MBO K8RS Translation Of The Original Operating Manual
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MBO K8RS Translation Of The Original Operating Manual

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  • Page 1 Folding machine Translation of the original operating manual K8RS Keep for future reference!
  • Page 2 06/08/2016 Dated: Machine no.: English BA_K8RS_M1-BF- Language: File name: Standard_Automatik_ V2.2_en MBO Maschinenbau Oppenweiler Binder GmbH & Co. KG PO Box 1169 71567 Oppenweiler GERMANY Manufacturer: Tel.: +49 7191 46 0 Fax: +49 7191 46 34 http://www.mbo-folder.com info@mbo-folder.com Subject to alterations! Copyright This documentation is subject to copyright law.
  • Page 3 Name plate and For all questions relating to your machine, please contact your MBO agen- CE marking You can find the address on our home page: www.mbo-folder.com. For the identification of the machine and the most important machine data, see the name plate on the machine.
  • Page 4 EC/EU Declaration of Conformity according to EC Machine Directive 2006/42/EC, Annex II, No. 1 A. The manufacturer MBO Maschinenbau Oppenweiler Binder GmbH & Co. KG Grabenstraße 4-6 71570 Oppenweiler GERMANY hereby declares that the machine described below Designation Folding machine...

  • Page 5: Table Of Contents

    Adjustment and operation ..........28 Falzmaschine K8RS...
  • Page 6 Standard equipment for K8RS........
  • Page 7 MBO-RAS (optional)........
  • Page 8 Safety messages ........... 140 Falzmaschine K8RS...
  • Page 9 8.4.15 <DB settings> page ..........185 Falzmaschine K8RS...
  • Page 10 Opening/closing the crossfold table........263 8.8.9 Adjusting the fold rollers and slitter shafts (standard) ..... . . 264 Falzmaschine K8RS...
  • Page 11 Checking the feeder ..........329 Falzmaschine K8RS...
  • Page 12 Disposal/recycling ..........367 Falzmaschine K8RS...

  • Page 13: About This Manual

    • Give this operating manual to any subsequent owner or user of the the machine machine. We reserve the right to make technical changes to improve the machine, even if these changes are not taken into account in this operating manual. Folding machine K8RS...

  • Page 14: Additional Documents

    Table 2: Supplier documentation Structure of the operating manual The table lists the chapters of the operating manual. It also describes the essential content of these chapters as well as the target groups at whom the chapters are directed. Folding machine K8RS...
  • Page 15 • Operating personnel machine back into • Storage • Maintenance personnel operation • Recommissioning • Service technicians Disposal Details for the environmentally friendly • Operator disposal • Maintenance personnel • Service technicians Table 3: Structure of the operating manual Folding machine K8RS...

  • Page 16: Signs And Symbols Used

    Here you will find the result of a sequence of instructions for action. <STOP> Push button with the label between the brackets (e.g. Stop). Additional information for use of the machine. Important notice, please observe. Table 4: Symbols, terms, and abbreviations Folding machine K8RS...

  • Page 17: Description Of Safety Messages

    • Type and source of the hazard • Possible consequences of the hazard • Measure(s) for avoiding the hazard Example: DANGER! WARNING! CAUTION! ( Signal word) Type and source of the hazard. Possible consequences of the hazard. Measure(s) for avoiding the hazard Folding machine K8RS...

  • Page 18: Safety Sign

    Table 6: Safety sign 1.4.3.1 Prohibition sign Depiction Meaning Entry of the area forbidden. This prohibition sign indicates that it is forbidden to enter the area. Table 7: Prohibition sign Folding machine K8RS...
  • Page 19 Warning of lifting heavy machine parts. You will see this warning triangle next to activities during which there is a hazard of overloading due to lifting heavy loads. Table 8: Warning sign Folding machine K8RS...
  • Page 20 Warning of stumbling points. You will see this warning-triangle next to activities during which there is a tripping hazard, possibly with deadly consequences. Table 8: Warning sign Folding machine K8RS...
  • Page 21 You will see this mandatory sign next to activities for which you should heed the maintenance chapter. Activate before maintenance or repair. You will see this mandatory sign next to activities for which the machine must be de- energized. Table 9: Mandatory sign Folding machine K8RS...

  • Page 22: Marking Of Danger Spots

    This hazard marking is affixed to constant danger spots and hindrances. Table 10: Marking of danger spots User assessment of the operating manual Our operating manuals are updated regularly. Help us with your suggestions for improvement; they make the manuals user-friendly. Folding machine K8RS...

  • Page 23: Basic Safety Instructions

    • Adhere to the inspection and maintenance intervals. • Use only original wearing parts and spare parts. Use the machine only as intended and when the protective device is working perfectly. This is the only way to guarantee the machine's operating safety. Folding machine K8RS...

  • Page 24: Reasonable Foreseeable Misuse

    The use of spare parts and wear parts from third-party manufacturers can wearing parts cause risks. Use only original parts or parts approved by the manufacturer. The manufacturer assumes no liability for damage from the use of spare parts and wearing parts not approved by the manufacturer. Folding machine K8RS...

  • Page 25: Obligation And Liability

    • not maintained or not maintained properly or serviced. The machine is only to be used: • For the intended use. • If it is in perfect condition with respect to safety. Faults that can compromise safety must be remedied immediately. Folding machine K8RS...

  • Page 26: Warranty

    • Defective monitoring of machine parts that are subject to wear, such as belts, tapes, brushes, and couplings. • Installation of spare and wearing parts that were not ordered from the manufacturer. • Cases of catastrophe and acts of God. Folding machine K8RS...

  • Page 27: Residual Risks

    • Discharge currents greater than 10mA. • Disconnected protective conductor connections. • Trip hazards due to connecting cables lying around. • Use of multiple adapter boxes in a machine combination. • Incorrect direction of rotation of the feeder motor. Folding machine K8RS...

  • Page 28: Adjustment And Operation

    • Use of compressed air. • Incorrect cleaning of the spiral fold rollers. • High-grip fold rollers cleaned incorrectly. • Penetration of foreign bodies into the pressure vacuum pump. • Incorrect maintenance intervals during multi-shift operation. Maintenance: • Hazardous voltage. Folding machine K8RS...

  • Page 29: Decommissioning, Storage

    • Rotating machine parts. • Crushing. • Winding up. • Wrong/poor maintenance tool. • Improper maintenance. • Incorrect maintenance intervals during multi-shift operation. Repair: • Improper maintenance. 2.5.5 Decommissioning, storage • Incorrect storage. 2.5.6 Disposal • Improper disposal. Folding machine K8RS...

  • Page 30: Product-Specific Hazards

     Work on the machine must always be performed by one person only.  There is also a risk of injuries when turning the machine with the safety handwheel.  Always hold the slitter shaft on the shaft and not on the tool.  Cutting injuries will be avoided. Folding machine K8RS...

  • Page 31: Noise

    Life time of the machine The life time of this machine is designed for 20 years. 2.7.2 Service life of the control-technical safety components All components of the control-technical safety circuits have a life time of more than 20 years. Folding machine K8RS...

  • Page 32: General Safety Instructions

    • Machine parts may not be used as climbing aids. If higher machine parts must be reached, a suitable working stage or other platform must be used, which fulfills the safety-technical requirements such as height, stability, etc. Folding machine K8RS...

  • Page 33: Maintenance And Repair

    • Only an electrically qualified person is permitted to perform work on the electrical systems or equipment. • In case of faults in the electrical power supply, the machine must be switched off immediately. • Only use original fuses with the prescribed amperage. Folding machine K8RS...

  • Page 34: Personnel, Qualifications And Duties

    • have understood and can implement practically the operating manual with respect to responsibilities, tasks, and activities for the machine. 2.9.1 Qualification of the personnel This table lists the necessary qualification of the personnel related to the various activities at or on the machine. Folding machine K8RS...
  • Page 35 Personnel, qualifications and duties Transportation Interim storage Set-up Electrical connections Stationary mains connection Commissioning Troubleshooting (mechanical/ electrical Installation, set-up Operation Operational mainte- nance (cleaning) Maintenance Repair Decommissioning Storage Disposal Table 11: Qualification of personnel Legend: X permitted, - not permitted Folding machine K8RS...

  • Page 36: Duties Of The Operator

    The requirements of the German Labor Protection Act (ArbSchG) and the German Health and Safety at Work Regulations (BetrSichV) must be adhered to. EC countries The requirements of the directives 89/391/EEC and 2009/104/EU must be adhered to. Folding machine K8RS...

  • Page 37: Duties Of The Operating Personnel

    • use the machine as intended, • wear the necessary personal protective equipment. The maintenance personnel is responsible for • protecting the machine against unauthorized use, • the maintenance being carried out according to the maintenance schedule. Folding machine K8RS...

  • Page 38: Personal Protective Equipment

    • Cut-resistant safety gloves • Safety shoes 2.10.2 Operational maintenance (cleaning) This personal protective equipment must be provided and worn for the proper maintenance (cleaning) of the machine: • Safety glasses • Suitable safety gloves • Safety shoes Folding machine K8RS...

  • Page 39: Work Areas And Workstations

    100 cm. • The service area is highlighted with shading. 2.11.1 Variants S-KTL, S-KTLT Unit of measure- 1 Workstations Figure 1: Work areas and workstations for S-KTLT Folding machine K8RS...

  • Page 40: Model S-Ktz

    Basic safety instructions Work areas and workstations 2.11.2 Model S-KTZ Unit of measure- 1 Workstations Figure 2: Work areas and workstations for S-KTZ Folding machine K8RS...

  • Page 41: Markings On The Machine

    Markings on the machine These markings must be on the machine and in an easily legible condition. If they are damaged or illegible, they must be replaced. For the appropriate MBO part number, see chapter "2.12.1 Position and meaning". 2.12.1 Position and meaning Pos.
  • Page 42 Meaning: <Use ear protection> mandatory sign High noise pressure level. Non-observance could result in hearing damage. • Always wear ear protection when working on the machine. • Always close the noise damping hoods whenever you work at or on the machine. Folding machine K8RS...
  • Page 43 Basic safety instructions Markings on the machine Pos. 5 MBO part number: 0128301 Meaning: <Hazardous voltage> warning sign Non-observance will result in serious injury or death. • Only an electrically qualified person may perform work on the machine's electrical system.
  • Page 44 Basic safety instructions Markings on the machine Pos. 7 MBO part No.: 0101730 Meaning: <Do not touch> prohibition sign Crushing hazard during automated format change. Non-observance could result in injury. When starting the automated format change, observe the following precautions: •...
  • Page 45 Basic safety instructions Markings on the machine Pos. 8 MBO part number: Meaning: <Do not enter> prohibition sign Non-observance could result in injury and/or property damage. Do not use any machine parts to climb on. Folding machine K8RS...

  • Page 46: Directions For Emergencies

    • Who's calling? • Wait for queries! • Provide help as necessary. 3 First aid • Check consciousness and breathing. • Protect against heat loss. • Provide support and assistance. Table 13: Behavior in case of accidents Folding machine K8RS...

  • Page 47: Product Description

    5 Crossfold 3 Parallel fold 6 Sound damping safety hood Figure 3: Overall view 3.1.2 Standard equipment for K8RS • M1-Control machine control, TOUCHSCREEN • FP800/130 palletized feeder with: - Feeder Loading Sytem FLS - Vaculift RS feeder head - Double Vacubelt •...

  • Page 48: Technical Data

    Product description Technical data Technical data 3.2.1 Floor plan 3.2.1.1 K8RS KTL, KTLT with palletized feeder K8RS Minimum room height = 300 cm Unit of measurement cm Figure 4: Floor plan for KTL /KTLT FP feeder 3.2.1.2 K8RS KTZ with palletized feeder...

  • Page 49: Performance Characteristics

    1) The maximum working speed depends on paper properties, format, fold type, temperature, and humidity, as well as various states at the operator that the manufacturer cannot influence. 2) All values refer to simple volume paper. 3) Including pallet height. Folding machine K8RS...

  • Page 50: Shipping And Transport Data

    4) Heed operating manual for the fork lift, load capacity depends on the load center of gravity (c). 5) Minimum carrying capacity of the underfloor where the machine is set up 6) In the area of the machine, the total height difference may not exceed 20 mm. Folding machine K8RS...

  • Page 51: Electrical Supply

    0.75 kW feeder Pressure/vacuum pump 5.5 kW Drive1 3 kW Power supply 0.25 kW 0.05 kW 1.5 kW With airstream table Power Operational readiness (stand-by) Current rate Table 16: Electrical supply 400V network 1) Stationary mains connection Folding machine K8RS...
  • Page 52 6) The total connected load depends on the feeder type, the equipment of folding unit I, as well as the number and equipment of the connected subsequent folding units and the delivery. 7) Add the connected values of the airstream table to the connection values of the corresponding machine. Folding machine K8RS...

  • Page 53: Compressed Air Supply, Control Air

    The values were determined in accordance with the noise emission standard DIN EN ISO 13023 using the basic standards DIN EN ISO 3746 and DIN EN ISO 11204 Table 18: Noise emissions 1) Noise measurement EN 13023 J.2.2.2 - Class 2 Folding machine K8RS...

  • Page 54: Ambient Conditions

    1) At temperatures below or above the permissible room temperature, special measures must be taken. 2) For installation at an altitude of 800 m above sea level or higher, special measures are necessary for the pressure vacuum pumps. Learn more about this from the manufacturer. Avoid direct sunlight and drafts. Folding machine K8RS...

  • Page 55: Structure And Function

    • During further transport through the fold rollers (1) and (3) a buckle fold arises in the buckling area (5). • The sheet of paper (2) is grasped on the buckle fold by the fold rollers (3) and (4) folded during its passage. Folding machine K8RS...
  • Page 56 • After triggering the knife movement, the folding knife conveys (4) the sheet of paper (1) in the direction of the fold rollers (2) and (3). • The sheet of paper (1) is grasped by the fold rollers (2) and (3) folded during its passage. Folding machine K8RS...

  • Page 57: Structure

    Structure Structure 4.2.1 Views of the palletized feeder The components are distributed across three sides of the palletized feeder. 1 Control cabinet side 3 Operator side 2 Loading side, rear Figure 8: Views of the palletized feeder Folding machine K8RS...
  • Page 58 7 Dual suction belt, sheet stops, smoothers, 3 Pile plate lateral ventilation, front ventilation. 4 Loading ramp 8 Valves for front ventilation 5 Loading direction, operator side 9 Control panel Figure 9: Components of the operator side Folding machine K8RS...
  • Page 59 Structure and function Structure 4.2.1.2 Components of the control cabinet side 1 Control cabinet 3 Pressure/vacuum pump with noise damping 2 Pile motor device Figure 10: Components of the control cabinet side Folding machine K8RS...
  • Page 60 Structure and function Structure 4.2.1.3 Loading side components, rear 1 Feeder head arm, pivoting 3 Loading side, rear 2 Noise damping device, pressure/vacuum 4 EMERGENCY STOP palm button pump Figure 11: Loading side components, rear Folding machine K8RS...

  • Page 61: Views Of The Machine

    6 Control panel 2 Palletized feeder 7 Outlet 3 Register table 8 Connection for subsequent units 4 Parallel fold 9 Cross fold 5 Three fold 10 Noise damping safety hood Figure 12: Operator side and exit side Folding machine K8RS...
  • Page 62 Structure 4.2.2.2 Drive side 1 Noise damping safety hood 5 Compressed air connection 2 Upper buckle plates 6 Lower buckle plates 3 Cross fold 7 Control cabinet 4 KTL plate Figure 13: Drive side of the machine Folding machine K8RS...

  • Page 63: Functional Description

    Required for broadsheets with a format length of less than 17 cm. Front ventilation Should only be used when utilizing a small sheet-size device. Used for ventilation and separation of the sheets from the paper pile. Pressure/vacuum Generates the required blast air/vacuum. pump Folding machine K8RS...

  • Page 64: Combi Folding Machine

    • Segments with plastic balls or steel balls • Brush units. Delivery: • After each folding unit. Combi folding machines can be used for: • Cross folds with up to four folds for book and brochure production • Various brochure folds. Folding machine K8RS...

  • Page 65: Register Table

    Figure 14: Overview of parallel fold folding unit The parallel fold folding unit alternatively has: • 4 or 6 buckle plates with swing deflectors, • Spiral or high-grip fold rollers that can be adjusted with quick-adjust elements. • Slitter shafts or slitter shaft cassette. Folding machine K8RS...

  • Page 66: Cross Fold Folding Unit

    • Quick-change slitter shafts (standard) 4.3.6 Waste paper deflector including ultrasonic double sheet detector. The swiveling sheet stop in the crossfold has the following functions: • Sheet stop for the crossfold • Waste paper deflector for double sheets and mis-folded sheets. Folding machine K8RS...

  • Page 67: Threefold Folding Unit

    The threefold folding unit consists of: • Transport table • Folding knife • Swiveling sheet stop • Fold rollers • Buckle plate for various fold types parallel to the threefold folding knife (variant S-KTLT). • Quick-change slitter shafts. Folding machine K8RS...

  • Page 68: Sheet Monitoring Of The Machine

    • If a sheet does not pass through one of these photo cells at the calculat- ed time: • the machine stops. • the appropriate error message is displayed. See chapter "4.3.8 Sheet monitoring of the machine". Folding machine K8RS...

  • Page 69: Delivery Systems

    Structure and function Variants 4.3.9 Delivery systems For the various demands with respect to format, fold type, and performance, MBO offers different delivery systems. For the corresponding descriptions, please see the operating manuals included with the delivery systems. Variants 4.4.1 FP800_130 RS The designation "FP 800 _130 RS"...

  • Page 70: Model S-Ktl

    Structure and function Variants 4.4.2 Model S-KTL Definition of terms The designation "K8RS S-KTL" means: Combi folding machine Designation of type High-speed version Super = full slitter shaft after the buckle plate in the crossfold Cross fold Buckle plate after the 1st folding knife (crossfold)

  • Page 71: Model S-Ktlt

    Structure and function Variants 4.4.3 Model S-KTLT Definition of terms The designation "K8RS S-KTLT" means: Combi folding machine Designation of type High-speed version Super = full slitter shaft after the buckle plate in the crossfold and threefold Cross fold Buckle plate after the 1st Folding knife...

  • Page 72: Model S-Ktz

    Structure and function Variants 4.4.4 Model S-KTZ Definition of terms The designation "K8RS S-KTZ" means: Combi folding machine Designation of type High-speed version Super = full slitter shaft after the buckle plate in the crossfold Cross fold Buckle plate after the 1st Folding knife Swiveling threefold area, optionally threefold to the left or the right of the sheet feed direction.

  • Page 73: Machine Control

    MBO-RAS (optional) The MBO remote maintenance package RAS (Remote Access Service) provides remote access for the MBO service team to your folding machine. This allows the MBO service team to operate the machine control, diagnostics using machine, job and job and folding imposition data as well as update the software from the Oppenweiler site.

  • Page 74: Protective Devices

    Only when the hazardous function has been eliminated safely is the locking reset and then the protective device can be opened completely. The machine can be restarted only after the protective device is closed. Folding machine K8RS...

  • Page 75: Explanation Of The Term "Protective Devices

    Protective devices include: • Two-hand switches • Sensitive protective devices such as: Contact mats, safety strips, switch rods and switch wires. • Optoelectronic, protective devices such as: Light barriers, laser scanners and camera-controlled safety systems. Folding machine K8RS...

  • Page 76: Overview Of Protective Devices On The Palletized Feeder

    Overview of protective devices on the palletized feeder The following protective devices are present on the palletized feeder. Operate the palletized feeder only if all protective devices are completely present and fully functional! 1 EMERGENCY STOP palm 2 Fixed guards button Folding machine K8RS...

  • Page 77: Overview Of Protective Devices On The Machine

    Operate the machine only if all protective devices are completely pres- ent and fully functional! 1 EMERGENCY STOP palm button 4 Fixed guards 2 Safety handwheel 5 Noise damping safety hood 3 Safety hood threefold Figure 21: Overview Folding machine K8RS...

  • Page 78: Main Switch

    • it is equipped with a device that enables it to be locked in the OFF position (e.g. by a padlock). When switching off the main switch during production: • the machine is stopped, • the drives gradually run down, • no emptying of the sheets takes place. Folding machine K8RS...
  • Page 79  Disengage the EMERGENCY STOP palm button by turning it towards the right.  The machine is ready for operation. When the EMERGENCY STOP palm button is pressed, the machine is stopped immediately. No emptying of the sheets takes place! Folding machine K8RS...

  • Page 80: Noise Damping Safety Hood

    The noise damping and safety hood (3) covers the entire parallel fold area and cross fold area. The safety hood (1) covers the threefold area.  Only open and close the noise damping safety hood using the handle (2).  Always open noise damping safety hood to the stop. Folding machine K8RS...

  • Page 81: Safety Switch

    • When opening the noise damping safety hood (1) during production, the safety switch (2) drops the drive of the machine. • With an open noise damping safety hood, the machine can be operated in set-up mode. See chapter "5.3.2 Set-up mode with open protective device" Folding machine K8RS...
  • Page 82 Threefold carriage Figure 27: Safety switch for threefold carriage The safety switch (2) stops the drive of the machine when the threefold carriage (1) is pulled out. For the switch position, see chapter "4.6.12 Checklists for protective devices" Folding machine K8RS...
  • Page 83 Protective devices 4.6.7.4 Guard over three fold Figure 28: Safety switch for guard hood three fold The safety switch (1) stops the drive of the machine as soon as the guard hood (2) over the threefold is opened. Folding machine K8RS...

  • Page 84: Operating The Safety Handwheel

     Press the EMERGENCY STOP palm button.  Pull the safety handwheel (3) towards you. The overrunning clutch is released.  Turn the safety handwheel. Direction of rotation: Clockwise = Machine rotates forwards. Counterclockwise = Machine rotates backwards. Folding machine K8RS...

  • Page 85: Fixed Guards

    For the corresponding inspection intervals, see chapter "4.6.12.2 Variant S-KTL, S-KTLT" For the corresponding procedure, see the Maintenance chapter. 4.6.12 Checklists for protective devices Use these checklists to check the protective devices of the machine regularly 4.6.12.1 FP800_130 RS Folding machine K8RS...
  • Page 86 Guard over control gear, Weekly drive side Guard over drive chain. Drive Weekly side Guard over suction wheel/ Weekly suction belt Guard in front of the suction Weekly belt/suction wheel. Table 20: Checklist for protective devices Folding machine K8RS...
  • Page 87 Weekly All fastening and stop screws must be safety screws. all safety screws secured using Weekly screw lock (e.g. Loctite 222). No illustration Plate - max. load Weekly Date: Name: Signature: Table 20: Checklist for protective devices Folding machine K8RS...
  • Page 88 Weekly Guard, KTL plate Weekly Guard, parallelfold (drive side) Weekly Safety switch, cross fold table Daily Noise damping safety over Weekly parallel fold and cross fold Date: Name: Signature: Table 21: Checklist protective devices variants S-KTL, S-KTLT. Folding machine K8RS...
  • Page 89 (operator side) KTLT guard, fold rollers, and Weekly slitter shafts, three fold KTL guard, fold rollers, and Weekly slitter shafts, three fold Guard, cross fold knife Weekly Date: Name: Signature: Table 22: Checklist protective devices designs S-KTL, S-KTLT. Folding machine K8RS...
  • Page 90 Cam disk of the noise damping safety hood. Form-closed. All safety screws are secured with screw locking (e.g. Loctite 222). Not marked in the figure Date: Name: Signature: Table 23: Checklist protective devices variants S-KTL, S-KTLT. Folding machine K8RS...
  • Page 91 Guard, three fold knife Weekly Guard, tape roller drive Weekly Safety switch, threefold Daily carriage Guard, threefold, tape roller Weekly Safety switch, safety hood, Daily threefold Date: Name: Signature: Table 24: Checklist protective devices variants S-KTL, S-KTLT. Folding machine K8RS...
  • Page 92 Structure and function Protective devices Visual Function- Inspection Pos. Designation inspec- Result ing control interval tion Guard over tape roller, Weekly threefold Guard under threefold Weekly Guard, removable Weekly Date: Name: Signature: Folding machine K8RS...
  • Page 93 EMERGENCY STOP palm Daily button, main control panel All safety screws are secured with screw locking (e.g. Loctite 222). Not marked in the figure Date: Name: Signature: Table 25: Checklist of protective devices for variant S-KTZ. Folding machine K8RS...
  • Page 94 Guard, threefold drive Weekly Guard, KTL plate Weekly Guard, parallel fold Weekly (drive side) Safety switch, cross fold table Daily Noise damping safety hood Daily Date: Name: Signature: Table 26: Checklist of protective devices for variant S-KTZ. Folding machine K8RS...
  • Page 95 Result ing control interval tion Guard, register table drive Weekly Guard, drive combi area Weekly Guard, threefold knife Weekly Guard, cross fold knife Weekly Date: Name: Signature: Table 27: Checklist of protective devices for variant S-KTZ. Folding machine K8RS...
  • Page 96 Safety switch, noise damping Daily safety hood Cam disk of the noise damping safety hood. Form-closed. Tighten grub screw with point forcefully; (greater than 9 Nm) Date: Name: Signature: Table 28: Checklist of protective devices for variant S-KTZ. Folding machine K8RS...
  • Page 97 Daily Guard, threefold knife Weekly Guard, tape roller drive Weekly Safety switch, threefold Daily carriage Guard, threefold, tape roller Weekly Safety switch, safety hood, Daily threefold Date: Name: Signature: Table 29: Checklist protective devices variants S-KTL, S-KTLT. Folding machine K8RS...
  • Page 98 Structure and function Protective devices Visual Function- Inspection Pos. Designation inspec- Result ing control interval tion Guard over tape roller, Weekly threefold Date: Name: Signature: Folding machine K8RS...

  • Page 99: Operating And Display Elements, Operating Modes

    See chapter "5.1.4 Main control panel". 3 Control panel in the crossfold and threefold. See chapter "5.1.18 Control panel in the cross fold and threefold" 4 EMERGENCY STOP palm button (FP130) See chapter "5.1.3 EMERGENCY STOP palm button on the FP130 feeder" Folding machine K8RS...

  • Page 100: Main Switch

    1 from the electrical supply. • It has only one OFF and one ON position, labeled as 0 and I. • It is equipped with a device that enables it to be locked in the OFF position (e.g. by a padlock). Folding machine K8RS...

  • Page 101: Emergency Stop Palm Button On The Fp130 Feeder

    Figure 33: EMERGENCY STOP palm button on the FP130 feeder 5.1.4 Main control panel Figure 34: Main control panel 1 TOUCHSCREEN See chapter "5.1.6 Touchscreen handling" 2 <Machine functions> key field See chapter "5.1.5 <Machine functions> key field" Folding machine K8RS...

  • Page 102: Machine Functions> Key Field

    Green = pile table has reached the "Floor" stop position. 8 <Switch air supply on / off> illuminated button. Status display of the illuminated ring: Off = The air supply is switched off. Green = The air supply is switched on. Folding machine K8RS...

  • Page 103: Touchscreen Handling

    Flashing green = The machine is running empty. 5.1.6 Touchscreen handling • Only use your finger or a stylus pen (part number 0131900) to oper- ate the touchscreen. • Ball-point pens or other metallic objects may damage the surface of the touchscreen. Folding machine K8RS...

  • Page 104: Touchscreen Structure

    2 <Page name, machine status, password level, date and time> info box. See chapter "5.1.8 Info box". 3 Current production speed, alarms, notices> display field. See chapter "5.1.17 Displaying alarms". 4 <Current page content> display. See chapter "8.4.2 Main page structure". Folding machine K8RS...

  • Page 105: Info Box

    3 <Machine status> display. Displays the current status of the machine. See chapter "5.1.10 Displaying machine status" 4 <Password> button. Displays the current password level. See Chapter "5.1.9 Entering the password". 5 <Current date> display. 6 <Current time> display. Folding machine K8RS...

  • Page 106: Entering The Password

    Password Area and authorization Symbol Area: • Diagnostics (view all/change something). Authorization for: Operator Area: • Diagnostics (view all/change something). • Service (view all/change some- XXXX thing). Authorization for: Machine setter with supervision Table 30: Password level Folding machine K8RS...
  • Page 107  Press the <Password> button (1). password level The password input window is opened.  Press the <C> button (7).  Press the <Enter> button (8). The <Password> button (3) displays a closed lock.  The password level is reset. Folding machine K8RS...

  • Page 108: Displaying Machine Status

    An alarm message is present. Black Yellow Black Rapidset or ARA drive not positioned. Black Yellow with Black Rapidset or ARA drive is positioned. gear wheels Black Black Green Machine is ready for production. Table 31: Operating states Folding machine K8RS...

  • Page 109: Description Of The Function Keys

    See chapter "8.4.2 Main page structure". 9 <Page back> button. Pages back to the previous pages selected. 10 <Large-scale display> button. Pressing the button displays the <Large-scale display> page. See chapter "5.1.14 Switching on the large-scale display". Folding machine K8RS...
  • Page 110 15 <Display favorite pages> button. Pressing the button displays the <Favorite> page. See chapter "5.1.13 Selecting favorite pages". 16 <Select favorite pages> button. Pressing this button saves this page as a <Favorite>. See chapter "5.1.13 Selecting favorite pages" Folding machine K8RS...

  • Page 111: Switching The Help On/Off

     Press the <Help> function key (3) again. help off The pop-up window (1) is closed.  The help is switched off. No other functions can be run when the help is switched on (<Help> function key is lit in yellow). Folding machine K8RS...

  • Page 112: Selecting Favorite

    (2) with a maximum of five favorite pages.  Press the required favorite page (2) in the selection list.  The required favorite page is displayed. The favorites list must be rebuilt again after switching the main switch off/on. Folding machine K8RS...

  • Page 113: Switching On The Large-Scale Display

     Press the required function. A checkmark is set.  The function is selected. Close the How to close the selection window (5): selection window  Press the <Close> button (4).  The selection window (5) is closed. Folding machine K8RS...

  • Page 114: Numeric Input Keyboard

    A minus sign is shown in front of the number entered.  Press the <Enter> button (8).  A negative number is entered. Depending on the unit to be changed, the structure of the numeric input keyboard can vary somewhat. Folding machine K8RS...

  • Page 115: Diagnosis> Page

    Pressing the keypad opens the <Statistics> page. See chapter "5.1.16.7 <Statistics> page". 9 <Alarms history> function key. Pressing the key displays the page. See chapter "5.1.17 Displaying alarms". 10 <Alarms> function key. Pressing the key displays the page. See chapter "5.1.17 Displaying alarms". Folding machine K8RS...
  • Page 116 This page displays the specific data for the selected station. How to select the required station:  Press the selection button (1). A selection list is displayed.  Tap on the required station.  The data for the selected station is displayed. Folding machine K8RS...
  • Page 117 This page displays the specific sensor data for the selected station. How to select the required station:  Press the selection list (4). A selection list is displayed.  Tap on the required station.  The sensor data for the selected station is displayed. Folding machine K8RS...
  • Page 118 This page displays the sheet monitoring data for the selected station. How to select the required station:  Press the selection list (4).  A selection list is displayed.  Tap on the required station.  The sheet monitoring data for the selected station is displayed. Folding machine K8RS...
  • Page 119 This page displays the data for the sensors and sheet lengths for the selected station. How to select the required station:  Press the selection list (4). A selection list is displayed.  Tap on the required station.  The data for the selected station is displayed. Folding machine K8RS...
  • Page 120 This page displays the specific data for the selected station. How to select the required station:  Press the selection button (1). A selection list is displayed.  Tap on the required station.  The data for the selected station is displayed. Folding machine K8RS...
  • Page 121 This page displays the general data for the selected station. How to select the required station:  Press the selection button (1). A selection list is displayed.  Tap on the required station.  The data for the selected station is displayed. Folding machine K8RS...
  • Page 122 This page displays the statistics data for the selected station. How to select the required station:  Press the selection button (1). A selection list is displayed.  Tap on the required station.  The statistics data for the selected station is displayed. Folding machine K8RS...

  • Page 123: Displaying Alarms

     The <Alarm history> page (6) is displayed. Scroll through the How to scroll through the <Alarm history> (6) page. alarm history  Press the function key <Scroll down> (7).  Press the <Scroll up> function key (8). Folding machine K8RS...

  • Page 124: Control Panel In The Cross Fold And Threefold

    3 <Set-up mode with open protective device> illuminated selecting switch. Position 0 = Set-up mode OFF. Position 1 = Set-up mode ON. 4 <Inching> enabling grip switch. 5 Plug connection for enabling grip switch. 6 <Two-hand switching> button. (press the buttons simultaneously (2 and 6)) Folding machine K8RS...
  • Page 125 Flashing green = The machine is running empty. 10 <Knife stroke, folding knife 2> illuminated button. Status display of the illuminated ring: Off = Folding stroke is switched off. Flashing yellow = A folding stroke can be triggered. Folding machine K8RS...
  • Page 126 Operating and display elements, operating modes Operating and display elements 11 <Knife stroke, folding knife 1> illuminated button. Status display of the illuminated ring: Off = Folding stroke is switched off. Flashing yellow = A folding stroke can be triggered. Folding machine K8RS...

  • Page 127: Compressed Air Nozzle With Manometer

    Figure 58: Compressed air supply combi area 1 Sign maximum operating pressure for waste paper deflector 2 Pressure regulator, waste paper deflector 3 Compressed air connection 4 Pressure regulator, folding knives 5 Sign maximum operating pressure for folding knives Folding machine K8RS...

  • Page 128: Operating Modes

    • All sockets (400 VAC and 230 VAC sockets) of the MBO machines must be monitored at all times according to the corresponding federal and local codes, guidelines and other regulations.

  • Page 129: Switching The Operating Mode Of The Folding Knives

     A knife stroke is triggered. Switching off the How to switch off the folding knife: folding knife  Press the <Folding knife 1 on/off> button (1). The illuminated ring (1) is off.  The folding knife is switched off. Folding machine K8RS...
  • Page 130  A knife stroke is triggered. Switching off the How to switch off the folding knife: folding knife  Press the <Folding knife 2 on/off> button (2). The illuminated ring (2) is not lit up.  The folding knife is switched off. Folding machine K8RS...

  • Page 131: Set-Up Mode With Open Protective Device

     Keep the enabling grip switch (3) held down as shown in the illustration.  Press the enabling grip switch until first lock-in position is reached.  Press the button (6) with your thumb.  After a delay time, the machine runs at 5 m/min. Folding machine K8RS...

  • Page 132: Creating Production Readiness

     Press the <Folding knife 1 on/off> button (1). The illuminated ring (1) is lit in green. 2) Press the <Folding knife 2 on/off> button (2). The illuminated ring (2) is lit in green.  The system is ready for production. Folding machine K8RS...

  • Page 133: Machine Control

    5.3.5 Self-control MBO units with M1 control are not prepared for the self-control operating mode. In other words, the MBO units can only be operated in combination with folding unit I with M1 control. Folding machine K8RS...

  • Page 134: Adapter Box

    The relevant adapter boxes are required to do this. Details of which adapter boxes can be used is available from MBO Service or from authorized customer services. A risk assessment of the machine combination must be carried out by the operator and their results are summarized in an operating manual.

  • Page 135: Transport, Interim Storage

    Qualification of personnel This table lists the necessary qualification of the personnel related to "Transport and interim storage" of the machine. Transportation Interim storage Table 32: Qualification of personnel; Transport, interim storage Legend: X permitted, - not permitted Folding machine K8RS...

  • Page 136: Safety Messages

    Check the properties and condition and load rating of the subsurface in the set-up location. • For necessary minimum requirements, please see the "Technical data" chapter. CAUTION! Incorrect storage. Non-observance could result in property damage. Observe the specified storage conditions. Folding machine K8RS...

  • Page 137: Packaging

    How to conduct an incoming inspection:  When you receive the shipment, check the packaging right away for transport damage.  Check the machine, feeder and accessories for transport damage.  Check that the shipment is complete based on the delivery note. Folding machine K8RS...

  • Page 138: Reporting A Damage Situation

     Only lift the transport pallet as high as absolutely necessary for the transport.  Transport the transport pallet as close as possible to the intended location.  Set the transport pallet down carefully.  Machine is transported. Folding machine K8RS...

  • Page 139: Interim Storage Of The Machine

    (danger of corrosion).  Loosen cover film from the transport pallet and lift it so that the air can circulate.  Machine is stored temporarily. 6.4.2 In a storage room For storage conditions, see chapter "3.2.7 Ambient conditions" Folding machine K8RS...
  • Page 140 Transport, interim storage Interim storage of the machine Folding machine K8RS...

  • Page 141: Installation, Commissioning

    This table lists the necessary qualification of the personnel related to "Set up and commissioning" of the machine. Set-up Electrical connections Stationary mains connection Commissioning Table 33: Qualification of personnel; Set-up, commissioning Legend: X permitted, - not permitted Folding machine K8RS...

  • Page 142: Safety Messages

    For necessary minimum requirements, please see the "Technical data" chapter. WARNING! Trip hazards due to cables and hoses lying around. Non-observance could result in serious injury or death. Lay the machine connections (cables, hoses, pipes) so that there are no tripping points. Folding machine K8RS...

  • Page 143: Setting Up The Machine

    • Separate installation and commissioning instructions are required for this. Only have the machine installed by MBO Service or by a customer service technician authorized by MBO. Making the stationary mains connection The electrical supply of the machine must be performed by a stationary mains connection.

  • Page 144: Safety Messages

    NFPA 70, as well as the technical connection requirements of the local power supply company. • This may not be connected by an MBO technician or a customer service technician. • For the electrical installation, EN 60204-1, Clause 6.3.3. "Protection through automatic switching off of the supply"...
  • Page 145 • All sockets (400 VAC and 230 VAC sockets) of the MBO machines must be monitored at all times according to the corresponding federal and local codes, guidelines and other regulations.

  • Page 146: Observe The Design Of The Stationary Mains Connection

    Design according to VDE 0100 Part 540 (IEC 60364-5-54) and EN 60204-1, Clause 8.2.8 Cross-section = 10 mm (Cu). Table 34: Design of the stationary mains connection 1) Prerequisite, see chapter "7.3.5 Connecting the protective equipotential bonding conductor". Folding machine K8RS...

  • Page 147: Making The Stationary Mains Connection On The Main Control Cabinet

    How to connect the stationary mains connection: 1) Feed the mains connection through the cable grommet into the main control cabinet. 2) Connect the power cable to the main switch (1) according to the wiring diagram.  The stationary mains connection is complete. Folding machine K8RS...

  • Page 148: Connecting The Protective Equipotential Bonding Conductor

    Non-observance could result in serious injury or death. Reconnect all protective conductor connections that were disconnected for transport. Check that all protective conductor connections that were disconnected for transport are reconnected correctly. Procedure:  Check this by visual inspection. Folding machine K8RS...

  • Page 149: Removing Transport Locks

    1) Remove the transport lock (1) from the threefold carriage as soon as the machine has reached its final set-up location.  The transport lock is removed. • Keep the transport lock for future use. • For any additional transport, secure the threefold carriage with the transport lock (1). Folding machine K8RS...

  • Page 150: Threefold, Variant Ktz

     Remove the transport lock (1) from the threefold carriage as soon as the machine has reached its final set-up location.  The transport lock is removed. • Keep the transport lock for later use. • Before every subsequent transport, secure the pivotable threefold using the transport lock (1). Folding machine K8RS...

  • Page 151: Connecting The Compressed Air Supply

    Non-observance could result in serious property damage to the folding knives and on the waste sheet deflector. It is essential to observe the specified operating pressures. Due to the closing of electrically-secured protective devices, unexpected pneumatic elements may be activated. Folding machine K8RS...

  • Page 152: Commissioning

    • After the mains connection, the machine must be commissioned. • Separate installation and commissioning instructions are required for this. Only have the machine commissioned by MBO Service or by a customer service technician authorized by MBO. Conducting a final check of the protective devices After commissioning the machine, be absolutely certain to carry out a final check of the protective devices.

  • Page 153: Operation And Adjustment

    • Using the check list for protective devices, check that all protective devices are on the machine. • Report any audible/visible safety-relevant alteration to the machine to the person responsible for the plant in your operation. Folding machine K8RS...
  • Page 154 Non-observance could result in serious injury or death. Make absolutely sure that there are no other people on the machine during when you are operating it in set-up mode. Folding machine K8RS...
  • Page 155 WARNING! High noise pressure level. Non-observance could result in hearing damage. • Always wear ear protection when working on the machine. • Always close the noise damping safety hoods whenever you work at or on the machine. Folding machine K8RS...
  • Page 156 Never reach into the register table while the machine is running. CAUTION! Incorrectly fixed buckle plates. Non-observance could result in personal injuries or damage to property. Make sure that the buckle plates are fastened securely by the clamping lever. Folding machine K8RS...

  • Page 157: Operating The Machine

    How to switch the main switch off:  Turn the main switch (1) to switch position 0. The display turns off.  The machine is turned off now. To save energy, a machine that is not being used should be switched off. Folding machine K8RS...

  • Page 158: Emergency Stop Palm Button

    3) Disengage the EMERGENCY STOP palm button (1) by turning it to the right.  The machine is ready for operation. When the EMERGENCY STOP palm button is pressed, the machine is stopped immediately. No emptying of the sheets takes place! Folding machine K8RS...

  • Page 159: Raising/Lowering The Pile Plate

    The pile plate is lowered to the ground. The illuminated ring is lit in green.  The pile plate is lowered to the ground. Raising the pile plate How to raise the pile plate:  Press the button (1). Folding machine K8RS...

  • Page 160: Switching The Feeder Loading System (Fls) On/Off

    • The feeder is loaded manually. • There must be a pallet on the pile plate. CAUTION! Crushing hazard. The light barrier opening represents a danger spot. Non-observance could result in personal injury. Never reach into the light barrier opening. Folding machine K8RS...
  • Page 161  Press the <Feeder Loading System on/off> button (4) again. The illuminated ring is not lit.  The FLS is switched off. Ventilate the paper pile before feeding in as this will ensure improved separation of the sheets away from the paper pile. Folding machine K8RS...

  • Page 162: Switching The Air Supply On/Off

    The illuminated ring is not lit.  The air supply is switched off. How to set the full blast air volume to adjust the feeder: • Stop the machine. • How to switch the air supply on: • Request a single sheet. Folding machine K8RS...

  • Page 163: Starting/Stopping The Machine

    The illuminated ring (2) is not lit.  The machine is run empty and then stopped. With a soft stop during production: • The sheet infeed is stopped. • The machine is run empty. • The machine is stopped. Folding machine K8RS...

  • Page 164: Starting/Stopping The Sheet Infeed

     Press the <Sheet feed, production> button (2) again. The illuminated ring (2) is not lit.  The sheet infeed is stopped. When the sheet infeed (1 + 2) is switched on, the air supply is started automatically. Folding machine K8RS...

  • Page 165: Brief Instructions For Adjusting The Machine

    • Placing the knives on the slitter shafts. See chapter "8.7.10 Installing/dismounting slitter shafts". • Paying attention to error messages. See chapter "8.5 Setting the feeder". • Remove the paper jam. See chapter "8.13 Removing the paper jam". Folding machine K8RS...

  • Page 166: Adjusting The M1 Control

    • A new folding imposition is selected, see chapter "8.4.7 Selecting a folding imposition". • A job is activated in the job management (see separate DATAMANAGER operating manual). "Setup" machine is finished automatically after the first sheet passes through all photoelectric sensors of the fully adjusted machinery. Folding machine K8RS...

  • Page 167: Main Page Structure

    Tapping the display field activates the <PB1 settings> page. See chapter "8.4.13 <PB1 settings> page". 7 <KB> crossfold display field. Tapping the display field activates the <KB settings> page. See chapter "8.4.14 <KB settings> page". 8 <DB> threefold display field. Folding machine K8RS...
  • Page 168 Operation and adjustment Adjusting the M1 control Tapping the display field activates the <DB settings> page. See chapter "8.4.15 <DB settings> page". 9 Not assigned Folding machine K8RS...

  • Page 169: Beginning A New Job

    The <Counter> page (2) is displayed. 2) Press the <Delete job> function key (4). The <Reset job counter> selection window is displayed. 3) Press the <Apply> button.  The counter readings of the job (3) and the signature are deleted. Folding machine K8RS...

  • Page 170: Beginning A New Signature

    The <Counter> page (2) is displayed. 2) Press the <Delete signature> function key (4). The <Reset signature counter> selection window is displayed. 3) Press the <Apply> button.  The counter readings of the signature (3) are deleted. "Calibrate machine" is not activated. Folding machine K8RS...

  • Page 171: Beginning A New Shift

    The <Counter> page (2) is displayed. 2) Press the <Delete shift> function key (4). The <Reset shift counter?> selection window is displayed. 3) Press the <Apply> button.  The counter readings of the shift (3) are deleted. "Calibrate machine" is not activated. Folding machine K8RS...

  • Page 172: Making The Counter Settings

    How to enter the <Sheets per batch> number:  Press the input field (3). A numeric input keyboard appears.  Enter the desired number here.  The <Sheets per batch> number is displayed in the input field (3). Folding machine K8RS...
  • Page 173 <Pre-print run> How to enter the <Pre-print run>:  Press the input field (4). A numeric input keyboard appears.  Enter the number of <Pre-print run>.  The <Pre-print run> is displayed in the input field (4). Folding machine K8RS...
  • Page 174 Switch on <Print run How to switch on the <Print run monitoring>: monitoring>  Press the <Print run monitoring> button (3). A blue OK mark appears in the button.  The <Print run monitoring> is switched on. Folding machine K8RS...

  • Page 175: Selecting A Folding Imposition

     Clamp 10 sheets of the paper to be processed using the knurled screw (1).  Divide the value displayed by ten. The result is the individual paper thickness (in this case 113).  The paper thickness is measured. Folding machine K8RS...
  • Page 176 1) Tap on the required folding imposition (6). 2) Press the <Folding imposition transfer> button (7). The <PB1 buckle fold> page is displayed. See chapter "8.4.13 <PB1 settings> page"  A new folding imposition is selected. Folding machine K8RS...
  • Page 177  Enter the measured sheet length in the input field (2).  Enter the measured sheet width in the input field (3).  Enter the measured paper thickness in the input field (4).  The sheet data is entered. Folding machine K8RS...
  • Page 178 The <Information> page displays the settings of the buckle plates, the fold rollers and the sidelays of the selected station. See two pages on. Parameter (2) Additional settings can be made on the <Parameter> page. See next page. Folding machine K8RS...
  • Page 179 Select the basic position of the alternating deflector. deflector (4) Close (5) Close the page with this button. Entering the <Number of sidelays> and <Multiple job factor per sidelay> affects the speed, the sheet monitoring and the counter data. Folding machine K8RS...
  • Page 180 <Information> page The <Information> page displays the settings of the buckle plates, the fold rollers and the sidelays of the selected station. Figure 88: <Information> page Use these values as adjustment tool for a machine without automation. Folding machine K8RS...
  • Page 181 The folding imposition selected in the selection window (11) is deleted from the folding imposition memory. Update list (6) The folding impositions displayed in the selection window (11) are updated. The number to the left of the button (6) displays the number of saved folding impositions. Folding machine K8RS...
  • Page 182  Press the <Apply> button (7) to finish the process of saving the folding imposition.  Press the <Cancel> button (5) to cancel the <Save folding imposition> process.  A folding imposition is saved. Proceed as follows to overwrite the folding imposition. Folding machine K8RS...

  • Page 183: Start Buckle Plate Positioning

    The button flashes blue and is marked <Start>. The positioning can be started. • The button is red and says <Stop>. The positioning can be canceled. • The button is green and says <Position OK>. The positioning is complete. Folding machine K8RS...

  • Page 184: Positioning Of The Fold Rollers

    • are at the target position, are green. The positioning of the fold rollers can take several minutes. Only start production if the display for the machine status (1) is green. Folding machine K8RS...

  • Page 185: Setup" Machine, Manual Activation

    • <Re-start setup> (4) is executed automatically with a speed change of <Re-start setup> (4) 20 % or over. • With <Re-start setup> (4) only the values for the sheet monitoring are recalculated. Manually-changed parameters are retained. Folding machine K8RS...

  • Page 186: Changing The Infeed Data

    Suction length (4) • Automatically calculated with <Setup> (approx. 1/3 of the sheet length). • Can be increased and decreased. Speed (2 + 9) • Displays the current speed of the machine. • Can only be increased. Folding machine K8RS...
  • Page 187 The sheet production speed is not changed. • An increase in speed has no effect on the output. It only increases the sheet gap. • Please note that after a calibration speeds can be increased but not reduced. Folding machine K8RS...

  • Page 188: Fp130 Settings> Page

    <PB1 settings> page Figure 96: <PB1 settings> page 1 <Buckle plates> input field 2 <Additional settings page> function key 3 <Station> selection button 4 <Additional settings> input fields 5 <Register table> input field 6 <Fold rollers> input field Folding machine K8RS...

  • Page 189: Kb Settings> Page

    <DB settings> page Figure 98: <DB settings> page 1 <Steadying distance> input field 2 <Additional settings page> function key 3 <Station> selection button 4 <Additional settings> input fields 5 <Threefold knife> input field 6 <Fold rollers> input field Folding machine K8RS...

  • Page 190: Setting The Feeder

    After inserting the pallet into the feeder, the feeder head must be lowered feeder head again. How to lower the feeder head:  Use the handle (1) to pull the feeder head (6) down to the bottom limit position. Folding machine K8RS...

  • Page 191: Set The Right-Hand Pile Stop

    Proceed as follows to set the right-hand pile stop:  Unfasten the clamp screw (2).  Set the pile stop (3) to half the sheet width using the scale (1).  Re-tighten the clamp screw (2).  The right-hand pile stop is set. Folding machine K8RS...
  • Page 192 Open page How to open the <FP130> page.  Press the <Home> function key (4). The <Main page> is opened.  Press the <FP130> (5) selection field on the <Main page>.  The <FP130> page is opened Folding machine K8RS...

  • Page 193: Loading The Feeder With A Pallet

    • With the pallet full, the front edge of the paper pile must be flush with the front edge of the pallet. Possible loading and The feeder can be loaded from the following positions: unloading positions • Loading side, rear • Operator side Folding machine K8RS...
  • Page 194 How to remove the empty pallet: empty pallet  Remove the empty pallet using a pallet truck.  The empty pallet is removed. Inserting a full pallet Ensure that the pallet truck forks do not project beyond the end of the pallet. Folding machine K8RS...
  • Page 195 - The light spot of the laser pointer (1) is located on the right-hand edge of the paper pile (2). - The front edge of the paper pile (3) is in gentle contact with the front plate (4).  The full pallet is inserted. Folding machine K8RS...

  • Page 196: Align The Paper Pile Laterally

    When processing a sloping paper pile, the paper pile always needs to be re-adjusted laterally multiple times. Basic setting When lowering the pile plate to the ground, the lateral adjustment is automatically moved back to the central position. Folding machine K8RS...

  • Page 197: Position The Feeder Head

     The feeder head is positioned. 8.5.5.2 Motorized The motorized positioning of the feeder head is carried out when calculating a new folding imposition. See operating manual for the folding machine. The feeder head is positioned via motor. Folding machine K8RS...
  • Page 198 A numeric input keyboard is opened.  Enter the new value.  Press the <Start> function key button (1).  The adjustment value is corrected. The input changes only become effective when the <Start> (1) button is pressed. Folding machine K8RS...

  • Page 199: Set The Left-Hand Pile Stop

     Loosen the clamp screw (1).  Position the left-hand pile stop (2) so that it is gently in contact with the left-hand edge of the paper pile.  Re-tighten the clamp screw (1).  The left-hand pile stop is positioned. Folding machine K8RS...

  • Page 200: Inserting The Smoothers

    Determine the number and position of the smoothers according to the paper format, as shown in the diagram. Proceed as follows to adjust the smoothers:  Loosen the locking screw (1).  Position the smoothers (2).  Re-tighten the locking screw (1).  The smoothers are adjusted. Folding machine K8RS...

  • Page 201: Adjusting The Pressure Vacuum Pump

    Operation and adjustment Setting the feeder 8.5.8 Adjusting the pressure vacuum pump 1 Pressure vacuum pump Figure 109: Pressure vacuum pump The settings for pressure and vacuum are specified by the manufacturer. Folding machine K8RS...

  • Page 202: Adjusting The Feeder Head, Vaculift Rs

    With paper bending downwards:  Turn the knurled screw (5) anti-clockwise.  The suction devices (2) are set higher. With paper rolled upwards:  Turn the knurled screw (5) clockwise.  The suction devices (2) are set lower. Folding machine K8RS...
  • Page 203 Reducing the holding vacuum:  Turn the stud screw (3) anti-clockwise. Increasing the holding vacuum:  Turn the stud screw (3) anti-clockwise.  The holding vacuum is set. Changing the holding vacuum does not affect the suction vacuum setting. Folding machine K8RS...
  • Page 204  Set the hold-down springs so that they - project into the paper pile by approx. 5-7 mm. - are pointing diagonally downwards. - are positioned gently against the paper pile.  The hold-down springs are set. Folding machine K8RS...
  • Page 205  Arrange the stop pins in accordance with the diagram. For large sheet formats:  Position stop retainers (1) as far as possible towards the outside.  Arrange the stop pins in accordance with the diagram.  The stop retainers are positioned. Folding machine K8RS...
  • Page 206 The following settings can be made on the external pre-blowers:  Position  Height  Pivot horizontally.  Air volume, with the valves (5 + 8)  The external pre-blowers are set. Use the external pre-blowers to fan out the sheets first. Folding machine K8RS...
  • Page 207 Proceed as follows to set the fanning blowers: Setting the blowing direction: The blowing direction cannot be changed. Setting the air volume:  Adjust the air quantity with the valve (2).  The fanning blowers are set. Folding machine K8RS...

  • Page 208: Setting The Paper Pile Level

    Increase the distance:  Turn the knurled screw (1) clockwise. Reduce the distance:  Turn the knurled screw (1) counterclockwise.  The distance is adjusted. Changes following "Increase distance" only become effective once the paper pile has been lowered. Folding machine K8RS...

  • Page 209: Setting The Lateral Ventilation

     Position the air nozzle (1) so that approx. 10 to 15 paper sheets are ventilated.  Set the required air volume using the valve (2).  Carry out the adjustment on both sides.  The lateral ventilation is set. Folding machine K8RS...

  • Page 210: Setting The Small Sheet-Size Device

     Slide the feeder head (4) backwards.  Secure the feeder head (4) using the clamping lever (3).  The feeder head is reset. Ensure that the clamping lever (3) is secure once more after moving the feeder head. Folding machine K8RS...
  • Page 211  The small sheet-size device is set. Adjusting the How to adjust the ventilation: ventilation  Only use front ventilation and lateral ventilation when using the small sheet-size device. See chapter "8.5.13 Adjusting the front ventilation". See chapter "8.5.11 Setting the lateral ventilation" Folding machine K8RS...

  • Page 212: Adjusting The Front Ventilation

    Figure 120: Adjusting the front ventilation Setting air nozzles How to adjust the air nozzles together: together  Position the adjustment lever (10) up or down until the required blow pattern is achieved.  The air nozzles are set together. Folding machine K8RS...
  • Page 213  Follow the allocation plan (3). Increasing the air volume:  Turn the valves 1 to 4 counter-clockwise. Reducing the air volume:  Turn valves 1 to 4 clockwise.  The air volume is set. Folding machine K8RS...

  • Page 214: Adjusting The Dual Suction Belt

     Re-tighten the nut (4).  Set the guard on the second suction belt evenly.  The guard is set. The distance between the pile surface and the guard must be set as small as possible, maximum 8 mm! Folding machine K8RS...
  • Page 215 How to increase the suction force for: • heavy papers.  Turn the knurled screw (1) clockwise. Set the suction force on both suction belts evenly. The sheets may be drawn in unevenly if the setting is not even. Folding machine K8RS...

  • Page 216: Setting The Standard Register Table

    The deflection roller at the end of the register table is a hazardous entanglement zone. Non-observance could result in injury. Do not reach into the alignment table when the machine is running. 1 Deflection roller 2 Parallel fold infeed Figure 123: Deflection roller danger spot Folding machine K8RS...

  • Page 217: Adjusting The Conveyor Table

     Position the transport belts (6) according to the sheet format. conveyor table  Position the smoothers (2) over the transport belts (6).  Position the ball holders (3) according to the sheet format.  The conveyor table is set. Folding machine K8RS...

  • Page 218: Switch Ultrasonic Double Sheet Detector On/Off

    • Foil-clad products Measure:  Switch off the ultrasonic double sheet detector. See chapter "8.6.3 Switch ultrasonic double sheet detector on/off"  Activate the <Manual double sheet detector>. See chapter "8.6.4 Adjusting the manual double sheet detector" Folding machine K8RS...
  • Page 219 3) Press the selection button (2). A selection list is displayed. 4) Select station PB1. 5) Press the <B122 double sheet> button (3). The <B122 double sheet> button displays a red warning mark.  The ultrasonic double sheet detector is switched off. Folding machine K8RS...

  • Page 220: Adjusting The Manual Double Sheet Detector

    1) Start the machine. 2) Push a strip of simple paper thickness under the smoother (7) until it is between the switching segment (5) and the transport roll (6). The double sheet detector may not switch. Folding machine K8RS...
  • Page 221 6) After securing, check the function of the double sheet detector again and readjust if necessary.  The double sheet detector is re-adjusted. To account for paper differences: • Turn the knurled screw (3) up to 1/4 turn to the right (clockwise). Folding machine K8RS...

  • Page 222: Adjusting For The Sheet Format

    1) Loosen the knurled screw (1). 2) Adjust the guide rail (2) so that the sheet edge runs in the middle of the guide rail. 3) Tighten the knurled screw (1).  The guide rail is set. Folding machine K8RS...
  • Page 223 3) Distribute the smoothers evenly (3). 4) Hook the smoothers (3) into the sheet guide plate of the parallel fold using the plate springs. 5) Tighten the knurled screws on the smoothers (3).  The smoothers are distributed. Folding machine K8RS...

  • Page 224: Adjusting The Angle For The Fold Rollers

     Loosen the knurled screw (3).  Adjust the eccentric (2) using the scale (1) according to the tilt of the fold.  Tighten the knurled screw (3).  Check the fold.  Correct if necessary.  The angle is adjusted. Folding machine K8RS...

  • Page 225: Adjusting The Vacuum

    The vacuum in the transfer area to the fold rollers can be reduced for large vacuum and long formats. How to reduce the vacuum:  Reduce vacuum by pushing the lever (3) in the direction <-> (feeder).  The vacuum is reduced. Heavy/thick paper requires more vacuum than light/thin paper. Folding machine K8RS...

  • Page 226: Adjusting The Parallel Fold

    The adjustment of the stop screws may not be changed (factory setting). CAUTION! Incorrectly fixed buckle plates. Non-observance could result in personal injuries or damage to property. Make sure that the buckle plates are fastened securely by the clamping lever. Folding machine K8RS...

  • Page 227: Adjusting The Roller Pressure (Standard)

    3 Fold roller pair 3 Figure 131: Parallelfold roller diagram The roller diagram is on the side wall of the parallel fold and serves as an adjustment aid. It shows the fold rollers and slitter shafts with the associated setting elements. Folding machine K8RS...
  • Page 228  The basic setting is adjusted. Always complete settings with a turn of the adjustment knob (6) clockwise (+). (roller pressure is getting looser). This way, an even roller pressure is guaranteed with the next paper change. Folding machine K8RS...
  • Page 229 How to lock the adjustment knobs: knobs against  Tighten the screws (5) on the adjustment knobs (6). twisting  The adjustment knobs (6) are secured. Do not tighten the screws (5) too much; otherwise you may damage the adjustment knobs (6). Folding machine K8RS...

  • Page 230: Changing The Fold Roller Setting (Automatic)

     Press the button (5) until the RL symbol appears on the button.  Press the input field (6). A selection window is opened.  Press the input field (7). A numeric input keyboard is opened.  Enter the new value for the left-hand side. Folding machine K8RS...

  • Page 231: Buckle Plate Positions

    8.7.3 Buckle plate positions 1 4 buckle plate parallel fold 2 6 buckle plate parallel fold Figure 134: Buckle plate positions The upper buckle plates have an uneven numbering. The lower buckle plates have an even numbering. Folding machine K8RS...

  • Page 232: Inserting The Buckle Plates

    Non-observance could result in personal injuries or damage to property. Make sure that the buckle plates are fastened securely by the clamping lever. 1 Stop screw 4 Stop bolt 2 Buckle plate 5 Support bars 3 Clamping lever Figure 135: Buckle plates Folding machine K8RS...
  • Page 233 Press the buckle plates (2) with the clamping lever eccentric in the direction of the rollers. • The stop screw (1) must lie on the stop pin (4). • Do not change the adjustment of the stop screws (factory setting). Folding machine K8RS...

  • Page 234: Pull Back/Remove The Buckle Plates

    There are also entanglement and crushing hazards when turning the machine with the safety handwheel! CAUTION! Incorrectly fixed buckle plates. Non-observance could result in personal injuries or damage to property. Make sure that the buckle plates are fastened securely by the clamping lever. Folding machine K8RS...
  • Page 235 Press the EMERGENCY STOP palm button. 2) Loosen the clamping lever (3). 3) Pull the clamping lever (3) outwards. 4) Pull out the buckle plate (2). 5) Place the buckle plate (2) correctly.  The buckle plate is removed. Folding machine K8RS...

  • Page 236: Adjusting The Buckle Plates (Standard)

    CAUTION! Misadjustment of the stop screws. Non-observance could result in serious property damage to the buckle plates and fold rollers. The adjustment of the stop screws may not be changed (factory setting). Folding machine K8RS...
  • Page 237  The knurled screw (metal) (9) must be tightened completely.  Tighten the knurled screw (1). Turn to the right = folding length is increased. Turn to the left = folding length is decreased.  Precise adjustment is adjusted. Folding machine K8RS...
  • Page 238  Tighten the knurled screw (plastic) (4).  The basic setting is adjusted. Depending on the print mark, it may also be necessary to change the angle of the register table. Folding machine K8RS...
  • Page 239 2) Loosen the clamping lever (3). 3) Pull back unneeded buckle plates. 4) Reverse the installed sheet deflector (2). 5) Push the buckle plate forwards. 6) Tighten the clamping lever (3).  The sheet deflector function is activated. Folding machine K8RS...
  • Page 240 How to make the basic setting: basic setting  The adjustment must be undertaken in small steps on both sides equally.  Turn both knurled screws (3) until both scales (2) are on zero.  The basic setting is adjusted. Folding machine K8RS...
  • Page 241  Turn the screws (1) to the left until they are flush with the surface of the reinforcement bar (2). Visual inspection: The reinforcement bar (2) must be straight. It may also be necessary to enlarge the inner width. Folding machine K8RS...
  • Page 242 Turn to the left = "inner width" becomes smaller.  The "inner width" is adjusted. Basic setting A basic setting is not required since the setting of the "inner width" must be made individually according to the properties of the paper to be processed. Folding machine K8RS...
  • Page 243 2) Pull back the buckle plate/sheet deflector a little or clamp strips of carton or several paper thicknesses between the stop pins and stop screw (1). 3) Adjust both sides equally.  The deflecting area/buckling area is increased. Folding machine K8RS...

  • Page 244: Adjusting The Buckle Plates (Automatic)

    Crushing hazard during automated format change. Non-observance could result in personal injury. When starting the automated format change, observe the following precautions: • Do not reach into the machine. • Make absolutely sure that there are no other people on the machine. Folding machine K8RS...
  • Page 245 A numeric input keyboard (7) is opened. Enter the desired value.  Large changes are made. Repositioning How to re-position the sheet stops: sheet stops  Press the <Start> button (8).  The sheet stops are positioned to the values entered. Folding machine K8RS...
  • Page 246  Turn the rear adjusting wheel (2) so that the markings on the two adjusting wheels are above one another.  Tighten the screw (1).  The basic setting is adjusted. Depending on the print mark, it may also be necessary to change the angle of the register table. Folding machine K8RS...
  • Page 247  The sheet deflector function is activated. 8.7.7.4 Additional settings of the buckle plates (automatic) Additional settings of the buckle plates (automatic) are identical to the settings of the buckle plates (standard). See chapter "8.7.6 Adjusting the buckle plates (standard)". Folding machine K8RS...

  • Page 248: Adjusting The Ftk Combination Buckle Plate

     Turn the rear adjusting disk (2) until the sheet stop (1) is in the sheet deflector position (5). Upper buckle plates 1, 3, 5. = turn right Lower buckle plates 2, 4, 6. = turn left  Tighten the knurled screw (metal) (3).  The sheet deflector function is activated. Folding machine K8RS...

  • Page 249: Correcting Skewed Perforation

     The skewed perforation is corrected. • The adjustment of the stop screws may not be changed (factory setting). • In case of deviations greater than 5 mm (0.0197 in.), distribute the setting across two sheet deflectors. Folding machine K8RS...

  • Page 250: Installing/Dismounting Slitter Shafts

     Unlock the slitter shaft cassette with the notch lever (1).  Pull out the slitter shaft cassette with the handle (5).  Loosen the grub screws (4) and (7) with the MBO ball Allen key SW4. Folding machine K8RS...
  • Page 251 The set collars (3) must life flush.  Fasten the slitter shafts (2) with the grub screws (4) and (7). To do this, use only the MBO ball Allen key SW4.  Push the slitter shaft cassette in with the handle (1) until it snaps in.

  • Page 252: Creasing, Cutting And Perforating Devices

    How to insert the perforating knife:  Loosen the nuts (2) with the hook wrench (10).  Insert the perforating disk (3) into the knife holder (5). The slotted knives need not be taken off the slitter shaft. Folding machine K8RS...
  • Page 253 Heed the attached TM 32/2 list of knives. Tooth forms Figure 152: Tooth forms  Use type of blade (1) for the 1st and 3rd folding unit.  Use type of blade (2) for the 2nd folding unit. Folding machine K8RS...
  • Page 254 Match the gap and installation method to the product to be processed. • Cutting and scoring edges may never touch the perforating knives. • However, the perforation cut of this knife will not be as sharp as a normal perforation. Folding machine K8RS...
  • Page 255 How to score brittle paper:  With brittle paper surfaces, score the paper on the rubber insert of a transport roll (2).  Use a scoring knife with a smaller diameter.  The brittle paper is scored. Folding machine K8RS...
  • Page 256  Set up the Super-Score device as shown in the illustration. • Use fewer distance pieces (2) if the rubber rings (3) are worn. • Use more distance pieces (2) if the paper is cut during scoring. Folding machine K8RS...
  • Page 257  Make sure that there is a distance washer (0.5 mm) between the rubber ring (8) and slitting disk (7).  Adjust the counter knife (5) on the bottom slitter shaft. Please follow the illustration for the proper position.  Use strippers (1) Folding machine K8RS...
  • Page 258 The best result is achieved with this mounting variant: • Position (2) on the top, position (3) at the bottom. • Knife cutting edge (2) towards the paper trim guided by the rubber ring (6). Folding machine K8RS...

  • Page 259: Adjusting The Crossfold

    The sheet should lie flat on the stop (depending on the fold type and paper).  Removing the index bolt (3). Withdrawing the  Pull the entire brush unit on the frame (2) forwards. brush unit This makes it easier to remove misfolded sheets. Folding machine K8RS...

  • Page 260: Adjusting The Cross Fold Stop (Standard)

     Loosen the plastic knurled screw (3).  By turning the front adjusting wheel (5), only the sheet stop on the drive side is adjusted. Turn to the right = folding length is increased. Turn to the left = folding length is decreased. Folding machine K8RS...
  • Page 261  The basic setting is adjusted. Also use the crossfold stop to change the length position of the folding knife. Thus the transport rollers remain in the right position. See chapter "8.8.7 Adjusting the folding knife in the lengthwise position (automatic)". Folding machine K8RS...

  • Page 262: Adjusting The Cross Fold Stop (Automatic)

    When calculating a new folding imposition, the angle adjustment is automatically set to 0.0 mm. Repositioning the How to re-position the stop: stop  Always press the <Start> function key (6) after the value is changed.  The crossfold stop is repositioned. Folding machine K8RS...

  • Page 263: Open/Close Crossfold Stop

     Push the crossfold stop on the index bolt (1) downwards.  Re-fit the index bolt (1).  The crossfold stop is closed. • When closing the crossfold stop (2), the crossfold and threefold knife is activated automatically. • Illuminated buttons (4 and 5) are lit green. Folding machine K8RS...

  • Page 264: Opening/Closing The Pneumatic Crossfold Stop (Option)

    How to close the crossfold stop:  Press the <Folding knife 1> (5) illuminated button again. crossfold stop The crossfold knife is switched on. The illuminated ring is lit in green.  The crossfold stop (2) is closed automatically. Folding machine K8RS...

  • Page 265: Adjusting The Folding Knife In The Lengthwise Position (Standard)

    The transport rollers fixed to the folding knife (2) are automatically adjusted with the folding knife carrier (1). • The transport rolls are aligned at the factory in a fixed position and they should not be moved. Folding machine K8RS...

  • Page 266: Adjusting The Folding Knife In The Lengthwise Position (Automatic)

    Only ever change the center position of the crossfold knife by pressing the button (3). This ensures a parallel correction of the sheet stop and transport rolls. • With negative numbers: First enter the number, then a minus sign. Folding machine K8RS...

  • Page 267: Opening/Closing The Crossfold Table

    How to close the crossfold table:  Secure the crossfold table by pressing up the handles (3). crossfold table  Pull the safety bolt (4).  Close the crossfold table (2) using the handle (3).  Close the clamping lever (1). Folding machine K8RS...

  • Page 268: Adjusting The Fold Rollers And Slitter Shafts (Standard)

    Figure 165: Setting elements fold rollers Setting elements for slitter shafts 1 Setting elements for slitter shafts at crossfold Figure 166: Setting elements slitter shafts For additional details for the set-up of setting elements, see chapter "8.7.1 Adjusting the roller pressure (standard)" Folding machine K8RS...

  • Page 269: Adjusting The Fold Rollers And Slitter Shafts (Automatic)

     Press the <Enter> button to complete the input.  Press the input field (2). A numeric input keyboard is opened.  Enter the new value for the right-hand side.  Press the <Enter> button to complete the input.  Both sides are changed unevenly. Folding machine K8RS...
  • Page 270 Operation and adjustment Adjusting the crossfold The input changes only become effective when the machine is restarted. Folding machine K8RS...

  • Page 271: Installing/Removing Slitter Shafts

     Open the flap (3).  Remove the strippers that get in the way of removal.  Loosen the screws (2) with the MBO ball Allen key size SW4.  Secure the slitter shafts. If necessary, seek the help of a second person.
  • Page 272  Install the slitter shafts.  Slide the plug bearings (1) into the bore of the slitter shaft stub.  Tighten the screws (2) with the MBO ball Allen key size SW4. While doing this, press the plug bearings (1) against the slitter shafts.

  • Page 273: Adjusting The Klt Buckle Plate (Standard)

     Loosen both screws (1).  Pull out the buckle plate (3) a little.  Fold down the attached swinging-sheet deflector.  Push the buckle plate (3) in up to the stop (2).  Tighten the screws (1). Folding machine K8RS...

  • Page 274: Adjusting The Ktl Buckle Plate (Automatic)

     Enter a new value for the folding length.  Press the <Start> button (2).  The sheet stop is repositioned. 8.8.13.1 Adjusting the angle of the sheet stop See chapter "8.7.7.2 Adjusting the angle of the sheet stop (automatic)" Folding machine K8RS...

  • Page 275: Adjusting The Threefold

    CAUTION! Crushing hazard on the threefold tape roller. Non-observance could result in injury. • Never reach towards the tape roller while the machine is running. 1 Tape roller Figure 171: Checking tape roller on the threefold outlet Folding machine K8RS...

  • Page 276: Set-Up Of Transport Brushes

    In case of tensions or shafts on the stop: • Reduce the pressure by placing several paper strips under the adjusting elements (1). • The sheet should lie flat on the stop (depending on the fold type and paper). Folding machine K8RS...

  • Page 277: Adjusting The Threefold Stop (Standard)

    Turn to the left = folding length is decreased.  The markings on the adjusting wheels provide a reference point for how far the adjustment was.  Tighten the knurled screw (plastic) (4).  Angle is adjusted. Folding machine K8RS...

  • Page 278: Adjusting The Threefold Stop (Automatic)

    When calculating a new folding imposition, the angle adjustment is automatically set to 0.0 mm. Repositioning How to re-position the stop: the stop  Always press the <Start> button (4) after the value is changed.  The threefold stop is repositioned. Folding machine K8RS...

  • Page 279: Open/Close Threefold Stop

     Push the threefold stop on the index bolt (1) downwards.  Engage the index bolt (1).  The threefold stop is closed. • When closing the threefold stop (3), the crossfold and threefold knife is activated automatically. • The illuminated button (4) is lit green. Folding machine K8RS...

  • Page 280: Pull Out The Three Fold Carriage

     The clamping levers (1) must remain pulled out.  Push the threefold carriage (2) in.  Push in the clamping lever (1).  Clamp the clamping levers (1) counter-clockwise.  The threefold carriage is pushed in. Folding machine K8RS...

  • Page 281: Adjusting The Fold Rollers (Standard)

    Adjust the fold rollers and slitter shafts to the number of sheets to run through using the setting elements (1) and (2). For additional details on adjusting setting elements: See chapter ."8.7.1 Adjusting the roller pressure (standard)". Folding machine K8RS...
  • Page 282 Adjust the fold rollers and slitter shafts to the number of sheets to run through using the setting elements (1) and (2). For additional details on adjusting setting elements: See chapter ."8.7.1 Adjusting the roller pressure (standard)". Folding machine K8RS...

  • Page 283: Adjusting The Fold Rollers (Automatic)

    A numeric input keyboard (3) is opened.  Enter the new value for the left-hand side.  Press the <Enter> button (3) to complete the input.  Press the input field (2). A numeric input keyboard is opened. Folding machine K8RS...
  • Page 284 Adjusting the threefold  Enter the new value for the right-hand side.  Press the <Enter> button (3) to complete the input.  Both sides are changed unevenly. The input changes only become effective when the machine is restarted. Folding machine K8RS...

  • Page 285: Installing/Removing Slitter Shafts

    See chapter "8.9.5 Pull out the three fold carriage."  Remove the stripper that prevents removal.  Loosen the screws (1) with the MBO ball Allen key SW4.  Hold the slitter shafts fast. If necessary, seek the help of a second person.

  • Page 286: Special Procedure With Threefold Work

     Insert the slitter shafts in their original position.  Insert the plug bearings (2) into the holes of the slitter shaft butt.  Tighten the screws (1) with the MBO ball Allen key SW4. While doing this, press the plug bearings (2) against the slitter shafts.
  • Page 287  The guard (3) has been removed. Fitting the guard How to fit the guard:  Re-fit the guard (3).  Fasten the guard (3) using the four screws.  The guard (3) has been fitted. Folding machine K8RS...

  • Page 288: Adjusting The Ktlt Buckle Plate (Standard)

     Push in the buckle plate (2) with the crank (1).  See chapter "8.7.3 Buckle plate positions" Adjusting the buckle plate 8.9.10.1 Combination buckle plate FTK For settings, see chapter "8.7.8 Adjusting the FTK combination buckle plate". Folding machine K8RS...

  • Page 289: Adjusting The Ktlt Buckle Plate (Automatic)

     Press the <Start> button (2). The buckle stop is repositioned.  The folding lengths have been corrected. 8.9.11.1 Adjusting the angle of the sheet stop See chapter "8.7.7.2 Adjusting the angle of the sheet stop (automatic)". Folding machine K8RS...

  • Page 290: Adjusting The Folding Knife

    Figure 185: Height adjustment folding knife Basic setting Red marking must be on zero (3).  Loosen the lock nuts (2) with the MBO ball Allen key SW4. Height adjustment  Turn the setting wheel (1) counter-clockwise. Setting the folding ...

  • Page 291: Adjusting The Angle

    Non-observance could result in property damage. • When adjusting, make sure that the folding knife is not set too low. • For an extreme incline adjustment, it may be necessary to set the folding knife a bit higher. Folding machine K8RS...
  • Page 292 Basic setting Adjusting the angle How to adjust the angle:  Open the screw (1) with the MBO ball Allen key SW4. (Relax the toothed belt).  Open the screw (3) with the MBO Allen key SW5  Adjust the eccentric (2) by hand.

  • Page 293: Enter Additional Steadying Distance

     Enter a value for the additional steadying distance.  An additional steadying distance has been entered. • The input of an additional steadying distance can change the sheet gap. • If the machine has been calibrated, the steadying distance can only be increased. Folding machine K8RS...

  • Page 294: Adjusting Outfeed Transport

    Figure 188: Adjusting outfeed transport Adjusting How to adjust the transport belts:  Loosen the screws (4) with the MBO ball Allen key SW4. transport belts  Position the supports (3) with transport belts (5) according to the paper format.

  • Page 295: Turning The Threefold Folding Unit (Variant S-Ktz)

    Closing the  Tighten the safety bolts (2). crossfold table  Close the crossfold table (5) using the handle (4).  Close the clamping lever (3). The crossfold table (5) is thus fixed in its working position. Folding machine K8RS...

  • Page 296: Removing The Paper Jam

     Feed a single sheet to check the correct function of the machine.  If OK, start production.  If not OK, determine and eliminate the cause.  Paper jam is removed. Turning the machine forwards/backwards using the safety handwheel makes it easier to remove the paper jam. Folding machine K8RS...

  • Page 297: Identification And Handling Of Malfunctions

    Brushes are too high or not far Brushes should be approx. 2-3 mm enough in the pile, sheets may above the pile and 5-6 mm in the pile. float away. Table 36: Error/cause/remedy on the flat pile feeder/palletized feeder Folding machine K8RS...

  • Page 298: Register Table

    Sheet stutters on register guide Increase vacuum, turn knurled screw at the transfer and tips over to to the right. the right, generally too less vacuum. Table 37: Error/cause/remedy on the register table Folding machine K8RS...

  • Page 299: Parallel Fold

    A lower buckle plate/ or sheet Position and clamp the buckle plate/ deflector is not properly sheet deflector properly. positioned in the folding space. Table 38: Error/cause/remedy at parallel fold Folding machine K8RS...

  • Page 300: Double Fold In The First Fold

    4 or 6 looser. Use hold-down springs in buckle plate 3 or 5. Use now gatefold plate. If double fold appears again, open fold rollers at exit up to 12 paper thicknesses. Table 39: Error/cause/remedy at first fold Folding machine K8RS...

  • Page 301: Edges/Dog Ears At Letter Fold, Gatefold

    • Turn sheet and fold downwards, e.g. in buckle plates 2 + 4. • Open fold rollers at exit, up to 6 paper thicknesses. • Use hold-down springs in buckle plate Table 40: Error/cause/remedy for letter and gatefold Folding machine K8RS...
  • Page 302 Operation and adjustment Identification and handling of malfunctions Folding machine K8RS...

  • Page 303: Maintenance

    See chapter "4.6.11 Checking protective devices". 9.1.1 Qualification of personnel This table lists the necessary qualification of the personnel related to "Maintenance" of the machine. Operational maintenance Maintenance Repair Table 41: Qualification of personnel Legend: X permitted, - not permitted Folding machine K8RS...

  • Page 304: Safety Messages

    Non-observance could result in serious injury or death. The protective devices protect against danger spots. • Never operate the machine without protective devices. • Note that after maintenance or repair work, all protective devices must be reinstalled. Folding machine K8RS...
  • Page 305 Entanglement hazard when removing the safety handwheel. Non-observance could result in serious injury or death. • Turn the main switch to the position <0>. • Use a padlock to secure the main switch from unintentionally switching on again. Folding machine K8RS...

  • Page 306: Customer Service

    Ordering spare and wear parts You can obtain the spare and wear parts worldwide via the corresponding MBO agency near you. For all questions relating to your machine, please also contact your MBO agency. You can find the address on our home page: www.mbo-folder.com.

  • Page 307: Operational Maintenance

    Non-observance could result in serious injury or death. • Make sure that the specifications for the respective gap are adhered • If a gap is too large, it must be re-adjusted by MBO Service or authorized customer service. • Never dismantle, bridge or bypass safety switches.
  • Page 308 4) After the test is complete, disengage the EMERGENCY STOP palm button.  EMERGENCY STOP palm button is checked. If the function does not match the description, have it checked by MBO Service or an authorized customer service agent. Folding machine K8RS...
  • Page 309 It is not permitted for the machine to turn as well.  The smooth running has been checked.  Pull the safety handwheel (3) towards you, turning the safety Checking the hand drive handwheel at the same time. Folding machine K8RS...
  • Page 310 If the safety switch does not switch on and off safely, the safety switch must be re-adjusted. • For safety reasons, the safety switch must be adjusted by MBO Service or an authorized customer service agent. See also Chapter"4.6.12 Checklists for protective devices"...
  • Page 311 If the safety switch does not switch on and off safely, the safety switch must be re-adjusted. • For safety reasons, the safety switch must be adjusted by MBO Service or an authorized customer service agent. See also chapter "4.6.12 Checklists for protective devices".
  • Page 312 If the safety switch does not switch on and off safely, the safety switch must be re-adjusted. • For safety reasons, the safety switch must be adjusted by MBO Service or an authorized customer service agent. See also chapter "4.6.12 Checklists for protective devices".
  • Page 313 If the safety switch does not switch on and off safely, the safety switch must be re-adjusted. • For safety reasons, the safety switch must be adjusted by MBO Service or an authorized customer service agent. See also chapter "4.6.12 Checklists for protective devices".
  • Page 314 • If the safe function of the safety switch is no longer guaranteed, it must be readjusted or replaced. • For safety reasons, this must be adjusted by MBO Service or an authorized customer service agent. Folding machine K8RS...
  • Page 315  Press buttons (1) and (4) simultaneously.  After a delay time, the machine runs at production speed. If the function does not match the description, have it checked by MBO Service or an authorized customer service agent. Folding machine K8RS...

  • Page 316: Checking The Pneumatic Springs

     The pneumatic springs (2) must be replaced if the supporting arm (1) is lowered automatically from the pivoted upwards position.  The pneumatic springs are checked. Only have the pneumatic springs replaced by MBO Service or by an authorized customer service agent. Folding machine K8RS...
  • Page 317  The pneumatic springs must be replaced when the noise damping safety hood lowers by itself from the completely open position.  The pneumatic springs are checked. Only have the pneumatic springs replaced by MBO Service or by an authorized customer service agent. Folding machine K8RS...
  • Page 318  The pneumatic springs must be replaced when the crossfold table lowers by itself from the completely open position.  The pneumatic springs are checked. Only have the pneumatic springs replaced by MBO Service or by an authorized customer service agent. Folding machine K8RS...
  • Page 319  The pneumatic springs must be replaced when the guard lowers by itself from the completely open position.  The pneumatic springs are checked. Only have the pneumatic springs replaced by MBO Service or by an authorized customer service agent. Folding machine K8RS...

  • Page 320: Cleaning The Machine

    CAUTION! Incorrect use of cleaning agents. Non-observance could result in personal injury. • Be sure to follow the manufacturer's safety instructions. • Avoid any skin contact. • Wear suitable safety gloves. • Wear safety glasses. Folding machine K8RS...
  • Page 321 Cleaning rollers MBO Binder GmbH & Co. KG recommends "Varn" cleansing agent with the designation: "VM 111 or VWM Wash". The "Varn" company delivers to the printing industry worldwide. It is therefore not impossible for different product names to be used in certain countries.
  • Page 322 The guides in the feeder head get dirty during production due to paper dust and printing powder. They should therefore be cleaned after each job (daily). How to clean the guides:  Clean the guides using a cloth.  Lubricate the guides using silicone spray.  The guides are cleaned. Folding machine K8RS...
  • Page 323 Clean the drive shaft (1) and guide rods (2) weekly to remove paper dust and ink powder. • Never clean the machine using compressed air (bearing damage). • Use only brushes and a vacuum cleaner for this. • The drive shafts and guides may not be greased. Folding machine K8RS...
  • Page 324 Clean the swiveling lever and the gap to the side frame monthly to remove paper dust and ink powder. • Never clean the machine using compressed air. (bearing damage) • Use only brushes and a vacuum cleaner for this. Folding machine K8RS...
  • Page 325 6) Dry the fold rollers with a dry linen cloth. 7) Remove the padlock on the main switch. Ensure that all persons are in the secured area. Turn the main switch to the position <1>.  Spiral fold rollers are cleaned. Folding machine K8RS...
  • Page 326 11)Remove the ink and powder particles thus flung out from the machine. 12)Remove the padlock on the main switch. Ensure that all persons are in the secured area. Turn the main switch to the position <1>.  High-grip fold rollers are cleaned. Folding machine K8RS...
  • Page 327 They should therefore be cleaned after each job (daily). How to clean the optical sensors:  Clean the optical elements of the sensors with a dry, lint-free cloth.  Optical sensors are clean. Folding machine K8RS...
  • Page 328 6) Grease the running surfaces of the telescopic rails slightly with a resin- free grease.  Slitter shaft cassette is cleaned. Never use silicone spray or WD40. Otherwise, the residue combines with the accumulating paper dust to make a gluey mess. Folding machine K8RS...
  • Page 329 Paper dust and printing powder influence the function of the guides significantly. Clean the guides monthly. How to clean the guides: 1) Vacuum out the paper dust with an industrial vacuum cleaner. 2) Rub the guides dry with a linen cloth.  The guides are cleaned. Folding machine K8RS...

  • Page 330: Cleaning/Replacing Air Filter Of The Pressure Vacuum Pump

     Fit the cover (4) and lock it by turning clockwise.  Replace the cover (2).  Re-tighten the knurled screws (3).  Confirm the maintenance on the display. See chapter "9.4 Maintenance"  The filters are clean. Folding machine K8RS...
  • Page 331 Maintenance Operational maintenance Replace the filter cartridges (1 + 5) every six months or as necessary. Folding machine K8RS...

  • Page 332: Maintenance

    Non-observance could result in serious injury or death. • Make sure that third parties are not endangered during any maintenance work. • Make sure that all persons are in a safe area prior to re-connection of the machine. Folding machine K8RS...

  • Page 333: Checking The Feeder

    Figure 205: Checking the drive chain Check the drive chain (1) every six months for its tension.  If the drive chain needs to be tightened, please inform MBO Service or an authorized customer service representative. For safety reasons, work is only permitted to be carried out on the feeder motor by MBO Service or an authorized customer service agent.
  • Page 334 Figure 207: Lubricate the pile plate axle Lubricate the pile plate axle (1) every 500 operating hours. How to lubricate the axle:  For this purpose, lubricate the lubrication nipples (2) on the left and on the right. Folding machine K8RS...
  • Page 335  Tension the belt (1) through turning in the screw (2). Do not tension the belt (1) too much.  Fasten nut (3).  Fix the guard (4) with the screws (5).  The belt is replaced. Folding machine K8RS...

  • Page 336: Checking The Register Table

    8) Tension the drive belt (1) with the tension lever (7). 9) Check the centric running of the belt.  Drive belt is replaced.  Mount the guards on the drive belt and the handwheel (3) Attaching the guard Folding machine K8RS...
  • Page 337 The row of holes on the alignment belt (3) must match the row of holes on the register guide.  Tighten the screw (7).  Check the position of the alignment belt again and re-adjust it if necessary. Folding machine K8RS...
  • Page 338  Unfasten the screw (10) Removing the  Relax the tension on the alignment belt (1) by loosening the screw (9). alignment belt  Unhook the lattice from the hooking points (4).  Unfasten the screw (3). Folding machine K8RS...

  • Page 339: Checking The Parallel Fold

    The rotating shaft represents a risk of entanglement Non-observance could result in serious injury or death. • Turn the main switch to the position <0>. • Use a padlock to secure the main switch from unintentionally switching on again. Folding machine K8RS...
  • Page 340 Make sure that the key is seated properly. 5) Pull the handwheel towards you and, at the same time, tighten the screw (2) with an inside hexagon wrench SW6. 6) Replace the end cover (5) on the handwheel (2).  The guard is fitted. Folding machine K8RS...
  • Page 341 4) Fit the new Poly-V belt (5). 5) Insert the flange (4) and fasten it with the screws (3). 6) Tension the Poly-V belt (5) with the tensioning roller (1) and tighten the screw (2).  The belt is replaced. Folding machine K8RS...
  • Page 342  Tension the Poly-V belt (4) by tightening the adjustment screw (2).  Loosen the lock nut on the adjusting screw (2).  Tighten the screw (3) on the tensioning roller (1).  The belt is replaced. Folding machine K8RS...
  • Page 343  Loosen the screws (2) and swivel the flange (1) downwards.  Remove the old Poly-V belt (3).  Fit the new Poly-V belt (3).  Swivel the flange (1) upwards and fasten it with the screws (2). Folding machine K8RS...
  • Page 344 MBO recommends having MBO Service or an authorized customer service agent change the drive belt. To replace the drive belt for the folding rollers, the following steps are required: •...
  • Page 345 • Check the belt tension monthly. To do this, turn the machine by hand. Here, the fold rollers may not be stopped by hand. • The center rollers on the drive belt have red markings on them. Folding machine K8RS...
  • Page 346 The belt tension device is under great spring tension. • Wear safety gloves when replacing. • When replacing the drive belt, call another person to help you. CAUTION! Material break. Non-observance could result in property damage. Never pull the drive belt over edges during installation! Folding machine K8RS...
  • Page 347  Loosen the nuts (1) at the adjustment roller (4).  Adjust the centric running of the drive belt (3) by turning the eccentric (2). Use a flat fork wrench size 17 for this.  Tighten the nut (1) again.  The belt running is centred. Folding machine K8RS...
  • Page 348 1 Drive belt for fold rollers in crossfold and threefold Figure 219: Checking drive belt for fold rollers in crossfold and threefold Only have the drive belt replaced by MBO Service or by an authorized customer service technician. Folding machine K8RS...
  • Page 349 If it is no longer possible to adjust centered running or achieve the necessary tension or if the general condition of the belt is poor, it must be replaced. MBO recommends having MBO Service or an authorized customer service agent change the drive belt. CAUTION! High spring tension.
  • Page 350  Measure the spring length (3) from eye to eye when the springs are Checking the spring length installed. The spring length should be 190 mm.  If the spring length is not correct, the correct length must be set with the belt length adjustment rollers. Folding machine K8RS...
  • Page 351  Adjust the centric running of the drive belt (1) by turning the eccentric behind the red-marked screw. Use a flat fork wrench size 17 for this.  Tighten the red-marked screw again.  Attach the guard over the drive again. Attaching the guard Folding machine K8RS...

  • Page 352: Checking The Fold Rollers And Slitter Shafts

    Check the fold rollers and slitter shafts in the: • Parallel fold • Crossfold • Threefold Only have the fold rollers replaced by MBO Service or by an authorized customer service technician. 9.4.4.1 Contamination and damage Check the fold rollers and slitter shafts weekly for contamination and damage: •...

  • Page 353: Checking The Buckle Plates

    Special attention should be paid to: • Sheet stop • Bottom plate lip • Top plate lip • Visual check of the screws Only have any damage repaired by MBO Service or by an authorized customer service agent. Folding machine K8RS...

  • Page 354: Checking The Slitter Shaft Cassette

    Figure 222: Checking the slitter shaft cassette. If the function is compromised, clean the slitter shaft cassette. See chapter "9.3.3.11 Cleaning the slitter shaft cassette" Only have any damage repaired by MBO Service or by an authorized customer service agent. Folding machine K8RS...

  • Page 355: Checking The Folding Knives

     Move the adjusting wheel forwards and backwards with both hands. The folding knife must move smoothly. Only have the smooth running restored by MBO Service or by an authorized customer service agent. 9.4.7.2 Checking the tension of the toothed belts Check the toothed belts in the folding knife units monthly for tension and their state and replace these if necessary.
  • Page 356  Pull out the threefold carriage.  Perform a visual check on the folding knives. See arrow direction. Only have the blades of the folding knives replaced by MBO Service or by an authorized customer service agent. Folding machine K8RS...

  • Page 357: Checking The Crossfold Table And Threefold Carriage

    Check the threefold table monthly for function and smooth running. Special attention should be paid to: • Smooth running of the telescopic rails • Locking device If the function is compromised, clean the telescopic rails. See chapter "9.3.3.12 Cleaning the guides on the threefold carriage". Folding machine K8RS...
  • Page 358  The brushes are adjusted. • Please see to an uniform height adjustment of all brushes to the register table. • Use a piece of paper to check that there is even pull across the entire surface. Folding machine K8RS...
  • Page 359 7) Adjust the brushes (5) with the screws (4) evenly, see above <Adjust brushes>.  The brushes are replaced. With new brushes, the distance <Top edge of the brush holder to the belt surface> approx. 51 mm. Folding machine K8RS...
  • Page 360 • Damage • Wear-off If necessary, clean transport belts with “Varn-Wash VM 111 or VWM“ and re-apply silicon carefully with silicon spray. Only have the transport tapes replaced by MBO Service or by an authorized customer service technician. Folding machine K8RS...

  • Page 361: Maintaining The Pressure Vacuum Pump

    Maintenance Maintenance 9.4.9 Maintaining the pressure vacuum pump The maintenance intervals and the corresponding procedure is described in the <C-KLR80/140> operating manual from the firm Elmo Rietschle. See chapter 7. Maintenance and repair Folding machine K8RS...

  • Page 362: Lubricating The Safety Handwheel

    1 Oiler Figure 227: Lubricating the safety handwheel How to lubricate the safety handwheel:  Clean the safety handwheel with a brush.  Lubricate the safety handwheel monthly on the oiler (1).  The safety handwheel is lubricated. Folding machine K8RS...

  • Page 363: Checking The Fan In The Control Cabinet

    • The fan wheel must be stationary. Opening the filter How to open the filter housing: housing  Pull the function symbol in the louvre grille upwards with a finger. The louvre grille will open up.  The filter housing is open. Folding machine K8RS...
  • Page 364 Compressed side of the filter mat pointing towards the fan wheel. Closing the fan case How to close the fan case:  Fold the louver grille back onto the filter housing until it clicks into place. The filter housing is closed. Folding machine K8RS...

  • Page 365: Maintenance Schedule

    "Checking the pneumatic Daily springs" 9.3.2.1 "Feeder head arm on the Daily feeder" 9.3.2.2 "Noise damping safety Daily hood" 9.3.2.3 "Crossfold table" Daily 9.3.2.4 "Guard over KTL plate" Daily 9.3.3 "Cleaning the machine" Weekly Table 42: Maintenance schedule Folding machine K8RS...
  • Page 366 9.4.1.2 "Greasing the chains" Monthly 9.4.1.3 "Lubricating the axle on Monthly the pile plate" 9.4.1.4 "Checking the suction Monthly belts" 9.4.2 "Checking the register Monthly table" 9.4.2.1 "Checking the drive belt" Monthly Table 42: Maintenance schedule Folding machine K8RS...
  • Page 367 9.4.7.2 "Checking the tension of Weekly the toothed belts" 9.4.7.3 "Check the blades of the Daily folding knife" 9.4.8 "Checking the crossfold Monthly table and threefold carriage" 9.4.8.1 "Checking the crossfold Monthly table." Table 42: Maintenance schedule Folding machine K8RS...

  • Page 368: Repair

    Repair work may only be performed by trained and authorized specialized personnel. • Heed the local occupational safety regulations. • Carry out a function test after the repair. Only have repair work performed by MBO Service or by an authorized customer service agent. Folding machine K8RS...

  • Page 369: Shutdown, Storage

    Non-observance could result in property damage. Observe the corresponding storage conditions. 10.2 Decommissioning 10.2.1 Temporary shutdown How to shut the machine down temporarily. Prerequisites These prerequisites must be fulfilled: • Main switch is switched off. • Compressed air supply is cut off. Folding machine K8RS...

  • Page 370: Final Decommissioning

     Observe the specifications regarding the weight and size of the machine when selecting the premises. See chapter "3.2 Technical data".  Use a suitable fork lift for transport. See chapter "3.2.3 Shipping and transport data".  Cover the machine with foil.  The machine is stored. Folding machine K8RS...

  • Page 371: Disposal

    • Comply with the corresponding national and regional laws and regulations. Non-EU countries: • Comply with the corresponding national and regional regulations, laws and directives. How to proceed to dispose of/recycle the machine. Prerequisites These prerequisites must be fulfilled: Folding machine K8RS...
  • Page 372  The machine is disposed of. All parts, consumables, and supplies of the machine: • Separate by type • Dispose of in accordance with local regulations, laws, and directives. If you have any further questions regarding disposal, please contact the manufacturer! Folding machine K8RS...
  • Page 373 FRANCE Tel.: +33 1 6935 5090 Fax: +33 1 6935 5099 www.mbo-folder.com info@mbofrance.fr MBO China MBO Binder Graphic Systems (Beijing) Co. Ltd. Haishunde Building, 201 room, No.A1, Donghuanbei Road, BDA Beijing 100176 P.R. CHINA Tel.: +86 10 6786 4021 Fax: +86 10 6787 3502 www.mbo-folder.com.cn...

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