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SM/CD102

Inking unit

4.1
4.1 Roller diagram
GR SG9011500000006000

UTKSG9011500010000000

4
4
Removing and installing the inking rollers

15

12
11

4
10

9
3

C
2

13
14
17
ZW
16
FEAW

19
DW
18
T

FR

11
Fig. 11
Roller diagram
Note
The roller designations 1...19 (removable) and A...D, FR (not removable)
are used repeatedly in the Inking unit
and Dampening system chapters.
The numbers 1...19 are binding for the
installation sequence! The rollers FR
and 16...19 are described in the
Dampening system chapter.

C.4.11

Inking unit

Fig.11
11

Designation

Color code

Material
/Remark

11
2
2
3
3
4
4
5
5
6
6
7
87

Plate
inking roller 2 2

Plate inking roller 3


3
Ink transfer roller

Ink transfer roller

Ink transfer roller

Ink transfer roller

Ink transfer roller


Ink
transfer roller

72
mm
72mm
66 mm
66mm
56 mm
56mm
80 mm
80mm
68 mm
68mm
72 mm
72mm
56 mm
56mm
60
mm

blue

red


yellow


blue


white

98

Ink
transfer roller

60mm
66
mm

red

Rubber

9
10

Ink
transfer roller

66mm
56
mm

Rilsan

11
10

Ink
transfer roller

80
mm
56mm

yellow


12
11

Ink
transfer roller

68
mm
80mm

Inking
form roller 4

Plate inking roller 1


4
Ink vibrator
1
Dampening form roller

Intermediate roller

Water pan roller

Metering roller
Ink
distributor roller

80
mm
68mm
60 mm
80mm
59 mm
60mm
78 mm
59mm
56 mm
78mm
108 mm
56mm
98 mm
108mm
85
mm

yellow

white

Ink
distributor roller

98mm
85
mm

Rilsan

CA

Ink
distributor roller

85mm
85
mm

Rilsan

DB

Ink
distributor roller

85
mm
85mm

Rilsan

FR
C

Dampening
distributor

85
mm
85mm

Chromium-plated

Tab. 1 D

85mm

85mm

13
12
14
13
15
14
16/FEAW
15
17/ZW
16/FEAW
18/T
17/ZW
19/DW
18/T
A
19/DW
B

FR
1

C.4.12

Rubber

Rubber

Rilsan

Rubber

Rilsan

Rubber

Rilsan

Rubber

Rubber

Rilsan

Rubber

Rubber

Rubber

Rubber

Rilsan

Rubber, crowned

Stainless steel

Rilsan

Inking
unit

UTKSG9011500___00000_014

4.2 Overview and concise instructions


4.2

Fig. 12

T-wrench

12T

GR SG9015564000000000
GR SG9015564000000000

If you are skilled in changing inking rollers, the


following diagrams show you the order in which se
quence the rollers must be removed and installed

and how the inking rollers are to be adjusted. You

can find detailed instructions in the sections


Remov

ing
inking
rollers
and
Installing
and
adjusting
inking

rollers.

Marker rings on the adjusting elements of the ink

form rollers and dampening form rollers facilitate the

adjustment. The color allocation corresponds to the

color of the roller journalsand/or


the roller locks.

Adjusting element for Color


Plate inking roller 1

Plate inking roller 2


1
Plate inking roller 3

Inking form roller 42

white

blue

red

yellow

3
Dampening form roller

green

4
Tab.
2

adjustment are
All
adjusting elements for roller
equipped with a hexagon socket (6 mm). Use the
2
T-wrench (Fig. 12) included in the press tool set for
adjustment.
6
6mm

Removing T
the
inking
rollers

12
Tip
Mount a printing plate prior to remov
ing and fitting the inking rollers to pre

damage on the plate cylinder.
vent






Note



The
rollers of the dampening system




1.
2.

16...19 must have been removed. All




parts are removed in the same way,




19 
following
the same 16
installation
instruc

tions but in the reverse order!


Open the
form roller locks.
Turn the adjusting

screws two revolutions to

disengage the inking form rollers 13, 2, 1 and


1
14 from the ink distributors.
2 2 
3. Remove the rollers 13, 8, 7, 6, 5, 4, 3, 2 and 1.

1321 14 
4.
Remove the rollers 14, 12, 11, 10 and 9.


3 138765432 1

4 14121110 9

C.4.13

GR SG9010870000000000

Inking unit

Ink stripe width












GR SG9010871000000000

13
Fig. 13
Ink stripe width

Note

Illustration
of the setting
values for
the



ink
stripe
width:

44 +1
mm =
the ideal setting value
is 
+ 1mm
4mm
4 mm. You may exceed this setting
1mm 
value by 1 mm. However, you must not
4mm 
set any value lower than 4 mm.
4
p0.5 mm = The ideal setting value is
0.5mm
4mm
44 mm.
You may deviate 0,5 mm above
0.5mm

or
below this setting
value.
1mm
4mm
44 1
mm = The ideal setting value
is
41mm
mm. You may
set a value 1 mm below
the setting value. However,
you

4mm

must
not
set
any
value
greater
than

4 mm.

Please use your ink strip card for roller adjustment to

measure the ink stripe width.











14
Fig. 14
Roller adjustment aid, ink stripe card

Note

The
following setting values refer to a

press
with inking and dampening system
rollers
at working temperature
(di



rectly
after completing a print job). If

the
press is cold, you should set the

rollers
to the lower limit of the toler
ance range, since the width of the con 40.5mm 
tact area increases when the rollers
3.5mm
heat up.
Example: For a 4 p0.5 mm width of
contact area you should set the width
of the contact area to 3.5 mm.

from

to

Ink
stripe width

Ink
vibrator

Ink
fountain roller 3

0.5mm
44 p0.5
mm

Ink
vibrator

A
Ink
distributor A

+ 2mm


55 +2
mm (for
mechanical reasons)

Ink
transfer roller, yellow

Ink transfer roller, red

Ink
transfer roller

B
Ink distributor B

1mm
mm
55 p1
1mm
mm
44 p1

Ink transfer roller, red


1
Inking form roller 1, white
2
Inking form roller 2, blue
3
Inking form roller 3, red
4
Inking form roller 4, yellow
1
Inking form roller 1, white
2
Inking form roller 2, blue

Ink transfer roller


C
Ink distributor C
C
Ink distributor C
D
Ink distributor D
D
Ink distributor D

Printing plate

Printing plate

4 1 mm
4 p1 mm
4 + 1 mm
4 +1 mm
4 + 1 mm
4 +1 mm
4 + 1 mm
4 +1 mm
4 + 1 mm
4 +1 mm
4 1 mm
4 1 mm
4 1 mm
4 1 mm

C.4.14


Inking unit

from

to

Ink
stripe width

Inking
form roller 3,3
red

plate
Printing

1mm
mm
44 1

Inking
form roller 4,4
yellow

Inking
form roller 1,1
white

plate
Printing
3roller
+ 1 mm
Intermediate

1mm
mm
44 1
3 +1 mm

GR SG9011534000006000

3
Tab. 3

4 p0,5 mm
5 +2 mm

15

5 p1 mm

A
11

12

4 +1 mm

7
8

4 +1 mm

9
C

2
13

10

4 +1 mm
3 +1 mm

14
17

4 1 mm
4 1 mm
4 1 mm

4 1 mm

16

19
18

FR

Fig. 15
Installing the inking rollers
15

1
1. 
Grease the roller journals and journal boxes.
2.
Fit rollers 1...8.
2 1 8
3. Fit the red rubber roller 9. Use a paper or
3
9
0.1mm
mounting film strip
(0.1 mm thick) to adjust
it


with respect toAstralon
ink distributor
B.
4.
B
Install Rilsan
roller 10. Use a paper or mounting
4
10thick)

0.1mm
film strip (0.1 mm
to adjust it with respect

9 
to rubber rollerAstralon
9.
5.
Install the yellow rubber roller 11.

4 p1 mm

4
3

4 +1 mm

4 p1 mm

Installing and adjusting the inking rollers

5 11
6. Install Rilsan roller 12. Use a paper or mounting
6
12thick)

0.1mm
film strip (0.1 mm
to adjust it with respect

Astralon

11
to rubber roller 11.

7. Close the roller locks of the rollers 13 and 14.


7
13 are
14not


The rollers
installed. Tighten the Allen



screws.


8. Feed a bright ink, allow for even distribution and


8 
stop the press.


9. Adjust the rubber rollers 1 (blue) and 2 (red) to


9
1

2


the ink distributors
C and
D respectively.
Ink


C

D

stripe width: 4 +1 mm.


4 +1mm 
10. Adjust the red rubber roller 9 to ink distributor


B. Ink stripe width: 4 p1 mm.
10 9 B
11. Adjust Rilsan roller 10 to the red rubber roller 9.

4 1mm 
Ink stripe width: 4 p1 mm.


12. Adjust Rilsan roller 12 to the yellow rubber roller
11 10 9 
11. Ink stripe width: 5 p1 mm.


4 1mm 
Install the rubber rollers
13 (yellow) and 14
13.
(white). Close the roller locks and tighten the
12 12 11 
Allen screws.

5 1mm 
Install the dampening system rollers.
14.
15. Throw on the
dampening
13
13
ink
form
rollers
14
and

form
rollers.
Engage
intermediate
roller 17.


16.
Adjust the rubber rollers 13 (yellow) and 14
(white)
to the ink distributors D and C. Ink stripe
14
width: 4 +1 mm.
15
Adjust the inking form
rollers 1...4 to the plate.
17.
17 
Ink stripe width: 4 1 mm.


16 13
14


D C


4 +1mm
17 1 4 


4 1mm 


C.4.15

Inking unit

UTKSG9011500___00000_015

GR LS9010185000003000

4.3

4.3 Preparing the removal of the


inking
rollers (only presses with AutoPlate Plus)

1
2

1
1. 
Secure the press against being started up:
Press the Emergency stop button on the near

est
control panel.
2

16/1 
2.



Hold the
AutoPlate Plus plate
changer
2
16/2 
(Fig.
16/1)
by
one
of
the
two
handles

(Fig. 16/2). This unlocks the plate changer and

the plate changer can be moved.


3 
3. Push the AutoPlate Plus plate changer up


wards. It locks into place in the maintenance


position (upper end position).

GR LS9014940000001000

16
Fig. 16
AutoPlate Plus plate changer in maintenance position


Fig. 17
Inking roller guard and blade trough
17

C.4.16

4.
Remove the blade
trough
(Fig. 17/2) to gain
4

17/2
access
to
the
inking
rollers
behind
the inking


17/1

roller
guard
(Fig.
17/1).


GR LS9014307000002000

Inking
unit

5

5. 2
Hold the inking roller guard by one
of the two


18/1

handles (Fig. 18/1) and swing it out of the print

ing unit. The inking roller guard is secured in a
horizontal position. The front handle segment


hangs down.


GR LS9016337000002000

18
Fig. 18
Handle on the inking roller guard
6.
Swing the front handle
segment
(Fig. 19/1) to6

19/1 
ward
the
printing
unit,
beneath
the
horizontal



inking
roller
guard.
Magnets
secure
the front


handle segment in this position.


Now you have free access to the inking rollers.

19
Fig. 19
Handle on the inking roller guard, folded
in


C.4.17


Inking unit
UTKSG9011500___00000_016

GR SG9011502000006000

Engaging the inking form rollers

GR SG9011501000006000

4.4
4.4 Removing the inking rollers

2.
Open the printing unit guard O.S.
2
3.
Remove the doctor blade.
3

1
2
14 turn
1 
1.
On D.S. and13onO.S.
(Fig. 20/1),
the adjusting screws on the journal boxes of the rubber



rollers
13
and
2,
and
14
and
1
two
revolutions

20/1 2 
to the left. As a result, the rollers move away


from the ink distributor. They can be removed


more easily.

1
2

Fig. 20
Adjusting screws of the rollers 2 and 13
20
on O.S.; roller 13 removed

21
Fig. 21
Roller locks from O.S.

C.4.18

4.
To open the form
roller
locks,
loosen the Allen
4
21/2

screws (Fig. 21/2).


5.
Press the safety
(Fig. 21/1) inwards,
5

bushes
21/1 
and pull out the knurled screws (Fig. 21/3) at


21/3
the same time.
6
6. Close the printing unit guard O.S.

GR SG9011503000006000

Inking
unit

Removing 13
the138 and
8 rubber rollers
7
13
roller
22/1 13

7.
Press the yellow rubber
(Fig. 22/1) towards the O.S. until the roller drops out of the


journal box on D.S.13 


8
8.


Press the yellow rubber roller


13 towards
D.S.

22/4

until the roller on O.S. drops out of the journal

box (Fig. 22/4).


9 13
22/1 
Using both
hands,
roll the yellow rubber
9.

22/3
roller
13
(Fig.
22/1)
over the guard (Fig. 22/3).


You need not remove the guard for this pur10


8
22/2 
pose.


10. Lift the white rubber roller 8 (Fig. 22/2) out of


the unit.

GR SG9011504000007000

Removing the Rilsan


roller 7

GR SG9011505000007000

Fig. 22
13 and 813rubber
22
8 rollers

Removing the blue


6 rubber roller

11.
Remove Rilsan 7
roller
7. To do this, press the
11

spring
bolt
(Fig.
23/1)
on O.S. upwards.
Re

23/1

move
the
roller
on
O.S.
first.




23
Fig. 23
Spring bolt, Rilsan rollers 7 and 87removed

8

12.
Remove the blue
roller
6 (Fig. 24/1).
12
6
rubber
24/1

24
6
Fig. 24
Blue rubber roller
6

C.4.19

GR SG9011506000006000

Inking unit

5
Removing the Rilsan
roller 5
13
5

25/1

13.
Remove the Rilsan
roller
5 (Fig.
25/1).

GR SG9011507000008000

Fig. 25
Rilsan roller 5
25
















Note

1 rollers
4 
To
remove
4...1: Raise the rollers
from
their
installation
position. First

insert
the
rollers
into
the
recess
(clear
26/1 
ance)
in
the
side
frame
on
D.S.

(Fig.
26/1). You can then remove the

rollers
from the press more easily on
O.S.

GR SG9011508000006000

26
Fig. 26
Free space above the spring bolt

Removing the yellow


rubber roller 4,3 Rilsan

roller 3, and
red rubber roller 2

2 the

14.
Raise the safety
(Fig.
27/1), and remove
14

flaps
27/1

the
yellow
rubber
roller
4
(Fig.
27/2).

4
27/2
15. Remove Rilsan 3roller
3.
15

16. Push the red rubber


roller 2 towards O.S.
16
2
17. Lift up the red rubber roller 2 on D.S. and take it
17
out.

Fig. 27
Stop catches and yellow rubber4 roller 4
27

C.4.20

GR SG9011509000005000

1
Removing the blue
rubber roller 1

GR SG9011518000005000

14
Removing the white
rubber roller 14

GR SG9011510000006000

Inking
unit

Removing the Rilsan


roller 12

12

18
1
roller
28/1 1
18.
Push the blue rubber
(Fig. 28/1) towards
O.S.


19.
Lift up the blue rubber roller 1 on D.S. and take
19
it out.

Fig. 28
Blue rubber roller
1
28
1

9 
You can14121110
access the rollers
14, 12,
11, 10 and 9 from
the printing unit side that faces the feeder.

20. 
Remove the metering and intermediate roller of
20
the dampening
system. Please refer


C.5
to the
Dampening system chapter.
21 14
29/1
Press the white rubber roller 14 (Fig. 29/1) to21. 
ward O.S. Pull the white roller 14 on D.S. out of


the journal box, and lift it out of the unit.

29
Fig. 29
White rubber14
roller 14

22.
Loosen the
adjusting
screws (Fig.
and the
22

30/2
30/3 30/2)

screw
Fig.
30/3
on
D.S.
and
on
O.S.
and
swing


off
the
connecting
link.


23.
Remove Rilsan roller
(Fig.
30/1).
23
12
1230/1

30
12 roller 12
Fig. 30
Adjusting screw and Rilsan

C.4.21

GR SG9011512000006000

11
Removing the yellow
rubber roller 11

GR SG9011513000005000

Inking unit

Removing Rilsan
10

10 roller

24
31/1
24.
Remove the yellow11

rubber
roller
11 (Fig. 31/1).

31
11 11
Fig.
31
Yellow rubber roller

3
4

2
1

25.
Swing down the blower bar.
25
26.
Loosen the
adjusting
screws (Fig.
and the
26

32/1
32/2 32/1)

locking
screw
(Fig.
32/2)
of
the
connecting
link


32/3 
on
D.S.
and
on
O.S.,
and
swing
off
the
connect

ing link (Fig. 32/3).


27 10
32/4
27. Remove Rilsan roller 10 (Fig. 32/4).

33
9
Fig. 33
Red rubber roller
9

C.4.22

GR SG9011517000006000

32
10 roller 10
Fig. 32
Adjusting screw and Rilsan
Removing the red rubber roller 9
9
28. Remove the red rubber roller 9 (Fig. 33/1).
28 9
33/1