Komori checklist

KOMORI KOMORI AMERICA CORPORATION

LITHRONE LS40 INSTRUCTIONAL CHECKLIST

June 2007 KOMORI AMERICA CORPORATION 5520 Meadowbrook Industrial Court • Rolling Meadows, Il. 60008 Phone: 847-806-9000 • Fax: 847-806-9036

INTRODUCTION TO KAC OPERATION AND MAINTENANCE TRAINING CHECKLIST Using This Checklist Properly The instruction course you are about to begin will present you with a large amount of information during your training. This Training checklist has been designed by Komori America Corporation to assist you in understanding the training, and in remembering the material covered in this training course. This June 2007 edition of the checklist applies to the current basic Lithrone S press models, and should be used instead of any prior editions of the checklist. The checklist gives you a summary of important features of the press that will be covered by your instructor during this training course. You must fully understand these features

in order to safely and efficiently operate the Komori Lithrone S press.

The material covered in this checklist can provide a quick and helpful reference as you start to operate the press on a daily basis. However,

please note that because it is a checklist, this checklist is not a complete guide for operating the Komori Lithrone S press. The Lithrone S press

Operation Manual provided with your press at the time of purchase contains complete information about the press and its safe operation. You

should always refer to the Operation Manual for complete information, instructions, and safety precautions before performing adjustments, maintenance, or service to your Komori Lithrone S press.

If you have any questions regarding the content of this checklist, or how it applies to your Komori Lithrone press, please contact the KAC Service or Training Department at 1-847-806-9000. Komori America Corporation and Komori Corporation must disclaim all liability for any improper use or misuse of this checklist, and any injury or damage resulting therefrom.

ANY WARRANTIES WITH RESPECT TO THE PRODUCTS REFERENCED IN THESE MATERIALS MUST BE SET FORTH IN THE WRITTEN SALES TRANSACTION DOCUMENTS BETWEEN THE PURCHASER OF THE PRODUCT AND THE SELLER AND ALL SUCH WARRANTIES ARE SUBJECT TO ANY LIMITATIONS AND EXCLUSIONS OF WARRANTIES AND REMEDIES AS SET FORTH IN SUCH DOCUMENTS. NOTHING IN THESE MATERIALS SHALL CONSTITUTE A WARRANTY OR REPRESENTATION BY THE MANUFACTURER OR SELLER WITH RESPECT TO THE PRODUCTS AND NEITHER THE PURCHASER NOR ANY USER OF THE PRODUCTS MAY RELY UPON ANY STATEMENTS OR EXPRESSIONS CONTAINED IN THESE MATERIALS AS CONSTITUTING ANY TYPE OF WARRANTY OR REPRESENTATION CONCERNING SUCH PRODUCTS. NEITHER THE PURCHASER NOR ANY USER OF THE PRODUCTS SHALL BASE OR ASSERT ANY LEGAL CLAIMS OR RIGHTS BASED UPON ANY STATEMENTS OR EXPRESSIONS CONTAINED IN THESE MATERIALS.

Revised 6/2007

KOMORI KOMORI AMERICA CORPORATION

TABLE OF CONTENTS Section

Page

Safety

1-17

Press Controls

18-23

Feeder And Infeed Register Mechanism

24-27

Printing Unit And Transfer System

28-32

Dampening System

33-35

Delivery

36-38

Automation

39-40

PQC Console

41-44

PQC – IV Touch Panel

45-64

Maintenance

65-67

KOMORI AMERICA CORPORATION Revised 6/2007

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SECTION TWO

PRESS CONTROLS

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ENERGIZING THE PRESS

Main press power Amp gauge – main motor draw Ground Fault Breakers

PROCEDURES FOR ENERGIZING THE PRESS

ON 1.

2.

3.

4.

5.

6.

7.

Rotary switch on the auxiliary power cabinet (UL) Rotary switch on blower cabinet PQC console KMS-IV computer PDC-S console Compressed air All auxiliary equipment

OFF 1.

2.

3.

4.

5.

6.

7.

KMS PDC-S Console PQC console Rotary switch on blower cabinet Rotary switch on auxiliary power cabinet Drain compressed air All auxiliary equipment

POINTS TO REMEMBER ABOUT COMPRESSED AIR 1. Press must be supplied with clean and dry air.

2. Drain air compressor nightly (every 24 hours).

3. Supply press with enough air pressure to close water traps on press.

*DO NOT RUN PRESS WITHOUT AIR IN LINES* KOMORI AMERICA CORPORATION

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IDENTIFICATION OF FEEDER CONSOLE CONTROLS

INFEED TRIP LIGHTS FEEDER ON AND TRIP IMPRESSION AUTO MAIN PRESS CONTROLS PAPER SIZE FINE ADJUST EMERGENCY TRIP EMERGENCY STOP SAFE (E-STOP) PRESS CONDITION LIGHTS PRODUCTS – STOP BUTTON FEEDER PUMP ON AND OFF KHS START AND RESET BUTTONS

IDENTIFICATION OF DELIVERY CONTROLS

PRESS COUNTERS SAMPLING BUTTON AIR CONTROLS MAIN PILE CONTROLS PUMP SWITCH SUCTION WHEEL KNOB (SPEED) SUCTION WHEEL VACUUM CONTROLS FAN ZONE CONTROLS RELEASE CAM CONTROL SIDE JOGGER CONTROLS

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SLOWDOWN WHEEL CONTROLS PRESS SPEED PRODUCTS BUTTON DAMPENING FORM ROLLERS INK ROLLER ALL OFF MAKE READY BUTTON (AMR) EMERGENCY TRIP BUTTON

MAIN PRESS CONTROLS E-STOP\SAFE BUTTON STOP BUTTON

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IDENTIFICATION OF PRESS CONTROLS AT THE PRINT UNIT

Print Unit Operators Side 1.

2.

3.

4.

5.

6.

7.

Emergency Trip E-Stop\ Safe Button Inch and Reverse Buttons Ink Fountain Roller Button Ink Ductor Button Ink Form Roller Button Press Condition Lights (ANSI)

Print Unit Gear Side 1.

2.

3.

4.

5.

6.

7.

Tune Up Button Cover Switch APC Clamp check Button APC Start Button Inch and Reverse Buttons Impression Button Press condition Lights (ANSI)

Print Unit Dampening Controls 1. Dampening Form Roller Button 2. Metering Roller Button 3. Fountain Roller Button

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DESCRIPTION OF MAIN PRESS BUTTONS AND THE CORRESPONDING REACTION OF THE PRESS

Emergency Stop / Safe Location

Feeder and delivery panels, every printing unit gear and operators side

Reaction

Press stops, impression on, ink forms on and dampening rollers off

Tune Up Location

Feeder and delivery panels and on every printing unit gear side

Reaction

Allows inching or reversing of the press when a safety guard is open

Emergency Trip Location

Feeder and delivery panels

Reaction

Trips Feeder, All Units off Impression at Once and Slows Press to Idle

Inch and Reverse Location

Feeder and delivery panels, every printing unit gear and operators side

Reaction

Moves the press in the direction selected (1 revolution maximum)

Product Start / Stop Button Location

Delivery Panel

Reaction

Starts press up, engages feeder and sheet feeding, fast production mode

Make Ready Button Location

Delivery Panel

Reaction

Starts the press in an interlock sequence programmed by the AMR Screen.

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Products – Stop Button Location Reaction

Feeder and delivery panels Stops feeder air, runs sheets off feed table, finishes Print Cycle and when press goes to IDLE SPEED, the press will stop (THIS BUTTON DOES NOT REACT IN THE SAME MANNER AS AN EMERGENCY STOP SAFE)

Ink Form Roller All Off Location

Delivery panel

Reaction

Removes ink forms off plate surface allowing ink removal from plate surface (Dampening form roller remains on the plate when this button is activated)

Dampening All On / All Off Location

Feeder and delivery panels

Reaction

Engages dampening form rollers on the units selected in the AUTO mode (Dampening Form rollers will go on automatically when sheet feeding begins, but after printing is done, water form rollers will remain on the plate unless taken off manually or the press is stopped).

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SECTION THREE

FEEDER AND INFEED REGISTER MECHANISMS

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FEEDER PILE CONTROLS

Main Pile Hoist Controls 1. Manual mode 2. Auto mode

Auxiliary Pile Hoist Controls 1. Manual mode 2. Auto mode 3. Continuous feeding

Feeder Platform Controls 1. Left to right operation 2. Limit switch activation 3. Manual backup control

Automatic Side Ways Pile Control

1. Procedure for activating pile control 2. Positioning device

Limit Switches

1. Platform switches 2. Auxiliary pile hoist switches

FEEDER HEAD

Pickup Suckers 1.

2.

3.

4.

5.

Height adjustment Front to back Side to side Removal and cleaning Vacuum adjustments

Forwarding Suckers 1.

2.

3.

4.

Height adjustment Skewing sheet feeding Removal and cleaning Vacuum adjustments

Blower Pressure Foot 1.

2.

3.

4.

Pile height sensor Foot to paper position Ionizer Air adjustments

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Tail Sheet Air Separators

1. Height and distance position adjustments 2. Air adjustments

Tail Sheet Separators

1. Height and distance position adjustments

Feeder Head Positioning 1.

2.

3.

4.

5.

6.

7.

Upper and lower limits Relation of paper position to front flipper Procedure for activating paper size conversion (AMR) AMR fine adjustments Manual backup adjustments Front to back limits Errors when converting paper size

FEED BOARD SECTION

Mechanical Double Sheet Detector

1. Run 3 and trip on 4 sheets – 470mm ~ 705mm 2. When to set to run 2 and trip on 3 sheets (sheet size of 470mm or less) 3. Run 4 trip 5 – 705mm ~ 720mm

Forwarding Wheels

1. Gap position for timing (0.20 mm = .008) 2. Positioning wheels 3. Adjusting tension

Suction Feeder Tapes

1. Position to head stops 2. Tension 3. Adjustment of suction

Feed Board Wheels

1. Different types 2. Positioning 3. Brush wheel rack adjustment

Feeder Timing 1.

2.

3.

4.

Sheet relative to head stops (240° + or – 5°) How to adjust timing Feeder drive chain tension Fine adjustment

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Paper Checker

1. When to use 2. How to adjust

INFEED REGISTER SECTION

Infeed Cylinder

1. Cocking adjustment 2. Concave sheet compensator

Air Side Guide

1.

2.

3.

4.

5.

Turning On and Off Adjusting the upper plate to suction plate using three sheets Positioning guide Manual backup adjustments Adjusting the amount of suction

Feeder Panel Trip Light Indicators 1. Layout of sensors 2. Function of each sensor

Eyecom

1. Cleaning the eyes 2. Testing the sensors

Sheet Smoother Assembly

1. Changing height 2. Brushes over head stop hooks

Head Stop Hook Height 1. Change setting 2. When to change

PAPER SIZE PRESET SCREEN

Display Layout 1.

2.

3.

4.

5.

Input sheet sizes Storing sheet sizes Selecting units to convert Procedure for activating a sheet size conversion on the press Backup buttons for disabling automatic devices

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SECTION FOUR

PRINTING UNIT AND TRANSFER SYSTEM

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ELECTRICAL OPERATION AT THE PRINTING UNIT

Operator and Gear Side panels

1. Layout of each panel 2. Function of each button 3. Hickey picker operation (Dust pan wiper)

INKING UNIT

Roller Diagram 1.

2.

3.

4.

5.

6.

7.

Explanation of diagram Roller durometers Order for removing roller train Procedure for removing endplay Order for installing rollers Different adjustments for roller settings Oscillating form rollers

Oscillation Timing

1. Home position (400mm from start of sheet) 2. Procedure for changing oscillation timing 3. When to change

Washing the inking unit up 1.

2.

3.

4.

5.

Speed Using the automatic cycle Changing the automatic cycle Manual mode Use of water and other chemicals

INK FOUNTAINS

Zero Setting - Calibration

1. Procedure for zero setting 2. Interval for zero setting

Washing The Ink Fountains 1.

2.

3.

4.

5.

No metal ink knives Procedure for cleaning Important cleaning points Replace if bent or damaged Important lubrication points

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LS INKING UNIT DIAGRAM

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PLATE CYLINDER

Undercuts

1. Undercut for Full-APC

Plate clamps 1.

2.

3.

4.

5.

Using split clamp Stretching or relaxing a plate Kicking a plate Zero plate clamps Manual mounting of plate

Maintenance

1. Clean the edges of the plate cylinder 2. Removing and replacing the bearer wipe pads 3. Lubrication of the plate changer

BLANKET CYLINDER

Undercut 1.

2.

3.

4.

Undercut of cylinder Packing requirements Packing styles Blanket types

Blanket Mounting 1.

2.

3.

4.

5.

Blanket size Locking into clamps Use of reels Torque specifications Use of blanket packing gauge

Maintenance

1. Cleaning of cylinder 2. Removing and replacing the bearer wipe pads 3. Oil blanket reels

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IMPRESSION CYLINDER

Overcut

of the Impression Cylinder

1. Setting the impression cylinder pressure

Maintenance

1. Cleaning the cylinder and bearers 2. Greasing the cam followers ( Once every 60 hours ) 3. Cleaning and greasing the cylinder grippers

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SECTION FIVE

DAMPENING SYSTEM

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DAMPENING SYSTEM DIAGRAM

A V

X 5

Y 6

W Z

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EXPLANATION OF THE DAMPENING SYSTEM

Reverse Nip

1. Roller direction 2. Water flow 3. Delta effect

Electrical Operation

1. Panel layout 2. Fountain roller switch 3. Procedure for cleaning dampner up with press

Settings of the Dampner 1.

2.

3.

4.

5.

6.

7.

8.

Water form to Plate Water form to Chrome Oscillator Recheck Water form to Plate Metering roller to Chrome Oscillator Bridge roller to Water form Bridge roller to “A” Ink form roller Metering roller to Pan roller Set rollers when cold

Maintenance 1.

2.

3.

4.

5.

Roller durometers Lubrication of Dampner gears Drain and refill water recirculation tank weekly Flush system monthly (clean water pan) Clean filters weekly

Water Quality

1. Temperature 2. Etch and wetting agents 3. Monitoring pH and Conductivity

Rules for the Dampner

1. Never run dampening system without water recirculating 2. Never run dampening system without air in the press 3. The metering should not take ink

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SECTION SIX

DELIVERY

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ELECTRICAL OPERATIONS AT THE DELIVERY PANEL

Counters 1.

2.

3.

4.

Total Job Stacking (In console) Preset (In Console)

Delivery Pump

1. On position 2. Clean delivery pump filters every week

Suction Wheel

1. Speed control 2. Individual vacuum adjustments 3. Different types of slowdown wheels

Pile Hoist Controls 1.

2.

3.

4.

5.

Manual button Continuos lower Check limit switches Electronic sensors Problems why the platform will not raise

Fan Zones

1. Layout 2. Speed of fans 3. Proper settings

Air Bar controls

1. Controls for delivery pile

Press Speed

1. Fast mode setting dial

Emergency Stop/ Safe Buttons

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DELIVERY ADJUSTMENTS

Delivery Side Joggers 1.

2.

3.

4.

Fine adjustments Error codes Deactivation of automatic preset devices Manual backup adjustments

Vacuum Slowdown Wheel Assembly 1.

2.

3.

4.

Fine adjustments Error codes Deactivation of automatic preset devices Manual backup adjustments

Cam Release

1. Setting release points 2. Manual adjustment

Continuous Delivery Pile Board Rails 1. Procedure for using racking system 2. Dangers of damage 3. Delivery board stop

Paper Jam Detector Delivery Air Controls

1. Segmented delivery pans 2. Controlling the sheet

Delivery Lubrication System

1. Chain oiler 2. Greasing chain rails and gripper bars

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SECTION SEVEN

AUTOMATION

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SEMI- APC

Operation 1.

2.

3.

4.

5.

APC button at unit Procedure for engaging plate change Changing one unit Errors Maintenance

AUTOMATIC INK ROLLER CLEANER

Operation 1.

2.

3.

4.

Adjusting solvent levels Adjusting sequence timing Adjusting doctor blade Procedure for washing up the roller train

AUTOMATIC BLANKET WASHERS

Operation 1.

2.

3.

4.

5.

6.

7.

Adjusting solvent and water levels Adjusting sequence timing Adjusting cloth applications Changing cloth rolls Different cloth material Procedure for washing blankets Maintenance of unit

AUTOMATIC IMPRESSION CYLINDER CLEANER

Operation 1.

2.

3.

4.

5.

6.

7.

Adjusting solvent and water levels Adjusting sequence timing Adjusting cloth applications Changing cloth rolls Different cloth material Procedure for impression cylinders Maintenance of unit

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SECTION EIGHT

PQC CONSOLE

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PQC BUTTON DESCRIPTION AND ACTIVATION

Power Switch Console All Lock Button Unit Select Unit Off Number Key Pad 1. Enter 2. Lock

Color Change

1. How to change sequence 2. Reset before recording

Difference Button All Unit Button Plate Register

1. Lateral 2. Circumferential 3. Cocking

Infeed Cocking Fan-out Adjustment Function Buttons 1.

2.

3.

4.

5.

6.

Memory Preset Check Full set and o-set Percentage key Stop key

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Ink Feed Display 1. Set values 2. Ratio values 3. Flush button

Water Feed Displays 1.

2.

3.

4.

Predamp Set value Ratio value Flush button

COMMON PROCEDURES

Reset Plate Register

1. All units at once 2. Individual 3. Using difference button

Ink Sweep And Ratio Rates Water Feed And Ratio Rates Ink Key Movements 1. Full set constant 2. Zero set constant 3. Using percentages

Entering A Job Number Adjusting “M” Values

1. Accepting or denying job data 2. Adjusting pre damp values

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Water Ratio Graph

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Ink Ratio Graph

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SECTION NINE

PQC-IV TOUCH PANEL

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SECTION TEN

MAINTENANCE

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MAINTENANCE ITEMS

Main Motor 1.

2.

3.

4.

Filter Grease Brushes Belt inspection

Feeder Section 1.

2.

3.

4.

5.

6.

Feeder head Forwarding wheels Drive chain – sprocket tension Grease points Side guide Grease points under feed board

Cylinder And Transfer System 1.

2.

3.

4.

5.

6.

Impression cylinder cam followers Cam follower brushes Gripper shafts Grippers and pads Blanket reel Bearer wipers (pads)

Inker And Dampner

1. Form roller hangers 2. Dampner roller hangers 3. Dampening gears

Water Recirculation 1.

2.

3.

4.

Flush monthly Change water weekly Change filters weekly Clean water pan monthly

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Delivery Section 1.

2.

3.

4.

5.

6.

7.

Automatic chain oiler Chain grease Clean sprockets and motor Side joggers shafts Vacuum slowdown wheel assembly Delivery gripper bars Cleaning delivery

Oil Pump

1. Filters 2. Pressure gauges 3. Clog sensor

Oil Change

1. Change after 90 days the once a year 2. Check level in sight glass before turning power on 3. Check oil flow in sight glasses after power is on

Compressor

1. Check sight glass for oil level 2. Drain water from tank every 24 hours 3. Air dryer

Separator / air regulators 1. Water traps 2. Oil misters 3. Regulators

Ring blower pumps

1. Clean paper filters every week 2. Replace if torn

Becker Pump

1. Canister filter 2. Internal monthly filter clean 3. Cooling duct coils

KMS-IV

1. Maintenance schedule 2. Input own scheduled maintenance

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KOMORI AMERICA CORP. Step-by-Step for Manual APC Box - LS Presses Start ON

Manual ON

Clutch ON

Select Unit

Position #1

Fix ON

Impression ON

Reverse Until Stops

Gripper ON/OFF (push twice)

Position #2

Reverse Until Stops

Plate Push 1 ON

Gripper ON/OFF (push twice)

Plate Push 1 OFF

Position #3

Reverse Until Stops

Eject ON

Suction Bar ON

Insert OFF

Gripper ON/OFF (push twice)

Fix OFF

Plate Push 1 ON

Plate Push 2 ON

Position #4

Inch until tail of plate at TOP of suction bar

Plate Push 2 OFF

Inch Until Stops

Plate Push 2 ON

Plate Pressure ON

Gripper ON/OFF (push twice)

Plate Pressure OFF

Plate Push 2 OFF

Plate Push 1 OFF

Eject OFF

Suction Bar OFF

Clutch OFF

Manual OFF

Impression OFF

Start OFF

PAPER SIZES 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.0 15.5 16.0 16.5 17.0 17.5 18.0 18.5 19.0 19.5 20.0 20.5 21.0 21.5 22.0 22.5 23.0 23.5 24.0 24.5 25.0

inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

254.0 266.7 279.4 292.1 304.8 317.5 330.2 342.9 355.6 368.3 381.0 393.7 406.4 419.1 431.8 444.5 457.2 469.9 482.6 495.3 508.0 520.7 533.4 546.1 558.8 571.5 584.2 596.9 609.6 622.3 635.0

mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm

25.5 26.0 26.5 27.0 27.5 28.0 28.5 29.0 29.5 30.0 30.5 31.0 31.5 32.0 32.5 33.0 33.5 34.0 34.5 35.0 35.5 36.0 36.5 37.0 37.5 38.0 38.5 39.0 39.5 40.0

inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch inch

= = = = = = = = = = = = = = = = = = = = = = = = = = = = = =

647.7 660.4 673.1 685.8 698.5 711.2 723.9 736.6 749.3 762.0 774.7 787.4 800.1 812.8 825.5 838.2 850.9 836.6 876.3 889.0 901.7 914.4 927.1 939.8 952.5 965.2 977.9 990.6 1003.3 1016.0

mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm

= = = = = = = = = = = =

0.3302 0.3556 0.3810 0.4064 0.4318 0.4572 0.4826 0.5080 0.5334 0.5588 0.5842 0.6098

mm mm mm mm mm mm mm mm mm mm mm mm

PAPER THICKNESS 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 0.010 0.011 0.012

inch inch inch inch inch inch inch inch inch inch inch inch

= = = = = = = = = = = =

0.0254 0.0508 0.0762 0.1016 0.1270 0.1524 0.1778 0.2032 0.2277 0.2540 0.2794 0.3048

mm mm mm mm mm mm mm mm mm mm mm mm

0.013 0.014 0.015 0.016 0.017 0.018 0.019 0.020 0.021 0.022 0.023 0.024

inch inch inch inch inch inch inch inch inch inch inch inch