GTOZ 52 Replace Front Lays Magnet

[orestes]

Hello,

Can somebody give me any pointers as to how to get to the front lays magnet (P/N: 42.111.031)?

I think the easiest way in would be to remove the silver feed board on top but so far I haven't been able to figure out how to get it off.

Can somebody give me a general overview of what I need to dissasemble in order to get to this solenoid? Thanks in advance.

 

[Mathew]

Hello,
You need to remove the gray plates and get into the magnet from Feeder pile side. It's quite narrow and tricky but possible.

 

[orestes]

Hello,
You need to remove the gray plates and get into the magnet from Feeder pile side. It's quite narrow and tricky but possible.

Hey Matthew, thank you for your reply.

Can you please explain what I need to remove in more detail? Unfortunately I don't have much experience working on this machine, I am just helping out.

The solenoid in the machine is shorted, I have a replacement coil for it but can't get to it!

 

[Mathew]

Have a look here...

 

[orestes]

Have a look here...

Thanks for the annotated excerpt from the parts manual Matthew. I've understood what needs to be done when I get there, but unforunately I haven't gotten that far yet - my main issue is having enough physical access to the solenoid itself in order to remove it from the machine.

I've tried removing the bolts on the top of the feed board that are visible in order to get it off so as to get access from the top, but it won't come out as it seems to be secured someplace by something farther inside the machine.

You mentioned gaining access through the feed pile - I've removed the feed table but it's impossible to stick my hand inside to get access to the solenoid, much less a screwdriver and a wrench in order to remove it. Can you please point me to what I need to dissasemble in order to be able to reach it?

 

[Mathew]

Have a look to this photo.

 

[orestes]

Have a look to this photo.

Alright I've removed these vertical bars behind the feed pile, but access to the solenoid is still rather limited - do I remove anything else or this is what I have to work with?

Thanks again for your help.

 

[junker1984]

Remove the crossbar/air valve assembly (the one with the air hose attached) to gain more room to work. Start by removing black plastic adjusting knob on operator side, disconnect hose and move bar towards gear side for complete removal. This g8ves you plenty of room to work. Three (5mm Allen cap) bolts attach the mounting bracket to the frame, mind closely the the position of the nuts on the threaded rod! I've done this many times, it's not as intimidating as it seems.

 

[orestes]

Well, this is strange.

I should start by mentioning that we stopped operating the machine not because it was 'malfunctioning' so to speak, as it was still printing normally when it was stopped just this morning. The reason is that ever since yesterday there was a foul smell of burnt wire coming off, which we pinpointed to the aforementioned solenoid. Funny thing is (aside from the coil having being burnt to a crisp), the rod that it actuates seems to have been completely knocked off, yet the machine still operates as usual.

I have no clue as to how long it has been this way. What does this solenoid actually actuate?

Remove the crossbar/air valve assembly (the one with the air hose attached) to gain more room to work. Start by removing black plastic adjusting knob on operator side, disconnect hose and move bar towards gear side for complete removal. This g8ves you plenty of room to work. Three (5mm Allen cap) bolts attach the mounting bracket to the frame, mind closely the the position of the nuts on the threaded rod! I've done this many times, it's not as intimidating as it seems.

Thanks for the tip! I also assume that this means that the whole assy has to be replaced instead of just the solenoid coil now!

 

[junker1984]

That's the only way I was able to get the replacement part, complete assembly.

 

[junker1984]

It operates the "barrier assembly", preventing unwanted sheets from entering machine after a feeder trip...skewed sheet, double sheet or m8sfed sheet. Without this functioning, you'll smash blankets or worse, damage cylinders due to multiple sheets entering press.

 

[orestes]

Well, after a lot of grunting, here's the carnage.

I might be able to machine a replacement pin to fix the solenoid actuator if I can't find a prefabricated one. There's replacement coils being sold online for this exact part. The OEM replacement is quite pricey at 400€+ and will take a while to get here, so repairing it seems like it's worth trying.

It operates the "barrier assembly", preventing unwanted sheets from entering machine after a feeder trip...skewed sheet, double sheet or m8sfed sheet. Without this functioning, you'll smash blankets or worse, damage cylinders due to multiple sheets entering press.

I wouldn't figure in a million years what it was actually actuating, thanks for that bit of information. It must have been this way ever since we got the press, the pin must have snapped ages ago and only now did we notice since the coil failed!

Do I need to take any special care with adjusting the spring tension on the rod once I put it back on the machine so the barrier will actuate properly? I have made a mark as to how it was before I took it out just in case.

Thanks a lot to both you and Matthew for your help, you really helped us out with this one.

 

[junker1984]

Just be sure to set spring rod/coupling/jam nut to the dimensions on the old one. Considering the vintage of the machine and possible wear factors, adjusting of the spring load may be required to assure that the pivoting pawl drops down into the stop lever approximately 4mm.