Maintenance Instructions 367227 241 242 247 P5111780 EN

Maintenance instructions
KBA RAPIDA 105U
Koenig & Bauer AG

Postfach 02 01 64
01439 Radebeul, Germany
Telephone + 49 (0)351 833-0
Fax +49 (0)351 833-1001
E-mail: office@kba-print.de
Internet web site: http://www.kba-print.de
367 227; 367 241; © 2007 Koenig & Bauer AG
367 242; 367 247

RAPIDA 105U
Table of contents
Important notes Lubricating the pull guides ......................................................................... 3-7
Structure of the maintenance instructions Lubricating the swing infeed ....................................................................... 3-8
Explanation of symbols Lubricating printing unit grippers ................................................................ 3-9
Care of the distribution cylinder ................................................................ 3-10
Daily maintenance tasks 1
Printing tower / varnish tower lubrication bar ........................................... 3-11
Cleaning the sheet monitoring units .......................................................... 1-1
Changing the oil in the circulation lubrication (500 operating hours) ....... 3-12
Cleaning the ColorTronic ink duct .............................................................. 1-2
Lubricating the chains .............................................................................. 3-13
Cleaning the impression cylinder ............................................................... 1-3
Lubricating the suction roller .................................................................... 3-14
Weekly maintenance tasks 2 Lubricating the gripper carriage ............................................................... 3-15
Cleaning the discharge unit and sensor .................................................... 2-1 Lubricating the gripper carriage chain ...................................................... 3-16
Cleaning the fan switch cabinet ................................................................. 2-2 Cleaning the alcohol stabilizer ................................................................. 3-17
Checking the belt tension .......................................................................... 2-3 Cleaning the electronic alcohol stabilizer (optional) ................................. 3-18
Cleaning the filter mat of the main drive motor .......................................... 2-4 Air filter of the control air compressor (Kaeser) ........................................ 3-19
Lubricating the ink zone lever .................................................................... 2-5 Control air compressor valves (Kaeser) ................................................... 3-20
Care of the bearer ring cleaner (optional) .................................................. 2-6 Cleaning the cold dryer (Kaeser) ............................................................. 3-21
Lubricating the dampening unit .................................................................. 2-7
Care of the plate tensioning system .......................................................... 2-8 Quarterly maintenance tasks 4
Cleaning the non-stop unit (optional) ......................................................... 2-9 Lubricating the pile lift chains on the sheet feeder ..................................... 4-1
Cleaning the delivery ............................................................................... 2-10 Cleaning the rotary valve ........................................................................... 4-2
Cleaning the feed table ventilator ............................................................... 4-3
Cleaning the dampening solution cooling unit (Baldwin) ......................... 2-11
Cleaning the side channel compressor unit ............................................. 2-12 Checking the carbon brushes .................................................................... 4-4
Oil level of the control air compressor (Kaeser) ....................................... 2-13 Setting the cable tension on the ink duct ................................................... 4-5
Checking the ink wiper ............................................................................... 4-6
Cleaning the filter in the vacuum pressure pumps (Becker) .................... 2-14
Cleaning the compressor filter ................................................................. 2-15 Checking the oil level in the circulation lubrication system ........................ 4-7
Changing the oil on the control air compressor (Kaeser) ........................... 4-8
Monthly maintenance tasks 3 Steam trap of the cold dryer (Kaeser) ........................................................ 4-9
Lubricating the adjustment spindles .......................................................... 3-1 Checking the compressor for wear and tear ............................................ 4-10
Lubricating the sheet separator ................................................................. 3-2 Cleaning the ventilation grate ................................................................... 4-11
Lubrication of the cam control .................................................................... 3-3
Cleaning the transport roller and other rollers ........................................... 3-4 Semi-annual maintenance work 5
Checking the color evaluation lamp ........................................................... 5-1
Checking the tension of the drive belt ........................................................ 3-5
Lubricating the infeed printing unit / feed drum .......................................... 3-6 Cleaning the maintenance unit for control air ............................................. 5-2
Lubricating the traversing ink form rollers .................................................. 5-3
P 511 1780_EN © 2007 Koenig & Bauer AG

367 227; 367 241; 367 242; 367 247 2
RAPIDA 105U
Lubricating the distribution cylinder ........................................................... 5-4 Hollow wrench ............................................................................................ 9-5
Changing the oil in the circulation lubrication system (2,000 operating Packing thickness measurement devices .................................................. 9-6
hours) ......................................................................................................... 5-5
Lubricating the side jogger ......................................................................... 5-6
Changing the dampening solution at the dampening solution cooling unit
(Baldwin) .................................................................................................... 5-7
Checking the Becker vacuum pressure pumps for wear and tear ............. 5-8
Annual maintenance work 6
Lubricating the impression cylinder and transfer drum bearings ............... 6-1
Lubricating the side alignment stops ......................................................... 6-2
Steam trap of the control air compressor (Kaeser) .................................... 6-3
Biannual maintenance tasks 7
Changing the oil in the circulation lubrication system ................................ 7-1
Changing the filter in the circulation lubrication system ............................. 7-2
Changing the oil in the duct motor gears ................................................... 7-3
Changing the support batteries at the EC581 controls .............................. 7-4
Changing the battery of the uninterruptible power supply ......................... 7-5
Overviews 8
Overview of lubricants ................................................................................ 8-1
Overview of lubricants - Suppliers and products ........................................ 8-2
Overview of lubricants - Suppliers and products ........................................ 8-3
Overview of lubricants - Commissioning package (variant no. 1)............... 8-4
Overview of lubricants - Commissioning package (variant no. 2)............... 8-5
Overview of process materials.................................................................... 8-6
Oil filling quantity for the lubrication circuit.................................................. 8-7
Operating and repair tools 9
Adjustment gauge for reflex scanning heads ............................................. 9-1
Clamping bar ............................................................................................. 9-2
Socket wrench, size 10 .............................................................................. 9-3
Extension, wrench size 10 ......................................................................... 9-4

367 227; 367 241; 367 242; 367 247 3
RAPIDA 105U
Important notes
Compliance with the instructions in the operating manual is required!
Please note:
Maintenance work is essential for maintaining the functionality of your printing press and its auxiliary units. All work involving assembly, installation, commissioning,
maintenance and repair must be carried out by qualified personnel and checked by competent specialists.
Deviations from normal operation (higher power consumption, temperatures or fluctuations, unusual noises or odors, triggering of the monitoring devices, etc.) indicate
that the printing press is malfunctioning. To prevent malfunctions that can cause direct or indirect harm to people or property damage, the corresponding unit must be
switched off immediately!
The servicing intervals are the minimum recommendations with 3-layered use (corresponding to approximately 80 company hours per week). Non-
compliance with the maintenance instructions as well as modifications and bridging of safety devices or taking them out of operation will result in the loss
of rights to assert claims under the warranty and exclude any liability on the part of the manufacturer. Please comply with the laws, provisions and
regulations of your country regarding the protection of people and the environment.
The maintenance instructions apply only in conjunction with the operating manual of the respective manufacturer. We reserve the right to make changes in content.
The maintenance instructions apply to various versions of the printing press. Sub-assemblies may therefore be described that are not included in the version of the
printing press you have selected. The list of maintenance work required for sub-assemblies is comprised only of excerpts. The binding specifications are contained in
the respective manufacturer documentation.
The process materials listed are recommendations for products commonly used in the industry. Our customer service department will be glad to help you with any
questions you may have.
When selecting the lubricants, you should choose products approved by the manufacturers in accordance with the lubricant tables (See “Overview of lubricants” 8-
1 ... 8-4).

367 227; 367 241; 367 242; 367 247 4
RAPIDA 105U
Structure of the maintenance instructions
1 Maintenance task
2 Location of
maintenance
3 Maintenance symbol Druckwerk 9
4 Lubricant number 1 5-3 Schmierung Traversierende Farbauftragwalzen
according to lubricant
overview in Chapter 8 2 Alle Farbwerke
5 Work steps required
Hauptschalter ausschalten und sichern;
6 Consumables, auxiliary 3 Farbwerkschutz öffnen;
materials, tools, and
4 IV alle davorliegenden Walzen aus dem Farbwerk nehmen, Lagerschlösser öffnen;
replacement parts die vier traversierenden Farbauftragwalzen (grau gekennzeichnet) auf ausreichende
Lagerschmierung kontrollieren;
7 Warnings 5 gegebenenfalls aus dem Farbwerk nehmen und beidseitig Laufflächen (1) und Nadellager (2)
einfetten;
8 Maintenance schedule /
chapter bei Schäden müssen die Nadellager (2) ausgetauscht werden; 10
9 Assembly for alle Walzen wieder in das Farbwerk einsetzen, Lagerschlösser schließen;
maintenance Ein- und Ausbau der Farbauftragwalzen siehe Betriebsanleitung
10 Illustration
6 Fett Nr. I (siehe Schmierstoffübersicht 8-1 ... 8-4)
7 Maschine gegen Wiederanlauf

sichern!
Überschüssigen Schmierstoff
sorgfältig entfernen!
alle zwei
8 1 täglich 2 wöchentlich 3 monatlich 4 vierteljährlich 5 halbjährlich 6 jährlich 7 Jahre

367 227; 367 241; 367 242; 367 247 5
RAPIDA 105U
Explanation of symbols
Please comply with the instructions in the operating manual. Change oil
Checks, inspections Clean filter, replace if necessary
Manual cleaning Check the filling level of the liquid,

top up if necessary.
Grease lubrication using the grease gun

(The number below the symbol indicates the lubricant to be used.)
(See “Overview of lubricants” 8-1 ... 8-4)
Grease
Spray
Oil lubrication using the oil can


367 227; 367 241; 367 242; 367 247 6
1 Daily maintenance tasks
Semi- Every two

1 Daily 2 Weekly 3 Monthly 4 Quarterly 5 annually
6 Annually 7 years
367 227; 367 241; 367 242; 367 247
RAPIDA 105U Infeed
1-1 Cleaning the sheet monitoring units
Infeed table, sheet monitoring unit

1 1
Press and lock the “Stop and lock” key;
Clean the reflex scanning heads (1) and double sheet control (2)
Dry, clean brush

2
Secure the printing press to

prevent it from restarting!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 1-1
RAPIDA 105U Printing unit
1-2 Cleaning the ColorTronic ink duct
Ink ducts on all printing units

3 1 2 3
When changing ink or cleaning the ink duct, you must also clean the sealing surfaces between
the strippers (1) and the ink duct roller (2). To do this, flip the lever (3) upwards and pull the ink
duct down.
Cleaning cloth
Washing solution

Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 1-2
RAPIDA 105U Printing unit / Varnish unit
1-3 Cleaning the impression cylinder
Impression cylinders in all printing and varnishing units
Open the footboard in the printing unit walkway.
Inch the first gripper system upwards.
After washing the impression cylinder, clean up the edges of the impression cylinder manually,
depending on how dirty they are.
Remove any dirt on the front edge (1) and rear edge (2) as well as the cylinder surface by hand.
Switch on the printing press again and repeat the steps for the second gripper system.
Cleaning cloth
Washing solution for stubborn dirt
Always wear protective goggles

Secure the printing press to Open the footboard only when the Always wear protective gloves
when you are working with
prevent it from restarting! printing press has stopped! when working with chemicals!
chemicals!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 1-3
2 Weekly maintenance tasks
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247
RAPIDA 105U Sheet feeder
2-1 Cleaning the discharge unit and sensor
Anti-static devices and front edge sensor at the sheet feeder

1 1
Lower the pile board completely.
Clean the tips of the anti-static devices (1) using the brass wire brush supplied; suction off or
blow off residual dirt.
Clean the front edge sensor (2) at the front edge of the pile with a soft clean cloth and an alcohol-
based cleaning agent.
Caution! Do not use any solvents or roller washing agents!
For further information, please see the operating manual.
Brass brush, compressed air (max. 2 bar)

Soft, clean cloth
Alcohol-based cleaning agent (such as Sonax) 2
Switch off the main switch before This work may be carried out only
beginning any maintenance work! when the feeder is stopped!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-1
2-2 Cleaning the fan switch cabinet
The fans are located in the switch cabinet of the sheet feeder
Turn off the main switch and secure it;
Remove the ventilation grates (1).
Blow out the filter mats underneath using compressed air, and replace if necessary.
Unscrew the fan casing on the inside of the switch cabinet cover at regular intervals. To do this,
open the switch cabinet cover using the switch cabinet key.
Clean the casing and fan wheel using a brush.
Switch cabinet key

Brush, compressed air (max. 2 bar)
Filter mats
Switch off the main switch before This work may be carried out only Always wear protective goggles
beginning any maintenance work! when the feeder is stopped! when working with compressed air!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-2
2-3 Checking the belt tension
Suction belts at the sheet feeder
Secure the printing press using “Emergency stop” and lock it.
Check the tension of the suction belts; to do this, lift the belt in the center of the feed table using
approximately 20 N (4.5 lbf) of force.
The distance between the feed table and the suction belt must be between 10 and 20 mm (0.4-
0.8 inch).
Check the spacing between the suction tape and the guard (1).
If the spacing is too small, loosen the screw (2) on both sides.
Align the guard (1).
Re-tighten the screws (2).
Replace defective suction belts.
For information on changing the suction belts, please see the operating manual.
2 open-end fork wrenches
Secure the printing press to This work may be carried out only
prevent it from restarting! when the feeder is stopped!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-3
RAPIDA 105U Main drive motor
2-4 Cleaning the filter mat of the main drive motor
Main drive motor on the drive side next to the second printing unit
Turn off the main switch and secure it.
Open the gallery casing on the second printing unit.
Using two fingers, press the protective grating (1) downwards and remove it from the prong (2).
Remove the filter mat and blow it out with compressed air.
Wash out greasy filter mats and dry them.
Important! Use original parts when replacing the filter mats!
Follow the steps in reverse to reassemble the unit;
For further information, see the supplier's documentation provided by Baumüller.
Compressed air (max. 2 bar)

Water with household detergent added
Switch off the main switch before Protect yourself against contact Always wear protective goggles
beginning any maintenance work! with hot surfaces! when working with compressed air!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-4
2-5 Lubricating the ink zone lever
Ink ducts on all printing units

1 2
unscrew the screw (1) in the ink stripper on the drive side half a turn, so that the groove in the
I, XIV screw (1) is pointing upwards;
grease the lubrication nipple (2) on the operating side with 8-10 shots from the lubrication gun;
screw the screw (1) on the drive side half a turn back in (tighten only slightly); create light grease
pressure by greasing the lubrication nipple on the operating side (2).
Important! Only allow a small amount of grease to seep out between the ink stripper and the ink
zone lever.
Move the adjacent ink zone levers on the ColorTronic desk against each other using individual
adjustment.
Carefully clean the ink duct of residual grease
Grease No. I without UV additive (See “Overview of lubricants” 8-1 ... 8-4)
Grease No. XIV with UV and changing additive (See “Overview of lubricants” 8-1 ... 8-4)
Cleaning cloth
Carefully remove all superfluous

lubricant!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-5
2-6 Care of the bearer ring cleaner (optional)
On all printing units between the plate cylinder and rubber cylinder
Move the rubber and plate cylinder guard upwards.

Press and lock the “Stop and lock” key.
Push out the lubrication felts (1) towards the middle of the press, wash them out in grease
solvent, let them dry and oil them lightly.
Push the oiled lubrication felts (1) back in.
IV Important! Protect the lubrication felts against damage and change them when they project only
2 mm (0.08 inch) out of their mounts. Reserve lubrication felts can also be stored in an oil bath.
Oil No. IV (See “Overview of lubricants” 8-1 ... 8-4)

Lubrication felt: KBA order number L 615 5720
White spirit

Secure the printing press to Always wear protective gloves Please comply with all regulations
prevent it from restarting! when working with chemicals! when using flammable liquids!
chemicals!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-6
2-7 Lubricating the dampening unit
On the drive and operating sides on all printing units towards the delivery

Open the upper flap guard (1).
Lubricate the lubrication nipples (2) on the drive side and operating side on the traverse using 2 -
I, XIV 3 shots of the lubrication gun.
Close the upper flap guard (1) again and flip the lower flap guard (3) upwards.
Unlock the “Stop and lock” key; inch both funnel-type lubrication nipples (4) on the operating side
into the visible area; press and lock the “Stop and lock” key.
VI Lubricate both funnel-type lubrication nipples (4) on the operating side as well as the two on the
drive side using 2 - 3 shots of the lubrication gun.
Important! Spray the tooth flanks of all gear wheels of the dampening unit on the drive side and
the operating side lightly with oil spray. Check plastic gear wheels (5) for wear and tear and
replace them if necessary (see the operating manual).
Close the lower flap guard (3).
Spray No. VI (See “Overview of lubricants” 8-1 ... 8-4)
Lubrication gun, cleaning cloth
Let the printing press dry for 15

Secure the printing press to Carefully remove all superfluous Always wear protective goggles minutes after applying spray
prevent it from restarting! lubricant! when spraying! before turning it on again - there is
danger of fire!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-7
2-8 Care of the plate tensioning system
Plate cylinders in all printing units, varnish form cylinders in all varnishing
units
Move the rubber and plate cylinder guard upwards and inch the tensioning rails (1) into the
visible area.
Clean the plate tensioning rails (1) and spray them lightly.
VII
Clean and lightly spray the adjustment screws (2) and other moveable parts through the
openings in the covers.
Carefully remove all superfluous lubricant.
Spray No. VII (See “Overview of lubricants” 8-1 ... 8-4)

Cleaning cloth
2 1 2 1 2
Secure the printing press to Carefully remove all superfluous

prevent it from restarting! lubricant!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-8
RAPIDA 105U Delivery
2-9 Cleaning the non-stop unit (optional)
Non-stop roller / non-stop board in the delivery

1
Retract and extend the non-stop roller (instructions in the operating manual).
Move the pile board downwards.
Blow out the guide rail (1) on the drive and operating sides.

Brush
Secure the printing press to Always wear protective goggles

prevent it from restarting! when working with compressed air!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-9
2-10 Cleaning the delivery
On the drive and operating sides of the delivery
Open the covers on the drive and operating sides and clean all powder from all moveable parts
(using suction).
Clean the powder from the telescopic springs (1) on the side stop.
Clean the interior space of the delivery, sheet guide plates and blower frame.
Warning! You must clean the delivery of paper and printing powder weekly. This avoids an
explosive atmosphere building up in the delivery.
Switch cabinet key

Vacuum cleaner 1
Brush
Cleaning cloth
Switch off the main switch before

beginning any maintenance work!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-10
RAPIDA 105U Auxiliary cabinets
2-11 Cleaning the dampening solution cooling unit (Baldwin)
Printing press peripherals
Turn off the main switch on the dampening solution cooling unit.
The following maintenance tasks must be performed:
• Check/change the dampening solution filters
• Clean the dampening solution containers
• Check/clean the freshwater and dampening solution additive filters
For further information, see the supplier's documentation provided by Baldwin.
Cleaning cloth
Water
Cleaning agents
Always wear protective goggles Dispose of used operating

Switch off the main switch before Always wear protective gloves
when you are working with materials in an environmentally
beginning any maintenance work! when working with chemicals!
chemicals! friendly manner!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-11
RAPIDA 105U Auxiliary units
2-12 Cleaning the side channel compressor unit
On the drive side under the platform or press peripherals
Open the cover of the (2) filter casing, remove the filter (1) and blow it out from the inside to the
outside using compressed air.
Change clogged, oily and greasy filters (half-yearly replacement is recommended).
For compressors without air filters, clean the filter sieve (3) on the suction side using a brush.
Remove mounted suction hoses if necessary.
Before putting the compressor into operation, disconnect the hose from the pressure outlet and
blow it off at full power into the air.
Clean the cooling ribs of the motor and casing using a brush.
For further information, see the supplier's documentation provided by the Becker company.
Brush
For filters, see the type label.
Cable lamp
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-12
2-13 Oil level of the control air compressor (Kaeser)
Check the oil level at the oil inspection glass (2).
If necessary, fill up the compressor oil through the filling opening (1).
For further information, see the supplier's documentation provided by Kaeser.

V
Oil No. V (See “Overview of lubricants” 8-1 ... 8-4)
Switch off the main switch before Protect yourself against contact
beginning any maintenance work! with hot surfaces!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-13
2-14 Cleaning the filter in the vacuum pressure pumps (Becker)
Unscrew the cover (1).

Remove the filter (2) and the pre-filter (3) if necessary, and blow out from inside to outside with
compressed air.
Replace clogged or oily and greasy filters with new ones (we recommend this be done twice a
year).
Clean the grating (4) and cooling ribs (5) using a brush.
Follow the steps in reverse to reassemble the unit.
For further information, see the supplier's documentation provided by the Becker company.
Brush
For filters to be used, please see the type label and supplier's documentation.
Cable lamp
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-14
2-15 Cleaning the compressor filter
Compressor for powder sprayer, on the operating side under the platform
Open the platform casing at the delivery.
Open the cover (1).
Remove the filter cartridges (2) and blow them out from the inside outwards;
replace deformed or heavily soiled filter cartridges with new ones (half-yearly replacement
recommended).
Clean the filter casing.
For further information, see the supplier's documentation provided by WeKo and Rietschle.

For filters, see the type label.
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 2-15
3 Monthly maintenance tasks
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247
3-1 Lubricating the adjustment spindles
Sheet feeder
1

2
Clean and lightly grease the adjustment spindles for the sheet separator (1), side alignment
stops (2) and pile board adjustment (3). 2
I, XIV
Cleaning cloth
Grease No. I, XIV (See “Overview of lubricants” 8-1 ... 8-4)
3
Secure the printing press to Carefully remove all superfluous This work may be carried out only
prevent it from restarting! lubricant! when the feeder is stopped!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-1
3-2 Lubricating the sheet separator
The sheet separator is located on the sheet feeder above the pile board
1
Lower the pile board to the floor.

IX
Thoroughly clean the sheet separator (1) (open from below) using compressed air and then
lightly spray the cam paths of the sheet separator with oil spray.
Caution! All extractors should be cleaned and must not come into contact with the spray!
Allen wrench
Spray No. IX (See “Overview of lubricants” 8-1 ... 8-4)
Cleaning cloth
Secure the printing press to This work may be carried out only Carefully remove all superfluous Always wear protective goggles
prevent it from restarting! when the feeder is stopped! lubricant! when working with compressed air!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-2
3-3 Lubrication of the cam control
On the drive side on the sheet feeder

1
Unscrew the longitudinal guard beside the pile stops on the drive side.
IX
Lightly spray the roller and cam path of the cam control (1).
Carefully remove all superfluous lubricant!
Unscrew the fan (2) below the actuator.
Clean the casing, fan wheel and ventilation grate using a brush.
Allen wrench
Spray No. IX (See “Overview of lubricants” 8-1 ... 8-4)
Cleaning cloth, brush 2
Switch off the main switch before This work may be carried out only Protect yourself against contact Always wear protective goggles
beginning any maintenance work! when the feeder is stopped! with hot surfaces! when spraying!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-3
3-4 Cleaning the transport roller and other rollers
Feed table
3 2 1
Clean the transport roller (1), the pacing rollers (2) and all brush, rubber and plastic rollers (3) of
the feed table using a dry process.
All rollers must rotate easily (danger of misaligned sheets).
XV Re-lubricate the roller bearings as necessary. To do this, remove the spring clip in front of the
respective roller, pull the roller off the shaft and apply a thin layer of grease to the needle
bearings.
For instructions on setting the spring resistance on pacing rollers, see the operating manual!
Brush
Cleaning cloth
Grease No. XV (See “Overview of lubricants” 8-1 ... 8-4) 3 3
Secure the printing press to This work may be carried out only Carefully remove all superfluous
prevent it from restarting! when the feeder is stopped! lubricant!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-4
3-5 Checking the tension of the drive belt
Main drive motor on the drive side next to the second printing unit
Loosen the counter-nut (1). Pre-tension the nut (2) until the socket (3) can no longer be rotated
manually.
Turn the nut (2) backwards until the socket (3) starts to move.
Re-tighten the counter-nut (1).
2 open-end fork wrenches
Secure the printing press to Protect yourself against contact

prevent it from restarting! with hot surfaces!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-5
RAPIDA 105U Infeed
3-6 Lubricating the infeed printing unit / feed drum
Infeed, operating side towards the feeder
Lubricate all lubrication nipples of the lubricating bar (1) for the infeed printing unit/feed drum
using 2 - 3 shots of the lubrication gun for each one, in the creep mode of the printing press if at
all possible.
I, XIV
Grease No. I, XIV (See “Overview of lubricants” 8-1 ... 8-4)

Lubrication gun
Cleaning cloth

lubricant!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-6
RAPIDA 105U Infeed
3-7 Lubricating the pull guides
Infeed printing unit; feed table
Set the printing press to a minimum format so that the lubrication nipples are accessible.
Flip up the guards over the feed table.
Clean the feed table thoroughly using a cleaning cloth.
Clean the adjustment spindle (1), the square shaft (2) and the joints and guide paths (4) of the
lattice grating (5) with a cloth, a brush or compressed air, and then spray them lightly.
X
Clean the double sheet control sensors (3).
Lubricate the lubrication nipples (6) using the lubrication gun (approximately 1 -2 shots).
I, XIV
Brush, cleaning cloth, lubrication gun

Spray No. X (See “Overview of lubricants” 8-1 ... 8-4)

Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-7
RAPIDA 105U Infeed
3-8 Lubricating the swing infeed
Infeed printing unit; above the feed table
Flip up the guard above the feed table.

Inch the printing press to approximately 65 to 85 degrees. Press and lock the “Stop and lock” key.
Lubricate the lubrication nipples (1) and (2) of the upper roller lever using the lubrication gun
I, XIV (approximately 1-2 shots).
Lubricate the gripper shaft bearing blocks (3) using the lubrication gun (approximately 1 - 2 shots
each).
Clean and lightly spray the bearing seats between the gripper and the gripper shaft.
X
Inch the printing press to approximately 180 to 190 degrees. Press and lock the “Stop and lock”
key. Lubricate the lubrication nipples (4) and (5) of the lower roller lever using the lubrication gun
(approximately 1-2 shots).
Spray the upper and lower running surfaces of the cam path (6).
Important! Rotate the gripper bar of the feeder drum by inching it into the visible area, press and
lock the “Stop and lock” key. Then carry out the same maintenance work as for the gripper
control.
Spray No. X (See “Overview of lubricants” 8-1 ... 8-4)

danger of fire!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-8
3-9 Lubricating printing unit grippers
Impression cylinders and transfer drums in all printing units
Important! When operating the machine without UV additive, the maintenance interval is
extended by 2 months!
Open the guard in the printing unit passageway.

Inch the first gripper system upwards.
XIV Lubricate the cam roller (1) and gripper shaft bearings (2) using the lubrication gun (each with 1
shot).
Clean and lightly spray the bearing seats between the gripper and the gripper shaft.
Spray the running surface of the cam path (3).
X, XII
Lubricate the second gripper system in the same fashion.
Grease No. XIV (See “Overview of lubricants” 8-1 ... 8-4)

Spray No. X without UV additive (See “Overview of lubricants” 8-1 ... 8-4)
Spray No. XII with UV and changing additive (See “Overview of lubricants” 8-1 ... 8-4)

danger of fire!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-9
3-10 Care of the distribution cylinder
All inking units
Open the inking unit guard.
Clean the polished areas (1) of the distribution cylinder legs (marked in gray) on both the
operating and drive side thoroughly with a dry cloth, and spray them lightly with oil spray.
VII, XII
Cleaning cloth
Spray No. VII without UV additive (See “Overview of lubricants” 8-1 ... 8-4)
Spray No. XII with UV and changing additive (See “Overview of lubricants” 8-1 ... 8-4)

danger of fire!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-10
3-11 Printing tower / varnish tower lubrication bar
On the operating side towards the feeder on all printing and varnish units
Lubricate all lubrication nipples of the lubricating bar (1) with 2 - 3 squirts of the lubrication gun, in
the creep mode of the printing press if at all possible.
I, XIV


lubricant!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-11
3-12 Changing the oil in the circulation lubrication (500 operating hours)
On the drive side of each printing unit/varnish unit below the gallery, once
after 500 operating hours:

Open the gallery casing on the drive side.
II Unscrew the plate beside the running plate of a printing unit passage way on the drive side.
Screw out the oil fill plug (1), suction out used oil with an external oil pump and dispose of it in an
environmentally friendly way.
Unscrew the discharge screws (3) on all printing and varnishing units. Catch the residual oil in a
basin and dispose of it in an environmentally friendly way.
Screw in the discharge screws (3) with new copper sealing rings.
Fill up fresh oil through any oil fill plug (1) up to the center of the inspection glass (2) (the printing
units are connected to each other).
Screw the oil fill plug (1) back in and reattach the plate.
Important! Change the oil filter whenever you change the oil! (See page 7-2)
Hexagon socket screw wrench, fork wrench

Gear oil No. II (See “Overview of lubricants” 8-1 ... 8-4)
External oil pump with hose
Copper sealing rings A 27x32 (KBA order number L 068 5460)
Switch off the main switch before Protect yourself against contact Carefully remove all superfluous Dispose of used fuels in an
beginning any maintenance work! with hot surfaces! lubricant! environmentally friendly manner!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-12
3-13 Lubricating the chains
Delivery
Lower the pile carrier plate and non-stop roller.
Clean and lubricate the pile lift chains (1) and the non-stop roller chains.
Replace damaged chains (use original parts).

VIII
White spirit
Brush, cleaning cloth
Spray No. VIII (See “Overview of lubricants” 8-1 ... 8-4) 1 1
Secure the printing press to Always wear protective gloves Please comply with all regulations
prevent it from restarting! when working with chemicals! when using flammable liquids!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-13
3-14 Lubricating the suction roller
On the drive side below the suction roller

1
Lower the delivery pile board to the floor.
I, XIV Grease the lubrication nipple (1) on the drive side using 2 - 3 shots of the lubrication gun.


Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-14
3-15 Lubricating the gripper carriage
On the operating side at the delivery, accessible from the delivery flap
guard 1 2
Move the gripper carriage into a suitable position.
I, XIV Press and lock the “Stop and lock” key.
Open the flap guard of the delivery (viewing window).
Clean the cam roller (1) of the gripper carriage thoroughly of lubricant and heavy powder
deposits;
Lubricate the cam roller (1) of the gripper carriage using the lubricating nipple (2) (approximately
1 shot).
Inch the machine until it is in a position so that all cam rollers of the gripper carriages can be
cleaned and lubricated (inch and secure).


Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-15
3-16 Lubricating the gripper carriage chain
On the drive side at the delivery
Check the filling level on the storage tank (1) for chain lubrication, and top up oil if necessary.
III
Clean the oil distribution brushes used for lubricating the gripper carriage chain and ensure that
they function properly. If they are very worn, replace them.
The lubrication cycle can be set at the central control console in a range between 500 and 3000
sheets.
Approximate value:
• 1000 sheets when powder or dryers are used
• 2000 sheets without the use of powder or dryers
Special oil No. III (See “Overview of lubricants” 8-1 ... 8-4)
Oil distribution brush: KBA Order No. L 064 7841

Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-16
3-17 Cleaning the alcohol stabilizer
Dampening solution cooling unit
Disconnect the alcohol pipes.
Unscrew and remove the electronics housing.
Important! Make sure the unit remains vertical, as otherwise water could get into the electronics.
Remove the float (1).
Disconnect the dampening solution pipes and remove and empty the analysis cabinet (2).
Clean all parts with a cloth and hot water.
Cleaning cloth
Hot water

chemicals!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-17
3-18 Cleaning the electronic alcohol stabilizer (optional)
Dampening solution cooling unit
Disconnect electrical connections and the dampening solution supply connection, then remove
the container lid.
Clean the sensor (1) with a cleaning cloth and hot water; empty the container (2) and wash it out
with hot water; clean the stand pipe (3) with a bottle brush; check the bore (4) for cleanliness.
Caution! Use only commercially available cleaning solutions for dampening solution systems!
Nitro-cellulose thinner, sandpaper, abrasives and mechanical cleaning are not permitted!
Hot water
Cleaning cloth
Bottle brush

chemicals!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-18
3-19 Air filter of the control air compressor (Kaeser)
Completely dismantle the air filter (1) on the cylinder head. To do this, push away the tensioning
bracket and open the filter casing.
Clean the insert and casing using the steam radiator or with diesel fuel (perform this work in open
air).
After drying, coat the air filter with a light film of oil.
Replace defective filters with original parts.
Follow the steps in reverse to reassemble the unit. (The suction opening must be pointing
downwards during assembly).
Screwdriver
High-pressure cleaner or diesel fuel
Air filter for EPC 440: KBA Order No. P 078 3230
Air filter for EPC 840: KBA Order No. P 095 4550
Switch off the main switch before Protect yourself against contact Please comply with all regulations
beginning any maintenance work! with hot surfaces! when using flammable liquids!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-19
3-20 Control air compressor valves (Kaeser)
Press the “Test” key (4) on the automatic steam trap for two seconds.
Check whether condensate is precipitating out.

Close the main tap (1).
Check the safety valve (2) by turning the knurled nut (3) to the left.
Empty the pressure tank.
Open the reflux valve (5) only when the manometer indicates 0 bar.
Clean the reflux valve (5).
Open the casing plug screw (6) and clean the valve cone.
Fork wrench
Cleaning cloth
Switch off the main switch before Protect yourself against contact Always wear hearing protectors
beginning any maintenance work! with hot surfaces! when inspecting the safety valve!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-20
3-21 Cleaning the cold dryer (Kaeser)
On the drive side below or adjacent to the printing press gallery
Switch off the printing press.

Turn off the main switch (1) of the cold dryer and secure it.
Blow out the cooling lamellae of the refrigeration agent liquefier (2) from outside to inside using
compressed air. Remove stubborn dirt with a cleaning agent.
Check visually whether condensate is being discharged from the hose of the steam trap.
Important! If no condensate is being discharged, the steam trap (3) must be cleaned.

Brush
Cleaning cloth
Switch off the main switch before Always wear protective goggles
beginning any maintenance work! when working with compressed air!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 3-21
4 Quarterly maintenance tasks
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247
4-1 Lubricating the pile lift chains on the sheet feeder
Sheet feeder
Clean and lubricate the pile lift chains (1).
Replace damaged chains (use original parts).

VIII
White spirit (hazard class A3)

Brush, cleaning cloth
Spray No. VIII (See “Overview of lubricants” 8-1 ... 8-4) 1 1 1
Secure the printing press to Please comply with all regulations Always wear protective gloves This work may be carried out only
prevent it from restarting! when using flammable liquids! when working with chemicals! when the feeder is stopped!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 4-1
4-2 Cleaning the rotary valve
Sheet separator at the sheet feeder
In the case of significantly changed control times (poor sheet travel), the rotary valve (3) must be
thoroughly cleaned of paper dust and powder!
Disassemble the guard (1) on the drive side.

Remove the locking ring (2).
Pull out the rotary valve (3) (if necessary, use the M6 thread for this).
Clean the removed rotary valve using compressed air.
Installation is done in the reverse sequence.
Note: During installation, make sure that the spring (4) of the rotary valve locks into the groove of
the shaft.
Compressed air
Cleaning cloth
Allen wrench
Switch off the main switch before Always wear protective goggles This work may be carried out only
beginning any maintenance work! when working with compressed air! when the feeder is stopped!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 4-2
4-3 Cleaning the feed table ventilator
Below the feed table
Pull the lever on the operating side to arrest the feed table.
Flip up the feed table.
Remove the ventilator casing by removing the screws (1).
Clean the ventilator casing and wheel with a brush.
Brush
Phillips screwdriver
Switch off the main switch before This work may be carried out only
beginning any maintenance work! when the feeder is stopped!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 4-3
4-4 Checking the carbon brushes
On the drive side next to the second printing unit
The brush holders and carbon brushes must be checked for wear, brush pressure, mobility of the
brushes in the holders as well as the contact bond strength between the brushes and the cord,
and cleaned.
Caution! Severe property damage is possible. For this reason, change the carbon brushes
before the cord damages the commutator! Use only original parts!
For further instructions and information, see the documentation provided by the supplier
Baumüller.
This work may be carried out only

by a trained electrician!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 4-4
4-5 Setting the cable tension on the ink duct
On the drive and operating sides of every print tower
Loosen and remove the trim panel in front of the servomotor using the hexagon socket screw
wrench.
When the ink duct is locked, tighten the nuts (1) using a fork wrench until the spring assembly is
fully tensioned, holding the thread piece against it with the allen wrench.
Turn the nuts (1) back one-half to three-quarters of a turn and lock them.
Adjust the settings on the drive and operating sides, then screw the trim panel back on and
repeat these steps on the next inking unit.
Warning: When screwing on the trim panel, make sure that no electrical cords are pinched on
the operating side!
Allen wrench
Fork wrench
1 1

Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 4-5
4-6 Checking the ink wiper
On the drive and operating sides of each ink cabinet
Press the “Stop and lock” key.

Checking the ink duct wiper (1) for leakage (visual check on whether ink is flowing into the ink
duct shell);
Disassemble and clean the ink wiper (1) with the pressure plate (4) and spring plate (5), clean
the duct running surfaces.
Check the running surface on the ink wiper (1), if necessary replace the ink wiper. Slide the ink
wiper (1) into the greased groove (2) as far as the ink duct roller (3); press in the pressure
plates (4) and assemble the spring plates (5); let the ink wiper run in in dry mode for about 15-20
minutes; close all ink zones while the ink duct roller is turning and there is little ink in the ink duct
and check whether the transition between wiper and ink is sharp edged. If necessary, let the ink
wiper run in again.
Caution! Only screw the supporting screw (6) in the ink wiper far enough that it lies against the
ink duct without clearance. Do not move the ink wiper out of the way!
Check the cable tension (See page 4-5).
Allen wrench, screwdriver, grease

Ink wiper on operating side: KBA Order No. P 365 8220
Ink wiper on drive side: KBA Order No. P 366 5840

lubricant!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 4-6
4-7 Checking the oil level in the circulation lubrication system
On the drive side on each printing unit below the gallery

Leave the machine switched off for at least 15 minutes.
Check the oil level in the inspection glass (1), the oil should be in the center of the inspection
glass.
II
Important! The printing units are connected to each other. The oil level only needs to be
checked at one printing unit.
In the case of oil loss, check the printing press for leakage and malfunctions and correct any
problems found!
If necessary, fill it with new oil using the fill screw (2) under the side foot board.
Cable lamp
Switch off the main switch before Protect yourself against contact Carefully remove all superfluous
beginning any maintenance work! with hot surfaces! lubricant!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 4-7
4-8 Changing the oil on the control air compressor (Kaeser)
Open the oil filler neck (1).

V Drain the old oil at the discharge screw (3) and catch it in a basin.
Flush the crankcase with a small amount of fresh oil.
Screw in the discharge screw (3) again and fill up the oil to the center of the inspection glass (2).
Close the filler neck (1) again.
Carry out the pressure tank inspection in accordance with local regulations.
Oil No. V (See “Overview of lubricants” 8-1 ... 8-4)

Box wrenches
Switch off the main switch before Protect yourself against contact Dispose of used fuels in an
beginning any maintenance work! with hot surfaces! environmentally friendly manner!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 4-8
4-9 Steam trap of the cold dryer (Kaeser)
On the drive side below or adjacent to the printing press gallery

Turn off the main switch (1) of the cold dryer and secure it.
Close the stopcocks for compressed air intake and output.

Unscrew the casing of the cold dryer.
Remove the insulation of the steam trap (2).
Remove the discharge hose. Activate the air bleed valve until no more air escapes.
Unscrew and remove the lower part of the casing. Remove the connection on the lower part of
the casing.
Disassemble the automatic steam trap by loosening the knurled screw from the lower part of the
casing and take it out.
Disassemble the automatic steam trap and clean all parts under running water.
Water
For spare parts, see the supplier's documentation provided by Kaeser.

Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 4-9
4-10 Checking the compressor for wear and tear
Compressor for powder sprayer, on the operating side under the platform

Open the platform casing at the delivery.
Unscrew the suction grating (1); screw off the housing cover (2) and pull off from the housing;
take out the lamellae (3); check the lamella width; if necessary, change lamellae; blow out the
suction grating, housing and rotor slots with compressed air
Important! New lamellae must be checked for the first time after one year! Change only
complete sets of lamellae!
For further information, see the suppliers' documentation provided by WeKo or Rietschle.
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 4-10
4-11 Cleaning the ventilation grate
Electrical cabinets, dryer cabinets, central control console
Lift off the ventilation grate (1) using a screwdriver.
Remove the filter mat (2) and blow it out with compressed air.
Replace worn filter mats with original parts.
Screwdriver
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 4-11
5 Semi-annual maintenance work
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247
RAPIDA 105U Central control console
5-1 Checking the color evaluation lamp
Lighting above the central control console
Important! The fluorescent bulbs in the color evaluation lamp (1) have a limited service life. At 1
the end of their service life, the color properties of the light change. This can lead to incorrect test
results.
Check the operating hours on the operating hour meter on the lower side of the color evaluation
lamp (1).
Replace all fluorescent bulbs after about 2,500 operating hours.
Ladder
Fluorescent bulbs
Protect yourself against contact Dispose of used fuels in an

with hot surfaces! environmentally friendly manner!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 5-1
RAPIDA 105U Infeed
5-2 Cleaning the maintenance unit for control air
On the drive side on the infeed printing unit towards the sheet feeder
Evacuate the maintenance unit using the turn-on valve (2).
Open the condensation drainage valve (1) by turning it to the left. Collect the condensate.
Remove the casing (3) (bayonet catch).
Unscrew the filter and blow it out from the inside to the outside.
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 5-2
5-3 Lubricating the traversing ink form rollers
All inking units

Open the inking unit guard.
XIV Remove all rollers lying in front of it from the inking unit. Open the bearing locks.
Check the four traversing ink form rollers (marked in gray) for sufficient bearing lubrication.
If necessary, remove them from the inking unit and grease the running surfaces on both sides (1)
as well as the needle bearings (2).
The needle bearings (2) must be replaced if damaged.
Re-install all rollers in the inking unit and close the bearing locks.
See the operating manual for instructions on installation and removal of the ink form rollers.
Grease No. XIV (See “Overview of lubricants” 8-1 ... 8-4)

Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 5-3
5-4 Lubricating the distribution cylinder
Above the plate cylinder on all printing units towards the delivery
1
Open the rubber and plate cylinder guards.
On the operating side, inch the funnel-type lubrication nipple on the leg of the traversing
I, XIV distribution cylinder into the visible area.
Lubricate the funnel-type lubrication nipple on the operating side and the drive-side conical
lubrication nipple (1) on the dial


Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 5-4
5-5 Changing the oil in the circulation lubrication system (2,000 operating hours)
On the drive side of each printing unit/varnish unit below the gallery, once
after 2,000 operating hours:

II Unscrew the plate beside the running plate of a printing unit passage way on the drive side.
Screw out the oil fill plug (1), suction out used oil with an external oil pump and dispose of it in an
Important! Change the oil filter whenever you change the oil! (See page 7-2)
Allen wrench, fork wrench

Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 5-5
5-6 Lubricating the side jogger
On the drive and operating side of the delivery, accessible from below
Lower the delivery pile board to the floor.

I, XIV Lubricate the lubrication nipples (1) on the drive side and operating side using 2 - 3 shots of the
lubrication gun.

Grease No. XIV with UV and changing additive (See “Overview of lubricants” 8-1 ... 8-4) 1

Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 5-6
5-7 Changing the dampening solution at the dampening solution cooling unit (Baldwin)
The following maintenance tasks must be performed:
• Clean the entire dampening solution system.
• Clean the cooling water filter.
Warning! The dampening solution is toxic and must not get into the sewer system!
Cleaning cloth
Water
Cleaning agents

Switch off the main switch before Always wear protective gloves Dispose of used fuels in an
beginning any maintenance work! when working with chemicals! environmentally friendly manner!
chemicals!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 5-7
5-8 Checking the Becker vacuum pressure pumps for wear and tear

Switch off the power to the compressors and secure them against being switched on again.
Unscrew the suction grating (1); screw off the housing cover (2) and pull off from the housing:
take out the lamellae (3); check the lamella width; if necessary, change the lamellae; blow out the
suction grating, housing and rotor slots with compressed air.
Important! New lamellae must be checked for the first time after one year! Change only
complete sets of lamellae!
Important! In some compressors, the roller bearings must be regreased.
For further information on disassembly, assembly, minimum lamella width, lubrication points and
lubricants, please refer to the supplier documentation provided by Becker.

For information on grease and tools, please refer to the supplier documentation.
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 5-8
6 Annual maintenance work
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247
6-1 Lubricating the impression cylinder and transfer drum bearings
On the operating side towards the delivery on all printing and varnish units
Lubricate all lubrication nipples of the lubricating bar (1) with 2 - 3 squirts of the lubrication gun, in
the creep mode of the printing press if at all possible.
I, XIV


lubricant!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 6-1
6-2 Lubricating the side alignment stops
On the drive and operating sides of the delivery
Open the covers on the drive and operating sides.
Clean the powder from the telescopic springs (1) on the side alignment.
Push back the telescopic springs (1) and grease the spindle below them.
I, XIV
Switch cabinet key, cleaning cloth

Grease No. I without UV additive (See “Overview of lubricants” 8-1 ... 8-4) 1

Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 6-2
6-3 Steam trap of the control air compressor (Kaeser)
Close the main tap (1).
Depressurize the steam trap (2) by pressing the “Test” (3) key.
Loosen four screws on the lower side (remove the steam trap if necessary) and disassemble the
steam trap.
Carry out the cleaning, inspection of parts subject to wear and replacement of parts subject to
wear.
Cleaning cloth
For spare parts and parts subject to wear, see the supplier documentation of Kaeser.
Switch off the main switch before Protect yourself against contact Always wear hearing protectors
beginning any maintenance work! with hot surfaces! when inspecting the safety valve!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 6-3
7 Biannual maintenance tasks
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247
7-1 Changing the oil in the circulation lubrication system
On the drive side on each printing/varnish unit below the gallery

Unscrew the plate beside the running plate of a printing unit passage way on the drive side.
II Screw out the oil fill plug (1), suction out used oil with an external oil pump and dispose of it in an
Important! Change the oil filter whenever you change the oil (See page 7-2)!
Allen wrench, fork wrench

Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 7-1
7-2 Changing the filter in the circulation lubrication system
On the drive side on each printing/varnishing unit
Place a container under the filter combination to collect the oil.
Unscrew and replace all filters (1).
After changing the filters, switch on the printing press and check for leakage.
Check the oil level 15 minutes after the machine has been switched off.
Special tool for filter changes (car accessories)

Filter cartridges: KBA order number L 267 9607 or Mann & Hummel W920/17
Dispose of used filters in an

Switch off the main switch before Carefully remove all superfluous
environmentally compatible
beginning any maintenance work! lubricant!
manner!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 7-2
7-3 Changing the oil in the duct motor gears
On drive side on printing / varnish tower

2
Hold the oil collecting tray under the upper ductor motor.
Open the oil discharge screw (1) and the oil fill plug (2) and drain old oil.
Close the oil discharge screw (1) again.
XVI
Pour in 450 ml (1 US pint) of fresh oil via the oil fill plug (2), then close the oil fill plug (2) again.
Repeat the oil change for the lower duct motor.
Oil catch pan

Allen wrench and fork wrench
Gear oil No. XVI (See “Overview of lubricants” 8-1 ... 8-4) 1
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 7-3
RAPIDA 105U Total printing press
7-4 Changing the support batteries at the EC581 controls
Sheet feeder: switch cabinet below the feed table

Infeed: on the drive side in the switch cabinet
Printing and varnish towers: cover behind the ink duct towards the feeder
Delivery: behind the upper cross beam
In the main switch cabinet
Important! The printing press must have run through its switch-on routine and be in an error-free 1
state. At the latest, the batteries must be changed when the “BATT” display (1) on the controls is
lit up.
Open the switch cabinets and covers.
Open the battery compartment (2) at the controls. Remove the support battery. Pull out the
connector. Connect the new battery and close the battery compartment.
2
Close the switch cabinets and covers.
Switch cabinet key

Batteries: KBA order number L 086 4384 or ABB 1SAP 180 300 R0001
This work may be carried out only Dispose of used fuels in an

by a trained electrician! environmentally friendly manner!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 7-4
7-5 Changing the battery of the uninterruptible power supply
Main switch cabinet

3 1
Open the main switch cabinet doors.

The battery unit is located on the upper left-hand side of the left side wall.
Pull out the fuse (1).

Unscrew and remove the connecting cable (2).
Loosen the fastening screws (3).
Remove and replace the battery.
Follow the steps in reverse to reassemble the unit. Replace the fuse last.
Switch cabinet key

Phillips screwdriver
Batteries: KBA Order No. L 086 4734 3 2
Switch off the main switch before This work may be carried out only Dispose of used fuels in an
beginning any maintenance work! by a trained electrician! environmentally friendly manner!
Semi- Every two

6 Annually 7 years
367 227; 367 241; 367 242; 367 247 7-5
8 Overviews

367 227; 367 241; 367 242; 367 247
RAPIDA 105U
8-1 Overview of lubricants
GREASE SPRAY
Serial no. / Marking on the Lubrication type Lubrication point Saponifi NLGI Worked Serial no. / Marking on the Lubrication type Lubrication point Class Viscosity at
Lubricant printing press cation class penetra- Lubricant printing press 40 °C in mm²/s
no. tion in no.
0.1 millime
ters VI Manual lubrication Toothed gear pairs 4000 - 5000
I Manual
lubrication
Roller bearings
Sliding bearings
Lithium 2 265-295
(without UV
VII *) Manual lubrication Plate clamping 2000 - 3500
additives)
XIV Manual Roller bearings Lithium 2 265-295 VIII *) Manual lubrication Exposed rollers,
chains, cams, joints
2000 - 3000
lubrication Sliding bearings
(UV additives and
high thermal load) IX Manual lubrication Sheet feeder cams 3000
XV Manual
lubrication
Sheet feeder 1 300-340
X *) Manual lubrication Gripper

maintenance in the
printing units
OIL (without UV
additives)
Serial no. / Marking on the Lubrication type Lubrication point Class Viscosity at
Lubricant printing press 40 °C in mm²/s XI *) Manual lubrication Gripper
maintenance in the
no.
varnish units
II Circulation and
immersion
Oil filling
Gear
ISO-VG 100 (without UV
additives)
lubrication
XII *) Manual lubrication Corrosion protection,
gripper maintenance
III Central lubrication Carriage chain
Delivery
ISO-VG 460 (UV additives)
XIII *) Manual lubrication Corrosion protection

(without UV
IV *) Manual lubrication Bearer ring
maintenance
ISO-VG 100
Special additives)
penetrating oil
V *) Immersion
lubrication
Kaeser piston
compressors
ISO-VG 150
VDL
XVI Immersion
lubrication
Duct motor gears PAO 460 414 - 506
Marking on the printing press

Lubrication oil Oil-based lubricating Special lubrication agent
grease
Red: 16 operating hours Daily Orange: 2280 operating hours Semi-annually

Yellow: 80 operating hours Weekly Blue: 4,560 operating hours Annually
White: 380 operating hours Monthly *) Unmarked on the printing press

367 227; 367 241; 367 242; 367 247 8-1
RAPIDA 105U
8-2 Overview of lubricants - Suppliers and products
FUCHS KLÜBER MOBIL CHEMIE ZEPF CASTROL SHELL DEA ROCOL AGIP
LUBRITECH LUBRICA- TECHNIK OPTIMOL
TION
I LAGERMEISTER
EP 2
MOBILUX EP 2 ELKALUB
GLS 75/N2
LONGTIME PD 2 LIPLEX EP 2 PARAGON EP 2 Sapphire 2 bearing
grease
II * GEARMASTER
CLP 100
LAMORA 100 MOBILGEAR 627 * ELKALUB * OPTIGEAR 100 OMALA 100 2) * FALCON CLP
100
Sapphire
hi-torque 100
BLASIA 100
LFC 1100 1)
III ELKALUB VISCOGEN KL 23 Chainguard 230

LFC 1460H 1)
IV ELKALUB VP ULTRA-SYNHEX-
KETTENÖL
VISCOGEN KL 9 Sapphire
hi-torque 100
785 1)
V RENOLIN
VDL 150 DD
RARUS 429 ELKALUB LFC CORENA P 150 ACTRO EP VDL
150
Sapphire
hi-torque 150
DICREA 150
9150 1)
VI
VII STABYLAN 5006
(spray)
ELKALUB VISCOGEN KL 300
(Spray)
Tufgear spray
FLC 8 H1 1)
VIII STABYLAN 5006

(spray)
GRAFLOSCON
CA 901
MOBILGEAR
OGL 007
ELKALUB VISCOGEN KL 300
(Spray)
Tufgear spray FIN 322F
FLC 8 H1 1)
IX Sapphire hi-load 2
bearing grease
X STABYLAN 5006
(spray)
SHC 634 ELKALUB VISCOGEN KL 300
(Spray)
Tufgear spray
FLC 1012 1)
XI ELKALUB VISCOGEN KL 300

(spray)
Tufgear spray
FLC 4010 1)
XII ELKALUB
FLC 4010 1)
XIII ELKALUB VISCOGEN KL 23

(spray)
Heavy duty rust
shield
MBF 370 1)
Z25
XIV LAGERMEISTER
XXL
ELKALUB RETINAX LX 2 2)
GLS 163 1)
XV KLÜBERPASTE
46 MR 401
ELKALUB PASTE WHITE T
GLS 163 1)
XVI KLÜBERSYNTH
GH6-460
GLYGCOYL 80 TIVELA SD
* Long-term oil: have changing intervals stipulated separately.

1
) See commissioning package variant 1.
2) See commissioning package variant 2.

367 227; 367 241; 367 242; 367 247 8-2
RAPIDA 105U
8-3 Overview of lubricants - Suppliers and products
ARAL BP DOW ESSO TRIBOLOGIE VEGRA LUBCON OKS BREMER TEXACO
CORNING TECH-LUBE &LEGUIL
I ENERGREASE
LS-EP 2
T-POLY-TECH #2 TURMOGREASE
LI 802 EP
OKS 402 RIVOLTA
S.K.D. 3802
MULTIFAK FT 2
II DEGOL BG 100 ENERGOL

GR-XP 100
SPARTAN EP 100 T-100 SPC TURMOFLUID
GV 100
MEROPA 100
III T-85/140 SPC TURMOFLUID

GV 460
OKS 340 2)
IV T-911 HTC VP 611 AC

(Special
TURMOFLUID
OM 3
OKS 353 2)
penetrating oil)
V MONTANOL HE
150
ENERGOL RC 150 Compressor oil
3022N
TACO 150 RIVOLTA
COMP 170
VI SYNTEMP 2000
OM spray
TURMOFLUID
4800
OKS 354
VII SYNTEMP 2000

OM spray
TURMOFLUID
OM 300 (spray)
OKS 3541 RIVOLTA
S.K.D. 2000
(spray) 2)
VIII SINIT FZL 3 ENERGREASE

LS-EP 2
SURETT FLUID 4K SYNTEMP 2000
OM spray
TURMOFLUID
OM 300 (spray)
OKS 3541 RIVOLTA
S.K.D. 2000
(spray) 2)
IX SYNTEMP 2000
OM spray
TURMOFLUID
OM 300 (spray)
RIVOLTA
S.K.D. 3000
X SYNTEMP 2000
OM spray
TURMOFLUID
OM 300 (spray)
XI SYNTEMP 2000
OM spray
TURMOFLUID NBI
grease spray
OKS 471 2)
(Grease spray)
XII TRIL OGL 21

spray
TURMOFLUID NBI
grease spray
OKS 3541
(spray) 2)
XIII SYNTEMP 2000

OM spray
KORROQUICK OKS 601 (spray) 2) RIVOLTA
T.R.S. plus
XIV T-POLY-TECH #2 TURMOGREASE

LI 802 EP Plus
RIVOLTA
S.K.D. 4002
XV MOLYCOTE(R)
BR 2-PLUS
GREASE
XVI DEGOL GS 460 ENERGOL

SG-XP 460
TURMOPOLOIL
460 EP
* Long-term oil: have changing intervals stipulated separately.


367 227; 367 241; 367 242; 367 247 8-3
RAPIDA 105U
8-4 Overview of lubricants - Commissioning package (variant no. 1)
No. Lubrication point Lubricant
NOTE XIII Corrosion protection Spray
All commissioning lubricants are included in the scope of delivery of the printing (without UV additives) (MBF 370)
press. Re-orders via Koenig & Bauer AG, Radebeul are not possible!
XIV Manual lubrication with grease High-temperature grease
(entire printing press) (GLS 163)
(UV additives and high thermal load)
III Delivery carriage chain Chain oil

(LFC 1460H)
IV Bearer ring maintenance Bearer ring oil

(VP 785)
V Kaeser piston compressors Compressor oil

(LFC 9150)
VII Plate clamping Spray

(FLC 8 H1)
VIII Exposed rollers, chains, cams, joints Spray

(FLC 8 H1)
X Gripper maintenance in the printing Spray

units (FLC 1012)
(without UV additives)
XI Gripper maintenance in the varnish Spray

units (FLC 4010)
XII Corrosion protection and gripper Spray

maintenance in the printing and (FLC 4010)
varnish units
(UV additives)

367 227; 367 241; 367 242; 367 247 8-4
RAPIDA 105U
8-5 Overview of lubricants - Commissioning package (variant no. 2)
NOTE XIII Corrosion protection Spray
All commissioning lubricants are included in the scope of delivery of the printing (without UV additives) (OKS 601)
press. Re-orders via Koenig & Bauer AG, Radebeul are not possible!
XIV Manual lubrication with grease High-temperature grease
(Total printing press) (RETINAX LX 2)
(UV additives and high thermal load)
III Delivery carriage chain Chain oil

(OKS 340)
IV Bearer ring maintenance Bearer ring oil

(OKS 353)
V Kaeser piston compressors Compressor oil

(Corena P 150)
VII Plate tensioning Spray

(OKS 3541)
VIII Exposed rollers, chains, cams, joints Spray

(OKS 3541)
X Gripper maintenance in the printing Spray

units (OKS 3541)
XI Gripper maintenance in the varnish Spray

units (OKS 471)
XII Corrosion protection and gripper Spray

maintenance in the printing and (OKS 3541)
varnish units
(UV additives)

367 227; 367 241; 367 242; 367 247 8-5
RAPIDA 105U
8-6 Overview of process materials
Process materials Important notes
DANGER Ink remover Manual cleaning for:
Danger of fire and explosion! • all rollers:
Death, serious accidents and severe damage to the printing press can result. Poropast (DC Druckchemie)
For this reason, clean the lubrication points only with white spirit of hazard
class A3! Manual deep-cleaning for:
• rubberized rollers:
CAUTION Rol-O-Past (Böttcher)

when using cleaning and care agents! • chrome-plated rollers and cylinders:
The roller coating and printing press varnish could be destroyed. Edoclean 210 (Dortschy)
For this reason, do not use any ketone-based paint removers or varnish Recyl Clean 2000 (Recyl)
care agents (such as acetone or butanone)! Paint Remover no. 15 (Skruvs
Kemiteknik)
Process materials Important notes Lime remover Manual cleaning for:

• all rollers:
Anti-drying agents Must not damage rollers with rubber or
plastic coverings. BöttcherPro EK (Böttcher)
BöttcherPro Calciumfix (Böttcher)
Compressed air Clean, oil-free, max. 2 bar (28.58 psi) Roller cleaning jelly 10 T 0023 (Huber
group)
Varnish care Used to clean all varnished parts and for
care of the printing press varnish unit with Cylinder preservative Used after manual deep cleaning for:
blanket and roller washing solutions.
• rough-chromed cylinders
Rejuvenators Recommended for the care of blankets Antiset (DS Druckerei-Service)
when the printing press is stopped for
longer periods.
White spirit (washing benzine) Cleaning grease or oil from the lubrication
points.

367 227; 367 241; 367 242; 367 247 8-6
RAPIDA 105U
8-7 Oil filling quantity for the lubrication circuit
Before putting the printing press into operation, fill the containers designated for this purpose on the lower part of the printing press (drive side) with oil. The oil is to be
supplied by the customer.
The entire quantity of oil can be poured into one printing unit, as the printing units are connected with each other.
Printing and varnish units 4 5 6 7
Liters of oil 110 135 160 185

(drive side only)
US gallons of oil 29.059 35.663 42.268 48.872

(drive side only)
When used with the long-term oil marked *, coordinate a longer change interval with Koenig & Bauer AG, Radebeul.
The oil filter must be changed once after 500 operating hours and 2,000 operating hours and then every two years!

367 227; 367 241; 367 242; 367 247 8-7
9 Operating and repair tools

367 227; 367 241; 367 242; 367 247
RAPIDA 105U Accessories
9-1 Adjustment gauge for reflex scanning heads
Area of use: Front guide control on the infeed
Use: Checking and adjusting the front guide control when the front guides have
been individually adjusted.
EINON AUSOFF
For information on the procedure, see the chapter entitled “Infeed” in the operating manual. ANLAGEKONTROLLE FRONTLAY CONTROL
EINSTELLEHRE
P0122040
Part No.: P 072 2040

367 227; 367 241; 367 242; 367 247 9-1
9-2 Clamping bar
Area of use: Plate tensioning rail of the plate cylinder
Use: Plate tensioning for zeroing and manual register corrections of the operating
components (1)
For the procedure, see the operating manual chapter entitled “Printing unit”.
Part No.: P 161 5360

367 227; 367 241; 367 242; 367 247 9-2
9-3 Socket wrench, size 10
Area of use: Tensioning rail of the rubber cylinder
Use: Tensioning the rubber blanket
Part No.: L 269 6011

367 227; 367 241; 367 242; 367 247 9-3
9-4 Extension, wrench size 10
Area of use: Tensioning rail of the rubber cylinder
Use: Tensioning the rubber blanket with the torque wrench
Part No.: L 601 9941

367 227; 367 241; 367 242; 367 247 9-4
9-5 Hollow wrench
Area of use: Cabinet doors, paneling
Use: Opening / closing locks
Part No.: L 615 7580

367 227; 367 241; 367 242; 367 247 9-5
9-6 Packing thickness measurement devices
Area of use: Printing unit, varnish unit (optional)
Use: Measurement of the packing height of the plate cylinder and rubber cylinder
or varnish cylinder above the bearer rings
Item numbers for printing unit: P 016 5280, L 115 0370, L 938 0003
Item numbers for varnish unit (optional): P 005 8490, L 115 0370, L 938 0003

367 227; 367 241; 367 242; 367 247 9-6

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Maintenance Instructions 367227 241 242 247 P5111780 EN

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Maintenance instructions

KBA RAPIDA 105U

Koenig & Bauer AG

367 227; 367 241; © 2007 Koenig & Bauer AG

367 242; 367 247

P 511 1780_EN © 2007 Koenig & Bauer AG

P 511 1780_EN © 2007 Koenig & Bauer AG

Compliance with the instructions in the operating manual is required!

P 511 1780_EN © 2007 Koenig & Bauer AG

maintenance Ein- und Ausbau der Farbauftragwalzen siehe Betriebsanleitung

6 Fett Nr. I (siehe Schmierstoffübersicht 8-1 ... 8-4)

7 Maschine gegen Wiederanlauf

P 511 1780_EN © 2007 Koenig & Bauer AG

Checks, inspections Clean filter, replace if necessary

Manual cleaning Check the filling level of the liquid,

Grease lubrication using the grease gun

Oil lubrication using the oil can

P 511 1780_EN © 2007 Koenig & Bauer AG

Semi- Every two

1-1 Cleaning the sheet monitoring units

Infeed table, sheet monitoring unit

Dry, clean brush

Secure the printing press to

Semi- Every two

1-2 Cleaning the ColorTronic ink duct

Ink ducts on all printing units

Secure the printing press to

Semi- Every two

1-3 Cleaning the impression cylinder

Impression cylinders in all printing and varnishing units

Open the footboard in the printing unit walkway.

Inch the first gripper system upwards.

Press and lock the “Stop and lock” key;

Always wear protective goggles

Semi- Every two

Semi- Every two

2-1 Cleaning the discharge unit and sensor

Anti-static devices and front edge sensor at the sheet feeder

Press and lock the “Stop and lock” key;

Caution! Do not use any solvents or roller washing agents!

For further information, please see the operating manual.

Brass brush, compressed air (max. 2 bar)

Semi- Every two

2-2 Cleaning the fan switch cabinet

Turn off the main switch and secure it;

Remove the ventilation grates (1).

Clean the casing and fan wheel using a brush.

Switch cabinet key

Semi- Every two

2-3 Checking the belt tension

Suction belts at the sheet feeder

Replace defective suction belts.

2 open-end fork wrenches

Semi- Every two

2-4 Cleaning the filter mat of the main drive motor

Turn off the main switch and secure it.

Open the gallery casing on the second printing unit.

Follow the steps in reverse to reassemble the unit;