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STAGE 2

Re-building program for totally rebuiltcylinder machine.

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We inspect all machines prior to purchase or if sourcing from overseas, the machines are checked via a competent body on our behalf. We will only purchase machines that are free from extensive damage.

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reb7.jpg (65132 bytes) Select machine from stock, connect electrical supply and test run, list any faults in the operation, abnormal noises i.e. worn bearings, bruised gears in gearbox.
Remove all chrome and anodised parts, send to plating company to be re-nickel plated or anodised.
Remove all wiring and dispose of. Whilst dismantling check all parts for wear or breakage, distribution links are dismantled, cleaned and seals are replaced.
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reb26.jpg (52174 bytes)

Dismantle the machine into six major components;
1 Feed Section
2 Delivery Section
3 Cylinder
4 Bed
5 Gearbox
6 Base

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preb13.jpg (53404 bytes) 1.  Feed Section:
Completely dismantle to individual side frames, observe for any broken or worn parts. These items are listed and replaced during the re-build cycle.
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preb14.jpg (55776 bytes) 2. Delivery Section:
Completely dismantle to individual side frames, observe for any broken or worn parts. These items are listed and replaced during the re-build cycle.
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preb12.jpg (53746 bytes) 3. Cylinder:
Remove gripper section and ratchet bars, slot ratchet bars for easier tensioning of the make ready material.

Check the cylinder for wear or damage, if damaged send to repair company to be ground, metal sprayed and re-ground to size.

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reb18.jpg (57771 bytes) 4. Bed:
Remove the bottom racks, side racks and bearers.
Depending on the system required;

Honeycomb System - Use existing bed as a template, make technical drawings for new bed, then store the old bed or dispose of. Click here for further details of Honeycomb system.

Infill System - Grind to accept 90mm diameter of foil. Machine bed if necessary to suit desired type height.

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reb27.jpg (43830 bytes) 5. Gearbox:
Remove the flywheel, drive gears and empty the old oil and dispose of.
Check for any bruised or worn gears and replace where necessary.
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reb28.jpg (57881 bytes) 6. Base:
Remove the connecting rod, check white wall bearings. If any wear is found the parts are sent to metal sprayers to be re-sized to original specification. Remove crankshaft, check two white wall bearings as above.

Remove bottom rack leaving base to be cleaned and sprayed.

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  Main machine control panel:
There are two options;
1. Inverter drive - All control gear is located in the conversion control panel. Completely remove the box and store.
2. Original control panel - Remove control gear panel from enclosure box, modify box and send to paint shop. Check resistor bank, replace or renew where necessary. Remove all control gear and rebuild to the new specifications using all new parts.
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reb19.jpg (67255 bytes) Main motor:
Completely dismantle, clean, change both bearings and check resistance on windings.

Check condition of slip rings and skim if necessary, change bushes. 

Paint and rebuild.

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preb4.jpg (57953 bytes) Cleaning:
Larger parts to be steam cleaned, all exposed metal to be sprayed with oil to prevent rusting. Smaller parts including nuts, bolts and springs are put into the parts washer. 

Separate the parts to be chemically blacked or painted.

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reb21.jpg (66574 bytes) Spraying:
Prepare parts, mask up exposed metal surfaces not to be painted.
Paint with two-pack air drying on larger items, smaller items are powder coated and oven baked.
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reb25.jpg (57444 bytes) Rebuild:
All sections are now rebuilt, parts are lubricated where necessary prior to fitting. Particular attention is given to shafts, bushes, slides, gears and castings and where wear might not have been obvious prior to cleaning.

Any parts found to be worn will be replaced or rectified at this stage. The motor and control panel are the first components to be fitted to the base. This will enable us to run the machine during the rebuilding process, ensuring that all the subsequent sections fitted run correctly prior to the next section being fitted.

preb2.jpg (59717 bytes) Once all the sections are fitted the machine is extensively tested with paper/card, minimum/maximum grip, minimum/maximum sizes of paper, to ensure that the timings are correct and the paper/card does not get damaged.

The bearers on the bed are checked with oil to see even pressure across.

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The machine is then run for 1 full day and re-checked. This process will continue until we are confident that the machine will run to your requirements.

If a foil conversion is to be fitted it is done now. If not, the machine is guarded for cutting and creasing.
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