1991 GTOF Alcolor dampening calibration problem.

[PrLogy]

Hello, good morning. My name is Andres, and I’m writing from Argentina. I am using an AI to translate this, so I hope the technical terms are clear.

We recently acquired a 1991 Heidelberg GTOF with an ALCOLOR system. We are having trouble calibrating the dampening unit because we don't have the manual or a settings diagram for the correct roller adjustment.

The problem is the following: we cannot get the form roller (16 FEAW) to make contact with both the plate cylinder and the intermediate/distributor roller (FR) at the same time. Has anyone encountered this before?

The diameter of our 16 FEAW is currently 67.5mm, which is 0.5mm less than the standard 68mm. Is it possible that this slight difference is preventing the adjustment? Is there a way to move the FR closer to the 16 FEAW?

If anyone could help or provide a diagram showing how each adjustment works, I would be very grateful. Thank you!

 

[junker1984]

Any measurement within 1mm of prescribed tolerance should allow you to make proper contact.

 

[PrLogy]

Hi Junker, I feel the same way; it shouldn't be giving me this much trouble. Do you know if the mechanical adjustment system can be moved or how it works? Should I calibrate it with the dampening system (pneumatic system) activated or deactivated?

Any measurement within 1mm of prescribed tolerance should allow you to make proper contact.

 

[junker1984]

Though I spent my career repairing, I seldom set rollers . I do remember the fact that you set all damps prior to inserting intermediate (bridge) roller. I think setting of bridge was done with pneumatic engaged. Someone with more experience could answer?

 

[Joe Burger]

An 16 FEAW roller with currently 67.5mm, which is 0.5mm less than normal, could not make these kind of problems. So, I guess there is something wrong with pneumatic valves which are located under the pan roller and water pan.
But first of all and before you try to adjust the roller closer to the plate cylinder, you have to check the pressure and stripe between FEAW (dampening form roller) to oscillator roller. There you should have 4-4,5mm stripe.
If the dampening form roller visually moving forward and backward when pushing the button (ON/OFF) - how is this working?

 

[PrLogy]

Hi Joe, if I can set the DW roller to a 4-4.5mm stripe, should it then press against the FEAW and bring it closer to the plate once the pneumatic system is activated? By that, are you referring to the chrome oscillator roller or the ZW roller?

When switching the system ON/OFF, I don't notice any leaks in the pneumatic system and it moves correctly, though I'm not sure if it's moving with the necessary force."

An 16 FEAW roller with currently 67.5mm, which is 0.5mm less than normal, could not make these kind of problems. So, I guess there is something wrong with pneumatic valves which are located under the pan roller and water pan.
But first of all and before you try to adjust the roller closer to the plate cylinder, you have to check the pressure and stripe between FEAW (dampening form roller) to oscillator roller. There you should have 4-4,5mm stripe.
If the dampening form roller visually moving forward and backward when pushing the button (ON/OFF) - how is this working?

 

[junker1984]

I recall a few instances where the blue air lines throughout the press, mostly the areas exposed to oil saturation, have degraded internally causing the plastic inner lining to break down into small particles and blocking the air flow at the exhaust fittings (brass colored cones) on the back of the directional control valves. On the affected units, you may wish to unscrew those fittings and visually inspect for blockage. These are under the operator side covers.

 

[PrLogy]

"I managed to get a mechanic to take a look, and we found the problem. We were able to adjust the FEAW so it barely touches the FR oscillator roller. Below the FR cylinder, there is an adjustment for the 'hit' against the plate, which needs to be minimal and even when the pneumatic system is activated.

It must be adjusted with the full pressure load, because if you test it several times in a row, the system doesn't have enough time to build up the proper pressure. Once we finish adjusting everything, I will upload some photos.

 

[junker1984]

There may still be an air pressure issue somewhere in the system, as there should be no reason to have to wait on the pressure to build back up.

 

[PrLogy]

Yes, they are currently checking the entire system. There seems to be a leak between the air moisture filters (we have three of them, and I don't like how the connections are laid out; that needs to be improved). It is worth mentioning that the compressor is not the original one; we have already sent it for repair and it should arrive this week.

 

[turbotom1052]

Yes, they are currently checking the entire system. There seems to be a leak between the air moisture filters (we have three of them, and I don't like how the connections are laid out; that needs to be improved). It is worth mentioning that the compressor is not the original one; we have already sent it for repair and it should arrive this week.

The problem with the press equipped compressor is common. I’ve seen many times where house air is plumbed into the small Heidelberg compressor to where the Heidelberg compressor is only there to bypass the low pressure safety on the press. Plumbing in dry house air will also aid in keeping noise at the press down and the moisture issues associated with moisture rich air