# Joint Appendix vol II — NTA Graphics, Inc. v. National Labor Relations Board > Briefs, arguments, decisions, and more. URL: https://www.frixlaw.com/law-library/documents/brief%3Amicro_IA40385017_1184%3A4 ## Record - **Collection:** Supreme Court brief - **Document type:** Joint Appendix vol II - **Published:** January 1, 1994 - **Citation:** 511 U.S. 1124 ## Text } Supreme ‘ny rm} , : i r j . a." & i 7. : f} 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 ne de BAD TM le. ete. ee 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. i it ls eae wiles Bog NE 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. [Naik Shc aes Pek ies Qed” aA alee a 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. cidade OOS SSAA ais Dialed alas ae inna once Sl adie Rul ideas GADUNER pao cons Rises Seabee ainda glee 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 - | - : : © Sete anhecte ee aT 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 - IMPO [Text truncated at 120,000 characters. The full text is on the page linked above.] --- Source: Frix Law Library, https://www.frixlaw.com/law-library/documents/brief%3Amicro_IA40385017_1184%3A4. Public record. Not legal advice.