Didde Apollo 11, 17" OLD STYLE Crestline® Altra SeriesTM

®
TM
Crestline Altra Series Dampening System
Installation Instructions
Didde Apollo 11, 17"
OLD STYLE
X88-62
01/2001
Rev-A
GENERAL INFORMATION
ATTENTION
CRESTLINE ®
ALTRA SERIESTM
DAMPENER
OWNER!
Accel Graphic Systems provides parts and service through its
authorized distributors and dealers. Therefore, all requests for
parts and service should be directed to your local dealer.
The philosophy of Accel Graphic Systems is to continually improve
all of its products. Written notices of changes and improvements are
sent to Accel Graphic Systems' Dealers.
If the operating characteristics or the appearance of your product
differs from those described in this manual, please contact your
local Accel Graphic Systems Dealer for updated information and
assistance.
Always update your dampener when improvements are made
available, especially those related to safety.
Your authorized Crestline® Altra SeriesTM Dealer is:
The serial number of your
CRESTLINE® ALTRA SERIESTM DAMPENER(S) IS:
SAFETY
INFORMATION
2
FOR YOUR SAFETY, DO NOT DISENGAGE OR REMOVE ANY
GUARDS FROM THE CRESTLINE ® ALTRA SERIES TM
DAMPENER. THE DAMPENER CONTAINS SOME INWARD
ROTATING ROLLER NIPS THAT CAN CAUSE INJURY IF LEFT
UNGUARDED.
GENERAL INFORMATION
BASIC
CONFIGURATION
OF CRESTLINE®
ALTRA SERIESTM
AND ROLLER
PRESSURES
c. 5/32"(5mm)
d. 3/16" (5mm)
M
b. 5/32" (4mm)
F
I
P
O
PLATE
CYLINDER
a. 5/32" (4mm)
Adjustments
Roller Description
a. Form to Plate
b. Form to Oscillator
c. Metering to Intermediate
d. Pan to Metering
F
O
I
M
P
TERMINOLOGY
TECHNICAL
ASSISTANCE
OPS
=
Operator's Side
NOPS
=
Non Operator's Side
=
=
=
=
=
Form
Oscillator
Intermediate
Metering
Pan
For technical assistance during the installation, contact:
ACCEL GRAPHIC SYSTEMS
11103 Indian Trail
Dallas, TX 75229
(972) 484-6808
FAX (800) 365-6510
E-MAIL [email protected]
WEB SITE www.accelgraphicsystems.com
Crestline® Altra SeriesTM is covered by U.S. Patents Pending
3
GENERAL INFORMATION
REQUIRED
TOOLS
4
1.
1/4" Punch
2.
3/16" Punch
3.
Spring Hook Tool
4.
Hammer
5.
5/16" Wrench
6.
7/16" Wrench
7.
1/2" Wrench
8.
9/16" Wrench
9.
5/8" Wrench
10.
3/32" Allen Wrench
11.
1/8" Allen Wrench
12.
9/64" Ball End Elbow Wrench
13.
5/32" Allen Wrench
14.
3/16" Allen Wrench
15.
1/4" Allen Wrench
16.
Phillips Head Screwdriver
17.
Drill
PRE-INSTALLATION INSTRUCTIONS
PRE-INSTALLATION PROCEDURES AND
HOW TO PARALLEL THE DAMPENER.
1. Cut the ties holding the rollers and examine the rollers for
gouges, scratches or nicks.
2. Check the box and parts boards to make sure all pieces are
present and nothing has been damaged in shipment.
3. Check the dampener alignment by setting it on end on a flat
surface such as a cutter bed. If dampener rocks, it needs to be
realigned. Loosen the tie bar bolt and align the frames on the flat
surface. Retighten bolt.
5
6
DISASSEMBLY
1
2
3
Remove ink form lever and water form levers (subject arrow).
At the OPS & NOPS, remove press side covers (subject arrow).
Cable guides from inside of press side covers must be disconnected before covers can be removed.
Remove entire chain guard (subject arrow 2 pieces) at OPS.
7
8
DISASSEMBLY
4
5
6
Remove water pan support bar (lower subject arrow) and water
filler cup (upper subject arrow).
Remove water pan (lower subject arrow), pan roller (upper subject
arrow) and drive chain. Drop the chain into the framework of the
press. Also, remove the fuse from the fuse box related to dampener
motor.
At OPS & NOPS, remove small plates (subject arrow).
9
10
DISASSEMBLY
7
At OPS remove set collar and spring (subject arrow) from ductor
shaft.
8
At OPS & NOPS, loosen ductor brackets (lower subject arrow) and
set collars (upper subject arrow).
9
At NOPS, remove snap ring and remove linkage mechanism from
ductor shaft.
11
12
DISASSEMBLY
10
At NOPS, pull ductor shaft through press side frames, sliding off the
ductor brackets and set collars.
11
At OPS & NOPS, remove shoulder bolt (subject arrow) from water
form adjustment arm. Save for reinstallation.
12
At inside OPS & NOPS, remove set collars (subject arrow) from
gear eccentric cam.
13
14
DISASSEMBLY
13
14
15
At outside OPS & NOPS, remove eccentric gear (subject arrow).
At OPS, remove oscillator linkage (subject arrow) from oscillator
drive housing. Save linkage and screws for reinstallation.
At OPS & NOPS, remove form roller housing (lower subject arrow)
and split set collar (upper subject arrow) from stock oscillating
roller. Save for reinstallation.
15
16
DISASSEMBLY
16
Remove 2 jam nuts (subject arrow) from oscillator drive housing
helical gear. The gear can now be removed. Save nuts for reinstallation.
17
Remove nut (subject arrow) from end of oscillator and save for
reinstallation. Remove oscillator housing at this time. Save for
reinstallation.
18
At OPS, remove roll pin (subject arrow) and loosen set screw on
worm gear from oscillator shaft.
17
18
DISASSEMBLY
19
20
21
Remove worm gear (lower subject arrow) and bearing (upper
subject arrow) from oscillator shaft. Save bearing for reinstallation.
At NOPS, remove nut (lower subject arrow) & washer, gear (upper
subject arrow) and woodruff key from oscillator shaft. Save for
reinstallation.
At OPS, remove retainer screws (marked by arrows) from oscillator
housing and pull housing out. Save for reinstallation.
19
20
DISASSEMBLY
22
23
24
From the OPS, remove oscillator roller from press.
At NOPS, remove large cap screw (subject arrow) holding the
press tie bar.
Prior to installation of Crestline® Altra SeriesTM, inspect the water
form roller housing removed in step 15. The bearing retainer cup
should rotate freely when lock nut is loosened. If it does not, please
disassemble and deburr as necessary.
21
22
INSTALLATION
1
2
3
Reinstall oscillator housing (subject arrow) from original oscillator
onto new oscillator provided. Install bearing from oscillator drive
housing onto oscillator.
Install new worm gear (subject arrow) using new roll pin provided.
NOTE: Hub of gear will face toward the threads of the roller.
Please refer to picture.
At OPS, reinstall oscillator from previous steps through OPS press
side frame.
NOTE: Be very careful not to damage roller when sliding it
through the press frames. It is a good idea to leave protective
wrapper on roller.
23
24
INSTALLATION
4
Install button head retainer screws (marked by subject arrows) in
oscillator housing as shown.
5
Install new helical gear (subject arrow) provided into oscillator drive
housing.. Tighten both jam nuts from original gear at this time.
6
At OPS, install oscillator drive housing (subject arrow) on oscillator
roller from previous step.
25
26
INSTALLATION
7
8
9
Install retainer nut on end of oscillator.
NOTE: Do not fully tighten nut. Leave approximately .020"
between nut and outside bearing (subject arrow).
Reinstall original oscillator drive housing linkage (subject arrow)
using 2 cap screws saved during disassembly step 14. The linkage
will reinstall in the same manner as the original with the connecting
link hooking to the new helical gear.
On inside NOPS & OPS, reinstall split set collar around oscillator
and flush against press frame. Saved during disassembly step 15.
27
28
INSTALLATION
10
Reinstall form roller housing (saved from disassembly step 15) next
to split set collar. Bearing retainer cup (subject arrow) should face
toward the inside of the press. The housing should rotate freely
whenever in position.
NOTE: Be sure retainer cup rotates freely as noted in last
disassembly step 24.
11
Install new form roller (subject arrow) provided into original form
roller position.
12
At OPS & NOPS, install lift gear provided (subject arrow). The
threaded portion on the end will be at the 6:00 position as shown.
"6:00" Position
29
30
INSTALLATION
13
14
15
At OPS & NOPS install thrust washer provided on lift gear at the
inside of the press frame. Install lift cams (subject arrow) provided
with dimple and set screw facing the feeder end of the press.
Alignment of these cams is done with dimples in the lift gear. The set
screws in the cams will fit in the dimples of the lift gear.
At OPS & NOPS, reattach water form roller adjustment arm to lift
gear using original shoulder bolts saved from disassembly step 11.
THIS STEP APPLIES ONLY TO DIDDE 11:
Mount the drill template to the frame of the press as shown in the
illustration. Drill out the holes shown using the drill bit provided.
31
32
INSTALLATION
16
Install OPS mounting frame using 2 small button head screws
provided (subject arrow).
NOTE: Be sure the threads are clean and have no debris. If
debris is found, clean out using an 8-32" tap.
17
Install NOPS mounting frame using 2 small button head screws
provided (subject arrow). Do not tighten at this time.
18
At NOPS, install provided drive gear & shaft (subject arrow) through
mounting frame and press side frame. At this time, tighten the 2
button head screws on the NOPS mounting frame.
NOTE: Make sure drive gear rotates freely.
33
34
INSTALLATION
19
At inside NOPS install bearing block using the 2 short spools, 2 hex
head bolts and 2 flat washers provided. Washers go on outside of
bearing block towards inside of press.
NOTE: Be sure drive gear rotates freely at this time.
20
21
At outside NOPS, install spacer bushing (subject arrow) on drive
shaft gear as shown.
At NOPS, install new drive gear with clutch bearing onto drive shaft
as shown. Be sure wording on bearing faces inside.
35
36
INSTALLATION
22
23
At NOPS, reinstall oscillator drive gear with original Woodruff key,
gear, nut and washer. Fully tighten at this time.
At outside NOPS, install new gear plate (subject arrow) with nylon
gear attached using large cap screw and medium cap screw with
lock nut.
NOTE: Finger tighten screws at this time.
24
It is necessary to adjust gear mesh between nylon gear (lower
subject arrow) and idler gear (upper subject arrow) to achieve
proper backlash. To adjust, slide gear plate up or down while
moving nylon gear back and forth by hand until a very small amount
of movement is possible (.004" - .005"). When finished, fully tighten
bolts near gear plate. (This can be adjusted further, later on if
necessary.)
37
38
INSTALLATION
25
Install thrust washer (upper subject arrow) on drive shaft next to
drive gear. Install bearing block (lower subject arrow) onto drive
shaft.
26
Secure bearing block using longer hex head bolt (marked by
subject arrows) and flat washer (washer to the outside). The longer
spools will be placed between the bearing block and gear plate.
NOTE: Make sure drive shaft rotates freely after tightening.
27
At outside NOPS, install thrust washer and split set collar (subject
arrow) on end of drive shaft.
39
40
INSTALLATION
28
29
Sit dampener into mounting frame bearing cradles as shown, and
center the dampener.
At OPS & NOPS, install mounting frame bearing caps (subject
arrow) securing dampener in place. Tighten cap screw and hex
head bolt at this time.
NOTE: Be sure cap numbering or letter designation coincide
with those on the mounting frame.
30
At inside OPS & NOPS install extension springs (subject arrow)
provided to spring studs on dampener side frame and dampener
mounting frame.
41
42
INSTALLATION
31
32
33
Install water pan as shown (subject arrow).
Install wash-up tray (subject arrow) with tabs on tray fitting over pins
on inside of dampener side frame. This will be secured to the lower
dampener tie bar.
Install NOPS guard mounting bracket to NOPS mounting frame
with 2 button head screws (subject arrow) provided.
43
44
INSTALLATION
34
35
36
Install OPS guard mounting bracket with microswitch (subject
arrow) to OPS mounting frame.
Install dampener guard, sliding hinges (subject arrow) attached to
guard towards the inside. This will allow the guard to slip easily into
the mounting hole on the guard brackets. Center guard in relation
to dampener and tighten the screws on the pivot hinges at OPS &
NOPS.
Install microswitch trip cam (subject arrow) to OPS guard hinge and
secure. With the dampener guard closed, the flat side of the cam
should be parallel with the microswitch lever.
45
46
INSTALLATION
37
At OPS, split common wire to upper microswitch of press. Then
using provided T-Tap connectors, connect one T-tap connector to
each wire previously sliced.
38
Using provided harness, connect male connectors to T-tap connectors and female connectors to the microswitch on the Crestline®
Altra SeriesTM unit.
39
Attach external bottle bracket assembly (subject arrow) to outside
NOPS mounting frame with 2 button head screws. This will fit just
below the guard mounting bracket.
47
48
INSTALLATION
40
41
42
Attach NOPS side cover (subject arrow) to stand-off in NOPS
mounting frame with button head screws provided.
At the OPS original press side cover, make a small notch as shown
(see diagram) and reattach cover to press with wiring harness of
Crestline® Altra SeriesTM routed through the notched-out area. With
cable guides provided, secure original wiring harness and Crestline® Altra SeriesTM wiring harness to inside of press side cover.
Reinstall OPS press side cover at this time.
Attach OPS side cover (subject arrow) to stand-off in NOPS mounting frame with button head screw provided.
Reinstall NOPS press side covers to original location. Reattach all
levers and knobs removed during disassembly.
YOU ARE NOW READY TO MAKE FINAL ADJUSTMENTS.
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50
FINAL ADJUSTMENTS
1
5/32" (4mm)
M
F
I
P
O
Plate
Cylinder
2
Make sure ink and water forms are in OFF position. Dab ink on the
water form roller and slowly run press for 30-40 seconds to distribute (only the form and oscillating roller will ink up at this time). Turn
off the press and allow sit still 15-20 seconds, then jog the press
forward slightly and observe the strip between the water form roller
and oscillating roller. It should be 5/32" (4mm) and parallel. To
adjust, loosen the nut on top of the form hanger (right subject arrow)
and with a punch or pin wrench, turn eccentric housing (left subject
arrow). Moving pin wrench toward ink rollers will increase the stripe
and vice-versa. When finished, retighten nut.
With a metal plate mounted to the cylinder, drop water form to plate
and observe the stripe. It should be 5/32" (4mm) and parallel. It is
adjusted with the nuts on the form roller eye bolt (subject arrow).
Backing the eye bolt out makes a thinner stripe and vice-versa.
Fully retighten nuts when finished.
NOTE: This will be more accessible with the metering roller
removed.
5/32" (4mm)
M
F
I
P
O
Plate
Cylinder
3
5/32" (4mm)
M
F
Plate
Cylinder
I
O
P
Temporarily remove the Crestline® Altra SeriesTM metering roller
and with a rag and roller wash, clean the Crestline® Altra SeriesTM
intermediate roller. Place water form lever in "ON" position and
then back to "OFF". In addition to the form roller lowering to plate,
the intermediate roller will lower to meet the oscillating roller. Spin
the intermediate roller around by hand and observe the stripe. It
should be 5/32" (4mm) and parallel. To adjust, loosen lock bolt on
eccentric on dampener frame (subject arrow), and turn eccentric
toward delivery end of press for a thinner stripe and vice-versa.
When finished, retighten bolt.
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52
FINAL ADJUSTMENTS
4
3/16" (5mm)
M
F
I
P
O
Plate
Cylinder
5
With all rollers in place, spin ratchet gear (lower subject arrow)
down until it stops against stud. It is not yet locked to the knurled
knob. Dab some ink on the metering roller and slowly run the press
30-40 seconds to distribute. Turn off the press and allow to sit still
for 15-20 seconds, then jog forward slightly and observe the stripe
between the metering and pan roller. It should be 3/16" (5mm) and
parallel. To adjust, turn knurled knobs (upper subject arrow) down
to increase stripe and vice-versa. When finished, lock ratchet gear
to knurled knob with set screws in gear. This sets the maximum
metering pressure (minimum water) on the Crestline® Altra SeriesTM
unit.
The water level in the pan must be set approximately 1/2 way up the
pan side wall. To adjust, place full water bottle in bracket and allow
pan to fill until bottle stops bubbling. To adjust level, loosen screws
in bracket (subject arrow) and raise bracket to raise level and vice
versa. Retighten screws when finished.
YOU ARE NOW READY TO PRINT.
M
F
Plate
Cylinder
I
O
P
1/2 way up
in pan
53
BASIC OPERATION
START OF DAY
A.
Make sure the oscillator and metering rollers are in
place.
B.
Spin knurled knobs until the shoulder on the ratchet
stops against the bar.
C.
Mount plate to cylinder. Wipe down all plates before
running. Pre-ink the Crestline® Altra SeriesTM dampener
before running the plates with an extremely light
coverage of ink.
D.
Place water bottle in bracket.
NOTE: Accel recommends using the proper fountain solution for
the plate material being run on the press. A good acid/gum etch
should be used with metal plates.
RUNNING
DURING THE DAY
54
A.
In general, the Crestline® Altra SeriesTM dampener should
not have to be adjusted from job to job. The form roller
settingshould never be changed unless it has deviated
from the factory specification of 5/32" to the plate.
B.
Adjustments to the amount of water fed to the plate are
made by the knurled knobs that apply pressure to the
metering roller. The dampener has been set up for
minimum water. To increase the water to the plate, turn
the knurled knobs counter clockwise 1 or 2 clicks at a
time. This opens the gap between the metering and pan
rollers and allows more water to the plate.
C.
In general, more water will only be required when going
from a metal plate to an electrostatic or Silvermaster type
plate.
CLEANING & MAINTENANCE
WASH UPS
DURING THE DAY
END OF THE DAY
1.
Remove bottle and drain the excess water from the pan.
2.
Mount clean-up mat to the press or if applicable, a washup attachment along with a metal plate to act as a bridge
between dampener and inker.
3.
Turn on the press and squirt a small amount of press
wash on the ink and dampener rollers. (Squirt ink rollers
only if using a wash-up attachment.)
4.
Drop both the dampener and ink forms to the plate. If
using an attachment, generally the dampener will pick up
enough roller wash off the plate to clean itself, so apply
wash directly to the dampener only when necessary.
5.
Remove water pan and clean any solution left in it.
6.
Be sure to wipe excess clean up solution from the ends
of the dampener metering and pan rollers.
1.
Wash up dampener as described above. Pay close
attention to cleaning the ends of the pan and metering
rollers that extend past the form rollers.
2.
Spin the knurled knobs up until the metering roller can be
removed.
3.
Remove metering roller and wipe down thoroughly to
remove any excess wash that may be on the roller.
55
CLEANING & MAINTENANCE
DEGLAZING
THE DAMPENER
OILING AND
GREASING THE
DAMPENER
56
Periodic deglazing of water-soluble contaminants will be
necessary with the Crestline® Altra SeriesTM. Typically, once
every 2-3 weeks will be sufficient, unless you are running
electrostatic plates on a daily basis whereas deglazing should
be performed weekly. A 50/50 solution of household ammonia
and hot water can be used for deglazing purposes. If you prefer
a commercially available deglazer, avoid those containing
pumice or gritty substances. Always follow deglazing with
straight water and then roller wash. Accel offers a product called
COMPOUND X that we recommend for deglazing our system.
Contact your dealer or Accel for more information.
A.
Place a small amount of grease on the gears once a
month.
B.
Inject grease into the oscillator grease fitting once a
month.
CLEANING & MAINTENANCE
CRESTLINE® ALTRA SERIESTM
CLEANING & MAINTENANCE CHART
Daily
Weekly
Bi-Weekly Monthly
Wash Rollers
Deglaze Rollers
Metal Plate Users
Silvermaster Plate Users
Electrostatic Plate Users
Grease Gears
Inspect Ball Bearings
Check Roller Pressures
Check Roller Surfaces
57
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11103 Indian Trail, Dallas, TX 75229 Phone 972-484-6808, Fax 800-365-6510
E-Mail [email protected], Web Site www.accel-us.com