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RVOBI 3304H OFFSET

PRESS

SERVICE

MANUAL

Feb.'97

Copyright© 1996 Ryobi Limited. All rights reserved. This manual may not be duplicated, reproduced

or transmitted

or mechanical, mation

(including

(in whole or in part) in any form or by any means, electronic without

limitation

photocopy,

storage and retrieval system)without

facsimile,

the prior written

recording

consent

or any infor-

of Ryobi Limited.

Disclaimer of Warranties (Express or Implied). While due care has been taken in the preparation

of this manual, Ryobi Limited

of the adequacy

or accuracy

merchantability

or fitness

for any particular

right to revise this publication in nature) Limited

in the contents

to notify

interlock herein

purpose.

any person

or organization

disconnection

or other safety or protective poses an undue safety

death,

or

disconnection, safety

property

by

or

knowledge

and safety

is not intended

training

program

of general

electrical

and safety.

protective

cover, safety described

for personal

(1) the

removal,

cover, safety interlock,

or other

described

safety

contained

only to supple-

who already

procedures.

training

the

herein.

possess

This document

repair of the subject equipment technical

of the

or repairing

herein are designed technicians

herein, (2) the

or (3) the failure

and warnings

service

and mechanical a formal

of

herein or servicing

procedures

for skilled

completed

or liability out

by RYOBI Limited,

to be a guide for "Do it yourself"

who has not successfully

of Ryobi

part of the equipment

arising

described

Recommended Technical Training. The instructions full

guard,

part of the equipment

the equipment

all operating

ment a formalized

and insubstantial

or changes.

any responsibility

caused

use of any parts other than the parts supplied same to observe

of

reserves the

hazard.

comprising

person or persons operating

warranties

obligation

for your protection

of any safety

of any safety guard, protective

device

without

of such revisions

device comprising

damage

or alteration

or protective

(both substantial

have been installed

or alteration

with respect

any implied

Further, Ryobi Limited

and to make changes

Disclaimer of Liability. RYOBI Limited disclaims injury,

or warranties

disclaims

hereof from time to time hereafter

Safety Warning. Safety devices The removal,

makes no representation

hereof and specifically

course

by anyone

on the subject

equipment.

FCC Warning (FCC Rules apply to U.S.A. only,) This equipment device,

has been tested and found

pursuant

reasonable

protection

a commercial frequency

harmful This

interference

area is likely

to correct

interference

equipment

energy and, if not installed

may cause harmful be required

against

environment.

in a residential

to comply with the limits for a Class A digital

to part 15 of the FCC Rules. These

limits

generates,

uses

and used in accordance

to radio communications. to cause harmful

the interference

are designed

when the equipment and

to provide

is operated

can

radiate

with the instruction Operation

interference

in

radio manual,

of this equipment

in which

case the user will

without

the permission

at his own expense.

Warning 1.

This manual may not be copied

partially

or fully

of Ryobi. 2. 3.

The contents

of this manual are subject to change without

Use of this manual confidential

should

information.

be strictly

superised

any notification.

to avoid disclosure

of

OFFSET

PRESS

RYOBI 3304H I SERVICE

MANUAL

I

CONTENTS Chapter 1 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11

1-12

Checking the installation space .. ... .. .. ... ... . .. .. ... .. ... .. ... .. ... . .. . .. .. ... . ... .. .... .. .. ... .. .... ... . .. ... .. ... .. ... ... .. .. .. .. .... .. Connecting the machine ...................................................................................................... '....... ... . . ... .. Installing the connected type press ...................................................................................................... Machine leveling ... ..... .. .. .. .. .. . .... .. . ... .. .. ... .. .... ... . .. ... . .. . . .. ... . .. ... .. .. . . ... .. ... .. ..... . ... ... . ... .. ... .. .. . .. ... .. .. . ... .. .. .. . .. Machine wiring . .. .. ... .. .. .. . .. .. .. .... ... ... .. . .. .. .. .. ... .. . . ... .. .. .. . .. ... .. ... .. ... .. .. .. .. .. . .... ... .. .. ... .. ... . ... .. . .. .. .. . .. .. ... ... . ..... Mount the external devices and the delivery guide rails .... ......... ........... ....... ......... .......... ....... ........ .... .. Pump cleaning ...................................................................................................................................... Lubrication and breaking in................................................................................................................... Electrical section checking and adjustment . . .. . .. ... .. ... .. .... . .. ... ... . .. . .. .... . .. .. .. .. .. .. .. ... ... . .. .... . .. ... .. .. .. .. ... ..... Checking items when installing the machine ........................................................................................ Periodic checking list .. .. ... .. .. .. ... .. ... .. ... .. ... . ... ... .. ... . .. .. . ... ... .. .. ... .. .. ... .. . ... . .. .... .. . ... ... ... ... . .. . . .... ... ... ... . ... .. ... Checking the assembly of the dampening solution cooling/circulation device (option) ........................

Chapter 2 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16

2-17 2-18 2-19 2-20 2-21 2-22

Machine Installation Edition 9 11 21 22 23 24 26 28 29 39 40 44

Base Machine Section Adjustment

Timing chart .. .. ... .. . .. .. .. .. ... .. .. .. ... ... .. .. ... .. . .. .. .. .. . ... ... . ... .... . .. ... ... . .. . .. .. ... ... ... ... . . .. .. .. .. ... .. ... .. .. ...... .. . ... .. .. ... .. Adjustment gauge and special tools ................................................................................... ,.. .. .. .... .. .. .... Base machine drive belt tensioning adjustment.................................................................................... Pump belt tensioning adjustment.......................................................................................................... Setting the timing plate ......................................................................................................................... Positioning adjustment between the paper feed drum and the impression cylinder............................. Positioning adjustment between the CD grippers and the impression cylinder .................................... Positioning adjustment between the plate cylinder and the blanket cylinder (Alignment) .. .... .. ... . ... .. .. . Positioning adjustment between the impression cylinder and the blanket cylinder (Alignment) ........... Cylinder ON cam positioning adjustment .............................................................................................. Cylinder ON mechanism adjustment between the plate cylinder and the blanket cylinder ................... Cylinder ON mechanism adjustment between the blanket cylinder and the impression cylinder......... Clearance adjustment between the plate cylinder and the blanket cylinder .. ...... . ... .............. ... .. ..... .. .. . Clearance adjustment between the blanket cylinder and the impression cylinder .. .. .. .. .. .. ... ... . ... .. .. ... .. Side play adjustment of the blanket cylinder......................................................................................... Cylinder ON linkage adjustment between the plate cylinder and the blanket cylinder (the first unit to the fourth unit), and between the blanket cylinder and the impression cylinder (the first unit) ..... ... .. .. ... ... . ...... .... .... .. .. .. ... .. . .. .. .. . . ..... .. . .. ..... ... . .... ... .. . .. .. .. ... .. ... .. .. .. .. . .. .. .. .. .. . ... .... .. ... . .. .. . ... Cylinder ON linkage adjustment between the blanket cylinder and the impression cylinder (the second unit to the fourth unit) ........................................................... Cylinder gear coring adjustment ... .. .. .. .... . .. ... .. .. .. ... .. .. .. .. .. ... . ... . .. .. ... .. .. . .. . .. .. ... . .... ... .. ... .. .. .... .. .. .. .. .. ... .. .. . Paper feed drum gripper adjustment .................................................................................................... Adjustment of the first, second and third transfer drum grippers and the first and second impression cylinder grippers.......................................................................... Paper feed drum gripper timing adjustment.......................................................................................... First and third transfer drum gripper timing adjustment ........................................................................

49 50 51 52 53 54 56 57 59 61 63 65 67 69 71

73 75 77 79 82 86 87

2-23 2-24 2-25 2-26 2-27 2-28 2-29 2-30

Second transfer drum gripper timing adjustment.................................................................................. 88 Impression cylinder gripper timing adjustment...................................................................................... 89 Plate clamp adjustment......................................................................................................................... 90 Encoder O point adjustment . ... ... .. ... .. ... . ... .. .. ..... . .. .. ... ... .. ..... .. .. .. .... .. . .. ... .. ... .. .. .... .. .. ... .. .. .... .. .. .. ... .. . . .. .. .. . 92 Operation shaft cam positioning adjustment......................................................................................... 94 Operation shaft positioning adjustment ... ... .. ... .. .. .... .. . .. .. ... . ... .. .. ... .... .. . .. ... ... .. .... .. .. .. .... .. .... .. .. .. . .. ... ... .. .. 96 Adjustment of the operation shaft brake section................................................................................... 99 Proximity switch timing adjustment (Sheet travel jam detector) ............................................................ 100

Chapter 3 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 3-12 3-13 3-14 3-15 3-16 3-17

Paper guide height adjustment ............................................................................................................. Side play stopping adjustment of the upper feed roller and the lower feed roller ................................. Pressure adjustment of the upper feed roller ........................................................................................ Paper stop finger height adjustment ..................................................................................................... Adjustment of the paper feed cam ........................................................................................................ Elevating timing adjustment of the paper stop finger ............................................................................ Stop finger and upper feed roller clutch adjustment ............................................................................. Positining adjustment of the sheet separator and the side blower ........................................................ Suction feet adjustment ........................................................................................................................ Connection timing between the feeder and the base machine ............................................................. Adjustment of the suction vacuum cam ................................................................................................ Feed lever section latch adjustment ..................................................................................................... Paper pile table chain tensioning adjustment ....................................................................................... Paper pile table guide roller adjustment.. .............................................................................................. Paper pile table drive arm adjustment .................................................................................................. Adjustment of mechanical type double sheet detector ......................................................................... Push guide adjustment .........................................................................................................................

Chapter 4 4-1 4-2 4-3 4-4 4-5 4-6

Registration Mechanism Section 105 107 109 111 112 113 115 117 118 120 123 125 127 128 129 131 133

Delivery Section

CD chain tentioning adjustment ............................................................................................................ CD gripper pressure adjustment ........................................................................................................... CD gripper closing timing adjustment ................................................................................................... Adjustment of the delivery table dolly guide roller ................................................................................ Adjustment of the delivery table dolly lower limit switch ....................................................................... Adjustment of the delivery paper jam detector device ..........................................................................

137 138 140 141 142 143

Chapter 5 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13

Checking and adjusting the roller pressure ........................................................................................... Ink form roller pressure adjustment ...................................................................................................... Adjustment of the ink ductor roller ........................................................................................................ Ink ductor roller drive timing .................................................................................................................. Adjustment of the ink ductor stop mechanism ...................................................................................... Side play adjustment of the ink form roller and the water form roller .................................................... Water form roller pressure adjustment.. ................................................................................................ Adjustment of the water form roller OFF clearance .............................................................................. Pressure adjustment between the metering roller and the water fountain roller ................................... Pressure adjustment between the metering roller and the water oscillating roller ................................ Parallel pressure adjustment between the bridge roller (water section cleaning roller) and the water oscillating roller .............................................................. Adjustment of the water roller cleaning lever limit switch ...................................................................... Water control wiper pressure adjustment .............................................................................................

Chapter 6 6-1 6-2 6-3 6-4 6-5 6-6

147 148 151 153 155 157 158 160 161 163 165 166 168

Blanket Cleaning Section

Roller pressure adjustment of the blanket cleaning device (The first and the third units) .................... Roller pressure adjustment of the blanket cleaning device (The second and the fourth units) ............ Positioning adjustment of the blanket cleaning solenoid ...................................................................... Spring pressure adjustment of the blanket cleaning operating lever .................................................... Pressure adjustment between the blanket cleaning roller and the blanket.. ......................................... Height adjustment of the blanket cleaning bottle ............................................. :....................................

Chapter 7 7-1 7-2

Ink and Water Section

171 172 173 174 175 177

PCS-F Adjustment

O point adjustment of the ink fountain key (When the machine has the PCS-F installed.) ................... 181 Disassembling and assembling the ink fountain ................................................................................... 183

Chapter 1 Machine Installation I

1-1

1-1 A.

Checking the installation space

Installation space • Indicate the machine dimensions. • There should be enough space between the wall and the machine to allow operation and maintenance. • Check the entrance that the machine is installed in.

Division [Unit:

mm]

[Unit:

mm]

[Unit:

mm]

Installation

D[f

I

1,000 I

I !

---710____..;

1, 130,.._,1

Work Space

about

9

1-1 Checking the installation space ~~~~~~~~~~~~~~~~~~~~~~~~~~-

B.

Machine installation place The foundation construction should be done by a specialist.

Floor load resistance per square meter is to be 850kg or more.

C.

When setting the oil pan

Non operation side

Operation side

10

1-2

1-2 A.

Connecting the machine

Connecting the machine

Purpose Connecting the firsVsecond unit with the third/fourth unit after segment installation.

B. Point

0

[Point 2]

[Point 1] The gear mark on the second transfer drum should be aligned with the gear mark of the third transfer drum.

C.

When connecting the first/second unit with the third/fourth unit, the A surfaces should be in contact.

Connecting procedures

Operation side

1)

Put the first/second unit at the installation position and position the oil pan.

Remove the protection cover of the second transfer drum gear and the base machine covers identified by the dotted lines in the illustration. (Operation side, Non operation side) (Note) The protection cover of the second transfer drum should be fixed using the 4 fixing bolts (1 ). Also this cover should not be used after the connection is completed. 2)

11

1-2

Connecting the machine

0~

3)

Set the height of the first/second unit bed to be parallel and 30mm or more above the oil pan.

4)

Slide the third/fourth unit by using a hydraulic pallet truck toward the first/second unit.

(Note) 1. At this time, the A surface should not be in contact. 2. The second transfer drum gear should not contact the third transfer drum gear.

(Reference) Hydraulic pallet truck

When not having a hydraulic pallet truck available

Round poles

Prepare a hydraulic pallet truck with a lifting capacity of 1.5 tons and width of 440mm for the connecting the machine.

Position the third/fourth unit on 025x1 ,OOOmmround poles to move it. At this time, the installation of the oil pan should be done after jacking up the base machine after the connection.

(Note) 1. At this time, the jack bolts on the feeder section should be released completely. 2. Before connecting, wipe off the anti-corrosion oil and dust which adhere on the connection surfaces of the base machine frame and the bed completely.

12

5)

Rotate the machine manually and stop at the position where the second transfer drum gear mark is aligned with the third transfer drum gear mark.

1-2

6)

Shift the third/fourth unit by using a crowbar and stop the unit just before it contacts with the bed frame B side.

8)

Remove the first and the second unit impression cylinder safety cover stopper on the non operation side.

9)

Lower the first/second unit without contacting the A side and do the leveling adjustment of the first/second unit in this condition. (Within 0.05mm)

Connecting the machine

7)

When the first/second unit frame lateral position is not aligned with the third/fourth unit frame, shift the third/fourth unit by the crowbar to align them.

10)

Do the leveling adjustment of the third/fourth unit. (Rough adjustment within 0.1 mm)

(1)

11)

Put the level on the second transfer drum frame and check the level of the machine.

12)

Slowly raise the third/fourth unit parallel and stop at the position where the level degree of the second transfer drum changes.

(Reference) [Positioning of the level] *On the ink fountain roller ................................................ (1) *On the frame (Operation side, Non operation side) ........ (2)(3)

13)

Do the leveling adjustment of the third/fourth unit at this point. (Micro adjustment within 0.05mm) (Note) At this time, do not change the level on the second transfer drum.

(Note) 1. The place where the level is put should be wiped off all oil and foreign particles. 2. After adjusting the leveling, apply the anti-corrosion oil at the level setting position.

13

1-2

14)

Insert the spacer between the units.

15)

(Operation side, Non operation side) (Note) Please be careful as there are different spacers for the operation side and the non operation side.

17)

Tighten the 3 connecting of the bed section.

bolts

Check that the 3 connecting bolts of the main frame are inserted properly.

16)

(Operation side, Non operation side)

(Operation side, Non operation side)

(Note) When the connecting bolt cannot be inserted, change the height of the first/second unit and the height of the third/fourth unit and then align the hole position of both units.

18)

Tighten the 6 fixing bolts of the bed section connecting plate.

(Operation side, Non operation side)

(Operation side, Non operation side)

First tighten the 6 fixing bolts of the bed section connecting plate and after completing the lateral positioning loosen them again.

19)

Tighten the 3 connecting of the main frame.

bolts

(Operation side, Non operation side)

(Reference)

~

Connecting plate of the main frame --Connecting plate of • the bed section

20)

Mount the 2 connecting plates of the main frame and tighten the 6 fixing bolts.

(Operation side, Non operation side)

14

There are a total of 6 connecting plates, 3 on the operation side and 3 on the non operation side.

(1)

Align the main frame connecting plate hole (1) in the center of the non operation side with the gripper closing cam fixing screw of the second transfer drum (2) and then mount the connecting plate.

1-2

D.

Piping

1)

Mount the third unit operation panel.

2)

Mount the lubrication pipe on the operation side.

3)

Connecting the machine

Mount the lubrication pipe on the non operation side.

Adjustment line

4)

Mount the water pipes (1 ), (2), (3) on the non operation side.

5)

Align the operation lever links at the adjustment line and then mount them so that the link joint is on the same straight line.

15

1-2

Connecting the machine

E.

Electric wiring

a.

Position of the control box

Main control box

b

PCS-F control box

Non operation side

b.

Wiring from the third and the fourth units to the main control box Connect the diagonal line section shown in the illustration

Sensor AMP board

0

Continuous dampening system control board

···

Relay board

l

[Resting connector]

100001 !MC41

16

!

DOO

ooa Doo

!MC43!

1/D board

1-2

[1/D board]

[Relay board]

[Sensor AMP board]

Connecting the machine

[Continuous dampening system control board]

·O

17

1-2

Connecting the machine

1)

Connect the MC connectors.

1/D board

Relay board Resting connector

4)

3)

Connect the blanket jam detector sensor connectors. Sensor AMP board

CIS5, CIS6

MC34, MC37, MC38 MC41, MC43

section

NH111, VH113 VH114, VH115 VH116, VH117 VH118

Connect the timing wiring for the powder spray device.

\ Relay board \

Connect the flat cables.

MC12, MC13 MC15, MC16 MC18, MC19 MC27(CE only) MC29

Connect the water connectors.

Continuous dampening system control board

7)

MC11, MC14, MC17, MC26, MC28,

2)

87 A, 52

5)

Connect the connectors.

\ Relay board \

8)

water

motor

VH13, VH14

Bundle the cords together using the fastening straps.

by

6)

Connect the encoder connector.

1-2

c.

Connecting the machine

Wiring to the PCS-F control box from the first and second units

u

CN16

u

CN15

D.,

c:::::===J"

1)

Connect the connectors (CN15, CN16) and wine the cords (8, 2, PE) and then bundle the cords together by using the fastening straps.

d.

Wiring the connector (LS60) at the operation side

1)

Connect the connector (LS60) .

19

1-2

Connecting the machine

e.

Other wiring

e u~p Single phase

1)

Route the hose to the static eliminator. U3

PE~E

t 2)

20

I

V3

From the first 1 and second unit bed.

Wire the delivery side pump. [Wiring number] · Three phase : U3, V3, W3, PE ' Single phase : U3, V3, PE

U3

1-3

Installing the connected type press

1-3 A.

Installing the connected type press

When jacking up

(2)

(1) 0

0

0

0

...

0

0

B

A

Pass the round pole through the bed frame holes (1 ), (2) and jack the round (Reference) pole up. Required round pole size 050 x1 ,350mm 4 jacks (with over 2 tons capacity) are needed. Position of the jack bolt ( •

Mark) [Unit:

198

-93-,

961

n

1,04s

mm]

290

r 5 16 c: '

!

-

Q

J

(Note) 1. The bed is connected at the A section and the B section. Therefore do not jack up at the diagonal line section on the feeder side. 2. Jack up the machine evenly by using the holes (1) and (2).

(Reference) For the position of the oil pans please see the item "1-1 Checking the installation space" on page 9.

21

1-4

Machine leveling

1-4 A.

Machine leveling

Purpose To remove any overload on each machine section by keeping the machine level.

B.

Point The level that is used should have an accuracy of 0.05mm per one meter. The level that is used should have an accuracy of 0.02mm per one meter. Using the level, check the machine leveling accuracy at the 4 places shown in the illustration. On the fourth unit ink fountain roller ...................... (1) On the frame of the second impression cylinder ... (2), (3) On the second unit ink fountain roller ................... (4) (2) Operation side (3) Non operation side (1)

C.

(4)

Adjustment procedures 1)

2)

3)

A

22

B

C

D

E

Adjust the level of (1 ), (2), (3), and (4) by using the 4 bolts at the A, D (Operation side, Non operation side). Adjust so that the load is equally on the bolts B and C. At this time, please be careful not to change the leveling of the base machine section. Fix the feeder section by using the bolts E.

(Note) 1. After adjusting the level, apply the anticorrosion oil at the level setting position (frame). 2. The place where the level is put should be wiped off all oil and foreign particles.

,-5

1-5 A.

Machine

Machine wiring

Power source wiring A 3 phase power source of 200V 14A or a single phase power source of 208V 24A is required. For the machine with a transformer, use a cord with the specifications below as the cord between the power source and the transformer. Sectional area : Over 5.5mm 2 Length : Less than 1Om

* *

Transformer

Primary side tap