We are happy to help. You will find the telephone number of your Heidelberg Systemservice team overleaf or at systemservice.

Transcription

1 We are happy to help. You will find the telephone number of your Heidelberg Systemservice team overleaf or at systemservice. Heidelberger Druckmaschinen AG Kurfuersten-Anlage Heidelberg Germany Phone Fax Publishing Information Printed in: 04/08 Photographs: Heidelberger Druckmaschinen AG Platemaking: Suprasetter Printing: Speedmaster Cover: etabind (patented) Fonts: Heidelberg Gothic, Heidelberg Antiqua Printed in Germany Trademarks Heidelberg, the Heidelberg logotype, Speedmaster, Stahlfolder and Stitchmaster are registered trademarks of Heidelberger Druckmaschinen AG in the U.S. and other countries. Eurobind, Original Heidelberg, Suprasetter and Systemservice are trademarks of Heidelberger Druckmaschinen AG in the U.S. and other countries. All other trademarks are property of their respective owners /01 en Subject to technical modifications and other changes.

2 Systemservice Original Heidelberg Service Parts for Folders, Saddlestitchers, Adhesive Binders and Thread-sealing Machines

3 Content 1 Heidelberg Systemservice 4 2 Folders 7 Mechanical Parts 9 Belts and transport tapes Toothed belts Performance blades Folding rollers Ball bearings Gears Grooved ball bearings O-rings Hickey removers Suckers/suction wheels Marbles Electrical and Electronic Parts 25 EPROM/pulse generators 26 Switches 27 Consumables 29 Lubrication cartridge 30 Banderoles 31 Filter cartridges 32 Options for Retrofitting 33 Knife shaft tools 34 Add-ons 38 3 Saddlestitchers 43 Mechanical Parts 45 Stitching heads 46 Knives 48 Belts 55 Suckers 56 Plugs/covers 57 Drivers 58 Fold pressing unit/chain covers 59 Bearings 60 Cam followers 61 Springs 62 Needles, needle supports, needle bushings 63 Brushes 64 Electrical and Electronic Parts 65 Fuses 66 Lamps 67 Switches, resistors 69 Consumables 69 Stitching wire 70 Lubricants 72 Options for Retrofitting 73 4 Adhesive Binders 83 Mechanical Parts 84 Milling tools 84 Milling discs 85 Suckers 86 Consumables 87 Glues/cleaners 87 5 Thread-sealing Machines/ 89 Thread-stitching Machines Mechanical Parts 90 Needles/razor blades 90 Thread plate chains/thread plates/ sealing threads 91 Other equipment 92 6 Index 93 3

4 Service Parts from Heidelberg. Nothing is as Good as the Original. The right choice Consistent quality, exceptional reliability and the best materials we apply the same stringent quality criteria to Original Heidelberg Service Parts as we do to our machines. They are subjected to tough load and fatigue tests and are continuously improved in line with the latest technical developments. All to ensure smooth production and optimum results. 24-hour delivery Virtually all Original Heidelberg Service Parts can be delivered within 24 hours worldwide. This outstanding service is provided by our logistics network, which is the largest in the industry. Our four logistics centers in Germany, the U.S. and Asia have 130,000 different parts in stock at all times. All to ensure you can get the parts you need quickly. Heidelberg Systemservice Over 4,500 highly trained and motivated technicians at Heidelberg Systemservice deliver our comprehensive service portfolio, which ranges from technical service to consulting. All to ensure your operations are running at optimum efficiency. Hotline and technical clarification Whether over the telephone or on site, our Systemservice team will identify which service parts you need and install these if required. Everything from a single source Whether machinery or workflow processes, pressroom or finishing, older or newer models Systemservice ensures that Heidelberg is always your first port of call. More for your money Compare the market before you buy. You will soon see that Original Heidelberg Service Parts offer the best value for money. Give us a call Find out about the outstanding quality and competitiveness of our Original Heidelberg Service Parts and accompanying services. 4

5 The Heidelberg Systemservice Portfolio. Value Chain: Prepress Press Postpress Production Availability. Maintenance, Technical Support, Repair, Remote Services, Monitoring, Cleaning, Refurbishment Output Optimization. Print Color Management, Quality Evidence, Software Upgrades, Hardware Upgrades, Workflow Optimization Service Parts and Logistics. Original Heidelberg Service Parts, Worldwide Logistics Business Optimization. Process Consulting, IT Integration, Business Development Project Management Services. Printshop Planning, Installation, Dismantling, Relocation Customized Onsite Training. Training on Machine Operation, Maintenance Training, Customized Application Training Life Cycle: Investment Production Phase Resale Service Contracts. Combine services to create customized packages. Technology, Know-How, Experts. It s the ideal combination of these three factors that makes Heidelberg Systemservice so unique. Always available when you need them, Heidelberg experts make sure they stay up-to-date with the latest technical developments, exchanging information and benefiting from each other s experience. Consumables. Carefully selected and tested consumables help safeguard the performance and quality of your machinery and print products. Just give us a call. Your personal Heidelberg contact will be happy to tell you about the services and Heidelberg consumables available in your country. 5

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7 Folders Folders This is the place to find service parts: Our catalog lists popular service parts together with their article number and the machines in which they are used. These are clearly categorized into mechanical and electrical/electronic parts. The options section includes accessories to make your machine even more productive. Unfortunately, as space in this catalog is limited, we have been unable to include all our service parts. If you can t find the part you are looking for, please give us a call. We ll be happy to find it for you. Easy to find. Our index on page 93 lists all the service parts included in the catalog, together with the relevant page number. Looking for other service parts? Check out one of the other Heidelberg part catalogs: Original Heidelberg Service Parts for Presses and CtP Devices Original Heidelberg Service Parts for Die Cutters and Folder Gluers Stahlfolder Performance Blades Technical assistance. We have marked a number of our service parts with the symbol. All these parts differ from each other depending on the specific machine con figuration. Please telephone our Systemservice experts to discuss your tec h ni cal re quirements. How much does my service part cost? Your Heidelberg Systemservice team will be happy to provide you with information on prices. See the back page of the catalog. Who installs the service parts? We have marked a number of service parts with the symbol. We recommend always having these parts replaced by a Heidelberg Systemservice engineer. Any questions? Just give us a call. If you are finding it difficult to track down an article, hav ing problems installing a service part or looking for assis tance, we ll be happy to help. Useful telephone num bers can be found at the back of our catalog or on line at

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9 Mechanical Parts Mechanical Parts Folders

10 2. Folders/Mechanical Parts Belts/Transport tapes Belts and transport tapes Belts and transport tapes are used in our folders, feeders and deliveries to transfer forces and torques. As the individual working areas have different requirements, we have developed our own belts and transport tapes for each machine in coop e ration with our suppliers. Like all Original Heidelberg parts, they are made of high quality textile, rubber and steel blends. Unfortunately, we are only able to show a selection of the pop ular items in our range here. All other articles can be ordered from us on request. Belts and transport tapes for combination folding machines in the Stahlfolder KD range Designation Description/size (mm) Poly V belt ZD Stahlfolder KD.2, KD , KD J8 Poly V belt ZD Stahlfolder KD.2, KD , KD J8 Poly V belt ZD Stahlfolder KD.2, KD , KD J8 Poly V belt ZD Stahlfolder KD.2, KD J8 Poly V belt ZD Stahlfolder KD.2, KD , KD J8 V belt ZD Stahlfolder KD.2, KD , KD XPZ 1187 LW V belt ZD Stahlfolder KD.2, KD , KD SPZ 1387 LW V belt ZD Stahlfolder KD.2, KD SPZ 1262 LW V belt ZD Stahlfolder KD.2, KD , KD SPZ 1537 LW V belt ZD Stahlfolder KD.2, KD SPZ 737 LW V belt ZD Stahlfolder KD.2, KD , KD SPZ 1237 LW V belt ZD Stahlfolder KD , KD SPZ 1162 LW Transport tape FH /02 Stahlfolder KD.2, KD ,KD ± 5 Transport tape FH /02 Stahlfolder KD.2, KD ± 5 Transport tape FH /02 Stahlfolder KD.2, KD , KD ± 5 Transport tape FH /02 Stahlfolder KD.2, KD , KD ± 5 Transport tape FH /02 Stahlfolder KD.2, KD ± 5 Transport tape FH /02 Stahlfolder KD.2, KD , KD ± 5 Transport tape FH /02 Stahlfolder KD.2, KD , KD ± 5 Transport tape FH /02 Stahlfolder KD.2, KD ± 5 Transport tape FH /03 Stahlfolder KD.2, KD , KD ± 5 Transport tape FH /02 Stahlfolder KD.2, KD , KD ± 5 Transport tape ZD Stahlfolder KD.2, KD , KD elastic L448; 440 Transport tape ZD Stahlfolder KD.2, KD , KD elastic L965; 951 Transport tape ZD Stahlfolder KD.2, KD , KD elastic L695; 685 Our experts will be pleased to provide technical advice when selecting this service part. The best solution depends on your machine configuration. 10

11 2. Folders/Mechanical Parts Belts/Transport tapes Belts and transport tapes for combination folding machines in the Stahlfolder KD range continued Designation Description/size (mm) High-performance belt ZD Stahlfolder FD 56-78, FD , RD 56-94, RD , PD, PD.1, PD High-performance belt ZD Stahlfolder FD 56-78, FD High-performance belt ZD Stahlfolder FD 56-78, FD High-performance belt ZD Stahlfolder RD 56-94, RD High-performance belt ZD Stahlfolder RD 56-94, RD High-performance belt ZD Stahlfolder PD, PD.1, PD High-performance belt ZD Stahlfolder PD, PD.1, PD Transport tape ZD Stahlfolder RD Transport tape ZD Stahlfolder RD 56-94, RD endless Transport tape ZD Stahlfolder RD Transport tape ZD Stahlfolder RD 56-94, RD endless Transport tape ZD Stahlfolder RD 56-94, RD endless Transport tape ZD Stahlfolder RD 56-94, RD endless Transport tape ZD Stahlfolder RD 56-94, RD endless Did you know... that Heidelberg offers customized Service Contracts with the flexibility to satisfy your specific requirements to the full? Inspection and maintenance of your machin ery at specific service intervals based on our maintenance checklists is just one example for reliable production, top quality and high value retention. Our experts will be pleased to provide technical advice when selecting this service part. The best solution depends on your machine configuration. 11

12 2. Folders/Mechanical Parts Belts/Transport tapes Belts and transport tapes for buckle plate folding machines in the Stahlfolder TD range Designation Description/size (mm) Belt ZD Stahlfolder TD 112, J 10 High-performance belt ZD Stahlfolder TD High-performance belt ZD Stahlfolder TD Poly-V-belt ZD Stahlfolder TD J6 Poly-V-belt ZD Stahlfolder TD J6 Narrow V-belt ZD Stahlfolder TD.1-52 SPZ 1037-LW Narrow V-belt ZD Stahlfolder TD.1-52 SPZ 1337 Narrow V-belt ZD Stahlfolder TD.1-52 SPZ 1222-LW Narrow V-belt ZD Stahlfolder TD.1-52 SPZ 1900 Transport tape ZD Stahlfolder TD Poly-V-belt ZD Stahlfolder TD 56.1, 78.1, TD J8 Poly-V-belt ZD Stahlfolder TD 56.1, 78.1, TD J8 Poly-V-belt ZD Stahlfolder TD 56.1, 78.1, TD J8 Poly-V-belt ZD Stahlfolder TD 56.1, 78.1, TD J8 Narrow V-belt ZD Stahlfolder TD 56.1, 78.1 SPZ 2087-LW Narrow V-belt ZD Stahlfolder TD 56.1, 78.1, TD SPZ 1958-LW Narrow V-belt ZD Stahlfolder TD 56.1, 78.1, TD SPZ 2065-LW Narrow V-belt ZD Stahlfolder TD 56.1, 78.1, TD SPZ 2172-LW Narrow V-belt ZD Stahlfolder TD SPZ 1637-LW Narrow V-belt ZD Stahlfolder TD SPZ 1462-LW Narrow V-belt ZD Stahlfolder TD SPZ 2000-LW Belts and transport tapes for buckle plate folding machines in the Stahlfolder TH range Designation Working width Description/size (mm) Poly-V drive belt, 4 buckle plates ZD Working width J8 V-belt (register table) ZD Working width 82, without front mounted slitter shaft SPZ 1662-LW Belts and transport tapes for combination folding machines in the Stahlfolder KH range Designation Working width Description/size (mm) Transport tape FH /01 Working width 78, cross fold ± 5 Toothed belts (folding knife drive) ZD Working width H 062 Transport tape FH /01 Working width 66, threefold ± 5 Toothed belts (folding knife for cross fold) ZD Working width XL 019 Our experts will be pleased to provide technical advice when selecting this service part. The best solution depends on your machine configuration. 12

13 2. Folders/Mechanical Parts Belts/Transport tapes Belts and transport tapes for buckle plate folding machines and combination folding machines in the Stahlfolder KI/TI range Designation Description/size (mm) Poly-V-belt ZD Stahlfolder TI.1 55, TI.1 52, TI 40, TI 55 nonstandard, TI J 6 Poly-V-belt ZD Stahlfolder TI.1 55, TI.1 52, TI J 6 Narrow V-belt ZD Stahlfolder TI.1 55, TI.1 52, TI 40, TI 55 SPZ 1222-LW Narrow V-belt ZD Stahlfolder TI.1 55, TI 55 SPZ 1312-LW Narrow V-belt ZD Stahlfolder TI.1 55, TI.1 52 SPZ 1900 Transport tape ZD Stahlfolder TI.1 55, TI.1 52, TI high-performance flat-belt ZD Stahlfolder TI.1 52, FI.1 55, FI Narrow V-belt ZD Stahlfolder TI.1 52 SPZ 1037-LW Narrow V-belt ZD Stahlfolder TI.1 52 SPZ 1337 high-performance flat-belt ZD Stahlfolder TI Round belt ZD Stahlfolder TI Transport tape ZD Stahlfolder TI Poly-V-belt ZD Stahlfolder KI J 8 Poly-V-belt ZD Stahlfolder KI J 8 high-performance flat-belt ZD Stahlfolder TI Transport tape FH /01 Stahlfolder KI ± 5 Narrow V-belt ZD Stahlfolder KI 55 SPZ 1162-LW Narrow V-belt ZD Stahlfolder KI 55 XPZ 1237 LW Round belt ZD Stahlfolder TI Transport tape ZD Stahlfolder TI Belts and transport tapes for feeders Designation Description/size (mm) high-performance flat-belt ZD Transport tape endless RH FH / endless Transport tape endless RH FH / endless high-performance flat-belt PH ZD Our experts will be pleased to provide technical advice when selecting this service part. The best solution depends on your machine configuration. 13

14 2. Folders/Mechanical Parts Toothed belts Toothed belts Toothed belts transfer forces and torques. All our Original Heidelberg toothed belts are specially adapted to the needs of our Stahlfolders for optimum precision and durability. They are manufactured in cooperation with selected suppliers from high-quality textile, rubber or steel blends. Unfortunately, we can only show a selection of the popular items in our Original Heidelberg toothed belt range here. All other toothed belts can be ordered from us on request. Just give us a call. For combination folding machines in the Stahlfolder KD range Description For buckle plate folding machines and combination folding machines in the Stahlfolder KI/TI range Description ZD Stahlfolder KD.2, KD ,KD H 062 ZD Stahlfolder TI.1 55, TI XL 031 ZD Stahlfolder KD.2, KD ,KD H 062 ZD Stahlfolder TI.1 55, TI XL 031 ZD Stahlfolder KD.2, KD H 062 ZD Stahlfolder TI.1 55, TI XL 031 ZD Stahlfolder KD.2, KD ,KD XL 031 ZD KD , KD H 062 ZD Stahlfolder TI XL 025 ZD Stahlfolder TI.1 52 XL 025 For buckle plate folding machines in the Stahlfolder TD range Description ZD Stahlfolder TD XL 025 ZD Stahlfolder TD.1-52 XL 025 ZD Stahlfolder TD.1-52, TD 56.1, 78.1, TD XL 031 For feeders Description FH /03 (image) Register table toothed belt for suction tape module ZD Stahlfolder RD XL 075 ZD ZD Stahlfolder TD.1-52, TD 56.1, 78.1, TD Stahlfolder TD.1-52, TD 56.1, 78.1, TD XL XL

15 2. Folders/Mechanical Parts Performance blades Stahlfolder performance blades Original Heidelberg blades are made of very high-grade steels, are extremely durable and are designed by us to handle very high speeds and loads. Replaced regularly, they ensure a high standard of work and efficient, pro blem-free production over the long term. Stahlfolder performance blades Designation Outside diameter Inside diameter Form Quantity of teeth Thickness Working width Crimping blade ZD mm 55 mm V /142 Perforating blade ZD mm 55 mm V /142 Scoring blade ZD mm 55 mm V /142 Scoring blade ZD mm 55 mm V /142 Trimming blade ZD mm 55 mm V /142 Punching knife ZD mm 55 mm V /142 Crimping blade ZD mm 40 mm V Perforating blade ZD mm 40 mm V Perforating blade ZD mm 40 mm V Scoring blade ZD mm 40 mm V Scoring blade ZD mm 40 mm V Trimming blade ZD mm 40 mm V Trimming blade ZD mm 40 mm V Punching knife ZD mm 40 mm V Perforating blade ZD mm 30 mm V Perforating blade ZD mm 30 mm V Perforating blade ZD mm 30 mm V Scoring blade ZD mm 30 mm V Trimming blade ZD mm 30 mm V Crimping blade ZD mm 26 mm V Perforating blade ZD mm 26 mm V Perforating blade ZD mm 26 mm V Scoring blade ZD mm 26 mm V Scoring blade ZD mm 26 mm V Trimming blade ZD mm 26 mm V Trimming blade ZD mm 26 mm V For a complete overview of all available blades, please consult your Stahlfolder Performance Blades Catalog or just give us a call. 15

16 2. Folders/Mechanical Parts Folding rollers Folding rollers for the Stahlfolder range Original Heidelberg folding rollers are available in Classic and Extra Grip versions. They consist of a hard steel core with a corrugated surface and large journals that ensure smooth running. 15 mm wide polyurethane rings are fitted into the steel core for transporting the folded sheet exactly in the direction of paper travel. The new Extra Grip folding roller for extra folding quality The Extra Grip folding rollers set new standards with their innovative configuration. The steel segments are just 9 mm wide, increasing the number of polyurethane rings by around 30 percent per folding roller. There are no longer any overlaps between the corrugated steel segments. This reliably prevents marks on the folded sheet, for example with concertina folds and letterfolds Benefits of the Extra Grip folding rollers: Perfect grip on the paper Higher traction No marks on sensitive papers Outstanding folding accuracy Fold sheets guided in an exact straight line Less static charge Steel-polyurethane grid of Extra Grip folding rollers. Folding layout. Steel-polyurethane grid of Classic folding rollers. Top Extra Grip folding roller. Bottom Classic folding roller. 16

17 2. Folders/Mechanical Parts Folding rollers Folding rollers for the Stahlfolder range Designation Classic folding roller Extra Grip folding roller Hard-PU 36 middle rubber 1.1 FH /00 FH /02 Stahlfolder TI 36, TI 36.2 Hard-PU 36 middle steel 1/2/4/6 FH /00 FH /02 Stahlfolder TI 36, TI 36.2 Hard-PU 36 middle rubber 3/5/7 FH /00 FH /02 Stahlfolder TI 36, TI 36.2 Soft-PU 36 middle rubber 1.1 ZD BG-01 FH /01 Stahlfolder TI 36, TI 36.2 Soft-PU 36 middle steel 1/2/4/6 ZD BG-02 FH /01 Stahlfolder TI 36, TI 36.2 Soft-PU 36 middle rubber 3/5/7 ZD BG-01 FH /01 Stahlfolder TI 36, TI 36.2 Soft-PU 40 middle rubber 1.1 ZD BG-01 FH /01 Stahlfolder TI 40* Soft-PU 40 middle steel 1/2/4 ZD BG-01 FH /01 Stahlfolder TI 40* Soft-PU 40 middle rubber 3/5 ZD BG-01 FH /01 Stahlfolder TI 40* Hard-PU 52 middle rubber 1.1 ZD BG-01 FH /01 Stahlfolder TI 52, TD.1-52* Hard-PU 52 middle steel 1/2/4/6 ZD BG-01 FH /01 Stahlfolder TI 52, TD.1-52* Hard-PU 52 middle rubber 3/5/7 ZD BG-02 FH /01 Stahlfolder TI 52, TD.1-52* Soft-PU 52 middle rubber 1.1 ZD BG-01 FH /01 Stahlfolder TI 52, TD.1-52* Soft-PU 52 middle steel 1/2/4/6 ZD BG-01 FH /01 Stahlfolder TI 52, TD.1-52* Soft-PU 52 middle rubber 3/5/7 ZD BG-02 FH /01 Stahlfolder TI 52, TD.1-52* Hard-PU 55 middle rubber 1.1 ZD BG-01 FH /01 Stahlfolder TI 55, Ki 55 parallel fold* Hard-PU 55 middle steel 1/2/4/6 ZD BG-01 FH /01 Stahlfolder TI 55, Ki 55 parallel fold* Hard-PU 55 middle rubber 3/5/7 ZD BG-01 FH /01 Stahlfolder TI 55, Ki 55 parallel fold* For KI: Soft-PU 55 middle rubber 1.1 ZD BG-01 FH /01 Stahlfolder TI 55, Ki 55* For TI: Soft-PU 55 middle rubber 1.1 ZD BG-01 FH /01 Stahlfolder TI 55, Ki 55* Soft-PU 55 middle steel 1/2/4/6 ZD BG-01 FH /01 Stahlfolder TI 55, Ki 55* Soft-PU 55 middle rubber 3/5/7 ZD BG-01 FH /01 Stahlfolder TI 55, Ki 55* Hard-PU 56 middle steel ZD BG-06 FH /01 Stahlfolder TD 56, TH 56, KD 56, KH 56* Hard-PU 56 middle rubber ZD BG-05 FH /01 Stahlfolder TD 56, TH 56, KD 56, KH 56* Soft-PU 56 middle steel ZD BG-05 FH /01 Stahlfolder TD 56, TH 56, KD 56, KH 56* Soft-PU 56 middle rubber ZD BG-06 FH /01 Stahlfolder TD 56, TH 56, KD 56, KH 56* Hard-PU 66 middle steel ZD BG-04 FH /01 Stahlfolder TD 66, TH 66, KD 66, KH 66* Hard-PU 66 middle rubber ZD BG-03 FH /01 Stahlfolder TD 66, TH 66, KD 66, KH 66* Soft-PU 66 middle steel ZD BG-04 FH /01 Stahlfolder TD 66, TH 66, KD 66, KH 66* Soft-PU 66 middle steel ZD BG-03 FH /01 Stahlfolder TD 66, TH 66, KD 66, KH 66* * with groove for gluing attachment Tip: Only use Saphira Special Cleaner for folding equipment to clean your folding rollers (see page 31). This cleaning agent offers outstanding cleaning properties and is particularly gentle on the polyurethane rings. Please note that not all folding rollers can be supplied within 24 hours. 17

18 2. Folders/Mechanical Parts Folding rollers/ball bearings Folding rollers for the Stahlfolder range continued Designation Classic folding roller Extra Grip folding roller Hard-PU 78 middle steel ZD BG-02 FH /01 Stahlfolder TD 78, KD 78* Hard-PU 78 middle rubber ZD BG-01 FH /01 Stahlfolder TD 78, KD 78* Soft-PU 78 middle steel ZD BG-02 FH /01 Stahlfolder TD 78, KD 78* Soft-PU 78 middle rubber ZD BG-01 FH /01 Stahlfolder TD 78, KD 78* Hard-PU 82 middle steel FH /01 Stahlfolder TH 82 Hard-PU 82 middle rubber FH /01 Stahlfolder TH 82 Soft-PU 82 middle steel FH /02 Stahlfolder TH 82 Soft-PU 82 middle rubber FH /02 Stahlfolder TH 82 Hard-PU 94 middle steel ZD BG-07 FH /01 Stahlfolder TD 94, KD 94* Hard-PU 94 middle rubber ZD BG-08 FH /01 Stahlfolder TD 94, KD 94* Soft-PU 94 middle steel ZD BG-07 FH /01 Stahlfolder TD 94, KD 94* Soft-PU 94 middle rubber ZD BG-08 FH /01 Stahlfolder TD 94, KD 94* Soft-PU 112 middle steel ZD BG-04 FH /01 Stahlfolder TD 112 Soft-PU 112 middle rubber ZD BG-03 FH /01 Stahlfolder TD 112 Soft-PU 142 middle steel ZD BG-02 FH /01 Stahlfolder TD 142 * with groove for gluing attachment Ball bearings for the Stahlfolder range In order to ensure the long-term smooth running of our Ori gi nal Heidelberg folding rollers, we only use special ball bearings made of high-grade materials. However, even the best ma te rial undergoes changes when subjected to prolonged mechanical stress, so precision of movement can decrease. It is therefore advisable to replace the bearings along with the folding rollers. Ball bearings for the Stahlfolder range Designation Ball bearing ZD Working width 52 to 94 Grooved ball bearing ZD Stahlfolder TI 36 Ball bearing KI ZD Stahlfolder TD 112 and 142 Ball bearing KI ZD Stahlfolder TD 112 and

19 2. Folders/Mechanical Parts Gears/Grooved ball bearings Gears for the Stahlfolder range Gears perform a wide variety of tasks in our Stahlfolder folding machines. In order to ensure optimum longterm performance, all our Original Heidelberg gears are made from selected, high-grade materials. Gears for the Stahlfolder range Designation Teeth Module Gear left ZD Stahlfolder KD/TD Gear right ZD Stahlfolder KD/TD Gear left ZD Stahlfolder TF/KC/KD/TD Gear right ZD Stahlfolder TF/KC/KD/TD Gear right ZD Stahlfolder KD/KH Gear left ZD Stahlfolder KD/KH Gear left ZD Stahlfolder TD Gear right ZD Stahlfolder KD/TD Gear right ZD Stahlfolder TF/KC/KD/TD Gear right ZD Stahlfolder TF/KC/KD/TD Gear right ZD Stahlfolder KD/TD Gear right ZD Working width 36 Gear left ZD Working width 36 Gear right ZD Stahlfolder TF/TD Gear left ZD Stahlfolder TF/TD Gear left ZD Stahlfolder KD 66 Gear right ZD Stahlfolder KD 66 Gear left ZD Stahlfolder KD Grooved ball bearings Grooved ball bearings are versatile, low-maintenance bearings particularly suited to high speeds because of their low frictio nal torque. Original Heidelberg grooved ball bearings are made of the plastics polyamide (PA) and polyoxymethylene (POM) and glass three mate - r ials with resistance to aggressive media and paper dust. They are manufactured by selected suppliers exactly in accordance with our dimensions and specifications. Grooved ball bearing glass ZD All machines We recommend always having these parts replaced by a Heidelberg Systemservice engineer. 19

20 Did you know that Heidelberg offers flexible, customized service packages compiled to meet your particular needs? The experts at Heidelberg Systemservice do not just repair your machines. They also ensure your quality standards are maintained by servicing your equipment at fixed intervals. This really pays dividends. Regular care re duces downtimes, extra work and waste, and throughput times are easier to plan. Consistently high-quality results also increase the satisfaction and long-term loyalty of your customers. And that s a promise!

21 2. Folders/Mechanical Parts O-ring/Hickey removers O-rings for the Stahlfolder range Our Original Heidelberg O-rings are precisely adapted in form and function to their respective tasks. They are made from various types of high-grade rubber and special elastomers with different properties depending on the specific requirements. This means that in addition to being ideally suited to the environment in which they are used, our sealing elements are also very durable. Hickey removers/strippers for the Stahlfolder range All our Original Heidelberg hickey removers are made from high-quality materials such as corrosion-resistant steel or chemical-resistant rubber. They are therefore optimally pro tected against all factors that might affect them during the production process. This ensures minimal wear and a long service life in our machines. O-ring for suction wheel Hickey removers/strippers for the Stahlfolder range Designation ZD Stahlfolder TH/KH Hickey remover ZD Hickey remover complete (above) ZD BG-02 Hickey remover ZD Hickey remover complete (below) ZD BG-01 Hickey remover THK FLM8 ZD Hickey remover VSA ZD Hickey remover complete VSA ZD BG-01 Hickey remover ZD Hickey remover complete after the cross fold ZD BG-01 Hickey remover complete ZD BG-01 Hickey remover complete ZD BG-02 Hickey remover ZD Hickey remover complete ZD BG-03 Hickey remover complete FH /01 Hickey remover complete b = 10, s = 1 ZD BG-03 Hickey remover complete ZD Hickey remover strip trimmer FH /02 Hickey remover FH /03 Hickey remover ZD Hickey remover ZD Hickey remover complete ZD BG-01 Hickey remover ZD Our experts will be pleased to provide technical advice when selecting this service part. The best solution depends on your machine configuration. 21

22 2. Folders/Mechanical Parts Suckers/Suction wheels Suckers for flat-pile feeders and pallet feeders Original Heidelberg suckers are designed to deliver precise suction force in order to provide the correct amount of suction for the sheet. They are very hardwearing and manufactured from high-grade plastics in cooperation with selected suppliers. Heidelberg gives you quality you can rely on, tried and tested in load tests. Suction wheels Suction wheels ensure precise paper travel and improve grip without leaving behind any unwanted marks. Original Heidelberg suction wheels are made from extremely hard-wearing materials, allowing long maintenance intervals. Heidelberg gives you quality you can rely on, tried and tested in load tests. Suckers Designation Suction wheels Designation Molded rubber sucker ZD Stahlfolder TH/KH Flanged gear PUsuction wheel, 3 holes FH /02 Stahlfolder TH/KH Lifting sucker ZD Stahlfolder TH/KH Suction wheel hard coat 3 holes Suction wheel hard coat 2 holes Suction wheel with PU 2 holes Suction wheel, nickelcoated, 3 holes Suction wheel, nickelcoated, 2 holes ZD Stahlfolder TH/KH ZD Stahlfolder TH/KH ZD Stahlfolder TH/KH ZD Stahlfolder TH/KH ZD Stahlfolder TH/KH Did you know that Heidelberg Systemservice offers training cour ses on special themes, starting from operating and main tain ing your Heidelberg machines and exten ding to opti mizing print applications? We train your staff wherever suits you best either on site or at the Heidelberg Print Media Academy. Increase your company s quality and productivity through a well trained workforce, the key to added success. If you would like further information on the courses on offer, just send an to: nadine.damnig@heidelberg.com. We recommend always having these parts replaced by a Heidelberg Systemservice engineer. 22

23 2. Folders/Mechanical Parts Marbles Marbles for Stahlfolder The quality of the marbles is key to determining whether unwanted marks appear on the printing stock. With this in mind, we have developed our special plastic marbles for sensitive printing stocks. If, however, heavy and less sensitive paper is to be processed particularly at high speeds then our steel marbles are the ideal solution. All marbles are tested and optimized at the company s own test facilities to ensure their high load-bearing capacity and durability. The benefits of this are reflec ted in not only minimal downtimes and reduced maintenance costs but also high product quality. Marbles for Stahlfolder Designation Plastic 14 mm ZD All feeders, working width 56 to 94 Plastic marble 35 mm ZD All feeders, working width 56 to 94 Plastic marble 24 mm ZD All feeders, working width 56 to 94 Plastic marble 20 mm ZD All feeders, working width 56 to 94 Steel marble 5 mm ZD All feeders, working width 56 to 94 Steel marble 10 mm ZD All feeders, working width 56 to 94 Steel marble 35 mm ZD All feeders, working width 56 to 94 Steel marble 24 mm ZD All feeders, working width 56 to 94 Steel marble 20 mm ZD All feeders, working width 56 to 94 Steel marble 8 mm ZD All feeders, working width 56 to 94 Steel marble 6.35 mm ZD All feeders, working width 56 to 94 Steel marble 14 mm ZD All feeders, working width 56 to 94 23

24 Did you know that only materials and parts that have passed the toughest Heidelberg load and fatigue tests can use the Original Heidelberg name? Take the recent cautionary tale from a printshop where a screw that was not from the Heidelberg range failed to cope with the mechanical stresses generated by the press. The result was EUR 300,000 of damage. Only Original Heidelberg Service Parts ensure top quality and fault-free operation because only they are tested in accordance with the toughest criteria and merit the name Original Heidelberg.

25 Electrical and Electronic Parts Electrical and Electronic Parts Mechanical Parts Folders

26 2. Folders/Electrical and Electronic Parts EPROM/pulse generators EPROM The EPROM control unit is a very important component in the operating system of every Stahlfolder. It is available from us in 16 different languages. As it is easy to mistake one for another, you should always order these units directly from us. To ensure your Stahlfolder functions smoothly after the changeover, the control unit should only be fitted by our service engineers. EPROM* Designation EPROM 64 K 8 FH /00 only Stahlfolder TD/KD series (SKO, MTV) EPROM 256 K 8 FH /00 only Stahlfolder TD/KD series Pulse generators In our Stahlfolders, pulse generators are responsible for keeping the paper distance precise, so their efficien cy is essen tial for continuous production. Without their precise synchronization in the control unit, it would not be possible to achieve the high production speeds in our Stahfolder range. Original Heidelberg pulse generators are therefore adapted to the latest devel opments on an ongoing basis and made from high quality, durable materials to ensure consistent, problem free production. Pulse generator ZD Stahlfolder TD, KD, TI, KI, TH/KH, ACC 2.4 Our experts will be pleased to provide technical advice when selecting this service part. The best solution depends on your machine configuration. * Some of the electronic components have to be individually programmed depending on the machine configuration. Please telephone our experts to discuss technical requirements. In these cases, the delivery time may be longer. 26

27 2. Folders/Electrical and Electronic Parts Switches Limit switch shut off 120 mm FH /01 Stahlfolder TH/KH Limit switch, preformed with cable 900 mm FH /00 Stahlfolder TH/KH Limit switch preformed with roll FH /00 Stahlfolder TH/KH Switch complete Microswitch Switch FH /02 Stahlfolder TH/KH FH /01 Stahlfolder TH/KH FH /03 Stahlfolder TH/KH Antenna/aerial switch Switch Inductive limit switch 1,550 mm FH /02 Stahlfolder TH/KH FH /01 Stahlfolder TH/KH FH /00 Stahlfolder TH/KH We recommend always having these parts replaced by a Heidelberg Systemservice engineer. 27

28 2. Folders/Electrical and Electronic Parts Switches Dummy plug Designation Dummy plug FH /03 Stahlfolder TH/KH Dummy plug ZD BG-01 Stahlfolder TD/KD Reflex switches Dummy plug ZD BG-01 Stahlfolder TI Designation Reflector FH /01 Stahlfolder Speedbander Reflector ZD Stahlfolder RD/RFH Reflex sensor (image) ZD Stahlfolder TD/TH mm Reflex sensor ZD Stahlfolder KH/ KD 10-19,5 mm Reflex sensor ZD Delivery Stahlfolder TD/KD mm Cable with plug Designation Cable with plug ZD BE-03 Stahlfolder TD/KD stations, deliveries and units Reflex sensor ZD Stahlfolder Speedbander Light barrier ZD Suction wheel Stahlfolder RD/ RFH/FI Light barrier ZD Stahlfolder Speedbander SFA 603/604, SBP Sensor FH /01 Stahlfolder Speedbander Strap Designation Strap ZD Stahlfolder TD Did you know... that over 95% of all Original Heidelberg service parts are delivered within 24 hours? Heidelberg Systemservice boasts an ultramodern logistics network. At its heart is the World Logistics Center in Wiesloch, which stocks over 130,000 service parts. North and Central America are supplied directly by the American Logistics Center in Indianapolis, while Asia s parts come from the Japanese Logistics Center in Tokyo and the Hong Kong Logistics Center. Every day, 1,600 customers around the world receive Original Heidelberg service parts within 24 hours. 28

29 Consumables Consumables Electrical and Electronic Parts Mechanical Parts Folders

30 2. Folders/Consumables Lubrication cartridge Lubrication cartridge The Original Heidelberg lubrication cartridge has been spe cial ly developed by us to reliably ensure clean, convenient long term lubrication for the Heidelberg Stahlfolder range. It consists of a special metering element that dispenses lubri cant continuously round the clock. This means you can pro vide premiumquality lubrication for your machine with practically no maintenance! There s another benefit, too. Thanks to its precise metering, the lubrication cartridge prevents dripping of surplus lubricant. Soiling is reduced to a minimum and your machine is kept permanently clean. There is also less risk of operator accidents, making the machines much safer to work with. We have optimi zed the quantity of lubricant dispensed to ensure the opti mum balance between lubrication and adhesion. This significantly reduces the risk of premature wear or rust. The lubrication car tridge must be replaced every six months. This not only gives your machines a long service life but also ensures that all the products you produce are high quality. The Original Heidelberg lubrication cartridge is suitable for all Stahlfolder folders from Heidelberg, the FS 100 thread sealing machine and the Stitchmaster ST 300 saddlestitcher. The lubricant has been specially formulated for use in Heidelberg postpress equipment and is not the same as standard commercial products. Lubrication cartridge Cycle Quantity required per machine ZD Stahlfolder K models 1990 and later ZD Stahlfolder T models 1990 and later Every 6 months Every 6 months 2 pcs 2 pcs per folding unit ZD Stitchmaster ST 300 Every 6 months 6 pcs ZD Thread sealing machine FS 100 Every 6 months 3 pcs Lubricant for Stahlfolder Cycle Quantity required per machine FH /00 All Stahlfolder for supplementary lubrication Cartouche, 400 gram FH /00 All Stahlfolder for supplementary lubrication Can, 900 gram 30

31 2. Folders/Consumables Banderoles Banderoles for the Stahlfolder Speedbander For our fully automated Stahlfolder Speedbander pack module, we can offer you a selection of Original Heidelberg banderoles available in two different widths, 30 and 48 millimeters. The banderoles can be exchanged easily as required. Unfortunately, we can only show a selection of the popular items in our Original Heidelberg banderoles range here. All other banderoles can be ordered from us on request. Just give us a call. Saphira Special Cleaner for folding equipment Saphira Special Cleaner cleans and revitalizes folding rollers such as those in the Stahlfolder range in a single operation. After cleaning, the rollers are left with a velvety smooth rubber surface with outstanding grip properties. Service life is extended significantly and no swelling takes place in the rubber rollers. Saphira Special Cleaner Packaging unit FH /00 All Stahlfolder Box ml Banderoles Designation Packaging unit Banderole 48 mm brown (K) FH /01 Box of 5 reels Banderole 48 mm green (K) FH /01 Box of 5 reels Banderole 48 mm red (K) FH /01 Box of 5 reels Banderole 48 mm white (K) FH /01 Box of 5 reels Banderole 48 mm brown (P) FH /01 Pallet with 150 reels Banderole 48 mm green (P) FH /01 Pallet with 150 reels Banderole 48 mm red (P) FH /01 Pallet with 150 reels Banderole 48 mm white (P) FH /01 Pallet with 150 reels Banderole 30 mm white (K) FH /01 Box of 8 reels Banderole 30 mm brown (K) FH /01 Box of 8 reels Banderole 30 mm green (K) FH /01 Box of 8 reels Banderole 30 mm red (K) FH /01 Box of 8 reels Banderole 30 mm white (P) FH /01 Pallet with 240 reels Banderole 30 mm brown (P) FH /01 Pallet with 240 reels Banderole 30 mm green (P) FH /01 Pallet with 240 reels Banderole 30 mm red (P) FH /01 Pallet with 240 reels 31

32 2. Folders/Consumables Filter cartridges Filter cartridges Filters are used in our Stahlfolders wherever unwanted suspended matter and impurities need to be removed, for instance in compressors and air supply cabinets. Original Heidelberg filters are therefore designed speci f- ic ally for their designated location and reliable air cleaning. All our filters are built to last and therefore ensure long-term machine availability. Filter cartridges for Stahlfolders Designation Cycle CLFT 101 D, TR 41 DV ZD months DVT 2.60 ZD months DVT 2.60 ZD months DVT 2.60, T3.60 DSK ZD months KTA 100/1, KTA 140/2 ZD months KTA 50/1 ZD months KTA 50/1 ZD months KTA 80/1 m ZD months KTA 80/1, KTA 100/1, KTA 140/2 ZD months Picco KLT 40 ZD months Picco KLT 40 ZD months Picco KLT 40 ZD months SKK (10) ZD months SKK (10), SKK (11) (19) ZD months SKK (10), SKK (11) (19) ZD months T 3.40, DVT 2.60, T 3.60 ZD months T 3.41 ZD months T 3.41 ZD months T 3.60 DSK ZD months T 3.60 DSK ZD months T 3.60 DSK ZD months TR 26 DV ZD months TR 26 DV ZD months TR 26 DV ZD months TR 41 DV ZD months TR 41 DV ZD months TR 61 DV ZD months TR 61 DV, TR 81 DV, TR 60 V ZD months TR 81 DV ZD months 32

33 Options for Retrofitting

34 2. Folders/Options for Retrofitting Knife shaft tools Knife shaft tools for the Stahlfolder range Modular machine add-ons generate added value. All our add-ons enable you to produce more variants of your end products and increase your long-term flexibility. For example, the Chan nel Score special scoring device prevents the paper coa t ing from cracking and the paper fibers from breaking during fold ing. It does this inline, during processing in the folder. This means there is no need for additional, expensive and time-consuming scoring on the impression cylinder. Inline proces sing also makes it possible to line up the scoring as closely as possible to the fold. Any corrections required can be easily performed while production is underway. The Channel Score therefore significantly enhances quality and cost-effective ness in the bindery. Knife shaft tools for the Stahlfolder range Designation Strip trimmer prior to parallel fold MWV ZD VG-00 TD 94 prior to parallel fold MWV ZD VE-00 TH, KH, TD 66/78, TMU 66/12 2 nd station prior to parallel fold MWV ZD VE-00 TD 112/142 prior to parallel fold MWV ZD VE-00 KD 56/66/78/94 after the parallel fold MWV ZD VE-00 TI 36 after the parallel fold MWV ZD VE-00 TD 112/142 after the parallel fold MWV ZD VE-00 TI 40, TI 52/55, TD 52 after the parallel fold MWV ZD VE-00 T 56/66 after the parallel fold MWV ZD VE-00 TD after the parallel fold MWV ZD VE-00 KD 56-94, KD after the parallel fold MWV ZD VE-00 KD 66/78/94, KD.2 66/78/94, KHC 66/78 after the parallel fold MWV FH /02 KH 56/66/78, TH 56/66/82 Edge trimming attachment right and left after the parallel fold MWN ZD VE-00 TI 36, TI 36.1, Proline right and left after the parallel fold MWN ZD VE-00 TD 112/142 right and left after the parallel fold MWN ZD VE-00 TX 52/4, T 50/52.3 T, T 52.2/52.3, TI 52/55, KI 55 right and left after the parallel fold MWN ZD VE-00 TD st -4 th station right and left after the parallel fold MWN ZD VG-00 TI 36.1 Proline right and left after the parallel fold MWN ZD VE-00 TD 112/142 right and left after the parallel fold MWN ZD VE-00 KD 56-94, KD Our experts will be pleased to provide technical advice when selecting this service part. The best solution depends on your machine configuration. Please note that not all knife shaft tools can be supplied within 24 hours. 34

35 2. Folders/Options for Retrofitting Knife shaft tools Knife shaft tools for the Stahlfolder range continued Designation Edge trimming attachment right and left after the parallel fold MWN ZD VE-00 KD 66/78/94, KD.2 66/78/94 right and left after the cross fold ZD VE-00 KB 52 right and left after the cross fold ZD VE-00 KB 52 right and left after the threefold ZD VE-00 KD 78, KD.1 78, KD.2 78, KH 78, KHC 78 right and left after the threefold ZD VG-00 KD 94, KD.2 94 right and left after the threefold ZD VG-00 KD 56/66, KD.2 66, KD.1 66, KI 55, KI.1 55, KIZ 55, KH 56/66, KHC 66 right and left after the threefold ZD VG-00 KD 78, KD.1 78, KD.2 78, KH 78, KHC 78 right and left after the threefold ZD VE-00 KD 94, KD.2 94 right and left after the parallel fold FH /04 TH 56/66/82 Punch perforating attachment after the parallel fold MWN ZD VE-00 TX 52/4, T 52.2, T 50, T 52.3, TI 52/55, KI 55, TD 52 after the parallel fold MWN ZD VE-00 KD 56/66/78, KC.2 56/66/78/94 after the parallel fold MWN ZD VE-00 TD 56/66/78/94 after the parallel fold MWN ZD VE-00 TD 112/142 after the parallel fold MWN ZD VE-00 KD 56-94, KD.1 66/78 after the parallel fold MWN ZD VE-00 KD.2 66/78, KD 66-94, KHC 66/78 after the cross fold KZ/KR FH /00 KD.1/KD.2 66/78, KD 66-94, KH 66/78 after the cross fold KTL 3MW FH /00 KD.1/KD.2 66/78, KD 66-94, KH 56-78, KI/KI1.55, KIZ 55 after the threefold ZD VE-00 KD/KD.1/KD.2 66/78, KH 56-78, KHC 66, KI/KI.1 55, KIZ 55 after the three/four fold KLL/KRR/KZRL/KTLL ZD VE-00 KD/KD.1/KD.2 78, KH/KHC 78 after the threefold ZD VE-00 KD/KD.2 94 after the cross fold K/KL FH /00 KD/KD.1/KD.2 66/78, KH 66/78, KI/KI.1 55 after the parallel fold MWN FH /02 TH 56/66/82, KH 56/66/78 after the cross fold ZD VE-00 KD/KD Perforating device after the parallel fold MWN ZD VG-00 TD 112/142 after the parallel fold MWN ZD VE-00 T 36.1/36.2/36U, TI 36 after the parallel fold MWN ZD VE-00 T 36.1/36.2/36U, TI 36 after the parallel fold MWN ZD VE-00 TI 36 after the parallel fold MWN ZD VG-00 TI 52/55, TD 52, T 52.3T, KI 55 after the parallel fold MWN ZD VE-00 TD 56/66/78/94 after the parallel fold MWN ZD VE-00 KD 56/66/78/94, KD.1 66/78 after the parallel fold MWN ZD VG-00 KB 52 + T/TD/TI 52/55 after the parallel fold MWN ZD VG-00 KD 66/78/94, KD.2 66/78, KHC 66/78 after the parallel fold MWN FH /01 KH 56/66/78, TH 56/66/82 prior to the parallel fold MWN ZD VG-00 TD 112/142 prior to/after the parallel fold MWV/MWN ZD BE-01 KD/TD 56-94, KH 56/66/78, TH 56/66/82 after the parallel fold MWN ZD BE-02 TI 40/52/55 after the parallel fold MWN ZD BE-03 TD 112/142 after the parallel fold MWN ZD BE-04 TI 36 after the parallel fold MWN ZD BE-07 TI 36 prior to the parallel fold MWN ZD VE-00 KD 66-94, KD.1/KD.2 66/78, KH/TH, TD after the parallel fold MWN FH /01 KH 56/66/78, TH 56/66/82 35

36 2. Folders/Options for Retrofitting Knife shaft tools Knife shaft tools for the Stahlfolder range continued Designation Perforating, trimming, scoring devices after the cross fold KL/KR/KZ ZD VG-00 KH 56/66/78, KHC 66/78, KD.1/KD.2 66/78, KD 66/78/94 after the cross fold 2MW ZD VG-00 KI/KI.1 55 after the cross fold 2MW ZD VG-00 KI/KI.1 55 after the threefold ZD VG-00 KD/KD.1/KD.2 66, KH 56/66, KHC 66 after the threefold ZD VG-00 KC/KD 78-94, KD.1/KD.2 78, KH 78, KL/KR/KZ/KTL after the threefold ZD VG-00 KC/KD 78, KH/KHC 78, KLL/KRR/KZRL/KTLL after the threefold ZD VG-00 KI/KI.1 55 after the cross fold KTL 3MW ZD VG-00 KH 56/66/78, KI/KI.1 55, KD.1/KD.2 66/78, KD 66/78/94 Perforating device left FH /01 KH 56/66/78, TH 56/66/82 Perforating device right FH /01 KH 56/66/78, TH 56/66/82 Scoring device against rubber ZD VE-00 KI 55, TI 40, TD/TI 52, TI 55 against rubber ZD VE-00 T/T.2/TI/TI.2 36 against rubber ZD VE-00 KD 94, KD.1/KD.2/TD.1 66/78, TD 56-94, TH against PU (image) ZD VE-00 KI 55, TI 40, TD/TI 52, TI 55 against rubber ZD VE-00 TD 112/142 against PU ZD VE-00 KD/TD 56-94, KD.1/KD2. 66/78, KH/TH, KHC 66/78 against PU ZD VE-00 TD 112/142 against PU ZD BE-01 KD/TD 56-94, KD.1/KD2. 66/78, KH/TH, KHC 66/78 against PU ZD BE-02 TD 112/142 against PU ZD BE-03 KI 55, TI 40, TD/TI 52, TI 55 Channel Score ZD VG-00 TI 40/52/55 Channel Score (image page 37) ZD VG-00 KH/TH 56-82, TD 56-94, KD.1/KD.2/TD.1 66/78 Channel Score ZD BG-01 KH/TH 56-82, TD 56-94, KD.1/KD.2/TD.1 66/78 Channel Score ZD BG-02 KI 55, TI 40, TD/TI 52, TI 55 36

37 2. Folders/Options for Retrofitting Knife shaft tools Knife shaft tools for the Stahlfolder range continued Designation Foot trimming device after the cross fold 3MW KT/KTL ZD VE-00 KH/KC 56/66/78, KC.2/KD 56-94, KD.1/KD.2 66/78, KI/KI.1/KIZ 55 after the cross fold 2MW ZD VE-00 KC 56/66/78, KC after the cross fold 2MW ZD VE-00 KD 66-94, KD.1/KD.2 66/78, KH 56/66/78, KHC 66/78, KI/KI.1 55 after the cross fold 3MW KTL ZD VE-00 KD 66/78/94, KD1./KD.2 66/87, KH 56/66/78, KI/KIZ 55 Head trimming device after the cross fold 2MW ZD VE-00 KD 66/78/94, KD.1/KD.2 66/78, KH 56/66/78, KHC 66/78, KI/KI.1 55, KC 56/66/78 after the cross fold 2MW ZD VE-00 KD 66/78/94, KD.1/KD.2 66/78, KH 66/78 after the cross fold 2MW KR/KL/KTL/KRR/ KLL/KTLL/KZRL ZD VE-00 KC 56/66/78, KC after the cross fold 2MW KZ ZD VE-00 KC 56/66/78, KC after the cross fold 3MW KT/KTL ZD VE-00 KH/KC 56/66/78, KC.2/KD 56-94, KD.1/KD.2 66/78, KI/KI.1/KIZ 55 after the cross fold 3MW KTL ZD VE-00 KD 66/78/94, KD1./KD.2 66/78, KH 56/66/78, KI/KIZ 55 Crimping tool after the parallel fold MWN ZD VE-00 KI/KI.1/KIZ 55, KC/KD 56/66/78/94 after the parallel fold MWN ZD VE-00 TD 56/66/78/94 after the parallel fold MWN ZD VE-00 TI 40/52/55 after the parallel fold MWN FH /04 KH 56/66/88, TH 56/66/82 Trimming attachment with double circular knife ZD VE-00 TI 36 with double circular knife ZD BE-05 TI 40/52/55 with double circular knife and PU ZD BE-08 KD 66-94, TD 56-94, MWS/SSP.D 66/94, KD.1/KD.2/TD.1 66/78, KH/TH with double circular knife and PU ZD BE-09 TD 112/142 with double circular knife and PU ZD BE-11 TD 52, TI 40/52/55 with double circular knife ZD VG-00 TD 56-94, TH 56/66/82 37

38 2. Folders/Options for Retrofitting Add-ons Strip trimmer, strip trim before the parallel fold MWV Description/size (mm) ZD VE-00 Stahlfolder TH/KH The strip trimmer is used for strip trimming of multiple-ups, but primarily for parallel-folded sheets. Trimmed strips of between 3 and 15 mm wide are possible. A special hickey remover must be used bet ween the two blades for guiding the trimmings smoothly down wards. The trim quality depends on the paper quality and the thickness of the fold sheets, i.e. the thicker the sheet, the poorer the trim quality. FH /02 Stahlfolder TH/KH see above Edge trimming attachment Description/size (mm) Edge trimming attachment after the threefold section ZD VE-00 Stahlfolder KH 56/66 The edge trimming attachment enables head and foot trimming to be integrated into the folding process for one-up fold sheets. Accurate trimming and problem-free removal of the waste strips are only ensured if the trimming edge is at least 6 mm wide and can be reliably transported by the guide rollers. Edge trimming right and left after the threefold section ZD VE-00 Stahlfolder KH 78 see above Edge trimming attachment R/L after the parallel fold FH /04 Stahlfolder TH/KH see above Punch perforating attachment Description/size (mm) after the cross fold KRBR KZ/KR FH /00 Stahlfolder KH In punch perforating, unlike normal perforating, not only is the paper slit but also rectangular paper particles are punched out. This enhances the product quality of the fold sheet considerably, because the air trapped in the fold sheet can escape even better and wrinkles are avoided. Punch-perforated sheets are also often turned into a book block in the adhesive binder without milling. The signatures remain together and the superior sheet edge adhesion produces a more durable end product. after the cross fold KRBR KTL FH /00 Stahlfolder KH see above after the threefold ZD VE-00 Stahlfolder KH see above 38

39 2. Folders/Options for Retrofitting Add-ons Perforating device after the parallel fold MWV Description/size (mm) FH /01 Stahlfolder TH/KH Paper and lightweight cardboard is scored or perforated in the folder to facilitate subsequent cross folding. Creaser Description/size (mm) against PU ZD VE-00 Stahlfolder TH/KH This is the ideal scoring device for preparing the fold in standard folding operations in order to ensure precision folding with paper thicknesses of gsm. Scoring against polyurethane generates a small, accurate score and ensures precise folding. Unlike with the Channel Score, scoring against polyurethane is not used to prevent the coating from cracking, but in order to execute standard folds precisely, here primarily with several folds running parallel to each other such as letterfolds and concertina folds. against rubber ZD VE-00 Stahlfolder TH/KH see above Channel Score ZD BG-04 Stahlfolder TH/KH Special scoring device for folders used for scoring covers and brochures with grammages of between 150 and 350 gsm. Channel Score prevents the paper coating from cracking and the paper fibers from breaking during folding. A particular advantage is the fact that it processes the printing stock inline inside the folders, which eli minates the need for the additional expensive and time-consuming scoring process on the impression cylinder. Inline processing also makes it possible to line up the score as closely as possible to the fold. Any corrections required are easily performed while production is underway. The Channel Score therefore enhances quality and promotes cost-effective manufacture of print products in the bindery. Edge trimming attachment with double circular knife Description/size (mm) ZD BE-08 Stahlfolder TH/KH Depending on the product requirements, multiple-ups can be separated using a parting cut in the folder. The trim quality depends on the paper quality and the thickness of the fold sheets, i.e. the thicker the sheet, the poorer the trim quality. 39

40 2. Folders/Options for Retrofitting Add-ons Crimping tool after the parallel fold Description/size (mm) FH /04 Stahlfolder TH/KH Crimping is used for finishing concertina-folded sheets on the saddlestitcher, protective covers on adhesive binders and in the manufacture of batches, where tear-off perforation for detaching is possible in addition to crimping. Crimping is a combination of per forating and embossing. The various layers of paper stick together, joining the sheets. Antistatic upgrade kit (1st station) for Stahlfolder TH/KH Description/size (mm) FH /00 Stahlfolder TH/KH 82 (for working width 82) FH /00 Stahlfolder TH/KH 66 (for working width 66) FH /00 Stahlfolder TH/KH 56 (for working width 56) Statically charged papers disrupt the production workflow relatively often in the folder. Passive measures like the use of nickel-coated buckle plates with carbon-fiber brushes help reduce this disruption. Static charges are most effectively removed by active measures (ionization rods). see above see above 40

41 Did you know that over 95% of all Original Heidelberg Service Parts are delivered within 24 hours? Heidelberg Systemservice boasts an ultramodern lo gistics network. At its heart is the World Logistics Center in Wiesloch, which stocks over 130,000 service parts. North and Central America are supplied directly by the American Logistics Center in Indianapolis, while Asia s parts come from the Japanese Logistics Center in Tokyo and the Hong Kong Logistics Center. Every day, 1,600 customers around the world receive Original Heidelberg Service Parts within 24 hours.

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43 Saddlestitchers Folders This is the place to find service parts: Our catalog lists popular service parts together with their article number and the machines in which they are used. These are clearly categorized into mechanical and electrical/electronic parts. The options section includes accessories to make your machine even more productive. Unfortunately, as space in this catalog is limited, we have been unable to include all our service parts. If you can t find the part you are looking for, please give us a call. We ll be happy to find it for you. Easy to find. Our index on page 93 lists all the service parts included in the catalog, together with the relevant page number. Looking for other service parts? Technical assistance. We have marked a number of our service parts with the symbol. All these parts differ from each other depending on the specific machine con figuration. Please telephone our Systemservice experts to discuss your tec h ni cal re quirements. How much does my service part cost? Your Heidelberg Systemservice team will be happy to provide you with information on prices. See the back page of the catalog. Who installs the service parts? We have marked a number of service parts with the symbol. We recommend always having these parts replaced by a Heidelberg Systemservice engineer. Mechanical Parts Electrical and Electronic Parts Saddlestitchers Consumables Check out one of the other Heidelberg part catalogs: Original Heidelberg Service Parts for Presses and CtP Devices Original Heidelberg Service Parts for Die Cutters and Folder Gluers Stahlfolder Performance Blades Any questions? Just give us a call. If you are finding it difficult to track down an article, hav ing problems installing a service part or looking for assis tance, we ll be happy to help. Useful telephone num bers can be found at the back of our catalog or on line at

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45 Mechanical Parts Mechanical Parts Saddlestitchers Consumables Electrical and Electronic Parts Mechanical Parts Folders

46 3. Saddlestitchers/Mechanical Parts Stitching heads Stitching heads Stitching heads are a very important component of our Stitchmaster saddlestitchers and need to be very hardwearing and easy to operate. All Original Heidelberg stitching heads are therefore designed to be highly durable. They are made from premium grade materials regularly tested for durability and low wear in fatigue and load tests. A further advantage is the optimized stitch spacing of 45 mm on the stitching heads. The innovative changeover system and control panel for man ual wire cutting further shorten makeready times. Ensure the productivity of your Stitchmaster saddlestitcher and keep it working at full capacity with Original Heidelberg stitching heads. Benefits for customers Longer service life thanks to low wear (reduced downtimes) Optimized 45 mm stitch spacing Shorter makeready times Innovative changeover system and control panel for manual wire cutting Stitching heads for Stitchmaster Designation Description/size (mm) Normal stitching head Normal stitching head 45 N FJ /02 Stitchmaster ST 400, ST 450 for processing stitching wire No. 21 (0.8 mm) to No. 23 (0.7 mm) Normal stitching head 45 N FJ /02 Stitchmaster ST 400, ST 450 for processing stitching wire No. 24 (0.6 mm) to No. 28 (0.4 mm) Normal stitching head 45 N FJ /02 Stitchmaster ST 400, ST 450 for processing stitching wire No. 26 (0.5 mm) to No. 30 (0.35 mm) Loop stitching heads Loop stitching head 50 L6 FJ /02 Stitchmaster ST 400, ST 450 Loop stitching head 50 L8 FJ /02 Stitchmaster ST 400, ST 450 Retrofit sets Set* with normal stitching head 45 N FJ /03 Stitchmaster ST 400 Set* with loop stitching head 50 L6 FJ /03 Stitchmaster ST 400 *Set with two stitching heads and additional small parts 46

47 3. Saddlestitchers/Mechanical Parts Stitching heads Stitching heads for Stitchmaster Designation Description/size (mm) Small stitching heads Small stitching head 48-N on request Stitchmaster ST 250, ST 270, ST 300, ST 350 Small stitching head 48-N FJ /01 Stitchmaster ST 250, ST 270, ST 300, ST 350 Small stitching head 48-N on request Stitchmaster ST 250, ST 270, ST 300, ST 350 Normal stitching heads Normal stitching head 52-N on request Stitchmaster ST 250, ST 270, ST 300, ST 350 Normal stitching head 52-N FJ /01 Stitchmaster ST 250, ST 270, ST 300, ST 350 Normal stitching head 52-N on request Stitchmaster ST 250, ST 270, ST 300, ST 350 Loop stitching heads Loop stitching head 52-L6 FJ /01 Stitchmaster ST 250, ST 270, ST 300, ST 350 Loop stitching head 52-L8 on request Stitchmaster ST 250, ST 270, ST 300, ST 350 Retrofit sets Set* with small stitching head 48-N Set* with small stitching head 52-N FJ /01 Stitchmaster ST 250, ST 270, ST 300, ST 350 FJ /01 Stitchmaster ST 250, ST 270, ST 300, ST 350 Set* with small stitching head 52-L6 FJ /01 Stitchmaster ST 250, ST 270, ST 300, ST 350 *Set with two stitching heads and additional small parts for processing stitching wire No. 21 (0.8 mm) to No. 23 (0.7 mm) for processing stitching wire No. 24 (0.6 mm) to No. 28 (0.4 mm) for processing stitching wire No. 26 (0.5 mm) to No. 30 (0.35 mm) for processing stitching wire No. 21 (0.8 mm) to No. 23 (0.7 mm) for processing stitching wire No. 24 (0.6 mm) to No. 28 (0.4 mm) for processing stitching wire No. 26 (0.5 mm) to No. 30 (0.35 mm) Stitching heads for Stitchmaster Designation Description/size (mm) Small stitching heads Small stitching head 52-N on request Stitchmaster ST 100 for processing stitching wire No. 21 (0.8 mm) to No. 23 (0.7 mm) Small stitching head 48-N FJ /02 Stitchmaster ST 100 for processing stitching wire No. 24 (0.6 mm) to No. 28 (0.4 mm) Small stitching head 48-N on request Stitchmaster ST 100 for processing stitching wire No. 26 (0.5 mm) to No. 30 (0.35 mm) Normal stitching heads Normal stitching head 52-N on request Stitchmaster ST 100 for processing stitching wire No. 21 (0.8 mm) to No. 23 (0.7 mm) Normal stitching head 52-N FJ /02 Stitchmaster ST 100 for processing stitching wire No. 24 (0.6 mm) to No. 28 (0.4 mm) Normal stitching head 52-N on request Stitchmaster ST 100 for processing stitching wire No. 26 (0.5 mm) to No. 30 (0.35 mm) 47

48 3. Saddlestitchers/Mechanical Parts Stitching heads/knives Stitching heads for Stitchmaster Designation Description Loop stitching heads Loop stitching head 52-L6 FJ /02 Stitchmaster ST 100 Loop stitching head 52-L8 on request Stitchmaster ST 100 Retrofit sets Set* with small stitching head 48-N14, FJ /01 Stitchmaster ST 100 Set* with normal stitching head 52-N14, FJ /01 Stitchmaster ST 100 Set* with loop stitching head 52-L6 FJ /01 Stitchmaster ST 100 *Set with two stitching heads and additional small parts Trimmer knives Trimmer knives work like scissors, i.e. knife against knife. To ensure maximum precision, we set extremely high standards for the material and cutting quality of our Original Heidelberg trimmer knives. High speed steel (HSS) is used as standard for the upper knife and chrome steel for the lower knife, i.e. the HSS blade is made from a composite material, while the chrome steel blade is made from solid material. The correct blade geometry evenness, angular dimensions, straightness of cut also has a significant influ ence on the durability of the blades. We can offer you a broad selection of Original Heidelberg cutting knives, punching knives and cut-off knives specially designed for our Stitchmaster saddlestitchers. The benefits for you Paper cutting knives in hard-wearing HSS quality Tolerances of a few hundredths ensured Shorter makeready times Optimum cutting performance Optimum matching of material quality and knife geometry Cutting knives for Stitchmaster Designation Description Knife set MS 100 FJ /01 Stitchmaster ST (from machine No incl. No. 0184) Complete knife set for ST 100.2, consisting of 3 upper knives and 3 lower knives, incl. reliable transport packaging Upper knife (V) FJ /02 see above Single upper knife front Upper knife (S) ZD BG-01 see above Single upper knife side Lower knife (V) FJ /01 see above Single lower knife front Lower knife (S) ZD BG-01 see above Single lower knife side 48

49 3. Saddlestitchers/Mechanical Parts Knives Cutting knives for Stitchmaster continued Designation Description Knife set MS ZD BE-01 Stitchmaster ST 100.2, ST 100.1, ST 100 (up to machine No. 0188, except No. 0184) Complete knife set for ST 100.2, ST 100.1, ST 100 consisting of 3 upper knives and 3 lower knives incl. secure transport packaging Upper knife complete ZD BG-01 see above Single upper knife Lower knife complete ZD BG-01 see above Single lower knife Knife set MS ZD BE-01 Stitchmaster ST 250, ST 270, ST 300 (from machine No. 0058) Upper knife (V) ZD see above Single upper knife front Upper knife (S) ZD see above Single upper knife side Lower knife (V) ZD see above Single lower knife front Lower knife ZD see above Single lower knife side Complete knife set for ST 270 and ST 300, consisting of 3 upper knives and 3 lower knives incl. secure transport packaging Knife set MS ZD BE-01 Stitchmaster ST 300 (up to machine No. 0057) Upper knife (V) ZD see above Single upper knife front Upper knife (S) ZD see above Single upper knife side Lower knife (V) ZD see above Single lower knife front Lower knife ZD see above Single lower knife side Complete knife set for ST 250, ST 270 and ST 300, consisting of 3 upper knives and 3 lower knives incl. secure transport packaging Knife set MS FJ /01 Stitchmaster ST 350, ST 450 Upper knife (V) FJ /01 see above Single upper knife front Upper knife (S) FJ /01 see above Single upper knife side Lower knife (V) ZD see above Single lower knife front Lower knife (S) FJ /01 see above Single lower knife side Complete knife set for ST 350 and ST 450, consisting of 3 upper knives and 3 lower knives incl. secure transport packaging Knife set MS FJ /01 Stitchmaster ST 400 Complete knife set for ST 300, consisting of 3 upper knives and 3 lower knives incl. secure transport packaging Upper knife (V) FJ /01 see above Single upper knife front Upper knife (S) FJ /01 see above Single upper knife side Lower knife (V) ZD see above Single lower knife front Lower knife ZD see above Single lower knife side All Heidelberg knives are supplied with secure transport packaging included. 49

50 3. Saddlestitchers/Mechanical Parts Knives Punching knives for Stitchmaster Designation Description Set of punching knives SMS 4 mm FJ /01 Stitchmaster ST 100.1, ST Complete set of 4 mm punching knives for ST 100.1, ST 100.2, consisting of one punching knife and two lower knives Punching knife 4 mm ZD BG-01 see above Single punching knife 4 mm Lower knife ZD see above Single lower knife Set of punching knives SMS 5 mm FJ /01 Stitchmaster ST 100.1, ST Complete set of 5 mm punching knives for ST 100.1, ST 100.2, consisting of one punching knife and two lower knives Punching knife SM 5 mm ZD BE-01 see above Single punching knife 5 mm Lower knife ZD see above Single lower knife Set of punching knives SMS 6 mm ZD BE-01 Stitchmaster ST 100, ST 100.1, ST Complete set of 6 mm punching knives for ST 100, ST 100.1, ST 100.2, consisting of one punching knife and two lower knives Punching knife SM 6 mm ZD BG-01 see above Single punching knife 6 mm Lower knife complete ZD BG-01 see above Single lower knife Set of punching knives SMS 8 mm FJ /01 Stitchmaster ST 100.1, ST Complete set of 8 mm punching knives for ST 100.1, ST 100.2, consisting of one punching knife and two lower knives Punching knife SM 8 mm ZD BG-01 see above Single punching knife 8 mm Lower knife ZD see above Single lower knife All Heidelberg knives are supplied with secure transport packaging included. 50

51 3. Saddlestitchers/Mechanical Parts Knives Punching knives for Stitchmaster continued Designation Description Set of punching knives SMS 10 mm FJ /01 Stitchmaster ST Complete set of 10 mm punching knives for ST 100.2, consisting of one punching knife and two lower knives Punching knife SM 10 mm ZD BG-01 see above Single punching knife 10 mm Lower knife ZD see above Single lower knife Set of punching knives SMS 4 mm ZD BE-01 Stitchmaster ST 250, ST 270, ST 300 Complete set of 4 mm punching knives for ST 250, ST 270 and ST 300, consisting of one punching knife and two lower knives Punching knife SM 4 mm ZD BG-01 see above Single punching knife 4 mm Lower knife ZD see above Single lower knife Set of punching knives SMS 5 mm ZD BE-01 Stitchmaster ST 250, ST 270, ST 300 Complete set of 5 mm punching knives for ST 250, ST 270 and ST 300, consisting of one punching knife and two lower knives Punching knife SM 5 mm ZD BE-01 see above Single punching knife 5 mm Lower knife ZD see above Single lower knife Set of punching knives SMS 6 mm ZD BE-01 Stitchmaster ST 250, ST 270, ST 300 Complete set of 6 mm punching knives for ST 250, ST 270 and ST 300, consisting of one punching knife and two lower knives Punching knife SM 6 mm ZD BG-01 see above Single punching knife 6 mm Lower knife ZD see above Single lower knife Set of punching knives SMS 8 mm ZD BE-01 Stitchmaster ST 250, ST 270, ST 300 Complete set of 8 mm punching knives for ST 250, ST 270 and ST 300, consisting of one punching knife and two lower knives Punching knife 8 mm ZD BG-01 see above Single punching knife 8 mm Lower knife ZD see above Single lower knife Set of punching knives SMS 9 mm ZD BE-01 Stitchmaster ST 250, ST 270, ST 300 Complete set of 9 mm punching knives for ST 250, ST 270 and ST 300, consisting of one punching knife and two lower knives Punching knife SM 9 mm ZD BG-01 see above Single punching knife 9 mm Lower knife ZD see above Single lower knife Set of punching knives SMS 10 mm ZD BE-01 Stitchmaster ST 250, ST 270, ST 300 Complete set of 10 mm punching knives for ST 250, ST 270 and ST 300, consisting of one punching knife and two lower knives Punching knife SM 10 mm ZD BG-01 see above Single punching knife 10 mm Lower knife ZD see above Single lower knife All Heidelberg knives are supplied with secure transport packaging included. 51

52 3. Saddlestitchers/Mechanical Parts Knives Punching knives for Stitchmaster continued Designation Description Set of punching knives SMS 12 mm ZD BE-01 Stitchmaster ST 250, ST 270, ST 300 Complete set of 12 mm punching knives for ST 250, ST 270 and ST 300, consisting of one punching knife and two lower knives Punching knife SM 12 mm ZD BG-01 see above Single punching knife 12 mm Lower knife ZD see above Single lower knife Set of punching knives SMS 4 mm FJ /00 Stitchmaster ST 350, ST 400, ST 450 Complete set of 4 mm punching knives for ST 350, ST 400 and ST 450, consisting of one punching knife and two lower knives Punching knife SM 4 mm ZD BG-01 see above Single punching knife 4 mm Lower knife FJ /00 see above Single lower knife Set of punching knives SMS 5 mm FJ /00 Stitchmaster ST 350, ST 400, ST 450 Complete set of 5 mm punching knives for ST 350, ST 400 and ST 450, consisting of one punching knife and two lower knives Punching knife SM 5 mm ZD BE-01 see above Single punching knife 5 mm Lower knife FJ /00 see above Single lower knife Set of punching knives SMS 6 mm FJ /00 Stitchmaster ST 350, ST 400, ST 450 Complete set of 6 mm punching knives for ST 350, ST 400 and ST 450, consisting of one punching knife and two lower knives Punching knife SM 6 mm ZD BG-01 see above Single punching knife 6 mm Lower knife FJ /00 see above Single lower knife Set of punching knives SMS 8 mm FJ /00 Stitchmaster ST 350, ST 400, ST 450 Complete set of 8 mm punching knives for ST 350, ST 400 and ST 450, consisting of one punching knife and two lower knives Punching knife SM 8 mm ZD BG-01 see above Single punching knife 8 mm Lower knife FJ /00 see above Single lower knife Set of punching knives SMS 9 mm FJ /00 Stitchmaster ST 350, ST 400, ST 450 Complete set of 9 mm punching knives for ST 350, ST 400 and ST 450, consisting of one punching knife and two lower knives Punching knife SM 9 mm ZD BG-01 see above Single punching knife 9 mm Lower knife FJ /00 see above Single lower knife Set of punching knives SMS 10 mm FJ /00 Stitchmaster ST 350, ST 400, ST 450 Complete set of 10 mm punching knives for ST 350, ST 400 and ST 450, consisting of one punching knife and two lower knives Punching knife SM 10 mm ZD BG-01 see above Single punching knife 10 mm Lower knife FJ /00 see above Single lower knife Set of punching knives SMS 12 mm FJ /00 Stitchmaster ST 350, ST 400, ST 450 Complete set of 12 mm punching knives for ST 350, ST 400 and ST 450, consisting of one punching knife and two lower knives Punching knife SM 12 mm ZD BG-01 see above Single punching knife 12 mm Lower knife FJ /00 see above Single lower knife All Heidelberg knives are supplied with secure transport packaging included. 52

53 3. Saddlestitchers/Mechanical Parts Knives Punching knives for Stitchmaster with air connection Designation Description Set of punching knives SMS 6 mm air ZD BE-01 Stitchmaster ST 250, ST 270, ST 300 Complete set of 6 mm punching knives with air connection for ST 250, ST 270 and ST 300, consisting of one punching knife and two lower knives Punching knife SM 6 mm air ZD see above Single punching knife 6 mm with air Lower knife ZD see above Single lower knife Set of punching knives SMS 8 mm air ZD BE-01 Stitchmaster ST 250, ST 270, ST 300 Complete set of 8 mm punching knives with air connection for ST 250, ST 270 and ST 300, consisting of one punching knife and two lower knives Punching knife SM 8 mm air ZD see above Single punching knife 8 mm with air Lower knife ZD see above Single lower knife Set of punching knives SMS 6 mm air FJ /00 Stitchmaster ST 350, ST 400, ST 450 Complete set of 6 mm punching knives with air connection for ST 350, ST 400 and ST 450, consist ing of one punching knife and two lower knives Punching knife SM 6 mm air ZD see above Single punching knife 6 mm with air Lower knife FJ /00 see above Single lower knife Set of punching knives SMS 8 mm air FJ /00 Stitchmaster ST 350, ST 400, ST 450 Complete set of 8 mm punching knives with air connection for ST 350, ST 400 and ST 450, consisting of one punching knife and two lower knives Punching knife SM 8 mm air ZD see above Single punching knife 8 mm with air Lower knife FJ /00 see above Single lower knife Set of punching knives SMS 9 mm air FJ /01 Stitchmaster ST 350, ST 400, ST 450 Complete set of 9 mm punching knives with air connection for ST 350, ST 400 and ST 450, consisting of one punching knife and two lower knives Punching knife SM 9 mm air FJ /00 see above Single punching knife 9 mm with air Lower knife FJ /00 see above Single lower knife Set of punching knives SMS 10 mm air FJ /01 Stitchmaster ST 350, ST 400, ST 450 Complete set of 10 mm punching knives with air connection for ST 350, ST 400 and ST 450, consisting of one punching knife and two lower knives Punching knife SM 10 mm air FJ /00 see above Single punching knife 10 mm with air Lower knife FJ /00 see above Single lower knife Set of punching knives SMS 12 mm air FJ /01 Stitchmaster ST 350, ST 400, ST 450 All Heidelberg knives are supplied with secure transport packaging included. Complete set of 12 mm punching knives with air connection for ST 350, ST 400 and ST 450, consisting of one punching knife and two lower knives 53

54 3. Saddlestitchers/Mechanical Parts Knives Cut-off knives for Stitchmaster Designation Description Set of cut-off knives TMS ZD BE-01 Stitchmaster ST 270, ST 300 Cut-off knife ZD see above Single cut-off knife Lower knife ZD see above Single lower knife Complete set of cut-off knives for ST 270 and ST 300, consisting of one cut-off knife and one lower knife Set of cut-off knives TMS FJ /01 Stitchmaster ST 350 Complete set of cut-off knives for ST 350, consisting of one cut-off knife and one lower knife Cut-off knife FJ /00 see above Single cut-off knife Lower knife FJ /00 see above Single lower knife Set of cut-off knives TMS FJ /00 Stitchmaster ST 270, ST 300, ST 350, ST 400, ST 450 Cut-off knife ZD see above Single cut-off knife Lower knife FJ /00 see above Single lower knife Complete set of cut-off knives for ST 270 to ST 450, consisting of one cut-off knife and one lower knife Set of cut-off knives Trio TMS ZD BE-01 Stitchmaster ST 270, ST 300, ST 350, ST 400, ST 450 Cut-off knife ZD see above Single cut-off knife Lower knife ZD see above Single lower knife All Heidelberg knives are supplied with secure transport packaging included. Complete set of cut-off knives for ST 270 to ST 450, consisting of two cut-off knives and two lower knives 54

55 3. Saddlestitchers/Mechanical Parts Belts Belts for Stitchmaster* The transport belts of the trimmers transport the paper sheet to the slitting discs. Good grip and precise movement are therefore key factors in producing accurately trimmed products. Our Original Heidelberg transport belts have been specially adapted to the needs of our saddlestitchers and are therefore very different from standard belts that may, at first glance, look similar. Choosing the right material is also crucial for ensuring our Original Heidelberg belts work with very low vibration even at extremely high speeds and deliver premium quality over the long term. Only Original Heidelberg belts ensure you can get top performance from your saddlestitcher over its entire, broad application spectrum. Folding belts Designation Belt FJ /00 All Stitchmaster* Round belts Designation Round belt ZD All Stitchmaster* Round belt ZD All Stitchmaster* Set of toothed belts Designation Set of toothed belts upper (2 belts) Set of toothed belts lower (2 belts) Set of toothed belts upper (2 belts) Set of toothed belts lower (2 belts) ZD Stitchmaster ST 250, ST 270, ST 300, ST 350, ST 400 and ST 450* ZD Stitchmaster ST 250, ST 270, ST 300, ST 350, ST 400 and ST 450* FJ /01 Stitchmaster ST 350 and ST 450* FJ /01 Stitchmaster ST 350 and ST 450* Belts Designation Belt ZD All Stitchmaster machines except for ST 100* Belt ZD All Stitchmaster machines except for ST 100* Belt ZD All Stahlfolder* Set of toothed belts Designation Set of toothed belts lower (2 belts) Set of toothed belts upper (2 belts) FJ /01 Stitchmaster ST 100.1, ST 100.2* FJ /01 Stitchmaster ST 100.1, ST 100.2* Belts Designation Chip transport tape ZD Our experts will be pleased to provide technical advice when selecting this service part. The best solution depends on your machine configuration. * A Heidelberg Systemservice engineer should exchange and adjust belts that are difficult to access. 55

56 3. Saddlestitchers/Mechanical Parts Suckers Suckers for Stitchmaster Original Heidelberg suckers are particularly resistant to wear. They are manufactured by our partners in the plastics industry from special plastics with a composition specifically chosen to reliably deliver the required suction force. Our suckers therefore have exactly the right qualities to meet the high standards of our Stitchmaster saddlestitchers. Trust our experience and Heidelberg quality tried and tested in load and fatigue tests. Plate sucker Sucker Sucker No. 1 ZD All Stitchmaster ZD All Stitchmaster ZD All Stitchmaster Knob sucker Sucker No. 2/Gripper pad Sucker No. 3 ZD All Stitchmaster ZD All Stitchmaster ZD All from S1000 ZD All from S1000 Sucker ZD Stitchmaster ST 100 Short neck sucker blue ZD Stitchmaster ST 100 Long neck sucker ZD Stitchmaster ST 100 Our experts will be pleased to provide technical advice when selecting this service part. The best solution depends on your machine configuration. 56

57 3. Saddlestitchers/Mechanical Parts Suckers/Plugs/Covers Suckers for Stitchmaster ST 100 Suckers Other suckers Designation Sucker (image) Short neck sucker Long neck sucker Knob sucker ZD ZD ZD ZD ZD (image) Stitchmaster ST 300, ST 350 ZD Stitchmaster ST 400 ZD /1 872/875/831 (image) ZD /1 872/875/831 ZD /1 872/875/831 ZD /1 872/875/831 ZD /1 872/875/831 ZD /1 872/875/831 Square plug Cover Threaded plug ZD Thread-sealing machine FS 100, Stitchmaster ST 300 ZD Stitchmaster ST 300 ZD Stitchmaster ST 300 Plug Tapered plug Plug ZD All Stitchmaster ZD From Stitchmaster ST 400 FJ /00 Stitchmaster ST 450 Our experts will be pleased to provide technical advice when selecting this service part. The best solution depends on your machine configuration. 57

58 3. Saddlestitchers/Mechanical Parts Drivers Driver ZD Stitchmaster ST Driver ZD Stitchmaster ST Driver FJ /01 Stitchmaster ST 350 Driver long ZD Stitchmaster ST 300 Driver split ZD Stitchmaster ST 300 Driver broadened ZD Stitchmaster ST 300 Driver complete, back FJ /00 Stitchmaster ST 400, ST 450 Driver complete, front FJ /00 Stitchmaster ST 400, ST 450 Driver complete, back ZD BG-01 Stitchmaster ST 400 Driver complete, front ZD BG-01 Stitchmaster ST

59 3. Saddlestitchers/Mechanical Parts Fold pressing units/chain covers Fold pressing unit right FJ /01 Stitchmaster ST 300 Fold pressing unit narrow FJ /01 Stitchmaster ST 300 Fold pressing unit external FJ /01 Stitchmaster ST 450 Chain cover FJ /01 Stitchmaster ST 400, ST 450 Other options for further enhancing the performance of your saddlestitchers can be found on page 74 ff. Why not take advantage of the benefits offered by the new Original Heidelberg stitching heads (page 46 ff)! Did you know that regular maintenance checks from Heidelberg Systemservice can help increase the resale value of your machinery by 7.5 percent. That was the finding of a survey Heidelberg conducted among customers and prospective purchasers. It also revealed that 77 percent of those surveyed felt there was a positive link between the resale value of machinery and its maintenance status. Our experts will be pleased to provide technical advice when selecting this service part. The best solution depends on your machine configuration. 59

60 3. Saddlestitchers/Mechanical Parts Bearings Bearings for Stitchmaster All the bearings we use are specially designed for use in our highly developed production systems. Original Heidelberg bearings are made from high-grade, fatigue-tested materials that far exceed the standard material specifications. This ensures a high load-bearing capacity and maximizes their service lives. Grooved ball bearing Grooved ball bearing Grooved ball bearing ZD Stitchmaster ST 300 to ST Stitchmaster ST 300 to ST 450 ZD All Stitchmaster Bearing with shaft Self-aligning roller bearing Needle bearing ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 Angular contact ball bearing ZD Stitchmaster ST 350, ST 400, ST 450 Linear ball bearing ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 Self-aligning ball bearing ZD Stitchmaster ST Other options are available in addition to the bearings listed here. Just give us a call. We recommend always having these parts replaced by a Heidelberg Systemservice engineer. 60

61 3. Saddlestitchers/Mechanical Parts Cam followers Cam followers for Stitchmaster Original Heidelberg cam followers are made from highgrade roller-bearing steels that far exceed the standard specifications. They are tested for high load-bearing capacity and long ser vice life in continuous fatigue tests and also regularly un der go rounds of enhancements. Their use therefore not only prevents machine downtimes, but also offers the benefits of long re place ment cycles. Cam followers Idler rollers for Stitchmaster ZD (image) Stitchmaster ST 100.2, ST 300, ST 350, ST 400, ST 450 ZD (image) Stitchmaster ST 100.2, ST 300, ST 400, ST 450 FJ /01 Stitchmaster ST 400, ST 450 ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 ZD Stitchmaster ST 400, ST 450 ZD Stitchmaster ST 100.2, ST 300, ST 350, ST 400, ST 450 ZD Stitchmaster ST 100.2, ST 350, ST 400, ST 450 ZD BG-01 Stitchmaster ST 300, with adhesive tape ST 350, ST 400, ST 450 ZD Stitchmaster ST 400, ST 450 ZD Stitchmaster ST ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 ZD Stitchmaster ST ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 ZD Stitchmaster ST 100.2, ST 300, ST 350, ST 400, ST 450 ZD Stitchmaster ST 100.2, ST 300, ST 350, ST 400, ST 450 FJ /03 Stitchmaster ST 400, ST 450 FJ /04 Stitchmaster ST 400, ST 450 ZD BG-01 Stitchmaster ST 350, ST 400, ST 450 ZD Stitchmaster ST 300, ST 350 ZD Stitchmaster ST 350, ST 400, ST 450 ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 ZD Stitchmaster ST 350, ST 400, ST 450 ZD Stitchmaster ST 400, ST 450 ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 ZD Stitchmaster ST 300 Our experts will be pleased to provide technical advice when selecting this service part. The best solution depends on your machine configuration. 61

62 3. Saddlestitchers/Mechanical Parts Springs Springs for Stitchmaster Springs need to function highly efficiently to achieve fast pro cessing speeds and smooth production. All Original Heidelberg springs are designed for maximum load-bearing and are made of premium-grade steels and hard-wearing materials. Their geometry is regularly tested and revised. Pneumatic spring ZD Stitchmaster ST 300, ST 400 Gas spring FJ /00 Stitchmaster ST Gas spring FJ /01 Stitchmaster ST 350, ST 400, ST 450 Compression spring Compression spring Compression spring ZD Stitchmaster ST 350 ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 ZD All Stitchmaster Tension spring Tension spring Tension spring ZD All Stitchmaster ZD All Stitchmaster ZD Stitchmaster ST 300, ST 350 Other options are available in addition to the springs listed here. Just give us a call. We recommend always having these parts replaced by a Heidelberg Systemservice engineer. 62

63 3. Saddlestitchers/Mechanical Parts Needles/Needle supports/needle bushings Needles, needle supports and needle bushings Needles, needle supports and needle bushings are used to fix the paper sheet during saddlestitching. The precision of their movement is therefore a crucial quality factor. All our Original Heidelberg needles, needle supports and needle bushings are made from hard-wearing steels and specially adapted to their particular tasks in terms of their function and design. They are regularly tested in our testing laboratory to en sure long-term stable results, stable production without downtimes and high-quality end results. Needle backward ZD Stitchmaster ST Needle ZD Stitchmaster ST 300, ST 400, ST 450 Needle ZD Stitchmaster ST Needle bushing ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 Needle bushing ZD Stitchmaster ST 300, ST 350 Needle bushing ZD Stitchmaster ST 100.2, ST 300, ST 350, ST 400, ST 450 Needle support complete FJ /00 Stitchmaster ST 350 We recommend always having these parts replaced by a Heidelberg Systemservice engineer. 63

64 3. Saddlestitchers/Mechanical Parts Brushes Brushes for Stitchmaster One of the functions of brushes in Heidelberg machines is to ensure reliable paper transport in the feeder where they have a considerable influence on the quality of the results. Original Heidelberg brushes are therefore made exclusively from high-grade, durable materials for top quality and minimal wear. Brush long Brush flat Brush complete ZD Stitchmaster ST 300 ZD Stitchmaster ST 100.2, ST 300, ST 350, FS 100 ZD BG-01 ZD BG-01 Stitchmaster ST 100.2, ST 300, ST 350, ST 400, ST 450 Stitchmaster ST 100.2, ST 300, ST 350, ST 400, ST 450 Did you know that Heidelberg Systemservice is geared to your entire value-added chain from prepress to press and postpress? Heidelberg Systemservice helps you opti mize results and keeps you at the cutting-edge of tech nology. Our experts analyze your processes and identify potential for optimization. Are you planning changes to your company? We can help you with project planning and printshop design and advise you on financing and safeguarding your new machines through innovative financial services. 64

65 Electrical and Electronic Parts Electrical and Electronic Parts Mechanical Parts Saddlestitchers Consumables Electrical and Electronic Parts Mechanical Parts Folders

66 3. Saddlestitchers/Electrical and Electronic Parts Fuses Fuses for Stitchmaster Choosing the right fuses is very impor tant to get the best out of your machines. Many faults occur as a result of incor rect fuse selection. Often the models offered on the market only differ minimally from the Original Heidelberg fuse. The conse quences of using the wrong fuse can be very serious, however, if for example a control unit fuses because fuse protec tion is insufficient. That s why all our Original Heidelberg fuses are precisely matched to the requirements of the relevant machine. This ensures opti mum quality and long term smooth operation. Fuses Designation Fuses Designation Fuse 14 51, 40 A Fuse 14 51, 20 A FJ /01 Stitchmaster ST 400, ST 450 FJ /01 Stitchmaster ST 400, ST 450 Fuse 5 20, 1.6 A Fuse 5 20, 2 A ZD Stitchmaster ST 100.2, ST 300, ST 350, ST 400, ST 450 ZD Stitchmaster ST 100.2, ST 300, ST 350, ST 400, ST 450 Fuse 5 20, 6.3 A ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 Fuse 5 20, 5 A ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 Fuse 5 20, 2.5 A ZD Stitchmaster ST

67 3. Saddlestitchers/Electrical and Electronic Parts Lamps Signal lamp Warning lamp Fluorescent lamp FJ /01 Stitchmaster ST 100.2, ST 350, ST 400, ST 450 FJ /00 Stitchmaster ST 450 ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 Fluorescent tube Lamp mm ZD Stitchmaster ST 300, ST 350, ST 400, ST 450 ZD Stitchmaster ST 100.2, ST 300, ST 350, ST 400, ST 450 Other options are available in addition to the lamps listed here. Just give us a call. Our experts will be pleased to provide technical advice when selecting this service part. The best solution depends on your machine configuration. 67

68 3. Saddlestitchers/Electrical and Electronic Parts Switches/Resistors Switches and resistors for Stitchmaster Switches and resistors keep your machine running reliably over the long term. They therefore play a key role in ensuring a fault-free production process. All switches, sensors and buttons used in Heidelberg machinery have specially developed properties and are selected to ensure optimum operation of your machine. They are made from robust, low-wear materials tested for durability in fatigue tests. This means you can always rely on Original Heidelberg quality to keep your production system running smoothly. Electric lifting magnet ZD Stitchmaster ST Light barrier ZD Stitchmaster ST 100.2, ST 300, ST 350, ST 400, ST 450 Reflex sensor Sensor ZD Stitchmaster ST 100.2, ST 300, ST 350, ST 400, ST 450 ZD Stitchmaster ST 300 Other options are available in addition to the switches listed here. Just give us a call. We recommend always having these parts replaced by a Heidelberg Systemservice engineer. 68

69 Consumables Consumables Electrical and Electronic Parts Mechanical Parts Saddlestitchers Consumables Electrical and Electronic Parts Mechanical Parts Folders

70 3. Saddlestitchers/Consumables Stitching wire Saphira Allround stitching wire for Stitchmaster* Allround stitching wire is versatile and suitable for most applications. It is manufactured according to our quality standards in Germany, is ideally suited to processing on all of our Stitchmaster saddlestitchers and delivers highly accurate results. The wire features excellent glide performance in the stitching head, low abrasion and an attractive stitch like appearance. A wide selection of wire thicknesses and coil sizes is available. The standard sizes Nos. 24 to 26 are permanently kept in stock and other wires can be supplied within two to three working days. Special sizes and grades are also possible. Under the brand name Saphira, Heidelberg offers a broad range of consumables covering your entire production needs in Prepress, Press, and Postpress. Our consumables have been tested and carefully selected by our experts to be the optimal fit for your solutions. Saphira Stitching Wire Allround* Designation 21 (0.80 mm) 22 (0.75 mm) 23 (0.70 mm) 24 (0.60 mm) 25 (0.55 mm) Description K155 FJ /00 FJ /00 FJ /00 FJ /00 FJ / kg coil SD300K FJ /00 FJ /00 FJ /00 FJ /00 FJ /00 15 kg coil BB20 FJ /00 FJ /00 FJ /00 FJ /00 FJ /00 18 kg coil Saphira Stitching Wire Allround* continued Designation 26 (0.50 mm) 27 (0.45 mm) 28 (0.40 mm) 29 (0.37 mm) 30 (0.35 mm) Description K155 FJ /00 FJ /00 FJ /00 FJ /00 FJ / kg coil SD300K FJ /00 FJ /00 FJ /00 FJ /00 FJ /00 15 kg coil BB20 FJ /00 FJ /00 FJ /00 FJ /00 FJ /00 18 kg coil * We keep a permanent stock of stitching wires nos. 25 to 26 in coil sizes K155 (4.1 kg) and SD300K (15 kg). Orders for other wire thicknesses may involve longer delivery times (approx. 2 3 working days depending on the order quantity). 70

71 3. Saddlestitchers/Consumables Stitching wire Saphira Extreme stitching wire for Stitchmaster* Heidelberg Extreme stitching wire is also manufactured in Germany and is extremely tough and strong, with excellent piercing properties. It also exhibits greater buckling strength than Allround stitching wire. Extreme stitching wire can therefore also be used to process thicker products that up till now could only be stitched with thicker wires. Although the greater strength of Extreme stitching wire increases wear and tear, for ex ample on the slitting discs in the stitching heads, its advantage is that you can meet a whole range of different requirements with just one wire. This not only eliminates the setup time needed for a change of stitching head but also saves on material and storage costs. What s the right wire to choose? Before application, determine the product thickness, what wire thickness needs to be used in the stitching heads, and what stitch shape is required. Each of our wires has its own specific strengths. The experts at Heidelberg Systemservice will be happy to help you with your selection. Saphira Stitching Wire Extreme* Designation 21 (0.80 mm) 22 (0.75 mm) 23 (0.70 mm) 24 (0.60 mm) 25 (0.55 mm) Description K155 FJ /01 FJ /01 FJ /01 FJ /01 FJ / kg coil SD300K FJ /01 FJ /01 FJ /01 FJ /01 FJ /01 15 kg coil BB20 FJ /01 FJ /01 FJ /01 FJ /01 FJ /01 18 kg coil Saphira Stitching Wire Extreme* continued Designation 26 (0.50 mm) 27 (0.45 mm) 28 (0.40 mm) 29 (0.37 mm) 30 (0.35 mm) Description K155 FJ /01 FJ /01 FJ /01 FJ /00 FJ / kg coil SD300K FJ /01 FJ /01 FJ /01 FJ /00 FJ /00 15 kg coil BB20 FJ /01 FJ /01 FJ /01 FJ /00 FJ /00 18 kg coil Large coils with the corresponding uncoiling device are available in addition to the standard coils listed here. Just give us a call we ll be happy to help. * We keep a permanent stock of stitching wires nos. 25 to 26 in coil sizes K155 (4.1 kg) and SD300K (15 kg). Orders for other wire thicknesses may involve longer delivery times (approx. 2-3 working days depending on the order quantity). 71

72 3. Saddlestitchers/Consumables Lubricants Lubricants for Stitchmaster To work at their best, our machines need not just regular lubri cation but also the right lubricants. Our portfolio therefore features special premium products that have been developed specifically to meet our needs. All Original Heidelberg lubri cants are extremely resistant to aging and demonstrate excellent temperature resistance, making them ideal for long-term con tinuous use in all manner of operating environments. However good a lubricant is, its quality can deteriorate when in continuous daily use. Consequently, perfect lubrication can only be ensured on a long-term basis by changing the lubricant as often as necessary. To make things easier, many Original Heidelberg lubricants come with a sticker indicating when they need to be changed. Lubricant spray FIN SUPER ZD Lubricant spray Hotemp 2000 ZD Saphira Slideway oil ZD Heidelberg Lubrication cartridge Postpress Equipment* Saphira Lubrication Paste High Performance Type of machine ZD Stitchmaster ST 300, thread-sealing machine FS 100, all Stahfolder Description Must be changed every 6 months, 6 pcs for ST 300 and 3 pcs for FS 100 ZD Eurotrim ET 1000, Stitchmaster ST 300, ST 400, ST 450 * The Original Heidelberg lubrication cartridge is suitable for all Heidelberg Stahlfolders, the FS 100 thread-sealing machine and the Stitchmaster ST 300. Find out about the benefits of the Heidelberg lubrication cartridge on page

73 Options for Retrofitting

74 3. Saddlestitchers/Options for Retrofitting Trimming and slitting options Transport equipment small format for Stitchmaster FJ /03 Description/size (mm) Stitchmaster ST 350, ST 450 ZD BE-01 Stitchmaster ST FJ /01 Stitchmaster ST This equipment is used for trimming products smaller than 80 mm. The product width is reduced from 80 mm to 64 mm. Product width: 64 mm, one-ups: Min mm, two-ups: Min mm (parting cut, punch cut; depending on the punching knife used) as above, but for ST (up to mid-2004) as above, but for ST (up to mid-2004) Equipment one-up folded sheet A6 for Stitchmaster FJ /00 Description/size (mm) Stitchmaster Knife set required ST 450 Center slitting attachment (no knife) for Stitchmaster FJ /01 FJ /00 Description/size (mm) Stitchmaster ST 350, ST 450 Stitchmaster ST Used to process the products as two-ups. Suitable for accommodating cut-off or punching knives in widths of 6 to 12 mm (additional option: Knives with airblast can also be used). Two sets of knives are required in each case. 1. Parting cut 2. Punch cut Formats: b a b a Untrimmed: Min mm Min mm Trimmed: Min mm Depending on the punching knife used Product thickness: Max. 10 mm Max. half punching knife width As above but for ST Center slitting attachment small format (no knife) for Stitchmaster FJ /03 FJ /00 Description/size (mm) Stitchmaster ST 350, ST 450 Stitchmaster ST Used for processing small formats in two-ups. Suitable for accommodating cut-off and punching knives in widths of 4 to 6 mm. (Additional option: Knives with airblast can also be used). Two sets of knives are required in each case. 1. Parting cut 2. Punch cut Formats: b a b a Untrimmed: Min mm Min mm Trimmed: Min mm Depending on the punching knife used Product thickness: Max. 10 mm Max. half punching knife width As above but for ST Cutting knives, cut-off knives and punching knives are available either individually or as complete sets of knives. For details, see pages Please note, that not all options for Retrofitting can be delivered within 24 hours. 74

75 3. Saddlestitchers/Options for Retrofitting Slitting and hole punching options Air distributor for knives with airblast for Stitchmaster FJ /02 Description/size (mm) Stitchmaster An air distributor is required for every knife with an air connection. ST 350, ST 450 Slitting device TRIO (no knife) for Stitchmaster FJ /03 Description/size (mm) Stitchmaster ST 350, ST 450 Used for processing small formats in three-ups. Suitable for accommodating cut-off or punching knives in widths of 6 to 9 mm. (Additional option: Knives with airblast can also be used). 3 sets of knives are required in each case (see pages 48-54) 1. Parting cut 2. Punch cut Formats: b a b a Untrimmed: Min mm Min mm Trimmed: Min mm Depending on the punching knife used Product thickness: Max. 5 mm Max. half punching knife width Calendar hole punching attachment (without punching tool) for Stitchmaster FJ /04 FJ /00 Description/size (mm) Stitchmaster ST 350, ST 450 Stitchmaster ST The universal LSK calendar hole punching attachment enables different punching tools to be installed with different hole diameters (4 to 7 mm). The attachment is adjustable over the entire format from back cut to front cut. The advantage of this is that a single attachment can be used for several punching tools with different hole diameters. Up to now, a specific hole punching device had to be bought for every hole diameter. The benefits of this unit include reduced costs and greater userfriendliness. The punching tools must be ordered separately. You can find details of this on page 78. It is advisable to order two sets in each case. Formats: Hole diameter: A: Max. 475 mm, min. 220 mm 4 to 7 mm B: Max. 315/310 mm, min. 80/89 mm C: 6 mm to (B 6 mm) As calendar hole punching attachment, for ST only 2-hole punch with hole spacing 80 mm (without punching tool) for Stitchmaster FJ /02 FJ /01 Description/size (mm) Stitchmaster ST 350, ST 450 Stitchmaster ST The universal LS 80 2-hole punch enables different punching tools to be installed with different hole diameters (4 to 7 mm). The advantage of this is that a single 2-hole punch can be used for several punching tools with different hole diameters. Up to now, a specific hole punching device had to be bought for every hole diameter. The benefits of this unit include reduced costs and greater user-friendliness. The punching tools must be ordered separately. You can find details of this on page 78. At least two sets need to be ordered in each case, but it is advisable to order four. With a pressure shoe, 210 mm (A5) is also possible. As above, 2-hole punch with hole spacing 80 mm, only for ST

76 3. Saddlestitchers/Options for Retrofitting Hole punching options Punching tools for Stitchmaster Designation Description/size (mm) Diameter 4 mm FJ /02 Stitchmaster ST 100.2, ST 350, ST 450 Diameter 5 mm FJ /02 Stitchmaster ST 100.2, ST 350, ST 450 Diameter 5.5 mm FJ /02 Stitchmaster ST 100.2, ST 350, ST 450 Diameter 6 mm FJ /02 Stitchmaster ST 100.2, ST 350, ST 450 Diameter 7 mm FJ /02 Stitchmaster ST 100.2, ST 350, ST 450 Each set of punching tools contains two punches and two bushes. Can be used in calendar hole punching attachment (: FJ /03 or FJ /00) and LS 80 2-hole punch (: FJ /01 or FJ /00) Each set of punching tools contains two punches and two bushes. Can be used in calendar hole punching attachment (: FJ /03 or FJ /00) and LS 80 2-hole punch (: FJ /01 or FJ /00) Each set of punching tools contains two punches and two bushes. Can be used in calendar hole punching attachment (: FJ /03 or FJ /00) and LS 80 2-hole punch (: FJ /01 or FJ /00) Each set of punching tools contains two punches and two bushes. Can be used in calendar hole punching attachment (: FJ /03 or FJ /00) and LS 80 2-hole punch (: FJ /01 or FJ /00) Each set of punching tools contains two punches and two bushes. Can be used in calendar hole punching attachment (: FJ /03 or FJ /00) and LS 80 2-hole punch (: FJ /01 or FJ /00) 2-hole punch incl. punch unit for Stitchmaster Designation Description/size (mm) 130 mm/ dia 6 mm ZD BG-01 Stitchmaster ST 100.2, ST hole punch (2 holes, spacing 130 mm, diameter 6 mm) incl. punch unit Formats: A Back: Min. 270 mm Max. 475 mm B Width: Min. 89 mm Max. 310 mm C Max.: 11 mm Product thickness: Max. 2 mm Hole diameter: 6 mm 3-hole punch for Stitchmaster Designation Description/size (mm) 108 mm/ dia 6 mm ZD BG-01 Stitchmaster ST 350, ST 450 Hole punch (3 holes, spacing 108 mm, diameter 6 mm) incl. punch unit Formats: A Back: Min. 297 mm Max. 475 mm B Width: Min. 220 mm Max. 315 mm C Max.: 8 20 mm Product thickness: Max. 2 mm 76

77 3. Saddlestitchers/Options for Retrofitting Hole punching options 3-hole punch for Stitchmaster continued Designation Description/size (mm) Hole punch 108 mm (without punching unit) ZD BG-01 Stitchmaster ST 350, ST 450 Hole punch (3 holes, spacing 108 mm, diameter 6.5 mm without punch unit) Formats: A Back: Min. 297 mm Max. 475 mm B Width: Min. 210 mm Max. 310 mm C Max.: 8 17,4 mm Product thickness: Max. 2 mm A punch unit for the hole punch must also be ordered. Punch units for Stitchmaster Designation Description/size (mm) for hole punch (dia. 6.5 mm) for hole punch (dia. 8.0 mm) for hole punch (dia. 9.5 mm) ZD BG-01 Stitchmaster ST 350, ST 450 ZD BG-01 Stitchmaster ST 350, ST 450 ZD BG-01 Stitchmaster ST 350, ST 450 Each set of punch units contains three punches and three bushes. Can be used in 3-hole punch (Article no.: ZD BG-01) Each set of punch units contains three punches and three bushes. Can be used in 3-hole punch (Article no.: ZD BG-01) Each set of punch units contains three punches and three bushes. Can be used in 3-hole punch (Article no.: ZD BG-01) 4-hole punch for Stitchmaster Designation Description/size (mm) incl. punch unit 80 mm/dia. 5.5 mm incl. punch unit 70 mm/dia. 5.5 mm FJ /01 Stitchmaster ST 350, ST 450 ZD BG-01 Stitchmaster ST 350, ST 450 Hole punch (4 holes, spacing 80 mm, diameter 5.5 mm) Formats: A Back: Min. 297 mm Max. 475 mm B Width: Min. 210 mm Max. 310 mm C Max.: 15 mm Product thickness: Max. 2 mm Hole diameter: 5.5 mm Important: Installation takes approx. 6 hours as the transport tapes have to be moved. Hole punch (2 holes, spacing 70 mm, diameter 5.5 mm) Formats: A Back: min. 255 mm max. 475 mm B Width: min. 89 mm max. 310 mm C Max.: 10 mm Product thickness: max. 2 mm Hole diameter: 5.5 mm Important: Installation takes approx. 6 hours as the transport tapes have to be moved. 77

78 3. Saddlestitchers/Options for Retrofitting Stitching and wire processing options Stitching and wire processing options for Stitchmaster Designation Description/size (mm) 52-N14 changing set, wire No N14 changing set, wire No on request on request Changing set former on request with wire clamper Stitchmaster ST 100.2, ST 350 Stitchmaster ST 100.2, ST 350 Stitchmaster ST 450 Clincher box FJ /00 Stitchmaster ST 450 Quick-action FJ /00 changing device for stitching heads Wire transport device 3rd/4th stitching head Wire transport device 5th/6th stitching head Fold pressing unit external (see p. 59 for fold pressing units) Support device wire transport Coil brace for small coils Coil brace for big coils 3rd/4th stitching head Coil brace for big coils 5th/6th stitching head FJ /01 FJ /01 FJ /01 FJ /02 FJ /02 FJ /01 FJ /03 Stitchmaster ST 450 Stitchmaster ST 450 Stitchmaster ST 450 Stitchmaster ST 450 Stitchmaster ST Stitchmaster ST 350, ST 450 Stitchmaster ST 350, ST 450 Stitchmaster ST 350, ST 450 Clamping piece FJ /00 Stitchmaster ST 450 Coil brace ground on request Stitchmaster ST 450 For changing wires from standard size to For changing wires from standard size to For all 45-N14 (magnetic, therefore for non-ferrous wires only) Clincher versions for all types of stitching head. With this option, the stitches are bent further inwards so that the ends cannot cause any injury. Used primarily for brochures for children. Recommended for special stitching such as loop stitches. By simply loosening clamping levers, the quick-change device for the stitching heads can be inserted into the stitcher without tools. Additional stitching-wire transport device for the 3rd and 4th stitching heads (if normal and loop stitching heads are used in parallel, wire transport device 5th/6th stitching heads FJ /01 is also required) Additional stitching-wire transport device for the 5th and 6th stitching heads (can only be used in conjunction with wire transport device 3rd/4th stitching heads FJ /01) For accommodating the fold pressing unit outside the stitching head. Used to fix the products in position if the fold pressing unit cannot be fixed on the stitching head for space reasons. For stitching wire coils BB20 (18 kg) For processing coils of size K155 (4.5 kg) For processing coils of sizes SD300K (15 kg) and BB20 (18 kg) at the 3rd/4th stitching heads For processing coils of sizes SD300K (15 kg) and BB20 (18 kg) at the 5th/6th stitching heads Required for unreeling wire from wire drums For processing coils of sizes K355 (50 kg) and MP100 (90 kg) The Heidelberg stitching wire range (Allround and Extreme in different wire thicknesses and coil sizes) can be found on pages Large coils are also available on request. 78

79 Did you know that there is always a Heidelberg service technician in your area? We are always there when you need us! With more than 4,500 well-trained specialists world wide, Heidelberg Systemservice is the industry s largest network. We are committed to Heidelberg quality standards and to providing a fully integrated and comprehensive level of service. In addition to repairs, our portfolio includes advice and improvements to production. Why not make use of the expertise that has grown out of cutting-edge tools, optimized structures and an ongoing exchange of information!

80 Did you know that Heidelberg Remote Services technology can connect your saddlestitcher at lightning speed to our service experts? No matter where you are in the world, once a machine is connected to Heidelberg via Remote Services, all options are possible. Whether you need remote diagnosis, maintenance or training, the experts from Heidelberg Systemservice can access your machine while you follow the measures sim ultaneously on the screen. This means we can solve application-related queries during normal business operation or solve faults remotely there s simply no quicker way!

81 3. Saddlestitchers/Options for Retrofitting Trimmer and stitching options Other trimmer options for Stitchmaster Designation Description/size (mm) Chip removal manifold ZD BE-01 Stitchmaster ST 350, ST 450 Chip removal manifold for direct assembly on the trimmer (200 mm connection diameter for central extraction) Trim quality inspector FJ /00 Stitchmaster ST 350, ST 450 The parallelism and angle of the product is monitored by the trim quality inspector. Important: Only in conjunction with conveyor table with reject gate (ULW) or conveyor table with marking device and reject gate (ULMW). Add-on kit double pressure shoe ZD BG-01 Stitchmaster ST Options for quality assurance in the saddlestitcher Designation Description/size (mm) Missing stitch detector ZD BE-01 Stitchmaster ST Detecting the stitches from underneath, suitable for normal and/or loop stitches Missing stitch detector FJ /01 Stitchmaster ST 450 Detecting the stitches from underneath, suitable for normal and/or loop stitches Signature width inspector FJ /02 Stitchmaster ST 450 Helps to recognize: Sheets where the spine rolls off the saddle chain Incorrectly folded sheets Crooked sheets within the product Open covers Missing sheet belt delivery FJ /00 Stitchmaster ST 350, ST 450 Delivery after the stitcher with transport tape. For the delivery of semi-finished products and faulty products with interval control Did you know that regular maintenance checks from Heidelberg Systemservice can help increase the productivity of your machinery by 23 percent? That was the finding of a survey Heidelberg conducted among customers and prospective purchasers. 90 percent of people surveyed have also noticed a positive link between the productivity of machinery and its maintenance status production stabilizes and downtimes become less frequent. 81

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83 Adhesive Binders Folders This is the place to find service parts: Our catalog lists popular service parts together with their article number and the machines in which they are used. These are clearly categorized into mechanical and electrical/electronic parts. The options section includes accessories to make your machine even more productive. Unfortunately, as space in this catalog is limited, we have been unable to include all our service parts. If you can t find the part you are looking for, please give us a call. We ll be happy to find it for you. Easy to find. Our index on page 93 lists all the service parts included in the catalog, together with the relevant page number. Looking for other service parts? Check out one of the other Heidelberg part catalogs: Original Heidelberg Service Parts for Presses and CtP Devices Original Heidelberg Service Parts for Die Cutters and Folder Gluers Stahlfolder Performance Blades Adhesive Binder Consumables Technical assistance. We have marked a number of our service parts with the symbol. All these parts differ from each other depending on the specific machine con figuration. Please telephone our Systemservice experts to discuss your tec h ni cal re quirements. How much does my service part cost? Your Heidelberg Systemservice team will be happy to provide you with information on prices. See the back page of the catalog. Who installs the service parts? We have marked a number of service parts with the symbol. We recommend always having these parts replaced by a Heidelberg Systemservice engineer. Any questions? Just give us a call. If you are finding it difficult to track down an article, hav ing problems installing a service part or looking for assis tance, we ll be happy to help. Useful telephone num bers can be found at the back of our catalog or on line at Mechanical Parts Electrical and Electronic Parts Saddlestitchers Consumables Mechanical Parts Electrical and Electronic Parts

84 4. Adhesive Binders/Mechanical Parts Milling tools Milling tools for Eurobind Paper fibers must be milled in order to ensure stable adhesive binding. Both the shape of the milling teeth and the quality of notching knives and roughening teeth is crucial to the durability of the binding. That is why Heidelberg has also developed new milling tools for use with the new adhesive binders. A modular design means that these tools are extremely versatile. For example, individual wear part groups such as knives and brushes can be exchanged individually, thereby avoiding the need to replace the entire tool. You can therefore respond to wear and tear as necessary. Milling tool EB4000 milling device 1 Milling tool EB 4000 milling devices 2 to 4 FM /01 FM /00 Dust cutting tool Stripe cutting tool FM /02 (image) Milling device 2 Combination tool (leveling, notching + fine notching) FM /00 Milling device 2 Combination tool (leveling + notching) FM /01 Milling device 2 Individual tool (leveling) FM /00 Milling device 3 Combination tool (notching + fine notching) FM /00 Milling device 3 Individual tool (notching) FM /00 Milling device 4 Individual tool (fine notching) Milling tool EB 4000 accessories Milling tools EB 600 and EB 1300* FM /00 FM /01 FM /00 FM /01 FM /01 FM /01 Set of brushes for milling tool milling device 2 (3 pcs) Set of knives for dust cutter (28 pcs) Set of knives for stripe cutter (5 pcs) Set of knives for leveling cutter (5 pcs) Set of knives for notching cutter (2 pcs) Set of knives for fine notching cutter (5 pcs) FM /00 FM /01 FM /00 FM /00 FM /00 FM /01 FM /01 Complete milling tool Set of milling knives Set of micro notching knives Set of notching knives Set of brushes Counter blade, milling knives Counter blade, notching and micro notching knives We recommend always having these parts replaced by a Heidelberg Systemservice engineer. * (models 02/2008 and later, earlier models on request) 84

85 4. Adhesive Binders/Mechanical Parts Milling discs Milling discs for Eurobind EB500 and EB1200 Milling prepares paper fibers for adhesive binding. The shape of the milling teeth and the quality of notching knives and roughening teeth is crucial to the durability of the binding. The new Original Heidelberg milling discs are therefore equipped with PICs small, highly efficient roughening teeth. They expose the fibers better, the glue is able to envelop the fibers more effectively and the binding is stronger and more stable. A further advantage is the height-adjustable notching knives that enlarge the glue s contact surface and ensure strong stapling. Milling disc with PICs ZD Eurobind EB 500 ZD Eurobind EB 1200 Upgrade kit ZD.44502/002 Eurobind EB 500 ZD.401RK-061 Eurobind EB 1200 Milling disc without PICs ZD Eurobind EB 500 ZD Eurobind EB 1200 Insert for milling discs with PICs ZD Eurobind EB 500 ZD Eurobind EB 1200 We recommend always having these parts replaced by a Heidelberg Systemservice engineer. 85

86 4. Adhesive Binders/Mechanical Parts Suckers Suckers for the Stitchmaster range Original Heidelberg suckers are particularly resistant to wear. The plastics they are made from are specially selected and combined by our partners to ensure optimum suction. Our suckers therefore have exactly what it takes to meet the high standards we set for our machines. Trust our experience and Heidelberg quality, which is tried-and-tested in load and fatigue tests. Sucker Sucker Plate sucker ZD Eurobind EB 500 and EB 1200 ZD Eurobind EB 500 and EB 1200 ZD Eurobind EB 4000 Sucker Sucker No. 2/Gripper pad Sucker ZD Eurobind EB 500 and EB 1200 ZD Eurobind EB 4000 FJ /00 Eurobind EB 4000 Sucker FJ /00 Eurobind EB

87 4. Adhesive Binders/Consumables Glues and cleaners PUR adhesives and cleaners for the Eurobind range Binding books and selecting the appropriate adhesives are complicated processes. Not every adhesive is suitable for every application. That is why our Saphira adhesives and cleaners have been carefully tested on our machines, ensuring they are ideal for a whole range of applications. Our specialists will be happy to offer any help and advice you might need. Just give us a call. Saphira Glue PUR 330 Designation 20 kg bucket FM /00 Eurobind EB 4000 Box with 9 2 kg candles FM /00 Eurobind EB 500, EB 600, EB 1300 and EB 1200 PUR cleaner Designation Description Saphira polyurethane cleaner blue (20 kg) Saphira polyurethane cleaner orange (20 kg) FM /00 All Eurobind Blue polyurethane cleaner on request All Eurobind Orange polyurethane cleaner Hotmelt glues and cleaners Saphira Glue Hotmelt Side 230 Designation Description 11.3 kg box FM /00 All Eurobind Inexpensive side glue with excellent adhesive properties Saphira Glue Hotmelt Spine 130 Designation Description 22.7 kg box FM /00 All Eurobind Inexpensive spine glue with a good open time and excellent adhesive properties on most coated and uncoated papers Hotmelt cleaners Designation Description Cleaner Hotmelt Cold FM /00 All Eurobind 1 liter spray can Cleaner Hotmelt Cold FM /00 All Eurobind 6 1 liter spray can 87

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89 Thread sealing Machines and Thread stitching Machines This is the place to find service parts: Our catalog lists popular service parts together with their article number and the machines in which they are used. These are clearly categorized into mechanical and electrical/electronic parts. The options section includes accessories to make your machine even more productive. Unfortunately, as space in this catalog is limited, we have been unable to include all our service parts. If you can t find the part you are looking for, please give us a call. We ll be happy to find it for you. Easy to find. Our index on page 93 lists all the service parts included in the catalog, together with the relevant page number. Looking for other service parts? Technical assistance. We have marked a number of our service parts with the symbol. All these parts differ from each other depending on the specific machine con figuration. Please telephone our Systemservice experts to discuss your tec h ni cal re quirements. How much does my service part cost? Your Heidelberg Systemservice team will be happy to provide you with information on prices. See the back page of the catalog. Who installs the service parts? We have marked a number of service parts with the symbol. We recommend always having these parts replaced by a Heidelberg Systemservice engineer. Thread sealingand Thread stitching Machines Adhesive Binder Consumables Folders Mechanical Parts Electrical and Electronic Parts Saddlestitchers Consumables Check out one of the other Heidelberg part catalogs: Original Heidelberg Service Parts for Presses and CtP Devices Original Heidelberg Service Parts for Die Cutters and Folder Gluers Stahlfolder Performance Blades Any questions? Just give us a call. If you are finding it difficult to track down an article, hav ing problems installing a service part or looking for assis tance, we ll be happy to help. Useful telephone num bers can be found at the back of our catalog or on line at Mechanical Parts Electrical and Electronic Parts

90 5. Thread sealing and Thread stitching/mechanical Parts Needles and razor blades Needles and razor blades Original Heidelberg sealing and stitch ing needles ensure optimum processing of sealing threads and stitching twine. Specially developed for our machines, these needles help prevent the thread from splitting open during incision and so minimize bulging on the paper re verse side. This ensures optimum seal ing of the thread and means the product can be transported through the machine without any problems. Like the Original Heidelberg razor blades, they are an essential tool for efficient production and are made from premium grade steels for reliable results and depend able product quality. Needle standard thin Needle special thick Hook needle ZD Thread sealing machine FS 100 ZD Thread sealing machine FS 100 ZD Thread sealing machine FS 140 Running stitch needle Sewing needle Brochure needle ZD Thread sealing machine FS 140 ZD Thread sealing machine FS 140 ZD Thread sealing machine FS 140 Special razor blade FJ /01 Thread sealing machine FS

91 5. Thread Sealing and Thread Stitching/Mechanical Parts Thread plate chains/thread plates/sealing thread Thread plate chains and thread plate Thread plates transport the sealing thread of our thread-sealing machines to the fold and are induced to do this by high-precision thread plate chains. To prevent the sealing thread from becoming roughened during this process, the surfaces of all Original Heidelberg thread plates are specially processed. Precision take-up of the thread and its accurate delivery in the fold is ensured by a special spring mechanism designed to withstand high mechanical, chemical and thermal stresses. To ensure smooth processes, thread plates and thread plate chains should be regularly tested, cleaned and replaced if necessary. Thread plate chain Thread plate ZD BE-01 Thread-sealing machine FS 100 ZD BE-01 Thread-sealing machine FS 100 Sealing thread Thread sealing effectively combines the benefits of the esta b lish ed thread stitching and adhesive binding processes, i.e. excellent durability and low manufacturing costs. The new threads from Heidelberg make the procedure even more cost-effective. They are very strong and can be easily processed even at sealing temperatures up to 300 Celsius. Other ad van tages include their high stitching and tensile strength. The enhanced sealing means almost no faulty stitching even on difficult papers. The sealing threads are available in two grades. The Original Heidelberg sealing thread Allround as an all-rounder, covers around 80 percent of all applications, i.e. almost the whole thread-sealing spectrum replaces the current threads 39/2 and 44/2 is suitable for fold sheets of up to 16 pages (up to 150 gsm) is suitable for fold sheets of up to 32 pages (up to 135 gsm) The Original Heidelberg sealing thread Extreme is designed for very special applications replaces the current threads 54/2 and 59/2 is suitable for fold sheets of up to 16 pages (up to 170 gsm) is suitable for fold sheets of up to 32 pages (up to 150 gsm) Heidelberg Allround sealing thread (11 cones/box) Heidelberg Extreme sealing thread (11 cones/box) FJ /00 Thread-sealing machine FS 100 FJ /00 Thread-sealing machine FS 100 We recommend always having these parts replaced by a Heidelberg Systemservice engineer. 91

92 5. Thread Sealing and Thread Stitching/Mechanical Parts Other equipment Cutting wheel complete Transfer chain, coated Roller (sheet transport) ZD BE-01 Thread-sealing machine FS 100 ZD BG-01 Thread-sealing machine FS 100 ZD BE-01 Thread-sealing machine FS 100 Forwarding roller shaft (lower) Forwarding roller shaft (upper) Puncture chain ZD BG-01 Thread-sealing machine FS 100 ZD BG-01 Thread-sealing machine FS 100 ZD BG-01 Thread-sealing machine FS 100 Set of bevel gears (incl. shaft) Set of bevel gears (incl. shaft) Lubrication cartridge Postpress Equipment* ZD ZD BG-01 Thread-sealing machine FS 100/66 ZD BG-01 Thread-sealing machine FS 100/56 Description ST 300, FS 100, all Stahlfolder Must be changed every 6 months, 6 for ST 300 and 3 for FS 100 We recommend always having these parts replaced by a Heidelberg Systemservice engineer. * The Original Heidelberg lubrication cartridge is suitable for all Heidelberg Stahlfolders, the FS 100 thread-sealing machine and the Stitchmaster ST 300. Find out about the benefits of the Heidelberg lubrication cartridge on page