430 Manual - 2006

DAUPHIN GRAPHIC MACHINES, INC.
BOX 573
ELIZABETHVILLE, PA 17023
Operation, Maintenance and

Illustrated Parts Breakdown Manual
April 2006 DGM - 430 Printing Press

Dauphin Graphic Machines, Inc.
Introduction
for
Pressroom Personnel
1. The most important part of presswork is proper training. Therefore, the necessity for safe press and
maintenance procedures can not be overstated. DGM, Inc. will not be responsible or held liable for
accidents or injuries to press operators. This is the responsibility of the purchaser, not the manufacturer.
The purchaser must be sure its’ press operators are properly trained and familiar with the characteristics of
the DGM - 430 unit.
2. If you have any questions concerning the DGM - 430 unit, special product requirements, or unusual
equipment conditions, contact a representative from DGM, Inc., toll free at 800 - 346-6119. Let the
friendly experts and staff at Dauphin Graphic Machines, Inc. serve you.
3. Before operating the unit, carefully read the entire operations manual. Take extra time to become
familiar with specific procedures to obtain efficient operation and maximize quality. NOTE: Section XI of
this manual can be treated as a “stand alone”, Illustrated Parts Breakdown section. Reference to figure
numbers indicated in this section, are solely within Section XI.
4. Establish a preventive maintenance program. Make periodic inspections of the unit for wear and
cleanliness. Good housekeeping maintains the unit’s performance and quality; it pays dividends in the long
run.
5. A complete selection of parts, optional equipment, service and training is available through our person-
nel at Dauphin Graphic Machines, Inc. We can be contacted 24 hours a day at our emergency service
number (717) 657-6089.
6. NOTICE! This manual may show some safety devices removed or out of position for illustrative
purposes only.
7. Never work alone.
8. KEEP THIS MANUAL WITH THE UNIT AT ALL TIMES.
Because of specific customer and manufacturing requirements, features and op-

tional equipment described or illustrated in this publication, may not apply to all
situations and products.
TABLE OF CONTENTS
Page
SECTION I - Safety And Precautions
General ---------------------------------------------------------------------------------------- I-2
Unit Safety Controls ----------------------------------------------------------------------------------- I-2
INCH/STOP Station-------------------------------------------------------------------------- I-2
INCH Button ----------------------------------------------------------------------------- I-3
STOP Button ----------------------------------------------------------------------------- I-3
Continuous Run ------------------------------------------------------------------------------- I-3
Interlocks and Guards ------------------------------------------------------------------------ I-4
Unit ---------------------------------------------------------------------------------------- I-4
Press (Units and Folders)--------------------------------------------------------------------- I-4
Lockout/Tagout ------------------------------------------------------------------------------- I-5
Steps and Platforms --------------------------------------------------------------------------- I-6
Electrical Equipment -------------------------------------------------------------------------- I-6
Terms ---------------------------------------------------------------------------------------- I-6
Operator Side ---------------------------------------------------------------------------- I-6
Drive Side -------------------------------------------------------------------------------- I-6
10-Side ----------------------------------------------------------------------------------- I-6
13-Side ----------------------------------------------------------------------------------- I-6
Specifications ---------------------------------------------------------------------------------------- I-6
21 1/2” Cutoff Specifications ----------------------------------------------------------------- I-7
22” Cutoff Specifications --------------------------------------------------------------------- I-7
SECTION II -Unit Operating Controls

Unit Overview ---------------------------------------------------------------------------------------- II-3
Compensator Handwheel--------------------------------------------------------------------- II-3
Ink Fountain Locking Handwheel ------------------------------------------------------------ II-3
Ink Fountain Levers --------------------------------------------------------------------------- II-3
Dampener Fountain --------------------------------------------------------------------------- II-3
Ink Feed Throwoff Levers ------------------------------------------------------------------- II-3
Ink Form Throwoff Levers ------------------------------------------------------------------- II-3
Plate Cylinder Running Sidelay Handwheel ------------------------------------------------- II-3
Dampener Form Throwoff Levers ----------------------------------------------------------- II-3
Unit Water/Dampener Control Panel -------------------------------------------------------- II-3
Running Circumferential Register Handwheel ----------------------------------------------- II-3
Unit Roll Stand ---------------------------------------------------------------------------------------- II-3
Lead-In Rollers-------------------------------------------------------------------------------- II-3
Paper Roll Sidelay Handwheel --------------------------------------------------------------- II-3
Paper Roll Spindle Shaft ---------------------------------------------------------------------- II-4
Brake Shoe Handwheel ---------------------------------------------------------------------- II-4
Tension Nut ------------------------------------------------------------------------------------ II-4
Tower Units ---------------------------------------------------------------------------------------- II-4
Page A
Table Of Contents (Continued) Page
Unit Control Panel ------------------------------------------------------------------------------------- II-4
Unit Control Panel ---------------------------------------------------------------------------- II-4
Pneumatic On/Off Toggle Switch ------------------------------------------------------- II-4
Dampener Fuses ------------------------------------------------------------------------- II-4
Dampener Motor Switch ---------------------------------------------------------------- II-4
Dampener Speed Control Dials --------------------------------------------------------- II-5
Stop-Safe Button ------------------------------------------------------------------------- II-5
Inch (Jogging) Button -------------------------------------------------------------------- II-5
Optional Tower Unit Control Panels -------------------------------------------------------- II-5
Affected Side Indicator ------------------------------------------------------------------ II-5
Ink Motor Toggle Switch ---------------------------------------------------------------- II-5
Ink Motor Selector Switch -------------------------------------------------------------- II-5
Ink Motor Speed Dial ------------------------------------------------------------------- II-6
Pneumatic Toggle Switch ---------------------------------------------------------------- II-6
Dampener Motor Toggle Switch -------------------------------------------------------- II-6
Dampener Speed Control Dial ---------------------------------------------------------- II-6
SECTION III - Press Make-Ready

Introduction ---------------------------------------------------------------------------------------- III-3
Unit Drive ---------------------------------------------------------------------------------------- III-3
Engaging a Unit -------------------------------------------------------------------------------- III-3
Disengaging a Unit ---------------------------------------------------------------------------- III-4
Horizontal Drive Clutch ----------------------------------------------------------------------- III-4
Engaging a Clutch ----------------------------------------------------------------------------- III-4
Disengaging a Clutch -------------------------------------------------------------------------- III-5
Roll Stand ---------------------------------------------------------------------------------------- III-5
Unloading The Roll Stand -------------------------------------------------------------------- III-5
Loading The Roll Stand ----------------------------------------------------------------------- III-5
Plates ---------------------------------------------------------------------------------------- III-6
Plate Care ------------------------------------------------------------------------------------- III-6
Plate Bending ---------------------------------------------------------------------------------- III-7
Plate Packing ---------------------------------------------------------------------------------- III-7
Plate Installation ------------------------------------------------------------------------------- III-7
Plate Removal --------------------------------------------------------------------------------- III-8
Plate Cylinders -------------------------------------------------------------------------------- III-8
Blankets ---------------------------------------------------------------------------------------- III-8
Blanket Care ---------------------------------------------------------------------------------- III-8
Blanket Packing ------------------------------------------------------------------------------- III-8
Blanket Installation ---------------------------------------------------------------------------- III-9
Lock-Up Procedures - “T”-Bar -------------------------------------------------------- III-9
Removal ------------------------------------------------------------------------------ III-9
Installation ---------------------------------------------------------------------------- III-10
Lock-Up Procedures - Reel Rod ------------------------------------------------------- III-11
Page B

Removal ------------------------------------------------------------------------------ III-12
Ink System ---------------------------------------------------------------------------------------- III-12
Ink Fountain Cleaning ------------------------------------------------------------------------- III-13
Ink Stripe -------------------------------------------------------------------------------------- III-13
Making Ink Stripes ---------------------------------------------------------------------------- III-13
Dampening System ------------------------------------------------------------------------------------ III-13
Water Stops ----------------------------------------------------------------------------------- III-13
Webbing The Unit -------------------------------------------------------------------------------------- III-14
Setting Web Tension -------------------------------------------------------------------------- III-14
Splicing ---------------------------------------------------------------------------------------- III-15
Make-Ready Checklist -------------------------------------------------------------------------------- III-15
SECTION IV - Running Procedure

Introduction ---------------------------------------------------------------------------------------- IV-2
Startup ---------------------------------------------------------------------------------------- IV-2
Running ---------------------------------------------------------------------------------------- IV-2
Shutdown ---------------------------------------------------------------------------------------- IV-3
Wash-Up ---------------------------------------------------------------------------------------- IV-3
Rollers ---------------------------------------------------------------------------------------- IV-3
Cylinders --------------------------------------------------------------------------------------- IV-3
Safety ---------------------------------------------------------------------------------------- IV-3
SECTION V - Page Imposition Or Plate Positioning

Introduction ---------------------------------------------------------------------------------------- V-2
Plate Positioning ---------------------------------------------------------------------------------------- V-2
Page Patterns ---------------------------------------------------------------------------------------- V-2
Some “Set Up” Questions ----------------------------------------------------------------------------- V-2
Terminology ---------------------------------------------------------------------------------------- V-3
Broadsheet ------------------------------------------------------------------------------------ V-3
Tabloid ---------------------------------------------------------------------------------------- V-3
Mini-Tab Or Signature ------------------------------------------------------------------------ V-3
Former ---------------------------------------------------------------------------------------- V-3
Upper Former --------------------------------------------------------------------------------- V-3
Center Spread --------------------------------------------------------------------------------- V-3
Unit Configurations ------------------------------------------------------------------------------------ V-3
Page Impositions --------------------------------------------------------------------------------------- V-4
SECTION VI - Roller Adjustments

Roller Pressure ---------------------------------------------------------------------------------------- VI-2
Roller Adjustments - Ink ------------------------------------------------------------------------------ VI-2
Ink Fountain Roller A ------------------------------------------------------------------------- VI-2
Ink Feed Roller B to Fountain Roller A ----------------------------------------------------- VI-3
Ink Transfer Rollers C and E ----------------------------------------------------------------- VI-4
Ink Form Rollers G and H-------------------------------------------------------------------- VI-5
Page C

Roller Adjustments - Dampener ---------------------------------------------------------------------- VI-6
Dampener Fountain Roller I ------------------------------------------------------------------ VI-6
Sock Feed Roller J --------------------------------------------------------------------------- VI-6
Dampener Form Roller L --------------------------------------------------------------------- VI-7
Gap Adjustments --------------------------------------------------------------------------------------- VI-8
Setting Cylinder Gaps - Timing --------------------------------------------------------------- VI-8
Spiral Brush Dampening Adjustment--------------------------------------------------------- VI-9
Iron-To-Iron Setting ----------------------------------------------------------------------------------- VI-10
Setting The Plate And Impression Cylinders ------------------------------------------------ VI-10
To Check The Settings------------------------------------------------------------------------ VI-10
To Adjust The Settings ------------------------------------------------------------------------ VI-11
13 Cylinder Set --------------------------------------------------------------------------- VI-11
13 - 12 Cylinder Set --------------------------------------------------------------------- VI-11
12 - 11 Cylinder Set --------------------------------------------------------------------- VI-12
11 - 10 Cylinder Set --------------------------------------------------------------------- VI-12
SECTION VII - Maintenance

Introduction ---------------------------------------------------------------------------------------- VII-2
Corrosion Control ------------------------------------------------------------------------------------- VII-2
Procedure -------------------------------------------------------------------------------------- VII-2
Plate Cylinders --------------------------------------------------------------------------- VII-5
Blanket Cylinders ------------------------------------------------------------------------ VII-5
Reference -------------------------------------------------------------------------------------- VII-6
Corrosion Develops--------------------------------------------------------------------------- VII-6
Lubrication ---------------------------------------------------------------------------------------- VII-6
Oil Level ---------------------------------------------------------------------------------------- VII-6
Oil Changing ---------------------------------------------------------------------------------------- VII-6
Oil Strainer ---------------------------------------------------------------------------------------- VII-7
Grease Fittings ---------------------------------------------------------------------------------------- VII-7
Lubrication Panel ------------------------------------------------------------------------------ VII-7
Ink System ---------------------------------------------------------------------------------------- VII-9
Ink Fountain Cleaning ------------------------------------------------------------------------- VII-9
Cleaning Rollers ------------------------------------------------------------------------------- VII-9
Cleaning Cylinders ---------------------------------------------------------------------------- VII-10
Dampener System ------------------------------------------------------------------------------------- VII-10
General ---------------------------------------------------------------------------------------- VII-10
Feed Roller Sock Installation----------------------------------------------------------------- VII-11
Roll Stand Brake Blocks ------------------------------------------------------------------------------ VII-11
SECTION VIII - Direct Printing

The Method ---------------------------------------------------------------------------------------- VIII-2
The Reverse Image ------------------------------------------------------------------------------------ VIII-2
The Impression ---------------------------------------------------------------------------------------- VIII-2
The Registration ---------------------------------------------------------------------------------------- VIII-2
The Conversion ---------------------------------------------------------------------------------------- VIII-2
Page D
Governor Roller To Compensator Conversion --------------------------------------------- VIII-2
Compensator to Governor Roller Conversion ---------------------------------------------- VIII-2
SECTION IX - Troubleshooting
Scumming ---------------------------------------------------------------------------------------- IX-2
Tinting ---------------------------------------------------------------------------------------- IX-2
Graininess ---------------------------------------------------------------------------------------- IX-2
Hickies ---------------------------------------------------------------------------------------- IX-2
Stripping ---------------------------------------------------------------------------------------- IX-2
Fill-In ---------------------------------------------------------------------------------------- IX-2
Slurring ---------------------------------------------------------------------------------------- IX-2
Streaking ---------------------------------------------------------------------------------------- IX-2
Catch-Up ---------------------------------------------------------------------------------------- IX-3
Blinding ---------------------------------------------------------------------------------------- IX-3
Loose Web ---------------------------------------------------------------------------------------- IX-3
Web Breaks ---------------------------------------------------------------------------------------- IX-3
SECTION X - Glossary
A-C ---------------------------------------------------------------------------------------- X-2
D-E ---------------------------------------------------------------------------------------- X-3
F-H ---------------------------------------------------------------------------------------- X-4
I-M ---------------------------------------------------------------------------------------- X-5
N-R ---------------------------------------------------------------------------------------- X-6
S-V ---------------------------------------------------------------------------------------- X-7
W-Z ---------------------------------------------------------------------------------------- X-8
SECTION XI - Illustrated Parts Breakdown

Illustrated Parts Breakdown --------------------------------------------------------------------------- XI-3
General ---------------------------------------------------------------------------------------- XI-3
Group Assembly Parts List (GAPL) --------------------------------------------------------- XI-3
Index Number --------------------------------------------------------------------------------- XI-3
Part Number----------------------------------------------------------------------------------- XI-3
Description ------------------------------------------------------------------------------------ XI-3
Vendor Codes --------------------------------------------------------------------------------- XI-3
Units per Assembly --------------------------------------------------------------------------- XI-3
Abbreviations Used Throughout the Manual

ANSI - American National Standards Institute
AR - As Required
DGM - Dauphin Graphic Machines
DP - Double Parallel
Fig. - Figure
ft. - Feet (length measure)
Page E
in. - Inches (length measure)

IPB - Illustrated Parts Breakdown
iph - inch per hour (length measure)
lb(s) - Pound(s) (weight measure)
kPa - Kilo Pascals
mm - Millimeter (length measure)
NS - Not Shown (within IPB)
OP - Operator (i.e., OP Side = Operator’s Side)
OSHA - Occupational Safety and Health Administration
P/N - Part Number
perf - Perforator (i.e., Trolley Perf.= Trolley Perforator)
PPH - Papers per Hour
R-P-F - Rollers-Point-Of-Former
R-T-F - Roller-Top-Of-Former
REF - Reference
sec - Second (time measure)
TYP - Type
Illustrations List
Figure Nr. Title Page
1-1 INCH/STOP Station or Safe Operation Panel (STOP/SAFE) ............... I-3

1-2 Locked and Inter-Locked Guards ......................................................... I-4
1-3 Cylinder Locations - Operator Side ...................................................... I-6
2-1 DGM-430 Floor Unit - Operator Side .................................................. II-3
2-2 DGM-430 Roll Stand ........................................................................... II-4
2-3 430 4-High Tower Unit ......................................................................... II-4
2-4 Standard Floor Unit Control Panel ........................................................ II-5
2-5 Optional Tower Unit Control Panels ...................................................... II-6
3-1 Pinion and Ring Gears ........................................................................... III-3
3-2 Clutch Rims .......................................................................................... III-4
3-3 Roll Stand ............................................................................................ III-5
3-4 Plate Lockup ........................................................................................ III-6
3-5 Blanket Cylinder (T-Bar) ...................................................................... III-9
3-6 Blanket Cylinder Reel Rod System ........................................................ III-10
3-7 Blanket Cylinder Torque Wrench .......................................................... III-10
3-8 Ink Fountain Assembly .......................................................................... III-11
3-9 Water Stop ........................................................................................... III-12
3-10 Water Stops In Place ............................................................................ III-12
3-11 Diagram of Web Lead - Unit ................................................................. III-13
3-12 Tension System Diagram ....................................................................... III-13
5-1 Mark-Up Example ............................................................................... V-2
5-2 Placement ............................................................................................. V-3
Page F
Illustrations List (con’t)

5-3 Using a “Balloon” Former ..................................................................... V-3
5-4 Broadsheet Page Imposition .................................................................. V-5
5-5 Tabloid Page Imposition ........................................................................ V-6
5-6 Mini-Tab Page Imposition ..................................................................... V-7
6-1 Roller Identification Chart ..................................................................... VI-2
6-2 Ink Feed Throwoff ............................................................................... VI-4
6-3 Ink Transfer Roller ................................................................................ VI-4
6-4 Ink Form and Transfer Rollers ............................................................... VI-5
6-5 Dampener Feed Roller Adjustments ...................................................... VI-6
6-6 Dampener Form Roller ......................................................................... VI-7
6-7 Gap Gauges ......................................................................................... VI-8
6-8 Cylinder Slip Bolts ................................................................................ VI-8
6-9 Gap Gauge - Reel Rod to Slot .............................................................. VI-9
6-10 Gap Gauge - Reel Rod Blanket to Blanket ............................................ VI-9
6-11 Spiral Brush Gauge ............................................................................... VI-10
6-12 Spiral Brush Dampener Adjustment ....................................................... VI-10
6-13 Iron-To-Iron Setting ............................................................................. VI-11
7-1 Gear Side View .................................................................................... VII-6
7-2 Oil Pump and Strainer ........................................................................... VII-7
7-3 Lubrication Panel .................................................................................. VII-7
7-4 Independent Lubrication Points ............................................................. VII-8
7-5 Ink Fountain in “Up” Position ................................................................ VII-9
7-6 Wash-Up Tray ...................................................................................... VII-10
7-7 Dampener Feed Roller Bracket ............................................................. VII-11
7-8 Roll Stand Break Block Assembly ......................................................... VII-12
8-1 Compensator Hardware ....................................................................... VIII-3
8-2 Direct Printing Web Leads .................................................................... VIII-4
11-1 DGM-430 Press Unit (Floor Model) .................................................... XI-5
11-2 Frame Sub-Assembly (Floor Unit) ........................................................ XI-8
11-3 Frame Sub-Assembly (Base Unit) ......................................................... XI-11
11-4 Frame Sub-Assembly (Stack Unit) ........................................................ XI-14
11-5 Ink and Dampener Form Roller Throwoff Assembly .............................. XI-17
11-6 Ink Ball Assembly - Operator Side ........................................................ XI-20
11-7 Ink Ball Assembly - Gear Side .............................................................. XI-23
11-8 Ink Fountain Assembly .......................................................................... XI-26
11-9 Swing Down Ink Fountain Assembly ..................................................... XI-29
11-10 Blanket Cylinder Throw-Off Linkage Assembly - Manual Operation ...... XI-32
11-11 Circ Shaft Assembly ............................................................................. XI-35
11-12 Governor Roller, Tension Control and Lead-In Assembly - Floor Unit .... XI-38
11-13 Blanket Cylinder Assembly ................................................................... XI-41
11-14 #10 Side Narrow Gap Lock-Up Assembly ........................................... XI-45
11-15 Narrow Gap Lock-Up ......................................................................... XI-48
11-17 #10 Side Wide Gap Lock-Up Assembly ............................................... XI-54
Page G

11-18 Wide Gap Lock-Up ............................................................................. XI-57
11-20 #10 Cylinder Assembly - Gear Side ...................................................... XI-63
11-21 #10 Cylinder Assembly - Operator Side ................................................ XI-66
11-22 #10/#13 Sidelay ................................................................................... XI-69
11-25 Lower Copper Assembly ...................................................................... XI-78
11-26 Upper Copper Assembly ...................................................................... XI-81
11-27 Water Pan Roller Assembly ................................................................... XI-84
11-28 Water Vibrator Assembly ...................................................................... XI-87
11-29 Water Vibrator Idler ............................................................................. XI-90
11-30 Micro Roller Assembly ......................................................................... XI-93
11-31 Micro Shaft .......................................................................................... XI-96
11-32 #10 Side Ink Vibrator ........................................................................... XI-99
11-34 Ink Vibrator Assembly .......................................................................... XI-105
11-35 #10 Side Water Vibrator ....................................................................... XI-108
11-37 Circ. Assembly ..................................................................................... XI-114
11-38 Drive Shaft ........................................................................................... XI-118
11-39 Oil Pump Assembly .............................................................................. XI-121
11-40 Gear Side Cover .................................................................................. XI-124
11-41 Paper Roll Sidelay ................................................................................ XI-127
11-42 Paper Roll Brake .................................................................................. XI-130
11-43 Paper Roll Sidelay and Brake Assembly ................................................ XI-133
11-44 Belt Register ......................................................................................... XI-136
11-45 Optional Pneumatic Assembly ............................................................... XI-139
11-46 Blanket Cylinder Throwoff Linkage - Optional Pneumatics .................... XI-142
11-47 Rubber Rollers ..................................................................................... XI-145
11-48 Nip Guards .......................................................................................... XI-147
11-49 Roller Guards ....................................................................................... XI-150
11-50 Upper Roller Guard .............................................................................. XI-153
11-51 Outer Roller Guard ............................................................................... XI-156
11-52 Operator Side Cover ............................................................................ XI-159
11-53 Color Drop Roller ................................................................................ XI-162
11-54 Lead-In Roller - Base Unit .................................................................... XI-165
11-55 Lead-In Roller and Under Unit Compensator Assembly - Stack Unit ..... XI-168
11-56 B1 Swing Compensator ........................................................................ XI-171
11-57A Full Page Motorized Compensator - Pre-2001 ...................................... XI-174
11-57B Full Page Motorized Compensator - Post-2001 .................................... XI-180
11-58 Belt Drive/Covers - Stack ..................................................................... XI-186
11-59 Belt Drive/Covers - 2 High ................................................................... XI-189
Page H

11-60 Belt Drive/Covers - 3 High - #10 Side .................................................. XI-192
ChartsTables List
Chart/Table Nr. Title Page
1 Roller Specification Chart VI-3

2 Lubrication Chart VII-2
3 Maintenance Chart VII-3
Page I
This page left intentionally blank.
Page J
SECTION I
SAFETY AND PRECAUTIONS
SECTION I - Safety And Precautions

General ---------------------------------------------------------------------------------------- I-2
Unit Safety Controls ----------------------------------------------------------------------------------- I-2
INCH/STOP Station-------------------------------------------------------------------------- I-2
INCH Button ----------------------------------------------------------------------------- I-3
STOP Button ----------------------------------------------------------------------------- I-3
Continuous Run ------------------------------------------------------------------------------- I-3
Interlocks and Guards ------------------------------------------------------------------------ I-4
Unit ---------------------------------------------------------------------------------------- I-4
Press (Units and Folders)--------------------------------------------------------------------- I-4
Lockout/Tagout ------------------------------------------------------------------------------- I-5
Steps and Platforms --------------------------------------------------------------------------- I-6
Electrical Equipment -------------------------------------------------------------------------- I-6
Terms ---------------------------------------------------------------------------------------- I-6
Operator Side ---------------------------------------------------------------------------- I-6
Drive Side -------------------------------------------------------------------------------- I-6
10-Side ----------------------------------------------------------------------------------- I-6
13-Side ----------------------------------------------------------------------------------- I-6
Specifications ---------------------------------------------------------------------------------------- I-6
22” Cutoff Specifications --------------------------------------------------------------------- I-7
I-1
1. GENERAL CAUTION
a. Safety requires a proper attitude. If a

person is careless, anything can happen. Properly CAUTION
plan ahead and use safe procedures to avoid
serious injuries. Hazards that are not immediately
available but can cause less serious
b. Never operate or perform maintenance injury. (Also used to describe safe
on this unit without proper training. By operating operating procedures.)
and maintaining this unit, you may expose yourself
to a hazardous situation. Hazardous situations e. Wear appropriate clothing. No loose
may lead to an accident or injury. Therefore, we sleeves or shirt-tails. Remove neckties and
stress the importance of proper training and necklaces.
operational practices.
f. Do not wear any jewelry. Jewelry may
c. Safety must be practiced as part of your cause additional injury to personnel.
company’s Standard Operating Procedures. Failure
to follow safety practices and precautions can lead g. Cover or tie back long hair. This helps to
to accidents and injury. Printing plants need to prevent entanglement in the unit or other equip-
maintain a regular program of safety to assure ment.
compliance to proper operating and maintenance
practices. h. Keep floors clean and dry to prevent
slips and falls. Maintain good housekeeping
d. While working on this unit, some operat- practices. Good housekeeping promotes produc-
ing and maintenance procedures may expose tivity and reduces waste while improving quality.
operators to hazardous situations. These areas
and situations can be identified in this manual, or i. Report safety hazards to supervisors.
on equipment, by the words DANGER, WARNING,
or CAUTION. These situations/hazards are defined j. Use caution and wear proper protective
as: clothing and equipment when using solvents in the
pressroom. Refer to the solvent manufacturer’s
DANGER MSDS sheets for specific precautions.
k. Locate and familiarize yourself with the

inter-locks and web break detector safety
STOP switches.
l. STAY ALERT - Remember, SAFETY IS

Hazards that are readily available and
AN ATTITUDE!
are capable of causing serious
personal injury or death.
2. UNIT SAFETY CONTROLS.
WARNING a. INCH/STOP Station. The INCH/STOP

Station; or, Safe Operation Panel, (See Figure 1-1)
contains both a STOP Button and an INCH Button.
As a minimum, one (1) of these panels is located
WARNING
on each side of the unit.
WARNING
Hazards that are not immediately
available but are capable of causing
serious personal injury or death. WARNING
Avoid injury. Be careful when inching

the press. Keep hands away from
Nip and Pinch points!
I-2
around the press. The minimum physical require-

ments for the STOP Button are outlined in ANSI
B65.1-1985, Safety Specifications for Printing
Press Control Drives. This button has two primary
functions: 1) for emergency stops; and, 2) to put
the press on SAFE.
(a) Activation is done by pressing

down on the STOP button. When this is done, the
operation of the unit should stop within 10 sec-
onds. When the press is used with additional
press and folder units in a press line, depressing
the STOP button on ANY unit within the press line
Figure 1-1. INCH/STOP Station or should stop ALL units within that pressline. Be-
Safe Operation Panel cause its primary function is a SAFETY FEATURE
(STOP/SAFE) - to provide for EMERGENCY STOPS - activation
of the STOP button should be taken very seri-
(1) INCH Button (Gray). The INCH ously. When purposefully activated, such as for
button, also known as the “jogging” button, is used maintenance, or setting up the press for a run, this
to initiate operation of the unit. When the INCH action is called “placing the press in SAFE mode”.
button is depressed, a warning bell or alarm will
ring/sound for approximately two (2) seconds then (b) Disengaging the button to allow
the press will begin to physically cycle the drives, normal operation, requires the operator to “pull” the
thus causing the machinery to begin to function. STOP-SAFE button straight out until the button
The cylinders will rotate at a very low speed as stops. As a safety precaution, disengaging the
long as ONLY the INCH button is held down. If the button should be completed ONLY by the individual
button is released and depressed within a four (4) who engaged, or activated, the STOP button.
second period after disengaging, NO ALARM WILL
SOUND UNLESS the STOP Button is depressed. b. Continuous Run. When the INCH, or
Once the STOP button is depressed, the cycle will jogging, button AND the faster button are de-
“restart” and alarms will reinitiate. pressed together during an existing INCH (or jog)
function, a continuous run condition will be initi-
ated. The unit will remain at the speed set at this
DANGER point. The continuous run can be terminated by a
STOP button being depressed, a web break, clutch
STOP fault, an open interlock or by a drive/motor fault.
Note
The STOP button, when engaged,
prevents the press from operating. If any switch is left in “Manual” mode,
Releasing or disengaging the button, when the press is locked into a
by any person other than the person continuous run, all manual settings
who engaged the STOP button, could will turn off. The result will be no
result in personal injury and or imprint or impressions. The impres-
equipment malfunction. The STOP sion cylinders, form, micrometric, ink
button is primarily used to perform and water cylinders will have disen-
minor adjustments, various align- gaged. It is recommended that the
ments, etc. Ensure the reason for pressline be stopped and all switches
engaging the STOP button has been be verified/returned to auto mode.
determined and that all personnel are Upon completion of verification, restart
clear of the unit prior to disengaging the pressline.
the STOP button.
Caution
(3) STOP Button (“Mushroom” shaped,
Red and Silver). The STOP Button, better known CAUTION
as the STOP/SAFE Button, is the standard
practice for makeready and some maintenance SAFE and READY lights are UNIT
I-3
SPECIFIC. When a unit is placed in running. All safety devices must be in place before
MANUAL mode and is in a “stacked” operating the press
configuration, that specific unit may .
indicate READY or SAFE. Prior to d. UNIT.
engaging the press line, the operator
should verify the condition of each (1) Use proper techniques for the safe
unit. handling of rags around the unit.
Note (2) Wear gloves sparingly, only when

necessary. Be sure that the gloves fit tightly.
While in automatic mode, and using a
master console, if ANY unit within the (3) Do not clean cylinders, rollers,
pressline individually falls into, or is drums, or other moving parts while the press is in
placed in a SAFE condition, the motion.
Master console indicator lights would
function, as well as the affected units (4) Be careful working around sharp
individual lights. objects, such as, the fountain blade, worn gears,
and plate edges.
c. Interlocks & Guards.
(5) Do not try to web the unit while the
press is in motion.
(6) Avoid standing between units while

the press is in motion.
e. Press (Units and Folders).
(1) Always have the press STOPPED

and on SAFE before any cleaning or maintenance
10 and 13-Side Outside Guards is performed on the press. Follow this procedure:
(a) Have the press stopped and

on SAFE.
(b) Complete the task in that
position.
(c) Remove rags, tools, supplies,
etc. from the operating area of the press.
(d) Remove the SAFE and inch
the press to the next work area.
Gear Side Guard (e) Stop the press, engage the
SAFE.
(f) Repeat as necessary.
(2) Do not disengage a SAFE button

that you have not personally engaged.
(3) If performing procedures which

place personnel in a hazardous location, follow
10 and 13-Side Inside Guards LOCKOUT procedures (see paragraph “e” below)..
Figure 1-2. Locked and Inter-Locked Guards (4) Do not operate the press at unsafe
speeds.
(1) Interlocks and guards are designed (5) The press alarm warns that the
for the protection of press operators. Therefore, press will start moving; be sure you are clear of the
DO NOT circumvent these devices. Safety press.
devices should be maintained and functional. DO
NOT open or remove guards while the press is
I-4
(6) Keep your hands clear of the operating, stop or shut it down by the normal
cylinder and roller nips. stopping procedures.
(7) Do not apply lubricants to the press 3 - Operate the switch, valve,
while it is in motion. or other energy isolating device(s) to isolate the
specific equipment from its energy source(s). All
(8) Remove all rags, tools, cans, electrical loads must be off or at a minimum before
supplies, etc. from the press frame, platforms, and the main disconnect is switched.
aisles immediately after using them.
4 - The authorized employee
(9) Inspect equipment and tools on a then locks out and/or tags out the energy isolating
regular basis. device(s) with his/her assigned lock and/or tag.
With a grease type pencil, note on the back of the
(10) HOUSEKEEPING - Keep the press tag the work location and, if necessary, the circuits
area clean. It is best to Pick-up and Clean-up. de-energized.
f. Lockout/Tagout. 5 - After ensuring that no

personnel are exposed and as a check on having
(1) The Occupational Safety and disconnected all energy sources/paths, the autho-
Health Administration (OSHA) published for general rized employee shall operate these normal operat-
industry the Lockout/Tagout Standard; it went into ing controls to make certain that the equipment will
effect January 2, 1990. Because this standard not move. Make sure these normal operating
applied to servicing or make-ready procedures, controls are returned to their neutral or off position
confusion arose as to how it applied to cleaning the after this test. For electrical lockout/tagout, test
cylinders and rollers, plate changes, lubrication, circuit voltage to assure de-activation. First, check
paper jams, and make-ready procedures. voltage tester on a known energized circuit. Then,
test the de-energized circuit on the load side and
(2) The proper use of the STOP-SAFE on the de-energized side. Finally, recheck the
button system provides equivalent protection. The voltage tester.
STOP-SAFE button system is published through
the American National Standards Institute (ANSI): 6 - The specific equipment is
Safety Specifications for Printing Press Control now locked or tagged out and servicing or mainte-
Drives (B65. 1-1985). nance may proceed.
(3) The following is a brief of the (b) Procedure for transfer or

Lockout/Tagout procedures. These procedures DO removal of locks/tags.
NOT override or replace the requirements as
specified in ANSI Lockout/Tagout procedures or 1 - When work covered by this
those procedures established at your facility. procedure is carried over from one shift to another,
the authorized employee working on the ending
(a) Sequence of lockout or shift shall remove his/her lock only after the person
tagout; starting the next shift has installed theirs. The
status of the work in progress must be totally
1 - After determining the exact discussed.
work required and all energy sources involved, the
authorized employee should notify all affected 2 - When the authorized
employees about the lockout/tagout that is going to employee who applied the lockout or tagout device
be implemented. There may be multiple energy is not available to remove it, the device may be
sources and possibly secondary energy paths to removed by his/her supervisor or a person so
address for any one energy source. Some specific designated. This person must be familiar with the
work on a unit, for example, may require certain applicable machinery and follow the steps to
electrical circuits, drive line clutches plus hydraulic restore the equipment to normal operation. This
and air lines to be locked or tagged out. Determine person is required to inform the authorized em-
where the various pertinent disconnects are located ployee that the lock or tag has been removed
before starting the work. before the authorized employee resumes work.
2 - If the specific equipment is (c) When locks and tags must
I-5
temporarily be removed to test or position the h. Electrical Equipment.

machine, the following sequence should be fol-
lowed. (1) You must be a qualified, licensed
electrician, or a properly trained DGM Service
1 - Clear the machine of all Technician, to inspect, test, adjust, or repair
tools or equipment. electrical components or equipment.
2 - Remove all employees (2) Follow Lockout/Tagout procedures.

from the area around the machine. If testing is
required under these circumstances, only properly (3) Wear insulated footwear and use
trained personnel are allowed to perform these insulated tools.
tests and all affected employees must be properly
notified of this testing. (4) Remove all jewelry.
3 - Remove the lockout or (5) Do not stand on a wet floor.

tagout devices.
(6) Do not allow fluids, of any kind, to
4 - Energize the machine and enter into circuits or electrical hand tools.
proceed with testing or positioning.
i. Terms. When describing locations on the
5 - De-energize all systems DGM - 430 unit, the following terms are used:
and reapply all locks/tags before continued servic-
ing and/or maintenance. (1) Operator Side - the side of the unit
where the controls are located.
(d) When restoring the equipment
to normal operation, the following procedures are (2) Drive Side - the side of the unit
suggested. where the drive shaft is located.
1 - After the servicing and (3) 10-Side - when facing the operator
maintenance is complete and the equipment is side of the unit, the 10-Side is on your left. The
ready for normal production operations, check the plate cylinder on the left side is called the 10-
area to ensure that no one is exposed. Notify Cylinder.
affected employees that the lockout/tagout is being
removed, and that the energy is being restored to (4) 13-Side - when facing the operator
the equipment. side of the unit, the 13-Side is on your right. The
plate cylinder on that side is called the 13-Cylinder.
2 - After all tools, loose parts,
etc., have been removed from the equipment, and
the guards, signaling systems, and other safety 10 13
devices have been reinstalled, and employees are
in the clear, remove all lockout and tagout devices, 11 12
and restore energy to the system.
3 - Test the equipment for

proper operation. Figure 1-3. Cylinder Locations - Operator Side
g. Steps And Platforms. 3. SPECIFICATIONS.
(1) To insure safe footing, keep steps Web Width .................. 35” Max.
and platforms free of rags, tools, paper, grease, oil,
etc. Undercuts - Standard
Plate Cylinder ... .014”
(2) Where available, always use Blanket Cylinder .081”
handrails or hand grips on steps and platforms.
Rubber Roller Durometer
(3) Use railings for their intended Ink Rollers ......... 26
purpose as a hand assist or safety barrier. Do not Water Rollers ..... 20
lean, sit, or climb on railings.
I-6
Max. Speed ................ 30,000 iph 22 3/4” Cutoff Specifications
Registration Adjustments - Max. Image Length

Plate Cylinder Sidelay +/- .125” Reel Rod Blanket Lockup w/Standard
Running Circumferential +/- .060” Slot Gap Plate Lockup 22 3/16”
Narrow Gap Blanket Lockup with
Weight (Gross) “On The Nose” Plate Lockup 21 15/16”
Floor Unit ........... 5,500 lbs Narrow Gap Blanket Lockup w/Standard
Stack Unit .......... 5,250 lbs Slot Gap Plate Lockup 21 15/16”
Base Unit .......... 6,000 lbs
Plate Thickness ......... 0.008-0.012”
21 1/2” Cutoff Specifications Total Thickness (Plate plus Packing) 0.014”
Max. Image Length Blanket Thickness ..... 0.064-0.066”

Reel Rod Blanket Lockup w/Standard Total Thickness (Blanket plus Packing 0.085”
Slot Gap Plate Lockup 20 15/16” .................. (0.083” After Compression)
“On The Nose” Plate Lockup 20 11/16”
Narrow Gap Blanket Lockup w/Standard
Slot Gap Plate Lockup 20 11/16”
Plate Thickness ......... 0.008-0.012”

Total Thickness (Plate plus Packing) 0.014”
Blanket Thickness ..... 0.064-0.066”

Total Thickness (Blanket plus Packing 0.085”
.................. (0.083” After Compression)
22” Cutoff Specifications
Max. Image Length

Reel Rod Blanket Lockup w/Standard
“On The Nose” Plate Lockup 21 3/16”
Narrow Gap Blanket Lockup w/Standard
Plate Thickness ......... 0.008-0.012”

Total Thickness (Plate plus Packing) 0.014”
Blanket Thickness ..... 0.064-0.066”

Total Thickness (Blanket plus Packing 0.085”
.................. (0.083” After Compression)
I-7
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I-8
SECTION II
UNIT OPERATING CONTROLS
SECTION II - Unit Operating Controls

Unit Overview ---------------------------------------------------------------------------------------- II-3
Compensator Handwheel--------------------------------------------------------------------- II-3
Ink Fountain Locking Handwheel ------------------------------------------------------------ II-3
Ink Fountain Levers --------------------------------------------------------------------------- II-3
Dampener Fountain --------------------------------------------------------------------------- II-3
Ink Feed Throwoff Levers ------------------------------------------------------------------- II-3
Ink Form Throwoff Levers ------------------------------------------------------------------- II-3
Plate Cylinder Running Sidelay Handwheel ------------------------------------------------- II-3
Dampener Form Throwoff Levers ----------------------------------------------------------- II-3
Unit Water/Dampener Control Panel -------------------------------------------------------- II-3
Running Circumferential Register Handwheel ----------------------------------------------- II-3
Unit Roll Stand ---------------------------------------------------------------------------------------- II-3
Lead-In Rollers-------------------------------------------------------------------------------- II-3
Paper Roll Sidelay Handwheel --------------------------------------------------------------- II-3
Paper Roll Spindle Shaft ---------------------------------------------------------------------- II-4
Brake Shoe Handwheel ---------------------------------------------------------------------- II-4
Tension Nut ------------------------------------------------------------------------------------ II-4
Tower Units ---------------------------------------------------------------------------------------- II-4
Unit Control Panel ------------------------------------------------------------------------------------- II-4
Unit Control Panel ---------------------------------------------------------------------------- II-4
Pneumatic On/Off Toggle Switch ------------------------------------------------------- II-4
Dampener Fuses ------------------------------------------------------------------------- II-4
Dampener Motor Switch ---------------------------------------------------------------- II-4
Dampener Speed Control Dials --------------------------------------------------------- II-5
Optional Tower Unit Control Panels -------------------------------------------------------- II-5
Affected Side Indicator ------------------------------------------------------------------ II-5
Ink Motor Toggle Switch ---------------------------------------------------------------- II-5
Ink Motor Selector Switch -------------------------------------------------------------- II-5
Ink Motor Speed Dial ------------------------------------------------------------------- II-6
Pneumatic Toggle Switch ---------------------------------------------------------------- II-6
Dampener Motor Toggle Switch -------------------------------------------------------- II-6
Dampener Speed Control Dial ---------------------------------------------------------- II-6
II-1
II-2
1. UNIT OVERVIEW On units with ink keys, increase the ink flow by
turning the ink keys counterclockwise.
d. Dampener Fountain. A pan that holds

dampener solution which is being picked up by a
set of rollers and delivered to the plate surface.
B A e. Ink Feed Throw-off Levers. Engages

and disengages the ink feed roller with the ink
F
fountain roller. When the ball of the handle is
E
pointing towards the CENTER of the unit, the roller
E is OFF (disengaged). When the ball of the handle
C G
F is pointing away from the center, the roller is ON
G H (engaged).
H
f. Ink Form Throw-off Levers. Engages
D J I and disengages the ink form rollers with the plate
cylinder surface. When the ball of the handle is
pointing towards the CENTER of the unit, the roller
is OFF (disengaged). When the ball of the handle
is pointing away from the center, the roller is ON
K
(engaged).
g. Plate Cylinder Running Sidelay Hand-

wheel. Used to adjust registration across the web
width. The maximum travel from operator side to
drive side of the plate cylinder is 0.250” (Ref. +/-
0.125”). A knurled locking handle, located in the
middle of the handwheel, holds the setting.
h. Dampener Form Throw-off Levers.

A - Compensator Handwheel Engages and disengages the dampener form rollers
B - Ink Fountain Locking Knob with the plate cylinder surface. When the ball of
C - Ink Fountain Levers the handle is pointing towards the TOP of the unit,
D - Dampener Fountain the roller is OFF (disengaged). When the ball of
E - Ink Feed Throwoff Levers the handle is pointing towards the OUTSIDE of the
F - Ink Form Throwoff Levers unit, the roller is ON (engaged).
G - Plate Cylinder Running Sidelay Handwheel
H - Dampener Form Throwoff Levers i. Unit Water/Dampener Control Panel.
I - Unit Water/Dampener Control Panel Houses some operating controls for a particular
J - Running Circumferential Register Handwheel unit. A detailed look at the unit control panel is
K - Impression Throw Lever discussed in paragraph 4 of this section.
Figure 2-1. DGM 430 Floor Unit - Operator Side
j. Running Circumferential Register
Handwheel. Used to adjust the back-to-back
a. Compensator Handwheel. Controls unit- registration lengthwise within the unit. The 10
to-unit registration or cutoff registration. cylinder is rotated in relation to the 13 cylinder.
The maximum image travel is 0.120” (Ref. +/-
b. Ink Fountain Locking Handwheel. 0.060”).
Secures the ink fountain in its operational position
or allows the fountains to be tilted down for clean- 2. UNIT ROLL STAND.
ing and color changes.
a. Lead-In Rollers. Directs the web into the
c. Ink Fountain Levers. Controls the unit.
amount of ink exiting the fountain and it’s distribu-
tion throughout the ink train. On units with levers, b. Paper Roll Sidelay Handwheel. Ad-
move the levers down to increase the flow of ink. justs the side-to-side position of the paper roll when
II-3
it is in the roll stand. To move the paper roll

towards the drive side of the press, turn the
handwheel clockwise.
F
D E
C B
A - Lead-In Roller (Not Shown)

B - Paper Roll Sidelay Handwheel
C - Paper Roll Spindle Shaft
D - Brake Shoe Handwheel
E - Tension Nut
F - Governor Roller
Figure 2-3. 430 4-High Tower Unit
Figure 2-2. DGM 430 - Roll Stand
b. The tower unit utilizes the same printing
c. Paper Roll Spindle Shaft. Supports the electro-mechanical principals as the floor unit - less
paper roll when mounted in the roll stand. The hub the roll stand. As an option, the operator side of
at the end of the spindle shaft helps to control web the tower may be enclosed by door panels to
tension as well as being part of the braking system provide additional safety considerations. The
of the paper roll. Loading the paper roll is dis- primary differences between the 430 Floor Unit and
cussed in section 3, paragraph 3.b of this manual. a 430 Tower Unit, besides the roll stand, is that the
unit controls are located on both the 10-side and
d. Brake Shoe Handwheel. Controls web 13-sides, vice the operator side.
tension by working with the governor roller. By
turning the handwheel clockwise, you increase the 4. UNIT CONTROL PANELS.
web tension.
a. Unit Control Panel. The Unit Control
e. Tension Nut. Controls the amount of Panel is located on the Operator side of each unit,
pressure being applied to the governor roller (F). as shown in Figure 2-1. Refer to figure 2-4.
Adjustment should be made by a trained service
representative. (1) Pneumatic On/Off Toggle Switch.
Toggle switch used to turn on either the 10-side or
3. TOWER UNITS. 13-side pneumatics.
a. Tower Units are comprised of two (2) or (2) Dampener Fuses. 1 1/2 amp fuses
more printing units. Each tower has a “Base” unit used to protect the dampener motors. To remove,
and subsequent “tower” unit(s), which is/are placed turn fuse holder knob counterclockwise and pull.
on top of the “base” unit. Figure 2-3 illustrates a 4-
High Tower Unit with optional doors. (3) Dampener Motor Switch. A toggle
switch used to turn on both the 10- and 13-Side
dampener motors.
II-4
STOP-SAFE button.
1
2 This button has two functions:
1. For emergency stops.
2. To put the press on SAFE.

3
4 The Stop-Safe button, when depressed, prevents
the press from operating. To disengage the button
and allow normal operation, it will be necessary to
6 “pull” the STOP-SAFE button straight out until the
5
button stops.
(6) Inch (Jogging) Button.

1 - Pneumatic On/Off Switchs
2 - Dampener Fuses WARNING
3 - Dampener Motor Switch
4 - Dampener Speed Control Dials
5 - STOP-SAFE Button (Red)
6 - Inch (or Jogging) Button (Gray) WARNING
Figure 2-4. Standard Floot Unit Control Panel

(4) Dampener Speed Control Dials. the press. Keep hands away from Nip
Adjusts the speed of rotation of the dampener and Pinch points!
motor; one for the 10-Side and one for the 13-Side.
The faster the motor speed, the more solution is The Inch, or Jogging, button allows the press to
being delivered to the plate surface. rotate as long as you hold in the button. The
inching speed is adjustable at the press control
(5) STOP-SAFE Button. panel. When depressing the inch button, a warning
bell or alarm will ring for approximately two (2)
DANGER seconds. The press will begin to move after this
warning is sounded. There is a four (4) second
period after disengaging the inch button in which
STOP the inch will work, unless the STOP is depressed,
then the cycle will “restart”.
The STOP-SAFE button, b. Optional Tower Unit Control Panels.

when engaged, prevents Optional Control Panels are available as shown in
the press from operating. figure 2-5.
Releasing or disengaging
the button, by any person (1) Affected Side Indicator. The
other then the person who shaded portion identifies which side the control(s)
engaged the STOP-SAFE will affect.
button, could result in
personal injury and or (2) Ink Motor Toggle Switch. Toggle
equipment malfunction. switch used to turn on (engage) or off the ink ball
The STOP-SAFE button is motor.
primarily used to perform
minor adjustments, (3) Ink Motor Selector Switch. Used to
various alignments, etc. place the unit in either AUTOMATIC or MANUAL
Ensure the reason for Mode. AUTOMATIC allows the unit to be con-
engaging the STOP-SAFE trolled through the use of a console unit. When
button has been deter- placed MANUAL mode, the unit is disengaged from
mined and that all person- the rest of the press line. This is used primarily
nel are clear of the unit during set-up or for various maintenance functions.
prior to disengaging the
II-5
(7) Dampener Speed Control Dial.

1 Adjusts the speed of rotation of the dampener
motor. The faster the motor speed, the more
solution is being delivered to the plate surface.
2 3 (8) STOP-SAFE Button.

4
5 DANGER
STOP
6
7
9
8
The STOP-SAFE button,
when engaged, prevents
the press from operating.
10-Side Control Panel Releasing or disengaging
the button, by any person
1
other then the person who
engaged the STOP-SAFE
button, could result in
3 personal injury and or
2 4
equipment malfunction.
The STOP-SAFE button is
5 primarily used to perform
minor adjustments,
various alignments, etc.
6
7
Ensure the reason for
8 engaging the STOP-SAFE
button has been deter-
9 mined and that all person-
nel are clear of the unit
13-Side Control Panel prior to disengaging the
STOP-SAFE button.
1 - Affected Side Indicator
2 - Ink Motor Toggle Switch (Engage/Off) This button has two functions:
3 - Ink Motor Selector Switch (Auto/Manual)
4 - Ink Motor Speed Dial 1. For emergency stops.
5 - Pneumatic Toggle Switch (Engage/Off)
6 - Dampener Motor Toggle Switch (Engage/Off) 2. To put the press on SAFE.
7 - Dampener Speed Control Dial
8 - STOP-SAFE Button (Red) The Stop-Safe button, when depressed, prevents
9 - Inch (or Jogging) Button (Gray) the press from operating. To disengage the button
and allow normal operation, it will be necessary to
Figure 2-5. Optional Tower Unit Control Panels “pull” the STOP-SAFE button straight out until the
button stops.
(4) Ink Motor Speed Dial. Adjusts the
speed of rotation of the Ink motor. The faster the (9) Inch (Jogging) Button.
motor speed, the more ink is being delivered to the
plate surface. WARNING
(5) Pneumatic Toggle Switch. Toggle

switch used to turn on the pneumatics. WARNING
(6) Dampener Motor Toggle Switch. A
toggle switch used to turn on (engage) or off, the
dampener motors.
II-6
the press. Keep hands away from Nip bell or alarm will ring for approximately two (2)
and Pinch points! seconds. The press will begin to move after this
warning is sounded. There is a four (4) second
The Inch, or Jogging, button allows the press to period after disengaging the inch button in which
rotate as long as you hold in the button. The the inch will work, unless the STOP is depressed,
inching speed is adjustable at the press control then the cycle will “restart”.
panel. When depressing the inch button, a warning
II-7
II-8
SECTION III
PRESS MAKE-READY
SECTION III - Press Make-Ready

Introduction ---------------------------------------------------------------------------------------- III-3
Unit Drive ---------------------------------------------------------------------------------------- III-3
Engaging a Unit -------------------------------------------------------------------------------- III-3
Disengaging a Unit ---------------------------------------------------------------------------- III-4
Horizontal Drive Clutch ----------------------------------------------------------------------- III-4
Engaging a Clutch ----------------------------------------------------------------------------- III-4
Disengaging a Clutch -------------------------------------------------------------------------- III-5
Roll Stand ---------------------------------------------------------------------------------------- III-5
Unloading The Roll Stand -------------------------------------------------------------------- III-5
Loading The Roll Stand ----------------------------------------------------------------------- III-5
Plates ---------------------------------------------------------------------------------------- III-6
Plate Care ------------------------------------------------------------------------------------- III-6
Plate Bending ---------------------------------------------------------------------------------- III-7
Plate Packing ---------------------------------------------------------------------------------- III-7
Plate Installation ------------------------------------------------------------------------------- III-7
Plate Removal --------------------------------------------------------------------------------- III-8
Plate Cylinders -------------------------------------------------------------------------------- III-8
Blankets ---------------------------------------------------------------------------------------- III-8
Blanket Care ---------------------------------------------------------------------------------- III-8
Blanket Packing ------------------------------------------------------------------------------- III-8
Blanket Installation ---------------------------------------------------------------------------- III-9
Lock-Up Procedures - “T”-Bar -------------------------------------------------------- III-9
Removal ------------------------------------------------------------------------------ III-9
Lock-Up Procedures - Reel Rod ------------------------------------------------------- III-11
Removal ------------------------------------------------------------------------------ III-12
Ink System ---------------------------------------------------------------------------------------- III-12
Ink Fountain Cleaning ------------------------------------------------------------------------- III-13
Ink Stripe -------------------------------------------------------------------------------------- III-13
Making Ink Stripes ---------------------------------------------------------------------------- III-13
Dampening System ------------------------------------------------------------------------------------ III-13
Water Stops ----------------------------------------------------------------------------------- III-13
Webbing The Unit -------------------------------------------------------------------------------------- III-14
Setting Web Tension -------------------------------------------------------------------------- III-14
Splicing ---------------------------------------------------------------------------------------- III-15
Make-Ready Checklist -------------------------------------------------------------------------------- III-15
III-1
1. INTRODUCTION. 2. UNIT DRIVE.
a. If the press requires prolonged mainte- WARNING

nance, the use of the Lockout/Tagout procedures
should be done. The STOP-SAFE button system
is the standard safety practice for make-ready and WARNING
some maintenance procedures around the press.
The physical requirements for the STOP-SAFE
button system is outlined in ANSI B65. 1-1985,
Safety Specifications for Printing Press Control Printing Units are supplied with
Drives and should not be over-ridden. The follow- covers, doors, and guards for your
ing is a summary of this practice: protection. Some of these items may
have interlocks which will prohibit the
(1) Inch the press to the desired work press from operating if left open. Be
position and put the press on SAFE. sure that when cleaning, performing
maintenance, or make-ready proce-
(2) Do the necessary cleaning, make- dures that the press is on SAFE
ready, or maintenance. Remove tools and acces- before any of these items are opened
sories. or removed.
(3) Take the press off of SAFE by pulling a. Engaging A Unit.

the button out until the button stops and inch the
press to the next desired work position then, put NOTE
the press on SAFE.
Upon installation, timing marks should
(4) Repeat this procedure until the re- be indicated on the unit so that the
quired cleaning, make-ready, or maintenance is drive shaft and the unit are in timing
completed. with the complete press line, including
folder unit.
WARNING
(1) Inch the press so that the timing
marks indicated on the drive shaft and the unit
align by using the Inch Button.
WARNING
(2) Put the press on SAFE.
The LEAD PRESS OPERATOR is (3) By opening the left access door on the
responsible for making sure all drive side (13-side) of the unit, you have access to
personnel are clear of the press the Ring and Pinion Gears (see figure 3-1). De-
before inching the press. All person- pending on the type of runs the unit is used for, the
nel are responsible for proper use of general practice has been found that color codes
the STOP-SAFE button. are used to identify different web color inking,
number of webs used, etc. These codes have
WARNING usually been placed on the inside of the access
door. Depending on the type of press run and
configuration of the web, further refinement of the
Ring and Pinion Gears may be necessary.
WARNING
(4) Loosen the locknut (B) and remove, or
clearly back off, the tapered setscrew (spotting
NIP POINTS between cylinders and bolt) from the pinion gear collar.
rollers can cause permanent injury.
Fold and hold rags properly; never (5) Place the shifting lever (E) under the
attempt to clean cylinders or rollers pivot stud (C) while at the same time placing the
while the press is moving. Never shifting lever pin into the groove around the pinion
attempt to remove “hickeys” with your gear collar. The pinion gear (A) should slide into
fingers or hand-held objects while the mesh with the bevel gear (D) easily. DO NOT
press is moving.
III-2
FORCE THE PINION GEAR. IF NECESSARY,

BAR THE UNIT SLIGHTLY TO MESH GEARS. (3) By opening the left access door on the
drive side (13-side) of the unit, you have access to
the Ring and Pinion Gears (see figure 3-1).
(4) Loosen the locknut (B) and remove the

tapered setscrew (spotting bolt) completely from
D the pinion gear collar.
C (5) Place the shifting lever (E) under the

pivot stud (C) while at the same time placing the
shifting lever pin into the groove around the pinion
gear collar. The pinion gear (A) should slide out of
Groove
mesh of the ring gear (D). Slide the pinion gear as
far as it will go until the tapered setscrew (spotting
bolt) hole in the pinion gear collar aligns with the
B hole in the horizontal drive shaft.
(6) Replace or tighten the tapered set-

A
Pinion Gear Collar screw (spotting bolt) and locknut into the same
hole of the pinion gear collar. Be sure the set-
screw is “bottomed out”. At this point, the locknut
should move freely. Now tighten the locknut.
(7) Close the access door.
c. Horizontal Drive Clutch.
(1) Because of various press and product

requirements, it may be necessary to disengage
the horizontal drive shaft. A manual drive shaft
A - Pinion Gear clutch can be supplied. Disengaging the clutch will
B - Locknut and Tapered Setscrew prevent all equipment from running beyond the
C - Pivot Stud point of the clutch.
D - Ring Gear (13 Cylinder)
E - Shifting Lever (Not Shown) d. Engaging A Clutch.
Figure 3-1. Pinion and Ring Gears
(6) If removed in item (4) above, return the marks on the driveshaft and the unit align by using
tapered setscrew and locknut (B) into the same the Inch button.
hole of the pinion gear collar. Be sure the set-
screw is “bottomed out”. At this point, the locknut (2) Put the press on SAFE.
should move freely. Now tighten the locknut.
(3) Remove the clutch cover on the unit
(7) Check oil level in the gear housing. by loosening the two clutch cover thumbscrews.
Be sure there is adequate oil.
(4) Refer to figure 3-2. Loosen or remove
(8) Close the access door. the setscrew (B) on the rim.
b. Disengaging A Unit. (5) Slide the clutch rim (A) on the drive
shaft until the setscrew hole aligns with the
(1) Using the procedures outlined in engagement hole position (C) in the drive shaft
paragraph 2.a(1) above, inch the press so that the gear. Reinsert and tighten the setscrew.
appropriate timing marks are aligned by using the
Inch Button. (6) Replace the clutch cover and retighten
the two clutch cover thumbscrews.
III-3
CAUTION
C
D CAUTION
Burns may result from

Driveshaft contacting the brake hub or
spindle shaft when removing
A or changing paper rolls. Do
B not touch the brake hub or
Engaged spindle shaft until they have
cooled down.
(2) Unlock the paper roll brake assembly

safety guard (H) by turning the T-handle (I) and
swinging the guard outward.
Gear
Disengaged (3) Loosen the brake shoe handwheel (G)
and separate the wooden shoe blocks (A) and (F)
from the brake hub (B).
A - Clutch Rim (4) Depending on the size of the paper roll

B - Setscrew on the spindle shaft (E), remove the paper roll
C - Setscrew Hole for Engaged Position either by hand or with the aid of the lifting levers.
D - Setscrew Hole for Disengaged Position If possible, remove the paper roll onto a dolly for
ease of transporting the roll.
Figure 3-2. Clutch Rims
(5) Remove the paper roll spindle shaft
(E) according to the particular design of the spindle
e. Disengaging A Clutch.
shaft.
b. Loading The Roll Stand.
marks on the driveshaft and the unit align by using
the Inch button.
(2) Load a roll of paper onto a paper roll
dolly. Be aware of the proper direction of rotation
(3) Remove the clutch cover on the unit
necessary for the run.
by loosening the two clutch cover thumbscrews.
(3) Place lifting levers onto pivot stud and
(4) Loosen or remove the setscrew (B) on
leave the handles resting on the floor.
the rim.
(4) Place paper roll spindle shaft (E)
(5) Slide clutch rim (A) backwards on the
through the core of the roll. NOTE: paper roll
drive shaft until the setscrew hole realigns with the
spindle shafts come in different designs. If you
disengagement hole position (D) in the drive shaft
need assistance, contact a DGM, Inc. Customer
gear. Reinsert and tighten the setscrew.
Service representative.
(6) Replace the clutch cover and retighten
(5) Position the paper roll spindle shaft (E)
the two clutch cover thumbscrews.
so that there is proper distance between the
spindle shaft brake hub (B) and the paper roll.
3. ROLL STAND.
(6) Once you have the desired distance,
a. Unloading The Roll Stand (See figure 3-
tighten the devices (depending on design) on the
3).
spindle shaft (E) to lock the paper roll in position.
You can then use the paper roll sidelay handwheel
(C) to make slight adjustments of the webs posi-
tion.
III-4
A
H I
B
G
C
D
E
F
A - Upper Brake Shoe and Block

B - Brake Hub
C - Paper Roll Sidelay Handwheel
D - Paper Roll Spindle Chuck
E - Paper Roll Spindle Shaft
F - Lower Brake Shoe and Block
G - Brake Shoe Handwheel
H - Safety Guard
I - Tee Handle
Figure 3-3. Roll Stand
(G) into the bracket on the upper brake shoe and

(7) Align the brake hub (B) with the brake block assembly (A). Then lightly tighten the
shoes (A) and (F). Push the dolly and paper roll handwheel (G).
into the roll stand, keeping the brake hub aligned
with the brake shoes. (10) The paper roll is now ready for web-
bing or splicing.
(8) With a crewperson on each side of
the unit, they should lift up on the lifting levers at 4. PLATES.
the same time to load the paper roll.
a. Plate Care.
WARNING
(1) Plates should be handled carefully to
avoid damage to either the plate itself or the image
WARNING area. Keep plates stored flat, out of the light, in a
cool and dry area. Handle plates by their edges.
WARNING
You must control the lifting levers.
The weight of the paper roll will shift
to the front of the lifting levers. This
causes the levers to spring up WARNING
quickly, therefore, it is recommended
that you stand to the side of the lifting
levers when using them. Plate edges and corners are sharp.
Severe cuts can occur from plate
(9) Connect the brake shoes (A) (F) to the edges. Handle with care.
brake hub (B) by placing the brake shoe handwheel
III-5
(2) It should be standard operating should cover the entire width of the plate cylinder
procedure to remove the plates after each press which is covered by the printing plate.
run. Preserve and store the used plate according
to the manufacturer’s recommendations. d. Plate Installation.
b. Plate Bending. Because various models of presses may have

specific lockup requirements, training will be
Each specific lockup requires precise bending of provided upon installation of the equipment.
the printing plate to maintain register control and
proper attachment to the plate cylinder. Depending The following is a general procedure for installing a
on the type of lockup, cylinder undercut and press plate.
model purchased, specific training has been
provided upon installation of the equipment.
c. Plate Packing. A
F
(1) DGM provides plate cylinders with
many different customer specified undercuts.
E
Those undercuts requiring packing can be packed
using either mylar or special “Printing Press Paper” B
packing. These products can be purchased from
your local pressroom supply dealers. The following C D
are two recommended methods of packing plates.
In both methods, when placing the packing mate-
rial on the back of the printing plate, ensure the
material is smoothed out to eliminate air pockets. A - Plate Lock-Up Spring
B - Lock-Up Shaft
(2) Printing Press Paper Packing. This C - Packing
type of packing should be purchased in a thick- D - Plate
ness that will require only one sheet of paper to E - Lock-Up Slot
make up the proper packing height. The sheets F - Tail Edge of Plate
should be trimmed so that they are approximately
1/2 inch narrower than the printing plate. Attach Figure 3-4. Plate Lock-Up
the packing to the back of the plate with a light
coat of spray glue along the lead edge of the plate. (1) Have the plate cylinder lockup (or
Be careful to only cover the area between the two cylinder gap) accessible by using the inch button.
inside bends with the packing. DO NOT allow the
packing to hang down into the plate lockup or (2) Put the press on SAFE.
around the gap edges of the cylinder. A light coat
of greaseless lube, sprayed on the back of the (3) Depending upon design, open or align
paper packing will aid in removing the plate after the plate cylinder lockup mechanism.
the printing run.
WARNING
(3) Mylar Packing. This type of packing
should be purchased in the proper thickness so
that only one sheet is required to achieve the
WARNING
desired packing height. When purchasing, ensure
that the mylar is specifically for use as plate
packing. This packing should be the grained type
and installed on the cylinder with the direction of Keep hands away from Nip Points.
the grain against and around the cylinder. Before
applying the mylar to the cylinder, it is recom- (4) Place the lead edge of the plate over
mended the grained side be lightly roughened and the lead edge of the cylinder. Align the plate
cleaned to provide better adhesion. Use a thin film according to your standard operating procedure.
of spray adhesive to secure the mylar to the Be sure that the leading plate edge is completely
cylinder. Any excess mylar should be trimmed off seated across the entire width of the plate cylinder.
to keep the lockup area clear. Mylar packing
III-6
(5) With the unit not webbed, engage the rust and corrosion. Therefore, it is good preventa-
impression lever and disengage the SAFE. tive maintenance to clean the plate cylinders after
each press run or at least after each eight hour
(6) While securely holding onto the tail shift. Simply clean the cylinder with a rag and
edge of the printing plate, inch the press slowly solvent, using the STOP-SAFE system. Then,
until the plate cylinder lockup is accessible once apply a thin film of oil to the cylinder surface.
again. Put the press on SAFE.
5. BLANKETS.
(7) Depending upon design, open or align
the plate cylinder tail clamp mechanism. a. Blanket Care.
(8) Insert the tail edge of the plate into the (1) New blankets may have a protective
gap of the plate cylinder. Close the clamp on coating put on by the manufacturer. Check with
Narrow-Gap design. your blanket manufacturer for the proper cleaning
solution to clean the blanket before installation.
(9) Disengage the SAFE, and disengage
the impression lever. (2) Blankets should be cleaned with a
blanket wash and perhaps water at the end of each
(10) With the inch button, make the press press run. The water will help remove paper fiber
move one revolution. and dust from the blanket surface.
(11) Put the press on SAFE. (3) Check the tightness of the blanket
every week; tighten if necessary. (Refer to
(12) Inspect the plate to be sure it is on the paragraph 5.c “Blanket Installation”.) A loose
cylinder squarely and securely. Any looseness blanket will cause print quality problems.
may cause a plate to come off while running, or
result in poor reproduction quality. (4) If the blanket packing becomes wet,
wrinkled, or torn, remove it immediately. Clean
e. Plate Removal. and dry the blanket cylinder before installing new
packing material.
(1) Have the plate cylinder lockup (or
cylinder gap) accessible by using the inch button. (5) Because the blanket is the final point
between ink and substrate, print quality can be
(2) Put the press on SAFE and verify the maintained through proper blanket handling.
impression lever has been disengaged. Consult your blanket manufacturer. Do not mix
compressible and non-compressible blankets on
(3) Depending upon the design, open the the same press.
plate cylinder lockup mechanism. The tail edge of
the plate should come off, or out, of the lockup b. Blanket Packing.
mechanism.
NOTE
(4) While using the heals of both hands on
the lead edge of the plate, push up, to separate the It may be easier to manage the
lead edge of the plate from the cylinder edge. blankets when starting by making a
sharp crease or bend on the lead
(5) Disengage the SAFE and keep the edge of the packing.
impression lever in the disengaged position.
(1) It is a good practice to use a dead
(6) Hold the lead edge of the plate se- weight micrometer to measure the thickness of a
curely while inching the press slowly for one blanket supplied by the manufacturer. Do not rely
revolution. This will allow the plate to come off the on the written thickness on the back of the blanket.
cylinder by the time the one revolution is com-
pleted. (2) The thickness of the blanket plus
packing, off the press, should be approximately
f. Plate Cylinders. 0.087 inches. The thickness may need to be
adjusted based upon the type of materials used
Moisture left on the cylinder surfaces can cause and the current condition of the press. After the
III-7
blanket and packing have been installed and 5- While holding the packing
“rolled-in”, the thickness, on the cylinder, should material in this position, adhere a one inch long by
measure no less then 0.083 and no more than .085 1/2 inch wide piece of transparent tape length wise
inches when measured with a blanket gauge. at the center of the width of the packing material.
Blanket gauges are manufactured by various The tape should be positioned so that approxi-
companies. Use the one that suits personnel and mately 3/8 of an inch extends past the edge of the
gives you the most accurate measurement. packing material while 1/8 of an inch is on the
packing material itself.
(3) It is recommended that you use the
fewest number of packing sheets as possible; but, 6- Place two more pieces of tape
no more than three sheets. in a similar manner at the packing materials’ width,
one at each end.
(a) The blanket packing material
should be cut slightly narrower than the blanket 7- Place the packing material
width and approximately one inch longer in length. along the edge of the cylinder gap toward the
blanket cylinders nip. Center the packing material
(b) Packing Installation One (1) across the cylinder.
Sheet:
8- Bend the tape over the edge
1- Adhere a one inch long by 1/2 of the cylinder gap and press the tape to the
inch wide piece of transparent tape lengthwise at cylinder gap wall
the center of the width of the packing material.
The tape should be positioned so that approxi- (4) While securely holding the packing
mately 3/8 of an inch extends past the edge of the material, bar or inch the unit one revolution while
packing material while 1/8 of an inch is on the smoothing the packing material around the cylin-
packing material itself. der. Stop the unit when the cylinder gap is once
again accessible.
2- Place two more pieces of tape
in a similar manner at the packing materials’ width, (5) Trim the excess packing material even
one at each end. with the cylinder gap.
3- Place the packing material (6) While holding the packing material in
along the edge of the cylinder gap toward the this position, adhere a one inch long by 1/2 inch
blanket cylinders nip. Center the packing material wide piece of transparent tape lengthwise at the
across the cylinder. center of the width of the packing material and at
each outside edge. Bend the tape over into the
4- Bend the tape over the edge cylinder gap.
of the cylinder gap and press the tape to the
cylinder gap wall. c. Blanket Installation.
(c) Packing Installation Multiple NOTE

Sheets:
Various models of presses may have
1- Lay the packing material on a specific lockup requirements. There-
flat table; a light table works very well. fore, depending upon the model of
press, training will be provided upon
2- Tape the first packing sheet installation of the equipment. The two
squarely to the table with the lead edge closest to most frequently used on the DGM 430
you. Press (“T”-Bar and Reel-Rod) are
discussed below.
3- Place the second piece of
packing material on top of the first leaving approxi- (1) Lock-Up Procedures - “T” Bar. The
mately 1/64 of an inch gap between leading edges. following is a general lockup procedure for blanket
cylinders equipped with a T-bar design. (Refer to
4- Place the third piece of figure 3-5.)
packing material on top of the second in like
manner. (a) Removal.
III-8
1 - Inch the press until the 2 - Inch the press until the
blanket cylinder gaps are accessible by using the blanket cylinder gaps are accessible by using the
inch button. inch button.
2 - Put the press on SAFE. 3 - Put the press on SAFE.
3 - Remove the six socket head 4 - Install the blanket packing

cap screws (D) from the T-bar (C) located in the according to the directions given in the paragraph
blanket cylinder gap. Remove the T-bar (C). 5.b, “Blanket Packing”.
4 - After noting the direction the 5 - After noting the direction the
cylinder will rotate, remove the lead edge of the cylinder will rotate, insert the lead edge of the
blanket (A) from the cylinder gap. blanket into the blanket cylinder gap. (The under-
side of the blanket should face the opposite
A
blanket cylinder.)
6 - Replace two socket head cap

screws (D), one at each end of the cylinder gap, to
hold the lead edge of the blanket in the gap.
B D Again, make sure the screws of the bolts are well
below the cylinder surface.
C
7 - Disengage the SAFE.
8 - While securely holding the

opposite edge of the blanket (tail edge), inch the
unit one revolution so that the cylinder gap is
A - Blanket accessible again. Be sure the blanket wraps
B - Blanket Packing around the cylinder squarely and tight.
C - T-Bar
D - Socket Head Cap Screw 9 - Remove the two socket head
cap screws (D) from the cylinder gap and insert the
Figure 3-5. Blanket Cylinder (T-Bar Design) tail edge of the blanket into the gap.
5 - Replace two socket head cap 10 - Install the T-bar (C) along with
screws (D), one at each end of the cylinder gap, to the six socket head cap screws (D) into the
hold the tail edge of the blanket in the gap. Make cylinder gap. Starting with the center screws and
sure the tops of the screws are well below the working to the outside, slightly tighten the socket
cylinder surface. head cap screws.
6 - Disengage the SAFE. 11 - Starting with the center socket

head cap screws and working to the outside,
7 - While securely holding the tighten the socket head cap screws using a
lead edge of the blanket, inch the unit one revolu- blanket T-wrench set for 35 inch-pounds.
tion so that the cylinder gap is accessible again.
12 - After both blankets are
8 - Put the press on SAFE. installed, engage the impression lever and run the
unit for approximately one-hundred revolutions to
9 - Remove the two socket head “roll in” the blankets.
cap screws from the cylinder gap; remove the
blanket and packing. 13 - Stop the press.
(b) Installation. 14 - Inch the press until the

blanket cylinder gaps are accessible by using the
1 - Using the STOP-SAFE inch button.
system, clean the blanket cylinder and especially
the cylinder gap. Remove dirt, oil, and old tape. 15 - Put the press on SAFE.
III-9
16 - Disengage the impression 3 - Put the press on SAFE.

lever.
4 - Loosen the socket head cap
17 - Retighten the socket head cap screws (2) from the clamp (1) located at the ends
screws in the same manner as previously de- of the blanket cylinder.
scribed.
5 - Install the blanket packing
18 - After 1,000 and 10,000 according to the directions given in the paragraph
impressions, check the hex-head bolts again. It is 5.b, Blanket Packing.
a good idea to periodically check the tightness of
the blanket and hex-head bolts until the blankets 6 - After noting the direction the
are changed again. cylinder will rotate, insert the lead edge of the
blanket into the lead edge gap (3) of the blanket
(2) Lock-Up Procedures - Reel Rod. cylinder gap. (The underside of the blanket should
The following is a general lockup procedure for face the opposite blanket cylinder.)
Reel-Rod Blanket cylinders. (Refer to Figure 3-6.)
7 - Disengage the SAFE.
Blanket Cylinder 8 - While securely holding the

opposite edge of the blanket (tail edge), inch the
unit one revolution so that the cylinder gap is
accessible again. Be sure the blanket wraps
4 around the cylinder squarely and tightly.
9 - Insert the tail edge of the

Cylinder Gap blanket into the tail edge gap (5).
5
2 Head of bolt is
1 recessed in block
1 - Clamp
Figure 3-7. Blanket Cylinder Torque Wrench
2 - Socket Head Cap Screw
3 - "Lead Edge" Gap
4 - 7/8" Hex Head Reel Rod Shaft 10 - Set the blanket lock-up torque
5 - "Tail Edge" Gap wrenches to 45 ft. lbs.
Figure 3-6. Blanket Cylinder 11 - Using a blanket lock-up torque

Reel Rod System wrench at each end of the blanket cylinder, turn the
reel rod shaft (4) OPPOSITE THE ROTATION of
the cylinder. As the shaft is turning, the tail edge
(a) Installation. Because the
of the blanket will wrap around the shaft, tightening
tightening of the reel rod is necessary at both ends
the blanket on the blanket cylinder.
of the blanket cylinder, it is highly recommended
that installation procedures be performed by two (2)
12 - At each end of the blanket
personnel.
cylinder, retighten the socket head cap screws (2)
into the clamp (1).
1 - Using the STOP-SAFE
system, clean the blanket cylinder and especially
13 - After both blankets are
the cylinder gap. Remove dirt, oil, and old tape.
installed, engage the impression lever and run the
unit for approximately one-hundred revolutions to
2 - Inch the press until the
“roll in” the blankets.
inch button.
III-10
14 - Stop the press.

8 - While securely holding the
15 - Inch the press until the lead edge of the blanket, place a slight “pull” on the
blanket cylinder gaps are accessible by using the blanket and inch the unit one revolution so that the
inch button. cylinder gap is accessible again. The blanket
should “peel” off the cylinder during the rotation.
16 - Put the press on SAFE.
17 - Disengage the impression
lever. 6. INK SYSTEM.
18 - Retighten the reel rod (4) in a. The DGM - 430 unit is equipped with a
the same manner as previously described. swing-down ink fountain (see figure 3-8) for com-
plete and easy cleaning. The ink from the fountain
19 - After 1,000 and 10,000 to the ink feed roller is controlled by either ink
impressions, check the reel rod (4) and the socket fountain screws or levers. Ink is transferred from
head cap screws (2) in the clamps (1) again. It is a fountain to plate by the ink train, consisting of the
good idea to periodically check the tightness of the ink feed roller, the rubber transfer rollers, the metal
blanket and clamp screws until the blankets are rollers or drums, and the form rollers. The ink form
changed again. and feed roller Throw-offs are controlled manually
or pneumatically.
(b) Removal.
1 - Inch the press until the

inch button.
2 - Put the press on SAFE. D

E
F
3 - Refer to figure 3-6. Loosen
the socket head cap screw (2) from the clamp (1)
C
located at the ends of the blanket cylinder.
4 - After noting the direction the B

cylinder will rotate, using a 7/8 inch open-end box A
wrench at each end, turn the reel rod shaft (4) IN
THE DIRECTION of the rotation of the cylinder.
A - Ink Fountain Levers
NOTE B - Cross Brace
C - Handknob
When the reel rod has been loosened, D - Ink Fountain Seal
using the palm of your hand against E - Ink Fountain Roller
the blanket and pushing upwards, will F - Ink Fountain Blade
help in loosening the blanket.
Figure 3-8. Ink Fountain Assembly
5 - Remove the leading edge of
the blanket away from the slot. Remove the tail CAUTION
edge of the blanket from the tail edge gap (5) on
CAUTION
the reel rod (4) but leave this edge in the slot.
Do not close the ink fountain lever or
6 - Retighten the socket head cap screws so that the ink fountain blade
screw (2), at each end of the blanket cylinder. comes into contact with the ink
Make sure the tops of the screws are well below fountain roller. This will cause
the cylinder surface. damage to both the blade and roller.
7 - Disengage the SAFE. b. The gap between the ink fountain blade
and the ink fountain roller determines the amount
III-11
of ink leaving the ink fountain. The gap between system is standard. An optional spiral brush or
the blade and roller is adjusted by either a lever or spray-bar dampening system is also available. A
a thumbscrew (ink key). manual or pneumatic dampener form roller throw-off
is used.
c. With lever up, ink flow is shut off. As the
lever is adjusted down, the ink flow increases. b. The speed of the dampener fountain pan
roller regulates the amount of dampener solution
d. With thumbscrews, turning clockwise being fed into the dampener roller train. The faster
decreases the ink flow while turning counterclock- the pan roller rotates, the greater the amount of
wise increases the ink flow. solution is being applied to the plate surface. The
speed of the pan roller is adjusted by the dampener
e. Ink Fountain Cleaning. feed motor speed control dial on the unit control
panel or by the dampener motor speed switch on
(1) If it is necessary to clean the Ink the press console, if so equipped. From a slow
Fountain, follow the procedures outlined in Section start to production speed, adjustments will be
VII, Maintenance, paragraph 8.a. necessary to maintain proper ink and water bal-
ance.
f. Ink Stripe.
c. The fountain pans and dampener circula-
(1) The pressure between a soft rubber tion system should be cleaned weekly. Follow the
roller and a harder metal drum causes the rubber directions of the circulation system manufacturer
roller to flatten and squeeze the ink film out from to clean the system.
between the two. Thus, this area of the rollers
appear as a long stripe, the length of the rollers. d. Water Stops.
This is called an ink stripe, but in fact, there is very
little ink at all. Another term which can be used is (1) Water stops are used for shutting off
an ink flat. In any case, this “No Ink”, ink stripe is or greatly reducing the amount of dampening
used to measure the ink roller settings throughout solution to a particular part of the dampening train.
the ink train. The ink stripe width should be When the product calls for the use of less than full
uniform the entire length of the roller.
Water Stop
(2) If equipped with a pneumatic throw-off

system, the air cylinders must be operative in
order to make your measurements. Measurements
made with air cylinders inoperative will not stay
maintained.
g. Making Ink Stripes. Figure 3-9. Water Stop

(1) With the ink train properly inked, run
the unit until all of the previous ink stripes have webs or for adjusting the demand on certain
disappeared. Check to make sure that the ink forms, then a water stop is placed in the fountain
rollers have inked up evenly. pan to squeegee off dampening solution from the
fountain pan roller.
(2) Stop the unit and engage, then
disengage, the ink rollers.
(3) Inch the unit until the desired stripe

you are checking becomes accessible.
(4) Put the press on SAFE. Figure 3-10. Water Stops In Place
(5) Inspect the ink stripe.
CAUTION
7. DAMPENING SYSTEM.
CAUTION
a. A sock type continuous feed dampening Do not place water stops in the
III-12
fountain pan unless the press is You will encounter various

completely stopped. nip points during this
operation which can cause
8. WEBBING THE UNIT. bodily harm. Care should be
observed in webbing the
a. Web lead patterns will vary depending press to ensure personal
upon the requirements of the end product. There- safety.
fore, the following are general procedures that can
be followed when webbing a press (refer to figure 3- (4) While an operator unrolls the paper roll
11). to create slack in the web, another operator pulls
the tapered lead-end of the web through the web
(1) Put the press on SAFE. tension rollers (C), between the blankets (B) in the
unit, and around the compensator rollers (A).
A
(5) When all of the webs are brought to
To the folder, consult the folder operator’s manual for
Folder procedures to web the folder.
b. Setting Web Tension.
F
D
E
B
C
C
B
A - Brake Drum
B - Brake Shoe
A - Compensator Rollers C - Brake shoe Handwheel
B - Blanket Nip D - Knurled Tension Spring Nut
C - Web Tension Rollers E - Tension Spring
Figure 3-11. Diagram of Web Lead - Unit F - Governor Roller
Figure 3-12. Tension System Diagram

(2) Disengage impression levers and
loosen the brake shoe handwheels.
(1) Refer to figure 3-12. The initial tension
(3) Produce a tapered edge at the lead- spring (E) setting is made upon installation of the
end of the web by tearing the paper at an angle unit. When the setting is complete, the length of
from the operator side to the drive side of the web. the spring will be 16 to 17 1/2 inches.
The tapered edge permits the web to pass through
the unit and press freely and evenly. (2) The unit farthest from the folder has
the lowest spring tension setting while the unit
closest to the folder has the highest. This gradual
CAUTION
increase in spring tension from farthest to nearest
CAUTION insures an even web feed to the folder.
III-13
(3) As the press runs and the paper roll Try to keep the tape or adhesive parallel to the tail
reduces, brake shoe (B) adjustments are neces- edge.
sary to keep the governor roller (F) perpendicular to
the floor to maintain proper web tension. (8) Remove the lead-end of the new roll
out from under the expired webs’ tail and attach it
(4) When the press is started, tighten the to the tape or adhesive. Tear off the excess paper
brake shoe handwheel (C) so that the governor from the lead-end of the new roll.
roller arm (F) just comes off of the nylon bushings
that they rest on when there is no web tension. (9) With the impression levers engaged,
run the press at a slow speed until the splice(s)
(5) As press speed increases, tighten the enter the folder. If the splice(s) are passing
brake shoe handwheel (C) to pull the governor roller through more than one unit, you may want to
(F). By production speed, the governor roller and disengage the impression levers while the splice
arm should be vertical to the floor. passes through those units; then re-engage the
impression levers.
(6) When running multiple webs, the
bottom web has the greatest amount of web 9. MAKE-READY CHECKLIST. (RECOM-
tension. The web tension is progressively less MENDED PROCEDURES TO BE COMPLETED
with each successive web. PRIOR TO ENGAGING THE PRESS DRIVE.)
c. Splicing. a. ___ If the press is supplied with pneumatic

controls, turn on the air supply to the press.
b. ___ Engage units to be used, disengage
(2) Loosen and disengage the brake shoe units not to be used. Disengage the folder.
handwheel (C).
c. ___ Load the unit roll stands to be used,
(3) Remove the expired webs’ core, with the proper kind and size of paper.
leaving a long tail for splicing, and install the new
paper roll according to the procedures outlined in d. ___ Fill appropriate ink fountains.
paragraph 3.b above, “Loading The Roll Stand”.
e. ___ Center register controls.
WARNING
f. ___ Install plates in proper position.
g. ___ Web the press.

WARNING
h. ___Turn on and adjust dampening system
and controls.
Contact with the spindle shaft or
brake hub of an expired paper roll can i. ___Check the level of the dampening
cause serious burns. Wait until the solution and its pH/conductivity.
shaft and brake hub have cooled
before touching. j. ___ Engage the folder, web the folder, and
adjust for the product requirements.
(4) Inspect the new paper roll for any
damage or defects. k. ___Engage the impression levers on the
units being used.
(5) Fold and tear off the lead-end of the
new roll square across the width of the web. l. ___ You are now ready to slowly start up
the press. As you do, adjust web tension as
(6) Lay the tail of the expired web over the needed. The webs may wander side-to-side for a
new paper roll, being sure it extents past the lead- short time. Once the press is running, apply
end of the new roll; fold and tear the tail of the old dampening solution to the plate from the dampener
web off square with the width of the web. form rollers, apply ink from the ink form rollers and
start registering the webs, images, and cutoff while
(7) Place double-sided tape or an adhe- controlling ink and water balance.
sive along the entire width of the expired webs’ tail.
III-14
SECTION IV
RUNNING PROCEDURE
SECTION IV - Running Procedure

Introduction ---------------------------------------------------------------------------------------- IV-2
Startup ---------------------------------------------------------------------------------------- IV-2
Running ---------------------------------------------------------------------------------------- IV-2
Shutdown ---------------------------------------------------------------------------------------- IV-3
Wash-Up ---------------------------------------------------------------------------------------- IV-3
Rollers ---------------------------------------------------------------------------------------- IV-3
Cylinders --------------------------------------------------------------------------------------- IV-3
Safety ---------------------------------------------------------------------------------------- IV-3
IV-1
1. INTRODUCTION. pre-ink the plates, before the press run, by follow-

ing these steps:
a. The following is a procedure outline for
setting and adjusting the operation controls of the (a) Disengage the folder.
DGM - 430 unit for a press run. Each procedure in
itself is complete. However, the skill of the (b) Run the unit at approximately
pressroom personnel and local conditions may 3000 iph.
require some minor changes for best quality and
performance. (c) Engage the ink feed throw-off
lever.
WARNING
(d) Start the dampener motors at both
the unit and the control panel/console.
WARNING
(e) When the ink form rollers are
evenly inked, disengage the ink feed throw-off
lever.
The DGM - 430 unit is equipped with
guards, doors and covers which may (f) When the dampener form rollers
have interlock safety devices for your are moist, engage the dampener form throw-off
protection. Never by-pass any safety lever.
device. Be sure that the press is on
SAFE before opening any of these (g) When the plate looks wet or shiny,
devices. engage the ink form throw-off lever to ink the
image on the plate.
2. STARTUP. (h) When the plate is evenly inked,

disengage the ink form throw-off lever, then the
a. Have all ink feed, ink form, dampener dampener form throw-off lever.
form, and impression throw-off levers disengaged.
(i) Shut off the unit and engage the
b. Set the master dampener motor toggle folder while the press is on “SAFE”.
switch to the ON position at the unit; the dampener
motors will be turned off at the control panel/ h. While bringing the press up to production
console. Set the dampener motor speed control speed, observe the webs and images. Make
dials at the unit to approximately 3. adjustments for web tension, ink and water bal-
ance, ink coverage and registration.
c. Engage the folder. Engage the impression
throw-off levers. i. Never adjust an ink or water feed roller
while the press is in motion. Always place the
d. Startup the press and run between 3000 press on “SAFE” before adjusting rollers.
and 4000 iph. Be sure that the web(s) are running
through the press and delivering properly. j. At the delivery, check the product for page
imposition, cutoff, and ink coverage.
e. Turn on the master dampening motors
from the control panel/console. k. Make fine adjustments as necessary.
f. Engage the dampener form rollers. Ob- 3. RUNNING.

serve the plate; it should reflect light from the
moisture and look shiny. WARNING
g. Engage the ink form rollers and the ink

feed throw-off levers; observe the plate. The non-
image areas should remain clean while the image WARNING
areas become inked.
(1) A “roll up” procedure can be used to Never attempt to clean or make
IV-2
adjustments while the press is f. Loosen the brake shoe handwheels.

running. Severe injury may occur.
Beware of nip points. g. Disengage the impression levers.
a. Establish proper ink and water balance as h. Disengage the folder.

soon as possible.
i. Remove and preserve the plates if neces-
b. Inspect the running web for ink coverage sary.
and dampener changes.
5. WASH-UP.
c. As soon as there is image on the web,
make the necessary register adjustments. Such a. Rollers.
as: side margin register, back-to-back register,
color register, cutoff register, and web-to-web Refer to Section VII, Maintenance, paragraph 8.b
register. for procedures applicable to cleaning rollers.
d. Adjust the folder delivery as necessary. b. Cylinders.
4. SHUTDOWN. By the use of the STOP-SAFE system:
a. Slow the press to a walking or inching (1) Clean the blankets used for the run
speed. with two rags and solvent. Break down the ink film
with a solvent soaked rag and then wipe dry with a
b. Disengage the ink feed roller, the ink form dry rag.
roller, and the dampener form roller throw-off
levers. (2) After removal of the plates, wipe the
plate cylinder surface dry. Then apply a thin film
c. Turn off the dampener motors at the unit or of oil to the cylinder surface.
at the control panel/console.
c, Safety.
d. Allow the press to rotate a few revolutions
to remove excess ink from the blankets. Wash-up procedures, as well as any work on the
press, should always be done with a helper, or at a
e. Stop the press. Inch the press to align the minimum, another person observing, who may
timing marks located on the driveshaft and the assist in cases of emergencies.
unit.
IV-3
IV-4
SECTION V
PAGE IMPOSITION OR PLATE POSITIONING
SECTION V - Page Imposition Or Plate Positioning

Introduction ---------------------------------------------------------------------------------------- V-2
Plate Positioning ---------------------------------------------------------------------------------------- V-2
Page Patterns ---------------------------------------------------------------------------------------- V-2
Some “Set Up” Questions ----------------------------------------------------------------------------- V-2
Terminology ---------------------------------------------------------------------------------------- V-3
Broadsheet ------------------------------------------------------------------------------------ V-3
Tabloid ---------------------------------------------------------------------------------------- V-3
Mini-Tab Or Signature ------------------------------------------------------------------------ V-3
Former ---------------------------------------------------------------------------------------- V-3
Upper Former --------------------------------------------------------------------------------- V-3
Center Spread --------------------------------------------------------------------------------- V-3
Unit Configurations ------------------------------------------------------------------------------------ V-3
Page Impositions --------------------------------------------------------------------------------------- V-4
V-1
1. INTRODUCTION. 3. PAGE PATTERNS.
a. Page imposition is the process of deter- a. A study of figure 5-1 will reveal a pattern for
mining where on the press the plates are to be numbering the pages. Page 1 is on the drive side
positioned to have the page sequence in proper of the unit farthest from the folder. The page
order in the finished product. numbers form
a “U” - shaped
2. PLATE POSITIONING. pattern from
16 1
the farthest
a. The physical arrangement of the press will unit to the
dictate the web lead. However, the following nearest unit 15 2
“Helps” can be used to determine the proper plate and back to
positioning. the farthest
unit. The first
Help #1 - The first and last page of a section are and last pages 14 3
located on the same plate. On a Broadsheet, they will be printed
are next to each other. on the printing 13 4
couple farthest
Help #2 - The page numbering will form a “U”- Op. Drive
from the folder,
Side Side
shaped pattern. while the
inside pages 12 5
Help #3 - Page 1 will be located on the farthest unit will be printed
being used, away from the folder. on the printing
couple nearest 11 6
Help #4 - The inside pages will be located on the the folder.
nearest unit being used, from the folder. Lower page
numbers are
Help #5 - The pages with the lowest numbers will 10 7
on the drive
be located on the drive side of the press. side and the
higher num- 9 8
Help #6 - The pages with the highest numbers will bers are on
be located on the operator side of the press. the operators
side. The sum
Help #7 - One DGM - 430 unit can produce 4 pages of the compan- Folder
in a broadsheet format; 8 pages in a tabloid format; ion pages
16 pages in a mini-tab or magazine (signature) equals the
format. number of 16 Page Markup for a
pages in the Broadsheet Product
Help #8 - If the pages are in their proper location, section plus
then by adding the page numbers on companion one. Figure 5-1. Markup Example
pages (pages next to each other), you should get a
sum equal to one more than the number of pages 4. SOME
in that section. “SET-UP” QUESTIONS.
Example: A 12 page section plus 1 = 13 a. A list of questions which need to be

answered, before marking up the page imposition,
Pages 1 plus 12 = 13 may be as follows:
Pages 2 plus 11 = 13
Pages 5 plus 8 = 13 (1) What type of format? Broadsheet?
Pages 6 plus 7 = 13 Tabloid? Mini-Tab?
b. The procedure to follow for positioning the (2) How many pages?
plates is based on the arrangement of the printing
units and the characteristics of the folder. On most (3) Is there any color? Spot? Process?
presses, when facing the former, page 1 is on the Location?
top of the uppermost web and is on the right hand
side (drive side) of the former. (4) How many sections?
V-2
(5) Size and location of paper rolls? tab pages. The mini-tab pages run head-to-head
across the width of each plate. A Quarter-Fold
(6) assembly on the folding unit, is normally needed for
Press and folder this product.
capacity? 20 1
d. Former - forms the first longitudinal fold of
(7) There the web. The web passes over and down a smooth
may be others 19 2 triangular plate located towards the top of the
depending upon folder. This triangular plate is called the former
your situation. board or pan.
18 3
5. TERMINOL- e. Upper Former - is sometimes called
OGY. balloon former. This is a second former pan
17 4 located above the first to allow for the running of an
a. Broad- additional section.
sheet - a stan-
dard newspaper f. Center Spread - It is a carryover term
sheet which 20 - Page from letterpress days and means a two-page center
contains 4 spread in the center of each section.
numbered pages. 16 5
2 pages on one 6. UNIT CONFIGURATIONS.
side of the sheet
15 6
(single-width web) a. As shown in figure 5-2, when using units in
and 2 pages on front of the folder, it will be necessary to visually
the other side. place that units’ run behind the folder and then
The head or top of 14 7 numbered. This would essentially place the first
the page image is and last pages farthest from the folder.
located on the
trailing edge of 13 8 b. If your press is equipped with a second
the plate. former located above the former on the folder, then
you have what is called a Balloon former. Each
b. Tabloid - 12 9 additional former increases the number of sections
the tabloid page that can be ran.
is half the size of
the standard 11 10
2A 7A
4A 5A
8A 1A
6A 3A
1
3
2
newspaper page;
each broadsheet
8
6
7
page area
becomes 2 Folder
tabloid pages.
Tabloid pages run
head-to-head; all
heads are located
toward the vertical 20 1
centerline of the
Figure 5-3. Using a "Balloon" Former
press. Tabloid
19 2
sizes can vary
depending on the c. The upper former can only be fed with
width of the web. webs from the farthest units that are being used or
18 3 from units in front of the folder using an over-the-top
c. Mini-tab web lead.
or Signature - is
half the size of 17 4 d. One set of eight pages is run over the
the tabloid page. balloon former while another set of eight pages is
Each newspaper run over the lower former.
page area Figure 5-2. Placement
becomes 4 mini- e. The web lead from the balloon former can
V-3
be brought down on either side of the lower former. 7. PAGE IMPOSITIONS.

When the web lead from the balloon former is
brought down on the operator’s side of the lower a. Figures 5-4, 5-4 and 5-6 show “Broad-
former, it will become the inside section. When the sheet”, “Tabloid” and “Mini-Tab” page impositions
web lead from the balloon former is brought down and is provided for reference purposes.
on the drive side of the lower former, it will become
the outside section.
V-4
4-Page 6-Page 8-Page 10-Page 12-Page 16-Page
4 1 6 1 8 1 10 1 12 1 16 1
3 2 5 2 7 2 9 2 11 2 15 2
Folder 3 6 3 3 10 3 14 3
4 5 4 4 9 4 13 4
Folder Folder
8 5 8 5 12 5
24-Page
7 6 7 6 11 6
20 5
Folder Folder
19 6 24-Page 10 7
24 1
20-Page
9 8
18 7 16 5
23 2
Folder
17 8 15 6 18-Page
22 3 18 1
16 9 14 7
21 4 17 2
15 10 13 8
20 5 16 3
14 11 12 9
19 6 15 4 Count Left to Right.
11 10
Start on the Drive side.
13 12
End on the Op side.
18 7 14
Folder Folder
Stop Start
17 8 13
24 1 16 9 20 1 12 5
Op Drive
Side Side
23 2 15 10 19 2 11 6
22 3 14 11 18 3 10 7
21 4 13 12 17 4 9 8
Folder Folder
Figure 5-4. Broadsheet Page Impositions
V-5
44-Page
40 5 6 39 38 7 8 37 36 9 10 35 44 1 2 43 42 3 4 41
Folder
18 27 28 17 16 29 30 15 14 31 32 13 12 33 34 11 22 23 24 21 20 25 26 19
36 5 6 35 34 7 8 33 32 9 10 31 40 1 2 39 38 3 4 37
40-Page
Folder
Figure 5-5. Tabloid Page Imposition

16 25 26 15 14 27 28 13 12 29 30 11 14 19 20 13 18 23 24 17
Drive
Side
32 5 6 31 30 7 8 29 36 1 2 35 34 3 4 33
36-Page
Folder

End on the Drive side.
Stop
14 23 24 13 12 25 26 11 10 27 28 9 18 19 20 17 16 21 22 15
Start
32 1 31 13 30 3 4 29
32-Page
28 5 6 27 26 7 8 25
Folder
16 17 18 15 14 19 20 13 12 21 22 11 10 23 24 9
Side
Op
16 1 2 15 14 3 4 13
16-Page
Folder
8 9 10 7 6 11 12 5
24 1 2 23 22 3 4 21 20 5 19 6
24-Page
Folder
12 1 2 11
12-Page
Folder
6 7 8 5 4 9 10 3 12 13 14 11 10 15 16 9 8 17 18 7
20 1 2 19 18 3 4 17
20-Page
1 8 2 7
Folder
8-Page
Folder
4 5 6 3 10 11 12 9 8 13 14 7 6 15 16 5
V-6
16-Page 24-Page 32-Page 40-Page

13 4 1 16 19 6 1 24 25 8 1 32 31 10 1 40
12 5 8 9 18 7 12 13 24 9 16 17 30 11 20 21
11 6 7 10 17 8 11 14 23 10 15 18 29 12 19 22
14 3 2 15 20 5 2 23 26 7 2 31 32 9 2 39
21 4 27 6 3 30 33 8 3 38
Folder 16 9 22 11 14 19 28 13 18 23
15 10 21 1 13 20 27 14 17 24
22 3 28 5 4 29 34 7 4 38
35 6
Folder Folder 26 15
25 16
48-Page 56-Page 64-Page
37 12 1 48 43 14 1 56 49 16 1 64 36 5
36 13 24 25 42 15 28 29 48 17 32 33
Folder
35 14 23 26 41 16 27 30 47 31 18 34
38 11 2 47 44 13 2 55 50 15 2 63
39 10 3 46 45 12 3 54 51 14 3 62
34 15 22 27 40 17 26 31 46 19 30 35
33 21 16 28 39 18 25 32 45 20 29 36
40 9 4 45 46 11 4 53 52 13 4 61
41 8 5 44 47 10 5 52 53 12 5 60
32 17 20 29 38 19 24 33 44 21 28 37 End on the Drive side.
Start
Stop
31 18 19 30 37 20 23 34 43 22 27 38
Op
Drive
42 7 6 43 48 9 6 51 54 11 6 59 Side
Side
49 8 55 10 7 58
Folder
36 21 42 23 26 39
35 22 41 24 25 40
50 7 56 9 8 57
Folder Folder
Figure 5-6. Mini-Tab Page Imposition
V-7
V-8
SECTION VI
ROLLER ADJUSTMENTS
SECTION VI - Roller Adjustments
Roller Pressure ---------------------------------------------------------------------------------------- VI-2
Roller Adjustments - Ink ------------------------------------------------------------------------------ VI-2
Ink Fountain Roller A ------------------------------------------------------------------------- VI-2
Ink Feed Roller B to Fountain Roller A ----------------------------------------------------- VI-3
Ink Transfer Rollers C and E ----------------------------------------------------------------- VI-4
Ink Form Rollers G and H-------------------------------------------------------------------- VI-5
Roller Adjustments - Dampener ---------------------------------------------------------------------- VI-6
Dampener Fountain Roller I ------------------------------------------------------------------ VI-6
Sock Feed Roller J --------------------------------------------------------------------------- VI-6
Dampener Form Roller L --------------------------------------------------------------------- VI-7
Gap Adjustments --------------------------------------------------------------------------------------- VI-8
Setting Cylinder Gaps - Timing --------------------------------------------------------------- VI-8
Spiral Brush Dampening Adjustment--------------------------------------------------------- VI-9
Iron-To-Iron Setting ----------------------------------------------------------------------------------- VI-10
Setting The Plate And Impression Cylinders ------------------------------------------------ VI-10
To Check The Settings------------------------------------------------------------------------ VI-10
To Adjust The Settings ------------------------------------------------------------------------ VI-11
13 Cylinder Set --------------------------------------------------------------------------- VI-11
13 - 12 Cylinder Set --------------------------------------------------------------------- VI-11
12 - 11 Cylinder Set --------------------------------------------------------------------- VI-12
11 - 10 Cylinder Set --------------------------------------------------------------------- VI-12
VI-1
CAUTION
(1) Cut two pieces of scrap film approxi-
mately 12 inches long and 1 inch wide.
STOP
(2) Insert the slip sheets between the two
Avoid personal injury,
rollers to be checked, about 3 inches in from each
observe nip points between
end of the rollers. (This may have to be done by
cylinders and rollers. Keep
inching the press.)
guards closed when running
the press. Do not defeat the
(3) Pull on the two slip sheets at the
interlock devices affixed to
same time. The tension or drag should be even on
the guards (if available).
both sides.
1. ROLLER PRESSURE.
d. Ink Stripe: The ink stripe method relies on
the pressure of the ink rollers to form an ink stripe
a. To obtain maximum efficiency from the
the length of the roller; then measure the width of
rollers, pressure settings between rollers should be
the ink stripe. This is not actually an ink stripe but
set as lightly as possible without affecting the
rather an area with very little ink. The softer
quality of the product. It is very important that the
transfer rollers flatten slightly when they rest
pressure be uniform the entire length of the roller. If
against a solid drum roller. As the transfer roller
even ink and dampener distribution can not be
flattens out, it pushes the film of ink out from
achieved, inspect the rollers for uneven wear or
between the two rollers and leaves a stripe of no
roller swell. Replace if necessary. Figure 6-1 is
ink. The stripe width must be uniform the length of
provided to aid in roller identification.
the roller. (If units are equipped with a pneumatic
system, air cylinders must be operative.)
B B A
A (1) Engage the ink feed roller and run the
C D C unit until the ink rollers are evenly inked. Be sure
D E
E the ink form rollers are in the off position.
F G
G F (2) Stop the press for a moment, engage
H H then disengage the ink roller so that a line of ink is
PLATE PLATE
(10-Side) (13-Side) made. Inch the press to observe the ink stripe on
L Blanket Blanket L the desired roller to be measured.
J K K J (3) Put the press on SAFE.

I I
(4) Measure the ink stripe and see if it is
A - Ink Fountain Roller H - Inside Ink Form Roller uniform the entire length of the roller.
B - Ink Feed Roller I - Dampener Fountain
C - Ink Transfer Roller Roller
D - Vibrator Ink Drum J - Dampener Feed (Sock) 2. ROLLER ADJUSTMENTS - INK.
E - Ink Transfer Roller Roller
F - Vibrator Ink Drum K - Water Vibrator Drum a. Ink Fountain Roller A.
G - Outside Ink Form Roller L - Dampener Form Roller
No adjustment should be necessary. For those
Figure 6-1. Roller Identification Chart
units which are equipped with ink fountain levers,
those levers should be set in the “O” or closed
b. There are two methods of checking roller position. If the ink fountain is equipped with ink
pressure settings; the slip sheet method and the fountain keys, the fountain blade should be set to
ink stripe method. The dampener rollers use the the fountain roller with a feeler gauge. In both
slip sheet method and the ink rollers use the ink instances, use a 0.002-in. (0.10mm) feeler gauge
stripe method. and the ink levers/keys so that there is a slight
drag on the feeler gauge between the fountain roller
c. Slip Sheet: The slip sheet method provides and the fountain blade.
a quick and accurate check of dampener roller
settings. (If units are equipped with a pneumatic b. Ink Feed Roller B to Fountain Roller A.
system, air cylinders must be operative.)
VI-2
Table 1. Roller Specification Chart
LETTER ROLLER DIA. In./mm TYPE SET TO... ADJUSTMENT SETTING
A Ink Fountain 4 / 102mm Fountain No Adjustment

Blade
B Ink Feed 3 / 76mm Steel Using a feeler gauge:

Plastic A 0.003 in./0.08mm GO
Covering 0.004 in./0.1mm NO GO
D
C Ink Transfer 2 3/4 / 70mm Rubber Then to Ink Stripe Method
B 1/8 to 3/16 in./3mm to 5mm
Vibrator Ink
D Drum 3 1/4 / 83mm Copper No Adjustment
D
E Ink Transfer 2 3/4 / 70mm Rubber Then to Ink Stripe Method
F 1/8 to 3/16 in. /3mm to 5mm
Vibrator Ink
F Drum 3 1/4 / 83mm Copper No Adjustment
F
G Ink Form 2 7/8 / 73mm Rubber Then to Ink Stripe Method
Plate 1/8 to 3/16 in. / 3mm to 5mm
F
H Ink Form 2 3/4 / 70 mm Rubber Then to Same as G above.
Plate
Dampener
I Fountain 3 1/4 / 83mm No Adjustment
Slip Sheet Method

K Snug, steady pull
J Dampener 2 3/4 / 70mm Rubber Then to
Feed (Sock) I Slip Sheet Method
Light pull/contact
Vibrator
K Drum 3 1/4 / 83mm No Adjustment
Slip Sheet Method

K Snug, steady pull
L Dampener 2 3/4 / 70mm Rubber Then to
Form Plate Slip Sheet Method
Slight, steady pull
gauge will go between the rollers. A 0.004-in.

(1) With clean rollers, turn the eccentrics (0.10mm) gauge will not.
at both ends of the roller until they are parallel to
each other, the ink feed throw-off lever engaged, (a) To adjust (refer to figure 6-2) and
and using a feeler gauge, a 0.003-in. (0.08mm) after both rollers are parallel to each other, perform
the following action.
VI-3
4 - Tighten locknut (B).
c. Ink Transfer Rollers C and E.
D Transfer Eyebolt
Adjuster
B
C
C B
A
A
A - Throwoff Lever
B - Locknut
C - Stopscrew
Figure 6-2. Ink Feed Throwoff
2 - Remove operator’s side cover.
3 - Place the ink feed throw-off A - Locknut

lever (A) in the on position. B - Locknut
C - Lockbolt
(b) To decrease the gap (ensure the D - Adjusting Bolt
rollers are parallel to each other).
Figure 6-3. Ink Transfer Roller
1 - Loosen locknut (B).
(1) IMPORTANT. It is necessary to first
2 - Insert feeler gauge between adjust the ink transfer rollers C and E to drum D of
rollers. figure 6-1, as follows (refer to figure 6-3).
3 - Turn stopscrew (C) clockwise (a) Put the press on SAFE.

to decrease the gap.
(b) Loosen the locking bolts (C)
4 - When the gap is correct, located at the ends of the rollers.
tighten locknut (B). IMPORTANT. The ink feed
roller must not come into contact with the ink (c) To decrease the ink stripe.
fountain roller.
1 - Turn the adjustment bolt (D)
(c) To increase the gap. counterclockwise.
1 - Loosen locknut (B) . (d) To increase the ink stripe.
2 - Turn stopscrew (C) counter- 1 - Turn the adjustment bolt (D)

clockwise to push on the throw-off lever (A) stop clockwise.
pin.
(2) When the adjustment is correct,
3 - Turn stopscrew (C) until the tighten the locking bolts (C).
0.003 in. feeler gauge fits between the rollers.
IMPORTANT. The ink feed roller must not come (3) It is very important that the ink stripe is
into contact with the ink fountain roller. rechecked after tightening the locking bolts.
VI-4
(4) IMPORTANT - After the adjustment plished, it is necessary to secondly, adjust rollers
performed in item 2(c) above has been accom- G and H to the plate cylinder after rollers G and H
plished, it is necessary to secondly, adjust the have been set to ink drum F.
transfer rollers (C to B and E to F as indicated in
figure 6-1) after rollers C and E have been set to the
ink drum D (refer to figure 6-3). This is done as
Ink Transfer Roller
follows.
(a) Put the press on SAFE.

Vibrator Ink Drum
(b) To decrease the ink stripe. Ink Transfer Roller

Ink Form Roller
1 - Loosen locknut (B) and tighten
locknut (A) against the frame stud. Roller Nip Guard
10-Cylinder
(c) To increase the ink stripe.
With Guard
2 - Loosen locknut (A) and tighten
locknut (B) against the frame stud. Vibrator Ink Drum
(d) After the rollers have been ad- Ink Transfer Roller
justed, tighten locknuts not in contact with the
frame studs.
(e) It is very important that the ink

Ink Form Roller
stripe is re-checked after tightening the locknuts.
d. Ink Form Rollers G and H.
(1) IMPORTANT - It is necessary to first,

adjust rollers G and H to ink drum F. (Refer to
figure 6-4). 10-Cylinder
(a) Put the press on SAFE.
(b) Loosen the lockbolt (B) located in No Guard

the form roller bracket at both ends of the roller.
A - Adjusting Bolt (In and Out Adjustments)
(c) To decrease the ink stripe. B - Lockbolt
C - Roller-To-Plate Adjusting Bolt (Up and
1 - Turn the adjusting bolt (A) Down Adjustments)
counterclockwise. D - Anti-Bounce Bolt
Figure 6-4. Ink Form and Transfer Rollers
(2) After completing the above adjust- (Guard Removed for Clarity Purposes)
ments at both ends of the roller, tighten the locking
bolt(s) (B).
(a) A properly packed plate must be
(d) To increase the ink stripe. mounted on the plate cylinder and the ink train
evenly inked.
1 - Turn the adjusting bolt (A)
clockwise. (b) Put the press on SAFE.
(3) It is very important that the ink stripe is (c) Being sure that the ink form rollers
rechecked after tightening the lockbolt(s) (B). will not fall into the plate cylinder gap, engage the
ink form rollers.
(4) IMPORTANT - After the adjustment
performed in item 2.d previously has been accom- (d) After several seconds, disengage
the ink form rollers.
VI-5
(e) Take the press off SAFE and inch (a) Turn the adjusting bolt (E) clock-
the unit to where the rollers contacted the plate. wise.
(f) The result should be an ink stripe A

the width of the plate with a uniform thickness.
(g) To adjust.
C B
1 - With the form rollers disen-
gaged, back off the Anti-bounce bolts about 3 full
turns counterclockwise. D
(h) To decrease the ink stripe.
1 - Turn the roller to plate adjust-

E
ing bolt counterclockwise.
(i) To increase the ink stripe.
1 - Turn the roller to plate adjust-

ing bolt clockwise.
(j) After completing adjustments at

both ends of the roller, engage the form rollers.
(k) Turn the anti-bounce bolts in, A - Locknut

clockwise, until they touch the stop plate. Turning B - Frame Stud
the anti-bounce bolt too far will decrease the roller C - Locknut
stripe. D - Lockbolt
E - Adjusting Bolt: Roller to Vibrator Drum
3. ROLLER ADJUSTMENTS - DAMPENER.
Figure 6-5. Dampener Feed Roller Adjustments
a. Dampener Fountain Roller I.
(4) After achieving a snug steady pull on
(1) No adjustment should be necessary. the slip sheets, tighten the lockbolt (D).
b. Sock Feed Roller J. (5) IMPORTANT - After the adjustment

performed in item 3.b above has been accom-
(1) IMPORTANT- It is necessary to first, plished, it is necessary to secondly, adjust the
adjust sock feed roller J to the vibrator drum K of sock feed roller J to the dampener fountain roller I
figure 6-1. Setting should be checked and made after roller J has been set to vibrator drum K.
with the sock material wet. (Refer to figure 6-5.) Setting should be checked and made with the sock
material wet.
(a) Insert slip sheets between roller J
and vibrator drum K. (a) Insert the slip sheets between
roller J and the dampener fountain roller I.
(b) Put the press on SAFE.
(c) Loosen the lockbolt (D).
(6) To decrease the pull on the slip sheet.
(2) To decrease the pull on the slip
sheets. (a) Loosen locknut (C) and tighten
locknut (A) against the frame stud (B).
(a) Turn the adjusting bolt (E) counter-
clockwise. (7) To increase the pull on the slip sheet.
(3) To increase the pull on the slip sheets. (a) Loosen locknut (A) and tighten
locknut (C) against the frame stud (B).
VI-6
(8) After achieving a slight steady pull on (1) Turn the adjusting bolts (G)
the slip sheets, tighten locknuts (A) or (C) not in clockwise.
contact with the frame studs.
(f) After achieving a snug steady pull
c. Dampener Form Roller L. on the slip sheets, tighten the lockbolt (B).
(1) IMPORTANT - It is necessary to first, (g) It is very important that the

adjust form roller L to the vibrator drum K of figure adjustment is rechecked after tightening the
6-1. lockbolt.
I (h) IMPORTANT - After the adjust-

ment performed in item 3.c above has been accom-
H plished, it is necessary to secondly, adjust roller L
G to the plate cylinder after roller L has been set to
E B vibrator drum K. (Refer to figure 6-6.)
F
D (1) A properly packed plate must
be mounted on the plate cylinder.
C
(2) Insert slip sheets between the
form roller L and the plate being sure that the form
roller will not fall into the cylinder gap.
A
(3) Engage the dampener form
roller. Check for a steady pull on the slip sheets.
A - Vibrator Drum Roller
B - Lockbolt - Roller To
(i) To adjust.
Vibrator Drum
C - Adjusting Bolt
(1) With the form rollers disen-
D - Locknut
gaged, back off the anti-bounce bolts (H) about 3
E - Nip Guard
full turns counterclockwise.
F - Dampener Form Roller
G - Adjusting Bolt - Roller To
(2) Engage the dampener form
Vibrator Drum
roller with slip sheets in place.
H - Anti-Bounce Bolt
I - Stop Plate
(j) To decrease the pull on the slip
Figure 6-6. Dampener Form Roller sheet.
(1) Turn the roller to plate adjust-

(a) (Refer to figure 6-6.) Insert slip
ing bolt (C) counterclockwise.
sheets between the form roller L and the vibrator
drum K.
(k) To increase the pull on the slip
sheet.
(1) Turn the roller to plate adjust-
(c) Loosen the lockbolt (B) located in
ing bolt (C) clockwise.
the form roller bracket at both ends of the roller.
(l) After achieving a steady pull on
(d) To decrease the pull on the slip
the slip sheets, disengage the dampener form
sheets.
roller.
(1) Turn the adjusting bolts (G)
(m) Remove the slip sheets and
counterclockwise.
engage the form roller.
(e) To increase the pull on the slip
(n) Turn the anti-bounce bolts (H) in
sheets.
clockwise, until they touch the stop plate. Turning
the anti-bounce bolt too far will decrease the roller
pressure.
VI-7
4. GAP ADJUSTMENTS. gears. During the setting of the gaps, it will be

necessary to place the unit off impression mode,
a. Setting Cylinder Gaps - Timing. loosen the slip bolts, place the unit into impression
mode, make the adjustment and tighten the bolts.
(1) During the course of normal usage, it It may be necessary to perform this procedure a
is recommended that the gaps between the #10, number of times until the cylinder gaps are ad-
#11, #12 and #13 cylinders be periodically checked equately set.
and reset if necessary. The particular gap gauge to
be used is dependent upon the type of cylinders (a) Place the unit off-line and ensure
and cutoffs of the unit. (See Figure 6-7 for ex- the SAFE button is engaged.
amples of gap gauges.) The order used in setting
the gap is as follows: (b) Remove the drive side cover from
the unit.
(a) #12 Cylinder to the #13 Cylinder.
(c) Loosen the slipbolts (see Figure 6-
(b) #11 Cylinder to the #12 Cylinder. 8) on the cylinder to be set. (Loosening all of the
slip bolts on that cylinder will allow free turning of
(c) #10 Cylinder to the #11 Cylinder. the particular cylinder.)
(2) The following procedures should be (d) Install the appropriate gap gauge
utilized to adjust the gap timing between the within the slot of the cylinder.
cylinders and will require access to the drive side
(e) Using your hand, turn the cylinder
C
D
B E F G
A
A - Narrow Gap Blanket to On-The-Nose Lockup (DGM111NN-1)

B - Narrow Gap Blanket to Slot Gap Plate (DGM111TG)
C - Reel Rod Blanket to Blanket Gap Gauge (M-M-G-0002)
D - Reel Rod to Slot Gap Plate (DGM111SR-1)
E - Narrow Gap Blanket to Blanket Gauge (DGM111NN-2)
F - Narrow Gap Plate to Narrow Gap Blanket Gauge (DGM111NN-3)
G - Wide Gap Plate Standard T-Bar to Blanket Gap Gauge (DGM111WN-1)
Figure 6-7. Gap Gauges
Slip Bolts
Figure 6-8. Cylinder Slip Bolts

VI-8
until the gap gauge is seated within the slots of slot of the #11 cylinder and turn the #10 cylinder by
both the cylinders to be set. hand to align the slot so that the gauge sets into
both slots.
(f) Retighten the slip bolts on the
cylinder. Torque all slip bolts to 30 ft.lbs. Remove (n) Tighten and retorque the #10
the gap gauge. cylinder slip bolts to 30 ft. lbs., and remove the
gauge.
#11
Cylinder
Reel Rod to
Slot Gap Gauge
#11
Cylinder
#10 Reel Rod Blanket to

Cylinder Blanket Gap Gauge
Figure 6-9. Gap Gauge #12

Cylinder
(g) Loosen the slip bolts on the next
cylinder.
Figure 6-10. Gap Gauge
(h) Install the appropriate gap gauge
within the slot of the cylinder. (o) Visually inspect all four cylinders
to ensure no gauges are between the cylinders.
(i) Using your hand, turn the loos-
ened cylinder until the gap gauge is seated within (p) Reinstall the drive side cover.
the slots of both the corresponding cylinders.
(q) Disengage the SAFE button once
(j) Retighten the slip bolts. Torque all the unit is ready for normal operation.
slip bolts to 30 ft.lbs. Remove the gap gauge.
b. Spiral Brush Dampening Adjustment.
(k) CRITICAL. The running circumfer-
ential assembly must be on-center to ensure (1) For those units utilizing a spiral brush,
smooth operation and alignment of the unit. Using adjustment of the dampening system, is completed
the handle on the #10 cylinder, turn the handle as follows.
counterclockwise until it stops completely. Count-
ing the number of complete turns, turn the handle (a) Put the press on SAFE and the
clockwise until it stops again. Divide the number of Master Water on AUTO.
turns by two (2). This establishes the center
position. (b) Remove the spiral brush cover to
allow access to the spiral brush assembly.
(l) Turn the handle the number of
turns established in (k) above to place the running (c) Insert the spiral brush gauge
circumferential assembly on center. between the water pan roller and the spiral brush
aluminum body. The gauge should be inserted
(m) Loosen the four (4) bolts on the between the rows of brush material towards both
#10 cylinder. Install the appropriate gauge on the ends of the spiral brush.
VI-9
(d) Adjust the spiral brush using the

transfer eye bolt located at the dampener bracket. (f) Perform the adjustments above
until no drag or pressure can be felt when moving
the gauge with minimal clearance between the pan
roller and the brush body. The settings should be
uniform at both ends of the spiral brush.
(g) After a uniform setting is com-

pleted, tighten the locknuts that are not in contact
with the transfer poppet.
5. IRON-TO-IRON SETTING
a. Setting The Plate And Impression

Cylinders.
(1) The iron-to-iron distance between the

plate and impression cylinders is set when the
press is installed and rarely, if ever, needs to be
adjusted.
Figure 6-11. Spiral Brush Gauge b. To Check The Settings

(4353-0162)
(1) To check the settings, use the gauges
(e) To change the distance settings: furnished with the press. The settings between all
of the cylinders are shown below. Plates and
1- Refer to figure 6-12. To blankets must be removed from the cylinders to
increase the distance loosen the locknut (B) on the check the iron-to-iron distances.
eyebolt and tighten the locknut (A) located on the
top of the eyebolt against the transfer poppet. (2) Distances are based on an undercut of
.081” which is considered the “standard” undercut.
Blanket - to - Blanket -- .158” GO, .159” NO-GO.

Plate - to - Blanket -- .091” GO, .092 NO-GO.
Transfer Poppet
(3) The Plate-to-Blanket distance may
vary for the following undercuts:
Locknut "A"
.012 - .089-.090
.010 - .087-.088
.008 - .085-.086
(4) The following procedures should be

Locknut "B" used in checking the settings. Refer to figure 6-13.
Transfer Eye Bolt (a) Remove the plates and blankets

from the cylinders.
(b) Throw the blanket cylinder impres-

sions ON.
Figure 6-12. Spiral Brush Dampener Adjustment
(c) Check the iron-to-iron distance
2- To decrease the distance between each of the cylinders. Check at both
loosen the locknut (A) located on top of the transfer sides, about two or three inches from the ends.
eyebolt and tighten locknut (B) on the transfer
eyebolt, against the transfer poppet. (5) The GO gauge must fit between the
cylinders, and the NO-GO gauge must not fit. If
VI-10
the settings are not within these limits, adjust (1) To adjust the settings, make the
them. following adjustments on both the operating and
drive side of the unit simultaneously. It is best to
c. To Adjust The Settings. have two persons, one on each side working
together.
10 Cylinder 11 Cylinder 12 Cylinder 13 Cylinder
(2) The following procedures should be
used in adjusting the settings.
(a) Remove the housings from both

13 A the operating and drive side of the unit. Ensure the
2
1 impression is ON and no packing, plates or
blankets are on the cylinders. Figure 6-13 shows
the linkage arrangement on the operating side. The
7 linkage on the drive side is identical.
3
(b) On turnbuckles (A) and (B), loosen
B 5 the locknuts (1 thru 4).
4
8
(c) Loosen the stop screw bolts (5)
6 9 and (6).
10 (d) 13 Cylinder Set - Verify and

ensure the bolt (7) is wrench tight. This holds the
13 cylinder in place.
A
(e) At turnbuckle (B), turn the stop
screw (8) to allow the impression lever assembly to
move slightly so that the pin (9) is slightly to the
left of the zerk (10).
(f) Retighten nut (6) until the nut is

sitting against the stop.
12
NOTE
5 Adjusting the tightness of turnbuckle

B (B) will “push” the eccentric for the
11 #11 cylinder upward. This will cause
the #12 cylinder eccentric to be
pushed downward, which in turn will
lower the eccentric ear down against
13 Cylinder 10 Cylinder the stop. The tightness of turn-
14 buckle (B) is essential for proper
iron-to-iron setting.
(g) 13 - 12 Cylinder Set - Simulta-

neously turn turnbuckle (B) and stop bolt (11) until
the specified iron-to-iron distance is obtained
between cylinders #12 and #13. During this
procedure, always keep the eccentric ear contain-
ing the pin (12) on the #12 cylinder tight against the
12 Cylinder 11 Cylinder stop bolt (11). When the proper distance is
obtained, retighten the locknut (5) on the stop bolt
(11).
Figure 6-13. Iron-To-Iron Setting
VI-11
(h) 12 - 11 Cylinder Set - Simulta- (j) 11 - 10 Cylinder Set - After the

neously turn turnbuckles (A) and (B) until the iron is set on the #11 to #12 cylinders, loosen bolt
specified iron-to-iron distance is obtained between (13) inside the “ear” of the eccentric on the #10
cylinders #11 and #12. During this procedure, cylinder on the Op side; and, loosen bolt (14)
ensure the ear pin (12) remains against the stop located at top right of the circumferential assembly.
bolt (11) and turnbuckle (B) is moderately snug.
This will be evident in the sound (“snap”) heard (k) Pivot the eccentric until the proper
when the impression is thrown on and off. setting is obtained.
(i) On turnbuckles (A) and (B), (l) Retighten bolts (13) and (14).
retighten the locknuts (1 thru 4) ensuring turnbuck-
les (A) and (B) do not move. Movement of either (m) Throw the cylinders off impression
of these turnbuckles will give false iron-to-iron and then on. Recheck all the iron-to-iron distances
setting. using the procedures previously described in
paragraph 5.b “To Check The Settings”.
VI-12
SECTION VII
MAINTENANCE
SECTION VII - Maintenance
Introduction ---------------------------------------------------------------------------------------- VII-2
Corrosion Control ------------------------------------------------------------------------------------- VII-2
Procedure -------------------------------------------------------------------------------------- VII-2
Plate Cylinders --------------------------------------------------------------------------- VII-5
Blanket Cylinders ------------------------------------------------------------------------ VII-5
Reference -------------------------------------------------------------------------------------- VII-6
Corrosion Develops--------------------------------------------------------------------------- VII-6
Lubrication ---------------------------------------------------------------------------------------- VII-6
Oil Level ---------------------------------------------------------------------------------------- VII-6
Oil Changing ---------------------------------------------------------------------------------------- VII-6
Oil Strainer ---------------------------------------------------------------------------------------- VII-7
Grease Fittings ---------------------------------------------------------------------------------------- VII-7
Lubrication Panel ------------------------------------------------------------------------------ VII-7
Ink System ---------------------------------------------------------------------------------------- VII-9
Ink Fountain Cleaning ------------------------------------------------------------------------- VII-9
Cleaning Rollers ------------------------------------------------------------------------------- VII-9
Cleaning Cylinders ---------------------------------------------------------------------------- VII-10
Dampener System ------------------------------------------------------------------------------------- VII-10
General ---------------------------------------------------------------------------------------- VII-10
Feed Roller Sock Installation----------------------------------------------------------------- VII-11
Roll Stand Brake Blocks ------------------------------------------------------------------------------ VII-11
VII-1
1. INTRODUCTION. proper training is required to

perform maintenance or
a. A routine maintenance schedule is critical adjustments. Work on the
for the production of a quality product plus adding press only if it is on safe or
to the longevity of your press. Maintenance is the locked out. Practice the
systematic inspection of your press and the STOP-SAFE-READY
performing of maintenance activities on a sched- method for safety. Refer to
uled basis. A maintenance schedule may vary safety practices and precau-
depending upon the degree of usage of the press. tions at the beginning of this
manual.
b. In this section, there are no instructions as
to the opening or lifting of doors, guards and c. IMPORTANT - All grease fittings should be
covers. When working on this unit, it will be cleaned before applying grease to prevent contami-
obvious as to which of these items must be moved nants from entering the bearings .
or removed to access areas of the unit.
2. CORROSION CONTROL.
CAUTION
a. Procedure. In order to help prevent
CAUTION corrosion from initiating in the cylinders, the
To avoid personal injury, following procedures should be adhered to.
Table 2. Lubrication Chart
Interval Part Lubricant Method
Daily Circulating Syst. - check sight window of unit Oil Pour in
Ink and Dampener Drum Bushings (Operator Side) Grease Grease Fitting
Dampener Fountain Roller Bushings (Op. and Grease Grease Fitting

Drive Side)
Roll Sidelay Screw and Brake Linkages Oil Oil Can
Brake Linkage Eccentric Grease Grease Fitting
Plate and Blanket Cylinder Bearings (Operator Side) Grease Grease Fitting
Weekly
Blanket Cylinder Impression Throw-off (Operator Grease Grease Fitting
Side)
Horizontal Drive Clutch Grease Grease Fitting
Annually or Unit Housing (Drive Side) Oil Drain and

as usage Refill
requires Oil Screen Remove, clean, replace
Recommended Lubricants:
Oil - Mobile Vactra #4, Exxon Mobile Corp., Fairfax, VA
Grease - Mobilith SHC 100, Exxon Mobil Corp., Fairfax, VA
VII-2
Table 3. Maintenance Chart
Interval Item Method
Daily Lubrication Perform all daily lubrication procedures

from Lubrication Chart under Daily.
Guards and All guards are closed before each press run;
Interlocks Do not circumvent interlocks.
Plate Cylinders At the end of each 8 hour shift, remove the

plates and packing. Clean cylinders. Coat
with a light film of oil.
Dampener Rollers At the beginning of each 8 hour shift, in-

spect the sock covered roller; replace as nec-
essary.
Clean rubber rollers with a solvent recom-

mended by the roller manufacturer.
Blankets Inspect surface for damage or wear. Clean

with recommended solvent. Replace as
necessary.
Ink Fountain, Clean with recommended solvent as necess-

Form, and ary.
Transfer Rollers
Dampener At the beginning of each 8 hour shift, in-

Fountains spect, clean as necessary.
Lead Rollers Inspect, clean as necessary.

and Water Pan
Web Scanners At the beginning of each 8 hour shift, clean

(if equipped) with a soft, lint free cloth.
Dampener At the beginning of each 8 hour shift, in-

Circulation spect, clean as necessary. Check for proper
System pH or Conductivity of the solution.
Pneumatic At the beginning of each 8 hour shift, in-

System spect the filters and sediment bowls.
(if equipped) Clean as necessary according to manufactur-
ers instructions.
General Good housekeeping promotes high quality,

minimal waste, high efficiency, and safety.
Weekly Lubrication Perform all weekly lubrication procedures

from Lubrication Chart under Weekly
Ink and Dampener Check roller settings as necessary to main-

Roller Settings and tain quality. Refer to Roller Adjustment
Cleaning section of the manual. Clean with recom-
mended solvent as necessary.
VII-3
Table 3. Maintenance Chart (Con’t.)
Dampener Drain and clean according to manufacturers

Circulation instructions. See Dampener System in this
System section.
Wash-up Attachment Inspect, clean as necessary. Replace scraper

blade if badly nicked.
Dampener Form Inspect, clean with recommended solvent

Rollers to remove gum, ink, lint buildup.
Dampener Drums Inspect, clean as necessary. Treat rollers

that are not water receptive with a con-
centrated fountain etch and 14 baume gum
arabic.
Blankets Inspect surface and wash with a recom-

mended deglazer. Replace if necessary.
Bi-Monthly Blankets Measure blanket height with chosen

Packing Gauge. Repack or replace as
necessary.
All Form and Check settings and make necessary ad-

Transfer Rollers justments. Refer to Roller Adjustment
section of this manual.
Monthly Lubrication Perform all monthly lubrication procedures

from Lubrication Chart under Monthly.
All Rollers Inspect bearing and bracket conditions.
Controls Check the operation of all switches and

pushbuttons.
Drive Belts Inspect for wear, replace as necessary.
Guards Inspect for loose, broken, or guards that have

been removed. Clean or replace as neces-
sary.
Ink Fountain Blade Inspect fountain blade for wear; replace as

necessary.
Every 3 Months Dampener Motor Inspect; replace as necessary.
Ink Feed Roller to Check the setting; adjust as necessary.

Ink Fountain Roller
Setting
Iron Check settings on plates and blankets.

to Adjust as necessary.
Iron
VII-4
Table 3. Maintenance Chart (Con’t.)
All Form and Transfer Check roller durometer and roller bearings.
Rollers
Dampening System Flush and clean dampening system according

to the manufacturer’s instructions.
Every 6 Months Web Break Detectors Inspect and check for proper operation.
Press Drive Motor Inspect and maintain according to

and Drive Belts manufacturer’s instructions. Check and adjust
drive belts as necessary.
Annually or Lubrication Perform all annual lubrication procedures

as usage from Lubrication Chart under Annual.
requires
CAUTION (c) Wipe cylinders dry with a clean

cloth.
CAUTION (d) Wipe plates and packing material

dry if re-using.
Known corrosive elements to the (e) Coat the cylinders with a light film
cylinders include, but are not limited of oil or grease.
to – chlorine, fluorine, and ammonia.
These elements may be present in (f) Avoid applying lubricants in areas
various cleaners or solvents in some where adhesive needs to stick to the cylinder.
form. (Products with ingredients
listing “chloro” in their formula descrip- (g) Re-install any packing and plate:
tion are made with chlorine or chlo-
rides). Water solutions should also (1) On cylinders designed for use
be checked for these elements. of plates with no packing, it is important to apply
Blankets may be manufactured with lubricants between the plate and cylinder. (See
one or more of these elements, and “Caution” above.)
could be released during use when
combined with fluids used in the (2) on cylinders that have mylar
printing operation. packing attached with adhesive, the entire inner
surface of the mylar, or the entire body of the
Prolonged contact of dissimilar cylinder, should be coated with a continuous layer
metals, such as aluminum (plates) on of adhesive or grease. In this case, the time
a bare cylinder, may also have a between cylinder cleaning may be extended to a
tendency to cause corrosion. maximum of 3 months.
(2) Blanket Cylinders. When changing

(1) Plate Cylinders. After each produc- blankets, or a minimum of 1 time every 3 months:
tion run:
(a) Remove blanket and any packing
(a) Remove plates and any packing material.
material.
(b) Wipe blanket cylinders with
(b) Wipe plate cylinders with solvent. solvent. (See “Caution” above.)
(See “Caution” above.)
VII-5
(c) Wipe cylinders dry with a clean lubricants are used, your supplier needs to know
cloth. the application in order to supply you with the
appropriate equivalent.
(d) Coat the cylinders with a light film
of oil or grease. b. When shipped within the U.S., each unit
is filled using Mobil VACTRA Oil Number 4 and
(e) Avoid applying lubricants in areas Mobilith SHC-100 grease, or equivalent products.
where adhesive needs to stick to the cylinder.
4. OIL LEVEL.
(f) Re-install packing and blanket.
b. Reference. Lubricants are used to repel

the elements listed in the “Caution”, and to deter
the formation of corrosion. Areas of the cylinder
that are not open to air and that tend to trap
moisture and fluids against the cylinder surface,
such as underneath plates and blankets, are most
susceptible to corrosion. Recommended lubricants
include: B A
Product Description Manufacturer
C
Rust Veto Heavy Grease Houghton International, Inc.
LPS 1 Greaseless Lubricant LPS Laboratories, Inc.
A - Access Doors
c. Corrosion Develops. If corrosion is seen B - Oil Inspection Window
on the cylinders, the following procedures should C - Oil Drain Plug
be used to correct:
Figure 7-1. Gear Side View
(1) Check all solutions, solvents, and
printing materials for corrosive elements. (See CAUTION
“Caution” above.)
CAUTION
(2) Mechanically remove as much of the Excessive skin contact with
corrosion as possible, using polishes, compounds, oil may cause skin irritation
or cleaners that do not contain the known corrosive and be harmful. Material
elements listed in the “Caution” above. Safety Data Sheets provide
safety precautions to be
(3) Apply a “rust converter” to neutralize followed.
the remaining corrosion.
a. (Refer to figure 7-1.) On a daily basis,
(4) Recommended products include: while the unit is running, check the oil level through
the inspection window (B) on the drive side of the
Product Description Manufacturer unit. The following instructions are provided if oil is
Extend Permatex for Balcamp, Inc. needed.
(5) Wipe cylinders clean and dry, and re- (1) Put the press on SAFE.
apply lubricants to the cylinders as described
above. (2) Open either access door (A) and add
an appropriate weight gear oil (see paragraph 3)
3. LUBRICATION. until the oil level is up in the inspection window (B)
(approximately 3.5 gallons).
a. Dauphin Graphic Machines, Inc. does not
endorse any one brand of lubricant, but relies upon 5. OIL CHANGING.
industry testing and standards for proper ratings.
Except under abnormal conditions, lubricants with a. (Refer to figure 7-1.) Depending upon the
proper service ratings should be used. If other usage of the press, change the oil and clean the
VII-6
strainer approximately every 2500 hours of running (1) Put the press on SAFE.
time or annually, whichever comes first. If the oil is
to be changed, wait until after a press run when the (2) Drain the unit oil according to the
oil is warm. To accomplish an oil change: instructions contained in paragraph 5 above.
(1) Put the press on SAFE. (3) Open the left access door (figure 7-1,
item A) and locate the Oil Pump (A).
(2) With a 5 gallon bucket under the drain
plug (C), remove the drain plug and open both (4) After loosening the oil tube nut (B),
access doors (A). remove the oil strainer (D) and oil tube (C) assem-
bly.
(3) Remove and clean the oil strainer by
following the instructions provided in paragraph 6 (5) To remove contaminants, rinse the
below. strainer (D) in a solvent. The use of a soft brush is
advised to help clean the strainer. If compressed
(4) Wipe out the inside of the unit to air is used, do not exceed 30 psi (207 kPa).
remove any sediment which might have settled in
the bottom. Replace the drain plug (C). (6) Reattach the oil tube (C) and oil
strainer (D) assembly and tighten the tube nut (B).
(5) Refill the unit with the recommended
oil lubricant or its equivalent gear oil until the level 7. GREASE FITTINGS.
is in the inspection window (B) (approx. 3.5 gal.).
a. Lubrication Panel. As shown in figure 7-
(6) Close the access doors (A) and run 3, two (2) lubrication panels are located on the
the unit. Operator side.
(7) Check the oil level while the unit is

running. Add additional oil if necessary.
A
C
6. OIL STRAINER.
a. Each time the unit oil is changed, the oil

strainer should be cleaned or replaced (Refer to
figure 7-2.).
B
PL CYK
BRG
A
D
A - Lubrication Panel
C B - Lubricate every 8 hours
C - Lubricate every 40 hours
A - Oil Pump Figure 7-3. Lubrication Panel
B - Tube Nut
C - Oil Tube
b. Utilizing the lubrication panels provides a
D - Oil Strainer convenient method of lubricating primary compo-
Figure 7-2. Oil Pump and Strainer nents on either the 10-side and 13-side. Depen-
dent on the model type, 5 or 6 additional single
VII-7
Lube
Lube
Lube
Lube
Lube Lube
Lube
Lube
Figure 7-4. Independent Lubrication Points
VII-8
entry lubrication points are located on the unit. handle up and down will rotate the
(Refer to figure 7-4.) These additional lubrication fountain roller in its normal direction.
points are located as follows:
(5) Using a recommended ink solvent and
(1) One on each side of the Ink Fountain rags, clean the fountain and fountain roller.
tray, located on the frame of the unit.
(6) Once the fountain and fountain roller
(2) One on each end of the turnbuckle are clean, again check to see that the ink keys are
attached to the number 11 and 12 Blanket Rollers. backed off at least 4 full turns.
(3) Two located on the operator side, just

under the number 10 Plate Roller and above the
impression lever linkage.
A
(4) For Floor Models, one additional
lubrication point is located on the upper portion of
the Roll Stand Brake Assembly.
c. When lubricating the unit via the installed B

grease fittings, use an appropriate grease for the
intended application. The grease should be
D
absolutely free of contaminants. Fittings should be
cleaned before application of grease. Do not
overgrease. Wipe off excess grease from fittings,
bearings, and sleeves.
d. A hand operated, low pressure, grease gun C

can be used or an air operated grease gun with no
more than 35 psi (241 kPa) can be used.
A - Ink Roller
8. INK SYSTEM. B - Ink Blade
C - Ink Fountain Levers
a Ink Fountain Cleaning. D - Handknob
(1) Put the press on SAFE. Figure 7-5. Ink Fountain in "Up" Position
(2) Refer to figure 7-5. Being careful not

(7) Swing the fountain back up into
to damage the ink fountain roller (A) or blade (B),
position and tighten handknobs.
remove the ink from the fountain.
b. Cleaning Rollers.
(3) If the fountain has ink keys, turn the
keys counterclockwise at least 4 full turns. If the
(1) When two people work as a team,
fountain has levers (C), no adjustment is neces-
roller cleaning is accomplished safely, easily, and
sary.
quickly. When using two wash-up trays, both
sides of the unit can be cleaned at the same time.
(4) Turn the handknobs (D) counterclock-
Follow the same steps, at the same time, on the
wise until the fountain can be lowered. DO NOT let
both sides of the unit.
the fountain drop.
WARNING
NOTE
Some units are equipped with a

fountain roller override handle. With WARNING
an override handle, the unit does not
have to be operated in order to rotate
the fountain roller. Moving the override Solvents used in the pressroom may
VII-9
emit vapors which are highly volatile. until the rollers are clean. Remember, too much
Obtain the Material Safety Data solvent will drip down onto the plate cylinder and
Sheets for your solvents and follow the dampening rollers. Wait until the rollers appear
the procedures for proper storage and dry before adding more solvent to the rollers.
handling.
(11) Stop and put the press on SAFE.
WARNING
(12) Open the guard and place twisted rags
into the wash-up tray. This should absorb most of
the ink solvent from the tray.
WARNING
(13) Remove the wash-up tray being sure
not to spill the contents.
Nip Points - keep hands away from
the cylinder and roller nip points. (14) Clean the wash-up tray being sure to
Severe injury can occur. Use the put used rags in a safety approved container.
STOP-SAFE system to clean the
cylinders and rollers. (15) Wipe the line of ink left by the wash-up
tray from the ink vibrator drum roller.
(2) Remove the web from the unit.
(16) Using the STOP-SAFE method, check
(3) Disengage the folder. all of the roller ends for ink buildup. Clean as
necessary.
c. Cleaning Cylinders.

B
(2) Clean all blankets used for the run with
a recommended ink solvent. Use one solvent
soaked rag and one dry rag. The solvent soaked
A rag is used to break down the ink and buildup on
A the blankets, then the dry rag is used to wipe the
blanket dry.
A - Attachment Bolt
B - Washup Tray (3) After removing the plate and packing,
clean the plate cylinder with an ink solvent. Then
Figure 7-6. Washup Tray apply a thin film of oil to the cylinder surface.
(5) Refer to figure 7-6. Open the guards 9. DAMPENER SYSTEM.

above the ink rollers and locate the attachment
bolts (A). The wash-up tray (B) should be placed a. General. The dampening system is a
such that they hangs on the attachment bolts. critical part of the printing process. Good house-
keeping will assure consistent dampening chemis-
(6) Hang the wash-up tray. try. Dampening solution chemistry affects print
quality. A dirty system breaks down the chemistry
(7) Position the roller guards on top of the thus producing poor quality. Use the
wash-up tray. manufacturer’s instructions for cleaning the damp-
ener circulation system. The following is a short
(8) Remove the SAFE and start up the outline for cleaning.
unit.
(9) With the unit running about 4,000 iph,
use a squeeze bottle to apply a recommended (2) Drain the circulation system which
solvent to the ink rollers. Apply the solvent through includes the fountains, reservoir, and filtration
the mesh of the guard. system if applicable
(10) Continue to apply solvent to the rollers (3) Fill the reservoir with hot water and
VII-10
circulate for approximately 30 minutes. ink solvent or blanket wash.
(4) Remove the fountain pans and clean (5) Measure and cut a length of sock
thoroughly. material approximately four inches longer than the
length of the roller.
(5) Drain the circulation system again and
clean the reservoir and filter system. Replace the (6) Slide the sock material over the fiber
fountains. tube supplied with the unit. Place the tube over the
roller.
(6) Refill the circulation system with a new
dampener solution. (7) While standing the roller on end, hold
onto the sock and one end of the roller together
b. Feed Roller Sock Installation. and pull the tube off of the roller; leaving the sock
on the roller.
(8) Place the tube over the roller and work
(2) Remove sock roller J from its mounting the sock back onto the tube for about 2/3 the
bracket (refer to figure 7-7) as follows: length of the roller.
a. Put the press on SAFE. (9) While holding the sock tightly onto the
tube, push the tube down to stretch the sock over
the roller.
(10) Remove the tube and tie the overlap of

sock material with a plastic tie. Be sure the sock
material is not twisted. Roll the remaining over-
C lap over the roller shaft, up to the plastic tie.
(11) Repeat steps 8 through 10 from the

other end of the roller.
B
(12) After completing the feed roller sock
installation, replace the feed roller into its mounting
brackets and adjust according to roller setting
procedure in this section of the manual.
A 10. ROLL STAND BRAKE BLOCKS.
a. Floor units with roll stands require addi-

A - Bracket tional application of lubricants. Refer to figure 7-4
B - Adjustment Bolt for locations of independent grease fittings.
C - Locking Bolt
b. The following information is provided when
Figure 7-7. Dampener Feed Roller Bracket changing brake blocks is necessary (refer to figure
7-8). Prior to changing the brake blocks, allow the
b. Remove the adjustment bolts (B) brake blocks to “cool-down” after the press run.
from each end of the dampener feed roller.
c. Loosen the locking bolt (C) at
each end of the dampener feed roller. (2) With the brake shoe assembly open,
remove the cotter pin (C) and clevis pin (D) from the
d. Remove the dampener feed roller brake block assembly (A).
from the brackets (A) at each end.
(3) Remove the old covering with a razor

blade being careful not to damage the rubber roller.
(4) Clean the roller with a recommended
VII-11
that the 1 - 1/2 inch (38mm) face of the block is

C facing the brake tension handwheel (or as you are
B
facing the operators side of the unit, the 10-side). If
the brake blocks are improperly positioned, loss of
tension control will result.
A (6) After aligning the hole of the brake

block assembly (A) with the hole of the brake block
bracket, replace the clevis pin (C) and cotter pin
(D).
Opened Brake Shoe Assembly
Rear View - Closed Brake Shoe Assembly
A - Brake Block
B - Brake Shoes (Wooden)
C - Clevis Pin
D - Cotter Pin
Figure 7-8. Roll Stand Break Block Assembly
(3) Remove the old brake blocks (A) by

sliding them off the bracket that supports the brake
block assembly.
(4) If you are choosing to replace just the

wooden brake shoes (B), the shoes will attach to
the block mount by either 4 wood screws (through
the base of the block mount) or by 2 bolt and nut
sets which pass through the block mount and shoe
laterally.
(5) Install the new brake shoes by sliding

them onto the brake block (A) bracket. Make sure
VII-12
SECTION VIII
DIRECT PRINTING
SECTION VIII - Direct Printing

The Method ---------------------------------------------------------------------------------------- VIII-2
The Reverse Image ------------------------------------------------------------------------------------ VIII-2
The Impression ---------------------------------------------------------------------------------------- VIII-2
The Registration ---------------------------------------------------------------------------------------- VIII-2
The Conversion ---------------------------------------------------------------------------------------- VIII-2
Governor Roller To Compensator Conversion --------------------------------------------- VIII-2
Compensator to Governor Roller Conversion ---------------------------------------------- VIII-2
VIII-1
1. THE METHOD. micrometer. Subtract the thickness of the web

from your normal amount of plate packing.
a. Depending upon the configuration of the
printing job, in direct printing, one unit is used to b. If the normal press run uses no packing,
print two colors, on one side of the web. have on hand thinner plates so that packing sheets
can be used to control the amount of impression
b. The web passes between the blanket squeeze.
cylinders in its normal travel, but then wraps
around the 13 side blanket cylinder and proceeds 4. THE REGISTRATION.
out from between the blanket and plate cylinder.
a. Use the plate sidelay handwheel to adjust
c. The first color comes from the 10 side for image registration across the web.
blanket and the second color comes from the 13
side plate. b. Circumferential register between the first
(offset) color and the second (direct) color is
d. The 13 side blanket functions as a com- adjusted by the circumferential register handwheel
mon-impression-cylinder. located on the operator’s side of the unit.
e. The plate on the 13 side prints directly 5. THE CONVERSION.

onto the web, therefore the image must be in
reverse. The plate must be underpacked to a. To register the image between the unit
compensate for the thickness of the web and a printing direct and the subsequent unit that the web
conversion apparatus is needed to change the travels through requires a conversion of the
governor roller assembly to a compensator adjust- governor roller assembly to a compensator assem-
ment. (Figure 8-1) bly. (Refer to figure 8-1.)
2. THE REVERSE IMAGE. b. Governor Roller to Compensator

Conversion.
a. The direct printing plate prints directly onto
the web. Therefore, it is necessary to have a (1) Put the press on SAFE.
reversed image on that plate in order to produce a
right-reading image on the web. There are 3 (2) Remove the cotter key and clevis pin
methods to produce the reverse image. which holds the brake linkage to the roller lever.
(1) Assemble the negative so that the (3) See Figure 8-1. Position the adjusting
base side is against the plate by simply flipping stud (B) on the compensator shaft (A) so that it
over the film. This works well for coarse line work can be inserted into the compensator bracket (D).
but not for high quality.
(4) Insert the swivel stud (C) into the roller
(2) Use a duplicating contact film to lever and the adjusting stud (B) into the compensa-
produce a negative from a negative but in the tor bracket (D).
process causing the emulsion side of the film to
change from the wrong reading side to the right (5) Secure the compensator assembly by
reading side. Consult your film customer service replacing the cotter key through the swivel stud.
representative.
c. Compensator to Governor Roller
(3) Place the film on the film board of your Conversion.
process camera with the emulsion facing the film
board. This method may have an adverse filtering (1) Put the press on SAFE.
and/or flaring affect because of the exposure
through the film base. (2) Remove the cotter key from the swivel
stud (C).
3. THE IMPRESSION.
(3) Remove the swivel stud (C) from the
a. To obtain proper impression squeeze roller lever and remove the adjusting stud (B) from
between the 13 cylinder plate and the web, mea- the compensator bracket (D).
sure the thickness of the web with a graphic arts
VIII-2
(4) Reattach the brake linkage to the roller

lever using the clevis pin and cotter key.
A - Compensator Shaft and Handle

B - Adjusting Nut
C - Swivel Stud
D - Compensator Bracket
Figure 8-1. Direct Print

Compensator Hardware
VIII-3
Three Colors
on Top of Web - 2 Units
Direct Printing on End Unit
Four Colors
Direct Printing on End Unit
Four Colors
Direct Printing on Middle Unit
Four Colors
on Bottom of Web - 3 Units
Direct Printing on Middle Unit
Figure 8-2. Direct Printing Web Leads
VIII-4
SECTION IX
TROUBLESHOOTING
SECTION IX - Troubleshooting
Scumming ---------------------------------------------------------------------------------------- IX-2
Tinting ---------------------------------------------------------------------------------------- IX-2
Graininess ---------------------------------------------------------------------------------------- IX-2
Hickies ---------------------------------------------------------------------------------------- IX-2
Stripping ---------------------------------------------------------------------------------------- IX-2
Fill-In ---------------------------------------------------------------------------------------- IX-2
Slurring ---------------------------------------------------------------------------------------- IX-2
Streaking ---------------------------------------------------------------------------------------- IX-2
Catch-Up ---------------------------------------------------------------------------------------- IX-3
Blinding ---------------------------------------------------------------------------------------- IX-3
Loose Web ---------------------------------------------------------------------------------------- IX-3
Web Breaks ---------------------------------------------------------------------------------------- IX-3
IX-1
Problem: SCUMMING - the printing plate is Problem: STRIPPING - uneven ink distribu-
picking up ink in the non-image area. tion in ink train; vibrator drum rollers do not ac-
cept ink..
Causes: 1. Too much ink
2. Insufficient dampening Causes: 1. Dampener solution too acidic
3. Dampener rollers dirty 2. Rollers are glazed
4. Improperly set form rollers 3. Improper roller settings
5. Improper dampener solution 4. Copper plating is worn or desens-
mixture itized on vibrator drums.
6. Improperly packed cylinders 5. Improperly formulated ink
7. Flattened form rollers
8. Blanket damaged or loose Problem: FILL-IN - areas around and between
9. Improperly processed plates type, screen tints, and halftone dots accepts ink
10. Incoming water supply too hard and plugs up.
Problem: TINTING - an overall color tint on Causes: 1. Too much ink

the press sheet. 2. Improperly set form rollers
3. Insufficient dampening
Causes: 1. Too much dampening solution 4. Overpacked cylinders
2. Improper dampener solution 5. Improperly formulated ink
mixture 6. Worn plate
3. Improperly formulated ink
Problem: SLURRING - areas of blurred image
Problem: GRAININESS - a gray or weak im- across the web; noticed as an elongation in half-
age characterized by unevenness, particularly in tone and screen tint dots.
halftones.
Causes: 1. Improper dampener solution
Causes: 1. Dampener motor speed is too fast. mixture
2. Insufficient ink 2. Improperly set form rollers
3. Insufficient impression 3. Over packed cylinders
4. Blanket is glazed or dirty 4. Ink dried on plate
5. Worn image 5. Worn image area
6. Improperly formulated ink 6. Lint build-up on form rollers or
blanket
Problem: HICKIES - White or black spots with 7. Worn roller bearings, eccentrics and/
rings around them in solid image areas. or sockets
Causes: 1. Foreign particles in ink Problem: STREAKING - ink in the non-image

2. Unclean ink and/or dampener area running parallel to the cylinders; appears as
rollers streaks across the web.
3. Unclean blankets
4. Too much lint from paper Causes: 1. Roller bounce caused by heavy form
5. Tacky blanket roller settings
6. Tacky ink 2. Improper ink /water balance
IX-2
Problem: CATCH UP - ink in the non-image area between units or between unit and folder.
running circumferentially around the cylinder.
Causes: 1. Low roll tension
Causes: 1. Insufficient dampening 2. Improperly set trolley wheels
2. Improperly set dampener form roller 3. Improperly set nipping rollers
3. Unclean or badly covered dampener 4. Tacky blankets
rollers. 5. Lint build-up on blankets
6. Overpacked blankets
Problem: BLINDING - an image that has lost
its ink-receptivity; parts of the image will not print. Problem: WEB BREAKS -
Causes: 1. Form rollers set too heavy Causes: 1. Too much dampener solution
2. Improper dampener solution 2. Improper web tension
3. Improperly processed plate 3. Paper problem
4. Dried ink on image
5. Over packed cylinders
Problem: LOOSE WEB - loose or baggy web
IX-3
IX-4
SECTION X
GLOSSARY
SECTION X - Glossary
A-C ---------------------------------------------------------------------------------------- X-2
D-E ---------------------------------------------------------------------------------------- X-3
F-H ---------------------------------------------------------------------------------------- X-4
I-M ---------------------------------------------------------------------------------------- X-5
N-R ---------------------------------------------------------------------------------------- X-6
S-V ---------------------------------------------------------------------------------------- X-7
W-Z ---------------------------------------------------------------------------------------- X-8
X-1
A ery.
Bar. 1) to turn a shaft or cylinder manually. 2)
Adjustable Idler. An idling roller that moves, Transferring the web from one side of the
or can be adjusted, to control the web. press to the other with angle bars. 3) To
Angle Bars. A pair of turning bars used to change the direction of the web with a
transfer the web from one side of the turning bar. 4) An angle bar or turning
press to the other. bar.
Anti-Friction. 1) A machine in which the Bay Window. An idling roller, or series of
majority of rotating parts are mounted in rollers, mounted on the side of the press
a ball or roller bearing. 2) A newspaper superstructure and set at right angles to
press in which the plate and impression the RTF, and a pair of turning bars set at
cylinders, inking roller, and web lead an angle of 45 degrees. Bay windows
rollers are mounted in roller or ball are used to turn the web over.
bearings. Blanket Creep. The slight forward move-
Artificial Tension. The amount of braking ment of that part of the blanket surface
force which must be applied to a paper that is in contact with the plate or paper.
roll by mechanical means. Blanket Thickness Gauge. A special mi-
Associate. 1) To bring together. 2) To bring crometer for measuring the offset blanket
the folded web from one former together and packing while on the press.
with the folded web from another former. Broadsheet. A full size newspaper page.
3) To “cross-associate”; to transfer a web Actual size depends on the size of the
from one side of the press to the other paper used and the cutoff of the press.
side. Butt. A roll of paper that has been partially
Automatic Lead Device. A mechanical used.
device for leading a web from a paper
roll to a printing couple. C
Automatic Paster. 1) by means of special
equipment, attaching a new roll of paper Catching Up. A term which indicates that the
to an expiring web without stopping the non-image areas of the plate are begin-
press. 2) The equipment used for attach- ning to take ink.
ing a new roll of paper to the expiring Chalking. The improper drying of ink; the
web without stopping the press. pigment dusts off due to lack of binding
vehicle.
B Cheekwoods. Blocks of wood, fibre or
plastic mounted on both sides of a knife
Backlash. 1) Machinery : the recoil or play in a folder cutting cylinder, usually spring
due to loose fitting or worn parts. 2) loaded.
Printing presses: the play which results in Chopper. 1) A reciprocating folding blade or
out-of-register print because of loose a folder using such a blade. 2) The knife
fitting or worn parts. assembly that severs the web during the
Back Pressure. The squeeze pressure be- paster cycle. 3) A web severing device.
tween the blanket and impression cylin- Chuck. A device for fastening a paper roll to
ders. a spindle shaft or for holding a roll
Balloon Former. Former pan located above between the spider arms of a reel.
the regular former pan on a folder deliv- Circumferential Register. 1) The position of
X-2
one plate in relation to another plate successive cuts in a folder or sheeter

around a plate cylinder. 2) The moving delivery.
or adjusting of a plate or cylinder so that
the printed design is moved along the D
web length.
Cocking Roller. An adjustable idling roller Dampener. 1) The form rollers which apply
that is fixed on one end and adjustable on dampening solution to the plate. 2) The
the other. Located between the paper roll entire dampening system.
and the printing couple to even or Dampeners. The cloth-covered rollers that
smooth the web. distribute the dampening solution.
Collect Cylinder. On a 2:1 folder, the section Dampening Solution. A water mixture used
to be collected travels around the cutting for wetting the non-image areas of the
cylinder while the next section is brought plate to prevent them for accepting ink.
into the folder. Dinky. 1) A quarter roll of newsprint. 2) A
Color Hump. A common-impression-cylinder newsprint web that is one page wide.
unit that allows three colors to be applied Direct Printing. A method of printing by
to one side of the web at one pass direct transfer of the ink from the plate to
through the unit. the paper.
Compensator. An adjustable idler roller Double Deck. Color printing equipment
which is moved to vary the length of the consisting of two extra printing couples
web path; adjusting color register or mounted above a press unit.
cutoff position. Double Truck. A design printed across the
Copy. The manuscript or text furnished to center pages of a newspaper section so
printers. there is no center margin.
Copyfitting. Calculations made in order to Drive Side. The side of a press on which the
determine the proper size of type and drive shafts and most of the gearing is
width of line to fit the copy into a given located.
area of space. Dry-Back. The change in color or finish of an
Core. A cardboard, wood or metal tube on ink film as it dries.
which the rolls of paper are wound. Dummy. A set of blank pages made up in
Core Tension. A tension system that exerts advance to show the size, shape, form,
the braking or restraining action through and general style and plan of a printing
the cores of the roll of paper. job.
Cross Associate. On a double-wide press
folder, bringing one web across the press E
from one former to the folder under the
adjacent former. Emulsification. The breaking down of ink in
Cutting Cylinder. A cylinder in a folder that the ink train due to excessive dampening
holds cutting knives which cut the web solution.
into sheets. Emulsify. To allow to mix. Absorption of
Cutting Rubber. In a folding cylinder, a water by ink.
rubber bar, inset in the cylinder, which Expiring Roll. A roll of paper which is
the cutting cylinder knife cuts against. approaching its end and is about to be
Cutoff. The length of the sheets between replaced by a new roll.
X-3
F roller to cut down on the amount of

water to a particular area of the plate.
Fan. In a folder, an arrangement of curved Full Roll. 1) A roll of newsprint which is four
metal fingers that receives the product broadsheet newspaper pages wide. 2) A
from the folding rollers and places it on roll of paper which is approximately as
the delivery conveyor belt. wide as the maximum web width of the
Fly. 1) In a folder, an arrangement of several press. 3) A new roll of paper.
fans on the same shaft. 2) The act of
manually removing papers, in groups or G
bundles, from a folder delivery or con-
veyor belt. Gear Side. Same as Drive Side.
Folder. A machine which folds and cuts the Gear Streaks. Parallel streaks appearing
web into sheets or signatures. across printed sheet at same interval as
Folding Blade. In a folding cylinder, a blade gear teeth on cylinder.
which raises the product from the cylin- Ghosting. A process in which heavy removal
der surface and inserts it between folding of ink, by a solid or other heavily inked
rollers or into folding jaws. (Also known areas, results in ink starvation to another
as a “Tucker Blade”. area.
Folding Cylinder. 1) In a folder, a cylinder Governor Roller. A movable idling roller
that holds the cutting rubbers and the located between the paper roll and the
tucker blade(s) for making the second printing couple; it is either spring loaded
fold. 2) In a folder, any cylinder that or pneumatically loaded. It absorbs the
includes a blade or blades which are shock of sudden changes in demand for
involved in folding the product. paper.
Folding Rollers. A pair of driven rollers Gumming. 1) The treating of surfaces with a
between which a sheet is tucked to form thin coating of gum arabic as a protection
a fold. against oxidation and ink-receptive
Form Rollers. The ink and dampening rollers coatings for image. 2) An aid to desensi-
which contact the plate surface. tize an offset plate.
Former. A triangular metal plate over which a Gum Streaks. Streaks produced by the
web passes to receive the first fold, uneven gumming of plates; most notice-
parallel to the web travel. able in halftones.
Fountain Blade. The blade in an ink fountain
that is supported under the fountain roller H
to control the amount of ink fed to the
ink train. Half Deck. An extra printing couple mounted
Fountain Keys. Thumbscrews used for above a unit.
controlling the amount of ink fed into an Half Roll. A roll of newsprint which is two
ink train and consequently to the plate. newspaper pages wide. This is the
Fountain Solution. “The water”; solution of widest roll that can be used on a single-
water, gum arabic, and other chemicals wide press.
used to dampen the offset plate and keep Hand Paster. 1) The method of manually
the non-image areas from accepting ink. attaching a new roll of paper to an
Fountain Stops. Movable strips of material expiring web. 2) The splice made by
placed to rest on the dampener fountain such a method.
X-4
Head. 1) The top of a page. 2) The edge of a Ink Receptive. Having a surface which will
plate nearest the top of the page. 3) A repel water and attract ink.
headline. Ink Repellent. Having a surface which will
Hickeys. An imperfection in the printed image attract water and repel ink.
due to several causes such as ink con-
taminated with dry ink, which works its J
way onto the plate or blanket.
Horizontal Drive Shaft. 1) The main drive K
shaft on a unit style press. 2) Any
driving shaft whose axis is parallel to the Kicker. In the delivery of a folder, a device
floor. which displaces a newspaper in the
Hydrometer. A generic term for various stream of the delivery to facilitate manual
instruments designed to determine the counting.
specific gravity of liquids. Knife. 1) The knife blade(s) on an automatic
Hydrophilic. Water-receptive. paster device that severs the web after the
Hydrophobic. Water-repellent. paste has been made. 2) The knife blade
Hygrometer. An instrument for measuring in the cutting cylinder of a folder that
atmospheric moisture. cuts the web into the finished product. 3)
The knife in a web severing device that
I cuts the web just below the unit.
Idling Roller. A free-turning roller used to L

guide and control a web through a press.
Image. The area of a plate which is intended Lead. 1) Lead and web are often used inter-
to print. changeably. A lead is usually used to
Imposition. The arranging and fastening of mean the beginning of the web or the
negatives or positives to a flat for use in beginning of the roll of paper that is
off-set platemaking. being threaded through the press.
Impression. 1) The amount of pressure on the 2) Also used to mean the web or the
paper needed to print. 2) The place at web pattern in the press.
which the printing takes place, i.e. the Line Copy. Any copy suitable for reproduc-
first or second impression. 3) The tion without using a screen; opposite of
printed image on the paper. continuous tone.
Inch. To run the press slowly by pressing the
inch button. The press will stop when M
the button is released.
Ink Train. A series of bare metal cylinders Make-ready. The proper adjusting of all
and rubber covered rollers which work devices and assemblies in order to
the ink to a thin uniform film and apply it prepare the press for a press run.
to the printing plate. Margin. The unprinted area surrounding the
Ink Drum. A metal roller, either solid or printed image.
hollow, that oscillates back and forth to Masking Paper. Opaque paper to which
aid in ink distribution. negatives are attached in image assembly
Ink Fountain. The reservoir that stores and to produce a flat.
supplies the ink to the ink train. Misting. A mist or fog of tiny ink droplets
X-5
being thrown off a press by the rollers. paper during printing. Picking occurs
Flying. when the ink tac is greater than the
Mottle. Spots, usually in printed solids, due to surface strength of the paper.
variations in ink absorption or paper Piling. The sticking or caking of ink pigment
finish. on the plate or blanket.
Pin Holes. The holes made by the pins of the
N folding cylinder along one edge of the
page.
Newsprint. A paper made mostly from Pins. 1) The pins that pull the paper around
groundwood pulp. Used for printing the folding cylinder. 2) The pins that
newspapers. hold the sections to a cutting or folding
Nipping Rollers or Nips. Driven rollers in a cylinder during a collect run. 3) Any set
folder that guide the folded web from the of pins that are used on the press.
former pan to the cutting and folding Plate Cylinder. The cylinder on a press to
cylinders. which the printing plates are attached.
Pre-drive. The device on an automatic paster
O system that brings the new roll of news-
print up to the speed of the expiring web.
Operator Side. The side of the press on Printing Couple. The combination of plate
which most of the controls are located. cylinders and its accompanying blanket
Overpacking. Packing the plate or blanket to cylinders in a 4 cylinder, perfecting unit.
a level that is excessive; above the level
for proper cylinder pressure. Q
P
R
Packing. The paper or plastic used to under-
lay a blanket or plate to bring the surface Reel. A roll stand that has the capacity to hold
to the desired height to establish proper 3 rolls of newsprint. Automatic pasters
cylinder pressures. are usually equipped on reels.
Packing Gauge. An instrument used on the Register. The placement of the image in
press to measure the difference between relation to its margins. This placement
the cylinder body and the height of the needs to be in an identical location on
plate or blanket surface. every sheet that passes through the
Paste. 1) A web splice to join the end of one delivery.
roll of paper to a second roll, made in the Rider Rollers. Metal or rigid plastic rollers in
pressroom. the ink train which serves to break down,
Paster. 1) The mechanism used to make a transfer, and distribute the ink.
splice. Roller Setting. 1) The degree of contact
Perfecting Press. A printing press of any kind between rollers in inking or dampening
that prints both sides of paper in one systems. 2) The act of adjusting roller to
operation or pass through the press. vary the contact.
pH. A scale used for expressing the acidity or Roller Striping. The ink does not adhere to
alkalinity of solutions. the metal rollers in the ink train.
Picking. The removal of part of the surface of R-T-F. Abbreviation for roller-top-of-former.
X-6
The driven roller directly behind the top signed to remove the static electricity
of the former on a folder. from the paper .
R-P-F. Abbreviation for roller-point-of- Striping. 1) The positioning of negatives or
former. The rollers that begin to fold the positives on a flat for imposition. 2) The
web lengthwise over the nose. condition under which metal rollers fail
Run. 1) The printing of a product from the to take up ink in an ink train.
time the press starts until the required
number of products have been produced. T
2) The number of products produced for
a given job. Tabloid. A newspaper or newspaper page
whose dimensions are 1/2 that of a
S broadsheet.
Tack. The force necessary to split a film of
Safe. A control pushbutton when actuated will ink.
prevent the press from starting. 10-Side. When facing the operator side of the
Scumming. The non-image areas of the plate unit, the 10-side is the left-hand side.
picks up ink. Tension. The amount of pull applied to the
Severing Device. A cutting device which web in the direction of travel.
automatically cuts the web when a web 13-Side. When facing the operator side of the
break occurs to prevent a wrap up. The unit, the 13-side is the right-hand side.
device is located between the roll of Tinting. An all-over color tint on the press
paper and the printing couple. sheet due to various reasons.
Sheeter. A device attached to a web press to Trapping. The printing of one ink film on
cut the web and deliver sheets rather than another. Proper trapping depends on the
a folded product. relative tack and thickness of the
Side Lay. 1) Controls which move the web inkfilms.
from side to side for side margin adjust- Trolley. A narrow roller or wheel which
ment. 2) The lateral movement of the presses webs against a driven roller (R-T-
plate and cylinder for registration. F) to control the web and tension.
Signature. 1) The folded product of a web Tucker Blade. See Folding Blade.
press. 2) A printed sheet consisting of a Turning Bar. A non-rotating shaft used to
number of pages that is correctly folded change the direction of travel of a web
to form a section of a book or magazine. by 90 degrees and to turn the web over.
Silenced. Not operating; disengaged.
Single Wide. A press that prints a web two U
newspaper pages wide.
Slitter. 1) A circular blade for cutting a web Undercut. The measured difference between
into ribbons of a desired width. 2) Any the surface of a cylinder and the height of
cutting device that makes a longitudinal the bearers.
cut. Upper Former. See Balloon Former.
Spider. The three arm arrangement that holds
the paper rolls on a reel. V
Spot Color. An area printed with a single
additional color. Vibrating Roller. A drum or roller that
Static Neutralizer. A press attachment de- oscillates back and forth for proper
distribution of water or ink.
X-7
W Web. Paper fed from a roll and threaded

through a press.
Wash. A special solvent or solvent mixture Web Break Detector. A device which brings
used to clean ink and lint from blankets the press to a stop whenever a web break
and/or rollers. occurs.
Wash-up. The process of cleaning rollers, Web Severing Device. See Severing Device.
cylinders, plates, and fountains of a Wrap. Paper wrapped around a press cylinder
press. or inking rollers as a result of a web break.
Water Fountain. The metal reservoir on a
press which holds the dampening solu- X-Y-Z
tion. No vocabulary words that start with X, Y or Z.
X-8
SECTION XI
ILLUSTRATED PARTS BREAKDOWN
SECTION XI - Illustrated Parts Breakdown

Illustrated Parts Breakdown --------------------------------------------------------------------------- XI-3
General ---------------------------------------------------------------------------------------- XI-3
Group Assembly Parts List (GAPL) --------------------------------------------------------- XI-3
Index Number --------------------------------------------------------------------------------- XI-3
Part Number----------------------------------------------------------------------------------- XI-3
Description ------------------------------------------------------------------------------------ XI-3
Vendor Codes --------------------------------------------------------------------------------- XI-3
Units per Assembly --------------------------------------------------------------------------- XI-3
Illustrations List
11-1 DGM-430 Press Unit (Floor Model) .................................................... XI-5

11-2 Frame Sub-Assembly (Floor Unit) ........................................................ XI-8
11-3 Frame Sub-Assembly (Base Unit) ......................................................... XI-11
11-4 Frame Sub-Assembly (Stack Unit) ........................................................ XI-14
11-5 Ink and Dampener Form Roller Throwoff Assembly .............................. XI-17
11-6 Ink Ball Assembly - Operator Side ........................................................ XI-20
11-7 Ink Ball Assembly - Gear Side .............................................................. XI-23
11-8 Ink Fountain Assembly .......................................................................... XI-26
11-9 Swing Down Ink Fountain Assembly ..................................................... XI-29
11-10 Blanket Cylinder Throw-Off Linkage Assembly - Manual Operation ...... XI-32
11-11 Circ Shaft Assembly ............................................................................. XI-35
11-12 Governor Roller, Tension Control and Lead-In Assembly - Floor Unit .... XI-38
11-13 Blanket Cylinder Assembly ................................................................... XI-41
11-15 Narrow Gap Lock-Up ......................................................................... XI-48
11-18 Wide Gap Lock-Up ............................................................................. XI-57
11-22 #10/#13 Sidelay ................................................................................... XI-69
11-25 Lower Copper Assembly ...................................................................... XI-78
11-26 Upper Copper Assembly ...................................................................... XI-81
XI- 1
11-27 Water Pan Roller Assembly ................................................................... XI-84

11-28 Water Vibrator Assembly ...................................................................... XI-87
11-29 Water Vibrator Idler ............................................................................. XI-90
11-30 Micro Roller Assembly ......................................................................... XI-93
11-31 Micro Shaft .......................................................................................... XI-96
11-34 Ink Vibrator Assembly .......................................................................... XI-105
11-37 Circ. Assembly ..................................................................................... XI-114
11-38 Drive Shaft ........................................................................................... XI-118
11-39 Oil Pump Assembly .............................................................................. XI-121
11-40 Gear Side Cover .................................................................................. XI-124
11-41 Paper Roll Sidelay ................................................................................ XI-127
11-42 Paper Roll Brake .................................................................................. XI-130
11-43 Paper Roll Sidelay and Brake Assembly ................................................ XI-133
11-44 Belt Register ......................................................................................... XI-136
11-45 Optional Pneumatic Assembly ............................................................... XI-139
11-46 Blanket Cylinder Throwoff Linkage - Optional Pneumatics .................... XI-142
11-47 Rubber Rollers ..................................................................................... XI-145
11-48 Nip Guards .......................................................................................... XI-147
11-49 Roller Guards ....................................................................................... XI-150
11-50 Upper Roller Guard .............................................................................. XI-153
11-51 Outer Roller Guard ............................................................................... XI-156
11-52 Operator Side Cover ............................................................................ XI-159
11-53 Color Drop Roller ................................................................................ XI-162
11-54 Lead-In Roller - Base Unit .................................................................... XI-165
11-55 Lead-In Roller and Under Unit Compensator Assembly - Stack Unit ..... XI-168
11-56 B1 Swing Compensator ........................................................................ XI-171
11-57A Full Page Motorized Compensator - Pre-2001 ...................................... XI-174
11-57B Full Page Motorized Compensator - Post-2001 .................................... XI-180
11-58 Belt Drive/Covers - Stack ..................................................................... XI-186
11-59 Belt Drive/Covers - 2 High ................................................................... XI-189
XI- 2
1. ILLUSTRATED PARTS BREAKDOWN. e. DESCRIPTION. This column lists the item

nomenclature plus those modifiers necessary to
a. GENERAL. The complete Illustrated Parts identify the item. The assemblies, subassemblies,
Breakdown (IPB) contains information applicable to detail parts and attaching parts properly identified
the Dauphin Graphic Machines DGM-430 Press (named or indented) to show their relationship to
Unit. It lists and describes the parts necessary for the assembly. Attaching parts are listed immedi-
equipment support and is used for requisitioning, ately after the part they attach and preceding any
identifying parts and for illustrating disassembly details of the assembly. All measurements are
and assembly relationships. When using the IPB, indicated using English vice Metric measurements
keep in mind that the press is “cutoff specific”. (except where specifically identified).
When ordering parts, inform the Customer Service/
Parts Department personnel of your cutoff of your f. VENDOR CODES. Part numbers, other
unit. than those of the manufacturer, are designated by
vendor names in // following the nomenclature of
b. GROUP ASSEMBLY PARTS LIST the part. Dauphin Graphic Machines, Inc., does
(GAPL). The GAPL consists of a breakdown of the not endorse any particular supplier/vendor; how-
complete unit into subassemblies and detail parts. ever it should be noted that standard hardware (i.e,
Attaching parts are generally identified immediately nuts, bolts, screws, etc.) used are of a grade 5 or
following the item they attach. The GAPL is a four better ASTM standard. The individual vendor part
column format. Standard symbols and abbrevia- numbers and vendor names have been excluded
tions for use on drawings and in technical type for ease of understanding.
publications are used in the GAPL.
g. UNITS PER ASSEMBLY. This column will
c. INDEX NUMBER. In this column the index list the total number of each part required per
numbers are assigned in numerical sequence and assembly or subassembly and are not necessarily
are essentially in disassembly sequence. After the the total number used in the end item of equip-
index numbers are assigned in this column, they ment. The letters "AR" (As Required) are used to
are then added to the line art exploded view of the identify bulk items. The abbreviation "REF"
equipment / repairable. Exception to the disas- (Reference) as used, indicates the part has been
sembly procedure are those items identified as listed and illustrated elsewhere in the IPB and is
“HARDWARE” which consists of standard nuts, included in the present listing for reference only.
bolts, screws, etc.
NOTE: Hardware items (i.e., bolts, washers,
d. PART NUMBER. This column lists the nuts, pins, etc.) will not be shown in picture
DGM prime part number. Because vendor part format; however, they are provided an Index
numbers change from item to item, the term Number for reference purposes.
HARDWARE is utilized to denote common, general
items used throughout the unit.
XI- 3
ILLUSTRATIONS AND PARTS
XI- 4
38
44 50
52
53
54
55
56
57
5 51 (Location
7 shown only)
6
23
24
25
26 2
27 3
28 4
29 39
30 40
46
47
45 41
42
1 43
8
9
10
35 11
17 12
36
21 13
37
31 14
32 15
33 16
34 18
19
20
22
48
49
Figure 11-1. DGM-430 Press Unit (Floor Model)
XI- 5
UNITS
ASSY
INDEX PART DESCRIPTION
PER
NO. NUMBER 1 23 45 67
DGM-430 PRESS, DAUPHIN GRAPHIC MACHINES, INC / 430 MODEL 1

1 SAF2150 • FRAME / FLOOR UNIT / 21 1/2” ............................................ 1
SAF2200 • FRAME / FLOOR UNIT / 22” .................................................. 1
SAF2275 • FRAME / FLOOR UNIT / 22 3/4” ............................................ 1
SAB2150 • FRAME / BASE UNIT / 21 1/2” .............................................. 1
SAB2200 • FRAME / BASE UNIT / 22” ..................................................... 1
SAB2275 • FRAME / BASE UNIT / 22 3/4” .............................................. 1
SAS2150 • FRAME / STACK UNIT / 21 1/2” ............................................ 1
SAS2200 • FRAME / STACK UNIT / 22” ................................................... 1
SA2275 • FRAME / STACK UNIT / 22 3/4” ............................................ 1
2 ASSEMBLY • • INK AND DAMPENER FORM ROLLER THROW-OFF ..... 1
3 ASSEMBLY • • INK BALL - OPERATOR SIDE ........................................... 1
4 ASSEMBLY • • INK BALL - GEAR SIDE ..................................................... 1
5 ASSEMBLY • • INK FOUNTAIN ................................................................... 1
6 SADGM890-2 • • • INK SWING DOWN FOUNTAIN ..................................... 2
7 ASSEMBLY • • BLANKET CYLINDER THROW-OFF LINKAGE ................ 1
8 ASSEMBLY • • CIRC SHAFT ....................................................................... 1
9 ASSEMBLY • • GOVERNOR ROLLER, TENSION CTRL, AND LEAD-IN .. 1
10 ASSEMBLY • • BLANKET CYLINDER ......................................................... 1
11 ASSEMBLY • • #10 SIDE NARROW GAP LOCK-UP ................................. 1
12 SA100029 • • • NARROW GAP LOCK-UP ............................................. 2
13 ASSEMBLY • • #13 SIDE NARROW GAP LOCK-UP ................................. 1
14 ASSEMBLY • • #10 SIDE WIDE GAP LOCK-UP ........................................ 1
15 SA91835 • • • WIDE GAP LOCK-UP .................................................... 2
16 ASSEMBLY • • #13 SIDE WIDE GAP LOCK-UP ........................................ 1
17 ASSEMBLY • • #10 CYLINDER - GEAR SIDE ............................................ 1
18 SA51945 • • • CIRC ASSEMBLY .......................................................... 1
19 ASSEMBLY • • #10 CYLINDER - OPERATOR SIDE .................................. 1
20 SA48879 • • • #10 AND #13 SIDELAY .................................................. 2
21 ASSEMBLY • • #13 CYLINDER - GEAR SIDE ............................................ 1
22 ASSEMBLY • • #13 CYLINDER - OPERATOR SIDE .................................. 1
23 ASSEMBLY • • LOWER COPPERS ............................................................ 2
24 ASSEMBLY • • UPPER COPPERS ............................................................. 2
25 ASSEMBLY • • WATER PAN ROLLER ....................................................... 1
26 ASSEMBLY • • WATER VIBRATOR ............................................................ 1
27 SA22141-10 • • • #10-SIDE WATER VIBRATOR ....................................... 1
SA22141-13 • • • #13-SIDE WATER VIBRATOR ....................................... 1
28 SA70170 • • • WATER VIBRATOR IDLER ............................................ 2
29 ASSEMBLY • • MICRO ROLLER ................................................................. 2
30 SA108643-3 • • • MICRO SHAFT ............................................................... 2
XI- 6
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
31 ASSEMBLY • • INK VIBRATOR/INK FOUNTAIN DRIVE ............................. 1

32 SA16366 • • • #10-SIDE INK VIBRATOR .............................................. 1
SA16367 • • • #13-SIDE INK VIBRATOR .............................................. 1
33 ASSEMBLY • • DRIVE SHAFT ..................................................................... 1
34 ASSEMBLY • • GEAR SIDE COVER .......................................................... 1
35 ASSEMBLY • • PAPER ROLL SIDELAY AND BRAKE .............................. 1
36 SA71624 • • PAPER ROLL SIDELAY ..................................................... 1
37 SA94282-3 • • PAPER ROLL BRAKE ........................................................ 1
38 SADG89706 • • • BELT REGISTER ............................................................ 1
39 ASSEMBLY • • PNEUMATICS (OPTIONAL) ............................................... 1
40 ASSEMBLY • • BLANKET CYLINDER THROW-OFF LINKAGE / .............. 1
OPTIONAL PNEUMATICS /
41 ASSEMBLY • • RUBBER ROLLERS ........................................................... 2
42 ASSEMBLY • • NIP GUARDS ...................................................................... 1
43 ASSEMBLY • • ROLLER GUARDS ............................................................. 1
44 ASSEMBLY • • UPPER ROLLER GUARD .................................................. 1
45 ASSEMBLY • • OUTER ROLLER GUARD .................................................. 1
46 ASSEMBLY • • OPERATOR SIDE COVER ................................................ 1
47 ASSEMBLY • • COLOR DROP ROLLER ..................................................... 1
48 ASSEMBLY • • LEAD-IN ROLLER - BASE UNIT ........................................ 1
49 ASSEMBLY • • LEAD-IN ROLLER & SWING COMP - STACK UNIT ......... 1
50 ASSEMBLY • • B1 SWING COMPENSATOR ............................................. 1
51 ASSEMBLY • • FULL PAGE MOTORIZED COMPENSATOR .................... 1
52 ASSEMBLY • • BELT DRIVE/COVERS (STACK UNIT ONLY) ................... 1
53 ASSEMBLY • • BELT DRIVE/COVERS (2 HIGH ONLY) ............................ 1
54 ASSEMBLY • • BELT DRIVE/COVERS (3 HIGH - 10 SIDE) ...................... 1
XI- 7
8
8
5 2
1
6
8
7 13
11 11
9
3 9
12
Figure 11-2. Frame Sub-Assembly (Floor Unit) (1 of 2)
XI-8
1
2
5 6
7
8 9
Figure 11-2. Frame Sub-Assembly (Floor Unit) (2 of 2)
XI-9
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
1 2C2789 • OPERATOR SIDE FRAME 21 1/2” ........................................ 1

2C2889 • OPERATOR SIDE FRAME 22” .............................................. A/R
2C2989 • OPERATOR SIDE FRAME 22 3/4” ........................................ A/R
2 1C2789 • GEAR SIDE FRAME 21 1/2” .................................................. 1
1C2889 • GEAR SIDE FRAME 22” ........................................................ A/R
1C2989 • GEAR SIDE FRAME 22 3/4” .................................................. A/R
3 4C2989FCF • • CROSS FRAME (FLOOR) .................................................. 1
4 3C2989FCF • • CROSS FRAME (#13 SIDE) .............................................. 1
5 5C2989FCF • • CROSS FRAME (#10 SIDE) .............................................. 1
6 DGM890-1 • • INK FOUNTAIN SUPPORT ................................................. 2
7 HARDWARE • • • 1/2 - 13 X 3 HEX HEAD BOLT ........................................ 8
8 HARDWARE • • • #7 X 2 1/2 TAPER PIN W/THREADS (NOT SHOWN) .. 8
9 HARDWARE • • • 5/8 LOCK WASHER ....................................................... 16
10 HARDWARE • • • 5/8 -11 X 1 1/2 HEX HEAD BOLT ................................... 8
11 HARDWARE • • • 5/8 -11 X 2 HEX HEAD BOLT ......................................... 12
12 HARDWARE • • • 5/8 -11 X 2 SOCKET HEAD CAP SCREW .................... 4
13 HARDWARE • • • 7/8 - 9 X 4 LEVELING BOLTS ........................................ 4
14 HARDWARE • • • 7/8 - 9 JAM NUT (OPTIONAL - NOT SHOWN) .............. 4
15 D1230-2 • • STEP, OPERATOR EXTENDED (NOT SHOWN) .............. 1
16 E1234-1 • • • BRACKET, RIGHT SIDE STEP (NOT SHOWN) ............ 1
17 E1234-2 • • • BRACKET, LEFT SIDE STEP (NOT SHOWN) .............. 1
XI-10
11
7
10 10
6 8
3
5
6
10 9
10
10 10
6
6
12 6
10
Figure 11-3. Frame Sub-Assembly (Base Unit) (1 of 2)
XI-11
Figure 11-3. Frame Sub-Assembly (Base Unit) (2 of 2)
XI-12
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
1 2C3789 • OPERATOR SIDE FRAME, 21 1/2” ....................................... 1

2C3889 • OPERATOR SIDE FRAME, 22” ............................................. A/R
2C3989 • OPERATOR SIDE FRAME, 22 3/4” ....................................... A/R
2 DGM890-1 • INK FOUNTAIN SUPPORT ..................................................... 2
3 DG897BP • BASE PLATE (BASE UNIT) ................................................... 1
4 1C3789 • GEAR SIDE FRAME, 21 1/2” ................................................. 1
1C3889 • GEAR SIDE FRAME, 22" ....................................................... A/R
1C3989 • GEAR SIDE FRAME, 22 3/4" ................................................. A/R
5 HARDWARE • • 1/2 - 13 X 3 HEX HEAD BOLT ............................................ 8
6 HARDWARE • • 1/2 - 13 X 1 3/4 HEX HEAD BOLT ...................................... 20
7 HARDWARE • • 7/8 - 9 X 4 LEVELING BOLT .............................................. 4
9 HARDWARE • • 1/2 - 13 X 1 1/2 SOCKET HEAD CAP SCREW ................ 2
10 HARDWARE • • 1/2 LOCK WASHER ........................................................... 24
11 HARDWARE • • #7 X 2 1/2 TAPER PIN W/THREAD (NOT SHOWN) ......... 8
12 HARDWARE • • #7 X 3 TAPER PIN W/THREAD (NOT SHOWN) ............... 4
XI-13
7
6
5
2
Figure 11-4. Frame Sub-Assembly (Stack Unit) (1 of 2)
XI-14
1
2
3
4
Figure 11-4. Frame Sub-Assembly (Stack Unit) (2 of 2)
XI-15
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
1 2C4789 OPERATOR SIDE FRAME, 21 1/2” ........................................... 1

2C4889 OPERATOR SIDE FRAME, 22” .................................................. A/R
2C4989 OPERATOR SIDE FRAME, 22 3/4” ........................................... A/R
2 5C4989FCF • CROSS BRACE ...................................................................... 2
3 DGM890-1 • INK FOUNTAIN SUPPORT ..................................................... 2
4 1C4789 • GEAR SIDE FRAME, 21 1/2” ................................................. 1
1C4889 • GEAR SIDE FRAME, 22” ....................................................... A/R
1C4989 • GEAR SIDE FRAME, 22 3/4” ................................................. A/R
8 HARDWARE • • #7 X 2 1/2 TAPER PIN W/THREAD (NOT SHOWN) ......... 8
XI-16
6 4
4 5
3
2
1 5 8
3 2 6
5 4
4
6 3 4
2
7
1
11
12 6
16
11 5
7 4
10 12
10
9 8
13 16
14 14
15 15
10
9
Figure 11-5. Ink and Dampener Form Roller Throw-Off Assembly (1 of 2)
XI-17
3 4
5 7
8 16
9
11
Figure 11-5. Ink and Dampener Roller Throwoff Assembly (2 of 2)
XI-18
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY INK AND DAMPENER FORM ROLLER THROW-OFF .............. REF

(See Fig 11-1, Item 2 for NHA)
1 119953 • 3/4 X 46" THROW-OFF SHAFT .............................................. 4
2 HARDWARE • • 3/4 STEEL SET COLLAR ................................................... 6
3 ST 2450-3 • • BRONZE WASHER ............................................................ 6
4 119950 • • THROW-OFF LINK ............................................................. 12
5 119951 • • CAM ................................................................................ 8
6 HARDWARE • • • 3/16 X 1 1/4 ROLL PIN ................................................... 8
7 40064-1610 • • 3/4 ID SPACER - 1" LONG ................................................ 4
8 12DU16 • • BUSHING ............................................................................ 8
9 94996-2 • • THROW-OFF HUB .............................................................. 4
94996-2-2 • • THROW-OFF HUB// PNEUMATICS OPTION // ................ 4
11 145026 • • THROW-OFF STOP ROD .................................................. 4
12 HARDWARE • • 3/8 X 2 ROLL PIN STOPS .................................................. 4
13 HARDWARE • • • 1/4 - 20 X 1/2 KNURLED POINT SOCKET .................... 4
HEAD SET SCREW
14 HARDWARE • • • 1/4 - 20 JAM NUT ........................................................... 4
15 HARDWARE • • • 1/4 - 20 X 1 3/4 SQUARE HEAD SET SCREW ............ 4
16 140765 • • POPPET STOP ................................................................... 4
(#13 SIDE SHOWN)

(#10 SIDE NOT SHOWN)
(TOTAL OF 4 SETS UTILIZED)
XI-19
10
9
11
7
6
5
4
11
12
Figure 11-6. Ink Ball Assembly - Operator Side (1 of 2)
XI-20
3 4
2
7 10
5
6
Figure 11-6. Ink Ball Assembly - Operator Side (2 of 2)
XI-21
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY INK BALL, OP SIDE (See Fig 11-1, Item 3 for NHA) ................ REF
1 119418-3 • INK BALL ROLLER - 37 1/2 BODY ........................................ 1
119418-4 MOTORIZED INK BALL (OPTIONAL) ................................... 1
2 62062RS • • BEARING ............................................................................ 1
3 40070D • • .562 ID X 1 1/2 OD X 1/4 MACHINE WASHER ................. 1
4 152549 • • STUD WITH PIN .................................................................. 1
5 HFL-2026 • • BEARING ............................................................................ 1
6 600130-3 • • RATCHET INK BALL ROD END ......................................... 1
7 41440070-2 • • MACHINE WASHER W/COUNTER SINK - OP STUD ...... 1
8 HARDWARE • • • 1/4 - 20 X 3/4 FLAT HEAD SOCKET CAP SCREW ..... 1
9 HARDWARE • • • 1/2 -13 JAM NUT ............................................................ 1
10 B-8 • • • • BLACK BALL - HANDLE END ................................... 1
11 HARDWARE • • • 3/8 X 2 1/2 ROLL PIN - HANDLE POSITIVE STOP ...... 2
12 HARDWARE • • • 3/16 X 1 1/2 ROLL PIN - STUD TO INK BALL ............... 1
(#10 SIDE SHOWN)
XI-22
1
6
4
7
5
3
5
7
11
13
4
15
6
17
8
10
12
14
16
18
Figure 11-7. Ink Ball Assembly - Gear Side (1 of 2)
XI-23
1 2
3
4
Photo Not Photo Not

Available Available
Item 8 Item 9
W-06 N-06
5
10
Photo Not
Available
Item 14
CMRTH-2
11
12
13
Photo Not
Available
Item 15
CMRTH-1
16
Figure 11-7. Ink Ball Assembly - Gear Side (2 of 2)
XI-24
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY INK BALL, GEAR SIDE (See Fig 11-1, Item 4 for NHA) ........... REF
1 119418-3 • INK BALL ROLLER - 37 1/2 BODY ........................................ 1
119418-4 • INK BALL ROLLER (OPTIONAL MOTORIZED) ..................... 1
2 62062RS • • BEARING ............................................................................ 1
3 40066-2127 • • BEARING SPACER ............................................................ 1
4 108701 (SUP.) • • • SHIM SET ....................................................................... 2
5 108290 • • END CAP ............................................................................ 2
7 HARDWARE • • • 1/4 - 20 X 3/4 HEX HEAD BOLT ..................................... 8
8 W-06 (SUP.) • • BEARING LOCK WASHER ................................................ 1
9 N-06 (SUP.) • • BEARING NUT .................................................................... 1
10 40072 • • • .752 ID X 1 1/2 OD X 3/16 MACHINE WASHER ........... 1
11 IR1220OH • • HARDENED SLEEVE - CLUTCH BEARING ..................... 1
12 RCB162117 • • TORRINGTON BEARING .................................................... 1
13 99704-2 • • GEAR ................................................................................ 1
14 CMRTH-2 • • • PLASTIC SHIM SET ....................................................... 1
15 CMRTH-1 • • • METAL SHIM .................................................................. 1
16 153568 • • WASHER W/STEP ............................................................. 1
18 HARDWARE • • • 3/8 - 16 X 1 HEX HEAD BOLT ........................................ 1
(#10 SIDE SHOWN)
XI-25
5
2
4
12 3
10 4
12
6
11
7 8
Figure 11-8. Ink Fountain Assembly (1 of 2)
XI-26
3b
3a
11a 11b
Figure 11-8. Ink Fountain Assembly (2 of 2)
XI-27
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY INK FOUNTAIN ASSEMBLY (See Fig 11-1, Item 5 for NHA) ... REF
1 SADGM890-2 SWING DOWN INK FOUNTAIN ASSEMBLY ........................... 1
2 SA119765 • SWING DOWN INK BLADE ASSEMBLY .............................. 1
3 DG127-1 • LEFT HAND SIDE MOLDED SEAL ........................................ 1
DG127-2 • RIGHT HAND SIDE MOLDED SEAL ...................................... 1
4 160493 • BRACKET - INK FOUNTAIN SEAL ........................................ 2
5 HARDWARE • • 5/16 - 18 X 2 SOCKET HEAD CAP SCREW ..................... 4
6 HARDWARE • • 1/4 - 20 X 3/4 SET SCREW ................................................ 2
7 HARDWARE • • 3/8 FLAT WASHER ............................................................ 6
10 HARDWARE • • 1/4 - 28 X 3/8 BUTTON HEAD ALLEN SCREW ................ 5
11 DG9018-3, -4 • COVER ................................................................................ 1
12 HARDWARE • • 1/4 X 3/4 ROLL PIN ............................................................. 2
XI-28
9 10
13
15
11
9 10
7
13
8
6
4 1
5
11
15
3
12
Ink Fountain
7
8
4
6
14
Ink Fountain Levers
Figure 11-9. Swing Down Ink Fountain Assembly (1 of 2)
XI-29
4 5
3
1 2
6 7
10
9
8
15
11
Figure 11-9. Swing Down Ink Fountain Assembly (2 of 2)
XI-30
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
SADGM890-2 SWING DOWN INK FOUNTAIN ASSEMBLY (See Fig 11-1, ... REF
Item 6 for NHA)
1 DGM890-2 • INK FOUNTAIN SWINGDOWN IRON ..................................... 1
2 DGM891S-2 • SHAFT - LEVER ..................................................................... 1
3 DGM891SBP • SUPPORT POST .................................................................... 7
4 DGM891P • ALUMINUM SPACER, PLASTIC ............................................ 18
5 DGM891LV • LEVER EYE ............................................................................ 24
6 DGM891LIN-3 • LEVER ................................................................................ 24
7 DGM891SPR • SPRING ................................................................................ 24
8 DGM891SP • LEVER POST .......................................................................... 24
9 147620 • HANDLE ................................................................................ 2
10 RC3A • • KNOB ................................................................................ 2
11 S100-37 • • SNAP RING ........................................................................ 2
12 HARDWARE • • 5/16 - 18 X 3 3/4" SOCKET HEAD CAP SCREW ............. 7
13 HARDWARE • • 1/8 X 1 1/4 DOWEL PIN ..................................................... 2
14 HARDWARE • • SPRING WASHER ............................................................. 6
15 DGM890-5S • • PIVOT PIN W/FLAT - 1/4 - 20 THREADS .......................... 2
XI-31
22 20 18
5 15 13
XI-32
16
21 7
27 18
27 27
18 20
6
17
14 18 21
27
25 22
16
8 27
18 26
2
2 3
1
15 18 9
15
18 13
4
10 16
22 20
11
21
27
14 18
19 12
26 16 27
23
20 18
30 27
24 21
28 22
29
Figure 11-10. Blanket Cylinder Throw-Off Linkage Assembly - Manual Operation (1 od 2)

5 7
3 6
8 12
10
9
11
1
13 14 18
17 20
19
24
29
25
Figure 11-10. Blanket Cylinder Throw-Off Linkage Assembly - Manual Operation (2 of 2)
XI-33
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY BLANKET CYLINDER THROW-OFF LINKAGE ......................... REF

(See Fig 11-1, Item 7 for NHA)
1 119420 • IMPRESSION SHAFT ............................................................. 1
2 HARDWARE • • 3/8 X 1 1/2 KEY .................................................................. 2
3 Q4-125 • QUAD SEAL ............................................................................ 1
4 HARDWARE • • 1/8 - 27 NPT STRAIGHT GREASE FITTING ...................... 1
5 TRE-8 • • 1/2 ROD END - 1 1/8 THD. RH THREAD, FULL LENGTH 1
6 TRE-8S • • 1/2 ROD END - 1 1/8 THD. RH THREAD, SHORT LENGTH 1
7 TREL-8 • • 1/2 ROD END - LH THREAD - 1 1/8 THD. FULL LENGTH 1
8 TREL-8S • • 1/2 ROD END - LH THREAD - 1 1/8 THD. SHORT LENGTH 1
9 TRE-8N • • 1/2 ROD END - 1 5/8 THD. RH THREAD, FULL LENGTH 1
W/ZERK
10 TRE8NS • • 1/2 ROD END - 1 5/8 THD. RH THREAD, SHORT LENGTH 1
W/ZERK
11 TREL-8N • • 1/2 ROD END - LH THREAD - 1 5/8 THD. FULL LENGTH 1
W/ZERK
12 TREL-8NS • • 1/2 ROD END - LH THREAD - 1 5/8 THD. SHORT LENGTH 1
W/ZERK
13 156765 • • 2 5/8 COUPLING NUT ........................................................ 2
14 108416-2 • • 1 3/8 COUPLING NUT ........................................................ 2
15 HARDWARE • • 1/2 - 20 LOCK NUT ............................................................. 3
16 HARDWARE • • 1/2 - 20 LOCK NUT - LH THREAD ..................................... 4
17 116103 • • 3/4 DIA. - 1/2 - 20 LOCK NUT ............................................ 1
18 156136-3 • • 1/2 X 1 3/8 LINKAGE PIN ................................................... 9
19 156136-4 • • 1/2 X 1 13/16 LINKAGE PIN ............................................... 1
20 108418-2 • • POPPET .............................................................................. 4
21 HARDWARE • • 3/8 - 16 JAM NUT ............................................................... 4
22 HARDWARE • • 3/8 - 16 X 2 SQUARE HEAD SET SCREW ....................... 4
23 HARDWARE • • 3/8 X 2 1/2 ROLL PIN ......................................................... 1
24 52288 • THROW-OFF LEVER - OP SIDE - MANUAL/PNEUMATIC .. 1
25 118306 • THROW-OFF LEVER - GEAR SIDE ...................................... 1
26 HARDWARE • • 1/4 - 20 X 3/8 KNURLED POINT SOCKET ........................ 1
HEAD SET SCREW
27 HARDWARE • • 10-24 X 3/8 SOCKET HEAD SET SCREW W/NYLOCK ... 10
28 HARDWARE • • 1/4 - 20 X 3/8 SOCKET HEAD SET SCREW .................... 1
29 108643-8 • • 3/4 X 14 IMPRESSION HANDLE - FLOOR UNIT .............. 1
108419-2 • • 3/4 X 18 IMPRESSION HANDLE - BASE UNIT ................. A/R
108419-3 • • 3/4 X 14 IMPRESSION HANDLE - STACK UNIT ............... A/R
30 HARDWARE • • 5/16 - 18 X 3/8 KNURLED POINT SOCKET ...................... 1
HEAD SET SCREW
XI-34
10
11
10
2
6 4
3
1
5
8
7
Figure 11-11. Circ Shaft Assembly (1 of 2)
XI-35
4a 5
4b
6
8
9
11
Figure 11-11. Circ Shaft Assembly (2 of 2)
XI-36
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY CIRC SHAFT ASSEMBLY (See Fig 11-1, Item 8 for NHA) ...... REF
1 159748 • CIRC SHAFT ........................................................................... 1
2 HARDWARE • • 1/4 X 1/2 KEY ..................................................................... 1
3 HARDWARE • • 1/4 - 20 X 3/4 FLAT HEAD SOCKET HEAD SCREWS ..... 3
4a 159765 • PLATE - CIRC SHAFT ............................................................ 1
b 159765-2 • PLATE - BLANK (USED W/O SHAFT) .................................. 1
5 Q4-116 • QUAD SEAL - CIRC SHAFT ................................................... 1
6 CIRCORK • • CORK GASKET .................................................................. 1
7 HARDWARE • 3/4 STEEL SET COLLAR ....................................................... 1
8 ST2450-3 • • BRASS WASHER - CIRC SHAFT ..................................... 1
9 16DU16 • BUSHING ................................................................................ 1
10 HARDWARE • • 10-24 X 3/8 SOCKET HEAD DOG POINT SET SCREW .. 2
11 M41HP50H • • CIRC DIAL GAGE ............................................................... 1
XI-37
XI-38
25
56 24
17 4
16 18
15 16 19 14
16
21 22 4
20 15
16 11 65
31 9
32 23 15
31 16 10
30 3
456
9 2
24 1
31 2
25 10
11
29 7
6
28 5
4
13
27 12
26
Figure 11-12. Governor Roller, Tension Control and Lead-In Assembly - Floor Unit (1 of 2)
12
2 4 11
13
1
5
14 16
15
18 20 26
17 19
27 30
32
28 29
Figure 11-12. Governor Roller, Tension Control and Lead-In Assembly - Floor Unit (2 of 2)
XI-39
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY GOVERNOR ROLLER TENSION CONTROL LEAD-IN .............. REF

ROLLER ASSEMBLY (FLOOR UNIT ONLY) (See Fig 11-1, Item 9 for
NHA)
1 53429-3 • 3" PIPE ROLLER - 36 LONG .................................................. 1
2 ERX20XLOA • BEARING ................................................................................ 2
3 96343-2 • 1 1/4 TGP GOVERNOR SHAFT - 47 1/2 LONG .................... 1
4 108467 • BUMPER ................................................................................ 4
5 HARDWARE • • 5/8 SAE FLAT WASHER ................................................... 4
7 89812 • LEVER ARM - OPERATOR SIDE .......................................... 1
8 HARDWARE • • 1/4 - 20 X 3/8 SET SCREW ................................................ 1
9 HARDWARE • • 3/8 - 16 X 5/8 KNURLED POINT SOCKET ........................ 4
HEAD SET SCREW
10 HARDWARE • • #7 X 2 1/2 TAPER PIN ........................................................ 2
11 SS4048-28 • • 1 1/4 ID X 1 1 /2 OD X 1 3/4 BRONZE BUSHING .............. 2
12 AR6216-2 • • 5/8 X 1 3/8 CLEVIS PIN W/FLAT ....................................... 1
13 108469-2 • BRAKE LINKAGE ................................................................... 1
14 90065 • LEVER ARM - GEAR SIDE .................................................... 1
15 108425 • • 1 7/8 LEAD-IN PIPE ROLLER ............................................ 3
16 RAL012NPP • BEARING/COLLAR SET / FAFNIR, COLFS450 .................... 6
17 108643-2 • • 3/4 TGP ROLLER SHAFT - 44 1/2 LONG .......................... 1
18 108642-1 • • 3/4 TGP ROLLER SHAFT W/THREADS - 41 LONG ......... 1
20 141745 • ROLLER MOUNTING BLOCK ................................................ 1
22 HARDWARE • • 1/4 20 X 1 SOCKET HEAD CAP SCREW ......................... 1
23 HARDWARE • • 5/16 - 18 X 3/8 SOCKET HEAD CAP SCREW .................. 1
24 HARDWARE • • 1/2 SAE FLAT WASHER ................................................... 2
26 108729 • LEVER - SPRING SHAFT ...................................................... 1
27 97542 • GOVERNOR TENSION BALL ................................................ 1
28 140856 • TENSION CONTROL SPRING ................................................ 1
29 108892 • TENSION CONTROL ROD ...................................................... 1
30 109657 • KNURLED NUT ....................................................................... 1
31 HARDWARE • • 5/8 - 11 JAM NUT ............................................................... 3
32 97543 • POPPET - TENSION CONTROL ............................................ 1
XI-40
18
16
19
17
11
10
15
1
7
3 9
5
7
2 12 13 14
4
6
21
8
23
25
26
17
20
22
24
27
16
Figure 11-13. Blanket Cylinder Assembly (1 of 3)
XI-41
Photo Not
Available
Item 1
38877-1SS
4
8
Photo Not Photo Not

Available Available
Item 16 Item 19
108369 EP-40
11
13
15
20 22
21
XI-42
24
27
23
XI-43
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY BLANKET CYLINDER ASSEMBLY (See Fig 11-1, Item 10 ...... REF
for NHA)
1 38877-1SS • BLANKET CYLINDER, STANDARD, 21 1/2” ......................... 1
28877-1SS • BLANKET CYLINDER, STANDARD, 22” ............................... A/R
18877-1SS • BLANKET CYLINDER, STANDARD, 22 3/4” ......................... A/R
2 HARDWARE • • 1/4 - 20 X 1 SOCKET HEAD CAP SCREW ....................... 4
3 HARDWARE • • 1/4 HI COLLAR LOCK WASHER ....................................... 4
4 46456-3 • CAP - GEAR SIDE .................................................................. 1
5 HARDWARE • • PLASTIC SHIM SET - GEAR SIDE .................................... 1
6 HARDWARE • • BRASS SHIM SET - GEAR SIDE ...................................... 1
7 368-902A5 • TIMKEN ROLLER BEARING SET W/RACE AND SPACER . 2
8 149045 • SPACER - GEAR SIDE JOURNAL ........................................ 1
10 HARDWARE • • 5/16 LOCK WASHER ......................................................... 3
11 48643-2 • CAP - OPERATOR SIDE ........................................................ 1
12 HARDWARE • • 7/16 X 2 KEY ....................................................................... 1
13 100741 • BLANKET BAR ....................................................................... 1
14 HARDWARE • • 1/4 - 20 X 2 SOCKET HEAD CAP SCREW W/NYLOCK .. 6
15 ACO-56008 • ECCENTRIC - #11 OPERATOR SIDE .................................... 1
ACP-56007 • ECCENTRIC - #12 OPERATOR SIDE (NOT SHOWN) .......... 1
16 108639 • • LOAD WASHER - OPERATOR SIDE ................................ 1
19 EP-40 • CAP PLUG .............................................................................. 1
20 Q4-246 • QUAD SEAL ............................................................................ 1
21 16973 • ECCENTRIC - #11 GEAR SIDE .............................................. 1
13851 • ECCENTRIC - #12 GEAR SIDE (NOT SHOWN) .................... 1
22 104795 • • GEAR HUB (22 3/4”) ........................................................... 1
104795-2 • • GEAR HUB (22, 21 1/2”) .................................................... 1
23 118310-2 • RING GEAR (21 1/2”) .............................................................. 1
106562-2 RING GEAR (22”) ........................................................................ A/R
118308 RING GEAR (22 3/4”) .................................................................. A/R
24 3424-3 • • SLIP WASHER (21 1/2” AND 22” ONLY) .......................... 4
3424 • • SLIP WASHER (22 3/4” ONLY) ......................................... 6
25 HARDWARE • • 1/2 LOCK WASHER (22 3/4” ONLY) ................................. 4
• • 3/8 HI COLLAR LOCK WASHER (21 1/2” AND 22” ONLY) 6
(22 3/4” ONLY)
HARDWARE • • 3/8 - 16 X 1 SOCKET HEAD CAP SCREW (21 1/2” AND 6
(22” ONLY)
27 148639-1 • • LOAD WASHER - GEAR SIDE .......................................... 1
(#11 SIDE SHOWN - 22 3/4 CUTOFF)

XI-44
7
8
10
3 4
6
5
2
4
1
3
9 10 12
8
11
7
Figure 11-14. #10 Side Narrow Gap Lock-Up Assembly (1 of 2)
XI-45
1 4
10
11
XI-46
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY #10-SIDE NARROW GAP LOCK-UP (See Fig 11-1, ................ REF
Item 11 for NHA)
1 18880-3SS PLATE CYLINDER (NARROW GAP - 22 3/4” CUTOFF) .......... 1
28880-3SS PLATE CYLINDER (NARROW GAP - 22” CUTOFF) ................ 1
38880-3SS PLATE CYLINDER (NARROW GAP - 21 1/2” CUTOFF) .......... 1
2 149800 • LEVER - AUTOMATIC PLATE LOCK-UP .............................. 1
4 99441 • • THROW-OFF LOCK-UP NUT ............................................. 2
5 SA100029 • NARROW GAP LOCK-UP SUBASSEMBLY ......................... REF
6 HARDWARE • • 8 - 32 X 3/4 SOCKET HEAD CAP SCREW W/NYLOCK .. 4
7 HARDWARE • • 1/4 - 20 X 3/4 HEX HEAD BOLT ......................................... 4
9 HARDWARE • • 1/4 X 1 1/4 DOWEL PIN (REGISTER BLOCK) .................. 1
10 148071 • LOCK-UP REGISTER BLOCK/N.G. ....................................... REF
11 104488-1 • STRIKER PLATE - #10 SIDE .................................................. 1
12 HARDWARE • • 3/8 - 16 X 1/2 SOCKET HEAD CAP SCREW .................... 2
XI-47
2 5
Figure 11-15. Narrow Gap Lock-Up (1 of 2)
XI-48
Figure 11-15. Narrow Gap Lock-Up (2 of 2)

XI-49
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
SA100029 NARROW GAP LOCK-UP (See Fig 11-1, Item 12 for NHA) ..... REF
1 99787 • LOCK-UP SHAFT/N.G. ........................................................... 1
2 HARDWARE • • 8 - 32 X 3/8 FLAT HEAD SOCKET HEAD SCREW .......... 16
3 148072 • • LOCK-UP SPRING CLAMP PLATE ................................... 4
4 35044 • • LOCK-UP SPRING/N.G. ..................................................... 8
5 150241 • • ANTI-RATTLE SPRING/N.G. .............................................. 1
6 100029 • • LOCK-UP BAR/N.G. ........................................................... 1
XI-50
10
7
8
3
1
4
12
11
5 6
2 5
4
9 10 3
8
7
XI-51
5
4
11
10
Figure 11-16. #13 Side Narow Gap Lock-Up Assembly (2 of 2)
XI-52
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY #13-SIDE NARROW GAP LOCK-UP (See Fig 11-1, ................ REF
Item 13 for NHA)
1 18878-3SS PLATE CYLINDER (NARROW GAP - 22 3/4” CUTOFF) .......... 1
28878-3SS PLATE CYLINDER (NARROW GAP - 22” CUTOFF) ................ 1
38878-3SS PLATE CYLINDER (NARROW GAP - 21 1/2” CUTOFF) .......... 1
2 149800 • LEVER - AUTOMATIC PLATE LOCK-UP .............................. 1
4 99441 • THROW-OFF LOCK-UP NUT ................................................. 2
5 SA100029 • NARROW GAP LOCK-UP SUBASSEMBLY ......................... REF
6 HARDWARE • • 8 - 32 X 3/4 SOCKET HEAD CAP SCREW W/NYLOCK .. 4
9 HARDWARE • • 1/4 X 1 1/4 DOWEL PIN (REGISTER BLOCK) .................. 1
10 148071 • LOCK-UP REGISTER BLOCK/N.G. ....................................... REF
11 104488-2 • STRIKER PLATE - #13 SIDE .................................................. 1
XI-53
6
4
5
3
12
4
11
3
4
2
5
6
9
10 4
12
8 11 1
6 7
Figure 11-17. #10 Side Wide Gap Lock-Up Assembly (1 of 2)
XI-54
Photo Not
Available
Item 1
18880-2SS
2
3
7 12
8 11
Figure 11-17. #10 Side Wide Gap Lock Up Assembly (2 of 2)
XI-55
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY #10-SIDE WIDE GAP LOCK-UP (See Fig 11-1, ....................... REF
Item 14 for NHA)
1 18880-2SS PLATE CYLINDER (WIDE GAP) ................................................ 1
2 SA91835 • WIDE GAP LOCK-UP ASSEMBLY ....................................... REF
3 104917 • REGISTER BLOCK/W.G. ....................................................... 2
4 HARDWARE • • 5/16 - 18 X 1/2 SHOULDER BOLT ..................................... 4
5 HARDWARE • • 3/16 X 1 1/4 DOWEL PIN ................................................... 4
8 94775 • LOCK-UP CLOSER/W.G. ....................................................... 1
9 HARDWARE • • 1/4 - 20 JAM NUT ............................................................... 1
10 HARDWARE • • 1/4 - 20 X 1/2 BUTTON HEAD CAP SCREW .................... 1
11 94778 • WIDE-GAP U-BOLT ADJUSTING SCREW ............................ 2
12 119471 • • WIDE-GAP U-BOLT BRACKET ......................................... 2
XI-56
Figure 11-18. Wide Gap Lock-Up (1 of 2)
XI-57
Figure 11-18. Wide Gap Lock-Up (2 of 2)
XI-58
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
SA91835 WIDE GAP LOCK-UP (See Fig 11-1, Item 15 for NHA) ............ REF
1 91835 • LOCK-UP L-BAR/W.G. ........................................................... 1
2 91836 • • LOCK-UP SHAFT/W.G. ...................................................... 1
3 25709 • • LOCK-UP SPRING/W.G. .................................................... 6
4 HARDWARE • • #6 LOCK WASHER ............................................................ 12
5 HARDWARE • • 6 -32 X 1/4 ROUND HEAD MACHINE SCREW ................. 12
6 118873 • • MYLAR SCREW W/NYLOCK ............................................ 2
XI-59
7
4
12
5
4
1
3
11
4
2
12
5
6
10 3
9
4 11
8
7 6
Figure 11-19. #13 Side Wide Gap Lock-Up Assembly (1 of 2)
XI-60
Photo Not
Available
Item 1
18878-2SS
11
7 8
3 12
Figure 11-19. #13 Side Wide Gap Lock Up Assembly (2 of 2)
XI-61
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY #13-SIDE WIDE GAP LOCK-UP(See Fig 11-1, ....................... REF

Item 16 for NHA)
1 18878-2SS PLATE CYLINDER (WIDE GAP) ................................................ 1
2 SA91835 • WIDE GAP LOCK-UP ASSEMBLY ....................................... REF
3 104917 • REGISTER BLOCK/W.G. ....................................................... 2
4 HARDWARE • • 5/16 - 18 X 1/2 SHOULDER BOLT ..................................... 4
8 94775 • LOCK-UP CLOSER/W.G. ....................................................... 1
9 HARDWARE • • 1/4 - 20 JAM NUT ............................................................... 1
11 94778 • WIDE-GAP U-BOLT ADJUSTING SCREW ............................ 2
12 119471 • WIDE-GAP U-BOLT BRACKET .............................................. 2
XI-62
5
1
3
4
11 8
12 9
10
13
12
14
20 19 15
21 16
17
18
14
22
23
Figure 11-20. #10 Cylinder Assembly - Gear Side (1 of 2)
XI-63
Photo Not
Available
Item 6
116327G
1
5
8
9
17
15
14
10
18
24
XI-64
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY #10 CYLINDER GEAR SIDE (See Fig 11-1, Item 17 for NHA) . REF
1 18880-3SS #10 CYLINDER (NARROW GAP - 22 3/4” CUTOFF) ................ 1
28880-3SS #10 CYLINDER (NARROW GAP - 22” CUTOFF) ...................... 1
38880-3SS #10 CYLINDER (NARROW GAP - 21 1/2” CUTOFF) ................ 1
2 HARDWARE • • 7/16 x 2 KEY ....................................................................... 1
3 HARDWARE • • • 1/4 - 20 X 1 1/4 SOCKET HEAD CAP SCREW ............ 4
5 116327 • CAP - GEAR SIDE .................................................................. 1
6 116327G • CORK GASKET ...................................................................... 1
7 368-902A5 • TIMKEN BEARING SET ......................................................... 1
8 Q4-243 • QUAD SEAL ............................................................................ 1
9 16972 • ECCENTRIC .......................................................................... 1
10 17269 • CIRC PLATE ............................................................................ 1
11 HARDWARE • • 5/16 HI COLLAR LOCK WASHER ..................................... 3
12 HARDWARE • • 5/16 - 18 X 3/4 BUTTON HEAD CAP SCREW .................. 3
13 HARDWARE • • 5/16 DOWEL PIN ................................................................ 2
14 SA51945 • CIRC SUBASSEMBLY (22 3/4”) ............................................ REF
SA51945-2 • CIRC SUBASSEMBLY (22”) ................................................... REF
SA51945-3 • CIRC SUBASSEMBLY (21 1/2”) ............................................ REF
15 148639-1 • LOAD WASHER ..................................................................... 1
16 HARDWARE • • 5/8 - 11 X 1 1/4 BUTTON HEAD CAP SCREW ................. 1
17 157092-3 • • .531 X .781 X 1.188 SLEEVE ............................................. 1
18 100935 • STUD - CIRC PLATE ............................................................... 3
23 HARDWARE • •1/2 - 13 X 1 1 /4 HEX HEAD BOLT ..................................... 3
24 SA51945-M CIRC SUB-ASSEMBLY (NOT SHOWN)
// USED WITH QUAD TECH MOTORIZATION OPTION //
SA51945-2M CIRC SUB-ASSEMBLY (NOT SHOWN)
SA51945-3M CIRC SUB-ASSEMBLY (NOT SHOWN)
XI-65
19
18
17
14
16
15
14
13
12
11 9
10 8
7
6
5
24
24
23
21
22
20
Figure 11-21. #10 Cylinder Assembly - Operator Side (1 of 2)
XI-66
1
3
4 5
18
10 16
13
Photo Not Photo Not Photo Not

Available Available Available
Item 21 Item 22 Item 24

88-LB-03X02 89-LB-03X02 4638K511
19 20
Figure 11-21. #10 Cylinder Assembly - Operator Sider (2 of 2)
XI-67
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY #10 CYLINDER - OPERATOR SIDE (See Fig 11-1, .................. REF
Item 19 for NHA)
1 18880-3SS #10 CYLINDER (NARROW GAP - 22 3/4” CUTOFF) ................ REF
28880-3SS #10 CYLINDER (NARROW GAP - 22” CUTOFF) ...................... REF
38880-3SS #10 CYLINDER (NARROW GAP - 21 1/2” CUTOFF) ................ REF
2 HARDWARE • • 5/16 - 18 X 1 HEX HEAD BOLT .......................................... 3
3 123472 • OPERATOR SIDE CAP .......................................................... 1
5 25351 • OPERATOR SIDE ECCENTRIC ............................................. 1
6 157092-3 • • .531 X .781 X 1.188 SLEEVE ............................................. 1
10 108639 • LOAD WASHER - OPERATOR SIDE .................................... 1
13 118344 • SIDELAY PLATE ..................................................................... 1
16 SA48879 • SIDELAY ................................................................................ REF
18 1084BW • BEVEL WASHER ................................................................... 1
19 108440-2 • SIDELAY LOCKING KNOB .................................................... 1
20 DG155GF • ELBOW BODY ........................................................................ 1
21 88-LB-03X02 • STRAIGHT PIPE FITTING ....................................................... 1
22 89-LB-03X02 • RIGHT ANGLE PIPE FITTING ................................................ 1
23 HARDWARE • • 3/16 OD HIGH PRESSURE GREASE LINE ...................... 1
24 4638K511 • • 1/8 PIPE PLUG ................................................................... 2
XI-68
Figure 11-22. #10/#13 Sidelay (1 of 2)
XI-69
1
2
Figure 11-22. #10/#13 Sidelay (2 of 2)
XI-70
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
SA48879 #10 and #13 SIDELAY (See Fig 11-1, Item 20 for NHA) .......... REF
1 94683 • SIDELAY HANDWHEEL HUB ................................................ 1
2 48879 • SIDELAY BRACKET ............................................................... 1
3 5IDE • ARBOR SHIM .......................................................................... 1
4 5100-262 • • 2 5/8 EXTERNAL SNAP RING ........................................... 1
XI-71
3
4
5
6
7
8
15 10
17
14
15
16
11
12
13
XI-72
Photo Not
Available
Item 2
1688-B
8
5
14
11 13
12
XI-73
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY #13 CYLINDER, GEAR SIDE (See Fig 11-1, Item 21 for NHA) . REF
1 18878-3SS • #13 CYLINDER (NARROW GAP - 22 3/4” CUTOFF) ............ 1
28878-3SS • #13 CYLINDER (NARROW GAP - 22” CUTOFF) .................. 1
38878-3SS • #13 CYLINDER (NARROW GAP - 21 1/2” CUTOFF) ............ 1
2 1688-B • GREASE FITTING - 45 DEGREE ........................................... 2
3 HARDWARE • • 5/16 - 18 X 1 1/4 SOCKET HEAD CAP SCREW .............. 4
5 123348 • RACE END PLATE ................................................................. 1
6 HARDWARE • CORK GASKET ...................................................................... 1
8 149090 • BEARING END PLATE ........................................................... 1
10 HARDWARE • • 3/8 - 16 X 2 1/2 SOCKET HEAD CAP SCREW W/ HI LOCK 3
11 Q4-258 • QUAD SEAL - GEAR SIDE .................................................... 1
12 49001 • SLEEVE - PUMPKIN .............................................................. 1
13 104484 • DRIVE SIDE GEAR HUB, 21 1/2” .......................................... 1
106586-2 • DRIVE SIDE GEAR HUB, 22” ................................................ A/R
70179 • DRIVE SIDE GEAR HUB, 22 3/4” .......................................... A/R
14 142024 • SHIFT LEVER BRACKET ....................................................... 1
17 HARDWARE • • 3/8 X 3/8 SHOULDER BOLT .............................................. 1
XI-74
19
18
17
14
9 16
8 15
7
6 14
5 13
12
11
24
10
23
22
21
20
4
3
2
XI-75
3
4
5
10
16
13
Photo Not
Available
Item 21
20 88-LB-03X02
19
18
Photo Not Photo Not

Available Available
Item 22 Item 24
89-LB-03X02 4638K511
XI-76
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY #13 CYLINDER, OPERATOR SIDE (See Fig 11-1, .................. REF
Item 22 for NHA)
1 18878-3SS • #13 CYLINDER (NARROW GAP - 22 3/4” CUTOFF) ............ REF
28878-3SS • #13 CYLINDER (NARROW GAP - 22” CUTOFF) .................. REF
38878-3SS • #13 CYLINDER (NARROW GAP - 21 1/2” CUTOFF) ............ REF
2 HARDWARE • • 5/16 - 18 X 1 HEX HEAD BOLT .......................................... 3
3 125527 • OPERATOR SIDE CAP .......................................................... 1
5 16700 • OPERATOR SIDE ECCENTRIC ............................................. 1
6 157092-3 • • .531 X .781 X 1.188 SLEEVE ............................................. 1
10 108639 • LOAD WASHER - OPERATOR SIDE .................................... 1
13 118344 • SIDELAY PLATE ..................................................................... 1
16 SA48879 • SIDELAY ................................................................................ REF
18 1084BW • BEVEL WASHER ................................................................... 1
19 108440-2 • SIDELAY LOCKING KNOB .................................................... 1
20 DG155GF • ELBOW BODY ........................................................................ 1
21 88-LB-03X02 • STRAIGHT PIPE FITTING ....................................................... 1
22 89-LB-03X02 • RIGHT ANGLE PIPE FITTING ................................................ 1
23 HARDWARE • • 3/16 OD HIGH PRESSURE GREASE LINE ...................... 1
24 4638K511 • • 1/8 PIPE PLUG ................................................................... 2
XI-77
15
24
14
10
7
6
7 8 9 8
6
11 12
3 13
12
13
9 10
2
23
10
2 1
6 4
7 5
8 9
6 9
11
7 13
12
13
10 12
11
24
14
17
15
19 16
21
18
20
22
Figure 11-25. Lower Copper Assembly (1 of 2)
XI-78
1
3
5
9
4
8
10 11 12 14
16
17
19
18
20
Figure 11-25. Lower Copper Assembly (2 of 2)
XI-79
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY LOWER COPPER (See Fig 11-1, Item 23 for NHA) .................. REF
1 94492 • COPPER ROLLER .................................................................. 1
2 HARDWARE • • 1 7/8 EXTERNAL SNAP RING ........................................... 2
3 130983 • OPERATOR SIDE BUSHING ................................................. 1
4 95421-3 • GEAR SIDE BUSHING ........................................................... 1
5 123199 • WIPER - GEAR SIDE BUSHING ............................................ 1
6 HARDWARE • • 5/16 - 24 X 1 1/2 SOCKET HEAD CAP SCREW W/NYLOCK 4
7 HARDWARE • • 10-24 X 1/4 SOCKET HEAD SET SCREW W/NYLOCK ... 4
8 122710 • FORM ROLLER BRACKETS .................................................. 4
9 119954 • POPPET ................................................................................ 4
10 120115 • ANTI-BOUNCE SCREW -1 3/4” .............................................. 4
120115-1 • ANTI-BOUNCE SCREW -1 1/4” // 21 1/2” CUTOFF ONLY // 4
120115-2 • ANTI-BOUNCE SCREW -1 1/2” //22” & 22 3/4” CUTOFFS // 4
11 122810 • ANTI-BOUNCE SPRING ......................................................... 4
12 119975 • L BRACKET (NOT USED ON #13 DRIVE SIDE) ................... 6
13 HARDWARE • • 1/4 - 20 X 1/2 BUTTON HEAD BOLT (ALLEN) .................. 8
14 DGM144 • WIDGET ................................................................................ 2
15 HARDWARE • • 1/4 - 20 X 1/2 FLAT HEAD BOLT (ALLEN) ........................ 2
16 70168 • GEAR ................................................................................ 1
17 113908-2 • BEVEL SPACER .................................................................... 1
18 113906-2 • BEARING HOUSING ............................................................... 1
19 5203ATN9 • BEARING ................................................................................ 1
20 113433 • • MACHINE WASHER W/PIN .............................................. 1
22 HARDWARE • • 5/16 - 18 X 3/4 HEX HEAD BOLT ....................................... 1
23 HARDWARE • • 1/4 X 1/4 X .600 KEY .......................................................... 1
24 HARDWARE • • SHIM ................................................................................ 2
(#10 SIDE SHOWN)
XI-80
13
23
14
7
9 8 11
6 10
10
9 9
9
8 6 7
3
2
1
22
9
8
10
2
4
9 5
8 6
7 7
12 11
6
9
9
10
13
14
16
15
18
20 17
19
21
Figure 11-26. Upper Copper Assembly (1 of 2)
XI-81
5 10
4
11 13
12
15
16
17 18
19
Figure 11-26. Upper Copper Assembly (2 of 2)
XI-82
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY UPPER COPPER (See Fig 11-1, Item 24 for NHA) .................. REF
1 94492 • COPPER ROLLER .................................................................. 1
3 130983 • OPERATOR SIDE BUSHING ................................................. 1
5 123199 • WIPER - GEAR SIDE BUSHING ............................................ 1
6 759000-6 • EYE BOLTS ............................................................................ 4
7 HARDWARE • • 3/8 X 1 1/2 PIN (TRANSFER BRACKET) W/HOLE ........... 4
8 HARDWARE • • 1/6 X 3/4 COTTER PIN ........................................................ 4
9 HARDWARE • • 3/8 - 16 JAM NUT ............................................................... 8
10 108532 • POPPET ................................................................................ 4
11 65996-2 • TRANSFER ROLLER BRACKET ........................................... 2
12 65996-1 • TRANSFER ROLLER BRACKET ........................................... 2
13 DGM144 • WIDGET ................................................................................ 2
14 HARDWARE • • 1/4 - 20 X 1/2 FLAT HEAD BOLT (ALLEN) ........................ 2
15 70168 • GEAR ................................................................................ 1
16 113908-2 • BEVEL SPACER .................................................................... 1
17 113906-2 • BEARING HOUSING ............................................................... 1
18 5203ATN9 • BEARING ................................................................................ 1
19 113433 • • MACHINE WASHER W/PIN .............................................. 1
22 HARDWARE • • 1/4 X 1/4 X .600 KEY .......................................................... 1
23 HARDWARE • • SHIM ................................................................................ 2
(#10 SIDE SHOWN)
XI-83
18
5 6
7
8 8
3
11
2 10
2
19
8 4
8
7
6
5
12
13
14
15
16
17
Figure 11-27. Water Pan Roller Assembly (1 of 2)
XI-84
3 4 6
2
5
1
9b
9a
10 12
15b
15a
18
Figure 11-27. Water Pan Roller Assembly (2 of 2)
XI-85
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY WATER PAN ROLLER ASSEMBLY(See Fig 11-1, Item 25 ..... REF
for NHA)
1 93547 WATER PAN ROLLER ............................................................... 2
2 5100-187 • 1 7/8 EXTERNAL SNAP RING ................................................ 4
4 143805-2 • OPERATOR SIDE BUSHING ................................................. 2
5 157119-P • WATER PAN BRACKET ........................................................ 4
6 148175 • CLIP ................................................................................ 4
8 HARDWARE • • 3/8 - 16 X 3.4 HEX HEAD BOLT ......................................... 8
9 114016-1 • #10 SIDE WATER PAN .......................................................... 1
114016-2 • #13 SIDE WATER PAN .......................................................... 1
10 750-OD • BRONZE WATER LEVELER .................................................. 2
11 HARDWARE • • 1/4 - 28 STRAIGHT GREASE FITTING (1641B) ................ 2
12 108487 • COUPLING .............................................................................. 2
14 HARDWARE • • 1/8 X 1/8 X 1 KEY ............................................................... 2
15a 02-99193A • #10 SIDE WATER MOTOR .................................................... 1
b 02-99194A • #13 SIDE WATER MOTOR (SHOWN) ................................... 1
18 935PLG • GEAR SIDE BUSHING PLUG ................................................ 2
XI-86
11
24
25
12
12 26
13
16
15 7
14 9
6 10
8
5
3
2
12 12
16 11
13
2
4
10
9
15 7
14 6 5
8
18
26
24
21 17
25
27 22 23
20
19
Figure 11-28. Water Vibrator Assembly (1 of 2)
XI-87
1 6
3 4
7
9 11
8 14
15
17
16
19 21
20
23 25 27
22
Figure 11-28. Water Vibrator Assembly (2 of 2)
XI-88
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY WATER VIBRATOR (See Fig 11-1, Item 26 for NHA) ................ REF
1 103678-1 • 3/4 - 10 RIGHT HAND ROLLER - #13 SIDE ........................... 1
103678-2 • 3/4 - 10 LEFT HAND ROLLER - #10 SIDE ............................. 1
3 130983 • • OPERATOR SIDE BUSHINGS .......................................... 2
4 95421 • • GEAR SIDE BUSHING - #10 SIDE .................................... 1
95422 • • GEAR SIDE BUSHING - #13 SIDE .................................... 1
5 HARDWARE • • • 5/16 -24 X 1 1/2 SOCKET HEAD BOLT W/NYLOCK .... 4
6 119954 • • POPPET - FORM ROLLER ADJUSTMENT ....................... 4
7 73460 • • SOCK ROLLER BRACKET ................................................ 4
8 122710 • • FORM ROLLER BRACKET ................................................ 4
9 157426 • • TRANSFER ROLLER EYE BOLT ...................................... 4
10 HARDWARE • • • 1/2 X 1/2 SHOULDER BOLT .......................................... 4
12011S-2 • • • ANTI-BOUNCE SCREW 1 1/2” // NOT SHOWN - 21 1/2”
CUTOFF ONLY //
11 108532 • • POPPET - TRANSFER ROLLER ADJUSTMENT .............. 4
12 HARDWARE • • • 3/8 - 16 JAM NUT ........................................................... 8
13 HARDWARE • • • 10 - 24 X 1/4 SET SCREW W/NYLOCK ........................ 4
14 120115 • • ANTI-BOUNCE SCREW 1 3/4 ............................................ 4
15 122810 • • ANTI-BOUNCE SPRING ..................................................... 4
16 119975 • • L-BRACKET (ANTI - BOUNCE) .......................................... 3
17 157943 • • OSCILLATOR ARM BOLT W/1 X 8 THREAD .................... 2
18 HARDWARE • • • 1" LOCK WASHER ........................................................ 2
19 34625 • • GUIDE ROD - 3/4 X 7 DOWEL ........................................... 2
20 SA22141-10 • • WATER VIBRATOR ASSEMBLY - #10 SIDE (SHOWN) .. REF
SA22141-13 • • WATER VIBRATOR ASSEMBLY - #13 SIDE ................... REF
21 SA70170 • • IDLER SUB-ASSEMBLY .................................................... 2
22 141206 • • PIVOT ARM - OSCILLATOR .............................................. 2
23 3424 • • • SLIP WASHER ............................................................... 2
24 HARDWARE • • • 1/4 - 20 FLAT HEAD BOLT (ALLEN HEAD) .................. 4
25 DGM144 • • • WIDGET .......................................................................... 4
26 HARDWARE • • • SHIM ............................................................................... 4
27 SS1620-10 • • • 1/2 X 5/8 X 5/8 BUSHING ............................................... 4
XI-89
Figure 11-29. Water Vibrator Idler (1 of 2)
XI-90
2
3
Figure 11-29. Water Vibrator Idler (2 of 2)
XI-91
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
SA70170 WATER VIBRATOR IDLER ASSEMBLY (See Fig 11-1, ........... REF
Item 28 for NHA)
1 70170 • IDLER GEAR ........................................................................... 1
2 WK2587 • BEARING ................................................................................ 1
3 5000-150 • • 1 1/2 I.D. INTERNAL SNAP RING ...................................... 2
XI-92
4
5
1
4
7 2
3
12
6
11 13
8 10
Figure 11-30. Micro Roller Assembly (1 of 2)
XI-93
7
3
2
9
10
13
Figure 11-30. Micro Roller Assembly (2 of 2)
XI-94
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY MICRO ROLLER ASSEMBLY (See Fig 11-1, Item 29, for NHA)
REF
1 95891N MICRO ROLLER - PLASTIC COATED ...................................... 2
2 62062RS • 6206 BEARING ....................................................................... 4
3 148137 • SPLIT ECCENTRICS ............................................................... 4
6 HARDWARE • • 3/4 SPLIT COLLAR ............................................................. 2
7 144600 • MICRO BUSHING ................................................................... 2
8 HARDWARE • 1 1/4 EXTERNAL SNAP RING ................................................ 2
9 12DU16 • BUSHING ................................................................................ 2
10 148127 • STOP POPPET ....................................................................... 2
11 HARDWARE • • 1/4 - 20 X 2 SQUARE HEAD BOLT ................................... 2
12 HARDWARE • • 1/4 - 20 JAM NUT ............................................................... 2
13 SA108643-3 • MICRO SHAFT ASSEMBLY .................................................. REF
XI-95
10
6
9
5
8
1
7
3
7
Figure 11-31. Micro Shaft (1 of 2)
XI-96
2a
2b
5
3 4
Figure 11-31. Micro Shaft (2 of 2)
XI-97
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
SA108643-3 MICRO SHAFT (See Fig 11-1, Item 30 for NHA) ........................ REF
1 108643-3 3/4 OD X 46 7/8 SHAFT .............................................................. 1
2a 95444-2 • LONG THROW-OFF HUB // NON-PNEUMATIC // ................ 1
b 95444-2-2 • THROW-OFF HUB // PNEUMATICS OPTION ONLY// .......... 1
3 145029 • POPPET // NON-PNEUMATIC // ............................................ 1
4 127712 • COMPRESSION SPRING/SOCK ROLLER SPRING// NON- 1
PNEUMATIC //
5 2528 • 3/4 OD X 4 3/4 THROW-OFF STOP ROD ............................. 1
6 145028 • SPRING SHAFT // NON-PNEUMATIC // ................................ 1
7 HARDWARE • • 3/8 - 16 JAM NUT ............................................................... 2
9 HARDWARE • • 1/8 X 3/4 SPRING PIN ........................................................ 1
XI-98
2
19
20 18
7
3
8
9
10
4
30
5
1
30
10
9
8
6
20
19
5
4 17
8
6 25
17
20 27
29
19 28
23 13 27
26
24 25
12
26
16
15
12
16
14
11
22
21
Figure 11-32. #10 Side Ink Vibrator (1 of 2)
XI-99
4
5
1 2
3
11
10
6 7 9 12
16 17
14 15
25 30
13
XI-100
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
SA16366 #10-SIDE, INK VIBRATOR ASSEMBLY (See Fig 11-1, Item 32,
REF
for NHA)
1 16366 • #10 HOUSING ......................................................................... 1
2 123676 • #10 COPPER OSCILLATOR GEAR ....................................... 1
3 48756-1 • COPPER OSC. WORM PINION SHAFT ............................... 1
4 L44610 • TIMKEN BEARING RACE ...................................................... 2
5 L44649 • TIMKEN ROLLER BEARING .................................................. 2
6 95332-1 • END CAP ................................................................................ 2
7 95332-2 • END CAP ................................................................................ 1
8 HARDWARE • SHIM SET ................................................................................ 3
9 1328 • TIMKEN BEARING RACE ...................................................... 2
10 1380 • TIMKEN BEARING .................................................................. 2
11 40070-310 • LOAD WASHER - INK VIBRATOR WORM GEAR ................ 1
12 108429 • ECCENTRIC CAM ................................................................... 2
13 122821 • SHAFT ................................................................................ 1
14 99704-1 • WORM PINION - COPPER OSC. ASSEMBLY ..................... 1
15 48756-2 • WORM GEAR ......................................................................... 1
16 108427 • LINK - BRONZE ...................................................................... 2
17 113907 • CONNECTORS - CAST .......................................................... 2
18 HARDWARE • • 5/16 X 1 3/4 KEY (705-020-020-148) .................................. 1
23 HARDWARE • • 1/4 X 2 1/4 KEY (705-016-016-216) .................................... 1
24 HARDWARE • • 1/4 X 5/8 KEY ..................................................................... 1
25 108387-2 • • 1/2 X 7/16 ROLL PIN ........................................................... 2
28 HARDWARE • • 5/16 - 18 X 3/4 SOCKET HEAD SET SCREW .................. 1
29 HARDWARE • • 5/16 - 18 JAM NUT ............................................................. 1
30 40064-2102 • • SPACER ............................................................................. 2
XI-101
3
19
18 4 20
5 7
8
9
10
30
5
1 4
8
30 6
8
10 20
6
9 19
20
19
13
27 26 23
25
17
24
28
29
12
27
25
17 16
15
12
21 16 26
14
11
22
XI-102
4
3
2
1
5 11
9 10
6
7
16 17
14 15
12
13 25 30
XI-103
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
SA16367 #13-SIDE, INK VIBRATOR ASSEMBLY (See Fig 11-1, ............ REF
Item #32, for NHA)
1 16367 • #13 HOUSING ......................................................................... 1
2 70177 • #13 COPPER OSCILLATOR GEAR ....................................... 1
3 48756-1 • COPPER OSC. WORM PINION SHAFT ............................... 1
4 L44610 • TIMKEN BEARING RACE ...................................................... 2
5 L44649 • TIMKEN ROLLER BEARING .................................................. 2
6 95332-1 • END CAP ................................................................................ 2
7 95332-2 • END CAP ................................................................................ 1
8 HARDWARE • SHIM SET ................................................................................ 3
9 1328 • TIMKEN BEARING RACE ...................................................... 2
10 1380 • TIMKEN BEARING .................................................................. 2
11 40070-310 • LOAD WASHER - INK VIBRATOR WORM GEAR ................ 1
12 108429 • ECCENTRIC CAM ................................................................... 2
13 122821 • SHAFT ................................................................................ 1
14 99704-1 • WORM PINION - COPPER OSC. ASSEMBLY ..................... 1
15 48756-2 • WORM GEAR ......................................................................... 1
16 108427 • LINK - BRONZE ...................................................................... 2
17 113907 • CONNECTORS - CAST .......................................................... 2
18 HARDWARE • • 5/16 X 1 3/4 KEY (705-020-020-148) .................................. 1
23 HARDWARE • • 1/4 X 2 1/4 KEY (705-016-016-216) .................................... 1
24 HARDWARE • • 1/4 X 5/8 KEY ..................................................................... 1
25 108387-2 • • 1/2 X 7/16 ROLL PIN ........................................................... 2
29 HARDWARE • • 5/16 - 18 JAM NUT ............................................................. 1
30 40064-2102 • • SPACER ............................................................................. 2
XI-104
4 1
Figure 11-34. Ink Vibrator Assembly (1 of 2)
XI-105
1a
1b
Figure 11-34. Ink Vibrator Assembly (2 of 2)
XI-106
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY INK VIBRATOR/INK FOUNTAIN DRIVE ASSEMBLY (See ....... REF

Fig 11-1, Item 37, for NHA)
1 SA16366 • #10 SIDE INK VIBRATOR ....................................................... REF
SA16367 • #13 SIDE INK VIBRATOR ....................................................... REF
5 HARDWARE • • 1/4 - 20 X 1 1/4 SOCKET HEAD CAP SCREW //NS// ...... 8
6 HARDWARE • • 1/4 HI COLLAR LOCK WASHER //NS// ............................ 8
XI-107
12
13
19
15 12
13
16
3
2
5
4
6 7
14
18
17
9 11
6
8
5
3
10
16
15
Figure 11-35. #10 Side Water Vibrator (1 of 2)
XI-108
6 7
2
3
1
8
19
10 11
17
XI-109
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
SA22141-10 #10 SIDE, WATER VIBRATOR ASSEMBLY (See Fig 11-1, ..... REF
Item 27, for NHA)
1 22141-1 • CASTING - OSC BOX ............................................................. 1
2 110697 • END PLATE - 4 HOLE ............................................................ 1
3 119885 • END PLATE - 3 HOLE ............................................................ 2
4 HARDWARE • • SHIM SET - 4 HOLE ........................................................... 1
6 62062RS • BEARING //SKF // .................................................................. 2
7 5203ATN9 • BEARING //MRC // ................................................................. 1
8 60072RS • BEARING // SKF // ................................................................. 1
9 103676-2 • WORM SHAFT W/RIGHT HAND THREADS - #10 SIDE ...... 1
10 70188 • GEAR - WATER OSCILLATOR .............................................. 1
11 127371 • WORM GEAR SHAFT - WATER OSCILLATOR .................... 1
12 HARDWARE • • 1/4 - 20 x 5/8 BUTTON HEAD CAP SCREW .................... 5
14 HARDWARE • • 5/16 X 1 3/4 KEY (705-020-020-148) .................................. 1
17 105603-3 • • SPOTTING BOLT ................................................................ 1
18 HARDWARE • • JAM NUT ............................................................................. 1
19 40070A-207 • • MACHINE WASHER .......................................................... 1
XI-110
12
19 13
15 12
13
16
3
2
5
4
6
7
14
18
17
11
9 6
5
8
3
16
10
15
XI-111
6 7
2
3
19
8 11 17
10
XI-112
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
SA22141-13 #13-SIDE WATER VIBRATOR ASSEMBLY (See Fig 11-1, ...... REF
Item 27, for NHA)
1 22141-1 • CASTING - OSC BOX ............................................................. 1
2 110697 • END PLATE - 4 HOLE ............................................................ 1
3 119885 • END PLATE - 3 HOLE ............................................................ 2
6 62062RS • BEARING //SKF // .................................................................. 2
7 5203ATN9 • BEARING //MRC // ................................................................. 1
8 60072RS • BEARING // SKF // ................................................................. 1
9 103676-1 • WORM SHAFT W/RIGHT HAND THREADS - #13 SIDE ...... 1
10 70188 • GEAR - WATER OSCILLATOR .............................................. 1
11 127371 • WORM GEAR SHAFT - WATER OSCILLATOR .................... 1
12 HARDWARE • • 1/4 - 20 x 5/8 BUTTON HEAD CAP SCREW .................... 5
14 HARDWARE • • 5/16 X 1 3/4 KEY (705-020-020-148) .................................. 1
17 105603-3 • • SPOTTING BOLT ................................................................ 1
18 HARDWARE • • JAM NUT ............................................................................. 1
19 40070A-207 • • MACHINE WASHER .......................................................... 1
XI-113
36
40
30 31 5 4 41
8 28 29 7 6
26 42
27 3 2 1 (Set) 1 (Set)
18 17
12
25
13 33 33 23 24
14
34 35 10 37 35 9 36
38
11
39
20
16 15
32 19
21
Figure 11-37. Circ Assembly (1 of 3)
XI-114
1
2
4 9
8
5
10
13 14
12 15
16
20
18
19
17
Figure 11-37. Circ. Assembly (2 of 3)
XI-115
Photo Not Photo Not

Available Available
Item 23 Item 24
W-00 N-00
22
21
33
41 42
Figure 11-37. Circ. Assembly (3 of 3)
XI-116
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
SA51945 CIRC ASSEMBLY - 22 3/4” CUTOFF ............................................... REF

(See Fig 11-1, Item 18, for NHA)
SA51945-M CIRC ASSEMBLY - 22 3/4” CUTOFF - MOTORIZED ........................ REF
SA51945-2 CIRC ASSEMBLY - 22” CUTOFF ...................................................... REF
SA51945-2M CIRC ASSEMBLY - 22” CUTOFF - MOTORIZED .............................. REF
SA51945-3 CIRC ASSEMBLY - 21 1/2” CUTOFF ................................................ REF
SA51945-3M CIRC ASSEMBLY - 21 1/2” CUTOFF - MOTORIZED ........................ REF
1 49203-2 • GEAR HUB .................................................................................... 1
2 123610 • GEAR, 21 1/2” CUTOFF ................................................................ 1
106563-2 • GEAR, 22” CUTOFF ...................................................................... A/R
123939 • GEAR, 22 3/4” CUTOFF ................................................................ A/R
3 158497 • • SLIP WASHER - BRASS W/FLAT ............................................. 4
4 158456 • PLATE - INNER BEARING RETAINER ......................................... 1
5 1209ETN • SKF BEARING .............................................................................. 1
6 HARDWARE • • SHIM SET ................................................................................. 1
7 123590 • BEARING CAP - #10 GEAR INNER SPLINE ................................ 1
8 30475-1 • CIRC BEARING SUPPORT CASTING - A .................................... 1
9 30475-2 • CIRC BEARING SUPPORT CASTING - B .................................... 1
10 W6N • • 3/8 - 16 X 3/4 BALL PLUNGER // NOT MOTORIZED // ............ 1
11 HARDWARE • • 3/8 - 16 JAM NUT ..................................................................... 1
12 155726 • CIRC LOCATOR W/THREADED CENTER HOLE ........................ 1
13 128109 • CIRC ADJ SCREW ....................................................................... 1
14 SS4048-10 • 1 1/4 ID. X 1 1/2 OD. X 5/8 BUSHING ........................................... 1
15 SS2432-8 • 3/4 ID. X 1 OD. X 1/2 BUSHING// NOT MOTORIZED // ................. 1
16 SF2432-8 • 3/4 ID. X 1 OD. X .545 BUSHING W/FLANGE// NOT ..................... 1
MOTORIZED //
17 51945 • CIRC PLATE ................................................................................. 1
18 150279 • NEW CIRC ADJ - TOP GEAR// NOT MOTORIZED // ..................... 1
19 127766 • CIRC PLATE// NOT MOTORIZED // .............................................. 1
20 159749 • STUD - CIRC PLATE// NOT MOTORIZED // ................................. 1
21 127820 • NEW CIRC ADJ - LARGE GEAR// NOT MOTORIZED // ................ 1
22 159764 • NEW CIRC ADJ - LOWER GEAR // NOT SHOWN // NOT ............ 1
MOTORIZED //
23 W-00 • • WASHER .................................................................................. 1
24 N-00 • • NUT .................................................................................... 1
25 HARDWARE • • 5/16 X 1.450 DOWEL PIN ........................................................ 1
26 HARDWARE • • 1/2 - 13 X 1 1/2 SOCKET HEAD CAP SCREWS ...................... 4
27 HARDWARE • • 1/2 HI COLLAR LOCK WASHERS ........................................... 4
28 HARDWARE • • 1/4 - 20 X 3/4 SOCKET HEAD CAP SCREWS ......................... 4
29 HARDWARE • • 1/4 HI COLLAR LOCK WASHERS ........................................... 4
30 HARDWARE • • 10 - 24 X 5/8 SOCKET HEAD CAP SCREWS .......................... 4
31 HARDWARE • • #10 HI COLLAR LOCK WASHERS .......................................... 4
32 HARDWARE • • 3/4 EXTERNAL SNAP RING ..................................................... 1
33 DG58062 • • BRASS WASHER ..................................................................... 2
34 HARDWARE • • 5/16 - 18 X 7/8 SOCKET HEAD CAP SCREW ......................... 4
35 HARDWARE • • 5/16 HI COLLAR LOCK WASHERS ......................................... 6
36 HARDWARE • • 1/4 X 1 DOWEL PIN .................................................................. 2
37 HARDWARE • • 5/16 - 18 X 1 SOCKET HEAD CAP SCREW ............................ 2
38 HARDWARE • • 1/4 - 20 SOCKET HEAD SET SCREW - KNURLED POINT .... 1
39 HARDWARE • • 3/8 - 16 X 1 1/4 HEX HEAD BOLT ............................................ 2
40 HARDWARE • • 5/8 - 11 X 1 1/4 BUTTON HEAD CAP SCREW ........................ 1
41 148639-1 • BEARING LOAD WASHER - #10 GEAR SIDE .............................. REF
42 158414 • CIRC SPACER .............................................................................. 1
NOTE: CIRC SUB-ASSEMBLY IS STRICTLY DEPENDENT ON CUTOFF SIZE
AND MOTORIZED OPTION.
XI-117
XI-118
23
22
18
21
20
18
14 19
13 15
12
11
10
9
8
4 7 17
4 16 14
2
3
5
6
8
9
10
11 12 13
Figure 11-38. Drive Shaft (1 of 2)

Photo Not
Available
Item 1
95833-K
2 3 4
Photo Not Photo Not Photo Not

Available Available Available
Item 7 Item 8 Item 9

CDSS W-09 N-09
5 6
11
18
Photo Not
Available
Item 23
COMR+P
21
22
Figure 11-38. Drive Shaft (2 of 2)
XI-119
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY DRIVE SHAFT (See Fig 11-1, Item 33, for NHA) ....................... REF
1 95833-K • DRIVE SHAFT - FLOOR UNIT/STACK ................................... 1
94097-2 • DRIVE SHAFT - BASE UNIT 4 HIGH ..................................... A/R
116720-2 • DRIVE SHAFT - 2ND UNIT 4 HIGH ........................................ A/R
101902-2 • DRIVE SHAFT - 3RD UNIT 4 HIGH ........................................ A/R
101903-2 • DRIVE SHAFT - 4TH UNIT 4 HIGH ......................................... A/R
94097-2 • DRIVE SHAFT - SINGLE STACK ........................................... A/R
2 123347-1 • OIL SLINGER - #13 SIDE ....................................................... 1
3 123347-2 • OIL SLINGER - #10 SIDE ....................................................... 1
4 63092RS • BEARING ................................................................................ 2
5 40065-4003 • • #10 SIDE SPACER ............................................................. 1
6 62092RS • BEARING ................................................................................ 1
7 CDSS • • .020 PLASTIC SHIM ........................................................... 1
8 W-09 • • BEARING LOCK WASHER ................................................ 2
9 N-09 • • BEARING NUT .................................................................... 2
10 HARDWARE • • DRIVE SHAFT CAP SHIMS - 1 SET ................................. 1
11 158762-2 • • DRIVE SHAFT CAP ............................................................ 2
12 HARDWARE • • • 3/8 HI COLLAR LOCK WASHER ................................... 8
13 HARDWARE • • • 3/8 - 16 X 1 1/4 SOCKET HEAD CAP SCREWS .......... 8
14 HARDWARE • • • 3/8 X 2 KEY .................................................................... 2
15 HARDWARE • • • 5/16 X 2 3/4 ..................................................................... 1
16 HARDWARE • • • 3/8 - 16 X 1 SPOTTING BOLT ........................................ 1
17 HARDWARE • • • 3/8 - 16 JAM NUT ........................................................... 1
18 70178 • • • RING AND PINION SET ................................................. 1
19 HARDWARE • • • 1/2 - 13 X 2 SOCKET HEAD CAP SCREW .................. 6
20 HARDWARE • • • 1/2 HI COLLAR LOCK WASHER ................................... 6
21 3424-2 • • • SLIP WASHER - BRONZE ............................................ 6
22 108384 • • • SLIP HUB ........................................................................ 1
23 COMR+P • • • RING AND PINION SHIMS - 1 SET ............................... 1
XI-120
18
11
12
13
18
14
2 (Located on pump shaft)

17
1
3 7 19
5 4 8
16 9
6 14 16 10
Figure 11-39. Oil Pump Assembly (1 of 2)
XI-121
1
3
Photo Not
Available
Item 6
89CO492
5
11
10
Figure 11-39. Oil Pump Assembly (2 of 2)
XI-122
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY OIL PUMP ASSEMBLY .............................................................. REF

1 116628 • OIL PUMP GEAR .................................................................... 1
2 HARDWARE • WOODRUFF KEY (12574) ..................................................... 1
3 1AC • OIL PPUMP // TUTHIL // ......................................................... 1
4 762948-46 • OIL FILTER .............................................................................. 1
5 B5631 • OIL SIGHT GLASS .................................................................. 1
6 89CO492 • 1/2 PIPE PLUG (OIL DRAIN) / NS / ....................................... 1
10 116616 • • OIL PUMP BRACKET ......................................................... 1
11 119966 • • HOLDER CLIPS .................................................................. 4
13 HARDWARE • • • 1/4 - 20 X 1/2 ROUND HEAD MACHINE SCREW ........ 4
14 HARDWARE • • 95 - LB - 04 X 04 FITTING ................................................... 1
18 HARDWARE • • • 1/4 OD SOFT COPPER TUBING ................................... 10 FT
19 HARDWARE • • • 1/2 OD SOFT COPPER TUBING ................................... 2 FT
XI-123
7
XI-124
6
10
9
7
7
10
2
5
8
9
4
3 Figure 11-40. Gear Side Cover (1 of 2)

Photo Not
Available
Item 9
95801
Figure 11-40. Gear Side Cover (2 of 2)
XI-125
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY GEAR SIDE COVER (See Fig 11-1, Item 34, for NHA) ............. REF
1 16431-2 • COVER W/DOORS AND HANDLES ..................................... 1
16431-4 • COVER W/DOORS AND HANDLES // MOTORIZED OPTION// 1
2 HARDWARE • • • CAUTION LABEL ............................................................ 1
4 DG006 • MYLAR ................................................................................ AR
5 HARDWARE • • CORK GASKET MATERIAL - 13 FT .................................. 1
6 145211-2 • PLATE - TOP .......................................................................... 2
8 DG897PLT • INSIDE LEG COVER (STACK UNIT) ...................................... 2
9 95801 • OUTSIDE LEG COVER (STACK UNIT) .................................. 2
XI-126
6 2
Figure 11-41. Paper Roll Sidelay (1 of 2)
XI-127
Figure 11-41. Paper Roll Sidelay (2 of 2)
XI-128
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
SA71624 PAPER ROLL SIDELAY ASSEMBLY (See Fig 11-1, Item 36, . REF
for NHA)
1 71624 • SIDELAY HANDWHEEL ......................................................... 1
2 144371 • BRACKET, BRAKE SIDELAY ................................................ 1
5 108466-1 • • SIDELAY SCREW 9 1/4 ..................................................... 1
NOTE: ASSEMBLY SA71624 IS MAINTAINED IN THIS MANUAL FOR RECORD PURPOSES ONLY.
XI-129
5
9
7 3
9
2
4
5
8
1
Figure 11-42. Paper Roll Brake (1 of 2)
XI-130
1 2
3 6
Figure 11-42. Paper Roll Brake (2 of 2)
XI-131
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
SA94282-3 PAPER ROLL BRAKE (See Fig 11-1, Item 37, fro NHA) .......... REF
1 94282-3 • UPPER/LOWER BRAKE SHOE LEVER ............................... 2
2 97326 • • BRAKE SHOE (NEW STYLE 1 PC) .................................. 2
3 97325 • • BRAKE BLOCK WOODEN ................................................ 2
4 HARDWARE • • 3/4 X 2 1/2 WORKING DISTANCE CLEVIS PIN ................ 2
5 HARDWARE • • #10 X 1 PHILLIPS HEAD WOOD SCREW ........................ 8
6 106700 • • BRAKE SHOE KNOB ......................................................... 1
7 119892-2 • • BRAKE TENSION SCREW ................................................ 1
9 HARDWARE • • 1/8 X 1 1/2 COTTER PIN .................................................... 2
XI-132
26
27
25
24
28
12 14
13 23
11
10 22
8 9 21
7
5
6
19
20
17
16
18
3 15
4
29
2
30
1
Figure 11-43. Paper Roll Sidelay and Brake Assembly (1 of 2)
XI-133
2
1
8 11
5 7
20
18 25 30
21
15
29
32 33
34
31
39 41
38
36
40
35 37
42
44
43 45
Figure 11-43. Paper Roll Sidelay and Brake Assembly (2 of 2)
XI-134
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY PAPER ROLL SIDELAY AND BRAKE (See Fig 11-1, .............. REF
Item 35 for NHA)
1 SA94282-3 • BRAKE ASSEMBLY ............................................................... 1
2 144371 • BRACKET, BRAKE SIDELAY ................................................ 1
3 HARDWARE • • 3/8 - 16 X 1 SOCKET HEAD SET SCREW ....................... 1
4 HARDWARE • • 3/8 - 16 JAM NUT ............................................................... 1
5 54484 • BRAKE DRUM (OPTIONAL) ................................................... 1
7 144365 • ECCENTRIC SHAFT ............................................................... 1
8 140764 • ROLL LIFTING STUD .............................................................. 2
11 122916 • ECCENTRIC SHAFT BUSHING .............................................. 1
12 HARDWARE • • 1/8 - 27 NPT GREAST FITTING - 90 DEG. ........................ 1
13 HARDWARE • • 7/8 - 14 JAM NUT ............................................................... 4
15 897322-3 • SIDELAY BAR ........................................................................ 1
16 HARDWARE • • 3/8 - 16 X 2 SQUARE HEAD SET SCREW ....................... 2
17 HARDWARE • • 3/8 - 16 JAM NUT ............................................................... 2
18 108418-3 • POPPET - SIDELAY LEVER STOP ....................................... 2
19 HARDWARE • • 1/4 - 20 X 1/2 MACHINE SCREW ...................................... 4
20 149042 • PLATE - POPPET KEEPER .................................................. 2
21 CF 2 1/4 S • 2 1/4 MCGILL CAM FOLLOWER ........................................... 4
22 HARDWARE • • 1/4 PRESS FIT GREASE FITTING .................................... 4
23 HARDWARE • • 1/2 - 13 NUT ........................................................................ 1
25 94291 • ECCENTRIC BRAKE LEVER ................................................. 1
26 HARDWARE • • 1/8 X 1 COTTER PIN ........................................................... 1
28 HARDWARE • • 5/8 X 1 1/2 WORKING DISTANCE CLEVIS PIN ................ 1
29 108466-1 • SCREW, SIDLAY 7” BRAKE DRUM ...................................... 1
30 77214 • KNOB, SIDELAY ADJUSTMENT ........................................... 1
31 68-10-101-20 LATCH, GUARD // NS // ............................................................. 1
32 77213-2 PLATE, MOUNTING BRACKET GUARD // NS // ...................... 1
33 77211-2 BRACKET, GUARD COVER LOWER // NS // ........................... 1
34 77212-2 BRACKET, GUARD COVER UPPER // NS // ........................... 1
35 77210-2 GUARD, PAPER ROLL BRAKE // NS // .................................... 1
36 77215 BRACKET, BRAKE GUARD HANDLE //NS // ........................... 1
37 TV8S-335-02Z SWITCH, INTERLOCK // NS // ................................................... 1
38 97543 TENSION SCREW THREADED POPPET // NS // .................... 1
39 97542 BALL, TENSION CONTROL // NS // .......................................... 1
40 140856 SPRING, TENSION SCREW ROD // NS // ................................ 1
41 109657 KNOB, TENSION SCREW ROD KNURL // NS // ...................... 1
42 108892 ROD, LINKAGE TENSION SCREW // NS // .............................. 1
43 77216 PLATE, SWITCH COVER // NS // .............................................. 1
44 77217 BRACKET, COVER SUPPORT // NS // ..................................... 1
45 ACP-77001 HANDWHEEL WITH SOCKET, PAPER ROLL SIDELAY // NS // 1
XI-135
12
8
9
8
11
10
2
3 4
13
14
1
5
2
3
4
6
7
5
6 7
Figure 11-44. Belt Register (1 of 2)
XI-136
5
6
9
10
14
11
Figure 11-44. Belt Register (2 of 2)
XI-137
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
SADG89706 BELT REGISTER ASSEMBLY (See Fig 11-1, Item 38 for NHA)
REF
1 DG89701 • BACKING PLATE .................................................................... 1
2 DG89704 • • ADJUSTING STUD BRACKET ........................................... 2
4 HARDWARE • • • 1/4 - 20 X 3/4 HEX HEAD BOLT ..................................... 6
5 DG89702-3 • • IDLER PULLEY MOUNTING BLOCK ................................. 1
6 DG89707 • • IDLER PULLEY ................................................................... 2
7 HARDWARE • • SNAP RING (5100-37) ........................................................ 2
8 HARDWARE • • 1/2 STEEL THREADED COLLAR ...................................... 2
9 DG89706 • • BELT REGISTER SUPPORT ............................................. 1
10 DG89710 • • HANDLE STUD ................................................................... 1
11 RC - 4A • • HANDLE .............................................................................. 1
12 HARDWARE • • 1/8 X 1 1/4 SPRING PIN ..................................................... 1
13 HARDWARE • • 1/2 X 3/4 SPRING PIN ........................................................ 1
14 DG89711 • • SPACER (4 HIGH ONLY) ................................................... 4
XI-138
8
6 10
9 12
11
3 3 4 5
2 7
7
8
10 15
4 8 10
9
7
8 16
7
1 2 14 13
9 5 7
4 7
8
9 5 8
10 10
5
9 6
10 5 4 3
9
10
1 2
4
5
XI-139
Figure 11-45. Optional Pneumatic Assembly (1 of 2)
Photo Not
Available
Item 2
172DP
5 6
11
7
Photo Not Photo Not

Available Available
Item 13 Item 18
I34 SCHRADER430KIT
16
12a 12b
Figure 11-45. Optional Pneumatic Assembly (2 of 2)
XI-140
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY PNEUMATICS (OPTIONAL) (See Fig 11-1, Item 39, for NHA) .. REF
1 HARDWARE • • 3/8 EXTERNAL SNAP RING .............................................. 6
2 172DP • BIMBA SMALL PNEUMATIC CYLINDER .............................. 6
3 HARDWARE • • 90 DEG. MALE ELBOW (CAMOZZI) ................................. 12
4 HARDWARE • • 7/16-20 JAM NUT ................................................................ 6
5 CFF7 • ROD END - SMALL CYLINDER ............................................. 6
6 157606 • PNEUMATIC STUD - THROW-OFF ....................................... 6
7 94997 • THROW-OFF COLLAR ........................................................... 6
10 HARDWARE • • 7/16 - 14 SOCKET HEAD CAP SCREW ........................... 6
11 156136-5 • • 1/2 X 2 LINKAGE PIN ......................................................... REF
12a 157601-3 • PNEUMATIC IMPRESSION COUPLING - 21 1/2” ONLY ...... REF
b 157601-2 • PNEUMATIC IMPRESSION COUPLING - 22 3/4” ................. REF
13 I34 • PNEUMATIC IMPRESSION CYLINDER W/JAM NUT ........... REF
14 HARDWARE • • 7/16 EXTERNAL SNAP RING ............................................ REF
15 HARDWARE • • 10 - 24 X 3/8 SOCKET HEAD SET SCREW W/NYLOCK REF
16 157605 • PNEUMATIC STUD - IMPRESSION ....................................... REF
17 HARDWARE • • 1/4 0D AIR LINE // NS // ..................................................... 32 FT.
18 SCHRADER430KIT • 430 PNEUMATIC KIT .............................................................. 1
XI-141
5
6
4
2
Figure 11-46. Blanket Cylinder Throw-Off Linkage - Optional Pneumatics (1 of 2)
XI-142
Photo Not
Available
Item 4
I34
2
5a 5b
Figure 11-46. Blanket Cylinder Throwoff Linkage - Optional Pneumatics (2 of 2)
XI-143
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY BLANKET CYLINDER THROW-OFF LINKAGE - OPTIONAL ... REF

PNEUMATICS (See Fig 11-1, Item 40 for NHA)
1 HARDWARE • 10-24 X 3/8 SOCKET HEAD SET SCREW W/NYLOCK ....... 1
2 157605 • PNEUMATIC STUD - IMPRESSION ....................................... 1
3 HARDWARE • • 7/16 EXTERNAL SNAP RING ............................................ 1
4 I34 • PNEUMATIC IMPRESSION CYLINDER W/JAM NUT ........... 1
5a 157601-3 • • PNEUMATIC IMPRESSION COUPLING - 21 1/2” ONLY .. 1
b 157601-2 • • PNEUMATIC IMPRESSION COUPLING - 22” AND .......... A/R
22 3/4” ONLY
6 156136-5 • • • 1/2 X 2 LINKAGE PIN ..................................................... 1
XI-144
11 Ink Transfer Roller
10 Ink Transfer Roller
9 Outside Ink Form Roller
2 8 Water Form Roller

3 2
3
7 Water Pick-Up Roller
A 12 Inside Ink Form Roller
4 4
A 1 5 6 5
Figure 11-47. Rubber Rollers
XI-145
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY RUBBER ROLLERS (See Fig 37, Item 41, for NHA) ................. REF
1 126209 • FORM ROLLER SHAFT ......................................................... 6
HARDWARE • • 1/4 - 20 X 2 HEX HEAD BOLT (FORM ROLLER BRACKET) 6
3 HARDWARE • • 1/4 ZIP WASHER ............................................................... 12
4 HARDWARE • • 1/4 - 20 X 1 1/2 SOCKET HEAD CAP SCREW W/NYLOCK 12
5 HARDWARE • • BEARING ............................................................................ 12
6 HARDWARE • • RUBBER ROLLER .............................................................. 6
Roller Positions
7 WATER PICKUP ROLLER (1 7/8” x 2.750” x 35 1/2” x 36 1/2”) .............................. 2
8 WATER FORM ROLLER (1 7/8” x 2.750” x 35 1/2” x 36 1/2”) ................................. 2
9 OUTSIDE INK FORM ROLLER (1 7/8” x 2.875” x 35 3/8” x 36 1/2”) ...................... 2
10 INK TRANSFER ROLLER (1 7/8” x 2.750” x 35 1/2” x 36 1/2”) ............................... 1
11 INK TRANSFER ROLLER (1 7/8” x 2.750” x 35 1/2” x 36 1/2”) ............................... 1
12 INSIDE INK FORM ROLLER (1 7/8” x 2.750” x 35 3/8” x 36 1/2”) .......................... 2
(#10 SIDE SHOWN)
XI-146
5
5
1
3 3 3
4
5
5
Figure 11-48. Nip Guards (1 of 2)
XI-147
Figure 11-48. Nip Guards (2 of 2)
XI-148
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY NIP GUARDS (10-SIDE SHOWN) (See Fig 11-1, Item 42, ....... REF
for NHA)
1 888IF-1 • GUARD - INK FORM - INSIDE ............................................... 2
2 93258 • GUARD - INK FORM - OUTSIDE ........................................... 2
4 888WF-1 • GUARD - WATER FORM - OUTSIDE .................................... 2
5 HARDWARE • • 1/4-20 x 1 1/2 SOCKET HEAD CAP SCREW ................... 4
XI-149
13
12
11
4
1
7 8 65
4 5 1
9
2 13
11
1 6
8 12 7
9 13
1 12
10 11 3
15 10
14
Figure 11-49. Roller Guards (1 of 2)

XI-150
1 1
9
5
7
1
11
11 11
Figure 11-49. Roller Guards (2 of 2)
XI-151
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY ROLLER GUARDS (See Fig 11-1, Item 43, for NHA) ................ REF
1 68-10-101-20 • HANDLE - DOOR LOCK ......................................................... 4
2 SA888OG • ASSEMBLY - OPERATOR SIDE ROLLER GUARD ............. 1
3 SA888GG-2 • ASSEMBLY - GEAR SIDE ROLLER GUARD ....................... 1
4 HARDWARE • • 5/16 X 3/4 SHOULDER BOLT ............................................ 2
5 ST14-RA-B1 • INTERLOCK KEY - RIGHT ANGLE ........................................ 2
6 HARDWARE • • 8-32 X 1/2 SOCKET HEAD MACHINE SCREW ................ 4
7 ST14-20K • INTERLOCK SWITCH W/O KEY ............................................ 2
8 HARDWARE • • 1/4 - 20 X 3/4 FLAT HEAD ALLEN HEAD SCREW ........... 4
9 888SB • SPACER BLOCK - SWITCH .................................................. 2
10 HARDWARE • • 5/16 X 1/2 SHOULDER BOLT ............................................ 4
11 888LP • LATCH PLATE - ROLLER GUARD ........................................ 4
14 888GM-3 • MOUNT - ROLLER GUARD - GEAR SIDE ............................ 1
15 888GM-4 • MOUNT - ROLLER GUARD - OPERATOR SIDE .................. 1
XI-152
3
1
2
3
2
3
3 3
3
2
3
2
Figure 11-50. Upper Roller Guard (1 of 2)
XI-153
Figure 11-50. Upper Roller Guard (2 of 2)
XI-154
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY UPPER ROLLER GUARD // 10-SIDE SHOWN // ...................... REF

1 888RG-4 • ROLLER GUARD .................................................................... 2
2 888GM-2 • MOUNT - ROLLER GUARD .................................................... 8
XI-155
Inside of frame 3
5
4 6
Figure 11-51. Outer Roller Guard (1 of 2)
XI-156
5 6
Figure 11-51. Outer Roller Guard (2 of 2)
XI-157
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY OUTER ROLLER GUARD // 13-SIDE SHOWN // (See Fig ....... REF
11-1, Item 45, for HNA)
1 888RG-5-1 • ROLLER GUARD, 22 3/4” CUTOFF ....................................... 2
888RG-5-2 • ROLLER GUARD, 22” CUTOFF ............................................. 2
888RG-5-3 • ROLLER GUARD, 21 1/2” CUTOFF ....................................... 2
888RG-5-1GMI • ROLLER BUARD // FOR USE WITH GMI PACKAGE .......... 2
2 ST14-20K • INTERLOCK SWITCH W/KEY ................................................ 2
3 19-14-10 • HANDLE, SWELL LATCH ...................................................... 4
5 888SB • SPACER BLOCK - SWITCH .................................................. 2
6 ST14-B • KEY, CLOSE RADIUS ............................................................ 2
XI-158
7
6
4
5
3
2
1
9 Figure 11-52. Operator Side Cover (1 of 2)
XI-159
7
7
3
Figure 11-52. Operator Side Cover (2 of 2)
XI-160
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY OPERATOR SIDE COVER (See Fig 11-1, Item 46, for NHA) ... REF
1 16418-3 • OPERATOR SIDE COVER - 21 1/2" ...................................... 1
16418-2 • OPERATOR SIDE COVER - 22" ............................................ A/R
16418 • OPERATOR SIDE COVER - 22 3/4" ...................................... A/R
16418-1-2 • OPERATOR SIDE COVER - 22 3/4" // PNEUMATIC ............ A/R
OPTION//
16418-2-2 • OPERATOR SIDE COVER - 22" // PNEUMATIC OPTION //A/R
16418-3-2 • OPERATOR SIDE COVER - 21 1/2" // PNEUMATIC ............ A/R
OPTION//
16418-1-4 • OPERATOR SIDE COVER - 22 3/4” // PNEUMATIC AND ... A/R
MOTORIZATION OPTION //
3 108703 • COVER MOUNTING BLOCK .................................................. 7
5 HARDWARE • • 5/16 FLAT WASHER .......................................................... 7
6 144608-1 • THROW-OFF RODS - 5" // NOT USED WITH PNEUMATICS // 10
7 B-8 • • BLACK BALL // NOT USED WITH PNEUMATICS // ......... 10
8 HARDWARE • • • CAUTION STICKER ........................................................ 1
9 HARDWARE • • • DGM-430 NAME PLATE ................................................ 1
XI-161
5
6
7
5 4
6
7
Figure 11-53. Color Drop Roller (1 of 2)
XI-162
3
1
Figure 11-53. Color Drop Roller (2 of 2)
XI-163
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY COLOR DROP ROLLER // 13 SIDE SHOWN// (See Fig 11-1, . REF
Item 47, for NHA)
1 108425 • 1 7/8 PIPE ROLLER ............................................................... 1
3 108642-6 • 3/4 ROLLER SHAFT W/THREADS - 42 1/2 .......................... 1
5 161384 • COLOR DROP BRACKET ...................................................... 2
XI-164
2
5
6
4 7
Figure 11-54. Lead-In Roller - Base Unit (1 of 2)
XI-165
Figure 11-54. Lead-In Roller - Base Unit (2 of 2)
XI-166
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY LEAD-IN ROLLER (BASE UNIT ONLY) (See Fig 11-1, ............. REF
Item 48, for NHA)
1 108643-2 • 3/4 TGP ROLLER SHAFT - 44 1/2 LONG .............................. 3
3 108425 • • 1 7/8 LEAD-IN PIPE ROLLER ............................................ 3
NOTE: CENTER ROLLER MAY BE REPLACED WITH A FAN-OUT ROLLER, P/N LTC100103.
XI-167
XI-168
13
1
3 12
10
11
9
2
4 3
5 2
6
7
12
14
13 18
10 21
11
15 23
16
17
19
20
Figure 11-55. Lead-In Roller and Under Unit Compensator Assembly - Stack Unit (1 of 2)
2
6
8
1
10
9
15 16
22
17 20
Figure 11-55. Lead-In Roller and Under Unit Compensator Assembly - Stack Unit (2 of 2)
XI-169
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY LEAD-IN ROLLER AND SWING COMP (STACK UNIT ONLY) . REF
1 108643-2 • 3/4 TGP ROLLER SHAFT - 44 1/2 LONG .............................. 1
3 108425 • 1 7/8 LEAD-IN PIPE ROLLER ................................................ 3
10 145225 • COMP BRACKET ................................................................... 2
12 HARDWARE • • 5/16 - 18 X 1 1/4 SOCKET HEAD CAP SCREW .............. 2
14 HARDWARE • • 1/2 X 3/8 SHOULDER BOLT .............................................. 1
15 145227 • COMP SCREW ....................................................................... 1
16 145228 • COMP ROD ............................................................................. 1
17 145229 • COMP BLOCK W/ 3/8 STUD ................................................. 1
18 HARDWARE • • 1/4 - 20 THUMB SCREW ................................................... 1
19 HARDWARE • • 1/2 SET COLLAR ................................................................ 1
20 145228-2 • COMP ROD EXTENSION ....................................................... 1
22 RC3A • HANDLE ................................................................................ 1
23 HARDWARE • • 1/8 X 1 ROLL PIN ................................................................ 1
XI-170
26
1
24
23
24
11 3
25
5
2
3
9 1
26
12 7
10 6 4
5
7 11
16
14
8 13 19
15 13
9
10
12
21
22
18
20
17
10
9
Figure 11-56. B1 Swing Compensator (1 of 2)
XI-171
7
1
3
4
2
6
16
11 14 18
8 15
20
23
24 25
Figure 11-56. B1 Swing Compensator (2 of 2)
XI-172
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY B1 SWING COMPENSATOR (See Fig 11-1, Item 50, for NHA) REF
1 E5064-SET • B1 TOP IRON - PAIR .............................................................. 1
2 53429-3 • 3 X 36 PIPE ROLLER ............................................................. 1
3 ERX20XLOA • BEARING ................................................................................ 2
4 96343-1 • 1 1/4 ROLLER SHAFT - 42 1/4 .............................................. 1
5 HARDWARE • 1/2 X 2 1/2 ROLL PIN .............................................................. 4
6 108425 • 1 7/8 PIPE ROLLER ............................................................... 1
8 108643-4 • 3/4 ROLLER SHAFT - 39 1/2 .................................................. 1
11 B108747-3 • BRACKET - 1 1/4 COMP ........................................................ 2
13 HARDWARE • • 5/8 - 11 JAM NUT ............................................................... 4
14 148582 • COMP SWIVEL PIN ............................................................... 1
15 148403 • COMP SCREW ....................................................................... 1
16 148489 • SCREW POPPET ................................................................... 1
18 RC3A • HANDLE ................................................................................ 1
20 148406-3 • COMP HANDWHEEL BRACKET ........................................... 1
21 HARDWARE • • 1/4 - 20 JAM NUT ............................................................... 1
22 HARDWARE •
• 1/4 - 20 X 3/8 SOCKET HEAD SET SCREW .................... 1
// SA108642-2 PIPE ROLLER (WITH SHAFT) ASSEMBLY) //
23 108425 • PIPE ROLLER - 1 7/8 ............................................................. 3
25 108642-2 • SHAFT - PIPE ROLLER - 39 3/4 W/THREADED ENDS ....... 3
XI-173
46
52 43
40 4
XI-174
3 50
8 47 57
32 19 24
5 17
47 45 41 42 29
48
31 20 28
6 8
48
17 29
5
2 47
40 50 53
38 39 25
10 22
23
6 24
33 57
32 47 29 22
54
29
28 54
53
39
28
29
50
29 20 18
47 38
26 42 48
27
48
38 45 48
9 41 19
7
47 33 18 48
35 13 50
32 15 48
34 4 43 48
44 51
5 10 43 16 21
48
12 49
37
1 47 46
36 55
40 3 40
47 52 56 14 48
Figure 11-57A. Full Motorized Compensator (Pre-2001) (1 of 4)
11 47
16
56
5 6
4
3
1 2
Photo Not
Available
12a
Item 11
BGFM-15-25-S60
9 10
8
12b
13 14 15
16
Figure 11-57A. Full Page Motorized Compensator - Pre-2001 (2 of 4)
XI-175
19 20
18
17
21
23
24
22
26 27
25
28
31
29 30 32 33
35
34
XI-176
36
38
37a 37b
61
59 60
58
64
62 63 65
XI-177
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY FULL PAGE MOTORIZED COMPENSATOR // PRE-2001 // .... REF

1 DG895-RH • RIGHT HAND SUPPORT PLATE ........................................... 1
2 DG895-LH • LEFT HAND SUPPORT PLATE ............................................. 1
3 DG895-1 • SUPPORT LEG ....................................................................... 2
4 DG895-2 • SUPPORT LEG ....................................................................... 2
5 DG895-3 • SUPPORT BLOCK .................................................................. 4
6 DG895-4L • LEFT HAND ADJUSTING SCREW BLOCK ........................... 1
7 DG895-4R • RIGHT HAND ADJUSTING SCREW BLOCK ......................... 1
8 DG895-5L • COMP SCREW - LEFT HAND THREAD ............................... 1
9 DG895-5R • COMP SCREW - RIGHT HAND THREAD ............................. 1
10 DG895-6 • SUPPORT ROD ...................................................................... 2
11 BGFM-15-25-S60 • MOTOR ................................................................................ 1
12a DG895MP-R • • MOTOR MOUNT - RIGHT (13 SIDE MOUNT) .................... 1
b DG895MP-L • • MOTOR MOUNT - LEFT (10 SIDE MOUNT) ...................... 1
13 DG895MPS • • MOTOR MOUNT SPACER ................................................. 1
14 DG1236 • BEVEL GEAR ......................................................................... 1
15 DG1218-1 • BEVEL GEAR ......................................................................... 1
16 DG895MC-1, -2 • • MOTOR GEAR COVER - 2 PC .......................................... 1
17 DG895LHC • • LEFT HAND GEAR COVER - 2 PC ................................... 1
18 DG895RHC • • RIGHT HAND GEAR COVER - 2 PC ................................. 1
19 DG1224-50 • BEVEL GEAR - 1/2 BORE ..................................................... 2
21 HT11R • • HANDLE .............................................................................. 1
22 108643-18 • • 24 X 3/4 SHAFT .................................................................. 2
23 ISCC-075-075 • COUPLING .............................................................................. 1
24 E5064-SET • B-1 TOP IRON - PAIR ............................................................. 1
25 108642-2 • SHAFT - PIPE ROLLER - 39 3/4 W/THREADED ENDS ....... 3
26 108643-4 • SHAFT - PIPE ROLLER - 39 1/2 ............................................ 1
27 108643-5 • SHAFT - PIPE ROLLER - 42 .................................................. 1
28 108425 • PIPE ROLLER - 1 7/8 ............................................................. 5
30 SS2432-20 BUSHING - HANDLE SHAFT - MOTOR SIDE .......................... 1
31 SS2432-8 • BUSHING - HANDLE SHAFT - NON - MOTOR SIDE ............ 1
32 SS1620-12 • BUSHING - COMP SCREW ................................................... 4
33 SS3240-24 • BUSHING - SUPPORT ROD .................................................. 2
34 80MXL025 • BELT - COUNTER ................................................................... 1
35 72MXL025 • COUNTER GEAR - COMP SHAFT ........................................ 1
36 10MXL025 • • COUNTER GEAR - COUNTER .......................................... 1
37a 5X71LAC101 • • COUNTER - LEFT HAND .................................................... 1
b 5X71RAC101 • • COUNTER - RIGHT HAND .................................................. 1
XI-178
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
38 DG895-7 • • BUSHING - B1 TOP IRON .................................................. 2

39 HARDWARE • • • 1/2 X 2 1/2 ROLL PIN ..................................................... 4
40 HARDWARE • • • 5/15 - 18 X 1 FLAT HEAD SOCKET HEAD SCREW .... 16
41 HARDWARE • • • 1/2 E-CLIPS .................................................................... 2
42 HARDWARE • • • 1/2 FLAT WASHER ........................................................ 2
43 HARDWARE • • • 5/16 LOCK WASHER ..................................................... 6
44 HARDWARE • • • 5/16 - 18 X 1 SOCKET HEAD CAP SCREW ................ 2
45 HARDWARE • • • 5/16 - 18 X 1 1/4 SOCKET HEAD CAP SCREW .......... 4
46 HARDWARE • • • 5/16 - 18 X 1 1/4 HEX HEAD BOLT ............................... 4
47 HARDWARE • • • 5/16 - 18 X 3/8 SOCKET HEAD SET SCREW .............. 8
48 HARDWARE • • • 1/4 - 20 X 3/8 SOCKET HEAD SET SCREW ................ 12
49 HARDWARE • • • 10 - 32 X 1/2 MACHINE SCREW ................................... 3
52 HARDWARE • • • 3/4 X 1 SHOULDER BOLT ............................................. 2
54 HARDWARE • • • 5/8 - 11 JAM NUT ........................................................... 2
55 HARDWARE • • • 6 - 32 X 1/4 MACHINE SCREW ..................................... 4
57 HARDWARE • • • 1/2 - 13 X 1 3/4 HEX HEAD BOLT ................................. 2
58 COMP-BOX • • ELECTRICAL BOX //NS// ................................................... 1
59 T3043 • • SWITCH SELECT SPRING RETURN //NS// ...................... 1
60 T2 • • BLOCK, CONTACT, 2 NORMALLY OPEN //NS// ............. 1
61 TM50 • • LEGEND PLATE, OFF/REVERSE //NS// .......................... 1
62 E-1PB • • ONE HOLE STATION BOX - HOFFMAN (STACKED UNITS 1
AND 3 AND 4 HIGHS ONLY) //NS//
63 COMP-BOX-C • • COVER, ELECTRICAL BOX // NS // .................................. 1
64 2W938 • • SWITCH, ELECTRICAL // NS // ......................................... 2
65 DG895-9 • • BRACKET // NS // .............................................................. 1
Page 179
40
46 37
34 44
Page 180
51
41
27 14 19
1 12
39 35 36 24
41 42
26 15 23
2 4
42
12 24
1
41 44
34 47
33 20
6 17
18
2 19
28 51
27 41 24 17
48
28 48
47
33
24
44
15 13
41 38
22 36 42
42
39 42
5 35 14
3
41 28 13 42
30 44
27 10 42
29 37 42
38 45
1 6 37 11 16
42
8 43
32
31 49 41 40
34 34
41 46 50 9 42
Figure 11-57B. Full Motorized Compensator (Post-2001) (1 of 4)
7 25
11
50
3
2
1
5 6
4
8a
8b
7 9
10
11
12
Figure 11-57B. Full Page Motorized Compensator - Post 2001 (2 of 4)
Page 181
15 16 18
14
17
13
19 20
24 25 28
26 27 30
29
31
32a
32b
21 22
23 52
Page 182
54
53 55
56
57
58
60
59
Page 183
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY FULL PAGE MOTORIZED COMPENSATOR // POST-2001 // .. REF

1 DG895-3 • SUPPORT BLOCK .................................................................. 4
2 DG895-4L • LEFT HAND ADJUSTING SCREW BLOCK ........................... 1
3 DG895-4R • RIGHT HAND ADJUSTING SCREW BLOCK ......................... 1
4 DG895-5L • COMP SCREW - LEFT HAND THREAD ............................... 1
5 DG895-5R • COMP SCREW - RIGHT HAND THREAD ............................. 1
6 DG895-6 • SUPPORT ROD ...................................................................... 2
7 BGFM15-040SFICX • MOTOR ................................................................................ 1
8a DG895MP-R • • MOTOR MOUNT - RIGHT (13 SIDE MOUNT) .................... 1
b DG895MP-L • • MOTOR MOUNT - LEFT (10 SIDE MOUNT) ...................... 1
9 DG1236 • BEVEL GEAR ......................................................................... 1
10 DG1218-1 • BEVEL GEAR ......................................................................... 1
11 DG895MC-1, -2 • • MOTOR GEAR COVER - 2 PC .......................................... 1
12 DG895LHC • • LEFT HAND GEAR COVER - 2 PC ................................... 1
13 DG895RHC • • RIGHT HAND GEAR COVER - 2 PC ................................. 1
16 HT11R • • HANDLE .............................................................................. 1
17 108643-18 • • 24 X 3/4 SHAFT .................................................................. 2
18 ISCC-075-075 • COUPLING .............................................................................. 1
19 E5064-3-SET • B-1 TOP IRON - PAIR ............................................................. 1
20 SA108642-2 • SHAFT - PIPE ROLLER - 39 3/4 W/THREADED ENDS ....... 5
21 108643-4 • SHAFT - PIPE ROLLER - 39 1/2 ............................................ 1
22 108643-5 • SHAFT - PIPE ROLLER - 42 .................................................. 1
23 108425 • PIPE ROLLER - 1 7/8 ............................................................. 1
25 SS2432-12 BUSHING - HANDLE SHAFT - MOTOR SIDE .......................... 1
26 SS2432-10 • BUSHING - HANDLE SHAFT - NON - MOTOR SIDE ............ 1
27 SS1620-12 • BUSHING - COMP SCREW ................................................... 4
28 SS3240-24 • BUSHING - SUPPORT ROD .................................................. 2
29 80MXL025 • BELT - COUNTER ................................................................... 1
30 72MXL025 • COUNTER GEAR - COMP SHAFT ........................................ 1
31 10MXL025 • • COUNTER GEAR - COUNTER .......................................... 1
32a 5X71LAC101 • • COUNTER - LEFT HAND .................................................... 1
b 5X71RAC101 • • COUNTER - RIGHT HAND .................................................. 1
33 HARDWARE • • • 1/2 X 2 1/2 ROLL PIN ..................................................... 4
34 HARDWARE • • • 5/15 - 18 X 1 FLAT HEAD SOCKET HEAD SCREW .... 16
35 HARDWARE • • • 1/2 E-CLIPS .................................................................... 2
36 HARDWARE • • • 1/2 FLAT WASHER ........................................................ 2
37 HARDWARE • • • 5/16 LOCK WASHER ..................................................... 6
Page 184
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
38 HARDWARE • • • 5/16 - 18 X 1 SOCKET HEAD CAP SCREW ................ 2

39 HARDWARE • • • 5/16 - 18 X 1 1/4 SOCKET HEAD CAP SCREW .......... 4
40 HARDWARE • • • 5/16 - 18 X 1 1/4 HEX HEAD BOLT ............................... 4
41 HARDWARE • • • 5/16 - 18 X 3/8 SOCKET HEAD SET SCREW .............. 8
42 HARDWARE • • • 1/4 - 20 X 3/8 SOCKET HEAD SET SCREW ................ 12
46 HARDWARE • • • 3/4 X 1 SHOULDER BOLT ............................................. 2
48 HARDWARE • • • 5/8 - 11 JAM NUT ........................................................... 2
51 HARDWARE • • • 1/2 - 13 X 1 3/4 HEX HEAD BOLT ................................. 2
52 COMP-BOX • • ELECTRICAL BOX //NS// ................................................... 1
53 T3043 • • SWITCH SELECT SPRING RETURN //NS// ...................... 1
54 T2CP • • BLOCK, CONTACT, 2 NORMALLY OPEN //NS// ............. 1
55 TM50 • • LEGEND PLATE, OFF/REVERSE //NS// .......................... 1
56 E-1PB • • ONE HOLE STATION BOX - HOFFMAN (STACKED UNITS 1
AND 3 AND 4 HIGHS ONLY) //NS//
57 COMP-BOX-C • • COVER, ELECTRICAL BOX // NS // .................................. 1
58 2W938 • • SWITCH, ELECTRICAL // NS // ......................................... 2
59 DG895-9 • • BRACKET, LIMIT SWITCH MOUNTING // NS // ................ 1
60 DG895-10 • CONDUIT SUPPORT BRACKET ............................................ 1
Page 185
6 7 6
10
11
7
12
7 11
6 11
10 10
11
10 7 6
7
6
6
13 7
11
10
8
6
9
7
6
11 10
Figure 11-58. Belt Drive/Covers - Stack (1 of 2)
XI-186
2
3
4 8
5
13
9 12
Figure 11-58. Belt Drive/Covers - Stack (2 of 2)
XI-187
UNITS
ASSY
PER
NO. NUMBER 12 34 56 7
ASSEMBLY BELT DRIVE/COVERS (STACK UNIT ONLY) (See Fig 11-1, ... REF
Item 52, for NHA)
1 P34 14M40 • PULLEY ................................................................................ 2
SK1 11/16 • • BUSHING ............................................................................ 2
2 2450 14M40 • DRIVE BELT ............................................................................ 1
3 SADG89706 • BELT REGISTER ASSEMBLY ............................................... 1
4 40669-22 • COVER - TOP SECTION - 2 PC. ........................................... 1
6 HARDWARE • • 1/4 - 20 X 1/2 BUTTON HEAD SOCKET ............................ 8
HEAD CAP SCREW
8 109957-6 • COVER - CENTER SECTION ................................................. 1
9 12170-6 • COVER - BOTTOM SECTION ................................................ 1
10 HARDWARE • • 5/16 - 18 X 3/4 BUTTON HEAD SOCKET .......................... 6
HEAD CAP SCREW
12 DG213-1 • DRIVE SHAFT END COVER - 2" DEEP ................................ 1
13 109957-3 • CENTER ACCESS PLATE ..................................................... 1
***** ITEMS 4,5,8,and 9 CAN BE COMBINED UNDER P/N SA12170-3
XI-188
5
6 5
11 6 4 6 5
6
5 5
12 6
9
10 9
6 8
5
9 10 10
6
5
5
6
10
9
Figure 11-59. Belt Drive Covers - 2 High (1 of 2)
XI-189
2
1
3
4
7
11
12
Figure 11-59. Belt Drive/Covers - 2 High (2 of 2)
XI-190
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY BELT/DRIVE/COVERS (2 HIGH ONLY) (See Fig 11-1, ............ REF

Item 53, for NHA)
1 P34 14M40 • PULLEY ................................................................................ 2
SK1 11/16 • BUSHING ................................................................................ 2
2 2450 14M40 • DRIVE BELT ............................................................................ 1
4 40669-3 • COVER - TOP SECTION ........................................................ 1
HEAD CAP SCREW
HEAD CAP SCREW
***** ITEMS 4,7,and 8 CAN BE COMBINED UNDER P/N SA12170-4
XI-191
5
6
3
4
4 5
3
6
6
5 2
5
6
3
4
4
3
6 5
6 1
5
Figure 11-60. Belt Drive/Covers - 3 High - #10 Side (1 of 2)
XI-192
XI-193
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY BELT DRIVE/COVER - 10 SIDE (3 HIGH ONLY) (See .............. REF

Fig 11-1, Item 54, for NHA)
HEAD CAP SCREW
HEAD CAP SCREW
XI-194
6
1 5
4
8
6 7
2 5
3
9
8
1 7 7
8
2 10
7
8
3 12
6
8 5
1 7
7
8
11
6
5
XI-195
2
1
10
11
9
12
13
XI-196
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67
ASSEMBLY BELT DRIVE/COVERS - 13 SIDE (3 HIGH ONLY) (See Figure REF

11-1, Item 55, for NHA)
1 P34 14M40 • PULLEY ................................................................................ 4
SK1 11/16 • BUSHING ................................................................................ 4
2 2450 14M40 • DRIVE BELT ............................................................................ 2
HEAD CAP SCREW
HEAD CAP SCREW
13 DG89711 • SPACER, BELT REGISTER ................................................... 4
***** ITEMS 4,9,10,and 11 CAN BE COMBINED UNDER P/N SA12170-2
XI-197
8
8
7
2
9 11
3
12
4
5 12 12
11
10 11
6 8
7
11 12 12
11
13
8
7
14
11
12
11 12
8
15 7
11 12
7
8
8 11
7
12
12 16
11

XI-198
2
1 3 4
5
6
10
15
14
16
13
XI-199
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67

1 24 x H200QD • PULLEY ................................................................................ 1
SF1 11/16 • BUSHING ................................................................................ 1
2 980 x H200 • DRIVE BELT ............................................................................ 1
3 DG89709 • IDLER PULLEY ASSEMBLY .................................................. 1
4 2450 14M40 • DRIVE BELT ............................................................................ 1
6 P34 14M40 • PULLEY ................................................................................ 1
SK1 11/16 • BUSHING ................................................................................ 1
HEAD CAP SCREW
9 101988-2 • COVER - TOP SECTION ........................................................ 1
HEAD CAP SCREW
13 40670-4-1 • COVER - BOTTOM SECTION - 3 PC. ................................... 1
***** ITEMS 9,10,13,14,and 15 CAN BE COMBINED UNDER P/N SA40670
XI-200
5
6
8 7
7
5
8
6
6 5
7
12
8 4
8
7
6
1 5 7
8
2 9
14 8 7
13
7
3
1 8
10 8
7
6
2 5
14
7
3
8
1
11
6
5
Figure 11-63. Belt/Covers - 4 High - #13 Side (1 of 2)
XI-201
2
1
10
11
9
13
14
12
XI-202
UNITS
ASSY
PER
NO. NUMBER 1 23 45 67

1 P34 14M40 • PULLEY ................................................................................ 4
SK1 11/16 • BUSHING ................................................................................ 4
2 2450 14M40 • DRIVE BELT ............................................................................ 2
HEAD CAP SCREW
HEAD CAP SCREW
14 DG89711 • SPACER, BELT REGISTER ................................................... 4
***** ITEMS 4, 9,10, and 11 CAN BE COMBINED UNDER P/N SA12170-2
XI-203
XI-204

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DAUPHIN GRAPHIC MACHINES, INC.

Operation, Maintenance and

April 2006 DGM - 430 Printing Press

7. Never work alone.

8. KEEP THIS MANUAL WITH THE UNIT AT ALL TIMES.

Because of specific customer and manufacturing requirements, features and op-

SECTION II -Unit Operating Controls

SECTION III - Press Make-Ready

Table Of Contents (Continued) Page

SECTION IV - Running Procedure

SECTION V - Page Imposition Or Plate Positioning

SECTION VI - Roller Adjustments

Table Of Contents (Continued) Page

SECTION VII - Maintenance

SECTION VIII - Direct Printing

SECTION XI - Illustrated Parts Breakdown

Abbreviations Used Throughout the Manual

in. - Inches (length measure)

1-1 INCH/STOP Station or Safe Operation Panel (STOP/SAFE) ............... I-3

Figure Nr. Title Page

Illustrations List (con’t)

Figure Nr. Title Page

Figure Nr. Title Page

1 Roller Specification Chart VI-3

SAFETY AND PRECAUTIONS

SECTION I - Safety And Precautions

a. Safety requires a proper attitude. If a

k. Locate and familiarize yourself with the

l. STAY ALERT - Remember, SAFETY IS

WARNING a. INCH/STOP Station. The INCH/STOP

Avoid injury. Be careful when inching

around the press. The minimum physical require-

(a) Activation is done by pressing

Note (2) Wear gloves sparingly, only when

(6) Avoid standing between units while

e. Press (Units and Folders).

(1) Always have the press STOPPED

(a) Have the press stopped and

(2) Do not disengage a SAFE button

(3) If performing procedures which

f. Lockout/Tagout. 5 - After ensuring that no

(3) The following is a brief of the (b) Procedure for transfer or

2 - If the specific equipment is (c) When locks and tags must

temporarily be removed to test or position the h. Electrical Equipment.

2 - Remove all employees (2) Follow Lockout/Tagout procedures.

3 - Remove the lockout or (5) Do not stand on a wet floor.

3 - Test the equipment for

g. Steps And Platforms. 3. SPECIFICATIONS.

Max. Speed ................ 30,000 iph 22 3/4” Cutoff Specifications

Registration Adjustments - Max. Image Length

Max. Image Length Blanket Thickness ..... 0.064-0.066”

Plate Thickness ......... 0.008-0.012”

Blanket Thickness ..... 0.064-0.066”

22” Cutoff Specifications

Max. Image Length

Plate Thickness ......... 0.008-0.012”

Blanket Thickness ..... 0.064-0.066”

This page left intentionally blank

UNIT OPERATING CONTROLS

SECTION II - Unit Operating Controls

d. Dampener Fountain. A pan that holds

B A e. Ink Feed Throw-off Levers. Engages

g. Plate Cylinder Running Sidelay Hand-