INSTRUCTIONAL MANUAL LAWSON TROOPER-PC

Transcription

1 INSTRUCTIONAL MANUAL LAWSON TROOPER-PC Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 1

2 Congratulations on your purchase of the Lawson Trooper-PC Press. To insure successful performance of your Trooper-PC Press, please read this entire manual thoroughly. The best equipment requires some minor preventive maintenance and a complete understanding of its operations and control systems. This manual is offered to help you get the best possible performance from this equipment. Your attention to the principles on which the Lawson Trooper-PC Press has been designed can help you make your new Trooper-PC one of the most profitable equipment investments you have ever made. Should you need it, Lawson s continued service is always available. If you have any questions about the Lawson Trooper-PC Press, please contact us. We are always ready to be helpful. Your comments and suggestions are always welcome. Phone: (314) Fax: (314) After Hours Pager: (314) and press option #6 Website: info@lawsonsp.com Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 2

3 Instructions: Lawson Trooper-PC The Lawson Trooper-PC Automatic Printing Press Manufactured by: Lawson Screen Products, Inc Penrose St. Saint Louis, MO Service Telephone: Fax: Serial Number: (Please fill-in for future reference) Refer to this serial number when speaking with Lawson s Service Department. It contains valuable information related to this piece of equipment. IMPORTANT NOTE: This machine is designed for the industrial/commercial textile printer. Do Not operate this machine without reading this entire instruction manual first! Do Not start adjusting the press until its entire function and operation is fully understood. If you have any questions, please call prior to operation. Remember, final installation of the Trooper-PC by a Lawson Service Technician is highly recommended. Additional training is available at our Saint Louis headquarters and site training is offered at your factory for a reasonable fee, plus expenses. Training at your facility is highly recommended. Features may be described in the instruction manual that may not exactly relate to your specific Trooper-PC. This manual is meant to serve as a general instructional reference for the entire Trooper-PC series of automatics. Lawson assumes no obligation regarding changes to the press, herein described. Designs and instructions are subject to change without notice. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 3

4 Installation: One feature of the Lawson Trooper-PC is its ease of installation. The press is shipped after being pre-assembled and adjusted, then disassembled. By following these detailed instructions, you may have the machine set up the same day it arrives. The Trooper-PC 8-Station Press usually is shipped in one very large crate. The crated size is approximately 52 wide x 120 long x 70 high and is approximately 1,650 lbs. The Trooper-PC 10-Station Press is 60 wide x 120 long x 80 high and weighs approximately 2,000 lbs. It is your responsibility to unload the press from the truck. The truck driver will not assist in the unloading of the press. The use of a forklift with extended forks (i.e. 6-8 long forks) is suggested. If you don t have a loading dock, professional riggers may be necessary. Safety Precautions: To ensure safe and reliable operation of your Trooper-PC press, all personnel should become thoroughly familiar with this unit. 1. Do not store any combustible material within three (3) feet of this unit. 2. It is your responsibility to ensure that the electrical hook-up, etc. is performed in accordance with local codes and regulations. 3. Proper electrical installation and grounding must be provided by a licensed, certified and bonded electrical. If the electrician has any questions at the time of installation, please have him/her call and as for the Service Department. 4. Proper clothing attire for operators: Because this press has moving parts, loose clothing is dangerous. 5. Maintain good housekeeping practice. 6. Disconnect pneumatic and electrical power supplies during maintenance work and when the press is not in use. 7. Pneumatic shut-off valve must be provided within 10 feet of the press. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 4

5 Uncrating: 1. Remove the crate and packing materials from the main control base and carousel, being careful not to damage any hoses, or switches. Clean any dust and remove any debris that may have fallen onto the press during shipment. 2. Use a forklift when lifting the control base from the skid. Approach the press so that the forks will be located under the side of the base with the positioning lock. Be sure the forks go far enough under the press to adequately balance the press when lifting. You should visually check to avoid any possibility of damage to wires or hoses that might have moved during transit prior to you moving it with a forklift. 3. If a forklift is not available and you need to muscle the press into place, use extreme care. Lift only from under the main frame. DO NOT LIFT OR POSITION THE UNIT USING THE CAROUSEL RING/DECK OR PRINT HEADS. Doing so may bend or damage the deck, (or heads) causing printing difficulties and/or registration problems. 4. While you have the machine lifted in the air, you should adjust the four leveling feet. It is best if you adjust the leveling feet 3 ¼ from the floor to the bottom of the base tube. This will allow for the QZE Shuttle Flash function. 5. Position the base where it will be operating. Take special notice of where the first open station is located (the carousel will rotate counter clockwise). This will be the loading station. It should be positioned near the dryer so the press operator will have easy access to the dryer. The open station is usually both the loading and unloading station. 6. When unloading the print heads, be sure to lift, not drag, the heads on the support posts. Notice the two electrical limit switches on each head. Be careful that they are not damaged during this process. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 5

6 Electrical and Air Requirements: The Lawson Trooper-PC is a pneumatic machine that also requires 120 volts, 5-amp electricity. Electricity demands for an optional flash unit is not covered in this manual. See the flash unit manual for it s technical data. Lawson recommends a minimum 5-7 HP air compressor delivering psi, with a minimum 80 gallon storage tank. Although the press itself does not require this volume of air, using any other air powered tools or equipment from the same compressor could cause the press to starve for air. A consequence of low air pressure or volume can be inconsistent press operation and press production speed. Be sure to use large enough pneumatic piping and or hose to deliver the proper volume to the press. Remember the distance length of the air supply must be considered in determining the I. D. size of the air supply. The final connecting hose should be 3/8 or ½ I. D. with a ¼ female quick connect fittings for a 6 or 8-Station Trooper-PC. For a 10- Station Trooper-PC, a ½ I.D. hose is required. The USE of an AIR DRYER is essential, because moisture develops when air is compressed, and this can cause damage to air cylinders. The air dryer is in addition to any water traps that may be mounted on the compressor and/or the press. An Air Drying System rated for the size air compressor you purchase is a requirement. A technical note on air dryers : a refrigerated air dryer combines an air-dryer, after-cooler and a re-heater. The unit you select needs a minimum of 96% moisture removal to be effective. Failure to use an adequate air dryer will void the warranty of the cylinders, valves and other related air components. Typical Compressor/Air Dryer Configuration Hose connection. Maximum pressure from air compressor is 135 psi. AIR COMPRESSOR Ball Valve Flexible Metal Hose Connecting Line (not included) Three-In-One Dryer Air pipe or hose to the press site Safety Note: PRIOR TO ANY SERVICE WORK, PNEUMATIC AND ELECTRICAL POWER MUST BE DISCONNECTED! Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 6

7 Print Head Install: The Lawson Trooper-PC is shipped without the print heads installed. Care must be taken in removing the print heads from the head crate. Each print head has a number indicating what number the print head location was used during the manufacturing process. It is best to put that head on the numbered top print head deck plate. Most customers will install the print heads with the configuration of print head #1, followed by a blank station (so a flash unit can be used while the printing is taking place), followed by the rest of the print stations. It is easy to remove a garment from a print station. This will then leave one open station for the operator to load a garment. Installing the print heads will require two people. One person will hold the front of the head while the other person installs the bolts (1/4-20x3/4 hex head) under the deck plate. All eight bolts should be installed prior to the final tightening. There can be a chance, during the shipping process, that the attachment block may have moved and thus the bolts will not alien with the holes. If this is the case, simply loosen the two bolts on the attachment block, align the bolts to the holes and then tighten the attachment block. Photo 1 Bolts and tools needed to mount print heads Photo 2 Two people lift and bolt the print head in position Photo 3 Deck Plate Locking Bolts Photo 4 Finished view Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 7

8 Connect the Airlines and Electrical Cables: Each head has four 1/4" airlines to connect: (red = squeegee flip; yellow = flood flip; green = print stroke; and clear = flood stroke). The Lawson Trooper-PC Automatic Printing Press Connect the red and yellow hoses to the indicated air manifold on the top deck. Simply push the hose into the fitting as far as possible. The green (left side) and clear (right side) hose per head needs to be matched to the same valve. The valve number represents the carousel positions for your press. The master open load position does not have a number. The number one print head will always be positioned to the right of the master open position and put into carousel position #1. The example shows position "2" plugged closed indicating an open position station. The second print head would then go into carousel position #3. The third print head would then go into carousel position #4. The positioning of the print head to the carousel position is important for the load-in, load-out and other PC press functions. The plugs can be moved for "flex head" position configurations. Connect the electrical cables. Make sure you connect the correct cable to each head. The cable plugs into the small plastic box on each head. Simply insert the plug into the slot and push. The connector should snap into place. Make sure the fitting goes in correctly. Do not flip the connector over or else it will not lock properly and the press will not operate. PC Flood & Print Valves 1 per head: Top Print Deck YVLV0206S 1. Rear/Back Limit Switch LPHJACK4 2. Front/Forward Limit Switch All switches are wired normal open and common Modular Cord LWCPH8-14 Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 8

9 Attach the head support rod: The Lawson Trooper-PC Automatic Printing Press Remove the nut from the top support platform and install the head support rod. The rod may need to be rotated so that the bolt will be aligned through the rod (A) end connection point. (Photo 1) The nut should then be tightened with a 9/16 opened end wrench. At this time there should not be any up or down pressure on this rod. (A = RE06LECON-EA) (Photo 1) The front head support rod locking nut (B) (Photo 2) should not be fully tightened until the task of leveling the Master Platen to each print head has been completed. (C = RE05RFECON-EA) (Photo 2) Attach the Optional Speed Rails: Speed Rail Device Notice the attachment locations. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 9

10 Installing the carousel arm: Locate the number on the carousel arm and match it to the number on the carousel plate. Hand tighten the bolts prior to the final tightening. The carousel arms will have the ability to have some tilt in the mounting holes. Check side to side visual level prior to final tightening. Note: The final tightening needs to be very tight, but not to the extent of collapsing the vertical tube support. Align the bolts for the platen arm Vertical tube support Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 10

11 Leveling the Base: The carousel arms must be leveled with the machine in its EXACT position and the shaft needs to be in a true VERTICAL position. By following these step by step instructions, it should take you an hour or so to level the machine. This is a very important process to insure print quality and proper mechanical functioning of the press. 1) Place a level along the centerline of the platen arm (lengthwise) and rotate the carousel until the platen arm is over a leveling foot of the press. Observe the bubble in the level (it does not need to be centered between the two lines but it should not be to the extreme in either direction). Rotate the platen arm over each of the leveling feet, stopping to observe the bubble. The bubble should be the same over all four leveling feet. Adjust the leveling accordingly. Remember, however, that adjusting a foot will affect the opposite side. Remember, the goal at this point is to get the bubble even over all four leveling feet. Again, the bubble may or may not be centered between the lines. Just make sure it is the same at all four positions. Once you have the bubble equal at all four areas, the shaft of the base will be truly vertical. Be sure to tighten the locking leveling nut upon completion of this task. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 11

12 Slip Tube Reference Page: The standard slip tube should be set (item#1) so that the distances on the carousel arms are all the same. In practical application, the slip tube should be left in the same position for all jobs. It is easier to move the screen an inch than the slip tube. Item #2 Item #3 Item #4 Item #5 Shows how the slip tube is locked into position. Is used to set the platen height and allows compliance for centering the platen. Is used when more compliance for platen centering is needed. The platen will need to be removed for this adjustment. Indicates where the platen attachment bolts are inserted. There is a slight amount of space for platen compliance centering. It is important that the proper length of bolt is used: if the bolt is too long, it could damage the platen or will not allow the platen to be tightened correctly: too short of a bolt could damage the platen attachment insert device. Install platens before going to next step. Note: The holes in the rear of the platen are closer to the edge. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 12

13 Setting the Print Head Position: The first step in the final preparation of setting the print heads to the carousel platen arms is setting all the print heads in parallel to the Master Platen #1. The slip tubes holding the platens should all be located the same distance from the end of the arm. Please refer to the slip-tube page. The carousel Master Platen #1 should be rotated to Print Head #1 to start the process. Using the setup box and flipping the toggle switch to the up position raises the carousel arm platform. This lifts the carousel platform to the printing position. Apply slight downward pressure on print head #1 by adjusting the head support rod till the distance between the bottom of the Print Head rail and the top of the platen is 6 1/8 inches*. Having more or less than 6 1/8 inches space will cause problems later in setting the range of squeegee pressure adjustments. Measure all four corners The right front, the right rear, the left front and the left rear. *Old models with the extrusion front screen holder will need to have 6 1/4 inch space. Once the print head is adjusted, tighten the nuts on both ends of the head support rod. It is important to take the time to set each print head as exact in parallel in the front as the back of the platen: The next step will be setting the balance of the platens to match the fixed print heads. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 13

14 Adjusting the Platens to Match the Print Heads: After the print heads are all adjusted in parallel to the Master Platen, the remaining platens must now be adjusted to match the print heads. This is a critically important process to assist in consistent squeegee print pressure. This step averages 1-2 hours. Leveling the platens to the print head is achieved by adjusting the running thread support posts on the platen slip tube. Adjust each of the bolts and tighten the nuts a little at a time. Continue adjusting until the platen is in parallel to the print head. Remember to start with platen #2, and start the leveling process to print head #1. After finishing this step, lower the carousel arm, rotate the platen so that it is under print head #2 and raise the carousel arm. Continue this same procedure with each of the carousel platens until the process is complete Note: The carousel platen needs to be rotated under the print head and checked to be sure the platen is in parallel in the two front and rear positions, as indicated in the four photos. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 14

15 Adjusting The Screen Holders: Establishing Off-Contact The screen holders will need to be adjusted so that the screens are parallel to the platen. We suggest the screens be set 1/16 of an inch off contact. This is approximately the thickness of a quarter coin. After installing the set-up screen, adjusting the front and rear holders is simple. Adjust the screen stop nut as shown in the photo. Although the procedure is simple, adjusting the holders may take 1 hour. Be sure to use the same screen on each print head. Four quarter coins in position to set off contact. Close up of off contact with screen Manually checking off contact Adjusting the front screen height Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 15

16 Frame Size and Image Placement for Trooper: 16 Wide x 18 Stroke Print 1. The Trooper Series of automatic presses are designed to accommodate various size frames by moving the rear frame holder. However, most printers choose to standardize their frame size to be practical and efficient. 2. The ideal full size frame for the Trooper is 23 x 31 O.D. 3. Smaller size frames may be used (i.e. 18 x 20 I.D.) by moving the rear frame holder forward. Carefully move the frame holder forward, while making sure you do not accidentally pinch any air hoses inside the print head! Depending on how much you choose to move the rear frame holder, you may need to cut some wire/hose ties and adjust the air hoses inside the head. 4. Obviously, when you use a smaller frame, you will also reduce the available image size! 5. The ink well area is 5 from the inside edge of both the front and rear of the screen (as shown in the illustration above) is ideal. This allows the operator some compliance of the frame in the screen holder. For maximum stroke and/or maximum image size in a small screen (20 x 24 OD), the start of the image could be 4½ from the inside front frame edge. This is a critical dimension for the start of your print. You need to test and determine your frame s maximum parameters due to the many differences of OD and ID frame dimensions. 6. We suggest a minimum 2 free mesh area between your image and the inside of the frame. More free mesh is better for multi-color registration, ink handling and keeping the stencil from breaking down prematurely. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 16

17 Screen Size Selection: Although the Trooper has an 18 print stroke, selecting the correct screen size and artwork placement are important in making sure the entire image prints. You must understand there is limited free movement of the screen on the press, so proper positioning is crucial. You should allow a minimum inkwell of 4½ in the front and a minimum of 4½ in the rear for a total of 9 of non-image area that needs to be accounted. If you are not printing the maximum stroke, it is best to start the print 5 from the front inside screen dimension. This will allow the operator more area for screen alignment and placement/adjustment on the garment. By consistently starting the print in the same location, the operator will not need to adjust all of the platen support tubes! The ink well area on the sides of the image is really a matter of choice. Ideally there should be no less than 1½ space and preferred 2 minimum of space on each side of the image and the inside dimension of the frame. Two consequences of not leaving enough space are a problem with even print pressure (due to the stretch of the screen fabric) and life of the stencil, due to the pressure of the squeegee being so close to the edge of the frame. The illustration above is for a 16 wide x 18 long stroke print image. The lead edge (where the print starts) should be 5 from the inside of the frame. The press can adjust for most of the popular size textile screens ranging from 20 x 24 to 23 x 31 OD - but beware, a 20 x 24 OD frame will only allow a maximum of an 12 long print. Positioning the Image on the Screen: Center the image on the screen and make sure the top edge of the artwork is at the correct position. Expose the screen normally. If you are printing a multicolor design, then you must take more care in positioning the artwork. Ideally, you should have a registration board which has a grid pattern etched into it. This allows you to pre-register the transparencies on the board and to consistently place the image on the screen. The Lawson SSR System provides a low cost registration system that also provides the method to register the screen to the platen for instant registration placement! Remember, 4½ for maximum, 5 for ideal location for the start of the print. The Lawson Trooper-PC Automatic Printing Press Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 17

18 Using The Lawson SSR Registration System: 1. Position the image outline on the registration board. Make sure the proper front and rear well areas are taken into account. 2. Check all other transparencies to the outline again making sure none of the colors will be in the 4½ well area. 3. Place a couple of pieces of double-sided tape to the top of the transparencies in a non- printing area. The Lawson Trooper-PC Automatic Printing Press Register that transparency to the outline already positioned on the registration board. 5. Position the screen onto the transparency giving slight pressure at the tape locations. The transparency should adhere to the screen. Remove the screen from the board Repeat the procedure for each color, then expose the screens normally. 5. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 18

19 Stroke Adjustment: There is a front and rear printing stroke limit device per printing head. In practical application, the front limit switch is usually not moved because the artwork is based off the starting position (lead edge) being 4½ from the inside of the frame. To adjust the limit switch bracket, the two hex head bolts on each side of the mounting bracket must be loosened, adjusted, and then retighten. Care must be given to the movement of the electric wire. It is also important to know that the screen stroke limit bracket has some freedom of movement. The bracket can be set too low and thus create a situation that will break the limit switch arm. If the position is too high, the roller arm will not engage with the carriage plate and thus will not continue the printing process. The print carriage must be located in the front (closest to the operator) prior to adjusting the rear stroke switch to a shorter position. Trooper Rear Screen Stroke Limit Bracket Trooper Rear Screen Support Positioning Bracket Carriage Position Location: To position the print carriage during the set-up phase, a series of steps must be done: 1. Turn the desired print head on (Station Set-Up Screen). 2. The go to the Set-Up screen and press the set-up on box and then press the Cycle Start box. This allows the print carriage to move forward (flood coated the screen) and then stop. 3. Now the operator can move the rear limit switch bracket to the new position. 4. After making the adjustment, touch the Carousel Up/Down box, and then the Cycle Start box again to complete the print stroke. 5. The Carousel Up/Down box must be touched to lower the carousel arms. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 19

20 Basic Operation: 1. Individual Head Control You have the ability to turn off individual heads so that you can cycle with only the heads that are necessary. Touch the master screen display Sta. Set (or it might be labeled Heat-Set ), press the Press desired station to set round button box (*1) and then touch the left-hand box (*2) that will turn that individual head on or off. To print single or double stroke, per head touch the box (*3) that will state single or double, pending that last command the box was given. 2. Set Up/Run By touching the master screen for Set-Up, the operator will be able to make individual movements of each of the steps to complete one print cycle. First the set-up screen will need to be activated. The Cycle Start box when touched will make the print carriage move to the flood stroke position and then stop. The Carousel up/down box when touched will allow the carousel to come up and stop. Then when the Cycle Start box is touched again, the print carriage will complete the print stroke. To lower the carousel arms, touch the box for the Carousel up/down. The toggle switch should be in the down position to place the press into the normal printing mode. #2 Platform Guide Rod #3 Carousel Home Limit Switch #4 Limit switch Attachment Bolt #7 Carousel Vertical Support #8 Carousel Up Limit Switch Starts the print cycle ( ) Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 20

21 Micro Registration: Before you can adjust the micro, you need to release any squeegee pressure (if the squeegee is installed) by turning the squeegee pressure knob counterclockwise. You also need to loosen the rear screen clamps. The front screen clamp controls the movement. It is also best that the micro adjustment device starts in the middle of its range of motion. The zero target tab indicates the ideal starting location. To adjust the micro registration: 1) Loosen the two black ratchet knobs at the top-front of the print head (#1). There should be a slight amount of friction (drag) between the knob and the micro holder. 2) Turn the two black T- Knobs at the front end of the head (#2) for front to back movement. Turn the right knob to move the right side of the screen. Turn the left knob to move the left side of the screen. Turn both knobs to move the both sides at the same time. 3) Turn the turnbuckle coupler (#3) on the top right side of the head for side to side movement. 4) Re-tighten the ratchet knobs after adjusting. 5) Tighten the rear screen clamps. Rear Micro Registration A. Lock down knob ( ) B. Horizontal knob (KR2024R) C. Rod End (RE05RFECON) To use the rear micro, turn the horizontal rod knob. Loosen lock down knob when using the front micro only. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 21

22 Removing The Front Screen Holder: The front screen holder of each head unlocks and slides out for easy loading and unloading of the screen. To operate this mechanism, simply loosen the knobs on the front off-contact threaded rod. (#1) Be sure that one washer is under the knob and one is on top of the leveling nut. See photo. This action unlocks the joint allowing the shaft to slide. If you are unloading a screen, remember to loosen the front screen clamps from the frame.. Otherwise, the holder may not slide Note: Most operators install and remove the screen without utilizing this feature. Simply loosen the four screen clamps, slide the screen into or out of the holders and clamp the screen into the proper position. Item 1 Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 22

23 Registration Tabs and Bearings: The registration system on the Trooper-PC consists of a series of tabs and sets of bearings on the carousel arm platform. These bearings and tabs are factory set and should never be changed or adjusted! Only a qualified Lawson service representative will be able to accurately re-adjust this system, and the expenses for such a service call are not covered under Lawson s warranty. The bearings and tabs must be kept clean and greased. A build up of dirt and lint can cause the registration bearing and tabs to force the position of the screen out of location and out of register. A light coat of grease lubrication is needed to insure proper component life. Registration System *Never adjust the registration bearings without factory authorization. Foot Pedal: To cycle the press, the foot pedal must be depressed. In the general printing mode, the foot pedal will start the press cycle that consist of flood coating the screen, lifting the carousel arm platform, printing the image and then lowing the carousel arm platform. There is no foot pedal on a PC style press. Changing Off Contact Distance For A Special Job Requirements: Once the original off contact distance between the screen and the platen has been established, the operator can change this distance in three ways: 1) By equally adjusting the two master nylon off contact blocks (items # 5&6) will provide universal height adjustment for the entire platform. The platform height limit switch may need to be adjusted. 2) The off contact screen rods in the front and rear (the same rods adjusted when establishing the original spacing position) of the screen carriage. Each screen will need to be adjusted individually. 3) The most practical adjustment is also the most old fashion yet quick way. Simply place a spacer (like a paint stick) between the screen holder extrusion and the bottom of the screen frame. The off contact distance will be consistent from side to side and removing the spacer will place the screen in the original off contact position. This method saves a lot of effort of re-establishing the offcontact position between the screens and platens. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 23

24 Trooper s Electric/Air Sequence: 1. The main power toggle switch must be in the on position and 100 pounds of air must be supplied. 2. The platform guide rod (photo 1, #2) must be engaged (depressed) with the limit switch (photo 1, #3) for the press to lift the carousel arm platform. The guide will be aligned in the correct position when the registration tab and bearings are visually matched. At the master open station a visual guide (photo 2, #1) is provided to assist in this process. 3. The foot pedal starts the printing process. The flood stroke process will be the first function. Again, if the platform guide rod is not engaged, the platform will not lift. If the press flood coats and then the platform guide rod is engaged (by rotating the carousel arm platform), the platform will immediately rise! The platform guide should be engaged prior to starting the press cycle. 4. After starting the press in the proper position, the carousel arm platform will lift and the carriage will flood stroke the screen. 5. The squeegee shifts to the print position as soon as the front print head limit switches are depressed. 6. The carousel up limit switch (Photo 1 #8) must now be depressed for the printing stroke cycle to start. 7. At the end of the print cycle and when all (the slowest/ last) the rear screen limit switches are engaged, the carousel arm platform will drop down, the squeegees will shift to the flood coat position and the carousel will be ready to be rotated for the next shirt. After the carousel arm platform drops down, the bottom carousel limit switch (photo 4, #5) will be engaged: this allows the relay or PLC control (pending model of Trooper) to know it can start the next print cycle. Photo 1 Platform Guide Rod Photo 2 Visual Guide Photo 3 Deck Limit Switch Photo 4 Carousel Limit Switch Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 24

25 Trooper-PC Electric Sub-Panel (Overview Photo): The Lawson Trooper-PC Automatic Printing Press Trooper PC Electrical Panel - Left Side: PC Flood & Print Valves 1 per head: Top Print Deck YVLV0206S amp fuse: Incoming 120v. power Drawing #(F2) amp fuse: DC output 24v. Drawing #(F3) ma fuse: DC power supply of PLC#7 Drawing #(F4) ma fuse: DC power supply of PLC#8 Drawing #(F5) (Safety Reset) 5 K1 4 PDT Relay Quartz Flash Engage/Disengage LRE4-PT VDC Power Supply LXFMR105 7 PLC Controller Unit LPLCEX22 8 PLC Expansion Unit LPLCEX22X 9 Not Shown 1.5 amp fuse for touch screen power supply Drawing #(F1) Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 25

26 Trooper PC Electrical Panel - Right Side: The Lawson Trooper-PC Automatic Printing Press 9 Sleeve Up/Down Valve YVLV0705 9A Meter Exhaust - Sleeve Down Speed YFLEX03 9B Meter Exhaust - Sleeve Up Speed YFLEX03 10 Squeegee Shift Valve YVLV0206S/ 10 Station YVLV A Muffler Exhaust YMFL01BS 11 Carousel Up/Down Valve YVLV A Adj-Muffler Speed of down YAMF02BN 12 Carousel Indexer Valve YVLV A Muffler Exhaust YMFL02BN 12B Meter Exhaust Carousel Return YAMF02AW 13 Carousel Up Speed Control YFCLN04P 14 Squeegee Flip Regulator + Gauge YREGPM04/YGU04 Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 26

27 Trooper-PC Lift Cylinder: The Lawson Trooper-PC Automatic Printing Press Item #1 Item #1A Item #2 Item #3 Item # 4 Item # 5 There are two cylinders to lift the carousel arm platform. Is a flow control to adjust the cushion speed of the lift cylinder. Spring cylinder cushion. There is no adjustment for spring tension Detent pad. The final height of where the bearing makes contact with the print head deck plate is adjustable. Loosen the jam nut, spin the pad to the desired location and then tighten the jam nut. This factory setting should not be adjusted without consulting Lawson Service. Roller bearing detent locator device. The bearing rest in each of the carousel arms holes for quick platen alignment If the bottom collar slips, the guide post can come out of the tube and not allow the carousel arm to drop down. To put the pin back into place, the carousel arm must be blocked in a "up position" so the arm cannot fall while the pin is installed back into the tube. Loosen the bottom collar to do this procedure. 10 & 12 Station Press 6 & 8 Station Press Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 27

28 Print Carriage: 1. Squeegee Lock Pin Pull ring to remove. ( ) Squeegee Pressure Adjustment Rotate the pressure knob counter clockwise to raise squeegee, then insert squeegee in the slot and insert locking pin. The squeegee will free float in the holder. This design ensures equal squeegee pressure. The Lawson Trooper-PC Automatic Printing Press ( ) 2. Print Angle Ratchet Knob 3. Flood Angle Ratchet Knob 4. Head Back Limit Switch 5. Squeegee Flip Cylinder 6. SQ Flip U Channel Bracket Sliding the knob up in the slot increases the angle of the squeegee. The increase of angle will result in a heavier deposit of ink, which is great for dark shirts. Sliding knob down in slot decreases angle making it stand up straighter. This is good for printing on light colored shirts and process printing. Adjust the angle only when the carousel is in down position. ( ) Turn counter clockwise to loosen. Sliding the knob up in slot decreases the pressure against the screen. This degree of angle during the flood coat will leave more ink on top of the screen. Attached to back stroke adjustment bracket. This switch needs to be activated to start and or finish a cycle. ( ) Shifts the squeegee from flood to print position. ( ) 7. Carriage VC Main Plate Round Connecting Bar 9. VC H Bracket SQ Flip Attach Cross Bar Limit Switch: All switches are wired normal open and common. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 28

29 Carousel Indexing System: The Lawson Trooper-PC Automatic Printing Press 1. Left Side Carousel Index Cylinder or Larger Cylinder A. Return Speed Adjustment of Index Cylinder B. Extend Speed Adjustment of Index Cylinder & Carousel ( ) B is option pending model. 3. Pivot Mount w/pin Right Side Drive Cylinder C. Index Speed Control Factory Set Do Not Adjust Left Side Carousel Indexer Cylinder 1. Index Arm 2. Indexer Position Retract Home Limit Switch 3. Bumper Stop Bolt Hex Head Stop Bolt Important adjustment relating to index cylinder not releasing from pin. 5. Index Pin 5A. Index Pin Adjustment Bolts 6. Rod End (RE07F) Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 29

30 General Components Photo Listing Page 1: The Lawson Trooper-PC Automatic Printing Press Indexer Right Side Position 1. Indexer Arm 2. Extend Limit Switch 3. Hex Head Stop Bolt 4. Shock Absorber size related to number of stations. 5. Indexer Sleeve A. Indexer Sleeve Bushing A. Sleeve Alignment Block Sleeve Alignment Bushing 4. Carousel Home Position Limit Switch A. Attachment Ball Shock Absorber Adjustment Ring. The Adjustment is extremely sensitive. Clockwise increases the strength of the absorber. If the Absorber is bouncing less Absorber strength is needed. 5. Carousel Up Position Limit Switch Shock Absorber Adjustment Lock. This Allen Screw must be loosened prior to adjusting the ring adjustment. Be sure to lock the bolt after the final adjustment. 3. Shock Striker Pad Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 30

31 Carousel Position Cylinder System: The Lawson Trooper-PC Automatic Printing Press Carousel Position Cylinder System 1. Cylinder Trigger Disk 2. Index Sleeve Down Limit Switch - Not on all models makes index arm return home. 3. Index Sleeve Up Limit Switch. In the automatic carousel mode, this needs to be depressed before the press will index. Troubleshooting message check the wire connections on this switch. 4. Index Sleeve Cylinder ( ) Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 31

32 Control Panel Operation: The main control panel of the Trooper PC is a menu driven touch screen interface with plain language programming. All of the controls are easily accessible and the control base can be moved around the press to check the functions at any head. When you flip the toggle switch on the control panel to power up the control panel, the ON indicator light should illuminate and the touch screen display will display the start up information. The safety system will also be active and the push-button safety mushroom switch will be illuminated. To deactivate the safety system, simply touch the set-up box from the menu at the bottom of the displayed screen and then, touch the safety reset box. The mushroom switch light will then go out and the press will be operative. Touch Screen: Protect screen as with any computer. Never clean with solvent! The Main Toggle Switch must be turned on for power. (ESW003) The Emergency Stop Button must be in the extended out position to run: pushed in position for all control power off (ESW021) The Alignment Cycle lamp indicator lights must be lit (also called home position) for the press to cycle. This indicates that the carousel arm bearings will go straight up into the top deck plate registration tabs when the print cycle starts. Squeegee Shift Toggle Switch should be in the ON position for normal printing functions. It should be turned OFF to (a) remove the squeegee pressure so that the squeegee and flood angle adjustments can be made and (b) when the screen micro adjustments are being made. If the pressure if left on during the micro adjustment procedure, it is more difficult to register the print. ( ) Parts: Touch Screen LPLC910/LPLC912 (Color Screen) Emergency Stop ESW021 Power Toggle Switch ESW003 F1 Line Fuse Squeegee Shift Switch Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 32

33 Trooper PC Head Set Screen: To activate a print head Touch the Head Set box, from the menu at the bottom of the touch screen. Select the desired head to be set by touching the circle next to the head number. This allows you to turn the selected head On or Off, set it to Single stroke or Double stroke, and activate Auto-Flood. Print Head #1 Set Head #1 5 Off sgl Off sgl 4 Off/on Single/dbl Auto flood Off/on 6 7 Off sgl Off sgl 8 Off sgl Press desired print head to set Off sgl Off sgl Off sgl Set-up flash Head Set Runmode options Set- Up Diag. main Single/Double stroke. Touching the Single/Dbl box toggles the selected head from Single to Double stroke. If the selected heads are set to Single and turned On and the Cycle- Start function is initiated from the Run-Mode screen the press will go through a print cycle. All active heads will flood, the carousel will raise and then the carriages will print. Then the carousel will lower completing the cycle. Any head that is set to Double will go through one complete cycle. Then the heads that are set to Double will flood, the carousel will raise and the heads will print, then the carousel will lower completing the second print stroke. Auto-flood On/Off. Activating the Auto- Flood function allows the carriage to stop in the flooded (front) position rather than the standard rear position. This setting keeps the screen flooded during idle times, and may be helpful when printing with air dry inks. *If the Auto-Flood mode is activated for one head, all the heads will Auto-Flood. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 33

34 Trooper PC Set-Up Flash Screen: Set-Up Flash. From the Head Set screen touch the Set-Up Flash box. This new screen will appear: Flashes 1&2 now can be turned On/Off, flash at a Open Station or Print Station and flash Single or Double. You must assign each flash to a specific head location. To activate Flashes 3&4 go to Flash Set-Up Page 2. Flash #1 Flash #2 Flash #1 MID. Cycle Off/On Off/On Off/On open/print station Single/double open/closed station Single/double Flash #2 MID. Cycle Off/On Assign flash #1 to head # 0 Assign flash #2 to head# 0 Head#1 Returns to Head Set Screen On/Off. To activate the shuttle flash set the flash to On. This allows the press to control the function of the flash. Make sure the Master Switch on the flash is also in the On position. Open Station/Print Station. Select Open Station if you want the flash to shuttle while the carousel is up and the heads are printing. Carousel will not lower until flash is done. Select Print Station to flash at a print station or an open station. Use this function when you want to flash at a print station. The press will go through one print cycle, then the flash will shuttle. Also allows you to Double Stroke and Double flash at the same print head. To assign the flash unit to the print head, type the print head number into the keypad and enter. If the flash on the PC screen is turned on but the flash unit s toggle switch is turned off, the press will not operate. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 34

35 Trooper PC Run Mode Screen: Run-Mode 5 Off sgl Off sgl 4 Cycle-Start 6 Off sgl Off sgl 3 Dwell Off 7 Off sgl Off sgl 2 Safety Reset 8 Off sgl Off sgl Mis-Print Mis-Print Head Set Runmode options Set- Up Diag. main To enter the Run Mode. Touch the Run Mode box from the menu at the bottom of the touch screen. In the Run Mode you have the options of activating the Cycle-Start function, turn Dwell On or Off and Reset the Safety system. From this screen you may also activate the Mis-Print function. Cycle-Start. Touching the Cycle-Start box from Run-Mode screen starts the print cycle. All active heads will print unless you are in a special mode as Load-In, Load Out or Test-Print. If you are in the manual indexing mode (Index-Off) you must manually turn the carousel in order for the press to finish the print cycle. Dwell On/Off. Turns the Dwell timer On/Off. The press cycles automatically when the Dwell is on. Setting the Dwell Timer. 1. Go to the Options screen. 2. Touch the Dwell Time box. 3. Enter the amount of time and then select Enter. The time you enter will be the actual time the press is idle in seconds between cycles. Saftey Reset. The press activation system must be turned off in order to access any functions on the touch screen. Touch the Safety Reset box from the Run Mode screen or the Set-Up screen and the mushroom switch light will go out. Mis-Print. If the Mis-Print button is activated while the carousel is rotating but has not started the print stroke, then that platen will not be printed during one print cycle. If the button is activated once the print head has started the cycle, the Mis-Print function will not work. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 35

36 Options Screen: Dwell Time 00.0 SYSTEM #1 SYSTEM #2 Index OFF/ON Index SINGLE/DBL Options Load-In OFF Load-Out OFF Test Print OFF The Lawson Trooper-PC Automatic Printing Press Counter Reset Load-In OFF Load-Out OFF Test Print OFF Head Set Run- Mode Options Set- Up Diag. Main To enter the Options screen. Touch the Options box from the menu at the bottom of the touch screen. In the Options screen you have the ability to change the amount of Dwell Time, turn the Index On or Off, and activate the Load-In, Load-Out and Test Print for System 1& 2. Dwell Time. Displays the amount of time in seconds that the press is idle between cycles. Touch the Dwell Time box and enter the desired amount of dwell time needed and press enter. Note:.2 tenths of a second is the minimum amount of time that can be entered. Index On/Off. Turning Index on allows the indexer to rotate the carousel. You may, however, run the press with the indexer off. This allows you to perform various special procedures such as rotating the carousel in reverse or stroking the heads more than double. You must rotate the carousel manually when the index is off. Index Single/Double. Double Indexing allows the carousel to advance two positions before the carousel raises to print. Upon starting the cycle the carriages will flood and hold. The carousel will advance one position, the indexer will disengage and return to the home position. It will then re-engage the carousel and advance it another position. The press will then finish the print cycle. Load In. Activating the load in function allows the selected heads to begin printing in the correct sequence. The heads become active at the correct cycle. This allows the operator to begin the job with all necessary heads on. Example, if you are operating with heads 4,5,and 6, then the carousel will advance 3 positions before any printing action will occur. The press will be fully operational once the carousel has made one complete revolution. At the end of the Load-In cycle, the press will continue (if in the dwell mode) to print. Load Out. Activating the load out function allows the selected heads to end printing one at a time. The heads become inactive at the correct cycle. This allows the operator to end the job without having to turn off the heads manually during the cycle. Example, if you are operating with heads 4,5, and 6, then the carousel will advance 4 positions. After the fourth cycle, head 4 will shut off. Head 5 will shut off after the fifth cycle, and head 6 will shut off after the sixth cycle. After the cycle is completed, turn the Dwell to the Off position prior to pressing the Load Out to the off position. If the Dwell is on, the press will start to function as prior to the load out cycle. Test Print. Selecting this function allows the operator to print one sample without activating the whole press. The heads will print one at a time in the correct sequence. Be sure the dwell timer is off during this mode otherwise after the test print cycle is completed, all the print heads will start to print without the shirts being loaded correctly. Counter Reset. Touching the counter reset box resets the print counter. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 36

37 Set Up Mode Screen: Set-Up Off/On Freewheel Off/On Set-Up Mode Safety Reset Cycle-Start Carousel Up/Down Head Set Run Mode Options Set- Up Diag. Main To enter Set-Up. Touch the set-up box from the menu at the bottom of the touch screen. In the set-up mode you can activate the safety interlock system, turn freewheel on or off, activate the cycle start function and manually control the raising and lowering of the carousel. Set-Up Off/On. Used primarily when setting up screens. Set-up must on to activate cycle-start, carousel up/down and to turn freewheel on. Set-up must be in the off position before returning to print production. Cycle-Start. Touch the cycle-start box with set-up on, initiates all the active heads(head Set Screen) to go through the first half of the print cycle. The carriages will flood forward, and the carousel will raise. Then touch cycle-start again, the carriages will print and the carousel will lower completing the second half of the print cycle. Use this function to check print registration and/or ink deposit. Carousel Up/Down. Touching the carousel up/down box with set-up on allows the carousel to raise and /or lower. Use this function when setting screens into the screen holders, to adjust the flood angle and setting platen off contact height. Freewheel. Turning freewheel on allows the carousel to be turned by hand freely. Use this function when you want to check a particular platen or clean the bottom of the screen. It is also used in troubleshooting the index cylinder and setting the index pin alignment with the freewheel in the off position, the index cylinder lifts up. Flash Unit. The automatic flash unit can be operated in set-up mode in a limited way. With the flash unit turned off on the touch screen (but on the flash unit), when the platens are in the down position, the flash unit can shuttle in and out via the auto trigger push button. The flash unit will not operate with the carousel platens in the raised print position unless the communication cable from the press and the unit is disconnected. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 37

38 Example for 6 Color 8 Station Press The Lawson Trooper-PC Automatic Printing Press Diagnostic Screen #1 Print #1 Forward #2 Forward #3 Forward #4 Forward #5 Forward #6 Forward Head Back Diagnostic Screen #2 Head Back Carousel Up Carousel Down Indexer Cyl. Extended Indexer Cyl. Retracted Sleeve Up Cyl. Carousel Down Cyl. Carousel Home Foot Petal Emergency Stop Prev.Diag Diagnostic Screen #4 Head #7 Flood/Print Valve Head #8 Flood/Print Valve Shuttle #1 Retracted Shuttle #2 Retracted Shuttle #3 Retracted (Older Program) Shuttle #4 Retracted (Older Program) Shuttle Disable Emergency Lite Carousel Up/Down Valve Squeegee Flip Valve Prev.Diag Diagnostic Screen #5 Sleeve Up/Down Valve Indexer Extend Valve Indexer Retract Valve Diagnostic Screen #3 Shuttle #1 Retracted Shuttle #2 Retracted Shuttle #3 Retracted (Older Program) Shuttle #4 Retracted (Older Program) Head #1 Flood/Print Valve Head #2 Flood/Print Valve Head #3 Flood/Print Valve Head #4 Flood/Print Valve Head #5 Flood/Print Valve Head #6 Flood/Print Valve Prev.Diag Prev.Diag Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 38

39 Service and Maintenance Page 1: The Lawson Trooper-PC Automatic Printing Press Before you put the Trooper into production, you need to lubricate the inner carriage rail track with light sewing machine (three-in-one type product) or hydraulic oil so the carriage will move with less effort. This procedure should be done on weekly basis. It is also important that you don t allow lint build up on the print rails or carriage parts, as this will lead to non-warrantee failure. The micro knobs and lockdown ratchet knobs should be oiled monthly. The registration bearings and tabs should be kept free of lint and greased monthly. Note: These parts should never be adjusted! The main vertical shaft needs to be kept clean and lint free. The carousel platform should be greased quarterly. Only Synthetic Grease should be used. Lithium grease will damage the carousel hub. Insert synthetic grease via the zerk-fitting. Also apply grease to the outside of the shaft as needed. The platform guide rod should be kept lint free. The squeegee flip, stroke and indexer cylinder stroke rods should be lubricated monthly with #10 or #20 weight hydraulic or pneumatic tool oil. The water trap on in-coming air regulator needs to be checked on a weekly basis. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 39

40 Trooper-PC Trouble Shooting: 1. Carousel does not index and heads do not flood when cycle-start or foot switch is depressed. A. Check head back limit switches, indicator light. I-9 on PLC should be illuminated. B: Make sure carousel indexer is retracted, and retract switch is depressed. I-12 on PLC should be illuminated. C. Make sure the carousel is in the home position. I-16 should be illuminated. D. Make sure carousel down switch is depressed. I-11 on PLC should be illuminated. E. Make sure lock up switch is depressed. I-14 on PLC should be illuminated. 2. Carousel indexes, heads flood, but carousel does not rise. A. Is home position light on control panel illuminated? N - Check home position Y - Make sure index extend switch is depressed. I-12 on PLC will be illuminated. B. Make sure that all active print heads are depressing the head forward limit switches. C. Check auto flash condition/position. 3. Carousel indexes, heads flood, carousel raises but heads do not print. A. Make sure carousel up switch is depressed. I-10 on PLC should be illuminated. 4. Carousel does not lower after print stroke has finished. A. Make sure all head back limit switches are depressed. I-9 on PLC should be illuminated 5. Press competes one complete cycle and stops. A. Check to see if a flash has been programmed to cycle on at a print station. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 40

41 Trooper Trouble Shooting Guide: 1. Press has no response when foot switch is depressed. A. Be sure the master on/off switch is turned on. B. Make sure air is being supplied to the press. C. Be sure one print head is turned on. D. Check head back limit switches. Be sure all of the rear limit switches are depressed. Even if the print head is turned off, the print carriage may have come off the rear limit switch. E. Make sure the carousel home position switch is depressed. F. Be sure the carousel position cylinder trigger disk is depressed against the index sleeve up limit switch. G. Check to see if the flash unit switch is in the proper position. If the flash is turned off, the toggle switch must me in the open station position and the flash unit s toggle switch off. If the flash unit is turned on, the home flash position limit switch must be depressed. H. Make sure flood speed controller is not shut off. I. Be sure PLC controller has power. 2. Print heads flood but carousel does not rise. A. Make sure carousel home limit switch is depressed. B. Check to see if head forward limit switches are depressed. All head forward switches must be depressed before carousel will rise. C. Check auto flash condition/position. 3. Print heads flood, carousel raises and then stops. No print stroke. A. Make sure carousel up limit switch is depressed. B. Make sure print speed controller is not shut off. C. The head valve is not shifting. See the Carousel indexing system page. 4. Press goes through print cycle but carousel does not lower. A. Check head back limit switches. They all must be depressed before the carousel will lower. Be sure the limit switch bracket is not tilted and thus not making the correct contact. B. Index retract home position switch not being depressed. (Input #6 light). C. In the rare occasion, the lift cylinder guide post may not have retracted into the tube support and will physically hold the carousel in the up position. See the trooper lift cylinder page. 5. Press goes through one complete cycle and then has no response after foot switch is depressed. A. Make sure that the switches relating to the flash unit are set correctly. If the flash unit is turned on, be sure that the flash home position switch is depressed. B. Be sure that the cylinder trigger disk is depressing the index sleeve Up limit switch. See the carousel position cylinder system page. The light on the bottom of the air valve should be activated if the switch is depresses. 6. The indexer pin sleeve does not lift when switching to the auto index mode. A. Make sure carousel home position limit switch is depressed. B. Make sure indexer retract limit switch is depressed. For models with a reed switch; check for contact via PLC indicator light I The indexer pin sleeve does not lower at the end of the index. A. The indexer sleeve is binding. Never use grease. Lubricate with hydraulic cylinder oil. B. The sleeve up/down valve is sticking. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 41

42 8. The indexer does not return after indexing. A. The indexer sleeve down limit switch is not depressed. B. The indexer valve is sticking. 9. The press will go through the flood and print cycle, but not index when in the automatic carousel mode. A. The indexer sleeve up limit switch is not depressed. B. The indexer sleeve cylinder is faulty. C. The sleeve up/down valve is sticking. D. The indexer valve is sticking. 10. The carriage squeegee will not shift to the print position when the carousel raises. A. The cylinder rod is dry or dirty and needs a drop of hydraulic cylinder oil, or cleaning. B. The squeegee flip valve is sticking. C. Check to see if squeegee carriage is binding. If the pressure is adjusted too little it could bind on the forward stroke adjustment bracket. D. The squeegee pressure switch should be in the on position. E. Be sure the air hoses are connected correctly. 11. The carousel will not rise when the Set-Up box switch is toggled. A. Check head back limit switches. They must all be depressed. B. Make sure the carousel is in the home position and/or the carousel home position limit switch is depressed. C. Make sure carousel down limit switch is depressed. 12. Ink flood coats more on one side of the screen than the other side. A. Be sure the squeegee holder can swivel on the mount. B. Be sure the screen is parallel to the platen on all four corners. 13. The platens are moving up when the squeegee starts to print. A. The carousel up limit switch is being depressed too early. B. The lift cylinder cushion may need to be adjusted. 14. The carousel registration bearings are hitting the tab locators hard. A. Be sure the entire top head plate did not rotate. B. Be sure the spring on the main carousel lift cylinder did not break. C. Be sure the detent locator-bearing device is not broken. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 42

43 Trooper PC (plc) Diagnostic Indicator Lights #205 8 Heads, 4 Shuttles The Lawson Trooper-PC Automatic Printing Press If the indicator light is on, input power is being received: output power is being sent out to the valve. I-1 HEAD FWD #1 Q-1 HEAD #1 I-2 HEAD FWD #2 Q-2 HEAD #2 I-3 HEAD FWD #3 Q-3 HEAD #3 I-4 HEAD FWD #4 Q-4 HEAD #4 I-5 HEAD FWD #5 Q-5 HEAD #5 I-6 HEAD FWD #6 Q-6 SHUTTLE #1 EXT. I-7 HEAD FWD #7 Q-7 SHUTTLE #2 EXT. I-8 HEAD FWD #8 Q-8 SHUTTLE #3 EXT. I-9 HEAD BACK Q-9 SHUTTLE #4 EXT. I-10 CAROUSEL UP Q-10 HEAD #6 I-11 CAROUSEL DOWN Q-11 HEAD #7 I-12 INDEXER EXT. Q-12 HEAD #8 I-13 INDEXER RET. Q-13 SHUTTLES DISABLE I-14 SLEEVE UP Q-14 EMERGENCY LIGHT I-15 SLEEVE DOWN Q-15 HEAD UP/DOWN SQUEEGEE FLIP I-16 CAROUSEL HOME Q-16 SLEEVE UP/DOWN I-17 FOOT SWITCH Q-17 INDEXER EXT. I-18 EMERGENCY STOP Q-18 INDEXER RET. I-19 SHUTTLE #1 RET. I-20 SHUTTLE #2 RET. I-21 SHUTTLE #3 RET. I-22 SHUTTLE #4 RET. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 43

44 TROOPER Prod # Pic # Description 942-1A Head Shut Off Valve Print Speed Control Flood Speed Control E/W Micro Adjust w/ Assm Micro Clamp Disc Knob, Rachet 5/16-18 Male Micro Adj Knob w/ Shoulder Bolt Screen Rod Knob Front & Rear Screen Rod Rear Screen Holder Front Screen Holder Screen Clamp (x 2) Carousel Lift Cylinder - 6 & 8 station Carousel Lift Cylinder 8 & 10 station A Cushion Adjustment Cushion Lift Spring - 6 & 8 station Cushion Lift Spring - 10 station Detent Attachment Plate - 6 & 8 station Detent Attachment Plate - 10 station Roller Detent Bearing Front Head Bracket, Micro Reg Grid Plate: REGGRD A Micro Indicator Pointer Front Screen Angle Mount Bar Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 44

45 Carriage and Platform Parts: Pic # Description Prod # 1 Squeegee Flip Cylinder Mount A Squeegee Flip Cylinder B Squeegee Shift Rod End - Female C Squeegee Flip Cylinder Busing (pair) Squeegee Angle Adjustment Stop Knob /8 x 3/8 Shoulder Bolt Flood Angle Adjustment Stop Knob /2" Collar Carriage Pivot Shaft Squeegee Attachment Pin Front / Rear Mount Bracket Elec Stroke Limit Switch Head Bypass Tab # Stroke Adj Switch Actuator /4-20 Grade 8 x 3/4" Bolt 16 Squeegee Pressure Adjusting Knob + #17 + # Squeegee Pressure Connecting Rod Squeegee Pressure Connecting Collar, Bolt, Nut A Ratchet Knob, F. x Lower Slide Block, UHMW Carriage Plate Limit Switch, snap action Limit Switch "point of contact" Actuator Home Position - Carousel Height Adjustment Lock Nut Two on 10 Station Press Pad, Lift Cylinder 6 & 8 station Pad, Lift Cylinder 10 station Not Shown Upper Slide Block, UHMW Head Stroke Cylinder Mini-Trooper Head Stroke Cylinder Squeegee Pivot Bar VC Carriage Bumper Stop & 8 Station Press Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 45

46 Trooper Head Support Instructions The Lawson Trooper-PC Automatic Printing Press Install the print head supports after the heads have been adjusted, per prior instructions. To install the Trooper head supports, simply attach the head mounting bolts (#3 in photo) to the head mounting slide brackets. Then, adjust the mounting floor pads so that the print head has maintained its position of staying parallel to the printing platen. The last procedure is attaching the mounting pad to the floor. This is needed so that print head cannot float up or down. Fine tuning for the level of the print heads can still be achieved though the design of the components. If the Trooper head supports are purchased after the original shipment, additional steps must be taken before attaching the supports. First the front control panel faceplate must be removed (#1 in photo). Then the head mounting slide brackets must be installed in the head slot (photo #2). Now the above procedures can be followed. Trooper-PC Instruction Manual v.3.9 revised January 23, 2008 Page 46