Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
1

Table of Contents

2.1 Machine transport ............................................................................ 2
2.2 Hitching device................................................................................. 3
Feeder and delivery, printing, coating and transfer units.................... 3
Delivery with 945,4 mm extension...................................................... 4
Transport trolley for the feeder ........................................................... 5
2.3 Transport trolley for press and delivery (not for Airglide) ............ 6
Roller plates........................................................................................ 7
2.4 Zinc underlay plate (oil drip tray) .................................................... 8
Positioning and aligning the printing units .......................................... 8
2.5 Presses up to series 709.................................................................. 8
2.6 Setting the printing units ............................................................... 10
Presses up to series 709.................................................................. 10
Teeth engagement position .............................................................. 11
2.7 Positioning and aligning the printing units.................................. 12
Presses up to series 710.................................................................. 12
Printing unit 1.................................................................................... 13
Printing unit 2.................................................................................... 14
Printing unit 3.................................................................................... 16
Printing unit 4 and all following ones ................................................ 17
Fine alignment of the press .............................................................. 18
Checking tooth clearance for printing units 2 and 3.......................... 20
2.8 Tooth engagement position when assembling the printing units21
Presses as from series 714 .............................................................. 21
2.9 Aligning the printing unit ............................................................... 22
2.10 Installing and aligning the delivery............................................... 23
2.11 Aligning the feeder ......................................................................... 26
2.12 Aligning the printing units and coating units .............................. 27
Spirit level measurement log ............................................................ 27
Gear tooth clearance measurement log ........................................... 28
2.13 Machine relevel............................................................................... 28



Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
2

2.1 Machine transport

Transport of the machine from the delivery point
to its designated place in the pressroom may
only be done by qualified transport companies
with suitable moving equipment.
Important details such as delivery time, height of
access doors, etc. must be clarified in advance.



Before using transport and hitching
equipment, check that the fastenings are
secure!
It is strictly forbidden to stand below
hanging loads!
The transport and hitching equipment must
be tested! Be sure the safety-approved
badge is valid!
Only use hitching equipment provided by
MAN Roland!
The instructions and procedures given in
Data Base Documentation Transport,
Installation, Commissioning must be
followed!

Alternative means of transport
The printing or coating units can also be lifted
underneath the foundation tie-bars and
transported by a forklift. When doing this, the
following points must be taken into account:



The forklift should have hydraulically-
actuated forks.
The forklift must have min. 10 tons lifting
capacity.
The weight of the load must be correctly
spread over both forks.
The load must be braced against slipping
(e.g. clamp a rubber mat between the forks
and the foundation tie-bar).









Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
3
2.2 Hitching device
Feeder and delivery, printing, coating
and transfer units







Use lifting device RS-Nr. 843R 2000 13/1 for
transporting the units.
Slide the lifting device eyelet (1) to the
appropriate marking (3).

The marking indicates the center of gravity for
the particular load.
Tighten the screw (2).

Hitching the feeder requires two intermediate
plates (drawing no. 03076416) and two M 30
transport eyelets.

M7INS001
3 1
2



When assembling the stop plate RS-Nr. 01A
4739 30, it must be ensured that the drilled
holes (1) face towards the impression
cylinder.
1. Stop plate
2. Impression cylinder
3. Transferter

M7INS002
M7INS003
Z
Z
1
1
2
3




Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
4

Delivery with 945,4 mm extension



M7INS004



Lifting device 743 T 3152 13











Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
5

Transport trolley for the feeder



2
55
3
1 4
M7INS005

1 Fixed-wheel transport trolley
2 Steerable transport trolley
3 Pile plate
4 Mounting bracket
5 Transport tie-bar





Use the transport device designated
00SA33404-002 in the Mabeg parts list.

The pile plate (3) must be screwed firmly to
the devices (4 and 5).







Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
6

2.3 Transport trolley for press and
delivery (not for Airglide)



M7INS006
5 3
1 1 2
4

1 Adapter for delivery
2 Fastening screws
3 Steerable trolley
4 Transport tie-bar
5 Fixed-wheel trolley





The printing units and delivery can be
transported by the same trolleys (4 + 5):
Mount two adapters (1) at the front on the
sideframes.
At the delivery, fasten the steerable trolley (3)
to the pile plate side with the screws (2).









Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
7

Roller plates





The roller plates are used for fine alignment of
the printing units to each other.

There are special components for the R 700
which are contained in the roller plate set no.
843 R0576 13.

The individual units can be slid on foils (3
pieces, min. 0.5 mm thick) and LA 8 grease.
It is not permitted to use foils or similar
material for presses to be mounted on a
raised foundation.

M7INS007





Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
8

2.4 Zinc underlay plate (oil drip
tray)


For positioning the drip trays, please refer to the
drawings for the specific press designation.



The drawings zinc underlay plate and press
foundation plan can be found in the orange
fitters envelope which is in the start-up box.

Positioning and aligning the printing
units

2.5 Presses up to series 709



The location of the units and peripheral items as
well as the floor loading capacity have been
clarified during project planning.


The machine position is given in the project
documentation.
Before commencing installation, the floor
must be tested with a straightedge (or laser)
to be sure it is level.
If the floor is considerably uneven, use steel
plates (min. 100 x 100 x 15 mm) to
compensate.



Never place the press on one complete steel
plate.



The distance between the floor and the
underside edge of the sideframe is 120 10
mm.
The printing units are aligned using 2 spirit
levels (measuring accuracy 0.04 mm) on
the sideframes and a special cylinder spirit
level on the impression cylinder.









Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
9


M7INS009
2 2 1













The height of the printing units relative to one
another is determined by laying a 500 mm
long spirit level (1) ( 0,04 mm) on the two 50
mm locating bolts in the foundation tie-
bars.
To do this, the bolts must be pulled out
approx. 55 mm and a valve unit must be
dismounted.
Once alignment is finished, the deviation of
the spirit levels on the sideframes (1) should
be max. 0.02 mm and that of the spirit level
on the impression cylinder max. 0.01 mm.
Before moving the printing units together,
the points contained in the following pages
regarding press revolutions and gear teeth
position must be observed.

M7INS008

1 Spirit level 500 mm long
2 Locating bolts
3 "A" dimension = 55 mm





Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
10

2.6 Setting the printing units


Presses up to series 709


The following procedure must be carried out to
ensure that the ink ductor roller timing is correct:


Printing unit 1























Use two stud bolts and a bar to turn the
press until the yellow markings on the
impression cylinder drive gear and the ink
fountain roller drive gear face vertically
upwards.
Up to three press revolutions are necessary to
do this (min. ductor roller stroke).

This position ensures that the eccentric
markings for ductor roller stripe and ductor roller
movement, as well as the printing units, face
one another within one press revolution.
Printing unit 2
Use two stud bolts and a bar to turn the
press until the yellow markings on the
impression cylinder drive gear and the ink
fountain roller drive gear face vertically
upwards.
Up to three press revolutions are necessary to
do this (min. ductor roller stroke).

This position ensures that the eccentric
markings for ductor roller stripe and ductor roller
movement, as well as the printing units, face
one another within one press revolution.

M7INS010
4 3
1 1 2

1 Fountain roller gear (tooth marked yellow)
2 Tooth gap, impression cylinder (tooth
marked yellow)
3 Mounting position (teeth marked red)
4 Stud bolts and bar








Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
11

Teeth engagement position


Printing unit 1


40 tooth gaps in the forwards direction from the
yellow marking on the impression cylinder gear,
the mounting position is marked red.


Printing unit 2


Turn backwards until the red marking on the
Transferter gear matches the red marking of
the impression cylinder gear of unit 1.


Printing units 1 and 2


Move the printing units together.
Align them.
Bolt them tight.
Turn forwards to teeth engagement position
(see above).


Printing unit 3 and all following ones


As described above:
Position.
Align.
Move together.
Bolt tight.






Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
12

2.7 Positioning and aligning the
printing units


Presses up to series 710


















As from series 710, the sideframes of the R 700
are no longer filled with SKC 60.
The new sideframes are perfectly machined to
match.
The location of the units and peripheral items
have been clarified during project planning.
Draw the position of the press and drip trays
on the pressroom floor.
Before commencing installation, the floor
must be tested with a straightedge (or laser)
to be sure it is level.
If the floor is very uneven, use steel plates (min.
100 x 100 x 15 mm) to compensate.



Never place the press on one complete steel
plate.



- The distance between the floor and the
underside edge of the sideframe is 125 10
mm.
- The printing units are aligned using 2 spirit
levels (measuring accuracy 0.04 mm) on
the sideframes and a special cylinder spirit
level on the impression cylinder.
- Once alignment is finished, the deviation of
the spirit levels on the sideframes should be
max. 0.02 mm and that of the spirit level on
the impression cylinder max. 0.01 mm.









Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
13





The value inscribed on the Transferter or
turning drum bearers must be complied with
at the A side.
- At the B side, a tolerance of up to 0.04 mm is
permissible.
- The tooth clearance between the impression
cylinder gear and Transferter gear must be
0.06 0.10 mm.



Before moving the printing units together,
the points contained in the following pages
regarding press revolutions and gear teeth
engagement position must be observed.



Depending on local conditions, the installation
can start with the first or last printing unit, the
coating unit or the delivery. For example: R 705
3B 5/0, 2/3; printing unit 1 must be brought into
the pressroom first.


Lay down the drip tray for printing unit 1.

Printing unit 1






Place the unit in position ( 5 mm).
Set machine height to 125 mm (levelling screw
M 36 x 2 x 100 mm).

Make a rough alignment with the spirit level
on the ink fountain roller ( 0.04 mm) and the
sideframes ( 0.04 mm).
Place the unit on the roller plates.
Position exactly ( 1 mm), use laser if
available.
Remove the roller plates.
Turn the unit to the yellow machine setting
and red tooth engagement position (3).
The supply lines are fastened inside the unit
for transport purposes. Take these out.
Clean the faces of the sideframes, remove
any burs.
Mount the plates for lateral alignment to
printing unit 2.

M7INS010
4 3
1 1 2



Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
14

Printing unit 2
















Clean the faces of the sideframes, remove
any burs.
Apply sealing agent.
Insert the 5 x 750 round cord (2) (from
series 717) in the groove at the A side.
Lay down the drip tray.
Have the rigger place the unit in position with
approx. 20 mm distance to printing unit 2.
Set machine height to 125 mm (the height of
the sideframe contour of printing unit 2
should be approx. 0.3 0.5 mm lower than
printing unit 1).
Make a rough alignment (same procedure as
for printing unit 1).

M7INS012a





Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
15














Turn the gear train until the yellow machine
position and the red marking on the gear
coincide with the same positions in printing
unit 1.
Place the unit on the roller plates.
Move unit towards printing unit 1. (If
necessary use lower fastening bolts (4)).
Loosen or tighten lateral alignment plates as
required
Watch out for oil return flow lines and tooth
engagement position.
Screw in the fastening bolts (4) so they just
contact the frame, dont tighten them.
Remove the roller plates.
Make a rough alignment.
Turn tooth position to printing unit 3.
The supply lines are fastened inside the unit
for transport purposes. Take these out.
Clean the faces of the sideframes, remove
any burs.
Mount the plates for lateral alignment to
printing unit 3.
With perfecting presses, fit and secure the
blast rake.

M7INS011
M1 M2
2 3
1






Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
16

Printing unit 3





















Clean the faces of the sideframes, (3)
remove any burs.
Apply sealing agent (6).
Lay down the drip tray.
With perfecting presses, lay in the fan
housing for the sheet tracks beneath the
turning drum.
- Place the unit in position with approx 20 mm
distance to printing unit 2.
- Set machine height to 125 mm.
The height of the sideframe contour of printing
unit 3 should be approx. 0.3 0.5 mm lower
than printing unit 2.
Make a rough alignment (see above).
Turn the unit so that the yellow machine
position and the red marking (7) on the gear
tooth face towards printing unit 2.
With perfecting presses, pay attention to the
position of the switch lever for lifting the cam
followers on the turning drum.
Place the unit on the roller plates.
Pull unit towards printing unit 2. (If necessary
use lower fastening bolts (4)).
Take care not to damage the oil return flow
lines and the teeth at the engagement
position.
Perfecting presses: In the unit with the
turning drum, the lateral alignment plate at
the A-side must be removed !
Screw in the fastening bolts (4) so they just
contact the frame, dont tighten them.

M7INS012b




Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
17

Printing unit 4 and all following ones


Same procedure as for printing unit 3.



Leave the press to settle overnight..



On the next day, align the individual printing
units exactly, starting from the middle.






Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
18

Fine alignment of the press

Printing unit 2




Finely align the sideframes and the impression
cylinder with spirit levels having a measuring
accuracy of 0.02 mm.
After alignment is completed, the deviation of
the spirit levels should be max. 0.01 mm.

Printing unit 3






Finely align the printing unit (8).
Turn to gripper shaft 1 position (yellow
marking on Transferter gear (7)).
At gripper shaft 1 there is a value inscribed on
the A and B-side bearers.

This value indicates the distance between the
bearers of the turning drum / Transferter to the
impression cylinder.









Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
19

Printing units 2 and 3








Couple the printing units.
Lock them tight with the fastening screws (4
and 5).
Check distance between bearers (8) and adjust
if necessary:
- If the actual distance is less or more than the
value referred to above, the coupled units
must be decoupled and then lowered or
raised. (Per 0.01 mm deviation between the
bearers 0.054 mm height adjustment on the
dial gauge (1).
Use a dial gauge to check the height setting
at the A side.
Match the height at the B side using a spirit
level on the impression cylinder.
Screw the printing units firmly together.
Check both bearers as well as the spirit
levels on the sideframes and impression
cylinders.
Dismount the lateral alignment plates.

M7INS012d


The inscribed value must be reached at the
A-side.
At the B-side, a tolerance of up to 0.04 mm is
permissible.





Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
20

Checking tooth clearance for printing
units 2 and 3


Tooth clearance between the impression
cylinder gear and Transferter gear must be 0.03
- 0.10 mm at the highest point of the gears.

If this is not the case, then the unit in question
must be raised or lowered after consultation with
MRO SBDT.

Checking tooth clearance for printing units
1, 4 and 5


Same procedure as above.
Position and align the delivery.
Align the feeder (see Section 2.12 - Aligning
the feeder).
After all printing units have been aligned, all
measured values (distance between bearers,
spirit level readings, tooth clearance) must be
recorded in a measurement log and added to
the acceptance report.









Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
21

2.8 Tooth engagement position
when assembling the printing
units
Presses as from series 714














The following procedure makes sure that
all ink ductor rollers make contact with
the ink distributor roller within one press
revolution:
Use the stud bolts on the impression cylinder
drive gear to turn the printing units to be
coupled until the yellow markings on the ink
ductor roller drive (1) are matching.
At the same time, the tooth (3) marked yellow
on the impression cylinder gear must be
pointing upwards.
Up to three press revolutions (min. ink ductor
roller stroke) may be necessary.
When the correct position has been reached,
the gear tooth (2) marked red must point in
the direction of the following printing unit.
Turn the following printing unit backwards
until the red markings (2) on the impression
cylinder of printing unit 1 and the Transferter
of printing unit 2 coincide.
Push the printing units together and couple
them.
When alignment of both printing units is
completed, turn them both forwards until the
red marking (2) on printing unit 2 points in the
direction of printing unit 3.
Repeat this procedure until all printing units
are connected.

M7INS011
M1 M2
2 3
1







Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
22

2.9 Aligning the printing unit




0.054 height adjustment 0.01 mm change to
distance between the bearers












M7INS012a

1 0.054 height adjustment 0.01 play deviation
between the bearers
2 Round cord 5 x 750 (from series 717), 8
x 750 from series 710 716
3 Position printing unit 2 approx. 0.3 to 0.5 mm
lower
4 Fastening screw M 24 x 80 mm with USIT
ring
5 Fastening screw M 24 x 80 mm without USIT
ring
6 Sealing agent
7 Yellow marking on gear indicates gripper
shaft no. 1
8 Distance gauge i.e. feeler gauge






Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
23

2.10 Installing and aligning the
delivery



M7INS013a
1 6 3
8 7 5 4 2

1 Chisel mark
2 Yellow teeth engagement position mark
3 One spirit level (0.04 mm/m) at both A and
B-sides
4 Take-off drum: 1 spirit level in the middle
(0.04 mm/m)
5 Delivery stay: 1 spirit level (0.04 mm/m)
6 Sideframe contour for height difference
247.00 mm
7 Switch cabinet feet under the cover plate


Installation and alignment:
The supply lines are fastened inside the
delivery for transport purposes. Take these
out.
Coat the sideframes and oil pan on the A
side with sealing gel.
Insert both upper connecting bolts (M 24 x
135 mm) in the delivery boring.






Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
24


M7INS013b
3
4 2


Dismount the guide plate or Super Blue drum
on the take-off drum.
Turn the last printing unit and delivery so that
the yellow teeth positions (2) match.
Place the delivery on roller plates.
Pull delivery towards last printing unit:
- If necessary use lower fastening bolts.
- Loosen or tighten lateral alignment plates
as required.



Watch out for oil return flow lines, air hoses
and teeth engagement position.


Place one spirit level (measuring accuracy
0.04 mm/m) on the take-off drum (4).
Place two spirit levels (measuring accuracy
0.04 mm/m) (3) on the sideframes.








Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
25


M7INS013c
1 6 3
7 4



The cover plate must be removed to do this.
- The height of the delivery relative to the
printing unit is determined by the 0.05 0.08
mm tooth clearance which must be adhered
to.
- The tooth clearance can be corrected by
raising or lowering the delivery.
- Chisel marks (1) on the sideframes at A and
B sides indicate an approximate position.
- The height difference from the sideframes (6)
of the last printing unit to the delivery is
approx. 247.00 mm.


Set the B side (4) parallel using a spirit level.
Turn the four switch cabinet feet (7 at the A
side of the delivery downwards.
Use a spirit level (3) to level the sideframes.




Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
26

2.11 Aligning the feeder



M7INS014
6
1
2
3
5 4















Aligning:
Place a spirit level (measuring accuracy 0.04
mm/m) on both A and B side sideframes (1).
Place a spirit level (measuring accuracy 0.04
mm/m) on the belt drive shaft or similar (2).
Place a spirit level (measuring accuracy 0.4
mm/m) on the feeder stay (6).
- The height of the feeder is determined by
centering the fastening screws in the tie-bars
(3 and 4).
- The distance beween feeder and printing unit
1 is determined by the tie-bars (4).
- The lateral alignment feeder to printing unit 1
is determined by a tie-bar (5).









Service Training Mechanical Roland 700

Installation

2

C95A 6428 39 - 06. Aug. 2004
27

2.12 Aligning the printing units and
coating units

Spirit level measurement log



M7INS015



Service Training Mechanical Roland 700

2

Installation


C95A 642 39 - 06. Aug. 2004
28

Gear tooth clearance measurement
log

Gear tooth clearance must always be checked
on the high points of the gears.

The tooth clearance ascertained is to be entered
in the table below.



Machine no.:___________________________


Customer:
_______________________________


Type: _________________________________


Series: ________________________________


Tooth clearance Play ascertained
Tooth clearance PU 1 - PU 2 0.____ mm
Tooth clearance PU 2 - PU 3 0.____ mm
Tooth clearance PU 3 - PU 4 0.____ mm
Tooth clearance PU 4 - PU 5 0.____ mm
Tooth clearance PU 5 - PU 6 0.____ mm
Tooth clearance PU 6 - PU 7 0.____ mm
Tooth clearance PU 7 - PU 8 0.____ mm
Tooth clearance PU 8 - PU 9 0.____ mm
Tooth clearance PU 9 - PU 10 0.____ mm
Tooth clearance last PU - delivery 0.____ mm


2.13 Machine relevel


If you have to relevel the machine use the
original tools (roller plates,plates for laterial
alignement) !