General Maintenance of BOBST Spanthera

55
General maintenance
SPanthera 106 LER
=> 0035 / <=
0534A7 5552 0200

*0534A7 5552 0200*
0534A7 5552 0200 00132433 23.02.2006 A00 00 1  BOBST SA - All rights reserved 2006
SPanthera 106 LER => 0035 / <=
55 55 55
0534A7 5552 0200 0534A7 5552 0200 0534A7 5552 0200
=> 0035 / <= => 0035 / <= => 0035 / <=
MANUAL NUMBER
SPanthera 106 LER
SPanthera 106 LER

SPanthera 106 LER
0534A7 5552 0200
0534A7 5552 0200 00132434 23.02.2006 A00 00 2A  BOBST SA - All rights reserved 2006 2
Summary
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety and environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance - After the first month . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maintenance - Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Maintenance - Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Maintenance - Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Maintenance - Half-yearly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Maintenance - Yearly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Maintenance - Every 2 years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Maintenance - Non-periodic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Various information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Summary
0534A7 5552 0200 00132435 23.02.2006 Somm  BOBST SA - All rights reserved 2006 3
Preface
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reader’s comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Abreviations and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Page validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Preface
0534A7 5552 0200 00132436 23.02.2006 A00 01 1  BOBST SA - All rights reserved 2006 4
General
We reserve all rights in this document and in the subject Reserve
thereof. By acceptance of the document the recipient Some of the items shown in this manual are available as
acknowledges these rights and undertakes not to publish the options. Only those items will be supplied which figure in the
document nor the subject thereof in full or in part, nor to make order confirmation of BOBST SA.
them available to any third party without our prior express
written authorization, nor to use it for any purpose other than Reader’s comments
for which it was delivered to him. Please submit any remarks or suggestions that might help us
to improve this manual.
Safety
When applying to us, please do not omit to mention the
The instructions regarding the safety are described in a chap- manual number.
ter printed on yellow paper. Before proceeding to any opera-
m Make a photocopy of each page concerned, noting your
tion on or with the machine, operators, operator helpers,
remarks or suggestions.
mechanics, electricians, persons responsible of the machine
and its production or anyone else who comes into physical m Send these pages together to the address indicated
contact with the machine are imperatively asked to read this below.
chapter. Abreviations and symbols
cc Operator’s side (os)
coc Opposite operator’s side (oos)
U Keys on the CUBE keyboard
BOBST SA Documentation technique CH - 1001 Lausanne
TELEPHONE: +41 21 621 21 11 TELEFAX: +41 21 621 43 95

E-MAIL: doctech.bobst@bobstgroup.com WEB: http://www.bobstgroup.com
Preface
0534A7 5552 0200 00106883 17.12.2003 A01 01 1B  BOBST SA - All rights reserved 2006 5
Validity
Serial number This manual is valid for machine model:
0534 0035 01
SPanthera 106 LER No: From - to:
SPanthera 106 LER

.... .... .. 0534 0035 01
Machine code Serial order number Machine code on manual

first page
Serial number
Page validity In case of several page versions, choose corresponding

Pages are validated by serial numbers: one, making sure machine serial number is contained in
validity effective from series => till series <=. space indicated:
=> . . . . / . . . . <=
=> * <= :
Subject to modifications.
Refer to validity indicated on the page.
Preface
0534A7 5552 0200 00132437 23.02.2006 A02 01 1  BOBST SA - All rights reserved 2006 6
Safety and environment

General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Manuals and directions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General rules for all users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Switch cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fluidic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

0534A7 5552 0200 00132438 23.02.2006 B00 01 1  BOBST SA - All rights reserved 2006 7
General safety instructions

Introduction Manuals and directions for use
You should read and understand these instructions if you are The manuals supplied by the manufacturer with the machine
an operator, set-up person, mechanic, maintenance person, or after its delivery contain directions for use and must be
a helper or assistant to any of these people, or anyone else made available to any person working with the machine or
who comes into physical contact with the machine and if you having any responsibility with regard to it.
have administrative or supervisory responsibilities for the Anyone who will be working with the machine must read and
operation, maintenance, and use of the machine. understand the directions before beginning work on the
If there is anything about the instructions or about the machine. The directions must be followed by all workers.
machine that you do not understand, speak to your The manuals must be kept in a clean location and available
supervisor before you touch the machine. to anybody dealing with the machine. Everybody dealing with
YOUR FAILURE TO FOLLOW THESE INSTRUCTIONS the machine must be notified of all revisions.
MAY CAUSE SERIOUS INJURIES TO YOU OR TO To prevent injuries to people or damage to the machine,
SOMEONE ELSE. make sure that the whole machine receives regular
maintenance as described in the manual.

General rules for all users

To prevent injuries, you must:
m read and comply with the directions supplied with the m never put your hands, feet or any other part of your body
machine. Make sure the machine is operated only by inside the machine or near moving parts while the
people who have been trained according to manufactur- machine is in operation.
er’s directions. m never climb onto the machine while the machine is in
m not use the machine unless it is in good working condition operation.
and unless all safety guards and devices as well as all m make sure the work area around the machine and the
machine functions work properly. machine itself are clean and neat. Grease, oil, and other
m check whether safety devices are working properly. slippery substances are dangerous and should be
m never void any safety device and never prevent or stop cleaned up immediately. Do not leave any tools or other
a safety device from doing what it is supposed to do. objects on the floor, platform or in other working areas.
m immediately report any trouble compromising safety at m make sure that the machine is serviced according to
work to your supervisor and warn any person likely to manufacturer’s directions given in the maintenance
work with the machine of the trouble. manual.
m make sure before every start-up, that no one is inside the m make sure that the worker is not putting himself in such
machine, that everybody is standing away from the a state (alcohol, narcotics, etc.) that he might put himself
machine, and that no one is touching the machine. or other workers in danger.
Switch cabinets
Only a qualified person is authorized to intervene inside the
switch cabinets.

Fluidic equipment
Only a qualified person is authorized to intervene on the
fluidic equipment of the machine.
In fluidics, flexible conduits have a limited service life. A regu-
lar visual control, under the responsibility of the users, is nec-
essary to determine whether or not conduits must be
replaced.

Warning
Before carrying out any intervention on the machine, make
sure that you respect the safety instructions in the ”Safety
and environment” manual of the machine in question.
If you have several ”Safety and environment” manuals for the
same type of machine, watch the validities.
The ”Safety and environment” manual is composed of two
chapters:
m A chapter ”Safety” including:
D a section ”General safety instructions” (which exists
also in this manual).
D a section ”Personnel protection”.
D a section ”Safety instructions for operators and oper-
ators’ helpers”.
D a section ”Safety instructions for maintenance per-
sonnel”.
D a section ”Noise levels”.
m A chapter ”Protection of the environment” describing the
environmental policy of BOBST in accordance with the
ISO norm 14001.

Maintenance - General
How to use the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Explanation of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Control and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electric motor maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
0534A7 5552 0200 00132439 23.02.2006 M00 01 1  BOBST SA - All rights reserved 2006 12
How to use the manual
E4
Maintenance work according to symbols, see

What
list at the end of the manual
Cut and lock the different sources of energy according

to the instructions of chapter Safety
Link icon
A Illustrated machine side
Number of machine components to be serviced
Where 4 x cc
Components to be serviced Link to list of

symbols
Comments
Link to lubricant
How identification
A
Use small grease gun for concave grease nipples

Maintenance interval When Daily
Explanation of maintenance intervals

The maintenance intervals depend on the machine running
hours.
The correspondance between these intervals and the hour
counter is established based on a 2-shift operation. The run-
ning time being estimated at 5 hours for 8 working hours, it
results in:
❍ Daily = 10 hours
❍ Weekly = 50 hours
❍ Monthly = 200 hours
❍ Half-yearly = 1200 hours
❍ Yearly = 2400 hours
With machines equipped with an hour counter, carry out the
various periodic maintenances according to the above indi-
cations.
With machines equipped with a MSS, the latter will indicate
when the different periodic maintenances will have to be car-
ried out.
Control and cleaning

Photocells
All photocells and reflectors of the machine have to be
cleaned regularly with a smooth and dry rag.
Note: A dirty photocell may cause a machine stop.
Electrostatic assist devices
Refer to the documentation of the supplier in order to carry
out the maintenance of the devices.
Plastics
Machine elements made of plastic such as sight glasses and
Warning transparent safety guards have to be cleaned with a smooth
All elements requiring a control or a specific cleaning are rag slightly soaked with water and detergent.
periodically mentioned in this manual. For all others, proceed
according to the indications given below. For this reason, it Conveyor belts
is imperative to respect the safety instructions described in Conveyor belts have to be cleaned with a brush.
chapter ”Safety and environment”.
Waste
Waste which could impair the operation of the machine has
to be removed regularly.
0534A7 5552 0200 00119495 30.09.2004 M02 00 1A  BOBST SA - All rights reserved 2006 15
Seal gaskets and bellows

Seal gaskets and bellows have to be checked regularly.
When defective, they have to be exchanged by a person hav-
ing received the necessary instructions from BOBST.
Exhaust air gaskets
The status of the exhaust air gaskets must be checked regu-
larly. If one of these gaskets is defective, replace it immedi-
ately.
Flexible pneumatic and hydraulic pipes
The status of the pipes has to be checked regularly. If one of
these pipes is clogged or damaged, clean it or change it
immediately.
Lubrication
Lubricators and oilers
Pay attention to the following when lubricating:
❍ Clean lubricators and oilers with a rag first to avoid the
penetration of impurities.
❍ Lubricate moderately.
❍ Remove surplus grease or oil from the lubricator or oiler.
Important: Excess grease, particularly in bearings can
Warning cause heating.
All elements requiring a specific lubrication are periodically Sliding rails and shifting spindles
mentioned in this manual. For all others, proceed according Keep sliding rails and spindles in perfect condition enabling
to the indications given below. For this reason, it is imperative them to assure the displacement of related elements.
to respect the safety prescriptions described in the chapter Elements with plastic counterparts:
”Safety and environment”. ❍ Clean with a rag and do not lubricate.
Reduction gears, angular gear boxes and oil Elements with bronze, brass or steel counterparts:
reservoirs
❍ Clean with a rag and oil slightly.
Maintenance-free elements are not mentioned in this manual
and any intervention has to be performed according to the Roller running surfaces
prescriptions of the manufacturer. In general, roller running surfaces are cleaned with a rag.
Do not lubricate.
Elements to be lubricated are treated separately in this
manual.
Racks
Clean toothed racks and lubricate slightly.
Lugs and fixations of traction springs
Check lugs and fixations of traction springs and oil regularly.
Oil recovery basins
Empty and clean oil recovery basins regularly.
Electric motor maintenance

Brake motors
Maintenance consists of checking whether the brake motors
are in good working order.
Wear of the brake linings can cause trouble. Remedial mea-
sure:
❍ Adjust air gap and spring elasticity. Exchange brake lin-
ings if necessary respecting the manufacturer’s prescrip-
tions.
Asynchronous motors
Warning The asynchronous motors do not need any particular mainte-
Interventions on electric motors may exclusively be carried nance.
out by qualified persons.
WE DECLINE ALL RESPONSIBILITY IN THE EVENT
OF NON-OBSERVANCE OF THIS INSTRUCTION.
Some operations of general nature are to be carried out on
the electric motors as described hereafter. According to the
motor suppliers, other more specific operations have also to
be carried out. In this regard refer to the manufacturer’s docu-
mentation as well as to the indications given on the motor
identification plates.
For motor types as well as their location in the machine, refer
to the BOBST electric documents.
Maintenance - After the first month

General check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Oil reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

0534A7 5552 0200 00132440 23.02.2006 N00 01 1  BOBST SA - All rights reserved 2006 20
General check
After one month of operation the following has to be done:

❍ make sure the machine is running perfectly. This check
can be carried out in collaboration with a BOBST techni-
cian.
❍ carry out all operations described in the maintenance
intervals over one month.
❍ check the equipment for any water, air or oil leakages.

Oil reservoirs
Change the oil in the platen press oil tank after 500 operating
hours. To do so, refer to the procedure described in Chapter
”Yearly-Maintenance” in this manual.
A
P17610

Maintenance - Daily
Upper chase and lower diecutting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Maintenance - Daily
0534A7 5552 0200 00132441 23.02.2006 O00 01 1  BOBST SA - All rights reserved 2006 23
Upper chase and lower diecutting equipment
In case of heavy dirt marks use only the following products:

❍ Cyclohexan C6H12
❍ Ethanol C2H5 OH
❍ Ether (C2H5)2 O
❍ Isopropanol (CH3)2 CHOH
After use of above-mentioned products treat surfaces by pro-
ceeding as follows:
❍ Vaporize the different contact surfaces with a lubricating
❍ Every evening or on the occasion of a prolonged stop,
pull upper chase and lower diecutting equipment out. spray, for example Molykote 321 R, Rocket WD40 or
OKS 471 (Bobst No. 921.900.025).
❍ Open or remove the makeready protection plate(s).
❍ Wipe the treated surfaces with a clean cloth.
❍ Clean them with a dry cloth.
Maintenance - Daily
0534A7 5552 0200 00113299 06.04.2004 O01 00 1  BOBST SA - All rights reserved 2006 24
Maintenance - Weekly
Oil reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Central lubrication unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Upper and movable platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Front lays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
0534A7 5552 0200 00132442 23.02.2006 P00 01 1  BOBST SA - All rights reserved 2006 25
Oil reservoirs
A1
1 x coc
Check the oil level with the machine stopped and the main
motor in operation. The oil level has to be in the middle of the
sight glass.
2
A
1/
P17610
Check the oil level with the machine stopped and the main
motor in operation. The oil level has to be in the middle of the ESSO ATF LT 71141
sight glass.
3
2/
B
P000
1 x cc 1 x coc
Central lubrication unit
A
C4
1 x coc
If there is not enough oil in the tank, the red LED U S10
flashes. max.
min.
A
P16860
Air filters
1 x coc KDT 3.80

B A
C
1
❍ Remove filters 1 and clean with compressed air. Blow A
from the inside to the outside. P14890
❍ Clean cooling ducts 2 with compressed air. 2
1 x cc VT 4.25
SV 8.130 1 x coc VT 4.40

2 x coc
B C P10602
P14847
P16863
2
2 1
Upper and movable platen
Cleaning intervals depend on environmental and weather

conditions (levels of humidity), and machine working condi-
tions. Clean using a dry cloth, taking care not to remove the
”greasy” coating on the surfaces, as this is an anti-corrosion
product.
If removing this coating is unavoidable, the anti-corrosion
must be reapplied. To do so, refer to the procedure described
in chapter non-periodic maintenance in this manual.
Front lays
Check the condition of the teeth of the pinions.

Use a lubricant spray such as Molykote 321 R, Rocket WD40
or OKS 471 (Bobst n° 921.900.025). 4x
P17378
1x
4x
Maintenance - Monthly
Bernoulli braking tablets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Grease nipples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
0534A7 5552 0200 00132443 23.02.2006 Q00 01 1  BOBST SA - All rights reserved 2006 32
Bernoulli braking tablets
2x
Putting the tablets into service A

❍ Put the Bernoulli tablets into service (TEST position). P11103
❍ Set maximum suction force.
Cleaning procedure
This cleaning is done with the os and oos guards open.
❍ Clean all holes 1 with compressed air.
❍ Feel by hand which tablet holes 1 reject air.
Note: Make sure no air flows out from holes 1.If this should
happen, introduce cleaner 2 into hole 1 and move it through
channel 3 in order to remove dust.
P10775
P2931
2
1 1 1
ÇÇÇÇ
ÇÇÇÇÇ
ÇÇÇÇ ÇÇÇÇ
ÇÇÇÇ ÇÇÇÇ ÇÇÇÇ
ÇÇÇÇÇ
ÉÉÉÉÉÉÉ ÇÇÇÇ
ÇÇÇÇ
ÉÉÉÉÉÉÉ ÇÇÇÇ ÇÇÇÇ
ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ 3
ÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉ D10660
2
P11103
Checking procedure
Put a piece of cardboard on tablet and pull it by hand to check
braking efficiency.
Note: Satisfactory operation of the braking tablets depends
on the cleanliness of the compressor filters and the tubes.
P11103
Air filters 1
3
1 x coc
❍ Unscrew tabs 1 and remove filter 2.

❍ Dip the filter into a basin of cold or hot water with added
detergent or use a washing machine with medium pres- 1
sure (30 to 50 bar).
❍ Rinse it with clean water.
❍ Leave it drain and let it dry.
Important: Make sure the filter is fitted the right way round
as determined by screw 3.
A
P17610
Grease nipples
E4 E8
1 x coc 1 x cc / 1 x coc 2 x cc / 2 x coc
A B C
P16862 P16867
EDT 01
E4
D
F
1 x coc
2 x cc / 2 x coc 1 x cc / 1 x coc
E F
D P16870 P18585
P16869
EDT 01
Maintenance - Half-yearly
Flexible hydraulic conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Central lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rotor of the suction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
0534A7 5552 0200 00132445 23.02.2006 R00 01 1  BOBST SA - All rights reserved 2006 39
Flexible hydraulic conduits
If one of the following situations occurs, replace conduit

immediately:
❍ Fitting slides on the conduct.
❍ Leakage on fittings or conduit.
❍ Fittings are cracked, damaged or present severe corro-
sion traces.
❍ Outer sleeve of the conduit is damaged, deteriorated,
swollen, soft or unstuck.
Check state of hydraulic conduits and correct functioning of ❍ Conduit is hard, stiff, crazed or burnt.
driven elements. The maintenance program must include at
❍ Conduit is crushed, squashed or twisted.
least the following checkings.
Important: Within the framework of a preventive mainte-
If one of the following situations occurs, act quickly on the
nance, flexible conduits must be replaced every 5 years
conduit:
since the installation date of the machine.
❍ Leakage on couplings. In this case, tighten according to
suppliers prescriptions.
❍ Blocked or dirty conduit.
Central lubrication
A
P17377
Lubrication control of gripper bar chains

❍ Insert a strip of cardboard 1 between nozzles os / oos and 1
the gripper bar chains.
❍ Give a few impulses on push-button 2 and check that the
strips of cardboard have traces with the same amount of
oil from each nozzle.
If this is not the case, check the distributor or the nozzles 2
concerned and if necessary replace the defective pieces.
P16860
Rotor of the suction unit 2
A 1
1x
❍ Remove retaining flange 1.

❍ Extract rotor 2.
❍ Clean the rotor with a cleaning petrol soaked rag.
P17376
Important: Never dip the rotor into cleaning petrol as it
contains a bearing lubricated for life.
❍ If necessary, clean the rotor housing with a cleaning pet- 2
rol soaked rag.
❍ Put the rotor back into its housing, turning it around its
own axis to make sure it engages.
❍ Put the retaining flange 1 back into place.
A
P7475
Toothed belts
C A B Note: Only a person having been trained by Bobst will be

able to replace the belts.
1 x coc 1 x coc
A B
P16857 P16857
1 x coc
A B
C
P16868
❍ Check the belt tension with measurement device 1. To do

so, apply a force F and measure arrow x according to the
opposite table.
Note: It is also possible to verify the belt tension by using F (N) x (mm) f (Hz)
a frequency measurement device f according to the A 29 6 80 ± 2
opposite table. B 34 12 34 ± 2
C 38 17 23 ± 2
F (N) x
x (mm)
P13196
Chains
1 x cc
B A 2 x coc 1 x coc
D
A C
B P16857
A
1 x coc 1 x coc
B D
P16866
1 x cc
E F 1 x coc
F
1 x cc P17702
1 x coc
1 x cc
E G
P17701 P17703
V-belts
A B
P16874
Tightening the belts A A B 3

❍ Unscrew the 4 screws 1 of the main motor.
❍ Tighten the belts with the 2 screws 2.
❍ Block the screws.
Tightening the belt B
❍ Unscrew the 2 screws 3 of the hydraulic pump.
❍ Move pump to tighten belt.
P16875
P10801
Checking the tension

❍ Check the belt tension with measurement device 4. To do
so, apply a force F and measure arrow x according to the
opposite table. F (N) x (mm) f (Hz)
Note: It is also possible to verify the belt tension by using A 75 10,9 53 ± 2
a frequency measurement device f according to the B 20 10 ---
opposite table.
Important: Check that the main motor pulley or the hydraulic
pump pulley is aligned and parallel in relation to the flywheel
pulley.
F (N)
x
F
P13196 x (mm)
EDT 01
Replacing the belts A or B

❍ Unscrew both screws 3 to slacken belt B of the hydraulic A B 3
pump.
❍ Loosen the four screws 1 of the main motor.
❍ Unscrew screw 2.
❍ Unscrew the 2 screws 5 and remove the pneumatic
panel 6.
❍ Unscrew the 4 screws 7, withdraw shim 8 and let sup-
port 9 pivot. P16875
❍ Replace faulty belt(s).

❍ Reassemble everything in reverse order.
9
2
1 P16873
P10801
6 5 7 8
Maintenance - Yearly
Metal surfaces without coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Flat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Oil reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Pumps vanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Dust separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Reduction gears with plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Waste removal apron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
0534A7 5552 0200 00132450 23.02.2006 S00 01 1  BOBST SA - All rights reserved 2006 50
Metal surfaces without coating

H1
These surfaces are protected by a water-repellent product

that forms a very thin, strong coating, which is non-stick and
does not attract dust. P15802 P15588
Wipe the surfaces with a clean, dry cloth and then apply the
anti-corrosion, water-repellent product to the surfaces.
Drying time is approximately 30 minutes.
Important: The anti-corrosion product is flammable. No
smoking or naked flames during the procedure. Ensure that
the area is well-ventilated.
P15917 P15804
Flat belts
2x
A
P16877
Oil reservoirs
A A
A1
75 l
Note: Oil degrades gradually over a period of time. This deg-

radation process depends on several factors. An analysis
allows oil degradation times to be assessed, and the analysis
results allows the appropriate oil change intervals to be
1
applied.
❍ Unscrew cap 1 and drain the reservoir. P17610
❍ Remove the cover 2 from sector casing.

❍ Check condition and tension of chain 3.
❍ Clean the bottom of the gear case and tank 4 with a clean
cloth.
❍ Refit cap 1.
3
❍ Refit the cover 2 of sector casing.
❍ Fill the tank.
4
P16872
❍ Check the oil level with the machine stopped and the
main motor in operation. The oil level has to be in the
middle of the sight glass.
❍ Fill up if necessary.
A1
2
1/
P17610
Water separator
Dismantling
❍ Unscrew and remove cup 1. A
❍ Unscrew centring disk 2.
P16878
❍ Remove filter 3.
Filter cleaning
❍ Clean filter 3 with white spirit or kerosene and dry it with 3
compressed air. Blow from inside out.
Cup cleaning
❍ Clean cup 1 only with water, white spirit or kerosene. 2
Note: Do not use trichlorethylen-based products as ben-
zol or acetone.
Reassembly 1
❍ Proceed in reverse order.
Chains
1 x cc
A
P18148
4 x cc
4 x coc
2 x cc
2 x coc
Pumps vanes
A 4x
1 x coc KDT 3.80
A
Blow cylinder with dry compressed air. P14889
P10938
Minimum width of vanes for KDT 3.80:

x = min. 26 mm.
Minimum width of vanes for VT 4.25 / 4.40:
x = min. 27 mm.
1 x cc VT 4.25
1 x coc VT 4.40 7x
X
B
P14847 P3272
P3106
Dust separators
1x
KDT 3.80
A
P14890
A
P10935
Reduction gears with plug
C B A
F5
F5
B
P16865
A C
P16864
Waste removal apron
1 x cc/1 x coc
A
P17699 A
2
Tension of the apron
❍ Set springs by means of screws 1 at 47 mm.
❍ When starting up the machine, check and adjust if
required the centering of the apron:
D Loosen screws 2. 1 x cc/1 x coc
P17698
D Set by using screws 3.

3
D Tighten screws 2 again.
1
A2
4,4 l
P17716
47
Maintenance - Every 2 years

Reduction gears with plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

0534A7 5552 0200 00132453 23.02.2006 T00 01 1  BOBST SA - All rights reserved 2006 62
Reduction gears with plug
C B A
F5
0,9 l
1x
F5
1,4 l
2x
B
P16865
A C
P16864

0534A7 5552 0200 00122811 28.01.2005 T01 00 1  BOBST SA - All rights reserved 2006 63
Maintenance - Non-periodic
Suction cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Supporting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Upper and movable platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Replacing the backlighting of the CUBE interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Brake and clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
0534A7 5552 0200 00132454 23.02.2006 X00 01 1  BOBST SA - All rights reserved 2006 64
Suction cups 2
9x
A
If the suction cups are not moving correctly in vertical direc- A

tion, clean them as follows: P17379
❍ Remove suction cups.

❍ Remove rubber washers.
❍ Degrease outer and inner sliding surfaces with cleaning
5x
petrol.
❍ Dry with compressed air.
❍ Fit cups again without oiling them.
B
P17700
Supporting plate
While dismounting the lower cutting equipment, clean the

contact surfaces between supporting plate 1 and cutting
plate or compensating plate:
❍ Clean them with a dry cloth.
❍ Vaporize the different contact surfaces with a lubricating
spray, for example Molykote 321 R, Rocket WD40 or
OKS 471 (Bobst No. 921.900.025).
❍ Wipe the treated surfaces with a clean cloth.
In case of heavy dirt marks use only the following products,
then treat the surfaces as described above.
❍ Cyclohexan C6H12
❍ Ethanol C2H5 OH
❍ Ether (C2H5)2 O
❍ Isopropanol (CH3)2 CHOH
P12218
Upper and movable platen 2 H1
Basic anticorrosive treatment. Proceed as follows:

❍ Clean the surfaces with cleaning petrol.
❍ Wipe with a clean and dry cloth (after possible oiling).
❍ Apply grease ”OKS 260” (Bobst No. 921.200.023) with a
clean cloth by making circular movements.
A lubricating spray OKS 471 equivalent with OKS 260
can be obtained from Bobst No. 921.900.025.
❍ Treat the surfaces with the waterproof anticorrosive pro-
duct H1 (Bobst No. 932.400.007).
❍ Drying time is about 30 minutes.
Important: Since anticorrosive product is inflammable, do
not smoke during this procedure. The room also has be prop-
erly ventilated.
Replacing the backlighting of the CUBE interface
Colour CUBE
Caution: Use antistatic kit when handling electronic circuit 1
boards.
❍ Disconnect the flat cable 1.
P16108
❍ Unscrew the 4 nuts 2.

❍ Separate the electronic circuit board 3 from the front
plate 4.
❍ Unplug the plug 5.
P16109 P16110
2 3 4 5
❍ Unscrew the two maintenance screws of the backlight-

ing 7 through the two holes 6 of the electronic circuit
board 3.
❍ Replace the backlighting 7, then reassemble the entire
assembly in the reverse sequence of operations.
P16113
P16112 P16111
6 3 6 7
Brake and clutch
When the red LED U S10 flashes and the icon ”Braking dis-
tance too long” is indicated on the CUBE screen, proceed
described as follows.
Setting the brake

Checking the wear on the brake linings:
❍ Check the cleanness and the degree of wear of the lin-
ings before proceeding with the brake setting.
❍ The linings 1 are screwed onto the jaws. They have to be
replaced once the thickness reaches a minimum of 5 mm.
Setting the piston:
❍ In the braking position, use a screwdriver to push piston P16874
2 to the bottom of its housing.

❍ Check that there is a distance y of 2 to 3 mm between the
head of screw 3 and the jaw. If not, loosen screw 3 and 1
set the required distance. Lock the screw.
y = 2 - 3 mm
2 3
Setting the brake (continued)

Setting the lateral stop:
❍ Switch on the machine so that the push-button S25 for
releasing the brake manually is once again operational.
❍ Press the brake release push-button S25 and check that
the clearance x between brake drum 4 and brake linings 1
1 is equal on either side. If not, adjust with screw 5. 1
4
x x
S25
P16876
Setting the brake (continued)

Braking check:
❍ Run the machine at max. speed and cover the photocell
at the infeed with a piece of cardboard. The machine has
to come to a standstill between 270° and 290° MP:
D If the machine stops ahead of 270° MP, slacken the
springs of the air brake progressively.
D If the machine stops after 290° MP, compress the
springs of the air brake progressively.
Note: On a new air brake the prestressing distance of the
springs is 110 mm.
110
7 3 x 0,8 mm
Setting the clutch
The distance between armatures 6 is given by spacers 7 and
washers 8. The minimum distance is given by studs 9.
ÉÉ
ÉÉÉÉ
ÉÉÉÉ
ÉÉ
8
ÉÉÉÉ
ÉÉ
ÉÉÉÉ
ÉÉ ÇÇÇÇÇÉÉÉ
ÇÇÇÇÇ
❍ Measure distance b between the friction disks 10 and the
ÉÉÉÉ
ÉÉ
ÉÉÉÉÇÇÇÇÇÉÉÉ
armatures 8 (measure on the radius passing through the
ÉÉ ÉÉÉ
nuts 11). The normal operating distance b (0,25 -
0.45 mm) has to be equal on both sides. If it is unequal,
ÉÉÉÉ
ÉÉ
ÉÉÉÉ
ÉÉ ÉÉÉ
correct the centering and the parallelism of the disks with
in relation to the armatures by using nuts 11.
6
ÉÉÉÉ
ÉÉ ÉÉÉ
ÉÉÉ
6
❍ When the maximally tolerated distance b reaches or

exceeds 0.7 mm, remove a washer 8 and remount it on
ÉÉÉÉ
ÉÉ ÉÉÉ
the outer side of the armature in order to obtain again a
distance b = 0.25 - 0.45 mm. 10
b b
❍ Then adjust the centering and the parallelism of disks 10
in relation to the armatures 6 using nuts 11. 9
Note: Washers 8 may be ordered from BOBST.
0.8 mm thick: 1106 0776 00
11
P16681
Checking the programmed stop

After checking and setting air brake / clutch, proceed to check
the programmed stop:
❍ In the CUBE customer menu, set back brake compensa-
tion to its default value.
❍ Run the machine at maximum speed, then control pro-
grammed stop with push-button S30. Repeat this opera-
tion several times until machine learning device can be
initialized. The machine has to stop between 195 and
215° MP.
If this is not the case, contact the BOBST customer service.
S30
Lubricants
Use of charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Required brands and quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Lubricants
0534A7 5552 0200 00132456 23.02.2006 Y00 01 1  BOBST SA - All rights reserved 2006 77
Use of charts
Oil changing
BOBST
coc A2 reference DIN/ISO standard
Identification
1,5 l
GEAR OILS DIN 51517/3 CLP
A (Mineral base) ISO 12925-1 CKC
ISO VG ISO VG ISO VG
Quantity of VISCOSITY
680 460 150
oil
BOBST A4 A5 A2
Type and quantity required

Periodic maintenance BOBST
Angular gear box 1,6 l

Lifting and lowering of non-stop device 0,5 l A2
Non-stop rack 0,2 l
Lubricants
0534A7 5552 0200 00119512 30.09.2004 Y01 00 1C  BOBST SA - All rights reserved 2006 78
Required brands and quantities
Periodic maintenance BOBST
Oil reservoirs 75 l A1
Oil reservoirs (*:ESSO ATF LT 71141) 0,5 l *
Waste removal apron 4,4 l A2
Central lubrication unit 2,7 l
C4
Oil for various elements −−−−
Grease for various elements −−−− E4
1,4 l
Reduction gears 1,4 l F5
0,9 l
Metal surfaces without coating −−−− H1
The quantities are indicated for information only.

Lubricants
0534A7 5552 0200 00130805 14.11.2005 Y02 00 1  BOBST SA - All rights reserved 2006 79
Identification
Important: Do not mix lubricants of different types and viscosities.
GEAR OILS DIN 51517/3 CLP

(Mineral base) ISO 12925-1 CKC
ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG

VISCOSITY
680 460 320 220 150 100 68
BOBST A4 A5 A3 A1 A2 A7 A6
GEAR OILS DIN 51517/3 CLP HC

(Based on synthetic hydrocarbon oil of the PAO type)
ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG
VISCOSITY
1000 680 460 320 220 150 68 32
BOBST F2 F1 F3 F4 F5 F6 F7 F8
GEAR OILS DIN 51502 CLP PG

(Polyglycol base)
ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG ISO VG
VISCOSITY
1000 680 460 320 220 150 100 68
BOBST F11 F12 F13 F14 F15 F16 F17 F18
Lubricants
0534A7 5552 0200 00119503 30.09.2004 Y03 00 1B  BOBST SA - All rights reserved 2006 80
HL HYDRAULIC OILS DIN 51524/1 HL

(Mineral base) ISO 6743/4 HL
ISO VG ISO VG
VISCOSITY
100 68
BOBST D1 D3
HM HYDRAULIC OILS DIN 51524/2 HLP

(Mineral base) ISO 6743/4 HM
ISO VG ISO VG ISO VG ISO VG ISO VG
VISCOSITY
68 46 32 10 5
BOBST D10 D9 D6 D8 D12
HV HYDRAULIC OILS DIN 51524/3 HVLP

(Mineral base) ISO 6743/4 HV
ISO VG
VISCOSITY
46
BOBST D11
Lubricants
OILS FOR SLIDING RAILS DIN 51502 CGLP

(Mineral base) ISO 6743/13 G
ISO VG ISO VG
VISCOSITY
150 68
BOBST C5 C4
Lubricants
Important: Do not mix lubricants of different types and consistencies.
INDUSTRIAL GREASES DIN 51502 KP

(Based on lithium soap and mineral oil) DIN 51502 GP
NLGI NLGI NLGI

CONSISTENCY
2 00 000
BOBST E4 E7 E8
INDUSTRIAL GREASES DIN 51502 GP HC

(Based on complex lithium soap and synthetic hydrocarbon oil of the PAO type)
NLGI
CONSISTENCY
00
BOBST G11
GEAR GREASES DIN 51502 G PG

(Based on lithium soap and polyglycol oil)
NLGI
CONSISTENCY
00
BOBST G1
Lubricants
ANTICORROSIVE PRODUCTS
BOBST H1
Lubricants
Various information
List of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Various information
0534A7 5552 0200 00132457 23.02.2006 Z00 01 1  BOBST SA - All rights reserved 2006 85
List of symbols
Cut and lock the different sources of energy Check condition + operation
according to the instructions of chapter
Safety Check chain tension
Pull out key Check belt tension
Put in key
Check level
Clean Oil level in the sight glass
1 Water + detergent Change
2
Cleaning petrol * Fill in here
3
Petroleum (kerosene) Drain here
Clean with compressed air Grease
Use vacuum cleaner Oil
Lubricate with spray
* Flash point higher than 55°C. Fire protection class FE 3 Lubricate with spray for chains
according to EUR. INSUR. COMM. Do not use solvents
such as thinner or trichlorethylene. Do not oil
Various information
0534A7 5552 0200 00119508 30.09.2004 Z99 00 1E  BOBST SA - All rights reserved 2006 86
Intervention: see text Part to be maintained
Remove to reach the element

# On each printing unit
Exchange / Replace
C4 See oil and grease charts
Replace if necessary
cc Operator’s side (os)
Measure
coc Opposite operator’s side (oos)
320_
Machine position (°MP)
Board travel direction
Various information
0534A7 5552 0200 00076592 08.01.2001 Z99 00 2C  BOBST SA - All rights reserved 2006 87

General Maintenance of BOBST Spanthera

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General Maintenance of BOBST Spanthera

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55

SPanthera 106 LER

=> 0035 / <=

0534A7 5552 0200

=> 0035 / <= => 0035 / <= => 0035 / <=

SPanthera 106 LER

0534A7 5552 0200

BOBST SA Documentation technique CH - 1001 Lausanne

TELEPHONE: +41 21 621 21 11 TELEFAX: +41 21 621 43 95

Serial number This manual is valid for machine model:

SPanthera 106 LER

Machine code Serial order number Machine code on manual

Page validity In case of several page versions, choose corresponding

Safety and environment

Safety and environment

General safety instructions

Safety and environment

General rules for all users

Safety and environment

Safety and environment

Safety and environment

How to use the manual

Maintenance work according to symbols, see

Cut and lock the different sources of energy according

Components to be serviced Link to list of

Use small grease gun for concave grease nipples

Explanation of maintenance intervals

Control and cleaning

Seal gaskets and bellows

Electric motor maintenance

Maintenance - After the first month

Maintenance - After the first month

After one month of operation the following has to be done:

Maintenance - After the first month

Maintenance - After the first month

Upper chase and lower diecutting equipment

In case of heavy dirt marks use only the following products:

Central lubrication unit

1 x coc KDT 3.80

❍ Clean cooling ducts 2 with compressed air. 2

SV 8.130 1 x coc VT 4.40

Upper and movable platen

Cleaning intervals depend on environmental and weather

Check the condition of the teeth of the pinions.

Bernoulli braking tablets

Putting the tablets into service A

❍ Set maximum suction force.

❍ Unscrew tabs 1 and remove filter 2.

1 x coc 1 x cc / 1 x coc 2 x cc / 2 x coc

Flexible hydraulic conduits

If one of the following situations occurs, replace conduit

Lubrication control of gripper bar chains

Rotor of the suction unit 2

❍ Remove retaining flange 1.

C A B Note: Only a person having been trained by Bobst will be

❍ Check the belt tension with measurement device 1. To do

Tightening the belts A A B 3

Checking the tension

Replacing the belts A or B

❍ Replace faulty belt(s).

Metal surfaces without coating

These surfaces are protected by a water-repellent product

Note: Oil degrades gradually over a period of time. This deg-

❍ Remove the cover 2 from sector casing.