ColorlinerM PDF

SERVICE BULLETINS — MECHANICAL
COLORLINER
TABLE OF CONTENTS
Page
SBM1357 HYDRAULIC ACCUMULATORS .................................... 3
SBM5001 OIL LEAKS AT DRIVE SIDE COVERS . . . . . . . . . . . . . . . . . . . . . 13
SBM5004 REENGAGING THE OVERLOAD CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 14
SBM5006 OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SBM5014 ANTI-WRAP TROLLEY SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SBM5015 HORIZONTAL DRIVE CLUTCH LUBRICATION . . . . . . . . . . . . . . . . . . 21
SBM5016 PRESS DRIVE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SBM5017 DISTRIBUTION INK DRUM MOTOR GEARBOXES -

LUBRICATION, OIL SEALS, AND VENT PLUGS . . . . . . . . . . . . . . . . 24
SBM5018 DISTRIBUTION INK DRUM MOTOR GEARBOXES -
LUBRICATION, OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SBM5027 MAIN OIL PRESSURE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SBM5028 HYDRAULIC CYLINDER REPAIR KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SBM5033 HYDRAULIC INCH DRIVE MOTOR FRONT SEAL OIL LEAKS 28
SBM5034 SPRAY BAR WATER COUPLING RETROFIT . . . . . . . . . . . . . . . . . . . . 29
SBM5037 PREVENTING CORROSION ON DIGITAL PAGE PACKS . . . . . . . 31

SBM5039 SIDELAY ASSEMBLY MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SBM5041 DAMPENER DRUM ALTERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SBM5043 SPRAY BAR COUPLING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SBM5044 DIGITAL PAGE PACK CHECK VALVE RETROFIT . . . . . . . . . . . . . . 45
SBM5046 SPRAY BAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SBM5049 HYDRAULIC PUMP ADJUSTMENTS (CATCHING

FLUID SYSTEMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
PAGE 1 of 2
SERVICE BULLETINS — MECHANICAL (Continued)
COLORLINER
TABLE OF CONTENTS
Page
SBM5050 HYDRAULIC PUMP ADJUSTMENT (HYCONCO SYSTEMS) . . . 49
SBM5052 HYDRAULIC CYLINDER REPAIR/REBUILD . . . . . . . . . . . . . . . . . . . . . . 51
SBM5053 HYDRAULIC MANIFOLD SEAL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
SBM5054 LUBRICATION OIL CHANGE FOR DOUBLE-WIDTH

NEWSPAPER PRESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SBM5055 WITH AUTOGARD CLUTCHES AND DUMP VALVES —
CLUTCH WILL NOT DISENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SBM5058 SOCKET PLATE THREAD MODIFICATION FOR
STAINLESS STEEL INSERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SBM5059 PLATE CYLINDER ECCENTRIC LUBRICATION . . . . . . . . . . . . . . . . . 62
SBM5060 INK RAIL SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
SBM5062 UNIT HYDRAULIC STEEL TUBE AND HOSE REPLACEMENT 67

SBM5063 INK DRUM MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SBM5073 HARDENED INK TRAIN GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
SBM5074 HYDRAULIC OIL VISCOSITY CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . 73
SBM5078-10-6LUBRICATING OIL GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
SBM5079 SPRAY BAR MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
SBM5080 SIDELAY PERFORMANCE CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SBM0404-29 DAMPENER FORM ROLLER A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

SBM0404-30 ARCOSTRETCHER WEB-STRETCH ROLLER ASSEMBLY
CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
PAGE 2 of 2
Goss International Americas, Inc.
Customer Support Center
121 Broadway
Dover, NH 03820-3290 USA
Phone: (+1) 800-323-1200
Service Bulletin
Customer Service Fax: (+1) 603-743-5490
Service Parts Fax: (+1) 603-740-5970 SBM1357
Bulletin Type
ELECTRICAL Colorliner, Newsliner,
nMECHANICAL Equipment Type: and Headliner Units
OPERATIONAL
T o p ic : HYDRAULIC ACCUMULATORS
March 24, 2003 (Updated from October 22, 2002

and replaces SBM 1029 July 30, 1993)
INTRODUCTION Each unit configuration has its own accumulator which is mounted to the
RTP connecting frames for a Newsliners (Figure 6), the wall bracket for
Colorliners (Figure 1), and on the reelroom floor for Headliners. The accu-
mulators are steel tanks which hold 2.5 gallons (9.5 liters) of hydraulic
fluid. In order for the accumulator to function, the hydraulic power
unit must maintain an operating pressure of 1000 psi (6895 kPa) for
Colorliners and Newsliners. For Headliners refer to the NOTICE
below.
NOTICE: To determine the proper accumulator pressure for all
HEADLINER OFFSET PRESS UNITS consult your Goss
Representative.
PROCEDURE Inside the accumulator tank is a bladder which is nitrogen-charged to 800

psi (5516 kPa). THIS PRESSURE MUST BE CHECKED EVERY SIX
MONTHS. The basic function of this accumulator is to supplement hydrau-
lic fluid to the system during high volume usage. This is accomplished by
the bladder which expands against the 2.5 gallons of hydraulic fluid, forc-
ing it out of the tank to make up the difference in fluid volume. The accu-
mulators also function as shock absorbers against system pressure
spikes.
NOTICE: Use Texaco 561 WAY LUBRICANT 68 hydraulic oil for

Colorliners and Headliners and Mobil VACUOLINE 1409
for Newsliners or a Goss engineering approved
equivelent.
Sluggish blanket cylinder throwoff operation and registration “move errors”

are indicators of low accumulator pressure.
DANGER: DO NOT USE ANY GAS OTHER THAN DRY NITROGEN.

THE USE OF HIGH PRESSURE AIR OR OTHER GASES
CAN BE DANGEROUS.
CAUTION: THE ACCUMULATOR IS RATED FOR A MAXIMUM

WORKING PRESSURE OF 3000 PSI (20684 kPa). DO
NOT EXCEED THIS PRESSURE UNDER ANY CIRCUM-
STANCES.
SBM1357 L:\tp.ileaf\servicebulletins\newspaper Page 1 of 10

121 Broadway
Phone: (+1) 800-323-1200
Service Bulletin
HYDRAULIC AC-
CUMULATOR
WALL BRACKET
BLADDER
Figure 1 Coloriner Typical Accumulator Location
ACCESSORIES CHARGING THE ACCUMULATOR
When accumulators are shipped from the factory, they are not charged.
However, there may be a very low nitrogen charge left in the accumulator
from the factory test.
If the accumulator is being charged for the first time, pour some hydraulic
oil into its oil port and tilt the accumulator to allow the oil to coat the ID
of the shell. This provides initial lubrication between the bladder and the
shell.
To properly charge the accumulator, use the charging kit supplied with the
press. This kit (Part No. H01-1290) includes the items shown in Figure 2.
Page 2 of 10 L:\tp.ileaf\servicebulletins\newspaper SBM1357

121 Broadway
Phone: (+1) 800-323-1200
Service Bulletin
PRESSURE GAUGE — G-2.5

PART NO. 771500-00076
CHARGING HOSE — H-10

10 FEET PIPE PLUG
PART NO. 787501-00031
CHARGING VALVE — NV3

PART NO. 920500-00137
Figure 2 Accumulator Charging Accessories
The NV3 Charging Valve (Figure 3) thread onto the accumulator valve.
The connection can be made by hand, do not use a wrench. A leak-proof
seal is formed by the compression of the O-ring between these two valves.
The H10 charging hose connects the NV3 valve to the nitrogen bottle.
Turning the T handle opens the accumulator valve. Nitrogen can now flow
into the accumulator. Nitrogen charge is read on the gauge in the NV
valve.
After the accumulator is charged, the T handle is reversed allowing the
accumulator valve to close. The valve on the nitrogen bottle is also
closed.
Then the bleeder valve is opened to exhaust the nitrogen trapped in the
hose. The charging valve should not be left on the accumulator. After
charging, replace the cap nut on the accumulator valve for a secondary
seal.
Figure 3 Accumulator Charging Valve

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Service Bulletin
BLADDER TEST CHECKING THE ACCUMULATOR PRECHARGE PRESSURE

The precharge pressure of nitrogen gas in the accumulator bladder must
be checked at least once every six months. To check this pressure, do the
following:
1. Remove the gas valve guard. Refer to Figure 4. MAKE SURE THAT
THE GAS VALVE O-RING IS PROPERLY INSTALLED IN THE GAS
VALVE BODY.
GAS VALVE
GUARD
GAS VALVE
O-RING
TOP COVER
ASSEMBLY
TOP COVER
O-RING
Figure 4 Top Cover Assembly
2. Install a pressure gauge in the gauge port of the 3-way gas charging
valve. Refer to Figure 5 and 6.
3. Insert the pipe plug supplied with the charging kit in the charging port
of the valve. Tighten the plug securely.
4. Thread the 3-way valve onto the gas valve body located in the top cover
assembly of the accumulator.
5. Turn the bleeder valve counterclockwise to open it. Then close the
valve by turning it clockwise.
6. Turn the T-handle in the 3-way charging valve clockwise to depress the
stem in the gas valve body.

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Service Bulletin
7. Watch the pressure gauge. If the bladder is fully charged, the gauge
should read near maximum required. If the gauge reads less than re-
quired, charge the accumulator as described on the next page of this
manual.
8. Turn the T-handle counterclockwise as far as possible.
9. Turn the bleeder valve counterclockwise to bleed the pressure.
10. Remove the 3-way valve from the top of the accumulator. Then check
for leaks.
NOTICE: Do not leave the 3-way valve attached to the accumulator.

This valve is not intended to be a permanent leakproof
connection. The gas valve guard helps serve this pur-
pose.
11. Reinstall the gas valve guard.
THE CHARGING VALVE THREADS ONTO THE ACCUMULATOR VALVE. THE CON-
NECTION SHOULD BE MADE BY HAND; DO NOT USE A WRENCH. A LEAKPROOF
SEAL IS FORMED BY THE COMPRESSION OF THE O-RING BETWEEN THESE TWO
VALVES.
Figure 5 Pressure Check Assembly
Figure 6 Global Newsliner Typical Accumulator Location

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Service Bulletin
INSTALLATION OF KIT CONNECTING THE CHARGING ACCESSORIES
To connect the charging kit components, do the following:
1. Remove the gas valve guard. Refer to Figure 7. MAKE SURE THAT
THE GAS VALVE O-RING IS PROPERLY INSTALLED IN THE GAS
VALVE BODY.
valve. Refer to Figure 8.
3. Thread the 3-way valve onto the gas valve body located in the top cover
assembly of the accumulator.
4. Turn the bleeder valve counterclockwise to open it.
5. Turn the T-handle clockwise to depress the stem in the gas valve body.
This releases any pressure which may be in the bladder.
6. Turn the bleeder valve clockwise to close it.
7. Turn the T-handle counterclockwise to allow the stem in the gas valve
body to seat properly.
8. Connect one end of the charging hose to the charging port on the 3-way
valve.
9. Connect the other end of the hose to the regulator on the top of the
nitrogen bottle.

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Service Bulletin
THE CHARGING HOSE CONNECTS THE CHARG-

ING VALVE TO THE NITROGEN BOTTLE. TURNING
THE T-HANDLE OPENS THE ACCUMULATOR
VALVE ALLOWING NITROGEN TO FLOW INTO
THE ACCUMULATOR. THE NITROGEN CHARGE IS
READ ON THE GAUGE IN THE CHARGING VALVE.
Figure 7 Accumulator Assembly Figure 8 Charging Accessories

121 Broadway
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Service Bulletin
PROCEDURE CHARGING
Never start the hydraulic pump before charging the accumulator. The
pump pressure tends to force the bladder up into the charging valve at
the top of the accumulator and can damage the bladder.
To charge the accumulator, refer to Figure 9 and proceed as follows:
1. MAKE SURE THAT THE HYDRAULIC POWER UNIT IS OFF.

valve.
CAUTION: HYDRAULIC SYSTEM PRESSURE IS 1000 PSI (6895
kPa). BEFORE STARTING ANY MAINTENANCE WORK
ON THE SYSTEM, SHUT OFF THE POWER UNIT. WHILE
WORK IS IN PROGRESS, MAKE SURE THAT NO ONE
STARTS UP THE HYDRAULIC POWER UNIT AND THE
PRESS.
3. Turn the bleeder valve clockwise as far as possible.
4. Connect one end of the charging hose to the charging port on the 3-way
valve.
5. Turn the T-handle in the 3-way charging valve clockwise to depress the
stem in the gas valve body.
6. Open the valve in the top of the nitrogen bottle slightly to allow a small
flow of nitrogen into the accumulator.
NOTICE: If the nitrogen is allowed to flow too rapidly into the accu-
mulator, it can damage the bladder.
7. Watch the pressure gauges on the accumulator and the nitrogen bottle.
Allow the pressure to stabilize between 100 psi (689 kPa) and 200 psi
(1379 kPa). At this point, the bladder is fully expanded and you may
fully charge the accumulator.
8. When the pressure reaches near maximum required, allow the system
to stabilize for 5 to 10 minutes. Usually, the gas pressure will drop
slightly due to molecular movement of the gas. If the gas pressure does
drop slightly, add enough gas to bring the system up to the desired
precharge pressure.
9. When the gas charging procedure is completed, turn the T-handle
counterclockwise to allow the gas valve in the accumulator to seat.

121 Broadway
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Service Bulletin
10. Close the valve in the top of the nitrogen bottle.

11. Turn the bleeder valve counterclockwise to bleed the pressure in the
charging hose.
12. Remove the 3-way valve from the top of the accumulator. Then check
for leaks.
NOTICE: Do not leave the 3-way valve attached to the accumulator.

This valve is not intended to be a permanent leakproof
connection. The gas valve guard helps serve this pur-
pose.
13. Reinstall the gas valve guard.
RECHARGE KIT PARTS REPLACEMENT PARTS
A complete list of the replacement parts shown in Figure 10 is given in

the following chart. To order any of these parts, contact:
Goss International Corporation Customer Parts Dept.
WARNING: MAKE SURE THAT THE GAS CHARGE IS COMPLETE-

LY VENTED BEFORE DISASSEMBLING THE ACCUMU-
LATOR.
REPLACEMENT PARTS FOR MODEL R210-10

PART NUMBER PART NAME
1 Gas Valve Guard
2 Gas Valve O-Ring
3 Top Cover Assembly
4 Top Cover O-Ring
5 Bladder
6 Accumulator Shell
7 Oil Port Nut
8 Oil Port Housing
9 Oil Port O-Ring
10 Oil Port Backup Ring
NOTICE: Part 4 is supplied with Part 5

121 Broadway
Phone: (+1) 800-323-1200
Service Bulletin
THE CHARGING VALVE THREADS ONTO THE ACCU-
MULATOR VALVE. THE CONNECTION SHOULD BE
MADE BY HAND; DO NOT USE A WRENCH. A LEAK-
PROOF SEAL IS FORMED BY THE COMPRESSION OF
THE O-RING BETWEEN THESE TWO VALVES.
THE CHARGING HOSE CONNECTS THE CHARGING

VALVE TO THE NITROGEN BOTTLE. TURNING THE T-
HANDLE OPENS THE ACCUMULATOR VALVE AL-
LOWING NITROGEN TO FLOW INTO THE ACCUMULA-
TOR. THE NITROGEN CHARGE IS READ ON THE
GAUGE IN THE CHARGING VALVE.
Figure 9 Charging Accessories Figure 10 Accumulator Assembly

121 Broadway
Phone: (+1) 800-323-1200
Service Bulletin
Bulletin Type
ELECTRICAL
nMECHANICAL Equipment Type: Colorliner Unit
OPERATIONAL
T o p ic : Oil Leaks at Drive Side Covers

February 8, 1990
INTRODUCTION Due to the fact that the drive side covers do not seal off the ends of
the o-rings at the ends of the unit frame, oil leakage occurs.
Thererfore, before stacking unit frames, apply HYLOMAR sealant over
and under the o-rings at approximately the last three inches of the
frame ends.
Cut o-ring flush Cover

to end of frame.
3 inches
Apply
Hylomar
Sealant
Cut o-ring flush Top View — Units A and C

to end of frame.
3 inches
Apply
Hylomar
Sealant
Top View — Units B and D

121 Broadway
Phone: (+1) 800-323-1200
Service Bulletin
Bulletin Type
ELECTRICAL
OPERATIONAL
T o p ic : Reengaging The Overload Clutch

March 2, 1990
INTRODUCTION Each Colorliner Unit is equipped with an overload and a drive clutch
(Figure-1). The overload clutch is located directly behind the horizontal
drive shaft gear on the 10 side of the unit drive side. The function of
this clutch is to protect the unit in the event of a major malfunction
between the vertical drive and the cylinders.
PROCEDURE Adjacent to the overload clutch is the drive clutch. This clutch is
controlled by an air solenoid valve which is located on the operating 10
side of the unit behind the arch doors. The function of this clutch is to
transmit power from the horizontal drive shaft to the number 10 plate
cylinder.
An overload condition can occur due to:
a. Jamming in the cylinder nips.
b. Jamming in the gear train between the vertical drive and the cylin-
ders.
c. Excessive unit acceleration or deceleration.
In the event of condition (c.), the unit will break loose from the drive shaft
and will continue idling while the drive slows down and comes to a red
button stop. The unit may reengage on the run under these circumstances
or it may reengage 180 degrees out of time. If out of time reengagement
occurs, retime with auto retime switch. In general when the overload clutch
pops out due to a jam, it can be reengaged by following the instructions
below:
Reengage the overload clutch as follows:
1. PUT THE PRESS ON SAFE.
2. Bar the plate cylinder one half revolution. If the inital direction choosen
doesn’t reengage the clutch, it will be necessary to reverse direction
for one half revolution.
3. While barring the plate cylinder, listen for the clutch to snap into en-
gagement.
NOTICE: If the clutch should pop in 180 degrees before its timing
mark, retime the unit with the auto retime switch. The
drive clutch will then be engaged in the correct position.

121 Broadway
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Service Bulletin
The overload clutch may not reengage if the vertical drive is allowed to
rotate.
While reengaging the overload clutch, the drive clutch must remain en-
gaged. If the drive clutch is not in MAIN DRIVE it may be necessary to
manually override the air valve and bar the cylinder around to reengage
the drive clutch before proceeding with the overload clutch reengagement.
After the overload clutch has been reengaged, release the manual over-
ride solenoid valve.
DRIVE SIDE FRAME
HORIZONTAL GEARBOX
DRIVE SHAFT
VERICAL DRIVE
SHAFT GEAR
HORIZONTAL
DRIVE SHAFT
GEAR
DRIVE CLUTCH OVERLOAD CLUTCH
Figure 1

121 Broadway
Phone: (+1) 800-323-1200
Service Bulletin
Bulletin Type
ELECTRICAL
OPERATIONAL
T o p ic : Oil Level
May 29, 1990
INTRODUCTION It is critical to maintain proper oil level in the Colorliner base unit.
PROCEDURE To check the oil level proceed as follows:

1. ALWAYS MAKE SURE THAT THE PRESS IS STOPPED AND ON
SAFE.
2. If the press was running, wait approximately 1/2 hour before checking
oil level.
3. Open the doors on the drive side housing of the base unit.
4. Measure the distance from the oil surface to the top of the oil pump
mounting plate (Figure 1). The oil level should be 1-1/4 +1/4 inches
(31.75 +6.35 mm) below the top surface of this plate.
5. If the oil level is below this specification, proceed as follows:
a. Add Mobil Vactra Oil No. 2 to the base unit as specified above.
b. Run the press at 40000 IPH for approximately 10 minutes.
c. STOP THE PRESS AND PUT IT ON SAFE. Then wait approxi-
mately 1/2 hour before checking the oil level.
d. Recheck the oil level. If its within specifications, close the doors on
the drive side housing and continue with normal press operations.
If not, repeat steps a, b, c, and then recheck oil level.
e. If too much oil exist, drain it out at the oil drain valve and recheck
the oil level.
NOTICE: The oil drain valve is located in the oil return line on the
operating side of the unit, just above and to the left of the
hydraulic accumulator.
If necessary to change oil in the unit sump, refer to your Colorliner mainte-
nance manual. Always use Mobil Vactra Oil No. 2 in the unit sump.

121 Broadway
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Service Bulletin
VERTICAL DRIVE SHAFT DRIVE SIDE FRAME
TOP SURFACE OF
THE OIL PUMP
MOUNTING PLATE
OIL LEVEL
1-1/4 +1/4 Inches

OIL
(31.75 +6.35 mm)
PUMP
UNIT OIL SUMP
Figure 1 Unit Sump Oil Level

121 Broadway
Phone: (+1) 800-323-1200
Service Bulletin
Bulletin Type
ELECTRICAL
OPERATIONAL
T o p ic : Anti-Wrap Trolley Setup

June 11, 1991
INTRODUCTION All Colorliner presses now use the Goss style constant on
anti-wrap trolleys.
PROCEDURE If they are incorrectly adjusted or need to be re--adjusted, the

following procedure should be followed.
1. Put the press on safe.
2. Clean any paper dust, ink, etc. from the trolley arrangement.
3. Loosen the cap screw clamping the trolley assembly to the shaft. Slide
the trolley assembly along the shaft until the trolley is positioned over
the margin of the printed web.
4. Apply heavy grease to the following areas:
a. lever to shaft
b. adjusting screw to spring rod
c. spring rod to spring rod stud. (Figure 1)
5. Insert cotter pin in the middle hole of the spring rod and screw in the
adjusting screw. (figure 1)
6. Make sure the spring lever is loose on the shaft and the air cylinder
is in the ’TROLLEY ON’ position (note: some trolley arrangements re-
quire the air cylinder to be retracted in the ’TROLLEY ON’ position).
Then set the trolley wheel so that there is 1/16“ clearance from the
roller. Now clamp the spring lever to the shaft. (Figure 1)
7. Turn out the adjusting screw until there is 3/16” to 5/16” of clearance
between the cotter pin and the adjusting screw. (Figure 2)
8. Pull the trolley wheel away from the roller to check if the mechanism
moves freely under spring pressure. (Figure 2)
9. Cycle the air cylinder a few times to make sure the trolley assembly
works smoothly.
The 1/16” clearance is needed to isolate the air pressure from the trolley
wheel. Only the spring should be used to press the trolley wheel against
the roller.
Notice: KEEPING THE MECHANISM CLEAN AND GREASED WILL
GUARANTEE SMOOTH OPERATION.

121 Broadway
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Service Bulletin
FIGURE 1

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Service Bulletin
FIGURE 2
121 Broadway
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Service Bulletin
Bulletin Type
ELECTRICAL
OPERATIONAL
T o p ic : Horizontal Drive Clutch

Lubrication
January 7, 1992
INTRODUCTION The horizontal drive clutch has grease fittings located along the drive
shaft at each clutch position. These clutches require lubrication to
ensure proper operation.
PROCEDURE To insure proper lubrication of the horizontal drive clutch, make sure
that the following fittings are greased monthly (see picture on page 2):
1. FAR LEFT GREASE FITTING (FACING COUPLING)
The pilot bearing must be greased with the clutch in the OPEN or DIS-
ENGAGED position. Continue greasing until grease can be observed
between the two external clutch gears.
NOTICE: Initial greasing of the pilot bearing requires a consid-
erable amount of grease. If a pneumatic grease gun
is used, regulate the pressure so the grease shield on
the right side of the bearing is not blown out.
2. MIDDLE LEFT GREASE FITTING (Round Recess)
The clutch gears must be greased with the clutch in the CLOSED or
ENGAGED position. Add grease until it appears at the coupling side
of the internal gear. Wipe off excess grease.
NOTICE: A second grease fitting is located 180 degrees from
the first one. The horizontal drive shaft must be ro-
tated 180 degrees to locate this fitting.
3. MIDDLE RIGHT GREASE FITTING (Square Recess)
The clutch gear must be greased with the clutch in the CLOSED or
ENGAGED position. Add grease until it appears at the motor side of
the clutch gear slide.
NOTICE: A second grease fitting is located 180 degrees from
the first one. The horizontal drive shaft must be ro-
tated 180 degrees to locate this fitting.
4. FAR RIGHT GREASE FITTING
The yoke shifter bearing should be greased with the press “on a walk.”
Add grease until it appears from the motor side shield.
NOTICE: On Colorliner units, a second grease fitting is located
180 degrees from the first one.

121 Broadway
Phone: (+1) 800-323-1200
Service Bulletin
Lubricate where indicated.

121 Broadway
Phone: (+1) 800-323-1200
Service Bulletin
Bulletin Type
ELECTRICAL
OPERATIONAL
T o p ic : Press Drive Lubrication

January 7, 1992
INTRODUCTION Two possible reasons for a unit and/or folder oil pump to lose prime
are:
PROCEDURE 1. After changing oil in the unit or folder oil sumps, the unit or folder oil
pump can lose its prime.
2. If the vertical drive overload clutch on a unit disengages due to a wrap-
up or some other obstruction, the clutch must be reset. While resetting
the clutch, the unit oil pump can lose its prime.
TO PREVENT POSSIBLE PROBLEMS AFTER CHANGING OIL OR RE-
SETTING THE CLUTCH, RUN THE PRESS AT APPROXIMATELY
10,000 PPH AND VERIFY THAT OIL IS BEING SUPPLIED TO THE
HIGHEST PAN BEHIND THE DRIVE SIDE HOUSING.

121 Broadway
Phone: (+1) 800-323-1200
Service Bulletin
Bulletin Type
ELECTRICAL
n MECHANICAL Equipment Type: Colorliner Unit
OPERATIONAL
T o p ic : Distribution Ink Drum Motor

Gearboxes - Lubrication, Oil
Seals, and Vent Plugs
November 20, 1991
INTRODUCTION Each printing couple is equipped with its own distribution ink drum
motor and gearbox which is located on the operating side of the unit.
PROCEDURE LUBRICATION
The information in your manual should be changed to read: Change the
gearbox oil after the initial 100 hours of operation and thereafter at regular
intervals of 2500 hours or every 6 months.
OIL SEALS
The gearbox high-speed oil seals (between the gearbox and motor) are
replaceable maintenance items. These seals should be replaced after
3000 hours of operation. Refer to the Oil Seal Chart for the correct part
number.
OIL SEAL CHART
Manufacturer Colorliner Headliner Press #
Alling-Lander Ref. 2001-5, 1014-891559 (CR 9935) --
Boston Gear B/G #55905 B/G #55478
Dietz 2181-891557 (Metric 30 X 50 X 8)
-- 5001
Gear Motors to
Standard E20737 D43978 5020
D48339 present
Digital E27547 --
Reducer E27681 --
VENT PLUGS
Gearbox vent plugs should be checked and replaced if they do not have
a “zero” psi type breather. (Colorliner part number 7-727700, 3/8 NPT.
Headliner part number 302-C40054, 1/4 NPT.)

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Bulletin Type
ELECTRICAL
OPERATIONAL
T o p ic : Distribution Ink Drum Motor

Gearboxes - Lubrication
and Oil Seals
November 20, 1991
INTRODUCTION Each printing couple is equipped with its own distribution ink drum
motor and gearbox which is located on the operating side of the unit.
LUBRICATION
The information in your manual should be changed to read: Change the
gearbox oil after the initial 100 hours of operation and thereafter at regular
intervals of 2500 hours or every 6 months.
OIL SEALS
The gearbox high -- speed oil seals (between the gearbox and motor) are
replaceable maintenance items. These seals should be replaced after
3000 hours of operation.

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OPERATIONAL
T o p ic : Main Oil Pressure Setting

July 12, 1993
INTRODUCTION The Operation Manual supplied with Colorliner presses indicates

that there is a relief valve in the lubrication system for each
printing unit. This relief valve is located next to the oil filter at the
drive side of the unit on the 13 side.
The purpose of this valve is to control the oil pressure in the unit. THIS
VALVE IS ADJUSTABLE. It should be set to produce 40 to 45 psi (276
to 310 kPa) at a press speed of 40,000. This check should be made after
at least 1 hour of continuous operation to insure a warm oil condition. The
pressure can be read on the gauge mounted next to the oil filter.
To change the pressure, remove the cap on the relief valve and loosen
the locknut. To increase pressure, use a screwdriver to turn the adjusting
nut clockwise; to decrease pressure, turn the adjusting nut counterclock-
wise. When the correct pressure is reached, tighten the locknut and rein-
stall the relief valve cap.

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Bulletin Type
ELECTRICAL
OPERATIONAL
T o p ic : Hydraulic Cyliner Repair Kit

July 30, 1993
INTRODUCTION If you experience leaks from a hydraulic throwoff cylinder, be sure to

inspect the cylinder shaft seals. Worn seals can be replaced and are
available in kit form.
PROCEDURE Two types of cylinders have been used:
Earlier Colorliner units used cylinder #1--E19440.

The repair kit for these is 1--B163600.
Later Colorliner units and MetroColor units used cylinder # 1--E27549

The repair kit for these is 1--B163601.
Contact Goss Customer Parts Department at 1--800--323--1200 for order-

ing information.

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Bulletin Type
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OPERATIONAL
T o p ic : Hydraulic Inch Drive Motor

Front Seal Oil Leaks
August 24, 1993
INTRODUCTION Inch drive motors with leaky front seals should be carefully removed
from the unit and returned to the supplier, Nutron Motor Company, for
warranty repair. Nutron will replace defective shaft bearing assemblies
under warranty provided the motors have not been opened or
damaged.
When removing a motor, do not use any tool (ie. pipe wrench) that
may scratch or in any way damage the shaft surface. Any evidence of
damage will void the warranty.
Prior to shipping the motor, contact:

Arnold H. Beveridge
Nutron Motor Co., Inc.
Phone 207--439--5272
Mr. Beveridge will issue a return authorization number for the motor. This
number should be attached to the motor prior to shipment. Also include
a note indicating that the motor is being returned as per Rockwell Graphic
Systems agreement.
Ship the defective motor to:

Nutron Motor Co., Inc.
102 Dow Highway
Eliot, ME 03903
Attention: Arnold H. Beveridge
Nutron will repair and return the motor in approximately 2 weeks.

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Bulletin Type
ELECTRICAL
OPERATIONAL
T o p ic : Spray Bar Water

Coupling Retrofit
February 5, 1994
INTRODUCTION A new dampening feed coupling has been made available for Goss
Spray bars. Goss part # B163499 is made up of a new style coupling
(male & female), a new elbow, and a 6” length of tubing.
PROCEDURE 1. With the press at a standstill and unit power off, shut off the dampener
supply to the unit.
2. Disconnect the dampening feed coupling and cut the hose as shown
below.
3. Remove the elbow and fitting from the spraybar. Spraybar removal
may be necessary.
4. Install the new male connector assembly (with elbow and tubing) into
the spraybar.
5. Install the new female coupling’s barbed end into the dampening feed
hose.
6. Reinstall the spraybar if previously removed and connect the new cou-
plings.
7. Turn on the dampening supply for this unit and check for leaks.
Dampening
Return
Dampening
Feed Remove
Cut
Reuse Clamp
If Present
AirInlet

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Service Bulletin
Bulletin Type
ELECTRICAL
OPERATIONAL
T o p ic : Preventing Corrosion on
Digital Page Packs
April 21, 1994
INTRODUCTION When repairing and installing digital page packs, it is essential to apply
a thin even coat of ”Rustveto” corrosion inhibitor to the mating
surfaces. Failure to do so will allow corrosion to form and make future
removal difficult. See diagram below.
PROCEDURE In the event corrosion has already occurred, follow these steps.
1. Scrape any loose rust/corrosion from the cross brace and page pack.
Use a wire brush on both surfaces and wipe clean.
2. Use a suitable rust remover such as Mirachem 250 or equivalent, fol-

lowing the directions provided with the product. Be sure to follow all
recommended safety practices!
3. Apply a thin even coat of Rustveto to both surfaces and reinstall the
page pack.
Rustveto is available from Goss Customer Parts at 1--800--323--1200. The

part number is 51--775800.
DIGITAL INK
PAGE PACK
APPLY A THIN EVEN

COAT OF RUST--VETO
TO BOTH SURFACES

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Bulletin Type
ELECTRICAL
OPERATIONAL
T o p ic : Sidelay Assembly Modification

September 13, 1994 (Updated July 11, 1996)
INTRODUCTION The following modification can be made to update existing sidelay

assemblies to the newer enhanced design (new design started with
press serial number CN-2072). Modification will require purchase of
new parts and alteration of others. Before considering this
modification you should verify the following items, all of which
can impact sidelay performance.
PROCEDURE 1. Impression Setting: Verify correct impression settings using go/no go

gauge. Be sure to check cylinders at the ends and in the center. Check
center of cylinder by loosening one of the two blankets and slide it
toward the nearest unit side frame. This will give you enough room to
insert the go/no go gauge between the cylinders. Be sure to check
setting at centers of cylinders. Impressions can be OK at the ends but
tight at the center. This indicates a skewed (out of alignment and/or
un--level) cylinder. You will not realize this adverse condition unless the
impression is checked at three places: operators side, drive side, and
center!
2. Accumulator Pressure: Verify that pressure is at a minimum of 400

PSI. Use accumulator recharging kit as sold by Goss (ask for list
1290H1).
3. Main Hydraulic Pump Pressure: Verify that pressure is a minimum

of 1000 PSI.
4. Hydraulic Manifold Block: Test for manifold block leaks by cycling

sidelay from one extreme to the other extreme (either op to drive or
drive to op). Entire cycle should take 39 seconds or less. A cycle time
in excess of 39 seconds would indicate a manifold block or hydraulic
line leakage or blockage.
5. Side Lay Mechanism Backlash: Check assembly for excessive back-

lash by:
A. Hook up laptop computer to correct press unit & level.
B. Center sidelay adjustment.
C. Mount dial indicator base to inside of operators side frame then
zero dial indicator on outside edge of cylinder.
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D. Using the laptop, request a sidelay movement of .020” toward the

operators side. Read indicator and note reading, marking this
value ”Center to Oper.”
E. Zero dial indicator.
F. Using the laptop, request side lay move of .020” to the drive side.
Read and note dial movement. Mark this value ”Oper to Drive”.
G. Obtain the assembly backlash value by subtracting as follows:
”Center to Op”
-- ”Oper to Drive”
Total sidelay assembly backlash
NOTICE: An acceptable amount of sidelay assembly backlash is

.003 -- .004”
If these items all check satisfactorily, review the procedure below to be-
come familiar with the modification procedure.
PROCEDURE This modification requires the following parts (per sidelay assembly).
QTY.. DESCRIPTION PART NUMBER
1 Bearing & Sleeve set 1--B162671

2 Thrust Collars 1--B162611
2 Screws 1--B162696
1 Hardened Locknut 405--826300
2 Studs 1--D61636
1 Lockwasher 20--C40383
2 Washer Plates 1--B159505
1 Alignment Fixtures (special tools) (see page 6)
1 Screw Alteration Drawing E31706
1 Screw Sidelay Adjust E19309
1 Sidelay & Circumferential Assembly Drawing
Note: All new parts must be used for this alteration!
1. Existing screw shaft E19309 can be altered per drawing E31706. If

screw shaft was recently purchased from GIC, discard spacer
1--B162620 (1.5” O.D. x .125” thick). Drill .125” diameter lubrication
hole and cut the oil access groove on the journal as shown on the
following page.

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2. Bearing set 1--B162671 is assembled with the bearings FACE TO

FACE and the sleeve in the bearing bores between the two thrust col-
lars 1 --B162611 (1.5” O.D. x .281” thick). This assembly is held on the
shaft in the same manner as the original assembly with two excep-
tions:
Locknut 405--826300 is a hardened alloy whereas original locknut was
not.
Locknut 405--826300 is torqued to 30 ft. lbs.
The ground sleeve in the bearing set allows just enough clearance to
allow the bearings to relocate when required.
3. Sidelay plate will need to be realigned using special alignment fixtures

(see following pages).
4. Body fit washers on sidelay plate will need to be relocated and re--
pinned. New body fit cap screws B162696 and plate support studs
1--D61636, provide a more accurate location of sidelay plate because
a portion of the body fit screw engages the counterbore in the stud.

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NOTICE: DO NOT ATTEMPT TO REUSE OLD PIN LOCATIONS

FOR THE BODY FIT WASHERS. THERE IS ENOUGH
FLEX IN THE SYSTEM TO ACCOMPLISH THIS BUT
THE PLATE WILL MIS--ALIGN WHEN THE FIXTURE IS
REMOVED.
NOTICE: A FAILED SIDELAY BEARING THAT HAS DISINTE-

GRATED, OR REQUIRES GRINDING TO REMOVE IT,
CAN CAUSE CONTAMINATION OF THE GEAR HUB
AND CYLINDER SPLINE INTERFACE. THE GEAR
HUB MUST BE REMOVED AND THE GEAR HUB AND
CYLINDER SPLINES MUST BE THOROUGHLY
CLEANED. IF GALLING HAS OCCURRED IN THE
SPLINE INTERFACE, USE A VISUAL INDICATOR
(SUCH AS PRUSSIAN BLUE) TO DETERMINE ANY
HIGH SPOTS. DRESS ONLY THESE AREAS. DO NOT
DRESS THE ENTIRE SPLINE! THE SPLINE IS IN-
TENDED TO BE A VERY CLOSE TOLERANCE TRAN-
SITION LOCATION FIT AND EXCESS CLEARANCE
WILL RESULT IN PREMATURE WEAR AND DAMAGE
TO THE CYLINDER SPLINE AND HUB RESULTING IN
LOSS OF REGISTRATION. TAKE PRECAUTIONS TO
KEEP CONTAMINANTS OUT OF THE LUBRICATION
SYSTEM DURING THE REPLACEMENT PROCESS.

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NEW DESIGN
EXPLODED VIEW

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OLD DESIGN
EXPLODED VIEW

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Special Tools
The following is a list of special tooling fixtures required to perform this

alteration. Drawings are also provided for your convenience. Use them for
reference and direct any questions to Goss Field Service at
630--755--9300.
QTY. DESCRIPTION REF. DRWG

1 Sidelay plate removal stud (.735” X 10”) A
1 Sidelay plate removal stud (.735” X 8”) A
1 Bearing removal cup (3 1/2” X 3”) B
1 Spanner nut socket (1 3/8” X 1 1/4”) C
1 Spanner nut socket (2 3/4” X 1 5/8”) D
1 Sidelay assembly locating tool (7” X 3 5/8”) E
1 Bushing (1 7/8” X 2 1/2”) F
1 Drill fixture (5 5/16” diameter) G
1 Washer plate modification tool (1 5/16” X 2 1/4”) H
2 Washers (1.360” X .233”) J
DRWG A -- Sidelay Plate Removal Stud (1 each required)
This tool is used to remove the sidelay plates.
3/ x 10
4
.735
3/ 1”
1/ 4”
2
”A”
A & C levels ”A” 10”

B & D levels ”A” 8”

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DRWG B -- Bearing Removal Cup (1 required)
To help remove bearings, this tool is slid over the sidelay shaft and the
brass nut is tightened to draw out the sidelay bearings.
3”
3.5” 3” 1.020”
1 /2 ”
DRWG C -- Spanner Nut Socket (1 required)
This tool is used to tighten the spanner nut on the end of the sidelay shaft
to 30 foot pounds.
1/ 1”
8” .170”
3/
8”
Drive
Socket
1 3 /8 ” 1 1 /8 ”
1/
2”
.100”

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DRWG D -- Spanner Nut Socket (1 required)
This tool is used to torque the circumferential assembly nut to 5 foot
pounds (60 inch pounds).
.75” 5/
.25” 8”
3/
8”
Drive
Socket
2 3 /4 ”
2 3 /8 ”
.200”
.200”
DRWG E -- Sidelay Assembly Locating Tool (1 required)
This tool is bolted onto the plate cylinder and used to position the sidelay
plate. Refer to assembly drawing F18240.
1/
2” 3/
8”
5/ 2.25”
16” 7/
1.25” 8”
1.75 ”
1.25” 2”
3 5 /8 ” 1.370”
2 7 /8 ”
1/
2” x 13 x 1”
Thread Dimension
2.437”
+/-- .001

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DRWG F -- Bushing (1 required)
This tool is inserted through the sidelay plate onto the sidelay assembly
locating tool (above) to position the sidelay plate. See drawing F18240.
2.5”
1.875”
+ .000 1.378”
-- .001
DRWG G -- Drill Fixture (1 required)
This tool is used to drill the sidelay washer plates and the sidelay plate
after the sidelay assembly has been properly located.
5 5/16” 1” 5/
16”
3” 1 3 /8 ” 2”
3/
8”
11/ Reamer
32” Bushing
Drill
Bushing

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DRWG H -- Supplemental Washer Plate Modification Tool (1 required)
This tool is only used in conjunction with the drill fixture (above) when the
original washer plates are being reused. If new washer plates
(1--B159505) are provided, do not use this tool.
2 1 /4 ”
3/
4”
3/ 1 3 /8 ”
4”
1 5/16”
DRWG J -- Washer (3 required)
Install under lockwasher.
.233”
.780”
1.360”

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Bulletin Type
ELECTRICAL
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T o p ic : Dampener Drum Alteration

December 12, 1994 (Updated March 20, 1996)
INTRODUCTION It has been found that the potential exists for the water dampener drum
journal to break. In order to prevent this, the drive side journal
mounting has been redesigned. Below is a drawing showing the
addition of a third support bearing.
PROCEDURE 1. Remove drive gear and 1.25” spacer.
2. Remove seals from the new bearing before installing it.
3. Press bearing on adaptor and install snap ring.
4. Install bearing assembly and gear as shown.
SEALED BEARING
722605--1070 (remove seals)
EXISTING
4.000” SPACER
150--C40164 BEARING ADAPTOR

SNAP RING C145842
REFERENCE DRAWING C145844
Alteration parts are available from the Goss Customer Parts at

1-800-323-1200.

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Bulletin Type
ELECTRICAL
OPERATIONAL
T o p ic : Spray Bar Coupling Repair

February 1, 1995
INTRODUCTION A repair kit is now available for the spray bar air & water couplings.
This kit, part # 2--B163038, includes:
2 valves (1 male, 1 female)

2 springs (1 male, 1 female)
2 seal washers
The seal washers in this kit are made of an improved material that is more
resistant to chemicals commonly found in fountain solution. New couplings
may be purchased if necessary:
air coupling 1--B160935

water coupling 1--B160936
A retrofit kit that includes upgraded couplings is also available (part #

B163499) and is described fully in Service Bulletin SBM5034.
To order the repair and retrofit kits contact Goss Customer Parts at
1-800-323-1200.

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Bulletin Type
ELECTRICAL
OPERATIONAL
T o p ic : Digital Page Pack Check

Valve Retrofit
February 1, 1995
INTRODUCTION Under certain conditions, some Digital Page Packs have developed a
leak path between the valve cage and spool which allows line pressure
seepage. This is due to corrosive agents in some of the color inks.
Although this seepage does not impact the performance of the page
pack, it can result in tinting, excessive start--up waste and house
keeping issues.
The anti--leak check valve, # 1--C142398, is designed to stop the flow of
ink under normal line pressure while allowing ink to flow when the page
pack valve is open. The valve is installed between the ink manifold at the
output of the page pack and the individual ink column hose(s). One valve
is required for each ink column.
Use caution when installing the check valves since the lower seat on the
valves is made of Derlin which could be damaged if over--tightened. To
avoid this, use the flats on the lower seat to tighten the valve to the hose
manifold fitting. When tightening the hose to the valve, use a back up
wrench on the flats at the output side of the valve to prevent over tighten-
ing.
Contact Double Width Field Service at 630--755--9300, for more informa-
tion.

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OPERATIONAL
T o p ic : Spray Bar Maintenance

July 10, 1995
INTRODUCTION Each unit spray bar is equipped with eight solenoid valve coils. These
coils and their connectors should be protected from moisture which
may accumulate in the electrical cavity. When performing preventive
maintenance, be sure to inspect the coils for this condition.
PROCEDURE Check the solenoid valves using the following procedure.
1. Lift all of the solenoid valves and inspect them for signs of rust or corro-
sion on any mating surfaces. Clean as necessary and replace any coils
that are severely corroded (part # 1--C134347).
2. Inspect the harness for damaged/exposed wires or corrosion and re-

place the harness (1--E20341) if any of these conditions are present.
3. Apply liberal amounts of Dow Corning 44 Silicone Grease to the fol-

lowing locations:
A. Under the solenoid coil and around the actuator stem.
B. Into the wire grommet cavity on the solenoid.
C. The converging point of the harness wires at the bulkhead connec-
tion.
D. Inside and behind each half of the solenoid coil to harness connec-
tor.
E. Inside of each grounding connector.
F. All around the outside of the solenoid coil and completely around
the retaining nut (after tightening).
To order the repair kit contact Goss Customer Parts 1-800-323-1200.

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Bulletin Type
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OPERATIONAL
T o p ic : Hydraulic Pump Adjustment

(Catching Fluid Systems)
December 12, 1995
INTRODUCTION If your hydraulic system is running abnormally hot (over 100° F),
check for oil going over the relief valve. This can be determined by
listening for a shearing (hissing) noise near the relief valve (see below)
which may indicate that the pump compensator is set to the same
pressure as the relief valve. The compensator pressure should be
lower than the relief valve setting. Another indication would be if the
relief valve temperature is noticeably higher than the reservoir.
RELIEF
VALVE
GAUGE
NOTICE: Dual pump systems will have dual relief valves.

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To reset the compensator and relief valve adjustments, follow these steps:
1. Remove the plastic cap from the relief valve and loosen the locknut.
With the pump running and the system dead--headed (no flow/no units
running), turn the adjustment screw all the way in the clockwise direc-
tion.
2. Locate the pump compensator adjustment (below). Remove the acorn
nut and loosen the locknut.
PUMP COMPENSATOR
ADJUSTMENT
3. Turn the exposed allen screw clockwise until the pressure gauge reads
1500 PSI.
NOTICE: DO NOT LEAVE THE SYSTEM RUNNING AT THIS HIGH

PRESSURE FOR MORE THAN A FEW MINUTES!
4. Return to the relief valve and turn the adjustment counterclockwise
until the relief valve starts to crack (hissing sound). Tighten the locknut.
5. Now turn the compensator adjustment counterclockwise until the
gauge reads 1000 PSI. Tighten the locknut and replace any covers
previously removed.
6. Repeat for the other pump.

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T o p ic : Hydraulic Pump Adjustment

(HyConco Systems)
December 12, 1995
INTRODUCTION If your hydraulic system is running abnormally hot (over 100° F),
check for oil going over the relief valve. This can be determined by
listening for a shearing (hissing) noise near the relief valve (see below)
which may indicate that the pump compensator is set to the same
pressure as the relief valve. The compensator pressure should be
lower than the relief valve setting. Another indication would be if the
relief valve temperature is noticeably higher than the reservoir.
RELIEF
VALVE
(PRY OFF
COVER)
Note: Dual pump systems will have dual relief

valves.
PROCEDURE To reset the compensator and relief valve adjustments, follow these
steps:
1. Remove the plastic cap from the relief valve and loosen the locknut.
With the pump running and the system dead--headed (no flow/no units
running), turn the adjustment screw all the way in the clockwise direc-
tion.
2. Locate the pump compensator adjustment (below). Remove the acorn

nut and loosen the locknut.

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PUMP
COMPENSATOR
ADJUSTMENT
DO NOT
ADJUST!
3. Turn the exposed stem clockwise until the pressure gauge reads 1500
PSI.
NOTICE: DO NOT LEAVE THE SYSTEM RUNNING AT THIS HIGH

PRESSURE FOR MORE THAN A FEW MINUTES!
4. Return to the relief valve and turn the adjustment counterclockwise

until the relief valve starts to crack (hissing sound). Tighten the locknut.
5. Now turn the compensator adjustment counterclockwise until the

gauge reads 1000 PSI. Tighten the locknut and replace any covers
previously removed.
6. Repeat for the other pump.

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Bulletin Type
ELECTRICAL
OPERATIONAL
T o p ic : Hydraulic Cylinder
Repair/Rebuild
February 23, 1996
INTRODUCTION The hydraulic cylinders used for the impression throw--offs are subject
to wear, over time, and can develop leaks. The following explains seal
replacement for cylinders that have developed leaks as well as rebuild
information for those wanting to replace the internal piston seals.
Cylinder Seals
Earlier Version Cylinders

E19440
Later Version Cylinders

E27549

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E19440 Cylinder Seal Replacement -- Retrofit Seal Repair Kit Part

Number is B163600
NOTICE: It is important that the work area is clean and free of dirt
and dust. Contamination can cause cylinder damage
leading to premature failure.
1. Inspect the piston rod surfaces for deep scratches or scoring. Dam-
aged rods are not good candidates for rebuilding.
2. Remove one gland assembly using a 2” hex socket (replace only one
gland assembly at a time in order to maintain proper alignment of the
ram).
Back--Up
Washer
Rod Seal
Retaining Ring
’O’ Ring
GLAND ASSEMBLY
3. Fully extend the rod (towards the end of the removed gland) and in-
spect for scratches. If the surface has minor scratches you can clean
it up using a 250--320 grit emery paper. Cover the piston chamber with
a damp cloth to prevent contamination. Wipe all surfaces with a damp
cloth following the polishing.
4. Lubricate the rod surface, seal contact lips, and new ’O’ rings with hy-
draulic oil.
5. Carefully install the new gland assembly by gently rocking and twisting
it over the rod. Thread it into the cylinder head and tighten to 100 foot
pounds.
6. Repeat for the gland on the other end of the cylinder.

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Service Bulletin
E27549 CYLINDER SEAL REPLACEMENT -- RETROFIT SEAL

REPAIR KIT PART NUMBER IS B163601
NOTICE: It is important that the work area is clean and free of dirt
and dust. Contamination can cause cylinder damage
leading to premature failure.
1. Inspect the piston rod surfaces for deep scratches or scoring. Dam-
aged rods are not good candidates for rebuilding.
2. Remove one gland assembly by removing the four 3/16” allen head cap
screws (replace only one gland assembly at a time in order to maintain
proper alignment of the ram).
Rod Rod Seal

Wiper
GLAND ASSEMBLY
3. Remove the old seal by drilling two #55 X 1/4” deep holes @ 180°
apart into the seal. Insert 2 #4 X 1” phillips head wood screws into the
holes and carefully pry the old seal out.
4. Fully extend the rod (towards the end of the removed gland) and in-
spect for scratches. If the surface has minor scratches you can clean
it up using a 250--320 grit emery paper. Cover the piston chamber with
a damp cloth to prevent contamination. Wipe all surfaces clean follow-
ing the polishing.
5. Lubricate the rod surface and the inner & outer contact lips of the new
seal with hydraulic oil.
6. Temporarily install two 1/4 -- 28 X 3/4” set screws into the cylinder head
(180° apart). Slip the seal guide (one supplied per customer) over the
piston rod and position it’s mating holes over set screws ( see diagram
on following page).
7. Slide the new seal over the rod pushing it into the cavity of the installer
guide.
8. Using uniform hand pressure, push the seal into the cylinder cavity
with the seal press (supplied as part of the installer kit).

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Seal Press
Seal
Set Screw (2 used)

Seal Guide
Cylinder
Head
INSTALLING NEW SEAL
9. Remove the seal press, seal guide , and set screws.

10. Slide the new gland assembly over the rod and fasten to the cylinder
head with the four cap screws. Tighten alternately until snug then
torque alternately to 80 inch pounds.
11. Repeat for the gland on the other end of the cylinder.

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REBUILDING HYDRAULIC CYLINDER -- REPLACEMENT PISTON &

CYL. SEAL KIT PART NUMBER B164843
When rebuilding the hydraulic cylinder, follow these steps to replace the
internal piston seals and ’O’ rings.
Back--up
Retaining Washers
Nuts (torque
to 165 in/lbs)
Cylinder
Rod
Piston Seals
’O’ Ring
1. Remove the 4 retaining nuts at the threaded end of the cylinder rod
(see above).
2. Tape the threads of the cylinder rod to protect the new seals.
3. Slide the piston rod out of the cylinder and replace the seals and back--
up washers.
4. Lubricate the rod and seals with hydraulic fluid and reassemble.
5. Remove the retaining nuts from the other end of the cylinder and re-
place the ’O’ ring.
6. Reassemble, remove tape from threaded end, and test for leaks.

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T o p ic : Hydraulic Manifold Seal Kit

April 16, 1996
INTRODUCTION A seal kit is available for the hydraulic registration valves found on the
hydraulic manifold assembly. The part number for the kit is
813067--8022 and includes three (3) ”O” Rings and two (2) Split
Back--up Rings. Four (4) kits are required for each manifold assembly.
SEAL KIT
NOTICE: Be sure that the hydraulic system is turned OFF!
1. Remove the retaining nut at the top of the solenoid and slide the sole-
noid off of the valve assembly.
2. Unscrew the valve assembly and remove it from the manifold.
3. Replace the ”O” Rings and Split Back--up Rings on the valve assembly.
SOLENOID
4. Apply some clean hydraulic oil to the new ”O” Rings and carefully in-
sert the valve assembly into the manifold. Tighten to 35 to 40 FT--LBS.
5. Replace the solenoid and retaining nut. Tighten the retaining nut to 4--6
VALVE
FT--LBs (no more).
6. Repeat for the remaining valves.
”O” RINGS
BACK--UP
RINGS
MANIFOLD

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T o p ic : Lubrication Oil Change For

Double-Width Newspaper Presses
May 16, 1996
INTRODUCTION Due to changes by the Mobil Oil Company, Mobil VACTRA oil
No. 2 is no longer recommended for use in Goss double-width
newspaper printing presses. Customers are cautioned not to
order Mobil VACTRA oil No. 2 because of reduced amounts of
“tackifier” in the oil.
Effective immediately, Goss is specifying Texaco 561 WAY LU-

BRICANT 68 (or Goss Engineering approved equivalent) for
presses currently using Mobil VACTRA oil No. 2.
NOTICE: This change does not apply to Newsliner presses!
All Newsliner customers are advised to use Mobil VACUOLINE

1409 or Goss Engineering approved equivalent.
• VACTRA oil No. 2 does not have to be flushed from the press
when WAY LUBRICANT 68 is added.
• WAY LUBRICANT 68 must not be used in the hydraulic system.

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T o p ic : With Autogard Clutches

and Dump valves —
Clutch Will Not Disengage
October 14, 1996
INTRODUCTION All units experiencing a condition where the center 15 clutch will not
disengage, may find the cause to be a defective check valve assembly.
PROCEDURE If you suspect this, follow the steps below to effectively remove the
check valve and resolve the problem.
1. With the press at a standstill and on SAFE, shut off the air pressure
to the unit.
2. Locate offending check valve assembly (mounted on the center 15
clutch assembly).
Pilot Remove Elbow

Air
Check Valve
Assembly
Check Valve
3. Disconnect the pilot air line and tie it back. Remove the elbow and
replace with 1/4” pipe plug.
4. Remove the check valve assembly from clutch body.

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5. Grasp the check valve and pull it out of the assembly.

6. Disassemble the check valve and remove the internal components
(see below).
Remove Internal
Components
7. Reassemble the check valve valve body and reinstall the ”shell” to sta-
bilize the ’O’ ring between the manifold and clutch body.
8. Locate the pneumatic valve assembly for the level being modified (op-
erator side -- 10 side arch). Identify the Main Engage/Main Disengage
solenoids and find the A port on the manifold.
Main Engage/
Disengage
Solenoids
Port A
9. Remove the hose from port A and replace with a 1/4” tube plug (Goss
# 865500--3203). Tie back the hose.
10. Reapply air to the unit and test the clutch for proper operation.

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T o p ic : Socket Plate Thread Modification

For Stainless Steel Inserts
April 30, 1998
INTRODUCTION In some instances, damage to the socket plate threads for your
dampener form, ink form or transfer rollers has been encountered. This
can be resolved by re--drilling/tapping and installing a stainless steel
insert as shown on drawing C153297 (see page 2). An installation tool,
C139669--1 is recommended. All parts are available from our Customer
Parts department at 1--800--323--1200.

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THE ABOVE QUANTITIES ARE THOSE NEEDED ON A PER ROLLER BASIS

2
2
2

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T o p ic : PLATE CYLINDER
ECCENTRIC LUBRICATION
October 22, 2002
INTRODUCTION If you are experiencing corrosion between the plate cylinder eccentric
sleeve and frame bore, this may be caused by an aggressive washing
procedure with solvents that support corrosion. To correct this
situation, you may choose to install a lubrication line to the top of the
eccentric.
When proceeding with this modification, it is necessary to remove the ec-
centric sleeves from the unit and machine as shown below. Piping con-
nections are made to existing oil reservoirs utilizing port which are current-
ly available.
1/8 DRILL X .550 DP.

2 PLACES
1.500
.250
2.500
.250
TYPICAL FOR A OR C 1.810

LEVELS - 10 SIDE AND B TYP.
OR D LEVELS - 13 SIDE
(USE OPPOSITE HAND FOR 20O
REMAINING LOCATIONS) 28O GROOVE
NEW MALE ELBOW

EXISTING LUBE HOLE 10O 1/4 O.D. TUBE X 1/8 MPT
7/16 DRILL X 3.64 DP. PARKER NO. 169VL-4-2
1/4 - 18 NPT (REF.)
NEW STEEL TUBING

1/4 O.D. X .028 THK. (22 GA)
.563
2.222 NEW LUBE HOLE

.339 (R) DRILL X 4.25 DP.
1/8 NPT
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DRIVE SIDE PIPING

SEE VIEW A-A SEE VIEW B-B
UNIT B OR D
SLEEVE-PLATE CYLINDER
F19493
SEE VIEW C-C

SEE VIEW D-D
F19492
UNIT A OR C
NEW MALE-CONNECTOR
CURRENTLY UNUSED PORT. 1/4 O.D. TUBE X 1/4 MPT.
UNPLUG & CONNECT TO PARKER NO. 68VL-4-4
NEW LUB. HOLE ON SLEEVE
CURRENTLY UNUSED PORT.

NEW MALE-CONNECTOR UNPLUG & CONNECT TO
1/4 O.D. TUBE X 1/4 MPT. NEW LUB. HOLE ON SLEEVE
PARKER NO. 68VL-4-4 VIEW A-A VIEW B-B
PAN -OIL (E21100) PAN -OIL (E22339)
UNIT B OR D, 13 DR. SD. UNIT B OR D, 10 DR. SD.
NEW MALE-CONNECTOR CURRENTLY UNUSED PORT.

NEW MALE-CONNECTOR 1/4 O.D. TUBE X 1/4 MPT. UNPLUG & CONNECT TO
1/4 O.D. TUBE X 1/4 MPT. PARKER NO. 68VL-4-4 NEW LUB. HOLE ON SLEEVE
PARKER NO. 68VL-4-4
CURRENTLY UNUSED PORT.

UNPLUG & CONNECT TO
NEW LUB. HOLE ON SLEEVE
VIEW C-C VIEW D-D

PAN -OIL (E22337) PAN -OIL (E22336)
UNIT A OR C, 13 DR. SD. UNIT A OR C, 13 DR. SD.
REFERENCE DRAWING F54410

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OPERATOR SIDE PIPING

SEE VIEW A-A
UNIT B OR D
F19493
SEE VIEW A-A
F19492
UNIT A OR C
NOTES:
SEE NOTE 2 SEE NOTE 3 1. CURRENTLY UNUSED PORT, UNPLUG & CONNECT TO
(#13 UNIT B OR D) (#10 UNIT B OR D) NEW LUB. HOLE ON SLEEVE #10 A OR C OP. SD.
SEE NOTE 4 2. CURRENTLY UNUSED PORT, UNPLUG & CONNECT TO

(#13 UNIT A OR C) NEW LUB. HOLE ON SLEEVE #13 B OR D OP. SD.
SEE NOTE 1 3. CURRENTLY UNUSED PORT, UNPLUG & CONNECT TO
(#10 UNIT A OR C)
NEW LUB. HOLE ON SLEEVE #10 B OR D OP. SD.
4. CURRENTLY UNUSED PORT, UNPLUG & CONNECT TO
NEW LUB. HOLE ON SLEEVE #13 A OR C OP. SD.
VIEW A-A SEE NOTE 5 5. NEW MALE-CONNECTOR, 1/4 O.D. TUBE X 1/4 MPT.
PARKER NO. 68VL-4-4
PAN-OIL (E22026)
UITS A THRU D, OP. SD.
REFERENCE DRAWING F54411

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T o p ic : Ink Rail Shock Absorbers
April 30, 1998
INTRODUCTION To help maitain correct ink rail settings, adjustable shock absorbers are
available for A & C levels of your Colorliner units. These shock
absorbers mount to the operator side of the ink rails and provide a
softer landing even when the rail is released from its extreme position.
10 side assembly with instructions -- E44008--1
13 side assembly with instructions -- E44008--2

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T o p ic : Unit Hydraulic Steel Tube

and Hose Replacement
September 27, 2000
INTRODUCTION In order to help maintain the hydraulic system, replacement steel tubes and
hoses are available for all levels of your Colorliner units. These steel tubes
and hoses replace the existing one-piece continuous hose assemblies which
operate the form rollers. These lines are located above the blanket cylinders on
A & C levels and above the plate cylinders on B & D levels. When ordering,
refer to the following and request a copy of the appropriate assembly drawing.
Replacement Parts Assembly Drawing -- F73144

for 3 Form Roller
Arrangement
Hydraulic Piping Crossover Replacement Steel Tubes and Hoses for Units A and
C Operating and Drive Sides.
S F73144 - 00001 & 00004 10 and 13 Side, Complete A or C Level
S F73144 - 00002 & 00005 10 Side only
S F73144 - 00003 & 00006 13 Side only
Assembly Drawing -- F73205
Hydraulic Piping Crossover Replacement Steel Tubes and Hoses for Units B and
D Operating and Drive Sides.
S F73205 - 00001 & 00003 10 and 13 Side, Complete B or D Level
S F73205 - 00002 & 00004 10 or 13 Side

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Replacement Parts Assembly Drawing -- F77222

for 2 Form Roller
Arrangement
Hydraulic Piping Crossover Replacement Steel Tubes and Hoses for Units A and
C, Operating and Drive Sides.
S F77222 - 00001 & 00004 10 and 13 Side, Complete A or C Level
S F77222 - 00002 & 00005 10 Side only
S F77222 - 00003 & 00006 13 Side only
Assembly Drawing -- F77223
Hydraulic Piping Crossover Replacement Steel Tubes and Hoses for Units B and
D, Operating and Drive Sides.
S F77223 - 00001 & 00003 10 and 13 Side, Complete B or D Level
S F77223 - 00002 & 00004 10 or 13 Side

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T o p ic : Ink Drum Modification

April 26, 1999
INTRODUCTION In order to avoid the possibility of experiencing ink density fluctuation,

an ink drum modification kit is available. The modification provides
support of the ink drum closer to the press centerline by adding
bearing sleeves and machining the existing slow speed ink drum to
provide new bearing seats.
No drilling or tapping is required. Kits are available through our Customer

Parts Department. Call 1--800--323--1200 and ask for the following kit
number:
Kit Numbers F75374k--1 to retrofit any A or C level couple, 10 or 13 side
F75374k--2 to retrofit any B or D level couple, 10 or 13 side
F75374k--3 to retrofit any B or D level couple, 10 or 13 side. Ink mist guard

modification required.

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T o p ic : Hardened Ink Train Gears

September 27, 2000
Background Goss has implemented an ink train gear enhancement for Colorliner units.
The enhancement is designed to ensure the durability of gear wear perfor-
mance is maintained. It is retrofittable for existing units and will become
standard for future production.
Solution In order to achieve this enhancement, the face widths have been increased
on three gears – inker clutch gear, vibrator drive gear, and pick--up roller
gear. All ink train gears have increased hardness.
Replacement A complete ink train gear set for one printing couple consists of seven spur
Part Numbers gears, one that is part* of the inker clutch. In the following tables, the six
gears are identified in the first table; meanwhile, in the remaining two tables,
the clutch gear is identified based on manufacturer.
Ink Train Gears All tables reflect original gear numbers and their replacement gear numbers.
Excluding The table below displays either 10 or 13 side, all levels.
Clutch Gears Location Original Gear Number New Hardened Gear
(Do not use) Number
(Superseded by)
Main Ink Drum C126860 C156595
Vibrator Drive C127235 C156594
Aux. Ink Drum C126859 C156597
Third Ink Drum ** C126861 C156596
Idler Gear C127234 C156600
Pick--Up Roller C127233 C156599
* This applies to those units having a third form roller. A total of six gears are required for units without
a third form roller.
** Only used when third form roller is present.

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Clutch Gear The two sets of tables below provide information for the ink train clutch with
a hardened spur gear. Early Colorliner units used a Matrix engage--disen-
gage toothed clutch (CN2000--CN2043); units thereafter (CN2044--present)
used an Autogard version that had an overload feature. Complete clutch as-
semblies are cross referenced. Additionally, for those wishing to replace
only the spur gear, a cost reduced package is available to minimize cost.
It consists of a new mounting bracket and a new wider spur gear with bear-
ings. The clutch and helical gear are reused. For those wishing to modify
the existing bracket to avoid repinning, the spur gear can be purchased for
presses utilizing the Autogard overload clutches. The hub diameter on the
bracket must be reduced to 5.00 in. (refer to C158440).
T I Matrix Engineering, Ltd. -- For CN2000 to CN2043 -- All levels

Inker Silencing Original Clutch # Complete Pkg. Cost Reduced
Clutch (Do not use) Pkg.
Clutch with Hard-
ened Spur Gear # Hardened Spur
(Superseded by) Gear, Bracket &
Bearings
(Superseded by)
Press Size #10 / #13 #10 / #13 Regardless 10 or 13
15” E21094 / E21093 E78281 / E78282 E78287
14--1/2” E18989 / E22464 E78283 / E78284 E78289
14--1/32” E22465 / E22466 E78285 / E78286 E78290
American Autogard Corp. -- For CN2044 to present -- All levels

(Do Inker Si- Original Complete Cost Re- Clutch Spur
lencing/ Clutch # Pkg. duced Pkg. Gear
Overlaod Clutch with Hardened Requires qty.
Clutchnot Hardened Spur Gear, 2 bearings
use) Spur Gear # Bracket & C40100--06209
Bearings (not included)
(Superseded
by) (Superseded
by)
Press Size #10 / #13 #10 / #13 Regardless Regardless
10 or 13 10 or 13
15” E27783 / E27781 E78182 / E78183 E78157 D79183
14--1/2” E27784 / E27782 E78184 / E78185 E78153 D79184
14--1/32” E27785 / E27780 E78186 / E78187 E78152 D79185

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Installation Place the press in the SAFE mode and follow these steps...
Procedure
1. Before changing the clutch, make sure to check the iron setting of that
couple. It is important to get the correct backlash between clutch and
plate cylinder gear. Follow the standard cylinder setting procedures
outlined in the maintenance manual
2. When changing an ink train clutch, check the backlash of the helical
gear against the plate cylinder as well as the spur gear against the
main vibrator drum gear -- .003 to .006 is required. Goss advises to
check backlash at 120 degree intervals. If a significant variation is
measured, remove main ink drum gear and check shaft runout.
3. In many cases, the same dowel pin holes can be used. However, if
relocation is necessary, repin with the next larger size -- .625 diameter
4. Important -- be sure all lubrication lines are reconnected.
5. Remove SAFE the from press.
3rd Ink Drum

(if present)
Vibrator Drive
Inker Silencing Gear

Aux Ink Drum
Main Ink
Drum
Pick-- Up Roller
Idler Gear
Colorliner 10 side - Drive side shown for reference

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T o p ic : Hydraulic Oil Viscosity

Change
February 10, 2000
Enhancement A recent hydraulic oil change has been initiated with HO, Colorliner and Me-
trocolor press units using an independant hydraulic system*. In the past,
Mobile DTE 24, an ISO 32 viscosity hydraulic oil, was the recommended
choice. Based on our testing and customer feedback, we now suggest that
you use an ISO 68 viscosity hydraulic oil, such as Texaco Rando HD68, Mo-
bil DTE 26, or equivalent.
Hydraulic systems can be “topped off” with the higher viscosity oil. It is not
necessary to drain the entire system. However, it is necessary to stay with
the same brand if “topping off” is performed. For hydraulic systems that are
completely drained, use the new suggested oils mentioned above (in bold).
* This will provide a hydraulic fluid with the same viscosity as the lubrication system.

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Service Parts Fax: (+1) 603-740-5970 SBM5078-10-6
Bulletin Type
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T o p ic : Lubricating Oil Guidelines
October 6, 2001
Background Goss recommends using a high quality ISO 68 oil for units, folders, hori-
zontal drive gearboxes (using spiral bevel gears), and angle bars to prop-
erly protect gears and bearings.
Oil Most lubricating oils are tested against ASTM specifications. To satisfy
Specifications press requirements, the following are suggested guidelines:
Property ASTM Spec. Limits

Number
Viscosity, cst. @ 104° F. D445 65--75
(as received prior to use)
Viscosity Index D2270 85 min.
Corrosion -- Distilled Water D665 Pass
Corrosion -- Cu. Strip D130 1b min.
4 Ball EP Load Wear Index D2783 200 kg. min.
(weld point)
Foam Test, 75/10, sequence 1--3 D892 Pass
Tackifier, % N/A 1--3
Flash Point, CO ° F D92 400 min.
The oil should be shear stable and maintain a minimum viscosity of 62 cst.
at 40° C after 12 months of operation in a unit under normal operating
conditions, without dilution from outside sources. The oil supplier should
be ISO 9001 certified.
When a press user is considering changing the brand and/or type of oil
being used, it is advisable to pilot test selected units to establish confi-
dence. An occurrence of “sticking eccentrics” may be such an indicator.
Pilot testing is especially important if there is no history from other users
to call upon. It is also advisable to periodically sample “as received” oil
before using. It is also recommended that frequent oil analysis be per-
formed until confidence can be established.

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T o p ic : Spray Bar Modification

February 14, 2000
Background In some instances it may be desirable to add the following modification
to spraybars exhibiting a slight bowing in the center of the plastics shields.
Part Number The parts described here are available from Goss Customer Parts at
800--323--1200.
Center Clip for Spraybars D67645
Spraybar
Release Hole
Center
Clip

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Center- Line
of Spraybar
1.06
1.90
.25 Drill Thru

Existing
.375 Drill Thru Screws (4)
To install the Center Clip...
1. With the press stopped and on SAFE, remove power from the unit.
2. Disconnect and remove the spraybar assembly.
3. Locate the center of the spraybar and drill two holes in each shield (2)
as depicted above.
4. Using existing screws for the center hinges, mount the new Center
Clip.
5. Be sure the Clip ends go through the larger holes as shown on the
previous page.
6. Reinstall and connect the spraybar.

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T o p ic : Sidelay Performance Checkout

February 14, 2000
Background There are a number of scenarios that can effect the performance of the
Sidelay registration on Goss Colorliner & MetroColor units. The most com-
monly encountered problems are described here in an attempt to provide
a guide for troubleshooting.
Sidelay Move These occur when the requested sidelay move cannot be accurately ac-
Errors complished.
Check Hydraulic System

• System pressure should be 1000 PSI -- Check Daily
• Accumulator pressure should be 800 PSI -- Check Semi--Annually
• System should be free of air -- The hydraulic system should remain ON

at all times to prevent air from entering the system.
• Time cylinder travel -- The cylinder must travel from lock to lock in 35
-- 40 seconds. If the travel time is longer than 40 seconds, shorten the
capillary tube to increase travel speed. If the travel time is less than
35 seconds, install a flow control valve in line with the capillary tube
and adjust to achieve the proper speed (see diagram on following
page).
920520- 00066 Manifold

Flow Control Valve
Capillary Tube

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PROCEDURE To install a flow control valve...

1. With the press stopped and on SAFE, disconnect the capillary tube
from the output “C” port of the run/bypass manifold.
2. Install the flow control valve (Goss part # 920520--00066) into the out-
put port “C” of the manifold making sure the flow direction arrow (on
the flow control valve) is pointing away from the manifold.
3. Connect the capillary tubs to the output side of the newly installed flow
control valve.
4. Switch the selector valve to the BYPASS position and cycle the sidelay
back and forth a few times to purge air from the system.
5. Return the selector valve to the RUN position and drive the sidelay all
the way to the operator side.
6. Use a stop watch to time the sidelay travel from the operator limit to
the drive side limit. Adjust the flow control valve to achieve a 35 -- 40
second travel time.
7. Tighten the jam--nut on the flow control valve.
Reference Refer to the appropriate assembly drawings for the equipment under test.
Check Mechanical End Play

Using a dial indicator, check the backlash of the sidelay movement of the
cylinder in question.
1. With the indicator positioned to read sidelay movement, drive the cylin-
der briefly towards the operator side until movement is detected.
2. Zero the dial indicator and enter a sidelay move of at least .030 to the
drive side.
3. When the move is completed check the dial indicator reading and sub-
tract it from the amount requested in step 2. The resulting number is
the backlash amount.
Backlash amounts above .010 may indicate: worn or loose sidelay

bearings, miss--adjusted or worn rack & gear, loose or dirty taper lock-
nut on gear, or worn sidelay screw assembly.
Check Sidelay Screw Torque

• Check torque required to turn sidelay screw to move the cylinder. A
torque in excess of 20 ft. lbs. indicates binding.

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Check Sidelay Plate Alignment

• Best performance requires the sidelay plate to be centered with the
plate cylinder. This is best accomplished using a fixture, available from
Goss, while replacing sidelay bearings and must be performed after
proper setting of iron to iron.
Cylinder Does This will often result in a “move failure” message on the unit display.
Not Move
Check That the Solenoid Valves are Opening Upon Activation
• Contamination in the hydraulic system can impact valve operation.
Check For Sticking Eccentrics

• Insufficient lubrication, corrosion and galling can prevent sidelay move-
ment. Refer to Service Bulletin SBM5059 which addresses this issue.
Check For Gear Hub Stuck on Spline

• Hub galling can prevent sidelay movement. This condition will result
in the inability to make circumferential registration movements.
Check For Sidelay Gear Slippage on Screw

• The taper locknut that holds the sidelay gear to the screw and the
screw journal, must be free of oil, grease and dirt, and must be
torqued to 120 ft. lbs.
Check Rack & Gear Engagement

Erratic This will often result in position changes without requests.
Feedback
Check For Loose Connections at the Feedback Potentiometer.
Check For Oil in the feedback potentiometer.

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T o p ic : Dampener Form Roller A

April 30, 2004
INTRODUCTION DAMPENER FORM ROLLER (A) DIAMETER CORRECTION.
The diameter indicated for the Dampener Form Roller A in manuals

706 operation and maintenance and 758 operation and mainte-
nance is incorrect.
The Dampener Form Roller (A) diameter was stated to be 5.0 inch-
es (127.0 mm). When in fact the diameter of the Dampener Form
Roller A should be 5.125 (130.175 mm) inches.
Please make the change in the Sections of your Colorliner Unit op-
eration and maintenance manuals to correct this.
SBM0404-29 L:\tp.ileaf\servicebulletins\newspaper Page 1 of 1

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nMECHANICAL Equipment Type: Colorliner & MetroColor
OPERATIONAL
T o p ic : Arcostretcher Web-Stretch Roller

Assembly Care and Maintenance
April 30, 2004
INTRODUCTION Located above the RTP at the input to the unit is a spiral rubber
covered single grooved roller. This roller must be cleaned, checked,
and lubricated periodically. To clean, check, and lubricate this roller
refer to Figure 1, and perform the following procedure.
CLEANING
1. The roller should only be cleaned when the press is not running. The
roller should be periodically cleaned to maintain the proper Coefficient
Of Friction (COF) of the surface to the roller. This will avoid the web
from sliding over the roller surface and wearing the cover.
2. The roller may be cleaned using the same solvents used to clean the
ink rolls in the press. To clean grooves out, a shop air line maybe used
to blow out paper dust and dried ink. Safety glasses and protective
gloves should be worn when cleaning the roll.
3. Roller should be periodically inspected for wear. Edge wear can cause
the web to wrinkle. If wear is 1/16 ” or greater, roller should be replace.
CHECKING SHORE HARDNESS
1. The hardness of the roller when new is 23-28 Shore A. Measure the
hardness in the center of the roller away from the grooves using a
Shore A durometer gauge. If hardness is 35 shore A or greater, the
roller should be replaced.
NOTICE: The web stretch roller must be installed so that the spi-
ral grooves move outboard when the roller rotates in
the direction of the web path.
LUBRICATION
1. Bearings should be routinely checked and if required lubricated in ac-
cordance with the bearing manufacturer specifications.
2. This maybe done by a simple hand spin test to see how freely the roller
spins. The roller is equipped with low friction ER bearings and should
spin very freely.
SBM0404-30 L:\tp.ileaf\servicebulletins\newspaper Page 1 of 2

121 Broadway
Phone: (+1) 800-323-1200
Service Bulletin
DIRECTION OF ROTATION
APPARENT DIRECTION
OF GROOVE MOVEMENT
Figure 1 Arcostretcher Web-Stretch Roller Assembly
For Colorliners:
Refer to Assembly Drawing D56342
&
Rubber Covered Roller Drawing C132529
For MetroColors:
Refer to Assembly Drawing D62365
&
Rubber Covered Roller Drawing C140270
Page 2 of 2 L:\tp.ileaf\servicebulletins\newspaper SBM0404-30

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SERVICE BULLETINS — MECHANICAL

SBM5001 OIL LEAKS AT DRIVE SIDE COVERS . . . . . . . . . . . . . . . . . . . . . 13

SBM5004 REENGAGING THE OVERLOAD CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 14

SBM5006 OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SBM5014 ANTI-WRAP TROLLEY SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SBM5015 HORIZONTAL DRIVE CLUTCH LUBRICATION . . . . . . . . . . . . . . . . . . 21

SBM5016 PRESS DRIVE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SBM5017 DISTRIBUTION INK DRUM MOTOR GEARBOXES -

SBM5028 HYDRAULIC CYLINDER REPAIR KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SBM5034 SPRAY BAR WATER COUPLING RETROFIT . . . . . . . . . . . . . . . . . . . . 29

SBM5037 PREVENTING CORROSION ON DIGITAL PAGE PACKS . . . . . . . 31

SBM5041 DAMPENER DRUM ALTERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

SBM5043 SPRAY BAR COUPLING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

SBM5044 DIGITAL PAGE PACK CHECK VALVE RETROFIT . . . . . . . . . . . . . . 45

SBM5046 SPRAY BAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

SBM5049 HYDRAULIC PUMP ADJUSTMENTS (CATCHING

SBM5054 LUBRICATION OIL CHANGE FOR DOUBLE-WIDTH

SBM5060 INK RAIL SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

SBM5062 UNIT HYDRAULIC STEEL TUBE AND HOSE REPLACEMENT 67

SBM5073 HARDENED INK TRAIN GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

SBM5074 HYDRAULIC OIL VISCOSITY CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . 73

SBM5078-10-6LUBRICATING OIL GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

SBM5079 SPRAY BAR MODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

SBM5080 SIDELAY PERFORMANCE CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . 77

SBM0404-29 DAMPENER FORM ROLLER A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

March 24, 2003 (Updated from October 22, 2002

PROCEDURE Inside the accumulator tank is a bladder which is nitrogen-charged to 800

NOTICE: Use Texaco 561 WAY LUBRICANT 68 hydraulic oil for

Sluggish blanket cylinder throwoff operation and registration “move errors”

DANGER: DO NOT USE ANY GAS OTHER THAN DRY NITROGEN.

CAUTION: THE ACCUMULATOR IS RATED FOR A MAXIMUM

SBM1357 L:\tp.ileaf\servicebulletins\newspaper Page 1 of 10

Figure 1 Coloriner Typical Accumulator Location

ACCESSORIES CHARGING THE ACCUMULATOR

Page 2 of 10 L:\tp.ileaf\servicebulletins\newspaper SBM1357

PRESSURE GAUGE — G-2.5

CHARGING HOSE — H-10

CHARGING VALVE — NV3

Figure 2 Accumulator Charging Accessories

Figure 3 Accumulator Charging Valve

BLADDER TEST CHECKING THE ACCUMULATOR PRECHARGE PRESSURE

Figure 4 Top Cover Assembly

Page 4 of 10 L:\tp.ileaf\servicebulletins\newspaper SBM1357

NOTICE: Do not leave the 3-way valve attached to the accumulator.

Figure 5 Pressure Check Assembly

Figure 6 Global Newsliner Typical Accumulator Location

INSTALLATION OF KIT CONNECTING THE CHARGING ACCESSORIES

To connect the charging kit components, do the following:

4. Turn the bleeder valve counterclockwise to open it.

6. Turn the bleeder valve clockwise to close it.

Page 6 of 10 L:\tp.ileaf\servicebulletins\newspaper SBM1357

THE CHARGING HOSE CONNECTS THE CHARG-

Figure 7 Accumulator Assembly Figure 8 Charging Accessories

SBM1357 L:\tp.ileaf\servicebulletins\newspaper Page 7 of 10

To charge the accumulator, refer to Figure 9 and proceed as follows:

1. MAKE SURE THAT THE HYDRAULIC POWER UNIT IS OFF.

Page 8 of 10 L:\tp.ileaf\servicebulletins\newspaper SBM1357

10. Close the valve in the top of the nitrogen bottle.

NOTICE: Do not leave the 3-way valve attached to the accumulator.

RECHARGE KIT PARTS REPLACEMENT PARTS

A complete list of the replacement parts shown in Figure 10 is given in

Goss International Corporation Customer Parts Dept.