a ( % ‘operation of the Original Heidelberg Cylinder 22Y 90/4" and 22% x32¥4" ie very simple, A proof may be azen in the fact that by the end of 1967 approxi- mately 45000 Original Heidelberg Cylinders had been installed all over the world and enthueleeticly recsived ‘The purpose of thie instruction manus is to enable printers to abtain the meximum fcvantage from the machine, We hope that it will not only ensure thorough maintenance of the machine but willpromote a better understanding of progressive methods in preperation of the forme and make-ready, the use of inks and the care of rollers By following our advice, tested and proved the world over, the printer will obtain the maximum efficiency from his Originel Heidelberg Cylinder. HEIDELBERGER DRUCKMASCHINEN AKTIENGESELLSCHAFTCONTENTS: ‘Table of most important adjustments for various stock Specifications for the Original Heidelbers Gylinder 22%, x30%4" / 22Y2x32%4" Floor pian drip pan The design Original Heldelberg Cylinder Feeduction to the minimum ‘of make-ready time Cutting down unproductive time Printing in general CCorreet forme agement Block justifcation Mounting of blocks Wood mounts | Lead or iron mounts Light metal mounte ‘Slur — ink too acy Slur — caused by forme rollers Slur — caused by badly mounted blocks Slur — caueed by high or low blocks Remedies : Preemakexeody of Forme Inking Maintenance unning-in the machine Lubrication of the machine Daly, weekly, and semi-annual oiling 1 lubrication Grease lubrication Central. lubrication Gar box oll bath Cleaning the machine 4 ” 8 2 BReReS rn the suction and Cleaning the arf the air pum Cleaning the fiter ofthe air pump for the spraying davice leaning the main pinion, gear racks and crankshaft area Maintenance at longer intervals Readjustment of fiywhesl brake Exchange of V-belts Cleaning the suction and blast air pump for feeder ‘Operating the machine Control of the machine Electrical control equipment Operating electri controler Forme end roller guard ‘Single lever eontrel for ‘Stop-Fun-Paper-Impression ‘Stopping the machine . Two step pulley dnve Turing the machine by hand Treatment of rubber roll’ Treatment of plastic rollers Inking system ‘ When does the printer use 2. 3 or 4 forme rollers? Inserting rollers in the machine Inserting the forme rollere Teking out ofthe forme rollers Taking out of the distributor rollers Agjustment of the vibrator Adjusting the distributor rolers Adjusting the forme rollers Disengeging rollers Regulating the krife and ink strip Engaging and disengaging ink supply Regulating the recipraceting rollers Operating the roller washing dovice Cleaning the duct and the ductor blade CCeaning the splash guard a a a 2 4 4 6Positioning the forme Locking he forme on the bed Selecting cylinder packing Adjusting cylinder pressure on bearers Clamping the pecking Make-ready Leading the feed table Regulation of suction Fegulation of sucker ber tit Sheet separation Feguleting rte of lit of the feed table Use of tissue slides Use oF rubber suckers Use of rubber rollers on the feed control ber Use of tripping springs Setting the sie lays Adjusting the cover plate Micrometer adjustment of side-ey Adjustment of front lays Use of smocthers Use of sheet brekes Adjusting the swinging grippers ‘Alusting sheet calipers on the feed bosrd Operation of automatic cut-out Gylinder brush adjustment Fiting new brush Cleaning the brush Adjusting the delivery table ‘Adjustments on chain delivery system Ar blast for the sheet delivery Removing the wheeled delivery table Ponder oF lcuid. spraying ete fecsving moxactin Direeting the spray Clesning the spraying apparatus Powder apoaretus Clesning the powder apparatus Other points 10 be observed when using the spraying aoparatus Forme and delivery lighting Extra equipment Device for printing two up Locking forme when printing two-up Device for printing botwoen bearers Devies for het embossing Numbering with contrally controlled number 4 108 107 107 107 no 112 113 4 Ing boxes on the Original Heidelberg Cylinder Numbering with plunger operated numbering boxes Device for adjusting formes ‘Adjusting formes to be locked between the bearers Preloading device for feeder Device for continuous delivery Die-cuttng, scoring, creasing and siting on the Original Heléelberg Cylinder Device for carbon printing Device for eliminating static electricity Perforating and cutting onthe Original Heidelberg Cylinder . Device for printing onion skin Difficulties and remedies Paper Causes of bad sheet separation and pick up ‘of two sheets on the feed pile ‘Sheet Is not picked up Food table grippers do not catch the shest or 0 not catch it corecty “roubles on the feed table and at the side lay Sheet is not registered corectly at the side lay — bad regisienng . ‘roubles with transport of she board Slur ‘Working up in the forme Bad inking ‘The printed sheet shows harlne ‘The shoot shows broad emears ‘The print is scratched on the rear side of the shoot Troubles atthe devery ‘Shest ie taken back by the delivery carriage ‘Machina ie not cutout automaticaly it no ‘hoot i Fed Inatruetion for eliminating voubloe with the spraying apparatus Inetruetone for overcoming ~oubies with the Powder spraying equipmant Original Heldalbers Cylinder 22/4 x 324" Gutter ond Gresser “To the machine — minder opersting the 22, x30)4" / 225 x24" Original Hoidolborg Cylinder ‘The Haldslborg manufacturing programme ‘on the feed ns 116 116 120 122 105 126 127 128 129 131 138 134 135 138 136 196 136 137 17 13 128 138 138 138 138 138 139 140 a2 148 urA Accessories 108 ‘Air blast — delivery 20, 96, Air blast — feeder 79 Air fitero 36, $7, 82 ‘Air pump 36, 42 A suction regulation 78 ‘Ant-Offeet pray 97, 108 Automatic cut-out 88, 89, 198, ‘Automatic impreesion lever contral 46 8 Ball bearings — lubrication 32, 38 Ball handles 18 Base guards 97 Brake — adjustment 40, 41 Brush — adjustment 89, 0 ic Carbon printing 127 ‘Cardhoard feeding 8, 80,83, 83, 87,68 Center divider — delivery 111 Contor divider — feeder 110 Center side ly 111 Central lubricstion 34 ‘Chain delivery 94, 85 ‘Chases 10, 70,71, 112 Cleaning of the machine 35, 96 (Cteaning of the main pinion gear reck 37, 88 Climatic coneltions 133 ‘Composition ofthe packing 72 ‘Composition ofthe rollers 52, 53, 54 Continuous delivery 2, 97,125, 128, Contral box 44 Control lever 18, 46, 48 (Corn starch 39 Creasing 126, 127 Cutter and Creaser 142 INDEX Cylinder 17, 73 ylindor brush 89, 80 Cylinder sheet guide 86 D Delivering dividing plate 111 Dalwvery difcutis 139 Deivery lighting 44, 107 Delivery seperetion boards 108, Delivery shact stops 91, 92, 93, 04 Delivery star-wheels 84, 95, 198 Delivery table 1, 92, 97 Delivery table contol St Die cutting 126, Die cuting plates 127 Distributor rollers 67 Drip pan 12 Drive 44, 48 Ductor roller 68 E Electrical control box 44 Electrical equipment 44 Electricity — static 128, 188, 194 Embossing 114 F Feed lit 80 Feed suckere 81 Feed table 77, 122 Feed table height 77 Feed trouble 133 Feeder preloading device 122, 145 Feeding emll sizes 110 Filtre 96, 37,82 Floor plan 14 Flywneel guard 48 Forme and roller guards 45Forme gauging 22 Forme lighting 107 Forme looking 70 Forme positioner 118 Forme positioning and alignment 22, 69, 70 Fore rolles 19, 0, 52 Forme roller adjustment 58, 58, 6 Forme roller combinations 53, 54 Forme roller lubrication $8 Forme roller removal and replacement 55. 53 Front lays 85, 136 Front lay adustment 85, 87 Fuses 44 « Gouge for packing thickness 22, 23 Gouge for rollere 69 Gauge for ype height 22 Geer box lubrieaton 35 Groace gun 92,53 Grease nipples 33 Gripper margin 10, 68, 85 Guard between cylinder and inking mechaniom 68 Guerds for base 36 Guerds for delivery 38 Guerd for formes and rollers 45 4 Height control bar — feeder 82 Height of plates 22,23, 26 Honeycomb Base 23, 24 Hot embossing 114 Humiclty in the pressroom 199, 194, 197 1 Imposing board 70, 116, 121 Imposing surface (device) 19, 116 impression eyliner 17, 22, 26, 46,74 Ink dryers 30 Ink film 53, 54 6 Ink flow 61, 62 Ini duet 8t Ink duct blade 68 Ine duct heeting 128 Ink mixing 80 Ini rolorrociprocetion 63 Ink alur 25 Ink supply 61, 62 Inking 29, 30, 137 Inking aystem 19, 52 i Locking forme between bearers 118, 120, 121 Locking forme on bed 70 Locking forme for two-up 112 Lubrication 32, 33,24, 25 M Main control awit 44 Main pinion gear and racks 37 Maintenance 31 Makeready 76 Makereody, die-cutting 127 Makeready time 76 Metal mounts 23, Micrometor gauge 22 Microscope 26 Mixing of inks 90 Motor 44, 48 Moving sheot Guides 88 N Numboring and numbering boxee 118, 118 ° Oil dipstick 95, il gun 92, 93 il lever — contral lubrication 92, 34 alubrication 92,38, 94 (Ol nipples 82, 98 (Oi reservoir — contrsl lubrication 34 Onion skin paper 9, 78,60, 131 Pp Packing clamp 74, 75 Packing draw bar 75 Packing pine 75 Packing thickness 10, 22,27; 72 Paper dust $6, 37, 82 Paper margin 10,69, 5 Paper sizes 10 Paper storage 138, 135, 138 Perforating 129 Plate mounting 23, 24, 26 Plastic rollers 28, $0, 51, §8, 67 Position of side lays 84, 85, 110 Posttioning of forme 63, 70 Positioning for two-up printing 111 Positioning of forme between bearers 120, 121 Powder spraying apperetus 102 Pre-loading device for feoder 122, 148 Pre-makeready of forme 29, Press blanket 72,75, 78 Printing between bearers 118, 120, 121 Printing of small sizes 110, Printing oll 30 Printing paste 25, 20 Printing thin stocks 9,80, 81, 96 Printing troubles 25 Printing two-up 110 Problems and remedies 182 Pump 36, 42 Pump maintenance and lubrication 98, 42 Q (Quick stop 47, 48 R Feciprocation 63 Rogister 196, Regulation of ink strip 61 Regulation of speed 32, 4, 40 Fice flour 30,51 Roller cleaners 49, 50, 51 Foller combinations 52,53, 54 Roller gauge 58, 69 Rollor guards 45 Poller rack 50 Roller specifications 62,88, 54 Follar washing 6, 65, 88, 67 Follo-paste 49 Rubber rollers 29,49, 50 uber suckers 81 unningrin the machine $2 8 Sand paper sleeves 95 Scoring 126, 127, 181 Sembannual lbrication 32 Sheet-brakes £6 Shoot caliper 87, 88 Sheet counter 107 Sheet seperation 9, 79 Sheet emoothor 85, 136 ‘Shest travel on feed board 19, 198 Side standards 125, Single lever contol 45,46, Size ranges 10 Skeleton chases 10 Sltting 126, 127 Sludge trough 66 Shure 25 ‘Smesrs on printed choot 198 Special chases 10, 115 Specifications 10 Speod control 44, 48, Splash guerd 68 Starting the machine 45, 46 Stee! plate for die-cutting formes 127 Static electricity 128, 138 Static eliminator 128Star wheele 94, 05 ‘Stopping the machine 47, 8, 69,158 Spray trouble — correcting chart 140, 141 Suckers 80, 81 ‘Sucker bar tt 78 Suction regulation 78 Swinging gripper adjustment 87 uh Tiesve slides 80 Toole 107 “Transparent plastic shest 117 “Turning machine by hand! 49 Two-sided achesive 23, 26 “Two-up printing 110 v V-belts — replacement 41 Veriable speed control 44, 48 w Washup blade 64, 65 Washup solution 4, 50,51, 67 Washup sludge trough 64, 68 Wiring dlagram 44 Workup causes 137Table of most important adjustments for various stock ‘he ible con only give te approximate alustant. Maximum pradiston speed on (hey run dpende ian paper tam, and ins ihe xperanené iter wil, feeafo Free minor acsiwers enn beoceede nt he ‘ning spec ‘sina the highest poss Adjustments ‘Neda! ond Thin Pape Madiom:Weahe Bond cortboare Distance of Feed Pile Tp sree aprox op shew dcctiy unde from Sooke 8" ema) om suckers | 4° (6mm) tm eukere | Cuckore Sucker Tit nul use plenty ofa | Ti intone n conte | Np trator on bathers rein popare | postion "Sardbona ‘ich can be Wun Seer Peper Food Pape food indicater on a | Inet i con ae "Gardboors sting Popar Separation £° seprator sings str out oe possible pring xterang sgh ‘oer ee oF pls Feed Ai Bost duce arte. Blower | Medien to fl ar tae tor relton Tishow fers. lower In'midle poston Datvery At Blea Met fal i bat (hr Se metre i fw of wah 16 conolng the chet nian vorepertad to'eelvry pile) oper see and rt” Sety above he ‘sivey pie eparding upon pase Median $0 fa lat fe tat te eet fale idly dow onthe ple Fall ale ist ptnser Seat The poston ‘Bruch engeged in cours pont during the fret Fie engage brush se ‘rae fly ergapedSpecifications for the Original Heidelberg Cylinder Maximum sheet size Minimum sheot size Largest hal-sheet two up Inside measurement ‘Standerd chess ‘Skelaton chose Maximum forme standard chase skeleton chaee: between besrere Gripper margin adjustable between Length of forme from pitch lin to leave with 36" (10 mm) ripper margin Meximum speed Power requirements Net weight ‘approx Gross weight packed 9p9r0% ‘Overall length Overall width including motor Height to top of feeder Bont rails Number af ferme rollers Packing thicknoss spprox 10 22a 30%" Daven a0" 11 hex 154)" Whe 221" BYex 11" 22h x 26%" Dai/uax 2910" Difax 28%" 214x204) 2t/ax30" hw and isi 4600 ip HP as 11.700 bs 14600 be wer oe sir 4 4 aaYiax32'/e" aan aay" Thee 15" 15x 221)" vex tu" 22x 30%" 22x 3t%fu" 2Vlex 90%" 2Vaxarhe” 2Vax save" Si and" ait" 4600 Lp. HP 8s 12125 be 15000 ba ive" or srFloorplan forthe Original Heidelberg Cylinder 22": x 20" / 22%: x32%/" Move floor pan Floor pan here to base aK cappeoxeo" saxs04Foor pan sour eT Tontater wit resistor jeomactor and "uses Pattorm iL ee 30h Minimum distance on all 4 eides = 254s” (650 mn) Floor contact aurface = 22 sat. (21 m')2 i Drip Pan We urgently recommend placing the machine on an oll drip pan in order to prevent soiling of the floor. This ls especialy important on concrete which Is ‘subject to decomposition when saturated with oll or grease, Each stroke of the catral lubrication handle forces approximately 24 (40 com) ‘cubic inches of oll under high prassure into the bearings. The used oll which is nee wookly. forced out drains on the ip pan which should be cl ‘The rip pan generally comes wih a rolled Ye" or *h" bead and measures 68” by 83/3" (160 x 212 mm). Itis made of galvanized sheet iron.THE DESIGN“4 Original Heidelberg Cylinder Paper Size 22%, x 30'," (57 x 77 cm) 22Yp x 321," (57 x 82 cm) ‘Tho Original Heidelberg Cylinder is unique in its design end construction and cannot be compared In any way with orthodox stap-eylinder or two-revoltion presses. Its built on an entirely new principle, which results inthe production at feonamic costs of the finest quality of print, at speeds previously unknown on letterpress flatbed mechines The Original Heidelberg Cylinder has been installed by leading printers all over the world, which provides convincing evidence of the fact that ts unrivalled advantages heve been universally recognized. ‘The designers of the Original Heidelbers Cylinder planned to provide for the ‘every day requirements of the printer and to ensure thet he could successfully ‘meet competition and rising production cots. It was clear from the start that ‘an entirly new approach to the problems would heve to be made. A machine of revolutionary design was essentil. The designers did not even have to consider the machine from their own production angle, 28 new a pant was ta be Provided to meet their requirements. As a recut. the demands of the modem printing house were given the fret considretion. Briefly, these demands wore: 1. Greater output with improved quality. 2, Reduction in make- ady ime, 3, Reduction to the minimum of idle tine, to be achieved by simpliety and speed In changing jobs, forme adjustment, inking, washing-up, maintenance, and general opertion. 4. High production speed, postive sheet-contral and superb inking on all jobs with four forme rollers which clear the whole forme even when using the ‘maximum size forme. ‘These are the principles on which the Original Heidelberg Cylinder was planned ‘and built. The recult i ereator output end reduced costs, We do not intend to produce a technical treatise regarding the principle of the Original Heidelberg Cylinder, Such ¢ treatise would require too much space and ‘overlook the purpose of an operation manual. We propose, therefore, to conc ‘rate only on the points which ere of technical Interest for the méchine-minder ‘operating cur machine and of economic Importance to its owner. The Original Heidelberg Cylinder is a single revolution machine of spacial design. Whilat with the twosrevolution machine, the fret ravolution of the eyinder le used for the printing stroke end the second revolution for the return stroke ‘of the type-bed, the Original Heidelberg Cylinder printing stroke end return stroke of the type-bod take place within one revolution of its large cylinder.During the printing etroke the type-bed moves with reduced speed corresponding to the largo cylinder diameter of 21” (G40 mim) which was chosen. The speed reduction during printing, which results automatically In improved quality, Is ‘cod by a proportionale increase of speed on the retum stroke. As is well known, there fe no printing function in any machine on the return stroke, which Jaan idle evoke. Now pl study the drawing on page 16 very earefuly 15a Printing REVOLUTION-, IMPRESSION- AND DISTANCE-DIAGRAM A Two-Revolution Press of same size and 4 forme rollers of same size makes 4 impressions to a distance of 8,5 mtrs 340x3,14x2 = 2,12 mir. per impression Scale 50 Ist Revelation | 2nd Revoletion | Sed Revolution | ath Revteion [5m Revaution | 6th Revluin | 7th Revolution | fh Revoition Ist impression 2nd impression I 3rd impression th impression -| B H 1 a Total distance — 8,5 mtrs HC The OHC makes 5 impressions to a distance of 8,5 mtrs Production increase over two rev. press = 1 impression Increased Output = 25°/o 540x3,14x1 = 1,7 mtr. per impression Scale = 1:50 1st Revolution 2nd Revolution | 3rd Revolution | 4th Revolution ‘5th Revolution Titimpression | 2ndimpression | 3rdimpression | _ Ath impression ‘th impression Total distance = 8,5 mtrsReduction to the minimum of make-ready time achieved by rigid construction The oylinder Is ground and polished to the limits of mechanical perfection. With its beerings this fylinder weights one ton and with absolute rigiity fenaured, flexure during the printing of heavy formes ie impossible. The pressure of the cylinder fon the bearars ie greater than the counter proseure of the heeviest possible forme, Mokesresdy \s thus reduced to a minimum and Is confined as it should be, to correcting inaccurs cles In the forme alone. During make-reedy, the whole of the printing area is ia view and complete ly accessible without swinging away or removing ‘ny parts tie. 1Cutting down unproductive time for changing jobs, and adjusting forme. The operation of the Originel Heidelberg Cylinder |e simplicity itself. A single handlever controls starting, stopping, paperfeed and impression. The complics:ed controls and fitings which are usudlly found on cylinder machines heve been eliminated ‘Thore are no parte to be lied ar swung away and everything is easly accessible, The few essential ‘controle are clesrly visible and are marked with Instruction plates, All control levers connected with the starting, stopping or central lubrieavon of the machine are IMs. 2 implification of maintenance and operation eqvioped with red ball handles. The other control levers which pertain to the operation of the machine are provided with white ball hand Positioning the forme, adjusting feed and delivery piles, and setting the lays, are Jobe which are simplified by graduated scales on the chase, feed dolivery tables and side lay Furthermore, 2 device for adjusting the formes is supplied ae an extra with the Original Heidelberg Cylinder which ie instrumental in furhar racucingthe idle time of the machine. The various blocks of mmulticolour work ean be exactly positioned by meane of this attachment — outside of the press ‘whlle the pravious forme is stl printing. On epecial request we con also supply an imposing surface [composing stone) which, exactly a8 the type bed of the machine, is equipped with two bearers end ‘stops as well as chase locks. This will enable the printer to. completely lock, outside the press, even jabs which require perfect reclster. From the ead table to the delivery pila, the sheet 's controlled by mechanical grippers. These grip- ers need no adjustment and will deal effectively with any size or thicknass of stock. The grip 1s variable and is Sire” to %". The feader iteef ra- presents a complete brask from tredition, a8 no tepes, rollers, or similar frictional devices are ‘empleyed. Four mechanical grippers carry the sheet down the food board into the lays, and ae already mentioned, they need no acjustment whatsoaver, By eliminating tepes, rollors and all other encum- borances from the feed board, the danger of marc Ing freshly printad ehasta ie completely eliminated ‘A preloading device Is supplied a5 an extra with the Original Heidelberg Cylinder which makes it possible to reload the machine during the run. Thie euts down the idle time of the machine during relosding of stock ‘Tho food grippore take the chest right down to the front lays which are mounted on the ewinging arippor bar. The individually sprung grigpere move ‘lowly forward end in conjunotion with the side lay regiter the shoet. At the moment of grip, the ‘shoet lice perfectly fiat and the grippers. are stationery, ¢0 thet the amaunt of grip ia not varied with the apoed of the mechine and periect register ie ensured. The swinging grippers then move in unison with the oylinder and warsfer the eheet to the evlinder grippers. Ae they do not release it until the cylinder grippers have taken control of I register cannot be lost in transfer. ‘A four colour process job can be put on various Original Heidelberg Cylinder machines and printed at different speeds without feer of variation in register. By means of the device for printing two-up small sized jabs can be printed more economically. Tis Is of importance when offcuts are used up The inking system of the Original Heidelberg Cy- linder has been specially designed and ia crivan from both sides of the machine. The thorough breaking up of the Ink is caried out by four ylinders with diferent diameters, 1 vibrator and 3 rubber distrbutor rollers, The reciprocation can be adjusted from 0—45 mm. In order to guarantee 4 suficint coverage when printing large solide the Ink strip — which the vibrator takes from the cuet rollor — can be adjusted from 0—3!s" (090 mm) uring the runso that the amount of inkeean abaya bo adjusted exactly to the printing work which has to be done ‘The Original Heidelberg Cylinder Ia equipped with four forme rollers. All four forme rollers clear the maximum forme. Orly machine-minders who ‘work on the Original Heidelberg Cylinder ean Fully ‘appreciate what thie meane in every day printing The most delicate and dificult jobs.can be produced with ease. ‘A further big time saver on the Original Heidelberg Cylinder is the roller washing apparatus built ito the inking system. Washing up time is reduced to 5 minutes, the rollers remaining in the machine, ‘obviating the need for readjustment efter cleaning. ‘The operator hes only to sprinkle the rollers with some white spint from the container. apply the rollor washing device by releasing the lock on the handle and in a few minutes the machine ie ready for re-inking. “The printed sheet is taken from the cylinder by rippers travelling et the same speed a the cylin- der, placed printed side up on a sliding carriage and gontly deposited on the delivery pile without ‘any contact with the freshiy printed surface, The Grippers do net need any adjustment for changes In thickness or size of paper, Tapes strings or Sticks ar@ not employed as in most delivery sy- stems, therefore, no provision has to be made for rmergins or gutter. ‘An air blower is builtin the delivery and allows printing of airmail paper end all thinner stock at 19‘a considerebly high speed end with great certainty. “This device naturally improves the delivery of all ther kinds of stock as well. When printing thin paper the air blast can be reduced by adjusting 2 ‘he a special accessory for the delivery of very light stack, an affective blower device consisting fof an acjustable tube is fited to the machine, This tuba ie provided with blower nozzles ané can bo ewung over the delivery pile in sry desired po- ‘tion, Light weight stocks can thus be run at higher speeds. By means of the device for continuous delivery the full delivery pile cen be taken eway and a new 2 bbootd can be ineerted without the necessity of stopping the machine A builtin anti setolf apray eliminates any ni for interleaving, ‘Apart from the powder sprey spparstus 9 liquid ‘pray apparatus of our own design can be attached. Both soray attachments can be used altornatoly by a simple turn ofa lever. All the main besrings and important oling points ‘re eupallad with the correc: amount of oll by two trokee of the contral Iubnestion pump. All the floctncal equipment and bultin lighting units are ‘of the latest designPRINTING IN GENERALCorrect forme alignment The Original Heidelberg Cylinder ie a crafsmen's ‘machine, precision built and ebeolutely rigid in ell Ite parts, The cylinder of the Original Heidelberg Cylinder is free from deflection and romaine firmy fn Ite bearere under all conditions. Lack of such rigidity, eo often found in Ieee ealily conetructed machines, greatly ads to the machine minder's task. These facts play an all important part In reducing mako-ready time 8 the operator is not concerned with variations in the machine, but only in the inaccuracies of the forme. It i, therefore, worthwhile epending a litle time bringing the forme up to a similar state of accuracy. The solid area of a block requires mare impression than the reat of the form, It is incorrect to start with the cylinder packing at exactly the prescribed thickness. Start with @ properly adjusted forme then add or take away sheets from the cylinder packing according to the imeression equired. The specified eylinder packing is approx. 047" (1.2mm). Including the sheet to be printed. Block justifiation The height of @ block can only be accurately gauged by mons of a micrometer similar to the fone shown in Illustration 3, Type high rules and hand gauges are not accurate enough for madem standerds, tie. 3“Mounting of blocks ‘Tie ie @ matter of great importance becsuse many printers sil fall to recognize that much of today's unsatisfactory printing results are caused primarily bby poor mounting of blocks or pistes. With a modern precision press such as the Original Hei- dolberg Cylinder at your disposal, the forme must come up to the same standard in ordor to taka ful ‘advantage of this machine, Furthermore, printer ‘must remember that all makoreedy which hes to be done on the machine is idle time. Such lose of production is noodlees now thet a machine is av able on which 100% pre-prass mekeready is possible. ‘Wood mounts Pites that sre neiled oF glued to wood mounts do ‘ot come up to presentday precision requirements, ‘especialy if the plate is @ large one. tie possible to do a creditable job with a new accurate wood- mounted plete in a small sie, but generally the results are inconsistent because of the changing nature of the wood Lead or iron mounts Lead and iron mounts are esatsfactory Insofar ae precision is concerned, However, many progressive Printers will not use such mounts to any great degree because they make the forme unnecessarily heavy. Light metal mounts Great progress has bean made in tho use ef light ‘metal mounts. When put together propery, such « base can give outstanding printing results. How- ever; the following points must be considered: 1. The essembly of light matal mounts should consist of a8 many large places of bat possible 2, The base should nat heve ribbed this may cause the mounts to ri ides, since. and cause 3. Tho sides of the mounto must be absolutely squere 4. Similarly, the upper and lower surfaces of tha mounts must be absolutely Nat If they are not fla, hallowness between either the block and the mount or the mount snd the bed will resutt In a springy forme and slur trouble may occur 5. Bosring In mind the direction of the cylinder mavement goross the forme, it will be appreciat- fd thet It le best to sasemble the mounts 20 that they lie in aright angle to the cylinder axl 6. Light metal base should be purchased only from ‘approved supplirs. The blocks are fixed to alloy mounts with tworsided adhesive. We have found that a thin acheaive material of approximately 1006" in thicknese ie the most euitable, This ‘matarial will uarantea a fien and lacting contact with the mount. Never use a thick adhesive since there may be a tendency for the plate to slide ‘and result in slur, excessive wear, bad register ete. Honeycomb Base In the past years, lightweight honeycomb bace has been adopted by more printers than any other eyetem. We will comment briefly on one typo, Honeycom Base which lo mede of magnoeium. It le praciaion ground ta tolerances of plus or minus cone half of one thousanath of an inch. Honeyoom Bese lo avalable in stendord unite from which "L” sectione con be asvembled to ‘eccommosete the use of both 12-point plates with conventional type or blocks. Honeycomb bage cen foo be ordored In a completo unit cocurod in a quoinioss chase. 2} tue. 5 24 Honeycom’ Base gives the fllow- Ing advantages: Accuraie plate positioning Encior, faster positioning of plate Bettor quay Greater forme flexibility Honeycomb Base is made to a standard height of .744" for use with regular 186" (12-point) un- ‘mounted electros or original et ravings backed up to pica thick- ness. Honeycomb clips are mado in several liferent styles and sizes, Register cips are gonerally used for all. kinds of close register printing. anc are designed to permit adjusting the position of the platea over 2 range of 16 points, When this limit is reached ‘and furthar odjuetment Is necss- cary, the cp is taken out and put into the next hole, A wing key ‘employed to tighten the hooks. Tho deve of the Honeyeomb Bat register clp let calculated in re- lation to printer's measure. A ‘quarter turn of the key advances the clip ene point: @ half turn edvancee i two point, and a full turn of the key advances the clip four points. The lighter weights plus accuracy mean fastor chang fover because of the easier, speedier handling of formes, ‘The basic unit of base can be eed in ful for large forme of leo plates, but it can also be Used in port for mixed formes, ‘The photo on lot shows a mxed forme of type matter end pica patos.sir Sur ie one of the most annaying cificutiee the printar hae to face. It 8 a defect that can occur fon 2 whole heat or merely mar the appearance ‘af one halftone, Slur distorts dot or type face ‘nd if not remaciac st an early stage, can cause considerable damage 9 halftone. The causes ff elur are numerous, but it only develope into major problem wien the printer ie unable to detect ‘the cause and effect 2 romody. We do not propose in this book to deal with every cause of slur but to make a few helpful suggestions on diagnosis ‘andl cure ofthe mast commen varieties, However, before we deal with this subject wo would like to omphasize that oil on the bearers ‘may contribute to slur and particular care should bo takan to 00 that they are clean, ‘Slur — Ink too thin {A thin bodied ink ean cause @ slur on type matter, halftones and rule work. It can be detected by the fling up of the spaces between the screen dots Ina halftone (lustration 6) This slur is usually caused by a thin bodied ink by using too much ink with insufficien: impression fF by ferme rollers which are adjusted too low. Such slur is more readily detected in & halftone where the spaces between the dote sre compara tively small end fil up more easily. The slur is not 2 prominent on @ deeply etched halftone 3 the dots are more pointed compared to those of 1 halftone not as deeply etched. On stock with smooth surface, this type of slur will appaar more cften than it wil on rough stock, In colour work, 2 slur caused by thin-bodied ink can even make the spaces between the dots darker in tone than the dote themecives. When this slur first appea Ik-can be detected by small tals in the spaces of the sereen (ilustration 7) Slur — Ink too tacky The use of correct Ink hes bearing on the success ful printing of solids and helftones with a fine soreen. A slur ia the printing of a solid can often be traced to the ink being too tacky. It usuelly produces an uneven strip of colour which runs in ® curve from the leaving edge, end may be up to 14" wide. The edges of the slur are blurred. It follows thet the tack must be reduced and the addition of 8 reducing peste will generlly produce f better result. A transparent white should never be used, Slur — Caused by forme rollers While 2 slur caused by tacky ink appears on the leaving edge of the chest, ee diecussed above, a slur caused by either incorrectly eet or inferior 25forma rollers can eppeer enywhere an the printed sheet, When the forme rollers are set too low a dark smudge appears on each side of a halfione. ‘The edges of the page of type matter are blurred The first and last lines of the page eppear in a washed-out grey. A similar elur ean elac be caused by the rollers being uneven and not perfectly round. In thio caso, the slur wil eppeer wherever the uneven part of the roller contacts the forme. “his trouble may also be caused by rollers sipp Ing over the forme, 2s they do when they are too herd, to0 soft or lifeless. In such coses, the whole ‘rea ofthe block will have 8 streaky appearence, ‘Slur — Caused by badly mounted blocks If blocks aro not mounted on a perfectly accurate base, its not possible to lock up a forme preciaaly enough to get the best results. The material in the forme will spring towards the center, causing = Slur to appear on the printed sheet. In halftone | this slur is easily recognized by an elongated dot which points in the direction apposite to the move ment of the typa bed, or it can be recognized by general cistortion ofthe dat. Ifthe plate is not mounted correctly, twill lip and | again cause slur ‘Therefore, we recommend that the plates be fastened over their onto arse with two-sided adhesive on ight metel mounts Blocks too low — cylinder ovorpacked ‘Slur — Caused by high or low blocks ‘This Is @ common type of slur and te usually the result of the forme not being checked for height before being put on the machine. Ifthe blacks are not of the proper height, they are not in correct lavel with the cylinder radius. The machina-minder compensates for this diference by under- or fverpacking the cylinder. This affects the speed ratio of the cylinder to tha type bed and the half tone dots are elongated or pesrshaped, pointing ether t0 the gripper or tal edge of the sheet, epending on whether the block is #90 high or too low, Frequently, the printer is unable to tll ifthe orme is type high as he seldom has a micrometer available. As a result, the inaccuracies which are sectually present in the forme are often blamed on the press ‘An enginesr uses ¢ micrometer to determine In- ‘accuracies in a machine or an engine. Its just 3 necessary for the mechinesminder to use a micro metric gauge in selecting the proper amount of packing, and determining the heights of his blocks, We should also lke to recommend the use of Pocket microscopes which are on the market In magnifying powars of 50 or 60 times. With these, fa slur can be detected in its intial stage: that Is, ‘on the first proof. At this stage, it cannot be de- tected with the naked eye or with a common ma ‘nifying gless, unless itis quite « heavy slur Hf the blodks ore below type height, then the oylinder packing hes to be increased to mora than ite Drescibed thickness to get the necessary impression, The surface of the sheet then moves faster than the forme, e8 ite now further away from the center of the eylinder then whith the normal packing. Thle 26 Becauses the sheet on the cylinder to mave fractionally faster than the forme on the bed and distortion oF sur occurs. The diagnosis shows the screen dots to be elongated and pointing toward the tall edgo of the sheet (illustration 3), re 0 e.6.0 San @ Bp w win” ibe 100700 0 ont a Ree Blocks to0 high — cylinder underpacked Conversely, if the blocks aro above type height, 88 a compeneation the cylinder must of necessity be Lunderpacked in order to abtain the praper impression. In this cese the sheet on the cylinder moves fractionally slower than the forme. Distortion occurs and the elongated dots point toward the gripper ‘edge of the sheet (\lustration 9) } r te, 9 pooBlocks at correct height Ifthe block is adjusted to its correct printing helght the dot appears sharp end roune (illustration 10) Fomedios Before attempting to print, the machine-minder should examine the leaving edge of the sheet under his pecket microscope or magnifying glass From his observations it should nat be difficult to decide what he has to do if distortion of the dot 1. If he finds that the dot is slurred toward the leaving edge, the block is too low, It must be brought up to ‘ype height and the oyinger packing reduced, 2. It he finds that the dat is slured towards the friaper e€ge. the block is too high. It must be lowered and the eylinder packing incraesed The illustrations show an exaggerated alur eo that Its direction can be more sasily observed. Before running, the dot should appear round and sharp shown in our third example. There should not be tho slightest tendency to slur 36 thie can only 8 mean that there is a slight ciscrepancy botwoen the surface rotation epaed af tho rinted sheet and the corresponding speed of the forms on tho bd Even the smallest discrepancy will couse damage to the forme on a long un, The point must be harp and without a tandancy to slur toward tho head or the tall because only then cen a large run be printed without trouble, Tondancy to slur la more cesly recognized in the lighter shades of 9 halftone, where the dot is icolated. It ie more dificult to detect inthe deoper shades, where the dote cluster and the spaces between them are observed se white or negative circles. Sluring may be revognized in the deeper shades of a halftone whon thie “white” circle le flat on one aide inetoed of being perfectly round, ‘This fattening ofthe white circles is caused by the Clustered dots slurring aoreas them. IF the circles fre flattened in the direction of the gripper edge of tha sheet the alur lo in the direction of the leaving ‘edge, Conversely, if the circles are fat in the di-rection of the leeving edge of the cheet, the slur is in the direction of the grinper ede. ‘The direction of the slur i always detected by the fist part of the white circle and nat ay 2 heovier deposit of ink that fella to alter the shape of tho circle. This heevier deposit of ink usually occurs fan the opposite cide of the flatoned portion of the cirole, Wherever possible, cheok for slur on the single dot inthe lighter tones, where it is more easily recognize. Before closing this chapter on slur, wo appre ciate that in the past many causee of slur could rightly be attributed to faulty mechanical condi tions ina mechine. We aro confident that tho Original Heidelborg Cylinder ic a machine of mochanical perfection on which, erring acci- donts, slurring cannot oocur. In’ acknowledging ‘the printer's mechanical skill end his. technical ‘kil in tho aplication of ink to paper, we would ‘sak him to make certain that, when faced with ‘2 dificult case of slur, he explores every avenue before declaring the machine recponsible. Pre-Makeready of Forme In many printing works where four ar more Ori- {gal Holdelborg Cylindeag, havo boon installed, one of them hes bean sat esica for adjusting, rogietering and making formes ready for print ing on the other prosses as soon as the formes become avaiable. This system eliminstos 2 tre- mendoue amount of ise time ae the locked forme and prepered make-ready can be transferred with only minor sdusinents, To simplify positioning of the formes. when printing multi-colour work, fan extra sceassory ie available for the Original Heidelberg Gylindor. This pormits the exact po- Bttloning of various formes cutside the pret AA dotallod doccription of this dovico can be fn page 116 and the pages which follow. Inking The Orginal Heidelberg Cylinder is equipped eth rubbar rollers whieh are supplied by a firm with whom we have been co-operating and experi- menting for many years, It wa absolutely essen tial to encourage long ond exhaustive research because © modern cylinder press producing 4.00, Drints per hour simply must have the very best in rallers Fubber rollers are greatly improved today. They ‘do not show continual contraction and expansion during humidity changes. Higher speeds result In higher temperatures. Rubber, unlike other mate- rial, wil not soften end eventually pull away from the roller core. Fer this reason, we recom mend that rubber rollers be used on the Origin Heidelberg Cylinder. The very fine rubber rollers supplied with the Heldelberg can be used on all types of work with excellent results. The rubber roller also has @ much longer life than other types. We eppreciate the fact thet many machine minders are doubtful shout the efficlney of rubber rallrs, This undoubtedly emanates fram the early days of rubber rollers when many of them were hard, had an uneven surface, lacked life and tack, end coule be used only for simple jobs. ‘The use of rubber rollers in printing solide gives ‘excellant results because they do not “give fway” the ink after one tum oe rescly 32 oth types of rollers do. Rubber has a more. porous surface, which gives it an advantage in storing Ink The smooth surface of other types of rollers oes not have this quality, which is particularly Important when printing solids When printing on stocks that have an excessive emaunt of paper dust, many printers will make use of one plastic forme roll. This helps in pick Ing spots off the forme, In such cases, the plastic forme roller is placed nearest to the impression cylinder since this roller is the lest to leave the forme. In extreme casos, two plastic forme roll can releve the problem The Original Heidelberg Cylinder ia the only me chine of its size equipped with four forme rollers All four forme rollers clear the maximum sized forme, The entice inking system gives unprece- ented results, Every méchine-minder occasionally faces @ job that Is more elfficult than the average fram sn 2Inking stendpoint, It may be a solid oF a perticular shade of @ colour ors forme that is likely to Fepeat. We have experimented with such problems for s long time and can prove thet many inking troubles are exelly overcome with four rollers of varying élemtors On the Original Heidelberg Cylinder the forme roller nearest to the cylinder has = diameter of 2s" (65 mm). The next is 2." (57 mm), the third hss a clameter af 2%" (60 mm), and the fourth forme roller, which also clears the forme com pletely, has a clameter of 29:4" (68 mm). Having four forme rollers, all of which clear the maximum forme, increases the ability of the machine to cope with inking problems. However, the essen- tial need for suitable inks cannot be overompha- sized, The danger of repeating exista with all Colours that do not cover, and with inks having poorly ground pigment. To oliminate the reoul- tant blemishes, such inks should not be changed In any mannor which would reduce their colour strength AA transparent white should not be used with coloured Ink whenever it can be avoided. A soft Ink that Is not 100 tacky, Is preferable, Reducing oils and liquid driers should be avoided. Pastee for both purposes ara recommended. In short, everything should be done to maintain the etrength ‘and covering power of the ink When printing sols, the mixing of powdered material euch 28 ‘om starch or rice flour will help the ink to lie ‘smoothly and without matting, ite better to tart with a darker colour then ie required and to lighten It with an opaque white, oF with a atrong lighter colour unt the required ehade Ie obtained The advantage of using 2 colour lightened with epaque white is that Ils covering power Is not Weakened Even with @ four roller Inking it may sometimes be aificut to overcome repeats or “ghosting” ‘when printing @ certain colour tint from 9 large solid that Is provides with a cut-out. Inthe length wise direction the appearance of a “ghost” mark Is 65 far as possible avoded by the four forme rollers of diferent clameters. In order to make the ide edges of the “ghos!” mark dieappear one puts small mets! plates betwesn the side frame ofthe bese and the bearings forthe forme rallers, These plates can be supplied ae an extra acces- sory. When inserted they wil make the forma rot- lers oscillate a bit in a sidewige direction due to the lateral reciprocation of the distributing rollers This will eliminate the side edgos of the ghost mark so that to the naked eye they disappear. These metal plates need enly be inserted between the roller bearings on the operating side of the prose, There sre also inks especially manufactured for the printing of solide. These hava been intro duced to the merket in a full range of colour tones and are very good If @ machine-minder will follow our suggestions and those available from ink companies, every job that fits the size of tho Original Heidelberg Cylinder can be put ‘on the mechine without hesitation end without ‘experimenting and ean be printed at speeds here- {ofore unattainable on any cylinder printing press. Offset inks are also good for printing solids, a= they have a more concentrated colour then letter- press inks, They are more expensive but recam- mended when printing large solids. Ink makore aloo deliver inke in all colour tints which have been specially mixed for the printing of coli It the printer considers these indications con- eming the use of the right Ink he ean put any Job that fits into a chaee of the Original Heidel. berg Cylinder on the press and print it with an unsurpassed inking quality,MAINTENANCEunningrin the mechine Any new piece of machinery needs to be carefully “The precision built Original Heidelberg Cylinder is no exception to this rule During the first week of operation we recommend thatthe speed does not exceed 3,000 ph, With each of our machines we supply an cil chart developed In co-operation with several well-known ‘mineral oll frms. We would particularly refer you to the running-n oll forthe gear box listed under (0) in the oil chart. These running-in ails are encch- ed with additives agalnst wear and seizing: Do not fls0 use Molykote adeltives (we are not neces- sarily opposed to the use of Molykote provided the specified quantities en strictly adhered to) During normal operation, the pump handle of the one-shot central lubrication is pullad to the left twice every four operating hours. During the run- In petiod, we recommend two strakes of the ‘central lubrication lever every two hours, A careful ruin pariod wll assure many years ‘of troubletree service and a minimum of wear Lubrication of the machine To ald you in overall maintenance of the press, the lubrication points are divided into three ‘rau: 1. Dally — all oiling points and nipples in red must be lubricated daily, 2. Weekly — all yellow points and nipples should be lubricated weekly, ‘3 Semi-annual — all ports marked greon requiro lubrication every six months, The bearings of all inking rollers must only be lubricated with grease. To prevent any miup In lubricstion, the olling points have been given 2 different shaped nipple from those which require grease. Two diferent types of lubrication guns are supplied with all machines. The mouthpieces on thase are differant. ‘The short lubrication gun is for olling, while the longer one isto be used for grease points it lubrication All bearings which must be lubricated with oll are fitted with round protruding ripples. Illustration 11, 1 shows the shorter gun Lubrication must be made in accordance with the oiling specifications given on the instruction plates ofthe machine is 11tus. 12 shows the greese gun fan the forme roller nipales. (Groace lubrication ‘The following parts should be lubriceted only with crease: 16 bearings for the forme rollers, ductor roller and cistrbutor rollers. Lubricate these regu larly once @ week (8 bearings on each side) 1 lubricating ripple (yellow) at the outside of the Ink side frame (operating side) 1 lubricating nipple (yellow) at the Inside of the Inkor side frame (operating side) 1 lubricating nipple (yellow) at the outside of the inker aide frame (drive side — ewingup dsc querd) 2 lubricating nipples (red) for the bearing of the vibrator roller undemeath the duct role ‘These lubricating points have been fitted wih hollow type nipples and thus can be fed only by the long shaft grease gun, 1k should be especially emphasized that only high qualty ball bearing grease is used for the grease gun, Do not use ordinary cup grease as Wt has 2 tendency to get herd after @ certain time. ‘About once a month the teeth of the main pinion ‘49 woll aa the upper goar rack below tho type bed ‘and the lawer one in the base should be greased thoroughly by hand,Contra lubrication ‘The one-shot central lubrication pump supplies the exact smount of ll required to all major lubrication points. In operating the central lubrication the following points have to be observed 1. Ifthe machine is ile for 2 t0 3 days or longer, the rad ball handle has to be pulled fully to the lef least four times before starting the machine. About 10 minutes after starting the machine, we recommend a fith stoke of the ‘pump handle It ig of pericular importance to follow these Instructions since the all lines of the central lubrication system may partslly drain. When ‘operating the lever ® heavy counterprossure should build up. The presence of this counter- pressure guarantees that the oll dace get to the bearing points in the desired quantity. It Is therefore abeoluety imperative, that the lever for the central lubrication 1s pulled the full distance unt it roaches the red mark on the oll reservar. It may be necessary to operate the lever several times until the counterpressure builds up. 24 The oll reservoir for the one ‘shot central lubrication is fitted to the side frame of the delivery unit on the operstors side (Ilue- tration 13), us, 13 2. ARer this, the lubrication pump should be ‘operated every four hours while the machine | running. We recommend lubrication when running at low speed because this wll quaran- tee a batter oil cstribution \Whan the lover Ie operated without building up ‘counterpressure this Indicates thet the oll reser- Vole is empty and should be refiled immediately If the reservoir is allowed to become empty, it ie possible for air bubbles to form in the oll lines, ‘Therefore, on rafting, dlsconnact the all line Junetion, situated alongside the bed on the operat- Ing side of the machine, and then pull the handle to ite full extent soveral times to ensure. that fresh oll penetrates to all Lubrication points. Care must be taken to reconnect the oll junction 9 son 28 it ig clear thet the cil flow is free of sir bubbles, Tho oll level can be checked at the glass gauge of the pump. Should the oil level in the less gauge get below the mark, now oll hes to be ‘added, During the weokly cleaning of the machine It le advisable to fil the of roservor. Please do not remove the fiter. Any dirt or foreign matter {getting Into the aystem may have very serious ‘consequences.‘Gear box oil bath A further weekly check is that of the oll level in the gewr box Al geer wheels and bearings are Iubrleated from.an oil bath that hae a capacity of 14% pints (B I). This oll should be Energo! Ref 8109 or other olla with viscosity of 12° £/50° ©. A dipstick ie located on the flywheol side et the bottom of the gaer box. The dip stick should be removed, wiped clesn ond re-dipged to secortain the level oF the il while the machine le stati nary. If the level does not reach the mark on tho dipstick, it should be topped up unlit does, but should not be filled sbove the mark (Must tion 9}. It may often be found thet the level of cil in the geer box Is sbove the mark on the dip-stick a8 oll from certein bestinge which ore connected to the central lubrication system drops Into the gear box. The machine should not run ‘whilst measuring the oll level, |A white marked hexagon screw le locsted at the bottom of the goar-box housing underoath the fiyswheel and should be used to drain off any surplus ol It io recommended to change the cll in the gear box ance yeer Cleaning the machine ‘The machine must be thoroughly cleaned at loast once a week. Special care must be taken to re ‘move all spray deposit from open oll holes. All important oll holes on the Original Heidelberg Cylinder are provided with oiling niaples in order to prevent them from becoming clogged by the powder when using the powder spray apparatus, Al air blast holes on the feed table and on the delivery system should be cleaned weekly with brush, Only usea sereying fluid that ean be rubbed off with a dry rag When clean, all bright parts should be rubbed over with a greasy rag to prevent rust. Spraying Fluide that are inclined to produce rust should not be ued For the maintenance of the machine rustpreventive cil con algo be used, e.g. "Rust-Ban $370” manu factured by the ESSO CompanyThe automatic cutout device on the swinging (ripoer ber should be eleanes every three months wth the clesning fluld for the roller. The action Of the control rods should be chacked to ensure ‘hey move freoy. The sludge trough and blade of the raller wash Ing device should be cleaned dally, otherwise the Ink residue wil harden snd the device will lose its effectiveness In ordor to avoid as far as possible peper Falling Into the gears as may occur when a sheet has not been fed correctly or torn sheets are contained in the feed pile: and in order to prevent accumulated spray dust from the printed shests entering the ddeving aystem, the important pets of the machine re covered, tue. 15 ‘Cleaning the si flor inthe ‘uetion and air pump In Iustration 15 the cover of the fair pump '¢ shown withthe fiter through which the susked-in air has to pats. The filter chould be orewed off evory four woeks and clesned by whirling In benzene or ‘quick drying ferme cleaning so! ‘ont ito which it hae been dipped. Cloning fluid for the rollers should not be used ee it contsine 2 proportion oF oil end, therefore, dooe not dry quickly. Finally rub the. fltor with a dry rag and plac it on the pump cover. ~ These cover guards are designed in such @ way that they will push mis-fed sheets over the pinion shaft to the rear of the machine, where they can be removed, Nevertheless, as the bese cannot be entirely en closed it may happen that @ sheet fells Into the racks. The sheet should be remaved immediately and any small frogments of it that may stil be adhering to the rack pinior recovered. The rack beneath the type bed should be chocked and clasned if necessary ‘The interior of the base 1s accessible by removing tho front guard and sliding the reer guards to the eld, If all fragments of the sheet are not taken out the prints will show slur on those parts where paper is adhering to the racks, Ifthe run is lengthy the blocks mey even become discrted ™‘When does the pritor use 2,3 or 4 forme rollers? ‘The Original Heldelberg Cylinder is 2 general purpose mochine. lis inking system has been designed for use of 2.8 or 4 forme rollers, de pending on the type of Job thet Is to be printed ‘The most essential advantage is the use of 4 Ferme rollers on difficult halfiones or solids. I is wall known to printers that the ink film necessary to get good Ink coverage can be reduced when nore forme rollers are employed. When the ink film necessery for a given forme is assumed to bbe 100%, each forme roller must carry an ink film of 50% when only 2 forme rollers are used, With 3 forme rollers the figure would be 33% while the ink film for the use of 4 forme rollers would be only 25 % per roller. For machines with 2 or 3 forme rollers the ink flow from the top must be heavier in order to ‘obtain the same coverage as when employing 4 forme rollers, where from the very beginning 2 smaller ink flow is possible. The distribution of the ink on the forms takes place under consi- erably more fevourable cordtions. For thio reaeen haltones, inked with 4 forme rollare cen be run for many hours without wash- Ing the forme. The sereen file up considerably Jose than when the forme is inked with 2 or 3 forme roller. (Of course, it le not always necessary to use 4 forme rollers with the Original Heidelberg Gylinder. For many jobs 2 or 3 forme rollers will ive very satisfactory inking, ‘The following comments and drawings give mare detailed Information 2 forme rollers tus. 21 ‘Two forme rollete are generally used on simple ‘ype formes, formes with rules, or on jobs which cal for plunger operated numbering machine. (On sumbering work, plastic rollers ere preferable singe they are more resietant to cutting than rub- bor rollers) It i¢ recommended that the same two forma rallers alvays be used on such Jobs. Forme rallor scjustment should be exact. IF they are ‘adjusted too low, damage will result in time from the rules and the numbering box plungers saIe le up to tre machine:minder to decide whether combination, each roller would cor ‘wa rollers closest to the cylinder or the second procating stasl distributor roller fand third rollers ere to be used. In the latter the reci- 3 forme rollers General job work, especially large type formes, contacting the forme. The clatanos marked "x" ‘can be printed very nicely with thse forme rollers. in our diagram shows that the inking line of the Adequate inking Is possible since tha third forme third farme roller is considerably in advance of the roller is Inked over Its entire clreunference before printing line, 4 forme rollers \ \\ . tis, 99 Fine screen halftones, large solids or troublesome rollers of the Heidelberg Cylinder insure coverage king Jobs ere best handled with four forme rol- to mest every job requirement lers. The excellent inking system and four forme otus. 28 Incorting The cups for the forme snd distributing rollers ‘re 80 designed that all rollars can be inserted for taken out without loosening oF dlaplacement of @ single roller cup. All cups on the operator's fide ere provided with slide-n-bushes which can be lacked in the pushed-in pasition as well as in drawn back position. In the werklng postion of the rollers they have to be locked to prevent them from coming out When inserting the three distrisutor rollers and the vibrator the slidein-bushes are firet drawn back and locked, Now one roller afer ancther is inaertod, the lde-n-bushos aro released and pressed to the inside. Take care that the locking bolt drops into the groove of the bearing. lustration 34 shows the insertion of the vibrotor roller. The Bearing in the drawn back position is secured by the locking bol. After the roller end has been inserted in the bearing on the motor ‘ide the other end Ie put Into tho bearing on tho operator's side. Then the locking bolt shown in Illustration 24 ig raised and the beering is pushed to the inside til the locking bolt jumps In the ‘groove. The picture shows cleariy the position of the locking bolt of the inserted distributer roller underneath the bearing ofthe vibrator. Insertion. of the remaining distributor and the forme rollers is csrred out in the same way. Inserting the forme rollers 1. Fun type bed as far back under the eylinder 8 posable 2, Pull beck besrings on operator's side snd en- ‘9898 locking bolts. 4. Start with insertion of the forme roller nearest to the Impression cylinder, inserting it fist into the disengaged cup on the operators side 4. Insert roller end in the bearing on the moter side, 5. When Inserting the roller end on the motor side, the roller end on the operator's i slides out the cup as this is stil puled beck. ‘The roller end le put on the protection guard undemeath the bering, 6, Lightly lit roller end and st the came time disengage the bush of the bearing cap on the operator's side. The besring slips automatically by spring pressure over the roller end. 1. Cheok whether locking bolt le fastened cor rectly 8, Inger romeining rollers in the 6amo way.Teking out the forme rollers 1, Run type bed aa far back undor tho cylinder 26 possible. 2, Pull back bearings on the operstor’s side and ‘ngage locking bolts 4. The forme roller to be taken out is rensarted with 1s end in the pulled beck bearing on the operator's side. 4, The roller end slid out of the bearing on the ‘motor side during this operetion is swung a Dit end the roller agsin pulled out of the bearing on the operator's side, The roller le now frae on both ends and ean be taken out of the machine letibutor rollers Taking out tho | when teking out the remaining rllers the various locking bots are dlaengaged first, s0 that the bushes can be pulled beck. The locking bolts then trop inte the grooves provided for this positon fand keep the bushes beck, Now the rollers can bo taken out one after ancthe. ‘The beering cups which have been adjusted and screw should not be loosened to avaid s refed In thelr postion by means of a hexagon adjusting of the rollers after the new insartion. It goss Without saying thet the rollers, marked by grooves In the usual way, are always inserted in the sama bearings as minor differences in diameter exist Taking out the rubber rollers, and the forme rollers in particular, ie necessary only once a week In order to clesn them thoroughly. This is 2 further advantage of the rubber rolls. ‘Adjustment ofthe vibrator Tho vibrator Is pressud against the duct roller fn beth aides by means of springs compensating automatically differences in diameter. The con teot of the vibrator with the inking eylinder, how ‘ever, hes to be adjusted carefully a¢ the move- 58 ment of the vibrator to the inking cylinder is carried out positively. The adjustment is. shown In lustration 35 Before starting the adjustment run the type bed ‘about 8” (20 cin) chead of the dead centre posir tion on the inking apparatus side. In this position the vibrator should be in contact with the inking ovlinder. Undornesth the end of the duct roller @ hexagon sorew with nut ean be found on bath sides. The hexagon screws re adjusted on both sides in uch @ way that the vibretor ie in light contect with tho inking eylinder then the countar nut can be tightened. The correct contact of the vibrator with the inking cylinder is checked in the usual way with two pager stripe, |.e. they are put on beth sides between vibrator end inking eyinder ‘The adlustmant Is correct whon the paper strip can juet be pulled out elonly without tearing of. us. 35ue. 36 |Adjueting the distributor rollers The three dletnbutor rollers ere each located betwoon two inking cylinders and have to bo adjusted in such a ay that each dlstnibutor raller ually contects the two Inking eylinders, For ‘coract adjustment, loogan adjusting screws on both bearings. The distributor roller cen now de brought in contact with ona inking cylinder. The agjustment with the second inking cylinder Ie done by turning the eccentric bearing by moans of the eet ecrow with worm gear locsted at the Inside of the inking apparatus. This lite or lowers the rollor Ietration $6 shove the eet sorews with the worm gor and further demonstrates that the contra of the roller jo marked with © red point on the worm goar. According to the motion of tho point it-ean be noticed in which direction the roller ie adjusted. It is selFexplanatory thot the roller beating should not bo tightened while making this adjustment, i.e. the eet ecrew with hexagon hheed remsine loosened til the rollr touches bath inking cylinders, The correct adjustment is checked in the usual vay by maans of two papsr stripe. When the distributor roller le In coreect contact with both steel cylinders the roller bearings are tightened with box spanner. Finally the atop screws — which con also be seen on illustration 98 — ore edjsted 20 that the correct alignment will not be lost.A ating the forme rollers The forme rollers have to contact the Inking cylinder and be fedjusted to type-high, First loosen the set screws of the bearings fon motor and operator's side by means of the speclal spanner delivered withthe machine (see Ilustration 37, When the bearings are loosened, with the eid of en assistant, press the besrings with the roller equally against the Inking ylinder on both the motor end the operstor’s side till the raller touches the inking cylinder ith the type high gauge supplied with the machine the roller is adjusted to type high. Each roller can be tested without remov- ing any from the machine, |e, eech one can remain inthe machine uring the test. This Is of imporance wien the correct adjustment of a singe forme roller isto be checked. Insertion of the ‘remsining distributor and the forme rollers Ie ‘artiod out the same wey. To faciltate handling the gauge properly = white mark has bean recessed into the handle. The gauge ie in the correct position for chedking the rallers when the white mark le mad up. When the gauge Ie Inserted the mark canaot be seen from the top, 50 lus. 37Mus. $8 Ive. $8 Having adjusted the rollers to type-high, the con tact agsinet tho inking cylinder has to be chocked ‘once more and corrected if necessary. The gauge ie put on the typo bod with the flat cide and moved in thie postion bohind the roller to be adjusted {llwstration 38). The height of tho flat cide Is lower than type high eo the gauge can be put in without touching the roller, The gauge then is turned to bring the round portion on the type bed (Ilutra tlon 39). In this postion the gauge i exactly type high It fe now moved forward or backward beneath the roller. Before being pulled out, the gauge is turned again on its flat side 0 the preseman can check the ink etrip on round portion from contact veith the roller. The width of the ink strip should bbe approximataly "se" (1 mm). Sinco the adjust: ment of the roller for height is based on the ink ‘rip on the gauge, the roller must be inked,‘The adjustment in height of the rollers themselves ia effected by turning the mieto-adjustere with a tommy ber ee much oB needed (llustration 40) The micro-sdjuster again operates a worm drive at the eccentric roller bearing which lis or lowars the roller, This worm gear, too, Is provided with a red point showing whether the roller Ie lied oF lowered. After correct adjustment of the roller, the bear- Ings ere tightened with the box spanner and the stop screw at the bottom of the bearing is tumed ageinst ite stop and lacked, Digongaging rollere Disongaging the rollers is generally only necessary during @ long ‘stop oF over night. For this purpose the hexagon screws of the bearings are merely loosened on the operator's side with the box spanner. The bearing with the roller has to be mavad back from the cylinder and the set screw of the bearing slighty tightoned, Ie fe sutfietent when the pressure of the rollers against the inking finder Is eased. For engaging the rollers the operation Is done The vibrator roller is disengsged when the type bed is in its dead centre position at the inking ond. In this postion ll forme rollers clear the forme. It Is recommended that the machine should be left in this postion when it stands idle for any length of time © Is. 40Is, 42 ‘The duct roller has an adjustable Ink feed from 0-314" (0 to 90 mm) which can be adjusted Infinitely by tuning @ smell handwhes! on the ‘operator's side (lustration 42), It la advisable when setting the Ink at the be inning of @ run, t0 work a6 much as possible with the regulation of the Ink strip rather than with the aatting sorewe on the duct. Better dst bution is obtained s there is a thinner film of Ink to Bresk wp, The plexiglags guord can be removed for cleening Regulating the Knife and ink stip The Inke knife is regulated by 24 fine setting screws which can bbe adjusted to sult the require: ‘ments of any forme. The scale ‘on the ink duct is reproduced on the dalivery table. The two scales enable the operstor to regulate the Ink supply with accuracy. 6Engaging and disengaging ink supply It has previously been explsined vhat the singla lever contr ‘automatically trips the ink supply when the control laver off impression. When, however, the Ink is ta be run up with the contol lever off impression or it necessary to tip the ink supply when the control lever is on impression, a lever locsted on the side frame of the Inking apparatus hes’ to be employed accordingly. If the lever 12 engaged in “INK OFF” position the Ink eupply Ie trloped, oven wien the control lever le on impression. IF the lever is engaged in "INK ON” position the ink ia supplied even when the machine rune off impreseion (iustration 43). Normally the lever remains in disengaged position otherwiee the ‘automate function will not operate, 2Fegulating the reciprocating rollers The four steel distributors (3, 5, 7 and 9 ace ils tration 31 on page 52) with different diameters Feciprocets in opposite directons. Racipracstion ‘can be adjusted fram O—134" (0-48 men) The regulating moohanim ie located on the drive side behind @ deo guard which con be ewung Upward (Ilustration 44), Loosen the hexagon bolt with the box epanner (whichis eleo used for looking the forme rollers), tet the Indlestor on the required reciprocation ‘and ratighten the hexagon bott Tha amount of reciprocation depends on the requirements of the jab, Solids or reverses that tond to repoct ‘often need all the reciprocation that cen be ‘obtained. Most Jobe, however, can be inked sat faotorly with @ reciprocation of 1%", Reciproce- tion does, of course, mean added wear en the rubber rollers. So maximum reciprocation should bbe used only when absolutly necessary Me, 44The roller washing device is besed on the principle of epalving 8 blede to the eecond inking cylinder from ebove, The blede Is brought into. contact with the cyinder with a lover on the side frame of the inking unt on the deve ide. To operste the rollor washing device proceed 98 fllowe: lus. @5 1. Insert the sludge basin (Ilustration 45), 2. Set the control lever in "RUN" position. The Ink supply Is ‘automatically tipped provided that the lever for the ink supply Is in te normal position, 3, Set the speed control st the lowest speed Do not engage the washup blade bofore you have applied ashing fluid to the rollers, 4. Take the plastic tubs leading from the glass conteiner and hold the nozzle between the twumb and middle finger. Close the nozzle with the index finger so that the flud cannot spurt out whan the nozzle is below the level in the glass 6ue. 46 Holé the nozzle above the rollers, remove indax finger and allow the fluid to run on the ellrs, It is advisable to start cleaning one half of the rollers from one side, then repest on the other side. This insures just enough roller frietion necessary for cleaning (Illustration 46). ‘The lever for spplying the washup blade is positioned on the sida frame of the Inking unit below the cleaning fluid container. Normally this lever is on position "ROLLER WASHING COFF* (llustraton 47). When the lever 1¢ put on position “ROLLER WASHING ON” the bist ‘is ongaged (Ilustration 48) ‘The blade removes the ink sludge from the inking oylindar in @ manner similar to ® wiper blade cleaning a windshield Continue applying small quenttiee of uid unt the roller ere clean, Do not engege the bode to the DRY inking cylinder. Care should be taken that no washing flud Is spread on the roller cores, as this may result 19 @ washing out of the il film in the roller bearings due to the reciprocating move. us. 47 ‘mont of the dletrbuting rollers. Aer the was Ue the pump lever of the central lubrication should be operated,9. It i not necessary to clean the sludge trough ‘each time the rolers are washed. However, It should be taken out snd put on two angles lundemesth the foatnoard at the rear of the base (llustration 48), It Is practical to cleen the blade after each ‘washup. This will prevent sludge from drying find hardening on the blade making it rather dificult to clean, ue. 48 For easy cleaning, the blade can be dropped downward by pulling down a lever inside the side frame (llutration 49). When cleaning the bieds With @ rag, be eure sludge does nat érop on the forme since the slidge baein f out when tho blade is being clesned. ‘The lever must be retumed to ite previous posi- tion after cleaning hae been completed. ts, 49‘After washup the machine minder merely engages the ductor roller, runs. up his ink and continue the run. During @ long stop, al rollers should be disengeged When weshing up far a colour change, eay from black to yellow, the operator frst washes off the beck ink. He thon places a ita yellov ink on the ductor rollar and runs up the ink until ie ie evenly distributed. He then waehes up again It is advisable to reserva one set of rollers for Printing the dark colours, such os blue and black. The other set is used for the lighter colours, uch as red and yellow. This wil facilitate roller wash- Ing and reduce the time taken for washup. Ink and roller manufacturers sell praven raller wash Ing fluids, Under na circumstances should fluda which contain. eromatic hydrocarbons, such 2s carbontetrechioride and triclorosthylene be used. These agents attack the rollers. Be sure that con= tainers ere plainly labelled so that the forme and type cleaner is not mistaken for washup solution Wo recommend ¢ fluit that Is dyed, making mie. takes impossible. White pit ie suitable for roller washing ‘After washup, the forme should be cleaned with 4 brush and type cleaner in the uoual manner. The entite inking system should be thoroughly ‘leaned once each week. The rollers should be removed and washed by hand. This particularly pales to plastic rollers, The washup blade should be cleaned carefully Rollers should be treated with » rubber raller coneltioner or a regeneration paste (lke Rollo: paste) after the weekly cleening. The paste should be kept on the rollers atleast twelve hours. It is washed off with & rag sosked in lukewarm wate. The life of the rollers is considerably extended by such treatment. Plastic rollers should not be tested with regeno- ration paste since tho pasto will attack the surface of the plastic material. However, plaetic rollers should bo cleaned with special care at regular Interv 6Clearing the duet and the ductor blade The ink duct is provided with two handles and can be cropped ddavn after unacrewing two knabs and swinging the two latches Uuaward. The duct roliar and the Ink blade are then well accessible for cleaning (Wlustration 60) Before swinging back the ductor plate apply # drop of oil to the fend feces of the ductor roller to prevent seizing on the and pletes ofthe duct. tts. 51 tus, 50 Cleaning the splash guard ‘There is © splash guard fitted betwoon tho im: pression cylinder and tha inking system. Ths ‘querd prevents ink from gating an tho cylinder {uring the run The guard fits In guide rails on the drive side and operator's side, To clean, it ie pulled cut after falsing the sheet guide er, Removing of the ‘slash guard ie done without the use of toole {iustration 51, No lock or safety machanism is necessary: Before removing the guard, stop the machine with the tympen reels toward the ink fountain. Other wise the cylinder segment gears could make it difficult to replace the guard | secs yeeros EESPositioning the forme The positioning of the forme, setting the lays, and positioning tho papor on the feed tble are greatly feclltated by graduated scales on the chaeo, sido lay bar and food table. Markings on the chaso ber (llustrstion 52) aleo indicate the position of tho cylinder erippore, feed table grip pers, the four front lays, and the limits of the two side lave. The sesles and markings enable the forme to be locked up correctly relatve to the sheet, lay and the various grippers When locking up the forme, care should be taken that the type matter does not exceed the maxi= mum from ineide the chese ta the leaving edge. ‘As an extra precaution a line will be found on the type bed indicating the printing lim. The following points should slso be teken into con- sideration when positioning the forme inthe chase When a sheet has to be backed up, shvays use fide lay on the operator's side first as itis more ‘conveniently reached. When printing twe-up, both side lays are employed If the sheste hove to be backed up when print= ing two-up, an additional side lay can be inserted In the midele of the teble (see page 111), [After the forme hes been positioned, a sheet of the paper the job is to be printed on, Is laid on In It position. From the acale on the chase, @ reading (say 28) can be obtained. The feed table Is adjusted to the same reading 0 that the sheet | fed into the lay in the correct position, The side lay Is also adjusted to 28 on the graduated ber on which it is mounted, The reading for the side lay should be taken from the inside of the bracket on the graduated bar. This seting auto- matically allows for the lateral movament of the side ley OF the six front lays provided, only two ere employed at @ time, the remining few should be adjustod 60 that they do not make contact with the sheet. The size of the sheet determines which ‘wo front lays will be employed, and the forme shauld nat be positioned s0 that they come on the extreme ends of tho sheet, or register will be affected. With a fullsize sheet the first and lath lay, should be used. The ripper bite has also to be taken Into account ‘when positioning the forme, this varies from She” to */a” (B to 10 mm). The permanent front lays have @ %/e” (2 mm) adjustment. Position the forme 0 that adjustment in each direction is possible. Good quality metal quoins and accurate furniture avoid loss of tine through rising spaces and spring- ing blocks which cause slurring In order to facttate positioning and adjusting the formes when printing mult! colour work, an extea accessory is supplied with the Original Heidelberg Cylinder which allows to position exactly the various formes outside the press. A detailed das- cription of this adjusting device can be found on pages 116-121.Locking the forme on the bed ‘The rack guards on either side of the bed are provided with two ledges on which the metal imposing board can be mounted anc pushed forward, #0 that it lines up with and contacts the bed of the machine. The bed of the machine is run out as for es it will go for this purpose. The Imposing board greetly fecitstes the handling of the forme as it can be slid from the Imposing bord to the bed of the machine with ease. ‘As soon @8 the forme is on the bed and the imposing board moved, loscen all quoing in the forme and ewing the two chase Tooke, which secure the forme to the bed. into position. Tighten ‘and lock with a torvmy bar (Hlustration 58) tus. 88tus. 84 ‘Sunk Into the two side bars of the chase are two round-hoaded sat acrewe which when screwed ‘outwards, by means of a tommy bar, make con- tact with bearers and prevent the chase from ‘seriaging when it ie relacked, ‘They furthermore ensure that the chase can be replaced on the bed in deed regiater if It has to be removed at ary time during the printing. When Batting these screwe against the bearers, no force should be employed, merely adjust them to a fim fit against tho bearers. Thess screws eliminste the dangerous practice of Inserting leade of stripe of card botwoon chase and bearer to counteract chase expansion (lustraton 54), Ifthe chase has to be removed from the bed ster register has been obtained or during the working of @ four colour job, take care that only one of these set screws is loosened ata tim. The other acta as a guide when the forme is replaced on the bed, and register Is maintained Aer the set sorews have been adjusted ageinet the bearers, the forme can be relocked, planed down and tested for any “spring” in the usuel way. nOpinions very over the make up end selection of the correct ovlinder dressing se well se over the positioning and method of make-ready. These dferences mainly arise becuse no set packing can be used for all work Neither can it be femployed on all types of cylincer machines with ‘equal euccess. We recommend two types of peck: Ing: one for type matter and tabular work and one for mixed type end block formes. These packings have besn thoraughy tested, All sheets of the packing should have @ 90" fold ‘bout 44" (2 em) from the end so that they can bbe easily accurately inserted in the packing clamp. No sheets, whether card or paper, should be inserted loose In the packing. A steck ofall sheets cut to ‘ize for dressing the cylinder should be kept, so that machine minders have the same meteral available each time they require It. This achieves f big saving, especially whan there is more than ‘one machine, A, Packing suitable for type matter and tabular work 1. Manila top sheet, pulled tight by ca bar 2, Manila second sheer, loose end 3. 67 shecte MF. printing, loose ond approx (002" (40 to 60 g) each, to achieve thickness ‘of pecking 4, Menila to carry make-ready, loose end. 5. Two Ivory boards, loose end totalling 6p- prox. ,018” (045 mm) thickness 2 Packing eultable for without type ge block formes 1, Manila top sheet, pulled tight by draw bar. 2, Manila second sheet, loose ond 5. Heidelberg blanket 010" (.25 mm, 4, 45 shoots M.F. printing, loose end approx. 1002” (40 to 50 g) each, to achieve thickness of packing 5. Manile to carry make-ready, loose end. 16, One Nory board, loose end totalling approx 1008" (0.2 mm) thickness, The sheots of M.F. printing that sre positioned fon either side of the maka-roady should be tom ‘out a8 required to counteract make-ready addod tothe evlinder. We recommend good quality ivory board for ‘ylinder packing, as sheets will always be found to caliper the same. Boards of uneven thickness cause unnecessary delay in make-ready. Careful selection of the correct packing for ey linder dressing, end the carrying of adequate, cut to size stock, saves time and money. Only use the best quality mania, calipering 003" to .004 (0.08 10 0.1 mm), which can be stretched Wight without tearing. Always test paper thick: nesses with a micrometer, type high gauge or 2 pair of calipers. The prescribed thickness of the Pecking together with a sheet of the stock which is to be run should be approx. 047° (1.2 mm) We recommend that the meke-rendy be pasted ‘on the centre menila se thie practioo hae boon proved the most successful, Manila le smooth and will not allow the makersedy to croep at wil a rougher paper.