M7E02_Installation_02.pdf

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Service Training Mechanical Roland 700

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C95A 6428 39 - 06. Aug. 2004 1

Table of Contents

2.1 Machine transport ............................................................................ 2

2.2 Hitching device................................................................................. 3

Feeder and delivery, printing, coating and transfer units .................... 3

Delivery with 945,4 mm extension...................................................... 4

Transport trolley for the feeder ........................................................... 5

2.3 Transport trolley for press and delivery (not for Airglide)............ 6

Roller plates........................................................................................ 7

2.4 Zinc underlay plate (oil drip tray) .................................................... 8

Positioning and aligning the printing units .......................................... 8

2.5 Presses up to series 709.................................................................. 8

2.6 Setting the printing units ............................................................... 10

Presses up to series 709 .................................................................. 10

Teeth engagement position .............................................................. 11

2.7 Positioning and aligning the printing units.................................. 12

Presses up to series 710 .................................................................. 12

Printing unit 1.................................................................................... 13

Printing unit 2.................................................................................... 14

Printing unit 3.................................................................................... 16

Printing unit 4 and all following ones ................................................ 17

Fine alignment of the press .............................................................. 18

Checking tooth clearance for printing units 2 and 3.......................... 20

2.8 Tooth engagement position when assembling the printing units21

Presses as from series 714 .............................................................. 21

2.9 Aligning the printing unit............................................................... 22

2.10 Installing and aligning the delivery............................................... 23

2.11 Aligning the feeder ......................................................................... 26

2.12 Aligning the printing units and coating units .............................. 27

Spirit level measurement log ............................................................ 27

Gear tooth clearance measurement log ........................................... 28

2.13

Machine relevel............................................................................... 28


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2.1 Machine transportTransport of the machine from the delivery pointto its designated place in the pressroom mayonly be done by qualified transport companieswith suitable moving equipment.

Important details such as delivery time, height ofaccess doors, etc. must be clarified in advance.

Before using transport and hitchingequipment, check that the fastenings aresecure!

It is strictly forbidden to stand belowhanging loads!

The transport and hitching equipment mustbe tested! Be sure the safety-approvedbadge is valid!

Only use hitching equipment provided byMAN Roland!

The instructions and procedures given inData Base Documentation Transport,

Installation, Commissioning must befollowed!

Alternative means of transport

The printing or coating units can also be liftedunderneath the foundation tie-bars andtransported by a forklift. When doing this, thefollowing points must be taken into account:

The forklift should have hydraulically-actuated forks.

The forklift must have min. 10 tons liftingcapacity.

The weight of the load must be correctlyspread over both forks.

The load must be braced against slipping(e.g. clamp a rubber mat between the forksand the foundation tie-bar).


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2.2 Hitching device

Feeder and delivery, printing, coatingand transfer units

Use lifting device RS-Nr. 843R 2000 13/1 fortransporting the units.

Slide the lifting device eyelet (1) to theappropriate marking (3).

The marking indicates the center of gravity forthe particular load.

Tighten the screw (2).

Hitching the feeder requires two intermediateplates (drawing no. 03076416) and two M 30transport eyelets.

M7INS001

3 1

2

When assembling the stop plate RS-Nr. 01A4739 30, it must be ensured that the drilledholes (1) face towards the impressioncylinder.

1. Stop plate

2. Impression cylinder

3. Transferter

M7INS002

M7INS003

Z

Z1

1

23


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Delivery with 945,4 mm extension

M7INS004

Lifting device 743 T 3152 13


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Transport trolley for the feeder

2

55

3

1 4

M7INS005

1 Fixed-wheel transport trolley2 Steerable transport trolley3 Pile plate

4 Mounting bracket5 Transport tie-bar

Use the transport device designated00SA33404-002 in the Mabeg parts list.

The pile plate (3) must be screwed firmly tothe devices (4 and 5).


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2.3 Transport trolley for press anddelivery (not for Airglide)

M7INS006

53

1 1 2

4

1 Adapter for delivery2 Fastening screws3 Steerable trolley

4 Transport tie-bar5 Fixed-wheel trolley

The printing units and delivery can betransported by the same trolleys (4 + 5):

Mount two adapters (1) at the front on thesideframes.

At the delivery, fasten the steerable trolley (3)to the pile plate side with the screws (2).


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Roller plates

The roller plates are used for fine alignment ofthe printing units to each other.

There are special components for the R 700which are contained in the roller plate set no.843 R0576 13.

The individual units can be slid on foils (3pieces, min. 0.5 mm thick) and LA 8 grease.

It is not permitted to use foils or similarmaterial for presses to be mounted on a

raised foundation. M7INS007


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2.4 Zinc underlay plate (oil driptray)

For positioning the drip trays, please refer to thedrawings for the specific press designation.

The drawings zinc underlay plate and pressfoundation plan can be found in the orangefitters envelope which is in the start-up box.

Positioning and aligning the printingunits

2.5 Presses up to series 709

The location of the units and peripheral items aswell as the floor loading capacity have beenclarified during project planning.

The machine position is given in the projectdocumentation.

Before commencing installation, the floormust be tested with a straightedge (or laser)to be sure it is level.

If the floor is considerably uneven, use steelplates (min. 100 x 100 x 15 mm) tocompensate.

Never place the press on one complete steelplate.

The distance between the floor and theunderside edge of the sideframe is120 10mm.

The printing units are aligned using 2 spiritlevels (measuring accuracy 0.04 mm) on

the sideframes and a special cylinder spiritlevel on the impression cylinder.


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M7INS009

2 2 1

The height of the printing units relative to oneanother is determined by laying a 500 mmlong spirit level (1) ( 0,04 mm) on the two 50

mm locating bolts in the foundation tie-bars.

To do this, the bolts must be pulled outapprox. 55 mm and a valve unit must bedismounted.

Once alignment is finished, the deviation ofthe spirit levels on the sideframes (1) should

be max. 0.02 mm and that of the spirit levelon the impression cylinder max. 0.01 mm.

Before moving the printing units together,the points contained in the following pagesregarding press revolutions and gear teethposition must be observed.

M7INS008

1 Spirit level 500 mm long2 Locating bolts3 "A" dimension = 55 mm


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2.6 Setting the printing unitsPresses up to series 709

The following procedure must be carried out toensure that the ink ductor roller timing is correct:

Printing unit 1

Use two stud bolts and a bar to turn thepress until the yellow markings on theimpression cylinder drive gear and the inkfountain roller drive gear face verticallyupwards.

Up to three press revolutions are necessary todo this (min. ductor roller stroke).

This position ensures that the eccentricmarkings for ductor roller stripe and ductor rollermovement, as well as the printing units, faceone another within one press revolution.

Printing unit 2

Use two stud bolts and a bar to turn thepress until the yellow markings on theimpression cylinder drive gear and the inkfountain roller drive gear face verticallyupwards.

Up to three press revolutions are necessary todo this (min. ductor roller stroke).

This position ensures that the eccentricmarkings for ductor roller stripe and ductor rollermovement, as well as the printing units, faceone another within one press revolution.

M7INS010

4 3

1 12

1 Fountain roller gear (tooth marked yellow)2 Tooth gap, impression cylinder (tooth

marked yellow)3 Mounting position (teeth marked red)4 Stud bolts and bar


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Teeth engagement position

Printing unit 1

40 tooth gaps in the forwards direction from theyellow marking on the impression cylinder gear,the mounting position is marked red.

Printing unit 2

Turn backwards until the red marking on theTransferter gear matches the red marking ofthe impression cylinder gear of unit 1.

Printing units 1 and 2

Move the printing units together.

Align them.

Bolt them tight.

Turn forwards to teeth engagement position(see above).

Printing unit 3 and all following ones

As described above:

Position.

Align.

Move together.

Bolt tight.


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2.7 Positioning and aligning theprinting units

Presses up to series 710

As from series 710, the sideframes of the R 700are no longer filled with SKC 60.

The new sideframes are perfectly machined tomatch.

The location of the units and peripheral itemshave been clarified during project planning.

Draw the position of the press and drip trayson the pressroom floor.

Before commencing installation, the floormust be tested with a straightedge (or laser)to be sure it is level.

If the floor is very uneven, use steel plates (min.100 x 100 x 15 mm) to compensate.

Never place the press on one complete steelplate.

- The distance between the floor and theunderside edge of the sideframe is125 10mm.

- The printing units are aligned using 2 spiritlevels (measuring accuracy 0.04 mm) onthe sideframes and a special cylinder spiritlevel on the impression cylinder.

- Once alignment is finished, the deviation ofthe spirit levels on the sideframes should bemax. 0.02 mm and that of the spirit level on

the impression cylinder max. 0.01 mm.


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The value inscribed on the Transferter orturning drum bearers must be complied withat the A side.

- At the B side, a tolerance of up to 0.04 mm ispermissible.

- The tooth clearance between the impressioncylinder gear and Transferter gear must be0.06 0.10 mm.

Before moving the printing units together,the points contained in the following pagesregarding press revolutions and gear teethengagement position must be observed.

Depending on local conditions, the installationcan start with the first or last printing unit, thecoating unit or the delivery. For example: R 7053B 5/0, 2/3; printing unit 1 must be brought intothe pressroom first.

Lay down the drip tray for printing unit 1.

Printing unit 1

Place the unit in position ( 5 mm).

Set machine height to 125 mm (levelling screwM 36 x 2 x 100 mm).

Make a rough alignment with the spirit levelon the ink fountain roller ( 0.04 mm) and thesideframes ( 0.04 mm).

Place the unit on the roller plates.

Position exactly ( 1 mm), use laser ifavailable.

Remove the roller plates.

Turn the unit to the yellow machine settingand red tooth engagement position (3).

The supply lines are fastened inside the unitfor transport purposes. Take these out.

Clean the faces of the sideframes, removeany burs.

Mount the plates for lateral alignment to

printing unit 2.

M7INS010

4 3

1 12


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Printing unit 2


Apply sealing agent.

Insert the 5 x 750 round cord (2) (fromseries 717) in the groove at the A side.

Lay down the drip tray.

Have the rigger place the unit in position withapprox. 20 mm distance to printing unit 2.

Set machine height to 125 mm (the height ofthe sideframe contour of printing unit 2should be approx. 0.3 0.5 mm lower thanprinting unit 1).

Make a rough alignment (same procedure asfor printing unit 1).

M7INS012a


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Turn the gear train until the yellow machineposition and the red marking on the gearcoincide with the same positions in printingunit 1.


Move unit towards printing unit 1. (Ifnecessary use lower fastening bolts (4)).

Loosen or tighten lateral alignment plates asrequired

Watch out for oil return flow lines and tooth

engagement position.

Screw in the fastening bolts (4) so they justcontact the frame, dont tighten them.

Remove the roller plates.

Make a rough alignment.

Turn tooth position to printing unit 3.

The supply lines are fastened inside the unit

for transport purposes. Take these out.


Mount the plates for lateral alignment toprinting unit 3.

With perfecting presses, fit and secure theblast rake.

M7INS011

M1 M2

23

1


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Printing unit 3

Clean the faces of the sideframes, (3)remove any burs.

Apply sealing agent (6).

Lay down the drip tray.

With perfecting presses, lay in the fanhousing for the sheet tracks beneath theturning drum.

- Place the unit in position with approx 20 mmdistance to printing unit 2.

- Set machine height to 125 mm.

The height of the sideframe contour of printingunit 3 should be approx. 0.3 0.5 mm lowerthan printing unit 2.

Make a rough alignment (see above).

Turn the unit so that the yellow machineposition and the red marking (7) on the geartooth face towards printing unit 2.

With perfecting presses, pay attention to theposition of the switch lever for lifting the camfollowers on the turning drum.


Pull unit towards printing unit 2. (If necessaryuse lower fastening bolts (4)).

Take care not to damage the oil return flowlines and the teeth at the engagementposition.

Perfecting presses: In the unit with theturning drum, the lateral alignment plate atthe A-side must be removed !

Screw in the fastening bolts (4) so they justcontact the frame, dont tighten them.

M7INS012b


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Printing unit 4 and all following ones

Same procedure as for printing unit 3.

Leave the press to settle overnight..

On the next day, align the individual printingunits exactly, starting from the middle.


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Fine alignment of the press

Printing unit 2

Finely align the sideframes and the impressioncylinder with spirit levels having a measuringaccuracy of 0.02 mm.

After alignment is completed, the deviation ofthe spirit levels should be max. 0.01 mm.

Printing unit 3

Finely align the printing unit (8).

Turn to gripper shaft 1 position (yellowmarking on Transferter gear (7)).

At gripper shaft 1 there is a value inscribed onthe A and B-side bearers.

This value indicates the distance between thebearers of the turning drum / Transferter to theimpression cylinder.


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Printing units 2 and 3

Couple the printing units.

Lock them tight with the fastening screws (4and 5).

Check distance between bearers (8) and adjustif necessary:

- If the actual distance is less or more than thevalue referred to above, the coupled unitsmust be decoupled and then lowered orraised.(Per 0.01 mm deviation between the

bearers 0.054 mm height adjustment on the

dial gauge (1).

Use a dial gauge to check the height settingat the A side.

Match the height at the B side using a spiritlevel on the impression cylinder.

Screw the printing units firmly together.

Check both bearers as well as the spiritlevels on the sideframes and impressioncylinders.

Dismount the lateral alignment plates.M7INS012d

The inscribed value must be reached at theA-side.

At the B-side, a tolerance of up to 0.04 mm ispermissible.


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Checking tooth clearance for printing

units 2 and 3Tooth clearance between the impressioncylinder gear and Transferter gear must be 0.03- 0.10 mm at the highest point of the gears.

If this is not the case, then the unit in questionmust be raised or lowered after consultation withMRO SBDT.

Checking tooth clearance for printing units1, 4 and 5

Same procedure as above.

Position and align the delivery.

Align the feeder (see Section 2.12 - Aligningthe feeder).

After all printing units have been aligned, allmeasured values (distance between bearers,spirit level readings, tooth clearance) must berecorded in a measurement log and added tothe acceptance report.


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2.8 Tooth engagement positionwhen assembling the printingunits

Presses as from series 714

The following procedure makes sure thatall ink ductor rollers make contact withthe ink distributor roller within one pressrevolution:

Use the stud bolts on the impression cylinderdrive gear to turn the printing units to becoupled until the yellow markings on the inkductor roller drive (1) are matching.

At the same time, the tooth (3) marked yellowon the impression cylinder gear must bepointing upwards.

Up to three press revolutions (min. ink ductorroller stroke) may be necessary.

When the correct position has been reached,the gear tooth (2) marked red must point inthe direction of the following printing unit.

Turn the following printing unit backwardsuntil the red markings (2)on the impressioncylinder of printing unit 1 and the Transferterof printing unit 2 coincide.

Push the printing units together and couplethem.

When alignment of both printing units iscompleted, turn them both forwards until thered marking (2) on printing unit 2 points in thedirection of printing unit 3.

Repeat this procedure until all printing unitsare connected.

M7INS011

M1 M2

23

1


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2.9 Aligning the printing unit

0.054 height adjustment 0.01 mm change todistance between the bearers

M7INS012a

1 0.054 height adjustment 0.01 play deviationbetween the bearers

2 Round cord 5 x 750 (from series 717), 8x 750 from series 710 716

3 Position printing unit 2 approx. 0.3 to 0.5 mmlower

4 Fastening screw M 24 x 80 mm with USIT

ring

5 Fastening screw M 24 x 80 mm without USITring

6 Sealing agent

7 Yellow marking on gear indicates grippershaft no. 1

8 Distance gauge i.e. feeler gauge


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2.10 Installing and aligning thedelivery

M7INS013a

1 6 3

8 7 542

1 Chisel mark2 Yellow teeth engagement position mark3 One spirit level (0.04 mm/m) at both A and

B-sides4 Take-off drum: 1 spirit level in the middle

(0.04 mm/m)

5 Delivery stay: 1 spirit level (0.04 mm/m)6 Sideframe contour for height difference

247.00 mm7 Switch cabinet feet under the cover plate

Installation and alignment:

The supply lines are fastened inside thedelivery for transport purposes. Take theseout.

Coat the sideframes and oil pan on the Aside with sealing gel.

Insert both upper connecting bolts (M 24 x135 mm) in the delivery boring.


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M7INS013b

3

42

Dismount the guide plate or Super Blue drumon the take-off drum.

Turn the last printing unit and delivery so thatthe yellow teeth positions (2) match.

Place the delivery on roller plates.

Pull delivery towards last printing unit:

- If necessary use lower fastening bolts.

- Loosen or tighten lateral alignment plates

as required.

Watch out for oil return flow lines, air hosesand teeth engagement position.

Place one spirit level (measuring accuracy0.04 mm/m) on the take-off drum (4).

Place two spirit levels (measuring accuracy0.04 mm/m) (3) on the sideframes.


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M7INS013c

1 6 3

74

The cover plate must be removed to do this.

- The height of the delivery relative to theprinting unit is determined by the 0.05 0.08mm tooth clearance which must be adheredto.

- The tooth clearance can be corrected byraising or lowering the delivery.

- Chisel marks (1) on the sideframes at A andB sides indicate an approximate position.

- The height difference from the sideframes (6)

of the last printing unit to the delivery isapprox. 247.00 mm.

Set the B side (4) parallel using a spirit level.

Turn the four switch cabinet feet (7 at the Aside of the delivery downwards.

Use a spirit level (3) to level the sideframes.


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2.11 Aligning the feeder

M7INS014

6

1

2

3

5 4

Aligning:

Place a spirit level (measuring accuracy 0.04mm/m) on both A and B side sideframes (1).

Place a spirit level (measuring accuracy 0.04mm/m) on the belt drive shaft or similar (2).

Place a spirit level (measuring accuracy 0.4mm/m) on the feeder stay (6).

- The height of the feeder is determined bycentering the fastening screws in the tie-bars(3 and 4).

- The distance beween feeder and printing unit1 is determined by the tie-bars (4).

- The lateral alignment feeder to printing unit 1is determined by a tie-bar (5).


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2.12 Aligning the printing units andcoating units

Spirit level measurement log

M7INS015


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Gear tooth clearance measurement

logGear tooth clearance must always be checkedon the high points of the gears.

The tooth clearance ascertained is to be enteredin the table below.

Machine no.:___________________________

Customer:_______________________________

Type: _________________________________

Series:________________________________

Tooth clearance Play ascertained

Tooth clearance PU 1 - PU 2 0.____ mm









Tooth clearance last PU - delivery 0.____ mm

2.13 Machine relevel

If you have to relevel the machine use theoriginal tools (roller plates,plates for laterialalignement) !

M7E02_Installation_02.pdf

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