Joint Appendix vol II — NTA Graphics, Inc. v. National Labor Relations Board
Supreme Court brief1994
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No. 93-892
APR 25 eq |
In The OFECE OF ie ciLey |
Supreme Court of the United States
October Term, 1993
+
NTA GRAPHICS, INC.,
Petitioner,
VS.
NATIONAL LABOR RELATIONS BOARD,
Respondent.
+
On Writ Of Certiorari To The United States
Court Of Appeals For The Sixth Circuit
¢
JOINT APPENDIX
VOLUME Il
s
Timotny C. McCartny* Drew S. Days, III*
SHUMAKER, Loop & Kenpric« Solicitor General
North Courthouse Square
1000 Jackson
Toledo, OH 43624-1573
(419) 241-9000
Josep R. Damato
LAWRENCE P. Postou
DEPARTMENT OF JUSTICE
Washington, D.C. 20530
(202) 514-2217
Freperick L. Fermsteim
General Counsel
RONALD A. LinDsAy NATIONAL LABOR
SEYFARTH, SHAW, FAIRWEATHER RELATIONS BoarRD
& GERALDSON Washington, D.C. 20570
815 Connecticut Ave., N.W.
Suite 500 Counsel for Respondent
Washington, D.C. 20006-4004
(202) 463-2400
Counsel for Petitioner
*Counsel of Record
Petition For Certiorari Filed December 6, 1993
Certiorari Granted February 28, 1994
COCKXLE LAW BRIEF PRINTING CO, (800) 225-6964
OR CALL COLLECT (402) 342-2831
— ee OP,
oS. 2 hws, ‘ . * J , . —— ek ete, See a. Shiae $3 es
TABLE OF CONTENTS
Page
VOLUME I
Relevant Docket Entries in Nationa! Labor Relations
Board v. NTA Graphics, Inc., United States Court of
Appeals for the Sixth Circuit, Case No. 92-6085.. 1
Petition for Representation Election filed with
National Labor Relations Board (NLRB Case No.
ES PEE 6 ade veryduueidresesvccces ss )
Transcript of Hearing before National Labor Rela-
tions Board, pages 1-189 (NLRB Case No.
CHE PIE 6 vcevcwetladsbevescettebesees 15
Employer’s Exhibit 1 in Hearing before National
Labor Relations Board (NLRB Case No. 8-RC-
ED Io oa 6-6-4o.0'050 5.460 eee ees cote kehek os 188
Employer’s Exhibit 2 (NLRB Case No. 8-RC-
SB cece err ieee sewebeeunaeeee en 190
Joint Exhibit 1 (NLRB Case No. 8-RC-13648) 7/9/87
IE De Lee ee ee Pree Pp Pye n ee Era ne * 220
VOLUME II
Petitioner’s Exhibit (NLRB Case No. 8-RC-
Se SE Cov ab ssc dsb 0ahhe sedans Letcescasias 221
Decision and Direction of Election by National
Labor Relations Board Regional Director (NLRB
Case No. 8-RC-13648) 8/19/87*
Request for Review and Stay of Regional Director's
Decision and Direction of Election (NLRB Case No.
EE COL UL Yo ceescouseceeesses 314
Certification on Conduct of Election (NLRB Case No.
PE PIPED dv ccbebeeecéeceveccectesecs 338
Order of the National Labor Relations Board
(NLRB Case No. 8-RC-13648) 9/25/87*
* These materials have been omitted because they are included
in Appendix to Petition for Writ of Certiorari.
TABLE OF CONTENTS - Continued
Page
Certification of Representative (NLRB Case No.
S-RC-139648) D/OSOR ocvks ccudcnsacavavecesoseses 340
Letter from Robert J. Ogden to David Tremonti
1/B/92.. cavsscccestededewsenane meneeneaeaeeeeTes 342
Letter from Mark J. Jacoby to Robert J. Ogden
1/15/92... os000cnekeynn eee ee eeeeenens 344
Unfair Labor Practice Charge filed with National
Labor Relations Board (NLRB Case No.
6-CA-26277) L/BTITE vcinncted ceedeeerteibiesesas 346
Amended Unfair Labor Practice Charge filed with
National Labor Relations Board (NLRB Case No.
8-CA-24277) 2/6/92......... Veuvesewantact chee 349
Complaint and Notice of Hearing issued by National
Labor Relations Board (NLRB Case No.
S-CA-24277) SF EOP EE soc cccunccesccesteeseccces 352
Respondent’s Answer to Complaint (NLRB Case No.
8-CA-26277) B/BISE ci xcanceweedsecceuebececess: 357
Decision and Order of National Labor Relations
Board (NLRB Case No. 8-CA-24277) 7/24/92"
Application for Enforcement of an Order of the
National Labor Relations Board filed with the
United States Court of Appeals (Case No.
92-6065) 6/2B/SZ.. «0s inicis ees eeeiivdbdeseees 360
Answer to Application for Enforcement of an Order
of the National Labor Relations Board (Case No.
92-6065) D/IGIOE. «0 cicnweuuale pebmesneasen@es ss 362
Order of the United States Court of Appeals for
the Sixth Circuit 6/21/93*
* These materials have been omitted because they are included
in Appendix to Petition for Writ of Certiorari.
221
NOTICE!
DO NOT ATTEMPT TO OPERATE OR SERVICE
THIS PRESS UNTIL YOU HAVE READ AND
UNDERSTOOD THE INSTRUCTIONS CON-
TAINED IN THIS MANUAL.
HARRIS V-25
WEB OFFSET PRESS
OPERATING MANUAL
NATIONAL LABOR RELATIONS BOARD
Docket No. 8 RC-13648 OFFICIAL EXHIBIT NO.
Petitioner 1
Illegible 7
Disposition Received J
Rejected
In the matter of NTA Graphics Incorporated
Date 7-9-87 Witness Tremonti Reporter __ No.
Pages
(LOGO) HARRIS CORPORATION
HARRIS PRINTING PRESS DIVISION
COMMUNICATIONS P.O. BOX 15247
AND INFORMATION = FORT WORTH, TEXAS 76119
HANDLING 817/478-5431
222
HARRIS V-25 OPERATOR’S MA
TABLE of CONTENTS
Page
Section | — Description and Principles of Operation ..... 1
A crac 0 caGsbin cps scaevueaudihbenatariee nk ce 1
OER co's ctbens cacekupensanametas cosmmewues 2
ee fee ee ye ee ee eee 3
V-25 Printing Unit — Plate and Blanket Cylin-
co
Ink and Dampener Sys-
tem, Compensators, Infeed
JF-25 Folder — Trolley, Former, Conveyor,
Quarter Folder ................ 57
FUN SE 6 6 wk b oo wks docu avn dacucoewshashbuaes 8
Se SY SOD Vw, oh eweoe bb cuee eee ta 8
Printing Unit Control Panel..................... 10
TIN Si barvecepeuceasanetndaceeveucxeceins 14
Section II - Suggested Pressroom Safety Practices .... 15
Section IIA — Suggested Safety Procedures........... 18
Section II] - Makeready Procedure .................. 19
SNe 6b cre erate ceduledecdenW ove buieeenséenes 19
Preparation for the Makeready.................... 20
Operation I. Mill Roll Stand Preparation ........ 20
EE Sub étekedavhasckecnneesicnduassea 20
a oek oa au conyn dx sie kkaees 22
ee IG bh dui ab ocx eddcevedudececcus 23
Web Side Lay Adjustment .................... 23
223
Operation II. Printing Unit Preparation.......... 23
Silencing a Printing Unit....................5- 24
Printing Unit Timing Procedure............... 24
Protecting Press Plates............--.-.eeeeeee 25
Washing Ink Rollers with Wash-Up Device .... 25
Washing Ink Rollers without Wash-Up
ROWE ove cos Seo c ce cdenGareesive vb Nigaeenasess 25
Ink Fountain Wash-Up...............-+0ee eee 25
Cleaning the Blankets................+-0000005 26
Inking Supply Preparation..................-. 26
Filling Ink Fountains ....... 6... 6. see ee eees 26
Inking the Rollers ............-...eeeeeeeees 26
Setting Ink Fountain Blades................. 26
Changing Ink Fountain Roller Speeds....... 27
Dampening Supply Preparation.............-. 27
Preparing New Press Plates for Mounting..... 28
Plate Handling Cautions.................5.: 28
Making the Plate Locking Bends............ 28
Removing the Press Plates.................. 29
Cleaning the Plate Cylinders................ 29
Mounting the Press Plates ................-. 29
Blanket Removal and Installation ............. 31
Removing the Blanket .................00555 31
Mounting the Blanket and Packing.......... 32
Registering Printed Impressions.............-- 33
Side Register Adjustment .............-.++:. 33
\ 224
Circumferential Register Adjustment ........ 34
Compensator Adjustment................... 34
Operation III. Folder Preparation................ 35
Senin GHG TORE a cndenvicebeciedinnnccdsn 35
Folder Timing Procedure...................... 35
Hold Down Roller Adjustment................ 36
UND: TOE Pie is cide Ss cceviveccedte 36
Setting Stripper Fingers...........:ccccscssees 37
Setting and Adjusting the Trolleys and Slit-
OY TD 0 v0 ke cseebabdeuadderabonebalesnveiss 37
Quarter Folder Preparation ................... 38
Quarter Folder Timing Procedure ........... 38
Silencing the Quarter Folder................ 38
Section [IV - Press Operation ........cccccscccccccess 39
aly. Come: Gis és cannes vetondecieannann ee 39
ee 8 TT TE ne i Ds 40
FOUN WN oss ctucleuyeeetennvapieananereaenl 40
PORE «5 86 cnndads badiducdeunenieeastiaeeanenele 40
Coperating: Rap sn ona ts cake dex ccenasiecsis 40
Starting and Running the Press................. 40
Stops During the Run (Short Stops)............. 43
Starting Press after Short Stops................. 43
Shutting Down the Press (at end of run)........ 44
Section V — Adjustment and Part Replacements...... 45
Setting the Ink Distributor and Ink Form Rollers .... 46
Adjustable Ink Distributor Rollers............... 46
ink Form Rollers ....6.00cccccccccccccescceseces 46
Quick Check for Correct Settings of the Ink
eer rer err rrr rrr rere erie 49
Setting the Dampener Form Rollers..........--.-. 50
Setting the Ink/Dampener Ductor...........--. 50-51
Knife Blade Replacement ............005 600000005: 52
Impaling Pin Replacement ........-.----++-+++005: 52
Tucking Blade Replacement ..........-----+ss0005 53
Cutting Rubber Replacement..........------.++++: 53
Lap Adjustment - half fold..........--..-+e-+005: 54
Section VI - Lubrication. ..........-6- see cence eeeees 55
Methods of Lubrication..........-.....6 eee eeeees 56
Brush-on Lubrication ...........ccccceescccevces 56
Grease or Pressure Gun Lubrication............. 56
Printing Unit Lubrication .........----60++-+eee ees 56
Folder Lubrication ..........0cccccccecccscescrenes 57
Mill Roll Stand Lubrication ............-.-00++++5: 59
Section VII — Troubleshooting ...........--.+++-+0+55 60
Printing or Impression Troubleshooting ........-... 61
Web Feed Troubleshooting .........--......5055+55 61
Folding Troubleshooting ...........-66-.5+00+50005: 62
Electrical System Troubleshooting .......----....+- 63
Section VIII - Imposition Charts.............-++++++: 69
226
SECTION I
DESCRIPTION AND PRINCIPLES OF OPERATION
GENERAL
This manual should be read and understood
thoroughly before operating your new press.
The various sections of this manual will
describe the press itself, the operating controls,
operating procedures, maintenance and a
troubleshooting chart. The instructions are con-
cise and complete for operation of the press.
Recommendations to assure the best care and
performance are included. As you read the
instructions, keep in mind that maximum per-
formance and service depend on the owner and
operator. May we suggest that you practice the
step by step instructions to be certain you are
familiar with each operation.
DESCRIPTION
The Harris V-25 web offset printing press is a web-fed,
blanket-to-blanket, lithographic offset press which simul-
taneously and continuously prints both sides of the web
(perfecting press). Its folder gathers, folds, cuts and
counts the printed products and delivers them on a con-
veyor belt. A V-25 press with the 32-page JF-25 folder and
upper former can combine from one to eight printing
units, depending upon required printing capacity. These
units are normally installed in line. Each unit prints
either a standard four-page newspaper or an eight-page
tabloid (max. tabloid 6-webs) at speeds up to 25,000
impressions per hour.
ee ee Ce
227
When multicolor printing is desired, two or more print-
ing units operate to print successive impressions on a
web. Both lateral and circumferential adjustments are
provided to assure proper register between impressions.
Printed webs from all printing units move horizontally to
a jaw folder. This unit gathers, center folds and cuts the
webs. It then half-folds (quarter-folds with quarter-folder
engaged) to deliver finished copies. A conveyor trans-
ports these copies from the folder.
MILL ROLL STANDS
The V-25 includes a mill roll stand assembly (Figure X1-1)
for each printing unit. The roll stand is capable of han-
dling rolls to 36 inches in width and up to 40 inches in
diameter. .
FIGURE X1-1 - MILL ROLL STAND
[Omitted In Printing]
V-25 PRINTING UNIT
Printing is done when the web is fed between the blanket
cylinders which simultaneously prints both sides of the
web. The ink and water fountains and their associated
rollers are housed in the printing unit. Also housed in the
printing unit are the individual ink and water fountain
drive motors and throw-off control air cylinders for the
form rollers. One printing unit is capable of printing four
pages of standard one-color print. Each additional print-
ing unit will expand the capability of the press either to
print an additional color or to add four pages of one-color
printing capacity as desired. Provisions have been made
228
to silence a printing unit without interrupting the drive
to the other units. Each printing unit is supplied with its
own control panel. Provision has been made on the work
side of the unit to adjust each plate cylinder both laterally
and circumferentially. This insures correct back alignment
of the printed materia!. Adjustable compensator rollers
are located on the folder side of the unit where the web
exits from the printing unit. The compensator provides
for correct cutting of the web at the folder. Detailed
descriptions of the rollers in the printing unit, the ink and
water distributors, and the compensator are given in the
paragraphs that follow.
FIGURE X1-2 - V-25 PRINTING UNIT
[Omitted In Printing]
PLATE AND BLANKET CYLINDERS
The V-25 printing unit contains upper and lower plate
and blanket cylinders (Figure X1-2). The plate cylinders
allow for quick plate changes. One, two, or four page
(tabloid) plates are locked into position by means of a
quick set and release plate lockup. The rubber-faced blan-
ket cylinders transfer plate images from the printing
plates to the web. One blanket cylinder acts as an impres-
sion cylinder to the other.
BEARERS
Bearers between both plate and blanket cylinder (Figure
X1-3) assure long press life, minimize printing unit dis-
turbances and facilitate blanket and plate packing. Cor-
rect bearer pressure between cylinders is essential to
obtain proper printing pressure for clear, sharp printed
229
images, The bearer pressure is preset at the factory, will
be checked by the erector, and will rarely require further
adjustment. Bearer pressure adjustments should not be
attempted unless the operator fully understands the sys-
tem.
FIGURE X1-3 - PRINTING UNIT BEARERS
[Omitted In Printing]
INK SYSTEM
Each printing unit has an upper and lower ink fountain
(Figure X1-4 Photo). These ink fountains are adjustable
through a series of 25 fountain keys which allow the
pressman to control ink flow across the plate. Each ink
fountain roller is driven by a separate gear motor to
provide close control of inking. The inking system con-
sists of one ink fountain roller which rides in the ink
fountain, one ductor roller which conveys ink from the
fountain roller to the rest of the system - five distributor
rollers, two vibrator rollers, and two form rollers.
FIGURE X1-4 - INK and WATER DISTRIBUTION
[Omitted In Printing]
WATER SYSTEM
Each printing unit also has an upper and lower water
system. This system applies the proper amount of damp-
ener solution to the non-image areas of the plate surface.
The dampener solution repels ink, thus enabling the non-
image areas to run clean, leaving the printing image
sharp and clear. The water fountain roiler, which is
driven by a motor, collects dampener solution on its
surface as it rotates. As it turns, the fountain roller carries
230
the solution to the cloth covered ductor roller which
alternately contacts the fountain roller then the vibrator
roller. The solution then is transferred from the vibrator
to the water form roller which in turn applies it to the
plate. The water system is designed so there is contin-
uous circulation of the filtered solution.
COMPENSATORS
Two compensating rollers and a compensator adjustment
(Figure X1-5) comprise the compensator. The rollers and
adjustment are located on the folder side of the press
unit. When running color, a color image is applied to the
web by one printing unit, and the other color is added in
the following unit. To insure that the two colors are in
register to provide a clear and sharp image, the operator
can use the compensator to adjust color register between
units. Adjusting the compensating rollers lengthens or
shortens the web path thus changing the distance it must
travel to the following printing unit. This will cause the
image from the first printing unit to change its point of
contact with the image at the second printing unit. By
observing a finished product and operator can now move
the image back or forward as necessary to achieve an
exact register of color. The same procedure is used to
effect correct cutting of the web at the folder. This pro-
cedure may be used to register colors on both sides of the
web. To register color on one side of the web, register
adjustment must be made through the circumferential
register controls on the work side of the press.
FIGURE X1-5 - COMPENSATOR
{Omitted In Printing]
ee ee, meaner sae deals
— 1 lt Ni
eR eR pets St -
231
INFEED
The web infeed of the press unit (Figure X1-6) is con-
trolled by the infeed lever which engages and disengages
the infeed idler roller from the infeed roller. When moved
toward the roll stands of the press, it disengages these
rollers so that the web can be threaded. When moved
toward the delivery end of the press, it engages the web
to cause feeding when the press is operated.
FIGURE X1-6 - INFEED
[Omitted In Printing]
JF-25 FOLDER
The folder (Figure X2-1) is capable of producing either a
standard, tabloid, or quarter-folded product. The folder
and quarter-folder are engaged and disengaged by sepa-
rate clutches on the lower folder assembly. One clutch for
the folder assembly, the other for the quarter folder. An
electrical counter counts each folded signature.
The standard folding operation begins when the web is
routed over the web lead-in rollers, under the gathering
roll, over the roller top of former, through the trolleys
(where a slitter blade slits the web to tabloid width if
desired), and down the former into the nipping rollers.
The former folded web (or slit web for tabloid) is pulled
around the cutting cylinder by pins spaced across the
width of the cutting cylinder. These pins are projected
from the cylinder by a cam mechanism to pierce the web
and keep the sheets correctly positioned until they pass
through the cutting mechanism. The tucker blade on the
cutting cylinder tucks the web into the jaw blades of the
jaw cylinder, and the cutting knife cuts the former folded
232
web at the proper point. The jaw cylinder takes the cut-
and-folded signature from the cutting cylinder and car-
ries it around and through the hold-down rollers and lays
it down on the conveyor assembly or directs it to the
quarter folder table. An anti-jam switch is located on the
quarter folder frame above the quarter folder feed rollers.
In case of a paper jam at this point, the paper pressure
against the switch pin will actuate the switch to stop the
press. Detailed description of the trolley, the former, con-
veyor, and quarter folder are given in the paragraphs that
follow. \
FIGURE X2-2 ~ /F-25 FOLDER
[Omitted In Printing]
TROLLEY
The trolley assembly (Figure X2-2) is located above the
roller-top-of-tormer. The trolley shaft supports three
rollers and a slitter knife. The rollers hold the web
securely against the roller-top-of-former and the slitter
knife slits the web in tabloid operation. Each trolley roller
and the knife can be adjusted on the shaft by loosening its
clamp bracket. To disengage the entire assembly, the shaft
is rotated by a throw-off handle located on the folder
frame.
FIGURE X2-1 - TROLLEY ASSEMBLY
[Omitted In Printing]
FORMER
The former provides a smooth guiding surface for the
web to begin its fold. The web folds over the former and
passes through the forming rollers to the nipping rollers,
ee
ae i tla en Aa
BAe PON AG ee ey Pts
cat I bt NN tat i et tna al a eat eases en ee ee
233
where it is creased and fed to the cutting and jaw cylin-
ders of the folder.
CONVEYOR
The conveyor assembly delivers the finished product
from the folder in a uniform pattern. A counter is also
provided to hold every twenty-fifth product to facilitate
in counting newspapers. The papers ride on pulley
driven belts supported by rollers. The rollers are adjust-
able to provide for varying number of webs.
QUARTER FOLDER
The heavy duty quarter folder when used becomes part
of the folding operation. It provides for quarter-folding of
the standard or tabloid signature. The quarter folder is
put into operation by engaging the quarter folder clutch,
positioning the quarter-fold stripper fingers and remov-
ing the half fold cam. When the quarter folder is operat-
ing, the signature is routed from the jaw cylinder to the
quarter folder through the quarter-fold feed rollers. The
quarter folder tucker blade tucks the standard-foided
product between the folding rollers where it is quarter-
folded, creased, and dropped on the conveyor assembly
by the quarter folder fan. A side lay adjustment and an
adjustment for the fold rollers are located on the work
side of the quarter folder.
V-25 MANUAL
This section described in some detail the electrical con-
trols used in the operation of the V-25 press. The controls
234
and control functions on this press conform to the Ameri-
can National Standards Institute (ANSI) B65.1-1972 stan-
dard.*
The main operating controls for the V-25 are located in
the Master Folder Control Panel (Figure X-3-1) located on
the work side of the folder; the Unit Drive Station Panel
(Figure X-3-2); and the Printing Unit Control Panel (Fig-
ure X-3-4) which are both located on the work side of the
printing unit. There is also a drive control cabinet with
both amperage and voltage indicators for the main drive
motor and an indicator light showing power is available
to the drive control cabinet.
MASTER CONTROL PANEL (Figure X-3-1)
The Master Folder Control Panel contains those functions
necessary to make the press drive motor run in the for-
ward direction. Reversing (an optional feature) of press
motion is not possible from the Master Folder Control
Panel.
The Master Folder Control Panel contains the following:
Power Indicator Light: A red warning light indi-
cates that the press is receiving power from the
drive control cabinet and is lit when the power
switch is ON.
* American National Standards Safety Specifications for Controls
and Signaling Devices for Printing Presses ANS/ 565.1-1972
Available from: American National Standards Institute, 1430
Broadway, New York, New York 10018.
etna) i ee ee ~
235
Power ON-OFF Switch: Allows electrical opera-
tion of the press. In the OFF position, none of
the electrical controls will function.
PRESS DRIVE CONTROL FUNCTIONS
SAFE (Green) — A maintained contact push-button which,
when depressed, prevents the press from being started or, when
the press is moving, prevents further increase in speed (Speed-
lock).
When the press is at a standstill, depressing a SAFE push-
button at any station makes it impossible to start or move
the press from any push-button station. A steady green
safe light at the folder and at the location where
depressed will be lit, indicating the press is safe and can
be worked on to make adjustments.
Speed-lock occurs when the press is running at a contin-
uous desired speed. Depressing any SAFE push-button
will lock the press at that speed and will light the associ-
ated green safelight on the unit and folder. This will not
permit any further acceleration from the FASTER push-
button until the READY push-button is again depressed.
The press may be slowed down or stopped independent
of the SAFE push-button setting.
READY (Black) — A maintained contact push-button which,
when all READY push-buttons are depressed, establishes those
permissive circuits enabling the press to be started. The SAFE
and READY push-buttons in a given station are interlocked to
release each other. Any SAFE push-button prevents starting
the press; ALL READY PUSH-BUTTONS MUST BE
DEPRESSED TO PERMIT STARTING.
236
When all READY push-buttons are depressed while the
press is at standstill, the READY lights at all stations will
be flashing red, indicating the press is ready to run.
FASTER (Yellow) — A momentary contact push-button located
on the folder which increases press speed as long as this push
button is depressed and the press is in continuous run. Contin
uous depression of the push-button will eventually bring the
press to maximum press speed.
Depressing the FASTER push-button during continuous
run will cause the press to accelerate smoothly and run
continuously at the speed established when the FASTER
push-button is released.
When in continuous run and Speed-lock (SAFE
depressed), depressing the FASTER push-button will not
increase the established press speed.
FIGURE X3-1 - V-25 FOLDER MASTER
CONTROL PANEL
{Omitted In Printing]
FIGURE X3-2 - V-25 UNIT DRIVE STATION PANEL
{Omitted In Printing]
FIGURE X3-4 - V-25 PRINTING UNIT CONTROL PANEL
{Omitted In Printing]
SLOWER (Black) — A momentary contact push-button which
decreases press speed as long as it is depressed, eventually
bringing the press to inching speed. When the INCH push-
button is depressed and the press is rotating, simultaneous
depression of the SLOWER push-button with the depressed
INCH push-button will bring the press into continuous run.
a
ee ee er eee.
Seed
a Oe ee en te em re ee es
ete
237
Note: To bring the press to continuous run, depress the
INCH push-button which will result in a warning
period; then press rotation. After the press is
rotating in INCH, simultaneously depress the
SLOWER push-button, then release both buttons
and the press will continue to run. this is the only
recommended method of bringing the V-25 into
continuous run.
Once in continuous run, operation of the SLOWER push-
button becomes inoperative at the inching speed and the
press can only be stopped by depressing the STOP push-
button. If the FASTER and SLOWER push-buttons are
simultaneously depressed, the SLOWER push-button
takes precedence.
INCH (Light Gray) — A momentary contact push-button
which, when in the READY mode, moves the press at inching
speed as long as the INCH push-button ts held depressed.
When all READY push-buttons are depressed, depressing
an INCH push-button will cause the audible warning to
be sounded prior to press movement. The audible signal
allows sufficient time for pressmen to stand clear. Follow-
ing the warning signal, the press will immediately
respond to the INCH push-button as long as it is held
depressed. The press will immediately stop when the
INCH push-button is released.
Note: Response to succeeding inch operations is imme-
diate without the audible warning signal, but if a
permissive period (approximately 4 seconds)
elapses between inching operations, the system
will automatically reset, reinstating the audible
warning signal.
238
REVERSE (Yellow) — [Optional] A momentary contact
guarded push-button which, when in the READY mode, moves
the press in a reverse direction at an inching speed as long as
the push-button is held depressed.
When all READY push-buttons are depressed, depressing
the REVERSE push-button (located only on the Unit
Drive Station Panels) will cause the audible warning to be
sounded prior to reverse press movement. This audible
signal allows sufficient time for pressmen to stand clear.
Following the signal, the press will immediately respond
to the REVERSE push-button and will continue to run in
REVERSE at inching speed so long as the REVERSE push-
button is held depressed. The press will stop immediately
when the REVERSE push-button is released. REVERSE
WILL NOT FUNCTION IF FOLDER CLUTCH IS NOT
DISENGAGED.
Note: Response to succeeding reverse operations is
immediate without the audible warning, but if a
permissive period of approximately 4 seconds
elapses, the system will automatically reset,
repeating the audible warning signal before the
press will respond to the REVERSE push-button.
The SLOW push-button will not put the press in
continuous reverse.
PRESS PRINTING CONTROL FUNCTIONS
The Master Folder Control Panel contains a series of
master printing press controls permitting remote control
of all unit printing functions. The switches for the print-
ing functions at the Master Folder Control Panel are
illuminated rocker switches which control only the print-
ing unit whose related functions have been placed in the
—
OPS ale etl te Rell Ass a8
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239
AUTO position the Unit Control Panel. When the rocker
switch is lit, that printing function is active.
SEQUENCER Switch —- A momentary spring loaded, cen-
ter-OFF switch with a PREPARE and RUN position. If the
Sequencer Switch is pushed to PREPARE, all printing
functions come on with the exception of IMPRESSION,
which is inhibited. If the Sequencer Switch is pushed to
RUN, all functions can come on, including IMPRESSION.
The Sequencer Switch is the bottom rocker switch which
allows operation of the printing functions by remote con-
trol in a pre-established sequence.
Note: The sequence established by the cams can be
altered, however, it is recommended that factory
settings be maintained unless changed by a quali-
fied HARRIS representative.
Automatic sequential operation of the desired printing func-
tions on any selected printing unit is remotely accom-
plished when the press is in the READY mode by:
a) (Unit Control Panel) depressing the desired
unit printing function rocker switches to the
AUTO position, then
b) (Folder Control Panel) depress the desired
remote printing function switches to the
AUTO position, and then
c) (Folder Control Panel) momentarily depress
the SEQUENCER switch to either; PRE-
PARE, if all printing functions except
IMPRESSION are desired or; RUN, if all
printing functions including IMPRESSION
are desired.
240
Manual immediate operation of the printing functions on
any selected printing unit is remotely accomplished when
the press is in the READY mode by:
a)
b)
(Unit Control Panel) depressing the desired
unit printing function rocker switches to the
AUTO position, then
(Folder Control Panel) depress the desired
remote printing function switches to the ON
position at which time each unit’s selected
printing function will operate.
To defeat the automatic remotely energized printing func-
tions, it is necessary to either:
a)
b)
Cc)
Note:
depress a STOP push-button
push a unit printing function rocker switch
desired to OFF, or
push the folder printing function rocker
switch desired to the OFF position.
The SEQUENCER, when operating in the PRE-
PARE or RUN mode, rotates a cam through a 360°
cycle turning on all the printing control functions
that have been placed in AUTO. (It should be
further noted if the folder’s printing function
rocker switch is in the ON position, the printing
function will come on immediately after the STOP
button is released.) If the press is stopped during
cam rotation, the printing functions which the
sequence cam has gone through will not go back
on. However, those functions not completed in
the cycle will be completed. It is therefore recom-
mended once the remaining cycle is completed,
depress the STOP push-button to turn off those
functions subsequently energized.
EDI ae ee
a pene ee ee ee ae Se oe
241
The Master Folder Control Panel’s printing function
switches remotely control the unit control printing func-
tions. When each printing function switch is in the AUTO
position, all equivalent functions on each selected unit
will operate remotely in the sequence established by the
cams.
PRINTING CONTROL FUNCTIONS - the printing func-
tions are: WATER FOUNTAIN, WATER FORMS, INK
FORMS, INK FOUNTAIN and IMPRESSION. The unit
printing function switches are maintained rocker
switches in either the AUTO, OFF or ON position and
have related switches on the Master Folder Control Panel.
IMPRESSION - The function which brings the two blan-
ket cylinders together and squeezes the web. The
IMPRESSION function helps pull the web though the
units and is thrown on or off by pneumatic air cylinders.
WATER FORMS - When energized, one water form roller
makes contact with and supplies water to the plate cylin-
der. There is an upper and lower water distribution sys-
tem with the form roilevs thrown on or off by pneumatic
air cylinders.
INK FORMS — When energized, two ink form rollers
make contact with and supply ink to the plate cylinder.
There is an upper and lower ink distribution system with
the form rollers thrown on or off by pneumatic air cylin-
ders.
WATER FOUNTAINS - A driven roller in a water foun-
tain distributes water in the upper and lower system
respectively. The water fountain rollers, once set by the
control knobs do not track with press speed.
242
INK FOUNTAINS - A driven roller in an ink trough
distributes the ink in the upper and lower system respec-
tively. The ink fountain rollers track with and are a func-
tion of press speed if the RUN Track) mode is selected.
AUTO Light (Unit Control Panel) - When all the unit
printing functions on a given unit, including IMPRES-
SION, are on AUTO, this unit light is illuminated.
Speed Control Knobs (Unit Control Panel) —- These ver-
nier knobs are the ink and water (upper and lower)
fountain speed controls. This controls the fountain roller
speeds from zero to maximum available speed.
These controls are used to adjust the proper balance of
water to ink which eventually reach the plate.
INK, MAKE-READY and RUN (Master Folder Control
Panel) is a two position toggle switch.
When in the MAKE-READY position, maximum
power is supplied to the unit ink speed control
knobs. The ink speed control knob then controls
the unit ink fountains within the range selected
on the vernier.
When in the RUN position, a proportional
amount of power is supplied to the ink fountain
motors in direct relationship to press speed.
This varies the ink fountain speed with press
speed.
OTHER ELECTRICAL FUNCTIONS
TACHOMETER - Press speed expressed in impressions
per hour.
243
COUNTER - Two counters keep track of total and good
papers going through the press. The count difference aids
in determining waste paper. A manual ON-OFF switch
et ee ee
controls the good count. (Some presses contain only a
total counter.)
. MOTOR OPERATED SIDELAY CONTROL
: (Optional)
For Single Ended Presses — Sidelay controls are
located on the Master Folder Control Panel.
Sidelay motors can be operated only when the
press is running.
Roll stand selection is made by the folder
mounted rotary selector switch. The switch con-
trols the roll stand number to be adjusted.
Below the selector switch is a WORKSIDE- ,
GEARSIDE direction knob which trips back to a
neutral position when not held in place. First
the ROLL STAND requiring sidelay is selected,
then the WORKSIDE-GEARSIDE knob is held in
place until the needed lateral movement is com-
plete. When the roll has reached the end of its
sidelay travel, automatic limit switches prevent
further sidelay movement.
For Double Ended Presses - this is an identical
operation for sidelay control to that of single
ended presses. However, each roll stand has a
) toggle switch located on the roll stand junction
box which permits the roll stand to “select” the
folder from which it will be controlled. The
pressman must make this selection at the begin-
ning of the run.
244
WEB BREAK DETECTORS (Optional). The press speed at
which detectors become active is adjusted at press instal-
lation. No alteration to this system should be made with-
out first consulting with Harris Engineering.
The web break detector, at an active speed, will cause the
press to stop if it does not detect a web. A WEB-OUT
light on the Master Folder Control Panel will indicate that
some detector does not “see” a web, whether above or
below the active speed.
A unit web break detector may be defeated, above active
speed, only by having the unit IMPRESSION-OFF. Under
any other condition, the detector is active and will cause
the press to shut down if no web is detected in the unit.
DOUBLE ENDING (optional for ANSI presses only).
Selection of the desired double ending configuration is
electrically achieved by rotating one selector switch
mounted on the double ender control box. This box is
located on top of the printing unit closest to the center of
the press.
WARNING
ELECTRICAL PRESS CONFIGURATION MUST
AGREE WITH MECHANICAL PRESS CONFIG-
URATION AS DICTATED BY THE PRESS LINE
SHAFT CLUTCH WHICH IS DISENGAGED.
INADVERTENT STARTING OF A PRESS MAY
OCCUR BECAUSE ONE “PRESS” MAY BE
ELECTRICALLY CONTROLLED FROM “THE
OTHER PRESS”. IF THIS ELECTRO-MECHANI-
CAL AGREEMENT DOES NOT OCCUR, PROP-
ERLY MATCH THE ELECTRICAL TO
MECHANICAL CONFIGURATION.
are Falta te “ aan
245
Operation of the double ending switch electrically
divides the press into two completely independent
presses with respect to electrical functions. The indicator
plate associated with the switch has numbers represent-
ing printing units. The switch is positioned between the
two appropriate printing unit numbers defining the elec-
trical dividing line between the “two presses”.
Later serial number presses have a line shaft clutch detec-
tion system. This inhibits the press drive from starting
unless there is agreement between the electrical “clutch”
(double-ending switch) and at least one line shaft clutch
which is in the declutched position.
CAUTION - Whenever all units are directed to one folder
it is essential that the unused folder power switch be
turned off. Failure to do so can result in permanent
damage to the unused drive control. In the event that this
precaution is not observed, protective circuitry should
prevent damage. An indication that this protective cir-
cuitry has operated is that the unused drive will not
function when an attempt is made to use it to drive the
press. The dynamic brake resistor thermal overload cir-
cuit breaker must be manually reset.
DUPLEXING (Optional)
On some installations it is necessary to use the combined
horsepower of two drive motors to run a large number of
units configured as one press.
To accomplish duplexing, a control switch normally
located in one of the two drive cabinets must be operated.
This switch has three (3) positions -
1 - A center “OFF” position or “simplex” made
when the two drive motors run separate presses.
246
2 - A second position where the left folder con-
trol panel becomes the master operating posi-
tion for both motors.
3 -— A third position where the right folder con-
trol panel becomes the master operating posi-
tion for both motors.
When either of the duplex switch positions are selected,
both drives will respond simultaneously and in synchro-
nism to any push-button operation.
DRIVE CONTROL CABINET — Contains an ammeter,
voltmeter, and a power indicator light. This cabinet is
usually located away from the press proper. When the
indicator light is energized, power is available to the
drive control cabinet.
WARNING
ONLY QUALIFIED ELECTRICIANS SHOULD
WORK ON OR NEAR ELECTRICAL COMPO-
NENTS.
SPECIFICATIONS
Se re 22'/4 x 35'/2 inches
PR Mn co ccckncvcsoee 25,000 impressions per hour
Cylinder circumference (cut off) ............ 223/4 inches
ES SED oc vcerecevnciacteeyestaawan Y/4 inch
WU Ge GEE so cos vaccccsvcees 40 inch maxs.um
FEOOD GO GINOIOE, 5 oc ccc ccvcnccscccesesad 007 inch
Blanket cylinder undercut ..................... 070 inch
Register Control:
eee kt ebsdsoebcccvevedececssuaccvegal + 3/16 inch
RIED vtec cnc cncndsadésekvinibeanete + '/s inch
Sy CR ha once ceccuncavssvcenvaer 23°/a x 36 inches
EID PETE LIE Mcrae MY 009 inches
dria hh tints
Sime GE TEGMG ccc cvcccusccetaceees 25'/4 x 36'/2 inches
Blanket thickness (includes packing with
non-compressible blankets) ......... 073 to .074 inches
Dampening System:
PY SI cP ii ccc cccdtcestcetingves Motor-driven
COMING: ct be cescsi Infinitely variable (speed not effected
by press speed)
PPP Perr rrerreerriirr rrr Automatic
Inking System:
PO I on nanidcevawessardetenscars Motor-driven
Control ...Infinitely variable trimming (maintains speed
ration in relation to press speed)
Number of rollers in ink train.................62005. 11
Folder:
>, — RUPEE RES Jaw folder with heavy duty quarter fold
Product .. Standard broadsheet, tabloid and quarterfold
SN bv dive dads Vedsevevvteseecesovicve Creeping belt
Press Drive:
Power requirements ......... 220/240 volts, 3-phase AC
Motor..... Variable speed DC (through AC-DC rectifier)
Motor size (1-2 printing units with folder)........ 30Hp
Motor size (3-4 printing units, with folder) ....... 50Hp
Motor size (5-6 printing units, with folder) ....... 75Hp
Motor size (7-8 printing units, with folder) ...... 100Hp
Length:
One printing unit with roll stand and folder... .14'-7°/s"
Additional printing units with roll stands.......... 9'-0"
Width (folder including quarter folder) .......... 7'-89/4"
Height..... DRT a dea twewes tise vercevevesed 6'-8°/s"
Weight:
eee Rene epAShaRannarewe os were 4900
PE Tice nck os hkebdnnsnesondkrnnepsnntraed 6210
Single position mill roll stand (excluding mill roll). .400
248
SECTION II
SUGGESTED PRESSROOM SAFETY PRACTICES
Accident prevention is an activity which must
be planned, systematic, continual and tailored to
individual pressroom needs. Everyone should
actively participate, recognize his role and orga-
nize himself and his work for a safe environ-
ment.
The foremost safety objective is to prevent acci-
dents which could result in injury or death,
disrupt production or damage facilities, equip-
ment or property. Today, new materials, pro-
cesses and higher speed equipment add to the
potential accident exposure in the printing
industry. To maintain production and reduce
in «ry potentials, accident prevention must be
an integrated and equal function of the printing
operation.
Legislation from the federal, state or local level
dictates many of the requirements which are
minimal to reduce personal injury.
In the past it has been found that 85% of all
industrial accidents are caused by UNSAFE
ACTS and 15% by UNSAFE CONDITIONS. In
this instance people appear to be their own
worst enemy.
The following is a listing of some of the
UNSAFE ACTS or CONDITIONS relating to a
pressroom environment and are the usual cause
classifications for personal injuries:
249
UNSAFE ACTS -—- 85% of accidents
FAILURE TO PROPERLY SHUT DOWN
EQUIPMENT
This refers to failure of properly placing the press in
SAFE/READY or STOP position when working on
the units; or failure to turn equipment off when not
in use.
FAILURE TC WARN OTHERS OF YOUR
INTENDED ACTIONS
This includes failure to properly signal or display
appropriate warnings of an individual’s intent to
work in an area which may present a danger to him.
This can include verbal or printed warning, or use of
lights or warning signals. Action should be taken to
let others know when you are doing some operation
which will possibly endanger them.
FAILURE TO WEAR PERSONAL PROTECTIVE
EQUIPMENT
This includes use of foot, eye, hearing and head
protection, and other equipment where an exposure
may exist.
WEARING DANGEROUS ACCESSORIES AND
UNSAFE CLOTHING
Jewelry, wristwatches, loosely rolled sleeves, shirt-
tails, ties, belts or other apparel have historically
contributed to severe personal injuries around rotat-
ing and reciprocating machinery.
OPERATING WITHOUT PROPER AUTHORITY
Operation of equipment or use of tools without
proper indoctrination of authority is a major cause
of personal injury.
OPERATING AT UNSAFE SPEEDS
Use of excessive speeds or taking short cuts beyond
the recognized safe limits of the equipment can lead
to personal injury and/or property damage.
10.
11.
250
USING DEFECTIVE EQUIPMENT
This covers use of tools, machinery, or material
which may become defective through normal wear,
abuse or otherwise made unsafe. Included is
improper use of tools and using tools in an unsafe
manner for which they were not designed.
UNSAFE STORAGE AND OTHER HAZARDOUS
CONDITIONS
Overloading of pallets or tables; improper storage of
paper rolls and equipment parts or obstructing aisle-
ways unnecessarily triggers accidents. Examples of
hazardous conditions could be smoking where flam-
mables are stored; use of solvents which irritate the
skin or are excessively flammable; and allowing
housekeeping conditions to deteriorate by not clean-
ing away oil, water, grease, inks, paper, etc.
UNSAFE POSITIONS
Those exposures resulting from working in awkward
positions which could result in injury. This could
involve movement which obstruct the movements of
others, or entering an unsafe enclosure with regard
to temperature, gas, exposed electrical power lines,
or the method of physically handling materials.
HORSEPLAY
Improper conduct, such as teasing, abusing, startling
fellow workers, playing of practical jokes, quarrel-
ing, etc. are another major cause of industrial injury.
WORKING ON MOVING EQUIPMENT
Oiling, cleaning and adjusting equipment while it is
in motion; working on electrically charged equip-
ment without shutting off the power; or the unneces-
sary handling of material when in the act of being
processed by moving machinery.
251
UNSAFE CONDITIONS —- 15% of accidents
LACK OF PHYSICAL GUARDS
Because of the movement of material through the
press, there are some areas which cannot be physi-
cally guarded as well as other portions. Operators
should be made aware of exposed areas. Equipment
should not be operated with the guards removed.
INADEQUATE GUARDS
More often than not, a partially guarded hazard is
more dangerous that one that has no guard at all.
This may build a false sense of security and someone
may fail to take those safety precautions ordinarily
needed if no guards were used.
MACHINES AND TOOLS
The condition and maintenance of machines and
tools can effect the probability of an accident. They
should be checked for wear, repair or replacement
depending on the condition and exposure it repre-
sents.
HAZARDOUS ARRANGEMENTS OF MACHINES
AND AUXILIARY EQUIPMENT
This refers to equipment layout, space allocations for
floor and work areas, fire exits and aisles. Tool and
material storage, platform and table loads and waste
product disposal facilities should be evaluated.
ILLUMINATION
Lighting should be evaluated for need, such as glare,
coloration, excessive or inadequate lighting,
shadows and contrast.
VENTILATION
Air movement should be evaluated for movement or
control of airborne by-products of the printing
industry.
7 NOISE
The exposure to noise levels has been legislated and
controls have to be established.
Larger printing houses have organized safety programs
to meet their specific needs and many have no program.
Control of personal and property losses is important no
matter the size of the facility. For this reason, a list of
SUGGESTED SAFETY PROCEDURES have been included
for your study and application.
As a press operator you have a responsibility to members
of your press crew. They should be knowledgable and
abide by the safety precautions for your press area. Each
member should know where the various SAFE/READY
and STOP buttons are located, where the potentially
unsafe press areas are, and be made aware how to work
safely around the press. New press crew members should
be briefed on safety practices and you should set a good
example by following your safety practices.
Harris presses have been designed v‘‘th the elimination
of unsafe conditions foremost in mind. There has been a
concerted effort to provide safeguards without impairing
the function and operability of the press.
This information is designed to provide accurate and
authoritative information in regard to pressroom safety
considerations. Harris Intertype-Cottrell is not engaged
in rendering legal or professional safety and health ser-
vices. If expert assistance is required in these areas, the
services of that of a competent safety and health profes-
sional or that of counsel should be sought.
253
SECTION IL A
SUGGESTED SAFETY PROCEDURES
OPERATING PROCEDURES
l.
2.
1)
Replace all guards before operating equipment
Do not reach into the press to make adjustments
while equipment is running unless it is specified as
an “on-the-run” procedure with a warning posted in
the instruction and on the press.
Do not reach into the folder or delivery areas to
make adjustments, remove jams or grab signatures
while the equipment is operating.
Keep fingers, loose clothing, jewelry, neckties, and
long hair clear of nips, slitters, trolley rolls, etc.,
when operating and particularly when webbing up.
(Note: Long hair should be confined when in the
press area.)
Check for persons, tools or equipment between all
portions of the press, i.e., printing units, folder, roll
stands, gear and work sides before operating press
for run.
Unauthorized persons must not operate press and
must be kept away from press while it is operating.
Appropriate signs should be posted.
Head protection should be worn where there is dan-
ger from falling and flying objects-with appropriate
signs posted in designated areas.
If operating conditions exist where there are contin-
uous excessive noise levels which cannot be
reduced, personal protection equipment should be
provided and used. Appropriate warning signs
should be posted.
Periodically check the plates for any looseness or
cracks.
254
HOUSEKEEPING
l.
All platforms, floors, stairs, railing surfaces, equip-
ment, aisleways, etc., must be kept clear of unnecess-
ary obstructions, clean and free of grease, oil, dirt,
dust, ink, rags, paper, wearing apparel, etc.
2. Provide storage space for ink cans, tools or other
supplies used for press operations where they will
not cause obstructions.
3. Mark permanent aisies and passageways.
4. Before starting the press, remove all dead plates,
tools and equipment from the press area.
ELECTRICAL
1. Only qualified maintenance personnel should
replace fuses and circuit breakers.
2. Use extreme caution around the electrical equipment
to prevent fire and’ electrical shock.
3. Check electrical connections for tightness and bare
connections on a regular basis.
4. When electrical equipment is being worked on, cir-
cuits should be de-energized before any work is
attempted. Switches should be opened and equip-
ment circuit proof tested for de-energization before
work proceeds. The lock-out should be removed
only by the person who installed it.
5. Keep electrical areas and equipment dry.
GENERAL
1. Do not exceed the established posted building floor
loads.
2. Report al! personal injuries, no matter how minor.
;
|
/
255
Empty oil pans periodically as needed.
Periodically check all bolts for looseness.
SECTION III
MAKEREADY PROCEDURE
GENERAL
Makeready is the organized and systematic set-
ting up and adjusting of the press so that it will
efficiently and economically produce a quality
product with a minimum of spoilage. It is the
procedure followed whenever a new job is put
on the machine.
Extreme care must be taken in every step of the
procedure to see that it is done properly. Care-
less, inaccurate adjustments or failure to per-
form each detail can cause very serious
consequences to the job, to the press and to the
press crew. |
Members of the press crew or anyone perform-
ing maintenance on the press should be cau-
tioned to always locate and retrieve any
dropped tools or parts before putting the press
into motion. This policy can prevent expensive
damage to the press. Makeready is a team effort.
The head pressman is in charge of the operation.
Each member of the press crew is assigned a
series of duties to perform. The efforts of the
crew must be coordinated if the job is to be done
efficiently and in a minimum of time. Some of
the steps in the makeready procedure are one-
man operations, others are performed by two
men working together. You will be assigned
your part of the job to be done and will be
256
responsible for doing it properly and conscien-
tiously.
Safety considerations as outlined in Section Il
have been built into the makeready procedure
for your protection and the protection of your
fellow crew members. Follow the precautions to
the letter.
Accidents on a large web press like this can be
very serious. Safety is everyone’s responsibility.
Do your part.
The makeready procedure for the V-25 web
press has been divided into a sequence of opera-
tions. They are explained in detail in the follow-
ing pages.
PREPARATION FOR THE MAKEREADY
The purpose is to call to your attention the need for
organizing the change over from the last job to the new
one. This requires planning. It is primarily the respon-
sibility of the foreman of the pressroom and the head
pressman.
What paper, ink and other materials will be needed on
the job? Are they available? Have they been delivered to
the pressroom?
Check the webs through the press and the folder to see
that the impositions are correct and that you can get color
on the pages where it is required. Check the new press
plates to verify the page imposition. Determine where
each press plate is to be mounted on the machine and
mark it for identification.
257
If the last job that was run is very similar to the new job
coming up, which is generally speaking the case with
daily newspaper runs, it is possible that many of the
settings on the press can be left as they are. A check list of
the things to be done should be filled out so that each
member of the press crew is aware of the items to be
checked for this makeready. From this it is possible to
make assignments. The list will also be useful in checking
to see that every step or assignment in the makeready
process has received the required attention.
A general clean-up of the press and surroundings should
be done after completion of each job. Each man should
assume the responsibility for keeping the press area of his
regular duties clean. Between jobs and when down time
occurs, the head pressman will designate the mainte-
nance to be done. Even if he does not specifically assign
maintenance items each time, there is always work to be
done.
Any press problems which came up during the last run
and require attention should be taken care of now while
the press is down. Try to determine the cause of the
problem and eliminate its reoccurance.
It is essential that maintenance records be kept in order to
insure proper intervals of press and press component
lubrication.
Operation 1. Mili Roll Stand Preparation
Before the press can be operated, the paper roll must be
installed on the roll stand, the press must be webbed and
the tension and side lay of the web must be properly
258
adjusted. NOTE: Electrical sidelay adjustment, which is
optional, must be made with the press moving.
ROLL LOADING
Using the overhead chain hoist, unload and load the
paper roll (Figure X6-1) as follows:
a.
Using the roll chuck spanner wrench, loosen chuck
on press drive side of shaft, i.e. the side opposite the
brake. (Figure X6-2)
WARNING: FOLLOW THIS PROCEDURE
ONLY FOR ROLL BUTTS. FOR LARGER ROLLS
REMOVE ROLL BEFORE LOOSENING
CHUCK.
Loosen brake assembly and free brake shoes from
brake drum.
Using the hoist and roll hook, secure hook to shaft
and remove shaft and butt roll from stand.
Remove roll chuck (side opposite brake drum) and
roll core from shaft.
FIGURE X6-1 - MILL ROLL STAND
[Omitted In Printing]
Insert shaft into new paper roll and reinstall chuck
which was taken off the shaft. The paper roll should
be positioned on the shaft so the web will feed from
the top of the roll to the press.
Tighten the chuck and the bolts that clamp the chuck
to the shaft.
Hoist the roll into position on the roll stand.
Clamp the brake around the brake drum and tighten
the brake slightly.
259
Once the work side (brake side) roll chuck has been
properly positioned on the shaft, it will be unnecessary to
move it unless a different width web is used. Lubricate
the roll shaft and bearings in accordance with Figure
X-13-7.
FIGURE X6-2
[Omitted In Printing]
FIGURE X6-3
[Omitted In Printing]
a. Set the selector switch on the master control panel
(Figure X-3-1) to SAFE.
WARNING: DO NOT ATTEMPT TO JOB THE
PRESS WHEN WEBBING, SERIOUS PERSONAL
INJURY MAY RESULT.
b. Check the paper roll for damage, and remove any
damaged paper Make sure that all press lead in
rollers are clean and free of dirt and foreign particles.
c. Release the brake tension and route the web over the
mill roll stand idler, under the dancer roller, under
the roll stand idler roller, and on toward the printing
unit (fig. X-6-3). Check that the side of each roll is
aligned with the sides of other rolls. If necessary,
rotate the roll side lay adjustment handwheel (fig.
X-6-1) to get proper alignment. Thread the web
through the associated printing unit and on to the
folder as directed in the next paragraph. After thread-
ing is completed, close the brake shoe assembly and
moderately tighten the brake tension adjustment by
hand.
260
WEBBING THE PRINTING UNITS AND FOLDER
After the rolls are mounted on the roll stand, web the
printing units from the associated roll as shown in figure
X6-3. Do not apply brake tension on the roll until web-
bing is completed. Proceed as follows:
a.
Single Color Operation. To web printing units running
single colors, refer to figure X6-3. Note that the web is
threaded under the idler roller, between the smooth
idler roller and the infeed roller (pressure released by
operation of the infeed lever), over the knurled idler
roller, and between the upper blanket cylinder and
the lower blanket cylinder which are off impression.
From the blanket rollers, it is threaded over the fixed
compensator roller under the moveable compensator
roller over the upper lead-in rollers and under the
gathering roll. It then passes between the roller-top-
of-former and the trolleys (See Figures X2-1 and X2-2)
(pressure between rollers is released by operation of
trolley lever), over the former, between the forming
rollers, between the nip rollers and between the knife
and jaw cylinders. After the web is threaded, engage
all infeed levers and the trolley lever.
WARNING: DO NOT HAND FEED PAPER TO
THE CUTTING CYLINDER OR ANY NIPPING
ROLLERS WITH THE PRESS RUNNING.
Two or More Color Operation. To web the printing units
for printing of two or more colors, refer to figure
X6-3. Note that the first printing unit is webbed in the
same manner as for single color printing units until
the web passes through the compensator rollers.
From there it is threaded directly over the knurled
lead roller and between the upper and lower blanket
cylinders, through the compensator rollers, and either
to the upper lead roller assembly or to the knurled
lead roller of the next press unit to print a third color.
261
TENSION ADJUSTMENT
The normal operating position of the dancer roller is
approximately vertical in line with the upper idler roller
on the paper roll stand. Adjust tension as follows:
Start the press and run at a slow speed.
With the brake adjustment knob, (see Figure X6-1),
adjust the drag on the brake until the dancer roller is
in the normal operating position. (Clockwise rotation.
of the knob will increase the drag, counterclockwise
rotation will decrease the drag on the brake).
After adjustment is made and the dancer is in the
vertical position, proper tension is being applied to
the web. It should be noted that as the size of the roll
becomes smaller, less brake effort will be necessary.
During the run, as the roll becomes smaller, periodic
adjustment of the brake will be necessary to maintain
proper tension. Less drag will be needed so the brake
adjustment knob should be turned in a counterclock-
wise direction. This will decrease the brake drag and
bring the dancer roller back to its normal running
position.
WEB SIDE LAY ADJUSTMENT
Side lay of the web (Figure X6-4) should be adjusted
whenever a new paper roll is installed.
a.
With the press running at a slow speed, the head
pressman should observe the web as it passes over
the former or visually inspect finished folded prod-
ucts.
After making his observation, he should signai back
to the man at the roll stands as to which web to adjust
and in which direction.
262
c. The man at the roll stand should then make his
adjustment by turning the side lay adjustment handle
(See Figure X6-1) in the appropriate direction.
d. The head pressman should then make a second obser-
vation and verify the new setting. When dimension
B,=B, the web is centered on the former.
FIGURE X6-4
[Omitted In Printing]
OPERATION II.
PRINTING UNIT PREPARATION
Preparation of the printing unit consists of: preparing the
ink and water fountains, the ink and water rollers, install-
ing the plates and blankets and possibly silencing one or
more printing units. Instructions for these preparations
are covered in this section. The sequence of operations for
starting the press is given in Section IV.
SILENCING A PRINTING UNIT
The design of the main drive portion of the V-25 is such
that any printing unit may be placed in a non-operating
condition (Figure X7-1) without interfering with the oper-
ation of the other printing units. To silence the unit:
a. Stop the printing unit and the folder at the timing
mark.
b. Raise the clutch lever located on the gear side of the
press at the rear of the unit. The unit is now silenced.
FIGURE X7-1 - V-25 PRINTING UNIT CLUTCH
[Omitted In Printing]
FIGURE X7-2 - V-25 UNIT TIMING INDICATOR
[Omitted In Printing]
263
PRINTING UNIT TIMING PROCEDURE
Timing is necessary when a printing unit is engaged after
silencing, when engaging the folder, and when engaging
the quarter folder.
a. Ona silenced printing unit, verify that the unit is on
the timing mark. (Figure X7-2) (Timing mark located
on blanket cylinder journal with pointer on the side
frame.)
b. INCH press over until the folder timing points are
aligned.
Set the mode control switch to SAFE.
d. Re-engage the printing unit by moving the clutch
lever down. It may be necessary to rock the line shaft
with the barring lever to align clutch gear teeth.
PROTECTING PRESS PLATES
If the press plates are to [sic] set for more than 15 minutes
protect them with gum as follows:
WARNING: MAKE CERTAIN FINGER
GUARDS ARE IN PLACE BEFORE PROCEED-
ING WITH THIS OPERATION OTHERWISE
SERIOUS PERSONAL INJURY MAY OCCUR.
1) Using a damp gum sponge, dip into gum and INCH
press over, go over entire plate surface twice.
2) Smooth down the gum using a wipe rag leaving no
streaks.
3) Wipe the bearers clean, then idle the press to let the
gum dry.
NOTE: When washing-up and press is webbed, it is
recommended the folder be disengaged.
264
INCH the press around slowly until the timing marks
located on the blank t cylinder are in line with those
on the frame.
Disengage the folder by pulling the main folder
clutch of OFF.
WASHING INK ROLLERS WITH WASH-UP DEVICE
Be
Put press on SAFE, Ink motor switch on OFF. All
impression and form switches should be in the OFF
position. Folder should be disengaged.
Install wash-up device in printing unit on brackets
provided. Adjust wash-up blade to the vibrator roller
so that it is even across the width of the vibrator.
Remove SAFE and run press at slow speed.
Apply wash-up solution to the ink rollers. The ink
will be washed from the rollers and picked up on the
wash-up blade.
Continue to run the press at a slow speed until the
rollers are clean and the solvent is removed.
STOP the press, put the SAFE on and remove the
wash-up device from the press.
Clean the wash-up trough.
WASHING INK ROLLERS WITHOUT
WASH-UP DEVICE
(Cleaning up on a web)
1.
y
3
Put ink motor switch on OFF. Folder engaged.
Start press and run at a slow speed.
Put ink form rollers and impression ON. Apply sol-
vent to the ink roller train. Continue to apply solvent
until ink is removed from ink rollers. Continue to run
265
press until ink rollers are dry. Ink will pick up on web
passing through press.
INK FOUNTAIN WASH-UP
a. Remove all ink from the ink fountain. (Figure X7-3)
Back off ink keys INCH press until the ductor roller
moves away from the fountain roller. Place press on
SAFE.
b. Place bar in fountain base, loosen hinge bolts, and
lower fountain to stops.
c. Clean fountain and seals thoroughly.
d. Lubricate fountain seals with film of grease before
closing fountain.
NOTE: The fountain seals are set to the fountain with
.001" to .002" clearance. Less clearance than .001"
can overload the fountain motor while excess
clearance can cause ink leakage.
CLEANING THE BLANKETS
a. Mode switch should be set to READY. All control
switches should be OFF.
WARNING: MAKE CERTAIN FINGER
GUARDS (FIGURE X7-4) ARE IN PLACE
BEFORE PROCEEDING THIS OPERATION
OTHERWISE SERIOUS PERSONAL INJURY
MAY OCCUR.
FIGURE X7-4 - V-25 UNIT FINGER GUARD
(LOWER GUARD NOT SHOWN)
[Omitted In Printing]
b. Cover the lower ink fountains.
266
c. Wash the upper blanket first using a cleay; rag and
blanket wash.
d. INCH cylinder over being sure to clean the blanket
thoroughly. Remove all ink, gum and lint.
e. Dry the blanket with a clean cloth and wipe all
bearers clean.
f. Repeat same procedure on lower blanket cylinder.
INKING SUPPLY PREPARATION
Preparation of the ink system includes: filling the ink
fountains, setting the ink fountain blades, controlling the
ink fountain roller speed, and inking the rollers.
FILLING INK FOUNTAIN
Fill the ink fountain with the quantity of ink needed for
the run. Be sure the ink is spread evenly across the width
of the ink fountain. (If the fountain has ink in it from a
previous run, be sure to stir its contents before starting
up).
INKING THE ROLLERS
Preset fountain keys for .002" to .003" clearance. Fill the
ink fountain.
1.) Flip the ink switch on the master control panel to
“MAKEREADY”.
2.) Run press at a slow speed with folder disengaged,
impression OFF, and form rollers OFF.
3.) Turn each ink fountain motor switch to the ON posi-
tion and set the speed control knob at a low setting.
EE a
267
4.) Atiow motors and press to run until all the rollers
have picked up a thin film of ink.
SETTING INK FOUNTAIN BLADES
The quantity of ink carried by the ink fountain roller is
determined by the clearance between the fountain roller
and the ink fountain blade. (Figure X7-3) This clearance is
regulated by a series of thumbscrews on each ink foun-
tain. The initial clearance between the ink fountain roller
and the ink fountain blade is set at 0.002 inch nominal.
However, each run will require adjustment of this clear-
ance because of differences in plate image areas. If one
side of the plate contains a larger image area than the
other, it will require more ink. This requirement of more
ink than can be met by increasing the space between the
fountain blade and roller, by adjusting the thumbscrews.
FIGURE X7-3 - INK FOUNTAIN ASSEMBLY
{Omitted In Printing]
The fountain blade setting is adjusted by the following
procedure when the press is running:
1. Visually examine a printed copy. Take note of areas
where too much or too little ink appears.
2. Once these areas have been recognized, determine
which unit they are being printed on and their posi-
tion on the plate cylinder.
3. Then, go to the appropriate ink fountain (upper or
lower) and make the necessary thumbscrew adjust-
ments. Turning the thumbscrews to the right (clock-
wise) decreases the amount of ink, and turning them
to the left (counterclockwise) increases the ink flow to
the ink ductor roller.
268
CHANGING INK FOUNTAIN ROLLER SPEED
A genera! rule to follow when setting the ink fountain
roller speed is: “The heavier the concentration of ink
required, the faster the fountain roll speed should be”.
The ink fountain roller turns in proportion to the speed of
the press. This proportionate increase in speed is adjusted
by the speed control knob located on the unit control
panel. Turning the speed control knob clockwise
increases the speed of the fountain roller. Increasing the
fountain roll speed increases the amount of ink delivered
to the plate all across the unit.
DAMPENING SUPPLY PREPARATION
Preparation of the dampening system includes: preparing
the dampener fountain solution, and moistening the
dampener rollers.
The operator must obtain the correct ink-water balance to
provide the desired image. The proper amount of mois-
ture is the least amount possible to keep the non-image
areas clean. Running too much moisture will cause undue
emulsification of the ink which results in a gray washed-
out copy.
a. Fill the water tank, located on the gear side of the
unit, with solution. Prepare the solution following the
directions as given by the manufacturer of the chemi-
cals which are added to the water. (Each water tank
normally provides water to (2) printing units. With
one unit not in operation, the flow of water to the pan
may be shut off. A valve on the line which supplies
water to the pan is provided for this purpose).
269
b. Turn each water fountain motor switch to the ON
position and set the speed control knob at a low
setting.
c. Start the press. Run at slow speed with impression
and form rollers in the OFF position.
d. Allow the press and dampener rollers to run until
they have picked up enough moisture so they feel
moist against the back of the hand.
NOTE: The fountain solution should be drained from
the water trays whenever the press is to remain
idle for more than a few hours. A solution which
will not harm the dampener fountain roller
under normal conditions could possibly cause
some pitting if the rollers were allowed to stand
in the solution for an extended period of time.
PREPARING NEW PRESS PLATES
FOR MOUNTING
PLATE HANDLING CAUTIONS
The edges of the plate can be sharp. Be careful. If the
edges of the plate are burred, remove the burrs with a file
to prevent damage to form rollers, dampeners, and blan-
kets. Careless handling of press plates can cause kinks
and ruin the plate. Keep the plate dry. Don’t remove the
protective sheet of paper, if supplied.
MAKING THE PLATE LOCKING BENDS
Plates are received from the plate room after being
exposed, developed and gummed. The plate bending fix-
ture (Figure X7-5) is used to accurately make the leading
and trailing edge bends.
10.
11.
270
Make sure the plate bender work surface is clean and
dry.
Using the plate locking handle, raise clamping bar.
Raise the stop bar until it locks in the up position.
Take the developed plate placing it etched side down
leading edge (bottom of page) first. Place it into the
bender under the clamping bar until it locates against
the stop bar.
Lock plate into position using the plate locking han-
dle and lower the stop bar.
Swing break bar around thus putting first bend on
plate.
FIGURE X7-5
[Omitted In Printing]
Release plate and repeat above procedure for oppo-
site edge of plate (top of page). Swing the break bar
up enough to bend the plate so the bend angle is
approximately 150.
Raise stop bar and release plate.
Slide plate forward until second bend locates against
the stop bar. Lock plate into position and lower stop
bar.
Swing break bar around bending plate approximately
at a 32° angle.
Unlock and carefully remove plate from bender. (Fig-
ure X7-6) Plate is now ready for installation on print-
ing unit. Handle plates carefully to prevent damage
to the bends.
. 2 2 .
Marie Fer ee
~—
Se _
271
WARNING: MAKE CERTAIN FINGER
GUARDS ARE IN PLACE BEFORE PROCEED-
ING WITH THIS OPERATION OTHERWISE
SERIOUS PERSONAL INJURY MAY OCCUR.
FIGURE X7-6
[Omitted In Printing]
REMOVING THE PRESS PLATES
1.
If plates are to be reused be sure they have been
properly gummed and the blanket washed and dried.
Stop units and folder at the timing marks. Disengage
folder.
Set mode switch to READY. INCH press until gap of
plate cylinder is to your front. Put press on SAFE.
Insert '/s” allen “T” wrench in set screw on reel clamp
and loosen both work and gear side. (Figure X7-7)
Take a 1'/s” wrench and release plate by rotating plate
reel rod.
When trailing edge of plate is free, hold it up nearly
vertical while another crew member bars, by hand,
the unit over in the reverse direction. (Figure X7-8)
Removing the lower plate is done the same way
except the plate trailing edge is pulled down rather
than up.
CLEANING THE PLATE CYLINDERS
The plate cylinder must be absolutely clean. This includes
both the metal cylinder surface under the plate as well as
the bearers and gutters. These cylinders should be
cleaned every time a plate is removed from the press. It is
part of every makeready procedure.
272
Wash the plate cylinder using press-wash to remove
all foreign material. DO NOT USE ABRASIVES!
Be sure to clean and carefully wipe off the bearers
and gutters of both the plate and blanket cylinders.
Wash the blanket again to remove any dried ink or
foreign material that may have dropped on them.
FIGURE X7-7
[Omitted In Printing]
FIGURE X7-8
[Omitted In Printing]
MOUNTING THE PRESS PLATES
l.
Place mode selector switch to READY. INCH press
over until the plate cylinder gap is directly in front of
you. (Figure X7-9)
Be sure finger guards are in place between the plate
and blanket cylinders.
Put a 1'/4” wrench on the reel rod extension and turn
until the reel rod slot is centered in the plate cylinder
gap. Put cylinder impression ON.
INCH the press until the plate cylinder gap is about
2” from the blanket cylinder. Put SAFE on.
Insert the leading edge of the plate into the cylinder
gap. (Figure X7-10, View 1) Hook bent leading edge
over the leading edge lip of the plate cylinder, (on the
top plate cylinder the lip is on top and the plate is
pressed up to seat it firmly. On the bottom plate
cylinder the press plate is pressed down to seat it
over the lip). (See Figure X7-9) Be sure to center plate.
Continue to hold and slightly pull the tail end of the
plate. INCH the press slowly for one complete revolu-
tion. When the plate cylinder gap is again exposed
10.
11.
273
directly in front of you, stop press and put SAFE back
on. (Figure X7-11)
Insert the bent tail end of the plate into the reel rod
slot. (Figure X7-11, View 2) Two men work together
press and hold the tail end plate bend firmly into the
reel rod slot. The man on the operator side of the
press applies a 1'/s” wrench to the reel rod extension
and slightly tightens the plate.
Check to see that the ends of the plate align and seat
properly in the groove.
Once satisfied, tighten the reel rod. (Figure X7-11,
View 3)
Using a '/s” allen “T” wrench, tighten the set screws
on the reel rod clamp, both work and gear sides.
Revolve the plate cylinders several revolutions with
the impression ON. Recheck and tighten the plate
further if necessary.
FIGURE X7-9
[Omitted In Printing]
FIGURE X7-10
[Omitted In Printing]
FIGURE X7-11 - INSTALLING THE PLATE
{Omitted In Printing]
BLANKET REMOVAL AND INSTALLATION
REMOVING THE BLANKET
1.
Remove the web from unit (Figure X7-9) and rotate
the blanket cylinder gap until it is facing you. Put
press on SAFE. Cylinder impression should be OFF.
Remove the finger guard between the plate and blan-
ket cylinders.
274
Disengage ratchet by applying pressure on ratchet
pawl. (Figure X7-12) Take a 1” wrench and rotate the
reel rod to a position so as to release the trailing edge
of the blanket. Pull the trailing edge out of the slot.
FIGURE X7-12
[Omitted In Printing]
Upon freeing the trailing edge, work the leading edge
of the blanket free.
Take the press off SAFE. Holding the leading edge,
INCH the blanket cylinder over one revolution.
Remove the old blanket.
Clean the cylinder surface with press wash. Check
carefully to see that there are no particles of dirt or
foreign material sticking to the cylinder. Wipe the
cylinder dry and apply a thin film of oil to protect the
surface.
FIGURE X7-13
[Omitted In Printing]
FIGURE X7-14
[Omitted In Printing]
MOUNTING THE BLANKET AND PACKING
1.
ae
Make sure that the blanket cylinder is clean and dry.
Select packing sheet(s) of the proper thickness. The
size of packing is 36” wide by 22'/2” long. It may be
cut on the cylinder if necessary. (Figure X7-13)
Apply a bead of spray on glue to the leading edge of
the cylinder and afix the packing edge. (Figure X7-14)
Take the press off SAFE. INCH the press over for one
revolution.
275
5. Return press to SAFE. Cut the packing even with the
gap on the trailing edge. Do not glue the trailing
edge.
6. Take the new blanket and insert it into the leading
edge of the gap. (Figure X7-15, View 1) Hold the
blanket into position by catching the metal edge with
the flat on the reel rod. Check to see that the packing
sheet is centered and parallel with the side edges of
the blanket.
7. Take the press off SAFE. INCH the cylinder over one
revolution holding the trailing edge. Return to SAFE.
8. Apply grease to the blankets trailing edge prior to
tightening. The grease reduces friction between the
rubber surface of the blanket and cylinder. The blan-
ket will also conform better to the cylinder.
Insert the trailing edge bar into the slot on the reel rod.
(Figure X7-15, View 2) Check to see that the bar is square
in the reel rod also check to see that the leading edge is
trapped in its proper position.
Begin to take up on the reel rod to draw the blanket tight
around the cylinder. (Figure X7-15, View 3)
Replace the finger guard between the plate and blanket
cylinders.
To iron the blankets out and properly seat them, the press
is run with impression ON for a short time.
Stop the press. Rotate the blanket cylinder so the gap is
facing you. Put the press on SAFE. Check the blanket and
retighten the reel rod. Also check the blanket for uniform
tension. When thumped with the hand the blanket should
have the same sound across the width of the blanket.
276
If a gage is available, check the blanket for the correct
printing height. This should be about 0.003 inch above
bearers.
REGISTERING PRINTED IMPRESSIONS
The position of the printing on each side of the web must
be in relation to one another. This is back-up register. The
margins, head, foot, and side must be uniform on both
sides of the paper throughout the signature.
SIDE REGISTER ADJUSTMENT
1.Check that the side margins are even (Figure X7-16) and
opposite each other on both sides of the web. If the
impression of the upper printing cylinders (plates) are
off-center, adjust the upper plate cylinder (Figure X7-17)
using the special
FIGURE X7-15
[Omitted In Printing]
wrench provided to shift the position of the plate cylinder
and move the printed impression into proper register.
Clockwise rotation will shift the impression toward the
gear side of the printing unit, counterclockwise toward
the workside.
2. If the lower plates are off-center, adjust the lower
plate cylinder as described above.
3. Both upper and lower impressions should now be in
lateral register.
FIGURE X7-16
[Omitted In Printing]
277
CIRCUMFERENTIAL REGISTER ADJUSTMENT
If the upper impression does not coincide with the lower
impression (Figure X7-18) the impressions can be aligned
by rotating the citcumferential register caps (Figure
X7-17) with the special wrench provided. Clockwise rota-
tion of the upper register cap will advance the upper
impression while clockwise rotation of the lower cap
retards the lower impression.
COMPENSATOR ADJUSTMENT
Compensators either lengthen or shorten the distance of
web travel (Figure X7-19) and thus control the lengthwise
location of the webs for accurate association and uniform
cut-off register.
1. Check the register by taking a finished product and
visually examine the cut-off. (Cut-off register is
related to web-to-web register. Unless the webs are
properly associated one over the other, the cut-off
will not produce uniform head and foot margins on
each page).
2. Determine which web is not in register and the unit it
is being printed on.
FIGURE X7-17 - V-25 REGISTER CONTROLS
[Omitted In Printing]
3. Make the proper adjustment at that unit’s compensa-
tor. (Figure X7-20)
A. Turning the adjustment knob clockwise will
lengthen the web path.
B. Turning the adjustment knob counterclockwise
will shorten the web path.
278
4. Recheck to verify new compensator setting.
FIGURE X7-18
[Omitted In Printing]
FIGURE X7-1
{Omitted In Printing]
FIGURE X7-20 - V-25 UNIT COMPENSATOR
[Omitted In Printing]
NOTE: Cut-off register during the entire press run is
maintained by checking and adjusting the com-
pensators.
OPERATION III.
FOLDER PREPARATION
MAKEREADY ADJUSTMENT
SILENCING THE FOLDER
A clutch is provided on the folder to disengage it from
the press. The clutch makes it possible to operate the
printing units independent of the folder during the press
makeready, inking-up and wash-up. The folder clutch is
located on the workside of the folder gear case (Figure
X8-1). To silence the folder:
a. INCH the press over to the point when the timing
mark on the jaw cylinder and the pointer align.
b. Put press on SAFE.
c. Pull the folder clutch handle out and rotate to bottom
detent. Folder is now silenced.
a 279
FOLDER TIMING PROCEDURE
Timing is necessary when the folder clutch is engaged
after silencing.
a. Check to see that the timing points of the folder are
aligned. (If the points are not aligned, engage the
folder clutch and INCH the press over until the folder
timing points are aligned. Disengage the folder,
clutch. If the folder was disengaged on the marks,
this step is not necessary).
b. INCH the press over until the timing points on the
press are aligned. Put press on SAFE.
c. Engage the folder clutch. The press is now timed for
standard operation.
FIGURE X8-1 - FOLDER CLUTCHES
[Omitted In Printing]
HOLD DOWN ROLLER ADJUSTMENT
The hold down roller setting (Figure X8-3) is determined
by the number of webs to be run. If the number of webs is
increased, the clearance between the hold down rollers
and the jaw cylinder must be increased. The proper set-
ting exists when a crag is felt with the signature between
the jaw cylinder and the hold down rollers.
a. Inch the folder over until a folded product is between
the jaw cylinder and the hold down rollers.
b. Return to SAFE. Pulling the paper end, test for the
amount of drag which exists by pulling on the paper.
c. If an adjustment is required, there are two adjustment
knobs located on the inside of the folder frame.
Loosen the locking knobs. Turn the adjustment knobs
280
until the proper drag has been attained. Retighten the
locking knobs.
NOTE: It is important that all hold down rollers
have equal pressure on them.
FIGURE X8-4 - NIP ROLLER ADJUSTMENT
[Omitted In Printing]
FIGURE X8-3 - HOLD DOWN ROLLER ADJUSTMENT
[Omitted In Printing]
NIP ROLLER ADJUSTMENT
Just below the forming rollers are the nip rollers (Figure
X8-4). Two rollers with knurled surfaces press against
each other. Both these rollers are driven. The setting of
these nip rollers is critical since they keep the correct
tension on the web as it enters the cutting cylinder.
Varying tension seriously affects both the accuracy of the
second fold (half fold) and the accuracy and uniformity
of the cut-off. The proper setting exists when there is a
slight drag on the paper between the rollers (distinct
knurl marks on the web.)
a. Put press on SAFE.
b. Test to see if drag exists between the nip rollers by
trying to pull the web through.
c. If an adjustment is required, there are two nip roller
adjustment knobs located on the inside of the roller
frame. Loosen the locking knobs. Turn the adjustment
knobs until the drag is almost eliminated between the
rollers. Retighten the locking knobs.
d. The nip rollers and spacers are clamped into position
on the shaft and can be moved laterally for width of
the paper being run.
afd sas
281
SETTING STRIPPER FINGERS
Before each run, the stripper fingers must be checked and
set (Figure X8-5) as necessary to provide the proper rout-
ing of the signature. When running a standard half fold,
the quarter fold stripper fingers should be away from the
jaw cylinder. When running quarter fold the stripper
fingers should be positioned to strip off the signature and
guide the signature through the quarter folder. The quar-
ter fold stripper fingers are engaged and disengaged
through a lever handle located on the inside of the folder
frame.
FIGURE X8-6 - TROLLEYS AND SLITTER
[Omitted In Printing]
FIGURE X8-5 - QUARTER FOLDER STRIPPER
[Omitted In Printing]
SETTING AND ADJUSTING THE TROLLEYS AND
SLITTER KNIFE
The roll over former consists of a driven roller of the
proper diameter to maintain a pull on the webs. Two
propeller rollers or trolleys press against the driven roller
for control. There is a spring and a turn screw adjustment
to set the desired tension on the trolleys (Figure X8-6).
Also mounted on the propeller shaft is a slitter wheel.
The wheel is used when running tabloid only. When the
wheel is not used it must be disengaged by decreasing
the tension on the spring through the turn screw adjust-
ment. The trolleys may also be thrown ON-OFF simul-
taneously through a lever handle located on the outside
of the upper folder frame.
282
QUARTER FOLDER PREPARATION
QUARTER FOLDER TIMING PROCEDURE
Timing (Figure X8-7) is necessary when the quarter folder
drive gear is engaged after silencing.
a
INCH the press over to align the timing marks on the
folder and printing units.
Put press on SAFE.
Remove half fold cam from face of folder gear case
(Figure X8-8).
Rotate the quarter folder tucker blade assembly man-
ually until the pointer is aligned with the timing
mark.
Engage the quarter folder drive gear by moving
clutch handle to L/H detent. (See Figure X8-1, Page
35.)
FIGURE X8-7 —- QUARTER FOLDER TIMING
[Omitted In Printing]
FIGURE X8-8 - HALF-FOLD CAM
[Omitted In Printing]
SILENCING THE QUARTER FOLDER
1.
y 4
a
Put press on SAFE.
Re-install half fold cam.
Disengage the quarter folder drive gear by moving
clutch handle to R/H detent.
Disengage the quarter folder stripper fingers by mov-
ing them away from the jaw cylinder.
283
SECTION IV
PRESS OPERATION
DAILY CHECK LIST
Before the makeready operations and starting
the press for a production run, a check should
be made of the various press components. This
check will insure the operational condition of
the press.
The daily check list then should consist of:
j MILL ROLL STAND
|
4 1. Check brake shoes for wear.
2. Check spring tension.
3. Inspect paper rolls for damage.
PRESS UNIT
1. Check that no foreign objects are between the rollers.
2. Check rubber distributor and form rollers for cracks
or signs of excessive wear.
Fa idrihits Selina smash Mab Motorhea Tae
3. Check water transfer roller and water form roller for
cleanliness. Change covers if dirty.
4. Check condition and cleanliness of blankets.
5. Check water pans and tanks for cleanliness and for-
eign objects.
6. Check ink fountain for condition.
7. Check that all guards and shields are in place.
284
FOLDER
1. Check knife blades, cutting rubber, pins and tucker
blades for condition.
Check stripper fingers.
Check nip rollers for condition (clean if ink covered).
Check folder for freedom from foreign objects.
" - &
Check that all guards and shields are in place.
OPERATING INSTRUCTIONS
It is recognized there are innumerable ways of bringing
this press into a continuous printing mode. The following
instructions will familiarize the operator with the rela-
tionship of electrical and mechanical press functions
needed to safely operate this press.
This section describes in some detail the controls used to
bring an independent printing unit into continuous run
from the Unit Control Panel (Figure X10-1) and Unit
Drive Station Panel (Figure X10-2). After a unit is capable
of running independently, the remote control features of
running from the Master Folder Control Panel (Figure
X10-3) is described.
NOTE: Prior to operating the press, review the safety
precautions and electrical control sections out-
lined in this manual.
Safety features have been incorporated into the control
system to protect the operator and prevent the press from
being started at high speeds. This press can be stopped
by depressing the STOP push-button at any of the loca-
tions on the V-25.
285
PRESS OPERATION FROM THE PRINTING UNIT - This
is the time to make sure each printing unit is working
properly. It will be necessary to do certain functions from
other than the printing unit.
1. Turn the power ON at the wall disconnect and
observe the red power indicator light on the drive
control cabinet is lit. This supplies power to the
press drive control.
2. Load the roll stand with paper (Section III, Opera-
tion 1).
Fill the ink fountains (Section III, Operation 2).
Check the water supply (Section III, Operation 2).
install the plates (Section III, Operation 2).
- Ff PP FS
Disengage the folder clutch (Section III, Operation
3).
Turn the POWER switch-ON at the master folder
control panel and observe the power indicator light.
If illuminated, power is being received from the
drive control cabinet, allowing electrical operation of
the press.
8. Turn the INK switch to MAKEREADY at the Master
Folder Control Panel.
™s
2 Bi ce siti
9. Depress READY push-buttons on the Unit Drive
Station Panel and Master Folder Control Panel.
FIGURE X10-2 - V-25 UNIT DRIVE STATION PANEL
[Omitted In Printing]
FIGURE X10-1 - V-25 PRINTING UNIT
CONTROL PANEL
[Omitted In Printing]
286
FIGURE X10-3 - V-25 FOLDER MASTER
CONTROL PANEL
{Omitted In Printing]
NOTE: From this point on, the printing unit(s) can be
run independent of the Master Folder Control
Panel at an inching speed.
WARNING
MAKE SURE ALL GUARDS ARE IN PLACE AND THAT
ALL PERSONNEL ARE CLEAR OF THE PRESS BEFORE
OPERATING.
10. Depress and hold the INCH push-button in position
to begin press rotation at inch speed.
NOTE: The INCH button only moves the press as long
as it is the only one depressed. Once it is no
longer depressed, the press stops. The warning
and momentary press movement allows time to
safely clear and stop the press if required.
11. While the INCH button is depressed and the unit is
moving, simultaneously depress the SLOWER push-
button bringing the unit into continuous run.
NOTE: Ink and water rollers should not be run dry on
the press for extended periods of time.
12. Depress WATER FOUNTAIN switches (upper and
lower) — ON at the Unit Control Panel.
13. Depress WATER FORM switches (upper and lower)
— ON at the Unit Control Panel.
14. Depress INK FOUNTAIN switches (upper and
lower) ON at the Unit Control Panel.
15. The Speed Control Knobs for INK and WATER
(upper and lower) should be placed on a low setting.
Te re ea Oe eae ee ker th the sdi ts, Daas.
16.
17.
18.
287
Depress INK FORM switches (upper and lower) -
ON at the Unit Control Panel.
Depress the FASTER push-button on the MASTER
FOLDER CONTROL PANEL to bring the unit(s)
speed up.
This allows moisture in the dampeners to dissolve
gum on the plates and also brings a thin film of ink
up through the rollers to the plate.
Depress the INK and WATER FORM and FOUN-
TAIN (upper and lower), and IMPRESSION rocker
switches to AUTO on the Unit Control Panel(s).
Place the IMPRESSION switch on the Unit Drive
Station to ON.
NOTE: This disengages the printing functions for trans-
19.
fer to the remote automatic operation from the
Master Folder Control Panel.
Depress the SLOWER push-button and reduce the
unit(s) speed to inching; then depress the STOP
push-button. This can be done at the unit(s) or
folder.
PRESS OPERATION FROM THE MASTER FOLDER
CONTROL
The following procedures generally involve press opera-
tion from the Master Folder Control Panel and are a
continuation of the press operation from the printing unit
described previously.
}
Depress the SAFE push-button on the Master Folder
Control Panel.
288
2. Engage the folder clutch (Section III, Operation 3)
making sure the folder and unit(s) are on their tim-
ing mark. (Also applies to quarter folder clutch if
needed.)
3. Depress the INK and WATER FORM and FOUN-
TAIN, and the IMPRESSION rocker switch to AUTO
on the MASTER FOLDER CONTROL PANEL.
4. Turn the INK switch to RUN on the Master Folder
Control Panel. This allows the ink fountain motors
to track their speed in direct proportion to press
speed.
5. Depress the READY push-button on the Master
Folder Control Panel, taking the press off SAFE.
6. Depress the INCH push-button and hold it in posi-
tion to begin press rotation at inching speed.
7. Depress the SEQUENCER switch to the RUN posi-
tion. With all printing functions for INK, WATER
and IMPRESSION in the AUTO position, the
selected units will remotely and sequentially start
these functions.
8. While the INCH button is depressed and the press is
rotating, simultaneously depress the SLOWER push-
button bringing the press into continuous inching
speed.
NOTE: At this time, the press will produce printed
product through the folder.
9. Depress the FASTER push-button until the desired
press speed is maintained.
10. Check the web side lay at the former and make the
necessary adjustments at the roll stands.
11. Check a printed copy and make necessary adjust-
ments by increasing or lowering the ink and water
Speed Control Knobs.
Aiea ee ROE A i EEN “pie nk Deh oe
289
NOTE: If running color, check registration of color and
adjust the compensator and/or register if
needed.
12. Check the brake adjustment. At running speed, the
dancer roll should be approximately under the
smooth idler roller.
NOTE: The press should be monitored during the run
and the quality of the printed material should be
checked frequently. The ink fountain should be
kept at least half full during the run.
STOPS DURING THE RUN
(Short Stops)
If the press is to be stopped momentarily during the run,
complete shut off is not required. To stop the press dur-
ing a run, proceed as follows:
1. Depress the SLOWER push-button on the Master
Folder Control Panel until the press reaches inching
speed.
2. Depress the STOP push-button on the Master Folder
Control Panel and when the press has stopped,
depress the SAFE push-button.
At the time the STOP push-button is depressed, the
printing functions are inactive.
STARTING THE PRESS AFTER SHORT STOPS
If the press was momentarily stopped during a run, it can
be restarted as follows:
1. Depress the READY push-button, bringing the press
off SAFE.
290
2. Depress the INCH push-button; holding it in posi-
tion to bring the press into inching speed.
3. Depress the SEQUENCER switch to RUN while all
printing functions are in the AUTO position. The
selected units will remotely and sequentially start
the printing functions.
4. While the press is inching, simultaneously depress
the SLOWER push-button bringing the press into
continuous rotation at inching speed.
5. Depress the FASTER push-button bringing the press
to the desired continuous speed.
SHUTTING DOWN THE PRESS
(End of Run)
To shut down the press at the end of a run, proceed as
follows:
1. Depress the SLOWER push-button on the Master
Folder Control Panel reducing press speed near the
inching speed.
2. Depress the INK FOUNTAIN rocker switch - OFF
and allow the press to run. This will remove excess
ink from the inking system.
3. Depress the INK FORMS rocker switch - OFF.
4. Depress the WATER FOUNTAIN rocker switch -
OFF.
5. Depress the WATER FORM rocker switch — OFF.
6. Depress the SLOWER push-button bringing the
press to inching speed.
7. Depress the STOP push-button. This will take the
IMPRESSION off automatically.
291
8. Clean the press. Remove plates and wash blankets
(Section III, Operation 2).
NOTE: Plates left on the cylinder for long periods (over
a weekend) ray cause rust accumulations in the
lock-up reel area.
9. Turn the POWER switch - OFF at the Master Folder
Control Panel and observe that the power indicator
light extinguishes.
10. Depress the SAFE push-button at the Master Folder
Control Panel.
11. Turn off the power at the wall disconnect and
observe that the red power light extinguishes.
SECTION V
ADJUSTMENTS and PART REPLACEMENTS
The adjustments described in this section are
adjustments that are not made during the course
of normal operating procedure, but are required
to correct certain operating troubles or to meet
certain operating conditions. Also, adjustments
are required when consumable parts are
replaced periodically.
GENERAL
Your V-25 press unit is provided with adjustments that
allow some variation in roller size due to regrind and
normal manufacturing tolerances. In order to keep the
need for adjustments to a minimum replace all rollers in
the location from which they were removed.
292
SETTING THE INK DISTRIBUTOR AND INK FORM
ROLLERS
l.
The adjustable ink distributor rollers No. 2, No. 4, No.
6, No. 11, No. 13, and No. 15 (Figure X11-1) are set to
the stationary distributor No. 1, No. 3, No. 10, No. 14
and vibrators No. 5, No. 7, No. 12, No. 16 using pull
strips.
Adjustments are made to each adjustable ink distribu-
tor roller using the following procedure (Figure
X11-2):
a. Place pull strips between the adjustable distribu-
tor and stationary rollers. A strip should be placed at
each end of the rollers.
b. Pull on each set of strips, simultaneously testing
for sufficient and equal drag between the rollers.
c. If adjustment is required, loosen locknuts “D” and
“E” and make necessary adjustments with the thumb
and adjusting screw.
d. Retighten locknuts “D” and “E” after adjustment
is made and recheck drag.
e. If an uneven drag exist between the adjustable
roller and the two stationary rollers, then additional
adjustment is needed to make the drag equal between
the two sets of pull strips.
f. Determine in which direction adjustment is
required to equalize the drag between the two sets of
strips.
g. Tap the roller brackets in the desired direction
using a soft mallet. Both brackets on the roller should
be adjusted to keep the adjustable roller parallel with
the stationary rollers.
h. After adjustment is made, recheck drag.
293
FIGURE X11-1 - INK AND WATER DISTRIBUTION
[Omitted In Printing]
2. The ink form rollers No. 8, No. 9, No. 17 and No. 18
(Figure X11-1) are set to the vibrators and plate cylin-
ders using pull strips.
The adjustments are made to each ink form roller
using the following procedure.
A. Ink form roller No. 17 upper and 8 lower to ink
vibrator roller (Figure X11-3 upper; Figure X11-4
lower).
FIGURE X11-2
[Omitted In Printing]
FIGURE X11-3
[Omitted In Printing]
FIGURE X11-4
[Omitted In Printing]
} 1. Insert test strips between form roller No. 8 or
17 and the ink vibrator roller.
2. Pull both strips simultaneously testing for
sufficient and equal drag between the rollers.
Faced Pla PRA S ne ee
3. If adjustment is required, back off locknuts
“F” and turn vibrator pressure adjustment screws
on both ends to get the desired drag.
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4. Retighten locknuts “F” after adjustment is
made and recheck drag.
B. Ink form roller No. 8 lower and 17 upper to the
upper plate cylinder (Figure X11-3 upper; Figure
X11-4 lower). Plate must be installed on cylinder.
C.
294
|. Insert test strips between form roller No. 8 or
17 and the upper plate cylinders.
2. Throw the upper ink form rollers ON.
3. Pull both strips simultaneously testing for
sufficient and equal drag between the roller and
evlinder.
4. If adjustment is required, back off locknuts
“G”" and turn plate pressure adjustment screw
roller No. 8 or 17 on both ends to get the desired
drag.
5. Retighten locknuts “G” after adjustment is
made and recheck drag.
Ink form roller No. 9 lower and 18 upper to ink
vibrator roller (Figure X11-3 upper; Figure X11-4
lower).
D.
1. Insert test strips between form roller No. 9 or
18 and the ink vibrator roller.
2. Pull both strips simultaneously testing for
sufficient and equal drag between the rollers.
3. If adjustment is required, back off locknuts
“H” and turn vibrator pressure adjustment
screws on both ends to get the desired drag.
4. Retighten locknuts “H” after adjustment is
made and recheck drag.
Ink form roller No. 9 lower and 18 upper to the
upper plate cylinder (Figure X11-3 upper; Figure
X11-4 lower). Plate must be installed on cylinder.
1. Insert test strips between form roller No. 9 or
18 and the upper plate cylinders.
2. Place the upper ink form rollers ON.
295
3. Pull both strips simultaneously testing for
sufficient and equal drag between the roller and
cylinder.
4. If adjustment is required, back off locknuts
“I” and turn plate press adjustment screw roller
No. 11 on both ends to get the desired drag.
5. Retighten locknuts “'” after adjustment is
made and recheck drag.
FIGURE X11-5 - INK FORM ROLLER STRIPE TEST
[Omitted In Printing]
SETTING THE DAMPENER FORM ROLLERS
A. Set the form roller to the vibrator roller (Figure
X11-6).
1. Insert test strips between the water form and
vibrator rollers.
2. Pull strips simultaneously testing for suffi-
cient and equal drag between the rollers.
FIGURE X11-6
[Omitted In Printing]
3. If adjustment is required, back off locknuts
“C” and turn vibrator pressure adjustment screw
on both ends to get the desired drag.
| 4. Retighten locknuts “C” after adjustment is
: made and recheck drag.
B. Set the water form roller to the plate cylinder
4 (Figure X11-6). Plate must be installed on cylin-
der.
1. Insert test strips between the form roller and
plate cylinder.
2. Put the water form roller on.
296
3. Pull both strips simultaneously testing for
sufficient and equal drag between the roller and
plate cylinder.
4. If adjustment is required, back off locknuts
“D” and turn plate pressure adjustment screw on
both ends to get the desired drag.
5. Retighten locknuts “D” after adjustment is
made and recheck drag.
QUICK CHECK FOR CORRECT SETTING
OF THE INK FORM ROLLERS
After the initial setting of the form rollers to the plate
cylinder, they need only to be checked (Figure X11-5) at
the time of the makeready.
A visual check can be made \by bringing the inked-up
form rollers in contact with the plate while the unit is
stopped with impression ON and immediately taking
them off again. Once the form rollers have been thrown
ON and OFF, then INCH the unit over until both ink
stripes are visible. A correct ink stripe will be °/16” wide
and even across the plate. A press plate must be mounted
on the plate cylinder and impression must be ON in order
to set the ink form rollers properly.
SETTING THE DAMPENER FORM ROLLERS
The upper and lower dampener form rollers are set to the
vibrator and plate cylinder using pull strips (Figure
X11-6).
Mew +
BAD GEIS
297
SETTING THE INK DUCTOR
The ductor roll is adjusted using pull strips. The follow-
ing procedure is used (Figure X11-7):
1. INCH press until actuator rod “E” is at maximum
travel point with ductor roller against distributor
roller.
2. Place pull strips between the ductor roller and the
distributor roller. A strip should be used at each end
to insure even pressure.
3. Puil on the set of strips, simultaneously testing for
sufficient and equal drag between the rollers.
4. If adjustment is required, loosen locknut “A” and
adjust screw “B” on each side of the press.
5. Retighten the locknut and recheck the drag.
6. INCH press until actuator rod “E” is at maximum
travel with ductor roller against the fountain roller.
7. Place pull strips between ductor roller and fountain
roll. :
8. If adjustment is required, loosen locknut “C” and
adjust with screw “D”.
FIGURE X11-7
[Omitted In Printing]
9. Retighten locknut and recheck drag.
After the roller pressure had been set check the ductor
dwell. The ink ductor should make 4 to 4'/2 revolutions
while in contact with the distributor roller. Spring “F” is
adjusted with locknuts “G” to get the desired dwell.
Tighten against the spring for more dwell and loosen to
reduce dwell. Spring “H” is adjusted with locknuts “J”.
Spring “H” is set with a minimum of pressure. If spring
298
“H” is adjusted it may be necessary to readjust spring “F”
to maintain proper dwell. The minimum spring pressures
that will give the desired dwell should always be used to
prevent excessive wear and strain on the ductor compo-
nents.
SETTING THE DAMPENER DUCTOR
The dampener ductor (Figure X11-8) is adjusted using the
same methods described for the ink ductor. The only
difference is the dwell which is adjusted for 7 to 8 revolu-
tions of the ductor while against the dampener vibrator
roller. The ductor roller covering must be installed and
rolled down before adjustments are made.
V-25 INFEED ROLLER WEB TENSION ADJUSTMENT
The nip pressure between the infeed roller (Figure X11-9)
and the infeed idler roller is adjustable to control infeed
tension of the web to the blanket cylinders.
Nip pressure is set at the factory. The steel roller bears
approximately .030 into the infeed roller when the infeed
Cam Lever is in the “On” position shown. Changes to
web tension may be made as follows:
Increase of web tension between infeed and blanket cylin-
ders:
To increase web tension, the nip pressure between the
steel idler and infeed roller must be reduced. To accom-
plish this, stop the press and made the following adjust-
ments:
,
:
;
4
:
:
{
’
i
3
{
)
4
-
4
299
Loosen adjust screw “A” '/s turn or less and tighten
adjust screw “B” the same amount, — then tighten stop
screw “C”. Care must be taken in this adjustment not to
lose the web because of the reduction in nip pressure.
Decrease of web tension between infeed and blanket cyl-
inders:
To decrease web tension, the nip pressure between the
steel idler and infeed must be increased. To accomplish,
stop the press and make the following adjustments:
Loosen stop screw “C” several turns. Loosen adjust screw
“B” '/s turn or less, tighten adjust screw “A” the same
amount and retighten stop screw
FIGURE X11-8
{Omitted In Printing]
“C”. Care must be taken in this adjustment not to over-
feed the web creating slack between the infeed and blan-
ket cylinders.
FIGURE X11-9
[Omitted In Printing]
KNIFE BLADE REPLACEMENT
To replace the cutting knife blade (Figure X12-1), proceed
as follows:
1. Rotate the cutting cylinder until the knife blade
assembly is accessible.
2. Remove five retaining bolts “A” from the cheek-
wood retainer. Remove retainer from cylinder along
with four cheekwoods.
300
3. Remove the one blade retaining bolt “B” from the
cylinder.
4. Loosen four '/2” set screws (not shown) to free the
knife blade.
5. Remove worn knife blade from cylinder and thor-
oughly clean all paper dust and foreign matter from
cavity.
6. Replace worn blade with new blade.
7. Replace blade retaining bolt “B”. Hand tighten only.
8. Check to assure that all cheekwood springs are in
position and properly seated.
9. Replace cheekwoods and cheekwood retainer.
Tighten retaining bolts “A” in place.
10. Using the three blade adjustment screws “C”, back
off on the locknuts and adjust the blade so that the
cutting edge is flush with the top of the cheekwood.
Once the blade is adjusted, retighten locknuts.
11. Tighten bolt “B” and the four '/2” setscrews to clamp
the blade into position.
IMPALING PIN REPLACEMENT
Check each made-ready for bent or broken pins (Figure
X12-2). Replace any that are damaged. Care should be
taken when replacing pins not to disturb the pin holder
setting for they are pre-set at the factory.
FIGURE X12-1
[Omitted In Printing]
To replace the pins, proceed as follows:
1. Rotate the cutting cylinder until the pin holder is
accessible.
ln
301
2. Using the pin wrench provided, remove the old pin.
3. Insert new pin into holder. Care should be taken not
to over tighten pin at reinstallation.
FIGURE X12-2
[Omitted In Printing]
TUCKER BLADE REPLACEMENT
The tucking blade should be checked before each run. All
damaged blades should be replaced (Figure X12-3) at
once. Cuts in the folded edge of the signature will indi-
cate a damaged blade.
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at
To replace the tucker blade, proceed as follows:
1. Rotate the cutting cylinder until the tucker blade is
accessible.
2. Loosen the five blade retaining bolts. Blade should
break free.
3. Remove old blade from cylinder.
4. Install new blade into cylinder. Hand tighten bolts.
Check to see new blade is free of burrs and sharp
corners.
5. Using the tucker blade height gage, set the blade
* height across the length of the jaw cylinder.
6. Tighten all five blade retaining bolts and recheck
blade height.
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CUTTING RUBBER REPLACEMENT
The knife blade cuts the paper against a rubber insert
(Figure X12-4) in the jaw cylinder. This rubber insert
through normal use will become worn and ineffective. It
302
should be checked before each run and replaced when
needed.
To replace the cutting rubber, proceed as follows:
1. Rotate the jaw cylinder until the cutting rubber is
accessible.
2. Remove the four retaining bolts “A”. Remove the
cutting rubber keeper along with the worn rubber.
3. Clean all paper dust and foreign mater from the cav-
ity.
4. Insert new rubber and keeper taking care to align the
stripper finger grooves in the rubber with those in the
cylinder. Tighten retaining bolts “A”.
FIGURE Xi2-3
[Omitted In Printing]
FIGURE X12-4
[Omitted In Printing]
LAP ADJUSTMENT - HALF FOLD
Lap adjustment is obtained by adjustment of the tucker
blade and rotation of the jaw cylinder. Lap travel of up to
'/2 inch away from pins to facilitate trimming is available.
Reverse lap (toward pins) is restricted to '/s inch (See
Figure X12-5).
To lap away from pins proceed as follows (Figure X12-6):
1. Back off on lap adjustment screw “A”.
2. Reposition tucker blade one-half the amount of
desired length of lap away from pins using screw “B”.
3. Take up on screw “A” to lock blade into desired
position.
303
4. Open access door on rear of folder.
5. Loosen the six clamping screws on the jaw cylinder
drive gear (Figure X12-7).
6. Rotate jaw cylinder the same distance that the tucker
blade has been displaced (opposite direction of cylin-
der rotation).
7. Retighten clamping screws.
For reverse lap use opposite procedure of above.
FIGURE X12-5
[Omitted In Printing]
FIGURE X12-6
[Omitted In Printing]
FIGURE X12-7 - LAP ADJUSTING SCREWS
[Omitted In Printing]
SECTION VI
LUBRICATION
To keep the press operating smoothly, efficiently
and with a minimum of wear, the moving parts
must be lubricated regularly. The amount and
type of lubricant and frequency of application
depends on the type of bearing or bearing sur-
face to be lubricated. The recommended lubrica-
tion intervals given in this manual are based on
press operation at normal operating speeds.
METHODS OF LUBRICATION
The methods used to apply lubricant to the components
of the press are: brush-on, grease gun, cascading oil and
splash-type. Gears receive a cascading oil application of
304
lubricant. Bearings require application of lubricant by
means of a grease gun. The quarter folder is lubricated by
a splash-type system. Cams require a brush-on lubricant.
BRUSH-ON LUBRICATION
Use a soft-bristle brush to apply K-Forty/EP Non-Fluid
Oil to the parts of the press requiring brush-on applica-
tion of lubricant. The lubricant should be applied spar-
ingly to these areas.
GREASE OR PRESSURE GUN LUBRICATION
Lubrication for bearings is supplied through grease fit-
tings. It is not necessary to use an air pressure gun to
apply lubricant to the grease fittings. A hand-operated
grease gun is adequate and is preferred.
PRINTING UNIT LUBRICATION
The following press lubrication instructions will provide
you with the necessary information needed to completely
lubricate the V-25 printing unit. Listed are the methods of
application, lubricating points, intervals, and types of
lubricants. Use only the types of lubricants recom-
mended.
PRINTING UNIT MAIN DRIVE HOUSING
(CASCADING OIL)
A -_ Type of lubricant - Mobil D.T.E. - 25 or Gulf
Harmony
B - Maintain level
PTT MG EP OETEN IES MEALS. 4 HEF TS
;
1
7
;
4
- |
-
:
:
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sehen SOT Rte
cna wos oe
305
C- Drain and replenish with new oil every six
months
D- _ check monthly
PAN ROLL MOTORS
A- Type of Lubricant - MOBIL HEAVY MEDIUM
D.T.E.
B- Maintain level
C- Drain and replenish with new oil every six
months
AIRLINE LUBRICATORS
A- Mobil D.T.E. Light
B- Maintain level
PLATE AND BLANKET CYLINDER BOXES
A - Type of Lubricant - Mebilux EPO
B- Minimum lubrication - approximately one month
PLATE AND BLANKET CYLINDER BEARINGS
A - Type of Lubricant - Mobilux EPO
B- Minimum lubrication - approximately two weeks
TOGGLE LEVERS AND CONNECTIONS
A- _ Type of Lubricant - Mobilux EP1
B- Minimum lubrication - approximately two
months
PAN ROLL BEARINGS
A- _ Type of Lubricant - Mobilux EP1
B- Minimum lubrication - approximately two weeks
306
DUCTOR SHAFT AND LEVERS
A - Type of Lubricant - Mobilux EP1
B- Minimum lubrication - approximately two weeks
INK FOUNTAIN BEARINGS
A - Type of Lubricant - Mobilux EP1
B - Minimum lubrication - approximately two weeks
MAIN DRIVE BEARINGS
A - Type of Lubricant - Mobilux EP1
B- Minimum lubrication - approximately two weeks
DUCTOR CAMS AND GUIDES
A - Type of Lubricant - Mobilux EP1
B - Minimum lubrication - approximately two weeks
SIDE REGISTER MECHANISM
A- _ Type of Lubricant —- Mobilux EPO
B- Minimum lubrication —- approximately two weeks
LEAD AND FEED ROLLS
A- _ Type of Lubricant - Mobilux EP1
B- Minimum lubrication - approximately two weeks
FORM AND DAMPENER ROLL LEVER
THROWOFF BUSHINGS
A - __ Type of lubricant - Mobil D.T.E. - Heavy Medium
B- Minimum lubrication - approximately two weeks
307
BEARER WIPER FELTS
A - __ Type of lubricant —- Mobil D.T.E. - Heavy Medium
B - Each week clean felts with ink solvent. Check for
wear and relubricate.
CIRC. REGISTER MECHANISM
A- Type of Lubricant - Mobilux EPO
B- Minimum lubrication - approximately two weeks
PLATE AND BLANKET LOCKUP MECHANISMS
A - Clean and oil with a light machine oil
B- Approximately monthly
MAIN DRIVE MOTOR
A - See Drive Motor Mfg’s Specification Sheet.
UNIVERSAL JOINTS
A - Type of Lubricant - Mobilux EP1
B- Minimum lubrication - approximately two weeks
FOLDER LUBRICATION
The folder main drive lubrication is of the wet pump
type. Oil under pressure is supplied by an oil pump
which supplies oil to spray nozzles mounted in the gear
case. A filter is located in the pump suction line. Located
on the rear of the folder gear case, below and to the left of
the line shaft, is a sight gage for checking the oil level.
The proper oil level is halfway up the gage when the
folder is not running. The oil level should be checked
daily. In addition a visual check should be made through
the folder access door for operation of the oil spray
308
system on the first run of each day. The oil capacity of the
sump is 7 gallons (Mobil D.T.E-26).
The quarter folder main drive train is unclosed in a
gearbox and is lubricated by a pressure oil system similar
to the main folder drive. Oil capacity is 2-'/2 pints.
In addition, grease fittings are provided throughout the
folder unit. The following pages provide photographs
showing the location of the grease fittings. The photos
also show cam and gear locations requiring lubrication.
The following schedule should be used:
Lubrication
Point
Bearings &
Bushings
Cam Ways
Gear Teeth,
Chains
& Sprockets
Method
Grease Gun
Brush-On
Brush-On
Interval
(Operating
Lubricant Hrs.).
MobilPlex 4H 100
K-Forty/EP 40
Non-Fluid
or Oil
Equivalent
K-Forty/EP 40
Non-Fluid
or Oil
or Equivalent
FIGURE X13-1
[Omitted In Printing]
FIGURE X13-2
(SEE FIGURE X8-3)
[Omitted In Printing]
FIGURE X13-3
(SEE FIGURE X8-4)
[Omitted In Printing]
309
FIGURE X13-4
[Omitted In Printing]
FIGURE X13-5
[Omitted In Printing]
} FIGURE X13-6
: [Omitted In Printing]
MILL ROLL STAND LUBRICATION
Lubricate the roll stands in accordance with Figure X13-7.
FIGURE X13-7
[Omitted In Printing]
SECTION VII
TROUBLESHOOTING
This section lists trouble symptoms which may
be encountered in operation of the Harris V-25
web offset printing press. One or more probable
causes are listed under each symptom. Opposite
each probable cause a possible remedy is given
and where possible.
PRINTING OR IMPRESSION TROUBLESHOOTING
Trouble Probable Cause Remedy
Ink fails to Ink screws not Adjust ink
distribute set according to fountain thumb
| properly and image screws.
; evenly on ink requirements
rollers.
| Ink rollers will Ink may be Clean ink
not pick up ink. emulsified on rollers.
; rollers.
Trouble
Dampening
roller cover
becoming overly
dirty.
Scumming of
plate.
Ink fountain
roller becoming
scored.
Printed image
weak or gray.
Image fails to
pick up ink.
Image blurred.
Printed
impressions
misaligned in
finished product.
310
Probable Cause
Press being
operated with
too much ink
and moisture.
Too much ink
for amount of
moisture.
Ink thumb
screws set too
tightly against
fountain blade.
Too much water
or not enough
ink.
Insufficient ink
or too much
water.
Too much ink.
Side register
improperly
adjusted.
Circumferential
register
improperly
adjusted.
Compensator
adjustment
improperly set
at on printing
unit.
Clutch at one
unit engaged
out of phase.
Remedy
Adjust ink and
water balance.
Adjust ink and
water balance.
Adjust ink
fountain thumb
screws.
Adjust ink and
water balance.
Adjust ink and
water balance.
Adjust ink and
water balance.
Adjust the side
register
adjustment.
Adjust
circumferential
register
adjustment cap.
Adjust
compensator.
Re-engage clutch
in proper phase.
311
WEB FEED TROUBLESHOOTING
Trouble
Web tears.
Web running too
loosely
Web not cutting
at proper place.
Probable Cause
Too much
tension on
brake.
Running too
much moisture.
Insufficient
’ brake tension
Compensators
improperly
adjusted.
Printing unit not
timed properly
FOLDING TROUBLESHOOTING
Trouble
Web not cutting
at proper point.
Web will not
adhere to
cutting cylinder.
Web cut by
nipper rollers.
Web not being
cut cleanly by
knife.
Probable Cause
Folder not timed
to printing unit.
Pins broken or
bent.
Nipper rollers
improperly
adjusted.
Knife blades
improperly
adjusted.
Cutter rubber
worn
excessively.
Tabloid slitting
knife pressure.
Remedy
Loosen brake
tension.
Reduce amount
of moisture.
Adjust brake
tension.
Readjust
compensators.
Retime unit.
Remedy
Time the folder.
Replace pins.
Adjust nipper
rollers.
Adjust knife
blades.
Replace cutter
rubber.
Adjust slitting
knife pressure.
312
Trouble Probable Cause Remedy
Quarter folder Quarter folder Time the quarter
not operating not timed with folder.
properly. other units.
Quarter folder Engage quarter
not engaged. folder.
GENERAL
CAUTION
(1)
(2)
DANGEROUS VOLTAGES EXIST WITHIN
EVERY PRINTING PRESS ASSEMBLY. WHEN-
EVER ATTEMPTING TO LOCATE ELECTRI-
CAL FAULTS OR REPAIR OR ADJUST ANY
PART OF THE PRINTING PRESS OR ITS ASSO-
CIATED EQUIPMENT, EXTREME CAUTION
MUST BE USED TO INSURE THAT NO ELEC-
TRICALLY “LIVE” PARTS ARE TOUCHED.
ALWAYS DISCONNECT PRESS FROM POWER
LINE BEFORE OPENING ANY DOORS OR
ELECTRICAL PANELS.
Underlined items in the Fault Location Chart indi-
cate the correct state, i.e., energized relay or oper-
ated switch (even if a component is in its correct
state, such as an energized switch or relay, it may
still have defective contacts or other not obvious
defects).
If you are not able to locate the fault by using the
following charts, Ft. Worth (Harris) Service can
probably talk you through a more complete test pro-
cedure if you will provide yourself with Drawing,
No. 755275 and a 115VAC test light, or equivalent,
before calling for help.
313
(3) Possible malfunctions are listed in the order in
which they are likely to occur.
SECTION VIII - IMPOSITION CHARTS
[Omitted In Printing]
314
UNITED STATES OF AMERICA
NATIONAL LABOR RELATIONS BOARD
REGION 8
SFE EEE EEE
NTA GRAPHICS,
INCORPORATED,
Employer,
d Case No.
7 8-RC-13648
GRAPHIC COMMUNICATIONS
INTERNATIONAL UNION,
DETROIT-TOLEDO LOCAL 2839,
Petitioner.
Se ll
a a. a SS we te ae a
REQUEST FOR REVIEW AND STAY
OF REGIONAL DIRECTOR’S DECISION
AND DIRECTION OF ELECTION
Timothy C. McCarthy, Esquire
Shumaker, Loop & Kendrick
North Courthouse Square
1000 Jackson
Toledo, Ohio 43624-1573
(419) 241-9000
Counsel for Employer
315
UNITED STATES OF AMERICA
NATIONAL LABOR RELATIONS BOARD
REGION 8
LPP P PP PPP PPP 2 2
NTA GRAPHICS, ‘
INCORPORATED, *
Employer, :
al . Case No.
- " 8-RC-13648
GRAPHIC COMMUNICATIONS :
INTERNATIONAL UNION, :
DETROIT-TOLEDO LOCAL 289, .
Petitioner. *
Sa a a a a i i a a a a Bi Be Be Be ee Dee te tee tiated
REQUEST FOR REVIEW AND STAY
The employer, NTA Graphics, Incorporated, pursuant
to Section 102.67(b) of the Board’s Rules and Regulations,
hereby requests the National Labor Relations Board to
review the Decision and Direction of Election of August
19, 1987, issued by the Regional Director of Region 8, and
to stay such Decision and Direction of Election pending
such review, for the following reasons:
(1) The Regional Director’s decisions on
several substantial issues are clearly erroneous
on the record and these errors prejudicially
affect the rights of the employer by requiring it
to submit a representation election in a frag-
mented bargaining unit that is not appropriate
for the purposes of collective bargaining and
was not even described in the Petitioner's origi-
nal Petition for an election.
316
(2) A substantial question of law and pol-
icy is raised because the Regional Director's
decision to fragment an appropriate bargaining
unit constitutes a substantial departure from
officially reported Board precedent.
MEMORANDUM IN SUPPORT OF
REQUEST FOR REVIEW AND STAY
I. STATEMENT OF THE CASE
The Regional Director has directed an election in a
bargaining unit consisting of only the “full-time and reg-
ular part-time pressroom employees” at the printing
facility of NTA Graphics, Incorporated [hereinafter the
“Employer” or the “Company” ] in Toledo, Ohio. This unit
is different and smaller than the unit originally described
by the Graphic Communications International Union,
Detroit-Toledo Local 289 [hereinafter the “Union” or the
“Petitioner”] in its Petition in this case, which unit
included “all preparatory department and press depart-
ment employees.” }
The Employer asserts that the only appropriate bar-
gaining unit under the circumstances of this case is a
traditional production and maintenance unit, consisting
of hourly employees in the pressroom, pre-press depart-
ment, composition department, shipping and receiving
department, and maintenance department, all of whom
work at the Company’s facility in Toledo. Employees in
these various departments share common supervision,
enjoy a significant degree of interaction, receive very
similar compensation and virtually identical benefits,
work under identical employment policies, and generally
share a community of interest with respect to their terms
317
and conditions of employment. The employees in the
bargaining unit consisting only of the Press Department
determined by the Regional Director are not separate and
distinct in any relevant sense, nor do they merit separate
inclusion as a highly skilled craft unit, as the evidence at
the hearing in this case disclosed.
The Employer would also object to the determination
of a unit different and smaller than the original unit
petitioned for by the Union. In his Decision and Direction
of Election, the Regional Director stated that the Union
had, in effect, made a motion to contract the scope of the
bargaining unit it sought when it filed its post-hearing
brief after the representation hearing. The Regional Direc-
tor concluded that the Employer had not objected to this
“motion,” and then granted the “motion.” Significantly,
the Union never filed any motion seeking to amend the
unit, but simply made statements to that effect in its post-
hearing brief. The Employer’s post-hearing brief was due
on the same date as the Union’s and those briefs were
simultaneously exchanged. Thus, even assuming the
Union’s post-hearing brief was somehow transformed
into a “motion” seeking to reduce the size of the bargain-
ing unit, the Employer never had the opportunity to
object to such an altered unit.
The Company, therefore, at this time objects to the
eleventh hour amendment of the unit description in the
Petition for a representation election. This objection is
based upon two considerations. First, while preparing for
and actually participating in the representation hearing,
the Employer assumed that the unit choices would either
be the pre-press and press departments originally sought
by the Union or the production and maintenance unit
318
sought by the Employer. The presentation of its case on
an appropriate unit was premised upon that understand-
ing, and it would be entirely inequitable, not to say
inconsistent with the fundamental requirements of pro-
cedural due process, to allow the Petitioner to seek a
different unit after termination of the hearing.
Second, the Employer is severely prejudiced in any
attempt to campaign against Union representation among
its employees, since it has now been advised at the last
moment that the bargaining unit in which the election
will be held is very different from any unit that had
previously been contemplated.
For these reasons, the Employer would submit that
the Petitioner should not be permitted to make a last
minute alteration in the bargaining unit it seeks, and
should instead be compelled to either file a new petition
in the unit it actually desires to represent or amend its
current petition, with appropriate notice and an oppor-
tunity to respond afforded to the Employer. Absent such
a procedure, the Employer is unlawfully and severely
damaged in addressing what will be a most important
issue in the future of its business.
Il. STATEMENT OF EVIDENCE
The facts purportedly relied upon by the Regional
Director in issuing his Decision and Direction of Election
significantly distort the evidence presented at the hearing
with respect to the nature of the Employer’s operation
and the terms and conditions of employment of its
employees. In some instances, the Regional Director
shades the evidence to favor his foregone conclusion that
319
a small unit of press department employees should be
carved out of the Employer’s operation. Perhaps even
more importantly, though, the Regional Director simply
overlooks important evidence presented at the hearing
showing the community of interest shared by all of the
Employer’s hourly employees. The Employer will now
discuss what the evidence presented at the representation
hearing clearly disclosed concerning the role the Com-
pany’s employees play in its operations and the condi-
tions of their employment.
A. Introduction
The Company is a relatively simple commercial
printing operation, which prints essentially one type of
product. It prints advertising inserts for grocery stores to
be included in newspapers. (Transcript 15 [hereinafter
"a oe
In printing this product, the Employer has five
departments that participate in each project, namely, the
Composition Department, the Pre-Press Department, the
Press Department, the Shipping/Receiving Department
and the Maintenance Department. The petitioner in this
case, Graphic Communications International Union,
Detroit-Toledo Local 289 [hereinafter the “Union”] seeks
an election of only those employees included in the Pre-
Press and Press Departments. The Company, on the other
hand, submits that a typical production and maintenance
unit consisting of employees in all the departments is the
only appropriate unit.
320
B. Functional Integration of the Departments
As indicated above, the Company produces a stan-
dard product, which is a grocery advertising insert to be
included in newspapers. These inserts are printed on a
standard four-color offset Harris Web press. (T. 60, 79.)
As Mr. David Tremonti, the Company’s Operations Man-
ager testified, this process is a garden-variety offset print-
ing process, and the Employer is “not in the high tech
press areas.” (T. 28.)
A fundamental, yet erroneous, factor in the Regional
Director’s analysis of the Employer’s operation is that the
Press Department and its employees are separate and
distinct from the Employer’s other departments. The evi-
dence at the hearing was quite the contrary. In actuality,
there is, and must be, a great deal of contact and commu-
nication between the Press Department and the other
departments that precede and follow it in producing the
Company’s single product, an advertising insert.
Any project received from one of the Company’s
grocery clients begins with copy provided by the cus-
tomer, which usually has any art work and typesetting
either done or specified in advance. (T. 16.) The project
then proceeds to the Composition Department, where job
tickets are made instructing all departments on how the
job should be performed. These job tickets are then per-
sonally distributed to all the other departments. (T.
87-88.) The Composition Department consults with the
Pre-Press Department on color and configurations. It also
instructs the Press Department on paper size and quan-
tities. The Shipping / Receiving Department is given direc-
tions on the timing and destination of shipments. (T. 16.)
321
Initial preparation of the project requires the Compo-
sition Department to frequent the Pre-Press Department
regularly to review the copy and discuss the job. This
consultation takes from one to five hours per day. (T. 39,
164.)
After the project reaches the Pre-Press Department,
the copy provided by the grocery store is photographed,
and then the photograph is proofread against the original
copy. Strippers employed in the Pre-Press Department
take the photographic flats, strip out the color, and then
organize the pages in accordance with the instructions
provided by the Composition Department. Again, the
flats are proofread against the original.
Subsequently, plates are prepared and proofread, and
those plates are then assembled and organized, and skid
labels and bundle tags prepared by the Compositions
Department are attached. (T. 17-18.)
The order in which the projects are run is determined
by Plant Superintendent Frank Skwiera. (T. 18.) The var-
ious projects in the sequence determined by Mr. Skwiera
are then placed in folder racks and made available to the
Press Department. (T. 17-18.)
Employees in the Pre-Press Department perform a
number of different assignments, including stripping,
plating, photographing and proofreading. In the Com-
pany’s experience, all employees in the Department are
called upon to perform all those assignments. (T. 82-83.)
Once the plates are available, employees in the Press
Department obtain those plates from the Pre-Press
Department. The job is then run, after the plates have
322
been mounted from the web. The first readable copy is
proofread by the pressman against the job tickets pre-
pared by the Composition Department to make sure the
pagination is correct. An initial readable copy is also
taken back to the Pre-Press Department for proofreading
to make sure it conforms to the original copy provided by
the customer. (T. 18.)
The pressman is charged with the responsibility of
hanging the plates in accordance with instructiong on the
job ticket prepared by the Composition Department. In
addition to then running the job, the pressman checks the
ink and water levels, and is expected to do at least some
light maintenance. (T. 21-22, 73.)
The pressman is assisted by a jogger, who, in addi-
tion to providing miscellaneous help, takes the printed
product off the end of the press and sweeps up around
the press.
Once the jogger has taken the product off the press, it
is picked up by a material handler from the Shipping/
Receiving Department. (T. 21-22, 155.) In sum, the jogger
is an unskilled worker who helps the pressman. (T.
143-43.) The Company usually selects its pressmen from
the ranks of the joggers. (T. 78-79.)
As indicated above, the finished product is removed
from the Pressroom by the Shipping/Receiving Depart-
ment. In addition, Shipping/Receiving Department
employees bring the rolls of paper to the press before the
run. After the run itself, the Shipping/ Receiving Depart-
ment prepares the product for shipping, takes it to the
loading dock, and then stages the pallets of product for
323
shipping. On occasion, the material handlers in the Ship-
ping/Receiving Department assist the truck drivers in
loading the product onto the trucks. Also, those material
handlers remove waste from the presses. (T. 19.)
Although the Regional Director concludes that the
material handlers spend little time in the Press Depart-
ment (“a few minutes at most on each trip”), the evidence
presented at the hearing was that the material handlers
are in and out of the Pressroom “on a continual basis all
day long.” (T. 35.) They spend some four out of eight
hours per shift in the Pressroom. (T. 162-63.)
The Shipping/Receiving Department works off the
job tickets prepared by the Composition Department on
each and every job to make certain that quantities and
destinations are correct. These written instructions are
confirmed when the two Departments discuss jobs before
departure. (T. 16.)
The Maintenance Department is intimately involved
in the production process. The janitorial employees in the
Department clean the entire building, including the area
around the presses and the walkways through the Press-
room. They also remove ink baskets that the Pressmen do
not use. The janitors spend some two to three hours per
shift in the Pressroom, which is far more than the
Regional Director suggests in observing that they are in
the Pressroom “one to three times daily” and spend only
“a few minutes at a time.” (T. 20-22, 160.)
Other maintenance employees are the mechanical
employees, whose primary function is to keep the presses
running. In basic terms, they do more elaborate mainte-
nance that the pressmen are unable to do. (T. 20, 23.)
324
Again, a significant amount of time of the mechanical
employees is spent in the Pressroom, despite the Regional
Director’s implication that they spend little time there.
During the week of June 30, 1987, for example, they spent
some 30 hours in the Pressroom. (T. 161.)
C. Supervisory Structure
The Company’s supervisory structure in the produc-
tion area is decidedly lean. For most purposes, the only
ongoing supervisors are Operations Manager Tremonti
and Plant Superintendent Skwiera, and clearly these two
gentlemen supervise all the production and maintenance
areas. Most day-to-day supervision of all departments is
left to Mr. Skwiera - a gentlemen who is not even named
in the Regional Director’s Decision and Direction of Elec-
tion. (T. 23-28, 122-24, 127-29, 152.)
The Composition and Pre-Press Departments report
directly to Messrs. Tremonti and Skwiera. (T. 23-28,
122-24.) The Pre-Press Department has a group leader
who handles some of the clerical and report-writing func-
tions and prepares initial schedules to be approved by
Mr. Tremonti. (T. 127-28.) This group leader is clearly not,
though, a supervisor in most senses, and, in fact, he is an
hourly employee like others in his Department and actu-
ally makes less than some. (T. 146.) Thus, Messrs. Trem-
onti and Skwiera exercise direct supervision in both the
Composition and Pre-Press Departments.
Operations Manager Tremonti and Plant Superinten-
dent Skwiera, and particularly the latter, head up the
Pressroom. (T. 24-25, 128.) Although Scott Shaffer has
325
supervisory responsibilities during the day shift in the
Pressroom, he also serves as a pressman and mechanic. A
great deal of actual supervision is left to Messrs. Tremonti
and Skwiera. (T. 23-28, 122-24.)
There is a group leader on the night shift in the
Pressroom, Hollis Shaffer. Mr. Shaffer does not, though,
actually exercise any supervisory responsibility but,
rather, he serves to train the other pressmen. (T. 24-25.)
Direct supervision of the Maintenance and Shipping /
Receiving Departments is left to Operations Manager
Tremonti and Plant Superintendent Skwiera. There is a
group leader in the Shipping/Receiving Department,
whose job duties include primarily the handling of the
paperwork incidental to shipping functions. (T. 23-24.)
D. Employment Policies
The Company requires no particular educational or
experience levels for employees in any Department. (T.
28-29.) According to Operations Manager Tremonti, the
Company’s experience is that everyone is “learning on
the job.” (T. 154-55.) The Company has no apprenticeship
program, nor does it require any special technical school-
ing of any sort of any of its employees.
An attempt was made at the hearing in this case to
imply that the Company’s pressmen have certain
advanced skills. This contention does not square with the
facts of the Company’s operation and experience. Incredi-
bly, the Regional Director states that there is only one
trainee working in the Pressroom, while the unchallenged
326
testimony at the hearing was that, at present, eight of the
eleven pressmen are actually trainees who, like the Com-
pany’s other employees, are learning on the job. (T.
153-54.) Pressmen have no particular prior educational
experience requirements and, as mentioned above, are
typically drawn from the ranks of the unskilled joggers.
In actuality, the truck drivers are at least required to have
a chauffeur’s license, and some of the material handlers
have come with a forklift license. (T. 76-77, 93-84.)
Pressmen are given an operating manual prepared by
the manufacturer of the press. (Petitioner's Ex. 1.) Other
employees in the Pre-Press Department have similar
operating manuals for the equipment they use, and the
truck drivers are furnished special rules and regulations
applicable to them. (T. 91-92, 136.) There is no further
evidence of any special expertise required of the press-
men.
The Regional Director failed to even consider the
many similarities in wages, hours and working condi-
tions shared by Press Department and other employees.
All employees of the Company, with the exception of top
management, are hourly employees. (T. 53.) They all
punch the same time clock. (T. 40.) The hourly rates for
the various departments are largely consistent.
327
Maintenance Department $4.50 - $10.00
Shipping/Receiving Department $4.90 - $ 9.00
Composition Department $6.05 - $ 7.50
Pre-Press Department $4.90 - $ 9.50
Press Department $3.85 - $ 9.00
(T. 44, 143-52.) Employees in the Pre-Press, Maintenance
and Shipping /Receiving Departments all work basic shift
schedules on a two-to-three shift arrangement. (T. 46-50.)
Particular days off in the week may vary a bit from week
to week among all the departments, depending upon
workloads and the nature of the projects.
Employees in all the departments are subject to the
same employment policies and receive the same fringe
benefits - a fact overlooked by the Regional Director.
They are subject to the same disciplinary rules and pro-
cedures, including rules on absenteeism, smoking, tele-
phone calls, solicitation and security. (Employer's Ex. 2;
T. 50-51, 54-56.) They all enjoy the same vacation, life
insurance and health insurance benefits. (T. 51-53.) They
are subject to the same overtime assignment and compen-
sation programs. (T. 54.) They all receive the same shift
premium. (T. 159-60.)
E. Employee Facilities
In describing the physical layout of the Employer's
facility, the Regional Director ignores the fact that the
center of the Employer’s plant is the Pressroom where the
pressmen and joggers work for the bulk of their workday,
and where employees in several other Departments are
taken in the performance of their duties, as noted above.
(Jt. Ex. 1.) Adjacent to the Pressroom are the Pre-Press
328
Department, the Shipping/ Receiving Department and the
maintenance office.
All employees have an additional reason to be in the
Pressroom other than the performance of customary job
duties. The time clock is located there, which is punched
by everyone. (T. 39.) The plant includes a cafeteria and
there is a picnic table in front of the plant for use by the
employees. These facilities are used by employees in all
the departments in issue here, as only the office clerical
employees rarely use the cafeteria and picnic table facili-
ties. (T. 43, 118-19.)
The Press Department employees that the Union
seeks to include in its unit use a locker room in the
Pressroom. This same locker room is used by employees
in the Maintenance and Shipping/ Receiving Departments
that the Union seeks to exclude. (T. 167.) The Regional
Director mentions that pressmen are not permitted to
enter the front office because they are covered with ink,
but fails to mention that they share locker facilities with
other employees.
Press Department employees report to the Pre-Press
Department to pick up their plates as jobs are performed.
In addition, they have occasion to enter the Pre-Press area
when problems arise during press runs, for example, the
registration is not correct or the plate is not properly
fitting on the press. (T. 110, 156.)
Ill. LAW AND DISCUSSION
The facts presented at the hearing in this case show
that the Employer operates what is essentially a single-
a
329
product operation. Outside its office staff, all employees
are a functionally integral part of the production process,
and the single “product” produced by the Employer is
passed systematically through all the departments in
issue in this‘ case.
Although the Company’s production and mainte-
nance employees number some 45, its supervisory staff in
the production and maintenance areas is limited to only
three persons. As a result, all production and mainte-
nance employees share common supervisors, Operations
Manager Tremonti and Plant Superintendent Skwiera.
Hiring standards are the same for all employees, and
no particular education, training or experience is
required in any department. Different departments have
different skills, but employees in all departments are
essentially trained on the job.
All employees are hourly employees who punch a
time clock. The hourly rates in all the departments are
remarkably consistent. All work staggered shift schedules
that are largely dependent upon the particular projects
for the week.
Employment policies and disciplinary rules are uni-
form for employees in all departments. They are all pro-
vided identical fringe benefits. All the production and
maintenance employees use the same cafeteria and picnic
table.
The Pre-Press employees the Union originally sought
to represent share locker facilities with the Composition
employees the Union does not seek to represent. The
Press employees the Union seeks to represent share
330
locker room facilities with the Maintenance and Ship-
ping/Receiving employees the Union does not seek to
represent.
Finally, apart from the nearly uniform conditions of
employment that all employees share, the evidence is
clear that there is an extremely significant degree of
contact among the various departments. The Pressroom is
the focal point of most of the activity, and the Mainte-
nance and Shipping/Receiving employees spend time
there with the pressmen and joggers. There must be a
great deal of ongoing communication between the var-
ious departments as the project proceeds to completion,
with the Composition, Pre-Press and Press Departments
working closely together to make sure that the product is
correct, and the Shipping/ Receiving Department working
closely with the Press Department to keep it supplied
with paper and keep the product removed as the contin-
uous-shift press operation runs. The Maintenance Depart-
ment must be constantly available to maintain
cleanliness, which is important in the production of
newspaper copy that must be clean and readable, and to
assure that the presses continue to function. Overall quar-
terbacking of the operation is left to the Composition
Department.
In analogous relatively simple, single-product offset
printing operations, the Board has determined that the
only appropriate bargaining unit is a typical production
and maintenance unit. In Check Printers, Inc., 203 N.L.R.B.
1017, 83 L.R.R.M. (BNA) 1540 (1973), the employer was
primarily engaged in printing personal checks and
deposit slips for customers of local banks. It utilized an
7 eee
331
offset printing process, utilizing Web and Harris offset
presses.
The employer’s practice was to hire “employees for
its press department with a high school education, with-
out commercial printing experience.” The new hires par-
ticipated in a 24-month state-approved training program,
but were generally “able to acquire an acceptable skill
level for press work in two or three months.” The Board
noted that “[a]ll production employees punched the same
time clock, used the same facilities, and are under the
supervision of the general manager in charge of manufac-
turing.” The Board noted that the pressmen were “gener-
ally paid the same as other machine operators.” In
addition, “[a]ll employees share the same holiday and
vacation benefits.” 83 L.R.R.M. (BNA) at 1540-41.
After reviewing this evidence, the Board held:
“Contrary to the Regional Director, we con-
clude that the letterpress and offset pressmen
here involved, because of their specialized skills
and the fact that they are engaged mainly in
relatively simple, repetitive operations, do not
constitute the type of printing employees the
Board has found to be an appropriate separate
unit in commercial printing establishments as a
combination of letterpress and lithographic pro-
duction employees. We find, therefore, that the
requested unit is inappropriate... . ” 83
L.R.R.M. (BNA) at 1541.
In accordance with this reasoning, the Board concluded
that the unit requested by the union composed of only
pressmen was inappropriate, and that the appropriate
unit should be all production and maintenance
332
employees excluding office clerical employees, guards
and supervisors.
The Regional Director attempts to distinguish Check
Printers on the basis that the pressmen in that case were
able to function as such in some two to three months,
while the pressmen here supposedly remain trainees for a
period of three years. What the Regional Director conve-
niently fails to mention, though, is that eight of eleven
pressmen here are called trainees but presentiy serve as
pressmen and are able to function in that job, just like the
pressmen in Check Printers. The rule developed by the
Board in Check Printers is that when pressmen work in a
relatively simple, single-product operation and are able
to do their work without lengthy apprenticeship periods
and high skill levels and enjoy wages, benefits and work-
ing conditions similar to other employees — the exact
situation presented here — such pressmen do not warrant
inclusion in a separate craft unit, but, rather, should be
joined in a unit with other employees who participate in
the production process.
Similarly, in Texas Color Printers, Inc., 210 N.L.R.B. 30,
86 L.R.R.M. (BNA) 1089 (1974), the Board refused in a
commercial printing operation to carve out a unit com-
posed of only shipping and receiving employees. The
employer was engaged in the offset printing business,
and its products included catalogs, Time magazine and
other commercial printing products. It divided its plant
operations into five departments: Preparation, Press,
Bindery, Maintenance and Shipping and Receiving. A
group superintendent provided overall supervision to all
plant employees, although the shipping and receiving
ee
333
department was under the immediate supervision of a
warehouse foreman.
The Board noted that “|t]he shipping and receiving
department employees perform functions closely inte-
grated with plant operations,” pointing out that the ship-
ping and receiving employees “haul trash from the plant,
make local deliveries, and pick up raw materials, supplies
and equipment, as needed.” 86 L.R.R.M. (BNA) at 1090.
The Board pointed out that the shipping and receiving
employees spent a good deal of time in the press area
moving materials and cleaning, and that some shipping
and receiving employees substituted for joggers on an
occasional basis, as is the case here. The Board noted that
“[t}here are frequent contacts between the requested
employees and other employees in the plant.” 86
L.R.R.M. (BNA) at 1090.
The Board also emphasized:
“All plant employees punch the same
timeclock [sic] and share the same shift hours,
job benefits and working conditions. All enjoy
the same convenience facilities, such as the
lunchroom, parking area, restrooms, etc.” Id.
In view of the extensive contact and communication
among all employees and the similarity of working condi-
tions and benefits, the Board held that carving out a
subsection of the printing operation would not be appro-
priate:
“Here, in view of the frequent work con-
tacts and temporary interchange and overlap-
ping supervision of employees of the shipping
and receiving and bindery departments, and in
the absence of any bargaining history as to any
334
uf the plant employees, we find that the ship-
ping and receiving department employees do
not enjoy a sufficiently distinct community of
interest to warrant their establishment as a sepa-
rate appropriute [sic] unit apart from other
employees. Accordingly, we find the requested
unit to be inappropriate.”
See, also: W. F. Hall Printing Co. v. NLRB, 540 F.2d 873 (7th
Cir. 1976) (in offset printing operation, Court confirms
Board’s conclusion that bargaining unit should not be
limited to pressmen alone, but, rather, should include
pressmen, helpers, packers, stock handlers, Overlay and
Pre-make Ready employees).
These decisions by the Board confirmed that, in rela-
tively simple printing operations where pressmen are
performing repetitive functions with little or no training
or expertise, it is not appropriate to carve out a separate
unit for those pressmen. Instead, when such pressmen are
similar to all other employees in terms of prior education,
training and experience, in terms of supervision, in terms
of compensation and fringe benefits and do not represent
a homogeneous unit that performs a separate function, it
does not serve the purposes of the National Labor Rela-
tions Act to encourage stable labor relations to establish a
separate unit for the pressmen.
In this case, like the Board’s decisions discussed
above, all production and maintenance employees very
clearly share a community of interest. They are part of a
single-product, highly-integrated operation that calls for
constant interaction backward and forward as the prod-
uct moves to completion. They share common supervi-
sion and nearly identical wage structures and exactly
a
335
identical employee policies and fringe benefits. The only
appropriate bargaining unit in a case such as this is a
production and maintenance unit, which includes all the
employees in issue here who work together under vir-
tually identical conditions to produce the same product.
The Regional Director places primary reliance upon
the Board’s decision in Continental Web Press, Inc., 262
N.L.R.B. 1395, 110 L.R.R.M. (BNA) 1451 (1982). In that
case, the Board considered a situation much different
than that presented here. The commercial printing opera-
tion under consideration in Continental Web Press was a
sophisticated commercial printing operation where press-
men participated in an apprenticeship program in which
an employee moved over a period of time from being a
helper to a feeder to a second pressman to a first press-
man. The evidence disclosed that the pressmen never left
the pressroom even if corrections to the printing plate
were required, while the evidence in this case is that,
when corrections are necessary, the pressmen work in the
Pre-Press Department with employees there to make the
corrections. The Board concluded in Continental Web Press
that there was very little contact between the pressmen
and employees in other departments, which is not the
case here. Finally, the pressmen in that case had their own
locker room, their own employee handbook, and their
own wages and other conditions of employment.
Continental Web Press, decided subsequent to Check
Printers, did not overrule or comment upon the earlier
decision. No comment was, though, necessary because
the two cases consider different printing operations. Con-
tinental Web Press considered a sophisticated, highly-
skilled printing operation, while Check Printers sets forth
336
the rule in a case such as this in which pressmen assume
their duties with little prior skill or training and then
work in a single-product, integrated printing operation
under supervision and conditions similar to all other
employees. Under the Board's analysis in Check Printers,
which governs this case, all departments in the
Employer's operation in this case should be included in
the same bargaining unit, and there is no basis to carve
out a separate unit for the Press Department alone.
|
IV. CONCLUSION
For the foregoing reasons, the Employer submits that
all the Company’s production and maintenance
employees share a defined community of interest and
should be included in the same unit. For these reasons,
the Employer would submit that the Regional Director
substantially erred in isolating a unit consisting of only
the Press Department employees.
The Regional Director’s conclusion is incorrect and
the criteria for review by the Board prescribed by Section
102.67(c) are met. The Employer’s request for review
should be granted and the Regional Director’s Decision
and Direction of Election should be stayed pending the
result of such review.
Respectfully submitted,
SHUMAKER, LOOP &
KENDRICK
/s/ Timothy C. McCarthy
Timothy C. McCarthy
337
North Courthouse Square
1000 Jackson
Toledo, Ohio 43624-1573
(419) 241-9000
Attorneys for Employer
CERTIFICATE OF SERVICE
This is to certify that eight (8) copies of the foregoing
Request for Review and Stay of Regional Director’s Deci-
sion and Direction of Election were delivered to Federal
Express Courier Service for next day delivery to the
Executive Secretary, National Labor Relations Board, 1717
Pennsylvania Avenue, N.W., Washington, DC 20570, and
that one (1) copy each of same was served, by United
States Mail, upon Frederick J. Calatrello, Regional Direc-
tor, National Labor Relations Board, Region 8, 1695
Anthony J. Celebrezze Federal Building, 1240 East Ninth
Street, Cleveland, Ohio 44199, and Roger J. McClow,
Esquire, Klimist, McKnight, Sale & McClow, P.C., 26211
Central Park Boulevard, Suite 614, Southfield, Michigan
48076, this Ist day of September, 1987.
SHUMAKER, LOOP &
KENDRICK
/s/ Timothy C. McCarthy
Timothy C. McCarthy
Attorneys for Employer
338
NLRB-750
(5-1-45)
UNITED STATES OF AMERICA
NATIONAL LABOR RELATIONS BOARD
CERTIFICATION ON CONDUCT OF ELECTION
Name of employer NTA GRAPHICS, INCORPORATED
Case No. 8-RC-13648
Date of election September 25, 1987
Place Toledo, Ohio
The undersigned acted as agents of the Regional
Director and as authorized observers, respectively, in the
conduct of the balloting at the above time and place.
WE HEREBY CERTIFY that such balloting was fairly
conducted, that all eligible voters were given an oppor-
tunity to vote their ballots in secret, and that the ballot
box was protected in the interest of a fair and secret vote.
For NTA GRAPHICS, For the Regional
INCORPORATED Director, Region 8
/s/ John F. Jackson /s/ Nancy Butler
339
For GRAPHIC - For
COMMUNICATIONS
INTERNATIONAL
UNION,
DETROIT /TOLEDO/
LANSING
LOCAL 289, AFL-CIO-CLC
/s/ Steven J. Lonchyna
340
UNITED STATES OF AMERICA
NATIONAL LABOR RELATIONS BOARD
FORM NLRB-4279 RC-RM-RD
(2-88)
NTA GRAPHICS,
INCORPORATED
Employer
CASE
8-RC-13648
and
GRAPHIC COMMUNICATIONS
INTERNATIONAL UNION,
DETROIT /TOLEDO/LANSING
LOCAL 289, AFL-CIO-CLC
Petitioner
Nm ee ee ee ee et et ee et ee”
TYPE OF ELECTION
XXX RD DIRECTED
)
(CHECK ONE) ) (ALSO CHECK
) BOX BELOW
CONSENT ae
STIPULATED ) APPROPRIATE)
: 8(b)(7)
)
BOARD DIRECTED
CERTIFICATION OF REPRESENTATIVE
An election has been conducted under the Board's
Rules and Regulations. The Tally of Ballots shows that a
collective-bargaining representative has been selected.
No timely objections have been filed.
—EEEEEEE———————
341
As authorized by the National Labor Relations Board,
it is certified that a majority of the valid ballots have been
cast for
GRAPHIC COMMUNICATIONS INTERNA-
TIONAL UNION, DETROIT/TOLEDO/LANS-
ING LOCAL 280, AFL-CIO-CLC
and that it is the exclusive collective-bargaining represen-
tative of the employees in the following appropriate unit.
UNIT: All full-time and regular part-time press room
employees employed by the Employer at its
Toledo, Ohio, facility, excluding all office clerical
employees and professional employees, guards
and supervisors as defined in
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