Kensol-Franklin VALUE LINE User manual

- 1 - - 1 -
Instruction Manual
For
VALUE LINE
19" x 25" Cutting & Creasing Press
with
Computer Controlled
Foil Puller
from
Kensol-Franklin, Inc.
General Offices:
Kensol-Franklin, Inc.
842 Upper Union Street #1A
Franklin, MA 02038
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Web page: www.thethomsongroup.com
Instruction Manual - 19" x 25

Page
NOTICE
The American National Standards Institute has adopted a new set of safety standards for all
hand fed platen presses. We strongly urge that press users comply with these new standards.
To obtain a copy of ANSI B65.5-1996, please contact:
NPES
1899 Preston White Drive
Reston, VA 22091-4367
703/264-7200-phone
703/620-0994-fax
Once you have reviewed these standards, we urge you to contact us if you need any further
assistance.
FOREWORD
Instruction Manual - 19" x 25"

Page
This Instruction Manual has been prepared to give you helpful information on the installation, operation, care and
maintenance of Value Line Cutting and Creasing Presses, so that you may operate them at maximum efficiency and with a
minimum of maintenance.
♦♦♦♦♦♦♦♦♦♦♦♦♦♦♦♦
Your Value Line Cutting and Creasing Press is skillfully designed and expertly constructed of high grade materials, and will
easily meet all the service demands of normal use.
♦♦♦♦♦♦♦♦♦♦♦♦♦♦♦♦
To ensure the successful operation of the machine, it must be operated within its load limitations, using proper dies and
makeready procedure. The machine should be kept well lubricated, reasonably clean, and free from foreign matter.
♦♦♦♦♦♦♦♦♦♦♦♦♦♦♦♦
Operators are urged to read this manual thoroughly before operating the machine. Throughout the manual, warnings are
included as part of service and operating procedures. Warning signs are also placed on the machine to remind operators of
hazards resulting from improper procedures. Our intention is to prevent accidents and to establish safe operating practices with
these warnings.
Instruction Manual - 19" x 25"

Page
TABLE OF CONTENTS
SECTION - I
GENERAL DESCRIPTION
PAGE
Main parts 6
Distinguishing Operating Features 6
SECTION - II
INSTALLATION
Selecting Location 7
Leveling and Placement of Air Lock Pads 7
Cleaning Parts 7
Removing Parallel Bar 7
Wiring 8
Lubrication 8
Starting Up a New Machine 8
Gears - New Machine 8
Oil 8
Meter Units 8
Electric Motor or Variable Speed Drive 9
Connecting Rod Bushings & Impression Sleeve Bearings 9
Gears - Normal Operation 9
Flywheel Bearings 9
Inspection and Servicing 9
SECTION - III
OPERATION
Press Cycle - Start/Stop 10
Impression Adjustments - Dual Micrometer Design 10
Mounting Dies in Press 10
Die Mounting 10
Centering Die 11
Foil Pulling System 11
Instructions on Programming Foil Puller 11
Press Modes 11
Foil Programming Procedure 11
Error Indicators 12
Die Heater Controls 12
Die Loads and Press Capacity 13
Die Loads 13
Press Loads 13
Safe Platen Press Operation 14
The User's Responsibility 14
Guarding the Point of Operation 14
Safety Devices 14
Management Safety Tips 14
Press Operator's Safety Tips 15
Safety Test Trip 16
Instruction Manual - 19" x 25"

Page
SECTION - IV
CARE, MAINTENANCE, & OPERATIONAL DIFFICULTIES
General Care 17
Resetting Bridge Face Parallel With Frame Face 17
SECTION - V
TROUBLE SHOOTING
Bridge Stuck On Center 19
Causes of Bridge Cam Failure 19
Causes of Bridge Lugs Slipping 19
Bridge Face Not Parallel With Frame Face,
Resulting Problems 20
Makeready Problems 20
Problems with the Press (Inconsistent Cutting) 20
Interrupted Machine Cycles 21
Electrical System Failure 21
SPARE PARTS MANUAL 22
Instruction Manual - 19" x 25"

Page
SECTION I
GENERAL DESCRIPTION
The Value Line Cutting and Creasing Press is a hand-fed Platen Press designed for use with steel rule dies for the
manufacture of paper, corrugated and fiber boxes, display cutouts, paper toys, gaskets, greeting cards, automobile door and body
panels, decals and many other products of the paper and plastic industries.
These machines are also used with electric die heaters for roll leafing, embossing and hot die cutting.
The words PLATEN or BRIDGE as used in this manual are synonymous and refer to the same part.
The Value Line of machines is constructed with a cast iron frame bridge and dual micrometer impression control. It is
clutch operated, with a live flywheel, and is designed for continuous operation, manual start with automatic stop, automatic start
and stop with adjustable dwell in the open and closed position. This machine is crank action in design.
MAIN PARTS
The main parts of the machine are the frame, bridge, connecting rods, flywheel, pinion shaft, main shaft and gear wheels.
DISTINGUISHING OPERATING FEATURES
The bridge makes a direct, square and theoretically perfect impact upon the die, rolling to the frame face, free and
unrestrained with perfect parallelism.
Adjustable bridge lugs are provided for setting the face of the bridge parallel with the face of the frame.
The face of the frame is inclined from the vertical, eliminating the need for frisket fingers, as the processed sheet lies
naturally against the bridge on this inclined angle.
All dies must be properly located so that the press load is balanced relative to the connecting rod pull. If this is
impossible, then bearers must be used to balance the load and prevent tipping of the bridge, causing slippage of the bridge lugs.
(See Makeready Instruction Manual.)
A hard steel cutting plate should always be used on the press. Use of a "soft" cutting surface will increase the press load
and reduce die life. Proper makeready procedures will result in cutting operations which allow cutting without the necessity of
the die contacting the cutting plate.
Instruction Manual - 19" x 25"

Page
SECTION II
INSTALLATION
The complete machine comes with rust preventative on exposed surfaces to protect it from corrosion and is bolted to
heavy skids to protect it from damage.
SELECTING LOCATION
Leave the press on skids until it is moved into its permanent position. See the floor plan for the area required and
distribution of weight. A solid foundation is recommended for the machine. It should be located over the building beam supports
if possible. Proper consideration of working space around the installation area and good lighting for the operator are important
factors in selecting a location.
WARNING: Check the capacity of the lifting equipment in your plant before moving your new press.
LEVELING AND PLACEMENT OF AIR-LOC PADS
Remove the skids and place the vibration pads (if used) under the feet of the press. Thicker pads go down first, then the
thinner pads. Place a machine level on the main shaft or on the pinion shaft, and drive wedges under the frame corners until a
level position is obtained. Shims should be placed between thick and thin vibration pads. Remove the wedges and secure the
press to the floor.
CLEANING PARTS
Uncrate all parts and clean thoroughly to remove all dirt, foreign matter and protective coatings. Check all parts of the
machine to see that they are free from foreign matter that may be lodged in holes, pockets or gear teeth.
Check and clean out all oil holes to make sure they are not obstructed with dirt, grease or paint.
Instructions for Removing Parallel Bar
1. Wire main power lines from the disconnect switch to the press. (See wiring diagram)
2. Facing the right side of the press attach the supplied crank handle to the end of the flywheel shaft.
3. Turn the crank handle counterclockwise until the bridge opens.
4. Remove the parallel bar.
5. Remove the crank handle.
6. The press is now ready to run.
CAUTION:
TURN THE PRESS OVER VERY SLOWLY WITH THE FLYWHEEL RUNNING IN THE PROPER DIRECTION TO
MAKE SURE ALL FUNCTIONS ARE IN PROPER WORKING ORDER BEFORE APPLYING FULL POWER. THE
MAIN GEARS SHOULD REVOLVE AWAY FROM THE OPERATOR IN THE DIRECTION AS INDICATED BY THE
ARROW ON THE SIDE OF THE GEAR.
WIRING
Instruction Manual - 19" x 25"

Page
The machine is equipped with a master control console and panel box completely wired at the factory.
Only qualified personnel should install and service electrical equipment.
WARNING: Only connect incoming electrical power as indicated on the enclosed wiring diagram.
A separate, fused, wall disconnect switch should be installed for each machine.
LUBRICATION
WARNING: Turn off main electrical power and stop the flywheel before applying any lubrication.
Value Line presses have bearings that work under relatively slow speeds and extreme pressures. Proper lubrication
affects the life of a press and is one of the most important items affecting its proper operation. Better results will be obtained by
applying a small quantity of lubricant frequently rather than a large amount at long intervals.
We recommend SAE 30 oil in the lubrication system.
Starting Up a New Machine
Fill the oil reservoir. To fill lines and lubricate bearings before starting new machine, pull instant feed knob on Bijur
Lubricator and release to allow pump to discharge. Repeat until oil is in evidence at all bearings.
Gears - New Machine
IMPORTANT: Before starting up a new machine, make sure all gear teeth are well lubricated. Lubricate manually if
necessary. Never operate the machine with the gears dry.
Make sure that oil holes are free of dirt, paint, or any other foreign matter.
All areas of the machine that require oil lubrication are taken care of automatically by the Bijur lubricating system
consisting of a pump unit which forces oil through a branched tubing line to Meter-Units, one of these being located at or near
each bearing. The pump measures the total quantity of oil fed to the system and the Meter-Units proportion this quantity
according to the individual requirements of the bearings.
Oil
Use only a clean oil of SAE 30 viscosity. NEVER use oil containing graphite, soap, or other foreign substances. Refill
reservoir before oil level drops to the bottom of oil level gauge.
Meter Units
Meter-Units are self-contained, non-adjustable units. Letters stamped on them indicate the type and the flow rate; the
higher the number, the greater the flow. The Meter-Units offer such high resistance to oil flow that they are the controlling factors
in oil distribution. As a result, there is practically no variation in oil delivery, normally caused by flow resistance in the tubing,
variation in bearing wear or initial fit. Check valves in the Meter-Units prevent reverse flow and keep the tubing full of oil at all
times. A Meter-Unit may be mounted directly at a bearing, at an adjacent junction or at a tee head.
Use FJB Meter-Units with this pump.
Instruction Manual - 19" x 25"

Page
Electric Motor or Variable Speed Drive
All lubricating points must be checked and lubricated in accordance with manufacturer's recommendations furnished
with motor or drive.
Connecting Rod Bushings & Impression Sleeve Bearings
These bearings are lubricated by hand. Alemite fittings should be fed grease four times for an eight-hour shift.
Gears - Normal Operation
Lube lines are fed by the automatic lubricating system. Maintain oil level in oiling system and check occasionally for oil
film on gear teeth.
Flywheel Bearings
The flywheel bearings are greased with Alemite fittings. Lubricate every six months.
CAUTION:
AN EXCESS QUANTITY OF GREASE WILL CAUSE BEARINGS TO RUN WARM AND CAUSE DAMAGE TO
THE BEARING SEALS.
INSPECTION AND SERVICING
With the pump feeding the system, inspect for oil at the bearings: also, check that there are no leaks at the tubes or
connections.
IF SOME BEARINGS ARE GETTING INSUFFICIENT OIL, INSPECT FOR:
1. Low oil level in reservoir
2. Broken or cracked tubes or loose connections. Wipe off tubes and connections, and watch for leaks. When replacing a
tube, see that it is properly clipped to prevent vibration.
3. Flattened lubricator pump outlet tube.
4. Clogged lubricator pump filter. Remove filter disk and replace with a new one. Check every six months.
5. Dirt in Reservoir.
IF ONLY ONE BEARING IS GETTING INSUFFICIENT OIL, INSPECT FOR:
1. Flattened oil tube of loose connection to the meter-unit feeding this bearing.
2. Slow feeding Meter-Unit. Make sure oil reaches inlet of Meter-Unit when pump is feeding; also, check rate of feed with
Meter-Unit connected so as to drip free. Should there be any questions as to the rate, compare it with a Meter-Unit of the
same rate number on another part of the machine. If Meter-Unit is feeding a proper quantity in accordance with its rate
number, and an increased feed is desired, use same type and next higher number. The Meter-Units are replaced complete
with head. Never disassemble a Meter-Unit or drill it out, as this will ruin its operation. Do not try to test a Meter-Unit by
blowing through them. REMEMBER oil flows through Meter-Units very slowly, and IN ONE DIRECTION ONLY, as
indicated by the arrow plainly stamped on each Meter-Unit.
Instruction Manual - 19" x 25"

Page
SECTION III
OPERATION
PRESS CYCLE - START /STOP
-Turn power on
-Put main motor into operation (always starting the motor at low speed) and select desired speed
-Press should be in the "DIECUT" or "FOIL" mode
-Select desired cycle:
• "STOP OPEN" allows one press cycle only with the press stopping in the open position (generally used for
setting up)
• "STOP CLOSED" allows one press cycle only with the press stopping in the closed position (for
transferring counters)
• "DWELL OPEN" activates "dwell open" timer, allowing the press to stop in the opened position for the
amount of time set on timer
• Dwell closed activates dwell-closed timer, which allows the press to stop in the closed position for the
amount of time set on the timer
• Continuous allows press to run continuously
-Pull "STOP/SAFE READY" button out, placing it in the "ready position"
-Auxiliary safety must be placed forward in the "run" position
-Press cycle "START"
-To stop the machine, depress "STOP/SAFE - READY" button
IMPRESSION ADJUSTMENTS - DUAL MICROMETER DESIGN
The impression is adjusted using the dual micrometers. Each side of the bridge is adjusted separately. This allows for
faster and more accurate makeready, reducing down time to a minimum.
First loosen the impression sleeve locking bolts using the supplied wrench. With the other end of the wrench, turn the
impression sleeve to the desired setting and then re-tighten the lock bolts.
WARNING: Never advance one side of the bridge ahead of the other more than 0.015", or 1/64".
DO NOT PACK UNDER THE CUTTING PLATE IN PREFERENCE TO ADVANCING IMPRESSION BY
MICROMETER ADJUSTMENTS.
CAUTION
NEVER TAKE AN IMPRESSION WITHOUT FIRST TIGHTENING THE LOCKING BOLTS ON IMPRESSION
SLEEVE.
ALWAYS RETURN IMPRESSION ADJUSTMENT TO "0" WHEN STARTING A NEW JOB
MOUNTING DIES IN PRESS
Die Mounting
CAUTION: Before mounting die on press, refer to the safety standard for stand-alone presses, ANSI #B65.5-1996, section
18.2, Inch-safe-service method.
For your safety and for ease of operation, chaseless die mounting fasteners have been supplied with your press. Refer to
the makeready manual for proper die setup procedures.
Instruction Manual - 19" x 25"

Page
Centering Die
It is very important to have the center of force of the die located in line with the centerline of connecting rod pull to
prevent unnecessary tipping of bridge and movement of the bridge lugs. To help center dies in the press, a die-mounting template
has been supplied with the press.
CAUTION: Before mounting dies, turn off motor and return wrap around safety device to its back or "safe"
position.
If it is necessary to have an unbalanced load, bearers should be inserted for balance. When using bearers, note that
bearers increase the load on the press, while decreasing the available cutting load.
FOIL PULLING SYSTEM
The Value Line Foil Pulling System supplied with your machine is a programmable, computer controlled device
equipped with an unwind section where the new rolls of foil are mounted, a set of guide rolls, two drive rolls and two rewind
shafts.
The desired length of pull is programmed with thumbwheel switches on the control panel. Each roll may be individually
controlled to repeat the pre-programmed index length indefinitely or instructed to perform "feed and clean" cycles if required.
The Value Line Foil Puller is divided into three major sections:
• foil unwind
• foil puller/foil rewind
• programmer
CAUTION: Before stringing foil on press, refer to the safety standard for stand-alone presses, ANSI #B65.5-1996, section
18.2, Inch-safe-service method.
INSTRUCTIONS ON PROGRAMMING FOIL PULLER
Press Modes
DIE CUT POSITION: Use this position for die cutting or embossing.
SET POSITION: The foil readout does not function in this position. If changes are to be made to the lengths of the foil pull or to
the number of repeats, the switch must be turned to the set position to enter the new settings into the computer.
Note: The sheet counter will not count when the platen is in the "off impression" position.
Foil Programming Procedure
1. Enter the amount of pull required into the desired roll; either roll 1 or 2.
2. For a single operation enter the same amount of pull into the short pull and the long pull. Set the repeat at "1."
A. For multiple dies enter the required amount of pull into the short pull and the number of repeats.
B. Enter a clearing pull into the long pull. This amount must be greater than the short pull.
3. Place the press mode switch in the "SET" position so that the computer can read the new settings.
4. Return the press mode switch to the "FOIL" position in order to run the press.
5. After making any necessary changes to any pull amounts, step 3 must be repeated.
Instruction Manual - 19" x 25"

Page
Error indicators
Er 01- Short Pull greater than Long Pull- Roll #1
Er 02- Short Pull greater than Long Pull- Roll #2
Er 11- Long Pull exceeds max setting of 400.0 mm- Roll #1
Er 12- Long Pull exceeds max setting of 400.00 mm- Roll #2
Er 03- No repeats set on Short Pull- Roll #1
Er 06- No repeats set on Short Pull- Roll #2
Er 21- No distance set Short Pull- Roll #1
Er 22- No distance set Short Pull- Roll #2
Die Heater Controls
Zone 1 controls the right side of the heater
Zone 2 controls the center of the heater
Zone 3 controls the left side of the heater
Control Panel Indicator Lights
Red LED lights on the outline of the press show that all limit switches and the foil feeder are functioning.
*Rewind (unwind) off/on - "on" will put tension on the new foil, producing better foil stamping results
*Roll Rotation + - this enables the press operator to switch the rotation direction of the foil rollers for set up. This only
works using the Jog Buttons)
Instruction Manual - 19" x 25"

Page
DIE LOADS AND PRESS CAPACITY
The engineers at Value Line have performed years of testing to determine the amount of force necessary to cut or emboss
many materials.
The maximum tonnage recommended by various manufactures of cutting and creasing presses can become confusing
when a comparison of machines is made unless the basis used by each company is defined and understood.
Die Loads
Cutting and Creasing loads can be determined by testing a sample using a specially constructed laboratory press. This
test takes into consideration material grain, die construction, and stripping material load. The results can be converted to the
maximum die size allowable to stay within recommended die cutting load ratings.
Press Loads
The total load on a press is usually much greater than the theoretical die cutting load and is made up of the following:
1. Loads created by die imperfections such as:
A. Dull cutting rule
B. Cutting rule of unequal height.
C. Poor die design, specifying cutting rule of incorrect height, bevel, or thickness, or incorrect height of creasing rule,
lumber or stripping material.
2. Load created by poor makeready that is soft or excessive.
3. Load created by material variations caused by changes in moisture content, grain density or thickness.
4. Excess load created by careless impression micrometer settings.
5. Load created by a worn machine components and the natural deflection of highly stressed parts.
6. Load created during cutting and creasing of material. This is the diecutting load used as a basis for Value Line
recommendations.
The total press load will vary with the above conditions and can be up to 3 times the recommended die cutting load.
Instruction Manual - 19" x 25"

Page
SAFE PLATEN PRESS OPERATION
The User's Responsibility
This section of the Instruction Manual is not intended as a Safety Code. Its purpose is to alert persons associated with
platen presses to the importance of establishing safe operating and maintenance procedures.
Throughout this manual warnings have been inserted calling attention to safe practices and procedures. Day to day
safety is a vital part of everyone's job. A press accident can result in loss of production, damage to the press, personal injury and
breakdown of shop morale.
Make every effort to keep your presses safe for production. Daily press inspections, over and above normal
maintenance, of all guarding and safety devices and brakes is a good way to start.
Guarding the Point of Operation
The "point of operation" is the area created when the platen reaches a position of parallelism with the die face just before
contact between the die and material to be converted. The use of proper "point of operation" devices coupled with a well-trained
operator is the best insurance against mishaps.
It is the responsibility of the employer to provide and insure the use of properly applied and adjusted devices on every
operation performed on a platen press consistent with the dies being used, with the feeding methods being used, or other features
unique to operation, so as to provide maximum protection to the operator.
Safety Devices
The following safety devices are provided with your press and are the minimum required for proper operation. Other
devices may be required if the press is used for a purpose other than that for which it was originally intended.
1. WRAP AROUND SAFETY DEVICE
This device stops normal stroking of the press if the operator's hands are placed in the point of operation as the platen
closes. The die should not be removed except when this device is placed in its back safety position, causing the platen to become
inoperative.
2. PLATEN SAFETY DEVICE
Stops normal cycling of the press, when activated by the operator.
WARNING: This Auxiliary Safety Device & Platen Safety Device must be set and maintained according to the
requirements of ANSI B65.5-1996.
Management Safety Tips
1. Make certain that the press operators are trained and instructed in safe methods of operation and provide adequate
supervision to enforce safe operating procedures.
2. Set up a program of press inspection as required by ANSI 65.5-1996.
3. Establish a preventative maintenance program.
4. Make frequent evaluation checks of all press safety devices during actual production runs. Correct any unsafe conditions
before resuming operation.
5. Provide a clean, safe, uncluttered area around each press.
Instruction Manual - 19" x 25"

Page
6. Stop the press immediately when a malfunction is reported and correct before resuming operation.
7. Establish, publish and enforce a firm policy of safety regulations.
8. Take immediate action to prevent a recurrence of all "close calls" before they become accidents.
9. Never change wiring.
10. Never change air piping.
11. Never substitute component parts.
12. Dies and stripping material should be checked and maintained for proper cutting and stock ejection.
13. Never run a press that has been modified.
14. Only use the press for its intended use.
Press Operator's Safety Tips
1. Operator should never operate with any press or safety device malfunction.
2. Perform daily inspections as required by ANSI B65.5-1996 Section 16.3.1 (Refer to Safety Test Trip, and see figure 3.4)
3. Make a pre-operation check of all operating controls, safeguarding devices, bottom and side sheet or material guides, alert
signals, die and material being worked.
4. Never attempt to correct or remove misfed sheets before stopping the platen in the fully open position. Report die trouble
to supervisor.
5. Never operate, service or adjust the press, or install dies without proper understanding of the instructions in the Instruction
Manual.
6. Never sit on, stand on or bend over the platen with the flywheel turning.
7. Never makeready or set stock guides before stopping the motion of the flywheel.
8. Obey alert or warning signals on the press.
9. Stop the machine if it malfunctions. Report any questionable operation, unusual action, unsafe condition or improper
maintenance to the proper person.
10. When changing setting of press controls for a different mode of operation, test the machine cycle to be sure it operates as
expected.
11. Check the work area to be sure it is free of objects that could cause one to slip or trip.
12. Wear proper personal protective equipment specified by the employer.
13. Shut off power to the press when it is not in use.
14. Never talk to another person while feeding the press.
15. Never reach over, under or around press safety devices or try to bend, check, modify or remove, point of operation safety
devices.
Instruction Manual - 19" x 25"

Page
16. Develop a sense of personal safety awareness. Observe all safety regulations. Be on the lookout for hazardous conditions
and discuss control of them with your supervisor.
17. Always follow all operating procedures outlined in ANSI B65.5-1996
Safety Test Trip
The auxiliary safety test trip is a device to measure the acceptable distance between the platen and the die mounting
surface after the wrap around safety device is actuated. The test trip is installed by slipping the trip over the bolts, shown in the
assembly drawing. When the platen is cycled, the test trip contacts the top surface of the platen, causing the tripped wrap around
safety device to stop the press. To run the test, the press should be operating at its highest speed, to ensure that the requirement
for the minimum remaining distance is met at all operating speeds. After the platen strikes the removable test trip, the remaining
distance should be no less than 100mm between the platen and the die-mounting surface. The 1996 safety standard states that
operators MUST run this test before regular operation every day to guarantee the proper working condition of the safety
device and braking system. Return the safety test trip to back position after successful completion of the test for normal
operation of the machine. Below is a diagram of the proper test procedure.
Instruction Manual - 19" x 25"

Page
SECTION IV
CARE & MAINTENANCE
GENERAL CARE
In order to get the most efficiency from your Value Line Cutting and Creasing Press, it should be given the good care due
any precision machine. It should be kept reasonably clean and free from foreign matter. Do not allow waste material to collect in
bridge cam well, on rocker seats, or in gear teeth.
While the press is ruggedly built of high quality materials and relatively trouble free, you should carefully follow all
operating instructions, and check the machine for proper adjustments and wear at the first indication of improper performance.
Keep the machine properly lubricated at all times and do not abuse it by overloading, either with too heavy a job, poor
makeready, dull dies, or variations in material conditions such as thickness, moisture content, and grain.
RESETTING BRIDGE FACE PARALLEL WITH FRAME FACE
PROCEDURE FOR SQUARING BRIDGE & ADJUSTING BRIDGE CAM ROLLER ON VALUE LINE 19X 25
PRESSES
1. Cycle the press until the top bridge lugs are just on top of the frame rocker plates.
2. Turn off all power to the press and make sure flywheel motion has stopped.
3. Place the parallel bar (shipped with the press) into the machine, hanging it from the top of the platen by the pin sticking out
from the edge of the bar near the top. Be sure to place the bar an equal distance from each side of the platen.
4. With the special crank supplied with the press, move the bridge so that the bar is very close to contacting the frame face (about
.010").
5. Adjust the impression to lightly squeeze the parallel bar in the press. Be sure that both sides are adjusted such that the
indicators read exactly the same. The platen should not be tipped from side to side.
6. Loosen both the top and the bottom bridge lugs.
7. With the crank, move the bridge to firmly squeeze the parallel bar in the press.
8. Adjust the bridge lugs so that they are firmly against the bridge guide (tighten both the top and bottom securely).
9. Adjust the cam roller using the eccentrics on either end of the roller shaft such that the roller turns freely after locking the
adjusting eccentrics in place, as they may move while you tighten the locks.
10. With the crank turn in the opposite direction until the top bridge lug is within 1/4" of leaving the rocker plates.
11. Remove the parallel bar.
12. Using a .002" feeler gauge, check the clearance between each side of the roller and the cam way. The .002" feeler should
slide completely through from side to side without obstruction on one side of the cam way. On the opposite side of the cam
way you should be unable to start the feeler gauge in any position. This test is performed to assure that the cam roller is
parallel to the cam way and does not make contact with the front of the cam way on one end of the roller and the rear of the
cam way with the other end of the roller.
Instruction Manual - 19" x 25"

Page
13. Return the impression adjustments to zero settings on each side and mount your die. Be sure the die is mounted such that the
load is centered in the press. There is a tapped hole located at the center of the machine. Use that hole for reference
whenever you mount a die. If you subject the press to unbalanced loads you may have to repeat this squaring procedure.
CAUTION
IF THE BRIDGE CAM ROLLER STANDS MOVE FROM THEIR SELECTED SETTING, WEAR AND CAM
BREAKAGE MAY RESULT. CHECK SCREWS PERIODICALLY.
Instruction Manual - 19" x 25"

Page
SECTION V
TROUBLE SHOOTING
BRIDGE STUCK ON CENTER
A. Turn off the main motor and wait until the flywheel comes to a complete stop.
B. Follow the procedure for the removal of the parallel bar.
C. Turn the flywheel in the direction opposite the arrow.
D. Once the press opens, remove any obstructions and inspect the makeready and the press for damage.
E. Return the press to "run" condition.
CAUSES OF BRIDGE CAM FAILURE
1. Worn bridge cam and bridge cam roller
2. Bridge cam roller shaft out of adjustment
3. Bridge face not parallel with frame face, causing it to rise on impressions.
4. Bridge lugs adjusted improperly, causing straining action with motion of bridge cam.
5. Machine operating backwards.
6. Machine operating at excessive speeds.
7. Bridge Cam Roller Stand Bolts loose.
CAUSES OF BRIDGE LUGS SLIPPING
1. Dies mounted off center or unbalanced load.
2. Cutting rule in die is dull.
3. Extra stock fed into, or fell into press.
4. Parts of die, such as rule or quoins, fall into the press.
5. Tools left on steel cutting plate.
6. Lug bolts loose.
7. Bridge Cam Roller out of adjustment.
Instruction Manual - 19" x 25"

Page
BRIDGE FACE NOT PARALLEL WITH FRAME FACE - RESULTING PROBLEMS
1. Bridge lifts on impression
2. Cutting rules are abused and become dull.
3. Uneven cut top to bottom.
4. Overload of press.
5. Unnecessary makeready
6. Steel cutting plate is cut into and damaged.
7. Slippage of bridge lugs.
8. Bridge Cam failure
9. Unsatisfactory die cutting.
MAKEREADY PROBLEMS
If the makeready is soft due to special low rule, or for other reasons, the job will continually fade away and will also tend
to dull the cutting rule more than necessary.
Never use more than .003 gummed paper for spotting up. Gummed paper .006" thick will bear the form off and cause
overloading of the press.
Never use any kind of tape other than make-ready tape.
If a soft steel plate or brass plate is substituted for hard cutting plates, it is very likely that the machine will be
overloaded, causing a main shaft, bridge shaft, crank pin, or connecting rods to break.
Fiberboards that have been bonded together with silica, and also metal lined boards, which have uneven perforations and
are used for blow out proof gaskets, cause considerable trouble in fading out of work.
Plastics of varying density may cause inconsistent cutting.
Variation in moisture content of board and change in direction of grain will affect die cutting results.
Consult Make-ready manual for proper make-ready instructions
PROBLEMS WITH THE PRESS (INCONSISTENT CUTTING)
A. Impression sleeve lock bolts loose.
B. Crank pins loosened or bent.
C. Worn main shaft bushings, or a broken main shaft
D. Connecting rod bushings are worn
E. Worn or stretched connecting rod
F. Insufficient impression to take up machine clearance.
Instruction Manual - 19" x 25"