder after the
B- S 5 A- S reversing device
7008.cdr/wmf
7 as of series 344- overrun sheet control
sheet travel direction
C 95A 6423 39 – 23. Jul. 2004 7-9

7 Infeed
Checking the reflex light sensing heads
Check:
- Place a sheet in running direction up to the front lays and use a pen to mark the sheet end on the feedboard.
- Pull the sheet back and push it forward again until the symbol on the display just turns black .
- Use a pen to mark the sheet end on the feedboard.
- Use a slide gauge to measure the distance between the two marks. The distance should be 2.75 mm.
Readjustment:
- Release screw and move sensing head.
- Tighten screw and repeat checking
procedure.
Error messages on the

display:
1 early sheet
2 late sheet
3 skew sheet A-side
4 skew sheet B-side
5 missing sheet side guide B-side
6 missing sheet side guide A-side
7-10 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
7.2 Electrical double sheet detection

DB 12 till series 343
Components:
LEUZE KA 905 (design is same as in KA 868; control device)
LEUZE DB 07 Se (reflex detector and light barrier transmitter
LEUZE KA 817/3 (light barrier receiver)
Function:
- Computer assisted optical double sheet detection for the detection of multiple sheet layers.
- The sheet is checked by a measuring light barrier and compared with
the previously saved reference value of the original sheet.
- An arriving double sheet is detected immediately and reported by a corresponding output signal.
- Before the check of the sheets it is necessary to adjust the functional unit to the given substrate.
- Each sheet is checked by an external detection impulse (RTR).
Adjustment: 1. stage
- no substrate available
- determination of adjustment and contamination
2. stage
- substrate available
- optimal determination of the working point
- detection of substrate that cannot be checked
(degree of absorption is below or above the functional range of the device)
LED’s:
Exit RK Rk active
red
too thin
too thick inquiry

green
double sheet DBK active
C 95A 6423 39 – 23. Jul. 2004 7-11

7 Infeed
Error messages on the display:
1 substrate too thick

2 substrate too thin
3 contamination
4 adjustment impossible
5 double sheet feeder
6 double sheet feeder
Checking the double sheet sensors on the feeder:
Preamplifier:
KA 905-100M
Measuring device:
double sheet
Leuze electronic:
Type KA 902
Setting:
- Switch off machine. Extract cord from
preamplifier and plug in measuring
device.
- Switch on machine again.
- Align sensors U100 and U101.
(it may be necessary to readjust holder)
- Sensor U101 has to be about 0.5 mm below the register plate.
- Move sensor U100 up until all red LED’s and at least 3 green LED’s glow.
- Optimal alignment: all red and all green LED’s glow.
7-12 C 95A 6423 39 – 23. Jul. 2004

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7
DB 14 as of series 344
DB / DBK = double sheet detection US = Ultrasonic Sensors
The optical double sheet control DB 12 used by Starting from series of 344 the double sheet
series of 311 to 343 had e.g. problems with the control DB14 comes in use.
! collection of the materials with strongly varying
opacity, metallised or transparent foils and The sheet pre detection is integrated.
As of series
344 changing printing on within the detection range.
There are no additional Tools necessary for the Test options by representation with LEDs in
sensor setting! mode parameterising
Mounting position of the US = Ultrasonic Sensors in infeed table printing unit 1:
1 B 287 receiver and mounting

2 Feed register table
3 B 286 sender / transmitter
1
10]
5 2
3 0 [±
30°
3
R3K7_48.cdr/wmf
4 A348 evaluation unit PU1 5 4

B-side outside
6
5 connecting to the machine
6 connecting DB18SE sender
7 connecting DB18E receiver
8 connecting K1 capacitive sensor
7
8 R3K7_49.cdr/wmf
The Ultrasonic Sensors are mounted with an Sender -B286 und receiver -B287 are to be
angle from 30° to the feed register table. installed with a distance between 20 till 40 mm
(Oscillation overlays are to be avoided thereby) If the distance is later changed, the DBK has to
be parameterised new.
The transmitter -B286 is to be fixed, measured With the parameterising, the US sensors are
by the housing centre, 5 mm underneath the adjusted on the installation conditions.
metallic surface of the feedboard That is necessary by the first commissioning,
By the ultrasonic waves the housing surface of after exchange (even the evaluation-unit)
the transmitter cleans itself automatically.
C 95A 6423 39 – 23. Jul. 2004 7-13

7 Infeed
At present materials longer than 540mm can not Note:

! be scanned! Active only possible for 1/2, i.e.1sheet = OK,
2sheets between the sensors = not OK!
A capacitive sensor is at present only optionally Applications are:

i offered. Multiply materials, corrugated board, grammage > 200 g
Preparation for 2/3 scanning (materials > 540 mm)
Parameterising
Prerequisite: The evaluation unit DB14 implements a self

• no sheet run active check.
• no sheet between the DBK sensors After the automatic recognition of the attached
• “Activate“ in the 7-Segment display must not sensor technology the signal status is queried
light (evaluation unit). With ideal level the green and yellow LED lights
up.
Press the button “DBK calibration” > 10 sec. If that is not the case, readjust the sensors.
For terminating the calibration press the button
DBK calibration again.
Before start up the electronic DBK it is absolute

necessary to do a calibration.
DBK calibration
Contrary to the predecessors, the reference

i value for the printing materials remains stored
(also after main switch off / on)
+BA, control panel The alignment takes place in the same way as
on the DB12.
electronic double sheet detector calibration (DBK
calibration).
DBK On / Off
+BA, control panel:
electronic double sheet detector On / Off

(DBK On / Off)
7-14 C 95A 6423 39 – 23. Jul. 2004

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7
7.3 Front lays

Unit 2, bus address 1 - 5, (Slides: individual setting)
Starting from series 344 the middle front lay is void.

On this position than will be mounted the “over run sheet detector”
Coding of the front lay motors (ink slide motors)
A-side B-side
front lay no.: 1 2 3 4 5
motor no.: M 407 M 406 M 405 M 404 M 403
code 01 02 03 04 05

1 Plug hand-held terminal in printing unit 1.
2 Press reset switch in the control cabinet B-side (active mode). Electricians only!
3 Enter code, in unit 2, menu 3, select Slides: Individual setting
4 Slides 1 - 5 correspond to front lays 1 – 5.
5 Use arrow keys to set all front lay potentiometers to 0.135 mm.
Display in:
Hand-held terminal 0 mm 0.135 mm 0.270 mm
menu 3
Hand-held terminal 1130 mV 3320 mV 5520mV
menu 7
Leitstand -0.50 0 0.50
Gripper margin 6.3 mm 5.8 mm 5.3 mm
Caution: In menu 3 do not move beyond 0.270 mm or

in menu 7 do not move beyond 5520mV, danger of breaking !!!
C 95A 6423 39 – 23. Jul. 2004 7-15

7 Infeed
Basic position
Basic position during the assembly of front lays (at first in a disassembled state)
1 Set coding 01 to 05, see drawing.

2 Use hand-held terminal to set potentiometer to 0.135 mm.
(Connect front temporarily lay motor to cable harness.)
3 Use sliding gauge to check distance of 6.6 mm between disk and console.
(if necessary connect potentiometer and device and turn motor shaft)
4 Screw intermediate piece (5) on to the bolt (6) to 5.3 mm.
5 Mount the (now adjusted) front lay motor in the follower (4) and tighten set screws
(if necessary redrill one set screw with a point).
6 Fix front lay motor to rail.
Setting the front lay angles:

7 Turn the control cam of the front lays (B-side inside) to the top
position.
8 Screw on feeler gauge. In its place dismantle a front lay (take care
of the shims).
9 Loosen locking screw (3) and place feeler gauge at exactly 90° to
the register plate, tighten locking screw (3).
10 Remove feeler gauge and mount front lay again.
Front lays to the register plate:

11 Check distance of 3 mm between front lay and front edge of the
register plate.
12 Loosen fixing bolts of the front lay motor and move the whole unit.
13 Note: Once the two outer front lays are adjusted, it is possible to
check the middle front lays
by a straight cut sheet. All front lays have to be in an even and
parallel position.
gauge no.:
M 760 011-7
7-16 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
Basic position (3 mm)
From series 322
Front lay design
C 95A 6423 39 – 23. Jul. 2004 7-17

7 Infeed
Arrangement of the front lays (view from machine to register mechanism)
Checking front lay movement:

- Condition: control time (suction air off) of the side guides is adjusted.
- Advance machine by hand crank until the front lays reach the top idle position
(high point of the front lay cam).
- Position measuring dial, set pointer to “0“ (measuring point X see drawing).
- Use hand crank to advance machine until the front lays move 0.05 mm
from the register plate.
- The display of DW 1 indicates 166.4° -1°.
Readjustment:
- Loosen locking screws on the front lay cam and adjust the cam.
- Repeat check.
Front lay lock:

- Advance machine by hand crank until the front lays reach the top
idle position
(high point of the front lay cam).
- Set a gap of 0.5 mm between the stop bolt (3) and lever (2).
Then move appropriately the holder for the stop bolt
and the holder of the solenoid.
- Set the movement range of the stop bolt to 9 mm above the
threaded rod and lock (see drawing).
Procedure: (for example with double sheets)

- When a double sheet occurs the solenoid (4) pulls and
the stop bolt (3) moves up.
- The stop bolt moves quite up and holds the control lever (2) tight
when reaching the high point of the front lay cam (1)
- The front lays that stay in the top position prevent the double sheets
from entering the press.
1 Control cam
2 Control lever
3 Stop bolt
4 Solenoid Y 112
7-18 C 95A 6423 39 – 23. Jul. 2004

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7
7.4 Side guide / suction wheels

Side guide design
Air control roller (1), cam (2), suction element and front lay cam (16)
7003.cpt
Suction plate (6), sheet stop (2) and hold-down device (9)
7005.cpt
C 95A 6423 39 – 23. Jul. 2004 7-19

7 Infeed
Suction wheels design

Design of the suction wheels (4). Suction air timing can by adjusted by the gear wheel (6).
7004.cpt
Motor
Lateral adjustment drive by motor and lead screw (13)
7006.cpt
7-20 C 95A 6423 39 – 23. Jul. 2004

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7
Drive
Side guide drive, suction wheels and front lays
7007.cpt
Side guide, from series 311 to 314
- The front lay cam is firmly attached to the drive shaft of the side guide from series 311 to 314.
- The adjustment of the front lay control automatically leads to the adjustment of the side guides.
Control times: Suction air off Suction air on

Side guide 147° ± 2° (87° ± 2°)
Suction wheel 35° - 4 (215° - 4°)
- Side guides A- to B-side are synchronously adjusted via a coupling.

- Values in brackets are generated automatically.
Position of parts 3, 4, 5 during assembly:
1 locating bore of the pull-type side guide

cam (set screw with notch)
2 set screw
3 drive shaft (hexagonal)
4 side guide cam
5 front lay cam
6 adjusting spring
C 95A 6423 39 – 23. Jul. 2004 7-21

7 Infeed
Pneumatic side guide Series 315 to 316
- Starting from series 315, the side guide can be dismantled without having to extract feed register cross bar.
- The control times of the side guides and suction wheels can be adjusted separately.
: till series 315 from series 316

Control times Suction air off Suction air on Suction air off Suction air on
Side guide 120° ± 2° (60° ± 2°) 120° ± 2° (60° ± 2°)
Suction wheel 17° - 4° (175° - 4°) 162° - 4° (313° -4°)
- Values in brackets are generated automatically and need not be checked.

- Side guides A- to B-side are synchronously adjusted via a coupling.
- The suction wheels can be individually exactly adjusted (the gear wheel is adjustable via oblong holes).
Sequence of adjustment steps for all series
Side guides:
1. Use hand crank to advance machine and check suction air “off“ by a strip of paper on the B-side guide.
For control times, depending on the given series, see Section 2 “Reference values”.
2. If necessary, correct setting via the coupling (4 clamping segments) on B-side.
3. The A-side guide can be adjusted via the coupling in the middle of the rive shaft.
Suction wheels:
4. Use hand crank to advance machine and check suction air “off“
by a strip of paper on the both suction wheels.
For control times, depending on the given series, see Section 2 “Reference values”.
5. If necessary correct setting via the gear wheels on the drive shaft.
Front lays:
6. Use hand crank to advance machine until the front lays reach the
uppermost idle position (between 9° - 163°).
7. Position measuring dial. Use hand crank to advance machine
until the front lays have moved away from the register plate by 0.05 mm.
The display on the monitor of DW 1 shows 166.4° -1°.
8. If necessary, readjust front lay cam B-side inside.
7-22 C 95A 6423 39 – 23. Jul. 2004

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7
Side guide basic position
Pull type side guide

1 Zero detector, B - 095, cable no. 32.1, B-side

2 Sheet stop B-side, (side edge detection B 111)
3 Max. detector, B - 094, cable no. 32.2, B-side
4 Motor M 397, drive no. 5
5 Motor M 398, drive no. 4
6 Max. detector, B - 093, cable no. 31.2, A-side
7 Sheet stop A-side, (side edge detection B 110)
8 Zero detector, B - 092, cable no. 31.1, A-side

Example B-side
1. Plug hand-held terminal in printing unit 1
2. Press reset switch in control cabinet A-side (active mode). Electricians only!
5. Use arrow keys to move side guide to a distance of 115 mm from the side frame.
6. Use Exit to leave menu 7 and select menu 8.
7. Call drive no. 5 and set zero detector (from ON to OFF).
9. Select drive no. 5 and execute auto-calibration, 115 mm check!
10. Move along total distance of 195 mm (with A4, 245 mm).
12. Select drive no. 5 and set max. detector to lever (from ON to OFF).
13. Move sideways max. detector 2 mm (from OFF to ON).
14. In menu 6 move side guide back to 0 mm.
Adjust A-side in the same way.
C 95A 6423 39 – 23. Jul. 2004 7-23

7 Infeed
7.5 Cover guide

Design and arrangement
7008.cpt
View from machine to feeder
Notes for assembly:

- Device no. M 760 013 – 1 is used in preassembly to align and bolt the bearing block (22) A-side frame.
- The eccentric bushings (20 and 3) are positioned in parallel and bolted together with the lid (7)
- on the shaft (8).
- All cover guides (see arrangement) are bolted to the cover guide shaft (9) and aligned.
See drawing below. The cover guide shaft is placed on two prisms and the cover guides
are adjusted so as to be in parallel.
- Push shaft (8) with eccentric bushings (20) into the cover guide shaft (9).
- Assemble preassembled cover guide shaft in the bearing block (22) and the side frame B-side.
- For further adjustments see following pages.
7-24 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
Drive
7009.cpt
1 front lay
2 catch
3 cover guide
4 eccentric bushing
5 control lever
A bolt
B bolt
HL main control cam
BL auxiliary control cam
7010.cpt
C 95A 6423 39 – 23. Jul. 2004 7-25

7 Infeed
Adjustment to register plate
Conditions:
- Infeed cross bar and gripper margin are adjusted.
- Cover guide shaft is completely assembled.
- Infeed drum with adjusted double cams is assembled.
- Front lay in “0“ position.
Setting:
- Advance machine until the front lays and cover guides are in the
uppermost position (159°-163°).
- Set distance of 4.6 mm between cover guides and front lays.
- Clamp and bolt lever (1) drawing 7008.cpt.
From series 317

- The distance between the cover guides and register plate should be 4
mm.
- Clamp lever (1) drawing 7008.cpt. Bore a set screw with point for
positioning.
Check double cams:
- Advance machine until the front lays and cover guides are in the
uppermost position (159°-163°).
- Position measuring dial - see drawing.
- Use hand crank to advance machine.
- When the cover guides have moved 0.05 mm away from the register
plate,
the display has to indicate 168.6° ± 0.5°.
- Otherwise readjust cams.
Caution: The double cams have to be marked by ø 10 mm bolt and

turned together.
Bolt double cams or finish-ream.
7-26 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
Cover guides height adjustment
Servomotor, drive no. 6, unit 2, bus address no. 65
Notes for assembly:

- Advance machine until the cover guides are in the uppermost
position (159°-163°).
- Screw spindle (25) into the catch (26) until the spindle extrudes 6
mm
from the catch
- Assemble motor M393 (31) and holdings (23, 24),
clamp motor drive shaft to spindle.
7011.cpt
1. Plug hand-held terminal in printing unit 1.

2. Press reset switch in control cabinet B-side (active mode). Electricians only!
5. Use arrow keys to move cover guides to a distance of 0.3 mm from the register plate.
To check all cover guides a 0.3 mm thick plate is used in the assembly (no.: 043P1067 13/4).
Set potentiometer to 2451mV, or
6. select menu 6, unit 2, drive no. 6 and set potentiometer to 0.15 mm.
7. Check whole movement track.
Distance between Hand-held terminal

register plate and
cover guides Menu 7 Menu 7 Menu 6
direct adjustment direct adjustment Individual
bus address 65 bus address 65 adjustment
(new) (old) drive no.: 6
0.15 mm 2150 mV 7844 mV 0 mm
0.3 mm 2451 mV 7246 mV 0.15 mm
3 mm 7844 mV 2150 mV 2.85 mm
Caution: The cover guides are always 0.20 mm higher than the substrate if the substrate thickness is
preselected at the Leitstand.
If necessary, the cover guides can be moved up from the Leitstand.
C 95A 6423 39 – 23. Jul. 2004 7-27

7 Infeed
7.6 Air control

Till series 330
1 Setting button suction air side guide A- or B-side

2 Manometer for suction air side guide
3 Manometer for suction air suction wheels
4 Manometer for blast suction device
5 Suction air A-side guide
6 Suction air B-side guide
7 Control button for suction air side guide
8 Control button for suction air suction wheels
9 Control button for blast suction device
2a Suction air supply line for side guide

(reduction in hose)
3a Suction air supply for suction wheels
4a Hose to blast suction device
4b Supply for blast suction device
7015.cpt
7-28 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
Air distributor design
7014.cpt
Connection diagram:
7013.cpt
From series 331
Refer to feeder from series 331. The distributor and air control are mounted at the feeder
C 95A 6423 39 – 23. Jul. 2004 7-29

7 Infeed
7.7 Pregripper bearings
1 Cylindrical roller bearing B-side 9 Gear wheel

2 Pregripper shaft 10 Set screw M 6x6
3 Bearing body 11 Adjustment plate 50x62x2 DIN 988
4 Guard ring 80x2,5 DIN 471 12 Inclined ball bearing
5 Adjustment plate 80x100x1.5 DIN 988 13 Protection plate S50x62 DIN 988 and
6 Eccentric bushing adjustment plate 50x62x(0.1+0.2) DIN 988
7 Grooved ball bearing 61821-RZ 14 Control lever
8 Cam 15 Gauge
Caution: It is important to install bearing (12) on A-side correctly.

If the outer races are provided with markings, install bearings in this way (< >).
7016.cpt
7-30 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
Design
7017.cpt
Setting the gripper margin:

- Advance machine to 256° and lock it.
The position is the transfer point between the pregripper and the register feeder drum.
- Use 1.6 mm thick feeler gauge no. 099 J 0774 13 to check distance between
the pregripper tips (2) and pad bar (1) of the register feed drum (see drawing 7032.cdr).
- Screw feeler gauge (15) on to the shaft notch and clamp the bearing (12) from the side without backlash.
- Pin control lever (14) and remove feeler gauge (15) (see drawing 7031.cdr).
1. Pad bar on register feeder drum 2. Gripper of the pregripper 3. Feeler gauge no. 099 J 0774 13
C 95A 6423 39 – 23. Jul. 2004 7-31

7 Infeed
Drive
7018.cpt
Double cam check:
- The torsion spring pre-load (1) is 20 Nm

(drawing 7033.cdr).
- Position measuring dial at ~165°, drawing 7034.
- Use hand crank to advance machine until the pregripper
have moved 0.05 mm away from the register plate.
- Indication on display 174° ± 0,5°.
Adjustment:
- Lock the two cams (2 and 5) together by a bolt
(no. M 760 026 – 1) Ø 20 mm inserted through the
marking hole (3) (drawing 7033.cdr).
- Loosen clamping screws and turn the two cams.

- Tighten clamping screws and repeat check.
Pin when the setting is correct.
1 torsion spring
2 auxiliary control cam
3 marking bores
4 register feeder drum
5 main control cam
6 tapered pin
7 pregripper shaft
7-32 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
Pregripper control and pregripper stop
7019.cpt
Setting of the pneumatic piston:
- Move pneumatic piston quite out, drawing

7035.cdr
- Set a distance of 39.518 mm between the infeed
table (2) and bolt (1).
(device no. M 760 028 – 2)
- This setting is done by turning the pivot head on
the pneumatic piston.
- Lock pivot head by a locking nut when the setting
is correct.
Device no.: M 760 028 – 2
1 bolt, ø 10mm
2 infeed table
3 pneumatic piston
C 95A 6423 39 – 23. Jul. 2004 7-33

7 Infeed
Gripper opening cam
- Advance machine to 256°.

- Move quite out pneumatic cylinder (12) (provided the piston is adjusted).
- Turn cam holder from the cam so that there is a distance of 31.7 mm between the bolt and the bolt hole (10).
The bolt hole (10) is the middle hole of the upper cam half (9)
(in this area a cam radius is detectable).
- Mount intermediate gear wheel (3).
It has to be possible to bore the tapered pin (1) on the gear wheel (2) if required.
- Assemble and adjust both cam halves (6 and 9).
- Grippers open at 257° and close ate 161°.
1 tapered pin 7 shock absorber

2 gear register feeder drum 8 energy (adjustable)
3 gripper register feeder drum 9 upper cam half
4 gripper of the pregripper 10 bolt hole Ø 7 mm
5 intermediate gear wheel 11 infeed table
6 lower cam half 12 pneumatic cylinder
Damping, from series 311 to 326
Setting energy:
- Turn setting ring to stop, to the right into “-“,
then 3.5 - 4 screen to “+“.
- Assemble shock absorber with holder.
The shock absorber still has to have a backlash of 1 mm to the holder,
when the pneumatic piston is quite inside (drawing 7038.cdr).
- Tighten clamping screw.
Caution: Energy has to be readjusted when the operation

pressure to the machine is changed!
7-34 C 95A 6423 39 – 23. Jul. 2004
Infeed
7
Pneumatic cylinder from series 327 or upgrade
If a new pneumatic cylinder with limit position damping (item no. 0 94K 1454 13) is mounted in the pregripper
control system, then it is necessary to dismantle the shock absorber with the complete holder.
Positions 21, 22, 23 and 25 do not apply – see drawing.
The pneumatic cylinder can hit against and thus destroy the shock absorber.
Caution during the disassembly of the old cylinder!

Before the disassembly of the old cylinder it is necessary to measure the length of the completely extruded piston
connecting rod including the pivot head (1). Set the piston connecting rod of the new cylinder (2) via the thread of
the pivot head to the previously determined dimension.
Setting instructions for the damping of the new cylinder!

Screw in completely the setting screw (X) located on the side of the pneumatic piston.
Then unscrew it by about ½ to ¾ of a revolution and check the limit position of damping function.
Switch the pneumatic piston manually several times.
7020.cpt
C 95A 6423 39 – 23. Jul. 2004 7-35

7 Infeed
7.8 Infeed drum
Bearing, double cams, gripper opening cam and gear wheel
7021.cpt
Design
7022.cpt
7-36 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
Complete infeed drum
7023.cpt
C 95A 6423 39 – 23. Jul. 2004 7-37

7 Infeed
Checking the gripper margin
- Advance machine to 20° and lock.

This position represents the transfer point between the infeed drum and impression cylinder.
- Use 1.6 mm thick feeler gauge no. 099 J 0774 13 to check distance between the gripper tips of the infeed
drum and the front edge of the impression cylinder (drawing 7039.cdr)
2 feeler gauge
3 infeed drum
View from B-side
Correcting the gripper margin:
- Loosen clamping bolts (2) and turn infeed drum (drawing 7040.cdr).
- Tighten clamping bolts (2) and repeat check (drawing 7039.cdr).
1 Infeed drum hub

2 Clamping bolts between
infeed drum and driving gearwheel
View from A-side
7-38 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
Auxiliary gear adjustment
1 Direction of rotation
2 auxiliary gear
3 Clamping bolts / auxiliary gear
4 Infeed drum, hub
5 Clamping bolts between
infeed drum and gearwheel
6 Eccentric cam
View from A-side
Setting:
- Stop and lock the machine in position allowing to adjust the eccentric cam (6).
- Loosen clamping bolts (3), if necessary use tool no. 094 L 0135 50
(shortened Allen key SW5).
- Turn eccentric cam (6) counter clockwise (see arrow),
until a gear clearance of 0.01 – 0.02mm is reached.
- Tighten clamping bolts (3).
Check:
- Position two dial gauges (measuring accuracy of min. 0.01mm) with magnetic holders on the side frames.
- Set to zero the dial gauges on the driven gear flange of the infeed drums
and the driving gear flange of the impression cylinder.
- Use hand crank to move machine back and forth while checking clearance
(the difference between the two dial gauges).
- Repeat measuring in other positions.
C 95A 6423 39 – 23. Jul. 2004 7-39

7 Infeed
Repair of gripper shaft bearings

Page 1 of 4
For bearing bushing only! From series 328 – needle bearings.
7022.cpt
Example: Exchange of bushing, B-side
Caution: Each time just one bearing bushing can be changed

since the other bearings are necessary for alignment!
The following tools are required:
- 1x bushing 010 T 4617 30

- 1x complete gripper shaft A 99 B 4363 90
- 1x can SKC 60 and setting agent 094 R 7018 40
- (1x can SKC 55 and setting agent 094 R 7025 40)
- 1x separating agent 774 980 390
- 1x cartridge 094 N 0210 40
(silicon injection, small propeller for stirring)
- 1x alignment shaft M 760 014-15
- 1x plate B 760 114 001-2/37
- 1x plate B 760 114 001-2/6
- 1x bolt M 8x50, 2x bolt M8 x 20
- 1x extracting device M 760 014-14
- 1x bolt M 12x80, continuous thread
- power drill, drill bits ø 4 and 5 mm
7-40 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
Page 2 of 4
Repair procedure:
On B-side:
- dismantle operating board of the air control system and cover
- unscrew front part from protection frame
- loosen cog belt tensioner and remove cog belt (drive front lays/side guides)
- dismantle cog wheel disk on the infeed drum (locking ring, plate, adjusting spring)
- loosen tracking cam from cover guides (plate springs)
- dismantle casting holder (2x pins M6 outside, 3x bolts)
- dismantle cam pair with bolts (1x tapered pin M4 inside, 4x bolts)
Note: a thin long pin extractor is necessary
On the infeed drum:

- dismantle plastic protection and metal sheet guard in front of the water fountain
- remove both cylinder-halves on the infeed drum
Caution: take care of the cover guides when turning the machine!
- dismantle GTW and guard over the impression cylinder
- loosen torsion bar, A-side, and remove bolt lever
- unscrew all grippers
- dismantle gripper crank B-side, (loosen 1x tapered pin, 1x bolt), if necessary move gripper shaft
- dismantle upper half of the gripper opening cam, use feeler gauge to measure gap
- advance machine to 40° and push gripper shaft through B-side frame (Seeger ring, plate)
- use extracting tool no. M 760 014-14 to dismantle bushing (with SKC)
*Extracting tool no. M 760014-14
*1 bolt
2 bushing
3 SKC
*4 cartridge
*5 screw DIN 912 M12x80
C 95A 6423 39 – 23. Jul. 2004 7-41

7 Infeed
Page 3 of 4
Assembly of the bushing:

- unscrew grease nipple and drill an air bleed hole ø 5mm, clean everything
- push alignment shaft B 760 014-15 through the side frame in the bearings (display 40°)
- position new bushing and a. check the grease groove position, can be rotated by 180°!
b. small blind hole points to grease nipple hole!
- screw on device plates laterally on both sides of the bearing
- stir SKC and mix with setting agent (use propeller and power drill)
- fill SKC into cartridge and place cartridge into silicon injection
- apply silicon injection to grease nipple hole and pump until SKC starts running out of the air bleed hole
- allow SKC to harden for about 24h
Position of the bushing: The air bleed hole should point upwards,
to allow air to escape. If necessary drill second hole
and keep old hole closed (SKC).
1 air bleed hole

2 gap for SKC
3 bushing
4 grease groove
5 blind hole
6 grease nipple hole
View from B-side View from B-side
Alignment shaft and plates:
1 Alignment shaft M 760 014-15

2 Screw DIN 912 M8x20
3 Plate no. B 760 114 001-2/37
4 Grease nipple hole
5 Plate no. B 760 114 001-2/6
7-42 C 95A 6423 39 – 23. Jul. 2004

Infeed
7
Page 4 of 4
Operations following the hardening:
- dismantle device plates and alignment shaft, 40°

- drill grease nipple hole ø 4mm into bushing
- remove excessive SKC if necessary, finish bearing sideways by a smooth-cut file, clean bushing
- push torque bar into the new gripper spindle and mount through the side frame
(take care of the Seeger ring and plate)
- mount gripper crank and, eliminate possible lateral backlash (finish-ream tapered pin)
- mount all grippers, tighten screws with 25Nm
- screw in grease nipple, grease shaft and check ease of operation
- reassemble upper cam half and set to determined distance (feeler gauge)
- reassemble cam pair and casting holder
- load plate spring package at 22.4mm
- advance machine to 130°, load torque bar
- clamp gripper setting feeler gauge, 11.7mm, between the cam and cam roller
- set 0.1mm clearance evenly on all grippers and remove gripper setting feeler gauge
- check transfer points, grippers close at 255° and open at 21°
- mount guard over impression cylinder, take care of the grippers from the side, clamp
- assemble GTW, cylinder-halves, plastic guard and metal guard in front of the water fountain
- mount cog-belt disk and cog belt, tension
- advance machine to 166.4°and position measuring dial on a front lay, set pointer to “0“
- loosen 4x screws on the coupling (front lays / side guide drive)
- turn drive shaft (SW 13) in forward direction until the front lays move forward by 0.05mm
- tighten screws on the coupling and check setting. Refer to: Checking front lay movement
- mount front part of the protection frame
- screw on guard and operation board
- test run
C 95A 6423 39 – 23. Jul. 2004 7-43

7 Infeed
7-44 C 95A 6423 39 – 23. Jul. 2004

Printing units
8
8 Printing units
8.1 Press main drive............................................................................ 8-3
Gearbox and motor.......................................................................... 8-4
Construction of the gearbox for middle drive ................................... 8-5
8.2 Cylinders ........................................................................................ 8-6
Cylinder bearings............................................................................. 8-6
Dismounting the cylinder roller bearing ........................................... 8-7
8.3 Impression cylinder....................................................................... 8-8
Impression cylinder mountings ........................................................ 8-8
Removing the impression cylinder................................................... 8-9
Replacing the impression cylinder ................................................... 8-9
Base setting of the drive gear ........................................................ 8-10
Base setting to 1st transfer cylinder................................................ 8-11
Angle encoder ............................................................................... 8-12
8.4 Blanket cylinder........................................................................... 8-16
Mounting........................................................................................ 8-16
Impression on / off ......................................................................... 8-17
Stock thickness pressure setting ................................................... 8-20
Start of print - blanket and plate cylinders ..................................... 8-21
Start of print: Example: R 302........................................................ 8-22
Blanket tensioning bars ................................................................. 8-24
Blanket size ................................................................................... 8-25
8.5 Plate cylinder ............................................................................... 8-26
Mountings: Standard ..................................................................... 8-26
Mountings: CPL ............................................................................. 8-27
Bearer pretensioning ..................................................................... 8-37
8.6 Intermediate drum mountings .................................................... 8-39
1st and 3rd transfer cylinders .......................................................... 8-39
Gripper shafts ................................................................................ 8-42
C 95A 6423 39 – 11. Nov. 2003 8-1

8 Printing units
8.7 2nd transfer cylinder .....................................................................8-43

Mountings ......................................................................................8-43
Construction of the mounting .........................................................8-43
8.8 Storage drum................................................................................8-44
Mountings ......................................................................................8-44
Construction of the mountings .......................................................8-44
Cam adjustment.............................................................................8-45
Air control valve .............................................................................8-47
Suction box adjustment..................................................................8-48
Sheet length correction ..................................................................8-49
8.9 Pneumatic brake ..........................................................................8-50
For the passive sheet turning units ................................................8-50
Explanation: ...................................................................................8-51
8.10 Cylinders - general.......................................................................8-52
Power Clean Gel............................................................................8-53
C 95A 6423 39 – 11. Nov. 2003 8-2

Printing units
8
8.1 Press main drive

• With R 302 presses, the main drive motor is fastened to the base plate in the first printing unit.
• With R 304 to R 306 presses, the main drive motor is mounted in front of the first printing unit.
• With R 308 presses, the main drive motor is located in the middle of the press.
• From series 329, all presses with more than 5 printing units have the main drive motor in the middle.
Example R 302
Example R 304
8003.cpt
8002.cpt
8004.cpt
C 95A 6423 39 – 11. Nov. 2003 8-3

8 Printing units
Example R308
Gearbox and motor
For instructions on aligning the motor,
see Chapter 5, Installation
View from above

Sectional view of the gearbox
8001.cpt
C 95A 6423 39 – 11. Nov. 2003 8-4

Printing units
8
Construction of the gearbox for middle drive
8005.cpt
8006.cpt
C 95A 6423 39 – 11. Nov. 2003 8-5

8 Printing units
8.2 Cylinders
Cylinder bearings
Example: 2nd transfer cylinder, operating side
Overview of locations of
cylinder roller bearings:
- Pregripper, op. side
- Infeed drum, op.side
- Impression cylinder, op. side
- 1st, 2nd and 3rd transfer cylinder, op. side
- Turning drum, op.side
- Standard plate cylinder, drive and op. side
- CPL plate cylinder, op. side
8008.cpt 8007.cpt
Check bearer pretensioning:
8009.cpt 8010.cpt 8011.cpt 8012.cpt
1 2 3 4
The "ring" of the cylinder Use enveloping circle Turn the enveloping The eccentric bushing
roller bearing (2-17 measuring device to circle measuring device has been mounted in the
drawing 8008) is determine the outer ø on the setting ring sideframe with the
mounted first onto the and set the indicator to backwards and place it bearing outer ring. Now
cylinder axle and then "0". carefully in a mounting. use the inner diameter
the inner ring. Adjust the indicator gauge to determine the
The bearing is mounted above the setting ring inner Ø. The measured
and clamped firm with back to "0". Use an inner difference from outer to
the aid of the device. diameter gauge to inner is the
determine the inner Ø, pretensioning.
et the indicator to "0".
C 95A 6423 39 – 11. Nov. 2003 8-6

Printing units
8
Cylinder bearing tolerances:
- At the plate cylinder, pretensioning on drive and operating sides must be between - 0.005 and - 0.015 mm.
- At the pregripper, infeed drum and impression cylinder, as well as the 1st, 2nd and 3rd transfer cylinder,
pretensioning must be between - 0.000 and - 0.020 mm (mountings at the operating side).
If necessary, the ring on the axle must be changed. See the table for ring thickness.
Order number: Ring thickness in Enveloping circle measuring device, ∅ 105 mm:
mm
At plate cylinder op. and drive sides, infeed drum,
005 C 6726 30 8,856
105 C 6726 30 8,880 impression cylinder 1st 2nd and 3rd transfer cylinder
205 C 6726 30 8,904 operating side.
305 C 6726 30 8,928
405 C 6726 30 8,952 Enveloping circle measuring device, ∅ 91 mm:
505 C 6726 30 8,976
At pregripper and turning drum, operating side.
605 C 6726 30 9,000
705 C 6726 30 9,024
805 C 6726 30 9,048
905 C 6726 30 9,072
A05 C 6726 30 9,096
B05 C 6726 30 9,120
C05 C 6726 30 9,144
D05 C 6726 30 9,168
E05 C 6726 30 9,192
F05 C 6726 30 9,216
Dismounting the cylinder roller bearing

Using plate cylinder operating side as an example
1 M5 drilled hole for dismounting the outer ring

Dismounting instructions:
(when only the bearing on the operating side is
to be dismounted)
- Prop the cylinder and block it so it cannot
move sideways. Remove whatever parts are
necessary so that the bearing can be pulled
out.
- Dismount the gear (ink vibrator control).
- Take out the DIN 472 155x4 circlip (circlip
pliers type J4, inner, straight) and the disc
0 10T4737 30
- Screw a grease nipple into the cylinder axle.
- Use a grease gun to pump in grease until
the inner bearing comes off the axle.
Attention: The inner bearing can spring off
the axle so secure it against falling out.
- Pull out the taper pin and unscrew the 3
bushing fastening screws.
- Use two screws to press the bushing out of
the sideframe.
- The bearing outer ring can be taken out of
the bushing by using two M5 screws.
Attention: The "ring" on the axle belongs to

the cylinder and determines 8013.cpt
bearing pretensioning.
The ring need not be renewed when the bearing is changed.
C 95A 6423 39 – 11. Nov. 2003 8-7

8 Printing units
8.3 Impression cylinder

Impression cylinder mountings
A side B side
Mountings of
impression cylinder
after a turning station
(missing sheet
detector)
Mounting (without
missing sheet detector)
8014.cpt
8015.cpt
8016.cpt
8017.cpt
C 95A 6423 39 – 11. Nov. 2003 8-8

Printing units
8
Removing the impression cylinder
See illustrations 8016 / 8017.
− Remove the A and B side guards and the platform.
When carrying out repairs, only dismount the parts absolutely necessary.
− Dampener: take out the metering roller, pan roller, forme roller and bridge roller.
− Dismantle the sheet guides (paper or carton) and the blast tube above the impression cylinder.
− Slacken the torsion bar of the gripper shaft and remove the tightening lever.
− Screw the hitch eyelet into the threaded hole (M16).
− Position the gantry. Turn the press to the dismounting position and slightly tension the cable between the hitch
eyelet and the cable winch.
Switch the press off and secure it against being switched on again.
− Clamp the impression cylinder between the sideframes with bolts.
− Mark the drive gear (impression cylinder to 1st and 2nd transfer cylinder and blanket cylinder).
− Cover the 1st and 3rd transfer cylinder with paper to avoid damage.
− Mountings B side: Screw off the ring and cover plate on the outside of the sideframe.
Screw a grease nipple into the cylinder axle and use a grease gun to loosen the inner ring of the bearing.
Remove the screws from the ring (16) at the inside of the sideframe.
− Mountings A side: Pull off the drive gear (1) along with the hub.*
Remove spacer ring (9) and clamp ring (8). Use a pin puller to pull out the taper pin at the bearing bushing (7)
and unscrew the bearing bushing fastening screws.
Screw two bolts (M10x100 mm long, continuous thread) into the forcing holes and force the bearing bushing
against the sideframes.
Move the bearing bushing with the gripper cams out through the sideframes.
− Carefully loosen the lateral clamping bolts.
Attention: Impression cylinder is loose, retighten the cable if necessary.
− Remove the impression cylinder: Check that the cylinder can be moved freely!
Move the impression cylinder to the A side until the cylinder axle is no longer in the sideframe at the B side.
Take out the inner ring of the bearing and slide the ring onto the axle.
Raise the impression cylinder and move it towards the A side at the same time until the cylinder axle is free on
the A side. Remove the impression cylinder entirely.
Replacing the impression cylinder

Replacing the impression cylinder is done in the reverse sequence.
Observe the following points:
− Insert the impression cylinder with ring (16) and
mount the A side bearing bushing.
− Screw on ring (16) at inside of the B side.
− Mount the A side cylinder bearing:
Compare the bearing numbers on all parts, these
must be the same. Designation on inner ring "A" on
the outside, "B" or "C" on the inside (B = SKF, C =
Timken). Mount inner ring first. The markings on the
inner rings and the outer rings must be identical. Fill
the bearing with grease before mounting the outer
ring!
− Lock the cylinder bearing with the ring.
− Mount the B side cylinder roller bearing fill it with
grease and close the bearing.
− Mount the A side gear and hub. Pay attention to the
markings on the gear teeth!
Check that the gear runs true.
− Turn the press to the transfer line and use gauge no. 099 J0156 50 to check the distance to the cylinder edge,
see description and illustration 8003.cdr.
− Tighten the torsion bar, check gripper opening and closing times.
C 95A 6423 39 – 11. Nov. 2003 8-9

8 Printing units
Base setting of the drive gear
8018.cpt 8019.cpt
Base position between gear rim and "0° gauge" on the assembly line.
impression cylinder. Position: 0°
Mounting instructions:
- Heat the gear rim to 30°C and mount it on the cylinder hub.
- The gear rim must be mounted so that at ”0 degree" the bolt can still be easily slid into
the sideframe (see fig. 8018).
- If this is not the case, loosen the 4 clamping bolts gear rim/hub and turn the cylinder body..
To do this, connect a hydraulic device to the hub and build up an oil film.
- Tighten the clamping bolts and check that the bolt moves freely at ”0 degree”.
The impression cylinder gear must be mounted in the same way in all units to ensure that gear meshing is correct
later when the printing units are pushed together. Finally, check the gripper margin with paper or a gauge.
Hydraulic device
When mounting or exchanging a cylinder with grippers, the position to the

following cylinder must be checked.
This setting determines the gripper margin (~ 5,8 mm).
Function:
- Loosen the clamping bolts (6).
- Connect the hydraulic device (4) to the hub.
- Pressing in oil forms an oil film (2).
- The cylinder can be turned easily in the circumferential direction.
- Tighten the clamping bolts.
- Dismount the hydraulic device.
Hub with slot:

1st and 3rd transfer cylinders plus impression and blanket cylinders.
1 Gear rim
2 Oil film
3 Connection for hydraulic device (or grease nipple and
grease gun)
4 Hub
5 Cylinder axle
6 Locking screws
C 95A 6423 39 – 11. Nov. 2003 8-10

Printing units
8
Base setting to 1st transfer cylinder
Setting:
- Turn press to 237°.
- Check the distance of 1.6 mm between impression cylinder gripper tips to the edge of the 1st transfer cylinder
(gauge no. 099 J 0774 13).
Or check gripper tips of 1st transfer cylinder to the edge of the impression cylinder.
Both gripper tips should be the same distance from the cylinder edges.
- To correct: Loosen the clamping bolts on the gear and turn the cylinder in the circumferential direction.
See the description of the hydraulic device.
Tighten the clamping bolts and repeat the check.
Check the gripper margin once again with paper or gauge no. 099 J0156 50 (see Chapter 7, feeder tie-bar).
Check: Impression cylinder to 1st transfer cylinder, 1st transfer cylinder to impression cylinder
2 Impression cylinder grippers
3 Gauge no. 099 J0156 50
4 1st transfer cylinder
5 Cylinder front edge
C 95A 6423 39 – 11. Nov. 2003 8-11

8 Printing units
Angle encoder
Mounting the angle encoder and setting the sensor B 124 in 1st printing unit
Press STOP (HALT SECURITY) button, turn the press with crank handle only!
Angle encoder:
- Dismount both halves of the infeed drum.
- Take out the blanket washing device.
- Detach the blanket washer outlet hose inside the A side sideframe.
- Turn the press so that setting gauge no. 099 J 5132 30 can be laid on the edge of the
impression cylinder, lay it there and hold it firmly.
- Turn the press slowly until the tip of the gauge and the ”0° scribe mark”
coincide. See fig. 8004.
- The angle encoder must be electrically connected but not firmly fastened.
- With the press in this position, turn the angle encoder to 0° (see indication in the display)
and fasten it with two clamping bolts.
Attention: When turning the press, be sure there are no tools or gauges
left inside.
A- Side
Sensor B 124 Version 1

- Turn the press until the clamping bolt (A side inner) of the
suction box adjustment is in the upper position.
The suction boxes are integrated in the storage drum.
- The suction box indicator shows a sheet size of 520 mm.
- Note the degree number in the display.
- Loosen the two screws (7) on the subplate (8) and
carefully raise the angle encoder (3). Attention: the
coupling is very sensitive and can easily be damaged!
- Turn the gear (4) so that the detector segment (6) is
centered to the sensor B124 (5).
- Fasten the subplate and clamp the angle encoder back to
the previous degree number. Watch out for backlash!
1 Locking screws 5 Sensor B 124

2 Gear 6 Detector segment
3 Angle encoder 7 Screws
4 Gear 8 Subplate
C 95A 6423 39 – 11. Nov. 2003 8-12

Printing units
8
Sensor B 124 Version 2

- Turn press to 0°.
- Loosen the two screws (7) on the subplate (8) and
carefully raise the angle encoder (3). Attention: the
coupling is very sensitive and can easily be damaged!
- Turn gear (4) to the right (clockwise) until the LED at
sensor B124 (5) lights up.
- Fasten the subplate and clamp the angle encoder back to
the previous degree number.
Watch out for backlash!
Check:
- Turn the press one revolution past 0° and check the
”0° scribe mark” with gauge no. 099 J 5132 30. Reset the
angle encoder if necessary.
Check the function

- Press the straight printing key at the perfecting unit: ”1”
blinks in the 7-Segment display and the crawl speed key is
enabled.
- Press the crawl speed key: ”4” blinks in the 7-Segment
display and the crawl speed key is enabled.
- Press the crawl speed key: Press moves to suction box
adjustment position.
8
0
20.cpt
Construction of the angle encoder up to series 324
1 Setscrew SW 2.5 7 Locking screws

2 Coupling 8 Angle encoder
3 Impression cylinder 9 Sensor B 124
4 Secured with Loctite 290 10 Screws
5 Gear 11 Detector segment
6 Subplate
C 95A 6423 39 – 11. Nov. 2003 8-13

8 Printing units
Angle encoder with new coupling:
From series 325
Positioning the subplate with the index bolts:
Index bolts: Gauge no. M760008-23
C 95A 6423 39 – 11. Nov. 2003 8-14

Printing units
8
Blast tube above the impression cylinder
The blast tube is aligned parallel to the impression cylinder at a distance of 10,5 mm.
If necessary, the mountings must be reset.
The blast nozzles must be positioned at an angle of 20° counter to paper travel direction.
To correct: open the clamping bolts on the A side and turn the blast tube.
Retighten the clamping bolts.
C 95A 6423 39 – 11. Nov. 2003 8-15

8 Printing units
8.4 Blanket cylinder

Mounting
8022.cpt
Eccentric taper roller bearings at A and B side
8021.cpt
C 95A 6423 39 – 11. Nov. 2003 8-16

Printing units
8
Impression on / off
Mounting and adjusting the pneumatic cylinder
Series 311 to 316
− Mount the pneumatic cylinder in the two retainer bolts by screwing in the piston rods (9, 12).
Ensure the mounting position is correct!
1st switch step, stroke 30 mm, 2nd switch step, stroke 27 mm.
− Activate impression "ON", both piston rods move inwards.
− Screw the piston rods in until an 0.2 mm feeler gauge can be pulled lightly between the stop and the
setscrews. The setting must be identical on both A and B sides.
(387.8 +/- 0.02 mm between top edge of the sideframe and the middle bolt, can only be done in the factory)
− Clamp the piston rods and tighten the setscrews (8, 13).
−
Impression "ON" position
1 Marking on eccentric bushing, 2.00 mm, red

2 Marking on eccentric bushing, 2.50 mm, green
3 Marking on spindle and cover, at 2.00 mm
4 Fine-pitch lead screw
5 Setscrew
6 Potentiometer
7 Motor M400 A side, M401 B side
8 Setscrew
9 Piston rod
10 1st step, stroke 30 mm
11 2nd step, stroke 27 mm
12 Piston rod
13 Setscrew
14 Valve Y025
15 Valve Y026
View from B side
C 95A 6423 39 – 11. Nov. 2003 8-17

8 Printing units
From series 317 to ....

− Mount the pneumatic cylinder in the two retainer bolts by screwing in the piston rods (9, 12).
Ensure the mounting position is correct!
1st switch step, stroke 30 mm, 2nd switch step, stroke 27 mm.
− Activate impression "ON", both piston rods move inwards.
− Screw the piston rods in until the gauge can be slid lightly through the lever in the hole in the sideframe. Check
A and B sides.
− Clamp the piston rods and tighten the setscrews (8, 13).
Series 317 to 324 From series 325
1 Marking on eccentric bushing, 2.00 mm, red

2 Marking on eccentric bushing, 2.50 mm, green
3 Marking on spindle and cover, at 2.00 mm
5 Setscrew
6 Potentiometer
7 Motor M400 A side, M401 B side
8 Setscrew
9 Piston rod
10 2nd step, stroke 27 mm
11 1st step, stroke 30 mm
12 Piston rod
13 Setscrew
14 Valve Y026
15 Valve Y025
V
iew from B side
Series Gauge nos.: Diameter
317 to 324 M 760 015-6 ø 20 mm, ø 22 mm
from 325 M 760 015-5 ø 20 mm, ø 27 mm
C 95A 6423 39 – 11. Nov. 2003 8-18

Printing units
8
Stock thickness pressure settings via the eccentric bearing housing of the blanket cylinder
Overview of positioning drives
1st printing unit

Side Drive no. Einheit / Unit Bus address
A side 9 2 60
B side 10 2 61
Intermediate printing units

Side Drive no. Unit Bus-address
A-Side 4 1 63
B-Side 5 1 64
Adjustment:
Prerequisites: The cylinders are running true,

the pneumatic pistons for impression "ON / OFF" are adjusted,
the blanket and underpacking have been removed.
− Activate impression "ON", both pneumatic pistons move inwards.
− Check the distance between impression and blanket cylinders with a feeler gauge.
The blanket cylinder is set exactly parallel to the impression cylinder at a distance of 2.00 mm by turning the
eccentric bearing housings at A and B sides.
The eccentric bushings can be moved without the drive motors by means of the fine-pitch lead screw (SW 6
Allen key).
When the drive motors are mounted, the adjustment is made via the hand terminal.
Attention: The eccentric bearing housings should always be moved simultaneously and
parallel to the impression cylinder!
Individual adjustments can be made step-wise from A to B sides.
Do not move them closer than 0.02 mm to each other!
Check:
− With impression "ON", feed a lead wire* between impression and transfer
cylinders on both A and B sides and back it out again.
− Measure the thickness of the lead wire with a micrometer. Base setting = 2.00 mm.
− Mark this setting with a scribe mark on the inside between the eccentric bushings and sideframe.
Mark the scribe mark as well as the position of the fine-pitch lead screw with red paint.
− At a gap of 2.50mm, make another scribe mark on the eccentric bushings and the sideframe
(mark this with green paint).
* Lead wire: ø 3 mm, DIN 1719, L – PB 99,94%
C 95A 6423 39 – 11. Nov. 2003 8-19

8 Printing units
Stock thickness pressure setting

1 Marking 2.00 mm (red)

2 Marking 2.50 mm (green)
3 Marking 2.00 mm (red) fine-pitch lead screw
5 Guide hole for clamping the drive shaft
6 Potentiometer
7 Pressure setting motor
Mounting the pressure setting motor
− Connect power to the pressure setting motor (7)

then switch on the press.
− Use the hand terminal to turn the drive shaft so that the milled surface stands parallel to the
lateral edge of the motor housing.
− Turn the lead screw (4) until the locking screw can be seen through the guide hole (5).
− Screw the motor onto the mountings and fasten the drive shaft.
− Use the hand terminal to move to the red markings(A and B side plus lead screw).
− Carry out the lead wire measurement, the thickness of the compressed lead wire should be 2 mm.
− Hand terminal: Check the actual value display of the potentiometer! In Menu 6 it should be 0.00 mm
Position 2,0 mm Position 2,5 mm
Console: Hand terminal Lead wire

measurement
Stock thickness Menu 6 Menu 7
0,00 mm -0,10 mm 1,90 mm
0,10 mm 0,00 mm 2851 mV 2,00 mm
0,60 mm 0,50 mm 2,50 mm
C 95A 6423 39 – 11. Nov. 2003 8-20

Printing units
8
Start of print - blanket and plate cylinders
A Printed sheet: full solid without dampening

B Printed sheet with dampening
C Printing plate with CPL register system
D Printing plate with Grapho Metronic register system
E Printing plate with Bacher register system
1 Paper front edge

2 Start of print 9.2 to 9.5 mm with dry
full solid
3 Start of print 10 mm with dampening
4 Middle of the sheet
5 Print-free area "gripper margin"
6 Plate front edge
Plate front edge punching with:
CPL Grapho Metronic Bacher normal
C 95A 6423 39 – 11. Nov. 2003 8-21

8 Printing units
Start of print: Example: R 302
Prerequisites:
- Press in "make ready" mode, deselect inking and dampening units, select impression "ON".
- Sheet size: 500x700 mm, 100gsm.
- Press must be in straight printing mode!
- Check that the stop (single-side printing) of the gear wheel clamp A side is on the key.
- Check that the gripper opening cam of the storage drum is in base position..
The markings on the bushing and cam retainer at the A side inner sideframe must be exactly opposite!
Connect hand terminal to printing unit 2.
Menu 6, Unit 1, Pos. 6, Gripper opening cam, display = "0 mm".
Check: storage drum grippers open at 55.5°, perfecting cylinder grippers close at 53.5°.
Checking "gripper margin" (paper in gripper):
- Move all frontlays to "0" from the central control console.

Hand terminal display: Menu 3 ,Unit 2, Slides 1-5 must read "0.135 mm" !
− Dismount blanket washing device in printing unit 1 and screw off the plate above the impression cylinder.
− Lay a square trimmed sheet on the frontlays and carefully turn the press clockwise with the crank handle until
the sheet is in the impression cylinder grippers.
− Use gauge no. 099 J 0156 50 to check that the gripper margin is 5.8 mm at both A and B sides.
(It may be necessary to reset the infeed tie-bar)
− Once the gripper margin in printing unit 1 is correct, turn the press further with the crank
handle and check the gripper margin in all impression and transfer cylinders!
Checking the stock thickness pressure setting:
− Input stock thickness 0.1 mm, individual setting 0.00 mm at the central control console.
− Check all red markings (blanket cylinder eccentric bushings, lead screw).
Hand terminal: Printing unit 1: Menu 6, Unit 1, with CPL Unit 2, Motor no. 9, 10 must show "0mm",
Printing unit 2: Menu 6, Unit 1, Motor no. 4, 5 must show "0mm".
Checking impression "ON / OFF" setting:
− Select "impression ON" at the printing unit. Both pneumatic pistons must be driven in.
− Check the index drill holes with gauge no. M 760 015-6.
Checking the cylinder packings:
− Check the cylinder packings with the dial gauge.

− Blanket cylinder: blanket with underpacking = 0.03 to 0.05 mm above bearer.
− Plate cylinder: plate with underpacking = 0.1 mm above bearer.
C 95A 6423 39 – 11. Nov. 2003 8-22

Printing units
8
A "dry" full solid is printed in every printing unit:
− Set rough register at all plate cylinders to "0".

− Print a "dry" full solid in printing unit 1.
- Remove the sheet and measure start of print (gripper margin).
The distance from the sheet front edge to start of print should be 9.2 to 9.5 mm.
To correct:
- Blanket cylinder - mark the position of the gear rim to the hub with a scribe.
- Connect a hydraulic pump (or grease gun) to the blanket cylinder hub.
- Loosen the locking screws, activate the hydraulic pump and turn the blanket cylinder accordingly.
- Tighten the locking screws, remove the hydraulic pump and pull a solid to check the setting.
- Check all printing units in the same manner.
Checking start of print at the plate cylinder:
− Move rough register and register adjustment to "0" from the central control console.
− All frontlays must be in the middle position.
− Move the sidelay "Off-centre" to 0 mm and "Image position correction" to 0.00 mm.
− Printing plates: The start of print (43, 52 or 53 mm depending on the system) and press centre should be
printed out as lines.
− Print a sheet "wet" in printing unit 1and check start of print.
Circumferential register: the "start of print line" must be exactly 10 mm from sheet front edge.
Lateral register: the sheet must run exactly to the middle of the press.
Corrections with standard register (EU and US):
− Circumferential rough register must be corrected and the "0" position repinned.
− With lateral register, the front plate clamp is adjusted laterally.
Corrections with the CPL register system:
− In the circumferential direction, the CPL module can only be moved away from the plate
cylinder front edge!
For corrections in plate cylinder front edge direction, the plate cylinder must be adjusted via coarse register.
Finally, the indicator must be reset to "0".
− For both lateral and circumferential register adjustments, the complete CPL module moves.
C 95A 6423 39 – 11. Nov. 2003 8-23

8 Printing units
Blanket tensioning bars

Series 311 to 329
Tensioning device Tensioning bars
8024.cpt 8023.cpt
From series 330
Tensioning device Tensioning bars
8035.cpt
Tensioning bar mountings
8037.cpt
8036.cpt
C 95A 6423 39 – 11. Nov. 2003 8-24

Printing units
8
Blanket size
Blanket
Series Length x width Marking at start of print
310 to 324 770 x 750 mm 75 mm
325 to 329 760 x 750 mm 65 mm
From 330 730 x 750 mm 45 mm
Series 310 to 324
Series 324 to 329
From series 330
C 95A 6423 39 – 11. Nov. 2003 8-25

8 Printing units
8.5 Plate cylinder

Mountings: Standard
B side
A-side
8026.cpt 8025.cpt
8028.cpt
8027.cpt
8029.cpt
C 95A 6423 39 – 11. Nov. 2003 8-26

Printing units
8
Mountings: CPL
A-side
8038.cpt
The mountings at the B side are identical to the

standard plate cylinder (see Fig. 8025.cpt)
8031.cpt
8030.cpt
8029.cpt
C 95A 6423 39 – 11. Nov. 2003 8-27

8 Printing units
Register adjustment A side
C 95A 6423 39 – 11. Nov. 2003 8-28

Printing units
8
Design
8033.cpt
Circumferential and lateral register drive
8034.cpt
C 95A 6423 39 – 11. Nov. 2003 8-29

8 Printing units
Setting wedge guide
Adjustment:
− The setting wedge guide must be set play-free
in order to prevent misregister (position shift).
− Position magnetic base on the gear and place the dial gauge feeler on the hub.
Play is measured by moving the gear rim to and fro.
− Play is reduced by turning the self-locking M6 nut clockwise.
− Set the self-locking nut so there is no more play.
The right pretension is achieved by turning the nut one flat further.
Check:
− Check the two outer rails of the setting wedge guide.
The rails should still be able to be moved by light hammer blows.
− The gear must still be able to be easily moved axially by hand on the hub.
Attention:
− If the setting wedge guide is set too tight, the register motor can jam!
− Ensure that the flat retainers can move freely.
− One flat of the self-locking M6 nut must be parallel to the wedge, risk of damage!
8039.cpt
C 95A 6423 39 – 11. Nov. 2003 8-30

Printing units
8
Circumferential register base setting
Drive no. 1, Unit 1, Bus address no. 60, Circumferential register
Using the hand terminal:

1. Plug the hand terminal into the printing unit concerned.
2. Press the reset button in the A side switch cabinet (active mode). Only to be done by
trained personnel!
3. Enter the code and select Menu 7.
4. Enter the code and select Bus address no. 60.
5. Use the arrow keys to set the gear to a distance of 110 mm from the sideframe.
6. Turn the potentiometer shaft until a value of 5000 mV is indicated.
7. Leave Menu 7 via Exit and select menu 6, display of Drive no. 1 shows 0 mm.
8. Check that total travel of the circumferential register is +/- 1.5 mm.
9. To change from active to passive mode: Switch press off then on again.
General information
When the plate cylinder is moved +/- 1.5 mm in the circumferential direction,
the gear moves +/- 5.44 mm in the axial direction.
Dismantling tips:
6 holding bolts are needed for dismantling the register.
Dimensions: M6 x 55mm, 12.9, continuous thread.
The pressure of the individual compression springs is retained by the holding bolts.
Attention: Always secure the compression springs first before dismantling the register!
The compression springs should be preset before fitting.

Setting distance: 18 mm between gear and hub.
Don't forget: After assembly, the holding bolts must be removed!
Circumferential register base setting: 110 mm

from tooth front edge to A side sideframe
Register motors
1. Circumferential register
2. Lateral register
8040.cpt
C 95A 6423 39 – 11. Nov. 2003 8-31

8 Printing units
Lateral register base setting
Drive no. 2, Unit 1, Bus address no. 61, lateral register

1. Plug the hand terminal into the printing unit concerned.
2. Press the reset button in the A side switch cabinet (active mode). Only to be done by
trained personnel!
3. Enter the code and select Menu 7.
4. Enter the code and select Bus address no. 61
5. Use the arrow keys to set the plate cylinder laterally to a distance of 85 mm between the A side sideframe and
bearer.
6. Turn the potentiometer shaft until a value of 5000 mV is indicated.
7. Leave Menu 7 via Exit and select menu 6, display of Drive no. 2 shows 0 mm.
8. Check that total travel of the lateral register is +/- 1,5 mm.
9. To change from active to passive mode: Switch press off then on again.
Attention: The registers must not be moved while the press is stopped!
Display at the central control console monitor:
Circumferential register:
− When direction ”-” is selected at the central control console, the plate cylinder moves forwards in press running
direction.
− The circumferential register motor turns anti-clockwise
and the gear moves towards the sideframe.
Lateral register:
− When direction ”-” is selected at the central control console, the plate cylinder moves to the A side.
− The lateral register motor turns clockwise.
C 95A 6423 39 – 11. Nov. 2003 8-32

Printing units
8
Ternes plate clamps in the standard plate cylinder
Standard sheet size 530 x 740 mm
8044.cpt
8042.cpt
C 95A 6423 39 – 11. Nov. 2003 8-33

8 Printing units
Option: 590 x 740 mm sheet size
8045.cpt
Base setting of the front clamp:
− Move circumferential and lateral register to the

middle position from the central control console.
Lateral register:
− The front clamp is set laterally to a distance
of 172.5 mm between the inside of the register pin
and
the inside of the bearer. This setting is done via the
adjustment screws located on the side of the clamp.
Lateral play of the clamp must not exceed
0.03 mm.
C 95A 6423 39 – 11. Nov. 2003 8-34

Printing units
8
Base setting of the front clamp:
− Circumferential register:
The front clamp (start of print) is circumferentially set as follows:

− With the standard sheet size (530x740 mm) X = 3 mm to plate cylinder front edge.
− With the optional (US) sheet size (590x740 mm) X = 5 mm to plate cylinder front edge.
− With the CPL- System:
Move circumferential and lateral registers to the middle position from the central control console.
Carry out auto calibration.
Front clamp 8.5 mm from the plate cylinder front edge.
Lateral position: 20 mm from the A side bearer to the clamp.
−
Standard- version
(US) version
8043.cpt 8041.cpt
Fine adjustments to the clamps are done by print testing the press with identical plates.
Plate front edge punching with:
CPL Grapho Metronic Bacher normal
C 95A 6423 39 – 11. Nov. 2003 8-35

8 Printing units
Cylinder packings
Plate cylinder
with standard clamps
Blanket cylinder
Note: To compensate for print length differences, the packing on the plate cylinder in printing unit 1
is increased by 0.01 to 0.02 mm (0.11 to 0.12 mm above bearer).
Presses with the CPL
R302 R304 R305 R306 R307 R308

AD GF DF AD GF DF AD GF DF AD GF DF AD GF DF AD GF DF
M1 0,25 0,11 0,14 0,25 0,11 0,14 0,25 0,11 0,14 0,26 0,10 0,16 0,26 0,10 0,16 0,26 0,10 0,16
M2 0,24 0,10 0,14 0,24 0,10 0,14 0,24 0,10 0,14 0,25 0,11 0,14 0,25 0,11 0,14 0,25 0,11 0,14
M3 0,24 0,10 0,14 0,24 0,10 0,14 0,24 0,10 0,14 0,25 0,11 0,14 0,25 0,11 0,14
M4 0,24 0,10 0,14 0,24 0,10 0,14 0,24 0,10 0,14 0,25 0,11 0,14 0,25 0,11 0,14
M5 0,24 0,10 0,14 0,24 0,10 0,14 0,24 0,10 0,14 0,25 0,11 0,14
M6 0,24 0,10 0,14 0,24 0,10 0,14 0,24 0,10 0,14
M7 0,24 0,10 0,14 0,24 0,10 0,14
M8 0,24 0,10 0,14
AD = Packing without printing plate

GF = Base foil
DF = Cover foil
Recommendation: The thickness of the foils given in the table are for guidance only
(provided with the press).
The correct printing length should be determined by a print test ( grid forme).
Use other foils depending on print test results.
Note: When impression is ON, the press always runs in bearer contact. This setting cannot be changed! (by
the operator).
C 95A 6423 39 – 11. Nov. 2003 8-36

Printing units
8
Bearer pretensioning
The explanation of bearer pretensioning is given here using the procedure

followed for individual printing units on the assembly line as an example:
Setting
− Remove the plate, blanket and underpacking.
− Activate impression "ON". The pneumatic pistons at B side are driven in.
The bearers must not be in contact!
− Set the stock thickness pressure to 0.1 mm (2 mm gap between blanket and impression cylinders).
− Position the feelers of the two gauges (Millitron Type 1200 IC. No. 000000 0162897) under the
blanket cylinder bearers at A and B sides. Set the indicator to ”0”.
− The plate cylinder is moved towards the blanket cylinder by turning the eccentric bushings.
Once the bearers make contact, set a pretension of 0.018 to 0.020 mm.
Check:
− Check with a hydraulic device how many bar is needed to detect light between the bearers.
− Once the setting is correct, pin the eccentric bushings.
Plate cylinder B side with the device for turning the eccentric bushings.
8046.cpt
Measuring gauges: Millitron Type 1200 IC. No. 000000 0162897
8047.cpt
C 95A 6423 39 – 11. Nov. 2003 8-37

8 Printing units
Lead wire measurement
Plate cylinder
Blanket cylinder
Impression cylinder
Lead wire:
Lead wire measurement ø 3.0 mm
L - PB 99.94 %
− Remove blanket and underpacking, clean the cylinder. DIN 1719
− Check that plate, blanket and impression cylinders are running true.
− Set stock thickness pressure at the central control console to 0.1 mm.
Set individual adjustment to 0.00 mm.
− Set impression "ON" and place a 3 mm ø lead wire between impression and blanket cylinders.
− Turn the press a short distance forwards and backwards then remove the lead wire.
− Measure the thickness of the lead wire with a micrometer.
Take three measurements in three different places.

The measuring positions across the cylinders are:
− One lead wire 50 mm from the bearers (inner edge) on both sides of the cylinders
and one in the middle.
The measuring positions around the cylinders are:
− 50 mm from the edges (start of print and end of print) and one in the middle.
Cylinder undercuts:
Standard plate cylinder 0.50 mm

CPL plate cylinder 0.40 mm
Blanket cylinder 2.00 mm
Lead wire measurements:
With a stock thickness of 0.1 mm.

Gap between blanket and impression cylinders 2.00 mm +/- 0.015 mm
With a stock thickness of 0.6 mm.
Gap between blanket and impression cylinders 2.50 mm +/- 0.015 mm
C 95A 6423 39 – 11. Nov. 2003 8-38

Printing units
8
8.6 Intermediate drum mountings
1st and 3rd transfer cylinders
Mounting
of the 1st transfer cylinder
before the storage drum
Mounting
of the 3rd transfer cylinder
8050.cpt A-Seite
Mounting
before the 2nd transfer cylinder
and mounting
in the coating module
8049.cpt A-Seite
C 95A 6423 39 – 11. Nov. 2003 8-39

8 Printing units
Mounting
after the turning drum
with detector
8048.cpt B-side
Mounting
before the 2nd transfer cylinder
or storage drum
without detector
Mounting
8052.cpt B-side
C 95A 6423 39 – 11. Nov. 2003 8-40

Printing units
8
Mounting of 1st transfer cylinder
8054.cpt
Mounting of 1st transfer cylinder before the turning drum
8053.cpt
Mounting of 3rd transfer cylinder
8055.cpt
C 95A 6423 39 – 11. Nov. 2003 8-41

8 Printing units
Gripper shafts
Mounting of the gripper shaft with bronze bushings
Series 311 to 327
Construction of the gripper shaft with torsion bar (6) 8056.cpt
8057.cpt
Mounting of the gripper shafts from series 328 with needle bearings Series 311 to 327
with bronze bearings
8051.cpt
C 95A 6423 39 – 11. Nov. 2003 8-42

Printing units
8
8.7 2nd transfer cylinder

Mountings
A side
B-side
8061.cpt
8060.cpt
Construction of the mounting
8062.cpt
8063.cpt
C 95A 6423 39 – 11. Nov. 2003 8-43

8 Printing units
8.8 Storage drum

Mountings
A-side
B-side
8061.cpt
8067.cpt
Construction of the mountings
8064.cpt
C 95A 6423 39 – 11. Nov. 2003 8-44

Printing units
8
Cam adjustment
A side, View from above
8059.cpt
8068.cpt 8066.cpt
C 95A 6423 39 – 11. Nov. 2003 8-45

8 Printing units
Drive no. 6, unit 1, Bus address no. 65, Gripper opening cam
Base setting of the gripper opening cam
1 Fixed cam, transfer from 1st transfer cylinder to

the storage drum
2 Marking on the bearing bushing
3 Moving cam, transfer from storage drum to
turning drum
4 A side sideframe
5 Moving cam holder
6 Potentiometer
7 Motor
8 Cam holder, division and
scribe mark must match
View from above

1. Plug the hand terminal into the unit to be adjusted.

2. Press the Reset button in the B side switch cabinet (active mode). Only to be done by trained personnel !
3. Enter the code and select Menu 6, Unit 1.
4. Select drive no. 6 gripper opening cam.
5. Move the cam holder so that the markings match, see sketch.
6. Turn the potentiometer axle until 0 mm is displayed as actual value.
or after points 1 and 2.

8. Enter code and select Bus address no. 65.
9. Use the arrow keys to move the cam to the marking.
10. Turn the potentiometer axle so that 8924mV is displayed for EURO format
or 9440mV for US format.
9440mV in base position is the right setting for all presses as from series 320 !
Note:
- Ensure that the value displayed in the hand terminal +6 mm actually corresponds to the sheet size! (Menu 6)
Example:
Display in hand terminal 514 mm [+ 6 mm gripper bite] = sheet size 520 mm central control console.
C 95A 6423 39 – 11. Nov. 2003 8-46

Printing units
8
Air control valve
B side
8065.cpt
Checking the air control valve (4)
Prerequisites:
- Press is in perfecting mode.
- Turning drum grippers are correctly set.
1 Check the closing time of the perfecting gripper on the turning drum with
a feeler gauge and write down the degree number.
2 Switch on the pumps.
3 Set the suction/blast air valves for the suction boxes to "1".
4 Set the suction air at the manometer to -0.6 bar.
5 Turn the regulating taps at the suction boxes on.
6 Lay paper strips on all suction boxes and fasten the ends onto the cylinder with adhesive tape.
7 Turn the press slowly forwards with the crank handle until the suction air can no longer hold the paper strips.
(in this position the suction air changes to blast air to release the vacuum).
8 Write down the degree shown in the display.
9 The settings are correct when there is a 3° difference between perfecting gripper closed and suction air
off/blast air on.
10 If necessary the air control valve (4) must be readjusted via the eccentric bolt (5).
C 95A 6423 39 – 11. Nov. 2003 8-47

8 Printing units
Suction box adjustment
1 Cam for suction box

movement
2 Sheet size scale
3 Indicator, arrow shows setting
edge
4 Locking screw, sheet size
5 Locking screw for suction box
movement
6 Stop
7 Suction box lever, arrow
shows contact point
8 Corner of the suction box
9 Sheet rear edge
10 Suction plates
11 Air holes in the suction plate
Base setting of the suction box control
− All suction box levers must rest evenly on the stop (6).
Check contact with an 0.03 mm feeler gauge.
− If necessary, loosen locking screw (4) and adjust the suction box levers.
− The height of the suction plates (10) and cylinder surface must be the same.
It may be necessary to rework the suction plates.
− In perfecting mode, the suction boxes must be set manually to the sheet size.
Please observe the following when doing this:
− Example: Sheet length 520 mm; loosen locking screw (4) and push the suction box until the
indicator (3) points to 520 mm. Tighten the locking screw.
− Run paper and check whether the sheet rear edge (9) covers all holes or
lies flush with the corner of the suction box.
If necessary, correct the setting and reset the indicator.
Note: The indicator is read from the left side (see arrow) !
C 95A 6423 39 – 11. Nov. 2003 8-48

Printing units
8
Sheet length correction
At the storage drum when perfecting (S&W) as from series 325
Explanation:
The correction device integrated in the storage drum is used to correct
perfecting misregister in "two-sheet rhythm".
The correction device consists of two split rails located on both sides directly behind
the gripper pad bar.
The split rails can be elevated parallel or diagonally.
The device no. 760.007-27 is used to carry out exact settings.
Setting:
Prerequisites:
- All press settings have been carried out correctly.
- The turning drum is in perfect condition.
- The storage drum is clean and the suction boxes are working properly.
- The split rails are clamped in "base position".
- Base position: same height as the cylinder surface.
- Press is set to perfecting mode for the test.
Make a print test. In the event of misregister, proceed as follows:

- To determine which side of the rail needs to be adjusted, apply adhesive tape
to one side of the gripper pad bar.
- Repeat the print test to check the reaction.
- To adjust: Loosen locking screws (3) and use the stop screws (4) to make the correction.
Then retighten the locking screws (3). Remove the adhesive tape!
- Repeat the print test and check the setting, readjust if necessary.
Notes:
- The rail (1) could be under tension and may move when the locking screws (3)
are opened. Measure the height of the rail in advance with device no. 760.007-27.
- When adjusting the rail (1), always check the height at several positions!
- If misregister is determined on one side, only one rail can be corrected (from middle
of the cylinder). Be sure that the rail (1) surfaces are flush (2).
- If there is a burr on the raised rail, this must be reworked.
1 Rails
2 Rail division
3 Locking screws (SW 5)
4 Allen key (SW 2.5)
for the stop screws
5 Device no. 760.007-27
C 95A 6423 39 – 11. Nov. 2003 8-49

8 Printing units
8.9 Pneumatic brake

For the passive sheet turning units
with middle drive and for retrofitting
Example: Position for the pneumatic brake at the turning unit with middle drive
8061.cdr
The turning unit is marked grey
Example: Position for the pneumatic brake after the turning unit, drive from unit 1
8061.cdr
The turning unit is marked grey
Pneumatic brake and valve Y118
8062.cdr
C 95A 6423 39 – 11. Nov. 2003 8-50

Printing units
8
Explanation:
− From program version 314F5, the perfecting stop brake that blocks the
passive press unit is triggered during changeover.
− The brake engages when the clamp is opened and remains engaged during the entire changeover.
− When the clamp closes, the brake disengages again.
− Triggering takes place whether the press actually has a
brake or not i.e. the outlet (Byte X, Bit Y) is always triggered.
− One brake per sheet turning unit must be installed.
6 7
1
1 Gear
2 Compressed air supply pipe
3 ValveY118 0,5 0,5
4 Cable 2
5 Setting screw (M16) A350/14
6 Side frame B.B,20.5
7 Switch cabinet B-side
turning unit A335
X Stop bolts(M6) 3 X75
X
X 6 14
4 2 1
5 (-24V) (0V)
8060.cdr
Setting:
− Screw the pneumatic brake onto the side frame.
− The settings will be made when the brake is released, without pressure
− The brake shoes are set 0.5 mm away from the gear via the stop bolts.
− In this position, the screw (M 16) is turned to the
pneumatic piston and locked.
(The head of the screw only just touches the piston)
− Connect T-piece with the compressed air pipe on B-side
− The electrical connection has to be established by an electrician.
Switch cabinet B-side/ rack A350 / slot 14 / byte 20 / bit 5 / distribution board A335 / plug X75 /
cable no. 1 with Pin 14 and cable no. 2 with Pin 6
Check the function with the function test no.20 in the printing unit before the turning unit
C 95A 6423 39 – 11. Nov. 2003 8-51

8 Printing units
8.10 Cylinders - general

Fastening the hubs on the cylinder axles.
Cylinders concerned: 1st and 3rd transfer cylinders and impression cylinder
Version 1 Version 2 Version 3

Cylindrical axle Conical axle with Conical axle
with locating key positioning pin without positioning pin
C 95A 6423 39 – 11. Nov. 2003 8-52

Printing units
8
Power Clean Gel
For cleaning the textured surfaces of the R 300 / R 700 impression and transfer cylinders
Attention!
This cleaning agent is caustic!

Protective gloves made of neoprene and safety glasses must be worn when working with it!
The cleaning agent can be applied for deep cleaning of the impression and transfer cylinder surfaces every 2 - 4
months depending on how dirty the cylinders are.
Instructions for use:
1. Pre-clean the impression and transfer cylinders with a washing agent such as Böttcherin 60 and water.
2. Apply Power Clean Gel generously with a brush (polyamide bristles).
3. Leave it on the cylinders for at least 4 hours then wash it off with water.
Do not under any circumstances use the impression cylinder washing device to wash it off.
4. The residue must not come into contact with other machine components and it must not be put into
the drains.
It must be disposed of as special waste!!!
5. The grippers must be lubricated after every cleaning with Power Clean Gel.
It is available packed as follows:
Power Clean Gel 2x1 kg / Roland item number 0 94N 5284 90
This amount is sufficient for cleaning two R 700 cylinders and

eight R 300 cylinders.
In addition to this information, please also refer to the Product Information bulletin as well
as the Safety Data sheet relating to EU guideline 91/155/EWG and instructions for use 1834-01 (for MRO
personnel only)
Power Clean Gel can only be delivered to Sales and Service Partners after it has been established that an
adequate handling and product liability contract has been concluded.
C 95A 6423 39 – 11. Nov. 2003 8-53

8 Printing units
C 95A 6423 39 – 11. Nov. 2003 8-54

S&W 8A
8A S&W
8.1 Operating sequence ...................................................................... 8-3
8.2 The changeover program.............................................................. 8-4
From straight printing to perfecting .................................................. 8-4
8.3 Mountings ...................................................................................... 8-6
8.4 Sensors at the turning drum......................................................... 8-7
Active sensors when perfecting ....................................................... 8-9
Setting the sensors........................................................................ 8-10
8.5 Gear wheel clamp ........................................................................ 8-12
Series 310 to 324 .......................................................................... 8-12
Setting the clamp segments .......................................................... 8-13
Setting the clamping screw and sensors ....................................... 8-14
Series 325 till 327 .......................................................................... 8-16
Setting the clamping segments...................................................... 8-17
Setting the clamping screw and sensors from series 325 to ........ 8-18
Series 328 to ....... ......................................................................... 8-19
Setting the clamp segments .......................................................... 8-20
Installation of the clamping disk..................................................... 8-20
Mountings and gear wheel clamp from series 334 to .... ............... 8-21
Sensors ......................................................................................... 8-22
Cam adjustment at the B side........................................................ 8-23
Special design ............................................................................... 8-24
C 95A 6423 39 – 12. Nov. 2003 8-1

8A S&W
8.6 Turning drum................................................................................8-25

Setting the gripper margin..............................................................8-25
Perfecting stops of the gripper systems .........................................8-26
Base position of the gripper spindle stops .....................................8-27
Gripper pads and springs...............................................................8-27
Movement of the tumbling shafts. ..................................................8-28
Base setting of the anchor cam......................................................8-29
Base setting of the two gripper cranks ...........................................8-30
Shaft control when perfecting.........................................................8-31
Assembling the gears, segments and segment lever:....................8-31
Setting the cam rollers on the segment lever .................................8-32
Sheet turning diagnosis .................................................................8-33
8-2 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
8.1 Operating sequence
8071.cpt 1 8072.cpt 2
8073.cpt 3 8074.cpt 4
Explanation of the paper run functions in perfecting mode
1. While the sheet front edge is held by the cylinder grippers,

the rear edge is sucked onto the suction boxes and pulled flat
around the cylinder.
The sheet is taken over by the perfecting gripper system.
At this moment, the sheet front edge which is register-critical
is released by the storage drum grippers.
2. Both gripper systems of the turning drum are now working.

The sheet is transferred from the perfecting gripper system
to the straight printing gripper system.
Differences in sheet length do not matter so long as
they remain within a band of +/-1.5mm
3. The straight printing gripper system has taken over the sheet.
4. The straight printing gripper system transfers the sheet to the impression cylinder
grippers. The sheet has now been turned and is passed along as in straight printing mode.
C 95A 6423 39 – 12. Nov. 2003 8-3

8A S&W
8.2 The changeover program

From straight printing to perfecting
7-segment indicator operating cycle printing machine command
CS
select symbol single-side printing
1 or perfect printing on the panel; out of action
JR JF
selected symbol blinks
CS
2 "1" press the crawl speed key out of action JR JF
CS
moves to change-over
3 "1" position
JR JF
CS
release the terminal screw
4 1
until "2" appears
out of action JR JF
CS
CS
6 "2" drives on size JR JF
CS
screw down the terminal
7 2
screw until "4" appears
out of action JR JF
CS
moves to the change-over CS

9 "4" "4" keeps on shining
for approximate 7sec. position of the suction boxes JR JF
CS
10 adjust suction boxes out of action JR JF
8036e.cdr
CS = crawl speed "1" = number blinks

JF = jog forward 1 = shines statically
JR = jog reverse
= signal "LOW"
= signal "HIGH"
8-4 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
Explanation of the seven-segment display at the perfecting station
Left right
7-segment Left Right

display
blinking executing #) Function #) selected
static Function #) executed -
correctly
The following functions can / must be executed:
7-segment Function Description

display #)
1 Changeover Press moves to changeover position, sensor B120 is
position covered
2 Sheet size Press moves to the sheet size entered at the central control
console or the straight printing position.
Attention: If the press has not been made ready, it moves to
the maximum perfecting sheet size (in MMS configuration).
3 Format correction With the Inch forwards and Inch backwards keys, the sheet size
(blinks constantly) (gripper margin) can be finely adjusted by max. + 4mm (+ 2mm
is recommended).
4 Suction box setting Press moves to the position for setting the suction boxes of the
position storage drum (sensor B124).
To adjust the gripper opening cam:
a) Press the perfecting key for more than 2 seconds.

b) "50" appears in the 7-segment display.
c) With the Digit + keys, the gripper opening cam can be moved by max. + 5 digits.
d) You can exit this function by pressing the perfecting key again.
C 95A 6423 39 – 12. Nov. 2003 8-5

8A S&W
8.3 Mountings
A side B side
8075.cpt 8076.cpt
8077.cpt
8078.cpt
8-6 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
8.4 Sensors at the turning drum
Overview at the A side
1 Motor for gripper opening cam

2 Turning drum
3 Pneumatic piston for turning cam
4 Sensor B88.1, first side cam
5 Sensor B87.1, second side cam
6 Storage drum
7 Sensor, tensioning disk, B89.1
8 Tensioning disk
9 Limit switch S638
10 Sensor, clamping disk B89
11 clamping disk
12 Turning drum
Overview at the B side
1 Contact plate for R302, on sprocket wheel shaft

2 Sensor B120
3 Contact plate on 3rd transfer cylinder
4 Transmitter for missing sheet sensor
5 Pneumatic piston for turning cam
6 Sensors, S cam B87, P cam B88
7 First side cam valve
8 Second side cam valve
As of series 325, valves 7 and 8

are not provided because they are
included in the pneumatic block.
C 95A 6423 39 – 12. Nov. 2003 8-7

8A S&W
B 87 Initiator, single-side-p. curve, O-side A350/5 B.B 8.2
B 87/1 Initiator, single-side-p. curve, D-side A350/5 B.B 9.0 PO

A350/13 Y109
B 88 Initiator,second-side-p. curve, O-side A350/5 B.B 8.3 B.B 18.2
Magnet valve,
B 88/1 Initiator, second-side-p. curve, D-side A350/5 B.B 9.1 single side printing
A335, X62, KNO.: 0025
B 89 Clamping, clamping disk A350/5 B.B 8.4
MMS
B 89/1 Clamping, tensioning disk A350/5 B.B 8.5
B 120 reference point, machine size A350/5 B.B 8.1 PO

A350/13 Y110
B 124 Initiato, machine cycle, storage drum A350/5 B.B 9.7 B.B 18.3
Magnet valve,
S 638 Limit switch, protection guard A350/5 B.B 3.5 second side printing
8041e.cdr A335, X79, KNO:. 0012
B 116 Missing sheet detector
8-8 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
Active sensors when perfecting
Position of the cams in straight printing mode

Sensors B 87 and B 87.1 are active
B-Seite A-Seite
Operating side Drive side
Kurven
cams
0,5 0,5
B 87.1
B 88.1
B 89
B 89.1
B 87
B 88 S 638
8043.cdr
Position of the cams in perfecting mode

Sensors B 88 and B 88.1 are active
C 95A 6423 39 – 12. Nov. 2003 8-9

8A S&W
Setting the sensors

Sensor B 120
- Sensor B 120 provides an additional check of the changeover position.
- If the control detects a difference between the mechanical position and the
calculated position, the cams will not switch.
In this case, a blinking "85" appears in the 7-segment display.
Checks:
- To check the switching time, the press must always be turned forwards!
- The press must be in straight printing mode.
- To exactly determine the switching time, turn the press with the crank handle!
- Switching distance from sensor to contact plate ~ 0.7 mm.
-
Turning between Changeover B120 covered

PU position
From to
1-2 265° 260° 270°
2-3 170° 165° 175°
3-4 75° 70° 80°
4-5 340° 335° 345°
On the R302 the contact plate is On the R304 to R308 the contact plate is
mounted on the sprocket wheel shaft. mounted on the 1st transfer cylinder.
8-10 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
Cam adjustment on the A side
Sensors B 87.1 and B 88.1
Sensor B 87.1
Single side cam
Sensor B 88.1
Second side cam
8079.cpt
Explanation:
- There is a permanent magnet inside the pneumatic piston which
affects the initiators.
- When setting the initiators, the direction of travel of
the magnet inside the block must be considered.
Setting:
- Press in straight printing position
- Push sensor B 87.1 away from the sideframe until the LED lights up, go 1 mm further and then fasten it.
- Press in perfecting position
- Push sensor B 88.1 away from the sideframe until the LED lights up, go 1 mm further and then fasten it.
Cam adjustment on the B side

Sensors B 87 and B 88
Setting:
- Press in straight printing position
- Push sensor B 87 towards the sideframe
until the LED lights up, go 1 mm further and then fasten it.
- Press in perfecting position
- Push sensor B 88 away from the sideframe until the LED
lights up, go 1 mm further and then fasten it.
Switching distance sensor / rail ~ 0,7 mm
8080.cpt
8081.cpt
C 95A 6423 39 – 12. Nov. 2003 8-11

8A S&W
8.5 Gear wheel clamp

Series 310 to 324
1 Sensor B 89.1 to tensioning disk

2 Sensor B 89 to clamping disk
A 0.5mm with screw tight.

B Clamping screw
C ~ 3,2 mm with clamping screw
tight and switch plate engaged.
D Bond the screws with Delo ML
5249
8082.cpt
8085.cpt
8-12 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
Setting the clamp segments
Series 310 to 324
Setting gauge
Nr. 760 009-22
Shim 0,1 mm 8086.cpt
Settings:
- Check cylinder gears (7) for horizontal run-out, max. 0.02 mm.
- Turn the cylinder screws (2) to move the pressure bolt 24.2 mm out of the seat (1).
The clamping screw (2) must be resting on the pressure bolt (4).
Use setting gauge no. 760 009-22.
- Coat the screws (6) with Delo ML 5249.
Fasten the clamp segments (5) with the screws (6) to the cylinder gears (7).
- Before tightening the screws (6), place 0.1 mm shims between
contact surface and cylinder gear.
- Tighten the screws evenly with a pressure of 10 Nm. Once the screw bonding has
hardened (hand tight), loosen clamping screw (2). Remove the shims.
- Use plastic caps to prevent the hexagon socket of the cylinder screws (6) turning.
- Before screwing the clamping screw (2) in, apply a sufficient amount of Molykote 1000
to the thread of the clamping screw and the pressure bolt.
C 95A 6423 39 – 12. Nov. 2003 8-13

8A S&W
Setting the clamping screw and sensors

Series 310 to 324
Setting the clamping disk
In order to achieve the necessary clamping power on the gear wheel, the clamping screw (4) must be tightened
with a torque of 180 N/m.
Repeat this procedure a few times so that the parts can settle.
Then set the clamp ring (2) in engaged position 2.5 mm away from the clamping disk(3) and firmly fasten the ring
to the head of the screw.
Attention:
- The clamping disk must have sufficient switch activation distance
when the clamping screw (4) is loosened.
- In the disengaged position, the gap between the clamp ring (2)
and clamping disk (3) must be at least 0.5 mm !
Sensors: In engaged position, gap between: tensioning disk/sensor B 89.1 ~ 0.6 mm

Clamping disk/sensor B 89 ~ 3.2 mm
8088.cpt
8087.cpt
1 Sensor B 89.1
2 Clamp ring
3 Clamping disk
4 Clamping screw
5 Sensor B 89
6 tensioning disk
8-14 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
Clamp closed
1 Gear
2 Tensioning disk
3 Clamping disk
The following clamp conditions are possible:
B89 B89.1 Condition

Clamping disk Tensioning disk
0 0 Malfunction
0 1 Clamp closed
1 0 Clamp open
1 1 Clamp released
Setting the sensors B89 and B89.1
a) With the clamp open (1/2 to max. 3/4 turn), set the sensors so that B89.1 is exactly
"0" and B89 is exactly "1".
b) Check switching distance (run press at crawl speed).
c) Check whether the clamp is actually open when "2" blinks in the 7-segment display.
d) Close the clamp (Clamping disk (3) engages) and check that sensor 89.1 is ”1” and
sensor B89 is ”0”. (Caution: sensor B89.1 has a hysteresis.)
C 95A 6423 39 – 12. Nov. 2003 8-15

8A S&W
Series 325 till 327
8083.cpt
8089.cpt
8-16 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
Setting the clamping segments
Series 325 to 327
Setting:
- Turn the clamping screw (4) to move the pressure bolt (3)
out of the seat (5).
Use a ruler (setting gauge) to check that the pressure bolt (3)
is at the same height as the face of the gear wheel.
The clamping screw (4) must be resting on the support bolt (6).
- Coat the threads of the screws (7) with Delo ML 5249.
Fasten the clamp body (1) with the screws (7) to the cylinder
gears (2).
- Before tightening the screws (7), place 0.1 mm spacer plates
between contact surface and cylinder gear.
- Tighten the screws evenly with a pressure of 10 Nm.
Once the screw bonding has hardened (hand tight), loosen
clamping screw (4). Remove the spacer plates.
- Use plastic caps to secure the hexagon socket of the
screws (7).
- Before screwing the clamping screw (4) in, apply a sufficient
amount of Molykote 1000 to the thread and pressure bolt.
8091.cpt
Installation of the clamping disk
Installation instructions:
The clamping disk is fitted in the press position given below:

- Turn single printing units (with degree disk) to
”0” degrees
(changeover position for perfecting)
- Turn assembled presses to the degree number
given below (display at PU1).
Sheet turning between: PU 1 and 2 = 265°

PU 2 and 3 = 170°
PU 3 and 4 = 75°
PU 4 and 5 = 340°
To fit the clamping disk:
Stop (1) points upwards (12 o'clock), segment (6) below left
(7 o'clock).
1 Stop in straight printing position

2 Gear wheel
3 M20 tapped hole
4 Locating key for pressure bolt
5 Clamping disk retaining bolt
6 Segment on clamping disk
C 95A 6423 39 – 12. Nov. 2003 8-17

8A S&W
Setting the clamping screw and sensors

from series 325 to ...
1 Screw
2 Clamping screw
3 Carriers on clamp ring
4 Clamp ring
Setting the switch plate:
In order to achieve the necessary clamping power on the gear 8090.cpt

wheel, the clamping screw (4) must be tightened with a torque
of 180 N/m. Repeat this procedure a few times so that the Clamp closed
parts can settle.
Then mount the clamp ring (4), in engaged condition, on the
clamping screw head so that the carrier (3) engages in the
clamping disk. If this is not possible, tighten the clamping screw (2)
a little more.
Set a distance of 3.5 to 4 mm between clamping disk and clamp ring
and tighten the clamp screw (1).
The following clamp conditions are possible:
B89 B89.1 Condition

Clamping disk Clamping disk
segment
0 0 Clamp released
0 1 Clamp open
1 0 Clamp closed
1 1 Malfunction
When the clamp opens, the spring washer raises

and covers sensor B89.
The input -A350/5 Byte 8, Bit 4 becomes LOW
(sensor B89 is LOW active).
After approx. a 3/4 turn to the left, sensor B89.1
is covered by the clamping disk segment
and the input -A350/5 Byte 8, Bit 5 becomes HIGH.
"2" appears in the 7-segment display of the perfecting station.
Clamp open
8-18 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
Series 328 to .......
8084.cpt
C 95A 6423 39 – 12. Nov. 2003 8-19

8A S&W
Setting the clamp segments

Series 328 to ...
Setting:
- Turn the clamping screw (4) to move the pressure bolt (3)
out of the seat (5).
Use a ruler to check that the pressure bolt (3) is at the same
height as the disk (gear wheel face + 3mm).
The clamping screw (4) must be resting on the support bolt (6).
Coat the threads of the screws (7) with Delo ML 5249.
Fasten the clamp body (1) with the screws (7) to the cylinder
gears (2).
- Place 0.1 mm spacer plates between clamp body and disk
(or between disk and gear wheel).
- Tighten opposed screws (7) to 10 Nm.
- Remove the spacer plates.
- Tighten clamping screw (4) with 200 Nm.
- Tighten screws (7) crosswise to 80 Nm.
- Loosen clamping screw (4) then tighten it again with 200 Nm.
The entire setting should be done quickly and without interruption.
- After the screw bonding (Delo) has hardened, secure the clamping
screws (7) with plastic caps.
- Before screwing the clamping screw (4) in, apply a sufficient 8092.cpt
amount of Molykote 1000 to the thread and pressure bolt.
Installation of the clamping disk

Series 328 ...
installation instructions:
The clamping disk is fitted in the press position given

below:
- Turn single printing units (with degree disk) to
”0” degrees
(changeover position for perfecting)
- Turn assembled presses to the degree number
given below (display at PU1).
Sheet turning between: PU 1 and 2 = 265°

PU 2 and 3 = 170°
PU 3 and 4 = 75°
PU 4 and 5 = 340°
To fit the clamping disk:
Stop (1) points upwards (12 o'clock), segment (6) below left
(7 o'clock).
1 Stop in straight printing position

2 Gear wheel
3 M20 tapped hole
4 Locating key for pressure bolt
5 Clamping disk retaining bolt
6 Segment on clamping disk
8-20 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
Mountings and gear wheel clamp from series 334 to ....
From series 339

1 Flat greasenippel
2 Grease entrance
Grease No.094S025440
Microlube GL 261,
Klüber Lubrication
Sectional view from the side, gear wheel clamp is closed, the cams are in perfecting mode position.
Cams for straight printing mode and perfecting mode are one piece, and spouted out with SKC.
Only in a certain position the cams can be mounted to the cam holder.
The cams can only be set with the bearing bush.
Setting of the clamp segments: refer to series 328
From series 339, cams and camholder are one piece.
C 95A 6423 39 – 12. Nov. 2003 8-21

8A S&W
1 Pneumatic cylinder (stroke 25mm).

2 O-Ring, to seal the air chamber.
3 Screw, set with 0,5mm clearance to the cam holder and secured with DELO 5249.
Sensors
Straight printing mode – position:
The piston rod is retracted and both sensors are covered.

Distance between the guiding bolt and sensors 0,7mm
B087.1 / B088.1 = 1 / 0 in straight printing mode
Perfecting mode – position:
The piston rod is extended and both sensors are not covered 1 guiding
2 guiding bolt
B087.1 / B088.1 = 0 / 1 in perfecting mode
8-22 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
Cam adjustment at the B side
Series 310 to 328
The pneumatic piston moves the cam over the bar and bolts.
The bearing bushing serves as a cam guide.
The diagram shows the cam in perfecting position.
8101.cpt 8103.cpt
From series 329

The pneumatic piston moves the cam over the bar and hexagonal bolts.
The bolts are fixed in the sideframes and serve as cam guides.
The diagram shows the cam in perfecting position.
8104.cpt 8102.cpt
C 95A 6423 39 – 12. Nov. 2003 8-23

8A S&W
Special design
1 Bar
2 Stud bolt
3 Spring washer assembly,
8 x 092G 7555 40
4 Locknut
5 Setting nut
6 Lubrication hole
Tasks:
- Change the press over to straight printing mode and stop it in the changeover position.
Lock the press with STOP (SECURITY) !
- Remove the guards on the B side of the turning station concerned.
It is only necessary to loosen the front half of the cover.
- Remove rail (1) and stud bolts (2).
Assembly:
- Screw in the new stud bolts and mount the spring washer assemblies (each 8 x 092G 7555 40)
according to the arrangement shown above.
- Fasten the new bar and mount the spring washer assemblies and nuts.
Setting:
- In the straight printing position, the control cam must be set to a distance of 0.5 mm from the
sideframe. If necessary put washers between the bar (1) and the pneumatic piston.
- Switch the cams manually to perfecting at the control valve Y109/Y110.
- Screw the setting nuts (5) on the spring washers into contact, prestress them by turning 8 flats
further and secure them with the locknuts (4).
- Switch the cams back to the straight printing position and replace the guards.
Attention: When carrying out repairs and when compressed air is turned off, be careful of the perfecting
cam on the B side when turning the press! The cam can collide with the segment lever!
Check:
- Check with a grease gun that the lubrication hole (6) is actually drilled.
8-24 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
8.6 Turning drum

Setting the gripper margin.
Position: Transfer line turning drum to impression cylinder.
2 Gauge
3 Turning drum
Turning drum Transfer line at

between
1 and 2 239°
2 and 3 144°
3 and 4 49°
4 and 5 314°
Example: Turning drum in 2nd printing unit
Prerequisites: Press is in straight printing mode

A degree disk is mounted in the 2nd printing unit!
− Turn the 2nd printing unit to the transfer line and secure it.
(degree disk in 2nd printing unit at 334°, with an assembled press 239° in the display of printing unit 1)
− Rotate the turning drum so that there is a distance of 1.6 mm between the gripper tips of the straight printing
gripper system and the impression cylinder front edge. Check this with a gauge.
− Tighten the four screws on the cover plate and pin the cover plate to the cylinder shaft.
Adjusting the transfer cams:
Degrees will be shown in display at printing unit 1

Check with a feeler gauge that there is 0.1 mm between grippers and gripper pads.
Straight printing grippers open at 335° and close at 148°.
Perfecting grippers close at 94°.
See Chapter 2 "Reverence values" for further information.
C 95A 6423 39 – 12. Nov. 2003 8-25

8A S&W
Perfecting stops of the gripper systems
Note: The stops are set to exactly 0.01 mm in the factory.

They are an absolute prerequisite for proper function of the turning drum.
We recommend that you never dismount the stops!
During repairs, do not loosen the stops, take them out together with the gripper system!
Distance between the spindles: 37.25 mm

Distance between spindles and shafts: 5.11 mm
8093.cpt
First side stop Second side stop
8094.cpt 8095.cpt
Prerequisites:
The bearing blocks in the cylinder are aligned.
The stops (at bearing blocks) and spindles are mounted.
First side printing stops:

The height of the four stops are set in the factory so that there
is a distance of 37.25 mm between the gripper spindles
and 5.11 mm between the gripper spindles and the shafts.
Second side stops:

To set the second side stops, the tension springs and chains must be mounted!
Bring both gripper systems to the perfecting position.
At the B side (S I), set 26.1 mm (from series 334 25,6mm) to the spindle.
At the A side (S II), the dimension 26.07 mm (from series 334 25,57mm)results from torsioning the shaft.
Push the stops apart sideways and adjust them to the gripper spindle bearings.
Pin the stops after they are adjusted.
8-26 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
Base position of the gripper spindle stops
Prerequisites:
- The first and second side stops are set.
- All parts needed for setting are mounted.
Adjustment:
− Extend the screw-down surface
of the gripper pad mounting with a rail.
− Place device on the shafts.
− Turn the shafts so that the rail
touches the edge of the device.
Perfecting side 61° 35´
Straight printing side 61° 52´
− Set the shafts with no lateral play
and pin the stops.
1 2 3 4
24,8 25
8053.cdr
Gripper pads and springs
1 Second side gripper pads, height 24.8 mm

2 Each of the outer 3 springs with 25N, inner 8 springs with 12N
3 13 springs with 9N
4 First side gripper pads, height 25 mm
Note: From series 320, the perfecting gripper pads are equipped with a sheet guide (sheet metal rail).
Requiered glue:
1. Loctite cleaner 7063 (green tin)
2. Loctite activator 7649 (green bottle)
3. Loctite Kleber 326 (yellow bottle)
C 95A 6423 39 – 12. Nov. 2003 8-27

8A S&W
Movement of the tumbling shafts.

Up to series 336 chains for the Movement of the tumbling shafts.
8064.cdr
From series 337 steel wire for the movement of the tumbling shafts.
8063.cdr
8-28 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
Base setting of the anchor cam
Adjustment:
− The press must be in straight printing mode.

− Stop the press so that the support roller stands
at minimum radius.
− Place gripper setting gauge (7.68 mm) between
support roller and cam.
(Use the device, see Chapter 3)
− Turn the eccentric bolts (7) of the support roller
in the arrow direction so that the anchor cam also
moves in the arrow direction (see diagram). X
− Place an angle bracket on the gripper spindles and
extend
the edge of the anchor cam.
− The correct position is reached when the edge
of the anchor cam stands 90° to the gripper spindles.
X = 44.61 mm
X = 30.11mm (from series 334, thicker shaft)
This dimension X is only for internal use.
In the press:
X = cam + gauge of 7.68 mm 8054b
Cam holder (1) with anchor cam (11) as well

as gripper spindles with gripper crank (4)
8097.cpt
Control with roller lever (5) and eccentric bolt (7)
8098.cpt
C 95A 6423 39 – 12. Nov. 2003 8-29

8A S&W
Base setting of the two gripper cranks
Prerequisites:
− Press is in straight printing mode.
− The anchor cam has been set.
− The support roller stands at minimum radius
− The gripper setting gauge (7.68 mm) is between the support roller and the cam.
Setting:
− Clamp an 0.45 mm feeler gauge package (9 x 0.05 mm) between each of the cam followers
and the anchor cam simultaneously.
− All grippers must be contacting the pads by spring pressure.
− In this position, turn the gripper spindles so that there is a distance of 0.7 to 0.8 mm
between the hexagonal stop and the underside of the gripper.
One of the flats of the hexagonal stop must be parallel to the underside of the gripper!
− Set the gripper cranks with no lateral play, clamp them to gripper spindle and pin them.
− Adjust all the grippers (see Chapter 3).
8-30 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
Shaft control when perfecting
Segment lever mountings In assembled condition
8099.cpt
8100.cpt
Assembling the gears, segments and segment lever:
− The press must be in straight printing mode.
− Check whether the first side stops are in contact.
− Mount both gears on the shafts so that
a) one tooth fits into the 4th tooth space of the segment (see marking in diagram)
b) there is 0.4 - 0.5 mm distance between the straightedge and the tooth tips.
If necessary, dismount the gears and put them back in a more favourable position.
− Mounting the gears like this ensures that the setting distance of the eccentric is sufficient.
Segment lever:
− Fasten the segment to the segment lever and mount the segment lever.
− First check gear backlash (0.02 - 0.05mm) then pin the segment to the segment lever.
− Set the high point of the cam roller eccentric to the cylinder axle.
− Mount the segment lever.
Setting the eccentric: see next page.
C 95A 6423 39 – 12. Nov. 2003 8-31

8A S&W
Setting the cam rollers on the segment lever
1 Beginning of cam contact

2 End of cam contact
3 The high point of the cam is between
these markings
A1+A2 first side stops
B1+B2 second side stops
D1+D2 Segment lever fulcrums
E1+E2 Cam roller eccentrics
M Middle point of the cylinder axle
W Second side print
S First side print
Adjusting the eccentric:

− Set press to perfecting mode
− Place two steel shims (0.03 x 500 mm) between the verso print stops.
− Turn the press carefully until the cam rollers stand at the high point of the cam
(between the markings 3).
− Turn the eccentric in arrow direction until the shims are clamped.
Turn the eccentric back just a little, remove the shims and lock the eccentric.
− Check beginning of cam contact / end of cam contact (1+2) of the cam rollers.
− Attention: The two cam rollers must not touch one another!
General repair hints:

− During repairs, always pull the pins of the stops and check them.
− In the event of damage to the segment lever etc., release the tension on both gripper shafts
and check that they move freely. Check that the gear journal is concentric.
8-32 C 95A 6423 39 – 12. Nov. 2003

S&W 8A
Sheet turning diagnosis
In the event of sheet turning malfunctions,

using a crank handle to move the press in any manner is FORBIDDEN !
The R 300 sheet turning system is equipped with active error correction which
in most cases permits compulsory changeover to straight printing
i.e. the control tolerates the failure of certain assemblies)
The compulsory changeover is menu controlled from the
perfecting station and therefore easily carried out.
Trouble
When errors occur, there are perfecting
two fundamental procedures:
POWER OFF/ON does not help because the error

will only appear again and, depending on the
nature of the error, a compulsory changeover cannot
be avoided.
Trouble shooting and Active failure correction
acknowledgement at the action:
console
After the error has been corrected, it is strongly Forced change-over into
recommended to make another changeover! Machine is released for all single side printing mode
operation
Machine released for
To be done only by trained operations in single side
personal printing mode only
7-segment display at the turning station
Different perfecting error numbers are displayed at the printing unit.

So that error conditions can be eliminated better, the display at the printing unit
always first shows the error that must be eliminated first.
Once the first error has been eliminated, the next error is indicated or compulsory
changeover to first side printing is activated automatically.
Error-codes at the 7-segment display at the perfecting unit

80 Perfecting printing-cam. D-side not activated
81 Perfecting printing-cam. O-side not activated
82 Single side printing-cam. D-side not activated
83 Single side printing-cam. O-side not activated
The errors 82 and 83 require electrical or mechanical trouble shooting and the error message
(38 036 or 38 045 or 38 046) has to be acknowledged.
85 Sensor (B120 reference point machine size)electrically or mechanically defective
87 Sequence units left reverse position (size error)
The error message (38041)at the console has to be acknowledged, and a forced change-over
into single side printing has to be realised (sensor searching mode).
88 Clamping should not be open/closed
89 Position was not reached correctly.
The error message (17 aaa 00)at the console has to be acknowledged to continue the
change-over
It is recommended to repeat the whole change-over , because the machine size is no longer
correct
Attention: Errors 80, 81 and 82, 83 can be confused with software versions prior to A310A1!
C 95A 6423 39 – 12. Nov. 2003 8-33

8A S&W
8-34 C 95A 6423 39 – 12. Nov. 2003

Delivery
9
9 Delivery
9.1 Mounting ........................................................................................ 9-3
9.2 Programmed switching device..................................................... 9-4
9.3 Pile supporting plate ..................................................................... 9-5
9.4 Transfer line ................................................................................... 9-6
9.5 Delivery chains .............................................................................. 9-8
9.6 Gripper opening cam .................................................................. 9-11
9.7 Sheet jogger................................................................................. 9-12
9.8 Suction roller ............................................................................... 9-13
9.9 Air control .................................................................................... 9-14
9.10 Lubrication ................................................................................... 9-15
C 95A 6423 39 - 12. Nov. 2003 9-1

9 Delivery
9-2 C 95A 6423 39 - 12. Nov. 2003

Delivery
9
9.1 Mounting
Sprocket wheel shaft
A side B side
up to series 321
As from series 322
C 95A 6423 39 - 12. Nov. 2003 9-3

9 Delivery
9.2 Programmed switching device

Programmed switching device A 366
1 2 3 4 5 6
1 S600 Pile down
2 S613 Pile up
Paper stop 3 Reserve
4 S615 Pile up to 50mm
5 S621 Pile down 120mm
5 6 S622 Pile down 120mm
Pile table
12.1 12.0 12.2 Lower edge

Paper stops
-S830*
sideframe
-S803
-S802
3.3
S 618
-S675
242
292 140
S 613
50 S 615
max. limit is reached
Cable limit
with table
with rake
Programmed switching switch S 670

device A366
with table 1 1 1
without table 0 1 1
with rake 1 0 1 Pile motor
table at max. limit 1 0 1 M 006
rake at max. limit 1 0 0
S 621 +
S 622
120
S 600
3K09_07E.cdr A-side B-side
• When installing the press, the two pile guide rails must be checked and if necessary
lengthened or shortened!
• If the press is to be installed on a higher or lower level than in the factory,
the switching point of 120 mm (S 621 and S 622) between the floor and underside of
the pile supporting plate (S 600) must be checked and readjusted.
• When adjusting the setting disc S600 "Pile fully down", be sure that the pile table is on the ground
but the cable limit switch S 670 has not yet switched.
• The upper switch point S 613 must be set so that the top edge of the pile table stands
max. 5mm above the sheet stops.
• The uppermost limit of the pile is switch S 618 on the suction roller.
*S830 (old designationS804)
9-4 C 95A 6423 39 - 12. Nov. 2003

Delivery
9
9.3 Pile supporting plate
Cables and cable limit switch S670
Adjustment: Cable limit switch S670
Raise the pile table slightly so that it

is off the ground.
Align the suspension so that the pile table

Is lying horizontal and all cables are evenly
tensioned.
Now open the regulating screw until the

cable limit switch S 670 switches.
Check: when the cable is slackened, the pile motor
M 006 must stop!
Once the pile supporting plate has reached the ground, the cable
limit switch must NOT switch!
1 Regulating screw
2 Grub screw
From series 328, larger deflection pulleys are used for the steel
cable. The fastening bolts (screws) for the steel cable above the
deflection pulleys are now accessible from the outside.
These can be retrofitted, see Fitter Info 29/98
9.4
C 95A 6423 39 - 12. Nov. 2003 9-5

9 Delivery
Transfer line
Impression cylinder / Delivery gripper fields
Impression cylinder
3K09_01.cdr
B side inner
A = Distance from 13 chain roller seats.
The seat of a gripper system has a length of three chain rollers.
The gripper system is mounted to the sprocket wheel so that there are 13 chain roller seats on both sides
remaining to the 1st mounting hole.
The screws of the chain guides behind the sprocket wheels can be accessed through the mounting holes. To do
this, the last printing unit must be turned to a certain position.
9-6 C 95A 6423 39 - 12. Nov. 2003

Delivery
9
1. Torsion bar
2. Shoulder bolt, 45Nm
Shoulder bolt ∅ 10mm, Shoulder bolt torque = 45Nm, use thread locker!!.
Prestress of the torsion bar: Prestress moment = 1547 +/- 200Ncm, prestress angle 46.5°.
Checking the gripper margin - frontlays in middle position
See the table in Chapter 2 for information on degrees for the transfer line.
Turn the press to the transfer point and use gauge no. 099J0774 13 to check that
the distance between the delivery gripper tip and impression cylinder edge is 1.6 mm.
Attention: Lock the press!

If necessary, loosen and reset the screws on the sprocket wheels (A and B side).
Run paper through the press until the sheets are in the delivery grippers.
Make a mark on the gripper tips, run the sheets out of the press and check the gripper margin.
It should be 5.8 mm. Reset if necessary.
Check all gripper fields (8x or 11x)!
Attention:The gripper margin for presses with a coating module and extended delivery should be 4mm!
C 95A 6423 39 - 12. Nov. 2003 9-7

9 Delivery
9.5 Delivery chains
The delivery chains run in an enclosed system i.e. they are always driven by the chain guides.
It is normally not necessary to retighten the chains.
But in case this must be done, proceed as follows:
Note: The maximum retightening distance is 5 mm!
If this is not sufficient, they must be replaced. For more information see next pages
1. Inch the press forwards until the three fastening bolts of the bearing block can be seen
through the holes in the front sprocket wheel. Now lock the press!
2. Open the three bolts of the bearing block through the holes in the sprocket wheel.
(A to B side laterally reversed)
3. Loosen three screws from the front chain guide (4)
4. Loosen four screws from the plate (3)
(There are ten screws to loosen at both A and B sides)
A side inner
1 Chain guide
2 Gripper field
3 Plate
4 Front chain guide
5 Sprocket wheel
9-8 C 95A 6423 39 - 12. Nov. 2003

Delivery
9
Tensioning the chains
1 Chain guide
2 Height = 1 x roller diameter
3 Setting screw
Dismount chain guide (1) so the gripper field can be raised.

The chain can be tensioned by turning the setting screw.
Always tension A and B sides evenly!
Check: It should be possible to raise the gripper field between 10 mm and one chain roller diameter!
Replace all parts and tighten the screws.
Attention: Set the front chain guide with 0.1 mm play to the chain and check the chain guide junctions.
C 95A 6423 39 - 12. Nov. 2003 9-9

9 Delivery
Chain designations
A 736.50 mm (27 rollers and 1 special link)

B 13 rollers
C Special link for mounting the gripper field
D 14 rollers
XX Coulor code
Arranged and colour-coded in groups:
Gr. 1 736.16 to 736.27 blue

Gr. 2 736.28 to 736.39 red
Gr. 3 736.40 to 736.50 white
Gr. 4 736.51 to 736.61 green
Gr. 5 736.62 to 736.72 yellow
Gr. 6 736.73 to 736.84 black
Note: Only two different groups can be used in any one delivery,
whereby the designation of the respective groups is not fixed.
Only adjacent groups can be combined!
Possible combinations: Gr. 1 + Gr. 2, blue + red (shortest chain)

Gr. 2 + Gr. 3, red + white
Gr. 3 + Gr. 4, white + green
Gr. 4 + Gr. 5, green + yellow
Gr. 5 + Gr. 6, yellow + black (longest chain)
Normal delivery, A and B side 8x chain segments

Extended delivery, A and B side 11x chain segments
♦ Combinations presently delivered: for normal delivery = 7x blue + 1x red

for extended delivery = 9x blue + 2x red
The chain guide rails are set with a tolerance of 16 ± 0.05 mm. Gauge 343T380313
Reinforced chains from series 341 due to increased performance to 16000s/h
9-10 C 95A 6423 39 - 12. Nov. 2003

Delivery
9
9.6 Gripper opening cam
Servomotor: Unit 1, Drive No.: 4, Bus address no.: 63
View from B side
1 Potentiometer shaft
2 Potentiometer
3 Motor M349
4 Stop or locknut
5 Gripper opening cam
1 Plug the hand terminal into the delivery

2 Press the reset switch in the switch cabinet A side (active mode). Only to be done by an electrician!
3 Input code and select Menu 7
4 Select menu 7, input code and select Bus address no. 63
5 Use the arrow keys to move the cam to a distance of 1 mm from the stop (2)
Spread a thin layer of grease on the gripper opening cam run-in area, run the press
for a short time then check the cam follower touchdown point.
Up to series touchdown point 25 mm
As from series touchdown point 42 mm
6 In Menu 7, set potentiometer voltage to the value of 8864mV
or in Menu 6 to 27.4mm
7 Turn main switch off and then on again. .
Menü 6 Menü 7 7-segment display

27,4mm 8864mV "99“
C 95A 6423 39 - 12. Nov. 2003 9-11

9 Delivery
9.7 Sheet jogger
A side, Stepper motor, Drive no. 2, Bus address no. 61

B side, Stepper motor, Drive no. 3, Bus address no. 62
Attention: During setting, the sheet jogger must be disengaged. ("0" position)
Example for the A side, set the B side in the same manner
1. Plug the hand terminal into the delivery

2. Press the reset switch in the switch cabinet A side (active mode). Only to be done by an electrician!
3. Enter code and select Menu 8
4. Select drive no. 2 and check the sensors, cover the sensor with a metal strip,
min. - max.- sensor should change from ON to OFF
5. Select Menu 7, enter code and select Bus address no. 61
6. Use the arrow keys to move the sheet jogger 147.5 mm away from the A side sideframe
7. Leave Menu 7 via Exit and select Menu 8
8. Call drive no. 2 and set min. sensor (from ON to OFF)
9. Leave Menu 8 via Exit and select menu 6
10. Select drive no. 2 and carry out AUTO CALIB
11. Move a total distance of 230 mm (with A4, 235 mm) and set max. sensor
to 3 mm distance
12. Move sheet jogger back to 0 mm
9-12 C 95A 6423 39 - 12. Nov. 2003

Delivery
9
9.8 Suction roller
Stepper motor, Unit 1, Drive no. 1, Bus address no. 60
1 Sheet stop
2 Stop screw
3 Sheet stop on the suction roller
4 Suction wheels
5 Stop screw
6 Regulating motor M 346 (at 99% = 300 rpm)
1. Plug the hand terminal into the delivery

4. Select drive no. 1 and check the sensors, cover the sensor with a metal strip,
min. - max.- sensor should change from ON to OFF
5. Select Menu 7, enter code and select Bus address no. 60
6. Use the arrow keys to move the suction roller 610mm away from the sheet stop
7. Leave Menu 7 via Exit and select Menu 8
8. Call drive no. 1 and set min. sensor (from ON to OFF)
9. Leave Menu 8 via Exit and select menu 6
10. Select drive no. 1 and carry out AUTO CALIB
11. Set stop screw (5) to 3 mm distance and lock it
12. Move a total distance of 350 mm (with A4, 400 mm) and set max. sensor
to 2 mm distance
13. Set stop screw (2) to 3 mm distance and lock it
14. Move suction roller back to 0 mm
C 95A 6423 39 - 12. Nov. 2003 9-13

9 Delivery
9.9 Air control
Standard delivery
Blowing suction / blowing
3K09_11E.cdr
blowing /suction blowing / suction

(Option:Preparation for water cooling)
Extended delivery and coating module
Blowing 5x blowing/suction 5x blowing/suction 5x blowing
3K09_12E.cdr
5x blowing/suction 5xblowing/suction 5x blowing/suction 5x blowing
The arrows indicate the primary direction of air flow.

During the installation of the ventilators you should pay close attention to the air flow indicator arrows.
9-14 C 95A 6423 39 - 12. Nov. 2003

Delivery
9
9.10 Lubrication
Lubricating the delivery chains
The oil pump (LA8) for the delivery is kept in the central lubrication station.
As from series 325, the oil pump (LA8) is mounted at the delivery, B side.
The progressive distributor at the delivery B side is no longer needed.
Supply tank
BMK Function I/O

B129 Stroke magnet control -A353/7, 10.3
B130 Level control -A353/7, 10.0
Y123 Stroke magnet -A353/13; 17.6
C 95A 6423 39 - 12. Nov. 2003 9-15

9 Delivery
Dosage pump stroke magnet
If lubricant (LA 8) penetrates into the magnet and the front chamber of the dosage pump magnet, this blocks the
stroke.
To clean older dosage pumps, the magnet must be removed.

With pumps supplied as from December 1995, the LA 8 can be drained off through a drain plug at the bottom of the
pump.
In both cases, the magnet and front chamber need to be cleaned and filled with "ARAL DE22" oil prior to closing.
This is already done in the factory to impede penetration by the LA 8 lubricant.
If the magnets are assembled without this filling of oil, the dosage pump will break down almost immediately.
New pumps for delivery chain lubrication have been provided as from series 328 (a round magnet, identical to that
used on the R700).
9-16 C 95A 6423 39 - 12. Nov. 2003

Inking unit
10
10 Inking unit
10.1 Mounting position / Oscillation timing....................................... 10-3

Mounting position inking unit to printing unit .................................. 10-3
10.2 Inking rollers ................................................................................ 10-4
Roller diagram ............................................................................... 10-4
Rollers - Table ............................................................................... 10-5
Rollers - removing and fitting ......................................................... 10-6
Rollers - locks and semi-shells ...................................................... 10-7
Spring-loaded transfer and intermediate rollers............................. 10-8
Rollers - adjustment screws........................................................... 10-9
Rollers - adjustment..................................................................... 10-10
Inking forme rollers ...................................................................... 10-13
10.3 Ink distributors .......................................................................... 10-14
Dismounting................................................................................. 10-14
Mounting...................................................................................... 10-14
10.4 Oscillation .................................................................................. 10-15
Mounting instructions................................................................... 10-15
10.5 Ductor roller ............................................................................... 10-18
Ductor roller - control ................................................................... 10-18
Ductor roller – Stripe width .......................................................... 10-19
Mounting...................................................................................... 10-20
10.6 Ink fountain roller ...................................................................... 10-21
Construction of the ink fountain roller .......................................... 10-21
10.7 Ink fountain ................................................................................ 10-22
10.8 Ink slides .................................................................................... 10-23
Ink slide construction ................................................................... 10-23
Exchanging ink slides .................................................................. 10-24
C 95A 6423 39 – 12. Nov. 2003 10-1

10 Inking unit
C 95A 6423 39 – 12. Nov. 2003 10-2

Inking unit
10
10.1 Mounting position / Oscillation timing
Mounting position inking unit to printing unit
- Plunger pin for coarse register adjustment engaged.

- Indicator (4) points to "G" and stands at the right side (to feeder).
- Oscillation is set to max. 38,5 mm (earlier 35 mm) oscillation stroke.
- The oscillation drive (2) is parallel to the guide (3).
1 Fountain roller drive

2 Oscillation drive
3 Guide
4 Indicator (drill ø 3 mm)
5 Plate cylinder gear
View from B side
Mounting the inking unit on the 1st printing unit
- The diagram above shows the inking unit from the B side.
- In this position, the inking unit is mounted on the printing unit at 249° (from series 315).
From series 311 to 314, position from printing unit: 63°

From series 315 onwards, position from printing unit: 249°
To do this work in the intermediate printing unit, a degree disk must be fitted (see Chapter 2).
Aligning the inking unit:

Locating keys are screwed onto the printing unit sideframes as guides so that the inking unit only needs to be
aligned laterally.
Lateral alignment: Check the retaining bolt 1st Inking forme roller to printing unit sideframe!
Test the Inking forme roller ON/OFF switching.
Check gear backlash A and B sides: 0.10 to 0.30mm.
C 95A 6423 39 – 12. Nov. 2003 10-3

10 Inking unit
10.2 Inking rollers
Roller diagram
Position numbers and diameters
View from B side
Position 48 (grey) omitted as from series 325
C 95A 6423 39 – 12. Nov. 2003 10-4

Inking unit
10
Rollers - Table
Pos. Designation ø new min. ø Material Series Shore

mm Inch mm inch
11 Transfer roller 83.6 3.291 - - Rilsan from 310 -
12 Transfer roller 60 2.362 - - Rilsan from 310 -
13 Transfer roller 65.9 2.5945 - - Rilsan from 310 -
16 Intermediate roller 45 1.7717 - - Rilsan from 310 -
21 Ink fountain roller 92 3.622 - - Stainless from 310 -
steel
45 Water fountain roller 75 2.9528 - - Stainless from 310 -
steel
Ceramic from 325
46 Dampening forme 86 3.3858 85 3.3465 Böttcher 119 310 - 316 25
roller to rubber
320 Aquafloc 930 317 - 324 30
rubber
46 Dampening forme 68.6 2.7008 68 2.6614 Böttcher 144 from 325 25
roller from rubber
321
Westland 328 25
C253-01
Böttcher 144 331 25
rubber
47 Water metering 65 2.5591 63 2.4803 Böttcher 119 310 - 316 35
roller rubber
Aquafloc 940 from 317 40
rubber
Westland from 328 40
C403-01
48 Bridge roller 60 2.3622 - - Rilsan 310 - 320 -
48 Bridge roller 50 1.9685 - - Rilsan from 321 -
51 Ink ductor roller 55 2.1654 54 2.126 Böttcher 179 from 310 25
rubber
52 Transfer roller 70 2.7559 68 2.6772 Böttcher 179 from 310 25
rubber
rubber
rubber
rubber
57 Inking forme roller 62 2.4409 59 2.3228 Böttcher 179 from 310 25
rubber
rubber
rubber
rubber
C 95A 6423 39 – 12. Nov. 2003 10-5
10 Inking unit
Rollers - removing and fitting
Removal sequence Fitting sequence
View from B side
The rollers shaded grey in the diagram are not removed.
♦ To remove or fit the ø 56 and ø 58 rollers, the Inking forme roller s

must be set in contact to the plate cylinder!
Dismounting the water fountain roller (ø 75)
♦ Activate stripe test at the printing unit, select 03 and press the + key
♦ Water fountain roller must be moved as far as possible to the B side, release the + key
when the locking screws of the semi-shells are facing upwards.
Exit stripe test.
After fitting the water fountain roller, be sure to carry out the following instructions:
♦ Open the A side guard door.
♦ Unscrew the oil pipelines of the water fountain roller mountings (fork wrench 8 mm).
♦ Pump around 20 squirts of oil into the mountings with an oil can.
♦ Replace the oil pipelines and close the guard door.
C 95A 6423 39 – 12. Nov. 2003 10-6

Inking unit
10
Rollers - locks and semi-shells
Roller locks in closed position, up to series 329.
View from B side
1 Roller lock must be engaged

2 Direction of roller movement
3 Pivot point
4 Pay attention to the numbering on the
semi-shells
C 95A 6423 39 – 12. Nov. 2003 10-7

10 Inking unit
Spring-loaded transfer and intermediate rollers

As from series 330
The other rollers are to be set as previously described.
3K10_19.cdr
3K10_20.cdr
C 95A 6423 39 – 12. Nov. 2003 10-8

Inking unit
10
Rollers - adjustment screws
Up to series 329
51
51
54b b 52a
54a 52 52b
56a a
54 a
56b b
55a
16b a a
59b 56 55
59a b a 58a
16a
60a a 16 58b
60b a b
a a 57b
59
58 57a
60 b
b a
b Red Blue 48b
57
Yellow b 48 48a
b
Black
a
b 46 46b
White 46a
Setting screws
a
colour coded 47
47
3K10_05E.cdr
View from B side
♦ Adjustments to the Inking forme roller s 57, 58, 59, 60; intermediate roller 16 and transfer roller 56
must always be done in the Rollers "ON" position!
♦ The setting screw to the eccentric must always be adjusted first!
Example: first 60a, then 60b.
♦ Transfer roller no. 54 (inking unit separation) must be deselected at the central control console(" - ").
♦ Adjustments to ink ductor roller no. 51 must be done with the cam at its "high point".
The high point is marked in colour on the gear at the B side.
Rotating direction for all adjustments:

Setting screw to the right: roller stripe increases
Setting screw to the left: roller stripe decreases
C 95A 6423 39 – 12. Nov. 2003 10-9

10 Inking unit
Rollers - adjustment
51
51
8 51 to 11, reverse, 3mm
(highest point of cam,
11 52a see “ductor roller”)
b
7 52 to 11, forwards, 4mm
52
a 6 52 to 12, reverse, 4mm
12
52b
55a
a 55
a
5 55 to 15, reverse,
15 57a check only

a
48
57
a 2 48 to 46, forwards, 5mm
48a
Oscillating rollers 46 1 46 to 45,

46a Test 01, 03
a
45 5mm
View from B-side
3K10_06E.cdr
Explanation 1 .... 23 46 to 45, forwards, 5mm
Stripe width
No. Of roller to be set No. Of roller to be set to Inching direction

of press
C 95A 6423 39 – 12. Nov. 2003 10-10

Inking unit
10

54b
54a
19 56 to 16, forwards, 3mm 56b a
54
56a 12
b
17 Swing 56 downwards 13
56 a
* 13 14 See next page 14 b
16 16a
12 59 to 14, 16b a
b 15 58a
forwards, 4mm 59a
60a a a a
59
11 60 to 14, 58
reverse, 4mm 60


9 Swing 56 upwards
View from B-side 3K10_07E.cdr
C 95A 6423 39 – 12. Nov. 2003 10-11

10 Inking unit
59b
60b 22 48 to 57, Test 04

Nut into contact,
58b than ¼ turn further
59 and secure
60 b 58 57b
b
b 4
2 3 b 57 48
48b
4 b
b 46
45
13 57, 58, 59, 60 to plate, 47
forwards
3K10_08E.cdr
14 46 to plate, Test 01, 02, 23

Forwards, 5 47 to 45, move metering roller into contact,
A-side 25 lines
B-side 30 lines
View from B-side set indicator to "0"
from serie 328 A-and B-side 30 lines
Stripe width to the plate:
1. Set inked-up rollers to the plate

2. Turn the press 2-3 revolutions (inch forward key)
3. Set Dampening forme roller (see Pos. 14) on
4. Let the press stand still for approx. 10 seconds
5. Set Dampening forme roller off (exit test).
Inch press forwards and check the stripe width on the plate.
C 95A 6423 39 – 12. Nov. 2003 10-12

Inking unit
10
Inking forme rollers
Inking forme roller s, positions 57, 58, 59 and 60
Sometimes the Inking forme roller s have too much lateral play.
An examination of the dimensions and tolerances showed that the oscillating
Inking forme roller s 58, 59, and 60 can have between 1.10 mm and 1.96 mm play,
and the fixed Inking forme roller 57 can have between 0.60 and 3.16mm play.
Where necessary, the ball bearings must be shimmed (1).
The remaining play should be between 0.3 and 0.6 mm.
♦ It must be borne in mind that rollers can be interchanged in a press.
Until Series 333

Inking forme roller 57 is fixed.
Inking forme roller s 58, 59 and 60 can be steplessly
adjusted for lateral oscillation from 0 - 25 mm.
As of Series 334
Inking forme roller 60 is fixed.
Inking forme roller s 57, 58 and 59 can be steplessly
adjusted for lateral oscillation from 0 - 25 mm.
To make this adjustment, loosen locking screws (3), slide the set collars (2) outwards and then retighten the locking
screws (3).
(See diagram below).
Note:
If splashes from roller washing or ink build-up are noticed on the end of the rollers, then
any play must be reduced for all rollers as described above.
A further check:
At oscillation distance "0", the stroke of the distributors and the inking rollers must end
together.
Adjustment is made via the threaded rod at the B side.
Maximum oscillation distance is 38.5 mm.
Construction of the oscillating form inking rollers Pay attention to the position
of the locking screws (3)!
View from B side
C 95A 6423 39 – 12. Nov. 2003 10-13

10 Inking unit
10.3 Ink distributors
Dismounting
1. Take out all inking rollers.

2. Turn the press until the ink distributor to be removed is at its closest point to the A side.
3. Remove the three fastening screws (8) at the B side.
4. Turn the press carefully until the ink distributor to be removed is at its closest point to the B side.
5. Remove the three fastening screws (6) at the A side.
6. Turn the press carefully until the ink distributor to be removed is at its closest point to the A side.
Attention: Prop ink distributor (7).
7. Slide guide journal (9) to the B side.
8. Pull ink oscillator (7) by the guide journal (5) (slide to the B side) and remove it.
A side B side
1 Carrier 5 Guide journal A side

2 Taper pin 6 Fastening screws
3 Spur gear 7 Ink distributor
4 Fastening screws 8 Guide journal B side
Mounting 3K10_17.cdr
1. Push ink distributor (7) onto the guide journal (5).

2. Push guide journal (9) into the ink distributor (7) and slightly tighten the fastening screws (8).
3. Turn the press carefully until the ink distributor to be mounted is at its closest point to the B side.
4. Insert and tighten the fastening screws (6).
5. Turn the press carefully until the ink distributor to be mounted is at its closest point to the A side.
6. Fully tighten the fastening screws (8).
7. Remove any props and check the concentricity of the ink distributor.
Maximum deviation 0.02 mm.
8. Fit all inking rollers and check the settings.
C 95A 6423 39 – 12. Nov. 2003 10-14

Inking unit
10
10.4 Oscillation
Mounting instructions
Needle bearing with lubrication
View from B side (see spare parts catalogue)
Dismounting:
Remove shank screw (26) and take out shim ring (28) and groove ball bearing (27).
Mounting:
Screw in shank screw (26) with shim ring (28) and needle bearing (supplied).
Replace the 3-part oil distributor with a 4-part oil distributor (supplied) and connect an oil line
directly to the shank screw.
Attention:
1. Loctite is used to assemble the shank screws so when they are replaced a medium-strength bonding agent
must be applied to the thread!
2. The needle bearings must not touch the face of the carrier, min. play 0.3 mm!
3. Be sure the needle bearing is properly mounted!.
C 95A 6423 39 – 12. Nov. 2003 10-15

10 Inking unit
Needle bearing with lubrication
View from A side
0,3mm
X
X
0,3mm
3K10_10.cdr
X Elbow joint/oil line
Dismounting:
Take out the three shank screws (9) as shown above, remove the shim ring (11)
and groove ball bearing (10).
Mounting:
Screw in shank screw (9) with shim ring (11) and needle bearing (supplied).
Connect the 3-part oil distributor from the B side to the distributor on the A side.
Screw three elbow joints 504201K, drawing no.: 004420801 into the shank screws
and connect the oil lines from the 3-part oil distributor to the elbow joints.
Attention:
1. Loctite is used to assemble the shank screws so when they are replaced a medium-strength bonding agent
must be applied to the thread!
2. The needle bearings must not touch the face of the carrier, min. play 0.3 mm!
3. Be sure the needle bearing is properly mounted!
C 95A 6423 39 – 12. Nov. 2003 10-16

Inking unit
10
Cam rollers instead of support rollers for lateral oscillation, as from series 329
C 95A 6423 39 – 12. Nov. 2003 10-17

10 Inking unit
10.5 Ductor roller
Ductor roller - control
1 Magnet Y 105
2 Pawl
3 Setscrew
4 Clamp ring *
5 Screws *
6 Cam follower
7 Marking
8 Vibrator cam
9 Gear wheel
* Valid up till
series 324.
From series 325
locknut
View from B side
Screw (3) setting:
Turn the press until the marking (7) stands below the cam follower (6).
Attention: The high point of the ductor roller cam (8) is very short.
Loosen locking screws (5) and set the screw (3) 0.1 mm away from the pawl (2).
Re-tighten the locking screws (5). Locknuts as from series 325.
Set the ductor roller stroke from the operating panel and check its function. The pawl (2) must move freely and fit
underneath the head of the screw (3).
C 95A 6423 39 – 12. Nov. 2003 10-18

Inking unit
10
Ductor roller – Stripe width
Ductor roller stripe width

Servomotor, Drive no. 3, Bus address no. 62 (Unit 1)
1 Ink fountain roller

2 Sliding block
3 Stop pin
4 Motor M 336
5 Potentiometer
XXX High point of the ductor roller
cam, marked in color
1. Plug the hand terminal into the printing unit

4. Enter code and select Bus address no. 62
5. Use the arrow keys to move the sliding block to ~0.5 mm distance from min. stop.
In this position, the ductor roller should no longer turn when the press is running
6. Leave Menu 7 via Exit and select Menu 6, drive no. 3
7. Set an actual value of 0% by turning the potentiometer shaft
8. Move all the way to 100% and check the function
9. Move the drive back to 0%
10. Turn the main switch off and on again
C 95A 6423 39 – 12. Nov. 2003 10-19

10 Inking unit
Mounting
From series 335
Needle bushing
Ink ductor roller

Shaft
1
2
3
Needle bushing (both sides covered), OPTIMOL LONGTIME PDO lifelong filling
C 95A 6423 39 – 12. Nov. 2003 10-20

Inking unit
10
10.6 Ink fountain roller

Construction of the ink fountain roller
Dismounting the ink fountain roller
1. Switch ink fountain roller off (auxiliary drive)

2. Lock the press
3. Remove the ink from the ink fountain with a spatula
4. Swing the ink fountain open
5. Clean the parts with the prescribed washing agent
Caution: The ink slides have sharp edges, risk of injury!
6. Remove the semi-shells A and B sides
7. Turn the ink fountain roller to the right position and take it out (watch out for the coupling)
Mounting the ink fountain roller
1. Fit parts no. 6 Nilosring 6009 AU, no. 5 groove ball bearing 6009-2RS DIN 625 and
no. 4 circlip 45x1.75 DIN 471 onto the journal at the B side
2. Turn the coupling into position and lift in the ink fountain roller
3. Mount the semi-shells A and B sides
4. Check the concentricity, maximum deviation 0.005 mm
Setting the brake
The brake (7) is set by two setscrews (1). During production, the ink fountain roller
must not be moved by the turning ductor roller when this touches the ink fountain roller.
C 95A 6423 39 – 12. Nov. 2003 10-21

10 Inking unit
10.7 Ink fountain
Arrangement of the cup washers
9 cup washers are fitted (A and B sides)

Spring column with 3 spring assemblies in a row each containing 3 spring washers
The setting distance of spring assemblies (A and B sides) is 10.7 mm. Lock the nuts
The setting distance of the stop screw (A and B sides) is 22 mm. Lock the screws.
C 95A 6423 39 – 12. Nov. 2003 10-22

Inking unit
10
10.8 Ink slides
Ink slide construction
2 0,5 +0,3
3
1
4
5
5,3
6
50N
7
8 - 0,6
52 +/- 0,2
90 -0,3
3K10_13.cdr
1 Ink slide tip 0.5+0.3 Lateral play in the coupling

2 Plate -0,6 inwards position
3 Potentiometer 52+/-0,2 at potentiometer zero position
4 Potentiometer shaft (outwards position)
5 Locking ring 90-0,3 at zero position
6 Screw
7 Motor and drive unit
8 Motor shaft (handwheel)
Dismounting the motor and drive unit
Turn off the press at the main switch

Loosen the cable connection
Open screw no. 6 and remove locking ring 5
Remove motor and drive unit from the front
C 95A 6423 39 – 12. Nov. 2003 10-23

10 Inking unit
Exchanging ink slides
Dismounting
- Switch off the press

- Dismount the ink fountain cheeks (14+16)
- 1 stud bolt (pos. 18, SW 10) and 2 screws (Allen 5 mm) on each side
- Dismount the upper part of the ink fountain
- 1 screw (Allen 6 mm) each side and 7 screws (Allen 6 mm) from below
- Clean the channel of the upper part of the ink fountain
- Detach the ribbon cable from the defective ink slide
DO NOT DETACH UNDER POWER!!!
Dismount the defective ink slide (pos. 34), 2 x 3mm Allen screws.
Note the coding.
XX Upper part of ink fountain

YY Lower part of ink fountain
C 95A 6423 39 – 12. Nov. 2003 10-24

Inking unit
10
Mounting:
Code the new ink slide

Brush white OPTIMOL-PASTE on the sides of the ink slide tip and mount the slide
The new ink slide tip must not protrude
Attach the ribbon cable
Do not attach under power!!!
Ink fountain roller
Optimol-Paste GLS 69 Upper part of the

weiß / white ink fountain roller
Terostat 33
3k10_14E.cdr
- Fill the rear area between the ink slides with TEROSTAT 33
- Let this harden for 6 hours!
- Fill slot with GLS 69. Let this harden for 3 hours!
- Apply TEROSTAT 33 (2 mm beads) to the rear area of the ink slide
- Fill the channel in the upper part of the ink fountain with GLS 69, mount the upper part of the ink fountain and
fasten it
- Brush the contact faces of the ink fountain cheeks with TEROSTAT 33, place them in position and slightly
tighten
- Swing the ink fountain closed with an 0.03 mm shim between the support roll and ink fountain roller
- Attach the ink fountain cheeks to the fountain roller and tighten, check the seal with 0.02 mm shim
- Remove the 0.03 mm shim
- Carry out ink slide zero adjustment. See operating manual
Materials required:
GLS69 RS-Nr.094S 0197 40

Terostat 33 RS-Nr.094R 8054 40
Loctite fast cleaner RS-Nr.094R 8029 40
C 95A 6423 39 – 12. Nov. 2003 10-25

10 Inking unit
C 95A 6423 39 – 12. Nov. 2003 10-26

Dampening unit
11
11 Dampening unit
11.1 Roller diagram ............................................................................. 11-3

11.2 Metering roller.............................................................................. 11-4
Basic position ................................................................................ 11-4
Metering roller - basic setting......................................................... 11-6
11.3 Water fountain roller ................................................................... 11-7
Mountings ...................................................................................... 11-7
Characteristic curve..................................................................... 11-10
Gumming ..................................................................................... 11-11
11.4 Dampening forme roller ............................................................ 11-12
Mounting...................................................................................... 11-12
11.5 Fountain solution sensor.......................................................... 11-13
Fountain solution level monitor (NEGELE) .................................. 11-13
C 95A 6423 39 – 12. Nov. 2003 11-1

11 Dampening unit
11-2 C 95A 6423 39 – 12. Nov. 2003

Dampening unit
11
11.1 Roller diagram

Up till series 320
57 48
46
ø236
47
45
From series 321
57
48 (321-324)
48
46
ø236
47
45
3K11_01.cdr
Pos. Designation ø new min. ø Material Series Shore

mm inch mm inch
45 Water fountain roller 75 2.9528 - - Stainless steel from 310 -
ceramic from 325
46 Dampening forme 86 3.3858 85 3.3465 Böttcher 119 310 - 316 25
roller to rubber
320 Aquafloc 930 317 - 324 30
rubber
46 Dampening forme 68.6 from 321 2.7008 68 2.6614 Böttcher 144 from 325 25
roller rubber
Westland C253-01 328 25
Böttcher 144 331 25
rubber
47 Metering roller 65 2.5591 63 2.4803 Böttcher 119 310 - 316 35
rubber
Aquafloc 940 rubber from 317 40
Westland C403-01 from 328 40
48 Bridge roller 50 1.9685 - - Rilsan from 321 -
57 Inking forme roller 62 2.4409 59 2.3228 Böttcher 179 rubber from 310 25
C 95A 6423 39 – 12. Nov. 2003 11-3

11 Dampening unit
11.2 Metering roller
Basic position
Up to series 328
45
47
2
3
4
AB/OFF
AN/ON
3K10-02.cdr 5
1 Handwheel with dial gauge

2 Lever
3 Setting screw
4 Nut
5 Lever
45 Water fountain roller ø 75
47 Metering roller ø 65
Basic position:
- Insert ø 62 mm metering roller gauge.

- Turn handwheels (1) A and B sides clockwise to the stop.
- Press lever (5) downwards, working position.
- At the B side, use setting screw (3) to set gear backlash of min. 0.05 mm
to the water fountain roller drive.
- At the same time, set the metering roller gauge parallel to the water fountain roller (A side).
- Glue both nuts (4) A and B side onto the setting screws (3) with LOCTITE 601 (high-strength)
and turn the nuts against the lever (2).
- The setting must not change.
- Turn the handwheels (1) anti-clockwise to the stop.
- Remove the plexiglass cover and set the indicator to - 40.
- Turn handwheels (1) to "O".
- Use the setting screws (3) to set a gap of 1.8 mm between the metering roller gauge and water fountain roller.
The nuts (4) serve as stops.
11-4 C 95A 6423 39 – 12. Nov. 2003

Dampening unit
11
From series 329

Metering roller permanently cocked
45
47
2
3
4
AB/OFF
AN/ON
3K10-02.cdr 5
1 Handwheel with dial gauge

2 Lever
3 Setting screw
4 Nut
5 Lever
45 Water fountain roller ø 75
47 Metering roller ø 65
Basic position:
- Insert ø 62 mm metering roller gauge.

- Turn handwheels (1) A and B sides clockwise to the stop, set the dial gauges to +30.
- Press lever (5) downwards, working position.
- Use the setting screws (3) to set a distance of 0.05 mm A+B sides from the water fountain roller.
- Check at the B side that there is gear backlash of min. 0.05 mm to the water fountain roller drive, tightest point.
- Glue both nuts (4) A and B side onto the setting screws (3) with LOCTITE 601 (high-strength)
and turn the nuts against the lever (2).
- The setting must not change.
- Turn handwheels (1) to "O".
- Use the setting screws (3) to set a gap of 1.8 mm between the metering roller gauge and water fountain roller.
(at the B side ~ 3/4 turn, at the A side ~ 4/4 turn).
The nuts (4) serve as stops.
C 95A 6423 39 – 12. Nov. 2003 11-5

11 Dampening unit
Metering roller - basic setting
Prerequisite: Metering roller ø 65 and water fountain roller ø 75 are fitted

Fountain solution circulation unit is switched on
1. Use the lever to set the metering roller on, A+B sides.
2. Use the handwheels to preset the dial gauges to minus 15.
3. Use the setting screws to set the contact pressure of the metering roller.
Squeeze off the water until an evenly thin water film can be seen. This should be done
by step-wise even engagement at A+B sides.
The 17 nut must not come off the setscrew. This serves as a stop to prevent turning too
deeply into the gear teeth.
4. Turn handwheels with the dial gauges to "0".
The "0" position is the metering roller working position, more or less water is set
from the central control console.
5. Print a few sheets below the smearing limit.
Take a look at the leading edge of the printing plate and decide whether a correction
needs to be made to achieve even dampening.
6. In most cases, slightly more fountain solution needs to be fed on the A side.
Therefore the setting screws for the metering gap on the B side should be readjusted
slightly tighter and on the A side slightly looser.
After every correction, print a few sheets to assess the changes at the plate leading edge.
An even line approx. 0.3-0.5 mm wide without any smear threads should be visible at
the plate leading edge.
Once this is achieved, leave the handwheel settings as they are!
11-6 C 95A 6423 39 – 12. Nov. 2003

Dampening unit
11
11.3 Water fountain roller

Mountings
A side up till series 328
1 O-Ring
When mounting the water fountain roller:

Screw off the A side oil lines and use an oil can to fill the bearings. Then replace the oil lines!!
From series 329
1 O-Ring
2 Oil groove for the bronze bushing

Be sure the O-ring is properly seated and set the oil groove for the bronze bushing facing downwards.
C 95A 6423 39 – 12. Nov. 2003 11-7

11 Dampening unit
From series 335
1 O-Ring
3 O-Ring

Be sure the O-ring is properly seated and set the oil groove for the bronze bushing facing upwards!!
From series 342
1 O-Ring
3 O-Ring
4 O-Ring

Be sure the O-ring is properly seated and set the oil groove for the bronze bushing facing upwards!!
11-8 C 95A 6423 39 – 12. Nov. 2003

Dampening unit
11
B side mountings
Water fountain roller drive with lateral oscillation - up to series 332
Water fountain roller drive with lateral oscillation - up to series 333
C 95A 6423 39 – 12. Nov. 2003 11-9

11 Dampening unit
Characteristic curve
The purpose of the characteristic curve is to increase the revolution speed of the water fountain roller as
press speed increases.
*Fountain roller revolution speed ranges from 0% to 99%.

*At any press speed, the fountain roller revolution speed can be set to any value within the 0% to 99% range.
*Fountain roller revolution speed is displayed numerically and also in bar form.
*The characteristic curve increase can be set to the %-values 0; 1; 2; 3; 6.5; 8 (even finer in future). The setting
applies to all printing units and is made in Menu: PRINT-PRESETTING-[F9] SET CHARC...-[F3] DAMP.UNIT
*If characteristic curve increase >0% is selected, after the start-up speed the fountain roller revolution speed
increases as press speed increases.
*Should the characteristic curve reach the 99% value, dampening remains at that value even if press speed
increases even further.
Example:
Increase: 5% per 2,000 sheets/hour
Revolution speed change: from 5,000 sheets/h to 13,000 sheets/h
water fountain
roller speed
[%]
38
36
s /h
34 000
er 2
5 %p
rade
32 ti o of g
r a
30
13000 s/h
5000
4000 6000 8000 10000 12000
machine speed
3K11-06.cdr
min. production speed [s/h]
11-10 C 95A 6423 39 – 12. Nov. 2003

Dampening unit
11
Gumming
Semi-automated gumming of the water fountain roller and printing plate

from series 332 / program version 330C1
If it is not properly protected, the ceramic water fountain roller used at present tends to accept ink when
the press restarts after a stop of several hours.
The new gumming program [0201] can be selected in Menu "Aggregates ROLLER WASH-UP DEVICE".
When a gumming program is preselected, and when the automatic function inking rollers is selected, the indication
text "Wash rollers with gumming" appears in the Menu "Machine".
The washing functions Gumming and Blanket Washing cannot be carried out at the same time because they work
with different washing revolution speeds and are therefore mutually locked in the central control console.
The following sequences take place:
Step a: Inking roller washing plus dampening forme roller and bridge roller.
Step b: All rollers washed as in "Step a" plus the printing plate, water fountain roller
and metering roller.
Step c: Gumming
Step d: Washing with water (degumming)
C 95A 6423 39 – 12. Nov. 2003 11-11

11 Dampening unit
11.4 Dampening forme roller

Mounting
A side
1 Free-wheel, from series 330 no longer used
A-side from series 335
1 Gearwheel, driven by plate cylinder

2 Bearing and gap filled with OPTIMOL LONGTIME PDO
(lifelong filling)
3 Drive gear for the water forme roller
11-12 C 95A 6423 39 – 12. Nov. 2003

Dampening unit
11
11.5 Fountain solution sensor

Fountain solution level monitor (NEGELE)
Up to series 329
-A003
-A381
3K11_03.cdr
Function test:
a) Switch on the press and activate the dampening unit.
b) Check MIN level: Turn the sensitivity control (Level 1) until K1 switches
in the level monitor (at approx. 4.5).
c) Take sensor B003 out of the water fountain. An acoustic signal sounds and
the message "Water fountain in printing unit @ is empty"
appears at the central control console.
d) Check MAX level: Submerge the sensor in the water to simulate max. water.
Turn the sensitivity control (Level 2) until K2 switches in the
level monitor (at approx. 3). An acoustic signal sounds and
the message "Water fountain in printing unit @ is too full"
appears at the central control console.
e) Put the sensor back in the water fountain.
C 95A 6423 39 – 12. Nov. 2003 11-13

11 Dampening unit
Fountain solution sensor B003
High/low water level sensor:
B 003
3
3K11_04.cdr
1 High-water level
2 Normal water level
3 Low-water level
Byte 10
Bit 4 Bit 5 Water fountain level
0 0 ----------
0 1 Low-water level, roller stopped
1 0 High-water level, roller turning
1 1 Normal water level
- At high-water level, the press is enabled. After pressing a run command key,
the press starts to run and stops after 3 seconds.
After that neither production nor washing is possible.
- High and low water levels are reported after a time delay of 15 seconds.
Fountain solution sensor from series 330
20
14
11-14 C 95A 6423 39 – 12. Nov. 2003

Washing devices
12
12 Washing devices
12.1 ABD Blanket washing device (GTW).......................................... 12-3
12.2 AID Impression + 1st transfer cylinder washing device (DZW) 12-4
1st printing unit and intermediate printing units .............................. 12-4
Setting the doctor blade ABD / AID (GTW / DZW)......................... 12-5
Last printing unit ............................................................................ 12-6
AID control disc ............................................................................. 12-7
12.3 Washing programs ...................................................................... 12-8
Description of the washing programs (until PS 335D3) ................. 12-8
Description of the washing programs (as of PS 335E1) ................ 12-9
Working sequence....................................................................... 12-10
12.4 ARD Roller washing device (WW) ............................................ 12-11
12.5 Connections / supply tank ........................................................ 12-12
12.6 Overview of electrical components ......................................... 12-14
ABD (GTW) ................................................................................. 12-14
AID (DZW) ................................................................................... 12-15
12.7 Washing agents ......................................................................... 12-16
C 95A 6423 39 – 23. Jun. 2004 12-1

12 Washing devices
12-2 C 95A 6423 39 – 23. Jun. 2004

Washing devices
12
12.1 ABD Blanket washing device (GTW)
1 2 3 4 5 6
Gummi-
zylinder/ 14
Blanket
cylinder 10
12
11
12
7 8 9 13 13 3K12_01
1 Brush Ø 70 8 Doctor blade

2 Water 9 Washing agent
3 Toothed belt 10 Adjusting screw
4 Motor 11 Sieve
5 Pneumatic cylinder 12 Marking
6 Adjusting spindle 13 Nozzle
7 Gauge Ø 68 14 Guide rail
i
From series 336, twin plastic pipes are used instead of nozzles.
From series 337, the mounting for the AID is controlled by a sensor, not so in unit 1!
Contact pressure to blanket cylinder
- Stop and secure the press.

- Lay a foil 0.1mm thick between the blanket and the brush.
- Activate function test 14.
- The foil must be able to be pulled out using the same force at both A and B sides.
This can be set by the adjusting screws.
Function test till S336 from S337

Brush roller motor turns 02 02
Solenoid valve water 03 03
Solenoid valve washing 05 04
agent
Swing ABD on/off 14 01
C 95A 6423 39 – 23. Jun. 2004 12-3

12 Washing devices
AID Impression + 1st transfer cylinder washing device (DZW)

1st printing unit and intermediate printing units
1
5
2
4 6
3 7
Druck-
zylinder
Impression
cylinder
8
12
9 13
10 3K12_03
11 Transferzylinder
Transfer cylinder
1 Adjusting nut 8 Marking

2 Guide rail 9 Eccentric bolt
3 Water 10 Locking screw
4 Washing agent 11 Doctor blade
5 Marking 12 Gauge Ø 55
6 Nozzle 13 Brush Ø 60
7 Sieve
From series 336, twin plastic pipes are used instead of nozzles.
Basic adjustment
- Loosen the locking screw and turn the eccentric bolt until the brush contacts the
impression cylinder and transfer cylinder simultaneously.
- Adjust the contact so it is parallel at both A and B sides.
- The marking (punch mark) indicates the high point of the eccentric bolt.
12-4 C 95A 6423 39 – 23. Jun. 2004

Washing devices
12
Contact pressure of the brush to the cylinders

- Lay a foil 0.1mm thick between the cylinders and the brush.
- Activate function test 15

Swing AID on/off 15 15
Solenoid valve washing agent 17 18
Checking the sense of rotation of the AID motor
Open the guard above the AID, activate function test 18 (till S 336) 16 (from S 337) (contactor K409) and
check sense of rotation (left).
The sense of rotation can be seen at the gear attached to the AID motor. The washing brush should rotate in
the counter direction to the impression cylinder. If rotation is wrong, swap over connections 2 and 4 at motor
safety switch Q409. Only an electrician may do this!
Sense of rotation: K409 forward, K410 backward
from series 344, the sense of rotation for K409 and K410 is forward
Setting the doctor blade ABD / AID (GTW / DZW)
A B
2 1 Doctor blade
2 Housing
3 Locknut
3
3K12_02
1. Turn all 5 setting screws one thread into the doctor blade A.
2. Then turn all 5 setting screws one thread into the housing B.
3. Turn each of the 5 setting screws one after the other one further turn into the doctor blade and housing until the
edge of the doctor blade makes contact.
4. Tighten the locknuts.
Doctor blade position: ABD brush Ø 70mm,

Set blade edge with a gauge Ø 68mm
AID brush Ø 60mm,

Set blade edge with a gauge Ø 55mm
C 95A 6423 39 – 23. Jun. 2004 12-5

12 Washing devices
Last printing unit
1 3
4
7
2 5
Druck-
zylinder
Impression
cylinder
8
9 10
Kettenführung
Chain guide
Kettenrad 3K12_06
Sprocket wheel
1 Adjusting nut 6 Brush Ø 60
2 Nozzle 7 Gauge Ø 55
3 Marking 8 Guide
4 Water 9 Washing agent
5 Sieve 10 Doctor blade
Contact pressure of the brush to the cylinder

- Lay a foil 0.1mm thick between the cylinder and the brush.
- Activate function test 15

Swing AID on/off 15 15
Solenoid valve washing agent 17 18
In the test, all brush rollers turn in the same direction!! See sketch above. Contactor K409 closes.
12-6 C 95A 6423 39 – 23. Jun. 2004

Washing devices
12
AID control disc
When setting the control disc for swinging the AID on/off, the following points must be observed:
a) Control disc settings must be made with the press in straight printing mode!
b) The degree numbers given in the table below indicate the respective switching position
of the "AID engage" signal. They can be read in the display at the first printing unit.
c) The switching position is determined as follows:
The sensor is visible in the control disc recess. The diode is "off". When the sensor lights up
With the press running forward, the switching position has been reached.
Up to series 324, the control disc is on the

impression cylinder.
1
From series 325 till 336 the control disc is
on the blanket cylinder. 2
B 408
As of S337 the signal for the AID

"Swing On and OFF" is controlled solely
by the Software!
1 Blanket cylinder
3
2 Control disc
3 Impression cylinder 2
B408 Sensor
B 408
3K12_05
Switching position of the control disc on the signal "AID engage". Tolerance: +/- 0.15°
PU 1st and intermediate PU Last PU

1 187.5° ---
2 92.5° 69°
3 357.5° 334°
4 262.5° 239°
5 167.5° 144°
6 72.5° 49°
7 337.5° 314°
8 ---- 219°
C 95A 6423 39 – 23. Jun. 2004 12-7

12 Washing devices
12.2 Washing programs
Central control console
F5
Printing unit 1 2 3 4 5
Preselect washing + - - + +
Amuont of water sprayed 1 3 - 1 4
Amount of washing agent sprayed 2 1 4 1 1
Program 01....... 99
3K12_07E
Description of the washing programs (until PS 335D3)
Washing programs for GTW
Program Program
No.
1 Standard washing program
2 Standard washing program A3 and washing agents
with higher boiling point
67 MAN Roland test program
70 Additional program A3 and washing agents with
higher boiling point (with higher water supply than
program 0002 used especially after a longer
production break, e.g. final cleaning)
99 Self-cleaning of the washing device
Washing programs for DZW
Program Program
No.
1 Standard washing program
57 MAN Roland test program
61 Additional program A3 and washing agents with
higher boiling point (with lower water supply than
program 0063)
63 Standard program A3 and washing agents with higher
boiling point
98 Self-cleaning of the washing device
99 Self-cleaning of the washing device (opposite
direction of revolution of the washing brush than in
program 0098)
The washing programs are in the menu AGGREGATE-GTW or -DZW.
12-8 C 95A 6423 39 – 23. Jun. 2004

Washing devices
12
Description of the washing programs (as of PS 335E1)
The wash-up programs can be selected in the LSR menu [MACHINE] as follows:
• preselection WW + GTW ⇒ wash-up speed = 6000 S/h (GTW-brush does not lift-off when the channel
passes)
• preselection DZW + GTW ⇒ wash-up speed = 200 S/h (GTW- and DZW brush lift-off when the channel
passes)
• preselection GTW ⇒ wash-up speed = 200 S/h (GTW-brush lifts-off when the channel passes)
• preselection DZW ⇒ wash-up speed = 200 S/h (DZW-brush lifts-off when the channel passes)
• preselection WW ⇒ wash-up speed = 6000 S/h
• WW + gumming (program 0201) can be selected alone only (without GTW)
The following programs are available
Washing programs for GTW and DZW (printing units)
Program Program
No.
0001 slightly contaminated
0002 contaminated
0003 very contaminated
0004 paper build-up
0005 biological solvent
0099 self-cleaning of the washing device
Washing programs for GTW and DZW (coating module)
Program Program
No.
0101 slightly contaminated
0102 contaminated
0103 very contaminated
0104 paper build-up
0105 biological solvent
0199 self-cleaning of the washing device
Info: The wash-up program for the ink roller wash-up device is started 0,5s delayed from unit to unit.
Information on "Wash impression cylinder"
Washing program / degree of soiling Spray cycles

1-4= 4 x washing agent, 3 x water
- Impression and first transfer cylinders are washed simultaneously.

- In the last printing unit, only the impression cylinder is washed.
- With program 0001 = 12 cycles (12 cylinder revolutions), the brush changes direction at the end of the
cylinder for the first 8 cycles.
- In the last printing unit, the brush only changes direction after 9 cycles.
During the remaining 4 (respectively 3 for the last printing unit) cycles, the brush only turns in one
direction.
C 95A 6423 39 – 23. Jun. 2004 12-9

12 Washing devices
Working sequence
Working sequence AID

Failures:
a.) Run the press.
a.) Failure of the AID signal "Disengaged" (B406):
b.) Input the desired AID washing program (0001 .. Continual tests are made to see whether the AID is in
0009 in the "Print/Preselect/AID" mask at the central the rear position when output "Swing AID" (Output-
control console. Byte 20.4) is switched off. This requires that the
For each individual printing unit, you can determine initiator signal "AID disengaged" (Input-Byte 9.2) is
whether it is to be washed or not and how long the set within 3 seconds after the output is switched off. If
water and solvent spray is to be applied (100ms .. this is not the case, a Fast stop is triggered and an
400ms). error message appears.
c.) Switch menu item "AID" in the mask b.) Failure of the AID signal "AID Start" (B408):
"Print/Machine" at the central control console to "+". Continual tests are made to see whether the "AID
This "+" then changes back to '-' for a moment. The Start" signal appears cyclically. This requires that the
MMS loads the washing program specified at the signal (Input-Byte 9.3) changes the condition at least
central control console in the form of a table from the once within two press revolutions. If this is not the
MMS ROM disk. Once the washing program has case, an error message appears and the washing
been successfully loaded and started, the menu item program is interrupted or does not even start.
at the central control console computer changes back
to "+". c.) Press shutdown:
If the press is shut down by activation of the
d.) Press revolution speed reduces to 200 rph. "Emergency Stop" or "Stop Secure" buttons, or the
During the first revolution, the starting angle at the washing program is interrupted by deselect ion, the
impression cylinder at every printing unit is AID is disengaged. These functions have a single-
ascertained with the initiator "AID Start" (B408). channel monitor (MMS only) because they only
protect the press (no danger to personnel)
e.) Once the start angle is ascertained, the washing
program table runs individually in each printing unit.
f.) Once the washing program is finished in all

preselected printing units, the menu item at the
central control console computer changes back to "-".
Press rph increases again to basic speed.
12-10 C 95A 6423 39 – 23. Jun. 2004

Washing devices
12
12.3 ARD Roller washing device (WW)
Commissioning the roller washing device
To be sure that the roller washing device functions drip-free, all the lines must be free of air bubbles.
Therefore attention must be paid to the following points when commissioning the roller washing device.
1. The lines must be laid at floor level with no "air pockets" in them.
Especially important for the washing agent lines.
2. Bleeding the main lines.
First bleed the main train (LW 13) at both sides from the ballcocks located at each end.
Rinse the entire system once with approx. 2-3 l.
(Use a clean container, the washing agent can be re-used.)
3. Bleed the spray pipes and the infeed lines.
Hold the spray button pressed for approx. 30 sec until an even jet of spray comes out of all spray pipes.
(Collect the washing agent in a suitable receptacle).
Waschmittel Waschmittel
H²O
WW GTW/DZW
Function test WW
till S336 04 water
from S337 05 water
06 washing agent
WW
1 2
3 4
5 6
3K12_04
C 95A 6423 39 – 23. Jun. 2004 12-11

12 Washing devices
12.4 Connections / supply tank

Washing agent Washing agent
RW ABD/DWD
Supply tank,
A- side
Cut_off valve
PU1, B-side
Roller washing
device
Blanket washing
device
Impression and
1st transfer cylinder
washing device
Return flow
Connection to
collectig tank
(customer) 1 2
S879 3 4
M 217 5 6
S880
3K12_08E
Bleed valve
Functions test no. Solenoid Hose type BMK

till S336 / from S337 valve
04 05 1 WW, water, thin blue hose Y 045
03 03 2 GTW, water, thick blue hose Y 031
06 06 3 WW, washing agent, thin white hose Y 044
05 04 4 GTW, washing agent, thin white hose Y 030
16 17 5 DZW, water, thin blue hose Y 407
17 18 6 DZW, washing agent, thin white hose Y 408
12-12 C 95A 6423 39 – 23. Jun. 2004

Washing devices
12
Machine
V4
Return flow A L1 A L2 A L3 L1
pump ABD H2O
Return flow RW L2
tank
L3
A S1 A S2 A S3
V1 V2 V3
Distributor Tank Compressor 1

3K12_10E
Control lamps: L1 = RW, L2 = H2O, L3 = ABD
V1 = Valve ABD AS1 = Regulating tap ABD AL1 = Drain cock ABD
V2 = Valve H2O(ABD) AS2 = Regulating tap H2O AL2 = Drain cock H2O
V3 = Valve RW AS3 = Regulating tap RW AL3 = Drain cock RW
V4 = Valve H2O (RW)
Outlet container: Water and ABD washing agent residue after washing
Outlet pump: When the outlet container is full and the max. float switch (S 879) in the
container reacts, the outlet pump (M 217) starts pumping the fluid out of the
container. As soon as the min. float switch (S 880) in the container reacts,
the outlet pump stops pumping.
Supply tank pressure: a) ABD p =2.5...3bar (above V1)

b) H2O p (ABD) = 2.5...3bar (above V2)
p (RW) = 0.8...1bar (above V4)
c) RW p = 0.8...1bar (above V3)
Replenishing the supply tank:

- Close the appropriate regulating tap (this disconnects the tank(s) in question from the compressed air
..supply)
- Open drain valve AL (releases pressure in the tank), open the lid of the supply tank and fill it until the
control lamp lights up.
C 95A 6423 39 – 23. Jun. 2004 12-13

12-14
12
12.5
main switch cabinet +AX
Service Training Mechanics
ABD (GTW)
Washing devices
Roland 300
M 217 M 015 M 015 M 015 M 015 M 015
B105 B105 B105 B105

Overview of electrical components
S 879
S 880
Y 116 Y 107 Y 030 Y 031 Y 107 Y 030 Y 031 Y 107 Y 030 Y 031 Y 107 Y 030 Y 031 Y 107 Y 030 Y 031
C 95A 6423 39 – 23. Jun. 2004

Y 108 Y 044 Y 045 Y 108 Y 044 Y 045 Y 108 Y 044 Y 045 Y 108 Y 044 Y 045 Y 108 Y 044 Y 045
Y 194
delivery +EA +DA +CC +CB +CA +BA feeder

M 217: used fluid pump GTW B 105: sensor GTW installed (as of S337)
S 879: floating switch for used fluid water GTW M 015: GTW main drive
high level (low active) Y 107: GTW swivel
Y 108: WW-ductor blade on/off
S 880: floating switch for used fluid GTW
low level (low active) Y 030: solenoid valve GTW-washing agent
Y 031: solenoid valve GTW-water
Y116: solenoid valve return GTW/DZW
Y 044: solenoid valve WW-washing agent
console +FA Y194: solenoid valve washing agent
Y 045: solenoid valve WW-water
suction GTW/DZW (as of S333)
main swtch cabinet +AX
AID (DZW)
Washing devices
B406 B406 B406 B406 B406

B408 B408 B408 B408 B408
B429 B429 B429 B429 B429
M 217 M409 M409 M409 M409 M409
S 879
S 880
C 95A 6423 39 – 23. Jun. 2004

Y 116 Y 406 Y 407 Y 408 Y 406 Y 407 Y 408 Y 406 Y 407 Y 408 Y 406 Y 407 Y 408 Y 406 Y 407 Y 408
Y 194
delivery +EA +DA +CC +CB +CA +BA feeder

M 217: used fluid pump GTW/DZW-TZW B 406: wash-up device DZW-TZW disengaged M 409: DZW-TZW motor
B 408: wash-up device DZW-TZW engage/disengage Y 406: solenoid valveDZW-TZW engaged-disengaged

S 879: floating switch for
used fluid GTW/DZW-TZW Y 407: solenoid valve DZW-TZW water
high level (low active) B 429: protective switch
Y 408: solenoid valve DZW-TZW washing agent
S 880: floating switch for Y116: solenoid valve return GTW/DZW
used fluid GTW/DZW-TZW

low level (low active) Y194: solenoid valve washing agent suction GTW/DZW
(as of S333)
console +FA
12
12-15
Roland 300
12 Washing devices
12.6 Washing agents
Washing solvents must have the following properties to be considered suitable:
* high cleaning strength with low consumption and short drying times
* must not contain hydrocarbons hazardous to health or the environment
(CFC-free, FCFC-free)
* no benzol, no hexane, no tuluol
* flashpoint over 55° C (A2 washing agent)
* must not damage the printing plate
* must not cause corrosion of machine parts
* must not deposit or contaminate
* must be recyclable
* boiling point under 210° C (only with distillation)
* ignition temperature over 240° C (only with distillation)
* must not impair (swell or shrink) blankets and roller material
The latest list of washing agents can be found in the press documentation.
"Care and Maintenance"

- Maintenance Overview
- MAN Roland list of approved washing agents
MAN Roland accepts no liability for the composition of washing agents - especially for any
later changes to the composition.
12-16 C 95A 6423 39 – 23. Jun. 2004

Lubrication
13
13 Lubrication
13.1 Lubrication interval ..................................................................... 13-3

13.2 In case of failure .......................................................................... 13-4
13.3 Checklist of the lubrication points............................................. 13-5
C 95A 6423 39 – 12. Nov. 2003 13-1

13 Lubrication
13-2 C 95A 6423 39 – 12. Nov. 2003

Lubrication
13
13.1 Lubrication interval
Lubrication
The R 300 is lubricated with three independently working pumps (central oil pump
(M218), central grease pump (M219) and on delivery chain grease pump (M216)).
Sorts of lubrication:
Manual lubrication: lubrication released from the console
Lubrication dependent on the revolutions of the machine (RM)

The revolutions of the machine are configured in the MMS.
Forced lubrication, if there is no lubrication impulse released for longer than

one week (i.e. the machine is switched off for longer than one week).
After every successful lubrication, the central oil lubrication keeps on lubricating for 5s.
The lubrication running time is controlled by the MMS, this means there will be
an error message in case that the lubrication runs to long.
Lubrication running times:
type of lubrication max. switch input byte signal to end

lubrication time -A353/7 the lubrication
Byte. Bit
central grease lubrication 900 B077 10.4 1-0
delivery chain lubrication 180 B078 10.3 1-0
central oil lubrication 50 (+5) F002 10.0 0-1
central grease lubrication B077 sensor at the progressive distributor
delivery lubrication B078 sensor at the progressive distributor
central oil lubrication F002 pressure switch (12 bar) in +DA

(+JX, B-side in machines with coating unit)
Normally the chain lubrication is only active (machine ready, no malfunction) when the machine turns.
C 95A 6423 39 – 12. Nov. 2003 13-3

13 Lubrication
13.2 In case of failure

Because of the fact, that all three lubrication pumps (M 216, M 218 and M 219)
work independently, there will be an error message at the console in the case
that anyone lubrication cycle is not finished successfully.
In case of error it is possible to run through five intervals. As soon as there is a

successful run through one interval, the following intervals will not be run.
In between the single intervals, the error messages have to be acknowledged at the
console.
Characteristic features of the intervals:
1. Interval: - the machine has to be running to activate the lubrication
2. Interval: - same as 1. Interval
3. Interval: - the machine does not necessarily to be running, to activate

the lubrication
5. Interval: - the machine can not run, until the

lubrication is successful, this means:
- the machine has to be stopped, to activate

the lubrication
after a successful lubrication, a forced lubrication

is released (Interval 1)
If there is no successful run through the 5. Interval, it might be for the following
reasons, i.e.:
- cycle switch defect

- pressure switch defect
- pipe damaged
- Input-board defect
13-4 C 95A 6423 39 – 12. Nov. 2003

Lubrication
13
13.3 Checklist of the lubrication points

Refer also to: Care and maintenance to the actual series.
Location quantity tool operating hours
Feeder
Suction head guide 2x brush (oil) 1000 h
Pile guide 2x brush (oil) 1000 h
Pile supporting plate 4 x chain brush (oil) 1000 h
* Nonstop 4 x chain brush (oil) 1000 h
Feed register:
Side lay A- and B-side 2 x oil nipples oil press 50 h
Front lay cam roller B- side 1 x grease nipple grease pump 50 h
Front lays cam B- side 1x brush (grease) 50 h
Swing gripper:
Grease strip B- side 5 x grease nipples grease pump 50 h
Cam roller A- side x grease nipple grease pump 50 h
Cam A- side 1x rush (grease) 50 h
Feed register drum:

Gripper shaft bearings 4 x grease nipples grease pump 50 h, 100 *, 1000 h**
Cam roller B- side 1 x grease nipple grease pump 50 h
Cam B-side 1x brush (grease) 50 h
Printing unit B- side:

Ink vibrator roller drive 2 x grease nipples grease pump 50 Std.
Distribution - carrier 1x brush (grease) 50 Std.
Ink ductor cam (behind gear) 1x brush (grease) 50 Std.
Dampening unit:
Bridge roller A and B- side 2 x grease nipples grease pump 50 h
Inking unit:
Ink fountain A and B- side 4 x grease nipples grease pump 50 h
Form roller A and B- side 6 x grease nipples grease pump with tip 50 h
Blanket cylinder:
Worm clamp A and B- side 2 x grease nipples grease pump 50 h, 1000 h**
Gripper shaft bearings A- side 4 x grease nipples grease pump 50h, 100h*,
1000h**
Cam roller A- side 1 x grease nipple grease pump 50 h
Cam A- side 1x brush (grease) 50 h
C 95A 6423 39 – 12. Nov. 2003 13-5

13 Lubrication
2. Transfer cylinder. System:

Gripper shaft bearings A- side 4 x grease nipples grease pump 50 h, 100 h*, 1000 h**
Cam carrier A- side 1 grease nipple grease pump 50 h, 1000 h**
Cam for the suction boxes B-side 1 x brush (grease) 50 h
Perfecting cylinder:
Cam roller A- side 1 x grease nipple. grease pump 50 h
Control lever A- side 2 x grease nipples grease pump 50 h
Anchor control A- side 1 x grease nipple grease pump 50 h
Anchor cam A- side 1x brush (grease) 50 h
Gripper shaft B- side 2 x grease nipples. grease pump 50 h, 1000 h**
Cam roller B- side 2 x grease nipples. grease pump 50 h
Segment lever B- side 2 x grease nipples. grease pump 50 h
Tooth segment B- side 2x brush (grease) 50 h
1. and 3. transfer cylinder:

Delivery:
Gripper opening cam B- side 2x brush (grease) 1000 h
Thread spindle cam B- side 1x brush (grease) 1000 h
Thread spindle blast tube B- side. 1 x brush (grease) 1000 h
Cam sheet jogger A-and B- side. 2 x brush (grease) 1000 h
Chain for suction roller A- side 1 x brush (oil) 1000 h
Chain for pile A- side 1x brush (oil) 1000 h
Gripper shaft 4 x grease nipples grease pump with tip 1000 h**
Cam roller (gripper bar) 1 x grease nipple grease pump with tip 1000 h**
Steel cable for pile table 4x brush (grease) 2000 h
Example: Gripper shafts with slide bearing grease GLS 75/N2 50 h

* Gripper shafts with slide bearing grease GLS 163 100 h
** Gripper shafts with needle bearing grease GLS 163 1000 h (from series 328)
13-6 C 95A 6423 39 – 12. Nov. 2003

Lubrication
13
3K13_02E
C 95A 6423 39 – 12. Nov. 2003 13-7

13 Lubrication
3K13_01E
13-8 C 95A 6423 39 – 12. Nov. 2003

Lubrication
13
13 Lubrication
13.1 General references to the lubrication ........................................ 13-3

Bleeding oil lines............................................................................ 13-4
13.2 Lubrication interval ..................................................................... 13-5
13.3 In case of failure .......................................................................... 13-6
13.4 Lubrication points ....................................................................... 13-7
Refer always to: "Care and maintenance" to the actual series. ..... 13-7
C 95A 6423 39 – 08. Jul. 2004 13-1

13 Lubrication
13-2 C 95A 6423 39 – 08. Jul. 2004

Lubrication
13
13.1 General references to the lubrication
Since correct lubrication of the press is an Care and maintenance From series 311
essential part of the warranty conditions and
also makes a major contribution to trouble-free
running, special attention must be paid to this.
Only oil and grease approved by MAN Roland,

for which lists are available, should be used.
The maintenance manual which is provided with

every press describes the greasing intervals.
This manual forms part of the technical Products to be used

documentation of the machine. Additionally as single document, from series 341
The manual describes the lubricants,
consumables, washing agents and dampening
solution additives permitted by MAN Roland for
the press operation.

- Repairs
C 95A 6423 39 – 08. Jul. 2004 13-3

13 Lubrication
Bleeding oil lines

- Repairs
R3K13_01.jpg
Gauge No: 343 T 5608 13
In all printing units, A- and B-side (highest

position) the oil lines have to be bled
In the coating unit only on A-side.
Therefore unscrew the plug and put in gauge

No: 343 T 5608 13.
Than activate the oil pump at central control

console as long as no air is in the lines.
Afterwards unscrew gauge No: 343 T 5608 13

and mount the plug.
3K13_02
View A-side
3K13_03
View B-side
13-4 C 95A 6423 39 – 08. Jul. 2004

Lubrication
13
13.2 Lubrication interval
Lubrication
The R 300 is lubricated with three independently working pumps (central oil pump (M218),
central grease pump (M219) and on delivery chain grease pump LA8 (M216) [as of series 325 direct
at the delivery.
Sorts of lubrication:
Manual lubrication: lubrication released from the console
Lubrication dependent on the revolutions of the machine (RM)

The revolutions of the machine are configured in the MMS.
Forced lubrication, if there is no lubrication impulse released for longer than

one week (i.e. the machine is switched off for longer than one week).
After every successful lubrication, the central oil lubrication keeps on lubricating for 5s.
The lubrication running time is controlled by the MMS, this means there will be
an error message in case that the lubrication runs to long.
Lubrication running times:
type of lubrication max. switch input byte signal to end

lubrication time -A353/7 the lubrication
Byte. Bit
central grease lubrication 900 B077 10.4 1-0
delivery chain lubrication 180 B078 10.3 1-0
central oil lubrication 50 (+5) F002 10.0 0-1
central grease lubrication B077 sensor at the progressive distributor
delivery lubrication B078 sensor at the progressive distributor
central oil lubrication F002 pressure switch (12 bar) in +DA

(+JX, B-side in machines with coating unit)
Normally the chain lubrication is only active (machine ready, no malfunction) when the machine turns.
C 95A 6423 39 – 08. Jul. 2004 13-5

13 Lubrication
13.3 In case of failure

Because of the fact, that all three lubrication pumps (M 216, M 218 and M 219)
work independently, there will be an error message at the console in the case
that anyone lubrication cycle is not finished successfully.
In case of error it is possible to run through five intervals. As soon as there is a

successful run through one interval, the following intervals will not be run.
In between the single intervals, the error messages have to be acknowledged at the
console.
Characteristic features of the intervals:
1. Interval: - the machine has to be running to activate the lubrication
3. Interval: - the machine does not necessarily to be running, to activate

the lubrication
5. Interval: - the machine can not run, until the

lubrication is successful, this means:
- the machine has to be stopped, to activate

the lubrication
after a successful lubrication, a forced lubrication

is released (Interval 1)
If there is no successful run through the 5. Interval, it might be for the following
reasons, i.e.:
- cycle switch defect

- pressure switch defect
- pipe damaged
- Input-board defect
13-6 C 95A 6423 39 – 08. Jul. 2004

Lubrication
13
13.4 Lubrication points

Refer always to: "Care and maintenance" to the actual series.
Feeder
Suction head guide 2x brush (oil) 1000 h
Pile guide 2x brush (oil) 1000 h
Pile supporting plate 4 x chain brush (oil) 1000 h
* Nonstop 4 x chain brush (oil) 1000 h
Feed register:
Side lay A- and B-side 2 x oil nipples oil press 50 h
Front lay cam roller B- side 1 x grease nipple grease pump 50 h
Front lays cam B- side 1x brush (grease) 50 h
Swing gripper:
Grease strip B- side 5 x grease nipples grease pump 50 h
Cam roller A- side x grease nipple grease pump 50 h
Feed register drum:

Gripper shaft bearings 4 x grease nipples grease pump 50 h, 100 *, 1000 h**
Cam roller B- side 1 x grease nipple grease pump 50 h
Cam B-side 1x brush (grease) 50 h
Printing unit B- side:

Ink vibrator roller drive 2 x grease nipples grease pump 50 h.
Distribution - carrier 1x brush (grease) 50 h.
Ink ductor cam (behind gear) 1x brush (grease) 50 h.
Dampening unit:
Bridge roller A and B- side 2 x grease nipples grease pump 50 h
Inking unit:
Ink fountain A and B- side 4 x grease nipples grease pump 50 h
Form roller A and B- side 6 x grease nipples grease pump with tip 50 h
Blanket cylinder:
Worm clamp A and B- side 2 x grease nipples grease pump 50 h, 1000 h**
Gripper shaft bearings A- side 4 x grease nipples grease pump 50h, 100h*,
1000h**
C 95A 6423 39 – 08. Jul. 2004 13-7

13 Lubrication
2. Transfer cylinder. System:

Cam carrier A- side 1 grease nipple grease pump 50 h, 1000 h**
Cam for the suction boxes B-side 1 x brush (grease) 50 h
Perfecting cylinder:
Cam roller A- side 1 x grease nipple. grease pump 50 h
Control lever A- side 2 x grease nipples grease pump 50 h
Anchor control A- side 1 x grease nipple grease pump 50 h
Anchor cam A- side 1x brush (grease) 50 h
Gripper shaft B- side 2 x grease nipples. grease pump 50 h, 1000 h**
Cam roller B- side 2 x grease nipples. grease pump 50 h
Segment lever B- side 2 x grease nipples. grease pump 50 h
Tooth segment B- side 2x brush (grease) 50 h
1. and 3. transfer cylinder:

Delivery:
Gripper opening cam B- side 2x brush (grease) 1000 h
Thread spindle cam B- side 1x brush (grease) 1000 h
Thread spindle blast tube B- side. 1 x brush (grease) 1000 h
Cam sheet jogger A-and B- side. 2 x brush (grease) 1000 h
Chain for suction roller A- side 1 x brush (oil) 1000 h
Chain for pile A- side 1x brush (oil) 1000 h
Gripper shaft 4 x grease nipples grease pump with tip 1000 h**
Cam roller (gripper bar) 1 x grease nipple grease pump with tip 1000 h**
Steel cable for pile table 4x brush (grease) 2000 h
Example: Gripper shafts with slide bearing grease GLS 75/N2 50 h

* Gripper shafts with slide bearing grease GLS 163 100 h
** Gripper shafts with needle bearing grease GLS 163 1000 h (from series 328)
13-8 C 95A 6423 39 – 08. Jul. 2004

Lubrication
13
3K13_02E
C 95A 6423 39 – 08. Jul. 2004 13-9

13 Lubrication
3K13_01E
13-10 C 95A 6423 39 – 08. Jul. 2004

Air supply / Pneumatics

14
14 Air supply / Pneumatics
14.1 Air connections ........................................................................... 14-3

14.2 Pneumatics .................................................................................. 14-7
Connections................................................................................... 14-7
Plan of installation ....................................................................... 14-10
Compressed air supply ................................................................ 14-13
Valve blocks ................................................................................ 14-14
Setting of the pressure regulator ................................................. 14-19
Maintenance unit ......................................................................... 14-20
Compressor ................................................................................. 14-25
C 95A 6423 39 – 12. Nov. 2003 14-1

14-2 C 95A 6423 39 – 12. Nov. 2003


14
14.1 Air connections

Air supply R 302
1.1 Lw O 25 Blast tube perfecting
1.2 Lw O 25 Blast air 2. transfer. with sucker
1.3 Lw O 25 Blast nozzles infeed register plate
1.4 Lw O 25 Vacuum 2. Transfer with suckers

1.5 Lw 25 Vacuum side lay
O
2.1 Lw O 25 feeder side blower
2.2 Lw O 25 Blast air suction head
2.3 Lw O 25 Vacuum suction wheels
2.4 Lw O 25 Vacuum suction head
3.1 Lw O 25 Blast tube printing unit

3.3 Lw O 25 Blast tube inking unit
4.1 Lw O 40 Blast air suction wheels
4.2 Lw O 40 Blast air blast frame
5.1 Lw O 40 sheet decurler
6.1 Lw O 13 compressed air 40l reservoir
7.1 Dry sprayer
Connection and numbering on aircenter: R 302
1.1 1.4 2.1 3.1
1.2 1.5 2.2 3.2 2.3 2.4 7.1 6.1

4.1
1.3 3.3
4.2
3.4
4.3 5.1
3K14_01
LW Ø = diameter inside
C 95A 6423 39 – 12. Nov. 2003 14-3

Air suply R 304 - 4/0 - 2/2
1.1 Lw 25 Fedder side blower

O
1.2 Lw 25 Blast air suction head
O
1.3 Lw 25 Vacuum suction wheels
O
1.4 Lw 25 Vacuum suction head
O
2.1 Lw O 25 Vacuum side lays

2.2 Lw O 25 Vacuum 2. transfer. suckers (1.perfecting)
2.3 Lw O 25 Blast nozzles feed register plate

2.4 Lw 25 Blast nozzles 2. transfer. with suckers
O
2.5 Lw O 25 Blast tube (1. Perfecting)


5.1 Lw O 40 Sheet decurler
6.1 Lw O 13 compressed air 40l reservoir
7.1 Dry sprayer
8.1 Lw O 40 Blast tube at sprocket wheel shaft at coating unit

3K14_02E
14-4 C 95A 6423 39 – 12. Nov. 2003


14
Air supply R 306 with two perfecting

1.1 Lw 25 feeder side blower
O
O
O
O
2.1 Lw O 25 Vacuum side lays
2.2 Lw O 25 Vacuum 2. Transfer. with suckers (1. perfecting)
2.3 Lw O 25 Vacuum 2. Transfer. w ith suckers (2. Perfecting)
2.4 Lw O 25 Blast nozzles feed register plate

2.5 Lw 25 Blast air 2. Transfer with suckers
O
O
2.7 Lw 25 Blast tube 1. perfecting
O
O
Reserve
Reserve
Reserve
Reserve
5.1 Lw O 40 Blast air suction head
5.3 Lw O 40 Vacuum suction head
6.1 Lw O 40 Sheet decurler
7.1 Lw O 13 Comprerssed air 40l container
8.1 Dry sprayer

3K14_03E
C 95A 6423 39 – 12. Nov. 2003 14-5

Air suply R 306 with perfecting and coating unit

1.1 Lw 25 Feeder Side blowers
O
O
O
O
2.1 Lw 25 Vacuum side lays
O
2.2 Lw 25 Vacuum 2. Transfer with suckers (1. perfecting)
O
2.3 Lw 25 Blasdüsen Anlageblech
O
O
O
Reserve
Reserve
Reserve
Reserve
6.1 Lw O 40 sheet decurler
7.1 Lw O 13 Compressed air 40l container

3K14_04E
14-6 C 95A 6423 39 – 12. Nov. 2003


14
14.2 Pneumatics
Connections
Example 4 colour with coating unit and extended delivery
5
4
Washing agent container ABD ARD

7
Compressed air maintenance unit

Valve dampening solution supply
3
Compressor and reservoir

Waste solution container
Break S&W
2
(DWD)
Valve
1
2
3
4
5
6
7
1
C 95A 6423 39 – 12. Nov. 2003 14-7

After the Compressed air maintenance unit
Without preparation for dryer at the delivery

Technotrans standard dampening cooling unit (little)
ø12mm, closed circular pipeline (blue) Ø12mm to the feeder
ø6mm, valve for gumminig

T-piece
093D759140
Reduction 6 / 12
Ø8mm to the washing agent container 093E043940
Joining12
reduction8 / 12 193D742540
093E044240
Reduction 12 / 14
093E044840
ø12mm, closed circular pipeline (blue) Air reservoir
Compressed air
maintenance unit
3k14_17E
With preparation for dryer at the delivery

Technotrans standard dampening cooling unit (little)
Ø12mm, closed circular pipeline (blue) Ø12mm to the feeder
ø6mm, valve for gumminig

T-piece
093D759140
Ø8mm to the washing Reduction 6 / 12
agent container 093E043940
Valve
(always open)
Joining12
Reduzierung 8 / 12 193D742540
093E044240
Reduction 12 / 14
093E044840
Compressed air
maintenance unit
3K14_18E
14-8 C 95A 6423 39 – 12. Nov. 2003


14
With preparation for dryer at the delivery
Technotrans dampening cooling unit, controlled by central control console
ø12mm, closed circular pipeline (blue) ø12mm to the feeder
ø8mm to the washing T-piece

agent container Valve 093D759140
(always open)
Joining12
Reduzierung 8 / 12 193D742540
093E044240
Reduction 12 / 14
093E044840
Compressed air
maintenance unit
3k14_19E
C 95A 6423 39 – 12. Nov. 2003 14-9

14-10
14
Perfecting 14.2
44
72
74
112
22
134
132
114
102
104
122
124
second side
24
Perfecting 14.4
single side
Operating side
DWD 13
Roland 300
CPL pressure 12
Plan of installation
roller
-
2
Wendung Widerd.
4
Guard 11 Wendung Schönd.
DZW
Water form 10
4 4
2 2
CPL Andrückwalze
roller to plate Schutzleiste 15
54
52
2 2
4 4
Water form 9 Feuchtauftr. Platte
64
62
Feuchtauftr. Chrom.
roller to
84
82
Brückenwalze
chrome roller
4 4 4
2 2 2
14.2 14.4 13 12 11 10 9 8 7
142
Farbauftragwalze
92
94
32
Farbwerkstrennung
34
Bridge roller 8
4 4
2 2
6 5
Farbduktor
144
Ink form rollers 7 WW Rakel
4 4
2 2
4 3
24
GTW
4
2
2
Ink unit splitting 6 Schutzleite 14
C 95A 6423 39 – 12. Nov. 2003

4
2
1
Schutzkitter
22
Ink fountain 5
roller
ARD ductor 4
piston inside
3K14_06
Kolben innen
Kolben außen
piston outside
blade
ABD 3
Guard 2
Guard 1

14
Drive side
072 074 072 074
Kolben außen
piston outside
Kolben innen 062

piston inside 064
044
082
084 0124
0122
094
092
014
034
032
0104
0102
0142 0144 0132

0134
3K14_07
C 95A 6423 39 – 12. Nov. 2003 14-11

Delivery
22
24
32
3 2 1 1
34 2 2 2 -
Sheet catcher out
Sheet jogger out

Non-Stop rails
Shet jogger in
4 4 - 4
piston ouside View from B-side
piston inside
012
014
032
034
View from A-side 3K14_08E
14-12 C 95A 6423 39 – 12. Nov. 2003


14
Compressed air supply
Valve combination till series 323
3K14_09E
C 95A 6423 39 – 12. Nov. 2003 14-13

Valve blocks
Printing units till series 324
Valve blocks
1 Test pin
2 LED
3 Electrical connection
4 Compressed air supply
5 Connection No. 2
6 Connection No. 4
♦ In every printing unit, a valve block is installed on the operating side of the base frame.
♦ The valves are numbered from 1 to 13. Valve No.12 (CPL pressure roller) is mounted separate
on the operating side of the base frame.
♦ Valves number 2 and 11 are not installed on the first printing unit.
♦ The connections are identified by embossed numbers 2 and 4 on the valve block.
Compressed air is always supplied to connection No.2, if the valve was not
electrically actuated.
♦ If a valve was actuated electrically, this is indicated by a LED.

Compressed air is now supplied to connection 4.
♦ For testing, a pin can be actuated - refer to drawing.
14-14 C 95A 6423 39 – 12. Nov. 2003


14
From series 325
9 8 7 6 5 4 3 2 1 running no.
9 8 7 6 5 4 3 2 1 designation
Y097 Y098 Y014 Y012 Y099 Y108 Y107 Y111 Y013 magn. valve no.
9 8 7 6 5 4 3 2 1 pin-no. at
25 pol. plug
water form bridge ink form ink unit auxiliary. ARD ABD guard guard function
roller. to roller roller splitting drive. ink ductor.
chrome ON/OFF fountain blade
roller roller ON/OFF
12 12 12 12 12 12 12 12 12 output -A350/..
19.1 19.2 19.3 19.4 19.5 19.6 19.7 20.0 20.1 byte.bit
option
x x x x x x x leer x printing unit 1
x x x x x x x x x without
perfecting
x x x x x x x x x with perfecting
15 14 13 12 11 10 running no.
14.2 14.4 13 12 11 10 designation
Y110 Y109 Y406 Y065 Y011 Y096 magn. valve
no.
15 14 13 12 11 10 pin-no. at
25 pol. plug
perfecting Perfecting DWD CPL guard water form function
cam cam pressure roller to
second side single side roller plate
13 13 14 14 12 12 output -A350/..
18.3 18.2 20.4 21.0 20.3 19.0 byte.bit
* option
leer leer X / leer x leer x printing unit 1
leer leer X / leer x x x without
perfecting
x x X / leer x x x with
perfecting
C 95A 6423 39 – 12. Nov. 2003 14-15

Coating unit
7 6 5 4 3 2 1 running no.
6 5 4 3 2.2 2.4 1 designation
Res. Y413 Y406 Y412 Y409B Y409A Y063 magn. valve no.
7 6 5 4 3 2 1 pin-no. at
25 pol. plug
res. guard DZW forme cyl.- chamber chamber coating function
2.transfer. wash up blade blade forme
device. roller.
13 13 13 13 13 13 out. -A348-A/..
18.2 18.6 18.3 18.0 18.0 18.5 byte.bit
* * * option
res. x X / not used x X/not X/not x coating unit
used used
Delivery
4 3 2 1 running no.
3 2 1.2 1.4 designation
Y124 Y093Z Y094Y Y094Z magn. valve no.
4 3 2 1 pin-no. at
25 pol. plug
Non-stop Sheet Sheet Sheet function
rail out catcher jogger jogger
out in out
11 13 13 13 out. -A348-A/..
18.2 0.1 0.2 0.3 byte.bit
x x x x delivery
14-16 C 95A 6423 39 – 12. Nov. 2003


14
Pneumatic control
Position of pneumatic pistons, if valves were not selected electrically. Compressed air is
connected to terminal „2“ of the valve block!
Festo block on operating side of printing unit Piston
Valve 1 Inrunning guard blanket/plate retracted

Valve 2 Inrunning guard 1st, 2nd and 3rd transfer cyl.. extended
Valve 3 ABD blanket wash up device retracted
Valve 4 ARD ductor blade extended
Valve 5 Ink fountain roller, auxiliary drive retracted
Valve 6 Ink splitting extended
Valve 7 Ink form rollers extended A- S
Ink form rollers retracted B- S
Valve 8 Bridge roller retracted
Valve 9 Water form roller to chrome extended
Valve 10 Water form roller to plate retracted
Valve 11 guard, 3rd transfer cyl. - imp. cyl retracted
Valve 12 CPL, pressure roller retracted
Valve 13 DWD impression wash up device retracted
Valve 14 perfecting cam, single side
Valve 15 perfecting cam second side
Till series 324 valve No.12 is mounted at the base frame B-side!!!
Valve No.14 and 15 is mounted at the side frame B-side!!!
Feeder/Suction head brake extended

(only till series 330 at the old feeder)
Feed register/pre-gripper extended
Perfecting cams A- side extended till series 333

extended from series 334
B- side extended
Impression ON/OFF B- side extended 2x
Delivery
Sheet jogger extended
Sheet catcher extended
Non Stop retracted A- and B- side
C 95A 6423 39 – 12. Nov. 2003 14-17

Numbering
Numbering of the pneumatic tubes (4 mm) at valve block

Example: ABD blanket wash up device No. 3
Valve No.
A-side Connection at valve block
034
32
No No. Connection at valve block

B- side 3K14_05E
Valve No.
♦ The number „0“ means hose pipe to A- side.
♦ NO number means hose pipe to B- side.
♦ The second number is the valve number
♦ The third number means exit 2 or 4 at the valve.
♦ When the valve is not switched electrically, the compressed air is always at connection 2
14-18 C 95A 6423 39 – 12. Nov. 2003


14
Setting of the pressure regulator
At the tank till series324
The setting of the pressure over the installed

pressure regulator is only possible, when
the device is under pressure!
- switch on the compressor and let the air pressure

raise
- the shut-off cock (11, page 2) must be closed!
Read the switching point at the manometer:
Turn-off pressure: max. 10 bar X
3K14_10
turn-on pressure, when pressure sinks: 8 bar
Correct the setting, if necessary:

X pressure regulator
Switch off pressure P Pressure difference ∆ P

5
1 2
P P
P P
3 4
3K14_11
Depress the hand wheel
1 P lower, turn the hand wheel anti clockwise 3 P smaller, turn the HW clockwise
2 P higher, turn the hand wheel clockwise 4 P bigger, turn the HW anti clockwise
5 the spindle is not allowed to follow-on
At the tank from series325 -

1 P lower, turn the setting screw anti clockwise
P higher, turn the setting screw clockwise
2 P smaller, turn the setting screw clockwise

 P bigger, turn the setting screw anti clockwise
1 turn-off pressure: max. 10 bar

turn-on pressure, when pressure sinks: 8 bar
P
p
From series 330 (150l tank/reservoir)
2 turn-off pressure: max. 14-15bar
turn-on pressure, when pressure sinks: 10-11bar
k14_12
C 95A 6423 39 – 12. Nov. 2003 14-19

Maintenance unit
Setting the maintenance unit, series324-329 (3 electrical connections)
1. Setting of the manostat (10) F 005.2 (max. air pressure)

a. close the shut-off cock (6)
b. switch on the compressor, let the pressure raise to “10” bar (see manometer at the
pressure regulator)
c. from 7,5 bar (see manometer at the pressure regulator) the LED 8.1 at AX 354/5 must be
high (adjust the setting screw (16), if necessary (old system: 2,5 mm Allen key, new system:
opening of the spanner 13))
Caution: Switch off the compressor and deaerate tank 1 (12), to check the setting,
repeat point 1.b and c!
d. open the shut-off cock (6)
2. Setting of the pressure regulator (9)

a. the compressor is on and the pressure (7,5 to 10 bar) is built up, shut-off cock (11) is open
b. set the pressure regulator (9) over set knob (7) to 7 bar (see manometer 8)
3. Setting of the manostat (2) F005.1 (min. air pressure)

a. the compressor is on and the pressure is built up, shut-off cocks (6 and 11) are open
b. magnetic valve (5) Y 88 must have switched, so LED (4) must be high!
(if LED (4) is not high, test button (3) can be actuated)
c. close shut-off cock (11)
d. LED 6.0 at AX 354/5 must be high
e. open knurled screw (15) slowly (lower pressure) and observe manometer (8)
f. at 5 bar LED 6.0 at AX 354/5 must become low
(correct the setting over setting screw (13), if necessary)
Caution: close the knurled screw (15) and open the shut-off valve (11) until LED 6.0 at
AX 354/5 is high, to check the setting; repeat points 3. c to 3. f
1 2 3 4 5 6 7 8 9 10 11 12
F 005.1 Y 88 F 005.2
(min.) (max.)
5 bar 7 bar 7,5 bar
A582, X2 (W8116)
A582, X1 (W8115)
3K14_13
- + - +
13 14 15 16
1 connection to machine 7 set knob 13 setting screw
2 manostat F 005.1 8 manometer 14 connection GTW or 2nd tank
3 test button 9 pressure regulator 15 knurled screw
4 LED 10 manostat F 005.2 16 setting screw
5 magnetic valve Y 88 11 shut-off cock
6 shut-off cock 12 1st tank
14-20 C 95A 6423 39 – 12. Nov. 2003


14
Valve combination till series 323
Y088 F005
AIR AIR
-A354/13 -A354/4
Byte 16, Bit 1 Byte 6, Bit 0
Pressure build-up sequence using valve combination I
pressure/bar
8 9
7
5,5
t
F005
t
0
Y088/machine release
1
60s
t
0
C 95A 6423 39 – 12. Nov. 2003 14-21

Valve combination series 324-329
F005 Y088 F005.1

AIR AIR
-A354/4 -A354/13 -A354/4
Byte 6, Bit 0 Byte 16, Bit 1 Byte 8, Bit 1
Pressure build-up sequence using valve combination II

pressure/bar (tank)
10
8
7,5
5
t
F005.1 (max)
t
0
Y088/machine release
t
0
F005 (min)
t
0
pressure/bar (machine)
7
5
t
3K14_15E
14-22 C 95A 6423 39 – 12. Nov. 2003


14
Maintenance unit series-329
3 electrical connections
Maintenance unit series 330-333
C 95A 6423 39 – 12. Nov. 2003 14-23

Maintenance unit series from series 334-
Maintenance unit series from series 334- (domestic air supply)
3 electrical connections and dust filter
14-24 C 95A 6423 39 – 12. Nov. 2003


14
Compressor
MAHLE Druckluftanlage MKG 271H/MKG 421H/150 (S330 bis S337)
Option:
Kältetrockner
Kesselvolumen: 150l
Einschaltdruck: 10...11bar
Ausschaltdruck:14...15bar
KAESER Druckluftanlage (ab S338)
Kolbenkompressor KCTM 550-100 St (Standard EUROPA)
Kesselvolumen: 90 l
Einschaltdruck: 8,5bar
Ausschaltdruck: 9,5bar
1 Kolben- und Führungsringsatz

2 Membrantrockner DM 2.3
3 Luftfiltereinsatz
4 Druckschalter
5 Einsatz Zyklonabscheider EA 10
6 Einsatz Mikrofilter EE 10
7 Schwimmerableiter
C 95A 6423 39 – 12. Nov. 2003 14-25

until S339: Rotary screw compressor SX3-DM2.3-180/10bar (Standard USA, Option EUROPA)
from S340/341: Rotary screw compressor SM11-5.1-180/12,5bar (Standard USA, Option EUROPA)
tank volume: 2 x 90l
until S339:
switch on pressure: 9,5bar
switch off pressure: 10bar
from S340/341:
switch on pressure:: 12,0bar
switch off pressure: 12,5bar
14-26 C 95A 6423 39 – 12. Nov. 2003

Electrical Information
15
15 Electrical Information
15.1 Control panels ............................................................................. 15-3
Feeder till series 330 ..................................................................... 15-3
Feeder from series 331 ................................................................. 15-4
Printing unit 1 B-side ..................................................................... 15-6
Printing unit B-side ........................................................................ 15-7
Sequential printing unit A-side ....................................................... 15-8
Central control console .................................................................. 15-8
Delivery A-side .............................................................................. 15-9
Delivery B-side .............................................................................. 15-9
Coating unit B-side feeder ........................................................... 15-10
Coating unit B-side delivery ......................................................... 15-11
15.2 Foil keyboard ............................................................................. 15-12
15.3 Portable terminal / Hand terminal ............................................ 15-13
Overview...................................................................................... 15-13
Hand terminal, operating and display elements........................... 15-16
Screen layout............................................................................... 15-17
Structure of the operating surface ............................................... 15-18
Periodical pass over limit of the ink slides ................................... 15-19
Parallel setting of the ink slides with pass over limit .................... 15-19
Ink slides individual setting .......................................................... 15-20
Successive setting of the ink slides ............................................. 15-20
Ink slides zero setting (customer function)................................... 15-21
Preparing the mechanical zero adjustment with the clamping device:15-21
Individual setting of the positioning motors.................................. 15-22
Display of the potentiometer actual voltage and direct setting..... 15-23
Stepper motors sensor display .................................................... 15-24
Logging on the hand terminal ...................................................... 15-25
Dealing with errors in the positioning motors with potentiometer. 15-26
Dealing with errors (continued).................................................... 15-27
Missing drives:............................................................................. 15-27
Status error messages at inking units (ink slides)........................ 15-28
Status error messages (continued).............................................. 15-29
C 95A 6423 39 – 12. Nov. 2003 15-1

Status error messages for the positioning motors........................15-30

15.4 Protective equipment (without CPL, DWD and coating unit) .15-31
15.5 Signals ........................................................................................15-33
15-2 C 95A 6423 39 – 12. Nov. 2003

15
15.1 Control panels

Feeder till series 330
A-side
2 3 4
2 Pile STOP (Halt-safe)
3 Automatic pile rise
5 Normal pile UP
6 Non-stop pile UP
7 Free
8 Normal pile DOWN 5 6
9 Non-stop pile DOWN
8 9
3K15_01
B- side
12 13
12 Suction head UP
13 Suction head DOWN
14 Suction head BACK 14 15
15 Suction head FORWARD
16 Free 16 17
17 Free
18 Pile stop B-side BACK
19 Pile stop B-side FORWARD 18 19
20 Pile stop A-side FORWARD
21 Pile stop A-side BACK
22 Move pile to B-side 20 21
23 Move pile to A-side
24 Free
22 23
25 Free
26 Feeder positioning motors
One step ON / OFF 24 25
27 Free
26 27
3K15_02.cdr
C 95A 6423 39 – 12. Nov. 2003 15-3


B-side
1 Pile stop-secure
2 Main pile: raise
3 Main pile: lower
4 Automatic pile control
5 Residual pile. Raise
6 Residual pile: lower
7 Service socket
8 Speaker
9 EMERGENCY stop
Fine adjustments
Suction head:
10 lower
11 higher
13 to a larger size
Lateral blower A-side:
15 to a larger size
Pile supporting plate/lateral blowers B-side:
16 to the B-side
17 to the A-side
18 Pre-setting step size for keys 10-15
LED on small steps
LED off motor will turn as long as
you press the key
19 feeder: on / off
to get sheets out of the feeder
(only possible at base speed)
Keys without numbers have no function.
15-4 C 95A 6423 39 – 12. Nov. 2003

15
B-side
1 Pressure gauge side guide
2 Pressure gauge suction rolls
3 Pressure gauge blast/suction device
4 Suction tapes 1st suction chamber

(feeder)
5 Side blowers A-side
6 Suction air side guide A-/B-side
7 Suction air side guide
8 Suction air suction rolls
9 Blast/suction device
10 Suction tapes 2nd suction chamber
11 Side blowers B-side
C 95A 6423 39 – 12. Nov. 2003 15-5

Printing unit 1 B-side
3000
Sheets/h
1
1 Display -:
Speed - sheets/h
sheet trend: graphical and numerical
detectors in feed register 2 13
error while calibrating double sheet control
error in sheet travel in the feed register
3 14
degree value for stopped machine
2 Bell 4 15
3 Pumps ON/OFF
4 Feeder air ON/OFF
5 Make ready - (Minus) 5 16
6 Double sheet control ON/OFF
and calibration
7 No function 6 17
8 Machine speed minus
9 Digital - Display 7 18
10 Bell
11 Jog reverse
12 EMERGENCY STOP 8 19
13 Offset OFF; all printing units OFF; feeder OFF
14 Automatic production ON - OFF
15 Feeder ON/OFF 9 20
16 Make-ready + (plus)
17 Early / late sheet
18 No function
19 Machine faster
20 Make-ready preselection
21 Run
22 Jog forwards 10 21
23 Stop (security)
11 22
12 23
3K15_03.cdr
15-6 C 95A 6423 39 – 12. Nov. 2003

15
Printing unit B-side
2 13
3 14
4 15
2 Bell
3 Water form roller ON - OFF 5 16
4 Ink fountain roller ON - OFF
5 Ductor blade ON - OFF
6 Make-ready multicolour 6 17
7 Make-ready for PR
8 Make-ready - (minus)
9 No function 7 18
10 Bell
11 Jog reverse
8 19
12 EMERGENCY STOP
13 Offset OFF
14 Ink fountain rollers ON - OFF 9 20
15 Ink ductor roller ON - OFF
16 Protective grating
17 Changing plates
18 Impression ON - OFF
19 Make-ready + (plus)
20 Make-ready preselection
21 Crawl speed
22 Jog forward 10 21
23 Stop (security)
11 22
12 23
3K15_04
This control panel is also at perfecting unit on the A-side.
C 95A 6423 39 – 12. Nov. 2003 15-7

Sequential printing unit A-side
31
10 Bell
11 Jog reverse
12 EMERGENCY STOP
21 Crawl speed
22 Jog forward
23 Stop (security)
31 Portable terminal 10 21
11 22
12 23
3K15_05
Central control console
10 Bell
12 EMERGENCY STOP
21 Reserved for CPL
23 Stop (security)
10 21
12 23
3K15_06.cdr
15-8 C 95A 6423 39 – 12. Nov. 2003

15
Delivery A-side
3K15_07
25 Non - Stop device 29 Pile raise quickly
26 Pile raise slowly 30 Pile lower quickly
27 Pile lower slowly 31 Portable terminal
28 Stop (security) 32 Ventilator regulation
Delivery B-side
2 13
3 14
10 21
4 15
5 16
6 17
11 22
7 18
8 19
9 20 12 23
3K15_08.cdr
2 Bell 12 EMERGENCY STOP

3 Counter ON/OFF 13 Offset OFF; all printing
units OFF; feeder OFF
4 Make ready - (minus) 14 Automatic production ON/OFF
5 Suction roller, size correction 15 Make ready + (plus)
6 Sheet jogger A-side 16 Suction roller Faster/slower
7 Inspection sheet removal 17 Sheet jogger B-side
8 Machine slower 18 Gripper opening cam sooner / later
9 Digital - display 19 Machine faster
- Suction roller speed in % 20 Make ready preslection
- Gripper opening cam in % 21 Run
- No. of the PU in which the
- impression is thrown ON
10 Bell 22 Jog forwards
11 Jog forwards 23 Stop (security)
C 95A 6423 39 – 12. Nov. 2003 15-9

Coating unit B-side feeder
2Bell
3Not used
4Not used
5Not used
6Not used
7Coating form roller ON/OFF

8Adjustment MINUS
9Digital display
10Horn
11Inch REVERSE
12EMERGENCY OFF
13Impression pressure OFF, Feeder OFF
14Not used
15Not used
16Not used
17Not used
18Impression pressure ON/OFF

19Adjustment PLUS
20Make ready
21Crawl speed
22 Inch FORWARD
23 STOP - SAFE
15-10 C 95A 6423 39 – 12. Nov. 2003

15
Coating unit B-side delivery
2 Bell
3 Coating feed ON/OFF
4 Cleaner ON/OFF
5 Operating position OFF
6 Preselection: Coating application
Drive side and operating side
(Parallel adjustment)
7 Coating form roller ON/OFF
8 Adjustment MINUS
9 Digital display
10 Horn
11 Inch REVERSE
12 EMERGENCY OFF
13 Impression pressure OFF, Feeder OFF
14 Preselection of coating quantity
15 Spray bar
16 Operating position ON
Operating side only
Skew adjustment
18 Impression pressure ON/OFF
19 Adjustment PLUS
20 Make ready
21 Crawl speed
22 Inch FORWARD
23 STOP - SAFE
Multiple functions
Press for 3 seconds
3 Time preselection for coating feed

6 Preselection of metering gap
15 Extended wash-up period
C 95A 6423 39 – 12. Nov. 2003 15-11

15.2 Foil keyboard
1 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 8
2 1 2 3 4 5 6 7 8 9 10
CCI
Q W E R T Y U I O P 7 8 9 ? PRINT
A S D F G H J K L 4 5 6 0 +
4
CAPS
LOCK Z X C V B N M TAB ENTER
1 2 3
SIHIFT Ctrl SIHIFT +/- 0
5 6 7
1 Function keys
2 Printing unit keys
3 Over dampening keys
4 Text keys
5 Numeric keys
6 Control keys
7 Main menu select keys
8- Program level keys
15-12 C 95A 6423 39 – 12. Nov. 2003

15
15.3 Portable terminal / Hand terminal

Overview
1. SLIDES: PASS OVER LIMIT Farbschieber überdrücken

2. SLIDES: PARALLEL SET. Farbschieber parallel verstellen
3. SLIDES: INDIV. SETTING Farbschieber Einzelverstellung
4. SLIDES: SUCCESSIVE SET. Farbschieber gegenläufig
5. SLIDES: ZERO SETTING Farbschieber Nulljustage
6. POS.- MOTORS: INDIV. SET. Pos.- Motor Einzelverstellung
7. DIRECT SETTING Pos.- Motore Direktverstellung
8. TEST OF END SENSORS Endsensoren
Overview in the program Übersicht im Programm:

6. POS.- MOTORS: INDIV. SET.Pos.- Motor Einzelverstellung
FEEDER Anleger
UNIT 1 Einheit 1
1. SUCTION HEAD HEIGHT ADJ. Saugkopf Höhenverstellung
2. SUCTION HEAD SIZE ADJUST. Saugkopf Formatverstellung
3. FEEDER TIMING Anleger Bogenankunft
4. SIDE STOP DRIVE SIDE Seitl. Papieranschlag A - Seite
5. PILE SUPPORTING PLATE Stapletragplatte seitl. Verstellung
6. SIDE STOP OPERATING SIDE Seitl. Papieranschlag B - Seite
Printing u it 1 1. Druckwerk
UNIT 1 Einheit 1
1. NO DRIVE PLANNED kein Antrieb (CPL)
1. CIRCUMFERENCE REG. Umfangsregister
2. SIDE REGISTER Seitenregister
3. DUCTOR ROLLER STRIP WIDTH. Farbduktorantrieb
4. PULL TYPE SIDE GUIDE A Seitenmarke A - Seite
5. PULL TYPE SIDE GUIDE B Seitenmarke B - Seite
C 95A 6423 39 – 12. Nov. 2003 15-13

Übersicht im Programm:
6. POS.- MOTORS: INDIV. SET. Pos.- Motore Einzelverstellung
Printing unit 1 1. Druckwerk
UNIT 2 Einheit 2
6. COVER GUIDE HEIGHT ADJUST. Deckmarken Höhenverstellung
7. NO DRIVE PLANNED kein Antrieb
8. NO DRIVE PLANNED kein Antrieb
9. MATERIAL THICKNESS A- SIDE Bedruckstoffbeistellung A - Seite
10. MATERIAL THICKNESS B- SIDE Bedruckstoffbeistellung B - Seite
UNIT 2 Einheit 2
3. SLIDES: INDIV. SETTING Farbschieber Einzelverstellung
1.- 5. FRONT GUIDE ADJ. 1. bis 5. Vordermarken
INTERMEDIATE PRINTING UNIT

WITH PERFECTING CYLINDER Zwischendruckwerk mit Wendezylinder
UNIT 1 Einheit 1
6. GRIPPER OPENING CAM Greiferöffnungskurve
INTERMEDIATE PRINTING UNIT Zwischendruckwerk
UNIT 1 Einheit 1
15-14 C 95A 6423 39 – 12. Nov. 2003

15
Übersicht im Programm:
6. POS.- MOTORS: INDIV. SET. Pos.- Motore Einzelverstellung
DELIVERY UNIT Ausleger
UNIT 1 Einheit 1
1. SUCTION ROLLER Saugwalze Format
2. SHEET JOGGER A- SIDE Bodengeradestoßer A - Seite
3. SHEET JOGGER B- SIDE Bodengeradestoßer B - Seite
4. GRIPPER OPENING CAM Greiferöffnungskurve
COATING UNIT Lackwerk
UNIT 1 Einheit 1
5. METERING GAP A-SIDE Dosierwalzenspalt A - Seite
6. METERING GAP B-SIDE Dosierwalzenspalt B - Seite
C 95A 6423 39 – 12. Nov. 2003 15-15

Hand terminal, operating and display elements

7
Exit
Exit Start
1 2 3 4 5 6
R7k14_00
1 Exit keys
2 – 5 Arrow - Keys
6 Start Key
7 LCD Display
8 Connection - Cabel
15-16 C 95A 6423 39 – 12. Nov. 2003

15
Screen layout
1 2
3
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
4
ID: XX V: XX
1: Slides: Pass over Limit
2: Slides: Parallel Setting
3: Slides: Indiv. Setting
4: Slides: Successive Set.
UNIT 1 ACTIVE
R7k14_01
6 5
1 ID number
2 Name of the process slave ID (e.g. R 700 printing unit 1)
3 Version of the ZPD (Central Parameter File) loaded
4 Selection area of the menu running: nominal value - actual value
5 Display for active / passive modes
6 Always 1 with the R 700 (physical/logical unit)
Nom. value: Values are displayed in a defined value range

Act. value with the physical unit of measurement.
Status: Condition information, has the following meaning:
READY: Positioning OK.

NEW VALUE: A new nominal value has been selected.
STOPPED: Positioning has been interrupted.
ERROR 3: Positioning error, incorrect actual value course with stepper motors. For example, the storage
module has lost the actual value; switched off while running; Max sensor was approached during
auto calibration; error occurred already during last operation.
ERROR 4: Positioning error, time out. With stepper motors: the motor did not run out of the sensor range.
ERROR 5: Positioning error, value range exceeded. With stepper motors: the Max sensor was approached.
ERROR 6: Positioning error, erratic actual value change. With stepper motors: defective drive card.
ERROR 7: Analog bus is blocked.
ERROR 8: Ink slide / Pos. drive not detected.
C 95A 6423 39 – 12. Nov. 2003 15-17

Structure of the operating surface
R700 Printing Unit 1

Menu of
Testprograms
ID: XX V: XX
1: Slides: Pass over Limit Ink slides

2: Slides: Parallel Setting 1. Pass over limit
3: Slides: Indiv. Setting 2. Parallel setting
3. Individual setting
4. Successive setting
UNIT 1 ACTIVE

Menu of
Testprograms
ID: XX V: XX
5: Slides: Zero Setting 5. Zero setting ink slides

6: Pos. Motors: Indiv. Set. 6. Individual setting Pos. motors
7: Direct Setting 7. Actual value display in mV
8: Test of End Sensors 8. Sensor display
UNIT 1 ACTIVE
R7bild7.pre
R7k14_02
Operation in selection menu:
Vertical arrow keys: (Keys 3+4). Selection of a program which is marked by an arrow. When moving from 4 to 5
and vice versa, the program list switches over.
Horizontal arrow keys: (Keys 2+5). With a double control (R600), the logical unit can be selected (unit 1 or 2).
Start: The selected program starts.
Exit: The help text is displayed to explain the functions of the keys. On pressing this key again, the program
reverts to the selection menu.
If the arrow keys are held pressed down, the function is repeated automatically after approx. 0.5 seconds.
Should individual positioning drives not be available in a process rack, the attendant test programs in the hand
terminal are locked.
15-18 C 95A 6423 39 – 12. Nov. 2003

15
Periodical pass over limit of the ink slides
Return to
Exit selection menu
1: Slides : Pass over Limit
ID: 10 V: 16
Cycles : 1 Cycles 1 to 10
Nom. Value: 0.125mm Displays nominal value
Status : Running
Status of all slides
.. Exit to Stop & Main Menu
UNIT 1 ACTIVE
R7bild7.pre
R7k14_03
10 cycles parallel setting all slides from -32 µm to +125 µm. Dwell time at -32 µm 10 seconds. End position after
Exit: all slides at +125 µm. Automatic Exit after 10 cycles. The status display reports Pos. Error when one or
several ink slides have a positioning error.
Parallel setting of the ink slides with pass over limit

2: Slides Parallel Setting
ID: 10 V: 16 + / - nominal
value
All Slides Active
Nom. Value : 0.000mm
Act. Value : 0.000mm Exit Return to
selection menu
Status : Ready
UNIT 1 ACTIVE
Start Start menu
(only in active
R7k14_04
All slides are set parallel with possible nominal values from –32 µm to +500µm (a prerequisite is standard offset
values).
End position after Exit: all slides at 0 µm.
C 95A 6423 39 – 12. Nov. 2003 15-19

Ink slides individual setting
Selection of the
slide address
3: Slides Ind. Setting
ID: 10 V: 16 Nominal value + / -

Slide no. : 1
Nom. Value : 0.000mm Return to
Act. Value : 0.000mm Exit selection menu
Status : Ready
UNIT 1 ACTIVE
Start Start menu
(only in active mode)
R7k14_05
The status line indicates the current operating condition of the slide.
In this menu, the slides can be individually selected and adjusted.
Successive setting of the ink slides
Selection of the
slide address
Exit
4: Slides : Successive Setting
ID: 10 V: 16 Nominal value + / -

Cycles : 1 R7k14_06
Return to
Status : Runn. Parallel selection menu
.. Exit to Stop & Main Menu
UNIT 1 ACTIVE Start menu
(only in active mode)
R7bild7.pre Start
Firstly all ink slides move parallel to 250 µm. Then, with a time lag of approx. 0.5 seconds, one slide after the other
moves alternately to 0 and 500 µm.
15-20 C 95A 6423 39 – 12. Nov. 2003

15
Ink slides zero setting (customer function)
Selection of the
slide address
Nominal value + /
1 -
with simultaneous
0 movement of the
32 32 slide
40
Exit Return to
selection menu
1 2 3 1 4 5 6 The status line
indicates the
R7bild7.pre current operating
condition of the
slide.
R7k14_08
Operating condition of the ink slides: ??= ink slide defective

.. = presently moving
32 = offset actual value
The ink slides zero setting must be changed individually. The total setting range (with the hand terminal) is from 0
µm to 40 µm. The 32 µm value is the offset position. Each individual ink slide can therefore be closed by 32 µm or
opened wider by 8 µm.
After calling the menu, the slides are passed over limit twice and then opened 50%. Finally, all slides
move to the current offset position.
The arrow keys are used to select the slide to be adjusted and to set the new offset value.
There are two Exit possibilities:
Press the Exit key once:

The new offset values are stored in the EEPROM module at the backplane and then all slides move alternately to
100 µm and back to 0 µm to allow the inking unit to ink up.
End position: All slides at 0 with new offset.
Press the exit key twice:

The new offset values are not stored and the inking unit will run with the old offset values to 0 µm.
Preparing the mechanical zero adjustment with the clamping device:

With the Start key, all ink slides move to 0-position (32 µm). As a result, the entire setting range of the hand
terminal is available after mechanical zero adjustment has been carried out.
C 95A 6423 39 – 12. Nov. 2003 15-21

Individual setting of the positioning motors
R700 Printing Unit 1 Selection of the

6: Pos. Motors: Indiv. Setting
Pos. drive
ID: 10 V: 16
1.Circumferential Register + / - nominal

Nom. Value : 0.00mm value
Act. Value : 0.00mm Exit
Status : Ready
Return to
UNIT 1 ACTIVE selection menu
Start
Start adjustment
to nominal value
R7k14_09 (only in active
mode)
The status line indicates the current operating condition of the slide.
The drives can be individually selected and adjusted within their respective value ranges. No and
Display for designation of the Pos. drives:
1. Circumferential Register
Name of drive
= physical unit 1
= phylical unit 2
Drive number in phys. unit
A special characteristic of stepper motor drives:
Should a drive report Status ERROR 3, it can be adjusted no further except with the automatic zero
adjustment.
This requires that the minimum nominal value be selected. If one keeps trying to reduce the nominal
value,
AUTO CALIB. appears in the status line.
This indicates that an automatic zero adjustment will be carried out (after pressing the Start key), the Pos. drive
moves in the direction of minimum until the zero sensor responds. The Pos. drive is now operable again.
15-22 C 95A 6423 39 – 12. Nov. 2003

15
Display of the potentiometer actual voltage and direct setting
(bypassing all control procedures)

7: Direct Setting
ID: 10 V: 16
Bus Address : 60
Pot. Voltage : 5000 MV
!Attention ! Exit
! Travel not Limited !
UNIT 1 ACTIVE
R7bild7.pre
R7k14_10
This program is normally always passive (the poti actual values are indicated).
It can be activated by a special key combination (identical to the procedure for “Logging on the hand terminal”).
All drives can be individually adjusted.
Attention!
This program intervenes directly in the hardware without regard for positioning areas and limit switch!
With analog motors, the voltage is indicated on a potentiometer. With stepper motors, the display is “Stepper motor
: Status xx”. The value xx is an internal value for the positioning routines and normally of no interest to the operator.
The drive numbers are address- and hardware-related:

1..59 ink slide, 60..67 Pos. drives number 1 – 8 in the process rack and process expansion rack.
The unit (1 or 2) set in the selection menu is interpreted as a physical unit.
Attention!
No checks are made of the limit value or direction of rotation, which means it is possible for the poti to move out
beyond the stop. With stepper motors, the sensors are not interrogated! Extreme care must be taken to ensure that
no mechanical collision occurs.
C 95A 6423 39 – 12. Nov. 2003 15-23

Stepper motors sensor display
Motor
selection
8. Test of End Sensors
ID: 10 V: 16
Motor No. : 1 Return to the

Min. Sensor : OFF selection
Exit menu
Max. sensor : ON
UNIT 1 ACTIVE
R7bild7.pre
R7k14_11
The drives can be individually selected. The status of the end sensors are displayed.
(With poti motors, “----“ is displayed).
Status OFF means that the sensor is covered, status ON means the sensor is not covered. The sensors can be
covered by a feeler gauge to check their function and the correct mounting position.
15-24 C 95A 6423 39 – 12. Nov. 2003

15
Logging on the hand terminal
From control console version 3.40, only the MAN Roland logo is displayed when the hand terminal is plugged in.
Exception: The hand terminal has been activated from the control console for ink slides zero adjustment
(see below).
Service can activate the customary program selection menu by a special key combination.
This requires that three hand terminal keys be pressed in succession.
Activating procedure to enter the service menu

and to activate program 7
To switch the
hand terminal
to ACTIVE
mode, the
RESET button
in the switch
cabinet of the
Exit unit concerned
must be
pressed as
well.
Exit Start
R7k14_12 1 2 3
Press these 3 keys in

succession
The customer function ink slides zero adjustment can be enabled from the control console (only in
PRODUCTION mode).
The program 5 screen surface appears. The ink slide motors are shown here in active mode.
C 95A 6423 39 – 12. Nov. 2003 15-25

Dealing with errors in the positioning motors with potentiometer

The test run carried out after RESET (key in the process rack) detects faulty or missing ink slides and Pos. drives
(referred to as drives on the rest of this page).
In the event that one or more drives are defective and thus block the analog part of the ink slide bus, the inking unit
and the attendant analog Pos. drives cannot be operated because this would result in wrong actual values.
Since all drives are connected parallel, it is not always possible to clearly identify the faulty drive.
In this case, the program “Test !Analog bus error!” appears in the selection menu instead of the program
“Slides: Pass Over Limit”

Menu of Testprograms
ID: 10 V: 16
1: Test !Analog Bus Error!
2: Slides: Parallel Setting
3: Slides: Indiv. Setting
UNIT 1 ACTIVE Start
R7k14_13
!Analog Bus Blocked!
ID: 10 V: 16
Possible error in...
Possible Error in...
Phys. Adress: 1
Bus Voltage : 1100 MV Physical address:
In Phys. Unit : 1
1..59 =
UNIT 1 ACTIVE
slides
60..67 =
Pos. drives
1..8
Step 1:
By turning the drive indicated it can be seen whether the value of the bus voltage changes. If it does then this is the
defective drive.
Step 2:
If the above doesn’t help, use the horizontal arrow keys to select another drive that is suspected to be faulty.
By repeating steps 1 and 2, the defective drive can be quickly identified.
15-26 C 95A 6423 39 – 12. Nov. 2003

15
Dealing with errors (continued)
Sometimes the computer cannot localize the defective drive and “?” appears in the display instead of a number.
Cause:
When only one analog switch path is energized (normally 2 are needed for differential measurement), the voltage
on the bus is subject to extreme fluctuation and this voltage cannot be allocated to any specific drive.
In this case, proceed as follows:
- Call Menu 7 “Direct Setting”,

- select bus address 0,
- turn the drives in succession until the indicated voltage changes radically (over and above normal fluctuation).
This is then the defective drive.
With defective ink slides:
Check the coding (position of the coding switch must conform to the ink slide number), since incorrect coding with
values >80 can cause ink slides to behave abnormally. If there is no coding error, then the ink slide must be
replaced.
Attention! Switch off voltage before doing this!
If coding is altered, the selection menu can be restarted with the RESET button on the process computer.
Missing drives:
This does not limit inking unit operation. Wrong coding can simulate this.
For example: Ink slide no. 20 is coded as 30, in which case no. 20 is determined to be missing because it is
addressed parallel with no. 30.
In program 3 “Slides: Indiv. Setting”, the presence of the ink slide in question can be checked at the status display.
Display ERROR 8: means missing.
C 95A 6423 39 – 12. Nov. 2003 15-27

Status error messages at inking units (ink slides)
Example:
PosCtrl: inking unit 2 (status 4 wrong)
Explanation of the status messages:
Status 1 Ink slide is still positioning
No error message; acknowledge the message

If this message is frequently repeated, determine:
1. Which adjustments cause this message?
2. Do the ink slides still achieve their nominal values?
Possible cause: no indication
Status 2 Positioning interrupted by emergency stop
No error message; acknowledge the message;

repeat the last adjustment.
If this happens often, determine:
1. Which actions cause this message?
2. Do the ink slides still achieve their nominal values?
Possible cause: no indication
Status 4 Wrong actual value course
The change to the potentiometer voltage does not

conform to the expected course
Possible causes: Motor blocked; ink slide defective;

no power supply to the ink slide or is incorrectly
wired; cable/contact problems in parallel bus.
Status 8 Ink slide no longer addressable
If the ink slide is addressed, then .........

- no potentiometer voltage is measurable
- the potentiometer voltage is out of range
Possible causes: Ink slide defective; wiring

to the poti is defective; wrong address set;
potentiometer voltage is out of range
Potentiometer voltage is out of range

This may be resolved by turning the motor by hand
back into the setting range (approx. 1.1V to 9V).
15-28 C 95A 6423 39 – 12. Nov. 2003

15
Status error messages (continued)
Staus 32 EEPROM error / wrong offset values (ink slide zero setting)
Possible help: erase EEPROM with/without offset values
Possible causes: defective EEPROM; faulty EEPROM contents;

analog bus error.
Help: Hand terminal programs ........

2 - Ink slide parallel setting
(test which ink slides don’t move)
3 - Ink slide individual setting
(test individual slides by moving)
7 - Direct setting of the drive
(Poti voltage display; ink slides
conform to bus addresses 1 to 54)
NOTE: Ink slide status error messages can also

be displayed combined in a printing unit.
For example:
PosCtrl: Inking unit 2 (status 12 wrong)
This means that status error 4 and 8
has occurred in the same unit.
C 95A 6423 39 – 12. Nov. 2003 15-29

Status error messages for the positioning motors
Example:
PosCtrl: Printing unit 2 (status 608 wrong)

or
PosCtrl: Feeder drive 9 (status 5 wrong)
The number in the first example is a compound value from the drive number and
the status value. 608 thus means:
Drive no. 6 (vibrator stripe width), status 8 (drive not detected).
The status value is always the last two digits.
In the second example, drive number and status value are displayed separately.
List of the drive numbers:
1 Ink slides 20 Pressure setting A side, R600D

2 Register circumferential 21 Pressure setting B side, R600D
3 Register lateral 22 Test drive
4 Register diagonal 23 Gripped pad bar
5 Distribution commencement 24 Cover guide height
6 Ductor roller strip width 25 Spacer, not connected
7 Pressure setting R 700 26 Side guide A side
8 Lateral pull guide 27 Side guide B side
9 Suction head height 28 Metering roller A side
10 Suction head size 29 Metering roller B side
11 Feeder timing 30 Feed angle
12 Pile supporting plate 31 Front lays A side
13 Side stop drive side 32 Front lays B side
14 Side stop operation side 33 Suction tape roller
15 Suction roller 34 Air commencement timing
16 Sheet jogger drive side 35 Sheet slowdown
17 Sheet jogger operation side 36 Coating volume adjustment
18 Gripper opening cam 37 Gripper pad bar Transferter 1
19 Front edge 38 Gripper pad bar Transferter 2
15-30 C 95A 6423 39 – 12. Nov. 2003

15
15.4 Protective equipment (without CPL, DWD and coating unit)

8 27 33/34 5 7 4 6 3 2 1
16 31 15 32 23 24
29
28
35
17 14 13 12
25
3K15_10.cdr
21 22 26 11 20 10 9 18 30
designation Electrically machine jog jog jog jog crawl speed crawl speed
prot protected stop forw. rev. lim. travel lim. travel forward reverse
no. forward reverse
1 sheet feeding safety device ● ● ● ●
2 inking/dampening unit safety device, feeder ● ● ● ●
side
3 ink ductor roller safety device ● ● ● ●
4 inking unit safety device, delivery side ● ● ● ●
5 safety device before the plate/ blanket ● ● ● ● ●
cylinder
6 hand guard at plate cylinder at final ink from ● ●
roller
7 hand guard at plate/ blanket cylinder ● ●
8 hand guard at blanket cylinder/step ● ●
9 hand guard at blanket cylinder/impression ● ●
cylinder
10 hand guard at transfer cylinder 1&2 ● ●
11 hand guard at transfer cylinder ● ●
3/impression cylinder.
12 swivel step between printing units ● ● ● ●
13 protection device before blanket/impress. ● ● ● ● ●
cylinder feeder side
14 swivel step after the final printing unit ● ● ● ●
15 safety device at delivery ● ● ● ●
16 safety device at delivery ● ● ● ●
17 sheet running back into the press ● ●
18 hand crank pinion gear ● ●
19
C 95A 6423 39 – 12. Nov. 2003 15-31

8 27 33/34 5 7 4 6 3 2 1
16 31 15 32 23 24
29
28
35
17 14 13 12
25
3K15_10.cdr
21 22 26 11 20 10 9 18 30
designation Electrically machine jog jog jog jog crawl speed crawl speed
prot protected stop forw. rev. lim. travel lim. travel forward reverse
no. forward reverse
20 gear train gate (adjusting size, perfecting) ● ●
21 cover after the delivery pile
22 step on operating/drive side
23 feeder covering
24 STOP push-button for the feeder pile ● feeder
25 foreign body guard
26 intermediate step
27 Handle
28 Channel covering on blanket cylinder
29 Channel covering on plate cylinder
30 Covering on main drive
31 Delivery covering
32 Suction head drive covering
33 Printing unit covering on operating side
34 Printing unit covering on drive side ● ●
35 Plexiglas flap delivery ● ●
15-32 C 95A 6423 39 – 12. Nov. 2003

15
15.5 Signals
Following signals will be generated:
1. Signal before machine run

(alternating signal)
2. Warning device for communication between operators

(continuous signal)
3. Warning signal when maximum water level is reached in the preselected printing unit
(alternating signal) till series 330
4. Warning signal when minimum water level is reached in the preselected printing unit
5. Warning signal after X sheets when the inspection sheet removal is actuated,
so that the production will be stopped after X sheets.
6. Warning signal by non-stop or intermediate pile operating, when the sheet detector
recognises paper, so that the production will be stopped
after X sheets.
7. Warning signal for the side lay
8. Starting signal forwards / backwards
C 95A 6423 39 – 12. Nov. 2003 15-33

15-34 C 95A 6423 39 – 12. Nov. 2003

CPL
16
16 CPL
Part 1 Mechanic
16.1 Abridged summary...................................................................... 16-3
Function......................................................................................... 16-3
16.2 General comments ...................................................................... 16-4
16.3 Removal position = loading position ......................................... 16-5
16.4 Tools............................................................................................. 16-7
16.5 CPL in plate cylinder ................................................................... 16-9
16.6 Survey ........................................................................................ 16-12
16.7 Zero-Position ............................................................................. 16-13
Eccentric...................................................................................... 16-13
16.8 Position transducer ................................................................... 16-14
16.9 Stops .......................................................................................... 16-15
Adjustable stops till Series 317.................................................... 16-15
Fixed stops from Series 318 ........................................................ 16-17
16.10 Plate clamp / potentiometer...................................................... 16-18
Adjustment of the plate clamp ..................................................... 16-19
16.11 Small stop blocks ...................................................................... 16-22
16.12 PIN - strip.................................................................................... 16-24
16.13 Pressure roller ........................................................................... 16-25
Pneumatic.................................................................................... 16-25
16.14 Transmitter................................................................................. 16-28
Weko ........................................................................................... 16-28
Mercotac...................................................................................... 16-29
16.15 Replacement CPL ...................................................................... 16-30
Disassembly ................................................................................ 16-30
Assembly ..................................................................................... 16-31
16.16 Register adjustment .................................................................. 16-32
Axiale adjustment device ............................................................. 16-34
16.17 Foil .............................................................................................. 16-35
C 95A 6423 39 – 12. Nov. 2003 16-1

16 CPL
Part 2 Elektronics
Extract from the: - R300 CPL-Servicetools Version

descriptions V02.00 Index4. (0 39E 7151 39)
- CPL-Calibration (0 39F 2413 39)
16-2 C 95A 6423 39 – 12. Nov. 2003

CPL
16
16.1 Abridged summary
CPL COCKING PLATE LOADING
Semi-automatic plate change, requiring no tools, with deformations are excluded; even plates only 0,1 mm
automatic positioning of the printing plate on the plate thick are undamaged. The high accuracy of the plate
cylinder. Fine alignment of the printing plate via clamping procedure includes minute register
Central Control Console with regards to lateral corrections. The register adjustment of front, lateral
register, circumferential register and diagonal and diagonal register is made at the Central Control
register. Console during operation of the press. Not the plate
To change plates, the cylinder advances to the cylinder is moved, but the plate on the cylinder is
position best suited for the operator. The used plate moved instead; the big advantage of this method is,
is automatically moved out of the press. Now, the that - as far as the diagonal register is concerned - it
new plate has to be aligned along the register pins in does not affect the setting of ink form rolls and water
the clamping bar. After actuating the release key, the form rolls with respect to the plate cylinder. Also,
printing plate is clamped in the clamping bar, since the parallel alignment of plate cylinder and
thereafter it is automatically pulled in, tensioned and blanket cylinder is maintained, there is no impairment
positioned precisely in register. of the printing zone
Due to the patented fixation of the printing plate -
without use of clamps - at the end of the plate,
Function
- The three brass sliding blocks in the upper - The thrust bearings themselves are adjusted so
movable rail are to be fitted so as to be that a force of 50 - 60N is required to move them.
easily movable and without play. - The centre plates of the thrust bearings are
- The two outside sliding blocks are used for the bolted to the base plate and thus establish the
circumferential register. connection between base plate and upper
- The centre sliding block is used for the lateral movable strip.
register - a compression spring eliminates the - All three gear boxes are adjusted without
play. backlash with respect to the worm gear and
- The brass sliding blocks are provided with pinned.
pressed-in needle bearings, into which the - Motor shaft and gear shaft are connected with
eccentric bolts of the base plate are fitted. each other, both locking screws are accessible
- The four centre bolts of the thrust bearings are through a bore in the gear box.
screwed and cemented into the upper movable - Motor 2 (circumferential register, operating side)
strip. and motor 3 (lateral register) can only be
removed together with the gear boxes.
C 95A 6423 39 – 12. Nov. 2003 16-3

16 CPL
16.2 General comments
Essentially, the CPL module consists of three modules
Cylinder: Undercut 0,4 mm
Diameter 235.2 mm
Plate size 740 x 605 mm Standard-size
740 x 676 mm Special-size(US)
Plate thickness 0,1 - 0,3 mm
Packing Polyester foil H 45 cemented to cylinder, thickness

thickness depending on printing unit (see foil)
Leading edge of print 43 mm
Circumferential register +/- 1,25 mm
Lateral register +/- 1,25 mm
Diagonal register +/- 1,25 mm
Clamping system: Clamping bar and base plate, approx. 30 kg

Gap cover, approx. 10 kg
4 motors 1 x clamping and potentiometer

1 x lateral register
2 x Circumferential register, drive side and
operating side
4 thrust roller bearings, free from play
3 adjusting cams 1 x lateral register

operating side
3 position transducers 1 x lateral register

operating side
Pin-Strip: Pin strip with resiliently mounted holding pins
Option: correcting device at tail edge (only standard)
16-4 C 95A 6423 39 – 12. Nov. 2003

CPL
16
16.3 Removal position = loading position
Removal
- Actuation of key for removal position

- Cylinder advances to removal position
- Clamping bar advances to a point shortly ahead of the loading position
- Inking unit guard opens - the opening is program-controlled
- Printing plate still is under some tension
- Clamping bar advances to removal position
- Printing plate tension is relieved
- Actuation of control "remove printing plate"
- Plate cylinder advances
- Clamping bar starts to open
- Operator manually guides the plate out of the press
Plating
- Clamping bar is opened

- Printing plate is inserted manually into the clamping strip
- Operator positions the plate by way of the register pins
- Actuation of keys for printing plate positioning and introduction of the
clamping procedure
- Plate cylinder advances
- Pressure roller guides printing plate on cylinder
- Blanket cylinder irons printing plate on the cylinder
- Pressure roller maintains position of printing plate by way of holding pins
- Blanket cylinder thrown-off
- Clamping bar moves to zero position
- Pressure roller is thrown-off
- Inking unit guard closes
- Ready for printing
C 95A 6423 39 – 12. Nov. 2003 16-5

16 CPL
Inserting and clamping the plate
Function sequence: drawing in the printing plate
2
3k16_11
Function sequence: securing the plate rear edge Function sequence: moving to zero position
with the front plate
Electronic positioning of
plate clamp
System accuracy:
0,01 mm
Diagonal register
adjustment +/- 1,25 mm
3 4
3k16_12 3k16_13
16-6 C 95A 6423 39 – 12. Nov. 2003

CPL
16
16.4 Tools
Assembly and transport device No. 099J513313 (2 pieces)
Gauge No. 099J515813 (2 pieces)

(to use till series 326)
Hexagon socket screw key No. 013A067730

(6 mm with spherical head, short)
Hexagon socket screw key 6 mm (offset)

6 mm (shortened)
5 mm (shortened)
4 mm (shortened)
3 mm (shortened)
Lever gauge No. 099J512630 (3 pieces)

Tesatast DIN 2270
and
magnetic holder No.099M548740 (3 pieces)
Feeler gauge 0,05 - 1 mm
For a service check CPL-Service-Tool-Disc

Note book incl. adapter, connecting cable
and program HOST.
Lock screws on the CPL module with LOCTITE 242; do not use adhesive !!!
C 95A 6423 39 – 12. Nov. 2003 16-7

16 CPL
Gauge: composed by:
Height of small stop blocks 013A071830

standard series 324 - 336 090L018840 2x straight pin Ø 6x28
090F150940 set screw DIN 915 M5x16
090F515840 pressure piece GN 614-6-N
standard series 337 – 399 013A073230

090L018840 2x straight pin Ø 6x28
Height of small stop blocks 013A071930

special size series 314-399 090L018840 2x straight pin Ø 6x28
Height PIN-strip 013A072530

standard series 314-399 090L019140 4x straight pin Ø 6
Height PIN-strip 013A072430

special size series 329-399 090L019140 4x straight pin Ø 6
Height clamping system series 324 – 399 013A072030

standard 090F515840 2x pressure piece GN 614-6-N
Special size only cylinder with No.

+05C661263
+05C673863
+05C679363
16-8 C 95A 6423 39 – 12. Nov. 2003

CPL
16
16.5 CPL in plate cylinder
Standard-size
1 2 3 4 5 6 7 8 9 10
3k16_34
11 12 13 14 15
1 Tail edge of print 9 Tensioning flap

2 Cover 10 Leading edge of print
3 Pin 11 Centre plate
4 Pin strip 12 Thrust bearing
5 Base plate 13 Centre bolt
6 Small cowl 14 Thrust bearing
7 Wedge segment 15 Taper head screw
8 Ball end screw
C 95A 6423 39 – 12. Nov. 2003 16-9

16 CPL
A-S
347,5 K
20
8,5
8 8
7 1 2 3 V 4 T 5 6 7 3k16_21
1, 3, 4, 6 Mounting screws (with recess)
2, 5 Screws in gear box, to be removed for lift-in devices,

from series 327 the gear boxes are bolted from the back side.
7 Small stop blocks
8 Hinge bolt and locking screw for the brass hinge in the bearer ring
(till series 323, only standard)
T Position transducer lateral register,

by special size mounted underneath
V lateral adjusting device, only used for settings!!!!
20mm Basic setting,
8,5mm Basic setting,
K Taper head screws, may only be reached through the module with using
hexagon socket screw key No. 013A067730
Brass hinge example A-side
1 Bearer ring plate cylinder

2 Locking screw
3 Hinge bolt
4 Brass hinge
1 2 3 4 3k16_22
16-10 C 95A 6423 39 – 12. Nov. 2003

CPL
16
Checking the height of clamping system
3k16_35
Detail X
0,5
3k16_36
1 Tensioning flap
2 Clamping system
3 Complete gauge
4 Leading edge without foil
- The inspection has to be done without foil
- With gauge 013A072030 and 2X pressure piece 090F515840, check the height from the clamping system
to the leading edge of print, should be 0.3-05mm higher.
Shims to level Standard 1x No. 005F685430 and 1X No. 005F685330

and the taper head screws No. 090B397550
Option 1x No. 005F685330 and 3x No. 005F685330

and the taper head screws No. 090B397550
When levelling the CPL-System, check the gap cover for clearance!!!
C 95A 6423 39 – 12. Nov. 2003 16-11

16 CPL
16.6 Survey
CPL-System
Grundplatte
P G2 M2 G2 M3 G1
K1 M4 M1
Z
T T
K2 3k16_15
CPL – System Movable upper bar

tensioning flap
Base plate Gear boxes

Motors
M1 Motor Circumferential register, drive side

M2 Motor Circumferential register, opera. side
M3 Motor lateral register
M4 Motor Plate clamping
G1-G3 Gear boxes for M 1 - M 3
K1 Single strand roller chain

K2 Double strand roller chain
Z Timing belt
T Position transducers, circumferential register
P Potentiometer
16-12 C 95A 6423 39 – 12. Nov. 2003

CPL
16
16.7 Zero-Position
Eccentric
A-S B-S
Grundplatte
1 2 3
-8000 -8000
1,5
R4,5
1,5
-1500 -1500
-1250 -1250
0 0
+1250 +1250
+1500 +1500
-1250 +1250
-1500 0 +1500 3k16_16
1 Eccentric circumferential A-side
- The centre of the eccentric is 1,5 mm below the centre of rotation of the
eccentric bolt
- The mark points toward the outside
2 Eccentric lateral register
- The centre of the eccentric is the lowermost position

- The mark points downward
3 Eccentric circumferential B-side
- The centre of the eccentric is 1,5 mm below the centre of rotation of the
eccentric bolt
- The mark points toward the outside
During a run, lateral register and circumferential register may be adjusted between plus
+1250 µm and -1250 µm only.
C 95A 6423 39 – 12. Nov. 2003 16-13

16 CPL
16.8 Position transducer
NOVO Position transducer for lateral register 1 piece / circumferential 2 piece
3K16_17
To prevent any distortion, the position transducers are tightened to 8 Nm.

Both position transducers for the circumferential register measure indirectly by way of an incline.
In contrast, the position transducer for the lateral register operates directly.
TESA operates 1:1. 1mm at position transducer is 1mm movement at CPL-system.

Both position transducers of the circumferential register require an operating range of 9500 µm, i.e., even in
position minus 8000 µm (load plate) a preload of the position transducers by 300µm is necessary.
NOVO operates 1:2. 1mm at position transducer is 2mm movement at CPL-system.

Also in position plus 1500 µm (maximum plate plus position), the position transducer system must not be driven all
the way to solid.
The lateral register requires an operating range of only 3000 µm, but it must neither be operated without pre-load,
nor must it be driven all the way to solid.
Circumferential register
12 0 34 5
Lateral register
12 0 34 3k16_17
1 plus 1500 µm (max. plus)

2 plus 1250 µm
0 ZERO zero position / starting position
3 minus 1250 µm
4 minus 1500 µm (max. minus)
5 minus 8000 µm plate load / unload
Position 5 can only be attained during plate loading / plate removal procedure
(or by way of the special program HOST)
Position 1 and 4 can only be attained using the special program HOST!
16-14 C 95A 6423 39 – 12. Nov. 2003

CPL
16
16.9 Stops
Adjustable stops till Series 317
A-S B-S
1XX 2XX
R 5 R
5
X2/ X5/ 2 X6/ X3/
X4 X1
XXX
S1 X2 1 X3
X5 X1/ X6
X4/
S2 3 4 S3
3K16_19
1 CPL-base plate
2 Clamping bar
3 Stop for zero position of drive side circumferential register

and lateral register
4 Stop for zero position of operating side circumferential register
5 Tensioning flap
R Register pin
1XX Measuring point of clamping bar with regards to base plate for
zero position of drive side circumferential register, dimension stamped
on face. (eccentric position, for internal use)!
zero position of operating side circumferential register, dimension stamped
on face. (eccentric position, for internal use)!
XXX Number of complete CPL-module,

when exchange, please not the number
of the old and new CPL-module in the report
C 95A 6423 39 – 12. Nov. 2003 16-15

16 CPL
A-S B-S
1XX 2XX
R 5 R
5
X2/ X5/ 2 X6/ X3/
X4 X1
XXX
S1 X2 1 X3
X5 X1/ X6
X4/
S2 3 4 S3
3K16_19
S1 Stop screw for auto-zeroing of lateral register

X1 Reference dimension for auto-zeroing
X1/ Measuring point
S2 Stop screw for auto-zeroing of circumferential register, drive side

X2/ Measuring point
S3 Stop screw for auto-zeroing of circumferential register, operat.side

X3/ Measuring point
X4 Reference dimension for manual auto-zeroing of lateral register

X4/ Measuring point
X5 Reference dimension for manual auto-zeroing of circumferential

register, drive side
X5/ Measuring point
X6 Reference dimension for manual auto-zeroing of circumferential

register, operating side
X6/ Measuring point
16-16 C 95A 6423 39 – 12. Nov. 2003

CPL
16
Fixed stops from Series 318
A-S B-S
1XX 2XX
R R
R
5 5
X2/ X3/
2
X1 X2 X3
XXX
1
X1/
3 4
3K16_20
1 CPL base plate
2 Clamping bar
X1 Reference dimension for auto-zeroing of lateral register

X1/ Measuring point
X2 Reference dimension auto-zeroing of circumferential register, drive side

X2/ Measuring point
X3 Reference dimension auto-zeroing of circumferential register, operating side

X3/ Measuring point
zero position of drive side circumferential register,
dimension stamped on face. (cam position, for internal use)
zero position of operating side circumferential register,
dimension stamped on face. (cam position, for internal use)
C 95A 6423 39 – 12. Nov. 2003 16-17

16 CPL
16.10 Plate clamp / potentiometer
B-S
62 60 62 60 62 42
4
1 2 3
P
K1
M4
K2 3k16_23
1 INA flat retainer
2 Wedge segment
3 Trapezoid thread spindle
4 Pinion shaft and coupling
P Potentiometer (poti)
M4 Motor Plate clamping
KI Single-strand roller chain
K2 Double-strand roller chain
In order to avoid, that the full force necessary to clamp the printing plate is
required all at once, the wedge segments are arranged alternately. The first
operating side wedge segment is provided with a small hook on the
underside, to keep the flat retainers in place.
Thanks to a small cowl, the first and the last segment each support the opening
of the clamping bar.
Adjusting the potentiometer:
- Align potentiometer with pinion shaft and clamp

- Adjust first operating side wedge segment to 42 mm distance.(or second to 104 mm)
- Turn potentiometer all the way to the right (as looking at the spindle),
then turn back one turn.
-
After electrical start-up, the dimension "42 mm" (104 mm) can no longer be checked
Dimension to the second wedge segment:

Clamping close ~ 110 mm / poti voltage ~ 3,66 V
Clamping open ~ 125 mm / poti voltage ~ 0,56 V
16-18 C 95A 6423 39 – 12. Nov. 2003

CPL
16
Adjustment of the plate clamp
Adjustment of the clamping with the current indicator
1. General information
The indicator is used as an adjustment help, when the mechanical pre-tension of the
clamping is not correct and the CPL-system indicates "Plate too thick" or. "Plate too thin".
2. Adjustment range
The mechanical pre-tension is shown in the form of a normed current in the

seven-segment-display.:
left display-field : normed current in decimal notation

right display-field : sense of screwing ( ">" right, "<" left, " " mechanical
pre-tension is in the recommended range)
Adjustment range:
Left Right Signification

display field display field
9 < Plate too thick, readjustment absolutely
necessary
8 < Mechanical pre tension for the clamping is
correct.
A readjustment is recommended
7 none Mechanical pre tension is in the in the
6 none recommended range.
5 none No further adjustments necessary
4 > Mechanical pre tension for the clamping is
3 > correct.
2 > A readjustment is recommended.
1 > Plate too thin, readjustment absolutely
necessary.
Caution: Adjust pre-tension of the clamp by turning all screws equally.
C 95A 6423 39 – 12. Nov. 2003 16-19

16 CPL
3. Sequence of the adjustment during a plate loading
In case that the plate thickness is not correct in step 4 (clamping the plate,
error code 86 respectively 87), complete the following points:
a) Acknowledge the error message at the console.
b) Push the crawl speed key. The machine moves to the adjustment position.
c) Adjust the pre-tension of the clamping.
d) Push the crawl speed key. The clamping opens.
e) Push the crawl speed key. The clamping closes. The plate thickness is
checked once again by the MMS.
f) In case that the plate thickness is correct after the adjustment, the LED of
plate change key flashes and the crawl speed key is released.
The operator can go on with the plate change program (step 5) or he can
optimise the adjustment (when current is 2, 3, 4 or 8 at the seven-segment-
display).
• readjustment: push the crawl speed key

• go on with the plate change program:
push the plate change key
g) In case that the plate thickness is still not correct (current is 1 or 9 at the
seven-segment-display ), the LED of the plate change key is statically on.
The operator has to push crawl speed key and to readjust the pre-tension
of the clamping.
Display at the printing unit

Example
B
A 1
(600mA)
2
1 3
2 1 4
3 86 2 5
4 87 4 1 3 6
5 2 4 7
6 3 5 8
7 (1500mA)
4 6 9
8
10
5 7
6 8
7 9
8
9
3k16_37
A Sequence: plate change program

B Sequence: plate thickness adjustment program (only possible when error 87 / 86 appears)
16-20 C 95A 6423 39 – 12. Nov. 2003

CPL
16
Basic adjustment
1 2 3 4 5 6 7
9
10
3k16_02
1 small cowl
2 roll
3 wedge segment
4 ball end screw
5 tensioning flap
6 clamping system
7 plate stripe (0,3mm)
8 pressure piece
9 grub screw
10 Centre bolt
- With the grub screws adjust, the ball end screws to a torque from 8Nm.
- Behind each ball end screws, put in a stripe from a printing plate (20mm wide, 0.3mm thick)
between tensioning flap and clamping system.
- Close clamping, rolls are at the high point of the wedge segments.
- Tighten all ball end screws with a torque from 10Nm.
- Open clamping / close clamping,
rerun the event several times
- Check current, should be between 950-1100mA.
- If the current is lower, increase (11Nm / 12Nm........) the torque as long as the current is in the right range
between 950-1100mA.
- If necessary use new ball end screws and mark them new
The inspection can be done with the Service TOOL Disc from central control console,
or with an external lap top incl. adapter and connecting cable.
C 95A 6423 39 – 12. Nov. 2003 16-21

16 CPL
16.11Small stop blocks

Alignment of the small stop blocks
Standard size
0,5 0,5
Pin Pin
DE DE
769 103 127 01/02 0 05C6703 30

0 05C6517 30 0 05C6704 30
Serie 314-317 Serie 324-336
0,5 0,5
Pin Pin
DE
DE
0 05F6575 30 (L+R) 0 05C6996 30
0 05F6590 30 (L+R) 0 05C6997 30
Serie 318-323 Serie 337-399
Optional size
0,5 0,5
Pin Pin
769 103 320 00 0 05C6858 30

S. 314-320 S. 329-332
0 05C6707 30 0 05C6942 30
S. 321-328 S. 333-399 3k16_28
DE – Tail edge of print
- The listed numbers are part numbers
- The small stop blocks are lieing 0.5mm higher than the tail edge of print, measured without foil.
- The adjustment of the small stop blocks is important for an exact loading / unloading of the printing plate,
that the plate will not be bended!!!!
16-22 C 95A 6423 39 – 12. Nov. 2003

CPL
16
Standard – size
From Series 333
3k16_30
1 Gauge complete
2 Stop block
Optional - size
From Series 333
3k16_29
1 Gauge complete
2 Stop block
Gauge 1 has to lay on the bearer ring and at the tail edge of print.
C 95A 6423 39 – 12. Nov. 2003 16-23

16 CPL
16.12 PIN - strip
Standard Option
1 1
1
1
2
3 X 2
X
3
4
3k16_03 3K16_05
1 Gauge complete 1 Gauge complete

2 PIN 2 PIN
3 Support for the pins 3 Support for the pins
4 PIN – strip 4 PIN – strip
5 Shim 005F691930 5 Shim 005F692330
X 15,5mm X 17,3mm
- Pins are resiliently mounted STANDARD- AND OPTION.

- The force, by which the printing plate is held, results automatically
- In lateral direction, the pins are centred with respect to the bearer rings
- The rear pin strip is adjusted, so that a dimension X between pins and tail edge
of print is established
- Distance between pin and gauge should be 1mm
if necessary it can be corrected with the shim
- The Parallelism can be checked from the tail edge of print to the support for the pins
16-24 C 95A 6423 39 – 12. Nov. 2003

CPL
16
16.13 Pressure roller

Pneumatic
The pressure roller has the function to guide the printing plate during plate loading / unloading
A-S B-S
0 12 4
12 4
0 12 2
12 2
1
4 4
2
Y 065
3k16_33
8
Y065 Solenoid valve at operating side on the base
from Series 325 the valve is at the valve block (15 valves),
position 12 stays.
1 One –way restrictor

2 Adjusting screw – roller on
3 Adjusting screw – roller off
Speed adjustment
- Select in function test No. 19

- Push the button + for pressure roller on
- The Solenoid valve Y065 is mounted to the operating side
- The Solenoid valve Y 065 controls the inserting assist device (pressure roller)
it is exhaust controlled
- By unscrewing the knurled screw, the speed of the piston is increased
- By screwing the knurled screw further in, the speed of the piston is reduced
- The contact pressure stays always
Before the plate cylinder starts to turn, the pressure roller has to be in contact to the printing plate,
but the roller must not push to hard against the plate
C 95A 6423 39 – 12. Nov. 2003 16-25

16 CPL
Fine adjustment of the pressure roller / special program "03"
0,5 - 1,0 mm
3k16_27
1 Pressure roller
2 Tail edge of print
3 PIN
- printing plate has to be removed

- clamping has to be opened
- push the plate change key longer than 2s
- select with the keys Digit Plus and Digit Minus the special program" 03 "
- push the plate change key to confirm the selection
- push the crawl speed key, then the machine moves automatically to the check position
- the distance between the pressure roller and the pins has to be 0.5-1mm
- rerun the event several times
- readjust the sensor B410 (drive side outside) if necessary
Cylinder Pressure roller Brass roller

Ø 33mm
Rilsan (blue) continuous Ø 33mm
Rilsan (blue) recessed Ø 33mm
Plasma (silver) recessed Ø 33,6mm
16-26 C 95A 6423 39 – 12. Nov. 2003

CPL
16
Roller replacement
A Thread
B Set screw
C Flat
10 Lever
11 Bolt
12 Disk
13 Roller
- Unscrew set screw B

- Support disk 12 and roller 13
- Insert screw M6 into thread A
- Remove bolt 11 towards drive side
- Remove disk 12
- Remove roller 13 towards drive side
- Insert new disk 12 on operating side
- Install roller 13 towards operating side
- Insert new disk 12 on drive side
- Push in bolt 11; it is imperative, that the surfaces on bolt 11
and on lever 10 correspond
- Tighten set screw B
Using "Special program 03", check position of pressure roll with regards to pins !!
C 95A 6423 39 – 12. Nov. 2003 16-27

16 CPL
16.14 Transmitter
Weko
Till series 330
A-S
2
0.3 - 0.5
3k16_31
1 Gear
2 Stud bolt
3 Secondary transmitter
4 Primary transmitter
5 Bracket
3k16_32
- The secondary transmitter is mounted on the cover disk, the radial run out of the face
has to be checked, max. 0,1 mm.
- The primary transmitter is bolted to the bracket.
- The correct distance is obtained by adjusting the stud bolts.
- Do not use a metal feeler gauge too adjust the distance.
- Use paper of correct thickness.
16-28 C 95A 6423 39 – 12. Nov. 2003

CPL
16
Mercotac
From series 331
Replacement of the MERCOTAC translator
F switch off the machine

F disconnect the power supply – and the data cable of the translator
F unscrew the driving screw
F dismount the holding device
F unscrew the 4 screws at the plate cylinder neck
F pull down carefully the translator and loosen the 3 cable connections
F connect the cables with the new translator
F install the translator, do not chock and do not squeeze the cables
F align the translator with a dial gauge (lateral- and radial deviation) and attach it with the 4 screws
F install the holding device
F screw the driving screw into the driving hole of the translator
CAUTION: The driving screw must not press the translator, because the arrangement of bearings is very
sensitive to tilt!
F connect the power supply – and the data cable of the translator
F switch on the machine
F install the firmware (current V181.HEX; see „Description R300 CPL-Servicetools“)
F switch off the machine, wait approx. 20s and switch it on again
F check all CPL functions (see the manual „Putting into operation of the machine“)
B410
sensor
driving screw
power supply cable

(black) data cable
(orange)
fig.: Mercotac translator, printing unit A-side
C 95A 6423 39 – 12. Nov. 2003 16-29

16 CPL
16.15 Replacement CPL
Disassembly
For every operating step, advance press using the hand crank, and lock !!!
- Remove printing plate

- Actuate program "Plate change", do not insert a plate and confirm
step 4; an error message will be displayed - then abort program,
Lock Stop (Stop-Secure)
Press Plate change starting key for 3 sec.
Release Stop (Stop-Secure)
- The clamping device must be closed
- Remove gap cover
- Remove folding guard (till series 323)
- Remove nip guard and the associated brackets
- Disassemble stud bolt and bracket for gap cover (drive side and operating side)
- Disassemble lock screws and hinge bolts of brass hinges (till series 323)
- Remove small stop blocks of pressure roller (till series 323)
- Using hexagon socket screw key No. 013A067730 screw taper head screws (Accessible through
module) into the cylinder edge, "leading edge of print"
- Lock safety grid to prevent lowering
- Switch-off press
- Loosen measuring system of lateral register (if necessary)
- Install assembly assist devices; to this end, remove two M8 screws of gear boxes., (till series 323)
- Remove the four screws of the base plate; to remove, it is important to use the offset no.6 hexagon socket
head key for the last outside screw on the drive side and for the screw underneath position transducer system
for the lateral register
- Carefully lift out CPL module and place on step
- Disconnect cable connections
When exchange, please not the serial number of the old and new CPL-
module in the report!!!
also refer to "CPL in plate cylinder"
16-30 C 95A 6423 39 – 12. Nov. 2003

CPL
16
Assembly
- Prepare new CPL module and install lifting devices

- Place CPL module step, connect cables and wrap the connections using
the chafing protectors provided
- Carefully lift in CPL module - pay attention to position of cables!!
- Screw in the four base plate screws
- Remove lifting devices and re-install the 2 screws for the gear boxes (till series 323)
- Tighten lateral register measuring system to 8 Nm
- Switch-on press
- Align small stop blocks - tighten
- Screw in drive side and operating side hinge bolts, until the brass hinge starts to lift from the
bearer ring, then turn in reverse by three quarters of a turn and lock by means of the lock screw.
- Carry out auto-zeroing procedure on printing unit
- On Central Control Console, put register on "0"
- Alignment: Adjust distance between clamping bar and edge of cylinder
(leading edge of print) to 8,5 mm min. using the two adjusting screws and lock.
Adjust distance between clamping bar and bearer ring (drive side, inside) to 20 mm
- Tighten base plate screws, check adjustments
- Unscrew the tapered head screws - they clamp the base plate to the bottom of the cylinder
- Actuate program "Plate change", do not insert a printing plate and confirm step 4 - an error message will be
displayed, abort program
- Install stud bolts and gap cover brackets
- Together with the gap cover, align brackets and tighten - gap cover must not distort; if necessary,
re-align stud bolt
- Install bracket and nip guard
- Check plate drawing-in procedure with New plates
C 95A 6423 39 – 12. Nov. 2003 16-31

16 CPL
16.16 Register adjustment
Standard size
1. On Central Control Console, move all front lays to "0"
2. On Central Control Console, move registers to "0"
3. Run a print test on PU 1, check that the print test is parallel (start of print:10mm) and centered.
If necessary, adjust the register according to the following points
Afterwords printing unit 1 is the reference for the following units.
4. Run print test and evaluate register
5. Centre the circumferential register of the following units via the rough register adjustment,
6. Remove gap covers
7. Install adjusting device for lateral register
8. Place measuring dials for circumferential register on drive side and operating side
and lateral register into position
9. Loosen tapered head screws and mounting screws for base plate
10. Adjust entire CPL module corresponding to evaluation
11. Tighten tapered head screws and base plate mounting screws
12. Remove measuring dials and adjusting device
13. Install gap cover
15. if necessary, repeat procedure
Optional size
1. On Central Control Console, move all front lays to "0"
2. On Central Control Console, move registers to "0"
3. Run a print test on PU 1, check that the test form is parallel (start of print:10mm) and centered.
If necessary, adjust the register according to the following points
Afterwords printing unit 1 is the reference for the following units.
5. Remove the printing plate of the PU to be adjusted
6. Remove gap covers
7. Remove PIN strip
8. Install adjusting device for lateral register
9. Place measuring dials for circumferential register on drive side and operating side
and lateral register into position
10. Loosen tapered head screws and mounting screws for base plate
11. Adjust entire CPL module corresponding to evaluation
12. Tighten tapered head screws and base plate mounting screws
13. Remove measuring dials and adjusting device
14. Install PIN strip
15. Install gap cover
16. Install printing plate
18. if necessary, repeat procedure
It is also possible to use feeler gauges instead of measuring dials
Refer to chapter 8 Start of print.......
16-32 C 95A 6423 39 – 12. Nov. 2003

CPL
16
Register adjustment under consideration of the rough register
Example: R 306
PU Printing unit
A Circumference drive side
B Circumference operating side
S Lateral register
UR Circumferential register (rough register)
PU A B S
1 0,00 0,00 0,00
2 -0,25 -0,15 0,10
3 -0,30 -0,30 0,15
4 0,15 0,35 -0,15
5 -0,15 -0,35 0,00
6 0,05 0,25 0,00
Printing unit 1 is already adjusted, "Reference printing unit".
PU A B S UR
1 0,00 0,00 0,00 0,00
2 0,05 -0,05 -0,10 0,20
3 0,00 0,00 -0,15 0,30
4 0,10 -0,10 0,15 -0,25
5 -0,10 0,10 0,00 0,25
6 0,10 -0,10 0,00 -0,15
The rough register has to be distorted according to column UR.

(gaer rim / plate cylinder A-side outside)
The complete CPL-sytem has to be aligned, according to column A / B and S.
From series 336 [LSR-Version V17.00 / PS 335B1], the electrical calibration of the CPL-systems is possible.
The CPL-calibration can be carryed out from central control console with the shop supervisor disk.
The maximum range is ±0,1mm.
With the CPL-service tools disk it is possible to reset a CPL calbration. (refer to: CPL Electronics)
When the register in central control consol is at "0", the distance between the CPLsystem and the
edge of the cylinder must not be less than 8.3mm!!!!
Check the Zero position for the zeroing pin, if the rough register has been adjusted.
Readjust if necessary.
Refer also to chapter 8, "Start of print – blanket and plate cylinder"
C 95A 6423 39 – 12. Nov. 2003 16-33

16 CPL
Axiale adjustment device
- For the axial adjustment of the CPL-system, a device is delivered with the machine
- To fit the device for the optional size, first the pin strip has to be removed
- The device has to be removed after usen
1 2 3 3k16_24
1 Adjustment device
2 PIN-strip
3 Base plate
Standard
1 2 3 1 3k16_25
1 Setscrews
2 U-bolt, screwed on the base plate
3 Stop, screwed on the pin strip in each unit
Option
1 2 3 1 3K16_26
1 Setscrews
2 U-bolt, screwed on the base plate
3 Stop, screwed on the pin strip
16-34 C 95A 6423 39 – 12. Nov. 2003

CPL
16
16.17 Foil
R302 R304 R305 R306 R307 R308

AD GF DF AD GF DF AD GF DF AD GF DF AD GF DF AD GF DF
M1 0,25 0,11 0,14 0,25 0,11 0,14 0,25 0,11 0,14 0,26 0,10 0,16 0,26 0,10 0,16 0,26 0,10 0,16
M2 0,24 0,10 0,14 0,24 0,10 0,14 0,24 0,10 0,14 0,25 0,11 0,14 0,25 0,11 0,14 0,25 0,11 0,14
M3 0,24 0,10 0,14 0,24 0,10 0,14 0,24 0,10 0,14 0,25 0,11 0,14 0,25 0,11 0,14
M4 0,24 0,10 0,14 0,24 0,10 0,14 0,24 0,10 0,14 0,25 0,11 0,14 0,25 0,11 0,14
M5 0,24 0,10 0,14 0,24 0,10 0,14 0,24 0,10 0,14 0,25 0,11 0,14
M6 0,24 0,10 0,14 0,24 0,10 0,14 0,24 0,10 0,14
M7 0,24 0,10 0,14 0,24 0,10 0,14
M8 0,24 0,10 0,14
AD = Packing without printing plate

GF = Base foil
DF = Cover foil
The above recommended foil thicknesses are only guide values.

Due to tolerances, the foiles can differ slightly.
Foil sizes:
STANDARD
548 x 740 mm . No. : 0,10 mm — 013 D 0038 30
0,11 mm — 113 D 0038 30
0,12 mm — 013 D 0039 30
0,14 mm — 113 D 0039 30
0,16 mm — 213 D 0039 30
0,18 mm — 313 D 0039 30
Option
621 x 740 mm . No. : 0,10 mm — 013 D 0040 30
0,11 mm — 113 D 0040 30
0,12 mm — 013 D 0041 30
0,14 mm — 113 D 0041 30
0,16 mm — 213 D 0041 30
0,18 mm — 313 D 0041 30
Refer also to Machine operation
C 95A 6423 39 – 12. Nov. 2003 16-35

16 CPL
The foils have to be sticked on the plate cylinder from the tail edge to the leading edge, and
centered between the bearer rings.
• With the 4th ink form roller, the foils have to be sticked on.
Therefore rotate the 4th ink form roller aprox. ½ revolution stronger
• Clean the cylinder surface, degrease. Don`t use plate cleaner
• Start at the taile edge.
• Switch ON the ink form roller`s.
• Prepare the foil, bezel the edge and yank off the protection foil.
• Put on the foil to the edge.
• Inch the machine “backwards”, the 4th Ink form roller presses the foil against the cylinder.
• Same procedure for base- and cover foil.
• Switch OFF ink form roller`s
• Turn back the 4th Ink form roller and check the setting.
• Load on new plates to protect the foils.
16-36 C 95A 6423 39 – 12. Nov. 2003

Service Training Electronics Roland 300
CPL 16
16 CPL Part 2 Electronic

16.1.1 Overview of the electrical components (to S330)............................................................................ 16-3
16.1.2 Conditions for plate change........................................................................................................... 16-10
16.1.3 Register menu ............................................................................................................................... 16-10
16.1.4 Description of plate change ........................................................................................................... 16-11
16.1.5 Adjustment of the clamping bar above the electric current value display ..................................... 16-14
16.1.6 CPL activation ............................................................................................................................... 16-15
16.1.7 CPL configuration .......................................................................................................................... 16-17
16.1.8 Rough adjustment of reference sensor B410 (without special program 03) ................................. 16-20
16.1.9 Special programs........................................................................................................................... 16-21
16.1.10 Conversion of TESA to NOVO measuring track systems ............................................................. 16-23
16.1.11 Mercotac transmitter (from S331).................................................................................................. 16-25
16.1.12 Diagnosis CPL ............................................................................................................................... 16-29
C 95A 6423 39 – 12. Nov. 2003 16-1

16 CPL
This page is empty for technical reasons.
16-2 C 95A 6423 39 – 12. Nov. 2003

Overview of the electrical components
WEKO CPL Plate cylinder

translator -A572
45 U6
Q 029 -A571
45 W6 CNO. 172 M60, M61, M62, M63,
T 100 X1 X2 -A572P -A572S -A573, -A574,
45 U5 WEKO
Q 041 distance measurement system 1, 2 and 3
control aparatus
45 W5 X3
CNO. 164
B2
-A351 Process rack
16.12.1997, 3CPL1000.CDR
16.1.1 Overview of the electrical components (to S330)
T100: Power supply CPL (2x45V AC) -A572P: Translator primary

Q029: Motor protection switch -A572S: Translator secondary
Q041: Motor protection switch -A573: WEKO cable distributer
-A571: WEKO control aparatus (signal -A574: Potentiometer CPL tensioning bar
transformation for the transmission (closed 3,66V, open 0,56V)
through -A571) M60: Circumference register A
C 95A 6423 39 – 12. Nov. 2003

Distance measurement system 1: TESA or NOVOTEC M61: Circumference register B
Distance measurement system 2: TESA or NOVOTEC M62: Side register
Distance measurement system 3: TESA or NOVOTEC M63: Tensioning bar
TESA: until S317
NOVOTEC: as of S318
CPL
Service Training Electronics
16
16-3
Roland 300
16 CPL
Overview plate cylinder
A-side B-side
-
- +
DA
+
plate cylinder CPL module with tensioning bar
Overview CPL module (removed and from side view)
tensioning bar
B-side A-side
register pins
-A574
potentiometer
tensioning bar M61 gear M62
circumf. o-side side side register
register
M63 -A573 M60
tesioning bar WEKO cable distributer circumf. d-side
31.01.1996, 3CPL1002.CDR
16-4 C 95A 6423 39 – 12. Nov. 2003

CPL 16
Overview CPL module (removed and view from above)

A-side releasing clamping B-side
distance measurement system distance system

circumferential register A-side circumferential B-side
Adjustment of the plate thickness (Version I)

thick thin
plate plate
scale
marking
Allen screw
cutout of the clamping
Adjustment of the plate thickness (Version II)

thick thin
plate plate
+ - + scale + - + - + -
marking
Allen screw
cutout of the clamping
The Allen screws of both systems shown above are set for 0,3mm plates.
This position corresponds to a current of 1000+/-100mA.
11.09.1996, 3CPL1007.CDR
C 95A 6423 39 – 12. Nov. 2003 16-5

16 CPL
CPL components on the A-side
plate cylinder
WEKO translator
B410 register sensor
mounting plate
view from above
gear of the plate cylinder
tooth segment
register
interrogator
0,7mm
WEKO
translator sensor B410, CNO. 21,
-A335.X46
+0,1mm axial
round out mounting plate
0,3mm-0,5mm
For the assembly of the WEKO translator see chapter CPL-training mechanics.
17.05.2002, 3CPL1001.CDR
16-6 C 95A 6423 39 – 12. Nov. 2003

CPL 16
Poti
Poti
WEKO cable distributer -A573 for TESA systems
31.01.1996, 3CPL1003.CDR
C 95A 6423 39 – 12. Nov. 2003 16-7

16 CPL
Poti
Poti
WEKO cable distributer for NOVOTEC systems
31.01.1996, 3CPL1013.CDR
16-8 C 95A 6423 39 – 12. Nov. 2003

CPL 16
WEKO control aparatus -A571
X2 X3 X1
Interface Interface Power supply
to the to the
CPL system process bus
and HOST
operating voltage >45V +10% LED red
operating voltage within tolerance LED green
operating voltage <45V -10% LED blue
data input RX active LED orange
data output TX active LED yellow
16.10.1998, 3CPL1004.CDR
C 95A 6423 39 – 12. Nov. 2003 16-9

16 CPL
16.1.2 Conditions for plate change
a) CPL is configured in MMS and in the LSR-config.

b) Machine is ready for operation ("green").
c) Machine standstill.
d) Machine is made-ready.
e) All CPL components are ready for operation.
f) All guards must be closed during selection from console.
One guard may be open during selection at printing unit.
16.1.3 Register menu
a) Register position white: Motor standstill

b) Register position yellow: Motor is pre-selected
c) Register position gray: Motor running
d) Register position red: Error, e.g. over current, positioning error
16-10 C 95A 6423 39 – 12. Nov. 2003

CPL 16
16.1.4 Description of plate change
7-SEGMENT DISPLAY OPERATING CYCLE PRINTING MACHINE COMMAND
SL
Activate the programm "changing plates" at
1 the console in the main menue MACHINE
Tz Tv
and select the desired printing units.
SL
Push the key "START: Automatic functions"
2 "1" at the console or the key "crawl speed" at
Out of action. Sounding of
the starting signal.
Tz Tv
the last selected printing unit.
SL
Machine moves to the changing
3 "1" plate position and the plate Tz Tv
tension is released
SL
The feed roller moves to the plate and
4 "2" smoothes it out. The plate is pressed out of
the pin strip and the pneumatic guard
Tz Tv
opens automatically. The tensioning bar opens.
5 "3" Push the key "crawl speed". Tz Tv
SL
Remove the plate while holding The tensioning bar is still open and
6 "3" the tail edge.
the plate is moved out (machine is Tz Tv
running reverse).
SL
7 "4" Insert a new/another plate.

Push the key "crawl speed".
Out of action. Sounding of the
starting signal (also within 12sec).
Tz Tv
SL
8 "4" Tensioning bar closes. Tz Tv
9 "5"
SL
Machine moves to the
Tz Tv
leading edge.
SL
The power roller moves to the plate. The
10 "6" plate is smoothed out and it´s tail edge
is pressed into the pin strip, impression on.
Tz Tv
SL = CRAWL SPEED "1" = NUMBER IS FLASHING

Tv = JOG FORWARD
Tz = JOG REVERSE
= SIGNAL "LOW"
= SIGNAL "HIGH"
The starting signal does not sound, when the functions are activated within 12sec.
31.01.1996, 3CPL1005.CDR
C 95A 6423 39 – 12. Nov. 2003 16-11

16 CPL
7-SEGMENT DISPLAY OPERATING CYCLE PRINTING MACHINE COMMAND
SL
The plate is pretensioned.
11 "7" The pneumatic guard closes Tz Tv
automatically.
SL
12 The plate is tensioned, Tz Tv

impression off.
SL
13 "1" "0" Push the key "crawl speed". Tz Tv
SL
The machine moves to the
14 changing plate position of the Tz Tv
next printing unit.
When "10" appears at the seven segment display, then the key "crawl speed" should be pushed within
10sec., otherwise the changing plate mode will be automatically turned off.
SL = CRAWL SPEED "1" = NUMBER IS FLASHING

Tv = JOG FORWARD
Tz = JOG REVERSE
= SIGNAL "LOW"
= SIGNAL "HIGH"
The starting signal does not sound, when the functions are activated within 12sec..
11.09.1996, 3CPL1006.CDR
Notes on the sequence of steps when changing the plate
Step 3: Machine moves in three steps to the plate change position:
242° The angles mentioned

a) are just valid for the first
263° printing unit.
b) All following printing units
300° differ by -95° each (in
c) single side printing
mode).
a) Position 242° is approached via optimized track, i.e. forwards or backwards.
b) Position 263° is approached forwards slowly (approx. 100 s/h). This angular value applies to the first
printing unit only. For angular values of the subsequent units see table in Section "Setting Sensor
B410".
c) Position 300° is approached forwards and fast (approx. 300 s/h).

This angular value applies only to the first printing unit. The angular values for the subsequent units
are determined similarly as in b).
Step 8: a) Remedy for error 86/87 Plate too thick/too thin (from PS 315A2 see "Adjustment of the
16-12 C 95A 6423 39 – 12. Nov. 2003

CPL 16
clamping bar above the electric current value display")
- Acknowledge error message at the Leitstand: Error message on the display of the printing unit
goes off and a "4" appears in the right field
- Press key Crawl speed
- Machine moves backwards to 255° (this value relates to printing unit 1 only). The user can
adjust the clamping bar of the printing plate in this position as necessary.
- Press again key Crawl speed
- Clamping opens
- Press Crawl speed
- Clamping closes
b) Any other error, e.g. overcurrent, positioning error
- Acknowledge error message at the Leitstand: Error message on the display of the printing unit
goes off and a "4" appears in the right field
- Press key Crawl speed
- Clamping opens
- Press Crawl speed
- Clamping closes
Step 11: The pretensioning of the printing plate (-8000µm to 250µm before target position) is done by MMS
Step 12: This step takes place in the background and is not displayed on the seven-segment display of the
printing units.
The LSR carries out the mounting of the printing plate (250µm before target position to target position).
Load plate when there is no plate in the cylinder and when the clamping is open.
Step 3: - see above

- Position before step 3 is assumed (in backward direction)
- Protection guards open automatically
Steps 4-6 are neither displayed nor executed. Plate loading continues as described above in Step 7.
Steps 4 and 6 are executed if the clamping is neither open nor closed.
C 95A 6423 39 – 12. Nov. 2003 16-13

16 CPL
16.1.5 Adjustment of the clamping bar above the electric current value display
1. General
The display is supposed to be a helping tool used when the mechanical pre-tensioning of the clamping
bar is incorrectly adjusted and the CPL system indicates " Plate too thick” or “Plate too thin ".
2. Display of the adjustment range
The mechanical pre-tensioning is indicated on the seven-segment display in form of a standardized

current value:
left display field : standardized actual current values in decimal form

right display field : screwing direction ( " " right, " " left, " " mechanical pre-tensioning within
recommended range)
Adjustment range:
Left display Right display Significance Current

field field consumption
9 Plate too thick – readjustment is absolutely I>1500m
necessary. A
8 Mechanical pre-tensioning of the clamping bar
is correctly adjusted.
Readjustment is recommended.
600mA
7 none Mechanical pre-tensioning is within 1000mA <
6 none recommended range. + I
5 none Readjustment is unnecessary. 100mA <
4 Mechanical pre-tensioning of the clamping bar 1500mA
3 is correctly adjusted.
2 Readjustment is recommended.
1 Plate too thin - readjustment is absolutely
I<600mA
necessary.
CAUTION: Adjustment by evenly turning all locking screws.
3. Adjustment process during plate change
Proceed as follows if the plate thickness is indicated (error code 86 or 87) in Step 4 (clamp plate):
a) Acknowledge error message on the Leitstand.
b) Press the Crawl speed key. The matching position is approached.
c) Execute mechanical readjustment.
d) Press the Crawl speed key. Clamping opens.
e) Press the Crawl speed key. Clamping closes. The MMS software triggers again the plate
thickness testing process.
16-14 C 95A 6423 39 – 12. Nov. 2003

CPL 16
f) If the plate thickness is correct after readjustment, the Plate change key LED blinks and the Crawl
speed key is released. The operator can now continue the plate changing program (Step 5) or
optimize the adjustment (with current display values 2, 3, 4 or 8).
• Readjustment: press Crawl speed key

• Continuation of the plate changing program: press Plate change key
g) If the plate thickness is incorrect (current display 1 or 9), then the LED of the Plate change key is
static on. The operator must press the Crawl speed key and make the necessary readjustment.
16.1.6 CPL activation
LSR register MMS
CplComm
CPL systems
The CPL systems of the R300 are activated both from the Leitstand (Register menu) and from the MMS via
the process bus. The interface for both methods of activation is the module CplComm.MOD.
In-/Outputs
solenoid valve
I I for the CPL
-A350/4 -A350/4 power roller
Byte.Bit 4.6 Byte.Bit 4.3
Y 065
cable no. 53
X6(7) X6(4) X76

X46 X32 X77(17)
cable no. 21 cable no. 20
B 410 S 651 P.O.

-A350/14
CPL register CPL hand guard Byte.Bit 21.0
before 4th ink
form roller
POWER ON Start up sequence
C 95A 6423 39 – 12. Nov. 2003 16-15

16 CPL
POWER ON
LSR sends the actual CPL

parameter file CPLPARA.DAT
to the CPLCOMM.MOD.
The LSR parameter are

compared with the CPL
system parameter.
no Do the parameter
correspond?
yes
Parameter download (5s):

The LSR parameter are
loaded into the flash of the
CPL system.
The state of the CPL is stored

and sent to the MMS.
The nominal values are sent

to the register menue.
31.01.96, 2CPL2001.CDR
16-16 C 95A 6423 39 – 12. Nov. 2003

CPL 16
16.1.7 CPL configuration
LSR configuration
a) Use the key disk in menu GENERAL-SERVICE-CONFIG-EQUIPMENT to configure point

Plate change system:
• none (manual plate change system)

• CPL
• CPL with correction device
b) The CPL systems are sub-nodes 2 (see menu GENERAL-SERVICE-CONFIG-

PROCESS BUS NODES).
c) Check the ID number in menu GENERAL-SERVICE-CONFIG-ID-Numbers, or use key disk to make

correction (e.g. ID-CPL 107).
As of series 327 motors with a transformation ratio of 1760 instead of 1340 have been used in the
EURO-CPL-clamping bars. This resulted in a change of the CPL-ID.
The relation between clamping bar number*, CPL-ID and program version is as follows:
CPL- clamping bar no. CPL-ID program version LSR version

104 up to 314E1 V4.61-3
bis L1569 107 as of 314E2 V4.62-3
115 as of 314L1 V13.40-3
112 as of 314F1 V4.80
ab L1570
113 as of 314L1 V13.40-3
*CPL -clamping bar

number
C 95A 6423 39 – 12. Nov. 2003 16-17

16 CPL
Initial equipment
cylinder series program ID comment

version
Euro 314 to until 314E1 104 iteration number 15, max. deviation 14 µm
326 cutoff current limit motor 1-4 2000 mA
gear transmission ration 1340
distance NOVO-side 0
as of 314E2 107 iteration number 20, max. deviation 10 µm
327 to as of 314F1 112 gear transmission ration from 1340 to 1760
333
334 to 399 as of 330D3 113 MaxPosCircumference from 2000 to 1300
TESA as of 314Ex 107
US 314 to until 314E1 105 iteration number 15, max. deviation 14 µm
399 cutoff current limit motor 1-4 1800 mA
gear transmission ratio 1760
as of 314E2 108 iteration number 20, max. deviation 10 µm
as of 330D3 114 MaxPosCircumference from 2000 to 1300
Re-fitting / upgrades
cylinder series program ID comment

version
Euro 314 to as of 314E2 107 bars with gear transmission ratio 1340
326 as of 314K1
as of 314L1 115
327 to 329 as of 314F1 112 bars with gear transmission ratio 1760
until 314K1
330 to 334 as of 330D3 113 bars with gear transmission ratio 1760
until 330Dx
327 to 334 as of 314L1 113 bars with gear transmission ratio 1760
US 314 to 329 as of 314E2 108
until 314K1
330 to 334 as of 330D3 114
until 330Dx
314 bis 334 as of 314L1 114
Note: The program version 314L1 replaces program version 314K1 and 330Ax to 330Dx and is used as upgrade version from series 314 to series 334.
The 330xx versions are ceased. Starting with series 335 program version 335A1 is used.
d) When changing the LSR configuration do not forget to update both LSR-config disks (see Section MMS).
16-18 C 95A 6423 39 – 12. Nov. 2003

CPL 16
MMS configuration (to PS 335A4)
a) Boot Leitstand using MMS-Install disk 1.
b) No. 6 and then press <ENTER> key.
c) Enter KONFIG.
d) Select menu F3.
e) CPL rough adjustment of register 360° : No
f) Select menu F4.
g) Configure the register type in use:
• conventional (without CPL)

• CPL V1 (pneum. old protection guard)
• CPL V2.1 (pneum. new protection guard; Rilsan cylinder; blue)
• CPL V2.2 (pneum. new protection guard; plasma cylinder; silver)
h) When changing the MMS configuration carry out MMS installation and update both MMS-Install
disk 1. Make disk for archive and send it to MRO. See also section MMS.
C 95A 6423 39 – 12. Nov. 2003 16-19

16 CPL
16.1.8 Rough adjustment of reference sensor B410 (without special program 03)
a) The machine must be in single side printing mode and the rough register in zero position.
b) The distance between interrogation bolt and sensor must be 0.7mm (see page 12-6 in
Section Overview CPL.).
c) Switch impression on.
d) Move machine forward (without reversing direction of rotation) to appropriate position (see table).
Machine angle
Printing unit EUROPE USA
1 263° 323°
2 168° 228°
3 73° 133°
4 338° 38°
5 243° 303°
6 148° 208°
7 53° 113°
8 318° 18°
e) Position the sensor so that the switching shaft is at the bottom edge of the interrogation bolt
(accuracy 0.1mm).
Fine adjustment of reference sensor B410 with special program 03
See section Special programs.
CAUTION: The sequence of rough adjustment followed by fine adjustment must be observed to prevent
possible damage to the pressure roller.
16-20 C 95A 6423 39 – 12. Nov. 2003

CPL 16
16.1.9 Special programs
0 1 Setting the rough register
0 2 Auto-zero of the register motors
0 3 Setting the rough register sensor B410
Conditions for the activation of special programs
a) The machine is ready for operation (all command keys are released).
b) A job is prepared.
c) No more than one pneumatic protection guard is open.
Special programs 01 and 02 end automatically following a successful run.
0 1 Adjustment of the rough register
a) In normal operation keep the key Plate positioning pressed longer than 2s.
b) Use keys Digit Plus or Digit Minus to select special program 0 1.
c) Select by pressing briefly key Plate positioning, confirm.
d) Confirm key Crawl speed. 0 appears on the seven-segment display of the printing unit and the
machine moves into position.
0 2 Auto-zero of the register motors
a) A printing plate must not be inserted and the clamping mechanism of the given printing unit must be
open.
b) The machine must be ready for operation and made-ready.
c) No more than one protection guard may be open in the given printing unit.
d) Keep the Plate positioning key pressed down for longer than 2s.
e) Use keys Digit Plus or Digit Minus to select special program 0 2.
f) Press briefly key Plate positioning to confirm previous selection.
g) Activate auto-zero using the key Crawl speed.
h) The special program switches itself off automatically following successful auto-zero.
Finally, the registers move automatically to the position set on the Leitstand
C 95A 6423 39 – 12. Nov. 2003 16-21

16 CPL
(i.e. not necessarily zero-position).
i) Number 9 1 appears on the seven-segment display if auto-zero fails.
In this case take the following steps to abort the auto-zero procedure:
• Lock the Stop-Halt-Safe key.
• Keep the Plate positioning key pressed longer than

2s.
• Release the Stop-Halt-Safe key.
Activate again auto-zero.
0 3 (Fine) adjustment of rough register sensor B410
a) The clamping mechanism (no plate) of the corresponding printing unit must be open.
b) The machine must be ready for operation and made-ready.
c) The machine is in single side printing mode.
d) Sensor B410 is functional and connected.
e) No more than one pneumatic protection guard may be open in the given printing unit.
f) The rough register is in zero position.
g) Keep the Plate positioning key pressed longer than 2s.
h) Use keys Digit Plus or Digit Minus to select special program 0 3 .
i) Press briefly key Plate positioning to confirm previous selection.
j) Activate Crawl speed key.

First sensor B410 is interrogated. Then position of Step 10 (0 6) is automatically approached,
whereby impression and the pressure roller remain on.
k) Open the pneumatic protection guard.
l) The distance between the pressure roller and the pins must be 0.5...1mm.
Repeat several times points h) to k). If necessary readjust sensor B410
and cancel special program by briefly pressing the key Plate positioning.
Change plate on affected printing unit.
16-22 C 95A 6423 39 – 12. Nov. 2003

CPL 16
Emergency program
This program opens the clamping device to extract a plate in emergency.
a) Open protection guard.
b) Use keys Inch forward and Inch backward to move the clamping bar into an
easily accessible position.
c) Lock key Stop-Halt-Safe and keep the key Plate positioning pressed
longer
than 2 seconds, until the seven segment display shows 0 0.
d) Release again key Stop-Halt-Safe.
e) Press key Crawl speed -> clamping opens and exit emergency program.
f) Machine is ready for operation.
g) Use key Inch forward to extrude printing plate.
16.1.10 Conversion of TESA to NOVO measuring track systems
1. Required material
a) CPL modules with NOVOTEC measuring track systems

b) Secondary transmitter No. 0 37M 5993 44 Plate Cylinder B-Side
c) NOVOTEC firmware
2. Special tools and material A-Side
a) Laptop with HOST program Cable X1, X2, X3

b) 9-pole serial interface cable and
9-pole FF cable
c) Interface converter RS232<>RS485
Drawing 1
3. Conversion
a) Dismantle CPL modules with TESA measuring track systems (see Section "CPL- Training,
Mechanics").
b) Change cable position in plate cylinder according to Drawing 2. Cable clips must be repositioned and
the cables must be formed to make a loop.
The free space created in this way is needed for the new bigger cable distributor.
Plate Cylinder as viewed from above
A-Side
Cable X1, X2, X3
with loop
C 95A 6423 39 – 12. Nov. 2003 16-23

16 CPL
Caution: Make a note of the series numbers of the extracted and the newly mounted
CPL rails in the service report.
Caution: The cables must be attached closely to the cylinder wall at the "cylinder exit" on the
A-side (inside) (see drawing 3) otherwise there is not enough space for mounting the
CPL module.
Cut away of the Plate Cylinder, A-Side
The cable has to be

tight at this point.
Cable X1, X2, X3
c) Exchange secondary transmitter (see Section "CPL Training, Electrics").
d) Load NOVOTEC firmware (use HOST).
e) Mount CPL modules with NOVOTEC measuring track systems (see Section "CPL Training,
Mechanics").
Caution: Do not place the cable from the cable distributor of the CPL module under the
distributor (cable can be damaged by squeezing), but rather on the side around the
distributor.
4. Putting into operation
a) Put CPL into operation in keeping with instructions CPL Section in "Transport, Installation,
Putting into operation R300".
16-24 C 95A 6423 39 – 12. Nov. 2003

CPL 16
16.1.11 Mercotac transmitter (from S331)
General
A new CPL transmitter made by the company Mercotac is used instead of Weko (primary and secondary
transmitter, and control unit) from S331.
Firmware V181.HEX has been added to the CPL service tools disk can be used as before.
This firmware is used for WEKO and MERCOTAC transmission systems. The previous firmware versions
may be loaded into WEKO systems only.
Mercotac can be used as a substitute to S331. For this case the conversion catalog X03TY77603 applies
(parts with mounting plans and assembly instructions).
Overview of electrical components (from S331)

B-Side A-Side
-A350
B410
M1, M2, M3, M4,
B2 -A573, -A574, A572
A092
-A351 NOVO 1, 2 & 3
G057
29V
X057
F021
T100
Q029
BMK Description BMK Description

A092 RS422 adapter M1 Circumferential register, A-side
A350 SPS rack M2 Circumferential register, B-side
A351 Process rack M3 Lateral register
A572 Mercury transmitter Mercotac M4 Clamping
A573 Cable distributor NOVO measuring track systems 1, 2 & 3 (from
S317)
A574 Potentiometer (closed 3.66V, open 0.56V) Q029 Motor protection switch
B2 Interface sub-node 2 T100 Transformer
F021 Automatic cut-out for A572 X057 Terminal
G057 Power supply unit (29V)
Exchange of the MERCOTAC transmitter
C 95A 6423 39 – 12. Nov. 2003 16-25

16 CPL
● Switch off machine

● Loosen voltage supply cable and the data connection of the transmitter
● Loosen follower screw
● Dismantle holding mechanism
● Loosen four screws on plate cylinder
● Carefully push out transmitter and loosen the three cable connections
● Make cable connection to new transmitter
● Push transmitter onto cylinder pin – see that the transmitter does not cock and that the cables are not squeezed
● Use dial gauge to align transmitter (lateral- and radial deviation) and fix using four bolts
● Mount holding mechanism
● Screw follower screw into the guiding hole of the transmitter
CAUTION: The screw may not press against the transmitter since the bearing is very sensitive to cocking!
● Connect voltage supply cable and the data connection of the transmitter
● Switch on machine
● Load firmware (currently V181.HEX) (see description R300 CPL service tools)
● Switch off machine, switch on after approx 20s
● Check function (see instructions for putting into operation)
B410
Rough Reg.
Initiator
Rotation Stop Screw
Power Cable, Black

Data Cable,
Orange
Fig.: Mercotac transmitter, view printing unit A-side
16-26 C 95A 6423 39 – 12. Nov. 2003

CPL 16
Conversion from WEKO to MERCOTAC
● Dismantle WEKO control box, primary and secondary transmitters.

● Mount Mercotac transmitter and align using a dial gauge (lateral- and radial deviation).
● Mount Mercotac holding mechanism.
● Mount rough initiator B410 on new holder and adjust.
● Screw follower screw into the Mercotac guiding hole.
CAUTION: The screw may not press against the transmitter since the bearing is very sensitive to cocking!
● Wire according to circuit diagram.

● Set voltage of 29V on the power supply unit G057. (Trimmer under the cover Tag).
Load firmware V181 in all CPL pots and conduct auto-zero.
Trimmer
Fig.: Power supply unit for MERCOTAC transmitter
With integrated equipment for cardboard it is necessary to drill out the rail for the ELOBAU evaluation unit.
C 95A 6423 39 – 12. Nov. 2003 16-27

16 CPL
A new 35.5 cm long rail, that will carry the power supply unit and the evaluation units for the cardboard guides, will
be mounted.
Trimmer for
setting the Power
output.
G057
ELOBAU evaluation
untit
F21
Q29 new
F23
Fig.: Switch cabinet DW 2 after conversion
● Dismantle Q41 and Q29 including wiring (except for feedback)

● Mount Q29 (new) and line protection switch F21
● The feedback “Protection switch is triggered“ is used only with Q29,
Q29 connected before power supply unit G057
● F21 is used a secondary line protection switch (F023 is mounted only in the 2nd DW)
● G057 must be set to 29V. Currently the default setting from the manufacturer is 24V.
To make the adjustment attach Multimeter to + and – terminals and remove cover cap.
● Set 29V on trimmer.
● The setting can be made during idle run since the network voltage is stable.
CAUTION: The power supply unit in the 2nd printing unit supplies also the transmitter in DW 1. The line protection
switch F023 is therefore mounted only in DW 2.
16-28 C 95A 6423 39 – 12. Nov. 2003

CPL 16
16.1.12 Diagnosis CPL
Error codes on the seven-segment display
LSR No. Display DW Significance
21 001 x1 7 1 Wrong positioning circumference, A-side

21 001 x2 7 2 Wrong positioning circumference, B-side
21 001 x3 7 3 Wrong positioning lateral register
21 001 x4 7 4 Wrong positioning clamping motor
21 002 xx 80 Positioning timeout register motors
21 003 xx -- General communication timeout
21 004 xx -- General transmission error
21 005 xx 81 Positioning timeout clamping motor
21 006 xx -- Temperature rev transmitter too high

21 007 x1 90 Track measuring system 1 error
21 008 xx -- Initialization error
21 009 x1 61 Over Current error circumference, A-side

21 009 x2 62 Over Current error circumference, B-side
21 009 x3 63 Over Current error lateral register
21 009 x4 64 Over Current error clamping motor
21 010 xx -- No valid program in flash
21 011 xx -- No valid set of parameters in flash
21 012 xx 90 Data for measuring track system in flash

invalid
21 013 xx 90 Loss of actual value, new calibration required
37 065 xx 86 Plate too thick
37 066 xx 87 Plate too thin
37 067 xx 88 Sensor B410 defect
37 068 xx 91 Auto-zero error
37 071 xx 90 Communication LSR->CPL interrupted
Status CPL (offline)
C 95A 6423 39 – 12. Nov. 2003 16-29

16 CPL
The status of the CPL system can be determined by entering <ALT> 159 (press <Alt> key and enter 159)
in menu REGISTER.
To do so an external keyboard is necessary and plate change must be cancelled in all printing units.
The selection of the status mask is cancelled by pressing any key.
The following mask appears on the monitor after pressing <ALT> 159:
position of the circumference register A-side

bit 7...4 3...0 position of the circumference register B-side
high low nibble (HEX) position of the side register
PU
D0 D1 D2 D3 POS1 POS2 POS3
1 20 92 08 02 -100 0 5
DEC in mm
2 ... ... ...
3 ... ...
4 ...
.
.
.
As the status bytes D0, D1, D2 and D3 are presented in hexadecimal format they have to be converted to
binary format before they can be decoded.
Example: D1 = 92HEX
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

1 0 0 1 0 0 1 0
Note: If the statuses are filled by a string of zeros, then it means that CPL communication is
interrupted or was interrupted while booting.
16-30 C 95A 6423 39 – 12. Nov. 2003

CPL 16
Status Frame
D0 = Status_Byte 0
Bit 0 : 0 = Motor 1 required position achieved

1 = Motor 1 required position not achieved
Bit 4 : 0 = Emergency off not active

1 = Emergency off active (no new positioning possible)
Bit 5 : 0 = Clamping bar not clamped
1 = Clamping bar clamped
Bit 6 : 0 = Clamping bar not open
1 = Clamping bar open
Bit 7 : 0 = Temperature rev transmitter O.K.
1 = Limit temperature of the rev transmitter exceeded
D1 = Status_Byte 1
Bit 0 : 0 = No potentiometer error (as of V1.85)

1 = Potentiometer error (wrong pot. change in value; as of
V1.85)
Bit 1 : 0 = Readjustment switched off
1 = Readjustment switched on
Bit 2 : 0 = No error during positioning
1 = Error during positioning (required position
not achieved, command aborted)
Bit 3 : 0 = No error during flash programming
1 = Error during the programming of the flash
Bit 4 : 0 = No program in flash
1 = Valid program in flash
Bit 5 : 0 = Flash erase finished
1 = Flash erase in progress
Bit 6 : 0 = Flash programming of the last data set
completed
1 = Flash programming in progress
Bit 7 : 0 = Parameter set in flash invalid
1 = Parameter set in flash valid
D2 = Status_Byte 2
C 95A 6423 39 – 12. Nov. 2003 16-31

16 CPL
Bit 0 : 0 = Meas. system No. 1 O.K.

1 = Error in meas. system No.1
Bit 3 : 0 = No valid data for meas. system saved in flash
1 = Data for meas. system saved in flash are valid
Bit 5,4 : 00 = Plate thickness invalid

01 = Plate thickness too thin
10 = Plate thickness too thick
11 = Plate thickness O.K. (clamp)
Bit 6 : 0 = Actual position valid (TESA values)

1 = Actual position lost
Bit 7 : 0 = CPL system O.K.
1 = CPL system failed (positioning impossible)
D3 = Status_Byte 3
Bit 0 : 0 = Last positioning command completed

1 = Last positioning command in process
(only change from 1 to 0 is spontaneously indicated)
Bit 1 : 0 = Clamping bar closed below 60%
1 = Clamping bar closed above 60%
Bit 2 : 0 = Auto-zero O.K.
1 = Auto-zero error
Bit 3 : 0 = No timeout clamping
1 = Timeout clamping
Bit 4 : 0 = Current limit Motor 1 not exceeded
1 = Current limit Motor 1 exceeded
16-32 C 95A 6423 39 – 12. Nov. 2003

CPL 16
Hexadecimal – Binary conversion table
HEX BINARY
0 0 0 0 0
1 0 0 0 1
2 0 0 1 0
3 0 0 1 1
4 0 1 0 0
5 0 1 0 1
6 0 1 1 0
7 0 1 1 1
8 1 0 0 0
9 1 0 0 1
A 1 0 1 0
B 1 0 1 1
C 1 1 0 0
D 1 1 0 1
E 1 1 1 0
F 1 1 1 1
Example: 56HEX
HEX 5 6
BINARY 0 1 0 1 0 1 1 0
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
C 95A 6423 39 – 12. Nov. 2003 16-33

16 CPL
Service connection notebook to CPL
An RS232/RS484 converter must be used for the connection of a notebook to the CPL system.
To establish a connection pull out plug–A351/B2 and plug it into the interface converter.
1 5
HOS CPL-System
T
4a
2 3 4 -A351, B2,
RS232 Spannungs-
RS485
versorgung
Konverter
No. to S330 from S331

1 Notebook Notebook
2 MRO converter: 1:1 cable MRO converter: 1:1 cable
MRG converter: RODIMO cable MRG converter: RODIMO cable
3 MRO (from Parafin set) or MRG MRO (from Parafin set) or MRG
RS232/RS485 converter; RS232/RS485 converter;
Voltage supply via SPS power supply unit in Voltage supply via –A351/B2 (with
slot 1 (only for MRG converter), or –A351/B2 Y cable)
or external 5V power supply unit
4 1:1 cable (can: Y cable W0049/1 1:1 cable (must: Y cable W0049/1
item number: 1 37X 2851 90) item number: 1 37X 2851 90)
4a Branch from 4 to voltage supply; Branch from 4 to voltage supply;
plugged into –A351/B2 plugged into –A351/B2
5 WEKO control device –A571 MERCOTAC transmitter –A572
Voltage supply via SPS power supply unit in slot 1 (only for MRG converter):
SPS-Power supply,
!
Using the SPION08 program instead of
Slot 1
connecting the laptop to the converter via

the CPL-cable W0049/1 (1 37X 2851 90)
the CPL-cable W0906 (0 39G 0392 39)
5V has to be used.
0V
Program SPION08 has to be started
0V from HDD in DOS!
5V
16-34 C 95A 6423 39 – 12. Nov. 2003

Beschreibung / Description 0 39E 7151 39
R300 CPL-Servicetools
Version V02.00 Index 4CPL Service Tools Blatt : 1 von 44
File : M3E16_03_CPL-
Datum: 05.06.97 Name: WLaf / ABal/ KMet ServiceTools_01.doc Tel.: 3486 / 3738 / 3729
Beschreibung / Description
Version V02.00 Index 4
Version
Version Index Datum/Date Bemerkung/Comment verantwortl./responsible

V01.00 0 05.06.97 initial WLaf
1 03.12.97 neue Firmware V170 WLaf
2 16.12.97 R307 hinzu WLaf
V02.00 0 27.05.98 neue Firmware V180 WLaf
Mercotac-Übertrager
V02.00 1 18.09.98 neue Firmware V181 WLaf
2 22.09.99 neue CPLPARA.DAT WLaf
3 18.04.00 Reset LSR-CPL-Calib. ABal
mit hinzu
HOST05 V02.01 für
schnelle PC's (> 200MHz)
4 13.01.03 neue Firmware V185 KMet
Spion für Diagnose
Zyklisch V185T
Longstatus V185L
Inhaltsverzeichnis / Table of contents
1. Preface
2. Selection of the service tools
3. Description HOST05
3.1. General description

3.2. Functions
3.3. Description of functions
3.3.1. Tighten/untighten plate
3.3.2. Clamp tensioning bar
3.3.3. Open tensioning bar
3.3.4. Send new nom. values (travel)
3.3.5. Request actal values
3.3.6. Request status
3.3.7. Erase flash
3.3.8. Program download
3.3.9. Program version
3.3.10. Emergency stop
3.3.11. Calibrate measuring systems
3.3.12. New time/PWM - nominal values
3.3.13. Current- voltage- temperature
3.3.14. ASCII-string sensor
3.3.15. Auto calibration
3.3.16. Request parameters
3.3.17. Send new parameters
3.3.18. Readjustment ON
3.3.19. Readjustment OFF
3.3.20. Sum error sensor
3.3.21. Request measuring systems
3.3.22. Request measuring data
3.3.23. Hardware configuration
3.4. Messages
3.5. Modifications to the preceding description
3.5.1. Firmware
3.5.2. Parameter record
4. Description LSRHOST
4.1. Preface
4.2. Program start LSRHOST
4.3. Indication of the machine configuration
4.4. Selection of functions
4.5. Description of function
4.5.1. Tighten/untighten plate
4.5.2. Clamp tensioning bar
4.5.3. Open tensioning bar
4.5.4. Send new nom. values (travel)
4.5.5. Request measuring systems
4.5.6. Request status
4.5.7. Program version
4.5.8. Emergency stop
4.5.9. Calibrate measuring systems
4.5.10. New time/PWM - nominal values
4.5.11. Current- volatge - temperature
4.5.12. Auto calibration
4.5.13. Request parameters
4.5.14. Readjustment ON
4.5.15. Readjustment OFF
4.6. Termination of service tools LSRHOST
5. Description CPLINST (Download CPL-firmware)

5.1. General description of function
5.2. Program start
5.3. Indication of machine configuration
5.4. Selection of the CPL-version to be loaded
5.5. Display of the currently loaded CPL-versions
5.6. Download
5.7. Termination of the Download-program
6. Resetting the LSR-CPL-Calibration

6.1. Preface
7. Description Spion
7.2. Function V185T cycle
7.3. Function V185L Longstate
1. Preface
The CPL-service tools LSRHOST, CPLINST (download) and HOST05 offer you
possibilites of diagnosis as well as the download of the CPL-firmware for CPL-systems.
LSRHOST and CPLINST communicate with the CPL-systems via the central control
console.
The programs are on the bootable CPL-service tool diskette. Switch off the machine,
insert the diskette into the drive at the central control console and switch the machine
on again (cold start).
HOST05 establishes the connection to a CPL-system via the serial interface of a PC with
a converter directly via the control device. The PC starts the program with A:HOST05.
In this case, you must not boot with the CPL-service tool diskette.
From version V02.00, HOST05 offers user guidance in German and English.
Current versions:
HOST05 V02.01
LSRHOST V01.01
CPLINST (DOWNLOAD) V02.02
2. Selection of the service tools

The PC starts the program HOST05 with
A:HOST05
In this case, you must not boot with the CPL-service tool diskette.
To start LSRHOST, CPLINST or Reset LSR-CPL-Calibration, you must boot the central
control console from the CPL-service tool diskette. For this purpose switch off the machine,
insert the CPL-service tool diskette into the drive at the central control console and switch the
machine on again.
The following selection display will appear:
ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Ä¿
³ CCCCC PPPPP LL ³
³ CC PP PP LL ³
³ CC PPPPP LL - Servicetools ³
³ CC PP LL ³
³ CCCCC PP LLLLLL ³
³ ³
³ ³
³ ³
³ 1 Program LSRHOST ³
³ 2 Program CPLINST (DOWNLOAD) ³
³ ³
³ 3 Reset LSR-CPL-Calibration ³
ÃÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Ä´
³ ³
³ Select a number and press ENTER-key <Ù ³
³ ³
³ Nummer w„hlen und ENTER-Taste <Ù dr cken ³
ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
ÄÙ
To start the corresponding program, enter 1,2 or 3 and press ENTER.

3. Description HOST05
3.1. General Description
On the CPL-service tool diskette you will find the test and service program HOST05
version V2.00 for R300-machines with CPL together with the CPL-parameters and
firmware versions for TESA-measuring systems V101.HEX and NOVOTECHNIK-
measuring systems V185.HEX and a special HEX-file SPION. HEX / V185T.HEX /
V185L.HEX for the identification of measuring systems.
For communication between HOST05 and CPL (via the serial interface COM1), interface
converter RS232 - RS485 is absolutely required. Contact to the CPL will be established
only at least 45 seconds after application of voltage. Only after a status telegram request
can you receive spontaneous status telegrams.
After the program start with A:HOST05 a mask for selecting the user guidance in German
or English will appear. To select the desired language, use the arrow keys .
CCCCC PPPPP LL V2.00

CC PP PP LL
CC PPPPP LL - Servicetool HOST05
CC PP LL
CCCCC PP LLLLLL © 1997 by MAN-Roland, Offenbach
Ä¿
³ Version ³
³ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿
³
³³ Deutsch ³³
³³ English ³³
³³ ³³
³³ ³³
³³ ³³
³³ ³³
³ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ
³
³ = Auswahl <Ù = Enter F3 = Ende ³
ÄÙ
3.2. Functions
All functions are shown in the mask of HOST05:
ÉÍ HOST05 - commands V2.00 ÍÍÍÍÍÍÍÍÍ» ÉÍÍÍÍÍ Last frame from HOST ÍÍÍÍÍÍÍ»
º 1. Tighten/untighten plate º º º
º 2. Clamp tensioning bar º º º
º 3. Open tensioning bar º º º
º 4. Send new nom. values (travel) º º º
º 5. Request actual values º º º
º 6. Request status º º º
º 7. Erase flash º º º
º 8. Program download º º º
º 9. Program version º º º
º 10. Emergency stop º º º
º 11. Calibrate measuring systems º ÈÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ¼
º 12. New time/PWM - nominal values º ÉÍÍÍÍ Last frame from CPL ÍÍÍÍÍÍÍÍÍ»
º 13. Current- voltage- temperature º º º
º 14. ASCII-string sensor º º º
º 15. Auto calibration º º º
º 16. Request parameters º º º
º 17. Send new parameters º º º
º 18. Readjustment ON º º º
º 19. Readjustment OFF º º º
º 20. Sum error sensor º º º
º 21. Request measuring systems º º º
º º º º
ÈÍ ↑↓ ENTER STOP=Space ESC to exit Í¼ ÈÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ¼
By pressing the key you will receive a further function (shown in the next display) .
ÉÍ HOST05 - commands V2.00 ÍÍÍÍÍÍÍÍÍ» ÉÍÍÍÍÍ Last frame from HOST ÍÍÍÍÍÍÍ»
º 4. Send new nom.values (travel) º º º
º 11. Calibrate measuring systems º º º
º 12. New time/PWM - nominal values º ÈÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ¼
º 13. Current- voltage- temperature º ÉÍÍÍÍ Last frame from CPL ÍÍÍÍÍÍÍÍÍ»
º 14. ASCII-string sensor º º º
º 15. Auto-calibration º º º
º 16. Request parameters º º º
º 17. Send new parameters º º º
º 18. Readjustment ON º º º
º 19. Readjustment OFF º º º
º 20. Sum error sensor º º º
º 22. Request measuring data º º º
º 23. Hardware configuration º º º
º º º º
3.3.1. "Tighten/untighten plate"
After the selection of this function, enter the corresponding nominal values.
Example for entering the nominal position:
A- Nom. val. (travel) : -8000

B- Nom. val. (travel) : -8000
S- Nom. val. (travel) :0
Tolerance : 10
The value behind "Tolerance" indicates the max. deviation (in µm) that is tolerated
between nominal and actual value.
Actual positions of the measuring system are shown in the displayed status telegram.
This function is a special MMS nominal value command.
3.3.2. "Clamp tensioning bar"

This function serves to clamp the tensioning bar.

Information on plate thickness is given in column 3 of the status.
Plate OK too thinn too thick
PltT4 1 1 0
... 1 0 1
The max. armature current of the clamping motor, calculated from intervals of 100 ms,
is used for measurement.
I < 600 mA : Plate too thinn

600 mA < I < 1500 mA : Plate thickness correct
I > 1500 mA : Plate too thick
I > 2000 mA : Current limit, motor will be switched off
3.3.3. "Open tensioning bar"
This function serves to open the tensioning bar.
3.3.4. "Send new nom. values (travel)"
This function is identical with function 1, but the central control console command is
used here instead of the MMS-command. Moreover, there is no tolerance value. The
tensioning bar can only be moved between +1500µm and -1500µm.
3.3.5. "Request actual values"
This command serves to request the actual position of the measuring systems.
If a positoning is in process, the actual position will be indicated before positioning
start.
3.3.6. "Request status"
This command serves to request the status of the CPL-system.

Structure of the status mask:
ÉÍ HOST05 commands V2.00 ÍÍÍÍÍÍÍÍÍÍÍ» ÉÍÍÍÍÍ Last frame from HOST ÍÍÍÍÍÍÍ»
º 1. Tighten/untighten plate º º º
º 4. Send new nom. values (travel) º º º
º 11. Calibrate measuring systems º ÈÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ¼
º 12. New time/PWM - nominal values º ÉÍÍÍÍ Last frame from CPL ÍÍÍÍÍÍÍÍÍ»
º 13. Current- voltage- temperature º º M1....? RP....? Sys1..0 PosOn.? º
º 14. ASCII-string sensor º º M2....? RA....? Sys2..0 Tb60%.? º
º 15. Auto calibration º º M3....? PosEr.? Sys3..0 A-err.? º
º 16. Request parameters º º M4....? FPErr.0 F-Dat.1 To-cl.? º
º 17. Send new parameters º º STOP..? Prgr..1 PltT4.? ImM1..? º
º 18. Readjustment ON º º Tb.cl.? FlEr..0 ...? ImM2..? º
º 19. Readjustment OFF º º open.? FprgD.0 IposM.0 ImM3..? º
º 20. Sum error sensor º º Tmp...? Para..1 CPLErr0 ImM4..? º
º 21. Request measuring systems º º A-Act.val.: 200 B-Act.val.: 200 º
º 22. Request measurinmg data º º S-Act.val.: 30 º
º º º Cl-cu.max : 0 AD-v.poti : 0 º
In case of correct functioning, important status bits are designated with 0 or 1.
Status bits designated with "?" may be 0 or 1.
The values in the last line are only of importance to the clamping of the tensioning bar.
By pressing the space bar (STOP = space) you activate function 10 „Emergency stop“.
If you designate the columns in the lower right window as status byte 0 - 3 and the
lines as bit 0 - 7, the information can be assigned as follows:
Status-byte 0
Bit 0 : 0 = Motor 1, nominal position reached
:1 = Motor 1, nominal position not reached
Bit 4 : 0 = Emergency stop not in process
:1 = Emergency stop in process
Bit 5 : 0 = Tensioning bar not clamped
:1 = Tensioning bar clamped
Bit 6 : 0 = Tensioning bar not open
:1 = Tensioning bar open
Bit 7 : 0 = Temperature of rotary transformer OK
:1 = Limit temperature of rotary transformer exceeded
Status-byte 1
Bit 0 : 0 = Register pins open
:1 = Register pins closed
Bit 1 : 0 = Readjustment OFF
:1 = Readjustment ON
Bit 2 : 0 = Positioning: OK
:1 = Positioning: error
Bit 3 : 0 = When programming "flash": no error
:1 = When programming "flash": error
Bit 4 : 0 = No program in "flash"
:1 = Valid program in "flash"
Bit 5 : 0 = "Erase flash" terminated
:1 = "Erase flash" in process
Bit 6 : 0 = "Flash" programming of last data record terminated
:1 = "Flash" programming in process
Bit 7 : 0 = Invalid parameter record in "flash"
:1 = Valid parameter record in "flash"
Status-byte 2
Bit 0 : 0 = Measuring system 1: OK
:1 = Measuring system 1: Error
Bit 3 : 0 = No valid data for measuring system stored in "flash"
:1 = Data for measuring system in "flash" are valid
Bit 5,4: 00 = Invalid plate thickness
01 = Plate too thinn
10 = Plate too thick
11 = Plate thickness OK (clamps)
Bit 6 : 0 = Actual position: valid
:1 = Actual position: lost
Bit 7 : 0 = CPL-system: OK
:1 = CPL-system: failure
Status-byte 3
Bit 0 : 0 = last positioning command: terminated
:1 = last positioning command: in process
Bit 1 : 0 = Plate clamping: no 60%
:1 = Plate clamping: 60%
Bit 2 : 0 = Auto. calibration: OK
:1 = Auto. calibration: error
Bit 3 : 0 = Clamping: no timeout
:1 = Clamping: timeout
Bit 4 : 0 = Current limit, motor 1, not exceeded
:1 = Current limit, motor 1, exceeded
3.3.7. "Erase flash"
By entering "Y" after entering "Erase Flash", the flash-memory will be erased.
By using the function "DOWNLOAD", you can re-load it.
3.3.8. "Program download"
This function serves to load a new program into the flash-memory.

The flash-memory must be erased before, see point 3.3.7.
Hex-File for TESA-measuring systems : V101.HEX

Hex-File for NOVOTECHNIK- measuring systems : V18x.HEX
Procedure:
Function 6 "Request status"
Enter function 7 "Erase flash" and "Y".
Wait approx. 30 seconds
Select function 8 "Program download"
Enter the name of the Hex-File, e.g. V18x.HEX.
The code is now loaded into the flash.
The Hex-Code will be displayed.
The last loaded code remains in the displayed window.
Wait approx. 60 seconds.
3.3.9. "Program version"
This command serves to request the program version of CPL-system. The program
version of EPROM and FLASH will be displayed as well as the check sum.
3.3.10. "Emergency stop"
This command serves to switch off all motors. "Emergency stop" remains
active until you give the next positioning command.
3.3.11. "Calibrate measuring systems"
Systems for measuring travel will be calibrated electrically. Thus, they receive new
reference values (0) which will be stored in the flash memory.
3.3.12. "New time/PWM - nominal values"
This command serves to preset durations and PWM nominal values for the motors.
Example of input:
Time nom. val. motor 1 :0

Time nom. val. motor 3 : 600
PWM nom. val. motor 1 : 50
Executions [1..9] :1
In this example, the side register is moved toward "+".

In case of nominal values of less than 50 %, the register is moved toward "-".
The number behind "Executions" indicates how often the clamping bar will be moved
with the indicated values.
For motors you do not want to move, enter the value 50.
3.3.13. "Current - voltage - temperature"
This function serves to request the currents of the four motors, the operating voltage
and the temperature of the rotary transformer.
3.3.14. "ASCII-String Sensor"
This function refers to the Tesa-measuring systems only.

The V24-buffer of the Tesa-systems will be transferred.
3.3.15. "Auto calibration"
For a quick and easy resetting of the tensioning bar to the mechanical zero position
after a loss of data, function 15 ("Auto calibration") has been integrated in HOST05.
0
Initialization:
Iter.max := 30
Delta_nom_pos := 50
I_limit := 1000
2
Move motor 1 and 2
against block:
18 V (20%), max 10 pulses
each 1600 ms
I >= 500 mA
10 20
Move A away
from block: 99 Move B away
from block:
- Delta_nom_pos = 100 Motor 1 at block Motor 2 at block
- Delta_nom_pos = 100
- Calibrate TESA 1,2,3
- Move motor 1 to -1500
Motor 1 and. 2 at block
25
11 Move A/B away
21
Move mot. 2 against block: from block: Move mot.1 against block:
- 18 V (20%), max. 10 pulses - Delta_nom_pos = 100 - 18 V (20%), max. 10 pulses
each 1600 ms - Calibrate TESA 1,2,3 each 1600 ms
- Calibrate TESA 2 - Move motor 1, 2 to -1500 - Calibrate TESA 1
12 22
Move B away 88 Move A away
from block: from block:
- Delta_nom_pos = 100 - Delta_nom_pos = 100
- Move motor 2 to -1500 - Move motor 1 to -1500
- Calibrate TESA 2 - Calibrate TESA 1
30
Move motor 1 + 2
close to block
- Move motor 1 + 2 to +1200
31
Move circ.reg. A+B to block:
- Switch on motor 1 + 2
with 6 V (40%) for 3000 ms
77
to page
02
77
from page 01
32
Set registers to printing
leading edge:
- Move motor 1 + 2 to -1500
40
Move motor 3
against block:
18 V (20 %) max 10 pulses
each 1600 ms
- Calibrate TESA 3
41
Move S away from block:
42
Move motor 3
against block:
6V (40 %) max 10 pulses
each 1600 ms
- Calibrate TESA 3
43
Set registers to printing
leading edge:
200
Side register
printing leading edge:
66
End
3.3.16. "Request parameters“
The CPL-system sends its parameter record.

To display the parameters one by one, press the ENTER-key.
3.3.17. "Send new parameters"
This command serves to send the parameters of the entered ID-number from the file
CPLPARA.DAT to the CPL-system. When the central control console is booted,
the parameter record of the CPL-system will be overwritten by the parameter record
loaded in the central control console. Modifications to the parameter record must also
be made to the central control console so that they are effective during production.
Parameter file CPLPARA.DAT contains several parameter records designated by

different ID-numbers.
Example of a parameter record in CPLPARA.DAT (identical for TESA- and

NOVOTECHNIK-measuring systems)
103 ; (01) Parameter block-ID (V 1.03)

4 ; (02) Reg. pins: bounce stop period [* 50 ms]
8 ; (03) Measuring delay motor current[* 10 ms]
55 ; (04) Lower limit temperature [ C]
60 ; (05) Upper limit temperature [° C]
1500 ; (06) I max for plate OK [mA]
600 ; (07) I min for plate OK [mA]
-8000 ; (08) Min pos circumf. reg. [µm]
2000 ; (09) Max pos circumf. reg. [µm]
-1500 ; (10) Min pos side register [µm]
1500 ; (11) Max pos side register [µm]
-2000 ; (12) Min travel circumf. reg. [µm]
2000 ; (13) Max travel circumf. reg. [µm]
-1500 ; (14) Min travel side register [µm]
1500 ; (15) Max travel side register [µm]
-1500 ; (16) Deplacement circumf. reg. [µm]
0 ; (17) Deplacement side register [µm]
8000 ; (18) Eccentric radius circumf. [µm]
4500 ; (19) Eccentric radius side reg. [µm]
1340 ; (20) Escape gear ratio [/ 10]
235 ; (21) Worm gear ratio [/ 10]
110 ; (22) Armature resist. circ. reg. A [* 0.1 Ohm]
110 ; (23) Armature resist. circ. reg. B [* 0.1 Ohm]
110 ; (24) Armature resist. side reg. [* 0.1 Ohm]
420 ; (25) Motor constant circ. reg. A [* 0.1 mNm/A]
420 ; (26) Motor constant circ. reg. B [* 0.1 mNm/A]
420 ; (27) Motor constant side reg. [* 0.1 mNm/A]
10 ; (28) Max deviation nom. position [µm]
200 ; (29) Min switch-on period, motors [ms]
2000 ; (30) I max motor circ. reg. A [mA]
2000 ; (31) I max motor circ. reg. B [mA]
2000 ; (32) I max motor side reg. [mA]

2000 ; (33) I max motor clamping [mA]
400 ; (34) Current initial value motors [mA]

12 ; (35) Iteration step number [Steps]
1 ; (36) TesaMeas. gear ratio []
0 ; (37) Reserve37 []
0 ; (38) Reserve38 []
0 ; (39) Reserve39 []
0 ; (40) Reserve40 []
3405 ; (41) Distance TesaA-center [* 0.1 mm]

3248 ; (42) Distance TesaB-center [* 0.1 mm]
0 ; (43) Distance TesaS-center [* 0.1 mm]
0 ; (44) Reserve44 []
0 ; (45) Reserve45 []
0 ; (46) Reserve46 []
0 ; (47) Reserve47 []
0 ; (48) Reserve48 []
0 ; (49) Reserve49 []
0 ; (50) Reserve50 []
3.3.18. "Readjustment ON"
Readjustment will be switched on.

If the actual position deviates from the nominal position by more than the set
tolerance (e.g. 10 µm, see parameter 28 CPLPARA.DAT), the position will be
corrected automatically. The nominal position is set with an exactness of 10 µm.
When the CPL-system is started, the readjustment is always switched off.
3.3.19. "Readjustment OFF"
Readjustment will be switched off.
3.3.20. "Sum error sensor"
This function is effective only with TESA measuring systems.

The sum of the TESA errors will be displayed.
3.3.21. "Request measuring systems"
The actual values of the measuring systems are requested.

Contrary to 3.3.5., the measuring systems are requested directly here.
3.3.22. "Request measuring data"
Indication "Measuring data 0-2":

100 current values of drive motors 1-3 (each value determined within 10 msec)
are stored in a file (presetting MESS.DAT).
Indication "Measuring data No. 3":

100 current values of drive motor 4 (each value determined within 100 msec)
are stored.
Indication "Measuring data No. 4-6":

100 current values of drive motors 1-3 (each value determined within 100 msec)
are stored.
3.3.23. "Hardware configuration"
This function serves to determine the type of measuring system of a printing unit
(NOVO or TESA).
By selecting this function, you erase the flash. Load the file SPION.HEX with the
function DOWNLOAD. Thereafter the measuring system identification will be
requested and displayed automatically.
Once you have used this function, you can no longer activate the
other functions. For this purpose, you must reload the current
firmware version with the function DOWNLOAD (see function
DOWNLOAD).
3.4. Messages
3.4.1. Direction of sending
HOST signals: "Check the CPL system".

Command could not be sent to CPL.
HOST signals: "Signals from COM1 are not returned.

Check the connections".
Command could be sent to CPL, but the signals are not returned.
3.4.2. Direction of reception
HOST signals: " Frame - Error"

Telegram received with an unknown command.
HOST signals: "BCC - error"

Wrong check sum in telegram.
3.5. Modifications to the preceding decriptions
3.5.1. Firmware
Firmware version V160_L.HEX has been replaced by version V169.HEX.
Modifications made:
- Check of potentiometer for clamping. Check dU / dt during clamping

process. With modifications of minor importance, interruption of clamping
and signalization of positioning error. Protection for potentiomenter.
- When the side register is positioned, a compensational movement of the

circumferential register is carried out at the same time, i.e. the printing
tail ege will very quickly follow a displacement of the tensioning bar.
A slow, passive drifting of the register, especially at the tail edge, is thus
prevented or avoided.
With an intentional positioning of the side register, you first have to

pretension the circumferential register which is in the desired direction
toward the printing leading edge.
This pretension will be neutralized while positioning the side register.
Firmware version V169.HEX has been replaced by version V170.HEX.
Firmware version V185.HEX was not changed.
3.5.2. Parameter record
The parameter record in CPLPARA.DAT has been extended.
The parameter record has not changed from Version V170.HEX to V180.HEX.
The parameter record in CPLPARA.DAT has been extended (ID 113-115).

4. Description of LSRHOST
4.1. Preface
The CPL service tool LSRHOST, version V01.01, offers possibilities of diagnosis
for CPL-systems via central control console.
The diagnosis functions only relate to the selected CPL-system.
CPL-firmware and CPL-paramerter record cannot be modified.
Since the inputs and data requests must be plausible and will not be checked,
this service tool has to be used carefully.
The program starts from a bootable disk (cold start).
After booting and selecting function 1, the program will start.
After the program start, you can select between user guidance in English or German.
Enter the machine configuration in a selection mask.
If the number of the detected CPL-systems corresponds to the configuration, the operating
mask of the service tool will be displayed. If not, the program will be terminated after
the confirmation of the corresponding message.
4.2. Program start LSRHOST
Switch off the machine before you insert the CPL service tool disk into the disk drive of the
central control console. When the machine is switched on, the system will be booted from
the CPL service tool disk and the LSRHOST-program will start.
The mask for the selection of the user guidance in English or German appears.
To select the desired language, use the arrow keys .

CC PP PP LL
CC PPPPP LL - Servicetool LSRHOST
CC PP LL
Ä¿
³ Version ³
³
³³ Deutsch ³³
³³ English ³³
³³ ³³
³³ ³³
³³ ³³
³³ ³³
³
³ = Auswahl <Ù = Enter F3 = Ende & Boot ³
ÄÙ
This mask serves to enter the machine configuration. After selecting e.g. a R304 machine
in the left column, the selector bar will jump to „with coating“ in the right column.
In the right column you have to select between „with coating“ and „without coating“.
Wrong machine indications will lead to incorrect assignations of the CPL-systems

as well as to wrong indications.

CC PP PP LL
CC PPPPP LL - Servicetool LSRHOST
CC PP LL
Ä¿
³ Configuration ³
³
³³ R302 with coating ³³
³³ R304 without coating ³³
³³ R305 ³³
³³ R306 ³³ ³³
R307 ³³
³³ R308 ³³
³³ ³³
³
³ = Selection <Ù = Enter F3 = End & Boot ³
ÄÙ
4.4. Selection of functions
In this mask all operating functions will be displayed for selection in the left window.
For selection, use the arrow keys .
The selected CPL-system appears on a blue background in the left lower window.
For switching over to another CPL-system, use the arrow keys ⇔.
In the line being above, the node numbers of the central control console addresses
for the individual CPL-systems are displayed for information.
Inputs and input requests appear in the upper right window.

Outputs and indications appear in the lower right window.
All inputs and outputs relate to the selected CPL-system.
ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿ ÚÄÄÄÄÄ Last frame vom HOST ÄÄÄÄÄÄÄÄ¿

³ LSRHOST - commands V1.01 ³³ ³
³ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿³ ³ ³
³³ 1. Tighten/untighten plate ³³ ³ ³
³³ 2. Clamp tensioning bar ³³ ³ ³
³³ 3. Open tensioning bar ³³ ³ ³
³³ 4. Send new nom. values (travel) ³³ ³ ³
³³ 5. Request measuring systems ³³ ³ ³
³³ 6. Request status ³³ ³ ³
³³ 7. Program version ³³ ³ ³
³³ 8. Emergency Stop ³³ ³ ³
³³ 9. Calibrate measuring systems ³³ ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ
³³ 10. New time/PWM - nominal values ³³ ÚÄÄÄÄÄ Last frame vom CPL ÄÄÄÄÄÄÄÄÄ¿
³³ 11. Current- Voltage- Temperature ³³ ³ ³
³³ 12. Auto calibration ³³ ³ ³
³³ 13. Request parameters ³³ ³ ³
³³ 14. Readjustment ON ³³ ³ ³
³³ 15. Readjustment OFF ³³ ³ ³
³ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ³ ³ ³
³ ⇑⇓ <Ù STOP=Space F3=End ³³ ³
ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ ³ ³
ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿ ³ ³
³ Node 11 10 9 8 7 6 5 4 ³ ³ ³
³⇔ CPL 1 2 3 4 5 6 7 8 ³ ³ ³
ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ
ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ
4.5. Description of functions
4.5.1. "Tighten/untighten plate"
After selecting this function, enter the corresponding nominal values.

Example of entering the nominal position:
A- Nom. value (travel) : -8000

B- Nom. value (travel) : -8000
S- Nom. value (travel) :0
Tolerance : 10
The value behind "Tolerance" indicates the max. deviation (in µm) that is tolerated
between nominal and actual value.
Actual positions of the measuring system are shown in the displayed status telegram.
This function is a special MMS nominal value command.
4.5.2. "Clamp tensioning bar"
This function serves to clamp the tensioning bar.

Information on plate thickness is given in column 3 of the status.
Plate OK too thinn too thick
PltT4 1 1 0
... 1 0 1
The max. armature current of the clamping motor, calculated from intervals of 100 ms,
is used for measurement.
I < 600 mA : Plate too thinn

600 mA < I < 1500 mA : Plate thickness correct
I > 1500 mA : Plate too thick
I > 2000 mA : Current limit, motor will be switched off
4.5.3. "Open tensioning bar"
This function serves to open the tensioning bar.
4.5.4. "Send new nom. values (travel)"

This function is identical with function 1, but the central control console command is
used here instead of the MMS-command. Moreover, there is no tolerance value. The
tensioning bar can only be moved between +1500µm and -1500µm.
4.5.5. "Request measuring system"
The actual values of the measuring systems will be requested and displayed.
4.5.6. "Request status"
This command serves to request the status of the CPL-system.

Structure of the status mask:
ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿ ÚÄÄÄÄÄ Last frame from HOST ÄÄÄÄÄÄÄ¿

³ LSRHOST - commands V1.01 ³³ ³
³ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿³ ³ ³
³³ 1. Tighten/untighten plate ³³ ³ ³
³³ 2. Clamp tensioning bar ³³ ³ ³
³³ 3. Open tensioning bar ³³ ³ ³
³³ 4. Send new nom. values (travel) ³³ ³ ³
³³ 5. Request measuring systems ³³ ³ ³
³³ 6. Request status ³³ ³ ³
³³ 7. Program version ³³ ³ ³
³³ 8. Emergency stop ³³ ³ ³
³³ 9. Calibrate measuring systems ³³ ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ
³³ 10. New time/PWM - nominal values ³³ ÚÄÄÄÄÄ Last frame from CPL ÄÄÄÄÄÄÄÄ¿
³³ 11. Current- voltage- temperature ³³ ³ M1....? RP....? Sys1..0 PosOn.? ³
³³ 12. Auto calibration ³³ ³ M2....? RA....? Sys2..0 Tb60%.? ³
³³ 13. Request parameters ³³ ³ M3....? PosEr.? Sys3..0 A-err.? ³
³³ 14. Readjustment ON ³³ ³ M4....? FPErr.0 F-Dat.1 To-cl.? ³
³³ 15. Readjustment OFF ³³ ³ STOP..? Prgr..1 PltT4.? ImM1..? ³
³ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ³ ³ Tb.cl.? FlEr..0 ...? ImM2..? ³
³ ⇑⇓ <Ù STOP=Space F3=End ³ ³ open.? FprgD.0 IposM.0 ImM3..? ³
ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ ³ Tmp...? Para..1 CPLErr0 ImM4..? ³
ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿ ³ A-Act.val.: 200 B-Act.val.: 200 ³
³ Node 11 10 9 8 7 6 5 4 ³ ³ S-Act.val.: 30 ³
³⇔ CPL 1 2 3 4 5 6 7 8 ³ ³ Cl-cu.max : 0 AD-v.poti : 0 ³
ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ
ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ
In case of correct functioning, important status bits are designated with 0 or 1.

Status bits designated with "?" may be 0 or 1.
The values in the last line are only of importance to the clamping of the tensioning bar.
By pressing the space bar (STOP = space) you activate function 10 „Emergency stop“.
Description of status bits, see point 3.3.6.
4.5.7. "Program version"

This command serves to request the program version of CPL-system. The program
version of EPROM and FLASH will be displayed as well as the check sum.
4.5.8. "Emergency stop"
This command serves to switch off all motors. "Emergency stop" remains
active until you give the next positioning command.
4.5.9. "Calibrate measuring systems"
Systems for measuring travel will be calibrated electrically. Thus, they receive new
reference values (0) which will be stored in the flash memory.
4.5.10. "New time/PWM - nominal values"
This command serves to preset durations and PWM nominal values for the motors.
Example for input:

Time nom. val. motor 3 : 600
Executions [1..9] :1
In this example, the side register is moved toward "+".

In case of nominal values of less than 50 %, the register is moved toward "-".
The number behind "Executions" indicates how often the clamping bar will be moved
with the indicated values.
For motors you do not want to move, enter the value 50.
4.5.11. "Current - voltage - temperature"
This function serves to request the currents of the four motors, the operating voltage
and the temperature of the rotary transformer.
4.5.12. "Auto calibration"
For a quick and easy resetting of the tensioning bar to the mechanical zero position
after a loss of data, first move the tensioning bar against the adjusted stops. From this
defined position the mechanical zero position is determined and stored as working point.
Diagram of procedure, see 3.3.15.

4.5.13. Parameter request
The CPL-system sends its parameter record.

To display the parameters one by one, repeatedly press the <Ù -key.
103 ; (01) Parameter block-ID (V 1.03)

4 ; (02) Reg. pins: bounce stop period [* 50 ms]
8 ; (03) Measuring delay motor current[* 10 ms]
55 ; (04) Lower limit temperature [° C]
60 ; (05) Upper limit temperature [° C]
1500 ; (06) I max for plate OK [mA]
600 ; (07) I min for plate OK [mA]
-8000 ; (08) Min pos circumf. reg. [µm]
2000 ; (09) Max pos circumf. reg. [µm]
-1500 ; (10) Min pos side register [µm]
1500 ; (11) Max pos side register [µm]
-2000 ; (12) Min travel circumf. reg. [µm]
2000 ; (13) Max travel circumf. reg. [µm]
-1500 ; (14) Min travel side register [µm]
1500 ; (15) Max travel side register [µm]
-1500 ; (16) Deplacement circumf. reg. [µm]
0 ; (17) Deplacement side register [µm]
8000 ; (18) Eccentric radius circumf. [µm]
4500 ; (19) Eccentric radius side reg. [µm]
1340 ; (20) Escape gear ratio [/ 10]
235 ; (21) Worm gear ratio [/ 10]
110 ; (22) Armature resist. circ. reg. A [* 0.1 Ohm]
110 ; (23) Armature resist. circ. reg. B [* 0.1 Ohm]
110 ; (24) Armature resist. side reg. [* 0.1 Ohm]
420 ; (25) Motor constant circ. reg. A [* 0.1 mNm/A]
420 ; (26) Motor constant circ. reg. B [* 0.1 mNm/A]
420 ; (27) Motor constant side reg. [* 0.1 mNm/A]
10 ; (28) Max deviation nom. position [µm]
200 ; (29) Min switch-on period, motors [ms]
2000 ; (30) I max motor circ. reg. A [mA]
2000 ; (31) I max motor circ. reg. B [mA]
2000 ; (32) I max motor side reg. [mA]
2000 ; (33) I max motor clamping [mA]
400 ; (34) Current initial value motors [mA]
12 ; (35) Iteration step number [Steps]
1 ; (36) TesaMeas. gear ratio []
4.5.14. "Readjustment ON"
Readjustment will be switched on.

If the actual position deviates from the nominal position by more than the set
tolerance (e.g. 10 µm, see parameter 28 CPLPARA.DAT), the position will be
corrected automatically. The nominal position is set with an exactness of 10 µm.
When the CPL-system is started, the readjustment is always switched off.
4.5.15. "Readjustment OFF"
Readjustment will be switched off.
4.6. Termination of service tool LSRHOST
Remove the disk from the drive and press key „F3“ to leave the LSRHOST-program.
After terminating the LSRHOST-program restart the machine.

5. Description CPLINST (Download CPL-Firmware)
From the central control console, you can load the CPL-firmware with the CPLINST-
program V02.02 into all or the selected printing units. Only CPL-firmware for
NOVOTECHNIK- systems is offered for loading.
(You can select versions from V160 being on the CPL servicetool disk. For the
DOWNLOAD you can also use test versions, if there are any on the disk).
If the CPL-version designation indicates a firmware version for Tesa-systems, the message
„TESA-system update not necessary“ will be displayed instead of the DOWNLOAD-option.
In such a case, the DOWNLOAD will be carried out only for the printing units equipped with
the admissible firmware.
The program for the DOWNLOAD of the CPL-firmware starts form a bootable disk
(cold start).
After the boot and selection of the function 2 the program ist getting started.
After the program start, you can select between operational guidance in English or German.
Therafter enter the machine configuration in a selection mask.
In the following mask all CPL-versions delivered on the disk are displayed for selection.
Select the CPL-version to be loaded.
The currently loaded CPL-versions of all printing units are displayed in the next mask.
If one of the CPL-systems cannot be detected (no communication !), an error message
will be displayed and the respective CPL-system will not be updated. The entered machine
configuration serves to check the number of available CPL-systems.
The successful completion of the loading process will be displayed.

5.2. Program start
Switch off the machine before you insert the CPL servicetool disk into the disk drive of the
central control console. By switching on the machine, the system will be booted from the
CPL servicetool disk and the DOWNLOAD-program will start.
The mask for the selection of the operational guidance in English or German appears.
To select the desired language, use the arrow keys .

CC PP PP LL
CC PPPPP LL - Installation
CC PP LL
Ä¿
³ Download-Version ³
³
³³ Deutsch ³³
³³ English ³³
³³ ³³
³³ ³³
³³ ³³
³³ ³³
³
³ = Auswahl <Ù = Enter F3 = Ende & Boot ³
ÄÙ
This mask serves to enter the machine configuration. After selecting e.g. a R304 machine
in the left column, the selector bar will jump to „with coating“ in the right column.
In the right column you have to select between „with coating“ and „without coating“.
Wrong machine indications will lead to incorrect assignations of the CPL-systems

as well as to wrong indications or DOWNLOADs in unmarked CPL-systems.

CC PP PP LL
CC PP LL
Ä¿
³ Configuration ³
³
³³ R302 with coating ³³
³³ R304 without coating ³³
³³ R305 ³³
³³ R306 ³³ ³³
R307 ³³
³³ R308 ³³
³³ ³³
³
ÄÙ
5.4. Selection of the CPL-version to be loaded
All CPL-versions for NOVOTECHNIK-systems delivered on the disk are displayed for
selection in the mask. For selection use the arrow keys .
After the selection of the CPL-version, the HEX-file will be checked for completeness.
If a faulty HEX-file is detected, you will receive an error message. In such a case you
can leave the displayed mask only by repeating the booting procedure.
If the HEX-file is complete, you can activate the next mask.

CC PP PP LL
CC PP LL
Ä¿
³ CPL-Version ³
³
³³ V 1.69 ³³
³³ V 1.69T4 ³³
³³ V 1.85 ³³
³³ V 1.85T ³³
³³ V 1.85L ³³
³³ ³³
³
ÄÙ
5.5. Display of the currently loaded CPL-versions
The CPL-versions currently installed in the individual printing units will be determined
automatically and displayed in the mask.
In addition, the CPL-version to be loaded will be displayed in the page heading.

All displayed CPL-systems for DOWNLOAD are listed in this mask except TESA-
systems (for which you will receive the message „TESA-system update not necessary).
CPL-systems differing from the CPL-version to be loaded are automatically marked

(by a „+“) for DOWNLOAD.
If you want to carry out the DOWNLOAD for certain printing units only, mark the
CPL-systems you do not need by a „-“.
CPL-systems that cannot be detected (no communication !) in a printing unit, will not
appear in the selection mask and you will receive an error message.
These CPL-systems cannot be updated.
For selection, use the error keys .
To activate a general help text, enter „?“.

CC PP PP LL
CC PPPPP LL - Installation f r Version V 1.69 B897H
CC PP LL
ÄÄÄÄ¿
³ CPL Node Epromversion Flashversion Download ³
³ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
ÄÄ¿³ ³³ 1 9 V 1.20 7B5FH V 1.60L 1316H + ³³
³³ 2 8 V 1.20 7B5FH V 1.60L 1316H + ³³
³³ 3 7 V 1.20 7B5FH V 1.69 B897H - ³³
³³ 4 6 V 1.20 7B5FH V 1.69 B897H - ³³
³³ 5 5 V 1.20 7B5FH V 1.69 B897H - ³³
³³ ³³
³ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
ÄÄÙ³
³? = Help <Ù = Download F3 = End & Boot +/- = Selection Download³
ÄÄÄÄÙ
5.6. Download
After the deletion of the flashs of the corresponding CPL-systems the DOWNLOAD-
process for all marked CPL-sytems will start.
The DOWNLOAD will be carried out parallel for all systems.
After a successful DOWNLOAD the mask shown above with the current CPL-
versions will be displayed again. For leaving the DOWNLOAD program and for
rebooting, press key „F3“.
If you do not complete the DOWNLOAD correctly, do not forget that there is no
program in the CPL-system. The „flash version“ is missing in the corresponding line
of the mask shown above (V 0.00).
Occurring errors will be displayed.

For more detailled information select „?“.
After eliminating the error you have to repeat a DOWNLOAD.
5.7. Termination of the DOWNLOAD-program
Remove the disk from the drive and press key „F3“ to leave the DOWNLOAD-program.
After terminating the DOWNLOAD-program restart the machine.

(to supply new parameters for the CPL-systems).
6. Resetting the LSR-CPL-Calibration

6.1. Preface
This function serves to delete a CPL-calibration, carried out by the LSR (menu GENERAL,
SERVICE, ADJUST/POS, function key "CPL CALIBR"), simultaneously for all printing
units.
This function is required as soon as you have to restore the initial register of the press after
removing a CPL-bar from the plate cylinder of any machine for repair or service purposes.
Therefore a test print has to be performed with register plates and the calibrating values have
to be determined again. These values will then be saved in the LSR menu (GENERAL,
SERVICE, JUST/POS, function key "CPL CALIBR").
Switch off the machine and insert the CPL Service Tool Disk into the disk drive at the central
control console. When you switch on the machine, the program will be booted from the disk.
Select the function Reset LSR CPL calibration.
If you have an older machine which does not support the calibration function, you will
receive
the message that the calibration function does not exist and that a reset has not been carried
out.
ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿
³ LSR-CPL-Calibration does not exist, no reset possible! ³
ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ
If your machine supports the calibration function, the program will ask whether you really
want to reset the calibration.
³ Do you really want to reset the LSR-CPL-Calibration ? ³
³ ³
³ Press '1' to reset ³
³ Press '9' to quit ³
³ ³
Your choice ... ? _
To reset and display the calibration without further questions, press the key "1", to cancel the
reset, press "9".
³ Do you really want to reset the LSR-CPL-Calibration ? ³
³ ³
³ Press '1' to reset ³
³ Press '9' to quit ³
³ ³
Your choice ... ? 1
³ Reset done ! ³
7. Description Spion
Special byte Bit0 to Bit3
In contrast with the ususal "HOST05", there is no control menu in the left grey field. In the green status window
an additional status byte is displayed the first four Bits of which are used for diagnosis.
Bit 0 : 0 = WEKO-Hardware 1 = Mercotac-Hardware
Bit 1 : 0 = Auto adjustment not active 1 = Auto adjustment active
Bit 2 : 0 = no Timeout adjustment 1 = Timeout adjustment
Bit 3 : 0 = before the status request ,no reset activated.
1 = before the status request, a reset was activated. (CPL does not send a status without status request
by central control console after the reset.)
In case of a reset during the plate change, a system-hangup may occur because the LSR is waiting for a status
from the CPL.
After starting the program by entering "SPION08.EXE", the status request does not appear immediately because
the special host cable has no TX and TX wire. As soon as a CPL-Frame (USS-protocoll) will be transmitted via
the process bus, there will be a status request.
When you leave the SPION PROGRAM, a protocol file "PROTOKOLL.DAT" will automatically be saved. The
protocol includes the CPL-Frames from the corresponding printing units sent via the process bus. (Startpoint =
Start spion08.exe).
Together with the test program "Host08" you can display the advanced status. All status telegrams will be saved
in protocol file "Protokoll.dat". The analogous values of "Current/voltage/temperature" will also be saved in the
same file. The protocol file has a time stamp.
With the command "Meßdaten abfragen" you will get the last 30 iterations eof a positioning control and save
them in the files:
a) Messwert.dat (all measuring values)
b) el.dat
c) ist_soll.dat
d) pwm_t.dat
A new position command will clear the values of the last position control.
7.2. Range of functions V185T cyclical

Identical with version V185, only the status byte will be send cyclically (approx. every 2 seconds, after reset
approx. 4 seconds). After reset a manual status request is required ! "STATUSAUSGABE TRUE" will be
defined in Steuer.def. The status will be saved in the file "protoll.dat".
Example:
---------------------------------------------------------------------
25.10.2000 ,13:18:35, 13 Status = 22H 92H 08H 02H ext. Status = 03H
Ist_A : 6 um, Ist_B : 12 um, Ist_S : 6 um,
---------------------------------------------------------------------
---------------------------------------------------------------------
---------------------------------------------------------------------
---------------------------------------------------------------------
---------------------------------------------------------------------
---------------------------------------------------------------------
7.3. Range of functions V185L Longstatus

Identical with version V185, with the exception that the status-telegram contains more data. After reset a manual
status request is required ! "LONGSTATUS TRUE" will be defined in Steuer.def. The status will be saved in the
file "protoll.dat".
Example:
---------------------------------------------------------------------
M1....1 RS....0 Weg1..0 PosOn.1

M2....1 Nr....0 Weg2..0 SS60%.1
M3....0 PosEr.0 Weg3..0 A-Err.0
M4....0 FPErr.0 W-Dat.1 To-Kl.0
Not...0 Prgr..1 PltD4.0 ImM1..0
SpSzu.1 FlEr..0 ...0 ImM2..0
auf.0 FprgD.0 IposW.0 ImM3..0
Temp..0 Para..1 CPLErr0 ImM4..0
I-Klemm : 0 mA, Poti-Wert : 931 Digit

Ist_A : -8004 um, Ist_B : -7998 um, Ist_S : -3 um,
Soll_A : 0 um, Soll_B : 0 um, Soll_S : 0 um,
Im_A : 185 mA, Im_B : 175 mA, Im_S : 300 mA,
Imax_A : 222 mA, Imax_B : 205 mA, Imax_S : 0 mA,
Iueb_A : 0 mA, Iueb_B : 0 mA, Iueb_S : 0 mA,
Ub_m : 28373 mV, Ub_leer : 28463 mV, Temperatur : 39C
---------------------------------------------------------------------
IMPORTANT: After each program end, the protocol file will be saved and the old file will be overwritten. If you
need the old file, rename it.
Notes:
0 39F 2413 39
Beschreibung CPL-Kalibrierung
Description CPL-calibration Blatt: 1 von 6
File: M3E16_04_CPL- Tel:

Datum: 05.05.2000 Name: A.Baldes CALIBRATION_01.DOC 3738 Index: 01
Index Datum: Name: Änderungen: PS

00 05.05.00 ABal Ersterstellung 335B1
(S336)
01 19.06.00 ABal Dokument Deutsch/Englisch; Rechtschreibekorrekturen 335B1
02
03
Inhalt
1. Allgemeines ............................................ 2
2. Durchführen der Kalibrierung ............................................ 2
3. Einfluss der Kalibrierung auf Register-Ist- und Sollwerten ..... 3
4. Wiederholung der Kalibrierung ............................................ 3
Contents
1. General information ............................................ 4
2. Calibration ............................................ 4
3. Influence of the calibration on the actual and nominal register values ..... 5
4. Repeating the calibration ............................................ 5

0 39F 2413 39

1. Allgemeines
Ab der LSR-Version V17.00 (PS 335B1) wurde die elektrische Kalibrierung (Drucktechnische Nullung) der
CPL-Systeme für die Serie freigegeben.
2. Durchführen der Kalibrierung
Der ideale Anfangspasser wird durch Einstellen der Register im LSR mit Hilfe von Registerplatten
ermittelt. Anschliessend können die ermittelten Register-Offsetwerte in einer Datei auf der Festplatte abge-
speichert werden.
Für das Abspeichern der Registerpositionen muss die Taste im Menü [ALLGEMEIN] [SERVICE]
[JUST/POS] die Funktionstaste "CPL KALIBR" benutzt werden.
Beim Abspeichern werden die aktuellen Ist-Positionen der CPL-Meßsysteme als drucktechnische
Nullposition in die Datei C:\LEIT\LSRDAT\CPLOFS.DAT geschrieben.
Das Abspeichern der Ist-Positionen als Offsetwerte ist nur unter folgenden Bedingungen möglich:
) Der Plattenwechsel darf nicht aktiv sein, d. h. die Registerverstellung im Menü REGISTER muss
freigegeben sein.
) Die Positionierung aller Register muss fehlerfrei abgeschlossen sein. Die Anzeigen aller Sollwerte
im Menü [REGISTER] müssen weiss sein. Dies gilt auch für das Lackmodul, falls vorhanden !
) Die physikalischen Ist-Positionen der CPL-Schienen liegen in einem Toleranzfenster von +/- 0,1 mm
vom mechanischen eingestellten Schienenpasser.
) Die Saalmeisterdiskette muss im Diskettenlaufwerk eingelegt sein
Bei Betätigung Der Taste "CPL KALIBR" werden diese Bedingungen geprüft. Im ok-Fall kann mit ENTER
die Kalibrierung durchgeführt werden.
Falls eine der Bedingungen nicht erfüllt ist, erfolgt ein entsprechender Bedienhinweis.
! Hinweis !
Nach einer LSR-Erstinstallation sind die Offsetwerte=Null. Die Datei CPLOFS.DAT ist noch nicht angelegt.
Bei Updates bleibt die Datei erhalten !
Nach Durchführung der Kalibrierung werden automatisch folgende Schritte durchgeführt:
1. Die LSR-Registersollwerte werden auf Null gesetzt.
2. Aktualisierung der Offsetwerte (LSR-intern und auf der Festplatte).

Die Offsetwerte werden auf die mechanischen Ist-Positionen gesetzt. Hierzu werden die in der letzten
CPL-Statusmeldung übertragenen Istwerte herangezogen.
3. Die LSR-internen CPL-Soll- und Istwerte werden auf Null gesetzt.
4. Es erfolgt eine CPL-Statusmeldung mit den "neuen" Bediensollwerten an die MMS.

0 39F 2413 39

3. Berücksichtigung der Kalibrierung bei Register-Ist- und Sollwerten
Beim Senden der Sollwerte an die CPL-Systeme werden die Offsetwerte zu den LSR-/MMS-Sollwerten
addiert und beim Istwert-Empfang von den CPL-Istwerten subtrahiert.
In den internen Daten wird nur noch mit den Offset-korrigierten Soll- bzw. Istwerten gearbeitet.
Zur Kontrolle über den Erfolg der Kalibrierung können im Menü [REGISTER] folgende Tasten-
kombinationen mit einer externe Tastatur benutzt werden.
Alt +159 : In der CPL-Statusanzeige werden die ersten vier Original-Bytes des CPL-Status und dahinter
die korrigierten-Istwerte angezeigt.
Alt +160 : Es werden die aktuell eingestellten Offsetwerte sowie die mechanischen Istwerte der CPL-
Schienen (mechanische Istpositionen) angezeigt.
Alt +161: Es werden die aktuellen LSR-Sollwerte und die korrigierten Sollwerte an die CPL-Systeme
angezeigt.
4. Wiederholung der Kalibrierung
Die Kalibrierung kann beliebig oft wiederholt werden, sofern man sich im Toleranzfenster von +/-0,1 mm
vom mechanisch eingestellten Schienenpasser befindet.
Wird eine CPL-Schiene zu Reperatur- oder Servicezwecken aus dem Plattenzylinder ausgebaut, muss
anschliessend die Drucktechnische Null wiederhergestellt werden.
Dazu sollte die Maschine mit Registerplatten neu abgedruckt und die Offsetwerte neu ermittelt werden.
Das Rücksetzen aller Offsetwerte auf Null, kann man durch löschen der Datei CPLOFS.DAT im
Verzeichnis C:\LEIT\LSRDAT erreichen.
Hierzu wurde für den Service die CPL-Servicetools-Diskette in der Version V02.03 erweitert. Es steht
jetzt neben den Programmen LSRHOST und CPLINST unter [3] die Funktion "Reset LSR-CPL-Calibration"
zur Verfügung.
Eine ausführliche Beschreibung kann dem Dokument "R300 CPL-Servicetools Version 2.00 Index 3" (SNR
039E 7151 39) entnommen werden.
0 39F 2413 39

1. General information
From LSR* version V17.00 (prog. version 335B1), the electrical calibration of the CPL-systems has been
released for the series.
* = central control console
2. Calibration
The ideal initial register is determined by setting the registers in the LSR using register plates. The register
offset values determined can then be stored in a file on the hard disk.
To store the register positions, use the function key "CPL CALIBR" in the menu [GENERAL] [SERVICE]
[ADJUST/POS.].
The current actual positions of the CPL-measuring systems will be stored as zero-position in file
C:\LEIT\LSRDAT\CPLOFS.DAT .
Conditions to be fulfilled for storing the actual positions as offset values:
) Make sure that the plate change is inactive, i.e. register setting in menu REGISTER must be possible.
) Make sure that all registers are positioned correctly. All nominal values in menu [REGISTER]
must be displayed in white. This also applies to the coating module, if there is one.
) Make sure that the physical actual positions of the CPL-bars are in the tolerance range of +/- 0.1 mm
from the mechanically set bar register.
) Make sure that the shop supervisor disk is inserted in the disk drive.
When the key "CPL CALIBR" is actuated, these conditions will be checked. If OK, the calibration can be
performed by ENTER. Should one of these conditions not be met, you will receive a message.
! Notice !
After the first installation of the LSR, the offsets = zero. The file CPLOFS.DAT has not been created yet..
In case of updates, the file remains stored !
After the calibration, the following steps are performed automatically:
1. Zero-setting of the LSR-register nominal values.
2. Update of the offset values (within the LSR and on the hard disk).
The offset values are set to the mechanical actual positions.
The actual values transferred in the last CPL-status message are used for this purpose.
3. Zero-setting of the LSR-internal CPL-actual and nominal values.
4. Issuing of a CPL-status message to the MMS with the "new" nominal values for operation.
0 39F 2413 39

3. Influence of the calibration on the actual and nominal register values
When the nominal values are sent to the CPL-systems, the offset values are added to the LSR-/MMS-
nominal values and subtracted from the CPL actual values after receiving them.
In the internal data you work only with the corrected nominal or actual values.
To check the calibration, use the following key combinations of the external keyboard in menu
[REGISTER].
Alt +159 : In the CPL-status display the first four original bytes of the CPL-status are shown
followed by the corrected actual values.
Alt +160 : The currently set offset values and the mechanical actual values of the CPL-bars
are displayed (mechanical actual positions).
Alt +161: The current LSR nominal values and the corrected nominal values to the CPL-systems
are displayed (mechanical actual positions).
4. Repeating the calibration
You can repeat the calibration at will, as long as you are within the tolerance range of +/-0.1 mm
from the mechanically set bar register.
If you remove a CPL-bar from the plate cylinder for repair or service purposes, restore the zero-position
thereafter. Therefore a test print has to be performed with register plates and the offset values have to be
determined again.
To reset all offset values, delete file CPLOFS.DAT in directory C:\LEIT\LSRDAT.
On the CPL-Servicetools-disk (version V02.03) , the function "Reset LSR-CPL-Calibration" has therefore
been added under [3] to the programs LSRHOST and CPLINST. For a detailed description, see document
"R300 CPL-Servicetools , version 2.00 Index 3" (SNR 039E 7151 39).
0 39F 2413 39

Notes:
Coating unit
17
17 Coating unit
17.1 General Comments...................................................................... 17-3
Two roller system .......................................................................... 17-6
Camber blade system.................................................................... 17-6
Overview of electrical components ................................................ 17-7
Control panels ............................................................................... 17-9
17.2 Settings ...................................................................................... 17-11
Transfers on coating unit ............................................................. 17-11
Hand terminal .............................................................................. 17-13
17.3 Adjusting gauges ...................................................................... 17-14
17.4 Coating level detector ............................................................... 17-15
17.5 Function test .............................................................................. 17-16
tills series 336.............................................................................. 17-16
Setting up and function test from series 337................................ 17-16
17.6 Dimensions and weights........................................................... 17-18
17.7 Assembly.................................................................................... 17-19
17.8 Varnish circulation device ........................................................ 17-21
SERA circulation device connections .......................................... 17-21
Image of connections – Block switch diagram ............................. 17-22
17.9 Forme cylinder........................................................................... 17-23
Impression ON - OFF .................................................................. 17-23
Sensors ....................................................................................... 17-24
Material thickness adjustment ..................................................... 17-26
Mounting...................................................................................... 17-27
Basic adjustment of the clamping device..................................... 17-28
Register remote control ............................................................... 17-29
17.10 Impression cylinder................................................................... 17-30
Mounting...................................................................................... 17-30
Impression cylinder with segmented cams .................................. 17-31
Impression cylinder with continuous cams .................................. 17-32
17.11 Take off drum............................................................................. 17-33
Gripper adjustment ...................................................................... 17-33
C 95A 6423 39 – 12. Nov. 2003 17-1

17 Coating unit
17.12 2nd transfer cylinder ...................................................................17-34

Gripper adjustment ......................................................................17-34
17.13 Operation ....................................................................................17-35
General comments regarding the metering gap...........................17-35
Adjusting range ............................................................................17-37
Operating range ...........................................................................17-38
COATING / WASHING OPERATION ..........................................17-40
17.14 Rollers.........................................................................................17-41
Coating fountain roller bearing .....................................................17-41
17.15 Pneumatic...................................................................................17-44
Compartment blade / Check valve ...............................................17-46
17.16 Sheet guides...............................................................................17-47
17.17 Chambered doctor blade...........................................................17-48
Description ...................................................................................17-48
Setting..........................................................................................17-49
17.18 Dryer ...........................................................................................17-51
17-2 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
17.1 General Comments

Short description of the coating unit
The amount of applied coating or the adjustment of the machine to the applied coating type during
operation with dip and coating form roller is determined by the gap between the dip and coating form roller.
The speed of the dip roller is always constant at 25 rpm (i.e. this applies to all coating types and all
machine speeds). When the machine is at standstill and when coating is in the coating fountain (coating
level is monitored by sensor B004), the coating form roller with the gap closed (gap between the dip and
coating form roller) is driven via the dip roller by motor M410.
With the machine rotating and coating in the coating fountain, the coating form roller is driven via a
freewheeling mechanism by the machine itself at machine speed. The different speeds of the dip and
coating form roller and the ensuing friction leads to the formation of a coating film on the coating form roller
that is transferred to the sheet of paper.
2 1
R300 with Coater and Long Delivery 1 Coater 2 Long Delivery 3 Dryer
C 95A 6423 39 – 12. Nov. 2003 17-3

17 Coating unit
Coating unit
Length 1362 mm
Weight 4120 kg
Extended delivery
Length 3410 mm (1095 mm longer than standard delivery)
Weight 3490 kg - without dryer
Gripper sets 11
Impression cylinder 472 mm diameters (double size)

Sheet size 590 x 740 mm
Printing length 580 mm
Forme cylinder Combination clamping bar

Quick-lock blanket tensioning device (optional)
Ø 231,2 mm
Undercut 2,6 mm
Printing length 580,0 mm
Register remote adjustment motorised

Lateral register + 1,50 mm / - 1,50 mm
with CPL + 1,25 mm / - 1,25 mm
Circumferential register + 1,50 mm / - 0,50 mm

with CPL + 1,25 mm / - 0,50 mm
Take off drum Ø 472 mm (double size)
II Transfer cylinder Ø 472 mm (double size)
III Transfer cylinder Ø 236 mm
Coating fountain roller Ø 143,4 - 0,2 mm

Rubber: 50 Shore,
as of series 328: 80 shore
Coating form roller Ø 143,2 - 0,1 mm

Steel
Anilox roller Ø 143,2 ± 0,02 mm
17-4 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
1 Extension
2 Coating fountain roller
3 Form roller
4 Forme cylinder
5 Sprocket shaft
7 3rd transfer cylinder
8 2nd transfer cylinder
9 Take off drum
C 95A 6423 39 – 12. Nov. 2003 17-5

17 Coating unit
Two roller system
1 Coating fountain roller

2 Coating form roller
3 Coating pan
4 Collecting pan
5 Forme cylinder
Camber blade system
1 Chamber blade
2 Anilox roller
3 Collecting pan
4 Forme cylinder
17-6 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
Overview of electrical components

Drive side
M281 M280 B004
M431
B200
B232
S401
S403
Y409
S405
S402
S404
M400
FESTO
Y025
Descr. Function Plug I/O –A548-A4/… Process

B004 sensor min. varnish level -A545, X9 B.B. 5.7 ---
B200 sensor bailing roller built-in -A545, X58 B.B. 4.7 ---
B232 sensor coating overflow -A545, X7 B.B. 12.4 ---
M280 lateral register --- --- slot 5
M281 circumference register --- --- slot 4
M400 impression pressure adjustment, A-side --- --- slot 6
M431 metering gap adjustment, A-side --- --- slot 8
S401 chamber doctor blade ON -A545, X60 B.B. 5.2 ---
S402 chamber doctor blade OFF -A545, X87 B.B. 5.3 ---
S403 impression ON, step 1, forme cylinder, A-side -A545, X88 B.B. 5.4 ---
S404 impression OFF, forme cylinder, A-side -A545, X61 B.B. 5.5 ---
S405 impression ON, step 2, forme cylinder, A-side -A545, X69 B.B. 6.7 ---
Y025 impression ON-OFF, forme cylinder, A-side -A545, X70 B.B. 6.2/0.0 ---
Y409 chamber doctor blade ON-OFF -A545, X35 B.B. 18.0 ---
C 95A 6423 39 – 12. Nov. 2003 17-7

17 Coating unit
Operating side
S400
M410
M432
B233
S406
S408
S407
M401
FESTO
Y026
X1 X3 X5 X7
-A531 X8
X2 X4 X6 X8
X1 X3 X5 X7
-A506
-A530 X8
X2 X4 X6 X8
valves central central

wash-up oil pressure grease
devices switch F005 sensor B077
-A545, X35 Y401 Y403
FESTO valve block Y407 Y408
Descr. Function Plug I/O –548-A4/... Process

B233 Sensor coating overflow -A545, X7 B.B. 12.4
M401 Printing substrate pressure, B-side Slot 7
M410 Coating fountain roller motor
M432 Metering gap adjustment, B-side Slot 9
S400 Collecting rake mounted -A545, X59 B.B. 5.0
S406 Impression ON, level 2, form cylinder, B-side -A545, X63 B.B. 6.0
S407 Impression OFF, form cylinder, B-side -A545, X64 B.B. 6.1
S408 Impression ON, level 1, form cylinder, B-side -A545, X62 B.B. 5.6
Y026 Impression ON-OFF, form cylinder, B-side -A545, X70 B.B. 6.2/0.0
A506 Distributor for sheet guiding impress. cylinder
A530 Distributor for limit switch -A545, X32
A531 Distributor for limit switch -A545, X33
Y401 FZW water -A545, X101 B.B. 20.3
Y403 FZW solvent -A545, X103 B.B. 20.5
Y407 DZW water (option) -A545, X102 B.B. 20.4
Y408 DZW solvent (option) -A545, X104 B.B. 20.6
17-8 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
Control panels
Operating side, Delivery
2 Bell
3 Coating feed ON/OFF
4 Cleaner ON/OFF
5 Operating position OFF
Drive side and operating side
(Parallel adjustment)
8 Adjustment MINUS
9 Digital display
10 Horn
11 Inch REVERSE
12 EMERGENCY OFF
14 Preselection of coating quantity
15 Spray bar
16 Operating position ON
Operating side only
Skew adjustment
19 Adjustment PLUS
20 Make ready
21 Crawl speed
22 Inch FORWARD
23 STOP - SAFE
Multiple functions
Press for 3 seconds
3 Time preselection for coating feed

6 Preselection of metering gap
15 Extended wash-up period
C 95A 6423 39 – 12. Nov. 2003 17-9

17 Coating unit
Operating side, Feeder
2 Bell
3 Not used
4 Not used
5 Not used
6 Not used
8 Adjustment MINUS
9 Digital display
10 Horn
11 Inch REVERSE
12 EMERGENCY OFF
14 Not used
15 Not used
16 Not used
17 Not used
19 Adjustment PLUS
20 Make ready
21 Crawl speed
22 Inch FORWARD
23 STOP - SAFE
17-10 C 95A 6423 39 – 12. Nov. 2003

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17
17.2 Settings
Transfers on coating unit
Prerequisites:
Detector of angular displacement is installed on impression cylinder (Attention: double size)

Gauge aligned on scribed line
Detector for angular displacement set to "0°"
Take-off drum grippers close 23,2° 203,2°

Take-off drum grippers open 81,9° 261,9°
Grippers of 2nd transfer cylinder close 80,9° 260,9°
Grippers of 2nd transfer cylinder open 54,8° 234,8°
Grippers of 3rd transfer cylinder close 53,8° 233,8°
Grippers of 2nd transfer cylinder open 147,2° 327,2°
Grippers of delivery drum close 53,0° 233,0°
Impression cylinder grippers close 146,2° 326,2°
Impression cylinder grippers open 54,0° 234,0°
Gauge No. 343T380713 Drive side inside
From the delivery drum on, the gripper margin is reduced to 4 mm.
Prerequisite: Front lays are in center position
C 95A 6423 39 – 12. Nov. 2003 17-11

17 Coating unit
Center of transfer
Coating unit Last printing unit
The press must be in first-side-printing mode
The grippers close resp. open 1° ahead resp. 1° behind the centre of transfer (transfer lines)
302 / LW 304 / LW 305 / LW 306 / LW 308 / LW
1 2nd transfer cyl. - 3rd transfer cyl. 54,4° 224,5° 129,6° 34,7° 204,8°
2 3rd transfer cyl. - impr. cyl. 239,0° 49,2° 314,2° 219,3° 29,4°
3 impr. cyl. - take-off drum 141,0° 311,2° 216,2° 121,3° 291,4°
4 take-off drum - 2nd transfer cyl. 256,4° 66,6° 331,6° 236,7° 46.8°
5 2nd transfer cyl. - 3rd transfer cyl. 202,3° 12,5° 277,5° 182,6° 352,7°
6 3rd transfer cyl. - impr. cyl. 26,9° 197,1° 102,1° 7,2° 177,3°
7 impr. cyl. - delivery drum 200,5° 10,7° 275,7° 180,8° 350,9°
17-12 C 95A 6423 39 – 12. Nov. 2003

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17
Hand terminal
Display on hand terminal Drive Bus address Menu 6 Menu 7
Circumferential register: CPL 1 60 0,00 mm 3981mV

Standard 1 60 0,00 mm 3641mV
Lateral register 2 61 0,00 mm 5000mV
Substrate thickness adjustment - 3 62 0,00 mm 2383mV

Drive side
(measured with lead wire, 2,6 mm)
Substrate thickness adjustment - 4 63 0,00 mm 2383mV

Operating side
(measured with lead wire, 2,6 mm)
Metering gap adjustment - 5 64 0,610 mm 6525mV

Drive side (markings match)
Metering gap adjustment - 6 65 0,610 mm 6525mV

Operating side (markings match)
Circumferential register - Center position:

Impression cylinder gear and forme cylinder gear are flush
Lateral register - Center position:

Forme cylinder is in center position between the side frames
C 95A 6423 39 – 12. Nov. 2003 17-13

17 Coating unit
17.3 Adjusting gauges
1 No.: 343T380713 ”0” degree gauge impression cylinder

2 No.: 343T380313 Measuring gauge bolt for chain tracks
3 No.: 099I 260630 2nd transfer cylinder with continuous gripper cam
4 No.: 013A068730 Impression cylinder with continuous gripper cam
and cam roller Ø 40 mm
5 No.: 013A068830 Impression cylinder with continuous gripper cam
and cam roller Ø 38,1 mm
6 No.: 099A376913 3rd transfer cylinder
7 No.: 343T380513 Take off drum with continuous gripper cam
8 No.: 099J062530 2nd transfer cylinder with segmented cam
9 No.: 099B487630 Impression cylinder with segmented cam
and cam roller Ø 38,1mm
9 (No.: 099B487530 Impression cylinder with segmented cam
and cam roller Ø 40,0mm )
10 No.: 099B476013 Take off drum with segmented cam
17-14 C 95A 6423 39 – 12. Nov. 2003

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17
17.4 Coating level detector
1 Coating level detector

2 Bracket
3 Sheet metal guard
4 Bracket for the coating level detector. Drive side - inside
A Operating position
B Position for cleaning of coating pan
The operating range of the coating level detector is set to a fixed detecting range of 8 mm.
It is to be checked before installation
C 95A 6423 39 – 12. Nov. 2003 17-15

17 Coating unit
17.5 Function test

tills series 336
keyboard (on the delivery side of the printing unit). The different functions are selected by the same
To exit the function test press once (at the same time) and hold the two lowest keys of the membrane
keyboard.
Caution: During the test the machine must be out of action!
01 coating form roller ON/OFF (Y412)

02 chamber ductor blade system ON/OFF (Y409) This function is cancelled as of PS 314E1
03 blanket wash-up device motor forward (clockwise, K440)
04 impres. cylinder wash-up device motor forward (clockwise, K406)
05 blanket wash-up device ON/OFF (Y412)
06 blanket wash-up device water (Y401)
07 impression cylinder wash-up device water (Y407)
08 blanket wash-up device washing agent (Y403)
09 impression cylinder wash-up device washing agent (Y408)
10 SERA: returning pump ON (2K3)
11 SERA: shut off water (...)
12 SERA: spray arm (4Y5)
13 SERA: three-way ball cock: varnish absorption forward (5K2)
14 SERA: three-way ball cock: rinsing water (5K3)
15 SERA: three-way ball cock: runback varnish (6K2)
16 SERA: three-way ball cock: runback water (6K3)
17 SERA: regulator releasing, feeding pump ON
18 impression cylinder wash-up device ON / OFF (Y406)
Setting up and function test from series 337

Program version 335C1 ,from MMS 10.11 also backwards compatible
Coating unit: Function test

keyboard (on the feeder- side of the printing unit). The different functions are selected by the same
membrane keyboard.

17-16 C 95A 6423 39 – 12. Nov. 2003

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17
Coating unit: Setting-up
The setting-up is activated by pressing twice (together) the two lowest keys of the membrane
keyboard (on the feeder delivery side of the printing unit). The different functions are selected by
the same keys and activated by “+/-“ keys. (The functions are active as long as the “+” key is
pressed).
keyboard.

01 FZW - contact pressure, (switches sequentially) Y412 Byte 18, Bit 3 ---
feeder side K440 Byte 17, Bit 1 B.B. 4.1 & 9.2
02 DZW - contact pressure, (switches sequentially) Y406 Byte 18, Bit 6 Byte 4, Bit 6
delivery side K406 Byte 17, Bit 2 Byte 4, Bit 3

unit:
membrane keyboard.

01 DZW On/Off Y406 Byte 18, Bit 6 Byte 4, Bit 6
06 Chambered doctor blade
C 95A 6423 39 – 12. Nov. 2003 17-17

17 Coating unit
17.6 Dimensions and weights
1 Drive side
2 Operating side
The transport of the coating unit can be carried out - as far as the screw threads for the transporting the press are
concerned - similar to that of the printing units. (H-beam, lifting shackles, swivel hooks)
17-18 C 95A 6423 39 – 12. Nov. 2003

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17
17.7 Assembly
A Last printing unit

B Coating unit
C Extended delivery
1 Right-angled water level No.: 099M522540

2 Distance between floor and base frame 55 - 75 mm
3 Measuring points on drive side
4 Holder for dial indicator No.: 099J062630 and dial indicator No.:791032202
5 Tubular water level No.: 099M534240
6 Stops, drive and operating side, inside of the delivery
7 Water level 099M534140
8 Prism No.: 099J087930
9 3rd. transfer cylinder
11 Face of drive side frame
Tools: Special wrench SW 17 No.: 099M375950

Special wrench SW 17 No.: 099M375850
C 95A 6423 39 – 12. Nov. 2003 17-19

17 Coating unit
Alignment of coating unit and extended delivery
For presses equipped with coating units, the last printing unit, the coating unit itself and the delivery are delivered
separately. Before assembly, the units must be advanced so as to have the markings on drive side and operating
side line up. On the drive side, the meshing teeth are marked at the meshing point with a number; in addition, they
are provided with a red ink marking. The press may be aligned starting with either the 1st printing unit or with the
last unit. Also refer to Fitter Training chapter 5.
Coating unit:
Height of coating unit: Check the height difference between lower edge of side frame and last printing unit on the
Drive side, using gauge (No. 4). The side frames are brought to the same height, i.e. the height difference must
be 0,00 mm.
In lateral direction, carry out measurement on the drive side, using gauge (No. 4) on the measuring points (No. 3).
The difference between the side frames must be 0,00 mm.
To measure in cross direction, place prism on 3rd transfer cylinder (No. 9) and have the water level contact the
stop provided on the prism. This alignment automatically delivers the operating side height.
For the time being, the coating unit is bolted to the last printing unit without using shims. When tightening the
mounting screws, it is important, that the bubble of the tubular level (No. 5) does not move. The tubular water level
hence only serves to monitor any possible movement during tightening of the mounting screws - it is not to be
used for alignment in longitudinal direction!
The gear backlash on the drive side should be between 0,05 and 0,11 mm!
Extended delivery:
The stops (No. 6) on drive side and operating side indicate the lateral position (inside side frame) and the height
with regards to the base frame. Using a 0,03 mm feeler gauge the contact between the stops on the base frame
and the side frames is to be checked. When tightening the mounting screws, it is important that the bubble in the
tubular spirit level in the coating unit does not move!
Chains:
Once the delivery is aligned, the chain tracks between coating unit and delivery unit may be installed. The
mounting screws can be inserted and tightened through access holes in the sprockets. Check distance between
chain track and sprocket shaft, using the measuring bolt (refer to adjusting gauges). The meshing point
sprocket/gripper system is marked on the sprocket with ink. Align chain with sprockets properly, advance press
cautiously using the hand crank and make sure, that the grippers clear the impression cylinder edge. Install
shackle-type chain connectors. The chain tension is set at the factory; check tension. Assemble the remaining
chain tracks.
17-20 C 95A 6423 39 – 12. Nov. 2003

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17
17.8 Varnish circulation device
SERA circulation device connections
outside inside
1 Fresh water inlet

(The feed pressure should not be less than 2 bar)
2 Fresh water to spray bar above form cylinder
3 Varnish feeding pump suction line from varnish tank
4 Varnish feeding pump pressure to coating unit
6 Varnish suction pump suction line from coating unit
5 Varnish suction pump suction line from coating unit
7 Varnish suction pump feedback pipe to varnish tank
8 Varnish suction pump feedback pipe to flushing water

(To clean the coating unit, no hoses need to be changed)
9 Main switch
P1 Varnish feeding pump
P2 Double-headed varnish suction pump
No air pockets must develop in the return hoses, the hoses must be run as short as possible.
The operating side return hose is placed in an inclined pipe leading across the coating unit to the drive side.
C 95A 6423 39 – 12. Nov. 2003 17-21

17 Coating unit
Image of connections – Block switch diagram
Pos. Name Symbol: Pos. Name Symbol:

1 Coating transporting pump 12.3 Coating transporting pump suction 3
2 Double-head coating suction line from coating tank
pump
3 3-way valve, motor-driven 12.4 Coating transporting pump 4
4 3-way valve, motor-driven pressure line to coating unit
5 Locking valve, hand operated 12.5 Coating suction pump suction line 5
6 Pressure reducer from coating unit
8 Solenoid valve 12.6 Coating suction pump suction line 6
9 Solenoid valve from coating unit
11 Throttle valve 12.7 Coating suction pump return flow 7
13 Throttle valve line to coating tank
12 Hose couplings 12.8 Coating suction pump return flow 8
12.1 Fresh water input 1 line to rinsing water tank
12.2 Fresh water to coating unit 2
17-22 C 95A 6423 39 – 12. Nov. 2003

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17
17.9 Forme cylinder
Impression ON -
OFF
Example: operating side
1 Detector Impression OFF: Drive side: A548/Slot 4 2. Byte Bit 5

Oper. side: A548/Slot 4 3. Byte Bit 1
2 Detector Impression ON, "Stage 1" monitors the range for heavy stocks:
Drive side: A548/Slot 4 2. Byte Bit 4
3 Detector Impression ON, "Stage 2" monitors the range for light stocks:
Drive side: A548/Slot 4 3. Byte Bit 7
4 Stop for Impression OFF

5 Lever on eccentric bearing
6 Drive side motor: M 400, Operating side: M 401
7 Potentiometer
8 Bushing for form cylinder
A Position: Impression OFF

B Position: Impression ON
C 95A 6423 39 – 12. Nov. 2003 17-23

17 Coating unit
Sensors
Adjustment of the impression ON/OFF sensors of the form cylinder
One pneumatic cylinder each, equipped with 3 reed sensors, is provided for the drive side and the operating
side, to monitor the correct switching status
The reed contacts of the sensor respond to the magnetic bottom of the piston. Since the position of the piston
bottom in "Impression ON" mode depends on the selected substrate thickness and on the value of the
impression pressure adjustment, two sensors are provided, the detecting ranges of which are overlapping (in
the software "OR-wired")
For the univocal position "Impression OFF" only one sensor is provided.
The figure below shows the positions of the sensors on the pneumatic cylinder.
The interface between cylinder bottom and tube was selected as reference line.
The dimensions indicate the respective distance between this line and the front edge of the sensor.
Settings for the Impression ON/OFF-sensors on drive side and operating side
Type of sensor Settings

X Y Z
Hoerbiger RRK 48 42 55
Hoerbiger KY 3145 28 41 55
The dimensions listed indicate theoretical values, representing approximately the center of the tolerance range
(approx. 10 mm) of a sensor.
In any case, the function test described in the following has to be carried out in order to check resp. readjust
the proper position of the sensors.
17-24 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
Testing procedure:
Step 1.) Adjust sensor for drive side and operating side as indicated
(Tolerance: +/- 1 mm)
Step 2.) Check of the Impression OFF sensors:

With the form cylinder in OFF mode, the LED’s of the "Impression
OFF" sensors light up
Step 3.) Check of Impression ON sensors for light substrates

Preselect substrate thickness 0,00 and stock thickness regulation 0,10 on
the Central Control Console. Once the motors for the substrate thickness
adjustment have reached the position, the form cylinder is set to make
contact. Check, if the LED’s of the "Impression ON" sensors "2" light up.
Step 4.) Check of Impression ON sensors for heavy stock

Preselect substrate thickness 0,60 and stock thickness regulation -0,20 on
the Central Control Console. Once the motors for the substrate thickness
adjustment have reached the position, the form cylinder is set to make
contact. Check, if the LED’s of the "Impression ON" sensor "1" light up.
Step 5.) In a concluding test, run through the entire adjustment range, with
impression ON and check, if, during this procedure, a continuous
overlapping of the sensor pairs for "Impression ON" monitoring is guaranteed.
(Impression ON sensor 1 / Impression ON sensor 2)
C 95A 6423 39 – 12. Nov. 2003 17-25

17 Coating unit
Material thickness adjustment
Drive side, drive No. 3, Bus address No.: 62
F Flat
K Clamping screw
26 Motor and poti
Operating side, drive No. 4, Bus address No.: 63
F Flat
K Clamping screw
26 Motor and poti
Installation of the motors:
1. Connect the motors electrically before mechanical installation; switch to

Active mode and move motor shaft so that the flat is parallel with the motor housing
2. Rotate spindle for the adjustment of the substrate thickness enough so that the
clamping screw becomes accessible
3. Mount motors and clamp
4. Move motors in Direct mode, so that there is (in Impression ON mode) a 2,6 mm
gap between stencil cylinder and impression cylinder (use lead wire for checking)
5. In Direct mode (menu 7), adjust the potentiometer voltage to 2383mV, or: adjust
actual value on = 0,00mm in mode Individual adjustment of positioning motors (menu 6)
6. Switch press OFF and ON again
17-26 C 95A 6423 39 – 12. Nov. 2003

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17
Mounting
D rive side Operating side
C 95A 6423 39 – 12. Nov. 2003 17-27

17 Coating unit
Basic adjustment of the clamping device
Detail X
DA: Leading edge of print
DE: Tail edge of print
17-28 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
Register remote control
1 Circumferential register
Drive No.: 1, Bus address No.: 60 Center position 0 mm = 3981 mV - CPL
Center position 0 mm = 3641 mV - Standard
2 Lateral register
Drive No.: 2, Bus address No.: 61 Center position 0 mm = 5000mV -CPL + Standard
When installing the register remote control, adjust to 41,5 mm by turning the threaded bushing, the
Circumferential register then is approximately in center position.
Use screws M6 X 45 with continuous thread to disassemble the register adjustment!!!!!!
C 95A 6423 39 – 12. Nov. 2003 17-29

17 Coating unit
17.10 Impression cylinder
Mounting
Drive side Operating side
17-30 C 95A 6423 39 – 12. Nov. 2003

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17
Impression cylinder with segmented cams
Clamping mechanism Operating side Roller lever - Drive side
11 Locking screw
2 Adjusting screw
Gripper: basic position
1 Square socket (hexagon socket)

2 Cam roller Ø 38,1 mm . (Ø 40,0 mm)
3 Eccentric stop
4 Gauge.
5 Collar of bearing bushing
Ø 124 mm.
Adjust torsion:
- all grippers must be loose
- cam roller must not contact the cam
- remove lock screw
- the stop must be adjusted correctly
- turn adjusting screw (clamping mechanism operating side) until a torque of 45 Nm is required to lift the
roller lever off the stop
- The square (hexagon) on the roller lever serves as measuring point
- tighten lock screw
Adjust grippers:
- rotate impression cylinder into position and put press on STOP secure
- insert 106,505 mm gauge (105,555 mm) between cam roller and collar of bearing bushing
- check gap between roller lever and stop (0,7 mm)
- check basic position of grippers
- press grippers on gripper pad, align and tighten
- using a 0,1 mm feeler gauge, adjust gap between gripper and gripper pads
- remove gauge
Always adjust both sets of grippers!!!!
C 95A 6423 39 – 12. Nov. 2003 17-31

17 Coating unit
Impression cylinder with continuous cams
Clamping mechanism Operating Side Roller lever - Drive side
1 Locking screw
2 Adjusting screw
1 Square socket (hexagon socket)
Gripper: basic position 2 Cam roller Ø 38,1 mm . (Ø 40,0 mm)
Adjust torsion:
- all grippers must be loose
- advance cam roller to max. radius of cam
- remove lock screw
- turn adjusting screw (clamping mechanism operating side) until a torque of 45 Nm is required to lift the
roller lever off the stop
- The square (hexagon) on the roller lever serves as measuring point
- tighten lock screw
Adjust grippers:
- rotate impression cylinder into position and put press on STOP secure
- support roller lever and remove cam roller
- insert Ø 36,7 mm . gauge (Ø 38,6 mm )
- advance, together with gauge, to max. radius
- check basic position of grippers
- press grippers on gripper pad, align and tighten
- using a 0,1 mm feeler gauge, adjust gap between gripper and gripper pads
- remove gauge
Always adjust both sets of grippers!!!!
17-32 C 95A 6423 39 – 12. Nov. 2003

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17
17.11 Take off drum
Gripper adjustment
Take-off drum with segmented cam
- Rotate take-off drum into position and put press on STOP secure
- lift roller lever and insert 112,90 mm gauge between Ø 38,1 mm cam roller and Ø 114 mm collar of the
bearing bushing
- this represents a 0,4 mm gap between the stops
- adjust all grippers uniformly using a 0,1 mm feeler gauge
- remove adjusting gauge
- repeat entire procedure on the 2nd set of grippers
Always adjust both sets of grippers!
Take-off drum with continuous cam
- Rotate take-off drum into position and put press on STOP secure
- Cam roller on min. diameter of cam
- Lift cam roller and insert 17,633 mm gauge between cam roller and min. radius of cam
- repeat entire procedure on the 2nd gripper field
C 95A 6423 39 – 12. Nov. 2003 17-33

17 Coating unit
17.12 2nd transfer cylinder
Gripper adjustment
2nd transfer cylinder with segmented cam
- Rotate transfer cylinder II into position and put press on STOP secure
- lift roller lever and insert 92,35 mm gauge between Ø 38,1 mm cam roller and cylinder shaft
- this represents a 0,4 mm gap between the stops
2nd transfer cylinder with continuous cam
- Rotate transfer cylinder II into position and put press on STOP secure
- Release torsion bar on operating side
- Loosen Ø 38,1 mm cam roller and remove
- install Ø 36,85 mm gauge
- preload torsion bar
- gauge must be on max. radius of cam
- release torsion bar
- replace 36,85 mm gauge by 38,1 mm dia. cam roller and tighten
- preload torsion bar
17-34 C 95A 6423 39 – 12. Nov. 2003

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17
17.13 Operation
General comments regarding the metering gap
The metering gap is adjusted by way of two positioning motors (M341, drive side and M342, Operating side;
both are motor potentiometers). The gap may be set by parallel or one-sided movement of the fountain roller
to the desired gap width (only during standstill of the press). If one-sided movement is chosen (required in
case of one-sided wear of the fountain roller) only the operating side of the roller is moved. During standstill of
the press, the metering gap may also be closed while no coating material is present in the coating pan. Then,
however, the press can not be run, since, without coating material in the fountain, the fountain roller would be
destroyed. During operation of the positioning motors, the respective LED (Key 6 for parallel adjustment, key
17 for skew adjustment) lights up. Once the working position is attained, the respective LED is in ON mode.
Attention: The press is ready for operation, as soon as there is sufficient

coating material in the coating pan
Quantity of coating applied
The quantity of coating to be applied is set by adjustment of the metering

gap. By way of selecting "Preselection gap A/B", an operating point [“0” – “99”] may be entered.
The entire range, covered by this adjustment, is the operating range.
The adjustment on the control panel of the coating unit corresponds with the green bar graph
in the menu "Water/Ink" / Submenu: "Water / Coating"
Specifications concerning the gap adjustment
Entire adjustment range (motorised) : 2.000 mm
Kiss print : 0,610 mm
Minimum adjusting positions

Drive side : 0,270 mm
Operating side : 0,210 mm
Maximum adjusting positions

Drive side : 0,610 mm
Operating side : 0,670 mm
Maximum skew adjustment of

the operating ranges
(Drive side to operating side) : 0,060 mm
Operating range of values : 0 – 99
Operating step size : 0,004 mm / step
Operating range : 0,396 mm
C 95A 6423 39 – 12. Nov. 2003 17-35

17 Coating unit
Metering gap
1. Passive mode of the metering system
The status in which the distance between fountain roller and coating form roller reaches its maximum value
(gap opening approx. 1,2 mm) is designated as rest position of the metering system.
Due to the open gap, there is no danger of abrasion or dry running during press operation.
The press may be run irrespectively of the particular conditions of the coating unit.
2. Active mode of the metering system
Immediately upon leaving the rest position, the particular restrictions due to the coating unit take effect. The
press is locked to protect the coating form roller, running in contact with the fountain roller, from running dry,
until "--> complete production readiness" is achieved.
Once "complete production readiness" is achieved, the press is released.
None of the operating keys is free for actuation.
For a differentiated treatment of the various interfering influences during production, one should distinguish
between three states:
A) "Complete readiness for production - coating recirculation ON"
the metering gap is in working position

AND the fountain roller motor operates without difficulties
AND the operating mode "Coating" (Preselection Coating feed) is selected
AND The recirculation unit is in mode "Coating recirculation"
(The preparatory work cycles have been terminated -> There is no
longer any water in the system)
AND the detector in the coating fountain reads the presence of coating
material
B) "Reservoir-related readiness for production - without coating feed"

(Readiness for production, due to a reserve of coating material
existing in the fountain; supply is OFF)

AND the operating mode "Coating" was interrupted (-> exchange of
containers)
AND the detector in the coating fountain (still) reads the presence of
coating material
C) "Level does not come up to proper height"

AND the operating mode "Coating" is interrupted (-> exchange of
containers) OR the operating mode "Coating" is selected
AND the detector in the coating fountain does not read the presence of
coating material.
17-36 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
Adjusting range
2000µm rest position
670µm maximum adjusting position / only operating side
610µm maximum adjusting position / drive side / theoretical kiss print point
270µm minimum adjusting position / drive side
210µm minimum adjusting position / only operating side
C 95A 6423 39 – 12. Nov. 2003 17-37

17 Coating unit
Operating range
Example for the operating range
550µm - real kiss print point

- max. point of the operating range, [max. coat]
- coating form roller and fountain roller are just touching,
checked by light gap.
350µm - middle of the operating range
150µm - min. point of the operating range, [min. coat]
17-38 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
Operation
Explanation:
• Prolonged actuation of the key "Preselection Gap A/B" introduces the aligning
• Upon activation of the function, the metering gap automatically moves to the latest aligning position.
(Position “50” of the present working range)
• The latest aligning position - in 4-digit format of the nominal values of the hand-held terminal - appears
in the display
• Set the real kiss print point with the keys: Adjustment PLUS - Adjustment MINUS, checked by light gap,
both sides ( 550µm in the example)
• Once the function is introduced, a short actuation of the opposite preselection key is sufficient
to switch directly from mode Parallel Adjustment to mode Skew Adjustment
• Substrate 200µm from the real kiss print point, and drive to 350µm
• Actuation of the presently active preselection key (Gap A/B or Gap B) de-activates the function.
• The aligning points for drive side and operating side are permanently saved, the nominal value for the
coating film thickness is set to ”50”.
A = Drive side
B = Operating side
The value in ”µm” will be shown in the digital display as cycling numbers.
Example: “350µm”
550µm corresponds to “99” maximum of coat
350µm corresponds to “50”
150µm corresponds to “0” minimum of coat
C 95A 6423 39 – 12. Nov. 2003 17-39

17 Coating unit
COATING / WASHING OPERATION
COATING OPERATION
1. Close the gap. Install the collecting pan and the lateral guides.
(only possible, when the machine is stopped) Sensor is in working position.
Open the taps at the collecting pan!
2. The gap is closed (machine is blocked).
Error messages at the console: SPS: coating module 1; the
machine is blocked 36 01 700 and SPS: coating module 1; coating
request is not selected 36 01 400
3. Select the varnish feeding pump - pump starts to pump varnish - LED blinks "fast"
(coating unit turns - when guard (no. 55) is closed).
Error messages at the console: SPS: coating module 1; the
machine is blocked 36 01 700 and SPS: coating module 1; coating
level; working level not reached 36 00 500
The feeding pump pumps varnish with full power (time is
adjustable). -> push the key "feeding pump ON" for longer
Returning pump sucks into the waste tank: 100sec than 3sec and set the time with the + -keys
4. Feeding pump stops. - LED blinks "slowly"
Returning pump sucks into the waste tank: 60sec
Close the taps at the collecting pan!
5. Returning pump stops after 160sec. - LED "statically green"
The returning valve switches over to the varnish tank.
6. Feeding and returning pumps switch on. Varnish circulation. push the key "varnish volume preselection"
Returning pump runs always with full power. shortly and adjust the feeding pump with
Feeding pump adjustable from 10%-99% . -> the + - keys
7. Varnish level is OK, machine is released for production !
Varnish level too low: a) without paper in the machine - Slow Stop
b) with paper (production) - end of production -
Slow Stop
WASHING OPERATION
1. Stop the machine, deactivate the feeding pump. The "wash-up"-key is blocked during machine run.
Feeding pump (varnish) stops. Open the taps at the collec. pan!
2. Push the "wash-up"-key (machine is blocked). " LED "blinks"
Returning pumps keeps on pumping into the varnish tank for 60sec.
Feeding valve switches over to fresh water. Water tap must be open!
3. Returning pump stops.
Returning valve switches over to the waste tank.
4. Solenoid valve "water" switches on. - LED "statically green"
Feeding and returning pumps switch on (feeding pump runs at
50%). Spray bar sprays automatically 1x water.
5. Push the "wash-up"-key to stop the washing program. The feeding The end of the washing program is determined by the
pump stops . operator.
6. Spray bar can be activated manually as often as necessary by When the pump has stopped, it can be restarted by
pushing the "spray bar"-key. pushing the "spray bar"-key longer than 3sec.
Returning pump keeps on running for 75sec.
7. Open the gap, close the taps at the collecting pan.
The machine is released for production!
17-40 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
17.14 Rollers
Coating fountain roller bearing
Drive side
1 sensor, active if fountain roller is installed

2 Pin, depressed if fountain roller is installed
Operating side
C 95A 6423 39 – 12. Nov. 2003 17-41

17 Coating unit
Rollers
Coating form roller bearing
Drive side
1 Free-wheel FBF 57, Manufacturer: Ringspann
Operating side
2 Free-wheeling bushing HFL 3530 Manufacturer: INA
17-42 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
Drive side inside
The operating side is laterally reversed
3
1
1 Outer side frame

2 Inner side frame
3 Eccentric bushing
Through the bore in the inner side frame 2 both markings are visible.
One marking is provided on the eccentric bushing 3, the other on the outer side frame 1.
To obtain theoretical kiss print position, both markings have to be aligned.
The potentiometers of the positioning motors must then be set to the theoretical kiss-print point
0,610 mm = 6525 mV
C 95A 6423 39 – 12. Nov. 2003 17-43

17 Coating unit
17.15 Pneumatic
Valve block, operating side
A LED
B Pin for testing circuit LED
C Connection for electrician
X Compressed air
1 Y063 Coating feed (P.O. -A548-A/13 B.B.18.5 54.G)
2 Y409Compartment blade (P.O. -A548-A/13 B.B.18.0 54A)
3 Y412 Forme cylinder wash-up device (P.O. -A548-A/13 B.B.18.3 54.D)
4 (Impression cylinder cleaner, optional)
5 Y413 Inrunning guard 2nd transfer cylinder (P.O. -A548-A/13 B.B. 8.2 54.C)
6 -----
Piston:
1 extended
2 retracted
3 retracted
5 retracted
Compressed air is supplied to connection 2, if the valve is electrically not activated
Example for numbering of the lines
To drive side connecting no. 2 at the valve
To operating side connecting no. 4 at the valve
17-44 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
Pneumatic
GW Blanket washing agent r

H2O Water
WW Roller washing agent
M to machine
X from compressor
Kessel 1 Tank 1
Kessel 2 Tank 2
1 Magnetic valve
2 Shut- off valve
3 Flow control valve
4 Magnetic valve 60 sec. Valve
5 Pressure control switch
6 Maintenance unit
7 Pressure regulator + safety switch
Presses with coating units and extended deliveries are provided with a second pressure tank.
For safety reasons, the tanks of GW + WW are supplied with compressed air during the wash-up cycle only.
During production, the tanks GW + WW are without pressure; they bleed automatically.
The second tank (it is assigned to the wash-up medium containers only) is provided with a magnetic valve,
releasing compressed air for the wash-up cycle only.
The waiting time between production and between wash-up procedure and production each is 2 minutes.
For the purpose of testing the wash-up medium containers, the magnetic valve may be switched over
Position 1 = Production
2 = Testing
Basic position of flow control valve: screw adjusting screw in all the way, then back out six turns and lock.
C 95A 6423 39 – 12. Nov. 2003 17-45

17 Coating unit
Compartment blade / Check valve
Should a power failure occur (tank shut-off, broken pressure line etc.), then the check valve prevents the
compartment blade, filled with coating material, from lifting off the stencil cylinder and thereby spilling the
coating. The check valve keeps the compartment blade in contact until a switch-over is effected by way of the
electrical actuating valve.
outside, drive side
1 Switching shaft, compartment blade
2 Pneumatic cylinder (retracted Compartment blade OFF")
3 Check valve
4 Pressure gauge (operating side, near delivery)
17-46 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
17.16Sheet guides
Air cushion tracks
Arrow = PREFERRED direction
no. description amount function cable connection desig-

no. nation
1 blower under take off drum 5 blower W448 +JX, -A454, X12 -A503
2 Take off drum --- --- --- --- ---
3 curved guide over 2. transfer cylinder --- --- --- --- ---
4 2. transfer cylinder --- --- --- --- ---
5 curved guide at the impression cylinder --- --- --- --- ---
6 blower at the impression cylinder 5 blower W451 +JX, -A454, X15 -A506
7 blower/sucker at the sprocket wheel 5 sucker/blower W449 +JX, -A454, X13 -A504
shaft
8 blower/sucker under the sprocket 5 blower/sucker W161 +EA, -A334, X60 -A405
wheel shaft
9 sprocket wheel shaft --- --- --- --- ---
10 blower/sucker air cushion track 5 blower/sucker W160 +EA, -A334, X61 -A406
11 dryer (option) --- --- --- --- ---
12 blower/sucker air cushion track 5 blower/sucker W159 +EA, -A334, X62 -A407
13 blower/sucker air cushion track 5 blower/sucker W162 +EA, A334, X58 -A502
14 sheet decurler --- --- --- --- ---
15 fans over the delivery pile --- --- --- --- ---
C 95A 6423 39 – 12. Nov. 2003 17-47

17 Coating unit
17.17 Chambered doctor blade

Description
The chambered doctor blade/anilox roller method of applying coating is a significant new development in metering
technology. A chambered doctor blade takes the place of the metering roller and an anilox roller takes the place of
the coating forme roller. This method enables a defined coating film thickness to be applied over the entire width of
the sheet. Changeover from the two-roller system to the chambered doctor blade system can be done by the
operator. The coating film thickness can be varied by using anilox rollers with different specifications.
The user should place a gantry over the unit to simplify roller changing (this minimizes the risk of injury and
damage).
The chambered doctor blade
The chambered doctor blade consists of an enclosed aluminium chamber with two doctor blades, one of which is
set to the anilox roller in its direction of rotation, the other in the counter direction. The chamber is fixed in a bearing
to ensure the correct position of the system. A pneumatic device maintains a constant pressure between the
chamber and the anilox roller, thus ensuring minimal wear to the doctor blades and gaskets. After a one-time
adjustment to the blades of approx. 0.3 mm, the system automatically regulates the pressing force of the chamber
and equalizes wear to the blades. This ensures that t the scraping function is always correct and print quality is
consistent. The chamber is effectively sealed at the ends with patented sliding gaskets which keeps the faces of
the anilox roller dry.
The anilox roller
The anilox roller is made of steel and clad with ceramic (99% pure chromium oxide). Characteristics of this surface
are extreme hardness and very low porosity, which prevents corrosion between the steel core and the chromium
oxide layer when working with water-based coatings. The cells are engraved by a computer-controlled laser device
and the chromium oxide layer is applied by a vaporising process. Then the anilox roller is finely polished. A very
precise measuring process then determines the exact carrying capacity of the roller.
The anilox roller supplied as standard has a carrying capacity of 9 cm3/m2 with 200 lines/inch.
The amount of coating on the sheet amounts to approx. 4½ cm3/m2 (halved by splitting on the coating forme
cylinder). This specification has proven to be very practical for most purposes.
A wide variety of anilox roller specifications are available (for thin to very thick coating layers) and the most suitable
specifications for each individual user should be determined in consultation with MRO.
17-48 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
Setting
View A-side outside
1 Anilox roller (∅ 143.2 mm)

2 Sheet stop B
3 Collector doctor blade shaft
4 Eyebolt
5 Piston connecting rod
6 Pneumatic piston (stroke 25 mm)
7 Sensor B401 collector doctor blade „ON“
8 Sensor B402 collector doctor blade „OFF“
9 Complete collector doctor blade
10 Sheet stop A
11 Stop screw A
12 Holding device
13 Stop screw B
14 Clamp screw
X 28.6 mm (from s. 331, 25 mm)
C 95A 6423 39 – 12. Nov. 2003 17-49

17 Coating unit
Pneumatic piston / Sheet stop A-side outer side
• Screw in eyebolt completely and lock into the piston connecting rod.
• Extract by hand piston connecting rod 20 mm (from s. 331, 16.5 mm) from pneumatic piston
(without air pressure). Piston stroke is 25 mm.
• Set stop screw B at 1.5 mm to sheet stop B.
• Note: At the moment when stop screw B hits sheet stop B, pneumatic piston must not have reached its
maximum stroke!!!
Chambered doctor blade shaft and mounting
• In the Leitstand set Chambered doctor blade to „+“

• Lock indexing bolt on A-side.
• Turn impression pressure for setting the Chambered doctor blade all the way to MINUS (B-side, delivery
side).
• Press key no. 16 „Working position ON“ (B-side, delivery side).
• Insert 1.5 mm feeler gauge between sheet stop B and stop screw B.
• Increase impression pressure slowly. At 0.4 – 0.5 bar the Chambered doctor blade shaft and mount
have to move towards the anilox roller.
In this way the mechanics and mounting position of the relief valve can be checked.
(See Section: Pneumatics).
• The relief valve should be active at 0.5 bar.
Working pressure may not exceed 0.7-0.8 bar. A higher pressure increases excessively the wear
of the doctor blades.
If the relief valve is wrongly mounted then a pressure of about 1.4 bar is required for its activation.
• Set both holders of the Chambered doctor blade in parallel to the anilox roller at 28.6 mm (from s. 331,
25 mm – to do so use spacers) and tighten the clamping screws.
• Set sensor B401 (Chambered doctor blade ON) on the pneumatic piston so that the whole working
range is clearly included.
• Press key no. 5 „Working position OFF“ on the delivery side.
• Set sensor B402 „Chambered doctor blade OFF“.
Chambered doctor blade to anilox roller
• Preset stop screws A in the holders to 7.8 mm and lock, then check by Chambered doctor blade !!!
• Insert and fix Chambered doctor blade in the holding device.
• Extract indexing pins and carefully lean Chambered doctor blade on the anilox roller so as to check the
parallel position of doctor blades to the anilox roller. If necessary make corrections on stop screws A.
• Lock in indexing pins, mount varnish overflows and varnish supply. See operation instructions. When
checking function use at first just water.
17-50 C 95A 6423 39 – 12. Nov. 2003

Coating unit
17
17.18Dryer
Coating module with extended delivery

Example: “Seccomat Infrared - warm-air dryer”
1 8x Warm-air jets - Slit-type jets Heating capacity 18 kW
2 Push-in segment design in slide-in cassette
Medium wave length

4 radiators 1,8 kW = 7,2 kW
Short wave
4 radiators 4,0 kW = 16 kW
Total = 23,2 kW
C 95A 6423 39 – 12. Nov. 2003 17-51

17 Coating unit
17-52 C 95A 6423 39 – 12. Nov. 2003

MechanicsR300 Completo PDF

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What are the main components of a sheetfed printing press?

What are the main components of a sheetfed printing press?

What are the functions of the feeder, printing units, delivery and coating unit?

What are the functions of the feeder, printing units, delivery and coating unit?

Product Training Sheetfed Presses

Service Manual Mechanics

C95A 6423 39 - 12.11.2004

Dear course participant

Since the work on documentation is never complete, we always welcome suggestions,

MAN Roland Druckmaschinen AG

Copyright 2003 - 2005 MAN Roland Druckmaschinen AG

The copyright for this technical documentation remains with

C95A 6423 39 - 12.11.2004

4 Transport of the machine

5 Installation of the press

6 Feeder till series 330

14 Air supply / pneumatics

C 95A 6423 39 – 13. Nov. 2003 0-1

0-2 C 95A 6423 39 – 13. Nov. 2003

C 95A 6423 39 – 11. Nov. 2003 1-1

1-2 C 95A 6423 39 – 11. Nov. 2003

1 extended delivery 4 intermediate printing units

1 dry sprayer 6 washing agent reserve container

C 95A 6423 39 – 11. Nov. 2003 1-3

1 suction tape feed board

1.4 Printing unit

1 2nd transfer cylinder or

1-4 C 95A 6423 39 – 11. Nov. 2003

1 pile supporting plate 6 suction roller (sheet slow-down)

1.6 Extended delivery with coating module

C 95A 6423 39 – 11. Nov. 2003 1-5

1.7 Coating unit

1 bailing roller 6 3. transfer cylinder

Instead of 1+2 anilox roller and chamber blade

1-6 C 95A 6423 39 – 11. Nov. 2003

1.8 List of Assembly Groups

001 side frame 031 inking unit

The numbers correspond to those indicated in the catalogue of spare parts!

C 95A 6423 39 – 11. Nov. 2003 1-7

1-8 C 95A 6423 39 – 11. Nov. 2003

C 95A 6423 39 – 08. Jul. 2004 2-1

2.11 Inking units...................................................................................2-22

2-2 C 95A 6423 39 – 08. Jul. 2004

2.1 Machine Configurations

C 95A 6423 39 – 08. Jul. 2004 2-3

Maximal paper sizes for different size categories:

MAN Roland size identification

Size Max. paper Min. paper

00 Roland Practica 360 x 520 160 x 180

2-4 C 95A 6423 39 – 08. Jul. 2004

2.3 Abbreviations / Explanations

Used abbreviations (Fitters’ training)

C 95A 6423 39 – 08. Jul. 2004 2-5

2.4 Degree dial

Advance machine to “0°“ and clamp degree dial/pointer at “0°“.

0 2 70 80 90 100 110 240

The degree dial can be cut out and stuck on a board.

2-6 C 95A 6423 39 – 08. Jul. 2004

2.5 Gripper adjustment gauges