Aggregates: Service Training Mechanik

Service Training Mechanik

13
Aggregates
Page
1 Lubricants:.................................................................................................3
2 Lubrication:................................................................................................4
3 Oil supply, R 700:.......................................................................................5
4 Changing and cleaning oil filters:.............................................................6
5 Filling and pumping out machine oil: .......................................................7
6 32 bar oil circuit:........................................................................................8
7 Central lubrication pump LA 8 (up to series 720): ...................................9
8 Modular lubrication (from series 721):....................................................10
9 Magnetic dosage pump (from series 721): .............................................11
10 Basic setting values for the magnetic dosage pump:............................12
11 Function and switching of the magnetic dosage pump: .......................13
12 Air supply: ...............................................................................................14
13 Air supply diagram: .................................................................................15
14 Pneumatics: .............................................................................................16
15 Settings and dimensions: .......................................................................17
16 Compressed air connections:.................................................................18
17 Connections from distributor block to the valve blocks........................19
18 Assignment of the pneumatic valves: ....................................................20
19 Assignment of valve blocks (perfecting presses only): ........................21
20 Valve blocks (up to series 725): ..............................................................22
21 Valve blocks (as from series 726):..........................................................23
22 Fountain solution supply: .......................................................................24
Data Base Documentation 1

© MAN Roland Druckmaschinen AG - Offenbach

13
2 Data Base Documentation


13
1 Lubricants:
Non-ageing mineral oil with high lubricating film fastness, good surface moistening properties, water-repellent,
favourable foaming behaviour, very high pressure resistance, neutral against non-ferrous metals and dense
materials, with corrosion protection.
Lubricants designation:
H-LP 68 DIN 51.525

ISO VG 68 DIN 51.519
VI 95 ISO 3448
FZG Test A/8, 3/90 DIN 51.534
Working temperature: 0 – 100° C
Hydraulic symbols for oil circuit:
M
Oil pump Drip tray Container with Distributor
level control
Drip plate Filter Pressure monitor

S= Suction filter
Joint
D= pressure filter
Tube connector
Hose with Cap Overflow valve

flow direction data T - pipe connector
R7k13_00
Lubricants table:
The lubricants table is included in the maintenance manual.


13
2 Lubrication:
Since correct lubrication of the press is an essential part of the warranty conditions and also makes a major
contribution to trouble-free running, special attention must be paid to this.
Only oil and grease approved by MAN Roland, for which lists are available, should be used.
The maintenance manual which is provided with every press describes the greasing intervals as well as how often
the oil should be changed.
Here are a few basic rules:
1. The oil changing frequency and intervals between greasing specified in the maintenance manual are based on
8 operating hours per day. If actual operating time exceeds this, then the intervals between greasing shorten
accordingly.
2. The first oil change should be done 200 operating hours after the press is commissioned and this is to be
confirmed to MAN Roland using the oil change card enclosed with the maintenance manual. After this, the oil
should be changed once a year.
3. 20% LA1 is to be added to the oil. (Not with high-pressure oils)
4. Each grease nipple is colour coded which indicates the greasing intervals.
Red = daily
Blue = weekly
Yellow = monthly
Grease nipples with no colour marking are to be greased every three months.
Oil circulation lubrication:
The oil circulation lubrication system is equipped with pressure controllers that trigger a fault message at the control
console when the oil pressure is too low. When this happens, the oil filters must be cleaned or replaced or other
possible causes should be looked for (not enough oil, oil pump defective, etc.).
The R 700 has central oil filling.

An oil observation glass at the oil tank at the A-side of printing unit 1 serves for the entire press.
All gearboxes have a separate observation glass and stop-cocks that must be closed when the press is running.
The stop-cocks are only opened for oil changing or repairs. Each printing unit has an oil pan (A-side) that can
collect around 30 litres of oil. These oil pans are linked by pipes which are screwed together during press
installation.


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3 Oil supply, R 700:
11
1
3 DW 1
2
10
4
DW2
5 DW3
6
DW4
8
R7k13_01
7


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4 Changing and cleaning oil filters:
The R 700 uses two different oil filters. The DRG 100 suction filter (permeability 100 l) can be washed out ten
times. The MIC 10 pressure filter (permeability 10 l) can be used once only.
To change filters, press the ”Emergency stop” button which switches all oil pumps off.
Then screw off cartridges (1) and (2).
IMPORTANT: Pay attention to where the suction and pressure filters are located. The pressure filter hose is the
upper connection of the oil pump (P) and the suction filter hose is the lower connection (S) of the oil
pump (see diagram). Change or wash out the filters and put them back. Release the ”Emergency
stop” button. An acoustic signal sounds when the oil filters are clogged.
1 2
3
5
R7k13_02
Pressure filter:
The pressure filter is a paper filter without a bypass. It cleans the oil before it enters the press and protects against
wear caused by contaminated oil.
This filter is comprised of a filter head with differential pressure control, a filter cone and a replaceable filter
element.
The filter head is provided with two fastening holes and connections for inlet and outlet.
The flow direction is indicated by an oil-proof marking.
The filter cone can be dismounted downwards without tools in order to cahnge the filter element.
The filter element must be changed if the set differential pressure is exceeded.
Exceeded differential pressure is indicated at the control console.


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5 Filling and pumping out machine oil:
To fill or pump out machine oil, the hose (2) must be plugged onto the sleeve (1). The oil pump can be activated for
filling or pumping out from the control console. Remove the hose when done.
R7k13_03
st
Check the observation glass when filling is completed. The glass is located at the 1 printing unit
underneath the gearbox.
R7k13_04


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6 32 bar oil circuit:
A high-pressure connection hose for greasing the outer bearings of the blanket and plate cylinders is mounted on
the B-side. This oil line must be bled of air before the press is commissioned.
The air bleed cock sits on the highest point above the water fountain roller drive at the B-side of the last printing
unit.
To bleed the air, the valve needs to be electrically reversed. Turn the air bleed cock until oil flows bubble-free
through the line. Then close the cock again. To fill the oil lines (1) and (2), take off the union nuts (3) and fill the
lines with an oil can until oil emerges at the top of the bearing.
Plug in the oil lines and put the union nuts back on.
When the valve opens and the oil pressure of 32 bar ís not reached, an acoustic signal sounds and the press stops
immediately.
The first oil thrust is activated automatically 15 minutes after the press is switched on, then every 20,000 sheets
(only with impression on).
The 32 bar oil pressure builds up in the oil pump of printing unit 1 for 2-3 seconds, after this the oil circuit returns to
normal.
7
1 2
4
5 6
8 R7k13_05
One-way valve:
The numbers on the one-way valves indicate the rate of flow. The higher the number, the more oil is flowing
through the line.
Blanket cylinder oil line (one-way valve no. 5)
Plate cylinder oil line (one-way valve no. 1)


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7 Central lubrication pump LA 8 (up to series 720):
PU1
PU2
PU3
1
PU4
2
PU5
R7k13_06
Before they are connected to the central lubrication pump, all lubrication lines must be filled manually with a grease
gun until the grease can be seen emerging from the line.
!
Central lubrication pump (LA8) lubricates all gripper opening cams and the delivery chains. The volume can be
regulated for every line by the setting screw (2) on the grease pump. If there is not not enough LA8 in the grease
pump container, this is indicated by an error message on the monitor. The press will only start after the grease
container (1) has been refilled. The lubrication intervals can be altered via the control console (machine –
configuration).
Configuration adjustments:
Insert the diskette and select main menu

GENERAL
Press SERVICE (F2)
Call up the desired menu using the

overdamp keys (Press setting 1).
Press setting 1:
Counter for chain greasing Timer for chain greasing
Standard value Standard value

Up to 200 operating hours: 10000 Up to 200 operating hours: 120 s
After 200 operating hours: 15000 After 200 operating hours: 60 s
Setting range 4000 – 20000 Setting range 60 – 120 s


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8 Modular lubrication (from series 721):
Modular lubrication includes lubrication of the gripper cams and the delivery chains.
Cam lubrication looks after the cams of the
gripper control
infeed drum
impression cylinder
delivery drum and
the control cams of the frontlays and cover lays
Every printing unit has its own oil container with a magnetic dosage pump. Each magnetic dosage pump is a
combined pump and valve unit that moves the pump piston one time when the solenoid is triggered.
These pumps can be provided with either 2 or 3 dosage pistons. The working process is in each case monitored by
a stroke monitor (-B129) at the pump pistons. The level in the oil container is also monitored (-B130).
At the printing units (+BA,+C*,+DA) are
♦ the level monitor (-B130) at input: -A350/4, Byte 4, Bit 7 ;

♦ the stroke magnets (-B129) at input: -A350/7, Byte 10, Bit 6.
At the delivery (+EA) are

♦ the level monitor (-B130) at input: -A353/7, Byte 10, Bit 4 ;
♦ the stroke magnet (-B129) at input: -A353/7, Byte 10, Bit 1.
!
ATTENTION: No repairs can be made to the magnetic dosage pumps. If they are defective they
must be completely replaced. When ordering new pumps, be sure to specify the right connection
(2 or 3)!
ATTENTION: When assembling the pumps, the hoses and pipes must be pre-filled !
The lubrication interval can be set individually for each pump from the control console.


13
9 Magnetic dosage pump (from series 721):
3 2
R7k13_06
1. Level control ”ARAL DE22 oil is used as buffer medium for the front
2. Magnet space of the magnet.
3. Stroke monitor
Lubricants:
The lubricant must be temperature-stable, capable of bearing heavy loads, extremely adhesive, solvent-free and
bitumen-free.
It must be capable of being conveyed by the magnetic dosage pump.
Viscosity max. 30000cST/20°C, min. 200Cst/100°C
VKA value DIN 51.350
Working temperature: 10 – 120°C
The following lubricants meet these requirements:
EKALUB LA 8 the Chemie – Technik company

Struktovis BHG the Kluber Lubrikation company
Viskogen KL the Optimal Ölwerke company


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10 Basic setting values for the magnetic dosage pump:
Before the press is commissioned, the ”basic setting values” must be checked and altered if necessary. These
basic setting values can be found in the maintenance manual which comes with the press.
Alterations to the lubrication intervals can only be done with the control console program configuration diskette.
Prior to commissioning, lubricate the chains and cams by hand. (Remove the high-pressure hoses from the pump
and use the oil gun to pump LA8 lubricant onto the chains and cams).
!
ATTENTION: The control console program configuration diskette may only be made accessible
to authorized personnel. MAN Roland accepts no liability for damage to the press caused by
use of the diskette by unauthorized personnel !
Cams
The lubrication interval can be adjusted between 500 and 8,000 revolutions.
Basic settings:
Lubrication interval every 5,600 revolutions

With interdeck drying, every 4,000 revolutions
Delivery chains
The lubrication interval can be adjusted between 500 and 2,000 revolutions.
Basic settings:
up to 200 operating hours,

lubrication interval every 600 revolutions
after 200 operating hours,
lubrication interval every 1,200 revolutions
up to 200 operating hours when a dryer is installed,

after 200 operating hours when a dryer is installed,
!
ATTENTION: When fitting the chains, pre-lubricate them well with LA8 !


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11 Function and switching of the magnetic dosage pump:
Main switch ON:
a) Lubrication cycle starts when the press starts.

b) For lubrication impulse setting values, see page ”Basic setting values for the magnetic dosage
pump”. These can only be altered with the control console program configuration diskette.
c) Every press revolution in the modes:
♦running
♦crawl
♦inch forwards
are counted.
d) It is not possible to alter the lubrication intervals from the control console while the press is in
production.
Lubrication cycle
♦ Magnetic dosage pump switches ”ON”

♦ Press revolution counter for the lubrication interval is set to ”0”
♦ Press revolution counter for the monitoring is set to ”0”
♦ The lubrication points are supplied with lubricant. The magnet in the pump is energized for
approx. 2 seconds
♦ Then the magnetic dosage pump switches ”OFF” (magnet is dead)
Error messages, for both errors (level and stroke monitoring)
♦ Faults are indicated by error messages at the control console and also by a bell when:
a) the level of lubricant in the container falls below minimum
b) the lubricating cycle did not start after the set number of sheets
c) the lubricating cycle was not carried out after the set number of sheets
(the stroke monitor did not trip)
♦Delivery chains (after approx. 1,000 sheets)
♦Cams (after approx. 10,000 sheets)
♦Acoustic signal stops after 5 seconds

♦The error message remains at the control console until the fault is rectified
♦If the fault is not rectified after 2,000 more sheets have been run, then
• there is another acoustic signal and
• the transport and separating suckers switch off
• the last sheet is delivered
• the press shuts down
Remarks
a) If the main switch is turned off during a lubrication cycle, a new lubricating cycle starts when the main
switch is turned ”ON” again (operation) – see point 1a.
b) With Machine ”STOP”, a lubricating cycle that has started is not interrupted.


13
12 Air supply:
The R 700 is equipped with pumps and blowers. The position of the pumps, blowers and lines is shown in the air
supply diagrams.
R 702 – RZg.-No. 001 L 0297 39
R 704 – RZg.-No. 001 L 0298 39
R 702 – RZg.-No. 001 L 0299 39
R 702 – RZg.-No. 001 L 0300 39
Switching the pumps and blowers on/off is controlled from the first printing unit and the control console (pumps ±).
The feeder and delivery pumps have grease nipples that must be greased regularly.
The filters of the pumps and blowers must be regularly cleaned or replaced.
It is recommended to locate the pumps and blowers in an adjacent room.

13

Air supply diagram:
Data Base Documentation

Radial blower
for front suction chamber
and feedboard
R7k13_07

Decurler
für
Blower Delivery blower

Main air, blower
Feeder pump for air connection for air connection
for air connection
for air connection 32 suction air for the suction wheels 25 blast device transfer module
1 blast air, feeder 10 blast device M 1
34 Blast / suction bar in infeed 31 sheet blow-down rake
2 suction air, feeder 11 blast device M 2
3 lateral blowers, feeder 12 blast device M 3
4 suction air, infeed unit 13 blast device M 4
5 blast air, infeed unit 14 blast device M 5
13

15

13
14 Pneumatics:
Introduction:
The R 700 is equipped with a pneumatic system.

This must be regularly serviced and checked (empty the water separator, drain off water condensation from the
compressor, check the compressor oil).
The pneumatic control can be activated from the control console.
The pneumatic system consists of the following components:
Compressor – refrigerating dryer with oil separator – air tank – pressure reducer with water separator – distributor
block – valve block – air pistons.
The press requires an operating presssure of 8 – 11 bar (perfecting presses need 11 bar). If the press is connected
to a central air supply, operating pressure must be 10 – 14 bar.
System design:
With the component parts of the pneumatic system, a distinction is made between working components and control
components. When several component parts interact, this is known as a pneumatic control. The fundamental
components of a pneumatic control are compressed air cylinders and way valves.
Valves are component parts for controlling or regulating the compressed air. They control start, stop and direction,
as well as regulating pressure and the volume of compressed air.
Compressed air reservoir
The compressed air is stored in pressure containers and distributed to the user via a line network. The compressed
air supply is stabilized in the reservoir. The reservoir provides the network with the necessary reserves of air and at
the same time absorbs the pressure bumps coming from the compressor.
Conditioning the compressed air
To ensure that pneumatic components function perfectly in continuous operation, the compressed air must be
conditioned.
”Conditioning” means:
- removing dirt and condensation water from the compressed air.

- regulating the pressure of the air.
Filter with water separator
In the filter, the incoming air is whirled by a swirl vane so that the condensation water droplets and dirt particles in
the air are catapulted against the wall of the filter cage by centrifugal force and thus separated.
The separated condensation water collects in the filter shell and must be drained off. A filter insert holds back the
dirt particles.


13
15 Settings and dimensions:
Attention must be paid to the following points when connecting the compressor, the air tank and the house
compressed air facility:
1. Compressor and air tank are located at the press.

st
The length of the hose up to the pressure reducer must not exceed 5 m (1 printing unit). If the line has to be
longer than 5 m, a pipeline (3/4”) must be laid to the pressure reducer.
2. Compressor and air tank are located in a separate room.

st
In this case a a pipeline (3/4”) must be laid from there to the press (to the 1 unit pressure reducer).
3. Connection to the house compressed air facility.
The customer must lay a pipeline (3/4”) from the house facility to the pressure reducer. House compressed air
facility = pressure min. 10 bar – max. 14 bar.
Air volume R 202 – R 704 = 1.400 l/min.

R 705 = 1.800 l/min.
R 706 = 2.200 l/min.
R 707 = 2.600 l/min.
R 708 = 3.000 l/min.
The press documentation contains more specific information.


13
16 Compressed air connections:
Compressor – refrigerating dryer – air tank – pressure reducer with water separator – valve block connections to
the press.
M1 2
4
3
M2
5
1. Compressor
2. Refrigerating dryer
3. Compressed air tank
4. Pressure reducer with water separator
M3 5. Valve block
R7k13_08
M4


13
17 Connections from distributor block to the valve blocks
PU1
1. Valve block
2. Distributor block
PU2
2
PU3
PU4
Ausleger / Delivery R7k13_09


13
18 Assignment of the pneumatic valves:
Valve block no. Control function Location of air piston

1
2 Plate dampening roller clutch, upper A-side outer
3 Plate dampening roller clutch, lower A-side outer
4 Dampening unit motor clutch B-side outer
5 Intermediate roller separation B-side outer
6 Infeed barrier B-side inner
7 Plate dampening rollers ON/OFF B-side inner
8 Plate dampening rollers ON/OFF A-side inner
9 Metering roller ON/OFF B-side inner
10 Metering roller ON/OFF A-side inner
11 Roller washing device ON/OFF B-side outer
12 Roller washing device ON/OFF A-side outer
13 Plate inking rollers ON/OFF B-side outer
14 Plate inking rollers ON/OFF A-side outer
15 Separating inker/damper A-side outer
16 Separating inker/damper B-side outer
17 Metering roller wash position B-side outer
18 All guards A-side inner
19 Blanket washers ON/OFF A-side inner
20 Blanket washers ON/OFF B-side inner
21 Cloth transport (blanket washers that use cloths) A-side inner
22 Blow drying device (blanket washers that use cloths)
23 PPL force actuation B-side B-side outer
24 PPL pressing roller B-side inner
25 PPL pressing roller A-side inner
26 PPL bending bar B-side inner
27 PPL bending bar A-side inner
28 Washing agent container / outlet unit
29 DZW ON/OFF A-side inner
30 DZW ON/OFF B-side inner
31
32 PPL force actuation A-side A-side inner
33 Sidelay ”pull B-side”
34 Sidelay ”pull A-side”
35 APL transport rollers, insertion B-side inner
36 APL transport rollers, insertion A-side inner
37
38 Coating forme roller ON/OFF A-side inner
39 Coating forme roller ON/OFF B-side outer
40 Chambered doctor blade OFF A-side + B-side inner
41 Chambered doctor blade ON A-side + B-side inner


13
19 Assignment of valve blocks (perfecting presses only):
Valve block no. Control function Single perfector Multiple perfector

45-58 Central changeover shaft for perfecting X X
46-47 Lowering the sheet track in the delivery X X
48 Clutch for positioning motor X X
49 Lifting the cam rollers X X
50 Separating the double gear X
51 Clutch for gripper opening cam X X
52 Clutch for the longitudinal shaft X
53 Clutch for the gear train X
54-55 Swinging the impr. cyl. wash. device off X X
56 Control line suction and blast air X
57 Separating blowers X X


13
20 Valve blocks (up to series 725):
6. 28 29 7 9. 18 20 21
8 10 19
R7k13_10
3 11 13 15 17
1 5 22
2 12 14 16 4
R7k13_11
7 9. 18 20 21
29
8 10 19
R7k13_12
26 24
32 23 33 34
27 25
R7k13_13


13
21 Valve blocks (as from series 726):
Valve block M1:
Y126 Y125 Y085 Y086 Y087 Y084 Y082 Y083 Y003 Y079 Y134 Y020 Y018 Y013 Y033
A591
43 36 32 27 25 23 33 34 6 28 29 8 10 18 20
42 35 26 24 30 7 9 19
Connection " 36" Connection " 24 " Connection " 18 "

to air piston to air piston to air piston
R7k13_14
Valve block M 2...........M 10
Y126 Y125 Y085 Y086 Y087 Y084 Y134 Y020 Y018 Y013 Y033
A591
43 36 32 27 25 23 29 8 10 18 20
42 35 26 24 30 7 9 19
Connection " 36 " Connection " 24 " Connection " 18 "

to air piston to air piston to air piston
R7k13_15


13
22 Fountain solution supply:
- The R 700 is equipped with a ”Technotrans” fountain solution circulation and cooling unit. The purpose of the
unit is to continually circulate the fountain solution from the unit to the water fountains and back again. A
cooling device keeps the solution at a constant temperature.
- The unit is provided with three dosage devices:

For pure, distilled isopropyl alcohol; for acidic additives or for buffered additives. The dosage devices have
electronic displays and the setting values can be altered at any time. The keys for controlling the devices, the
signal and alarm lamps, as well as the preset counter and the corresponding displays for complete operational
control are arranged at the control panel of the fountain solution circulation and cooling unit.
- Before assembling the unit, it is essential to carefully study the operating manual that comes with it.


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3 Oil supply, R 700:.......................................................................................5

4 Changing and cleaning oil filters:.............................................................6

5 Filling and pumping out machine oil: .......................................................7

6 32 bar oil circuit:........................................................................................8

7 Central lubrication pump LA 8 (up to series 720): ...................................9

8 Modular lubrication (from series 721):....................................................10

9 Magnetic dosage pump (from series 721): .............................................11

10 Basic setting values for the magnetic dosage pump:............................12

11 Function and switching of the magnetic dosage pump: .......................13

12 Air supply: ...............................................................................................14

13 Air supply diagram: .................................................................................15

15 Settings and dimensions: .......................................................................17

16 Compressed air connections:.................................................................18

17 Connections from distributor block to the valve blocks........................19

18 Assignment of the pneumatic valves: ....................................................20

19 Assignment of valve blocks (perfecting presses only): ........................21

20 Valve blocks (up to series 725): ..............................................................22

21 Valve blocks (as from series 726):..........................................................23

22 Fountain solution supply: .......................................................................24

Data Base Documentation 1

2 Data Base Documentation

H-LP 68 DIN 51.525

Hydraulic symbols for oil circuit:

Drip plate Filter Pressure monitor

Hose with Cap Overflow valve

The lubricants table is included in the maintenance manual.

Data Base Documentation 3

Here are a few basic rules:

3. 20% LA1 is to be added to the oil. (Not with high-pressure oils)

Oil circulation lubrication:

The R 700 has central oil filling.

4 Data Base Documentation

3 Oil supply, R 700:

Data Base Documentation 5

4 Changing and cleaning oil filters:

6 Data Base Documentation

5 Filling and pumping out machine oil:

Data Base Documentation 7

6 32 bar oil circuit:

8 Data Base Documentation

7 Central lubrication pump LA 8 (up to series 720):

Insert the diskette and select main menu

Press SERVICE (F2)

Call up the desired menu using the

Counter for chain greasing Timer for chain greasing

Standard value Standard value

Setting range 4000 – 20000 Setting range 60 – 120 s

Data Base Documentation 9

8 Modular lubrication (from series 721):

At the printing units (+BA,+C*,+DA) are

♦ the level monitor (-B130) at input: -A350/4, Byte 4, Bit 7 ;

At the delivery (+EA) are

10 Data Base Documentation

9 Magnetic dosage pump (from series 721):

The following lubricants meet these requirements:

EKALUB LA 8 the Chemie – Technik company

Data Base Documentation 11

10 Basic setting values for the magnetic dosage pump:

Lubrication interval every 5,600 revolutions

up to 200 operating hours,

up to 200 operating hours when a dryer is installed,

12 Data Base Documentation

Service Training Mechanik