Eng 99C6778 PDF

ROLAND 700
Operation
Product-no.: R700
Program version: B747Ax
Language: EN
Ref.no.:: 80 95A EN 6778
Target group: Printer, Exploiter
Registered trademarks
HKS Warenzeichenverband e.V.: HKS is a registered trademark of the HKS association.

Pantone, Inc.: The PANTONE inks referred to in the software application or in the user documentation may not correspond to the
standards identified by PANTONE. Accurate inks can be found in current publications by PANTONE. PANTONE and other Pantone,
Inc. trademarks are the property of Pantone, Inc. Pantone, Inc., 2003., Pantone, Inc. is the owner of the copyrights to ink data
and/or software licensed to MAN Roland Druckmaschinen AG for sole use in conjunction with JobPilot, PrepressLink, PressMonitor,
PECOM PressManager, central control console, Multi-CCI, Multi-CCI 2D, PressPilot, and ColorPilot. PANTONE ink data and/or soft-
ware may only be copied to other data carriers or storage devices if this is necessary to run JobPilot, PrepressLink, PressMonitor,
PECOM PressManager, central control console, Multi-CCI, Multi-CCI 2D, PressPilot, or ColorPilot.
MAN Roland Druckmaschinen AG

Mhlheimer Strae 341
63012 Offenbach
Germany
Copyright by MAN Roland Druckmaschinen AG 2004
All parts of this documentation are protected by copyright.

Any use outside the limits of the copyright is not allowed without the written consent of MAN ROLAND. This applies, in particular, to
the publication, reproduction and translation of this documentation or parts of it as well as to the storage and processing of its con-
tents by electronic data processing systems.
Designation Operation - EN
Target group Printer, Exploiter
Product Roland 700, R700
Program version B747Ax
Ref.no.: 80 95A EN 6778
Contents
Contents
1 Documentation of your press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Contents of the documentation box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Components of the instructions manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2.2 Products for maintenance and care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2.4 Putting into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2.6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 Guideline indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3.1 Explanation of the pictographs used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3.2 Meaning accentuated words or passages in a text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4 Your opinion is important to us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 Using the operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5.1 Handling the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Safety declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.2 Printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.3 Impeccable technical condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.4 Printing process materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.5 Operating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.6 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.7 National laws and directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.8 CE mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.9 Decommissioning and dismounting of the press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.1 Printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
2.3 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.3.1 Oil leaks and spills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.2 Disposal of operating materials, printing process materials and wearing parts . . . . . . . . . . . 2-4
2.4 Structure of safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4.1 Designation of safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5 Safe working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5.1 Special fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5.2 Degree of qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5.3 Operating positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Roland 700 - Operation I

Contents
2.5.4 Safety-relevant operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.5.5 Safe working in the pressroom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6.1 Electrically secured guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.6.2 Mechanically secured guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.6.3 Light barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2.6.4 Safety label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
3 Printing machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Operation of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.1 Switching the printing press on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.2 General button functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.3 Machine run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3 Safety information for gas pressure springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.3.1 Wear of gas pressure springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4 Safety information for using driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.4.2 Washing agent when using an intermediate drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.4.3 Danger spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.5 Procedure of automatic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.5.1 PPL plate change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.5.2 Run up ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.5.3 Ink roller washing program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.5.4 Starting the blanket and impression cylinder washing program . . . . . . . . . . . . . . . . . . . . . . . 3-15
4 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Overview of the operating panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.1 Commands: pile control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.2 Control panel: Fine adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Pile controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.1 Raising the pile supporting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.2 Lowering the pile supporting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
4.3.3 Stopping the pile hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.4 Make-ready of the feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.1 Changing main pile at feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4.2 Changing main pile at feeder (option: base) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4.3 Making ready feeder after a size change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.5 Manual NONSTOP operation (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.5.1 Manual NONSTOP: transport aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.5.2 Starting manual NONSTOP operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
II Roland 700 - Operation

Contents
4.5.3 Pile loading during manual NONSTOP operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4.5.4 Continuing manual NONSTOP operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.5.5 Manual NONSTOP operation: removing carrier rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.6 Suction head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.6.2 Setting the working height of the pile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.6.3 Setting the suction head forward or backward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.6.4 Setting the height of the suction head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.6.5 Adapting separators and sheet separators to the pile surface . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.6.6 Setting separators and sheet separators individually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.6.7 Coordinating the settings at the suction head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.6.8 Forwarder suckers, auxiliary forwarder suckers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4.6.9 Pick-up suckers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4.6.10 Separating blast nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.6.11 Auxiliary blast nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.6.12 Sheet separator elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
4.6.13 Sheet stop and sheet hold-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
4.7 Sheet transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4.7.1 Sheet guiding rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4.7.2 Double sheet control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
4.7.3 Forwarder wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
4.7.4 Sheet guide rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
4.7.5 Sheet carrier rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
4.7.6 Sheet hold-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4.7.7 Suction tapes feed board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
4.7.8 Foot switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
5 Printing module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2.1 Printing module 1, feed register B-side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.2 Printing module 1, feed register B-side, front guides (QuickChange option) . . . . . . . . . . . . . 5-5
5.2.3 Printing module, delivery A-side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
5.2.4 Printing module, delivery B-side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.3 Turning the machine by hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.3.1 Electrical release of drive motor brake (Machine: switched ON) . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.3.2 Releasing drive motor brake by hand (Machine: switched OFF) . . . . . . . . . . . . . . . . . . . . . . 5-10
6 Feed register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2.1 Control console for air supply in the feed register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Roland 700 - Operation III

Contents
6.2.2 Control panel DM1, feed register B-side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2.3 Control panel DM1, feed register B-side (QuickChange option) . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.1 Displays (DM1, B-side, feed register) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.2 Display of faults during sheet travel (DM1, B-side, feed register) . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.3 Correcting crooked sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.4 Electronic double sheet control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.5 Setting the foreign object barrier to the sheet thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.4 Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.4.1 Setting the blast air of the blast/suction element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.4.2 Setting the air pressure of the blast/suction rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4.3 Setting the air pressure of the suction plate (side guide) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4.4 Setting the air pressure of the suction roll (side guide) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.4.5 Setting the blast air of the suction plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.4.6 Setting the blast air of the blast/suction element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.5 Side guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.5.1 Detector: setting the side edge control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.5.2 Checking the lateral sheet stop of the side guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.5.3 Setting the lateral sheet stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.5.4 Unlocking the side guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.6 Suction plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.6.1 Checking the suction plate for voluminous, porous printing materials, lightweight and
thin paper printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.6.2 Changing the suction plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6.6.3 Locking the movement of the suction plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.6.4 Checking the suction plates for cardboard and lightweight cardboard . . . . . . . . . . . . . . . . . 6-17
6.7 Sheet hold-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.7.1 Checking the sheet thickness of the sheet hold-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.7.2 Setting the sheet hold-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.7.3 Cardboard guide at the side guide: Setting the sheet thickness . . . . . . . . . . . . . . . . . . . . . . 6-19
6.8 Sheet guide in front of front guides and cover guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6.8.1 Setting the sheet guide brush in front of the front and cover guides to the sheet
thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
6.8.2 Changing sheet guide in front of front and cover guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6.8.3 Setting the sheet guide rollers in front of the front and cover guides to the sheet
thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6.9 Front guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.9.1 Feed register: basic setting of front guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.9.2 Skewing the feed register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6.9.3 Individual setting of the front guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6.9.4 Setting front guides on PU 1 (QuickChange Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
IV Roland 700 - Operation

Contents
6.10 Swing gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

6.10.1 Setting the gripper pad bar of the swing gripper to the sheet thickness . . . . . . . . . . . . . . . 6-28
6.11 Feed register drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6.11.1 Setting the gripper pad bar of the feed register drum to the sheet thickness . . . . . . . . . . . 6-29
6.11.2 Converting feed register drum for cardboard guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6.11.3 Resetting feed register drum to standard printing material . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6.11.4 Converting feed register drum (QuickChange option) for the cardboard guide . . . . . . . . . . 6-34
6.11.5 Resetting feed register drum (QuickChange option) to standard printing materials . . . . . . 6-35
7 Printing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Cylinder packings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2.1 Cylinder packings for printing with bearer ring contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2.2 Printing with bearer ring contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.2.3 Cylinder packings for printing without bearer ring contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2.4 Printing without bearing ring contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Plate cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3.2 Appropriate printing plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3.3 Changing the printing plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3.4 PPL Emergency program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.3.5 Removing an incompletely removed printing plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.3.6 Manual register corrections on the LE tensioning bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.3.7 Correcting (extending) the LE printing plate in the circumferential direction . . . . . . . . . . . . . 7-18
7.3.8 Manual register corrections on the TE tensioning bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7.3.9 Correcting (extending) the TE printing plate in the circumferential direction . . . . . . . . . . . . . 7-20
7.3.10 Moving TE printing plate in an axial direction (extending or buckling) . . . . . . . . . . . . . . . . . . 7-22
7.4 Blanket cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.4.2 Suitable blankets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.4.3 Changing the blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.5 Impression cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
7.5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
7.5.2 Impression cylinder blowing device (ICB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

7.6 Transferter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7.6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7.6.2 Gripper pad bar on transferter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7.6.3 Sheet guide underneath transferter (downstream of the reversing device) and delivery
drum (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
7.6.4 Setting sheet guide underneath transferter (downstream of the reversing device) and
delivery drum (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Roland 700 - Operation V

Contents
8 Inking unit and dampening unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Ink unit splitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2.2 Ink flow change-over (QuickChange option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 Setting symmetric ink flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.4 Ink fountain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4.1 Emptying the ink fountain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8.4.2 Cleaning ink fountain and ink fountain roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.4.3 Ink fountain separator (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8.5 Ink slide zero setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.5.1 Ink slide zero setting using the portable terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
8.5.2 Individual adjustment of the ink slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.5.3 Mechanical zero setting of the ink slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15
8.6 Mechanical make-ready work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.6.1 Setting the distribution path of the ink vibrator rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
8.6.2 Throwing off ink form rollers 453 and 454 from ink distributor 512 . . . . . . . . . . . . . . . . . . . . 8-20
8.6.3 Throwing on ink form rollers 453 and 454 against ink distributor 512 . . . . . . . . . . . . . . . . . . 8-21
8.6.4 Setting the axial play of the ink form rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
8.6.5 Locking and unlocking the axial play of ink form roller 454 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
8.7 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.7.1 Setting the ink roller blowing device (IRB) (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
8.8 Inking unit temperature control device (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.8.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
8.9 Dampening unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
8.9.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
9 Washing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Washing agent container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
9.3 Washing devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.3.1 Preselecting and starting washing programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.3.2 Gumming the printing plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
9.3.3 Decalcifying inking unit and dampening unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.4 Washing agent supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.4.1 Filling container for special cleaner (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.4.2 Venting container for special cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
9.5 Doctor blade collecting pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
9.5.1 Manually throwing the doctor blade collecting pan on and off . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
VI Roland 700 - Operation

Contents
9.5.2 Removing the doctor blade collecting pan: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

9.5.3 Installing the doctor blade collecting pan: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
10 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2 Overview of the operating panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.2.1 A-side delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.2.2 B-side delivery (top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
10.2.3 Additional functions (option: reversing device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
10.2.4 B-side delivery (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
10.2.5 Delivery, B-side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
10.2.6 Delivery, B-side (inside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.2.7 Ventilator controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
10.2.8 Air quantity controller: blast tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.2.9 Air quantity controller: blast tubes (QuickChange option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
10.2.10 Air quantity controller: suction roller and sheet decurler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.2.11 Air quantity controller: suction roller and sheet decurler (QuickChange option) . . . . . . . . 10-11
10.2.12 Air quantity controller: reversing device (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
10.2.13 Air quantity controller: reversing device (QuickChange option) . . . . . . . . . . . . . . . . . . . . . . 10-12
10.2.14 Access protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
10.3 Pile controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
10.3.1 Raising the pile supporting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
10.3.2 Lowering the pile supporting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
10.3.3 Stopping the pile hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
10.4 Pile change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
10.4.1 Changing pile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
10.5 Settings for sheet delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
10.5.1 Setting the pile height detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
10.5.2 Correcting the size adjustment of the suction roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
10.5.3 Correcting size adjustment of the side sheet joggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
10.5.4 Setting suction roller speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
10.5.5 Setting gripper opening for delivery systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
10.6 Inspection sheet and waste sheet removal mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
10.6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21

10.6.2 Inspection sheet removal in automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
10.6.3 Manual inspection sheet removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
10.6.4 Waste sheet removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
10.7 Blast frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
10.7.1 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
10.7.2 Preselecting individual ventilators or ventilator groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
10.7.3 Deselecting the ventilators individually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
10.7.4 Preselecting all ventilators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Roland 700 - Operation VII

Contents
10.7.5 Deselecting all ventilators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29

10.7.6 Setting the air volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
10.7.7 Positioning ventilators of the blast frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
10.7.8 Aligning the blast tubes of the blast frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
10.7.9 Shutting air off from the blast tube of the blast frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
10.8 Sheet braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
10.8.1 Suction roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
10.9 Access protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
10.9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
10.9.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
10.9.3 Responses of printing press on interruption of a light barrier . . . . . . . . . . . . . . . . . . . . . . . . 10-37
10.9.4 Temporary hiding of functionality of light barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
10.9.5 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
11 Central control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.2 Overview of the operating panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
11.2.1 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
11.2.2 Program level buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.2.3 Buttons of main menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
11.2.4 Machine function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
11.2.5 Control keys and input keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
11.3 Control console screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
11.3.1 Structure of the screen mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
11.3.2 Sheet trend indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
11.3.3 Info on diagnosis messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
11.3.4 Basic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
11.3.5 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
11.4 Program level Job Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
11.4.1 Main menu Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
11.4.2 Main menu Printing module (preselection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
11.4.3 Main menu Sheet guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36
11.4.4 Main menu Damp. / Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
11.5 Program level Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-53

11.5.1 Main menu Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-53
11.5.2 Main menu Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-61
11.5.3 Main menu Printing module (preselection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-74
11.5.4 Main menu Sheet guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-105
11.5.5 Main menu Damp. / Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-113
11.5.6 Main menu Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-129
11.5.7 Main menu AGGREGATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-136
VIII Roland 700 - Operation

Contents
11.6 Program level Production Data Acquisition (PDA) (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-161

11.6.1 Documenting events (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-161
11.7 Program level "Diagnosis" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-162
11.7.1 Viewing diagnosis messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-162
11.7.2 Viewing the readings of the counters for total sheets and operating hours . . . . . . . . . . . 11-164
11.8 Program level Service (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-164
11.8.1 Preselecting language, date, measuring and temperature units . . . . . . . . . . . . . . . . . . . . . 11-165
11.8.2 Reading and writing ink slide data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-166
11.8.3 Viewing the machine park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-168
11.8.4 Deactivating emergency mode detector in the water fountain (PR only) . . . . . . . . . . . . . . 11-168
11.8.5 Storing base job (PR only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-169
11.8.6 Switching off the printing machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-170
11.8.7 Settings in the menu Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-171
11.8.8 Activating ink slide zero setting (PR only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-173
11.8.9 Preselecting make-ready mode (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-174
11.9 Shop supervisor disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-175
11.9.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-175
11.9.2 Deleting a work step using the shop supervisor disk (JP only) . . . . . . . . . . . . . . . . . . . . . . 11-175
11.9.3 Changing the machine configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-176
11.9.4 RSD REMOTE SERVICE DIAGNOSIS (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-179
11.9.5 Resetting parameters for ink presetting (PR only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-180
11.10 Post Mortem Dump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-182
11.10.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-182
11.10.2 Measures to be taken after a POST MORTEM DUMP (PMD) . . . . . . . . . . . . . . . . . . . . . . . . . 11-183
11.11 Emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-184
11.11.1 Emergency disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-184
11.11.2 Working with the back-up copy of the central control console program . . . . . . . . . . . . . 11-185
11.12 Matching desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-186
11.12.1 Matching desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-186
11.12.2 Overview of the operating panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-187
11.12.3 Presettings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-187
11.12.4 Inking corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-192
11.12.5 Register corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-195
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
11.12.6 Dampening corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-196

11.13 JobCard Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-196
11.13.1 JobCard Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-196
11.13.2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-197
11.13.3 Handling the JobCard Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-197
11.14 Notes concerning printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-198
11.14.1 Ink slide presetting, based on surface areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-198
11.14.2 Low Coverage Stabilization (LCS ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-200
Roland 700 - Operation IX

Contents
11.15 Care of the central control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-201

11.15.1 Cleaning the central control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-201
12 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.1 Transport aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
12.3 Testing devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
12.4 Wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
12.4.1 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
13 Directories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
13.1 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
13.1.1 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
13.2 Roller plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
13.2.1 Strip prints of rollers in inking unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
13.2.2 Strip prints of rollers in dampening unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
13.3 List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
13.4 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
X Roland 700 - Operation

Documentation of your press
Contents of the documentation box 1
1 Documentation of your press

1.1 Contents of the documentation box
The technical documentation of your printing machine
is arranged in the document box (1) The document
box contains several files each with documents
treating different subjects. The files are provided with
colored guiding symbols. The colors have the following
meaning:
Orange: Instructions manual (2)
Red: Spare parts catalogue (3)
Blue: Electrical documentation (4)
Green: Mounting documentation (5)
Next to the MAN ROLAND DOCUMENTS you will also find
the documentation of the suppliers of ancillary equip-
ment. 01-04501-1
1.2 Components of the instructions manual

1.2.1 Safety
Rules of behavior to be observed in the printing room. Sicherheit an
MAN Roland-Druckmaschinen
Safety measures to be taken by the operating per- Safety on

MAN Roland printing presses
sonnel
Dealing with chemicals
Sicherheit
Receiver
Exploiter
Sales/Service Partner
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Sicherheitshinweise
Roland 700 - Operation 1-1

1 Components of the instructions manual
1.2.2 Products for maintenance and care

List of products, divided in groups.
Printing process materials
Operating materials
Wearing parts
Receiver
Exploiter
R700 Produkte zur Bed+Wart
1.2.3 Transport
Transport of the printing machine module from the
factory MAN ROLAND, unloading and further transport
to the installation place.
Weights and dimensions of the transport units
Use of transport devices
Transport way: Requirements
Information on an effective transport process
Receiver
Exploiter
Transport company R700 Transport
1.2.4 Putting into operation

List for checking the correct functioning, reliability and
safety of the printing machine after the installation.
Putting into operation (electrical)
Putting into operation (software)
Mechanical putting into operation
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Putting into operation (printing)

Putting into operation (safety)
Receiver
MAN Roland service
Exploiter R700 Inbetriebnahme
1-2 Roland 700 - Operation

Guideline indications 1
1.2.5 Operation
Safe, appropriate and economical use of the printing
machine.
Guide to the typical use of a printing press
Description of the press and its components
Handling of the press and its components
Handling of the central control console software
Receiver: Exploiter
R700 Bedienung
1.2.6 Maintenance
Checks and maintenance jobs to be carried out regu-
larly.
Maintenance schedule
Instructions for maintenance and inspection
List of tools
Receiver: Exploiter
R700 Wartung
1.3 Guideline indications

1.3.1 Explanation of the pictographs used
The following pictographs accentuate important passages in the technical documentation of your press:
Safety note
Warning symbols mark safety notes that describe possible damage to material or personal injury when
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
handling the press.
Danger classification
Additional pictographs symbolize the type of danger in a safety notice (e.g. danger of falling).
Information
Important additional information.
Tip
Instructions for the user to carry out a job efficiently.

1 Your opinion is important to us
Equipment
List of the equipment (tools, measuring tools, and devices) the operating personnel needs to carry out a
job.
Operating materials
List of the operating materials and printing process materials the operating personnel needs to carry
out a job.
Instruction
Instructions request the operating personnel to carry out a certain action.
Expected system reaction

Description of a reaction as defined by the job.
Unexpected system reaction

Description of a reaction that deviates from the target of the job.
1.3.2 Meaning accentuated words or passages in a text

The following typographical features accentuate important text passages in the technical documentation of your
press:
(1) Reference to a position number in a picture.

[ Crawl speed ] Designation of an input element.
MAN ROLAND Proper name
Color designation Text in the screen mask
Manual Machine Reference to another chapter or manual.
Operation
1.4 Your opinion is important to us

If you find any irregularities in our technical documentation or if you have any suggestions for improvement,
please let us know. We would really appreciate it.
Please send your comment or suggestion to the following address:
MAN Roland Druckmaschinen AG
Technical documentation
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Post office box 101264

63012 Offenbach
Germany
Telefax: +49 (0)69 / 8305-2969
E-Mail: [email protected]

Using the operating manual 1
1.5 Using the operating manual

1.5.1 Handling the printing press
Handling includes a product description and instructions for the correct use of the functions provided in the
design. This section is broken down according to the structure of the printing press (e.g. feeder, printing
module).
Use the overview illustrations for orientation.

Inform yourself about the handling of the functions by reading the instructions of the operating descriptions.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Safety
Intended use 2
2 Safety
2.1 Intended use
2.1.1 Safety declaration
The printing press is built according to the state of the art and acknowledged safety rules. Nevertheless, the use
of the printing press may cause risks to the life and limb of operators or third parties or impairments of the print-
ing press and other material assets (e.g. print products, print room equipment, etc.).
Always use the printing press in a safety-conscious and danger-conscious way and always observe the in-
structions manual.
Eliminate faults immediately, particularly faults impairing the safety of the printing press.
2.1.2 Printing press

This printing press is intended only for printing paper, cardboard and plastic. Printing wood, sheet metal or oth-
er materials is not permissible. Exceptions are possible only if they have been specifically agreed upon in writing
with MAN ROLAND and if the machine has been equipped accordingly.
Never use the machine for other purposes.
2.1.3 Impeccable technical condition

For safety reasons, only operate the printing press and the accompanying equipment from other manufacturers if
they are in an impeccable technical condition.
Check, especially after carrying out maintenance tasks, whether the protective equipment on the printing
press and all safety and warning devices in the printing room are installed and fully functional.
Always observe the prescribed maintenance intervals to guarantee the safety of the operating personnel as
well as the safety and profitability of your machine.
2.1.4 Printing process materials

Printing process materials are all substances required for the printing process, e.g. printing inks, coatings, print-
ing materials, dampening solution additives, washing agents. Only use the printing process materials for the pur-
pose they are expressly intended for. You must have read and understood all safety data sheets of the manufac-
turers of printing process materials before you handle these products.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Only use inks and coatings which cannot form an explosive atmosphere when heated in the drier. Inks which
cannot form an explosive atmosphere are marked as "not applicable" under the indication "explosion limit"
in the safety data sheet.
The printing inks must correspond to the commercially available offset printing inks for sheetfed offset printing
presses.
You should only use cut printing materials that are suitable for offset printing presses. Sheet size and sheet
thickness must not exceed nor fall below the values indicated in the Technical data section. The flexural
strength must be within the range of the usual printing materials.
Use only the printing process materials which conform to the technical data and requirements prescribed by
MAN ROLAND. As user, it is your responsibility to observe these directions.

Safety
2 Intended use
MAN ROLAND is not responsible for damage to the machine resulting from the use of printing process materi-
als that do not fulfill the listed technical data and requirements.
2.1.5 Operating materials

Only use the operating materials, e.g. lubricants, consumables and cleaning agents for the express purpose for
which they have been intended. You must have read and understood all safety data sheets of the manufacturers
of operating materials before you handle these products.
Only use the operating materials listed in this manual. These operating materials have been tested by MAN
ROLAND for material compatibility and reliability in the specified places of use.
MAN ROLAND is not responsible for damage to presses caused by the use of non-designated operating mater-
ials.
If the listed operating materials are not available through your specialist dealers, have the manufacturer or sup-
plier of the substitute product confirm in writing that the substitute product has the same properties as the
product required by MAN ROLAND.
You will find the admissible operating materials for equipment from other manufacturers in the documentation
of the third-party equipment suppliers.
2.1.6 Documentation
Operating manuals contain instructions for the safe, adequate and economical handling of your printing press.
Carry out all work exactly in accordance with the instructions of the operating manual to avoid dangers, to re-
duce repair costs and downtimes as well as to increase the reliability and service life of your printing press.
You must have read and understood all operating manuals belonging to the machine as well as the
manual "Safety for MAN Roland printing presses" before you start working with the machine.
You must have read and understood the documentation of the third-party equipment manufacturers. These
manuals are part of the technical documentation of your printing press.
2.1.7 National laws and directives

Follow all laws, regulations and directions of your country concerning accident prevention and environmental
protection.
2.1.8 CE mark
CE mark and EC Declaration of Conformity are valid only as long as you use the machine in the condition it was
delivered in. The CE mark will lose its validity in the following cases:
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
If you make any modifications to parts of the product concerning safety, e.g. to the footsteps or railings of the
printing press.
If you install auxiliary equipment.
Desired modifications must be arranged in writing with the MAN ROLAND sales / service partner and accepted in
writing by MAN ROLAND.
The exploiter has to make sure that he receives the new CE-symbol. The customer has to take the following
measures:

Safety
Misuse 2
You have to establish a hazard analysis together with a description of the possible solution (concerning integ-
ration and interaction of components). You have to take into account the set standards, the product liability,
the legislation relating to safety in the use of technical equipment and devices, the EC directive and other dir-
ectives.
You have to have the product examined for EMC (electro-magnetic compatibility).
You have to check the technical documentation (e.g. instructions manual, etc.) for correctness and complete-
ness. You have to preserve the documentation for 10 years.
You have to prepare a Declaration of Conformity.
You have to apply the new CE mark to the product together with the manufacturer plate.
2.1.9 Decommissioning and dismounting of the press

The decommissioning and the dismounting of the press involves certain dangers. In particular:
dangers caused by electrical current
dangers caused by machine components falling down or over
dangers caused by stored energy (e.g. pressurized elements, pretensioned springs, etc.)
dangers caused by operating and auxiliary materials
danger of falling for persons
dangers during the transport of machine components
Further dangers may occur depending on the type or size of the machine.
Have the tasks carried out only by specially trained and authorized expert personnel from MAN ROLAND or
your MAN ROLAND sales / service partner.
2.2 Misuse
2.2.1 Printing press
Misusing the machine will cause uncontrollable risks for life and limb and/or serious damage to the machine.
Any use that is not in compliance with the intended use or application is considered misuse. In case of a misuse
of the printing press, MAN ROLAND will disclaim any liability and transfer all responsibility exclusively to the user.
Any manipulation of limit switch systems on devices, e.g. electrical guards that serve to protect the operator, is
considered misuse. In such a case the life of the operators is extremely endangered. It is strictly prohibited to
use manual aids, e.g. magnets or spare keys, for simulating the existence of protective and safety devices or
machine parts properly installed in the factory.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Any modifications, additions or retrofittings to the printing press or equipment from other manufacturers that
have not been expressly approved in writing by MAN ROLAND are considered misuse. The following instructions
apply:
You must not put out of operation, bridge or modify protective devices.
You must not make any modifications to the delivered software.
You must not install third-party software that has not been expressly released by MAN ROLAND.
You must not make any modifications to the machine parameters.
You must not make any modifications to the electrical voltage and you must not lay cables for additional
equipment in the cable ducts.

Safety
2 Environmental protection
If you make any modifications, additions or retrofittings to the machine without the prior written consent of MAN
ROLAND the CE mark and thus the declaration of conformity will lose their validity.
2.3 Environmental protection

2.3.1 Oil leaks and spills
Spilled oil and leaks in the printing machine may cause damage to the environment.
Arrange with your MAN ROLAND sales / service partner how to eliminate leaks.
Always keep binding agent and containers for collecting oil at hand close to the printing machine.
Resorb spilled oil immediately with a suitable binding agent.
Take all measures to prevent oil from running into the sewer system or into the ground water.
2.3.2 Disposal of operating materials, printing process materials

and wearing parts
As the utilizer you are responsible for the disposal of the used operating materials, printing process materials and
wearing parts.
2.4 Structure of safety notes

2.4.1 Designation of safety notes
In the technical documentation, safety notes designate dangerous situations, when the operators have to carry
out tasks in a dangerous environment. If a safety note precedes the list of individual steps, it refers to a complete
operation. If a safety note directly precedes an operating step, it directly refers to the next step. The safety notes
of this manual consist of a triangular warning symbol and a signal word that indicates the degree of danger.
Dangerous voltage
Warning of an imminent danger caused by electrical voltage that will lead to serious injury or
death when ignored.
DANGER!:
Warning of an imminent danger that will definitely cause serious injury or death when ignored.
WARNING:
Warning of an imminent danger that may cause serious injury or death when ignored.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Caution!
Warning of a potentially dangerous situation that may cause less serious or minor injuries.
Attention!:
Warning of possible serious damage to the machine.

Safety
Safe working 2
Important!
Reference to possible harmful situations in dealing with the product.
Additional pictographs concerning the type of danger

Square pictographs symbolize the type of danger. They supplement the triangular warning symbols in
a safety note.
2.5 Safe working

2.5.1 Special fields
MAN Roland differentiates between the professions of the specialists required for the different jobs on the print-
ing press. Clearly determine the responsibilities and allocation of tasks.
Printer
Specially trained offset printer.
Mechanic
Mechanic, trained for the maintenance and repair of the press.
Electrician
Electrician, professionally trained for the maintenance and repair of the press.
Software support
Qualified personnel with PC-knowledge for installing software programs.
2.5.2 Degree of qualification

MAN Roland differentiates between the qualifications and authorizations required to carry out a certain job on
the printing press. The manual indicates the qualification and authorization required to carry out a certain job on
the product. As the user, make sure that the jobs marked correspondingly are carried out only by professional
specialists with a sufficient authorization. The individual levels of qualifications are listed in order with extended
authorizations:
Exploiter
Printing shop that uses anMAN ROLAND -product with the ancillary equipment belonging to it.
Employee of the sales / service partner who is authorized by MAN ROLAND to carry out service tasks.
MAN Roland service

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
MAN ROLAND EMPLOYEE who is authorized to carry out service tasks.

Safety
2 Safe working
2.5.3 Operating positions
3
1
1
3
4
1
2
1
1
3
1
5
1
01-00118-3
1 Operating positions at the feeder 4 Operating positions at the delivery unit

2 Operating positions at printing module 1 5 Operating positions at the central control
3 Operating positions at printing module console
2.5.4 Safety-relevant operation

In dangerous situations, the operators can carry out the following operations to bring the printing press to a safe
status.
Stopping the printing machine in dangerous situations: Emergency Stop

Dangerous voltage
Danger of electrical shocks when you
touch live parts after an "emergency
stop". "Emergency stop" only
disconnects dangerous machine
movements that are freely accessible. K521
The printing press as well as the

equipment from other manufacturers
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
remain live.
Disconnect the machine and the
equipment from other manufacturers from
voltage at the main switches. Secure the
main switches with a padlock against
being switched on again.
Press the [ emergency stop ] button until it engages.

The [ emergency stop ] button is locked.
The printing press stops as quick as possible with
a slow-down time that depends on the current ma-
chine speed.

Safety
Safe working 2
Press the key [ Emergency Stop ] in danger-

ous situations only.
If you press the [ emergency stop ] button
without a good reason, you risk damage to
the machine due to the excessive strain on
compressors and other components.
Unlocking Emergency Stop.

Turn the [ emergency stop ] button.
The [ emergency stop ] button is unlocked.
The printing machine is ready for operation.
K521
Switching off the printing machine

Dangerous voltage
Delayed discharge of the frequency con-
verters after turning off the main switch.
Dangerous residual voltages may still be
applied to devices and frequency convert-
ers.
Before starting any tasks, always check
that all terminals of the devices are dead.
Turn the main switch at the main switch cabinet of
the machine to [ O ].
The printing machine is switched off.

OFF
N
O
LS-03432-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Safety
2 Safe working
Securing the main switch of the printing machine against being switched on
again
Put the padlock into the main switch.
OFF
Lock the padlock and deposit the key in a safe
place.
N
O
02-03277-1
Stopping and locking the printing machine.

Press the [ Stop-Secure ] button and then turn it
clockwise.
The [ Stop-Secure ] button is locked.
The machine stops with a slow-down time that de-
pends on the current machine speed.
All run controls are locked.
K524
Unlocking the printing machine

Turn the [ Stop-Secure ] button anticlockwise.
The [ Stop-Secure ] button is unlocked.
All run controls can be used. The printing machine
is ready for operation.
K525
Stopping the pile hoist

Press the [ Pile: Stop-Secure ].
The pile hoist stops.
K550
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Securing the pile hoist

Press and then turn the [ Pile: Stop-Secure ] button
clockwise.
The button is engaged.
The [ Pile: Raise ] and [ Pile: Lower ] buttons are
locked.
K552

Safety
Safety devices 2
Stopping and locking the pile hoist.

Press and then turn the [ Pile: Stop-Secure ] button
clockwise.
The button is engaged.
The [ Pile: Raise ] and [ Pile: Lower ] buttons are
locked.
K552
Unlocking the pile hoist:

Turn the [ Pile: Stop-Secure ] button anticlockwise.
The pile hoist is unlocked.
K553
2.5.5 Safe working in the pressroom

Basic rules of behavior
Generally valid basic rules of behavior for a safe working on the press and in its environment.
Further information
Read the manual "Safety on MAN Roland printing machines".
2.6 Safety devices

2.6.1 Electrically secured guards
Standard
4 4
5 5
3 3
28.1 1 1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
41 41
60.1 13 1.1 6 1.1 6
7 7 12 27
9 10 9
7.1 7.1
40
8 8
11
TAI-00109-5

Safety
2 Safety devices
1 Guard in front of blanket cylinder and plate cylinder

IEE: S526
Reaction of the printing machine still possible run controls
The machine stops. Jog forward

Jog reverse
Turning the printing machine at Crawl speed
1.1 Guard in front of blanket cylinder and plate cylinder:

IEE: S590
The machine stops. Jog forward, limited travel

Jog Reverse (limited travel)
3 Guard in front of inking and dampening unit

IEE: S528

The water fountain roller motor is switched off. Jog Reverse (limited travel)
4 Guard above the inking unit

IEE: S528

The water fountain roller motor is switched off. Jog Reverse (limited travel)
5 Guard between ink form roller and plate cylinder

IEE: S523
The machine stops. When the guard is open or actuated, none of the run
controls is possible any more.
6 Guard between plate and blanket cylinder

IEE: S524
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
7 Guard in front of blanket cylinder and impression cylinder

IEE: S524

Safety
Safety devices 2
7.1 Guard in front of impression cylinder and blanket cylinder

IEE: S525
8 Guard between impression cylinder and cross-bar

IEE: S525
9 Guard above impression cylinder

IEE: S529

Jog reverse
10 Guard above transferter

IEE: S530

11 Guard below feed register

IEE: S576
12 Guard above swing gripper and feed register drum

IEE: S514

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
13 Guard above chain track, delivery drum

IEE: B285


Safety
2 Safety devices
27 Suction tapes feed board in working position (guard 12 and guard 18 open)
IEE: S827

The feeder drive is disengaged. Jog Reverse (limited travel)
27 Suction tapes feed board in working position (guard 12 and guard 18 closed)
IEE: S827
The feeder drive is disengaged. controls is possible any more.
28.1 Guard on A-side

IEE: B209
40 Guard in front of the sheet removal zone

IEE: B208

41 Pressure roller in front of plate cylinder (PPL/APL)

IEE: S523
60.1 Guard above chain track

IEE: B285

06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Safety
Safety devices 2
Feeder: NONSTOP device
107
TAI-05815-1
107 Slide guard
The movement of the pile supporting plate stops. When the guard is dismounted, the safety device is
Sub-function "Automatic NONSTOP", logistics system out of operation. The run controls will not be influ-
is locked enced.
Feeder NONSTOP device with base = 275 mm / 10.827 in (option)
110
TAI-05777-1
110 Platform
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
IEE: S214/S214A
Sub-function "Automatic NONSTOP", logistics system When the guard is open or actuated, none of the run
is locked controls is possible any more.

Safety
2 Safety devices
Tensioning bar (option)
TAI-00110-4
6 Guard between plate and blanket cylinder

IEE: S524
Intermediate drying/preparation for dryer (option)
9.4
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
9.1
TAI-00111-4

Safety
Safety devices 2
9.1 Guard above impression cylinder

IEE: S529
The machine stops. Jog reverse

Jog forward, limited travel
9.4 Guard above impression cylinder (in front of reversing device)

IEE: S529

Jog reverse
Sheet Inspection System (option)
9.8
TAI-05470-2

IEE: S529

06.09.2004 10:35:31 - 747 - 80 95A EN 6778


Safety
2 Safety devices
Coating module:
17
33
16
15
25.2
23
10.1 25.1
25 9.3
22.1 22
TAI-00112-4

IEE: S567

The function "Collecting blade On/Off" is locked. Jog reverse
10.1 Guard above transferter

IEE: S541

15 Guard in front of coating rollers

IEE: S561

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The coating metering roller motor is switched off. Jog Reverse (limited travel)
The function "Collecting blade On/Off" is locked.
16 Guard above the coating rollers

IEE: S566


Safety
Safety devices 2
17 Guard above forme cylinder

IEE: S569

22 Guard between impression cylinder and forme cylinder

IEE: S570
22.1 Guard between impression cylinder and delivery drum/transferter

IEE: S570
23 Coating fountain in installation position (collecting blade)

IEE: B146
The coating metering roller motor is switched off. controls is possible any more.
The coating pump is switched off.
25 Guard above the transferter

IEE: S568

25.1 Guard above the transferter

IEE: S558
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

25.2 Guard above the transferter

IEE: S530


Safety
2 Safety devices
33 Collecting blade in installation position collecting blade

IEE: B139
The coating metering roller motor is switched off. When the guard is open or actuated, none of the run
The coating pump is switched off. controls is possible any more.
Coating module 2 (option)
17 20 19
38.1
16 21
18
15
9.6
10
9.3
22.1
22 23
35.1
TAI-00113-4

IEE: S567

9.6 Guard above impression cylinder in front of delivery unit

IEE: B217
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

10 Guard above transferter

IEE: S530


Safety
Safety devices 2

IEE: S561


IEE: S566

17 Guard above forme cylinder

IEE: S569

18 Guard in front of forme cylinder

IEE: S560

The function "Collecting blade On/Off" is locked. Jog Reverse (limited travel)
19 Guard between forme cylinder and AFD

IEE: S565
20 Guard between ink form roller and forme cylinder

IEE: S564
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Safety
2 Safety devices
21 Guard between metering roller and ink form roller

IEE: S562
22 Guard between impression cylinder and forme cylinder

IEE: S570
22.1 Guard between impression cylinder and delivery drum/transferter

IEE: S570
23 Coating fountain in installation position (coating rollers)

IEE: S563
35.1 Guard between cross-bars

IEE: B291
38.1 Guard above washing device

IEE: S565
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Safety
Safety devices 2
Coating module coating pump
108
TAI-05816-1
108 Guard above the coating pumps (A-side)

IEE: B309
The coating pump is switched off. When the guard is open or actuated, none of the run
Printing plate cleaner (option)
16
23
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
15
9.7 9.2
44
TAI-00114-5

Safety
2 Safety devices

IEE: S567

The function "Clean block" stops. Turning the printing machine at Crawl speed

IEE: B217

The function "Clean block" stops. Turning the printing machine at Crawl speed

IEE: S561

The function "Clean block" stops.

IEE: S566

The function "Clean block" stops.
23 Coating fountain in installation position (collecting blade)

IEE: B146
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
44 Guard between coating fountain and sheet guide

IEE: B165

Safety
Safety devices 2
Reversing device (option)
42
TAI-00115-2
42 Guard in front of man hole

IEE: S901
Sheet distributor (option)
115
28.3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
01-05817-1
28.3 Guard on B-side (guard 115 closed)

IEE: B326
The sheet distributor is switched off. When the guard is open or actuated, none of the run

Safety
2 Safety devices
28.3 Guard on B-side (guard 115 open)

IEE: B326
115 Guard below sheet distributor

IEE: B327, B331
2.6.2 Mechanically secured guards

Feeder
141 145
142
141.1
137
138
143
138.1
144
139 133
99
74 98
140
TAI-05354-2
74 Guard in front of pile supporting plate

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
When the guard is dismounted, the safety device is When the guard is dismounted, the safety device is
out of operation. The printing machine is fully func- out of operation. The run controls will not be influ-
tional. enced.
98 Guard on B-side, outside
tional. enced.

Safety
Safety devices 2
99 Guard on A-side, outside
tional. enced.
133 Protective screen on suction head
tional. enced.
137 Guard for suction head height adjustment device
tional. enced.
138 Guard above cam control (A-side)
tional. enced.
138.1 Guard above cam control (B-side)
tional. enced.
139 Guard below suction tapes feed board tensioning roller
tional. enced.
140 Guard above pile supporting plate adjustment

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
tional. enced.
141 Guard above lateral drive stop (A-side)
tional. enced.

Safety
2 Safety devices
141.1 Guard above lateral drive stop (B-side)
tional. enced.
142 Guard above size adjustment
tional. enced.
143 Guard above suction head drive

tional. enced.
144 Guard above suction head drive shaft
tional. enced.
145 Guard above air control

tional. enced.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Safety
Safety devices 2
Feeder with base = 275 mm / 10.827 in (option)
74
140.1
74.1
TAI-05355-2
74 Guard in front of pile supporting plate
tional. enced.
74.1 Guard in front of pile supporting plate
tional. enced.
140.1 Guard above pile supporting plate adjustment
tional. enced.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Safety
2 Safety devices
Feeder with automatic NONSTOP device (option)
113
1 127
1
123
1
128
1
130
1
129
1
TAI-04797-2
113 Safety belts on NONSTOP feeder
tional. enced.
123 Guard above sheet feed

tional. enced.
127 Guard above rods
tional. enced.
128 Guard on A-side, inside
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
tional. enced.
129 Guard around valve block (A-side)
tional. enced.

Safety
Safety devices 2
130 Casing
tional. enced.
Feeder NONSTOP device with base = 275 mm / 10.827 in (option)
148
148.1
149
TAI-05776-1
148 Guard above residual pile drive (A-side)
tional. enced.
148.1 Guard above residual pile drive (B-side)
tional. enced.
149 Guard for protecting the area (B-side)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
tional. enced.

Safety
2 Safety devices
Printing module 1
62
1 12.1
1 83
1 97
97.1
TAI-03934-3
12.1 Guard above swing grippers and feed register drum of suction tapes feed
board
tional. enced.
62 Guard in front of ABD

tional. enced.
83 Foreign object barrier
tional. enced.
97 Guard below suction tapes feed board, outside (A+B-side)

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
tional. enced.
97.1 Guard below suction tapes feed board (A-side)
tional. enced.

Safety
Safety devices 2
Printing module
89
57 52
52.1
92
84
TAI-03935-3
52 Guard above lever for pressure roller (PPL/APL) on B-side
tional. enced.
52.1 Guard above lever for pressure roller (PPL/APL) on A-side
tional. enced.
57 Handle
tional. enced.
84 Guard in front of rotor blades of axial ventilator

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
tional. enced.

Safety
2 Safety devices
89 Guard above ink fountain support roller
tional. enced.
92 Guard below ink fountain roller

tional. enced.
Coating module:
35
1 57
1 45
1 39
1 38
1
TAI-03944-2
35 Guard between cross-bars

tional. enced.
38 Guard above washing device

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
tional. enced.

Safety
Safety devices 2
39 Guard in front of ink form roller

tional. enced.
45 Guard above ink form roller

tional. enced.
57 Handle
tional. enced.
ABD (for UV intermediate dryer: option)
147
1
TAI-04796-2
147 Guard above quick-action locks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
tional. enced.

Safety
2 Safety devices
A-side
54
1 58
1 50
1 88
1 49
1 56
1 49
1 51.1
1
TAI-03938-3
49 Guard above coupling disk
tional. enced.
50 Guard above pulley (main drive motor)
tional. enced.
51.1 Guard above shaft end
tional. enced.
54 Guard above feeder drive shaft

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
tional. enced.
56 Safety device on A-side, outside
tional. enced.

Safety
Safety devices 2
58 Railings
tional. enced.
88 Guard above positioning gearbox
tional. enced.
A-side with base = 275 mm / 10.827 in (option)
56
1 51
1
TAI-03939-2
51 Guard above main drive shaft
tional. enced.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
56 Safety device on A-side, outside
tional. enced.

Safety
2 Safety devices
B-side
55
1 58.1
1
TAI-03940-3
55 Safety device on B-side, outside
tional. enced.
58.1 Railings
tional. enced.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Safety
Safety devices 2
B-side with base = 275 mm / 10.827 in: man hole
55
1 42.1
1
TAI-03941-2
55 Safety device on B-side, outside
tional. enced.
42.1 Guard in front of man hole
tional. enced.
Sheet distributor (option)
117
1
116
1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
116.1
1
TAI-05379-2

Safety
2 Safety devices
116 Guard around waste sheet pile
tional. enced.
116.1 Guard around waste sheet pile (option: base)
tional. enced.
117 Guard behind the drum

tional. enced.
Standard delivery
93 48 47 48 109 48
14
60
28
84
TAI-03942-3
14 Guard in front of chain guide track

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
tional. enced.

Safety
Safety devices 2
28 Guard on B-side
tional. enced.
47 Guard behind pile supporting plate
tional. enced.
48 Guard above chain track
tional. enced.
60 Guard above chain track

tional. enced.
84 Guard in front of rotor blades of axial ventilator
tional. enced.
93 Guard above inspection sheet removal mechanism
tional. enced.
109 Partition plates

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
tional. enced.

Safety
2 Safety devices
Delivery unit with base = 275 mm / 10.827 in (option)
47.1 76 76
TAI-03943-2
47.1 Guard behind pile supporting plate
tional. enced.
76 Protective screen (A+B-side)
tional. enced. 06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Safety
Safety devices 2
Delivery unit with extension (option)
28.2
1
TAI-05352-2
28.2 Guard (A+B-side)
tional. enced.
Transfer module
59 61 59
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
TAI-03946-2

Safety
2 Safety devices
59 Guard above impression cylinder
tional. enced.
61 Guard above the transferter

tional. enced.
2.6.3 Light barriers

Feeder with base = 275 mm / 10.827 in (option)
43.1
112
1 111
1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
TAI-04811-2
43.1 Light barriers - manual NONSTOP with logistics system

IEE: B180, B181, B182, B183, B184, B185, B272, B273
The movement of the pile supporting plate stops. controls is possible any more.

Safety
Safety devices 2
111 Light barriers behind the pile - automatic NONSTOP.

IEE: B180, B181, B182, B183
Sub-function "Automatic NONSTOP", logistics system When the guard is open or actuated, none of the run
is locked controls is possible any more.
112 Light barriers on A-side - automatic NONSTOP.

IEE: B184, B185
The movement of the pile supporting plate stops. When the guard is open or actuated, none of the run
Sub-function "Automatic NONSTOP", logistics system controls is possible any more.
is locked
Access protection on delivery unit
160.2
160.1 160.1
159.2
159.1
159.1
158.2 158.1
158.1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
TAI-06099-1

Safety
2 Safety devices
158 Access protection on B-side

IEE: B117/1, B118/1
158.1 Access protection in front of pile supporting plate

IEE: B101/1, B102/1
158.2 Access protection on A-side

IEE: B103/1, B104/1

IEE: B117/2, B118/2

IEE: B101/2, B102/2

IEE: B103/2, B104/2
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

IEE: B117/3, B118/3

Safety
Safety devices 2

IEE: B101/3, B102/3

IEE: B103/3, B104/3
Light barriers on delivery unit (option)

Light barriers to protect feet are fitted on printing presses with automatic pile lowering and printing
presses with a base (= 275 mm / 10.827 in).
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
157.2
157.1
157.0
TAI-06098-1

Safety
2 Safety devices
157 Foot protection on B-side

IEE: B117, B118
157.1 Foot protection in front of pile supporting plate

IEE: B101, B102
157.2 Foot protection on A-side

IEE: B103, B104
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Safety
Safety devices 2
2.6.4 Safety label

Feeder
max.
XXX kg
XXX lbs
max.
XXXX kg
XXXX lbs
11
12
23
2.2
TAI-05818-1
1 Danger of crushing at the pile support

099U044613
2.2 Danger of crushing between pile table and rake

in case of an intermediate pile which cannot be
lowered
099U070513
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
11 Feeder: Max. pile weight without nonstop

device max.
XXX kg
XXX lbs
099U113613
12 Feeder: Max. pile weight; manual and auto- max.

XXX kg
XXX lbs
matic nonstop max.

XXXX kg
XXXX lbs
099U110513

Safety
2 Safety devices
12 Feeder: Max. pile weight; manual and auto- max.

XXX kg
XXX lbs
matic nonstop, roller track max.

XXXX kg
XXXX lbs
099U110613
23 Main switch for pneumatic system

099U150513
Printing module 1, feeder side
TAI-05819-1
3 Ingoing nip point between cylinders and rollers

099U046213
7 Danger of crushing with gripper systems run-
ning back into the press
099U046013
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Safety
Safety devices 2
Printing module and coating module, feeder side
TAI-05820-1

099U046213
Printing module, delivery unit side
4
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
TAI-05821-1

099U046213

Safety
2 Safety devices
4 Danger of cutting your hand

099U046113
7 Danger of crushing with gripper systems run-
ning back into the press
099U046013
Coating module, delivery unit side
TAI-05822-1

099U046213
4 Danger of cutting your hand
099U046113
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Safety
Safety devices 2
Underneath the intermediate steps
6 6
TAI-05828-1
6 Keep off
099U044513
man hole
3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
TAI-05830-1

Safety
2 Safety devices

099U046213
8 Danger to life in the manhole caused by rotating
rollers and cylinders
099U044413
Drive shaft
10
10
TAI-05823-1
10 Indication of turning direction of drive shaft

099U045613
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Safety
Safety devices 2
Platforms, A-side
1.
2. 2.
TAI-05824-1
9 Caution: Release brakes. Turn the drive shaft 1.
2. 2.
in direction of production with the appropriate

tool.
099U046413
Delivery unit, A-side
21
= =
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
21
= =
TAI-05826-1

Safety
2 Safety devices
21 Warning: Revolving gripper systems

001X539539
hhhhhhhhh
hhhhhhhhhhhhh
hhhhhhhhhhhhhh
hhhhhhhhhhhhhhh
hhhhh
hhhhhhhhhhhhhhh
hhhhhhhhhhhhhh
hhhhhhhhhhhhhhh
hhhhhhhhhhhhhhh
hhhhhhhhhhhhh
hhhhhh
hhhhhhhhhhhhhh
hhhhhhhhhhhhhhh
hhhhhhhhhhhhhhh
hhhhhhhhhhhhh
hhhhhhhhhhhhhh
hh
Delivery unit, B-side
2
2.2
21
11 12.1
= =
21
21
= =
= =
TAI-05825-1
2 Danger of crushing between pile table and rake

with an intermediate pile that is not lowerable.
099U045713
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
2.2 Danger of crushing between pile table and rake

in case of an intermediate pile which cannot be
lowered
099U070513
11 Delivery unit: max. pile weight without interme-

diate pile; intermediate pile (not lowerable) max.
XXX kg
XXX lbs
099U110713

Safety
Safety devices 2
12.1 Delivery unit: Max. pile weight; intermediate max.

XXX kg
XXX lbs
pile (lowerable); automatic nonstop max.

XXXX kg
XXXX lbs
099U110813
21 Warning: Revolving gripper systems

001X539539
hhhhhhhhh
hhhhhhhhhhhhh
hhhhhhhhhhhhhh
hhhhhhhhhhhhhhh
hhhhh
hhhhhhhhhhhhhhh
hhhhhhhhhhhhhh
hhhhhhhhhhhhhhh
hhhhhhhhhhhhhhh
hhhhhhhhhhhhh
hhhhhh
hhhhhhhhhhhhhh
hhhhhhhhhhhhhhh
hhhhhhhhhhhhhhh
hhhhhhhhhhhhh
hhhhhhhhhhhhhh
hh
Delivery unit, top
TAI-05827-1
6 Keep off
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
099U044513

2
2-56
Safety
Roland 700 - Operation

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Printing machine
Overview 3
3 Printing machine
3.1 Overview
A D
1
C 5 B
3
4
01-05795-1
Machine components Designation of the machine sides

1 Feeder A A-side (drive side)
2 Feed register (printing module 1) B B-side (operating side)
3 Printing modules 1 ... n C Delivery side (side pointing to the delivery
4 delivery unit unit)
5 Dampening solution refrigerator, switch cab- D Feeder side (side pointing to the feeder)
inet with main switch
6 Central control console with matching desk
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing machine
3 Operation of the printing press
3.2 Operation of the printing press

3.2.1 Switching the printing press on and off
Switching on the printing machine
Always switch on the central air supply.

the machine from [ O ] to [ I ].
The central control console computer will be
switched on automatically.
The list of work steps will be displayed.
Compressed air supply and machine control will be
OFF
switched on.
Turn on the main switches of the ancillary equip-
ment.
ON
02-03087-1
Ensure that there is nobody within the hazard zone

(1) of the delivery unit.
10-06101-1
Press the [ Enabling ] button.

The run controls of the printing press are enabled.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K927

Printing machine
Operation of the printing press 3
Switching off the printing machine

Dangerous voltage
Delayed discharge of the frequency con-
verters after turning off the main switch.
Dangerous residual voltages may still be
applied to devices and frequency convert-
ers.
Before starting any tasks, always check
that all terminals of the devices are dead.
The printing machine is switched off.
OFF
N
O
LS-03432-1
Securing the main switch of the printing machine against being switched on
again
Put the padlock into the main switch.
OFF
Lock the padlock and deposit the key in a safe

place.
N
O
02-03277-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing machine
3.2.2 General button functions

Explanation of the LEDs on the function keys
The LED is on.
The function is active.
K595
The LED is flashing.
An automatic setting is not yet finished.
Edit buttons "+" or "w": The buttons are active.
The LED is off
The function is locked.
Explanation of the telltale lamps on the control keys

e.g. crawl speed
The telltale lamp is on.

The function is active.
The telltale lamp is flashing.
An automatic setting is not yet finished.
The system waits for an action by the operator (e.g. in
the case of feeder make-ready: piling sheets).
K531
The telltale lamp is flashing quickly.
Fault: A diagnosis message is displayed.
The telltale lamp is off.
The function is locked.
3.2.3 Machine run

Preparing the machine run
Close all guards.
Unlock the printing press.
Terminate all positioning programs (e.g. plate
change, blanket change, washing programs).
Starting the printing machine

Close all guards.
Press the [ Run ] button
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The LED is on.

The start signal will sound.
Press the [ Run ] button again.
The printing machine will turn at base speed. K533
Basic speed: 3 000 Sh/h
You can also start the printing press using the [

Run ] button on the central control console.
K12-1

Printing machine
Restart the central control console

If the central control console does not boot automatic-
ally, carry out a restart.

OFF
Wait 20 seconds.
N
O
LS-03432-1

the machine from [ O ] to [ I ].
The central control console computer will boot.
Unexpected reaction: The central control console
computer still does not boot.
Different causes are possible.
OFF
Inform your MAN Roland sales / service partner.

ON
02-03087-1
Preselecting the production speed

Set the production speed (1) with the keys[ + ] or DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
[ w ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
The production speed depends on machine
type and configuration. DDDDDDDD DDDDDDDDDDDD DDDD
1 DDDDDD DDDDD
You can also change the production speed DDDDDDDD 4000 DDDDDDD D
DDDDD 2 3900 DDDDD DDDDDD
DDDDDDDD
using the [ Production speed + ] or [ Produc-
DDDDDD 3 2000 DDDDD
tion speed w ] button at PM 1 or the delivery
unit of the printing press. DDDDDDDD DDDDD
DDDDDDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-891-2

Printing machine
Starting automatic functions (central control console)

Press the [ Automatic functions: Start ] button.
The finger guide of the [ Automatic functions: Start ]
button is on.
K55-1
Starting the automatic sheet travel

Press the [ F2 ] key.
Program level Production (PR), main menu Machine.

The finger guide of the [ Run ] button is lit.
Press the [ Run ] button again. K12-1
The printing machine will turn at base speed.

Select the function Sheet travel with the key [ F2 ].

Only the sheet travel detectors are active F2
during sheet travel. All preset printing units, K101
inking units and dampening units are auto-

matically deactivated.
Start the sheet travel with the key [ Automatic pro-

duction ] or with the key [ F1 ].
The LED is on. K35-1
The pumps and blowers will be switched on.

The feeder will be engaged.
The feeder air will be switched on.
The machine is turning at the set starting speed.
The sheets will be transported into the machine.
The machine will accelerate to production speed as
soon as the first sheet has passed the front edge
control.
Production speed R 702 to R 709: 3 000 to
16 000 Sh/h
Production speed R 710 to R 711: max. 13 000 Sh/h
Production speed R 712: max. 12 000 Sh/h
During the sheet travel, all function keys are
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
deactivated except F1: Automatic produc-

tion.
Terminating the automatic sheet travel

Press the [ Automatic production ] button.
The LED goes out.
The air of the pick-up and forwarder suckers is K35-1
switched off.
The feeder will be disengaged.

Printing machine
The printing press will slow down to basic speed

as soon as the last sheet has been deposited in the
delivery unit.
Starting the automatic production.

The finger guide of the [ Run ] button is lit.
Press the [ Run ] button again. K12-1


The LED is on.
The pumps and blowers will be switched on. K35-1

The feeder air will be switched on.
The printing machine is turning at the set starting
speed.
The water form rollers will be thrown on.
The sheets will be transported into the printing ma-
chine.
While the first sheet is running through the printing
press, the ink form rollers and ink ductor rollers will
be thrown on, one by one.
The impression will be thrown on in all printing mod-
ules one by one.
Once the impression has been thrown on in the last
printing module, the printing press will accelerate to
production speed.
16 000 Sh/h
Interrupting the automatic production

Press the [ Feeder: On/Off ] button.
The LED goes out.
The impression will be thrown off in all printing units, K45
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
one by one.
The sheets which are not completely printed will be
transported to the delivery.
The feeder will be disengaged. The other sheets re-
main in front of the locked feed register.
The printing machine will slow down to base speed
delivery.

Printing machine
Continuing the automatic production

The LED is on.
The pumps and blowers are still switched on. K35-1

The feeder air is still switched on.
The printing machine is turning at the set starting
speed.
The water form rollers will be thrown on.
The sheets will be transported into the printing ma-
chine.
While the first sheet is running through the printing
press, the ink form rollers and ink ductor rollers will
be thrown on, one by one.
The impression will be thrown on in all printing mod-
ules one by one.
Once the first sheet has reached the last printing
module, the printing press will accelerate to produc-
tion speed.
16 000 Sh/h
Terminating the automatic production

The LED goes out.
As soon as the last sheet has passed the front edge K35
control, the feeder will be disengaged.

The impression will be thrown off.
While the last sheet is running through the printing
press, the ink and water form rollers will be thrown
off, one by one.
The pumps and blowers will be switched off.
The printing machine will slow down to base speed
delivery.
If you do not terminate production with the
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
[ Automatic production ] button, production

will be terminated automatically when the ac-
tual sheet counter shows the nominal num-
ber of sheets to be printed.
Following a machine stop: running the residual sheets out of the machine
Diagnosis message at the central control console.
There are still sheets in the machine

Printing machine
Press the [ Jog: Forward ] or [ Crawl speed ] button.

Important!
Danger of damage to the machine, if you
run residual sheets out of the machine
with "Jog: Reverse".
To run residual sheets out of the machine, K910
only use the "Jog: Forward" or "Crawl

speed" buttons.
Confirm the diagnosis message on the central con-

trol console after taking all residual sheets out of the
machine.

Press the [ Crawl speed ] button.
Press the [ Crawl speed ] button again.
The printing machine is running at Crawl speed.
Crawl speed, guard closed: 1 200 Sh/h
Crawl speed, guard open: 200 Sh/h K531
The control lamp of the key [ Crawl speed ] will be

flashing as long as the printing machine is turning.
Jog forward
Press the [ Jog: Forward ] button again.
Jogging mode: Guard closed: 1 200 Sh/h
Jogging mode: Guard open: 200 Sh/h
Release period of the start signal: 12 s
Press and hold down the [ Jog: Forward ] button. K527
The printing machine will turn forward as long as

you press the key.
Jog forward, limited travel

06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Each time you press the key, the printing machine
will turn a step forward. K527
Limited travel when jogging: 25 mm (0.984 in)

For reasons of safety, when a certain guard is
open, the control system only allows jogging
(limited travel).

Printing machine
Jog reverse
Important!
To run residual sheets out of the machine,
K529
speed" buttons.
Press the [ Jog: Reverse ] button again.

Press and hold down the [ Jog: Reverse ] button.
The printing machine will turn in reverse as long as
you press the key.
An alarm signal is issued as a warning if you
try to run the residual sheets out of the print-
ing press with the [ Jog: Reverse ] button.
This is forbidden.

Important!
To run residual sheets out of the machine,
K529
speed" buttons.

Each time you press the key, the printing machine
will turn a step backward.
Limited travel when jogging: 25 mm (0.984 in)
For reasons of safety, jogging (limited travel)
is possible only after opening certain guards.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing machine
Safety information for gas pressure springs 3
3.3 Safety information for gas pressure springs

3.3.1 Wear of gas pressure springs
Gas pressure springs (1) are attached to folding com-
ponents (2) and keep folded-up suction tapes feed 2
boards or folded-open steps open, for example.
As the wear of the gas pressure springs increases,
their holding power diminishes. Open components
may close unexpectedly, causing serious injury.
1
As soon as you detect defects in the gas pressure
springs, you must have the gas pressure springs
replaced with new ones by qualified personnel. The
installation of repaired gas pressure springs or
temporary components is prohibited.
Examples of signs of wear on gas pressure springs:
The component is hard to open.
The component does not stay in the required posi- 00-05362-2
tion.
3.4 Safety information for using driers

3.4.1 Overview
1 ABD
2 AID
3 Intermediate drier
3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
2 1
03-06118-1

Printing machine
3 Safety information for using driers
3.4.2 Washing agent when using an intermediate drier

You have two possibilities to avoid the ignition or de-
flagration of sprayed and evaporated washing agent:
Standard:
For safety reasons, there is a waiting period of 2
minutes between drying and washing or between
washing and drying.
Option:
The waiting period is not required if the following con-
ditions are fulfilled:
1. The washing agents used have a min. flash point of

62 C.
2. The driers used are approved by MAN Roland.
3. The settings of the washing device must not be
changed.
4. The printing press is equipped and prepared for this
type of operation.
3.4.3 Danger spot

WARNING:
Temperatures within the drier range are
high. Chemicals may ignite and explode.
This danger also remains when the drier
is switched off until the components have
cooled down to room temperature.
Only use inks and coatings which can-
not form an explosive atmosphere when
heated up in the drier. Inks which can
form an explosive atmosphere are marked
as "not applicable" in the safety data
sheet under "explosion limit".
WARNING:
Danger of death caused by the ignition
and explosion of vapors emitted by
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
solvents, if these solvents get into the

drier range, e.g. during the manual
cleaning of cylinders and rollers.
Never use, place or store solvents within
the drier range.

Printing machine
Procedure of automatic functions 3
WARNING:
Danger of burning yourself within the drier
range. Adjacent components may still be
hot even after switching off the drier.
Before you start work let the drier cool off
or wear safety gloves.
WARNING:
Risk of fire when printed sheets will be
pressed against hot elements. The sheets
may catch fire on hot surfaces and cause
severe injury as well as damage to the
machine.
Coordinate the setting of the blast and
suction nozzles in such a way that the
sheets cannot touch any hot elements.
WARNING:
Irreversible damage to eyes from radi-
ation of UV intermediate dryer emitted
from guard No. 10 (step guard).
Cover the guard with the cover plate
provided before operating the
intermediate dryer.
3.5 Procedure of automatic functions

3.5.1 PPL plate change
Removing
Course of a process
The machine will make several revolutions and set
the registers to zero.
The machine rotates and stops at the TE.
The TE tensioning bar will open and release the print-
ing plate.
The printing plate is guided to the ejecting slot.
The machine rotates and stops at the LE.
The LE tensioning bar will open and release the print-
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
ing plate.
After the removed printing plate has been lifted
slightly, it can remain in the ejecting slot until the end
of the plate change.
Mounting
Course of a process
Once the printing plate has been pushed in to the
inserting slot, the LE tensioning bar closes.
The pressure roller will be swung on.

Printing machine
3 Procedure of automatic functions
The machine rotates forwards and pulls in the print-

ing plate.
The machine rotates and stops at the TE.
The bending bar will be swung on.
The tail edge tensioning bar will open.
The printing plate will be guided into the tail edge
tensioning bar.
The tail edge tensioning bar will close.
The bending bar will be swung off.
The tail edge tensioning bar will be tensioned.
The pressure roller will be swung off.
The PPL plate change is terminated.
3.5.2 Run up ink

Course of a process
In the preselected inking units, the ink slides will be
set to the selected position.
The ink fountain roller accelerates to the maximum
speed.
The ink ductor roller strip will be set to the max. po-
sition to transfer as much ink as possible into the
inking unit.
The machine accelerates to ink run-up speed.
Ink run-up speed: 10 000 Sh/h
The ink flow is switched on. The ink runs up.
After a few revolutions, the ink flow is switched off
automatically.
If the Dampening roller function has been
preselected, the printing plate is inked up. The ink
form rollers will be thrown on and then the water
form rollers.
An indicating signal will sound when the run-up is
terminated.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The previously set values are set.

The ink run up is terminated.

Printing machine
Procedure of automatic functions 3
3.5.3 Ink roller washing program

Course of a process
The washing agent container will be pressurized.
The machine accelerates to washing speed.
Ink roller: Washing speed: 6 000 Sh/h
The ink on the rollers is removed with washing agent.
The doctor blade is thrown on.
The ink rollers will be washed.
If the Printing plate function has been preselected,
the printing plate is washed.
If the Dampening rollers function has been
preselected, the dampening rollers are washed.
The rollers are washed again with water.
The ink form rollers will be thrown off.
The doctor blade is thrown off.
The transition roller is thrown off (exception: if Gum-
ming or Decalcify has been preselected).
The washing agent container will be deaerated.
The washing program is terminated.
3.5.4 Starting the blanket and impression cylinder washing

program
Course of a process
The washing agent container will be pressurized.
The machine accelerates to washing speed.
Washing speed for ABD and AID: 600 Sh/h
The motors for the washing brushes are switched
on.
If more than 6 hours have passed since the last
washing, the washing brushes are predampened.
The Sheet edges function has been preselected:
The first wash-up is carried out with water.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Wash-ups with washing agent follow.

Wash-ups with water follow.
The blanket will be dried.
The washing brush will be cleaned.
The machine stops.
The Self-cleaning function has been preselected:
The brush is sprayed with washing agent and rotates
until 30 s after the end of the program.
The washing agent container will be deaerated.

Printing machine
3 Procedure of automatic functions
The washing program is terminated.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
Overview 4
4 Feeder
4.1 Overview
2 8 18 13
3
4 12
19 17
14
5
7
10
15 9 19
6
11
20
16 300
mm 11, mm
300 1" 81"
11,8
03-00127-5
1 Pile supporting plate: 11 Manual NONSTOP device (option)

2 Suction head 12 Tape shaft
3 Suction air setting 13 Blast air setting: Suction head
4 Side sheet stops 14 Blast air setting: side blower
5 Handwheel for sheet transport 15 Suction tapes feed board
6 Suction tapes, ventilator setting 16 Safety zone
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
7 Control panel, fine adjustment 17 Control panel, pile control

8 Manual suction head height adjustment (op- 18 Manual suction head size adjustment (op-
tion) tion)
9 Detector setting 19 Pictographs
10 Crooked sheet correcting device 20 [ Emergency stop ] (base option)

Feeder
4 Overview of the operating panels
4.2 Overview of the operating panels

4.2.1 Commands: pile control
1 Pile: Stop-Secure
2 Automatic pile control
3 Service plug by MAN Roland (service)
4 Pile: Raise 10
5 Residual/intermediate pile: Raise (option)
6 Loudspeaker
7 Pile: Lower
8 Residual/intermediate pile: Lower (option)
9 emergency stop
10 Incoming check: Free (option) 1 2 3
4 5 6
7 8 9
03-01089-4
Automatic pile control

Automatic make-ready of the feeder after size
changes.
K556
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
Overview of the operating panels 4
4.2.2 Control panel: Fine adjustment

1 Suction head: Lower
2 Suction head: Raise
3 Suction head: Forward 1 2
4 Suction head: Back
5 without function 3 4
6 without function
7 Pile stop, B-side larger 5 6
8 Pile stop, B-side: Smaller
9 Pile stop, A-side: Smaller 7 8
10 Pile stop, A-side: Larger
11 Pile supporting plate: B-side 9 10
12 Pile supporting plate: A-side
13 Positioning drives: Stepwise / without inter- 11 12
ruption
15 without function
03-01090-6
Suction head: Lower

Suction head moves downwards.
K567-1
Suction head: Raise

Suction head moves upwards.
K568-1
Suction head: Forward

Suction head moves in sheet travel direction (for smal-
ler sheet sizes).
K569-1
Suction head: Back

Suction head moves against sheet travel direction (for
larger sheet sizes).
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K570-1
Pile stop, B-side larger

Pile stop moves away from the pile.
K822-1

Feeder
4 Pile controls
Pile stop, B-side: Smaller

Pile stop moves towards the pile.
K823-1
Pile stop, A-side: Smaller

Pile stop moves towards the pile.
K820-1
Pile stop, A-side: Larger

Pile stop moves away from the pile.
K821-1
Pile supporting plate: B-side

The pile supporting plate moves towards the B-side.
K573-1
Pile supporting plate: A-side

The pile supporting plate moves towards the A-side.
K574-1
Positioning drives: Stepwise / without interruption

Preselection of the positioning drive.
Gradual or continual positioning of suction head, lateral
stops and pile supporting plate. K252
4.3 Pile controls

4.3.1 Raising the pile supporting plate
WARNING:
Danger of life in the moving range of the
pile supporting plate.
Make sure you have pressed and locked
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
the Pile: Stop-Secure button before you

enter the zone where the pile support-
ing plate is moving up or down. Before
you work on or under the pile supporting
plate, always clear it and place supports
under it.
Press and hold down the [ Pile: Raise ] button.

Feeder
Pile controls 4
The pile will be raised as long as you press the

button or until the detector in the sheet flap stops it
automatically.
K538
4.3.2 Lowering the pile supporting plate

WARNING:
under it.
Press and hold down the [ Pile: Lower ] button.
The pile supporting plate will be lowered as long as

you press and hold down the button. Right before
the pile supporting plate touches the floor, the plate
will be lowered slowly.
Safety distance for slow movement: 120 mm (4.724 in)
The pile supporting plate will stop right above the
K540
floor.
The automatic centering is not yet finished.
Wait a few seconds. Then lower the pile supporting
plate down to the floor.
4.3.3 Stopping the pile hoist

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K550

Feeder
4 Make-ready of the feeder
4.4 Make-ready of the feeder

4.4.1 Changing main pile at feeder
Moving the sheet pile out at the feeder
Procedure
WARNING:
under it.

K540
floor.
Move the empty pallet out of the feeder with a suit-

able lift truck.
Inserting the pile

Procedure
WARNING:
Danger to life or damage to material if the
max. pile weight or the max. pile height is
exceeded. The pile and the pile support-
ing plate may kill you.
Only if you do not exceed the admissible
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
pile weight (see Technical Data), are you

allowed to make use of the max. admiss-
ible pile height.
Move the new pile onto the pile supporting plate.

Pile table height or pallet height: 144 mm (5.669 in)
Pile height: main pile (without pallet): max. 1 180 mm
(max. 46.457 in)
Pile weight: main pile (without pallet): max. 1 300 kg
(max. 2 866.5 lb)

Feeder
Make-ready of the feeder 4
WARNING:
under it.

automatically.
K538
4.4.2 Changing main pile at feeder (option: base)

Moving the sheet pile out at the feeder (option: base)
Procedure
Pull the button (1) of the lock.
Swivel the railings (2) towards the machine.
Swing the step (3) upwards.
2
3
1
03-05793-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
WARNING:
under it.

Feeder

K540
floor.
Move the empty pallet out of the feeder with a suit-

able lift truck.
Pile loading (option: base)

Procedure
WARNING:
ible pile height.
Move the new pile onto the pile supporting plate.

Main pile with base: [ 275 mm / 10.827 in ]: max.
1 455 mm (max. 57.283 in)
1 730 mm (max. 68.11 in)
1 300 kg
1 300 kg
WARNING:
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

under it.

Feeder
Make-ready of the feeder 4

automatically.
K538
Swing the step (1) downwards.

1
Swivel the railings (2) forwards.
2
Close the button (3) of the lock.
The step (1) can be accessed again.
03-05794-1
4.4.3 Making ready feeder after a size change

Preliminary tasks
Make-ready of a work step (see page 11-59)
Procedure
WARNING:
under it.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

K540
floor.

Feeder
The pile supporting plate must be lowered

completely.
Switching on the automatic pile control

Press the [ Automatic pile control ] button.
The [ Automatic pile control ] telltale lamp is on.
The pile stops move to their outer end positions.
The suction head moves to its vertical and horizontal
end position.
The [ Automatic pile control ] telltale lamp flashes. K556
WARNING:
ible pile height.
Stack the sheets.

(max. 2 866.5 lb)
(max. 46.457 in)
WARNING:
ing plate is moving up or down. Before K538

under it.
Using the [ Pile: Raise ] button, move the pile sup-
porting plate upwards until the detector stops it.
At the feeder, the suction head and pile stops on the
A- and B-side are adjusted to the sheet size.
At the feed register, the pulling side guides are ad-
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
apted to the sheet size, the cover guides and the

gripper pads at the feed register drum to the sheet
thickness.
At the transferters, the gripper pads are adapted to
the sheet thickness.
After the positioning, the function Automatic pile
control will be deactivated automatically.
The telltale lamp on the [ Automatic pile control ]
button keeps flashing until the suction head is
automatically lowered onto the pile when production
starts.

Feeder
Manual NONSTOP operation (option) 4
The [ Automatic pile control ] telltale lamp goes out.

The [ Automatic pile control ] telltale lamp flashes.
The feeder is not ready.
A diagnosis message will be displayed at the central
control console.
Lower the pile supporting plate down to the floor.
Lowering the pile supporting plate
Press the [ Automatic pile control ] button again.
4.5 Manual NONSTOP operation (option)

4.5.1 Manual NONSTOP: transport aids
Overview
1. Carrier bar
2. Carrier rods
1
3. Magazine
3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-05788-1

Feeder
4 Manual NONSTOP operation (option)
4.5.2 Starting manual NONSTOP operation

Preliminary tasks
Requirement for manual NONSTOP operation: The
pile on the feeder is located on a NONSTOP pallet (1).
1
03-05779-1
Conditions
The printing press is in production.
Procedure
WARNING:
Danger of injury caused by incorrect non-
stop pallets and incorrectly inserted car-
rier rods. The carrier rods may slip and
fall down. The pile may tip over and cause
serious injury.
Only use original MAN Roland nonstop
pallets.
Insert the carrier rods completely.
Remove the carrier bar for the residual pile from the
magazine.
WARNING:
Danger of crushing your hands at the sup-
ports when the pile hoist is in motion.
1
Never touch the supports as long as the
pile hoist is in motion.
Insert the carrier bar (1) into the guide of the support
(2) (A-side).
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Push the carrier bar (1) toward the support in the 4 2

3
direction of the arrow.
The moving element (3) of the carrier bar moves in.
Insert the carrier bar (1) into the guide of the support
(4) (B-side) in the direction of the arrow.
03-05785-1

Feeder
Remove the carrier rods from the magazine.

Start inserting the carrier rods (3) as soon as the pile
supporting plate (2) clocks over the carrier bar (1).
Residual pile: max. 450 kg 3
Residual pile with base: [ 275 mm / 10.827 in ]: max.
450 kg
450 kg
Residual pile: max. 500 mm (max. 19.685 in) 2
500 mm (max. 19.685 in) 1
500 mm (max. 19.685 in)
03-00131-3
Insert the carrier rods (3) between the last sheet of
the residual pile and the pallet.
Select the corresponding number of carrier rods for
the weight of the residual pile and sheet size.
Number of carrier rods: 4 to 10 units
The number of carrier rods should be chosen
so that the residual pile does not protrude
between the carrier rods.
Press and hold down the [ Residual/intermediate
pile: Raise ] button.
The residual pile will be raised as long as you press

the button or until the detector in the sheet flap
stops it automatically.
K542
Raise the residual pile until the carrier bars (1) lift the
carrier rods (2).
The [ Automatic pile control ] telltale lamp is on.
2
The pile hoist (3) is stopped automatically.
The residual pile acts as a pile supporting plate and
therefore automatically clocks the rest of the pile up-
wards.
The pile supporting plate (3) automatically moves 3 1
downwards after a short delay, stopping just above
the ground.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Safe distance of pile supporting plate from the ground:

120 mm (4.724 in) 03-05786-1
WARNING:
Danger of crushing your feet when the
pile supporting plate is lowered. The pile
supporting plate may crush your feet.
Keep out of the danger zone as long as
the pile supporting plate is in motion.

Feeder
The pile supporting plate will move slowly

downwards as long as you keep the button pressed
down or until it is stopped by the floor.
K540
Move the empty NONSTOP pallet out of the feeder

using a suitable lift truck.
4.5.3 Pile loading during manual NONSTOP operation

Procedure
WARNING:
ible pile height.
Move the new pile of sheets onto the center of the

(max. 46.457 in)
1 455 mm (max. 57.283 in)
1 730 mm (max. 68.11 in)
(max. 2 866.5 lb)
After printing the new pile, you can continue
using the manual NONSTOP operation if the
pile is located on a NONSTOP pallet.
WARNING:
Danger of crushing your hands at the sup-
ports when the pile hoist is in motion.
Never touch the supports as long as the
pile hoist is in motion.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Raise the pile supporting plate to just below the carrier
rods of the residual pile.
Distance from the residual pile when raising the pile
supporting plate: 30 mm (1.181 in)

Feeder

automatically.
K538
4.5.4 Continuing manual NONSTOP operation

Preliminary tasks
Adjust the pile surface to the residual pile surface
where necessary by placing wedges (1) underneath
the pile.
03-05787-1
Align pile supporting plate to the side of the residual pile

Align the pile to the side of the residual pile if ne-
cessary using the [ Pile supporting plate: B-side ] or
[ Pile supporting plate: A-side ] button. K982
Procedure
Switching on the automatic pile control
Press the [ Automatic pile control ] button.
The [ Automatic pile control ] telltale lamp flashes.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The raising of the pile support plate is automatically

switched over to slow.
K556

Feeder
Raising the pile supporting plate to the residual pile

Press and hold down the [ Pile: Raise ] button until
the pile lifts the carrier rods.
Both carrier bars automatically move back down to
the limit stop.
The [ Automatic pile control ] telltale lamp goes out.
K538
4.5.5 Manual NONSTOP operation: removing carrier rods

Procedure
Slide a wedge (1) in the middle in between the pile
and residual pile .
So that the pile control is not affected, the
pile surface must not lower when the carrier
rods are removed.
Start pulling out the carrier rods.
The order in which the carrier rods are removed is
based on the pile surface.
1
03-05789-1
Flat pile surface: pulling out carrier rods

Pull the carrier rods out of the pile in the order (1 -
6).
As soon as you have pulled one carrier rod out, re-
move the wedge (7) from the pile piece by piece.
Do not remove the wedge (7) until the last 5 3 1 7 2 4 6
carrier rod has been pulled out.
Place the carrier rods back in the magazine.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-05790-1

Feeder
Pile surface higher in the middle (convex): pulling out carrier rods
Pull the carrier rods out of the pile in the order (1 -
6).
move the wedge (7) from the pile piece by piece. 5 3 1 7 2 4 6
Do not remove the wedge (7) until the last
03-05791-1
Pile surface lower in the middle (concave): pulling out carrier rods
Pull the carrier rods out of the pile in the order (1) to
(8).
move the wedge (9) from the pile piece by piece. 1 3 5 7 9 8 6 4 2
Do not remove the wedge (9) until the last
The manual NONSTOP operation is complete.
03-05792-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
4 Suction head
4.6 Suction head

4.6.1 Overview
1 3 5 3 1
4
1 2 4 6 7 8 9 2 1
03-05739-1
1 Separators 6 Auxiliary blast nozzles

2 Sheet stops with sheet hold-downs 7 Sheet separators
3 Forwarder sucker 8 Separating blast nozzle
4 Auxiliary forwarder sucker 9 Pressure foot
5 Pick-up suckers
4.6.2 Setting the working height of the pile

Procedure
Set the working height of the pile either by pressure
foot control or by the detector at the sheet flap. The
given value is a standard value. It applies to the pile
center.
Distance between the pile top edge and the sheet flap
top edge: 4 to 6 mm (0.157 to 0.236 in)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-04311-1

Feeder
Suction head 4
Setting the pile working height by pressure foot control

Press the [ Suction head: Raise ] button.
The suction head will be raised step by step.
K568-1
Press the [ Suction head: Lower ] button. Before

that, lower the pile by approx. 50 mm (1.969
inches). K567-1
The suction head will be lowered step by step.

Raise the pile again.
Setting the pile working height via the detector on the sheet flap
Set the height of the detector (1) on the rotating but-
ton (2) (B-side).
- +
03-05731-1
4.6.3 Setting the suction head forward or backward

Correct the suction head after the automatic
alignment, if the pressure foot is not positioned
correctly on the rear edge of the pile.
Procedure
Set the suction head against the pile rear edge us-
ing the [ Suction head: Forward ] or [ Suction head:
Reverse ] button. K980
Distance between the front edge of the pressure foot

and the rear edge of the pile: 12 mm (0.472 in)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-00143-2

Feeder
4 Suction head
4.6.4 Setting the height of the suction head

Thin printing material may require an alteration to the
distance between the intake sheet and the pile. This
change is achieved by adjusting the height of the pres-
sure foot.
Procedure
Caution!
Beware of crushing your fingers between
the pressure foot and neighboring com-
ponents.
It is prohibited to adjust the pressure foot
when the feeder is engaged.
Disengaging the feeder

Disengaging the feeder when the machine is turning at
basic speed
Press the [ Feeder: On/Off ] button.
The LED goes out.
Feeder Off:: The feeder is disengaged. K602-1
Set the distance between pressure foot and pile top

edge using the screw (1).
Distance: 12 mm (0.472 in)
Turning the screw clockwise will increase the distance.
Turning the screw anticlockwise will decrease the dis- 1
tance.
Before you lower the suction head, lower the
pile by approx. 50 mm (1.969 inch). Once
you have set the suction head, raise the pile
again.
03-00155-2
Check or correct the distance between the pile top

edge and the top edge of the sheet flap.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
Suction head 4
4.6.5 Adapting separators and sheet separators to the pile surface

Procedure
Actuate the lever (1) (A+B-side) to adjust the separ-
ators (2) and sheet separators (3) to the pile surface.
2 Lever
Using the lever (1) (A+B-side), move a whole

group at a time, comprising two sheet separ-
ators and two separators.
The sheet separators and separators can be
set individually where necessary.
1
3
2
03-05732-1
4.6.6 Setting separators and sheet separators individually

Preliminary tasks
Secure the pile hoist with the [ Pile: Stop-Secure ]
button - see chapter Safety -.
Procedure
Loosen the clamp (1) (A+B-side) of the sheet separ-
ators. 1
6 Sheet separators
Adjust the sheet separators (2) (A+B-side) to the pile

surface.
Close the clamp (1) (A+B-side) of the sheet separat-
ors.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-05734-1

Feeder
4 Suction head
Loosen the clamp (1) (A+B-side) of the auxiliary

blast nozzles and separating blast nozzles. 1
4 Auxiliary blast nozzles

2 Separating blast nozzle
Adjust the auxiliary blast nozzles and separating

blast nozzles (2) (A+B-side) to the pile surface.
Close the clamp (1) (A+B-side) of the auxiliary blast
nozzles and separating blast nozzles.
03-05733-1
4.6.7 Coordinating the settings at the suction head

Procedure
Setting the air pressure of the pick-up and forwarder suckers
To set the air pressure, turn the outer ring of the
manometer (1).
Voluminous, porous printing materials: -0.6 bar
Thin, lightweight and lightweight cardboard printing
materials and cardboard:: min. -0.5 bar
Check the setting on the scale (2).
0,4 0,6 -0,3

-0,4 -0,2
0,2 0,8
-0,5
-0,1
0 1,0 -0,6 0
03-05735-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
Suction head 4
Setting the air pressure of the separating blast nozzles and auxiliary blast nozzles
To set the air pressure, turn the outer ring of the
manometer (1).
Voluminous, porous printing materials: 0.5 to 0.7 bar
Printing lightweight paper: 0.3 to 0.5 bar
Lightweight and lightweight cardboard printing materi-
als and cardboard:: 0.5 to 0.7 bar
Check the setting on the display (2).
0,4 0,6 -0,3

-0,4 -0,2
0,2 0,8
-0,5
-0,1
0 1,0 -0,6 0
03-05736-1
Microsetting the air pressure of the auxiliary blast nozzles

To set the air pressure for the outer auxiliary blast
nozzles, turn the rotating button (1).
To set the air pressure for the inner auxiliary blast
3 2 3 2 3 2
1 1 1
0 0 0
1 2 3
03-05737-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
4 Suction head
Microsetting the air pressure of the separating blast nozzles

To set the air pressure of the separating blast
3 2 3 2 3 2
1 1 1
0 0 0
1 2 3
03-05737-1
Setting the air pressure of the side separators

To set the air pressure of the side separators on the
A-side, turn the rotating button (1).
To set the air pressure of the side separators on the
B-side, turn the rotating button (2).
03-05738-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
Suction head 4
Setting the air pressure of the flexible separators

Set the air pressure of the flexible separators (1)
(A+B-side) on the valve (2). 2
2
1
1
03-05741-1
Setting the separating blast nozzle

Loosen the screw (1) (A+B-side).
Set the separating blast nozzle (2) (A+B-side) to the 1
desired height.
Tighten the screw (1) (A+B-side).
Compress the holder (3) (A+B-side) in order to dis-
place the separating blast nozzle horizontally. 3
03-05742-1
Setting the auxiliary blast nozzles

Loosen the screw (1).
1
Set the auxiliary blast nozzle (2) to the desired
height.
The inner sheet separator elements and the
auxiliary blast nozzles are set at the same
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
time.
Retighten the screw (1).
03-05744-1

Feeder
4 Suction head
Setting the sheet separator elements and auxiliary blast nozzles

Loosen the clamp (1) (A+B-side).
1
Set the inner sheet separator elements to the de-
sired height using the auxiliary blast nozzles (2)
(A+B-side).
3
The inner sheet separator elements and the
auxiliary blast nozzles are set at the same
time.
Retighten the clamp (1).
Using the lever (3) (A+B-side), set the sheet separat-
or elements.
2
03-05746-1
Setting the sheet separator elements

Loosen the clamp (1).
1
Set the outer sheet separator elements (2) (A+B-
side) to the desired height.
Set the sheet separator elements (2) (A+B-side) ho-
rizontally by sliding or pulling.
Tighten the clamp (1) (A+B-side).
03-05747-1
Setting the side separators (height)

Using the nut (1) to set the height of the separators
(2). 1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-05740-1

Feeder
Suction head 4
Setting the separators

Set the flexible separators (1) (A+B-side) to the
sheet size.
Set the separators (3) (A+B-side) to the desired
height using the nut (2). 1
2
03-05748-1
Setting the pick-up suckers

Using the lever (1), position the pick-up suckers di-
agonally or vertically in relation to the sheet tail edge.
03-05750-1
The pick-up suckers are positioned diagonally in re-

lation to the sheet tail edge for lightweight printing
materials.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-04335-1
The pick-up suckers are positioned vertically in rela-

tion to the sheet tail edge for heavy printing materi-
als.
03-04646-1

Feeder
4 Suction head
4.6.8 Forwarder suckers, auxiliary forwarder suckers

Setting the height of the outer forwarder sucker
Conditions
An uneven pile surface may hinder the uniform suction
of the sheet. The height adjustment of the two outer
forwarder suckers can correct this unevenness.
Procedure
Using the lever (1), (A+B-side), set the outer for-
1
warder suckers (2).
Distance of the forwarder suckers to the sheet sucked
on.: 5 mm (0.197 in)
The inner and outer forwarder suckers are equidistant
from the intake sheet.
2
03-05749-1
Changing the auxiliary forwarder sucker (cardboard guide)

Removing auxiliary forwarder sucker
1 Auxiliary forwarder sucker
2 Forwarder sucker
3 Auxiliary forwarder sucker (replaceable)
1
2 2
3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-06110-1
Screwdriver set, hexagon, with

ball-shaped head, width across flats 2.5
(094L017213)

Feeder
Suction head 4
Preliminary tasks
WARNING:
under it.
Press the [ Pile: Lower ] button.
The pile will be lowered as long as you press and

hold down the button.
K540
Secure the printing press using the [

"STOP-secure" ] button - see chapter Safety -.
Procedure
Loosen the headless setscrew (1) on the auxiliary
forward sucker (2).
Screwdriver set, hexagon, with ball-shaped head, width
across flats 2.5 (094L017213)
1
5 Headless setscrews
Disconnect the auxiliary forwarder sucker(2) from

3
the terminal screw (3).
2
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-06109-1
Installing the auxiliary forwarder sucker

Auxiliary forwarder sucker: Cardboard
(021F017715)
Screwdriver set, hexagon, with
ball-shaped head, width across flats 2.5
(094L017213)

Feeder
4 Suction head
Procedure
Connect the auxiliary forwarder sucker (2) to the
terminal screw (3).
Use of auxiliary forwarder sucker (cardboard): min.
300 g/m
Auxiliary forwarder sucker: Cardboard (021F017715) 1
Tighten the headless setscrew (1). 3

Screwdriver set, hexagon, with ball-shaped head, width
across flats 2.5 (094L017213)
2
03-06109-1
Adapting the distance of the forwarder sucker to the sheet width

The forwarder suckers allow safe transport of the
sheets to the suction tapes feed board. The ideal
spacing (A) of the forwarder suckers (1) is
approximately 1/2 sheet width.
1 1
Double open-end combination spanner,
width across flats 10 (094L116240)
03-05762-1
Preliminary tasks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
Suction head 4
Procedure
Loosen the hose screws (1) (A+B-side).
Double open-end combination spanner, width across
flats 10 (094L116240)
4 Screws
2 Forwarder sucker
Slide the forwarder sucker (2) (A+B-side) into the

required position.
Spacing of forwarder suckers (A): max. 460 mm (max.
18.11 in)
Sheet width: 480 to 1 040 mm (18.898 to 40.945 in)
Tighten the screws on the (1) ( A+B-side).
1
2
03-05745-1
Adjusting the forwarder suckers and auxiliary forwarder suckers to smaller

sheet sizes
The side forwarder suckers (2) and the front auxiliary
forwarder sucker (1) are deactivated for very small
sheet sizes.
1
Covering for forwarder suckers
(021F047330) 2 2
03-05761-1
Preliminary tasks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
4 Suction head
Procedure
Close the valve for the auxiliary forwarder sucker (2)
using the lever (1).
The auxiliary forwarder sucker is depressurized.
Place the cover (4) on the forwarder sucker (3)
(A+B-side).
1
Covering for forwarder suckers (021F047330)
2 Forwarder sucker
2
3
03-05759-1
Checking the suction disks (forwarder suckers) for voluminous, porous printing
materials
Directions
Grammage: 40 to 100 g/m; SHEET: Voluminous,
porous printing material
Outer diameter of suction disk: 32 mm (1.26 in)
Inside diameter of the suction disk.: 15 mm (0.59 in)
Thickness of the suction disk: 0.7 mm (0.028 in)
Material of the suction disk: Rubber, blue
Determining the condition

Check whether the appropriate suction disks are
installed for the used printing material.
Possible result
The suction disks do not conform to specification.
Install the prescribed suction disks.
Changing the suction disk of the forwarder suckers
(see page 4-34)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Checking the suction disks (forwarder suckers) for thin paper printing
Directions
Grammage: 30 to 100 g/m; SHEET: Printing light-
weight paper

Feeder
Suction head 4

Possible result
(see page 4-34)
Checking the suction disks (forwarder suckers) for lightweight paper printing
Directions
Grammage: 70 to 150 g/m; SHEET: Light-weight
paper printing
Thickness of the suction disk: 1 mm (0.039 in)

Possible result
(see page 4-34)
Checking the suction disks (forwarder suckers) for lightweight cardboard

Directions
Grammage: 150 to 300 g/m; SHEET: Light card-
board
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Material of the suction disk: Vulkolan, brown

Possible result

Feeder
4 Suction head

(see page 4-34)
Checking the suction disks (forwarder suckers) for cardboard

Directions
Grammage: min. 300 g/m; SHEET: Cardboard

Possible result
(see page 4-34)

Removing the suction disk
Preliminary tasks
WARNING:
under it.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

K540

Feeder
Suction head 4

Procedure
03-05751-1
Remove the suction disks (1) from the forwarder suckers.

2 Forwarder sucker
Installing the suction disk

Procedure
Insert the new suction disk of the forwarder sucker.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Final tasks
Unlock the pile hoist by turning the [ Pile: Stop-
Secure ] button anticlockwise.
Checking the suction disks (auxiliary forwarder suckers) for voluminous, porous
printing materials
Directions

Feeder
4 Suction head


Possible result
(see page 4-34)
Checking the suction disks (forwarder suckers) for thin paper printing
Directions
weight paper

Possible result
(see page 4-34)
Checking the suction disks (auxiliary forwarder suckers) for lightweight paper
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
printing
Directions
paper printing

Feeder
Suction head 4

Possible result
(see page 4-34)
Checking the suction disks (auxiliary forwarder suckers) for lightweight

cardboard
Directions
board

Possible result
(see page 4-34)
Checking the suction disks (auxiliary forwarder suckers) for cardboard

Directions
06.09.2004 10:35:31 - 747 - 80 95A EN 6778


Possible result

Feeder
4 Suction head

(see page 4-34)
4.6.9 Pick-up suckers

Adjusting the pick-up suckers to the printing material
The structure and position of the pick-up suckers can
be changed according to the printing material.
Procedure
Use this bellow sucker for voluminous, porous print-
ing material.
Grammage: 40 to 100 g/m
SHEET: Voluminous, porous printing material
03-04328-1
For cardboard, use the bellow sucker without insert.

Grammage: min. 300 g/m
SHEET: Cardboard
03-04644-1
When using the following printing materials, install

the insert into the bellow sucker.
SHEET: Printing lightweight paper
SHEET: Light-weight paper printing
SHEET: Light cardboard
03-04327-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
Suction head 4
When using the following printing materials, position

the pick-up sucker diagonally in relation to the pile
rear edge using the lever (1).
Grammage: 30 to 100 g/m 1
SHEET: Light cardboard
03-05750-1
The suckers are inclined in relation to the pile rear edge

(seen from the B-side).
The pick-up suckers must not touch the pile.
03-04335-1
When using the cardboard, position the pick-up

sucker vertically in relation to the pile rear edge us-
ing the lever (1).
SHEET: Cardboard
1
03-05750-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The suckers are positioned vertically (seen from the

B-side).
The pick-up suckers must touch the pile.
03-04646-1

Feeder
4 Suction head
Changing the pick-up sucker nozzles

Removing pick-up sucker nozzles
Preliminary tasks
WARNING:
under it.

K540
floor.

Procedure
Unscrew the screw (1) as far as the limit stop.
3
Double open-end combination spanner, width across 1
flats 10 (094L116240) 3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Remove the pick-up sucker (2) from the guide (3).

4 Pick-up suckers 1
2
03-05760-1

Feeder
Suction head 4
Installing pick-up sucker nozzles

Procedure
Insert the spring into the pick-up sucker nozzle (1).
3 2
Insert the pick-up sucker nozzle (1) into the guide 2
(2).
Tighten the screw (3). 3
4 Pick-up suckers
1
03-05763-1
4.6.10 Separating blast nozzle

Setting the separating blast nozzle
Procedure
Set the separating blast nozzle (2) to the desired 1
height.

3
Compress the holder (3) in order to move the separ-
ating blast nozzle horizontally.
03-05742-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
4 Suction head
Adapting the separating blast nozzles to the sheets

1 Separating blast nozzle: rectangular
2 Separating blast nozzle: round
3 Separating blast nozzle: wavy
1 2 3
03-04342-1
Directions
Voluminous, porous printing materials: round or
rectangular shape
03-04066-1
The separating blast nozzles are positioned centrally
to the pile edge.
Thin, lightweight and lightweight cardboard printing

materials: round and rectangular shape 03-05604-1
The separating blast nozzles are at a level with the

pile top edge. The center of the separating blast
nozzles is at a level with the pile edge.
Cardboard: corrugated and rectangular shape

The separating blast nozzles are at a level with the 03-05605-1
pile top edge. The center of the separating blast
nozzles is at a level with the pile edge.

Check whether the appropriate separating blast
nozzles for the respective printing material are in-
stalled in the prescribed position.
Possible result
The type or the mounting position of the sheet separat-
or elements does not conform to specification.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Changing the separating blast nozzle

(see page 4-43)
Setting the separating blast nozzle (see page 4-41)

Feeder
Suction head 4
Changing the separating blast nozzle

Removing the separating blast nozzle
Preliminary tasks
WARNING:
under it.

K540

Procedure
Detach the hose (1) (A+B-side) from the separating
blast nozzle. 1
Compress the holder (3) (A+B-side) and remove the
separating blast nozzle (2) from the fastening.
3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-05743-1

Feeder
4 Suction head
Installing the separating blast nozzle

Procedure
Compress the holder (3) and insert the separating
blast nozzle (2) into the fastening. 1
Connect the hose (1) to the separating blast nozzle
(2).
03-05743-1
Final tasks
4.6.11 Auxiliary blast nozzles

Setting the auxiliary blast nozzles
Procedure
1
Set the auxiliary air blast nozzles (2) to the desired
height.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-05744-1

Feeder
Suction head 4
The auxiliary blast nozzles are positioned in the middle

between pile top edge and pick-up sucker.
Distance between auxiliary blast nozzle and pile front
edge: 5 mm
4 Auxiliary blast nozzles
03-02690-2
Tighten the screw.
4.6.12 Sheet separator elements

Checking the sheet separator elements for voluminous, porous printing
materials
Directions
B B
Type: Springs
Quantity (inside, outside): 3 units A C
Measure (A): 5 mm
Measure (C): 2 mm
Measure (B): 4 to 6 mm
03-05752-1

Check whether the appropriate sheet separator
elements for the respective printing material are in-
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Possible result
Changing the sheet separator elements
(see page 4-48)
(see page 4-49)

Feeder
4 Suction head
Checking the sheet separator elements for thin paper printing

Directions
B B
weight paper
Type: Springs
Quantity (inside, outside): 3 units A C
Measure (A): 4 mm
Measure (C): 2 mm
03-05752-1

Possible result
(see page 4-48)
(see page 4-49)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
Suction head 4
Checking the sheet separator elements for lightweight paper printing

Directions
B B
paper printing
Type: Springs
Number of springs (outside): 3 units A C
Number of springs (inside): 6 units
Measure (A): 3 mm
Measure (C): 2 mm
03-05754-1

Possible result
(see page 4-48)
(see page 4-49)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
4 Suction head
Checking the sheet separator elements for cardboard and lightweight cardboard
Directions
board B B
Type: Brush (outside) spring (inside)
A C
Measure (C): 2 mm
Measure (A): 3 mm
Number of springs (inside): 6 units
03-05755-1

Possible result
(see page 4-48)
(see page 4-49)

Removing the sheet separator elements
Preliminary tasks
WARNING:
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

under it.

Feeder
Suction head 4

K540

Procedure
Open the clamp (1) and pull the sheet separator
element (2) out of the fastening. 1
6 Sheet separator elements
03-05734-1
Installing the sheet separator elements

Sheet separator for lightweight cardboard
and cardboard
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
4 Suction head
Procedure
Slide the new sheet separator element (2) into the
fastening and close the clamp (1). 1
Sheet separator for lightweight cardboard and card-
board
03-05734-1
Final tasks

Preliminary tasks
Procedure
Loosen the clamp (1).
6 Clamps 1
Set the sheet separator elements (2) to the desired

height.
The two inner sheet separator elements and

the separating blast nozzles are set at the
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
same time.
Close the clamp (1).
03-05734-1

Feeder
Suction head 4
Slide the two inner sheet separator elements (1) ho-

5 4
rizontally towards the pile using the lever (2). 2
Open the clamp (5).
Slide the two outer sheet separator elements (3)
horizontally towards the pile using the lever (4).
Close the clamp (5).
1
03-05753-1
Final tasks
4.6.13 Sheet stop and sheet hold-down

Setting the sheet hold-down
The sheet hold-downs keep the printing material on
the pile while it is ruffled by the separators. The weight
of the sheet hold-downs is adapted to the printing ma-
terial used.
Preliminary tasks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
4 Suction head
Procedure
Slide the sheet hold-down (1) (A+B-side) out of the
guide of the sheet stop (2).
2 Sheet hold-down
Insert the steel weights (3) into the bore of the sheet
3
hold-down.
The steel weights must be chosen so that the
printing material is kept on the pile without
disturbing the sheet travel.
Slide the sheet hold-down (1) back onto the guide 1
of the sheet stop (2).
03-05757-1
Decommissioning sheet hold-downs

If the sheet hold-downs are no longer required on the
feeder, they can be lifted up and thus rendered non-
functional.
Preliminary tasks
Procedure
Slide the sheet hold-down (1) upwards until it en-
gages.
The sheet hold-downs do not touch the pile surface.
2 Sheet hold-down 06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-05756-1

Feeder
Sheet transport 4
4.7 Sheet transport

4.7.1 Sheet guiding rods
Setting the sheet guiding rods to size and height
4 5
2
1
03-05764-1
The sheet guide rods (1) to (6) support the transport of the sheet from the suction head to the suction tapes feed
board. The outer sheet guide rods (1), (2), (5) and (6) can be removed, depending on the sheet size.
Double open-end combination spanner, width across flats 10 (094L116240)
Preliminary tasks
WARNING:
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

under it.

Feeder
4 Sheet transport

K540
floor.

Procedure
Tighten the nut (2) and loosen the screw (1).
flats 10 (094L116240)
flats 10 (094L116240)
2 Double open-end combination spanner
Pull the sheet guiding element (3) out of the fasten-

ing (4).
2 Sheet guide rods for a sheet length of: 340 to
360 mm (13.386 to 14.173 in)
470 mm (14.173 to 18.504 in)
740 mm (18.504 to 29.134 in)
flats 10 (094L116240)
1
flats 10 (094L116240)
3
03-05766-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
Sheet transport 4
Pull the sheet guiding element (1) out of the fasten-

ing (2) at the side.
1
03-05765-1
Turn the nut (2) to set the distance between the

sheet guiding element (1) and pile.
Turning nut anticlockwise: distance between the sheet 2
guiding element and pile is reduced.
Turning nut clockwise: distance between the sheet
guiding element and pile is increased.
03-05767-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
4 Sheet transport
4.7.2 Double sheet control

Checking the function of the mechanical double sheet control
The feeder does not stop, even though you have simu-
lated a double sheet by means of a test strip.
Directions
The feeder stops as soon as the double sheet con-
trol has detected a double sheet.
Determining the condition: Checking the setting of the double sheet control
Test strips for the double sheet control
Conditions
The machine is running at sheet travel speed.
Procedure
Guide a long test strip (1) from the feed register side
underneath the roller (2) of the double sheet control.
03-00176-1
03-00176-2
Possible result
The feeder does not stop.
Readjusting the mechanical double sheet control
(see page 4-56)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
Sheet transport 4
Readjusting the mechanical double sheet control

Procedure
Turn the setting wheel (1) clockwise until the double
sheet control responds.
Vertical setting per notch: 10 m (0.000394 in)
The feeder will switch off.
Slowly turn the setting wheel (1) anticlockwise 2 or 3
notches.
Vertical setting per notch: 10 m (0.000394 in)
1
Start the sheet travel first using the key [ F2: Sheet
travel ] on the central control console (menu[ Ma-
chine ]) and then using the key [ F1 ] or [ Automatic
production ].
03-00177-2
Double sheet control: checking the setting for sheet thickness

Directions
Number of test strips: 2; Sheet length: max.
578 mm (max. 22.756 in)
Number of test strips: 3; Sheet length: min.
590 mm (min. 23.228 in)
The test strips must be cut from the printing material
of the new job.
The number of test strips to be used depends on
the sheet length.

Check the number of the test strips.
Check whether the test strips have been cut from
the printing material of the job.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-00175-2
Possible result
The test strips do not conform to specification.
Setting the double sheet control (see page 4-57)

Feeder
4 Sheet transport
Setting the double sheet control

Preliminary tasks
Conditions
The make-ready of the feeder must be completed.
Pile and suction head are in working position.
The calibration of the electronic double sheet control
must be completed.
Procedure
Cut several strips from the printing material to be
used for the job.
Width of the test strip: 10 mm (0.394 in)
Length of the test strip: 60 mm (2.362 in)
Pull back the yoke (1) of the double sheet control.

Insert the correct number of strips into the adjusting
slot of the double sheet control.
Number of test strips: 2
Sheet length: max. 578 mm (max. 22.756 in)
Number of test strips: 3
Sheet length: min. 590 mm (min. 23.228 in)
The double sheet control is automatically set to the
thickness of the printing material used. 1
2 Double sheet controls
For sheet lengths that are just over, within

or under the specified value, the number of
strips may vary. Check the setting during the
sheet travel.
03-00175-2
production ].
The machine is rotating at the set speed.
The feeder stops when the double sheet control has
detected a double sheet.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Setting the double sheet control to the size

When using printing materials that are sensitive to
pressure or with perfect printing, the rollers of the
double sheet control must be positioned on a print-free
zone.

Feeder
Sheet transport 4
Preliminary tasks
Procedure
flats 10 (094L116240)
Position the double sheet control on a print-free
sheet zone. 1
The roller must only be placed in the blank areas, never
on the grooves (2) of the tape shaft.
Tighten the screw (1).
flats 10 (094L116240)
03-00178-2
Setting the double sheet control to paper or cardboard

Preliminary tasks
Procedure
For printing cardboard, engage the tension spring in
bolt (1).
SHEET: Cardboard
For printing paper, engage the tension spring in bolt
(2).
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-00174-2

Feeder
4 Sheet transport
4.7.3 Forwarder wheels

Checking the position of the forwarder wheels
Directions
The distance between the forwarder wheels (1) is
approx. half a sheet width.
The narrowest position of the two forwarder wheels
for the minimum size is in the center of the suction
tape. The forwarder wheels must never be posi-
tioned between the suction tapes. 1
03-05768-1

Check whether the distance of the forwarder wheels
conforms to specifications.
Possible result
The distance does not conform to specifications.
Positioning the forwarder wheels (see page 4-60)
Positioning the forwarder wheels

Preliminary tasks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
Sheet transport 4
Procedure
flats 8 (094L116040)
1
Position the forwarder wheels as desired.
The forwarder wheels always have to rest on
the coated rollers of the tape shaft.
flats 8 (094L116040)
03-00179-3
Check the distance of the forwarder wheel to the tape shaft

Directions
The forwarder wheels (1) can be turned uniformly by
hand with a slight resistance.
The distance of the two forwarder wheels to the
tape shaft is identical.
03-05768-1
Measure between screw (1) and lever (2): 0.1 mm

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
1
2
03-00183-3

Feeder
4 Sheet transport
Determining the condition: Measuring the distance between forwarder rollers

and tape shaft
Feeler gauge 0.1x25x200 (094P015545)
Preliminary tasks
Setting the feeder timing to zero
Press the [ Feeder timing ] button.
The LED flashes.
The feeder timing will be set to zero. As soon as the K52
operation is finished, the LED on the button will go

out.
Procedure
production ].
Wait until several sheets have been guided to the
suction tapes feed board.
Stop the printing machine by pressing the key [

"STOP-secure" ].
An intake sheet is located on the forwarder suckers.
WARNING:
under it.
Lower the pile with the [ Pile: Lower ] button until
the forwarder wheels are easily accessible.
Remove the sheet sucked-on from the forwarder
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
sucker and replace it by a paper strip.

Jog the machine with the [ Jog: Forward ] button
until the paper strip becomes detached from the
forwarder suckers.
The info field of the key pad of PM 1, feeder side, indic-
ates an angle of machine position of 180 .

Feeder
Sheet transport 4
Measure the distance between screw (1) and the

lever (2).
Feeler gauge 0.1x25x200 (094P015545)
Turn the forwarder wheels by hand to check the
given values.
The forwarder wheels must be trailing on the
tape shaft with uniform pressure. Turning the
wheels by hand must still be possible.
1
2
03-00183-3
Possible result
The setting of the forwarder wheels does not conform
to specifications.
Setting the forwarder wheels to the tape shaft
(see page 4-63)
Setting the forwarder wheels to the tape shaft

Feeler gauge 0.1x25x200 (094P015545)
Preliminary tasks
Conditions
The info field of the key pad of PM 1, feeder side,
indicates an angle of machine position of 180 .
The forwarder wheel must uniformly contact the
tape shaft.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
4 Sheet transport
Procedure
Loosen the nut (1).
flats 10 (094L116240)
Turn the screw (2) until you can slide the setting 2
gauge (4) between screw (2) and lever (3).
flats 10 (094L116240)
Feeler gauge 0.1x25x200 (094P015545)
Set the contact pressure of the forwarder wheel us- 2
ing the screw (2).
The forwarder wheel can be turned with uniform pres-
sure trailing on the tape shaft. 3
4
2 Forwarder wheels
Make sure that the forwarder wheel is adjus-

03-05770-1
ted uniformly to prevent crooked sheets.
Tighten the nut (1) without changing the position of
the screw (2).
2 Nuts
4.7.4 Sheet guide rollers

Setting the contact pressure of the sheet guide rollers
Preliminary tasks
Procedure
Push the sleeve (1) in the direction of the fasten-
ing (2) while at the same time turning it to the left or
right.
Turning sleeve to the right: contact pressure of sheet
guide rollers (3) against the printing material decreases.
Turning sleeve to the left: contact pressure of sheet
guide rollers (3) against the printing material increases.
2
2 Sheet guide rollers
This instruction applies analogously to setting

the contact pressure of the cardboard guide
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
3 1
rollers.
The contact pressure of the sheet guide
rollers / cardboard guide rollers must be set
uniformly on both sides.
03-05778-1

Feeder
Sheet transport 4
Changing sheet guide rollers

Removing sheet guide rollers
Preliminary tasks
Procedure
Open the clamp (1) (A+B-side).
Pull the sheet guide rollers (2) out of the fastening
(3) (A+B-side).
2 Sheet guide rollers
1
3
03-05781-1
Installing cardboard guide rollers

Procedure
Insert the cardboard guide rollers (1) into the fasten-
ing (2) (A+B-side).
Close the clamp (3) (A+B-side).
2 Cardboard guide rollers 3
1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-05780-1
Final tasks
Setting the contact pressure of the sheet guide
rollers (see page 4-64)

Feeder
4 Sheet transport
Setting the contact pressure of the pneumatic sheet guide rollers (option)
The pneumatic sheet guide rollers (1) support the
transport of sheets from the tape shaft to the suction
tapes feed board.
03-05782-1
Procedure
Turn the button (1) (B-side) to set the contact pres-
sure of the pneumatic sheet guide rollers.
Check the setting on the display (2).
Air pressure of pneumatic sheet guide rollers: max. 1
6 bar
2
1
03-05783-1
Arranging the rollers / brushes on the suction tapes feed board

The rollers serve to transport the sheets to the feed re-
gister. The brushes at the sheet end correctly guide
the sheets under the cover guides.
Procedure
Set the contact pressure of the roller or brush by
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
turning the screw (1).

Move the brush or roller onto the rods by turning
screw (2).
The brush should be positioned at the sheet end when
the sheet is at the front guides. In this situation the
angle of the machine position is 250.
1
In case of a size change, you need not read-
just the forwarder wheels.
2
03-03111-3

Feeder
Sheet transport 4
4.7.5 Sheet carrier rods

Swinging the carrier rods on and off
Removing the sheets from under the carrier rods.
Preliminary tasks
Procedure
Pull the lock (1) and simultaneously swivel the lever
(2) in the direction of the arrow.
The carrier rods (3) swivel upwards.
Remove the sheet.
Swivel the lever (2) back so that the carrier rods (3)
are lying on the suction tapes feed board again. 3
The lock (1) engages.
1
03-00190-3
Changing carrier rods of sheet guide

Removing the carrier rods of the sheet guide
Preliminary tasks
Procedure
Loosen the clamp (1) and remove the carrier rod (2)
from the guide.
2 Carrier rods of the sheet guide
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
2
1
03-00191-2

Feeder
4 Sheet transport
Installing the carrier rods of the sheet guide

Procedure
Attach the carrier rods (2) to the guide and close the
clamp (1).
2 Carrier rods of the sheet guide
2
1
03-00191-2
4.7.6 Sheet hold-down

Setting the sheet hold-down
Preliminary tasks
Procedure
1
Important!
Danger of damage to the machine when
the side guides are positioned after chan- 2
3
ging the sheet width.
Before you change the sheet width, set
the sheet hold-downs to the new size in
order to prevent a collision with the side
guides.
Slide the sheet hold-downs (2) onto the shaft (3)

until they are adjusted to the new printing material
size.
4 Sheet hold-down 03-05771-1

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The installation of the sheet hold-downs must

not have a negative effect on the function of
the foreign object barrier.
Final tasks
Setting the foreign object barrier to the sheet thick-
ness (see page 6-7)

Feeder
Sheet transport 4
Removing the sheet hold-down

Preliminary tasks
Procedure
4
Remove the sheet hold-down (1) from the shaft (2).
4 Sheet hold-down 2 1
03-05774-1
Installing the sheet hold-down

Procedure
Install the sheet hold-downs (1) on shaft (2).

4
Turn the sheet hold-down in the direction of the ar-
row until the contact pressure of the plate (3) is ad-
apted to the sheet thickness. 2 1
4 Sheet hold-down
3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-05774-1
Setting the contact pressure of the sheet hold-down

Preliminary tasks

Feeder
4 Sheet transport
Procedure
1
Turn the sheet hold-down (2) in the direction of the
arrow until the contact pressure of the plate (3) is
adapted to the sheet thickness. 2
03-05772-1
4.7.7 Suction tapes feed board

Folding up the suction tapes feed board
Procedure
WARNING:
Danger of very serious injury when the
swung-up suction tapes feed board is not
locked correctly. The suction tapes feed
board may swing down abruptly. 1.
1. 2.
When you swing up the suction tapes 2.
feed board make sure that it is locked 1 3.
safely.
Fold the suction tapes feed board up using the

handle (1).
03-05696-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feeder
Sheet transport 4
The lock marked yellow (1) locks into position.
03-00873-3
Folding down the suction tapes feed board

Procedure
Lift the suction tapes feed board up slightly.
Push the lock marked yellow (1) in the direction of
the suction tapes feed board. 1
03-00193-2
Fold the suction tapes feed board downwards using

the handle (1). 1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
03-05697-1

Feeder
4 Sheet transport
Setting the suction air at the suction tapes feed board

Procedure
Set the suction air of the front pan using the rotating
button (2).
Pressure gauge (3) shows the set air quantity.
3
Suction air of the front pans: 0 to -40 mbar
Set the suction air of the rear pan using the rotating 4 5
6 4 5
6
button (1).
3 7 3 7
2 8 2 8
1 9 1 9
10 10
2 1
03-05775-1
Throwing on suction air for foil printing (option)

Procedure
Throw on the suction air using the lever (1).
1. 2.
1.
2.
3.
1
03-05698-1
Throwing off suction air for foil printing (option)

Procedure
Throw off the suction air using the lever (1).
1. 2.
1.
2.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
3.
03-03678-3

Feeder
Sheet transport 4
4.7.8 Foot switch

Removing the JobCard
Conditions
The printing press will rotate at the basic speed.
Procedure
Actuate the foot switch (1).
Remove the remaining sheets from the suction
tapes feed board.
The front guides remain blocked.
03-00194-2
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

4
4-74
Feeder

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Printing module
Overview 5
5 Printing module
5.1 Overview
1 Control panels on A-side
2 Control panels on B-side
05-06018-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing module

5.2.1 Printing module 1, feed register B-side
1 Info-field
2 Call-tone
3 All printing units: Off, feeder: Off: 1
4 Pumps: On/Off
5 Automatic production
6 Feeder air: On/Off
7 Feeder: On/Off
2 3
8 Edit Minus
9 Edit Plus
4 5
10 Press "Dampening rollers: On/Off
11 Feeder timing 6 7
12 without function
13 Electronic double sheet control: On / Off /
8 9
Comparison
14 Production speed: decreasing
10 11
15 Production speed: increasing
16 7-segments indicator
12 13
17 Make-ready
18 Loudspeaker
14 15
19 Run
20 Jog: Back
16 17
21 Jog: Forward
22 emergency stop
23 Stop-Secure
18 19
20 21
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
22 23
04-01091-4
Call-tone
Signal for communication among operating personnel.
K564-1

Printing module
All printing units: Off, feeder: Off:

To be used in emergencies only. (Exception: blanket
change.)
The impression will be thrown off spontaneously in all K562
printing units, the feeder will be disengaged.
Pumps: On/Off
Switching the pumps and blowers on or off.
K563-1
Automatic production
Switching the automatic production on or off.
K35
Feeder air: On/Off

Switching the feeder blowers on or off.
K88
Feeder: On/Off
Engaging or disengaging the feeder
K45
Edit Minus
Changing values.
K592-1
Edit Plus
Changing values.
K591-1
Press "Dampening rollers: On/Off

Throwing the dampening rollers on against or off from
the plate cylinder.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Make-ready mode: blanket washing device: On/Off K595-1
Feeder timing
In the event of early or late sheets: correction of sheet
travel by changing the feeder timing.
K52

Printing module
Electronic double sheet control: On / Off / Comparison

Switching the electronic double sheet control on and
off.
Calibrating the detector of the electronic double sheet K255
control to the sheet thickness for this print run.
Production speed: decreasing

Decreasing the machine speed during production.
K565-1
Production speed: increasing

Increasing the machine speed during production.
K566-1
Make-ready
The printing press is set to make-ready operation.
K575-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing module
5.2.2 Printing module 1, feed register B-side, front guides

(QuickChange option)
2 - 10 Front guides: Setting 1
11 Front guides: Minus
12 Front guides: Plus
13 All front guides
14 Front guides: Zero setting
1 2
2 3
3 4
4 5
5 6
6 7
7 8
8 9
9
10
11 12
0
13 14
04-05669-2
Front guides: Setting

Setting the front guides to the printing material
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
1 2
1 2
3 4
3 4
05-05068-1

Printing module
Front guides: Minus

Setting the front guides against the sheet travel direc-
tion.
K952
Front guides: Plus

Setting the front guides in the direction of sheet travel
K953
All front guides

Selecting or deselecting all front guides
K954
Front guides: Zero setting

The front guides will be set to zero. 0
K803
5.2.3 Printing module, delivery A-side

2 Loudspeaker
3 Crawl speed
4 Jog: Back
5 Jog: Forward 1
6 emergency stop
7 Stop-Secure
2 3
4 5
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
6 7
05-03744-3

Printing module
Service plug by MAN Roland (service)

Connection for the portable terminal.
5.2.4 Printing module, delivery B-side

1 Call-tone
2 All printing units: Off, feeder: Off: 1 2
3 Press "Dampening rollers: On/Off
4 Ink form rollers: On/Off 3 4
5 Ink fountain roller: On/Off
6 Ink ductor roller: On/Off 5 6
7 Ink flow: On/Off
8 Guard in front of blanket cylinder and plate 7 8
cylinder: ACTIVE/ INACTIVE
9 without function
9 10
10 Doctor blade collecting pan: On/Off
12 without function
13 Make-ready: deselect
13 14
14 Make-ready: select
15 16
16 Make-ready
17 Loudspeaker
18 Crawl speed
19 Jog: Back 17 18
20 Jog: Forward
21 emergency stop
22 Stop-Secure
19 20
21 22
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
05-01265-4
Call-tone
K564-1

Printing module

To be used in emergencies only. (Exception: blanket
change.)
The impression will be thrown off spontaneously in all K562
printing units, the feeder will be disengaged.
Press "Dampening rollers: On/Off

Throwing the dampening rollers on against or off from
the plate cylinder.
Make-ready mode: blanket washing device: On/Off K595-1
Ink form rollers: On/Off

Throwing the ink form rollers on against or off from the
plate cylinder.
K596-1
Ink fountain roller: On/Off

Switching the ink fountain roller on or off.
K258
Ink ductor roller: On/Off

Throwing the ink ductor roller on against or off from the
ink fountain roller.
K259
Ink flow: On/Off

Switching the ink flow in the inking unit on or off.
K789
Guard in front of blanket cylinder and plate cylinder: ACTIVE/ INACTIVE

Opening and closing the guard in front of the blanket
cylinder and plate cylinder.
K599-1
Doctor blade collecting pan: On/Off

Throwing the doctor blade collecting pan on against or
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
off from the ink vibrator roller.

K607-1
Make-ready: deselect
Deselecting the make-ready operation.
Pressure plate change emergency program: open the
tensioning bar. K601

Printing module
Turning the machine by hand 5
Make-ready: select
Selecting the make-ready mode.
PPL emergency program close the tensioning bar.
K600
Make-ready
The printing press is set to make-ready operation.
K575-1
5.3 Turning the machine by hand

5.3.1 Electrical release of drive motor brake (Machine: switched
ON)
Rod (002A301813)
Preliminary tasks
Stop and secure the printing press using the [
Conditions
The machine is switched ON.
Procedure
Open the panel (A-side) on the 1st printing module.
Actuate the switch (1) (A-side) behind the panel.

The drive motor brake is released.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
02-05796-1

Printing module
5 Turning the machine by hand
WARNING:
Dangerous ingoing nip and danger of
crushing! If you turn the machine by hand,
an acoustic start signal will not be giv- 3
en. All protective functions are canceled.
Turning rollers and cylinders as well as
revolving gripper systems may pull limbs
into the nip and crush them. 1
During work, all operators have to keep 2

away from ingoing nips and crushing
points. Seal off the danger zone with
warning signs.
Insert the rod (1) into one of the holes of the pulley
and rotate the machine in the desired direction: (2)= 02-05798-1
forwards, (3)= backwards.

Rod (002A301813)
Take the rod (1) out of the hole of the pulley.
Actuate the switch behind the panel.
The drive motor brake is closed.
5.3.2 Releasing drive motor brake by hand (Machine: switched

OFF)
Rod (002A301813)
Conditions
The machine is switched off.
Procedure
Open the panel (A-side) on the 1st printing module.
Caution!
Danger of burning yourself within the
drive motor zone. Adjacent components
may still be hot even after switching off
the motor.
Before you start work let the drive motor
cool off or wear safety gloves.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Press the lever (1) of the drive motor towards the

feed register side.
Hold the lever (1) in this position or clamp a wedge
between the yoke and engine block.
The brake is released. 1
02-05797-1

Printing module
Turning the machine by hand 5
WARNING:
Dangerous ingoing nip and danger of
crushing! If you turn the machine by hand,
an acoustic start signal will not be giv- 3
en. All protective functions are canceled.
Turning rollers and cylinders as well as
revolving gripper systems may pull limbs
into the nip and crush them. 1
During work, all operators have to keep 2

away from ingoing nips and crushing
points. Seal off the danger zone with
warning signs.
Insert the rod (1) into one of the holes of the pulley
and rotate the machine in the desired direction: (3)= 02-05798-1
forwards, (2)= backwards.

Rod (002A301813)
Take the rod (1) out of the hole of the pulley.
Release the lever of the drive motor or remove the
wedge.
The brake is activated.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing module
5
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register
Overview 6
6 Feed register
6.1 Overview
2
11 3
5
+0,5 7
9 0
8 0
8
7 0
6
1.
0 ...
.9
...
0
5 0
4 0 12 9
3 0 10
0
2 0
9..
..
.. .
.1
1 0
-0,5
13
04-00195-5
1 Feed register drum 8 Suction roller sheet orientation

2 Cover guides 9 Foreign object barrier
3 Front guides 10 Hold-down plates
4 Cardboard guide rollers (option) 11 Side guide
5 Sheet guide rollers 12 Front guide setting: parallel, diagonal
6 Blast/suction strip 13 Front guides: mechanical setting
7 Swing gripper
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register

6.2.1 Control console for air supply in the feed register
1 Control panel DM1, feed register B-side
1
1 Control panel DM1, feed register B-side
- +
- +
+
04-05641-2
6.2.2 Control panel DM1, feed register B-side

1 Air: Blast-suction rail
2 Air: Side guide
3 Air: Suction rollers
4 6 4 6 4 6
2 82 82 8
0 10 0 10 0 10
3 2 1
-0,3 -0,3
-0,4 -0,2 -0,4 -0,2
-0,5 -0,1 -0,5 -0,1
-0,6 0 -0,6 0
04-06117-1
Air: Blast-suction rail

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Setting the air pressure for the bast suction strip.
K987
Air: Side guide

Setting the air pressure for the side guides.
K989

Feed register
Air: Suction rollers

Setting the air pressure for the suction rollers.
K990
6.2.3 Control panel DM1, feed register B-side (QuickChange option)

1 Air: Blast-suction rail
2 Air: Side guide
3 Air: Suction rollers
- + - + - +
3 2 1
-0,3 -0,3
-0,4 -0,2 -0,4 -0,2
-0,5 -0,1 -0,5 -0,1
-0,6 0 -0,6 0
04-05640-2
Air: Blast-suction rail

Setting the air pressure for the bast suction strip.
K987
Air: Side guide

Setting the air pressure for the side guides.
K989
Air: Suction rollers

Setting the air pressure for the suction rollers.
K990
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register
6 Control devices
6.3 Control devices

6.3.1 Displays (DM1, B-side, feed register)
When the machine is stationary: display of the posi-
tioning angle of the machine. 137.37
Degrees
04-04655-1
When the press is revolving: display of the machine

speed and sheet trend. 2
These figures indicate the sheet trend (0 to 3: correct
9000
sheet travel).
Sheets / h
Upper value: A-side +2
Lower value: B-side
w sign: trend towards early sheets. 02-02854-1
02-02854-1
+ sign: trend towards late sheets.
When guard No. 12 above swing grippers and feed

register drum is open: display of detectors.
With numbers: detectors in sheet ascent ramp
Without numbers: detectors in the feed register. 12
.....
4 2
Filled square: the detector is covered by a sheet. .....

11 3 1
Empty square: the detector is not covered by a sheet. 04-02860-1
04-02860-1
6.3.2 Display of faults during sheet travel (DM1, B-side, feed

register)
Production is automatically suspended. The machine
will turn at basic speed.
A missing sheet (1) has been detected.

An overrun sheet (2) has been detected. 1 2
A double sheet (3) has been detected.

A crooked sheet (4) has been detected.
The sheet is not lying against the side guide (5).
The fault (5) is only reported acoustically. 3 4
Production is not suspended.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
A double sheet (3) has been detected.
5 6
02-00123-2

Feed register
Control devices 6
6.3.3 Correcting crooked sheets

Procedure
Correcting crooked sheets
The sheet trend display in the info field shows you a
crooked sheet tendency.
Correct the crooked sheet using the handwheel (1).
03-05769-1
[ Turning anticlockwise ]: The crooked sheet is cor-

rected towards the feeder.
04-04669-1
[ Turning clockwise ]: The crooked sheet is correc-

ted towards the delivery unit.
04-04670-1
Note the sheet trend indicator.

06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register
6 Control devices
6.3.4 Electronic double sheet control

Conditions
Only after a successful calibration to the printing ma-
terial can you switch on the electronic double sheet
control.
Procedure
Switching on the electronic double sheet control
Press the [ Double sheet control: On/Off ] button.
The LED is on.
The electronic double sheet control is switched on. K255
If the electric double sheet control will not

switch on, the calibration to the changed
sheet thickness was not successful. In this
case, the mechanical double sheet control
on the tape roller monitors the sheet travel.
Delete the saved value before performing a
new calibration.
Delete stored value

Press the [ Double sheet control: On / Off ] button
for 3 seconds.
The LED goes out. K255
The stored value is deleted.
Calibrating the electronic double sheet control

The LED flashes.
K255
Request in the info field: "Position a sheet at the

front guides".
04-04833-1
Position a sheet at the front guides.

Sheet length: max. 650 mm (max. 25.59 in)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
After successful calibration of the double sheet con-

trol, the LED on the [ Double sheet control: On/Off ]
button comes on. K255
The value remains stored even after the machine is

switched off.
If the LED on the [ Double sheet control: On/Off ]
button goes out, this may be due to one of the fol-
lowing causes:

Feed register
Control devices 6
Indication in the info field: Sheets too thick.

Measure to be taken 1
Only the mechanical double sheet at the tape roller
controls the sheet travel.
04-04834-1
Indication in the info field: Sheets too thin.

Only the mechanical double sheet at the tape roller
controls the sheet travel.
04-04835-1
Indication in the info field: Detector is dirty.

Clean the detector as described in the manual "Main-
tenance".
04-04836-1
Indication in the info field: Detector is defective.

Inform your sales / service partner.
04-04837-1
6.3.5 Setting the foreign object barrier to the sheet thickness

If foreign objects enter the feed register, the foreign ob-
ject barrier is lifted and the feeder and printing press
are switched off.
Preliminary tasks
Procedure
Place 3 to 4 sheets under the foreign object barrier
(1).
Set the distance of the foreign object barrier (1) from
the suction tapes feed board using the screw (2).
The sheets can be extracted from the foreign object 2
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
barrier with little resistance.
03-05773-1

Feed register
6 Air supply
6.4 Air supply

6.4.1 Setting the blast air of the blast/suction element
The blast/suction element also pulls down the sheet,
and, together with the sheet hold-down, it ensures
correct guiding of the sheet edge at the side guide
stop.
Preliminary tasks
Open guard No. 12 above swing gripper and feed
register drum.
Procedure
Set the air pressure of the blast-suction element (2)
using the rotating button (2) (A+B-side).
2
Adjust the air pressure in such a way that the sheet is
guided correctly into the feed register.
1
04-05166-1
Final tasks
Close guard No. 12 above swing gripper and feed
register drum.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register
Air supply 6
6.4.2 Setting the air pressure of the blast/suction rail

Procedure
Set the pressure of the blast air using the rotating
button (1).
4 6 4 6 4 6
2 82 82 8
0 10 0 10 0 10
3 2 1
-0,3 -0,3
-0,4 -0,2 -0,4 -0,2
-0,5 -0,1 -0,5 -0,1
-0,6 0 -0,6 0
04-06117-1
6.4.3 Setting the air pressure of the suction plate (side guide)
Procedure
Set the power of the air pressure to the printing ma-
terial using the rotating button (2).
Adjust the air pressure in such a way that the sheet to
be aligned is pulled correctly, without buckling, to the
stop.
4 6 4 6 4 6
2 82 82 8
0 10 0 10 0 10
3 2 1
-0,3 -0,3
-0,4 -0,2 -0,4 -0,2
-0,5 -0,1 -0,5 -0,1
-0,6 0 -0,6 0
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
04-06117-1

Feed register
6 Air supply
6.4.4 Setting the air pressure of the suction roll (side guide)
The suction rollers are positioned on a level with the
suction plates of the side guides and push the sheet
front edge over the feed register plate against the front
guides.
Procedure
Set the air pressure to the printing material using the
rotating button (3).
Adjust the air pressure in such a way that the sheet to
be aligned is pulled correctly, without buckling, to the
stop.
4 6 4 6 4 6
2 82 82 8
0 10 0 10 0 10
3 2 1
-0,3 -0,3
-0,4 -0,2 -0,4 -0,2
-0,5 -0,1 -0,5 -0,1
-0,6 0 -0,6 0
04-06117-1
6.4.5 Setting the blast air of the suction plate

The blast air for the return stroke of the suction plate
blows the paper dust out of the suction holes. The
blast air can be controlled at the rotating button.
Preliminary tasks
register drum.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register
Air supply 6
Procedure
Set the air pressure of the suction plate (1) using the
rotating button (1) (A+B-side).
2
Set the air pressure so that no paper dust accumulates
in the suction holes and the sheet is guided correctly
into the feed register. 1
04-05166-1
Final tasks
register drum.
6.4.6 Setting the blast air of the blast/suction element

The blast/suction element also pulls down the sheet,
and, together with the sheet hold-down, it ensures
correct guiding of the sheet edge at the side guide
stop.
Preliminary tasks
register drum.
Procedure
Set the air pressure of the blast-suction element (2)
using the rotating button (2) (A+B-side).
2
Adjust the air pressure in such a way that the sheet is
guided correctly into the feed register.
1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
04-05166-1
Final tasks
register drum.

Feed register
6 Side guides
6.5 Side guides

6.5.1 Detector: setting the side edge control
If the sheet does not reach the side edge stop of the
side guide, an acoustic signal will sound.
Procedure
Set detector (1) (A- or B-side) during the sheet
travel.
Turn screw (2) (A- or B-side) until the signal sounds.
Slowly turn the nut (2) (A- or B-side) in the opposite
direction until the signal stops.
2 1
04-05854-1
6.5.2 Checking the lateral sheet stop of the side guide

The lateral sheet stop serves to exactly align the lateral
sheet edge at the selected side guide (A- or B-side).
Directions
In the feed register, the lateral sheet edge must be
positioned exactly at the sheet stop. The lateral
sheet stop must not buckle the sheet.

Position a sheet so that it touches the front guides
and the side sheet stop (2) (A- or B-side). 1
Check whether the side sheet stop (2) (A- or B-side)
is set in accordance with the printing material. 2
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
04-05183-1

Feed register
Side guides 6
Possible result
The setting of the lateral sheet stop does not conform
to specification.
Setting the lateral sheet stop (see page 6-13)
6.5.3 Setting the lateral sheet stop

Preliminary tasks
register drum.
Procedure
Position a sheet so that it touches the front guides
and the side sheet stop (2) (A- or B-side). 1
Open the clamp screw (1) (A- or B-side).

flats 10 (094L116240)
Position the sheet stop (2) at the side sheet edge.
Tighten the clamp screw (1).
flats 10 (094L116240)
04-05183-1
Final tasks
Take the sheet out of the feed register.
register drum.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register
6 Suction plate
6.5.4 Unlocking the side guide

To print off-center, you must slide the non-pulling side
guide out from the relevant sheet size.
Screwdriver, hexagon, with a ball-shaped
head, width across flats 6 (094L017213)
Preliminary tasks
register drum.
Procedure
Turn the screw (1) (A- or B-side) from position (2) to
position (3).
Screwdriver, hexagon, with a ball-shaped head, width
across flats 6 (094L017213)
The side guide is unlocked
5
Push the side guide (4) in the direction of the arrow.
The side guide is outside of the sheet size.
On completion of the printing job, push back 2
3
the side guide and lock. 4
1
Push the side guide (4) back in the direction of the
suction roller (5).
Turn the screw (1) from position (3) back to position
(2).
Screwdriver, hexagon, with a ball-shaped head, width 04-05758-1
Final tasks
register drum.
6.6 Suction plate

6.6.1 Checking the suction plate for voluminous, porous printing
materials, lightweight and thin paper printing
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Directions
Suction plate: ceramic surface
weight paper
paper printing

Feed register
Suction plate 6

Check whether the appropriate suction plates (4)
(A+B-side) for the printing material are installed.
1
4
2
3
04-05158-1
Possible result
The suction plates do not conform to specification.
Install the prescribed suction plates.
Changing the suction plate (see page 6-15)
6.6.2 Changing the suction plate

Removing the suction plate of the suction slide
Phillips screwdriver (094L204040)
Preliminary tasks
register drum.
Procedure
Remove screws (1) (A+B-side) in order to remove
sheet hold-down (2) (A+B-side).
Screwdriver, hexagon, with a ball-shaped head, width 1
across flats 4 (094L017213) 4
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
2 Screws 2
Remove the screws (3) (A+B-side).
4 Screws
Remove suction plate (4) (A+B-side).

3
04-05158-1

Feed register
6 Suction plate
Installing the suction plate into the suction slide

Procedure
Install the new suction plate (1) (A+B-side).
Tighten screw (2) (A+B-side).
4
1
4 Screws
3
Screw down sheet hold-down (3) (A+B-side) with
the screws (4).
2 Screws
2
04-05159-1
Final tasks
register drum.
6.6.3 Locking the movement of the suction plate

To reduce friction between sheet and suction plate,
lock the suction plate you do not need (A- or B-side).
Preliminary tasks
register drum.
Procedure
Loosen the screw at the stop (1).
Push the screw to stop (2).
1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Tighten the screw at the stop (2).

The suction plate is locked. 2
To unlock the suction plate, loosen the
screw, pull the plate back from stop (2) to
stop (1) and retighten the screw.
04-05168-1

Feed register
Sheet hold-down 6
Final tasks
register drum.
6.6.4 Checking the suction plates for cardboard and lightweight

cardboard
Directions
Suction plate: gummed surface
board

Check whether the appropriate suction plates (4)
(A+B-side) for the printing material are installed.
1
4
2
3
04-05158-1
Possible result
The suction plates do not conform to specification.
Install the prescribed suction plates.
Changing the suction plate (see page 6-15)
6.7 Sheet hold-down

6.7.1 Checking the sheet thickness of the sheet hold-down
Directions
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Setting value of the sheet hold-down: two to three

times the sheet thickness
Determining the condition: Checking the distance to the printing material.

Preliminary tasks
register drum.

Feed register
6 Sheet hold-down
Procedure
Check whether the distance which is appropriate for
the printing material between the sheet hold-down
(1) (A+B-side) and side guide is set.
2
04-05853-1
Final tasks
register drum.
Possible result
The distance between sheet hold-downs and pull-type
guide does not conform to specification.
Setting the sheet hold-down (see page 6-18)
6.7.2 Setting the sheet hold-down

Preliminary tasks
register drum. 06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register
Sheet hold-down 6
Procedure
Set the distance of the sheet hold-down (1) (A+B-
side) to the side guide using the setting element (2).
Setting value of the sheet hold-down: two to three
times the sheet thickness 2
04-05853-1
Final tasks
register drum.
6.7.3 Cardboard guide at the side guide: Setting the sheet

thickness
In case of heavy printing materials (cardboard), the
rollers at the side guide improve the sheet transport to
the feed register. The rollers guide the sheet close
enough to the suction plate so that it can be sucked
on exactly by the suction plate.
Preliminary tasks
register drum.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register
6 Sheet guide in front of front guides and cover guides
Procedure
Move sheet hold-down (4) up to the stop using the
setting element (1) (A+B-side). 1 2
3
Move sheet hold-down (3) down to the stop using
the setting element (2) (A+B-side).
Set the sheet thickness at the rollers (3) (A+B-side)
using the setting element (1).
Place 2-3 sheets under the rollers (3) (A+B-side).
Measure between rollers and pull-type guides: two to
three times the sheet thickness
4
04-05184-1
Final tasks
register drum.
6.8 Sheet guide in front of front guides and cover guides

6.8.1 Setting the sheet guide brush in front of the front and cover
guides to the sheet thickness
Preliminary tasks
register drum.
Procedure
Loosen the clamp screw (2) of the sheet guide
brush (1).
Place 2 to 3 sheets under the sheet guide brush (1). 2
1
Turn the sheet guide brush downwards (1).
The sheet guide brush touches the sheets.
Tighten the clamp screw (2).
Remove the sheet from the feed register.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
04-05855-1
Final tasks
register drum.

Feed register
Sheet guide in front of front guides and cover guides 6
6.8.2 Changing sheet guide in front of front and cover guides

Removing sheet guide brush
Preliminary tasks
register drum.
Procedure
Loosen the screws (2) of the sheet guide brush (1).
4 Screws
Remove the whole sheet guide brush unit (1) from

the machine. 2
3 2
04-05856-1
Installing sheet guide rollers

Lever RD4x240 (094L250850)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register
6 Sheet guide in front of front guides and cover guides
Procedure
Insert the whole sheet guide roller unit(3) (A+B-side)
into the guide.
1
Tighten the screws (2) (A+B-side).
4 Screws
2
3 2
04-05856-1
Final tasks
Setting the sheet guide rollers in front of the front
and cover guides to the sheet thickness
(see page 6-22)
6.8.3 Setting the sheet guide rollers in front of the front and cover
guides to the sheet thickness
Lever RD4x240 (094L250850)
Procedure
Loosen the clamp screw (1) (B-side) of the sheet
guide rollers. 4
3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Place 2 to 3 sheets under the sheet guide rollers (2).

Turn the shaft (3) of the sheet guide rollers using a
2
tensioning pin (4).
The sheet guide rollers touch the sheets.
Lever RD4x240 (094L250850)
Tighten the clamp screw (1) (B-side).
04-05857-1
Remove the sheet from the feed register.

Feed register
Sheet guide in front of front guides and cover guides 6
Move the sheet guide rollers (2) on the shaft (3) in

order to adjust their position to the sheet to be prin-
ted.
Sheet guide rollers are only positioned on
print-free areas of the sheets.
Sheet guide: moving forward or backward

Loosen the clamp screw (1) (B-side) of the sheet
guide.
3
1
Position the shaft (2) of the sheet guide as required
using a tensioning pin (3).
Lever RD4x240 (094L250850)
Tighten the clamp screw (1) (B-side).
2
04-05861-1

register drum.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register
6 Front guides
6.9 Front guides

6.9.1 Feed register: basic setting of front guides
The setting for the front guides (1) is located on the B-
side of the first printing module.
04-05859-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register
Front guides 6
Procedure
Turn the buttons (1) and (2) to the zero setting.
Rotating button (1) for setting the front guide: A-side
Rotating button (2) for setting the front guide: B-side +0,5
The front guides are in their base position and paral-
lel to the feed register. 9 0
Reset the front guides to the base position

before each new job.
8 0
1
0
7 0
0,5
-0,5
9 ..
6 0 ..
.1
.. .
0
5 0
4 0 2
0
3 0
0
0,5
-0,5
2 0
1.
.9
...
...
1 0
-0,5
04-05858-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register
6 Front guides
6.9.2 Skewing the feed register

Procedure
Turn the buttons (1) and (2) until the scale on the
A+B-side shows different values.
Setting range: -0.5 to 0.5 mm (-0.02 to 0.02 in) +0,5
Setting range per graduation mark of the rotating but-
ton: 0.1 mm (0.004 in) 9 0
The graduation marks on the scale indic-
ate the distance of the front guides from the 8 0
1
base position. 0
Note the effects on the printed sheet and reset if 7 0
0,5
-0,5
necessary.
9 ..
6 0 ..
.1
.. .
0
5 0
4 0 2
0
3 0
0
0,5
-0,5
2 0
1.
.9
...
...
1 0
-0,5
04-05858-1
6.9.3 Individual setting of the front guides

Only the two outer front guides are used to feed the
sheet, depending on the size. The following descrip-
tion is only an example of a setting and relates to large
printing material.
Screwdriver, hexagon, width across flats
6x300 (094L014250)
Preliminary tasks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

register drum.

Feed register
Front guides 6
Procedure
Turn the screw (1) to set the outer front guide to the
front edge of the sheet.
Setting range: -0.5 to 0.5 mm (-0.02 to 0.02 in) +0,5
Screwdriver, hexagon, width across flats 6x300
(094L014250) 9 0
9
The outer front guide of the B-side touches the front
edge of the sheet.
8 0
0
Turn the screw (9) to set the outer front guide to the 7 0
front edge of the sheet.
0,5
-0,5
9 ..
6 0 ..
.1
Setting range: -0.5 to 0.5 mm (-0.02 to 0.02 in) .. .
0
(094L014250) 5 0
The outer front guide of the A-side touches the front
edge of the sheet. 4 0
0
The inner front guides remain in their base
3 0
0
position.
0,5
-0,5
2 0
1.
.9
...
...
1 0
1
-0,5
04-05860-1
Final tasks
register drum.
6.9.4 Setting front guides on PU 1 (QuickChange Option)

This function serves to optimize the basic setting of the
front guides being in operation for certain printing ma-
terials.
Press the [ Front guide: Set ] button for the front

guide that is to be set.
9 Front guides K805
Set the selected front guide using the [ Front guides:

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
w ] or [ Front guides: + ] button.

Setting range: -1 to 1 mm (-0.039 to 0.039 in), Step K957
width: 0.01 mm (0 in)
If you want to set all front guides:
Press the [ All front guides ] button.

All front guides are selected.
K954
Set the front guide using the [ Front guides: w ] or

[ Front guides: + ] button.
If you want to set all front guides to the zero setting: K957

Feed register
6 Swing gripper
Press the [ Front guides: Zero setting ] button. 0

All front guides will be set to the zero position.
See also the description in program level K803
Production (DR), main menu Register,

chapter Setting the front guides at the
central control console.
6.10 Swing gripper

6.10.1 Setting the gripper pad bar of the swing gripper to the sheet
thickness
Preliminary tasks
Position the printing press using the [ Jog: Forward ]
or [ Jog: Reverse ] button again.
Angle of machine position: 22
Machine site: Swing gripper
Machine position: Setting screw of gripper pad bar is
accessible.
register drum.
Procedure
Loosen the clamp screw (1) (B-side).
0,8
2
Set the desired value, depending on the sheet thick-
0,6 0
,4
0,2
ness, using the screw (2).

The marking (3) points to the set value.
3
0.2 on the sheet thickness scale: 0.04 mm/0.002 in to
0.5 mm/0.02 in
0.4 on the sheet thickness scale: 0.5 mm/0.02 in to 1
mm/0.04 in
Tighten the clamp screw (1) (B-side) again.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

04-05866-1
Final tasks
register drum.

Feed register
Feed register drum 6
6.11 Feed register drum

6.11.1 Setting the gripper pad bar of the feed register drum to the
sheet thickness
With the QUICKCHANGE option, the gripper pad bar is
automatically set to the sheet thickness input on the
Socket wrench, width across flats 13
(094L022340)
Preliminary tasks
Machine site: Feed register drum
Machine position: Setting screw of gripper pad bar is
accessible.
register drum.
Procedure
1
ness, using the screw (1) (B-side).
The marking (2) points to the set value.
2
0

2
0,
0,8
0.3 mm/0.012 in 0,6 0,4 0,3

0.6 mm/0.024 in
mm/0.04 in
Socket wrench, width across flats 13 (094L022340)
04-05865-1
Final tasks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

register drum.

Feed register
6 Feed register drum
6.11.2 Converting feed register drum for cardboard guide

The sheet guides of the feed register drum are
removed before printing on cardboard. The cardboard
guide rollers located under the sheet guides support
the sheet and thus allow perfect transfer of the sheet
to the impression cylinder of the first printing module.
Screwdriver insert 1/2", width across flats
10, hexagon 140L (094L026240)
Handle with sliding element 1/2"
(094L026340)
Preliminary tasks
Machine position: The 1st sheet guide is accessible.
register drum.
(see page 4-70)
Procedure
Remove the screws (2) on the A+B-side.
Screwdriver insert 1/2", width across flats 10, hexagon
140L (094L026240)
Handle with sliding element 1/2" (094L026340)
2
2 Screws
Take the 1st sheet guiding plate (1) out of the ma-
chine. 1
Unlock the printing machine by turning the key [

"STOP-secure" ] to the left.
Position the printing machine with the key [ Jog:
Forward ].
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Angle of machine position: 180 04-05862-1

Machine position: The 2nd sheet guide is accessible.

Feed register

140L (094L026240)
Handle with sliding element 1/2" (094L026340) 1
2 Screws
Take the second sheet guide (3) out of the machine.

"STOP-secure" ] to the left. 6

Forward ].
Angle of machine position: 270 2
Machine position: The 3rd sheet guide is accessible.
"STOP-secure" ] button - see chapter Safety -. 5
Screwdriver insert 1/2", width across flats 10, hexagon 3
140L (094L026240)
Handle with sliding element 1/2" (094L026340) 4
2 Screws 04-05863-1
Remove the third sheet guide (6) from the machine.

Position the printing machine with the key [ Jog: Re-

verse ].
Machine position: The nuts on the holders of the card-
board guide rollers are accessible.
Cardboard guide rollers are only used in the
print-free areas of the sheets.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Feed register
Loosen the nuts (1) on the fastening (2) of the card-

board guide rollers.
flats 10 (094L116240)
2 Nuts
Push the fastening (2) of the cardboard guide rollers

1
on the shaft (3) of the feed register drum into the
required position. 2
The cardboard guide rollers are located in the print-free 3
areas of the sheet.
Retighten the nuts(1).
flats 10 (094L116240)
2
4 Cardboard guide roller modules
Repeat the process for the rest of the cardboard 1

guide rollers.
04-05864-1
Final tasks
register drum.
(see page 4-71)
6.11.3 Resetting feed register drum to standard printing material

Torque wrench 40-200Nm 1/2"
(094L188940)
10, hexagon 140L (094L026240)
Preliminary tasks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

register drum.
(see page 4-70)

Feed register
Procedure
Insert the first sheet guide (1) onto the fastening of
the feed register drum.
Tighten the screws on the (2) A+B-side.
2
Torque: 50 Nm (5.1 kpm) (Fastening screws of sheet
guides)
Torque wrench 40-200Nm 1/2" (094L188940)
Screwdriver insert 1/2", width across flats 10, hexagon 1
140L (094L026240)
2 Screws
04-05862-1

Forward ].
Insert the second sheet guide (3) onto the fastening

of the feed register drum.
Tighten the screws on the (4) A+B-side. 1
guides)
140L (094L026240)
6
2 Screws
2
Forward ].
Machine position: The 3rd sheet guide is accessible. 5
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

3
Insert the third sheet guide (6) onto the fastening of 4
the feed register drum. 04-05863-1
Tighten screws (5).

guides)
140L (094L026240)
2 Screws

Feed register
Final tasks
register drum.
(see page 4-71)
6.11.4 Converting feed register drum (QuickChange option) for the

cardboard guide
The sheet guides of the feed register drum are
removed before printing on cardboard. The feed
register drum does not contain any cardboard guide
rollers.
10, hexagon 140L (094L026240)
(094L026340)
Preliminary tasks
register drum.
(see page 4-70)
Procedure
Screwdriver insert 1/2", width across flats 10, hexagon 1 6
140L (094L026240)
2 Screws
Take the 1st sheet guiding plate (1) out of the ma- 2
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
chine.
Forward ]. 5
Machine position: The 2nd sheet guide is accessible. 3
4
Secure the printing press using the [ 04-05811-2

Feed register

140L (094L026240)
2 Screws
Take the second sheet guide (3) out of the machine.

Forward ].
140L (094L026240)
2 Screws
Remove the third sheet guide (6) from the machine.

Final tasks
register drum.
(see page 4-71)
6.11.5 Resetting feed register drum (QuickChange option) to

standard printing materials
(094L188940)
10, hexagon 140L (094L026240)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Preliminary tasks
register drum.

Feed register

(see page 4-70)
Procedure
Insert the first sheet guide (1) onto the fastening of
the feed register drum. 1 6
guides)
Torque wrench 40-200Nm 1/2" (094L188940) 2
140L (094L026240)
2 Screws
3
4
04-05811-2

Forward ].
guides)
140L (094L026240)
2 Screws
Forward ].
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Insert the third sheet guide (6) onto the fastening of
the feed register drum.

Feed register

guides)
140L (094L026240)
2 Screws
Final tasks
register drum.
(see page 4-71)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

6
6-38
Feed register

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Printing unit
Overview 7
7 Printing unit
7.1 Overview
1 Plate cylinder
2 Blanket cylinder
3 Impression cylinder 1
4 Transferter
3
4
05-06019-1
7.2 Cylinder packings

7.2.1 Cylinder packings for printing with bearer ring contact
The measures indicated are only reference
values and may vary according to applica-
tion.
1 Plate cylinder
0,26 - 0,31 mm
0,12 - 0,15 mm
0.005 - 0.006 "
0.010 - 0.012 "

2 Bearing ring of the plate cylinder
3 Blanket cylinder
0,5 mm
0.020 "
4 Bearing ring of the blanket cylinder

0,35 mm
0.014 "
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
2 1
0,7 - 0,75 mm
0.028 - 0.03 "
2,6 mm
0.102 "
4 3
0 + 0,025 mm
1,95 mm
0.077 "
0 + 0.001 "
05-05868-1

Printing unit
7 Cylinder packings
Procedure
Measuring the cylinder packings using the dial
gauge.
Information on this can be found in the Main-
tenance manual.
W-027
7.2.2 Printing with bearer ring contact

The bearing rings of the blanket and plate cylinder cal-
ibrate themselves to each other against the vibration
damping with an additional contact pressure.
Conditions
Bearing rings are always absolutely clean.
Cleaning the bearing rings of blanket and plate cylin-
der - see Maintenance manual.
Exact contact around the entire circumference of
the bearing rings is ensured.
The packings of the blanket and plate cylinder are
correct.
Procedure
Set the handwheels (A+B-side) uniformly.
Basic setting: Both handwheels are in the positive
range as far as their limit stops.
0,2
0,1 .008
0,3
.004 .012
0,4
.016
0,1 0,5
.004 .020
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
05-05969-1

Printing unit
Cylinder packings 7
7.2.3 Cylinder packings for printing without bearer ring contact

The measures indicated are only reference
values and may vary according to applica-
tion.
1 Plate cylinder
0.008 - 0.016 "
0.012 - 0.02 "

0,2 - 0,4 mm
0,3 - 0,5 mm
2 Bearing ring of the plate cylinder
3 Blanket cylinder
0,5 mm
0.020 "
4 Bearing ring of the blanket cylinder
0.008 - 0.024 "

0,2 - 0,6 mm
2 1
0,7 - 0,75 mm
0.028 - 0.03 "
2,6 mm
0.102 "
4 3
0 - 0,05mm
1,9 mm
0.075 "
0 - 0.002 "
05-05968-1
Procedure
Measuring the cylinder packings using the dial
gauge.
Information on this can be found in the Main-
tenance manual.
W-027
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
7 Plate cylinder
7.2.4 Printing without bearing ring contact

Procedure
Set the handwheels (A+B-side) uniformly.
Calculating the setting using the packing values.
Pressing between blanket cylinder and plate cylinder.:
max. 0.15 mm (max. 0.006 in)
0,2
0,1 .008
0,3
.004 .012
0,4
.016
0,1 0,5
.004 .020
05-05969-1
7.3 Plate cylinder

7.3.1 Overview
1 Leading edge tensioning bar
2 Tail edge tensioning bar
2
05-05970-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
Plate cylinder 7
7.3.2 Appropriate printing plates

The printing plates must meet the following require-
ments:
The size must conform to the Technical specifica-

tions.
The printing plates must not be bent.
APL printing plate change: The printing plate
must not be bent. Used printing plates must be
straightened.
PPL printing plate change: Used printing plates
must not be too bent.
05-00234-1
The printing plate must be equipped with suitable re-

gister punch holes,(1), (2),on the front edge.
APL printing plate change: The following must also
be remembered when punching the printing plate:
The printing plate must pushed to the A-side limit
stop if the limit stop in the printing press is also loc-
ated on the A-side (standard).
The printing plate must pushed to the B-side limit
stop if the limit stop in the printing press is also loc-
ated on the B-side (option).
The centering device of the printing plate

punch must not be used. 1 2
PPL-01597-4
7.3.3 Changing the printing plate

Changing printing plates (PPL)
Semi-automatic printing plate change (power
plate loading)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The controls required for the plate change

are only released in the printing module in
which the printing plate is in the process of
being changed. On all other printing modules
the [ emergency stop ] and [ Stop-Secure ]
buttons are active. Only after the plate
change is terminated in a printing module,
will the controls for the plate change be
released in the next printing module.

Printing unit
7 Plate cylinder
Removing the printing plate (PPL)

Preliminary tasks
"STOP-secure" ].
Placing a new printing plate in the inserting slot
Attention!:
Incorrectly dimensioned plates will be
clamped incorrectly or not at all in the "tail
edge" tensioning bar and, thus, can cause
considerable damage to the machine.
Only use printing plates with the dimen- 1
sions prescribed in "Technical specifica-
tions".
Place the printing plate in the inserting slot (1) in
each printing unit until it sits on the limit stops.
05-06012-1
Start the printing plate change on the central control

console - see chapter Starting PPL printing plate
change -.
Conditions
All automatic functions are terminated (e.g. washing
programs, ink run-up).
All guards are closed.
All machine run controls can be used.
If you start the printing plate change on the cent-
ral control console using the [ Automatic functions:
Start ] button, the registers automatically move to
zero.
If you wish to start the printing plate change at the
printing module using the [ Crawl speed ] button,
you must first set all registers to zero on the central
control console - see Production (PR) program
level, main menu Register.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
Plate cylinder 7
Procedure
Attention!:
Danger of damage to the machine in
printing and coating modules that are
operated without a printing plate or
coating forme. The packing foil may come
off and get into the machine. Incorrectly
closed and incorrectly tensioned
tensioning bars can collide with other
components.
Mount a printing plate or a coating forme
in all modules, even in modules that are
not printing.
Start the selected automatic function on the central

control console.
The plate change starts - see also chapter
Sequence of automatic functions -.
K55-1
The removed printing plate is automatically pushed
into the ejecting slot.
Enabling period: max. 12 s
The enabling period begins when the re-
moved printing plate is in the ejecting slot
and ends when the new printing plate is
drawn in.
Raise the removed printing plate briefly and lower it
again.
approx. 150 mm (6 in)
The printing plate lies on the lower limit stops of the
ejecting slot.
You can leave the removed printing plate
in the ejecting slot until the plate change is
complete.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
7 Plate cylinder
Mounting the printing plate

Procedure
Caution!
Danger of cutting yourself on
sharp-edged printing plates. When you
insert or remove the printing plates, you
can cut your fingers on their sharp edges.
If possible, hold the printing plate at its 1
top edge when you insert it into or take it
out of the machine.
Carefully press the new printing plate into the insert-
ing slot (1).
7-segments indicator 11: The printing plate is sitting
correctly on both register pins.
Time gap between signal and insertion of printing plate:
12 seconds.
The LE tensioning bar is closed as soon as the print-
ing plate is sitting on the contacts. 05-06012-1
The printing plate will be mounted automatically -

see also chapter Sequence of automatic func-
tions.
The printing plate change is interrupted. The LE ten-
sioning bar is closed. The [ Crawl speed ] button
flashes.
The enabling period was exceeded.
Press the [ Crawl speed ] button to continue the print-
ing plate change.
The 7-segment display is showing 00, 01 or 10.
The detectors have not detected the printing
plate.
Closing the LE tensioning bar manually
Closing the LE tensioning bar manually

Close the LE tensioning bar using the [ Position + ]
button.
Check that the printing plate is sitting correctly on K600
both register pins in the LE tensioning bar.
If the printing plate is not sitting correctly on both

register pins, open the LE tensioning bar using the
[ Position w ] button. K601
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Correct the seating of the printing plate on the re-

gister pins if necessary.
Close the LE tensioning bar using the [ Position + ]

button.
The [ Crawl speed ] button flashes. K600

The plate change is continued.

Printing unit
Plate cylinder 7
Changing printing plates (APL option)

Fully automatic printing plate change (auto-
matic plate loading)
Removing printing plate (APL option)

Preliminary tasks
Placing a new printing plate in the inserting slot (APL option)
Attention!:
Incorrectly dimensioned plates will be
clamped incorrectly or not at all in the "tail
edge" tensioning bar and, thus, can cause
considerable damage to the machine.
Only use printing plates with the dimen- 1
sions prescribed in "Technical specifica-
tions".
Place the printing plate in the inserting slot (1) in
each printing unit until it sits on the limit stops.
Push the printing plate to the limit stop on the A-side
(standard) or B-side (option).
05-06012-1
Start the printing plate change on the central control

console - see chapter Starting APL printing plate
change -.
Conditions
All automatic functions are terminated (e.g. washing
programs, ink run-up).
All guards are closed.
All machine run controls can be used.
If you start the printing plate change on the cent-
ral control console using the [ Automatic functions:
Start ] button, the registers automatically move to
zero.
If you wish to start the printing plate change at the
printing module using the [ Crawl speed ] button,
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
you must first set all registers to zero on the central

control console - see Production (PR) program
level, main menu Register.

Printing unit
7 Plate cylinder
Procedure
Attention!:
Danger of damage to the machine in
printing and coating modules that are
operated without a printing plate or
coating forme. The packing foil may come
off and get into the machine. Incorrectly
closed and incorrectly tensioned
tensioning bars can collide with other
components.
Mount a printing plate or a coating forme
in all modules, even in modules that are
not printing.
Start the selected automatic function on the central

control console.
The plate change starts - see also chapter
Sequence of automatic functions -.
K55-1
The printing plates are removed from and mounted
in each printing module one after the other.
Mounting the printing plate

Procedure
The printing plates are automatically drawn in and
mounted in all printing modules.
Caution!
Danger of cutting yourself on
sharp-edged printing plates. When you
insert or remove the printing plates, you
can cut your fingers on their sharp edges.
If possible, hold the printing plate at its
top edge when you insert it into or take it
out of the machine.
You can leave the removed printing plates in the
ejecting slot until the plate change is complete.
Changing the packing foil

This section describes one of several pos-
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
sible ways of changing the packing sheets.

The description applies to the standard size
packing sheet and printing plate.
Pulling the packing sheet off from the plate cylinder

Lintfree cloth
Isopropanol
Ink washing agents according to list

Printing unit
Plate cylinder 7
Preliminary tasks
Guard No.1 in front of the blanket cylinder and plate cylinder: Open
Press the [ Guard No. 1 : button. OPEN / CLOSE ].
The guard will open.
K599-1
Conditions
Change the packing sheet if it is damaged or if it no
longer adheres to the full surface of the plate cylin-
der.
The printing plate is dismounted.
Procedure
The edge of the packing sheet at the printing tail edge
must be accessible.
Carefully loosen the packing sheet first in one
corner, and then in the other corner until you can
get a firm hold of the sheet.
Jog the machine with the [ Jog: Reverse ] button
and simultaneously pull the packing sheet off from
the plate cylinder.
Once removed, a packing sheet must not be
stuck on again.
Clean the cylinder surface.

Lintfree cloth
Degrease the cylinder surface.
Lintfree cloth
Isopropanol
Guard No.1 in front of the blanket cylinder and plate cylinder: Close
The guard will close.
K599-1
Mounting packing sheet without printing plate

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Conditions
The description applies to the standard printing plate
size.
Procedure
Select the appropriate packing foil.
Thickness (standard): 0.35 mm (0.014 in)
Width (standard size): 1 030 mm (40.551 in)
Length (standard size): 730 mm (28.74 in)
with printing plate length: 785 mm (30.905 in)
Length (standard): 785 mm (30.905 in)
Width (standard): 1 030 mm (40.551 in)

Printing unit
7 Plate cylinder

The edge of the cylinder channel at the TE must be
accessible.
Press the [ Make-ready ] button.
K575-1
K599-1
4 3 2 1 1 2 3 4
4 3 2
1
4 3 2 1
06-01932-2
Position the 4th ink form roller (454) closer to the plate cylinder. To do this, turn the screw (4) on the A+B-side
one revolution to the right (+).
Throw on the ink form rollers against the plate cylin-

der with the [ Ink rollers On / Off ] button.
K596-1
Pull the protective foil off a little bit from the packing
foil.
Length: 150 mm (5.906 in)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
Plate cylinder 7
Place the packing sheet directly behind the edge

of the cylinder channel (arrow). Always observe the
required distance between the cylinder edge and
the edge of the packing foil!
Distance between the edge of the cylinder channel and
the edge of the packing foil: 4 mm (0.157 in)
The packing sheet must be positioned parallel in the
center of the plate cylinder.
Press the packing sheet against the cylinder and
flatten it uniformly from the center to the edges.
and simultaneously pull off the protective foil.
Check that the foil at the leading edge is lying paral-
lel to the edge of the cylinder channel.
Distance from edge of cylinder channel: 3.5 to 4.5 mm
(0.138 to 0.177 in)
Jog the machine with the [ Jog: Reverse ] button a 05-06079-1
full revolution to press the foil against the cylinder

again.
The foil must lie absolutely flat on the plate cylinder
without blisters.
Throw off the ink form rollers from the plate cylinder
using the [ Ink rollers On/Off ] button.
K596-1
4 3 2 1 1 2 3 4
4 3 2
1
4 3 2 1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
06-01932-2
Position the 4th ink form roller (454) back to the original position. To do this, turn the screw (4) on the A+B-
side one revolution to the left (-).
K599-1

Printing unit
7 Plate cylinder
K575-1
Final tasks
Mount the printing plate.
By mounting the printing plate, the pack-

ing sheet that has just been stuck on will be
pressed against the plate cylinder.
7.3.4 PPL Emergency program

By means of the PPL Emergency program you can
manually dismount an incompletely mounted or dis-
mounted printing plate. The system will then be in its
defined state again.
The emergency program is activated in the following
conditions:
A guard was opened or actuated during the printing
plate change.
The [ Stop-Secure ] or [ emergency stop ] button
was pressed.
The following are characteristic reactions of the emer-

gency program:
The digits 00 on the 7-segment display of the con-

trol panel flash.
The printing plate change is interrupted. K637-1
A diagnosis message on the central control console

indicates why the printing plate change was inter-
rupted.
The [ Guard No. 1: Open/Close ] button is active.
The [ Guard No. 1: Open/Close ] button may K599-1

not be pressed if the printing plate is in the
guard.
The [ Crawl speed ], [ Jog: Forward ] and [ Jog: Re-

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
verse ] buttons are active.

Printing unit
Plate cylinder 7
7.3.5 Removing an incompletely removed printing plate

Procedure
The end of the printing plate protrudes from the slide guard
The emergency program was automatically activated.
Grip the printing plate at the TE, push the [ Crawl
speed ] button and pull out the printing plate while
the machine rotates in reverse towards the LE.
The machine automatically stops at the LE.
The LED on the [ Position w ] button flashes. K531
Press the [ Position w ] button.

The leading edge tensioning bar will be opened.
K601
Remove the printing plate.
Exit the emergency program by pressing the [ Stop-

Secure ] button.
K522
The printing plate does not protrude from the slide guard
The emergency program was automatically activated.
Take the new printing plate out of the inserting slot.
Jog the machine as far as the TE with guard No. 1

closed using the [ Jog: Forward ] button.
The printing plate must be transported completely out
of the guard.
K527
Open the guard in front of the blanket and plate cyl-

inder using the [ Guard No. 1: OPEN / CLOSE ].
K599-1
Grip the printing plate at the TE, push the [ Crawl

speed ] button and pull out the printing plate while
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
the machine rotates in reverse towards the LE.

The LED on the [ Position w ] button flashes.
K531

K601

Printing unit
7 Plate cylinder
Close the guard in front of the blanket and plate cyl-

K599-1

Secure ] button.
K522
Manually removing the printing plate from the TE tensioning bar

The printing plate is not guided into the ejecting slot.
Take the new printing plate out of the inserting slot.

until the [ Position + ] and [ Position w ] buttons flash.
K529
Press the [ Position w ] button four times in a row.

The tension of the tail edge tensioning bar will be re-
leased. K601
The TE tensioning bar is opened and the printing

plate is enabled.
The tail edge tensioning bar will be tensioned.
The TE tensioning bar is closed.

briefly until the [ Crawl speed ] button flashes.
K529
Open the guard in front of the blanket and plate cyl-

K599-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Grip the printing plate, push the [ Crawl speed ] but-

ton and pull out the printing plate while the machine
rotates in reverse towards the LE.
The LED on the [ Position w ] button flashes.
K531

K601

Printing unit
Plate cylinder 7
Close the guard in front of the blanket and plate cyl-

K599-1

Secure ] button.
K522
The digits 00 of the 7-segments indicator emit a

continuous light.
The printing plate change is activated again. K637-1
Starting the PPL plate change on the machine

Release period of the start signal (US version): 4 s
K531
Press the [ Crawl speed ] button again.

Once the release period has been exceeded,
you have to restart the program procedure.
The machine will position the plate cylinder at the
leading edge.
You can now mount the new printing plate.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
7 Plate cylinder
7.3.6 Manual register corrections on the LE tensioning bar

1. Leading edge tensioning bar
2. Screws for correcting the LE printing plate in the cir-
cumferential direction
2
1
05-05974-1
7.3.7 Correcting (extending) the LE printing plate in the

circumferential direction
The printing plate may show slight register
inaccuracies. Manual correction at the leading edge to
compensate these inaccuracies is possible.
Preliminary tasks
K599-1

Forward ].
The LE tensioning bar is accessible.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
Plate cylinder 7
Procedure
After each plate change, remove all screws (1) up to
the limit stop (2) from the LE tensioning bar.
The LE tensioning bar is in the zero setting.
flats 17 (094L116840)
3 Screws
To correct the LE printing plate, turn the screws (1)

clockwise as far as necessary according to the re-
gister inaccuracies.
Rotating angle: max. 70
1
Turning the screw by approx. 30 corresponds to
stretching the printing plate by approx. 0.1 mm / 0.004
in 2
flats 17 (094L116840)
05-05971-1
Position [ 5 ]: zero setting; the printing plate is not

stretched. The screws of the segments (1), (2) and 1 2 3
(3) are in the zero position.
Position [ 6 ]: The printing plate is stretched in the
middle. Turn the screws (1) and (3) clockwise.
flats 17 (094L116840) 5
The printing plate is extended on the A+B-side.
Position [ 7 ]: The printing plate is stretched on the
A+B-side. Turn the screw (2) clockwise. 1 2 3
flats 17 (094L116840)
The printing plate is extended in the middle.
1 2 3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
05-05976-1
Final tasks
K599-1

Printing unit
7 Plate cylinder
7.3.8 Manual register corrections on the TE tensioning bar

1. Tail edge tensioning bar
2. Setting point for correcting the TE printing plate in
the circumferential direction
3. Setting point for buckling or extending (axially) the
TE printing plate 2
05-05975-1
7.3.9 Correcting (extending) the TE printing plate in the

circumferential direction
inaccuracies. Manual correction at the tail edge to
Eccentric wrench (013A066713)
Preliminary tasks
K599-1

Forward ].
The tail edge tensioning bar is accessible.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
Plate cylinder 7
Procedure
To correct the TE printing plate, press the relevant
tensioning eccentric (1) using the eccentric wrench
(2).
7 Tensioning eccentrics
7 Sockets
2
The eccentric wrench is inserted into the
socket (3) for the relevant tensioning eccent-
ric.
05-05972-1
Insert the eccentric wrench (1) into the socket (2) of

the selected tensioning eccentric (3).
Make sure that the eccentric (4) is pointing to the right 1
towards the B-side. 2
WARNING:
Danger of crushing your fingers if the
printing plate tears during the stretch-
ing process and the segment snaps back
without control. 4 3
Always use both hands to operate the
eccentric key to avoid the danger of
05-05977-1
injuries.
Turn the eccentric key only slightly in
order to stretch the printing plate.
Turn the eccentric wrench (1) clockwise.

The tensioning eccentric points upwards and the
printing plate is extended.
Remove the eccentric wrench from the socket.
If the printing plate needs to be extended
considerably, move adjacent tensioning
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
eccentrics and repeat the process several

times.
Final tasks
K599-1

Printing unit
7 Plate cylinder
7.3.10 Moving TE printing plate in an axial direction (extending or

buckling)
inaccuracies. Manual correction at the tail edge to
Preliminary tasks
K599-1

Forward ].
The tail edge tensioning bar is accessible.
Procedure
To correct the TE printing plate, push the tension-
ing eccentric (1) in the required direction, depend-
ing on the register inaccuracies, using the eccentric
wrench (2).
The eccentric wrench is inserted in a bore (3)
between the tensioning eccentrics. 2
7 Tensioning eccentrics
8 Bores
3 3
1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
05-05973-1

Printing unit
Blanket cylinder 7
Insert the eccentric wrench (1) in the bore (2)

between the selected tensioning eccentrics (3) and
(4). 1
Make sure that the eccentric (5) is pointing downwards
towards the TE printing plate. 2
Turn the eccentric wrench (1) clockwise.
The tensioning eccentric (3) with the printing plate
moves towards the A-side.
4
Turn the eccentric wrench (1) anticlockwise. 3 5
The tensioning eccentric (4) with the printing plate
moves towards the B-side. 05-05978-1
Remove the eccentric wrench from the bore.
Final tasks
K599-1
7.4 Blanket cylinder

7.4.1 Overview
1 TE tensioning shaft
2 LE tensioning shaft
3 Clamping bar for packing sheets 1
3
05-03055-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
7 Blanket cylinder
7.4.2 Suitable blankets

The blanket must meet the following requirements:
The blanket must conform to the Technical specific-

ations.
The blanket must have a rail.
7.4.3 Changing the blanket

Removing blanket
(094L082640)
Wrench, width across flats 17, with T-
handle (094L082713)
Procedure
K575-1

The machine rotates forwards and stops at the TE
or LE.
If the machine stops at the LE, push the [ Crawl
speed ] button again.
The machine rotates forwards and stops at the TE. K531
The blanket change begins at the TE.

You can jog the blanket cylinder more accur-
ately into position if necessary using the[ Jog:
Forward ] or [ Jog: Reverse ] button.
For the sake of a better overview, the guard
has not been shown in the illustrations.
Loosen the clamp screw (2) by max. 1/2 revolution.
2
Turn the tensioning screw (1) carefully anticlockwise 1
to stop.
Wrench, width across flats 17, with T-handle
(094L082713)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The TE tensioning shaft (3) releases the blanket.

Grip the blanket with the packing sheets and
guide it manually in the following steps while
the machine is rotating.
05-04596-1

Printing unit
Blanket cylinder 7

The machine will rotate in reverse and stop auto-
matically at the printing leading edge.
K529
Loosen the clamp screw (2).

Turn the tensioning screw (1) carefully anticlockwise
1
to stop. 3
(094L082713)
2
The LE tensioning shaft (3) releases the blanket.
Remove the blanket.
05-04276-1
Push the packing sheet locking on the A+B-side

and remove the packing sheet together with the
clamping bar.
Mounting blanket
Wrench, width across flats 17, with T-
handle (094L082713)
(094L188940)
(094L082640)
Socket wrench insert 1/2", width across
flats 17 (094L057140)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
7 Blanket cylinder
Procedure
Push the packing sheets with the clamping bar into
the slot under the LE tensioning shaft (3).
The locking on the A+B-side engages.
1
Insert the blanket into the tensioning shaft (3). 3
Turn the tensioning screw (1) until the felt pen mark
on the blanket is positioned over the cylinder edge. 2
(094L082713)
The final blanket tension is created at the end
of the mounting process using the torque
wrench.
05-04276-1
Lay the blanket and packing sheets flat on the step

between the printing modules.
Press the [ All printing units: Off, feeder: Off ] but-

ton.
Printing is automatically thrown on. K562

Push the blanket onto the cylinder while the ma-
chine is rotating. Ensure that the blanket is fed in
straight.
The machine automatically stops at the TE.
K527
Place the blanket in the tensioning shaft (3) and

2
push the edge carefully into place by hand.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
05-03714-2
Press the [ All printing units: Off, feeder: Off ] but-

ton.
Printing is automatically thrown off. K562
Tighten the tensioning screw (1).

(094L082713)

Printing unit
Blanket cylinder 7
Tension the blanket at the TE with the torque

wrench.
Tension the blanket at the LE with the torque
wrench.
Torque: 100 Nm (10.2 kpm) (LE and TE tensioning
screws)
The cylinder edge must clearly show through under the
blanket. K527
Socket wrench insert 1/2", width across flats 17
(094L057140)
After setting the desired torque, tighten the clamp-
ing screws (2) at the LE.

Tighten the clamp screws (2) at the TE.
K527
K599-1
Exiting the blanket change

Press the [ Position + ] button.
The LED goes out.
The positioning program is exited. K600
Tension the blanket after several revolutions

of the machine, and then again after 3,000
and 10,000 printed sheets.
Check the tension, surface and packing
thickness of the blanket at regular intervals.
Exit the make-ready mode by pressing the [ Make-

ready ] button.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The LED goes out. K575-1

Printing unit
7 Impression cylinder
7.5 Impression cylinder

7.5.1 Overview
1 Gripper shaft
05-05999-1
7.5.2 Impression cylinder blowing device (ICB)

Removing the impression cylinder blowing device (PM 1)
The impression cylinder blowing device pre-
vents the sheet touching the blanket cylinder
too early (doubling).
If you want to print materials that are resist-
ant to bending, remove the ICB first, in order
to prevent the sheet jamming.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
Impression cylinder 7
1 Impression cylinder blowing device (PM 1)
05-05991-1
Slot screw driver (094L205340)
Preliminary tasks
In the main menu Sheet Guide on the central con-
trol unit, switch the impression cylinder blowing
device off.
Open guard No. 3 in front of the inking and
dampening unit.
(see page 4-70)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
Procedure
Loosen the screw (1) of the hose clamp (B-side).
To make it easier for you to remove the ICB,
you can first remove the sheet guides of the
feed register drum. A description of how to
do this can be found in the Feed register
2
drum section of the Feed register system
1
chapter.
Disconnect the hose (2) from the nipple (3) of the
ICB.
Tighten the screw (1) of the hose clamp (B-side) 4
again. 5 3
05-05992-1
Hold the ICB firm.

Press and hold down the lock (1) (A-side). 1
The shutter (2) is unlocked.
Push the shutter (2) (A-side) towards the ICB and 2
secure it by rotating.
05-05993-1
Lift the ICB (4) off the bolts (5) (B-side).

Remove the ICB carefully from the printing press.
2
1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
4
5 3
05-05992-1

Printing unit
Removing the impression cylinder blowing device (PM 2-n)

The impression cylinder blowing device pre-
vents the sheet touching the blanket cylinder
too early (doubling).
If you want to print materials that are resist-
ant to bending, remove the ICB first, in order
to prevent the sheet jamming.
1 Impression cylinder blowing device (PM 2-n)
05-05990-1
Preliminary tasks
device off.
Open step No. 10 above the transferter.
Forward ].
The transferter is horizontal.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
Procedure
Press and hold down the lock (1) (A-side).
The shutter (2) is unlocked. 1
Push the shutter (2) (A-side) towards the ICB and
secure it by rotating.
2
05-05996-1
Push the ICB (1) off the nipple (2) (B-side).

Remove the ICB from the printing press.
05-05995-1
Installing the impression cylinder blowing device (PM 1)

06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
Procedure
Lift the ICB into the printing press.
Place the ICB (4) on the bolts (5) (B-side).
2
1
4
5 3
05-05992-1
Turn the shutter (1) towards the impression cylinder.

The shutter (1) jumps out. 2
The bolt (2) jumps into the bore in the side frame (A- 3
side).
The lock (3) engages audibly. 1
The lock does not engage and the bolt is not in the
bore in the side frame.
Shake the ICB gently until the lock and bolt engage
audibly.
Check that the ICB is sitting perfectly on the
A+B-side.
The blast bores must point towards the im-
05-05994-1
pression cylinder.
Loosen the screw (1) of the hose clamp (B-side).

Slide the hose (2) onto the nipple (3) of the ICB.
Tighten the screw (1) of the hose clamp (B-side)
again.
Slot screw driver (094L205340) 2
1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
4
5 3
05-05992-1

Printing unit
Installing the impression cylinder blowing device (PM 2-n)

Procedure
Lift the ICB into the printing press.
Attach the ICB (1) to the nipple (2) (B-side). 2
Base position: pin (3) pointing to marking (4).
1
3
4
05-05998-1
Turn the shutter (1) towards the impression cylinder.

The shutter (1) jumps out. 2
The bolt (2) jumps into the bore in the side frame (A- 3
side).
The lock (3) engages audibly. 1
The lock does not engage and the bolt is not in the
bore in the side frame.
Shake the ICB gently until the lock and bolt engage
audibly.
Check that the ICB is sitting perfectly on the
A+B-side.
The blast bores must point towards the im-
05-05997-1
pression cylinder.
Setting the impression cylinder blowing device (PM 2-n)

The blowing device and distance of the ICB from the
impression cylinder can be set according to the print-
ing material.
Preliminary tasks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

device off.
Forward ].
The transferter is horizontal.

Printing unit
Removing the impression cylinder blowing device

(PM 2-n) (see page 7-31)
Procedure
Loosen the nut (1) of the fastening (2) (A+B-side).
1
flats 13 (094L116540) 4
2 Nuts
Slide the fastening (2) (A+B-side) into the required

position. 2
The bolt (3) is located in the same position (4) on the
A+B-side.
Tighten the hexagon nut (1) (A+B-side).
flats 13 (094L116540)
05-06000-1
Final tasks
When installing the ICB, note the position of the pin
(1) (B-side).
By turning the ICB (2), you can change the direction
of blowing on the impression cylinder. 2
1
05-06097-1
Installing the impression cylinder blowing device (PM

2-n) (see page 7-34)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
7 Transferter
7.6 Transferter
7.6.1 Overview
1 Gripper shaft
05-06100-1
7.6.2 Gripper pad bar on transferter

Setting the gripper pad bar of the transferter to the sheet thickness
With the QUICKCHANGE option, the gripper pad bar is
automatically set to the sheet thickness input on the
(094L026340)
Socket wrench insert 1/2", hexagon, width
across flats 17, 250L (094L025950)
Preliminary tasks
The screw and the scale for setting the gripper pad bar
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
is accessible.

Printing unit
Transferter 7
Procedure
ness, using the screw (1) (B-side).
The pointer (2) indicates the set value.
0.2 on the sheet thickness scale: 0.04 mm/0.002 in to 0,8
0,5 0,2
0.3 mm/0.012 in
0.6 mm/0.024 in 2
mm/0.04 in
Socket wrench insert 1/2", hexagon, width across flats
17, 250L (094L025950)
The gripper pad bar is mechanically set cent- 1
rally by means of a screw for each transfert-
er.
If necessary, set the automatic lock of the screw (1)
using the clamp screw (3). 3
Screwdriver, hexagon, with a ball-shaped head, width 05-05867-1
Repeat this process for all printing, coating
and transfer modules (option).
Final tasks
Close step No. 10 above the transferter.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
7 Transferter
7.6.3 Sheet guide underneath transferter (downstream of the

reversing device) and delivery drum (option)
Overview
05-05980-1
1. Mounting points of sheet guide rods

Adjustable sheet guide rods are located on the ventilator tracks underneath the transferters (downstream of the
reversing device) and underneath the delivery drum.
These sheet guide rods support the sheet to prevent smearing of the printing on the ventilator tracks.
The sheet guide rods must be positioned before each new printing job so that they are within the print-free area.
Position of sheet guide rods

Depending on the position of the print-free areas, 3, 4
or all 5 sheet guide rods can be used.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
Transferter 7
1. Ventilator tracks
2. Sheet guiding rods 4 1
3. Scale
2
4. Sheet guide rods outside of the size area
05-05981-1
7.6.4 Setting sheet guide underneath transferter (downstream of

the reversing device) and delivery drum (option)
The sheet guide rods are only used on printing and
coating modules downstream of the reversing device
(option), or at the delivery unit.
Procedure
Position the transferter horizontally using the [ Jog:
Forward ] button.
The transferter can be inspected through the
glass pane in step No. 10.
"STOP-secure" ] button - see chapter Safety -. K527

The sheet guide rods on the ventilator track are visible.
For setting the sheet guide rods at the deliv-
ery unit; Open guard No. 13 above the chain
guide track and delivery drum, first position-
ing the printing press so that the sheet guide
rods are visible.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Printing unit
7 Transferter
Loosen the clamp screws (1) of the sheet guide

rods (2).
Push the sheet guide rods (2) into the print-free
areas.
Use the scale (3) of the ventilator track and
matching desk as a guide. 3
Tighten the clamp screws (1) of the sheet guide

rods again. 2
05-05985-1
If necessary, push the two outer sheet guide rods

outside of the size area into the parking position (4). 4 1
2
05-05981-1
Final tasks
Close step No. 10 above the transferter.
Close guard No. 13 above the chain guide track
and delivery drum.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Inking unit and dampening unit
Overview 8
8 Inking unit and dampening unit

8.1 Overview
1 Ink fountain
2 Ink slides 2
3 Ink collecting channel 61
4 Ink roller blowing device (option) 1
71
61 Ink fountain roller 94
71 Ink ductor roller 514
82 4
82 Intermediate roller 3
83 Intermediate roller 93
91 Transfer roller
92 Transfer roller 513
93 Transfer roller
91
94 Transfer roller 512 92
451 Ink form roller 83
454 453
452 Ink form roller
452 511
453 Ink form roller
454 Ink form roller
451
511 Ink vibrator rollers 11.5
512 Ink vibrator rollers 11.4
513 Ink vibrator rollers 06-05869-1
514 Ink vibrator rollers
8.2 Ink unit splitting

8.2.1 Functional description
If production is interrupted, the ink flow to the ink form
rollers is automatically suspended. 513
QuickChange option: The automatic start/stop 91

512 92
sequence throws on the transfer rollers 91 and 92 at
staggered intervals after the restart of the machine. 83
Advance sheets with an excess of ink are minimized. 454 453
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
452 511
451
11.5
11.4
402
06-06019-1

8 Setting symmetric ink flow
8.2.2 Ink flow change-over (QuickChange option)

Front-heavy distribution of ink flow: The transfer roller
91 is thrown off from the central control console - see 513
main menu Printing Module (Preselection), Damp / 91
Ink function. 512 92
83
454 453
452 511
451
11.5
11.4
402
06-06013-1
Symmetrical distribution of ink flow: Transfer roller 92

is mechanically thrown off in the inking unit. 513
On the central control console, the setting Ink flow 91

512 92
symmetric is set to + - see main menu Printing Mod-
ule (Preselection), Damp / Ink function. 83
454 453
452 511
451
11.5
11.4
402
06-06014-1
8.3 Setting symmetric ink flow

Preliminary tasks
Conditions
The inking unit separation is active: Both transfer
rollers have been thrown off by the ink form rollers.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Procedure
dampening unit.

Setting symmetric ink flow 8
Swivel the lock (1) on the A+B-side in the direction

of the arrow.
06-05657-2
The transfer roller 92 is mechanical locked.

513
91
512 92
83
454 453
452 511
451
11.5
11.4
402
06-06014-1
The ink flow in the inking unit is guided to the ink

form rollers 452 and 453 via ink vibrator roller 91 513
and intermediate roller 83. 91
512 92
83
454 453
452 511
451
11.5
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
11.4
402
06-06014-1
Final tasks
On the central control console, set the setting Ink
flow symmetric to + - see main menu Printing
Module (Preselection), Damp / Ink function.

8 Ink fountain
8.4 Ink fountain

8.4.1 Emptying the ink fountain
Ink spatula (094M042040)
Preliminary tasks
Closing all ink slides at the central control console
Move the ink slides to the [ zero position ] with the DD DDDDDD
D DD
DD DD 0
DD DDDD
0 DDD DDDD
key F9. DDD / DDD DD D DD DDDD DDDD DDDD DDD DD
DDDD DDDD
The mark on the key disappears. DDDD 1 02.03.04 12.34
The last ink slide position will be stored and can be 1

100
2 3
100
4 5
100
- 90 -
- 90 - - 90 -
called up again in the color data storage Before - 80 - - 80 - - 80 -
- 70 - - 70 - - 70 -
zero setting (1). - 60 - - 60 - - 60 -
- 50 - - 50 - - 50 -
- 40 - - 40 - - 40 -
- 30 - - 30 - - 30 -
- 20 - - 20 - - 20 -
- 10 - - 10 - - 10 -
- 0- - 0- - 0-
33 20 31 20 28 20 29 20
1: 3 1: 3 1: 3 1: 3
F7 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-914-1
Procedure
Caution!
Danger of cutting yourself at the ink slide
edges and the ink fountain.
Always wear safety gloves at work.
Attention!:
Unsuitable ink spatulas, screwdrivers,
wire brushes and acidic agents may dam-
age the ink fountain roller.
Remove the ink from the ink fountain only
with a plastic spatula.
Remove the ink from the ink fountain with a plastic

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
spatula.

Ink fountain 8
8.4.2 Cleaning ink fountain and ink fountain roller

Lintfree cloth
Protective gloves

A III washing agents, Flash point range: 55
- 100 C
High-boiling agents, Flash point range:
100 C
Bio-washing agents, Flash point range:
100 C
UV washing agents, Flash point range:
55 C
Hybrid washing agents, Flash point range:
55 C
Preliminary tasks
D DD
DD DD 0
DD DDDD
0 DDD DDDD
DDDD DDDD

100
2 3
100
4 5
100
- 90 -
- 90 - - 90 -
- 70 - - 70 - - 70 -
zero setting (1). - 60 - - 60 - - 60 -
- 50 - - 50 - - 50 -
- 40 - - 40 - - 40 -
- 30 - - 30 - - 30 -
- 20 - - 20 - - 20 -
- 10 - - 10 - - 10 -
- 0- - 0- - 0-
33 20 31 20 28 20 29 20
1: 3 1: 3 1: 3 1: 3
F7 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-914-1
Emptying the ink fountain (see page 8-4)

06.09.2004 10:35:31 - 747 - 80 95A EN 6778

8 Ink fountain
Swinging off the ink fountain

Pull the lever (1) (A-side) of the ink fountain upwards.
Pull the lever (1) (A-side) away from the ink fountain
roller.
Insert the lever (1) (A-side) into the bore (2).
Repeat the process with the lever on the B-side. 1
Carefully pull both levers (1) (A+ B-side) away from

the ink fountain roller.
The ink fountain swings off.
06-05876-1
Procedure
Caution!
Danger of cutting yourself at the ink slide 3
Always wear safety gloves at work.
Attention!:
Danger of damage caused by corrosion
2
at the ink fountain roller when
acid-containing decalcifier is used for
cleaning jobs. 6
The ink fountain roller must not get into
4
contact with decalcifier.
1 5
Clean the ink fountain (1) and cam followers (3).
06-05878-1
Lintfree cloth
Switching on the ink fountain roller

Press the [ Ink fountain roller ] button
The LED is on.
Ink fountain roller On: The ink fountain roller is turning. K258
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Ink fountain 8
Clean the ink fountain roller (2).

3
Lintfree cloth
4
1 5
06-05878-1
Switching the ink fountain roller off

Press the [ Ink fountain roller ] button
The LED goes out.
Ink fountain roller Off:: The ink fountain roller stops. K258
Pull out the ink collecting pan (4).

3
Clean the ink collecting pan (4).
Lintfree cloth
A III washing agents, Flash point range: 55 - 100 C
High-boiling agents, Flash point range: 100 C
Bio-washing agents, Flash point range: 100 C
UV washing agents, Flash point range: 55 C
Hybrid washing agents, Flash point range: 55 C 2
Caution!
6
Danger of cutting yourself at the ink slide
4
Always wear safety gloves at work. 1 5
Clean the front edges of the ink slide (5) and the 06-05878-1
side frames (6) (A+B-side).

Protective gloves
Do not use a brush for cleaning the ink
slides.
The bristles might get caught between the
ink slides.
Insert the ink collecting pan (4).
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

8 Ink fountain
Swing the ink fountain on

Turn the lock (1) towards the ink fountain roller (3).
The ink fountain can be swung on.
Carefully push the ink fountain (2) towards the ink
fountain roller (3) using both levers (4) (A+B-side).
Pull the levers (4) (A+B-side) out of the bore. 4
Push both levers (4) (A+B-side) towards the ink 3

fountain roller (3).
1
The ink fountain is locked.
2
06-05877-1
Open all ink slides at the matching desk by some

digits to prevent the slides from touching the ink
fountain roller.
8.4.3 Ink fountain separator (option)

The ink fountain can be subdivided as required with
additional ink fountain separators for rainbow printing.
Spatula for Ink fountain separator
(094M042750)
(094M042350)
Preliminary tasks
Swinging off the ink fountain
Pull the lever (1) (A-side) of the ink fountain upwards.
Pull the lever (1) (A-side) away from the ink fountain
roller.
Insert the lever (1) (A-side) into the bore (2).
Repeat the process with the lever on the B-side. 1
Carefully pull both levers (1) (A+ B-side) away from

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The ink fountain swings off.
06-05876-1

Ink fountain 8
Procedure
Insert the Ink fountain separator (1) into the ink foun-
tain.
Use scale (2) as a guide for positioning the ink foun-
tain separator. 1
2
3
4
Ensure that the ink fountain separator is aligned par- 5
6
allel. 7
8
9
The ink fountain separators are held in posi- 2
tion by the bar (3). 1
06-05967-1
If using ink fountain separators, use a narrow plastic

spatula to fill the ink fountain.
Spatula for Ink fountain separator (094M042750)
Spatula for Ink fountain separator (094M042350)
These plastic spatulas can be obtained from
MAN Roland.
W-076
Final tasks
Swing the ink fountain on
Turn the lock (1) towards the ink fountain roller (3).
The ink fountain can be swung on.
Carefully push the ink fountain (2) towards the ink
fountain roller (3) using both levers (4) (A+B-side).
Pull the levers (4) (A+B-side) out of the bore. 4
Push both levers (4) (A+B-side) towards the ink 3
fountain roller (3).
1
The ink fountain is locked.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
2
06-05877-1

8 Ink slide zero setting
8.5 Ink slide zero setting

8.5.1 Ink slide zero setting using the portable terminal
1 [ Exit ]: to leave the program
2 [ Cursor: Left ], [ Cursor: Right ]: to select
the ink slides
3 [ Cursor: UP ] [ Cursor: DOWN ] increasing
ink slide aperture/reducing ink slide aperture
4 [ Start ]: to start the program 5
5 LCD display
6 Connecting cable
6 EXIT START
1 2 3 2 4
06-05169-1
If you detect significant roller strips on the ink fountain

roller in the zero setting or if a fault with individual ink
slides is indicated on the central control console under
the [ Ink Zones ] menu, the ink slides must be readjus-
ted.
Shop supervisor disk
(SAALMEISTERDISKETTE / SHOP SUPERVISOR
DISK)
Setting device for ink slide (007C428030)
Preliminary tasks
Activate the program level [ Production ] (PR).
Call the main menu [ Damp. / Ink. ].
Setting all ink zones to Printing on the central control console
Activate the function Ink zones using the [ F10 ]
key.
Select the desired setting (1) with the key [ Cursor: DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
DOWN ] or [ Cursor: UP ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Set the status of all ink zones to [ + ] using the print-
ing button.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Ink zone status green: Printing: normal status. A 3
manual or automatic change of the ink slide position is 4
possible. 5
In case of trouble with the ink slide, the ink

zone status will be displayed in red.
1
DDDDD 3 5 10 15 20 25 30
F1 F2 F3 F4 F5 F6 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-884-1

Ink slide zero setting 8
Confirm the entries with the [ Enter ] key.

The mark on the key disappears. K99-1
Setting ink ductor roller strips for ink slide zero setting
Activate the Ink ductor roller strips function using DD DDDDDD
D DD
DD DD 0
DD DDDD
0 DDD DDDD
the [ F3 ] key. DDD / DDD DD D DD DDDD DDDD DDDD DDD DD
DDDD DDDD
Select the printing module (1) with the[ Printing DDD
module keys ] or the keys [ Cursor: Right ] or [ Curs-
1
100
2 3
100
4
1
- 90 - - 90 -
or: Left ]. - 80 - - 80 -
- 70 - - 70 -
Set the ink ductor roller strip (2) with the key [ + ] or
- 60 - - 60 -
- 50 - - 50 -
[ w ]. - 40 -
- 30 -
- 40 -
- 30 -
Ink ductor roller strips for ink slide zero setting: 50 % - 20 -
- 10 -
- 20 -
- 10 -

- 0- - 0-
2
34 34 34 34
The mark on the key disappears. 1: 3 1: 3 1: 3 1: 3
Exit the Adjust / Position function using the [ F6 ] F3 F7 F10

key.
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-999-1

D DD
DD DD 0
DD DDDD
0 DDD DDDD
DDDD DDDD

100
2 3
100
4 5
100
- 90 -
- 90 - - 90 -
- 70 - - 70 - - 70 -
zero setting (1). - 60 - - 60 - - 60 -
- 50 - - 50 - - 50 -
- 40 - - 40 - - 40 -
- 30 - - 30 - - 30 -
- 20 - - 20 - - 20 -
- 10 - - 10 - - 10 -
- 0- - 0- - 0-
33 20 31 20 28 20 29 20
1: 3 1: 3 1: 3 1: 3
F7 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-914-1
Requirements for the ink slide zero setting

Pour the printing ink into the ink fountain.
approx. 2.5 kg cyan
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
If the inking unit temperature control (option) is avail-

able, set the appropriate temperature.
Nominal temperature: 26 to 28 C
Wait until the printing ink has run up before perform-

ing the ink slide zero setting.
Approx. 10 minutes
Activating ink slide zero setting (PR only)

(see page 11-173)

Procedure
Connect the connector of the portable terminal to
the [ service plug ] (printing module, A-side, deliv-
ery).
K535
Wait until the portable terminal shows the display

illustrated.
? ?
EXIT START
06-05171-1
Important!
Danger of damage to the machine, if
closed ink slides strip off the ink 0
32 32
completely from the ink fountain roller. 40
The ink slide presses against the ink
fountain roller. This may damage ink 1
fountain roller and ink slide.
After closing the ink slides, make sure
that there still is a very thin ink film on the
EXIT START
ink fountain roller. Otherwise you have to
correct the zero setting of the ink slides
immediately. 06-05172-1
Press the [ Start ] button on the portable terminal.

Run all ink slides to the zero position.
Ink slide setting range for zero setting: 0 to 40 m (0 to
0.001575 in)
Ink slide zero setting: Nominal value: 32 m
(0.00126 in)
The ink slide No. 1 is automatically preset.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

All ink slides are alternately opened completely and

closed again to guarantee an easy motion of the ink
20 21 22
slides.
11 12 13 14 15 16 17 18 19
Ink slide position: 0 to 125 m (0 to 0.004921 in) 10
LS-02852-2
The ink fountain roller is scraped bare (1) in one or

more ink zones.
Measure to be taken 1 18 19 20 21 22
14 15 16 17
The relevant ink slides must be mechanically opened 12 13
before the individual setting.
Mechanical zero setting of the ink slides
(see page 8-15)
06-05983-1
8.5.2 Individual adjustment of the ink slides

Procedure
Important!
Danger of damage to ink fountain roller
and ink slides during the zero setting. The
ink slides may be pressed against the ink
fountain roller. In this case, the ink foun-
tain roller will be deformed. This will in-
fluence the ink dosage of the adjacent ink
slides. The ink slide front edges will be
worn excessively.
Constantly observe the ink fountain roller
during the zero setting. When the ink slide
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
is in zero position there must still be a

very thin film of ink on the ink fountain
roller. The ink slides should NEVER strip
off the ink completely from the ink foun-
tain roller.
Move all front guides to the zero position.
Select the ink slide No. 1 with the [ Cursor: Right ]
or [ Cursor: Left ] key.
K963

Press the [ Start ] button.

All front guides move to the set position. START
K961
The portable terminal shows the base position dis-

play.
0
32 32
40
EXIT START
06-05174-1
Select the required ink slide using the [ Cursor: Left ]

or [ Cursor: Right ] key.
The display shows the number of the ink slide selec-
K963
ted.
Set the required value using the [ Cursor: Up ] or
[ Cursor: Down ] key.
K963
If you do not want to store the new value, press the

[ Exit ] key twice within one second. EXIT
The new value is not stored. The ink slide is reset
K960
from the previous value to zero.
If you want to store the new value, press the [ Exit ]

key once.
20 21 22
The new value will be stored. 15 16 17 18 19
10 11 12 13 14
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
LS-03780-1

All ink slides are alternately opened completely and

closed again to guarantee an easy motion of the ink
20 21 22
slides.
11 12 13 14 15 16 17 18 19
Ink slide position: 0 to 125 m (0 to 0.004921 in) 10
LS-02852-2
Final tasks
Pull the connector of the portable terminal out of the
[ service socket ].
Terminating the ink slide zero setting at the central control console
Deactivate the Slide adjustment function using the
[ F7 ] key. F7
The mark on the key disappears. K106
Exit the Adjust / Position function using the [ F6 ]

key. F6
The mark on the key disappears. K105
The ink slide zero setting is terminated.
8.5.3 Mechanical zero setting of the ink slides

If the operating range of the portable terminal is not
sufficient or if the ink fountain roller is scraped bare in
one or more ink zones, the ink slides must be adjusted
mechanically.
Preliminary tasks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Guard in front of ink fountain: unscrewing

Loosen the screws (1).
Remove the guard (2) from the ink fountain.
06-05984-1
Procedure
Attention!:
Danger of short circuits and damage to
the machine if you disconnect the con-
nectors of the ink slide motors.
Never disconnect the connectors.
Clamp the potentiometer of the ink slide using the
key (1).
Manually set the ink slide at the rotating button (2).
Anticlockwise rotation (-): ink slide closes, less ink
Clockwise rotation (+): ink slide opens, more ink
05-05509-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

There is a uniform and slightly visible ink film (1) on the

whole ink fountain roller.
Where ink zones (2) have been scraped bare, 18 19 20 21 22
14 15 16 17
first open the ink slide. 12 13
Set the ink slides toward the ink fountain
roller only. Start from the center and pro-
ceed to the A- and B-side. The setting is cor-
rect as soon as the ink film is uniform. The
clamping device prevents the position of the
servomotor from being changed.
1
18 19 20 21 22
14 15 16 17
12 13
2
06-05982-1
Remove the setting device from the ink fountain.

The setting is terminated.
Final tasks
Guard in front of ink fountain: fastening
Fasten the guard (2) to the ink fountain.
Tighten the screws (1). 2
06-05984-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

8 Mechanical make-ready work
8.6 Mechanical make-ready work

8.6.1 Setting the distribution path of the ink vibrator rollers
Function: The max. distribution path (ex works set-
ting) ensures the optimum distribution of ink in the ink- 2
ing unit. The distribution path of the ink distributor 511 513
(1) and 512 (2) can be reduced for certain applications
91
(e.g. rainbow printing). 512 92
Handle with sliding element 1/2" 83
(094L026340) 454 453
Socket wrench insert 1/2", width across 452 511
flats 24, hexagon (094L026140)
Torque wrench 40-200Nm 1/2" 1
451
(094L188940)
Screwdriver, hexagon, width across flats 06-05871-1
6x300 (094L014250)
Preliminary tasks
Setting the commencement of the distribution to zero
Select a printing module with the [ printing module ] DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
keys. DDDDDD
DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Set the commencement of the distribution (4) using 1 2 3 4 L
the button [ w ] to the value 0.

DDDDDDD - - - - - 1
With a distribution commencement of 0, the DDDDDD 2 - - - - +
distribution will start at the printing leading

DDDDD D 3
edge.
- - + - -
DDDDDD 4 + + - - -
DDDDDDD 20 20 20 20 20
5
DDDDDDD 6 0 0 0 0 0
DDDDDD D 4 7
DDDDDD D 8 2
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1116-1
Throwing off ink form rollers 453 and 454 from ink
distributor 512 (see page 8-20)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Mechanical make-ready work 8
Procedure
Position the printing press with [ Jog: Forward ],
[ Jog: Reverse ] or [ Crawl speed ].
To set the distribution path of the ink distributor, the
printing press must be positioned according to the
printing module selected.
Angle of machine position: indicated in the info field:
Printing module 1: 36
Place a rag on the step to absorb oil that might pos-

sibly come out. 2
Remove the screws (1) (A-side).
Remove the cover (2) from guard No. 56.
06-05870-1

1 2
Socket wrench insert 1/2", width across flats 24, 3
hexagon (094L026140)
Slide the joint (2) into the required position.
In the center of the disk (3): no distribution path
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
At the edge of the disk (3): max. distribution path

Distribution path of ink distributor 511: 0 to 36 mm (0
to 1.417 in)
Distribution path of ink distributor 512: 0 to 30 mm (0
to 1.181 in)
Torque: 160 Nm (Screw on distribution gearing)
Socket wrench insert 1/2", width across flats 24,
hexagon (094L026140)
06-05872-1

Final tasks
Throwing on ink form rollers 453 and 454 against
ink distributor 512 (see page 8-21)
Guard No.1.1 in front of the blanket cylinder and plate cylinder: Close
Swivel guard (1) downwards.
06-05875-1
K599-1
8.6.2 Throwing off ink form rollers 453 and 454 from ink distributor
512
To enable the distribution path to be set on the ink dis-
tributor 512, the ink form rollers 453 and 454 must be
briefly thrown off from the ink distributor.
6x300 (094L014250)
Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

K599-1

Guard No.1.1 in front of the blanket cylinder and plate cylinder: Open
Swivel guard (1) upwards.
06-05875-1
Turn the screw (1) of the ink form roller 453 and the
screw (2) of the ink form roller 454 one revolution
anticlockwise.
(094L014250)
2
1
06-05873-1
8.6.3 Throwing on ink form rollers 453 and 454 against ink
distributor 512
6x300 (094L014250)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Procedure
Turn the screw (1) of the ink form roller 453 and the
screw (2) of the ink form roller 454 one revolution
clockwise.
(094L014250)
2
1
06-05874-1
Final tasks
06-05875-1
K599-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

8.6.4 Setting the axial play of the ink form rollers

By changing the axial play of the ink form rollers (1 - 4),
you can reduce ghosting effects in the printing image.
6x300 (094L014250)
4 3
2
1
06-05894-1
Conditions
The axial play of the ink form rollers must only be set
while the machine is running.
Procedure
1
1 1
1
06-05962-1
Set the desired axial play of the ink form rollers with the screw (1) on the A+B-side.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Axial play of the ink form roller: 0 to 18 mm (0 to 0.709 in)

Axial play of the ink form roller: covering length 1045 mm / 41.142 in (option): 0 to 12 mm (0 to 0.472 in)
To decrease the axial play, turn the screw clockwise (-).
To increase the axial play, turn the screw anticlockwise (+).
Screwdriver, hexagon, width across flats 6x300 (094L014250)
The axial play of all ink form rollers is set with screw (1).

8.6.5 Locking and unlocking the axial play of ink form roller 454
The axial play of the ink form roller 454 (4) can be
thrown off separately without influencing the setting of
the axial play of the ink form rollers (1 to 3). The axial
play can be locked or unlocked as soon as the dot
gain is too high.
4 3
2
1
06-05894-1
Preliminary tasks
K599-1
06-05875-1
Removing the doctor blade collecting pan:

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
(see page 9-9)

Forward ].

The ink form roller 454 is located in the center between

the bearing halves (A+B-side).
06-05963-1

Procedure
Swivel the lock (A+B-side) into the desired position.
Position (1): axial play locked
Position (2): axial play unlocked
2 Lock
06-05964-1
Final tasks
Installing the doctor blade collecting pan:
(see page 9-10)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

8 Options
06-05875-1
K599-1
8.7 Options
8.7.1 Setting the ink roller blowing device (IRB) (option)
Excess dampening solution can be removed from the
ink rollers during the printing process using the IRB.
Preliminary tasks
dampening unit.
Procedure
The ventilators of the IRB can be controlled in 3
groups with 2 power stages for each group via a
control (B-side).
Phase I: Half power
Phase 0: Ventilator group switched off
Phase II: Full power
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Set the speed of the ventilators (B-side) using the

button (1).
2 ventilators
Set the speed of the ventilators (center) using the
button (2). 1 2 3
8 ventilators
06-05965-1
Set the speed of the ventilators (A-side) using the

button (3).
2 ventilators

Inking unit temperature control device (option) 8
The control of the IRB is linked to the signal

for Dampening roller: On.
Decide before starting to print whether the
IRB is to be used. If the IRB is switched on
or off during printing, fluctuations in density
may occur.
8.8 Inking unit temperature control device (option)

8.8.1 Overview
1 Supply of the temperature control medium
2 Return flow of the temperature control medi-
um 61
61 Ink fountain roller
512
511
06-05966-1

Even at high machine speeds the inking unit temperat-
ure control provides for a constant temperature in the
inking unit.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The constant inking unit temperature is reached by

tempering the following rollers:
ink fountain roller 61,
ink fountain roller 511 and
ink fountain roller 512.
For operation and maintenance of the tem-

perature control device, read the instructions
of the manufacturer.

8 Dampening unit
8.9 Dampening unit

8.9.1 Overview
The distribution path of the dampening rollers
11.4 and 11.5 is linked to the distribution
path of the ink distributors.
1 Dampening solution fountain

31 Water metering roller
21 Water fountain roller
402 Water form roller 11.5
11.4 Vibrator roller 11.4
11.5 Transition roller 402
31
21
1
07-05979-1
8.9.2 Operation
Controlling dampening
Procedure
The nominal values for temperature and alcohol are
determined on the central control console.
The dampening solution additive is set on the
dampening solution refrigerator.
The quantity of dampening solution is regulated at
the central control console during production.
Generate a short overdampening at the matching
desk or at the control panel on the delivery unit.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Washing system
Overview 9
9 Washing system
9.1 Overview
Ink roller wash-up device (ARD)
1 Doctor blade collecting pan
2 Spraying devices for water, washing agent,
2nd washing agent (option), special cleaner
(option)
1
Blanket wash-up device (ABD) 2
3 Washing device with brush
2nd washing agent (option)
5 Drive motor
6 Washing device with cloth (option)
Impression cylinder wash-up device 4

(AID)
5
7 Washing device with brush
2nd washing agent (option) 3
9 Drive motor 6
10 Washing device with cloth (option)
7
10
9
8
09-05807-2
9.2 Washing agent container

9.2.1 Location
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Up to max. 3 inks: The washing agent container are

next to the switch cabinets for the equipment.
4 inks or more: The washing agent containers are un-
derneath the step of printing module 3, A-side.

Washing system
9 Washing devices
1. Washing agent container 1

2. Reservoir for washing agent container 1
4
6
2
8
0
10
3. Reservoir for washing agent container 2 (option) 4

3
4. Washing agent container 2 (option)
5. Container for ARD special cleaner (option) 2 > 55C
6. Water supply
1 5
09-05662-2
The collecting container for waste washing agent is at

the last printing module on the A-side.
1. Level indicator detector

2. Collecting container 2
3. Collecting pan 3
4. Pump
09-05250-2
9.3 Washing devices

9.3.1 Preselecting and starting washing programs
Preliminary tasks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Preselecting the blanket washing program

(see page 11-139)
Preselecting the impression cylinder washing pro-
gram (option) (see page 11-149)
Preselecting the ink roller washing program
(see page 11-143)
Before starting the washing programs, check the
presettings in the Equipment main menu:
"STOP-secure" ].

Washing system
Washing devices 9
Preselecting automatic functions (see page 11-66)
Procedure
Blanket/impression cylinder wash-up device with cloth (option)
The impression cylinder wash-up device is only avail-
able with the cloth washing device option if there is no
reversing device.
Refer to the instructions manual of the manufacturer
of the cloth washing device.
During the washing process, the machine rotates
forwards.
9.3.2 Gumming the printing plate

As soon as the washing program is finished, an
acoustic signal requests you to gum the dampening
rollers. The dampening rollers transfer the gumming to
the printing plate. The gumming serves for a better
moistening of the non-printing zones of the printing
forme and protects the printing plate from oxidation.
Spray bottle (094Z901140)
Preliminary tasks
Call the main menu [ Aggregates ].
Activate the ARD function using the [ F3 ] key.
Gumming the printing plate
Activate the Gumming function (6) using the [ + ] DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
button before starting the washing program. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Gumming +: At the end of the washing program, you
can gum the printing plate and dampening rollers.
1 2 3 4
1
DDDDDDD 1 1 1 1
If you activate the Gumming function (6), D DDDDDDD + + + + 2

D DDDDDD + + + +
the Decalcify function (7) is automatically 3
deactivated. DDDD + + + +
DDDDDDD DDD + + + + 4
DDDDDDD 1 1 1 1
5
DDDDD :- 6
DDDDD :-
DD DDDDDD : 100% 7
DDDDDDDDDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
: A3
8
F1 DD DDD
F3 DDD 9 DD DDDD
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1139-1

Washing system
9 Washing devices
Procedure
Spray enough gumming agent through the slot in
the guard in front of the dampening unit.
Ratio of mixture (gumming agent/water): 1:1
Gum additionally in case of a longer standstill
of the machine (> 12 hours).
09-05879-1
Final tasks
As soon as the gumming agent is dry, throw off the
dampening rollers.
Throwing off the water form roller
The dampening rollers will be thrown off in all preselec-
ted printing modules.
Press the [ Dampening rollers on / off ] button.
The LED goes out.
Water form roller Lower: The water form roller will be K595-1
thrown off from the water fountain roller and the plate.
9.3.3 Decalcifying inking unit and dampening unit

As soon as the washing program has finished, an
acoustic signal prompts you to decalcify the inking unit
and dampening unit.
Decalcifier
Preliminary tasks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Decalcifying inking and dampening unit
Decalcifying the inking and dampening unit.

Washing system
Washing devices 9
Activate the Decalcify function (7) using the [ + ] DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
button before starting the washing program. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Decalcifying +: At the end of the washing program, you
can decalcify the inking. and dampening unit.
1 2 3 4
1
DDDDDDD 1 1 1 1
If you acticate the Decalcify function (7), the D DDDDDDD + + + + 2

D DDDDDD + + + +
Gumming function (6) is automatically deac- 3
tivated. DDDD + + + +
DDDDDDD 1 1 1 1
5
DDDDD :- 6
DDDDD :-
DD DDDDDD : 100% 7
DDDDDDDDDDD : A3
8
F1 DD DDD
F3 DDD 9 DD DDDD
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1139-1
Procedure
Attention!:
Danger of damage caused by corrosion
at the ink fountain roller when
acid-containing decalcifier is used for
cleaning jobs.
The ink fountain roller must not get into
contact with decalcifier.
Spray the decalcifier through the slot of the guard in
front of the dampening unit.
Decalcifier
The pH value of the decalcifier must not be
lower than 2.
09-05879-1
Leave the decalcifier to take effect.
Throw on the doctor blade collecting pan using the
[ Doctor blade collecting pan: On/Off ] button.
Water is automatically sprayed on and scraped off K607-1
by the rollers.
The doctor blade is automatically thrown off.
The machine stops.
The procedure is terminated.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Washing system
9 Washing agent supply
9.4 Washing agent supply

9.4.1 Filling container for special cleaner (option)
Procedure
Topping up special cleaner
Ensure by pulling on the ring (1) that the container is
depressurized.
1 2 3
Open the locking mechanism of the cover (2) and
remove the cover. 4
6
Place a funnel in the container and top up the spe-

8
0
10
cial cleaner.
Wipe off spilt special cleaner immediately and
dispose of the cleaning rags in an environ-
mentally friendly manner. 4
Assemble the cover (2) and close the locking mech- > 55 C
anism.
5
7
6
09-00289-2
Preselecting ink roller washing

Preselect the ink roller washing program (1) with the DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
key [ + ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Washing ink rollers +: The ink roller washing program is
activated. DDDDDDDD DDDDDDDDDDDD DDDD
DDDDDD DDDDD 1
The selected washing program will be displayed (ar- DDDDDDDD DDD DDDDDDD D
row). DDDDD DDD DDDDD DDDDDD 2
DDDDDDDD
DDDDDD DDD 3 DDDDD
DDDDDDDD DDDDD
DDDDDDDD
DDDDD
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
B-895-1

The container is automatically pressurized.
K99-1
Correct the operating pressure if necessary.

Operating pressure: 2 to 2.3 bar
The container with special cleaner is operational.
No special cleaner is required for the next washing
program.

Washing system
Washing agent supply 9
The ball valve is blocking access to the wash-

ing agent line.
Venting container for special cleaner (see page 9-7)
9.4.2 Venting container for special cleaner

When the container has nearly been pumped empty,
the float valve shuts and blocks access to the printing
press. The container must be vented in order for the
float valve to open again.
Procedure
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
key [ + ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
DDDDDD DDDDD 1
DDDDDDDD
DDDDDD DDD 3 DDDDD
DDDDDDDD DDDDD
DDDDDDDD
DDDDD
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-895-1

The container is automatically pressurized.
K99-1
Insert one end of the hose (7) into the socket above
the float valve and the other end into an empty con-
tainer. 1 2 3
Open the valve (6) until fluid emerges from the hose
(7).
4
6
2
8
0
10
Close the valve.

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
> 55 C
7
6
09-00289-2

Washing system
Topping up special cleaner

Ensure by pulling on the ring (1) that the container is
depressurized.
1 2 3
Open the locking mechanism of the cover (2) and
remove the cover. 4
6
Place a funnel in the container and top up the spe-

8
0
10
cial cleaner.
Wipe off spilt special cleaner immediately and
dispose of the cleaning rags in an environ-
mentally friendly manner. 4
Assemble the cover (2) and close the locking mech- > 55 C
anism.
The cleaner is distributed in the hose lines to the 5
printing press. 7
6
09-00289-2
Repeat the whole process until no more air

emerges.
1 2 3
4
6
2
8
0
10
> 55 C
7
6
09-00289-2
9.5 Doctor blade collecting pan

9.5.1 Manually throwing the doctor blade collecting pan on and off
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Preliminary tasks
Call the main menu [ Machine ].
Starting the idle running
Start the idle running with the key [ F3 ].
The machine is turning at the set idle running speed. F3
The ink flow in the inking unit is switched on. K102
The LED is on.
K789

Washing system
Doctor blade collecting pan 9
Procedure
Start the printing machine with the key [ Run ].
Washing speed: max. 6 000 Sh/h
K533

The doctor blade collecting pan is automatically

thrown off after 7 minutes or if the maximum
washing speed is exceeded.
The LED goes out.
9.5.2 Removing the doctor blade collecting pan:

Preliminary tasks
K599-1
1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
06-05875-1

Washing system
Procedure
Turn the lock (2) (A+B-side) in the direction of the
arrow.
Remove the doctor blade collecting pan (1) from the
2
guides.
06-05944-1
9.5.3 Installing the doctor blade collecting pan:

Procedure
Slide the doctor blade collecting pan (1) on the
guides as far as the limit stop.
Turn the lock (2) (A+B-side) in the direction of the
2
arrow.
06-05929-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Delivery
Overview 10
10 Delivery
10.1 Overview
10 12 11 2 12 6
5
4 3
7 8
9 14
13
13
10-01788-3
1 Pile supporting plate: 8 Air quantity controller: sheet decurler

2 Ventilators and blast tubes 9 Dry sprayer
3 Front sheet joggers 10 Ventilator controls: ventilators
4 Side sheet joggers 11 Guard in front of delivery unit
5 Air quantity controller: blast tubes 12 Pictographs
6 Control panels 13 Control panel: Access protection
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
7 Air quantity controller: Suction roller 14 Control lever: sheet removal

Delivery

10.2.1 A-side delivery
1 Automatic pile control
2 Pile: Stop-Secure
3 Residual/intermediate pile: Raise (option)
4 Pile: Raise
1 2 7
5 Residual/intermediate pile: Lower (option)
6 Pile: Lower
3 4
5 6
10-01886-3
Automatic pile control

Starting the automatic NONSTOP device.
K554
Service plug by MAN Roland (service)

Connection for the portable terminal. 06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Delivery
10.2.2 B-side delivery (top)

1 - 10 Printing module keys for overdampening
1, 2, 6, Additional functions (option: reversing
7 device) 1 6
1 6
11 Suction element: Presetting
12 Sheet jogger, front edge: On/Off
2 7
13 Sheet jogger A-side: On/Off 2 7
14 Sheet jogger B-side: On/Off
3 8
3 8
4 9
4 9
5 10
5 10
11 12
13 14
10-02369-3
Printing module keys for overdampening

Producing overdampening through brief speed
increase of water fountain roller.
Suction element: Presetting

Preselecting the suction elements on the suction roller.
K642-1
Sheet jogger, front edge: On/Off

Switching the sheet jogger on the sheet front edge on
or off.
K32
Sheet jogger A-side: On/Off

Switching the sheet jogger on the A-side on or off.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K31
Sheet jogger B-side: On/Off

Switching the sheet jogger on the B-side on or off.
K30

Delivery
10.2.3 Additional functions (option: reversing device)

1 Suction element (1): air off.
1 6
3 Suction element (3): air off. 1 6
2 7
3
4 9
4
5 10
5
7
5 6
4
3
2
1
10-06134-1
10.2.4 B-side delivery (bottom)

1 Call-tone
2 All printing units: Off, feeder: Off:
3 Sheet counter 1 2
4 Automatic production: On/Off
000
5 Edit Minus 3 4
6 Edit Plus
7 Waste sheet removal mechanism: Preset- 5 6
ting
8 Suction roller speed: Presetting
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
7 8
9 Sheet jogger, A-side: Presetting
10 Sheet jogger, B-side: Presetting 9 10
11 Rear sheet stop: Presetting
12 Gripper opening cam 11 12
13 Production speed: decreasing
14 Production speed: increasing 13 14
16 Inspection sheet removal mechanism 15 16
10-01887-4

Delivery
Call-tone
K564-1

To be used in emergencies only.
The impression will be thrown off spontaneously in all
printing units, the feeder will be disengaged. K562
Sheet counter
Switching the sheet counter on or off.
The number of printed sheets will be displayed on the
central control console. K807
Automatic production: On/Off

Switching the automatic production on or off.
K35
Edit Minus
Changing values.
K592-1
Edit Plus
Changing values.
K591-1
Waste sheet removal mechanism: Presetting

Preselecting the waste sheet removal mechanism.
K639-1
Suction roller speed: Presetting

Preselecting the suction roller speed.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K590-1
Sheet jogger, A-side: Presetting

Preselecting the sheet jogger on the A-side for a size
correction.
K27
Sheet jogger, B-side: Presetting

Preselecting the sheet jogger on the B-side for a size
correction.
K26

Delivery
Rear sheet stop: Presetting

Preselecting the size correction on the rear sheet stop
(suction roller).
K217
Gripper opening cam

Switching on or off, or preselecting the gripper opening
cam.
Changing the timing of the gripper opening. K216
Production speed: decreasing

Decreasing the machine speed during production.
K565-1
Production speed: increasing

Increasing the machine speed during production.
K566-1
Inspection sheet removal mechanism

Switching on or off, or preselecting the inspection
sheet removal mechanism.
K638-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Delivery
10.2.5 Delivery, B-side

1 Loudspeaker
2 Run
3 Jog: Back
4 Jog: Forward
7
5 emergency stop
6 Stop-Secure
7 Enabling
1 2
3 4
5 6
10-01790-3
Enabling
See chapter Printing press for information on enabling
the printing press after switching on.
Enabling the printing press following the interruption of
an access protection light barrier.
K927
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Delivery
10.2.6 Delivery, B-side (inside)

Access on the A-side.
1 Stop-Secure
08-02448-3
10.2.7 Ventilator controls

1 Selecting ventilator group / deselecting indi-
vidual ventilators
4
2 LED ventilator ON
3 LED-display: Quantity of air
4 Direction of sheet travel 2 3
5 All ventilators: preselecting 1
6 LCD-display: Ventilator group / air quantity
(%)
7 Air quantity controller
8 Ventilator: deselect
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
5 6 8
7
10-05162-1

Delivery
10.2.8 Air quantity controller: blast tubes

1 Air for outer bast tubes
2 Air for inner bast tubes
3 Air for middle blast tube
4 6 4 6 4 6
2 8 2 8 2 8
0 10 0 10 0 10
1 2 3
10-06135-1
Air for outer bast tubes

Setting the air pressure for the outer blast tubes.
K999
Air for inner bast tubes

Setting the air pressure for the inner blast tubes.
K1000
Air for middle blast tube

Setting the air pressure for the middle blast tube.
K1001
10.2.9 Air quantity controller: blast tubes (QuickChange option)

1 Air for outer bast tubes
2 Air for inner bast tubes 4
3 Air for middle blast tube
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
- + - + - +
1 2 3
10-05670-2

Delivery
Air for outer bast tubes

Setting the air pressure for the outer blast tubes.
K999
Air for inner bast tubes

Setting the air pressure for the inner blast tubes.
K1000
Air for middle blast tube

Setting the air pressure for the middle blast tube.
K1001
10.2.10 Air quantity controller: suction roller and sheet decurler

The suction power of the sheet decurler must
be adapted to the roller incline of the sheet. If
the reverse side of the sheet has been freshly
printed, switch off the sheet decurler at the
1 Air for suction disks

2 Air for sheet decurler
4 6 4 6
2 8 2 8
0 10 0 10
1 2
10-06120-1
Air for suction disks

Setting the air pressure for the suction disks.
K995
Air for sheet decurler

Setting the air pressure for the sheet decurler.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K992

Delivery
10.2.11 Air quantity controller: suction roller and sheet decurler

The suction power of the sheet decurler must
be adapted to the roller incline of the sheet. If
the reverse side of the sheet has been freshly
printed, switch off the sheet decurler at the

3
- + - +
1 2
10-06119-1

K995

K992
10.2.12 Air quantity controller: reversing device (option)

2 Air for suction rails (reversing device option)
3 Air for blowing devices between the suction
elements (reversing device option)
4 6 4 6 4 6 4 6 4 6 4 6 4 6
2 8 2 8 2 8 2 8 2 8 2 8 2 8
0 10 0 10 0 10 0 10 0 10 0 10 0 10
1 2 3 4
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
10-06136-1

K995

Delivery
Air for suction rails (reversing device option)

Setting the air pressure of the suction rails.
K996
Air for blowing devices between the suction elements (reversing device option)
Setting the air pressure of the blowing devices of the
suction roller.
K997

K992
10.2.13 Air quantity controller: reversing device (QuickChange

option)
5
2 Air for suction rails (reversing device option)
3 Air for blowing devices between the suction
elements (reversing device option)
5 7-segments indicator - + - + - + - + - + - + - +
1 2 3 4
10-05668-2

K995
Air for suction rails (reversing device option)

Setting the air pressure of the suction rails.
K996
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Air for blowing devices between the suction elements (reversing device option)
Setting the air pressure of the blowing devices of the
suction roller.
K997

K992

Delivery
10.2.14 Access protection

The control panels for the access protection
are situated on the delivery supports on the
A+B-side and at the front end.
Each control panel controls the light barriers
on the side on which it is installed.
A detailed description of the access protec-
tion can be found at the end of this chapter.
1 Hiding top light barrier

2 Access protection display: Run
3 Access protection display: Interruption
4 Pile change 1
10-05507-2
Hiding top light barrier

Hiding the top access protection light barrier for a peri-
od of 20 seconds.
This button may only be used to set pile wedges
and check the pile.
K968
The finger guide of the button lights up yellow: func-
tion of top light barrier is hidden.
The finger guide of the button flashes yellow: the
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
hide time is into the last 5 seconds.
Access protection display: Run

The LEDs flash green: the access protection is op-
erational.
Operation of the printing press for production or
positioning and pile movements is possible.
K969

Delivery
10 Pile controls
Access protection display: Interruption

The LEDs flash red: a light ray from the access pro-
tection was interrupted.
Operation of the printing press for production or
positioning and pile movements is not possible.
K970
Pile change
Hiding function of light barriers for the pile change.
Requirement: the pile supporting plate is moved down
to the ground.
This button only functions on the side spe- K971
cified for the pile change.
This button may only be used for a pile change by

inserting an empty pallet.
The finger guide of the button flashes green: light
barrier can be hidden.
The finger guide of the button lights up green: func-
tion of bottom light barrier is hidden.
The finger guide of the button lights up yellow: func-
tion of all light barriers is hidden.
10.3 Pile controls

10.3.1 Raising the pile supporting plate
WARNING:
under it.

06.09.2004 10:35:31 - 747 - 80 95A EN 6778

automatically.
K538

Delivery
Pile controls 10
10.3.2 Lowering the pile supporting plate

WARNING:
under it.

K540
floor.
10.3.3 Stopping the pile hoist

K550
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Delivery
10 Pile change
10.4 Pile change

10.4.1 Changing pile
Moving out the main pile
Procedure
WARNING:
under it.
The pile supporting plate will be lowered. The

lowering speed of the pile supporting plate will be
reduced, right before it touches the floor.
If light barriers for protecting the feet have
been installed (option), the pile supporting
K540
plate automatically moves down to the
ground.
The finger guide of the [ Pile change ] button flashes

green: function for hiding the light barrier is available
If you do not lower the pile manually, produc-
tion will stop automatically as soon as the pile
K971
supporting plate reaches the lowermost posi-
tion for lowering. A warning signal will sound.
A diagnosis message will appear at the cent-
ral control console.
You must move the pile out quickly during
a work step and insert an empty pallet. If
the specified period for access protection is
exceeded, the printing press automatically
interrupts the pile change process.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Press the[ Pile change ] button:

The finger guide of the [ Pile change ] button lights
up green: function of bottom light barrier is hidden.
The function of the light barrier on the specified side
of the pile change is hidden for 20 seconds.
Move the lift truck underneath the pallet within the
next 20 seconds and raise the pile.
up yellow: function of all light barriers is hidden.

Delivery
Pile change 10
The function of all light barriers on the specified side

Move the pile completely out of the hazard zone of
the delivery unit within the next 20 seconds using
the lift truck.
The finger guide of the [ Pile change ] button flashes
green: function for hiding the light barrier is available
All light barriers of the access protection are func-
tional again.
Inserting the pallet

Procedure
Press the [ Pile change ] button again within the next
50 seconds.
up yellow: function of all light barriers is hidden.
K971
The function of all light barriers on the specified side
After 50 seconds, it is no longer possible to
hide the function of the light barriers. You
can then only insert an empty pallet by stop-
ping the machine.
Move an empty pallet onto the pile support plate

within the next 10 seconds.
Pile table height or pallet height: max. 144 mm (max.
5.669 in)
If none of the light barriers is interrupted, the printing
press continues to rotate and the access protection
is functional.
If another light ray from the light barrier is interrupted
after 10 seconds, the printing press stops.

Secure ].
WARNING:
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

under it.

Delivery
10 Settings for sheet delivery
The pile will be raised as long as you press the but-

ton or until the detector stops it automatically.
K538
If the main pile on which a pallet with remain-

ing sheets is located is raised, it is imperative
to ensure that the side sheet joggers are set
to the size to be printed.
10.5 Settings for sheet delivery

10.5.1 Setting the pile height detector
By setting the detector you can influence the falling
height of the sheet and, thus, the quality of the pile
formation for the different printing materials.
Preliminary tasks
Procedure
Open guard No. 40 in front of the sheet removal
point.
Move the detector (2) as required for the sheet
thickness. 2
Lower detector: Cardboard
Upper detector: Paper 1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
10-06105-1
Final tasks
Close guard No. 40 in front of the sheet removal
point.

Delivery
Settings for sheet delivery 10
10.5.2 Correcting the size adjustment of the suction roller

Press the [ Rear sheet stop: Preselection ] button.
The LED is on.
K217
Press the [ Edit Minus ] or [ Edit Plus ] button.

If Edit Minus is activated, the suction roller moves to-
wards the pile: smaller size. K260
If Edit Plus is activated, the suction roller moves away
from the pile: larger size.
Exit the setting using the [ Rear sheet stop:
Preselection ] button.
The LED goes out.
10.5.3 Correcting size adjustment of the side sheet joggers

If a size correction is made to the suction roller, the
side sheet joggers are adjusted to the sheet center.
Press the [ Sheet jogger, A-side: Preselection ] or

[ Sheet jogger, B-side: Preselection ] button.
The LED of the selected button is on. K978

If Edit Minus is activated, the sheet jogger moves to-
wards the pile: smaller size. K260
If Edit Plus is activated, the sheet jogger moves away
from the pile: larger size.
Exit the setting using the [ Sheet jogger, A-side:
Preselection ] or [ Sheet jogger, B-side: Preselec-
tion ] button.
The LED of the selected button goes out.
If the main pile on which a pallet with remain-
ing sheets is located is raised, it is imperative
to ensure that the side sheet joggers are set
to the size to be printed.
10.5.4 Setting suction roller speed

The suction roller speed varies according to the sheet
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
size and printing material.
Press the [ Suction roller speed: Preselection ] but-

ton.

If the Edit Minus button is pressed, the drive motor of
the suction roller turns more slowly. K260
If the Edit Plus button is pressed, the drive motor of
the suction roller turns more quickly.

Delivery
10 Settings for sheet delivery
Exit the setting using the [ Suction roller speed:

10.5.5 Setting gripper opening for delivery systems

The timing of the gripper opening at the delivery sys-
tem can be changed if the pile formation is unsatisfact-
ory.
Procedure
Correcting gripper opening
The set gripper opening basically applies across the
whole speed range of the printing press. The higher
the value displayed, the later the sheets are released
by the grippers. The gripper opening can be set during
production.
Press the [ Gripper opening cam ] button.
The LED is on.
K216
The 7-segment display shows the value set.

Base position: 40
Setting range: 0 to 80 K1012

If Edit Minus is activated, the value is reduced and the
sheet is issued earlier. K260
If Edit Plus is activated, the value is increased and the
sheet is issued later.
Exit the setting using the [ Gripper opening cam ]
button.
The LED goes out.
Setting loading of gripper opening

At machine speeds upwards of 6,000 sheets/h, the
gripper opening can be influenced by inputting the
steepness. As the machine speed increases, the
gripper opening is then adjusted dynamically, resulting
in earlier release of the sheet by the grippers. The
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
setting for the loading of the gripper opening can only

be made when the press is shut down.
Press and hold down the [ Gripper opening cam ]
button.
K216
The 7-segment display shows the value set.

Setting range: 0 to -9
The setting 0 does not constitute a speed- K710-1
related change to the gripper opening.

Delivery
Inspection sheet and waste sheet removal mechanism 10

If Edit Minus is activated, the value is reduced and the
sheet is issued earlier. K260
If Edit Plus is activated, the value is increased and the
sheet is issued later.
A steepness setting of -5, for example,
means that with every increase in machine
speed by 1,000 sheets/h the grippers open
one value earlier than the input value.
Release the [ Gripper opening cam ] button.
The set value is stored.
Loading of the gripper opening is switched on.
Manual correction of the gripper opening
during production is also possible with act-
ive alignment.
10.6 Inspection sheet and waste sheet removal

mechanism
10.6.1 Overview
3 5
2 4
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
10-06111-1
1 Lever for actuating the inspection and waste 4 Sheet stops in idle position
sheet removal mechanism 5 Sheet catcher in idle position
2 Sheet stops in working position
3 Sheet catcher in working position

Delivery
10 Inspection sheet and waste sheet removal mechanism
10.6.2 Inspection sheet removal in automatic mode

Setting the number of inspection sheets for the automatic mode
Press the [ Inspection sheet removal mechanism ]
button.

Number of inspection sheets that can be preselected:
0 to 20 sheets K260
The 7-segment display shows the number of in-

spection sheets set.
K637-1

button again.
The number of inspection sheets set is stored. K638-1
Starting inspection sheet removal mechanism in automatic mode

The inspection sheet removal mechanism is available
during production.
WARNING:
1
Danger of crushing caused by gripper
systems when the sheet catcher is swung
off. If you are not careful when you re-
move inspection sheets, revolving gripper
systems may crush your hands and cause
serious injury.
3
Never reach with your hands into the
range of the gripper systems. Grasp
the sheet at its very front edge only.
If possible, use the automatic mode
for removing sample sheets and waste
sheets.
Briefly move the lever (1) (A- or B-side) to the left or 2
the right.
10-06112-1
On actuation of the lever (1), the top light barrier of
the access protection at the front end of the deliv-
ery unit is automatically hidden for a period of 20
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
seconds. During this period, the top hazard zone

of the delivery unit is not monitored. If the top light
barrier is interrupted at the end of the period during
which it is hidden, the printing press stops.
The finger guide of the button lights up yellow. the

function of top light barrier is hidden. For the last 5
seconds of the period when the light barrier is hid-
den, the finger guide of the button flashes.
K968

Delivery
The sheet lifters move to the working position.

1
The sheet stops (2) move to the idle position.
The preset number of inspection sheets are issued
into the sheet catcher (3).
The sheet catcher moves (3) to the idle position.
2
10-06112-1
Carefully remove the inspection sheets from the

printing press.
Actuate the lever (1) (A- or B-side) again.
The sheet stops (2) move back to the working posi-
tion.
The sheet lifters move to the idle position.
The sheet catcher moves (3) to the working posi-
tion.
If the sheet stops do not return to the work-
ing position as a result of actuating the lever
(1), an acoustic signal sounds and a diagnos-
is message appears on the central control
console.
Production is automatically interrupted when
the pile on the sheet lifters reaches a height
of 30 mm / 1.181 in.
10.6.3 Manual inspection sheet removal

Switching off the automatic inspection sheet removal
The automatic mode of the inspection sheet removal
mechanism is activated as standard.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

button and hold it down for 1 second.
The sheet catcher moves to the idle position.

The automatic mode of the inspection sheet remov-
al mechanism is deactivated.

Delivery
Starting the manual inspection sheet removal mechanism

WARNING:
1
serious injury.
3
sheets.
Carefully take hold of one or more inspection sheets 2
at the outermost front edge.
10-06112-1
With the other hand, briefly actuate the lever (1) (A-
or B-side) to the left or right.

K968

1
The sheet stops (2) move to the idle position.
Carefully remove the inspection sheets from the
printing press.
3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
2
10-06112-1

Delivery

tion.
console.
of 30 mm / 1.181 in.
Switching on the automatic inspection sheet removal mechanism

button and hold it down for 1 second.
The LED goes out. K638-1
The sheet catcher moves to the working position.

The automatic mode of the inspection sheet remov-
al mechanism is activated.
10.6.4 Waste sheet removal

Starting the waste sheet removal mechanism
The waste sheet removal mechanism is available dur-
ing production. Preselection of the waste sheet remov-
al mechanism is possible during production or during
the make-ready process.
Press the [ Waste sheet removal mechanism:

The LED flashes. K639-1
The sheet stops move to the idle position.

The waste sheets are issued into the sheet catcher.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Delivery
WARNING:
1
serious injury.
3
sheets.
When the required number of waste sheets has 2
been reached, actuate the lever (1) (A- or B-side)
briefly to the left or right. 10-06112-1


K968

1
The sheet catcher moves (3) to the idle position.
3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
2
10-06112-1

Delivery
Blast frame 10
Carefully remove the waste sheets from the printing

press.
tion.
The sheet catcher moves (3) to the working posi-
tion.
console.
of 30 mm / 1.181 in.
10.7 Blast frame

Assignment of ventilators to ventilator groups
The 25 ventilators of the blast frame are divided into 9
groups. The following assignment corresponds to the
buttons of the control panel.
Assignment of ventilator groups (1) to (9).
In the ventilator groups (4), (5) and (6), the 1

ventilators can only be deselected in pairs on
the A- or B-side
2 3 2
4 5 6 5 4
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
7 8 9 8 7
10-05672-2

Delivery
10 Blast frame
Buttons on the control panel (1) to (9).

1
2 3 2
4 5 6 5 4
7 8 9 8 7
10-05676-2
10.7.2 Preselecting individual ventilators or ventilator groups

Switch on a ventilator group using the [ Ventilator ]
button.
The LEDs of all ventilators which form a group are K780
on.
If you want to switch off individual ventilators, press
the corresponding button, [ Ventilator ].
The LCD shows the highest and lowest air quantity 83

of the ventilators switched-on. 53
K874
10.7.3 Deselecting the ventilators individually

Press the [ Ventilator ] button.
The LED goes out.
The ventilator is deselected. K780
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Delivery
Blast frame 10
10.7.4 Preselecting all ventilators

Press the [ All ventilators ] button.
All ventilators are preselected.
K775
10.7.5 Deselecting all ventilators

Press the [ Ventilator: Deselect ] button.
All selected ventilators will be deselected. The LEDs
K778
go out.
10.7.6 Setting the air volume

For regulating the air quantity, the corresponding vent-
ilators must be selected.
Turn the [ air quantity ] controller anticlockwise.

Quantity of air: 0 to 100 %, Step width: 1 %
The air quantity will be decreased.
Turn the [ air quantity ] controller clockwise. K777
Quantity of air: 0 to 100 %, Step width: 1 %

The air quantity will be increased.
The column diagram shows the set air quantity.
K781
The LCD shows the highest and lowest air quantity 83

of the selected ventilators. 53
K874
10.7.7 Positioning ventilators of the blast frame

Preliminary tasks
WARNING:
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

under it.

Delivery
10 Blast frame

K540
Procedure
WARNING:
Extreme danger to life caused by starting
and revolving gripper systems when you
work in the delivery unit. Starting and re-
volving gripper systems may catch parts
of the body and cause very serious injury.
You must set the main switch of the
switch cabinet to "O" and secure it
against inadvertent restarting using a
padlock before performing the follow-
ing cleaning and maintenance work
on the delivery unit (access via the
guard on the A-side). This prevents
persons carrying out these tasks at
points where they cannot be seen from
other operating positions from getting
caught by movable parts of the ma-
chine.
Sheet guide; ventilator tracks; dryer.
This also prevents persons carrying out
these tasks at points where they cannot
be seen from other operating positions
from getting caught by movable parts
of the machine.
Turn the [ main switch ] of the printing press to [ O ].
Push the ventilators in rows (1) and (2) by hand in

the sheet travel direction.
10 Ventilators
The optimum position of the movable vent- 1

ilators is based on the printing material, the
sheet size and the image to be printed.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
10-05674-2

Delivery
Blast frame 10
10.7.8 Aligning the blast tubes of the blast frame

Procedure
WARNING:
chine.
of the machine.
Guard No. 40 in front of the sheet removal point Open

Open guard No. 40 in front of the sheet removal
point.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
10-05721-1

Delivery
10 Blast frame
Using the lever (1), position the blast tubes diagon-

ally or vertically in relation to the sheet surface.
4 blast tubes
10-05675-2
10.7.9 Shutting air off from the blast tube of the blast frame
The blast tubes are provided with rings with which you
can shut off the flow of air from each individual blast
hole. This will help you achieve uniform sheet delivery.
Which individual blast holes are to be shut off depends
on the printing material, the sheet size and image to be
printed.
Procedure
WARNING:
chine.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

of the machine.

Delivery
Sheet braking system 10
Turn the selected ring (1) on the blast tube (2) clock-
wise.
The blast hole is closed. 2
Turn the selected ring (1) on the blast tube (2) anti-
clockwise.
The blast hole is open.
10-04045-2
10.8 Sheet braking system

10.8.1 Suction roller
Setting suction disks for heavy printing materials
The suction disks (1) to (7) of the suction roller are set
for lightweight printing materials as standard.
7
Screwdriver, hexagon, with a ball-shaped 6
5
head, width across flats 3 (094L017213) 4
3
2
1
10-06115-1
Preliminary tasks
WARNING:
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

under it.

Delivery
10 Sheet braking system

K540
floor.

Secure the main switch with a padlock against be-
ing switched on again.
Procedure
Set the suction disk for heavy printing materials us-
ing the Allan key (3).
Position (1) of cylinder pin: lightweight printing materi-
als
Position (2) of cylinder pin: heavy printing materials
7 Suction disks
2
Repeat this process for all suction disks of the suc-
tion roller.
3
1
10-06113-1
Shutting off air of suction disks

For a size change (e.g. min. size), the suction air of the
individual suction disks positioned outside of the size
zone can be shut off.
Preliminary tasks
WARNING:
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

under it.

Delivery
Sheet braking system 10

K540
floor.

Procedure
Turn the lever (1) on the selected suction element in
the direction of the arrow.
The valve closes and the suction ring (2) is depres-
surized. 1
10-06114-1
Adjusting suction disks to the sheet size

The suction disks of the suction rollers are aligned so
that they suck in and thus brake the sheet gliding over
the rollers at the print-free points of the underside of
the sheet.
Preliminary tasks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
WARNING:
under it.

Delivery
10 Access protection

K540
floor.

Procedure
Loosen the clamp screw (1) and push the suction
element (2) onto the shafts (3) in the required posi- 2
3
tion.
Close the clamp screw (1).
10-06116-1
10.9 Access protection

10.9.1 Overview
1 Top light barriers: A+B-side, front end
2 Middle and bottom light barrier: A+B-side,
front end 5
3 Light barrier to protect feet (option): A+B-
side, front end
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
4 Control panels
1
5 [ Enable ] button
4 4
2
2
3
10-06102-1

Delivery
Access protection 10

Purpose of access protection
The access protection is a safety device on the delivery
unit that, with the help of light barriers, monitors ac-
cess to the hazard zone of the delivery unit in which
the pile supporting plate and gripper systems are mov-
ing.
The access protection was designed so that people
are prevented from accessing the hazard zone with
their whole body.
There is still a risk to hands, arms and legs in the case
of incorrect operation.
1. Hazard zone to which access is monitored

2
2. Chain with continuous gripper systems
3. Pile supporting plate:
10-05397-2
10.9.3 Responses of printing press on interruption of a light barrier

The printing press does not rotate
All machine movements are locked on interruption of a
light barrier of the access protection.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Delivery
The printing press rotates (sheet travel)

If the main pile (1) is raised or lowered by a maximum
of 140 mm / 5.512 in, only the main pile stops when a
light barrier (2) is interrupted. The printing press con-
tinues to rotate
If the main pile (1) is lowered by more than 140 mm
/ 5.512 in, the printing press and the main pile stop
when a light barrier (2) is interrupted. 2
If there is an intermediate pile (option), the main and in- 1

termediate piles stop when a light barrier is interrupted.
The printing press continues to rotate
10-06103-1
The printing press rotates (no sheet travel)

The main pile (1) is raised and the pile stops moving
when a light barrier (2) is interrupted. The printing
press continues to rotate
The main pile (1) is lowered and the pile movement
and the printing press stop when a light barrier (2) is
interrupted.
2
If a board or rake is inserted into the intermediate pile
(option), the main pile stops when a light barrier is in- 1
terrupted. The printing press continues to rotate
10-06103-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Delivery
Access protection 10
Light barriers to protect feet (option)

If a light barrier (1) is interrupted, the main pile (2)
stops. The printing press continues to rotate
1
10-06104-1
10.9.4 Temporary hiding of functionality of light barriers

The functionality of light barriers can be temporarily
hidden. If the functionality of a light barrier is hidden,
the printing press does not respond when the light ray
is interrupted. However, the light barrier is not then
switched off. The functionality of the light barrier is dis-
played again after a period set by default.
The purpose of the temporary hiding of the functional-
ity of light barriers is to allow completion of work on the
delivery unit without having to stop the printing press.
The functionality of light barriers is hidden in the follow-
ing ways:
Manual hiding: temporary hiding of the functionality
of a light barrier by pressing a button.
Automatic hiding: temporary hiding of the function-
ality of light barriers for certain processes.
10.9.5 Safety notes

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The access protection of the delivery unit was

designed so that people are prevented from accessing
the hazard zone with their whole body. However, there
are still remaining risks, but these can be precluded
through correct conduct.
Observe the following rules:
Risk from willful misuse of the periods when the functionality is hidden

Delivery
Only use the periods when the functionality of light

barriers is hidden for the respective designated
work.
You are putting your life in danger if you use the
periods when the functionality is hidden for other
purposes.
Risk from circumventing the light barriers

Never climb over or creep under a light ray in order
to enter the hazard zone.
Never reach across or under a light ray in order to
enter the hazard zone.
You are putting your life in danger if you willfully cir-
cumvent a light barrier. This risk also applies to a
stationary machine that is ready for operation.
Risk from negligent enabling of the printing press

Only enable the printing press using the button [ En-
able ] button once you are certain that there are no
people within the hazard zone.
The access protection detects when a person
enters the hazard zone. However, the access
protection does not detect the fact that a person is
still in the hazard zone if none of the light barriers is K927
interrupted.
A person remaining in the hazard zone is at risk of a
fatal injury once the printing press is enabled, as the
printing press is then ready for operation.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Central control console
Overview 11
11 Central control console

11.1 Overview
7
5
LS-03273-3
1 Matching desk 5 Protocol printer

2 Monitor 6 Compartment for computer
3 Control panel, JOBCARD READER 7 Drawer insert (option)
4 Drawer for keyboard
06.09.2004 10:35:31 - 747 - 80 95A EN 6778


11.2.1 Control panel
7
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
8
2
1 ?
7 8 9
MAN
3
ROLAND
4 5 6
4 1 2 3
CLR 0 ,
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
LS-02605-4
1 Program level buttons 5 Function keys F1 to F10

2 Buttons of main menus 6 Printing module keys
3 Machine function keys 7 emergency stop
4 Control keys and input keys 8 Stop-Secure
Printing module keys

Selecting a printing module
A printing module can also be selected with
the [ Cursor keys ]. 11 10 9 8 7 6 5 4 3 2 1
LS-02577-2
emergency stop
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Stopping the printing press in dangerous situations.

After the button has been pressed, the printing
press will stop as quick as possible with a slow-
down time that depends on the current machine K01
speed.
The button is locked. All run controls are locked.
Only after unlocking the button (by turning anticlock-
wise or clockwise), is the operation of the printing
press possible again.

Stop-Secure
Stopping the printing press.
After the button has been pressed, the printing
press stops with a slow-down time that depends
on the current machine speed.
The button is locked. All run controls are locked.
Only after unlocking the button (by turning anticlock-
wise or clockwise), is the operation of the printing K02-1
press possible again.
The [ Stop-Secure ] button is operated differ-

ently on the central control console than on
the printing press.
11.2.2 Program level buttons

1 Job list
2 Job Preparation (JP)
1
3 Production (PR) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
2
4 Production Data Acquisition (PDA) (option)
5 Diagnosis 3
6 Service 4 ?
7 8 9
5
MAN
ROLAND
4 5 6
1 2 3
CLR 0 ,
6 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
LS-05643-1
Job list
In the present version, this program version is without
function.
K81-1
Job Preparation (JP)

Preparing a work step while another work step is being
printed.
The data input does not influence the current K85-1
production.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Production (PR)
Make-ready and printing of a work step.
All entries on the central control console dir-
ectly influence the settings on the press. K58-1
Production Data Acquisition (PDA) (option)

Documenting and further processing of events in a
Production-Planning-System.
K80-1

Diagnosis
Display of trouble on the printing press and help for a
quick elimination.
K74-1
Service
Changing basic settings of the printing press.
Archiving work steps.
K67-1
11.2.3 Buttons of main menus

The menus and functions differ in the pro-
gram levels (JP), Production (PR) and Ser-
vice.
1 Job
2 Machine
3 Printing module (preselection) 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
4 Sheet guide
5 damp./ink
1 2? 3 4 5 6 7 8
6 Register MAN
7 8 9
7 Supply units
ROLAND
4 5 6
1 2 3 000
8 ColorPilot (option) CLR 0 ,
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
LS-02666-1
Job
Creating a new work step with the specific machine
settings.
K86
Machine
Make-ready of the printing press to print a prepared
work step. All entries on the central control console
directly influence the settings on the press. K69
This main menu exists in program level Pro-

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
duction (PR) only.
Printing module (preselection)

Presettings of the printing press for the current work
step.
K932

Sheet guide
Settings of the air supply for an optimum guiding of the
sheets in the printing press.
K76
damp./ink
Settings of the ink control.
K77
Register
Settings of the registers and front guides.
This main menu exists in program level Pro-
duction (PR) only. K68
Supply units
Settings e.g. for dampening solution refrigerator, dry
sprayer and wash-up devices.
This main menu exists in program level Pro- K84
duction (PR) only.
ColorPilot (option)
Measuring and controlling the ink feed with a color
control system.
K83
11.2.4 Machine function keys

1 Automatic functions: Start
2 Run
3 Automatic production 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
4 Sheet counter
1
5 Air: On
6 Call-tone ?
7 8 9
2
4 5 6
3
4
1 2 3
CLR 0 ,
5
6
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
LS-02669-1
Automatic functions: Start

All preselected automatic functions will be started.
K55-1

Run
The printing press starts and turns at the preset speed.
K12-1
Automatic production
The automatic production will be started.
The automatic production can also be started with the
[ F1 key ( Production (DR) program level, main menu K35-1
Machine ].
Sheet counter
Switching the good sheet counter on and off. The
000
counter stops when switched off. When you switch
the counter on again, the system will continue counting K807-1
the sheets.
Air: On
Switching the pumps and blowers on and off manually.
K926
Call-tone
K564-2
11.2.5 Control keys and input keys

1 Digit keys
2 Sign
3 Plus / Minus 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
4 Delete
5 Cursor / Selection button 6
6 Help ?
5 3
7 8 9 1
7
7 MAN Roland button
4 5 6
8 4
1 2 3
8 Print
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
CLR 0 ,
9 CANCEL F1 F2
9 F3 F4
10 F5 F6
2 F7 F8 F9 F10
10 Enter
LS-02829-1

Digit keys
Entry of digits.
0: Selecting the ink zone status ink-free (see main 7 8 9
menu Damp / Ink).
4 5 6
1 2 3
0 ,
K57-1
Sign
Changing the sign preceding a value.
Selecting the ink zone status manual (see main
menu Damp / Ink). K936
Plus / Minus
Changing values
Selecting entries on the list
Selecting the ink zone status ink-free or locked
(main menu Damp / Ink)
Setting ink slides: pressing the button accel- K63-1
erates the procedure.
Delete
Deleting existing values before entering a new value.
CLR
K100-1
Cursor / Selection button

Changing between the input fields.
The selection button has the function of a tabulator.
In the main menu Damp / Ink, the beginning

of the ink zone block is marked with the se-
lection button.
K75-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Help
Activating the online or diagnosis help.
?
K72-1
MAN Roland button

In combination with the [ Print ] button: print-out of the MAN
ROLAND
entire screen contents.

K66-1

11 Control console screen
Print
Prints protocols, online-help or marked screen sec-
tions.
In combination with the [ MAN Roland ] button: print- K78-1
out of the entire screen contents.
CANCEL
Rejecting inputs that have not yet been confirmed with
[ Enter ]. The status valid last will be restored.
K60-1
Enter
Confirming inputs before leaving a menu.
The confirmation in the current menu always
applies to all printing modules, even if the K99-1
data of only one printing module is displayed.
11.3 Control console screen

11.3.1 Structure of the screen mask
1 Program level / main menu DD DDDDDD
D DD DDD D
DD DD 0 0 DDD DDDD
2 Print run, number of printed sheets DDDDDDD 1 DD 2 D DD DD DDDD DDD DD
DDDD DDDD DDDD DDDD DDDD
DDD DD DDDDD DDDD DD D DDDDDD DD DDD
3 Job number and job designation 3 4 6 5
DDDD 7 DDDDDD DDDDDDDD : DDDD
4 Sheet trend indication DDDDDDDD : DDDD
5 Date, time
6 Info on diagnosis messages
7 Info line with instructions and information. 8
8 Workspace
9 Screen keys (menus, functions)
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-861-2
11.3.2 Sheet trend indication

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Detectors in the feed register monitor the arrival of the

sheet at the front guides while the machine is running.
The trend indicator will show at a glance whether the
sheet will arrive too early, too late or crooked at the
front guides.

Control console screen 11
Sheet trend indication

1 Deviation on the A-side
4
2 Direction of sheet travel (arrow)
3 Deviation on the B-side 0 -4
4 Red or yellow bars indicate deviations from 1 3
the correct sheet travel 2
B-003-1
Correct sheet travel

If there are no color bars, the sheet travel is correct.
0 0
B-170-1
Warning: Early sheet

Sheet trend, 4 to 6
Color bar, yellow, Warning: Correct the sheet travel 4 4
at the next opportunity.
B-748-1
Alarm: Early sheet

Sheet trend, 7 to 10
Color bar, red, ALARM: Correct the sheet travel im- 8 8
mediately since a stoppage is possible.
B-751-1
Warning: Late sheet

Sheet trend, -4 to -6
Color bar, yellow, Warning: Correct the sheet travel -4 -4
at the next opportunity.
B-746-1
Alarm: Late sheet

Sheet trend, -7 to -10
Color bar, red, ALARM: Correct the sheet travel im- -8 -8
mediately since a stoppage is possible.
B-749-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Warning: Crooked sheet

Sheet trend, 4 to 6
Sheet trend, -4 to -6 0 -4
Color bar, yellow, 1 color bar, or 2 diagonally B-747-1
staggered color bars. Warning: Correct the sheet
travel at the next opportunity.

11 Control console screen
Alarm: Crooked sheet

Sheet trend, 7 to 10
Sheet trend, -7 to -10 0 -8
Color bar, red, 1 color bar, or 2 diagonally B-750-1
staggered color bars. Alarm: Correct the sheet
travel immediately since a stoppage is possible.
11.3.3 Info on diagnosis messages

Colored display fields in the status area show that
there are messages in the program level Diagnosis.
The colors indicate the degree of urgency of a
message.
Overview: Diagnosis messages

1 Ink, Grey, There are no diagnosis messages. DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
2 Ink, red, Alarm: Correct the trouble immedi- DDDDDDD DD D DD DDDD DDDD DDDD DDDD
ately since a stoppage is possible. 1 2 3
3 Ink, yellow, Warning: Correct the trouble at DDDD: DDDD DDD DDDDDDDD DD D DDDDDDD DDDDD 0241000
DDDD: DDDD DDD DDDDDDDD DD D DDDDDDD DDDDD 0259000
the next opportunity. DDDD: DDDD DDD DDDDDDDD DD D DDDDDDD DDDDD 0231000
F1 F2 F3 F4 F6 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-862-1
11.3.4 Basic functions

Function keys on the screen
(1): the menu / function is active. DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
The button has a colored mark. There is text on the DDDDDDD DD D DD DDDD DDDD DDDD DDDD
key symbol. DDD DD DDDDD DDDD DD D DDDDDD DD DDD
DDDDD DDDDDD
(2): the menu / function can be selected. DDDDD :
DDDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
:
The key symbol is not marked. There is text on the key DDDDD : DD DDDD
symbol.
(3): the screen key is without function.
The key symbol is not marked. There is no text on the
key symbol.
1 2 3
DDDD DDDD
DDDD
F2 DDDD
F4
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-860-1

Control console screen 11
Select a function with the keys [ F1 ] to [ F10 ] on the

central control console keyboard.
The screen key of the selected function is colored.

DDDDD
F1
B-294-1
Terminate the selected function with the keys [ F1 ]

to [ F10 ] on the central control console keyboard.
The mark on the screen key disappears. DDDDD

Most functions will be terminated when you
activate another function with the keys [ F1 ] F2
to [ F10 ]. B-035-1
Diagram of printing modules in the Machine main menu

A special diagram of the printing modules is DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
displayed if the APL printing plate change (1) is DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
preselected in the Machine main menu. The buttons DDDDD DDD DDDD DDDDDDDD
mean the following: DDDDDDDD DDDDDDDDDDDD DDDD
DDDDDD DDDDD
DDDDDDDD DDD DDDDDDD D
DDDDD DDD DDDDD 1 + DDDDDD
DDDDDDDD
DDDDDD DDD DDDDD
DDDDDDDD DDDDD DDDDDDD DDDDD
DDDDDDDD
DDDDD
MAN MAN MAN MAN MAN MAN MAN MAN MAN
700 700 700 700 700 700 700 700 700
9 8 7 6 5 4 3 2 1
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1065-1
the printing module is active.

Condition The key is pressed. (The PM number is light.) MAN
700
B-1113-1
the printing module is not active.

Condition The key symbol is not pressed. (The PM MAN
number is dark.) 700
B-1064-1
An Arrow up indicates that the printing plate is in

the process of being ejected.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
MAN
700
Condition PM number yellow
B-1114-1
An Arrow Down indicates that the printing plate is in

the process of being ejected. MAN
700
Condition PM number yellow
B-1115-1
A marking indicates that a printing plate is mounted.

Condition Marking in top right corner. MAN
700
B-1113-1

11 Program level Job Preparation
No marking is shown if no printing plate is mounted.

Condition No marking in top right corner. MAN
Condition Marking in top right corner.

700
B-1141-1
During the printing plate change, the symbol for

Automatic procedure will be displayed next to the
diagram of the printing modules. B-1067-1
If the automatic procedure has been interrupted, the

symbol Manual will be displayed next to the dia-
gram of the printing modules. B-1068-1
Eliminate the trouble at the printing modules.
11.3.5 Menu structure

The central control console program consists of hier-
archically arranged levels.
Program level
A program level, as the highest step of the hierarchy,
contains at least one main menu.
Main menu level

A main menu, situated in the middle of the hierarchy,
contains one or more menus and functions.
Menu and function level

This is the lowest level of the hierarchy and contains
submenus and functions.
11.4 Program level Job Preparation

11.4.1 Main menu Job
F1 Completing work step data DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
F2 Creating a new work step DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
F3 Copying the work step and storing it under a
new job number DDDD DDDDDD DDDD DDDD DDDD
F4 Viewing work step DDDD DDDD D DDD DD DDD DDDDD DD D
DDDD DDDD D DDD DD DDD DDDDD DD D
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F6 Searching work step DDDD DDDD D DDD DD DDDDD DD D

DDDD DDDD D DDD DD DDDD DDDDD DD D
F7 Deleting a work step
F8 Deleting CCI-protocols
F9 Viewing job papers
F10 Viewing the remaining columns of the table
DDDD
(Deviations are possible according to the
machine configuration) F1 F2 F3 F4 F6 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-859-1

Program level Job Preparation 11
Creating a new work step

Procedure
Activate the program level [ Job Preparation ] (JP).
K85-1
Call the main menu [ Job ].
K86
The list of all work steps will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
The list of work steps will not be displayed. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Another work step is being processed.
DDDD DDDDDD DDDD DDDD DDDD
Interrupt or terminate the work step you have just pro-
cessed - see chapter Interrupting or terminating the DDDD DDDD D DDD DD DDD DDDDD DD D
preparation of a work step. DDDD DDDD D DDD DD DDD DDDDD DD D
DDDD
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-813-1
Activate the New work step function using the [ F2 ]

key. F2
K101
Enter the job number (1). DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
STORE: max. 20 Characters DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Enter the job designation (product) (2). DDDDD DDDDDD
Product: max. 16 Characters DDDDD : 1
DDDDD 2 :
In the case of networked machines, enter the ma- DDDDD : DD DDDD
chine name in the Machine line (3).
F2
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-850-1
Confirm the entries with the key [ Enter ].

The work step is stored in the data base.
K99-1

The function Process will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
1 Name of the customer DDDDDDD DD D DD DDDD DDDD DDDD DDDD
2 Printing date DDDDD DDDDDD
3 No. of sheets DDDDD : DDD
DDDDD : DDD
4 Sheet data DDDDD : DD DDDD
5 Notice DDDD : DD DDDD 1 DDDDDDD :

DDDD : D D DDD 2 DDDDDDD : D DD
6 Number of colors / Grammage / Date / Addi- DDDDD 3: DDDD DD
tional note DDD DDD : DDD DD 6
F1 Function "Processing the work step" DDD DDDD : DDD DD 4 DDD :
DDD DDD : DDD DD DDDD :
(Deviations are possible according to the ma-

chine configuration) DDDD :
5
Create a base job, if you frequently print sim-
F1 F2 F4 F5 F8
ilar jobs - see program level Production F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
(PR), Service, chapter Creating a base job. B-875-1
When you create a new work step, the base

job data will be preset for the job data.
Complete the data or copy them from another work

step - see Completing work step data and Insert-
ing work step data.
Entered wrong job number?

Once a new job number has been issued, the work
step with this unique designation is stored in the data-
base. For changing the job number must be copied
and stored under another number.
Copy the work step - see Copying the work step.
Store the work step under the correct job number.
Thereafter, delete the work step with the wrong job
number - see Deleting the work step.
Completing work step data

Activate the Process function using the [ F1 ] key.
F1
K41
Enter the name of the customer (1). DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
Customer: max. 32 Characters DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Enter the printing date (2). DDDDD DDDDDD
Date: Calendar date DDDDD : DDD
DDDDD : DDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Enter the number of sheets to be printed (3). DDDDD : DD DDDD
DDDD : DD DDDD 1 DDDDDDD :

No. of sheets: 1 to 9 999 999 Sh, Step width: 1 Sh DDDD : D D DDD 2 DDDDDDD : D DD
DDDDD 3: DDDD DD
Enter the sheet data (4). DDD DDD : DDD DD 6
The sheet width also serves as a reference DDD DDDD : DDD DD 4 DDD :
value for the dry sprayer - see program level DDDD :

Production (PR), main menu Aggregates, 5
function F4: Powder.
F1 F2 F4 F5 F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-875-1
Inputs concerning (5) and (6) are optional.

K99-1
Inserting job data

Copying and inserting data of another similar work
step.
Activate the Insert job function using the [ F2 ] key.
The display changes over to the list of work steps. F2
K101
Select the work step (1), the data of which you want DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
to insert into the new job, from the list. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
The data will be copied into the new work step.
Deactivate the function Insert job with the key [ F2 ], DDDD 1 DDDD D DDD DD DDD DDDDD DD D
if you have not found a suitable work step.
The display changes over to the current work step.
DDDD
F1 F2 F3 F4 F6 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-883-1
Managing work steps

Searching for, viewing, copying and deleting work
steps.
Procedure
K85-1
K86
If required, interrupt or terminate the currently pro-

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
cessed work step.

The list of all work steps will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
If the list of work steps is incomplete, the DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
search mask (1) still contains data of a pre-
vious search. If required, delete the data -
see Searching for work step. DDDD DDDD D DDD DD DDD DDDDD DD D
DDDD DDDD : DDDD DDDD : DDDD

DDDD : DDD DDDD 1
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-849-1
Searching work step

The search mask will be displayed. F6
K105
Delete existing inputs with the key [ F10 ] Delete DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
search mask. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Enter the desired search criteria. DDDDD DD DDDDDD
STORE: max. 20 Characters
Product: max. 16 Characters DDDDD DD
Machine.: MAN Roland, Dummy ... DDDDD DD
DDDDD DD
Customer: max. 32 Characters
Date: Calendar date DDDDD DD
Date: Calendar date DDDDD DD DD
Number of colors: max. 6 Characters DDDDD DD DD
Info: max. 6 Characters DDDDD DD
The term you search for need not be com- DDDDD DD
DDDDD DD
plete. The system will also search for char-
acter strings. Enter a * before or behind the
F6 F10
term you search (e.g. *eck or Beck*, if you F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
are searching for Becker). B-836-1
Select a processing status with the key [ + ] or [ w ].

Status (search criteria): ALL JP, ALL IN, ALL T, ALL I,
ALL EPS, ALL PPS
K63-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K99-1
Start the search with the [ F6 ] key.

Only work steps which fulfill all entered F6
search criteria will be displayed. K105

The search result will be displayed. In the lower part DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
of the screen mask (1) you see the first 4 entered DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
search criteria.

DDDD : DDD DDDD 1
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-849-1
An arrow (1) will be displayed, if more than 4 search DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
criteria have been entered. Only the first 4 search DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
criteria will be displayed.
Delete the contents of the search mask with
the key [ F10 ], if you no longer need the sor-
ted search criteria.
As long as the search mask contains inputs,
only those jobs will be displayed which fulfill
these search criteria.
DDDD DDDD : 123 DDDD : DDDD

DDDD :P DDDD : 02.03.04 1
F1 F2 F3 F4 F6 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1034-1
Viewing work step

Select the work step from the list.
Activate the View function using the [ F4 ] key.

F4
K103
The job data will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
DDDDD DDDDDD
DDDDD : DDD
DDDDD : DDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
DDDDD : DD DDDD
DDDD : DD DDDD DDDDDDD :

DDDD : D D DDD DDDDDDD : D DD
DDDDD : DDDD DD
DDD DDD : DDD DD
DDD DDDD : DDD DD DDD :
DDDD :
F4
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-844-1

Exit the View function using the [ F4 ] key.

The mark on the key disappears. F4
The display changes over to the list of work steps. K103
Copying the work step and storing it under a new job number
Select a stored work step from the list.
Activate the Copy function using the [ F3 ] key.

F3
K102
Overwrite the indicated job number (1). DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
STORE: max. 20 Characters DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Enter the job designation Product (2). DDDDD DDDDDD DD DD
Product: max. 16 Characters DDDDD : DDD
1
DDDDD : DDD
2
In the line Machine you need not make any DDDDD : DD DDDD
modifications, if you want to create a new DDDD : DD DDDD DDDDDDD :

work step for your own machine. DDDDD : DDDD DD
DDD DDD : DDD DD
DDDD :
F3
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-851-1

The work step will be copied and stored under the
new job number. K99-1
The display changes over to the function F1: Pro-

cess.
Change or complete the other data (see Complet- DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
ing work step data). DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
DDDDD DDDDDD
DDDDD : DDD
DDDDD : DDD
DDDDD : DD DDDD

DDDDD : DDDD DD
DDD DDD : DDD DD

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
DDDD :
F1
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-853-1
Deleting a work step

Delete a work step only if you really do not need it any
more. Deleted job data is irretrievably lost.


The data of the selected work step will be displayed. F7
K106
Confirm the deletion using the [ F5 ] key. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
The work step will be deleted. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
The display changes over to the list of work steps. DDDDD DDDDDD
DDDDD : DDD
DDDDD : DDD
DDDDD : DD DDDD

DDDDD : DDDD DD
DDD DDD : DDD DD
DDDD :
F4 F5 F7
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-852-1
Deleting CCI-protocols
Deleting CCI-protocols that are no longer required to
have more space in the data storage.
Select a work step from the list. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Activate the Delete protocols function using the
[ F8 ] key.
DDDD
F4 F5 F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1020-1
Press the [ F5 ] key, Confirm.

The stored CCI-protocols will be deleted. F5
K104
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Processing job papers

Notes, information on the current work step, e.g. for
colleagues of the next shift.
Preliminary tasks
Select a work step from the list and activate the
function Process with the key [ F1 ]. F1
K41

Procedure
Activate the Job papers function using the [ F8 ]
key. F8
K107
Enter any information you like on the current work DD DDDDDD

D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
step in the input area (1). DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Job Papers: Alphanumeric characters
DD D DDD DDD DDDDDDDDD
DDDDDDDDDD
DDDDDDDD DDDD DDD
DDD DDD DDDDD
F1 F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-855-1
Editing the text input

With the key [ F9 ], select Overwrite or Insert.
The text on the screen key changes each time you F9
press the key. K108
Marking the text block

Mark the text blocks that you want to delete, copy or
print.
Position the insertion mark with the [ Cursor keys ]
under the first letter of the text blocks.
The text on the [ F6 ] key changes to Delete mark- F6
ing. K105
Position the insertion mark with the [ Cursor keys ]

under the last letter of the text blocks.
Press the [ Enter ] key.
The text block is marked.
K99-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Processing the marked text block

Move the insertion mark with the [ Cursor keys ] to
the position where you want to insert a text block.

The marked text block will be inserted. F7
K106
Print the marked text block with the key [ F10 ].

The text of the screen button F10 changes to Print F10
text. K109

Delete the marked text block with the key [ F6 ].

The text on the [ F6 ] key changes to Mark block. F6
K105
Once again press the key [ F8 ] to terminate the

function Job papers. F8
K107
Interrupting or terminating the preparation of a work step

Procedure
K85-1
K86
Interrupting the preparation

Interrupt the preparation of the work step using the DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
[ F4 ] key. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Status JP I: The preparation of a work step has been DDD DD DDDDD DDDD DD D DDDDDD DD DDD
interrupted and is to be continued at a later date. DDDDD DDDDDD
DDDDD : DDD
DDDDD : DDD
DDDDD : DD DDDD

DDDDD : DDDD DD
DDD DDD : DDD DD

DDDD :
F4 F5
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-979-1
Terminating the preparation

Exit the preparation of the work step using the [ F5 ] DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
key. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Status JP T: Preparation is terminated. The work step DDD DD DDDDD DDDD DD D DDDDDD DD DDD
has been released for printing. DDDDD DDDDDD
DDDDD : DDD
The display changes over to the list of work steps. DDDDD : DDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
DDDDD : DD DDDD
The work step will be stored in the data base. DDDD : DD DDDD DDDDDDD :
DDDDD : DDDD DD
DDD DDD : DDD DD

DDDD :
F4 F5
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-979-1

11.4.2 Main menu Printing module (preselection)

1 Entering the color designation of the printing DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
plate DDDDDDD DD D DD DDDD DDDD DDDD DDDD
2 Selecting printing and coating modules (op-
tion) DDDDDD 1 2 3 4 L
DDDDDDD 1
3 Preselecting inking units
B C M Y /
DDDDDD 2
4 Switching on the ink fountain roller
+ + + + +
DDDDDD 3 + + + +
5 Preselecting the dampening rollers DDDDDD

4
DDDDDD 5 + + + +
6 Activating the permanent damping DDDDDDDD

6
7 Preselecting the coating application (option
coating module) DDDDDDDDDD + 7
8 Reversing device (option): preselecting DDDDDDD 8
printing sequence
F1 F2 F4 F7 F10
F1 Changing sheet data F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
F2 Function Feeder / Delivery B-157-1
F4 Presetting Damp / Ink

F10 Interchanging the color sequence
machine configuration)
Determining the color sequence

Procedure
K85-1
Call the main menu [ Printing module ] (preselection).
K932
Entering the color designation of the printing plate

By entering the plate name, you assign the surface
area data measured with the plate scanner or
PREPRESS LINK to a printing module. The plate name
consists of a letter for the color, e.g. B and, if required,
an additional identification number, e.g. 2.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Select the plate name (1) with the key [ + ]. DD DDDDDD

D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
Printing plate names B, B2, B3..B6: Black DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Printing plate names C, C2, C3..C6: Cyan
Printing plate names M, M2, M3..M6: Magenta DDDDDD 1 2 3 4 L
Printing plate names Y, Y2, Y3..Y6: Yellow DDDDDDD B C M Y /

1
Printing plate names S, S2, S3..S6: Special color DDDDDD + + + + +
DDDDDD + + + +
In case of identical color designations, enter an ad- DDDDDD
DDDDDD + + + +
ditional number by pressing the key [ Cursor: Right ] DDDDDDDD
once and by selecting a consecutive number with

the key [ + ].
DDDDDDDD +
Use the same plate names that are stored on

the JOBCARD for each printing module.
If the names differ, the system cannot assign F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
the EPS-printing plate names and transfers B-873-1

wrong data or no data at all for the selected
printing module.
Deleting the assignment of the colors

Move the cursor to the desired printing module (1). DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
Press the [ CLR ] button.
The color assignation will be deleted. DDDDDD 1 2 3 4 L
In the main menu Damp / Ink the ink slide profile of DDDDDDD B C M Y /
1
the corresponding printing module will be displayed DDDDDD + + + + +
DDDDDD + + + +
in gray. DDDDDD
DDDDDD
After pressing the [ F5 ] key, Working position, in
+ + + +
DDDDDDDD
main menu Damp. / Ink the ink slides of the printing

module will be closed.
DDDDDDDD +
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-873-1

The color assignment is terminated.
K99-1
Selecting printing and coating modules (option)

Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K85-1
K932

The main menu Printing module (preselection) will DD DDDDDD

D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
be displayed. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
1 Selecting printing and coating modules (op-
tion) DDDDDD 1 2 3 4 L
2 Preselecting inking units DDDDDDD B C M Y /
3 Switching on the ink fountain roller DDDDDD + + + + +

1
DDDDDD 2 + + + +
4 Preselecting the dampening rollers DDDDDD

3
DDDDDD 4 + + + +
5 Activating the permanent damping DDDDDDDD
5
coating module)
(Deviations are possible according to the ma- DDDDDDDD +
6
chine configurations)
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-867-1
Selecting printing and coating modules (option)

Activate the printing and coating modules (1) in- DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
volved in the printing using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Impression ON +: When you start production, the im-
pression will be thrown on in the selected printing and DDDDDD 1 2 3 4 L
coating modules. DDDDDDD B C M Y /
In the selected printing and coating modules, the DDDDDD + + + + +

1
DDDDDD 2 + + + +
other settings will automatically be set to [ + ]. DDDDDD
3
The settings Ink, Ink fountain roller On and DDDDDD 4 + + + +
DDDDDDDD
5
Dampening On will automatically be set to [ w ] in
the printing modules that have not been selected.
DDDDDDDD +
6
For better sheet guiding, you can set Im-
pression ON to [ + ] in a printing or coating
module that is not printing. F1 F2 F3 F4 F5 F6 F7
F7
F8 F9
F10
F10
B-867-1
Preselecting inking units

Activate the inking units (2) involved in the printing DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Ink ON +: When you start production, the ink form
rollers and the ink ductor roller will be thrown on in the DDDDDD 1 2 3 4 L
selected printing modules. DDDDDDD B C M Y /
DDDDDD + + + + +
1
DDDDDD 2 + + + +
DDDDDD
3
DDDDDD 4 + + + +
DDDDDDDD
5
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
DDDDDDDD +
6
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-867-1


Activate the ink fountain roller (3) in the desired DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
printing modules using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Ink fountain roller ON +: The ink fountain roller will turn
in the selected printing modules. DDDDDD 1 2 3 4 L
Ink fountain roller ON w: The ink fountain roller is not DDDDDDD B C M Y /
turning. DDDDDD + + + + +
1
When the ink fountain roller is switched on, DDDDDD 2 + + + +
DDDDDD
3
it keeps turning even during interruptions of DDDDDD 4 + + + +
DDDDDDDD 5
production.

DDDDDDDD +
6
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-867-1
Preselecting the dampening rollers

Activate the dampening units (4) involved in the DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
printing using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Dampening on +: When production starts, the water
form roller will be thrown on in the selected printing DDDDDD 1 2 3 4 L
modules. DDDDDDD B C M Y /
The water fountain roller keeps turning even DDDDDD + + + + +

1
during interruptions of production. DDDDDD 2 + + + +
DDDDDD
3
DDDDDD 4 + + + +
DDDDDDDD
5
DDDDDDDD +
6
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-867-1
Activating the permanent damping

Activate the permanent damping (5) in the desired DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
printing modules using the [ + ] button DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Permanent dampening +: The water fountain roller
remains switched on despite "Impression OFF". The DDDDDD 1 2 3 4 L
printing plate will be dampened as long as the machine DDDDDDD B C M Y /
keeps turning at base speed.

DDDDDD + + + + +
1
You can activate the Permanent damping DDDDDD 2 + + + +
DDDDDD 3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

only if Dampening On is activated. DDDDDD 4 + + + +
DDDDDDDD
5
DDDDDDDD +
6
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-867-1

Preselecting the coating application (option coating module)

Activate or deactivate the coating application (6) DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Coating application +: The screen roller will be thrown
on against the forme cylinder when production starts. DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
DDDDDD + + + + +
1
DDDDDD 2 + + + +
DDDDDD
3
DDDDDD 4 + + + +
DDDDDDDD
5
DDDDDDDD +
6
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-867-1
Reversing device (option): preselecting printing sequence

Set the printing sequence in the Reversing device DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
line (1) using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
DDDDDD + + + + +
DDDDDD + + + +
DDDDDD
DDDDDD + + + +
DDDDDDDD
DDDDDDDDDD +
DDDDDDD 1
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1043-1
Each time the button is pressed, one of the possible

printing sequences, e.g. bottom (1) through to 1st 1 2 3
reversing device, then bottom (2) again through to
2nd reversing device, followed by top (3), is
displayed. The position of the reversing device is
4
marked by a vertical line (4).
B-162-1

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The machine data is stored.

K99-1
Changing sheet data

Procedure
K85-1

K932
Activate the Printing material function using the

[ F1 ] key.
The function Printing material will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
1 Changing sheet data DDDDDD
DDDDDDD DD D DD DDDD DDDD DDDD DDDD
2 Changing the cover guide height
DDDDDDDDDDDD : DDD D 1
(Deviations are possible according to the ma- DDDDDDDDDDDD : DDD D
chine configuration) DDDDDDDDDDDD : DDD D
2
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-868-1
Changing sheet data

Enter the sheet data (1) using the [ + ] or [ w ] button DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
or using the [ digit keys ]. DDDDDD
The sheet width also serves as a reference
value for the dry sprayer. DDDDDDDDDDDD : DDD D
DDDDDDDDDDDD : DDD D
2
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-868-1
Changing the cover guide height

The cover guide height depends on the sheet thick-
ness.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Change the cover guide height (2) for the current DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
work step using the [ + ] or [ w ] button. DDDDDD
Cover guide height: 0.1 to 3 mm (0.004 to 0.118 in),
Step width: 0.01 mm (0 in) DDDDDDDDDDDD : DDD D 1
DDDDDDDDDDDD : DDD D
The cover guide height must not be lower DDDDDDDDDDDD : DDD D
2
than the sheet thickness.
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-868-1
K99-1
Presetting Feeder / Feed register

Procedure
K85-1
K932
Activate the Feeder / Delivery function using the

[ F2 ] key. F2
K101
The function Feeder / Delivery will be displayed. DD DDDDDD

D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
1 Selecting the pile height detector DDDDDD
2 Selecting the front edge detectors
DDDDD DDDDD
3 Selecting the side guide DDDD DDD DDDDD
DDDDD DDDDD DDDDD 1 DDDDDDDD 0.50 6
4 Activating or deactivating the side edge con-
trol
5 Select the side guide (pulling or pushing), op- DDDD
tion DDDDDDD DDD 2
DDDDDDD 3 B
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
6 Settings at the delivery unit DDDDDDDDD +

4
F2 Function Feeder / Delivery
(Deviations are possible according to the ma- DDDDDDDDDDDD 5 DDDDD
chine configuration)
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-148-1

Selecting the pile height detector

Select the pile height detector (1) using the [ + ] DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
button. DDDDDD
Pile height detector Pressure foot: The pressure foot in
the suction head scans the rear pile edge. DDDDD DDDDD
Pile height detector Front edge: The front edge detect- DDDD DDD DDDDD
DDDDD DDDDD DDDDD 1 DDDDDDDD 0.50
or in the sheet flap of the feeder scans the pile front
edge.
DDDD
DDDDDDD DDD 2
DDDDDDD 3 B
DDDDDDDDD +
4
DDDDD DDDDD DDDDD

5
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-111-1
Selecting the front edge detectors

The front edge detectors check the correct position of
the sheet at the feed register.
Select the active front edge detectors according to DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
the sheet width (2) using the [ + ] button. DDDDDD
Front edge detector Small: The inner front edge de-
tectors will be activated. DDDDD DDDDD
Small (size 3B): max. 670 mm (max. 26.378 in) DDDD DDD DDDDD
Front edge detector Large: The outer front edge de-

tectors are activated.
Large (size 3B): min. 671 mm (min. 26.417 in) DDDD
DDDDDDD DDD 2
DDDDDDD 3 B
DDDDDDDDD +
4
DDDDD DDDDD DDDDD

5
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-111-1
Selecting the side guide

Pull-type guide for the sheet transport.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Select the active side guide (3) with the key [ + ]. DD DDDDDD
D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
Side edge A: The sheet will be pulled on the A-side. DDDDDD
Side edge B: The sheet will be pulled on the B-side.
DDDDD DDDDD
DDDD DDD DDDDD
DDDD
DDDDDDD DDD 2
DDDDDDD 3 B
DDDDDDDDD +
4
DDDDD DDDDD DDDDD

5
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-111-1
Activating or deactivating the side edge control

The side edge control checks whether the sheets are
pulled correctly against the side guide stop. If the
optical detector does not detect a sheet, a signal will
sound.
Activate or deactivate the side edge control (4) with DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
the key [ + ]. DDDDDD
- if side edge control detector reacts (feed register) +:
The optical side edge control is activated. DDDDD DDDDD
DDDD DDD DDDDD
Always switch on the side edge control. DDDDD DDDDD DDDDD 1 DDDDDDDD 0.50
Switch off the side edge control only if -

again and again - there are false alarms DDDD
DDDDDDD DDD 2
because the detector does not detect e.g. DDDDDDD 3 B
DDDDDDDDD +
4
transparent foils or black printing materials.
As long as the side edge control is switched
DDDDD DDDDD DDDDD
5
off, you must pay utmost attention to a cor-
rect sheet guiding since the guiding is not
automatically controlled. F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-111-1
Select the side guide (pulling or pushing), option

Selecting the type of motion of the side guide
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Select the setting(5) using the [ + ] button. DD DDDDDD

D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
Side guide Pulling: The active side guide pulls the DDDDDD
sheet.
Side guide Pushing: The sheet will be pushed to the DDDDD DDDDD
active side guide. DDDD DDD DDDDD
DDDD
DDDDDDD DDD 2
DDDDDDD 3 B
DDDDDDDDD +
4
DDDDD DDDDD DDDDD

5
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-111-1
K99-1
Presetting the delivery unit

Procedure
K85-1
K932

[ F2 ] key. F2
K101
Setting the pile stroke

Duration for the automatic lowering of the pile after the
reaction of the detector.
Set the pile stroke (1) using the [ + ] or [ w ] button. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Pile lowering/raising: 0.5 to 2 s, Step width: 0.01 s DDDDDD
DDDDD DDDDD
DDDD DDD DDDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
DDDDD DDDDD DDDDD DDDDDDDD 1 0.50
DDDD
DDDDDDD DDD
DDDDDDD B
DDDDDDDDD +
DDDDD DDDDD DDDDD
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-092-1

K99-1
Presetting Damp / Ink

Procedure
K85-1
K932
Activate the Damp / Ink function using the [ F4 ]

key. F4
K103
The function Damp / Ink will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 Setting the integrated damping DDDDDD
2 Removing hickeys (Delta effect) automatically
1 2 3 4 L
3 Selecting symmetric ink flow (QuickChange
option) DDDDDDD - - - - - 1
4 Switching to front-heavy ink flow (option) DDDDDD 2 - - - - +
3 Setting the commencement of the distribution DDDDDDDD - - + - -

3
F4 Presetting Damp / Ink DDDDDDDD 4 + + - - -
(Deviations are possible according to the ma- DDDDDDD 0 0 0 0 0

5
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1112-1
Setting the integrated damping

Optimizing the ink / dampening solution-balance for
different printing images.
Activate the integrated dampening (1) in the de- DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
sired printing modules using the [ + ] button DDDDDD
Integrated dampening +: When production starts, the
transition roller will be thrown on against the first ink 1 2 3 4 L
form roller.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
DDDDDDD - - - - - 1
DDDDDD 2 - - - - +
DDDDDDDD - - + - -
3
DDDDDDDD 4 + + - - -
DDDDDDD 0 0 0 0 0
5
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1112-1

Removing hickeys (Delta effect) automatically

Activating the Delta effect when printing solids or critic-
al types of printing material.
Attention!: DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Danger of damage to the water form roller DDDDDD
which is neither moistened nor inked-up
while the Delta effect is activated. 1 2 3 4 L
Activate the Delta effect only when the DDDDDDD - - - - - 1

water form roller is inked up and DDDDDD 2 - - - - +
moistened. DDDDDDDD - - + - -
3
Activate the Delta effect (2) in the desired printing

modules using the [ + ] button. DDDDDDD 0 0 0 0 0
5
Delta effect +: The water form roller turns slower than
the plate cylinder whereby the hickeys will be removed
from the image to be printed.
Change the water form roller in good time. F1
F1
F2
F2
F3 F4
F4
F5 F6
F6
F7 F8 F9 F10
The roller surface wears out quicker owing to B-1112-1

the different speed of water form roller and
plate cylinder.
Selecting symmetric ink flow (QuickChange option)

A symmetric ink flow is achieved in the inking unit
through mechanical throwing off of transfer roller 92.
This setting must be entered on the central control
console so that the control software can align the
automatic start/stop sequence to this flow.
Enter the printing modules in which you have mech- DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
anically thrown off transfer roller 92 in the line Sym- DDDDDD
metric ink flow (3) using the [ + ] button.
1 2 3 4 L
Ink flow w: Standard: Both transfer rollers are thrown
on. DDDDDDD
Ink flow +: Symmetric: Transfer roller 92 was mechan-
- - - - - 1
DDDDDD 2 - - - - +
ically thrown off from the inking unit.
DDDDDDDD - - + - -
3
DDDDDDD 0 0 0 0 0
5
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
B-1112-1

Symmetric ink flow: Transfer roller 92 was thrown

off mechanically. The ink flow in the inking unit is 513
guided to the ink form rollers 452 and 453 via ink 91
vibrator roller 91 and intermediate roller 83. 512 92
83
454 453
452 511
451
11.5
11.4
402
06-06014-1
Switching to front-heavy ink flow (option)

Change over the ink flow (4) in the desired printing DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
modules with the key [ w ]. DDDDDD
on. 1 2 3 4 L
Ink flow +: Front-heavy: Ink flow on the ink form rollers

451 and 452 (option) DDDDDDD - - - - - 1
DDDDDD 2 - - - - +
DDDDDDDD - - + - -
3
DDDDDDD 0 0 0 0 0
5
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1112-1
Standard ink flow: Transfer rollers 91 and 92 are

thrown on. The ink flow in the inking unit is guided 513
to ink vibrator roller 511 and to intermediate roller 83 91
and from there to the ink form rollers 451, 452 and 512 92
453 83
454 453
452 511
451
11.5
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
11.4
402
06-06015-1

Ink flow predominantly on the ink form rollers 451

and 452: Transfer roller 91 will be thrown off from 513
intermediate roller 83. Transfer roller 92 remains 91
thrown on. The ink flow in the inking unit is guided 512 92
to ink vibrator roller 511 and from there to the ink 83
form rollers 451and 452. 454 453
452 511
451
11.5
11.4
402
06-06013-1
Setting the commencement of the distribution

Equalizing a gradual fading in circumferential direction
by changing the positioning angle of the machine.
Set the commencement of the distribution (5) using DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
the [ + ] or [ w ] button. DDDDDD
Distr. commen.: 0 to 360 , Step width: 30
in steps of 30 1 2 3 4 L
With a distribution commencement of 0, the DDDDDDD - - - - - 1

distribution will start at the printing leading DDDDDD 2 - - - - +
edge. DDDDDDDD - - + - -
3
DDDDDDD 0 0 0 0 0
5
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1112-1

The entered values will be stored.
K99-1
Interchanging the color sequence

Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K85-1
K932
Activate the Change plate function using the [ F10 ]

key.

Using the [ + ] button, select the printing module (1) DD DDDDDD

D DD
DD DD
DDD D
0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
for which you want to change the ink assignment DDDDDD
(e.g. printing module 2, color: cyan). DDDD DDDDD DD DDDD DDDDDDD
1 2
DDDDDD D D D D D
Confirm with the key [ Enter ]. DDDDDDD D D D D D
Using the [ + ] button, select the second printing DDD DD D D D D D
module (2) (e.g. printing module 3, color: magenta). DDD DD D D D D D
DDDDDDD DD D D D D D
DDDDDD DD D D D D D
Confirm with the key [ Enter ]. DDDDDDDDDDDD D D D D D
All stored, color-related data will be interchanged.
DDD DDDD DDDD DDDD

DDDD DDDD
F1 F2 F3
DDDD
F4 F5 F6 F7 F8 F9
F10
F10
B-100-1
11.4.3 Main menu Sheet guide

1 Setting the individual ventilator tracks DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
2 Setting all ventilator tracks DDD / DDD
F4 Blower function Presettings
F7 Delivery: presetting blower
F9 Printing module / coating module: preset-
ting blower
0 0 0 0 0
F10 Feeder / feed register: presetting blower 0 0 0 0
1
(Deviations are possible according to the 0
0
0 0 0
machine configuration) DDD DDDDDD DDDD : 2
F1 F2 F4 F6 F7 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1117-1
Presetting all ventilator tracks

The settings in this screen apply to all ventilator tracks.
Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K85-1
Call the main menu [ Sheet guiding device ].
K76
Setting ventilator tracks

For a better overview, the ventilator tracks have been
marked in color.

Change the values for individual (1) or for all ventilat- DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
or tracks (2) using the [ + ] or [ w ] button. DDD / DDD
Quantity of air: 1 to -100 Suction rail
Quantity of air: 1 to 100 Blast air
Air: Off:: 0
The ventilator tracks in the delivery unit are only
switched on when the machine is rotating. 0 0 0 0 0
0 0 0 0
When the reverse side of the sheet is freshly 0 0 0 0

1
printed, set the blast air to as low value. 0
DDD DDDDDD DDDD : 2
F1 F2 F4 F6 F7 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1117-1
K99-1
Blower function Presettings

Procedure
K85-1
K76
Activate the Blower function using the [ F4 ] key.

F4
K103
The Blower function is displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 Setting the blower, according to the machine DDD / DDD
configuration.
F4 Blower function
50 50 50 50 50
- - - - -
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
0 0 0 0 0
DDD DDDDDD DDDD :
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1135-1
K993

Set the quantity of air for individual or all impres-

sion cylinder blowing devices using the [ + ] or
[ w ] button. K993
Quantity of air: 1 to 100

Air: Off:: 0
For rigid printing materials, first set the blast
air to the maximum to prevent the sheet from
striking against the impression cylinder blow-
ing device.
Activate or deactivate all impression cylinder

blowing devices using the [ + ] button.
The individual setting of the impression cylin- K993
der blowing devices in the individual printing

modules is overwritten.
Blower: Options
Activate or deactivate the suction rail for light-
weight paper printing (option) using the [ + ] but-
ton. K1011
The suction rail straightens the sheet in the

sheet ascent ramp, thus, improving the guid-
ing of the sheet.
Set the air quantity for the suction rail for light-
weight paper printing using the [ + ] or [ w ] button.
Air: Off:: 0
Activate or deactivate the blast air upstream of the

reversing device (option: reversing device) using
the [ + ] button. K1006
Set the air quantity for the blast air upstream of

the reversing device using the [ + ] or [ w ] button.
Air: Off:: 0
Activate or deactivate the suction air upstream

of the reversing device (option: reversing device)
using the [ + ] button. K1007
Set the air quantity for the suction air upstream of

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Air: Off:: 0
K99-1

Delivery: presetting blower

Procedure
K85-1
K76
Activate the Delivery function using the [ F7 ] key.

The number of ventilator tracks and the con- F7
tent of the screens vary according to the ma- K106
chine configuration.

marked in color.
Change the values of the individual ventilator tracks DD DDDDDD
D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
(1) using the [ + ] or [ w ] button. DDD / DDD
Air: Off:: 0
The ventilator tracks are only switched on when the DDDDDDD 01 0
machine is rotating. DDDDDDD 02 0
DDDDDDD 03 1 0
When the reverse side of the sheet is freshly DDDDDDD 04 0
printed, set the blast air to as low value.
F1 F2 F4 F6 F7
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1128-1
Move between screens using the [ F1 ] or [ F2 ] but-

ton. F1
K41
The Delivery function is displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 Position of blower (arrow) DDD / DDD
2 Setting the blower, according to the machine
configuration. 1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1, F2 Changing between the Delivery, Printing

Module / Coating Module and Feeder DDDD DDDD
screens.
-
- DDDD DDDD
F7 Delivery function - DDDDDDD 0
DDD DDDDDD D DDDD 1000
F1 F2 F4 F6 F7
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1127-1

Activate or deactivate the sheet decurler using the

[ + ] button.
Switch off the sheet decurler when you print K992
sheets with a printed rear side.
Activate or deactivate the blast tubes in the blast

frame using the [ + ] button.
Set the air quantity for the blast tubes in the blast K994
frame using the [ + ] or [ w ] button.

Air: Off:: 0
Setting ventilators in the blast frame

Using the [ + ] [ w ] button, set the machine speed DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
from which the ventilators in the blast frame (1) are DDD / DDD
to be switched on.
Speed: 1 000 to 10 000 Sh/h
The ventilators will be switched on as soon as the
printing machine has reached the set speed.
-
DDDD DDDD
- DDDD DDDD
- DDDDDDD 0
1 DDD DDDDDD D DDDD 1000
F1 F2 F4 F6 F7
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1126-1
Activate or deactivate the suction air to the suc-

tion roller (option) using the [ + ] button.
Quantity of air: 1 to 100 K995
Air: Off:: 0
Delivery blower: Options

Swing down the PP sheet decurler (reversing
device option) using the [ + ] button.
Settings S/W: The sheet decurler is swung off, the air is K992
switched off.
Settings On: The sheet decurler is swung on, the air is
switched on.
Settings Off: The sheet decurler is swung on, the air is
switched off.
During make-ready of a perfecting job, the sheet de-
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
curler will be switched off and swung off.
Activate or deactivate all auxiliary blast nozzles

(option) using the [ + ] button.
K1002
Activate or deactivate the sheet distributor (non-

stop option) using the [ + ] button.
K1003

Activate or deactivate the suction plates (option)

using the [ + ] button.
The function is used to stretch printed sheets K1004
which have a tendency to roll in the sheet

ascent ramp.
Deactivate the suction plates when printing
K99-1
Printing module / coating module: presetting blower

Procedure
K85-1
K76
Activate the Printing module / Coating module

function using the [ F9 ] key. F4
K103
The Printing module / Coating module function is DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
displayed. DDD / DDD
1 Position of blower (arrow)
configuration.
1
3 Setting the air for the ventilator tracks - DDDDD DDDDDD 0 DDDDDDD 01 0
DDDDDDD 02 0
Module / Coating Module and Feeder
screens.
F9 Printing module / Coating module function 2 3
The values set here are exceeded if the set-

ting for all blowers and ventilator tracks is
overwritten. F1 F2 F4 F6 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1129-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Activate or deactivate the impression cylinder

blowing device using the [ + ] button.
Set the nominal value using the [ + ] or [ w ] button. K993

Air: Off:: 0
ing device.

Change the values of the ventilator tracks using the

[ + ] or [ w ] button.
Air: Off:: 0
When the reverse side of the sheet is freshly
K99-1
Feeder / feed register: presetting blower

Procedure
K85-1
K76
Activate the Feeder / Feed register function using

the [ F10 ] key. F10
K109
The Feeder / Feed register function is displayed. DD DDDDDD

D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
configuration.
F1, F2 Changing between the Delivery, Printing 1
Module / Coating Module and Feeder/ Feed + DDDD DDDD
Register screens. + DDDDD DDDD
F10 Feeder / Feed register function + DDDDDDDDD
+ DDDDDDD
+ DDDDDD DDDDD 2
DDDDDDDD DD 0
DDD DDDDD 0
+ DDDDDD DDD
F1 F2 F4 F6 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1118-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

tion head using the [ + ] button.
K984
Activate or deactivate the blast air to the suction

head using the [ + ] button.
K985
Activate or deactivate the blast-suction rail using

the [ + ] button.
K987

Activate or deactivate the side guard and suction

rollers using the [ + ] button.
K988
Activate or deactivate the front suction zone using

the [ + ] button.
K991
Feeder blower: Options

Activate or deactivate the swing grippers and side
blower (option) using the [ + ] button.
K986
Set the air quantity for the side guide using the [ + ]
or [ w ] button.
Air: Off:: 0
You can also set the nominal value directly at
the controller on printing module 1.
Set the air quantity for the suction rollers (option)

using the [ + ] or [ w ] button.
Air: Off:: 0
Activate or deactivate the suction tapes blower

K1005

The air on the printing press is active only after the
function Pumps / blowers has been set to + (- see K99-1
main menu Machine).

06.09.2004 10:35:31 - 747 - 80 95A EN 6778

11.4.4 Main menu Damp. / Ink

1 Color data storage DD DDDDDD
D DD
DD DD 0
DD DDDD
0 DDD DDDD
2 Numbers of the printing modules DDD / DDD DD D DD DDDD DDDD DDDD DDD DD
DDDD DDDD
3 Bar diagram Ink ductor roller strip DDD 1
4 Ductor roller strip width 1
100
2 3
100
4
2
- 90 - - 90 -
5 Ink ductor roller cycle - 80 - - 80 -
- 70 - - 70 -
F1 Setting the ink slide profile - 60 - - 60 -
- 50 - - 50 -
F2 Changing the ink slide position according to 3 - 40 - - 40 -
the set percentage

- 30 - - 30 -
- 20 - - 20 -
F3 Setting the ink ductor roller strip

- 10 - - 10 -
- 0- - 0-
F4 Setting the ink ductor roller cycle 34 34 34 34 4

F5 Viewing read surface area data 1: 3 1: 3 1: 3
5 1: 3
F6 Starting the reading procedure F1 F2 F3 F4 F5 F6 F7 F10

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
F7 Presetting correcting values

B-876-1
F10 Changing the ink zone status
Reading surface area data

Conditions
JOBCARD with surface area data.
The plate names on the JOBCARD must be identical
with those entered in main menu Printing module.
If the plate names differ, the system will not transfer
any values.
Procedure
K85-1
K77
Insert the JOBCARD into the JOBCARD READER.

Insert the JOBCARD into the slot (1) of the JOBCARD
READER with the arrow pointing upwards .
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Both LEDs (3) on the ejection key (2) light up.

The JOBCARD will be ejected.
1
You have not inserted the JOBCARD correctly. 3
Check the direction of the arrow and insert the
JOBCARD once again into the JOBCARD READER.
2
LS-03036-1

Starting the reading procedure

Start the function Read area with the key [ F6 ]. DD DDDDDD
D DD
DD DD 0
DD DDDD
0 DDD DDDD
The surface areas will be read from the JOBCARD. DDD / DDD DD D DD DDDD DDDD DDDD DDD DD
DDDD DDDD
DDD
1 2 3 4
100 100
- 90 - - 90 -
- 80 - - 80 -
- 70 - - 70 -
- 60 - - 60 -
- 50 - - 50 -
- 40 - - 40 -
- 30 - - 30 -
- 20 - - 20 -
- 10 - - 10 -
- 0- - 0-
34 34 34 34
1: 3 1: 3 1: 3 1: 3
F6 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1003-1
Ejecting the JOBCARD.

Press the ejection key (2).
The red LED goes out.
Take theJOBCARD out of the inserting slot (1) of
JOBCARD READER.
1
3
LS-03036-1
Viewing read surface area data

Activate the Surface function using the [ F5 ] key. DD DDDDDD
D DD
DD DD 0
DD DDDD
0 DDD DDDD
The surface area data of printing module 1 stored in DDD / DDD DD D DD DDDD DDDD DDDD DDD DD
DDDD DDDD
the job will be displayed. DDDDD
DDDD 100
The left half of the screen displays the max. (1) and
DDD 1
the mean (2) surface areas. The value Zone (3) dis-
80
35.7
plays the surface area of the selected ink zone. 60
DDDD 2
If you have not yet read any surface area 10.6 40
data, no ink profile will be displayed.

DDDD 3
20
Change over to the view of the surface areas in the

1.8
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
other inking units with the [ Printing module keys ] or

DDDDD 1
the key [ Cursor: UP ] or [ Cursor: DOWN ].

5 10 15 20 25 30 35 40 45 50
F5 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-995-1
Presettings for calculating the ink slide positions

Preliminary tasks
Reading surface area data (see page 11-44)

Procedure
K85-1
K77
Activate the [ Presetting ] function using the [ F7 ]

key.
The Presetting function is displayed. DD DDDDDD

D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 Selected inking units DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
2 Preselecting procedures
DDDDDD 1 2 3 4 L
F7 Presetting function DDDDDDD B C M Y /

chine configuration) DDDDDD + + + + 1
DDDDDDD 2 100 100 100 100
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-985-1
Deselect the inking units (1) in which you do not

want to adopt the ink slide values to be calculated
using the [ w ] button.
Presetting the inking unit w: The new ink slide profile
will not be preset in this inking unit.
Presetting the inking unit +: The ink slide profile will be
preset in this inking unit.
Presetting correcting values

If you see that the calculated ink slide opening is gen-
erally too low or too high, you can enter a correcting
value.
Enter a correction value (2) for each inking unit using DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
the [ + ] or [ w ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Calculating the ink slide positions (correcting value): 10
to 400 % DDDDDD 1 2 3 4 L
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
A value of 100 indicates that the result of the calcula- DDDDDDD B C M Y /
tion will be accepted without correction.

DDDDDD 1
The correcting value depends, among other
+ + + +
DDDDDDD 2 100 100 100 100
things, on the ink and the printing material.
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-985-1

Settings for the LCS- control (option)

- see also the description in chapter Notes concern-
ing printing.
Activate the Presetting function using the [ F7 ] key.
For presetting the ink slides, choose the procedure DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
LCS, AUTO or EPS (1). DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Presetting the ink slides LCS: Each second ink zone is
printing. A max. ink ductor roller strip is set. DDDDDD 1 2 3 4 L
Presetting the ink slides Auto: The system will auto- DDDDDDD B C M Y /
matically set the appropriate procedure (EPS or LCS).

Presetting the ink slides EPS: The ink slide position is DDDDDD + + + +
automatically calculated with the aid of the EPS-char- DDDDD 1 Auto LCS LCS LCS
DDDDDDDD 100 100 100 100
acteristic curve and the ink ductor roller strip.
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1023-1

In the program level Production (PR), the
calculation of the ink slide positions will be K99-1
started from the surface areas read in.
K99-1
Preselecting the quantity of ink

Procedure
K85-1
K77
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Setting the ink ductor roller strip

Activate the Ink ductor roller strips function using DD DDDDDD
D DD
DD DD 0
DD DDDD
0 DDD DDDD
DDDD DDDD
1
100
2 3
100
4
1
- 90 - - 90 -
or: Left ]. - 80 - - 80 -
- 70 - - 70 -
Set the ink ductor roller strip (2) with the key [ + ] or
- 60 - - 60 -
- 50 - - 50 -
[ w ]. - 40 -
- 30 -
- 40 -
- 30 -
Ink ductor roller strip: 0 to 99 %, Step width: 1 % - 20 -
- 10 -
- 20 -
- 10 -

- 0- - 0-
2
34 34 34 34
The mark on the key disappears. 1: 3 1: 3 1: 3 1: 3
F3 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-999-1
Setting the ink ductor roller cycle

Activate the Ink ductor roller cycle function using DD DDDDDD
D DD
DD DD 0
DD DDDD
0 DDD DDDD
DDDD DDDD
1 2 3 4
100
- 90 -
100
- 90 -
1
or: Left ]. - 80 - - 80 -
- 70 - - 70 -
Set the ink ductor roller cycle (2) for each printing
- 60 - - 60 -
- 50 - - 50 -
module with the key [ + ] or [ w ]. - 40 -
- 30 -
- 40 -
- 30 -
Ink ductor roller cycle 1 : 0: The ink ductor roller is - 20 - - 20 -
locked.
- 10 - - 10 -
- 0- - 0-
Ink ductor roller cycle 1 : 3 2

1
Ink ductor roller cycle 1 : 6
34 34 34 34
1: 3 1: 3 1: 3 1: 3

Ink ductor roller cycle 1 : 18 F4 F7 F10
Number of cylinder revolutions after which the ink duct-
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
or roller is thrown on and off. B-881-1

The mark on the key disappears.
Changing the ink zone status at the central control console

Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K85-1
K77
Activate the Ink zones function using the [ F10 ]

key. F10
K109

Changing the ink zone status

Setting individual ink slides to ink-free or locking or
closing them before the start of production.
Select one or all printing modules (1) with the key DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
[ Cursor: DOWN ] or [ Cursor: UP ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Position the frame on the ink zone in which you
want to change the status. 1
For a fast change-over between the first and 3
last ink zone, press the key [ Cursor: Left ]

4
or the key [ Cursor: Right ], if the frame is

positioned on the last ink zone.
With the key [ w ] set the ink zone status to locked.
Ink zone status grey:: Locked: The current ink slide
1
DDDDD 3 5 10 15 20 25 30
position cannot be changed. The ink slide keys are

locked.
F1 F2 F3 F4 F5 F6 F7 F10
With the key [ 0 ] set the ink zone status to ink-free. F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
Ink zone status white display: Inkfree: The ink slides B-1006-1
are closed. The ink slide keys are locked.

With the key [ + / w ] of the [ block of numerical
keys ] set the ink zone status to manual control.
Ink zone status Gray, hatched: Manual (with option ink
control system): The ink slides will not be controlled
automatically.
With the key [ + ] set the ink zone status to printing.
Ink zone status green: Printing: normal status. A
manual or automatic change of the ink slide position is
possible.
zone status will be displayed in red.

In the ink slides profile, locked ink zones will be dis-
played as grey bars, manually controlled ink zones K99-1
as hatched bars.
Adjusting the ink slides

Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K85-1
K77
Comprising several ink zones in a block

Simultaneous changing of ink slide positions in neigh-
boring or all ink zones.

Activate the function F1: Parallel or F2: Percent. DD DDDDDD

D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
For changing the ink slide setting in several adjacent DDD / DDD
ink zones, position the frame to the beginning of
the block with the keys [ Cursor: Left ] or [ Cursor:
Right ].
Press the [ selection button ].
Pull the frame with the key [ Cursor: Right ] to the
end of the block.
The bar on the left side of the screen shows the D
mean ink slide position of the selected ink zones. DDDDD D D D D D D D D D D D D D
If you want to activate all ink zones, position
the frame on ink zone 1, press the [ Selection F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
key ] and then the key [ Cursor: Left ]. B-1002-1
The frame comprises all ink zones.
To cancel the ink zone block, press the key

[ CLEAR ]. CLR
K100-1
Setting the ink slide profile

Activate the Parallel function using the [ F1 ] key.
Select a printing module with the [ Printing mod-

ule keys ] or the keys [ Cursor: UP ] or [ Cursor:
DOWN ]. 11 10 9 8 7 6 5 4 3 2 1
LS-02577-2
Form an ink zone block. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
The bar on the left side of the screen shows the DDD / DDD
mean value of the selected ink zones.
D
DDDDD D D D D D D D D D D D D D
F1 F2 F3 F4 F5 F6 F7 F8 F10
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-898-1

Press the [ Enter ] key. DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
In the selected ink zones, the ink slide profile is set DDD / DDD
to a mean value.
D
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-981-1
Changing the ink slide position according to the set percentage

Activate the Percentage function using the [ F2 ]
key. F2
K101

DOWN ]. 11 10 9 8 7 6 5 4 3 2 1
LS-02577-2

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Change the ink slide position with the keys [ + ] or DDD / DDD
DDD DD DDDDD DDDD DD D
[ - ]. D
Changing the ink slide position (%): -25 to 25 %, Step
width: 1 %
The bar(1) shows the modification in %. 1
D
D
DD
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-997-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Mirroring the ink profile

For applications such as CITYLIGHT posters in which
the same motif is printed on the reverse side in mirror
image in the second printing cycle.
key. F2
K101

Activate the Reflect all function using the [ F9 ] key. DD DDDDDD

D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
The note line indicates the following: All inking DDD / DDD
units will be changed.
D
F1 F2 F3 F4 F5 F6 F7 F8
F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1110-1
Confirm the selection with the [ F8: Start ] button. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
The ink profile is mirrored in all inking units. DDD / DDD
Create one ink zone block for all ink zones and re-
duce the ink feed by the required percentage.
D
F1 F2 F3 F4 F5 F6 F7 F8
F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1111-1
Copying the ink slide profile

Activate the function F1: Parallel or F2: Percent.
Activate the Copy ink slides function using the

[ F8 ] key.
All ink zones are selected automatically.
Select the printing module (1) the ink slide profile of DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
which you would like to copy into another printing DDD / DDD
module with the [ Printing module keys ].
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Select the printing module into which you would

like to copy the ink slide profile with the [ Printing
module keys ].
1
DDDDD 4 5 10 15 20 25 30 35 40 45 50 55 60
F1 F2 F3 F4 F5 F6 F7 F8
F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1000-1

Program level Production 11

The ink slide profile has been copied.
K99-1
11.5 Program level Production

11.5.1 Main menu Job
F1 Completing work step data DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
F4 Viewing work step DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
F6 Searching work step
F9 Viewing job papers
F10 Viewing the remaining columns of the table DDDD DDDD D DDD DD DDD DDDDD DD D
DDDD DDDD D DDD DD DDDDD DD D
(Deviations are possible according to the DDDD DDDD D DDD DD DDDD DDDDD DD D
DDDD
F1 F4 F6 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-858-1
Processing the work step

Changing work step data, searching for work steps
Procedure
K58-1
K86

F1
K41
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

11 Program level Production
The function Process will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
1 Name of the customer DDDDDDD DD D DD DDDD DDDD DDDD DDDD
2 Printing date DDDDD DDDDDD
3 No. of sheets DDDDD : DDD
DDDDD : DDD
4 Sheet data DDDDD : DD DDDD
5 Notice DDDD : DD DDDD 1 DDDDDDD :

DDDD : D D DDD 2 DDDDDDD : D DD
6 Number of colors / Grammage / Date / Addi- DDDDD 3: DDDD DD
tional note DDD DDD : DDD DD 6
F1 Function "Processing the work step" DDD DDDD : DDD DD 4 DDD :

chine configuration) DDDD :
5
F1 F2 F4 F5 F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-874-1
Completing work step data

Enter the name of the customer (1). DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
Customer: max. 32 Characters DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Enter the printing date (2). DDDDD DDDDDD
Date: Calendar date DDDDD : DDD
DDDDD : DDD
Enter the number of sheets to be printed (3). DDDDD : DD DDDD
DDDD : DD DDDD 1 DDDDDDD :

No. of sheets: 1 to 9 999 999 Sh, Step width: 1 Sh DDDD : D D DDD 2 DDDDDDD : D DD
DDDDD 3: DDDD DD
Enter the sheet data (4). DDD DDD : DDD DD 6
The sheet width also serves as a reference DDD DDDD : DDD DD 4 DDD :
value for the dry sprayer (main menu Ag- DDDD :

gregates, function F4: Powder). 5
After changing the sheet thickness, you have to F1 F2 F4 F5 F8

readjust the double sheet control, the sheet hold- F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
downs and the sheet hold-downs at the side guide B-874-1
to avoid damage to the machine during the auto-

matic setting of the feeder.
Inputs concerning (5) and (6) are optional.
K99-1
Inserting job data

Copying and inserting data of another similar work
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
step.
Activate the Insert job function using the [ F2 ] key.
The display changes over to the list of work steps. F2
K101

Select from the list the work step (1) whose data DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
you want to insert into the new job. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
The data will be copied into the new work step.
Deactivate the function Insert job with the key [ F2 ], DDDD 1 DDDD D DDD DD DDD DDDDD DD D
if you have not found a suitable work step.
The display changes over to the current work step.

DDDD : DDD DDDD
F1 F2 F3 F4 F6 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-961-1
Managing work steps

Searching for and viewing work steps
Procedure
K58-1
K86
If required, interrupt or terminate the currently pro-

cessed work step.
The list of the work steps with the status JP term. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
and PR int.. will be displayed. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Status (search criteria) JP T: Search for all prepared
work steps. DDDD DDDDDD DDDD DDDD DDDD
Status (search criteria) PR I: Search for all interrupted
work steps. DDDD DDDD D DDD DD DDD DDDDD DD D
If the list of work steps is incomplete, the
search mask (1) still contains data of a pre-
vious search. If required, delete the data -
see Searching for work step.
DDDD DDDD DDDD DDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
DDDD DDDD
:
: DDD DDDD 1
:
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-854-1
Searching work step

The search mask will be displayed. F6
K105

Delete existing inputs with the key [ F10 ] Delete DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
search mask. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Enter the desired search criteria. DDDDD DD DDDDDD
STORE: max. 20 Characters
Product: max. 16 Characters DDDDD DD
Machine.: MAN Roland, Dummy ... DDDDD DD
DDDDD DD
Customer: max. 32 Characters
Date: Calendar date DDDDD DD
Date: Calendar date DDDDD DD DD
colors: max. 6 Characters DDDDD DD DD
Info: max. 6 Characters DDDDD DD
The term you search for need not be com- DDDDD DD
DDDDD DD
plete. The system will also search for char-
acter strings. Enter a * before or behind the
F6 F10
term you search (e.g. *eck or Beck*, if you F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
are searching for Becker). B-978-1
Select a processing status using the [ + ] or [ w ] but-

ton.
Status (search criteria) JP T: Search for all prepared
work steps.
Status (search criteria) PR I: Search for all interrupted
work steps.
K63-1
K99-1
Start the search with the [ F6 ] key.

Only work steps which fulfill all entered F6
search criteria will be displayed. K105
The search result will be displayed. In the lower part DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
of the screen mask (1) you see the first 4 entered DDDDDDD DD D DD DDDD DDDD DDDD DDDD
search criteria.

DDDD : DDD DDDD 1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-854-1

An arrow (1) will be displayed, if more than 4 search DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
criteria have been entered. Only the first 4 search DDDDDDD DD D DD DDDD DDDD DDDD DDDD
criteria will be displayed.
Delete the contents of the search mask with
the key [ F10 ], if you no longer need the sor-
ted search criteria.
As long as the search mask contains inputs,
only those jobs will be displayed which fulfill
these search criteria.
DDDD DDDD : 123 DDDD : DDDD

DDDD :P DDDD : 02.03.04 1
F1 F2 F3 F4 F6 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1035-1
Viewing work step

Activate the View function using the [ F4 ] key.

F4
K103
The job data will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
DDDDD DDDDDD
DDDDD : DDD
DDDDD : DDD
DDDDD : DD DDDD

DDDDD : DDDD DD
DDD DDD : DDD DD
DDDD :
F4
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-810-1
Exit the View function using the [ F4 ] key.

The display changes over to the list of work steps.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Processing job papers

Notes, information on the current work step, e.g. for
colleagues of the next shift.
Preliminary tasks
Select a work step from the list and activate the
function Process with the key[ F1 ] F1
K41

Procedure
Activate the Job papers function using the [ F8 ]
key. F8
K107
Enter any information you like on the current work DD DDDDDD

D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
step in the input area (1). DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Job Papers: Alphanumeric characters
DD D DDD DDD DDDDDDDDD
DDDDDDDDDD
DDDDDDDD DDDD DDD
DDD DDD DDDDD
F1 F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-857-1
Editing the text input

With the key [ F9 ], select Overwrite or Insert.
The text on the screen key changes each time you F9
press the key. K108
Marking the text block

Mark the text blocks that you want to delete, copy or
print.
Position the insertion mark under the first letter of
the text block using the [ cursor keys ].

The text on the [ F6 ] key changes to Delete mark- F6
ing. K105
Position the insertion mark under the last letter of

the text block using the [ cursor keys ].

The text block is marked.
K99-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Processing the marked text block

Move the insertion mark to the position where you
want to insert a text block using the [ cursor keys ].

The marked text block will be inserted. F7
K106
Print the marked text block with the key [ F10 ].

The text of the screen button F10 changes to Print F10
text. K109

Delete the marked text block with the key [ F6 ].

The text on the [ F6 ] key changes to Mark block. F6
K105
Exit the Job papers function using the [ F8 ] key.

F8
K107
Make-ready of a work step

Procedure
K58-1

The list of work steps will be displayed.
K86
Select the work step you wish to make ready.

F1
K41
Make the work step ready with the [ F7 ] key. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
The job data will automatically be transmitted to the DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
machine. DDDDD DDDDDD
The mark on the key F7: Make-ready disappears DDDDD : DDD
DDDDD : DDD
when the process is terminated. DDDDD : DD DDDD

DDDDD : DDDD DD
DDD DDD : DDD DD

DDDD :
F1 F7
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-977-1
Interrupting or terminating the production of a work step

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Procedure
K58-1
K86

Interrupting a work step

Interrupt the work step using the [ F4 ] key. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
Status PR I: The production of the work step has been DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
interrupted and can be continued at a later date. DDD DD DDDDD DDDD DD D DDDDDD DD DDD
DDDDD DDDDDD
DDDDD : DDD
DDDDD : DDD
DDDDD : DD DDDD

DDDDD : DDDD DD
DDD DDD : DDD DD

DDDD :
F4 F5
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-980-1
Terminating a work step

Exit the work step using the [ F5 ] key. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
Status PR T: The production of the work step is termin- DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
ated. DDD DD DDDDD DDDD DD D DDDDDD DD DDD
The display changes over to the list of work steps. DDDDD DDDDDD
DDDDD : DDD
The terminated work step is no longer available in DDDDD : DDD

DDDDD : DD DDDD
the work step list of program level Production (PR). DDDD : DD DDDD DDDDDDD :
DDDDD : DDDD DD
DDD DDD : DDD DD

DDDD :
F4 F5
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-980-1
To reactivate a terminated work step, change over

to the program level [ Job Preparation (JP) ].
K85-1

F1
K41
Press the [ F5 ] key, End.

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The work step is available again for further F5

processing in the work step list of program level K104
Production (PR).

11.5.2 Main menu Machine

1 SPEEDS DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
2 Sheet travel (pumps/blower) DDDDDDD DD D DD DDDD DDDD DDDD DDDD
3 Automatic functions (changing plates, wash-
ing ink rollers, washing blanket, washing im- DDDDDDDD DDDDDDDDDDDD DDDD
DDDDDD DDDDD
pression cylinder) DDDDDDDD DDD DDDDDDD
5 D
DDDDD 1 DDD DDDDD 3 DDDDDD
4 Display of the selected automatic functions DDDDDDDD
5 Indication Current DDDDDD DDD DDDDD
F1 Starting the automatic production. DDDDDDDD DDDDD DDDD
DDDDDDDD 2
F2 Start sheet travel DDDDD 4 6 4/4
F3 Starting the idle running
F4 Selecting the ink run-up
F5 Throwing on the impression F1 F2 F3 F4 F5 F6
F6 F7 F8
F8 F9 F10
F6 Throwing on the ink ductor roller
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
F7 Throwing the water form rollers on B-163-1
F8 Throwing on the ink form rollers

F10 Switching the sheet counter on and off
F10 Preselecting several automatic functions at
the same time (QUICKCHANGE option)
Presetting the machine run / sheet travel

Procedure
K58-1
K69
The following settings are available: DD DDDDDD

D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
1 Preselecting the production speed DDDDDDD DD D DD DDDD DDDD DDDD DDDD
2 Preselecting the starting speed
DDDDDDDD DDDDDDDDDDDD DDDD
3 Preselecting the idle running speed 1 DDDDDD DDDDD
4 Preselecting the pumps and blowers
DDDDDDDD 4000 DDDDDDD D
DDDDDDDD
DDDDDD DDDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
chine configuration) 3 2000

DDDDDDDD DDDDD
DDDDDDDD 4
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-891-2

Preselecting the production speed

Set the production speed (1) with the keys[ + ] or DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
The production speed depends on machine
1 DDDDDD DDDDD
You can also change the production speed DDDDDDDD 4000 DDDDDDD D
DDDDDDDD
using the [ Production speed + ] or [ Produc-
DDDDDD 3 2000 DDDDD
tion speed w ] button at PM 1 or the delivery
unit of the printing press. DDDDDDDD DDDDD
DDDDDDDD 4
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-891-2
Preselecting the starting speed

Set the starting speed (2) with the keys[ + ] or [ w ]. DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
Starting speed: 3 000 to 5 000 Sh/h, Step width: 100 DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD

1 DDDDDD DDDDD
DDDDDDDD
DDDDDD 3 2000 DDDDD
DDDDDDDD DDDDD
DDDDDDDD 4
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-891-2
Preselecting the idle running speed

Set the idle running speed (3) with the keys[ + ] or DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
The idle running speed depends on machine
1 DDDDDD DDDDD
DDDDDDDD
DDDDDD DDDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
3 2000
DDDDDDDD DDDDD
DDDDDDDD 4
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-891-2

Preselecting the pumps and blowers

Switch on the pumps and blowers (4) with the key DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
[ + ] or [ Air: ON ] at the central control console. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Pumps / blowers +: When production starts, the
pumps and blowers will be switched on automatically. DDDDDDDD DDDDDDDDDDDD DDDD
1 DDDDDD DDDDD
The LED is on. DDDDDDDD 4000 DDDDDDD D
The pumps and blowers cannot be switched DDDDDDDD
off during production. DDDDDD 3 2000 DDDDD
DDDDDDDD DDDDD
DDDDDDDD 4
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-891-2
At the end of production: Removing the ink from the printing plate (option)
At the end of production or in case of interruptions of
production: Removing the ink from the printing plate.
Enter the number of sheets to be used for remov- DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
ing the ink (1) at the end of production. DDDDDD
Removing ink: 0 to 50 Sh
The ink fountain roller will be switched off at the end DDDDDDD DDDDDDDDDDD DDDDD
DDDDDDDDDD - DDDDDDDD DDDDDDD
DDDDDDDDDD DD DDDDD DD
of production or after pressing the key F1: Auto-
-
DDDDDDDDD DD DDDDDDDDDD - DDDDD -
DDDDD - DD
matic production. DDDDDD
DDDDDDDDDDD 15 1
The preselected sheets will be transported through DDDDDDDDDD DD
the printing machine and remove the excessive ink DDDDDDD DDDDDD
DDDDDDDDDD
from the printing plate within the sheet size.
-
The ink will not be removed from areas that

are not within the sheet size.
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1053-1
K99-1
Starting the automatic production.

Prerequisite: The machine is turning at base speed.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Start the automatic production with the key [ Auto-

matic production ] or with the key [ F1 ].
K35-1
Start sheet travel

e.g. checking and optimizing the running properties
of a printing material before make-ready. Prerequisite:
The machine is turning at base speed.

Select the function Sheet travel with the key [ F2 ].

Only the sheet travel detectors are active F2
during sheet travel. All preset printing units, K101
inking units and dampening units are auto-

matically deactivated.
Start the sheet travel with the key [ Automatic pro-

duction ] or with the key [ F1 ].
During the sheet travel, all function keys are K35-1
deactivated except the function F1: Auto-

matic production.
The sheet travel (key [ F2 ]) can be deselec-
ted only when the machine is not turning.
Starting the idle running

e.g. switching the ink flow on or off in case of
overinked sheets after printing interruptions.
Prerequisite: The machine is turning at base speed.
Start the idle running with the key [ F3 ].
The machine is turning at the set idle running speed. F3
The ink flow in the inking unit is switched on. K102
The LED is on.

Water fountain roller and water metering roller will
automatically be set to w. K789
You can switch the ink flow on or off at the

key field while the machine is idling.
Quickstart (option)
QUICKSTART reduces the number of start-up waste
sheets.
Select the function QUICKSTART (1) with the key [ + ]. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Quick start +: Starting from the first sheet, QUICKSTART DDDDDDD DD 1 D DD DDDD DDDD DDDD DDDD DDDD
immediately accelerates the machine to production
speed. DDDDDDDDDDDD DDDD
DDDDDDDD 1 + DDDDDD DDDDD
The set starting speed (2) will automatically be de-
activated. DDDDD 2 3900 DDDDD DDDDDD
DDDDDDDD
If QUICKSTART is activated, the missing sheet DDDDDD 2000 DDDDD
detectors in each printing module must be DDDDDDDD DDDDD
activated - see main menu Printing module, DDDDDDDD
DDDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

chapter Setting the missing sheet detect-
ors.
If there are still sheets on the suction tapes
feed board when production starts and the F1 F2 F3 F4 F5 F6 F7 F8 F10
pick-up suckers are switched on, the printing F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
machine will start without QUICKSTART. B-1025-1
Throwing on the impression

Throwing on the impression when the machine does
not print, e.g. after changing the blanket or for setting
the bearer ring contact.

Throw on the impression in all selected printing

modules with the key [ F5 ]. F5
When a guard is open, you cannot throw on K104
the impression from the central control con-

sole.
Throwing on the ink ductor roller

Throwing on the ink ductor roller. Prerequisite: No
automatic production, no sheet travel
Throw on the ink ductor rollers in all printing mod-
ules with the key [ F6 ]. F6
The ink ductor roller transport ink to the inking unit in K105
all selected printing modules.
Throwing the water form rollers on

e.g. to remove the gumming from the plate or to check
whether the printing plate is running clean. Prerequis-
ite: The printing machine is turning at base speed.
Activate the dampening units with the key [ F7 ].
The plates will be moistened in all preselected F7
dampening units. K106
You need not throw on the water form rollers,

if the function Permanent damping, which
automatically controls the water form rollers,
is activated.
Throwing on the ink form rollers

Activate the inking units with the key [ F8 ]
The printing plates will be inked up in all preselected F8
inking units. K107
Switching the sheet counter on and off

This function is not available on the central control con-
sole if the [ F10 ] key includes the automatic functions
option.
Switch the sheet counter on the central control
000
console on or off with the key [ F10 ] or with the key
[ Sheet counter ]. K807-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

With the sheet counter switched on, the counting DD DDDDDD

D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
starts or is continued. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
The number of printed sheets is displayed in the info
field ACT in green. DDDDDDDD DDDDDDDDDDDD DDDD
DDDDDD DDDDD
A soon as the number of sheets to be printed is DDDDDDDD DDD DDDDDDD D
DDDDD DDD DDDDD DDDDDD
reached, the display ACT changes over to yellow. DDDDDDDD
the automatic production stops. DDDDDD DDD DDDDD
You can also switch the sheet counter on DDDDDDDD DDDDD
DDDDDDDD
and off at the delivery unit. DDDDD
DDDD DDDD DDDD DDD DDDD DDDD DDDD DDDD

DDDD DDDD DDDD DDDD DD
F1 F2 F3 F4 F5 F6
DD DD
F7
DD
F8 F9
F10
F10
B-896-1
Preselecting automatic functions

Preliminary tasks
Before starting the washing programs, check the
presettings in the Equipment main menu:
(see page 11-143)
(see page 11-139)
Preselecting the impression cylinder washing pro-
gram (option) (see page 11-149)
"STOP-secure" ].
Conditions
Depending on the machine configuration, the printing
modules for the automatic functions are preselected
in the Equipment main menu (standard) or in the Ma-
chine main menu described here (QUICKCHANGE op-
tion).
Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K58-1
K69
Starting the plate change

Preselect the plate change (1) with the key [ + ].
Changing the printing plate +: The function Plate
change is selected.

A diagram of the printing modules is shown (PPL DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
printing plate change). DDDDDDD DD D DD DDDD DDDD DDDD DDDD
DDDDD DDD DDDD DDDDDDDD
DDDDDD DDDDD
DDDDDDDD
DDDDDD DDD DDDDD
DDDDDDDD
DDDDD
1 2 3 4 5
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-892-1
A diagram of the printing modules is shown (APL DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
printing plate change (option)). DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
DDDDD DDD DDDD DDDDDDDD
DDDDDD DDDDD
DDDDDDDD
DDDDDD DDD DDDDD
DDDDDDDD
DDDDD
MAN MAN MAN MAN MAN MAN MAN MAN MAN
700 700 700 700 700 700 700 700 700
9 8 7 6 5 4 3 2 1
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1065-1
Activate the required printing modules using the

[ printing module keys ].
APL plate change: The printing module graphic shown
is described in the chapter Basic functions.

The machine is ready for the plate change.
The plate change starts automatically and begins in K99-1
the last selected printing module (e.g. in case of a

4-color machine: Printing module 4 w Printing mod-
ule 3 w Printing module 2 w Printing module 1).
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The process for changing the printing plate is

described in the Operation manual, chapter
Changing the printing plate.

Select the washing program only when the wash-up
device is installed.

D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
DDDDDD DDDDD 1
DDDDD DDD DDDDD DDDDDD 2
DDDDDDDD
DDDDDD DDD 3 DDDDD
DDDDDDDD DDDDD
DDDDDDDD
DDDDD
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-895-1
QUICKCHANGE option only: Activate the required

printing modules using the [ printing module keys ].
The printing module graphic shown is described in the
chapter Basic functions.
Without QUICKCHANGE option: The printing
modules are preselected in the main menu
Equipment.

The dampening solution feed is blocked while the
ink rollers are washed. The dampening solution K99-1
fountain is drained.
If the dampening solution supply was switched on
before the washing, it will be released again after the
washing.
Preselecting blanket washing

Select the automatic function Blanket (2) with the DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
Washing blanket +: The blanket washing program is
DDDDDD DDDDD 1
DDDDDDDD
DDDDDD DDD 3 DDDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
DDDDDDDD DDDDD
DDDDDDDD
DDDDD
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-895-1



Equipment.
K99-1
Preselecting impression cylinder washing (QuickChange option)

Select the automatic function Impression cylinder DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
(3) with the key [ + ], if you want to wash the impres- DDDDDDD DD D DD DDDD DDDD DDDD DDDD
sion cylinder at the same time.
Washing the impression cylinder +: The impression DDDDDDDD DDDDDDDDDDDD DDDD
DDDDDD DDDDD 1
cylinder washing program is activated. DDDDDDDD DDD DDDDDDD
DDDDD DDD DDDDD DDDDDD D
The selected washing program will be displayed (ar- DDDDDDDD
2
row). DDDDDD DDD 3 DDDDD
DDDDDDDD DDDDD
DDDDDDDD
DDDDD
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-895-1

Equipment.
K99-1
Preselecting several automatic functions at the same time (QUICKCHANGE option)

Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K58-1
K69
Activate the automatic functions using the [ F10 ]

key. F10
K109

The preselected automatic functions are DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
displayed. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
1 Washing the impression cylinder
2 Washing blanket DDDDDD DDDDDD 1 2 3 4 5 L
3 Washing ink rollers 1 DDD

2 DDD
4 Changing the printing plate +

3 DDD
4 DDDDDDDDDD
DDDDDDDD
5 Run up ink 5 DDDDD DDD
6 Display of automatic function (e.g. Washing 6
ink rollers) just performed.
7 Progress bar with time indication
7
(Deviations are possible according to the ma- 00:00
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1108-1
Preselect the required automatic functions (1) (2) (3)

(4) or (5) using the [ + ] or [ w ] button.
Select the required printing modules using the [ + ]
or [ w ] button.
Starting preselected automatic functions

F10
K109
Start the automatic cycle of the automatic func-

tions using the [ F5 ] key, Start. F5
The function F4: Cancel is activated. K104
The display changes to the input screen of the Ma-

chine main menu.
If the machine does not run, you must also
press the [ Automatic functions: Start ] but-
ton to start the automatic functions.
If you want to cancel the automatic cycle, press the
[ F4 ] key, Abort.
Inking up the rollers

The automatic sequence after starting the ink run up is
described in chapter Sequence of automatic func-
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
tions.
Conditions
The ink fountains are filled with ink.
The machine will turn at base speed.
Procedure
K58-1

K69
Activate the Run up ink function using the [ F4 ]

key. F4
K103
The function Run up ink will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 Activating the printing modules DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
2 Throwing on the transition roller after the ink
run-up DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
3 Setting the ink slides
F4 Selecting the ink run-up
DDDDDD
1
(Deviations are possible according to the ma- DDDDDD
chine configuration) 2 + + + +
DDDDDDD 15 15 15 15
3
F4 F5
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-893-1
Selecting the ink run-up

Select the printing modules for the ink run-up (1) DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
with the key [ + ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Run up ink +: The program Run up ink will be started
in this inking unit. DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
To start the ink run-up program, at least one
printing module must be selected.
DDDDDD
1
Select the setting Dampening rollers (2). DDDDDD 2 + + + +
DDDDDDD 15 15 15 15
3
Dampening roller +: Once the run-up is finished, the
transition roller will be thrown on against the ink form
roller and inked up.
Set the ink slides (3) with the key [ + ].
Adjusting the ink slides: 0 to 50 Digit
Standard setting 15 digits. F4 F5
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
The ink slide opening must not be too large. B-893-1
Increasing the ink dosage is easier than re-

moving excessive ink from the inking unit
later on. This applies in particular to printing
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
images with low surface areas .
K99-1
Starting the ink run-up

Prerequisite: The printing modules are selected for the
ink run up. An ink slide position is entered for each
printing module.

Start the ink run-up program with the key [ F5 ].

The text on the keys changes to Abort. You can F5
abort the ink run-up any time by pressing this key. K104
The ink run up starts.

After the end of the ink run up an indicating signal
will sound. The text on the keys changes to Start.
The previously set water fountain roller values will be
reset automatically.
The automatic sequence of the ink run up is
described in chapter Sequence of automat-
ic functions.
Aborting "Ink up"

Abort the procedure Run up ink with the key[ F5 ].
The program will be aborted. The machine will turn F5
at base speed. K104
Setting the reversing device

Procedure
K58-1
K69
Display of the setting of the reversing device

Display of the preselected setting - see main menu
Printing module (preselection).
If the numbers in the display (1) are white, you need DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
not take action. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
The current setting of the printing machine
corresponds to the presetting in main menu DDDDDDDD DDDDDDDDDDDD DDDD
DDDDDD DDDDD
Printing module (preselection). DDDDDDDD DDD DDDDDDD D
The numbers in the display (1) are red. DDDDDDDD
The reversing device is being converted. DDDDDD DDD DDDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
You need not take action. DDDDDDDD DDDDD DDDD

DDDDDDDD
The numbers in the display (1) are red. DDDDD 1 4/4
The current setting of the printing machine
does not correspond to the presetting in main
menu Printing module (preselection).
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
Adapt the setting of the reversing device on the ma- F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
chine to the preselection at the central control con-

sole. B-1063-1
The numbers in the display (1) are red.

The sheet size does not correspond to the

setting of the reversing drum.

Change the sheet size or the setting of the reversing
drum.
If you have changed the size during perfect
printing operation, you have to reset the re-
versing device - see chapter Converting the
reversing device.
Converting the printing machine to perfect printing

Press the [ F9 ] key. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
The function S/W-conversion is activated. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD

DDDDDD DDDDD
DDDDDDDD
DDDDDD DDD DDDDD
DDDDDDDD DDDDD DDDD
DDDDDDDD
DDDDD 1 4/4
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1063-1

on AUTOMATIC FUNCTIONS.
After the conversion, the display (1) changes over to
white, if it was red before.
K55-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

11.5.3 Main menu Printing module (preselection)

1 Entering the color designation of the printing DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
plate DDDDDDD DD D DD DDDD DDDD DDDD DDDD
2 Preselecting printing and coating modules
3 Preselecting inking units DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
1
4 Switching on the ink fountain roller
DDDDDD + + + + +
2
5 Preselecting the dampening rollers DDDDDD 3 + + + +
DDDDDD
4
6 Activating the permanent damping DDDDDD 5 + + + +
DDDDDDDD
6
coating module) DDDDDD 7 +
8 Preselecting the coating control (option DDDDDDDD +

8
coating module) DDDDDDD 9
9 Reversing device (option): preselecting
F1 F2 F4 F7 F8 F9 F10
printing sequence F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
F1 Changing sheet data B-158-1
F2 Setting Feeder / Delivery

F7 Setting the missing sheet detectors
F8 Oil: preselecting oil change, oil circulation
lubrication
F9 Setting the characteristic curve
F10 Interchanging the color sequence
Determining the color sequence

Procedure
K58-1
K932
Entering the color designation of the printing plate

By entering the plate name, you assign the surface
area data measured with the plate scanner or
PREPRESS LINK to a printing module. The plate name
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
consists of a letter for the color, e.g. B and, if required,

an additional identification number, e.g. 2.

Select the printing plate name (1) using the [ + ] but- DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
ton. DDDDDD
Printing plate names B, B2, B3..B6: Black
Printing plate names C, C2, C3..C6: Cyan DDDDDD 1 2 3 4 L
Printing plate names M, M2, M3..M6: Magenta DDDDDDD B C M Y /

11
Printing plate names Y, Y2, Y3..Y6: Yellow DDDDDD + + + + +
Printing plate names S, S2, S3..S6: Special color DDDDDD + + + +
DDDDDD
In case of identical printing plate names, enter an DDDDDD + + + +
DDDDDDDD
additional number by pressing the key [ Cursor:

Right ] once and by selecting a consecutive num- DDDDDDDD +
ber with the key [ + ]. DDDDDDDD +
Use the same printing plate names that are

stored on the JOBCARD for each printing F1 F2 F4 F6 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
module.
B-976-1
If the names differ, the system cannot assign
the EPS-printing plate names and transfers
wrong data or no data at all for the selected
printing module.
Deleting the assignment of the colors

Position the cursor on the desired printing module DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
(1). DDDDDD
Press the [ CLR ] button.
DDDDDD 1 2 3 4 L
The color assignation will be deleted. DDDDDDD B C M Y /

11
In the main menu Damp / Ink the ink slide profile of DDDDDD + + + + +
DDDDDD
the corresponding printing module will be displayed
+ + + +
DDDDDD
in gray. DDDDDD + + + +
DDDDDDDD
After pressing the [ F5 ] key, Working position, in

main menu Damp. / Ink the ink slides of the printing DDDDDDDD +
module will be closed. DDDDDDDD +
F1 F2 F4 F6 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-976-1

The color assignment is terminated.
K99-1
Preselecting printing and coating modules

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Procedure
K58-1
K932

Preselecting printing and coating modules

Activate the printing and coating modules (1) in- DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
volved in the printing using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Impression On +: When you start production, the im-
pression will be thrown on in the selected printing and DDDDDD 1 2 3 4 L
coating modules. DDDDDDD B C M Y /
In the selected printing and coating modules, the DDDDDD + + + + +

1
DDDDDD 2 + + + +
other settings will automatically be set to [ + ]. DDDDDD
3
The settings Ink (2), Ink fountain roller On (3) and DDDDDD 4 + + + +
DDDDDDDD
5
Dampening On (4) will automatically be set to [ w ]
in the printing modules that have not been selected. DDDDDD 6 +
DDDDDDDD +
7
For better sheet guiding, you can set Im-
pression ON to [ + ] in a printing or coating
module that is not printing. F1
F1
F2
F2
F3 F4
F4
F5 F6 F7
F7
F8
F8
F9
F9 F10
F10
B-991-1
Preselecting inking units

Activate the inking units (2) involved in the printing DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
Ink ON +: When you start production, the ink form
rollers and the ink ductor roller will be thrown on in the DDDDDD 1 2 3 4 L
selected printing modules. DDDDDDD B C M Y /
DDDDDD + + + + +
1
DDDDDD 2 + + + +
DDDDDD
3
DDDDDD 4 + + + +
DDDDDDDD
5
DDDDDD 6 +
DDDDDDDD +
7
F1 F2 F4 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-991-1

Activate the ink fountain roller (3) in the desired DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
printing modules using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Ink fountain roller ON +: The ink fountain roller will turn
in the selected printing modules. DDDDDD 1 2 3 4 L
Ink fountain roller ON w: The ink fountain roller is not DDDDDDD B C M Y /
turning. DDDDDD + + + + +
1
When the ink fountain roller is switched on, DDDDDD 2 + + + +
DDDDDD 3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
it keeps turning even during interruptions of DDDDDD 4 + + + +
DDDDDDDD 5
production.

DDDDDD 6 +
DDDDDDDD +
7
F1 F2 F4 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-991-1

Preselecting the dampening rollers

Activate the dampening units (4) involved in the DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
printing using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Dampening on +: When production starts, the water
form roller will be thrown on in the selected printing DDDDDD 1 2 3 4 L
modules. DDDDDDD B C M Y /
The water fountain roller keeps turning even DDDDDD + + + + +

1
during interruptions of production. DDDDDD 2 + + + +
DDDDDD
3
DDDDDD 4 + + + +
DDDDDDDD
5
DDDDDD 6 +
DDDDDDDD +
7
F1 F2 F4 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-991-1
Activating the permanent damping

Activate the permanent damping (5) in the desired DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
printing modules using the [ + ] button DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Permanent dampening +: The water fountain roller
remains switched on despite "Impression OFF". The DDDDDD 1 2 3 4 L
printing plate will be dampened as long as the machine DDDDDDD B C M Y /
keeps turning at basic speed.

DDDDDD + + + + +
1
You can activate the Permanent damping DDDDDD 2 + + + +
DDDDDD
3
only if Dampening On is activated. DDDDDD 4 + + + +
DDDDDDDD
5
DDDDDD 6 +
DDDDDDDD +
7
F1 F2 F4 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-991-1
Preselecting the coating application (option coating module)

Activate or deactivate the coating application (6) DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Coating application +: The screen roller will be thrown
on against the forme cylinder when production starts. DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
DDDDDD + + + + +
1
DDDDDD 2 + + + +
DDDDDD 3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
DDDDDD 4 + + + +
DDDDDDDD
5
DDDDDD 6 +
DDDDDDDD +
7
F1 F2 F4 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-991-1

Preselecting the coating control (option coating module)

Activate or deactivate the Coating control function DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
(7) using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Coating control +: When the max. coating level is
exceeded, the sense of rotation of the pumps will DDDDDD 1 2 3 4 L
change. Excessive coating will be sucked off. DDDDDDD B C M Y /
Switch off the function coating control when DDDDDD + + + + +

1
DDDDDD 2 + + + +
you rinse the coating system. DDDDDD
3
DDDDDD 4 + + + +
DDDDDDDD
5
DDDDDD 6 +
DDDDDDDD +
7
F1 F2 F4 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-991-1
Reversing device (option): preselecting printing sequence

Set the printing sequence in the Reversing device DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
line (1) using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
DDDDDD + + + + +
DDDDDD + + + +
DDDDDD
DDDDDD + + + +
DDDDDDDD
DDDDDD +
DDDDDDDD +
DDDDDDD 1
F1 F2 F4 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1044-1
Each time the button is pressed, one of the possible

printing sequences, e.g. bottom (1) through to 1st 1 2 3
reversing device, then bottom (2) again through to
2nd reversing device, followed by top (3), is
displayed. The position of the reversing device is
marked by a vertical line (4). 4
B-162-1

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The machine data will be stored.

Colored symbols in the line "Ink fountain roller on" K99-1
indicate the following statuses:

Ink fountain roller ON + (red): The ink fountain roller is
not turning yet.
Ink fountain roller ON w (red): The ink fountain roller is
still turning.

Changing sheet data

Procedure
K58-1
K932
Activate the Printing material function using the

[ F1 ] key.
The function Printing material will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 Changing sheet data DDDDDD
2 Changing the cover guide height
DDDDDDDDDDD : 1200 D DDD DDDD :
4 0 D
3 Image pos. correct DDDDDDDDDDD : D 1
DDDDDDDD 5 DDDD
1620
4 Printing "off-center" DDDDDDDDDDD : 0.10 D :
DDDDDDDDDDD :
2 0.20 D
5 Setting the size correction (option reversing DDDDDDDDDDD : 0.00 D 3
device)
6 Changing the printing pressure adjustment DDDDDDDDDD :
1 2 3 4
F1 Changing sheet data 6
0.03 0.04 0.05 0.00
F3 Changing the printing pressure adjustment

simultaneously in all printing modules
chine configuration) F1 F2 F3 F4 F6 F7 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
You cannot change the sheet data when B-890-1

there are sheets in the machine.
Changing sheet data

Enter the sheet data (1) using the [ + ] or [ w ] button DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
or using the [ digit keys ]. DDDDDD
The sheet width also serves as a reference
value for the dry sprayer - see main menu DDDDDDDDDDD : 1200 D DDD DDDD :
4 0 D
DDDDDDDDDDD : D 1
DDDDDDDD DDDD
1620
Equipment, function F4: Dry spray. DDDDDDDDDDD : 0.10 D : 5

DDDDDDDDDDD :
2 0.20 D
After changing the sheet thickness, you have to DDDDDDDDDDD : 0.00 D 3
readjust the double sheet control, the sheet hold- DDDDDDDDDD :
downs and the sheet hold-downs at the side guide 1 2 3 4
to avoid damage to the machine during the auto- 6

0.03 0.04 0.05 0.00
matic setting of the feeder.

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F3 F4 F6 F7 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-890-1
Changing the cover guide height

The cover guide height depends on the sheet thick-
ness.

Change the cover guide height (2) for the current DD DDDDDD
D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
work step using the [ + ] or [ w ] button. DDDDDD
Cover guide height: 0.1 to 3 mm (0.004 to 0.118 in),
Step width: 0.01 mm (0 in) DDDDDDDDDDD : 1200 D DDD DDDD :
4 0 D
DDDDDDDDDDD D 1
The cover guide height must not be lower
:
DDDDDDDD DDDD
1620
DDDDDDDDDDD : 0.10 D : 5
than the sheet thickness. DDDDDDDDDDD :
2 0.20 D
DDDDDDDDDDD : 0.00 D 3
DDDDDDDDDD :
1 2 3 4
6
0.03 0.04 0.05 0.00
F1 F2 F3 F4 F6 F7 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-890-1
Image pos. correct

Side guide correction during production
Enter a value for the position correction (3) using the DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
[ + ] or [ w ] button. DDDDDD
Image position corrections: -2 to 2 mm (-0.079 to
0.079 in) during production DDDDDDDDDDD : 1200 D DDD DDDD :
4 0 D
DDDDDDDDDDD D 1
In case of corrections of >1 mm, the lateral
:
DDDDDDDD 5 DDDD
1620
DDDDDDDDDDD : 0.10 D :
sheet stops will be set automatically. DDDDDDDDDDD :

2 0.20 D
DDDDDDDDDD :
1 2 3 4
6
0.03 0.04 0.05 0.00
F1 F2 F3 F4 F6 F7 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-890-1
Printing "off-center"
Side guide correction during make-ready
WARNING:
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

ing plate is moving up or down. Before K540

under it.
Move the pile supporting plate at the delivery to the
lowermost position.
In case of size changes, the pile supporting
plate at the delivery must be in the lowermost
position.

Enter a value(4) using the [ + ] or [ w ] button. DD DDDDDD

D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
Image position corrections: -30 to 30 mm (-1.181 to DDDDDD
1.181 in) during make-ready
The adjustable correcting range depends on the sheet DDDDDDDDDDD : 1200 D DDD DDDD :
4 0 D
width. DDDDDDDDDDD : D 1
DDDDDDDD DDDD
1620
The lateral sheet stops will be set automatically. DDDDDDDDDDD : 0.10 D : 5

DDDDDDDDDDD :
2 0.20 D
DDDDDDDDDD :
1 2 3 4
6
0.03 0.04 0.05 0.00
F1 F2 F3 F4 F6 F7 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-890-1
Setting the size correction (option reversing device)

Set the size correction (5) using the [ + ] or [ w ] but- DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
ton. DDDDDD
Size correction: -5 to 5 mm (-0.197 to 0.197 in)
If the sheet length is changed, the new value DDDDDDDDDDD : 1200 D DDD DDDD :
4 0 D
DDDDDDDDDDD : D 1
DDDDDDDD 5 DDDD
1620
will automatically be displayed in the line size DDDDDDDDDDD : 0.10 D :
correction. DDDDDDDDDDD :
2 0.20 D
DDDDDDDDDD :
1 2 3 4
6
0.03 0.04 0.05 0.00
F1 F2 F3 F4 F6 F7 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-890-1
Changing the printing pressure adjustment

The value 0.00 corresponds to an actual printing pres-
sure adjustment of 0.10 mm.
Select a printing module with the [ printing module ] DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
keys. DDDDDD
Using the F3: All printing modules function,
you can change the printing pressure adjust- DDDDDDDDDDD : 1200 D DDD DDDD :
4 0 D
DDDDDDDDDDD : D 1
DDDDDDDD 5 DDDD
1620
ment in all printing modules at the same time. DDDDDDDDDDD : 0.10 D :
DDDDDDDDDDD 2 D
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
: 0.20
Change the preset printing pressure adjustment (6) DDDDDDDDDDD : 0.00 D 3

for the current work step using the [ + ] or [ w ] but- DDDDDDDDDD :
ton. 1 2 3 4
Printing pressure adjustment, printing module: -0.1 6

0.03 0.04 0.05 0.00
to 0.1 mm (-0.004 to 0.004 in), Step width: 0.01 mm
(0 in)
Printing pressure adjustment, coating module: -0.5 to
0.1 mm (-0.02 to 0.004 in), Step width: 0.01 mm (0 in)
F1 F2 F3 F4 F6 F7 F8 F9
Printing pressure adjustment + (white): The setting is F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
terminated.
Printing pressure adjustment + (yellow): The new value B-890-1
is in the process of being set.

Printing pressure adjustment + (red): The setting has
been interrupted. Reconfirm the value by [ Enter ].

In case of sheet thicknesses below 0.10 mm, DD DDDDDD

D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
the lower setting range will be limited auto- DDDDDD
matically since the distance between the im-
pression cylinder and the blanket cylinder DDDDDDDDDDD : 1200 D DDD DDDD :
4 0 D
DDDDDDDDDDD : D 1
DDDDDDDD DDDD
1620
cannot be less than 0.00 mm. DDDDDDDDDDD : 0.10 D : 5
DDDDDDDDDDD :
2 0.20 D
DDDDDDDDDD :
1 2 3 4
6
0.03 0.04 0.05 0.00
F1 F2 F3 F4 F6 F7 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-890-1

The sheet data will be stored.
K99-1
To activate automatic setting operations after a

change of the sheet thickness, press the key [ Auto-
matic functions: Start ].
The cylinders and transferters will be positioned.
K55-1
Cover guides and printing pressure will be adjusted
automatically.
Following a change to the sheet thickness: Setting gripper pad bar

After changing the sheet thickness, the gripper pad bar
has to be readjusted.
Press the key [ Automatic functions: Start ]
The machine will be positioned automatically.
K55-1
Press and hold down the [ Jog: Forward ] button.

The printing machine must turn min. 2 revolutions.
While the machine is turning, the gripper pad bars
will be set automatically.
Gripper pad bar, setting range: 1
Sheet thickness: 0 to 0.3 mm (0 to 0.012 in)
Gripper pad bar, setting range: 2 K527
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Sheet thickness: 0.31 to 0.7 mm (0.012 to 0.028 in)

Gripper pad bar, setting range: 3
Sheet thickness: 0.71 to 1 mm (0.028 to 0.039 in)
The control lamp of the key [ Automatic functions:
Start ] goes out. The setting is terminated.

Presetting Feeder / Feed register

Procedure
K58-1
K932

[ F2 ] key F2
K101
The function Feeder / Delivery will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 Selecting the pile height detector DDDDDD
2 Selecting the front edge detectors
DDDDD DDDDD
3 Selecting the side guide DDDD DDD DDDDD
DDDDD DDDDD DDDDD 1 DDDDDDDD 7 0.50
4 Activating or deactivating the side edge con-

trol
5 Preselecting the sheet guide in front of front DDDD
guides and cover guides (suction rail) DDDDDDD DDD 2
DDDDDDD 3 B
6 Select the side guide (pulling or pushing), op- DDDDDDDDD
DDDDDDDDD 5 + 4
+
tion DDDDDDDDD +
7 Settings at the delivery unit

DDDDDDDDD 6 +
chine configuration) F1
F1
F2
F2
F3 F4
F4
F5 F6
F6
F7 F8 F9 F10
B-149-1
Selecting the pile height detector

Select the pile height detector (1) using the [ + ] DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
button. DDDDDD
Pile height detector Pressure foot: The pressure foot in
the suction head scans the rear edge of the main pile. DDDDD DDDDD
Pile height detector Front edge: The front edge detect- DDDD DDD DDDDD
or in the sheet flap scans the front edge of the main
pile. DDD DDDDDDDD
DDD DDDDD
1
1
DDDD
DDDDDDD DDD 2
DDDDDDD 3 B
DDDDDDDDD +
4
DDDDDDDD +
5
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1056-1
Selecting the front edge detectors

The front edge detectors check the correct position of
the sheet at the feed register.

Select the active front edge detectors according to DD DDDDDD

D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
the sheet width (2) using the [ + ] button. DDDDDD
Front edge detector Small: The inner front edge de-
tectors will be activated. DDDDD DDDDD
Small (sizes from 7): max. 1 400 mm (max. 55.118 in) DDDD DDD DDDDD
Front edge detector Large: The outer front edge de-

tectors are activated. DDD DDDDDDDD
DDD DDDDD
1
1
Small (sizes from 7): min. 1 401 mm (min. 55.157 in) DDDD
DDDDDDD DDD 2
DDDDDDD 3 B
DDDDDDDDD +
4
DDDDDDDD +
5
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1056-1
Selecting the side guide

Pull-type guide for the sheet transport.
Select the active side guide (3) with the key [ + ]. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Side edge A: The sheet will be pulled on the A-side. DDDDDD
Side edge B: The sheet will be pulled on the B-side.
DDDDD DDDDD
DDDD DDD DDDDD
DDD DDDDDDDD
DDD DDDDD
1
1
DDDD
DDDDDDD DDD 2
DDDDDDD 3 B
DDDDDDDDD +
4
DDDDDDDD +
5
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1056-1
The automatic pile control aligns the pile according

to the selected side guide.
If you want to change the side guide imme-
diately before sheet travel, you have to lower
the pile completely and raise it again. The
automatic pile control will then realign side
stops and suction head. K556
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Activating or deactivating the side edge control

The side edge control checks whether the sheets are
pulled correctly against the side guide stop. If the
optical detector does not detect a sheet, a signal will
sound.

Activate or deactivate the side edge control (4) with DD DDDDDD

D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
the key [ + ]. DDDDDD
- if side edge control detector reacts (feed register) +:
The optical side edge control is activated. DDDDD DDDDD
DDDD DDD DDDDD
Always switch on the side edge control. DDDDD DDDDD DDDDD 1 DDDDDDDD 0.50
Switch off the side edge control only if - DDD DDDDDDDD

DDD DDDDD
1
1
again and again - there are false alarms DDDD

DDDDDDD DDD 2
because the detector does not detect e.g. DDDDDDD 3 B
DDDDDDDDD +
4
transparent foils or black printing materials. DDDDDDDD +
5
As long as the side edge control is switched
off, you must pay utmost attention to a cor-
rect sheet guiding since the guiding is not
automatically controlled. F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1056-1
Preselecting the sheet guide in front of front guides and cover guides (suction rail)
Switch the suction rail in front of the front and cov- DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
er guides (5) on or off using the [ + ] button. DDDDDD
Suction rail, cover / front guides +: When production
starts, the suction rail of the sheet guiding device will DDDDD DDDDD
automatically be switched on. DDDD DDD DDDDD
At speeds = basic speed, the suction rail automatic- DDD DDDDDDDD

DDD DDDDD
1
ally switches off. DDDD

1
DDDDDDD DDD 2
DDDDDDD 3 B
DDDDDDDDD +
4
DDDDDDDD +
5
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1056-1
Select the side guide (pulling or pushing), option

Selecting the type of motion of the side guide
Select the setting (6) using the [ + ] button. DD DDDDDD
D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
Side guide Pulling: The active side guide pulls the DDDDDD
sheet.
Side guide Pushing: The sheet will be pushed to the DDDDD DDDDD
active side guide. DDDD DDD DDDDD
DDD DDDDDDDD
DDD DDDDD
1
1
DDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
DDDDDDD DDD 2
DDDDDDD 3 B
DDDDDDDDD +
4
DDDDDDDD +
5
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1056-1

Setting the pneumatic sheet guide rollers for printing corrugated cardboard (option)
Improvement of the guiding of the sheets when print-
ing corrugated cardboard
Set the type of contact pressure of the pneumatic DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
sheet guide rollers using the [ + ] button. DDDDDD
Pneumatic feed rollers Permanent pressure: The con-
tact pressure of the feed rollers corresponds to the set DDDDD DDDDD
value. DDDD DDD DDDDD
DDDDD DDDDD DDDDD DDDDDDDD
DDD DDDDDDDD
0.50
Pneumatic feed rollers Reduced pressure: Starting
from the 2nd sheet, the contact pressure of the feed DDD DDDDDDDD
DDDDD
-
rollers will be reduced. DDDD DDD DDDDD DD
-
DDDDDDD DDD DDD DDDDD DD

DDDDDDD B DDD DDDDD DD
DDDDDDDDD +
DDDDDDDD +
DDDDDDD 1 DDD
DDDDDDD DDD
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-118-1
Selecting the InlineSheeter (option)

Selection of the feeder type
Select the setting roller (1) using the [ + ] button if DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
using an INLINESHEETER. DDDDDD
Feeder Reel: InlineSheeter (option): The sheets are
automatically cut by the roller. DDDDD 1 DDDDD
DDDD DDD DDDDD
Feeder Sheet: Standard feeder DDDDD DDDDD DDDDD DDDDDDDD
DDD DDDDDDDD
0.50
DDD DDDDDDDD
DDDDD
-
DDDD DDD DDDDD DD

-

DDDDDDD B DDD DDDDD DD
DDDDDDDDD +
DDDDDDDD +
DDDDDDD DDD
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-116-1

Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K58-1
K932

[ F2 ] key F2
K101


F3
K102
Confirm with the [ Enter ] key.

The feeder timing will automatically be set to zero.
K99-1
Presetting the delivery unit

Procedure
K58-1
K932

[ F2 ] key F2
K101
Setting the pile stroke

Duration for the automatic lowering of the pile after the
reaction of the detector.
Set the pile stroke (1) using the [ + ] or [ w ] button. DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
Pile lowering/raising: 0.5 to 2 s, Step width: 0.01 s DDDDDD
DDDDD DDDDD
DDDD DDD DDDDD 1
DDDDD DDDDD DDDDD DDDDDDDD 0.50
DDD DDDDDDDD
DDD DDDDD
-
DDD DDDDD DD
-
DDDD DDD DDDDD DD
DDDDDDD B
DDDDDDDDD +
DDDDDDDD +
DDDDDDD DDD
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-113-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

The data will be stored.
K99-1
Manual nonstop operation (option)

This description applies to the manual nonstop opera-
tion with intermediate pile (lowerable or not lowerable).

Procedure
K58-1
K932

[ F2 ] key F2
K101
Setting the pile change ("Small pile" deactivated)

During the manual pile change, the intermediate pile is
held by a pile board or a pile rake.
Deactivate the Stacking small piles function (1) DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
using the [ w ] button. DDDDDD
Stacking small piles w: During the manual pile change,
the intermediate pile is held either by a pile board or a DDDDD DDDDD
pile rake. DDDD DDD DDDDD
DDD DDDDDDDD
After raising the main pile, the pile board re-
0.50
mains on the pallet. After raising the empty DDDD DDD DDDDDDDD
DDDDDDD DDD
- 1
pallet you can pull out the pile rake. The in- DDDDDDD B
termediate pile will be deposited directly on DDDDDDDDD +

DDDDDDDD +
the pallet.
DDDDDDD DDD
DDD DDDDDDDDDDD DD
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1060-1
Preselecting the mode "Stacking small piles"

Each small pile will be deposited on a pile board and
separated from the next small pile by means of
spacers.
Activate the Stacking small piles function (1) using DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
the [ + ] button. DDDDDD
Stacking small piles +: Forming small piles. For insert-
ing the pile board, the main pile will be lowered until it DDDDD DDDDD
is under the angle rails. DDDD DDD DDDDD
DDD DDDDDDDD 0.50
For a description of the pile change and the

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
mode "Stacking small piles" - see manuals DDDD DDD DDDDDDDD 1

DDDDDDD DDD
-
option Intermediate pile (not lowerable) DDDDDDD B

DDDDDDDDD
and Intermediate pile for nonstop opera-
+
DDDDDDDD +
tion. DDDDDDD DDD

DDD DDDDDDDDDDD DD
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1060-1

Semi-automatic nonstop device, with rake (option)

Procedure
K58-1
K932

[ F2 ] key F2
K101
The following settings are available for nonstop op- DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
eration with rake: DDDDDD
1 Selecting the operating mode
2 Selecting the opening time of the sheet distrib-
utor (option: sheet distributor):
DDD DDDDDDDD DDD 1
DDD DDDDD DDD 2
F5 Function "Sheet distributor". DDDD
DDDDDDD DDD
(Deviations are possible according to the ma- DDDDDDD B
chine configuration) DDDDDDDDD +
DDD DDDDDDDD DDD
F1 F2 F4 F5 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1059-1
Selecting the operating mode

Select the desired delivery operating mode (1). DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Operating mode Nonstop: (Separation of pile with DDDDDD
board or blast rake): The main pile is lowered to the
ground following a pile change.
Operating mode Small pile: Forming small piles. (Sep-
aration of pile with board): For inserting the pile board, DDD DDDDDDDD DDD 1
the main pile will be lowered until it is under the angle
rails. DDD DDDDD DDD 2
DDDD
DDDDDDD DDD
DDDDDDD B
DDDDDDDDD +
DDD DDDDDDDD DDD

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F4 F5 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1059-1

Selecting the opening time of the sheet distributor (option: sheet distributor):
Select the desired opening time of the sheet distrib- DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
utor (2) for the pile change. DDDDDD
Sheet gap short: Min. opening time with optimum con-
ditions (e.g. stable printing materials).
Sheet gap Long: Max. opening time in case of condi-
tions that are not optimal (e.g. instable printing materi- DDD DDDDDDDD DDD 1
als). DDD DDDDD DDD 2
DDDD
For a description of the pile change - see DDDDDDD DDD
DDDDDDD
manual option Intermediate pile / sheet
B
DDDDDDDDD +
distributor.
DDD DDDDDDDD DDD
F1 F2 F4 F5 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1059-1
Automatic nonstop device, with retractable boards and sheet distributor (option)
Procedure
K58-1
K932

[ F2 ] key F2
K101
The following settings are available: DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 Selecting Nonstop operation DDDDDD
2 Selecting the opening time of the sheet distrib-
utor DDDDD
DDDD
3 Setting the pile height DDDDD DDDDD DDDDD
DDD DDDDDDDD DDD 1
DDD DDDDDDDD 2 DDD
F5 Function "Sheet distributor". DDDD
DDDDDDD DDD DDD DDDDDDDD DDD 3
(Deviations are possible according to the ma- DDDDDDD B
chine configuration) DDDDDDDDD +

DDDDDDDD +
DDDDDDD DDD
DDD DDDDDDDDDDD DD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F4 F5 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1057-1

Selecting Nonstop operation

Select the delivery operating mode (1) nonstop. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Operating mode Nonstop: The pile change will be DDDDDD
triggered automatically as soon as the set pile height
is reached. The retractable boards will be extended DDDDD
and hold the intermediate pile. DDDD
Operating mode Manual: The pile change is not started DDDDD DDDDD DDDDD
automatically, but by using [ Pile change: On ] button DDD DDDDDDDD DDD 1
on the delivery unit. DDD DDDDDDDD 2 DDD
DDDD
The only difference between the operat- DDDDDDD B
ing modes Manual andNonstop is that the DDDDDDDDD +

DDDDDDDD +
pile change is started by pressing the [ Pile DDDDDDD DDD

change: On ] button. DDD DDDDDDDDDDD DD
F1 F2 F4 F5 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1057-1
Selecting the stacking small piles operating mode

Select the (1) stacking small piles operating mode. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Operating mode Small pile: As soon as the set num- DDDDDD
ber of sheets is reached, the retractable boards will be
extended. The retractable boards then hold the inter- DDDDD
mediate pile during the insertion of the pile board. DDDD
DDDDD DDDDD DDDDD
Once you have inserted pile board and spacers, the DDD DDDDDDDD DDD 1
main pile will move upward and lift the pile board of DDD DDDDDDDD 2 DDD
DDDD
the new small pile out of the angle rails. DDDDDDD DDD DDD DDDDDDDD DDD 3
DDDDDDD B
DDDDDDDDD +
DDDDDDDD +
DDDDDDD DDD
DDD DDDDDDDDDDD DD
F1 F2 F4 F5 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1057-1
Selecting emergency operation

In the emergency mode, the words are not in opera-
tion.
Select the delivery operating mode (1) emergency DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
operation. DDDDDD
Operating mode EMERGENCY OPERATION: The re-
tractable boards remain in their idle position. The inter- DDDDD
mediate pile is formed by a pile board. DDDD
DDDDD DDDDD DDDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
DDD DDDDDDDD DDD 1

DDD DDDDDDDD 2 DDD
DDDD
DDDDDDD B
DDDDDDDDD +
DDDDDDDD +
DDDDDDD DDD
DDD DDDDDDDDDDD DD
F1 F2 F4 F5 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1057-1

Selecting the opening time of the sheet distributor

Select the desired opening time of the sheet distrib- DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
utorsheet gap) (2) for the pile change. DDDDDD
Sheet gap short: Min. opening time with optimum con-
ditions (e.g. stable printing materials). DDDDD
DDDD
Sheet gap Long: Max. opening time in case of condi- DDDDD DDDDD DDDDD
tions that are not optimal (e.g. instable printing materi- DDD DDDDDDDD DDD 1
als). DDD DDDDDDDD
DDDD 2 DDD
Sheet gap Normal: Mean opening time DDD DDDDDDDD DDD 3
DDDDDDD DDD
Sheet gap Auto: Nonstop operating mode: The sheet DDDDDDD B
distributor is closed as soon as the detectors of the DDDDDDDDD +
nonstop device signal that the retractable boards have DDDDDDDD +
reached the working position. DDDDDDD DDD

DDD DDDDDDDDDDD DD
F1 F2 F4 F5 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1057-1
Setting the pile height

Nonstop or Stacking small piles operating mode:
height of main pile at which the pile change is to take
place. The max. pile height depends on the machine
configuration.
Set the pile height (3) using the [ digit keys ]. DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
Pile height (nonstop operating mode only): min. DDDDDD
200 mm (min. 7.874 in), Step width: 1 mm (0.039 in)
Pile height (nonstop or stacking small piles operating DDDDD
mode): min. 100 Sh, Step width: 1 DDDD
DDDDD DDDDD DDDDD
For a description of the pile change and the DDD DDDDDDDD DDD 1
DDD DDDDDDDD 2 DDD
mode "Stacking small piles" - see manual DDDD
option Automatic nonstop / sheet distrib- DDDDDDD B
utor. DDDDDDDDD +
DDDDDDDD +
DDDDDDD DDD
DDD DDDDDDDDDDD DD
F1 F2 F4 F5 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1057-1
Setting the sheet distributor

Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K58-1
K932

[ F2 ] key F2
K101

Activate the Sheet distributor function using the

[ F5 ] key. F5
K104
The function Sheet distributor will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 Advance sheets, washing blanket DDDDDD
2 Advance sheets, stoppage
3 Advance sheets, start of production DDDDD DDDDD DD 1
2 DDDDD
DDDDD
DDDDD
DDDDD
0
4 Residual sheets, stoppage DDDDD DDDDD
0
+
3
4
F5 Function "Sheet distributor".
F1 F2 F4 F5 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1052-1
Enter the number of advance sheets after washing

the blanket, after a stoppage and after starting
production using the [ + ] or [ w ] button.
Advance sheets, washing blanket: 0 to 25 Sh
Advance sheets, stoppage: 0 to 25 Sh
Advance sheets, start of production: 0 to 25 Sh
Activate or deactivate the Residual sheets stop-
page function using the [ + ] button.
Residual sheets, stoppage +: In case of a stoppage,
e.g. by means of the [ All printing units Off, feeder Off ]
button, the sheets that are still in the machine will be
sorted out.
Residual sheets, stoppage w: The residual sheets will
not be sorted out.
The setting of the sheet distributor is terminated.
For a description of the sheet distributor - K99-1
see manual option Sheet distributor.
Presetting Damp / Ink

Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K58-1
K932
Activate the Damp / Ink function using the [ F4 ]

key. F4
K103

The function Damp / Ink will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
1 Setting the integrated damping DDDDDD
2 Removing hickeys (Delta effect) automatically
1 2 3 4 L
3 Selecting symmetric ink flow (option)
4 Switching to front-heavy ink flow (option) DDDDDDD - - - - - 1
DDDDDD 2 - - - - +
5 Setting the basic dampening

DDDDD D - - + - - 3
6 Setting the commencement of the distribution DDDDDD 4 + + - - -
7 Setting the start of the decoating (option coat- DDDDDDD 20 20 20 20 20

5
ing module) DDDDDDD 6 0 0 0 0 0
8 Setting the start of the precoating (option DDDDDD D 4 7

coating module) DDDDDD D 8 2

(Deviations are possible according to the ma- F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1116-1
Setting the integrated damping

Optimizing the ink / dampening solution-balance for
different printing images.
Activate the integrated dampening (1) in the de- DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
sired printing modules using the [ + ] button. DDDDDD
Integrated dampening +: When production starts, the
transition roller will be thrown on against the first ink 1 2 3 4 L
form roller.
DDDDDDD - - - - - 1
DDDDDD 2 - - - - +
DDDDD D - - + - - 3
DDDDDD 4 + + - - -
DDDDDDD 20 20 20 20 20
5
DDDDDDD 6 0 0 0 0 0
DDDDDD D 4 7
DDDDDD D 8 2
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1116-1
Removing hickeys (Delta effect) automatically

Activating the Delta-effect when printing solids or critic-
al types of printing material.
Attention!: DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Danger of damage to the water form roller DDDDDD
which is neither moistened nor inked-up
while the Delta effect is activated. 1 2 3 4 L
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Activate the Delta effect only when the DDDDDDD - - - - - 1

water form roller is inked up and DDDDDD 2 - - - - +
moistened. DDDDD D - - + - - 3
DDDDDD 4 + + - - -
Activate the Delta effect (2) in the desired printing DDDDDDD 20 20 20 20 20

5
modules using the [ + ] button. DDDDDDD 6 0 0 0 0 0
Delta effect +: The water form roller turns slower than DDDDDD D 4 7
the plate cylinder whereby the hickeys will be removed DDDDDD D 8 2
from the image to be printed.

F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1116-1

Change the water form roller in good time.

The roller surface wears out quicker owing to
the different speed of water form roller and
plate cylinder.
Selecting symmetric ink flow (option)

A symmetric ink flow is achieved in the inking unit
through mechanical throwing off of transfer roller 92.
This setting must be entered on the central control
console so that the control software can align the
automatic start/stop sequence to this flow.
Enter the printing modules in which you have mech- DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
anically thrown off transfer roller 92 in the line Sym- DDDDDD
metric ink flow (3) using the [ + ] button.
1 2 3 4 L
on. DDDDDDD
Ink flow +: Symmetric: Transfer roller 92 was mechan-
- - - - - 1
DDDDDD 2 - - - - +
ically thrown off from the inking unit.
DDDDD D - - + - - 3
DDDDDD 4 + + - - -
DDDDDDD 20 20 20 20 20
5
DDDDDDD 6 0 0 0 0 0
DDDDDD D 4 7
DDDDDD D 8 2
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1116-1
Symmetric ink flow: Transfer roller 92 was thrown

off mechanically. The ink flow in the inking unit is 513
guided to the ink form rollers 452 and 453 via ink 91
vibrator roller 91 and intermediate roller 83. 512 92
83
454 453
452 511
451
11.5
11.4
402
06-06014-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Switching to front-heavy ink flow (option)

Change over the ink flow (4) in the desired printing DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
modules with the key [ w ]. DDDDDD
on. 1 2 3 4 L
Ink flow +: Front-heavy: Ink flow on the ink form rollers

451 and 452 (option) DDDDDDD - - - - - 1
DDDDDD 2 - - - - +
DDDDD D - - + - - 3
DDDDDD 4 + + - - -
DDDDDDD 20 20 20 20 20
5
DDDDDDD 6 0 0 0 0 0
DDDDDD D 4 7
DDDDDD D 8 2
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1116-1
Standard ink flow: Transfer rollers 91 and 92 are

thrown on. The ink flow in the inking unit is guided 513
to ink vibrator roller 511 and to intermediate roller 83 91
and from there to the ink form rollers 451, 452 and 512 92
453 83
454 453
452 511
451
11.5
11.4
402
06-06015-1
Ink flow largely on the ink form rollers 451 and 452
(front-heavy) Transfer roller 91 is thrown off by inter- 513
mediate roller 83. Transfer roller 92 remains thrown 91
on. The ink flow in the inking unit is guided to ink 512 92
vibrator roller 511 and from there to the ink form 83
rollers 451 and 452. 454 453
452 511
451
11.5
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
11.4
402
06-06013-1
Setting the basic dampening

Setting the water fountain roller speed before starting
or when interrupting production

Set the basic dampening (5) in the desired printing DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
modules using the [ + ] or [ w ] button. DDDDDD
Basic speed: 5 to 100 %
1 2 3 4 L
The setting is correct when the printing plate
does not smear in the printing zones while DDDDDDD - - - - - 1
DDDDDD 2 - - - - +
the permanent damping is switched on.
DDDDD D - - + - - 3
DDDDDD 4 + + - - -
DDDDDDD 20 20 20 20 20
5
DDDDDDD 6 0 0 0 0 0
DDDDDD D 4 7
DDDDDD D 8 2
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1116-1
Setting the commencement of the distribution

Equalizing a gradual fading in circumferential direction
by changing the positioning angle of the machine.
Set the commencement of the distribution (6) using DD DDDDDD
D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
Distribution insert: 0 to 360 , Step width: 30
in steps of 30 1 2 3 4 L
With a distribution commencement of 0, the DDDDDDD - - - - - 1

distribution will start at the printing leading DDDDDD 2 - - - - +
edge. DDDDD D - - + - - 3
DDDDDD 4 + + - - -
DDDDDDD 20 20 20 20 20
5
DDDDDDD 6 0 0 0 0 0
DDDDDD D 4 7
DDDDDD D 8 2
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1116-1
Setting the start of the decoating (option coating module)

With this setting you specify how many sheets before
Impression Off the coating form roller is to be thrown
off from the forme cylinder.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Set the desired number of sheets (7). DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
Coating roller OFF (de-coating): 0 to 9 Sh DDDDDD
The function will be carried out only, if the
1 2 3 4 L
Coating application function is activated.
DDDDDDD - - - - - 1
DDDDDD 2 - - - - +
DDDDD D - - + - - 3
DDDDDD 4 + + - - -
DDDDDDD 20 20 20 20 20
5
DDDDDDD 6 0 0 0 0 0
DDDDDD D 4 7
DDDDDD D 8 2
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1116-1
Setting the start of the precoating (option coating module)

With this setting you specify how many sheets before
Impression On the coating form roller is to be thrown
on against the forme cylinder.
Set the desired number of sheets (8). DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Coating roller ON (pre-coating): 0 to 9 Sh DDDDDD
The function will be carried out only, if the
1 2 3 4 L
Coating application function is activated.
DDDDDDD - - - - - 1
DDDDDD 2 - - - - +
DDDDD D - - + - - 3
DDDDDD 4 + + - - -
DDDDDDD 20 20 20 20 20
5
DDDDDDD 6 0 0 0 0 0
DDDDDD D 4 7
DDDDDD D 8 2
F1 F2 F4 F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1116-1

K99-1
Setting the missing sheet detectors

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
The missing sheet detectors in the sheet guiding track

between the printing modules monitor the transport of
the sheets to the delivery.
Procedure
K58-1

K932
Activate the Missing sheet function using the [ F7 ] DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
key. DDDDDD
Always switch on the missing sheet detect-
ors.
Switch the missing sheet detectors off only
if - again and again - there are false alarms 1 2 3 4 DD
because the detector does not detect e.g.
transparent foils or black printing materials. DDDDD + + + + 1
As long as the missing sheet detectors are
switched off, you must pay utmost attention
to a correct sheet guiding since the sheets
are not automatically controlled any more.
F1 F2 F4 F6 F7 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-885-1
Activate or deactivate the missing sheet detectors

(1) in the desired printing modules using the [ + ]
button.
K99-1
Oil: preselecting oil change, oil circulation lubrication

Switching the oil circulation lubrication off and on, e.g.
for oil change (Instructions for oil change and intervals:
see Maintenance manual.)
Procedure
K58-1
K932
Activate the Oil function using the [ F8 ] key.

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F8
K107

Switching the oil circulation / central lubrication off

Switch off the oil circulation / central lubrication DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
(1) using the [ w ] button. DDDDDD
Oil circulation / central lubrication w: The circulating-oil
lubrication system is switched off..
DDDDD DDDDD DDDDDDDDDD : + 1
When the oil circulation / central lubrication DDDDD DDDDD DDDDDDDDDD : 2 -
DDDDD DDDDD DDDDDDDDDD : -
3
are switched off, only the run controls [ Jog:
Forward ] or [ Jog: Reverse ] are available.
The circulating-oil lubrication does not switch
on automatically. After the oil change you
have to switch the oil circulation lubrication
on again by hand.
F1 F2 F4 F6 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1049-1
Confirm with the key [ Enter ].
K99-1
Switching the oil circulation / central lubrication on

Switch on the oil circulation / central lubrication DD DDDDDD
D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
(1) using the [ + ] button. DDDDDD
Oil circulation / central lubrication +: The circulating-oil
lubrication system is switched on.
DDDDD DDDDD DDDDDDDDDD : 2 -
3
F1 F2 F4 F6 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1049-1
Confirm with the key [ Enter ].
K99-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Activating the pumping out of waste oil

Activate the Empty oil change pump function (2) DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
using the [ + ] button. DDDDDD
The waste oil will be pumped out.
3
F1 F2 F4 F6 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1049-1
Activating the filling with fresh oil

Activate the Fill oil change pump function (3) using DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
the [ + ] button. DDDDDD
Fresh oil will be filled in.
3
F1 F2 F4 F6 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1049-1
Giving an additional lubricating pulse

Using the [ F9 ] key, Central lubrication, trigger an DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
additional lubrication pulse. DDDDDD

3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F4 F6 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1049-1

Setting the characteristic curve

Procedure
K58-1
K932
Activate the Characteristic curves function using

the [ F5 ] key. F9
K108
Changing the characteristic dampening curve

Each time the current machine speed increases /
decreases by more than 2000 s/h, the water fountain
roller speed will be increased / decreased according to
the entered percentage value. If a characteristic
dampening curve is set, the main menu Damp / Ink
shows the real fountain roller speed.
Activate the Characteristic dampening curve
K102
Set the Characteristic dampening curve (1) using DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
Characteristic dampening curve: 0 to 8 %, Step width:
0.5 % DDDDD DDDDDD : D 1
Select the setting ----, if you do not want to enter a
characteristic dampening curve.
F3 F4 F5 F9
F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-887-1
Setting the characteristic inking curve (inking compensation)

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
If the current machine speed is changed, the ink duct-

or roller strip will be increased or decreased according
to the entered percentage value.
Activate the Inking unit function using the [ F4 ] key.
If there are no experience values: Change F4
the characteristic inking curve by 1, if the col- K103
or density changes by more than 0.1 density

after reaching the production speed.

Set the inking compensation (1) using the [ + ] or DD DDDDDD

D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
[ w ] button. DDDDDD
Characteristic curve for the inking (inking compensa-
tion): -5 to 5 %, Step width: 1 % DDDDD DDDDDD
Confirm with the [ Enter ] key. DDDDDDDDDDDDDDD : D 1
The ink ductor roller strip will be set adapted auto- DDDDDDD DDDDDD
matically when the machine speed changes. DDDDDDDDDDDDDDD :
2 D
DDDDDDDDDDDDDDD : D 3
DDDDDDDD D D D D D
DDDDDDDDD DDDD D D D D D 4
F3 F4 F5 F9
F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-888-1
Activating the reverse rotation

The ink fountain roller will rotate in reverse in
preselectable intervals to transport ink residues from
the ink slides.
Activate the Inking unit function using the [ F4 ] key.
F4
K103
Set the reversing travel (2) using the [ + ] or [ w ] DD DDDDDD

D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
button. DDDDDD
Reverse rotating ink fountain roller (travel): 5 to 15 mm
(0.197 to 0.59 in), Step width: 1 DDDDD DDDDDD
Change the value for the interval (3) using the [ + ] DDDDDDDDDDDDDDD : D 1
or [ w ] button. DDDDDDD DDDDDD
Reverse rotating ink fountain roller (interval): 20 to 60 s, DDDDDDDDDDDDDDD :
2 D
Step width: 1 DDDDDDDDDDDDDDD : D 3
Activate the Reverse rotation function (4) in the DDDDDDDD D D D D D

DDDDDDDDD DDDD D D D D D 4
desired printing modules using the [ + ] button.
Reverse rotating ink fountain roller +: The ink fountain
roller will rotate in reverse in preselectable intervals.
F3 F4 F5 F9
F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-888-1

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K99-1
Setting the characteristic curve of the suction air of the suction tapes
The entered value depends on the sheet thickness.
Activate the Suction tapes function using the [ F5 ]
key. F5
K104

Set the suction air of the suction tapes (1) for vari- DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
ous machine speeds using the [ + ] or [ w ] button. DDDDDD
Characteristic curve of the suction air, suction tapes: 0
to 100 %, Step width: 1 DD
D
D
Confirm the entries with the [ Enter ] key. D
The new characteristic curve is stored in the job. D
D
The current suction roller nominal value is shown D
D
at the bottom right-hand corner of the screen for the D
D
Feeder / Delivery function. D
1 DDD DDD DDD DDD DDD DDD DDD DDD DDDD DD
DD DD DD DD DD DD DD DD DD
F3 F4 F5 F9
F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-889-1
Interchanging the color sequence

Preliminary tasks
Store color data (see page 11-124)
Procedure
K58-1
K932
Activate the Change plate function using the [ F10 ]

key.
Store the ink slide positions in the printing units in
which you want to change the ink assignment - see
main menu Damp / Ink, function F7: Store job.
Select the printing module (1) the color assignment DD DDDDDD

D DD
DD DD
DDD D
0
DD DDDD
0 DDD DDDD
DDD DD
of which you want to change (e.g. printing module DDDDDD
2, color: Cyan) with the key [ + ]. DDDD DDDDD DD DDDD DDDDDDD
1 2
DDDDDD D D D D D
Confirm with the key [ Enter ]. DDDDDDD D D D D D
Select the second printing module (2) (e.g. printing DDD DD D D D D D
DDD DD D D D D D
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
module 3, color: Magenta) with the key [ + ]. DDDDDDD DD D D D D D

DDDDDD DD D D D D D
Confirm with the key [ Enter ]. DDDDDDDDDDDD D D D D D
DDD DDDD DDDD DDDD

DDDD DDDD
F1 F2 F3
DDDD
F4 F5 F6 F7 F8 F9
F10
F10
B-975-1
Set the ink slides to the working position - see main

menu Damp / Ink, function F6: working position.

All color-related data will be interchanged.

Ink slide position: 0 to 250 Digit, Step width: 1 Digit
Ink zone status: printing, uncontrolled, ink-free, locked,
Trouble
Ink ductor roller strip: 0 to 99 %, Step width: 1 %
Ink fountain roller speed: 0 to 100 %, Step width: 1 %
11.5.4 Main menu Sheet guide

1 Setting the individual ventilator tracks DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
2 Setting all ventilator tracks DDD / DDD
F1 Storing ventilator values
F2 Loading stored ventilator values
F4 Blower function Presettings
F7 Delivery: presetting blower 0 0 0 0
0
F9 Printing module / coating module: preset- 0 0 0 0

1
ting blower
0 0 0 0
F10 Feeder / feed register: presetting blower DDD DDDDDD DDDD : 2

F1 F2 F4 F6 F7 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1130-1
Presetting all ventilator tracks

The settings in this screen apply to all ventilator tracks.
Procedure
K58-1
K76

marked in color.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Change the values for individual (1) or for all ventilat- DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
or tracks (2) using the [ + ] or [ w ] button. DDD / DDD
Air: Off:: 0
The ventilator tracks in the delivery unit are only
switched on when the machine is rotating. 0 0 0 0 0
0 0 0 0
When the reverse side of the sheet is freshly 0 0 0 0

1
printed, set the blast air to as low value. 0
DDD DDDDDD DDDD : 2
F1 F2 F4 F6 F7 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1130-1
K99-1
Storing ventilator values

The values currently stored for the ventilator tracks in
the Sheet Guide main menu are written to a memory
and are available for subsequent jobs.
Store the current values for the ventilator tracks us-
ing the [ F1: Store values ] key. F1
The values set at this point are stored. K41
A data record is stored for each setting of the

printing press (single side printing, position of
reversing device).
Loading stored ventilator values

Values stored for the ventilator tracks are loaded into
the current work step.
Load the values stored for the ventilator tracks us-
ing the [ F2: Load values ] key. F2
Depending on the setting of the printing press K101
(single-side printing, position of reversing device),

the relevant data record is loaded and displayed.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Blower function Presettings

Procedure
K58-1
K76

Activate the Blower function using the [ F4 ] key.

F4
K103
The Blower function is displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 Setting the blower, according to the machine DDD / DDD
configuration.
F4 Blower function
-
DDDD DDDD
- DDDD DDDD
- DDDDDDD 0
1 DDD DDDDDD D DDDD 1000
F1 F2 F4 F6 F7
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1132-1
Set the quantity of air for individual or all impres-

sion cylinder blowing devices using the [ + ] or
[ w ] button. K993

Air: Off:: 0
ing device.
Activate or deactivate all impression cylinder

blowing devices using the [ + ] button.
The individual setting of the impression cylin- K993
der blowing devices in the individual printing

modules is overwritten.
Blower: Options
Activate or deactivate the suction rail for light-
weight paper printing (option) using the [ + ] but-
ton. K1011
The suction rail straightens the sheet in the

sheet ascent ramp, thus, improving the guid-
ing of the sheet.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Set the air quantity for the suction rail for light-
weight paper printing using the [ + ] or [ w ] button.
Air: Off:: 0
Activate or deactivate the blast air upstream of the

reversing device (option: reversing device) using
the [ + ] button. K1006
Set the air quantity for the blast air upstream of

Air: Off:: 0

Activate or deactivate the suction air upstream

of the reversing device (option: reversing device)
using the [ + ] button. K1007
Set the air quantity for the suction air upstream of

Air: Off:: 0

main menu Machine).
Delivery: presetting blower

Procedure
K58-1
K76
Activate the Delivery function using the [ F7 ] key.

The number of ventilator tracks and the con- F7
tent of the screens vary according to the ma- K106
chine configuration.

marked in color.
Change the values of the individual ventilator tracks DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
(1) using the [ + ] or [ w ] button. DDD / DDD
Air: Off:: 0
The ventilator tracks are only switched on when the DDDDDDD 01 0
machine is rotating. DDDDDDD 02 0
DDDDDDD 03 1 0
When the reverse side of the sheet is freshly DDDDDDD 04 0

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F4 F6 F7
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1133-1
Move between screens using the [ F1 ] or [ F2 ] but-

ton. F1
K41

The Delivery function is displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
configuration. 1
Module / Coating Module and Feeder DDDD DDDD
screens.
-
- DDDD DDDD
F7 Delivery function - DDDDDDD 0
F1 F2 F4 F6 F7
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1131-1
Activate or deactivate the sheet decurler using the

[ + ] button.
Switch off the sheet decurler when you print K992
Activate or deactivate the blast tubes in the blast

frame using the [ + ] button.
K994

tion roller (option) using the [ + ] button.
Air: Off:: 0
Set the air quantity for the blast tubes in the blast
frame (QUICKCHANGE option) using the [ + ] or [ w ]
button. K994

Air: Off:: 0
Setting ventilators in the blast frame

Using the [ + ] [ w ] button, set the machine speed DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
from which the ventilators in the blast frame (1) are DDD / DDD
to be switched on.
Speed: 1 000 to 10 000 Sh/h 1
The ventilators will be switched on as soon as the
printing machine has reached the set speed.
-
DDDD DDDD
- DDDD DDDD
DDDDDDD 0
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F4 F6 F7
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1131-1

Delivery blower: Options

Swing down the PP sheet decurler (reversing
device option) using the [ + ] button.
Settings S/W: The sheet decurler is swung off, the air is K992
switched off.
Settings On: The sheet decurler is swung on, the air is
switched on.
Settings Off: The sheet decurler is swung on, the air is
switched off.
During make-ready of a perfecting job, the sheet de-
curler will be switched off and swung off.
Activate or deactivate all auxiliary blast nozzles

K1002
Activate or deactivate the sheet distributor (non-

stop option) using the [ + ] button.
K1003
Activate or deactivate the suction plates (option)

using the [ + ] button.
The function is used to stretch printed sheets K1004
which have a tendency to roll in the sheet

ascent ramp.
Deactivate the suction plates when printing

main menu Machine).
Printing module / coating module: presetting blower

Procedure
K58-1

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K76
Activate the Printing module / Coating module

K103

The Printing module / Coating module function is DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
displayed. DDD / DDD
1 Position of blower (arrow)
configuration.
1
3 Setting the air for the ventilator tracks - DDDDD DDDDDD 0 DDDDDDD 01 0
DDDDDDD 02 0
Module / Coating Module and Feeder
screens.
F9 Printing module / Coating module function 2 3
The values set here are exceeded if the set-

ting for all blowers and ventilator tracks is
overwritten. F1 F2 F4 F6 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1134-1
Activate or deactivate the impression cylinder

blowing device using the [ + ] button.
Set the nominal value using the [ + ] or [ w ] button. K993

Air: Off:: 0
ing device.
Change the values of the ventilator tracks using the

[ + ] or [ w ] button.
Air: Off:: 0
When the reverse side of the sheet is freshly

main menu Machine).
Feeder / feed register: presetting blower

Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K58-1
K76
Activate the Feeder / Feed register function using

the [ F10 ] key. F10
K109

The Feeder / Feed register function is displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
configuration.
F1, F2 Changing between the Delivery, Printing 1
Module / Coating Module and Feeder/ Feed + DDDD DDDD
Register screens. + DDDDD DDDD
F10 Feeder / Feed register function + DDDDDDDDD
+ DDDDDDD
+ DDDDDD DDDDD 2
DDDDDDDD DD 0
DDD DDDDD 0
+ DDDDDD DDD
F1 F2 F4 F6 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1119-1

tion head using the [ + ] button.
K984
Activate or deactivate the blast air to the suction

head using the [ + ] button.
K985
Activate or deactivate the blast-suction rail using

the [ + ] button.
K987
Activate or deactivate the side guard and suction

rollers using the [ + ] button.
K988
Activate or deactivate the front suction zone using

the [ + ] button.
K991
Feeder blower: Options

Activate or deactivate the swing grippers and side
blower (option) using the [ + ] button.
K986
Set the air quantity for the side guide using the [ + ]
or [ w ] button.
Air: Off:: 0
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Set the air quantity for the suction rollers (option)

using the [ + ] or [ w ] button.
Air: Off:: 0

Activate or deactivate the suction tapes blower

K1005

main menu Machine).
11.5.5 Main menu Damp. / Ink

1 Color data storage DD DDDDDD
D DD
DD DD 0
DD DDDD
0 DDD DDDD
2 Numbers of the printing modules DDD / DDD DD D DD DDDD DDDD DDDD DDD DD
DDDD DDDD
3 Bar diagram Ink ductor roller strip DDDD 1 02.03.04 12.34
4 Bar diagram Water fountain roller speed 1

100
2 3
100
4 2 5
100
- 90 -
- 90 - - 90 -
5 Ink ductor roller strip and water fountain - 80 - - 80 - - 80 -
- 70 - - 70 - - 70 -
roller speed (%). - 60 - - 60 - - 60 -
6 Ink ductor roller cycle

- 50 - - 50 - - 50 -
3 - 40 - - 40 - - 40 -
F1 Setting the ink slide profile

- 30 - - 30 - - 30 -
- 20 - - 20 - - 20 -
F2 Changing the ink slide position according to 4

- 10 - - 10 - - 10 -
- 0- - 0- - 0-
the set percentage 33 20 31 20 28 20 29 20

5
F3 Setting the ink ductor roller strip 1: 3 1: 3 1: 3
6 1: 3
F4 Setting the ink ductor roller cycle F1 F2 F3 F4 F5 F6 F7 F8 F9 F10

F5 Setting the water fountain roller speed F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
F6 Moving the ink slides to the working position B-880-1
F7 Writing the ink slide profile into the job stor-

age
F8 Storing color data in the intermediate stor-
age
F9 Closing all ink slides at the central control
console
F10 Changing the ink zone status
Presetting the color data

Preliminary tasks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Procedure
K58-1
K77

Viewing read surface area data

Select the color data storage Job with the key [ + ].
Activate the Surface function using the [ F5 ] key. DD DDDDDD

D DD
DD DD 0
DD DDDD
0 DDD DDDD
The surface area data of printing module 1 stored in DDD / DDD DD D DD DDDD DDDD DDDD DDD DD
DDDD DDDD
the job will be displayed. DDDDD
DDDD 100
The left half of the screen displays the max. (1) and
DDD 1
the mean (2) surface areas. The value Zone (3) dis-
80
35.7
plays the surface area of the selected ink zone. 60
DDDD 2
If you have not yet read any surface area 10.6 40
data, no ink profile will be displayed.

DDDD 3
20
Change over to the view of the surface areas in

1.8
the other printing modules with the [ Printing mod-

DDDDD 1

5 10 15 20 25 30 35 40 45 50
DOWN ]. F5 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-994-1

key.

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
2 Correcting calculation
DDDDDD 1 2 3 4
F7 Presetting function DDDDDDD B C M Y

chine configuration) DDDDDD + + + + 1
DDDDDDD 2 100 100 100 100
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-897-1

want adopt the new ink slide profile using the [ w ]
button.
Selection w: The new ink slide profile will not be preset
in this inking unit.
Selection +: The ink slide profile will be preset in this
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
inking unit.
Correcting calculation
If you see that the calculated ink slide opening is gen-
erally too low or too high, you can enter a correcting
value.

Enter a correction value (2) for each inking unit using DD DDDDDD
D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
the [ + ] or [ w ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Correction range: 10 to 400 %
The value 100 indicates that the result of the calcula- DDDDDD 1 2 3 4
tion will be accepted without correction. DDDDDDD B C M Y
The correcting value depends, among other DDDDDD + + + + 1

things, on the ink and the printing material. DDDDDDD 2 100 100 100 100
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-897-1
Selecting LCS control (option)

ing printing.
For presetting the ink slides, choose the procedure DD DDDDDD
D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
LCS, AUTO or EPS (1). DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Presetting the ink slides LCS: Each second ink zone is
printing. A max. ink ductor roller strip is set. DDDDDD 1 2 3 4 L
Presetting the ink slides Auto: The system will auto- DDDDDDD B C M Y /
matically set the appropriate procedure (EPS or LCS).

Presetting the ink slides EPS: The ink slide position is DDDDDD + + + +
automatically calculated with the aid of the EPS-char- DDDDD 1 Auto LCS LCS LCS
DDDDDDDD 100 100 100 100
acteristic curve and the ink ductor roller strip.
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1040-1
K99-1
Activate the [ Parameters ] function using the [ F8 ]

key.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

The Parameters function is displayed. DD DDDDDD

D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
1 Preselecting surface areas DDD / DDD
2 Preselecting ink ductor roller strips
DDDDDD 1 2 3 4 L
3 Preselecting characteristic curves DDDDDDD B C M Y /
DDDDD DDDDD D 0.0 0.0 0.0 0.0
F7 Presetting function
DDDDDD + + + +
F8 Parameters function DDDDDDD 100 100 100 100

chine configuration) DD
1 DDDDDD D
DDDDDD D 2
20 50 100
Only change the parameters if even a re- DD DDDD

20 30 50
peated modification of the correction value 3 DDDDDDDDD 10 8 7
does not lead to the desired result - see also

the description in chapter Notes concerning F7 F8 F10
printing.
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-986-1
The preset values are standard values that
you can edit.
Preselecting surface areas

Set the limit values for low and mean surface areas DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
(1) with the key [ + ] or [ w ]. DDD / DDD
EPS surface areas: 10 to 100 %
Standard setting 20 % (low surface areas) DDDDDD 1 2 3 4 L
Standard setting 50 % (mean surface areas) DDDDDDD B C M Y /

DDDDD DDDDD D 0.0 0.0 0.0 0.0
Standard setting 100 % (high surface areas) - cannot

be edited - DDDDDD + + + +
DDDDDDD 100 100 100 100
The limit value for low surface areas must be

below that for mean ones. DD
1 DDDDDD D
DDDDDD D 2
20
20
50
30
100
50
DD DDDD
3 DDDDDDDDD 10 8 7
F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-986-1
Preselecting ink ductor roller strips

Set the ink ductor roller strips (2) for low, mean, and DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
high surface areas with the key [ + ] or [ w ]. DDD / DDD
Presettings, inking unit: 10 to 99 %
Standard setting 20 % (low surface areas) DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
Standard setting 30 % (mean surface areas) DDDDD DDDDD D 0.0 0.0 0.0 0.0
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Standard setting 50 % (high surface areas) DDDDDD + + + +
DDDDDDD 100 100 100 100
DD
1 DDDDDD D
DDDDDD D 2
20
20
50
30
100
50
DD DDDD
3 DDDDDDDDD 10 8 7
F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-986-1

Preselecting characteristic curves

Change the characteristic curve (3) for converting DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
the surface areas into ink slide data with the key [ + ] DDD / DDD
or [ w ].
Presettings, inking unit: characteristic curve: 1 to 11
DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
A smaller ink slide opening will be calculated for a lower DDDDD DDDDD D 0.0 0.0 0.0 0.0
characteristic curve number, a larger opening for a DDDDDD + + + +

higher number. DDDDDDD 100 100 100 100
DD
1 DDDDDD D
DDDDDD D 2
20
20
50
30
100
50
DD DDDD
3 DDDDDDDDD 10 8 7
F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-986-1
Setting parameters for LCS control (option)

ing printing.
Set the limit of the surface area (2) up to which you DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
want to use the LCS-procedure. DDD / DDD
Surface area: 1 to 20 %
Standard setting 10 % DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
The presetting of the ink ductor roller strip (3) DDDDD DDDDD D 0.0 0.0 0.0 0.0
of 99 % cannot be edited. DDDDDD + + + +

DDDDD 1 EPS EPS EPS EPS
Enter the ink slide setting for LCS (4). DDDDDDDDDD 100 100 100 100
Ink slide position: 1 to 100 Digit, Nominal value: 20 Di- DD

git DDDDDD D 20 50 100
DD 2 DDDDDD D 20 30 50
Standard setting: 25 digits. All opened ink slides will DDDDD D DD DDDD
automatically be set to the same value.
10
99 DDDDD D 3 DDDDDDDDD 10 8 7
25 DDDD DD
4
F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1022-1
K99-1

The newly calculated values will overwrite the ink
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
slide values in the job storage.

The ink slides will be set to the new working posi-
tion.

In the inking units in which the LCS procedure has DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
been set, only every second ink slide is open. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
DDDDD
DDDD
250
200
150
100
50
DDD
48
0
DDDDD 3 5 10 15 20 25 30 35 40 45 50 55 60
F1 F2 F3 F4 F5 F6 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1026-1
Viewing the calculated ink slide profile

Select the color data storage Job or the intermedi-
ate storage Slides.. (1) with the key [ + ].

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
The ink slide profile of the printing module (2) set DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
last will be displayed. DDDDD
DDDD
250
The left half of the screen displays the ink slide posi- 200
tion (1) in the selected ink zone.

150
If no ink slide values have been read yet, the
100
screen mask is empty. 50
DDD 1
48
Change over to the view of the ink slide profile in the 0
other inking units with the [ Printing module keys ] or DDDDD 2 3 5 10 15 20 25 30 35 40 45 50 55 60
the key [ Cursor: UP ] or [ Cursor: DOWN ].

F1 F2 F3 F4 F5 F6 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-882-1
Presetting ink using the Self-learning function (option)

Preliminary tasks
Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K58-1
K77

key.


D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
1 Selected inking units DDDDDDD DD D DD DDDD DDDD DDDD DDDD
DDDDDD 1 2 3 4 L
3 Correcting calculation DDDDDDD B C M Y /
F6 Function Start
DDDDDD + + + +
1
F7 Presetting function DDDDD 2 Auto Auto Auto Manu
DDDDDDDD
(Deviations are possible according to the ma- 3
F6 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1147-1

button.
inking unit.
Preselecting procedures
Select the procedure (2) using the [ + ] button. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Procedures MAN: The calculated ink slide position is DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
used and the correction value (ink film thickness) is
taken into account. DDDDDD 1 2 3 4 L
Procedures LCS (option): Each second ink zone is DDDDDDD B C M Y /
printing. A max. ink ductor roller strip is set.
Procedures Auto: The system automatically sets the DDDDDD + + + +
1
appropriate procedure (MAN or LCS). DDDDD 2 Auto Auto Auto Manu
DDDDDDDD
- See also description in the chapter Notes 3
concerning printing -.
F6 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1147-1
Correcting calculation
For MAN procedure only: If you see that the calcu-
lated ink slide opening is generally too low or too high,
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
you can enter a correcting value.

Enter a ink film thickness correction value (3) for DD DDDDDD

D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
each inking unit using the [ + ] or [ w ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Correction range (self-learning option): 0.5 to 5 m,
Step width: 0.01 m DDDDDD 1 2 3 4 L
The value 1.00 indicates that the result of the calcula- DDDDDDD B C M Y /
tion will be accepted without correction. This setting

corresponds to the average ink film thickness of scale DDDDDD + + + +
1
inks printed (between 0.8 and 1.2 Nm). DDDDD 2 Auto Auto Auto Manu
DDDDDDDD 3
The correcting value depends, among other
things, on the ink and the printing material.
F6 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1147-1
K99-1
Activate the [ Extended ] function using the [ F8 ]

key.
The Extended function is displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
1 Preselecting LCS slide aperture DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
2 Preselecting ink slide correction value for small
surface areas DDDDDD 1 2 3 4 L
F8 Extended function DDDDDDD B C M Y /

DDDDDDD 24.6 50.9 55.4 53.1
(Deviations are possible according to the ma- DDDDDD

+ + + +
DDDDD LCS Auto Auto Manu
DDDDDDDD
DDDDDD 20 1
DDDDD 8 8 8 8
2
F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1148-1 06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Preselecting LCS slide aperture

Change the LCS slide position (1) using the [ + ] or DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
[ w ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Ink slide position: 1 to 100 Digit, Nominal value: 20 Di-
git DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
DDDDDDD 24.6 50.9 55.4 53.1
DDDDDD + + + +

DDDDDDDD
DDDDDD 20 1
DDDDD 8 8 8 8
2
F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1148-1
Preselecting ink slide correction value for small surface areas

Set the ink slide correction value (2) using the [ + ] DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
or [ w ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Ink slide position: 1 to 50 Digit, Nominal value: 8 Digit
Ink slide position for extremely low surface coverages DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
DDDDDDD 24.6 50.9 55.4 53.1
DDDDDD + + + +

DDDDDDDD
DDDDDD 20 1
DDDDD 8 8 8 8
2
F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1148-1
K99-1
Exit the Parameters function using the [ F8 ] key.

F8
K107
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Press the [ F6 ] key, Start.

The newly calculated values will overwrite the ink F6
slide values in the job storage. K105
The ink slides will be set to the new working posi-

tion.
Exit the Presetting function using the [ F7 ] key.
F7
K106

Activating the self-learning function (option)

Automatic optimization of preset values for scale inks.
Before use, read the description of the Self-learning
function in the chapter Notes concerning printing.
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
The system automatically optimizes the ink preset- DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
ting in the inking units in which the AUTO procedure
(1) has been set. DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
Do not activate the Self-learning function

DDDDDD
until a good sheet is present. DDDDD
+ + + +
Auto Auto Auto Auto

1
You can reset the calculated preset values DDDDDDDD 100 100 100 100
again using the shop supervisor disk ([ F2 ]

key, Reset self-learning.
F6 F7 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1149-1
Moving the ink slides to the working position

Procedure
K58-1
K77
Moving the ink slides to the working position

Select the color data storage (1) with the key [ + ]. DD DDDDDD
D DD
DD DD 0
DD DDDD
0 DDD DDDD
Color data storage Display Actual values": Current ink DDD / DDD DD D DD DDDD DDDD DDDD DDD DD
DDDD DDDD
slide positions of the work step just produced.
Color data storage STORE: Ink slide positions in the DDDD 1 02.03.04 12.34
job memory calculated from EPS surface areas or from

1 2 3 4 5
100 100 100
a repeat job.
- 90 - - 90 - - 90 -
- 80 - - 80 - - 80 -
Color data storage Before zero: Last ink slide position - 70 - - 70 - - 70 -
before closing the ink slides. - 60 -
- 50 -
- 60 -
- 50 -
- 60 -
- 50 -
Color data storage Memory 1 - 99: Intermediate stor- - 40 - - 40 - - 40 -
age with a consecutive number for up to 99 color data. - 30 - - 30 - - 30 -
- 20 - - 20 - - 20 -

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
- 10 - - 10 - - 10 -
- 0- - 0- - 0-
The machine moves the ink slides of all activated 33 20 31 20 28 20 29 20
printing units into the working position. 1: 3 1: 3 1: 3 1: 3
In printing modules in which you have not F6 F7 F10

defined any colors, the ink slides will be set
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
to zero. B-993-1

The functions F1: Parallel, F2: Percent, F3: Ink
ductor roller strip and F4: Ink ductor roller cycle K99-1
are active.

Setting the quantity of ink and dampening solution

Procedure
K58-1
K77
Setting the ink ductor roller strip

Select the color data storage Actual values (1) with DD DDDDDD
D DD
DD DD 0
DD DDDD
0 DDD DDDD
the key [ + ]. DDD / DDD DD D DD DDDD DDDD DDDD DDD DD
DDDD DDDD
Activate the Ink ductor roller strips function using DDDD 1 02.03.04 12.34
the [ F3 ] key.
1 2 3 4 5
100
- 90 -
100
- 90 -
2 100
- 90 -
- 80 - - 80 - - 80 -
Select printing module (2) with the [ Printing module - 70 - - 70 - - 70 -
keys ] or the keys [ Cursor: Right ] or [ Cursor: Left ].

- 60 - - 60 - - 60 -
- 50 - - 50 - - 50 -
- 40 - - 40 - - 40 -
Set the ink ductor roller strip (3) with the key [ + ] or - 30 - - 30 - - 30 -
- 20 - - 20 - - 20 -
[ w ]. - 10 - - 10 - - 10 -
- 0- - 0- 3 - 0-

33 20 31 20 28 20 29 20
Press the [ F3 ] key. 1: 3 1: 3 1: 3 1: 3
The mark on the key disappears. F3 F7 F10

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-992-1
Setting the ink ductor roller cycle

D DD
DD DD 0
DD DDDD
0 DDD DDDD
DDDD DDDD
Activate the Ink ductor roller cycle function using DDDD 1
the [ F4 ] key.
1 2 3 4
100
- 90 -
100
- 90 -
2
- 80 - - 80 -
Select printing module (2) with the [ Printing module - 70 - - 70 -

- 60 - - 60 -
- 50 - - 50 -
- 40 - - 40 -
Set the ductor roller cycle (3) for each printing mod- - 30 - - 30 -
- 20 - - 20 -
ule with the key [ + ] or [ w ]. - 10 - - 10 -
- 0- - 0-
Ink ductor roller cycle 1 : 0: The ink ductor roller is

locked. 33 20 31 20 28 20 29 20 3
Ink ductor roller cycle 1 : 3 1: 3 1: 3 1: 3 1: 3
Ink ductor roller cycle 1 : 6 F4 F7 F10

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
Ink ductor roller cycle 1 : 18 B-987-1

Number of cylinder revolutions after which the ink duct-
or roller is thrown on and off.

Setting the water fountain roller speed

D DD
DD DD 0
DD DDDD
0 DDD DDDD
DDDD DDDD
Activate the Water fountain roller function using DDDD 1
the [ F5 ] key.
1 2 3 4
100
- 90 -
100
- 90 -
2
- 80 - - 80 -
Select printing module (2) with the [ Printing module - 70 - - 70 -

- 60 - - 60 -
- 50 - - 50 -
- 40 - - 40 -
Set the water fountain roller speed (3) with the key - 30 - - 30 -
- 20 - - 20 -
[ + ] or [ w ]. - 10 - - 10 -
Water fountain roller speed: 0 to 99 %, Step width:

- 0- - 0-
3
1% 33 20 31 20 28 20 29 20
1: 3 1: 3 1: 3 1: 3
F5 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-988-1
K99-1
Store color data

Procedure
K58-1
K77
Writing the ink slide profile into the job storage

Storing ink slide profile, ink ductor roller strip and water
fountain roller speed in the job storage.
Using the [ + ] button (1), select the Actual values DD DDDDDD
D DD
DD DD 0
DD DDDD
0 DDD DDDD
ink data memory. DDD / DDD DD D DD DDDD DDDD DDDD DDD DD
DDDD DDDD
Press the [ F7 ] key. DDDD 1
1 2 3 4
The current ink slide settings will be written into the 100
- 90 -
100
- 90 -
storage Job. - 80 -
- 70 -
- 80 -
- 70 -
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
- 60 - - 60 -
- 50 - - 50 -
- 40 - - 40 -
- 30 - - 30 -
- 20 - - 20 -
- 10 - - 10 -
- 0- - 0-
33 20 31 20 28 20 29 20
1: 3 1: 3 1: 3 1: 3
F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1004-1

Storing color data in the intermediate storage

Storing ink slide profile, ink ductor roller strip and water
fountain roller speed in a temporary storage.
Select the color data storage Actual values with the DD DDDDDD
D DD
DD DD 0
DD DDDD
0 DDD DDDD
key [ + ] (1). DDD / DDD DD D DD DDDD DDDD DDDD DDD DD
DDDD DDDD
Press the key [ F8 ]. DDDD 1
1 2 3 4
The current ink slide positions will be written into the 100
- 90 -
100
- 90 -
intermediate storage. - 80 -
- 70 -
- 80 -
- 70 -
Color data storage Memory 1 - 99: Intermediate stor- - 60 - - 60 -
age with a consecutive number for up to 99 color data.

- 50 - - 50 -
- 40 - - 40 -
The number of the intermediate storage is counted

- 30 - - 30 -
- 20 - - 20 -
consecutively (storage 1, storage 2 etc.). - 10 -
- 0-
- 10 -
- 0-
As soon as the job is finished, the contents of 33 20 31 20 28 20 29 20
the intermediate storages will be deleted. 1: 3 1: 3 1: 3 1: 3
F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1005-1

Procedure
K58-1
K77

Setting individual ink slides to ink-free or locking or
closing them before the start of production.
Activate the function Ink zones using the [ F10 ]
key.
Select one or all printing modules (1) with the key DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
[ Cursor: DOWN ] or [ Cursor: UP ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Position the frame on the ink zone in which you
want to change the status. 1
For changing over faster between the first

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
and the last ink zone, press the key [ Curs-

4
or: Left ] or [ Cursor: Right ], if the frame is

positioned on the last ink zone.
With the key [ w ] set the ink zone status to locked.
1
Ink zone status grey:: Locked: The current ink slide DDDDD 3 5 10 15 20 25 30
position cannot be changed. The ink slide keys are

locked.
F1 F2 F3 F4 F5 F6 F7 F10
With the key [ 0 ] set the ink zone status to inkfree. F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
Ink zone status white display: Inkfree: The ink slides B-884-1
are closed. The ink slide keys are locked.

With the key [ + / w ] of the [ block of numerical DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
keys ] set the ink zone status to manual control. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Ink zone status Gray, hatched: Manual (with option ink
control system): The ink slides will not be controlled
automatically. 1
With the key [ + ] set the ink zone status to printing. 3
Ink zone status green: Printing: normal status. A 5
manual or automatic change of the ink slide position is

possible.
zone status will be displayed in red. 1
DDDDD 3 5 10 15 20 25 30
F1 F2 F3 F4 F5 F6 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-884-1

In the ink slides profile, locked ink zones will be dis-
played as grey bars, manually controlled ink zones K99-1
as hatched bars.
Adjusting the ink slides

Preliminary tasks
Presetting the color data (see page 11-113)
Conditions
Changing the ink slide position is possible only in the
display mode Actual values.
Procedure
K58-1
K77
With the key [ + ] change over to the display Actual

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
values.
Comprising several ink zones in a block
Simultaneous changing of ink slide positions in neigh-
boring or all ink zones.

Activate the function F1: Parallel or F2: Percent. DD DDDDDD

D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
For changing the ink slide setting in several adjacent DDD / DDD
ink zones, position the frame to the beginning of
the block with the keys [ Cursor: Left ] or [ Cursor:
Right ].
Press the [ selection button ].
Pull the frame with the key [ Cursor: Right ] to the
end of the block.
The bar on the left side of the screen shows the D
mean ink slide position of the selected ink zones. DDDDD D D D D D D D D D D D D D
If you want to activate all ink zones, position
the frame on ink zone 1, press the [ Selection F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
key ] and then the key [ Cursor: Left ]. B-1001-1
The frame comprises all ink zones.
To cancel the ink zone block, press the key

[ CLEAR ]. CLR
K100-1
Setting the ink slide profile

Activate the Parallel function using the [ F1 ] key.

DOWN ]. 11 10 9 8 7 6 5 4 3 2 1
LS-02577-2

D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
The bar on the left side of the screen shows the DDD / DDD
mean value of the selected ink zones.
D
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-877-1


D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
The ink slide profile in the selected ink zones will be DDD / DDD
set to a mean value.
D
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-878-1

key. F2
K101

DOWN ]. 11 10 9 8 7 6 5 4 3 2 1
LS-02577-2

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Change the ink slide position with the keys [ + ] or DDD / DDD
DDD DD DDDDD DDDD DD D
[ - ]. D
Changing the ink slide position (%): -25 to 25 %, Step
width: 1 %
The bar(1) shows the modification in %. 1
D
D
DD
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-879-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778


D DD
DD DD 0
DD DDDD
0 DDD DDDD
DDDD DDDD

100
2 3
100
4 5
100
- 90 -
- 90 - - 90 -
- 70 - - 70 - - 70 -
zero setting (1). - 60 - - 60 - - 60 -
- 50 - - 50 - - 50 -
- 40 - - 40 - - 40 -
- 30 - - 30 - - 30 -
- 20 - - 20 - - 20 -
- 10 - - 10 - - 10 -
- 0- - 0- - 0-
33 20 31 20 28 20 29 20
1: 3 1: 3 1: 3 1: 3
F7 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-914-1
Calling the last ink slide profile

Select the color data storage Before zero with the DD DDDDDD
D DD
DD DD 0
DD DDDD
0 DDD DDDD
key [ + ]. DDD / DDD DD D DD DDDD DDDD DDDD DDD DD
DDDD DDDD
Press the [ F6 ] key. DDDD 02.03.04 12.34
1 2 3 4 5
In all activated printing modules, the ink slides will be 100

- 90 -
100
- 90 -
100
- 90 -
set to the last profile before the zero setting. - 80 -
- 70 -
- 80 -
- 70 -
- 80 -
- 70 -
The function F9: Setting to zero can be reselected. - 60 -
- 50 -
- 60 -
- 50 -
- 60 -
- 50 -
- 40 - - 40 - - 40 -
- 30 - - 30 - - 30 -
- 20 - - 20 - - 20 -
- 10 - - 10 - - 10 -
- 0- - 0- - 0-
33 20 31 20 28 20 29 20
1: 3 1: 3 1: 3 1: 3
F6 F7 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-913-1
11.5.6 Main menu Register

1 Setting range for side register DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
2 Setting range for circumferential register DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
3 Setting range for diagonal register
DDDDDD
1 2 DDDD
3
4 Diagram of the deviation of the circumferen- D DDD DDD
tial and side register from the zero position D DDD DDD DDD
D DDD DDD DDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
5 Diagram of the deviation of the diagonal re- D DDD DDD DDD

D DDD DDD DDD
gister from the zero position
4 5
F1 Display of relative values (active only if a
printing module is selected)
F2 Changing registers in several printing mod-
ules at the same time
F3 Setting all registers to zero
F8 Setting the front guides F1 F2 F3 F8
F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
(Deviations are possible according to the B-904-1


Setting the registers

Conditions
The machine is turning.
Procedure
K58-1
Call the main menu [ Register ].
K68
The positions of side register (1), circumferential DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
register (2) and diagonal register (3) will be dis- DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
played as numerical value and as a diagram with
marks (crosses) (4) and diagonal lines (5). DDDDDD
1 2 DDDD
3
D DDD DDD
D DDD DDD DDD
D DDD DDD DDD
D DDD DDD DDD
D DDD DDD DDD
4 5
F1 F2 F3 F8
F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-904-1
Setting the registers in individual printing modules

Select a printing module with the [ printing module ]
keys.
11 10 9 8 7 6 5 4 3 2 1
LS-02577-2
Set the side register (1) with the key [ Cursor: DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Right ] or [ Cursor: Left ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Side (lat.) register: -1 to 1 mm (-0.039 to 0.039 in),
Step width: 0.01 mm (0 in) DDDDDD
1 2 DDDD
3
Side register (coating module): -2 to 2 mm (-0.079 to D DDD DDD
D DDD DDD DDD
0.079 in), Step width: 0.01 mm (0 in) D DDD DDD DDD
D DDD DDD DDD
Set the circumferential register (2) with the key D DDD DDD DDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
[ Cursor: Up ] or [ Cursor: Down ].

Circumferential register: -1 to 1 mm (-0.039 to
0.039 in), Step width: 0.01 mm (0 in)
The diagonal register can be set only in the
printing units 2 to X. For this purpose, the
transferter is inclined on the B-side. The F1 F2 F3 F8
range that is available for setting the diagonal F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
register depends on the sheet size. General B-1083-1
rule: The smaller the size, the more limited

the setting range.

Set the diagonal register (3) with the keys [ + ] or

[ w ].
Diagonal (Cook.) register: -0.4 to 0.4 mm (-0.016 to
With each register correction the neighboring trans-
ferter is automatically inclined in the opposite direc-
tion so that the sheet can be taken parallel again in
the next printing module. The setting path in the fol-
lowing printing modules will thus be limited.
Always adapt the diagonal register in the
printing modules 2 to X to printing module
1.
Reason: In printing module 1 there is no set-
ting possibility because there is no transfert-
er.
The values will be adopted automatically
after 4 seconds even without confirmation
by [ Enter ].
As soon as the registers are positioned at the
printing machine, the color of the digits and diagram
changes from yellow to white.
In the function F1: Relative you can set the
registers of the selected printing module as
described, with the only difference that only
the value of the current modification (relative
display) is displayed, not the absolute dis-
placement of the registers from zero position
Setting the circumferential and side registers in all or several printing modules simultaneously
Activate the + / w function using the [ F2 ] key DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
The displays for circumferential and side register are DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
automatically activated and set to 0.00 in all printing
DDDDDD
1 2 DDDD
modules. D DDD DDD
D DDD DDD DDD
Deselect the printing modules in which you do not D DDD DDD DDD
want to change the register setting by the same D DDD DDD DDD
D DDD DDD DDD
amount with the [ Printing module keys ].
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F1 F2 F3 F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1084-1
Set the side register (1) with the key [ Cursor:

Right ] or [ Cursor: Left ].
Step width: 0.01 mm (0 in)

Set the circumferential register (2) with the key

[ Cursor: Up ] or [ Cursor: Down ].
On the display you see the value of your current
change (relative display).
The values will be adopted automatically
after 4 seconds even without confirmation
by [ Enter ].
As soon as the registers are positioned at the
printing machine, the color of the digits and diagram
changes from yellow to white.
Setting all registers to zero

Activate the Reset function using the [ F3 ] key.
F3
K102

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
The registers move to the zero position. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
The values set last before the zero setting remain
DDDDDD DDDD
stored. D DDD DDD
D DDD DDD DDD
The text on the key changes to F3: Before zero. D DDD DDD DDD
D DDD DDD DDD
D DDD DDD DDD
F1 F2 F3 F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1008-1
Setting all registers to the values "Before zero"

Activate the Before zero function using the [ F3 ]
key. F3
K102
06.09.2004 10:35:31 - 747 - 80 95A EN 6778


D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
The registers move to the stored values. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
The text on the keys changes to Reset.
DDDDDD DDDD
D DDD DDD
D DDD DDD DDD
D DDD DDD DDD
D DDD DDD DDD
D DDD DDD DDD
F1 F2 F3 F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1008-1
Setting the front guides at the central control console

Procedure
K58-1
Call the main menu [ Register ].
K68
Activate the Front guides function using the [ F8 ]

key.
The function Front guides will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
1 A-side DDDDDDD DD D DD DDDD DDDD DDDD DDDD
2 Direction of sheet travel
3 Line zero position
4 Display of the front guide position in relation to
the zero position.
5 B-side 1
5
A
F3 Setting the front guides to zero 2 3
F7 Skewing the infeed register
F8 Setting the front guides at the central control
console 4
chine configuration) F7 F8
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F3 F6 F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1125-1
Parallel displacing of the infeed register

Only the Front guides function key must be activated
for a parallel displacement of the feed register.
Activate the function Front guides using the [ F8 ]
key.

Shift the infeed register with the key [ Cursor: DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
Down ] or [ Cursor: Up ] in or against the sheet DDDDDDD DD D DD DDDD DDDD DDDD DDDD
travel direction.
DDD D DDD1
During the setting, colored lines in the diagram show
in which direction the infeed register moves.
The setting is terminated. A
The profile (set before) of the front guides that are

in operation and of those that are not in operation
remains unchanged.
F3 F6 F7 F8
F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1151-1
Skewing the infeed register

Inclining the infeed register at the B or A-side.
Activate the Individual function using the [ F7 ] key.
The outer front guide at the A-side is marked. F7
K106
Press the key [ Cursor: Right ], if you want to incline DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
the infeed register at the B-side. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
With the key [ Cursor: Up ] or [ Cursor: Down ] the
desired inclination (1).
Front guides: Setting range: -0.5 to 0.5 mm (-0.02 to
0.02 in), Step width: 0.01 mm (0 in) 1
Confirm the entries with the [ Enter ] key. A
F3 F6
F6 F7 F8
F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1121-1
Setting the front guide profile

Activate the Individual function using the [ F7 ] key.
F7
K106
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Select the front guides that you wish to set using the DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
[ Cursor: Left ] [ Cursor: Right ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
The selected front guide is marked.
Change the setting using the [ Cursor: Down ]
[ Cursor: Up ] button.
Front guides: Setting range: -0.5 to 0.5 mm (-0.02 to
0.02 in), Step width: 0.01 mm (0 in) A
During the setting, a colored line in the diagram

shows the direction in which the front guide moves.
F3 F6 F7 F8
F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1120-1
Setting the front guides to zero

The front guides will be set to zero. A profile set before
will be deleted.
Activate the Front guides to zero function using the
[ F3 ] key. F3
K102
Confirm the entries with the [ Enter ] key. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
All front guides move to the zero position (arrow). DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
F3 F6 F7 F8
F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1124-1
Loading front guide profile

Activate the Loading profile function using the
[ F9 ] key. F9
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K108

With the key [ Cursor: Up ] or [ Cursor: Down ], se- DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
lect the desired memory (1). DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Storage: Front guides 1 to 10: Storage space
DDD D DDD1
The displayed front guide profile will be loaded.
F3 F6 F7 F8
F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1123-1
Storing the front guide profile

Activate the Store profile function using the [ F10 ]
key. F10
K109
With the key [ Cursor: Up ] or [ Cursor: Down ], se- DD DDDDDD

D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
lect the desired memory (1). DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Storage: Front guides 1 to 10: Storage space
DDD D DDD1
The displayed front guide profile will be stored.
F3 F6 F7 F8
F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1122-1
11.5.7 Main menu AGGREGATES

F1 Preselecting the dampening solution refri- DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
gerator DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
F2 Preselecting the blanket washing program
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F3 Preselecting the ink roller washing program

F4 Preselecting the dry sprayer
F5 Preselecting the impression cylinder wash-
ing program (option)
F6 Preselecting the coating (option coating
module)
F7 Preselecting "rinse coating" (option coating
module)
F8 Settings "F8: System"
F1 F2 F3 F4 F5 F6
F6 F7 F8
F8 F10
(Deviations are possible according to the F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
machine configuration) B-1019-1

Preselecting the dampening solution refrigerator

Adjusting the temperature, composition and character-
istics of the dampening solution.
Procedure
K58-1

The main menu Aggregates will be displayed.
K84
Activate the Dampening solution refrigerator func-

tion using the [ F1 ] button. F1
K41
The function Dampening solution refrigerator will DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
be displayed. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
1 Switching on dampening solution refrigerator
DDDDDDD DDDDDD
2 Setting the temperature of the dampening
solution DDDDDDD : DDDDDDD
DDDDDDD : 1 :
3 Setting the alcohol content

DDDDD DDDDD DDDDD
4 pH-value: Setting the alarm limits 2 DDDD DDDD
5 Activating powder suction device (option) 3 DDDDDDD DD 7.0 0.0 10.0 0.0
DDDD DD 0.0 0.0 3.0 0.0
6 Actual value of the additive DDDD 2.0 2.0 2.0

4 DDDDDDDDD DDD 0.20 0.20 0.20
F1 Function "Dampening solution refrigerator" DDDDDDDDD DDD 0.20 0.20 0.20

(Deviations are possible according to the DDDDDDD DD 0.0
dampening solution refrigerator used.) 6

F1 F2 F3 F4 F5 F6 F7 F8 F10
The field readiness - above the table, on the right - F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
indicates whether the dampening solution refrigerat- B-1007-1
or is ready for operation.

ready for operation +: The dampening solution refriger-
ator is ready for operation.
ready for operation w: The dampening solution refriger-
ator is not ready for operation. After the switching-on,
the dampening solution refrigerator is, e.g., not immedi-
ately ready for operation (no indication, no alarm).
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Switching on dampening solution refrigerator

Switch on the dampening solution refrigerator (1) DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
with the key [ + ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Refrigerator (option) +: When you start and termin-
ate the automatic production, the supply pump will DDDDDDD DDDDD
automatically be switched on and off. The dampening DDDDDDDD : DDDDDDDD :
solution circuit is closed. DDDDDDDD : 1

DDDDDD DDDDDDDD DDDDD
DDDD DDDD
DDDDDDD DD 7.0 0.0 10.0 0.0
DDDDD DD 0.0 0.0 3.0 0.0
DDDDD 2.0 2.0 2.0
DDDDDDDDDD DD 0.20 0.20 0.20
F1 DD DDD DDD DD DDDD

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-912-1
Setting the temperature of the dampening solution

Set the nominal value of the dampening solution DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
temperature (2) with the key [ + ] or [ w ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Nominal temperature: 7 to 20 C (44.6 to 68 F)
DDDDDDD DDDDDD
Set the upper or lower alarm limit with the key [ + ] DDDDDDD : DDDDDDD
DDDDDDD : 1 :
or [ w ].
Alarm limits: 0 to 25.5 C (32 to 77.9 F) DDDDD DDDDD DDDDD
2 DDDD DDDD
Max. setting of the lower alarm limit: 3 % below the
nominal value. 3 DDDDDDD DD 7.0 0.0 10.0 0.0
DDDD DD 0.0 0.0 3.0 0.0
Min. setting of the upper alarm limit: 3 % above the DDDD 2.0 2.0 2.0
nominal value. 4 DDDDDDDDD DDD 0.20 0.20 0.20

DDDDDDDDD DDD 0.20 0.20 0.20
DDDDDDD DD 0.0
6
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1007-1
Setting the alcohol content

Set the nominal value of the alcohol content (3) with DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
the key [ + ] or [ w ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Alcohol nominal value: 0 to 15 %
DDDDDDD DDDDDD
The current alcohol content is displayed in
DDDDDDD : DDDDDDD
the column Actual value. DDDDDDD : 1 :
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Set the values for the upper and lower alarm limit DDDDD DDDDD DDDDD
2 DDDD DDDD
with the key [ + ] or [ w ]. DDDDDDD DD
3 DDDD DD
7.0 0.0 10.0 0.0
Alcohol alarm limit: 0 to 24.5 % DDDD

0.0 0.0
2.0
3.0
2.0
0.0
2.0
Max. setting of the lower alarm limit: 3 C below the 4 DDDDDDDDD DDD 0.20 0.20 0.20
nominal value. DDDDDDDDD DDD 0.20 0.20 0.20
Min. setting of the upper alarm limit: 3 C above the

DDDDDDD DD 0.0
nominal value. 6
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1007-1

pH-value: Setting the alarm limits

Set the upper and lower alarm limit for the pH- DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
value (4) with the key [ + ] or [ w ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
pH-value: Alarm limits: 2 to 9
DDDDDDD DDDDDD
DDDDDDD : DDDDDDD
DDDDDDD : 1 :
DDDDD DDDDD DDDDD

2 DDDD DDDD
3 DDDDDDD DD 7.0 0.0 10.0 0.0
DDDD DD 0.0 0.0 3.0 0.0
DDDD 2.0 2.0 2.0
DDDDDDD DD 0.0
6
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1007-1
Conductivity: Setting the alarm limits

Set the upper and lower alarm limit for conductivity DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 (dampening solution container) (5) with the key DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
[ + ] or [ w ].
DDDDDDD DDDDDD
Conductivity: alarm limit: 0 to 5 mS/cm
DDDDDDD : DDDDDDD
DDDDDDD : 1 :
Set the upper and lower alarm limit for conductivity

2 (water) (5) with the key [ + ] or [ w ]. DDDDD DDDDD DDDDD
2 DDDD DDDD
Conductivity: alarm limit: 0 to 5 mS/cm DDDDDDD DD
3 DDDD DD
7.0
0.0
0.0
0.0
10.0
3.0
0.0
0.0
Set the upper and lower alarm limit for conductivity 4 DDDD 2.0 2.0 2.0
3 (water with additives) (5) with the key [ + ] or [ w ]. DDDDDDDDD DDD 0.20 0.20 0.20
Conductivity: alarm limit: 0 to 5 mS/cm DDDDDDD DD 0.0
6
The currently measured values - also for the additive
F1 F2 F3 F4 F5 F6 F7 F8 F10
(6) - will be shown in the column Actual values. F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
The entered values will be stored irrespective B-1007-1
of the job.
K99-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Changing the preset washing programs.
Procedure
K58-1
K84

Activate the ABD function using the [ F2 ] key.

F2
K101
The ABD function is displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 Preselecting washing program DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
2 Removing paper residues from the blanket
1 2 3 4 L
3 Activating self-cleaning (only with brush option) DDDDDDD o o o o o

1
3 Activating water form rollers (only with cloth DDDDD - - - - -
2
option) DDDDDDDDD + + + + +
3
3 Preselecting printing modules (only without
automatic functions option) DDDDDDDD 4 + + + + +
4 Preselecting washing agent quantity (only with

brush option)
5 Selecting washing agent in washing agent DDDDDDDDD : 100%
5
container 1 DDDDDDDDD DD
F2 Function "ABD" 6
(Deviations are possible according to the ma- F1 DD DDD DDD DD DDDD
chine configuration) F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1
Change the presetting only if you are not sat-
isfied with the washing result.
Preselecting washing program

Set the washing program (1) using the [ + ] or [ w ] DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Washing program 1: Low soiling
Washing program 2: Medium soiling 1 2 3 4 L
DDDDDDD 1
Washing program 3: Heavy soiling o o o o o
DDDDD - - - - -
2
DDDDDDDDD + + + + +
3
DDDDDDDD 4 + + + + +
DDDDDDDDD : 100%
5
DDDDDDDDD DD
6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1
Removing paper residues from the blanket

A wash cycle is automatically added to the blanket
wash-up program in order to remove paper residues
from the blanket.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Using the [ + ] button, set the printing modules in DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
which sheet edges (2) are visible on the blanket. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Sheet edges +: The blanket wash-up program is ex-
tended. 1 2 3 4 L
Sheet edges w: The standard blanket wash-up pro- DDDDDDD o o o o o

1
gram runs. DDDDD - - - - -
2
DDDDDDDDD + + + + +
3
DDDDDDDDD : 100%
5
DDDDDDDDD DD
6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1
Activating self-cleaning (only with brush option)

Activate the setting for Self-cleaning (3) using the DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
[ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Self-cleaning +: After the washing, the system will
clean itself. 1 2 3 4 L
Self-cleaning w: No self-cleaning. DDDDDDD o o o o o

1
DDDDD - - - - -
2
DDDDDDDDD + + + + +
3
DDDDDDDDD : 100%
5
DDDDDDDDD DD
6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1
Activating water form rollers (only with cloth option)

Activate the setting for water form rollers (3) using DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Water form rollers +: The water form rollers will be
thrown on. The dampening unit is also washed. 1 2 3 4 L
DDDDDDD 1
Water form rollers w: The water form rollers remain o o o o o
thrown off. DDDDD - - - - -

2
DDDDDDDDD + + + + +
3
DDDDDDDD 4+ + + + +
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
DDDDDDDDD DD 5

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1146-1
Preselecting printing modules (only without automatic functions option)

This function is only displayed if the Machine main
menu does not include the F10: Automatic Func-
tions (QUICKCHANGE option) function.

Select the printing modules (Start function) (4) for DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
washing using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Selection +: The printing module is activated and is
washed when the washing program is started. 1 2 3 4 L
DDDDDDD 1
Selection w: The printing module is not washed. o o o o o
DDDDD - - - - -
2
DDDDDDDDD + + + + +
3
DDDDDDDDD : 100%
5
DDDDDDDDD DD
6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1
Preselecting washing agent quantity (only with brush option)

Set the washing agent quantity (5) using the [ + ] DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Washing agent quantity: 75 to 125 %, Nominal value:
100 %, Step width: 25 % 1 2 3 4 L
DDDDDDD o o o o o
1
DDDDD - - - - -
2
DDDDDDDDD + + + + +
3
DDDDDDDDD : 100%
5
DDDDDDDDD DD
6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1
Selecting washing agent in washing agent container 1

The washing program is adapted to the washing agent
used.
Using the [ + ] button, set the washing agent you are DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
using in washing agent container 1 (6). DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Washing agent container A3: Standard washing agents
Washing agent container Bio: Biodegradable washing 1 2 3 4 L
1
agents/high-boiling agents DDDDDDD o o o o o
DDDDD 2
Washing agent container UV: Washing agents for UV
- - - - -
DDDDDDDDD + + + + +
inks
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Washing agent container Hyb: Hybrid/combination

3
washing agents for standard and UV inks DDDDDDDD 4 + + + + +
Washing agent container Spec: Washing agents for

special inks
DDDDDDDDD : 100%
5
DDDDDDDDD DD
6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1

Selecting washing agent in washing agent container 1 and 2 (option)

Washing agent alternating mode option: 2 washing
agent containers for various washing agents.
Set the washing agent used for each individual DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
printing module separately using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Using the [ + ] button, set the washing agent you are 1 2 3 4
using in washing agent container 1 and washing DDDDDDD 1 1 1 1

DDDDDDDD + + + +
agent container 2 (3). D DDDDDDD + + + +
DDDDDD 1 DD DD DD DD
Washing agent container A3: Standard washing agents DDDD + + + +
Washing agent container Bio: Biodegradable washing

agents/high-boiling agents
inks DD DDDDDD : 100%
Washing agent container Hyb: Hybrid/combination DDDDDDDDDDD : A3
washing agents for standard and UV inks DDDDDDDDDDD : DD 2

special inks DD DDD
F3 DDD DD DDDD
F1
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1142-1
K99-1
viewing set washing parameters

Activate the Parameters function using the [ F10 ] DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
1
Select the required combination (1), (2), (3) using DDDDD : DDDDDDD DD
DDDDD : DDDDDD DDDDDDDD

2
the [ + ] or [ w ] button. : DDDDD
DD DDDDDD
Washing agent container: A3, Bio, UV, Hyb, Spec 3
DDDDDDDDD DDDDDD DDDDDD
DDD
Washing program: 1, 2, 3 1 DD DDD DDDD 2 7
2 D DD DDDDDDD
Wash mode: With sheet edges, Without sheet edges 2 7
3 D DD DDDDDDD 2 7
Program steps: 1 Water:, 2 Washing agent, 3 Water:,
7 Re-rinse quantity
The parameters for the selected combination are 7 DDDDDDD 20
shown.
The parameters are predefined and cannot
be edited. F1 DD
F2 DDD DDD DD
F5 DDDD F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1145-1

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Procedure
K58-1
K84


F3
K102
The ARD function is displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 Preselecting washing program DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
2 Washing inking unit + printing plate 1 2 3 4
1
3 Washing inking unit + printing plate + DDDDDDD 1 1 1 1
dampening rollers D DDDDDDD + + + + 2

D DDDDDD + + + +
4 Preselecting printing modules (only without 3
automatic functions option) DDDD + + + +
5 Preselecting re-washing DDDDDDD DDD + + + + 4

DDDDDDD 1 1 1 1
6 Gumming the printing plate 5

DDDDD :- 6
7 Decalcifying inking and dampening unit DDDDD :-
DD DDDDDD : 100% 7
8 Preselecting washing agent quantity DDDDDDDDDDD : A3
8
9 Selecting washing agent in washing agent
container 1 F1 DD DDD
F3 DDD 9 DD DDDD
F3 Function "ARD" F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
(Deviations are possible according to the ma- B-1139-1

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Washing program 2: Medium soiling
1 2 3 4
1
DDDDDDD 1 1 1 1
Washing program 3: Heavy soiling D DDDDDDD + + + + 2
D DDDDDD + + + +
3
DDDD + + + +
DDDDDDD 1 1 1 1
5
DDDDD :- 6
DDDDD :-
DD DDDDDD : 100% 7
DDDDDDDDDDD : A3
8
F1 DD DDD
F3 DDD 9 DD DDDD
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1139-1
Washing inking unit + printing plate

When the washing program starts, the ink form roller
are thrown on against the printing plate.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Activate the Printing plate function (2) using the DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
[ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Printing plate +: The printing plate is also washed. 1 2 3 4
1
Printing plate w: The printing plate is not washed. DDDDDDD 1 1 1 1
D DDDDDDD + + + + 2
D DDDDDD + + + +
3
DDDD + + + +
DDDDDDD 1 1 1 1
5
DDDDD :- 6
DDDDD :-
DD DDDDDD : 100% 7
DDDDDDDDDDD : A3
8
F1 DD DDD
F3 DDD 9 DD DDDD
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1139-1
Washing inking unit + printing plate + dampening rollers

The dampening solution supply is automatically locked
when the washing program starts. Once the ink
fountain has been emptied, the water form rollers are
thrown on.
Activate the Dampening unit function (3) using the DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
[ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Dampening unit +: The dampening rollers are also
washed.
1 2 3 4
1
Dampening unit w: The dampening rollers are not DDDDDDD 1 1 1 1
washed.
D DDDDDDD + + + + 2
D DDDDDD + + + +
3
DDDD + + + +
DDDDDDD 1 1 1 1
5
DDDDD :- 6
DDDDD :-
DD DDDDDD : 100% 7
DDDDDDDDDDD : A3
8
F1 DD DDD
F3 DDD 9 DD DDDD
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1139-1

06.09.2004 10:35:31 - 747 - 80 95A EN 6778


D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
DDDDDDD 1
DDDDD - - - - -
2
DDDDDDDDD + + + + +
3
DDDDDDDDD : 100%
5
DDDDDDDDD DD
6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1
Preselecting re-washing
Additional wash cycle, e.g. for an ink change. The Ink
infeed automatic function automatically starts at the
end of the washing program. The washing program is
then repeated automatically.
Activate the Re-washing function (5) using the [ + ] DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
Re-washing +: At the end of the washing program: ink
is fed in. Washing is then repeated. 1 2 3 4
1
DDDDDDD 1 1 1 1
Using the [ + ] button, set the program for D DDDDDDD + + + + 2

D DDDDDD + + + +
Re-washing (5). 3
DDDD + + + +
Re-washing 1: 1 x re-wash DDDDDDD DDD + + + + 4
Re-washing 2: 2 x re-wash DDDDDDD 1 1 1 1
5
Feed the new ink into the ink fountain before start- DDDDD :- 6
DDDDD :-
ing the washing program, as the Ink feed function DD DDDDDD : 100% 7
DDDDDDDDDDD
starts automatically.
: A3
8
F1 DD DDD
F3 DDD 9 DD DDDD
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1139-1
Preselecting re-wash cycles with special cleaner (option)

The option includes a separate wash cycle with its own
spraying device for special liquid cleaners. The use of
wash pastes is then superfluous.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Important! DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
Special cleaners may damage the copying DDDDDDD DD D DD DDDD DDDD DDDD DDDD
film on the printing plate. 1 2 3 4
1
Test the special cleaner for compatibility DDDDDDD 1 1 1 1
D DDDDDDD + + + + 2
before use, if you want to reuse the print- D DDDDDD + + + +
ing plate. 3
DDDD + + + +
Using the [ + ] button, set the program for DDDDDDD 1 1 1 1
5
Re-washing (5). DDDDD :- 6
with special cleaner (option) 1S to 5S: 1-5 x DDDDD :-
DD DDDDDD : 100% 7
re-wash(es) with special cleaner (inking unit only) DDDDDDDDDDD : A3
with special cleaner (option) 1SF to 5SF: 1- 5 x re- 8

wash(es) with special cleaner (inking unit + dampening
unit + printing plate) F1 DD DDD
F3 DDD 9 DD DDDD
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
Never use special liquid cleaners for the en-

B-1139-1
tire washing program, as this will impair the
washing result.
Gumming the printing plate

Activate the Gumming function (6) using the [ + ] DD DDDDDD
D
DD
DD
DD
DDD D
0
DD DDDD
0 DDD
DDD
DDDD
DD
Gumming +: At the end of the washing program, you
can gum the printing plate and dampening rollers.
1 2 3 4
1
DDDDDDD 1 1 1 1
If you activate the Gumming function (6), D DDDDDDD + + + + 2

D DDDDDD + + + +
the Decalcify function (7) is automatically 3
deactivated. DDDD + + + +
DDDDDDD 1 1 1 1
5
DDDDD :- 6
DDDDD :-
DD DDDDDD : 100% 7
DDDDDDDDDDD : A3
8
F1 DD DDD
F3 DDD 9 DD DDDD
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1139-1
Decalcifying inking and dampening unit

Decalcifying the inking and dampening unit.
Activate the Decalcify function (7) using the [ + ] DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Decalcifying +: At the end of the washing program, you
can decalcify the inking. and dampening unit.
1 2 3 4
1
DDDDDDD 1 1 1 1
If you acticate the Decalcify function (7), the D DDDDDDD + + + + 2

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
D DDDDDD + + + +
Gumming function (6) is automatically deac- 3
tivated. DDDD + + + +
DDDDDDD 1 1 1 1
5
DDDDD :- 6
DDDDD :-
DD DDDDDD : 100% 7
DDDDDDDDDDD : A3
8
F1 DD DDD
F3 DDD 9 DD DDDD
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1139-1

Preselecting washing agent quantity

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
100 %, Step width: 25 %
1 2 3 4
1
DDDDDDD 1 1 1 1
D DDDDDDD + + + + 2
D DDDDDD + + + +
3
DDDD + + + +
DDDDDDD 1 1 1 1
5
DDDDD :- 6
DDDDD :-
DD DDDDDD : 100% 7
DDDDDDDDDDD : A3
8
F1 DD DDD
F3 DDD 9 DD DDDD
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1139-1

used.
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
using in washing agent container 1 (9). DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Washing agent container A3: Standard washing agents 1 2 3 4
1
Washing agent container Bio: Biodegradable washing DDDDDDD
1 1 1 1
D DDDDDDD + + + + 2
Washing agent container UV: Washing agents for UV D DDDDDD + + + +
inks 3
Washing agent container Hyb: Hybrid/combination DDDD + + + +
washing agents for standard and UV inks

DDDDDDD 1 1 1 1
Washing agent container Spec: Washing agents for 5
special inks DDDDD :- 6
DDDDD :-
DD DDDDDD : 100% 7
DDDDDDDDDDD : A3
8
F1 DD DDD
F3 DDD 9 DD DDDD
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1139-1

06.09.2004 10:35:31 - 747 - 80 95A EN 6778


D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
printing module separately using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD

D DDDDDDD + + + +
agent container 2 (3). D DDDDDD + + + +
Washing agent container Bio: Biodegradable washing DDDDDDD DDD + + + +
agents/high-boiling agents DDDDDDD 1 1 1 1
Washing agent container UV: Washing agents for UV DDDDD :-

inks DDDDD :-
Washing agent container Hyb: Hybrid/combination DD DDDDDD : 100%
washing agents for standard and UV inks DDDDDDDDDDD : A3

DDDDDDDDDDD 2 : DD
special inks
F1 DD DDD F3 DDD DD DDDD
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1144-1

The washing programs are preselected and the
printing modules, in which you want to wash, are K99-1
activated.
ARD: viewing set washing parameters
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1

2
DD DDDDDD
DDDDDDDDD DDDDDD DDDDD DDDDDD
DDD DD DD
Washing program: 1, 2, 3 1 DD DDD DDDD 3 4 0.30
2 D DD DDDDDDD
Wash mode: Inking unit, Inking unit + plate, Inking unit 5 7 0.25
3 D DD DDDDDDD
+ plate + dampening unit 2 4 0.25
4 D DD DDDDDDD 1 4 0.20
The parameters for the selected combination are

6 DDDDDDD DDD 5 5 0.30
shown. 7 DDDDDDD 20
8 DDDDDDDD DD
The parameters are predefined and cannot 9 DDDDDD DD DD DD
be edited.
F1 DD DDD
F3 DDD DD DDDD F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1140-1
Preselecting the impression cylinder washing program (option)

Changing the preset washing programs.
Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K58-1
K84
Activate the AID function using the [ F5 ] key.

F5
K104

The AID function is displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
1 Preselecting washing program DDDDDDD DD D DD DDDD DDDD DDDD DDDD
2 Removing paper residues from the impression
cylinder 1 2 3 4 L
1
3 Activating self-cleaning (only with brush option) DDDDDDD o o o o o
DDDDD - - - - -
2
3 Activating water form rollers (only with cloth DDDDDDDDD + + + + +
option) 3
4 Preselecting printing modules (only without DDDDDDDD 4 + + + + +
automatic functions option)

5 Preselecting washing agent quantity (only with
brush option)
DDDDDDDDD : 100%
5
6 Selecting washing agent in washing agent DDDDDDDDD DD
container 1 6
(Deviations are possible according to the ma- DD DDD DDD DD DDDD
chine configuration) F1
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
Change the presetting only if you are not sat- B-1138-1
isfied with the washing result.

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Washing program 2: Medium soiling 1 2 3 4 L
DDDDDDD 1
Washing program 3: Heavy soiling o o o o o
DDDDD - - - - -
2
DDDDDDDDD + + + + +
3
DDDDDDDDD : 100%
5
DDDDDDDDD DD
6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1
Removing paper residues from the impression cylinder

A wash cycle is automatically added to the impression
cylinder washing program in order to remove paper
residues from the blanket.
Using the [ + ] button, set the printing modules in DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
which sheet edges (2) are visible on the blanket. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Sheet edges +: The blanket wash-up program is ex-
tended. 1 2 3 4 L
1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Sheet edges w: The standard blanket wash-up pro- DDDDDDD o o o o o
gram runs. DDDDD - - - - -

2
DDDDDDDDD + + + + +
3
DDDDDDDDD : 100%
5
DDDDDDDDD DD
6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1

Activating self-cleaning (only with brush option)

Activate the setting for Self-cleaning (3) using the DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
[ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Self-cleaning +: After the washing, the system will
clean itself. 1 2 3 4 L
Self-cleaning w: No self-cleaning. DDDDDDD o o o o o

1
DDDDD - - - - -
2
DDDDDDDDD + + + + +
3
DDDDDDDDD : 100%
5
DDDDDDDDD DD
6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1
Activating water form rollers (only with cloth option)

Activate the setting for water form rollers (3) using DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Water form rollers +: The water form rollers will be
thrown on. The dampening unit is also washed. 1 2 3 4 L
DDDDDDD 1
Water form rollers w: The water form rollers remain o o o o o
thrown off. DDDDD - - - - -

2
DDDDDDDDD + + + + +
3
DDDDDDDD 4+ + + + +
DDDDDDDDD DD 5

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1146-1

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
DDDDDDD 1
DDDDD - - - - -
2
DDDDDDDDD + + + + +
3
DDDDDDDDD : 100%
5
DDDDDDDDD DD
6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1

Preselecting washing agent quantity (only with brush option)

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
100 %, Step width: 25 % 1 2 3 4 L
DDDDDDD o o o o o
1
DDDDD - - - - -
2
DDDDDDDDD + + + + +
3
DDDDDDDDD : 100%
5
DDDDDDDDD DD
6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1

used.
D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
using in washing agent container 1 (6). DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Washing agent container A3: Standard washing agents
Washing agent container Bio: Biodegradable washing 1 2 3 4 L
1
agents/high-boiling agents DDDDDDD o o o o o
DDDDD 2
- - - - -
DDDDDDDDD + + + + +
inks
Washing agent container Hyb: Hybrid/combination
3
washing agents for standard and UV inks DDDDDDDD 4 + + + + +

special inks
DDDDDDDDD : 100%
5
DDDDDDDDD DD
6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1138-1

06.09.2004 10:35:31 - 747 - 80 95A EN 6778


D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
printing module separately using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD

DDDDDDDD + + + +
agent container 2 (3). D DDDDDDD + + + +
Washing agent container Bio: Biodegradable washing

inks DD DDDDDD : 100%
Washing agent container Hyb: Hybrid/combination DDDDDDDDDDD : A3
washing agents for standard and UV inks DDDDDDDDDDD : DD 2

special inks DD DDD
F3 DDD DD DDDD
F1
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1142-1
K99-1
viewing set washing parameters

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1

2
DD DDDDDD
DDDDDDDDD DDDDDD DDDDDD
DDD
Washing program: 1, 2, 3 1 DD DDD DDDD 2 7
2 D DD DDDDDDD
Wash mode: With sheet edges, Without sheet edges 2 7
3 D DD DDDDDDD 2 7
Program steps: 1 Water:, 2 Washing agent, 3 Water:,
7 Re-rinse quantity
The parameters for the selected combination are 7 DDDDDDD 20
shown.
The parameters are predefined and cannot
be edited. F1 DD
F2 DDD DDD DD
F5 DDDD F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1145-1
Preselecting the dry sprayer

Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K58-1
K84
Activate the Dry sprayer function using the [ F4 ]

key. F4
K103

The function Dry sprayer will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
1 Preselecting dry spraying width DDDDDDD DD D DD DDDD DDDD DDDD DDDD
2 Preselecting quantity of spray-powder
3 Activating dry sprayer DDDDD DDDDDD 1 :
4 Preselecting dry spraying mode DDDDDDDDDDD 2 : 15
5 Activating powder suction device (option) DDDDDDD : 15
DDDDDDD 3 : 15
F4 Function "Dry sprayer" DDDDDDDDD : 15
4
(Deviations are possible according to the ma- DDDDDDDDD : 15
chine configuration) 5
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1012-1
Preselecting dry spraying width

If necessary, change the preset width of the area DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
to be dry sprayed (1) using the [ + ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
max. setting = max. configured sheet width
DDDDD DDDDDD 1 :
DDDDDDDDDDD 2 : 15
DDDDDDD : 15
DDDDDDD 3 : 15
DDDDDDDDD : 15
4
DDDDDDDDD : 15
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1012-1
Preselecting quantity of spray-powder

Set the quantity of spray-powder (2) using the [ + ] DD DDDDDD
D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
or [ w ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Dosing of spray powder: 0 to 100 %
DDDDD DDDDDD 1 :
DDDDDDDDDDD 2 : 15
DDDDDDD : 15
DDDDDDD 3 : 15
DDDDDDDDD : 15
4
DDDDDDDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
: 15
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1012-1

Activating dry sprayer

Activate or deactivate the dry spraying (3) using the DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
[ + ] or [ w ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Dry spraying +: When you start and terminate the
automatic production, the dry spraying will be activated
or deactivated automatically. DDDDD DDDDDD 1 :
Dry spraying w: The dry spraying remains deactivated. DDDDDDDDDDD 2 : 15

DDDDDDD : 15
DDDDDDD 3 : 15
DDDDDDDDD : 15
4
DDDDDDDDD : 15
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1012-1
Preselecting dry spraying mode

Set the dry spraying mode (4) using the + or [ w ] DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Dry-spraying mode Auto: Quantity of spray-powder
adapted to the machine speed
Dry-spraying mode fix: Constant quantity of spray- DDDDD DDDDDD 1 :
powder, regardless of the machine speed.

DDDDDDDDDDD 2 : 15
DDDDDDD : 15
DDDDDDD 3 : 15
DDDDDDDDD : 15
4
DDDDDDDDD : 15
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1012-1
Activating powder suction device (option)

Activate or deactivate the suction device (5) using DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
the [ + ] or [ w ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Powder suction +: When you start and terminate the
automatic production, the powder suction will be activ-
ated or deactivated automatically. DDDDD DDDDDD 1 :
Powder suction w: The powder suction device remains DDDDDDDDDDD

deactivated. 2 : 15
DDDDDDD : 15
DDDDDDD 3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
: 15
DDDDDDDDD : 15
4
DDDDDDDDD : 15
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1012-1


Only the setting powdering will be stored in
the job data. All other values remain stored K99-1
irrespective of the job.
Preselecting the coating (option coating module)

Procedure
K58-1
K84
Activate the Coating function using the [ F6 ] key.

F6
K105
The function Coating will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
1 Slow-down time to full stop DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
2 Preselecting supply
1 DDDDDDD
DDDDD
3 Preselecting return flow
DDDDDD 2 60
4 Preselecting emptying time DDDD 50
DDDDD 3 50
5 Coating supply DDDDDD 30

DDDDDDD 4 DDDDD
F6 Function "Coating"
The emptying time (1) indicates when the coating

circulation system is empty after switching off the
coating supply. F1 F2 F3 F4 F5 F6
F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
The slow-down time to full stop can only be

B-1015-1
changed using the SHOP SUPERVISOR DISK.
Preselecting supply
Set the supply (2) using the [ + ] or [ w ] button. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Supply: 0 to 100 % DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Setting in % of the quantity to be supplied to the coat-
ing module. 1 DDDDDDD
DDDDD
DDDDDD 2 60
DDDD
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
50
DDDDD 3 50
DDDDDD 30
DDDDDDD 4 DDDDD
5
F1 F2 F3 F4 F5 F6
F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1015-1

Preselecting return flow

Set the return flow (3) using the [ + ] or [ w ] button. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Return flow: 0 to 100 % DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Setting in % of the coating quantity to be returned to
the coating container. 1 DDDDDDD
DDDDD
DDDDDD 2 60
DDDD 50
DDDDD 3 50
DDDDDD 30
DDDDDDD 4 DDDDD
5
F1 F2 F3 F4 F5 F6
F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1015-1
Preselecting emptying time

The emptying time determines when the collecting
blade is empty so that it can be swung off.
Set the emptying time (4) using the [ + ] or [ w ] but- DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
ton. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
emptying time: 30 to 60 s
1 DDDDDDD
DDDDD
You cannot change the settings for coating
DDDDDD 2 60
supply (5). DDDD 50
DDDDD 3 50
DDDDDD 30
DDDDDDD 4 DDDDD
5
F1 F2 F3 F4 F5 F6
F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1015-1
K99-1
Preselecting "rinse coating" (option coating module)

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Procedure
K58-1
K84

Activate the Rinse coating function using the [ F7 ]

key. F7
The input function Rinsing coating will be K106
displayed.
You can set 6 rinsing programs.
Preselecting pre-rinse time

Set the Pre-rinse time (1) using the [ + ] or [ w ] but- DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
ton. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Pre-rinsing: 0 to 250 s
Pre-setting: 60 (rinsing phase with waste rinsing agent)
1 2 DDDDDDDD
3 4 5
D DDDDDD DDDDDDD DDDDDDDDD DDDDDD
DDD DDD
D D D D
1 60 30 50 50
2 90 30 50 50
3 120 30 50 50
4 120 30 50 50
5 120 30 50 50
6 120 30 50 50
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1014-1
Preselecting clear rinse time

Set the clear rinsing time (2) using the [ + ] or [ w ] DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Clear rinsing: 0 to 250 s
Pre-setting: 30 (rinsing phase with clean rinsing agent)
1 2 DDDDDDDD
3 4 5
DDD DDD
D D D D
1 60 30 50 50
2 90 30 50 50
3 120 30 50 50
4 120 30 50 50
5 120 30 50 50
6 120 30 50 50
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1014-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Preselecting rinsing agent supply quantity

Set the rinsing agent supply quantity (3) using the DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
[ + ] or [ w ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Quantity of rinsing agent (supply): 25 to 99 %
Pre-setting: 50
1 2 DDDDDDDD
3 4 5
DDD DDD
D D D D
1 60 30 50 50
2 90 30 50 50
3 120 30 50 50
4 120 30 50 50
5 120 30 50 50
6 120 30 50 50
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1014-1
Preselecting rinsing agent return flow quantity

Set the rinsing agent return flow quantity (4) using DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
the [ + ] or [ w ] button. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Quantity of rinsing agent (return flow): 25 to 99 %
Pre-setting: 50
1 2 DDDDDDDD
3 4 5
You can enter your notes in the Remarks D DDDDDD DDDDDDD DDDDDDDDD DDDDDD
DDD DDD
field (5) using the [ PC keyboard ]. D D D D
1 60 30 50 50
2 90 30 50 50
3 120 30 50 50
4 120 30 50 50
5 120 30 50 50
6 120 30 50 50
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1014-1
K99-1
Settings "F8: System"

Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K58-1
K84
Activate the System function using the [ F8 ] key.

The function System will be displayed. F8
K107

Activating the ionization system (option)

Activate or deactivate the ionization system at the DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
feeder and delivery. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Ionization +: When you start and terminate production,
the ionization will be activated or deactivated automat-
ically.
Ionization w: The ionization system remains deactiv- DDDDD DDDDDD :
DDDDDD DDDDDD :
ated.
F1 F2 F3 F4 F5 F6 F7 F8
F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1013-1
Setting the powder suction (option)

Activate or deactivate the dust exhauster. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
Vacuum cleaner +: When you start and terminate the DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
production, the dust exhaustion will be activated or
deactivated automatically.
Vacuum cleaner w: The dust exhaustion remains deac-
tivated. DDDDD DDDDDD :
DDDDDD DDDDDD :
Set the suction power of the dust exhauster.
Suction power: 0 to 100 %
F1 F2 F3 F4 F5 F6 F7 F8
F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1013-1
K99-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Program level Production Data Acquisition (PDA) (option) 11
11.6 Program level Production Data Acquisition (PDA)

(option)
1 List of available events (source: Production- DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
Planning System) DDDDDDD DD D DD DDDD DDDD DDDD DDDD
2 Indication: Connection to the Production
Planning System is active. DDDD DDD :
1
3 Selected event (number) and display of the 01: 16: 31:
02: 17: 32:
last event called up. 03:

04:
18:
19:
33:
34:
F1 List of selected events during production 05:

06:
20:
21:
35:
36:
F2 Manual input of a bar code

07:
08:
2 22:
23:
37:
38:
09: 24: 39:

10: 25: 40:
11: 26: 41:
12: 27: 42:
machine configuration) 13:
14:
28:
29:
43:
44:
15: 30: 45:
DDDD : 0 DDDD3DDDD :
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1016-1
11.6.1 Documenting events (option)

Procedure
Activate the program level [ PDA ] (Production Data
Acquisition).
The program level PDA will be displayed. K80-1
Enter the number of the event (2) with the [ digit DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
keys ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Confirm the entry with the key [ Enter ]. 1
The entered event(3) will be transmitted to the Pro- DDDD DDD :
01: 16: 31:
duction Planning System (PPS). 02:

03:
17:
18:
32:
33:
04: 19: 34:
If there is no icon (1) in the upper right corner of the 05:
06:
20:
21:
35:
36:
screen, the PPS is not connected. In such a case, 07:

08:
2 22:
23:
37:
38:
the inputs will be stored locally and transmitted the

09: 24: 39:
10: 25: 40:
11: 26: 41:
next time the PPS is connected. 12:

13:
27:
28:
42:
43:
Do not work for a longer time without con- 14:

15:
29:
30:
44:
45:
nection to the PPS. DDDD : 0 DDDD3DDDD :
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1016-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Using the barcode reader

Entering events is also possible with a barcode reader
irrespective of the selected main menu.
Hold the objective on the barcode and press the key
to start the reading.
Activate the List function using the [ F1 ] key.

11 Program level "Diagnosis"
Entering the bar code by hand

Activate the Mark code function using the [ F2 ] DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
If a Production Planning System (PPS) is connected,
1
an icon (1) will be displayed.
DDDD DDDDD DDD
Enter the bar code (2) with the [ digit keys ].
:

If no Production Planning System (PPS) is connec-
ted, the bar code will be stored locally and transmit- DDD :
2
ted next time the system is connected.
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1018-1
11.7 Program level "Diagnosis"

F1 Diagnosis messages, Prot. guards DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
F2 Diagnosis messages, Sheet travel DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
F3 Diagnosis messages, Machine.
F4 Diagnosis messages, ELECTRONIC DDDD: DDDD DDD DDDDDDDD DD D DDDDDDD DDDDD 0259000
DDDD: DDDD DDD DDDDDDDD DD D DDDDDDD DDDDD

F5 Diagnosis messages, OTHER CAUSE
0231000
F6 Total sheet counter / total operating hours

counter
F7 Last alarm messages
F1 F2 F3 F4 F5 F6
F6 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-989-1
11.7.1 Viewing diagnosis messages

Procedure
Activate the program level [ Diagnosis ].
The program level Diagnosis will be displayed.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K74-1

Program level "Diagnosis" 11
Select the diagnosis messages for certain zones of DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
the machine with the keys [ F1 ] to [ F5 ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Diagnosis messages Prot. guards
Diagnosis messages Sheet travel DDDD: DDDD DDD DDDDDDDD DD D DDDDDDD DDDDD 0241000

Diagnosis messages Machine. DDDD: DDDD DDD DDDDDDDD DD D DDDDDDD DDDDD 0231000
Diagnosis messages ELECTRONIC DDDD: DDDD DDD DDDDDDDD DD D DDDDDDD DDDDD 0179000
Diagnosis messages OTHER CAUSE

Certain diagnosis messages (e.g. open
guard) will be confirmed automatically as
soon as the cause is eliminated (e.g. the
guard has been closed).
Select the diagnosis messages with the keys [ Curs-
or: Up ] or [ Cursor: Down ]. F1 F2 F3 F4 F5 F6
F6 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-989-1
Press the key [ ? ].

You receive information on causes and possible ?
measures you can take. K72-1
WARNING:
Danger of serious injury and damage to
the machine, if you try to solve problems
that only trained service personnel is al-
lowed to eliminate!
NEVER carry out instructions that are
strictly reserved for trained service per-
sonnel. Such instructions are designated
by the message "The following informa-
tion is for trained and authorized service
personnel only!".
Only carry out those measures to eliminate the

trouble that are not reserved to authorized and
trained service personnel.
Confirm the diagnosis message with the key [ Enter ]

when the trouble is eliminated.
The diagnosis message will be deleted from the list. K99-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

11 Program level Service (General)
Activating last alarms

Activate the Last alarms function using the [ F7 ] hh hhhhhh
h hh
hh hh
hhh h
0 0 hhh hhhh
key. hhhhhhh
hh h hh
hh
hhhh
hhhh
hhhh
hhhh
hhh
hhhh
hh
hhhh
The diagnosis messages of the last 24 hours will be 19-02-04 09:10:00 65-1-0-0-0
displayed. hhhh hhhh hhhhhhhh

18-02-04 15:35:20 65-1-0-0-0
hhhh hhhh hhhhhhhh

Scroll in the list with the key [ Cursor: Up ] or [ Curs- 18-02-04 15:29:30 63-7-0-1-0
or: Down ].
hh hhh hhhh hhhh hhhh
18-02-04 15:28:00 65-1-0-0-0
hhhh hhhh hhhhhhhh

18-02-04 15:17:10 63-7-0-1-0
hh hhh hhhh hhhh hhhh

18-02-04 14:41:33 2-6-16-0-0
hhhh hhh hhhh hhhhh hhhhh

18-02-04 14:25:36 65-1-0-0-0
hhhh hhhh hhhhhhhh
F1 F2 F3 F4 F6 F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-996-1
11.7.2 Viewing the readings of the counters for total sheets and
operating hours
Procedure
Activate the program level [ Diagnosis ].
The program level Diagnosis will be displayed.
K74-1
Activate the function Totalizer with the key [ F5 ].

The reading of the counter for total sheets and op-
erating hours will be displayed.
11.8 Program level Service (General)

The functions of the Service program level vary ac-
cording to whether the JP (preparations) or PR (pro-
duction) program level has been selected.
F1 RSD REMOTE SERVICE DIAGNOSIS (option) DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
F2 Function "Service" DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
F3 Preselecting language, date, measuring and
temperature units DDDD DDDDD DDDDDDDD : DDDDD
DDDDDD : DDDD
F4 Writing ink slide data on a JobCard
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F5 Viewing the machine park

F6 Preselecting make-ready mode (option)
F9 Storing base job (PR only)
F10 Switching off the printing machine
F1 F2 F3 F4 F5 F6 F7 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1066-1

Program level Service (General) 11
11.8.1 Preselecting language, date, measuring and temperature

units
Procedure
K58-1
Activate the program level [ Service ].
K67-1
Activate the Setting function using the [ F3 ] key

The current settings will be displayed. F3
K102
If more than one language is configured, you can DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
change the language with the key [ + ]. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Change date and time with the keys[ + ] or [ w ].
DDDDDD : DDDDD DDDDDD : DDDDD
Change the date format with the key [ + ] or [ w ]. DDDDDD : 14 : 35 DDDDDD : DDDDD
DDDDD : 19 . 03 .2004
Date mode Europe: Day.month.year DDDDD DD : DDDDD

DDDDDDD : DDD
Date mode USA: Month.day.year DDDDDDD : DD
Date mode Japan: Year.month.day
Change the measuring unit with the keys [ + ] or
[ w ].
Date mode mm: Millimeter
Date mode in: inch
Change the temperature measuring unit with the F1 F2 F3
F3
F4 F5 F6 F7 F8 F9 F10
key [ + ] or [ w ].
B-1027-1
Date mode C: Degree Centigrade
Date mode F: Fahrenheit
The program and text version is displayed in
the upper right corner of the mask. This data
cannot be edited.
K99-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

11.8.2 Reading and writing ink slide data

Reading ink slide data from a JOBCARD or writing them
to a JOBCARD.
Procedure
K85-1
K67-1
The program level Service will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD 1DDDD
0 DDD DDDD
DDD DD
DDDD DDDDDD DDDDDDDD : DDDD

DDDDDDDD : DDDD
F2 F3 F4 F5
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-863-1

1
2
LS-03036-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Activate the Ink slide data function using the [ F4 ]

key. F4
K103

Reading ink slide data from a JobCard (PL JP only)

Activate the Read function using the [ F7 ] key. DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
The ink slide data are read from the JOBCARD and DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
written into the job storage.
After the end of the reading procedure, the mark on
the key [ F7 ] will disappear.
F4 F6 F7
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1054-1
Writing ink slide data on a JobCard

Activate the Write function using the [ F6 ] key DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
The ink slide data of the job data storage will be DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
written to the JOBCARD.
F4 F6 F7
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1054-1

JOBCARD READER.
1
3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
LS-03036-1

11.8.3 Viewing the machine park

Procedure
K58-1

The program level Service will be displayed.
K67-1
Activate the Machine park function using the [ F5 ]

key. F5
K104
All machines in the network will be displayed. The DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD DD
DDDD
data cannot be edited. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
DDDDDDDD DDDDDD DD DD
30286B DDDDDD 5 54
DDDDDD 10 24
DDDDDD 10 34
DDDDDD 10 48
DDDDDD 10 54
DDDDDD 10 62
F5
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1029-1
11.8.4 Deactivating emergency mode detector in the water fountain

(PR only)
Failure of the sensor in the water fountain of a printing
module. The sensor must be deactivated so that the
current work step can be finished and the ink rollers
can be washed.
Procedure
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K58-1

K67-1
Activate the Emergency operation function using

the [ F7 ] key. F7
K106

Enter the number of the printing module with the

key [ + ] or [ w ] in which you want to deactivate the
water fountain sensor.
The entered printing module number will
automatically be reset to 0 when the printing K99-1
machine is switched off.

Have yourMAN ROLAND sales / service partner or
qualified and specialized service personnel repair
the defective sensor immediately.
The sensor will be activated again as soon
as you make the next work step ready - see
function F9: Make-ready in the main menu
Work step. The printing module number is
displayed in red. By reconfirming with the
key [ Enter ], you can reactivate the sensor.
11.8.5 Storing base job (PR only)

Storing a model job with frequently used data for an
easier creation of new work steps.
Conditions
A work step must be in process in the program level
[ Production (PR) ].
Procedure
K58-1

K67-1
Activate the Base job function using the [ F9 ] key. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
A message box will be displayed. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Message: Do you want to store the current job as a
model for future jobs?
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Possible operations DDDDDDD DDDDDDDD

F4: NO
F5: YES DDD DDDD DDD DDD DD DD DDDDD DDDDDDD
DDDDD DD DD DDDDD DDDDDDD
Store the current job data with the key [ F5: Yes ] as
base job.
By storing a new base job, you overwrite the
existing base data.
F4 F5 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1031-1

11.8.6 Switching off the printing machine

Conditions
If a COLORPILOT ink control system is connected, the
machine must be disconnected appropriately at the
central control console to avoid loss of data.
Procedure
K58-1

K67-1
Switch off the printing machine with the key [ F10 ]. DD DDDDDD
D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
A message box will be displayed. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Message: Do you want to switch off the machine?
Possible operations
F4: NO DDDDDDD DDDDDDDD
F5: YES
Confirm the switching-off of the printing machine
with the key [ F5: Yes ].
The central control console shuts down. The print-
ing machine will be switched off.
F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-846-1
The main switch switches to a neutral position.

OFF
ON
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
LS-03391-1

11.8.7 Settings in the menu Service

Procedure
K58-1
K67-1
Activate the Service function using the [ F2 ] key.
The storage capacity of the computer that is still DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
available will be displayed. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Storage capacity: 1 to 100 %
DDDDDDDDDDDDDDD
DDDDD D : DD D DDD
DDDDD D : DD D DDD
F2
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-847-1
If there is not much storage capacity left on drive 2,

delete jobs and CCI-protocols you do not need any
more.
Automatic zero adjustment (PR only)
Activate the Automatic zero adjustment function DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
using the [ F5 ] key.. DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
Select the printing machine module in which you
want to set the positioning drives to zero with the DDDDDDD DDDDD DD DDDDDDDDDD
keys [ F6 ] to [ F9 ].
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
F2 F5 F6 F7 F8 F9
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1032-1

The display changes over to the selected module DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
(e.g. delivery) . DDDDDDD DD D DD DDDD DDDD DDDD DDDD
DDDDDDD D DDDDD D DDDDD DDDDD

DDDDDDDDD D 52 0
DDDDDDDDD D 52 0
DDDDDDD 255 0
F1 F2 F3 F4 F5 F6 F7 F8 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1033-1
Select the desired component and press the key

[ + ].
Automatic zero setting +: The stepping motor will be
set to zero.

Components that are not relevant to safety, e.g. cir-
cumferential registers, will be set immediately. K99-1
In case of components that are relevant to safety,

e.g. at the feeder or delivery, the corresponding
LED will be lit on the key of the key field of the
printing machine, e.g. Sheet jogger, A-side.
The LED next to one of the [ Edit keys ] is flashing.
K260
Press and hold down the [ Edit key ] until the detect-
or stops the drive.
The automatic zero setting is terminated.
Executing the test programs (with MAN Roland service only)

Activating test programs upon consultation with the
sales / service partner
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Activate the Test function using the [ F8 ] key. DD DDDDDD

D DD DDD D
DD DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
A message box will be displayed. DDDDDDD DD D DD DDDD DDDD DDDD DDDD
Message: After TEST, the machine must be
switched off and on.
Possible operations DDDDDDD DDDDDDDD
F4: NO
F5: YES DDD DDDD DDD DDD DD DD DDDDD DDDDDDD
After confirmation with the key [ F5 ], the test pro- DDDDD DD DD DDDDD DDDDDDD
grams will be activated.
Activate the test programs with the key F5: Yes.
Follow the instructions of the sales / service partner.
F4 F5 F8
Press the key [ ESC ] on the PC-keyboard, if you F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
wish to terminate the test program. B-1036-1
11.8.8 Activating ink slide zero setting (PR only)

Procedure
K58-1
K67-1
Activate the Service function using the [ F2 ] key.
Activating the ink slide zero setting at the central control console
Activate the Adjust / Position function using the
[ F6 ] key. F6
K105
Activate the Slide adjustment function using the

[ F7 ] key. F7
The ink slide zero setting at the printing modules is K106
activated.
The ink slides zero setting with the portable
terminal is described in the chapter Printing
module.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Final tasks
Ink slide zero setting using the portable terminal
(see page 8-10)
Resetting parameters for ink presetting (PR only)
(see page 11-180)

11.8.9 Preselecting make-ready mode (option)

Preselecting a make-ready function at the central con-
trol console
Procedure
K58-1
K67-1
Activate the Make-ready function using the [ F6 ]

key.
Preselect a function. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
No. 19: AID: Installing / Removing DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
No. 20: Operational test
No. 21: AID: Setting the contact pressure DDDDDDDDD
D DDDDDDD
No. 22: ABD: Setting the contact pressure 19 DD DDDDD DDDD
No. 31: Positioning the machine to check the begin- 20 DDDDDD
ning of the powdering 21 DD DDDDDDD DDD
22 DD DDDDDDD DDD
No. 32: Feed register: Parameterizing the double 31 DDDD DDDDDD D DDDDD DD DDDDDD
sheet control 32 DDDD DDDDDDDD DDD
33 DDDDD DDDD D DDDDDD
No. 33: Printing unit: Adjusting the plate tensioning 34 DDDD DDDDDDDD
bar
No. 34: Coating module: Changing the coating forme
F6
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1041-1
K99-1
The 7-segments indicator shows the selected func-

tion at the printing module.
K637-1
Press the key [ Make-ready ] at the printing module.

Execute the preselected function.
K575-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Shop supervisor disk 11
11.9 Shop supervisor disk

11.9.1 Description
A Shop Supervisor Disk on which the configuration
of the central control console and printing machine is
stored, is included within the delivery of the printing
machine. The text on the shop supervisor disk is in 0 35H xxxx 35 V04.40-x
German and English (SHOP SUPERVISOR DISK).
Datendiskette Leitstand
Only specially authorized personnel are allowed to use Saalmeisterdiskette
the shop supervisor disk; keep it in a safe place, in- Shop supervisor disk
Maschinennummer: xxxxxB
accessible for unauthorized persons. We do not ac-
cept any liability for damage to the machine and loss
MAN Roland 2004
of data resulting from the disk being used by unauthor-

ized personnel.
With the shop supervisor disk you can change printing
machine parameters in different program levels (e.g.
Program level Service, function F7: Configuration).
LS-05511-1
11.9.2 Deleting a work step using the shop supervisor disk (JP only)
Deleting work steps that erroneously have the status
IN JP or IN PR although they are terminated.
DISK)
Procedure
K85-1
K86
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

11 Shop supervisor disk
Insert the shop supervisor disk into the disk drive.

Shop supervisor disk (SAALMEISTERDISKETTE / SHOP SU-
PERVISOR DISK)
LS-03696-1
Deleting a work step

CAUTION: With the shop supervisor disk you
can delete work steps that are still being pro-
cessed.
The data of the selected work step will be displayed. F7
K106
Press the [ F5 ] key, Confirm. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD
DDD
DDDD
DD
A notice is displayed: JOB CANNOT BE DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
DELETED. DDDDD DDDDDD
Press the [ F5 key, Confirm ] again. DDDDD : DDD
DDDDD : DDD
The work step has been deleted. DDDDD : DD DDDD

After completion of the tasks, immediately DDDD : D D DDD DDDDDDD : D DD
take the shop supervisor disk out of the drive DDDDD : DDDD DD
DDD DDD : DDD DD
and keep it in a safe place, inaccessible for DDD DDDD : DDD DD DDD :
DDD DDD : DDD DD DDDD
unauthorized persons.
:
DDDD :
F4 F5 F7
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-852-1
11.9.3 Changing the machine configuration

06.09.2004 10:35:31 - 747 - 80 95A EN 6778

DISK)
Procedure
K58-1
K67-1


On the disk there is the following text: SHOP SUPERVISOR
DISK
PERVISOR DISK)
After completion of the tasks, immediately

take out the shop supervisor disk and keep it
in a safe place, inaccessible for unauthorized
persons.
Activate the Service function using the [ F2 ] key. 1
Activate the Config function using the [ F7 ] key.
To change over between the different menus, use LS-03696-1
the keys [ F4 ] or [ F5 ].
With the shop supervisor disk, you can
change the configuration in the following
menus:
Menu 01 Machine description
Assigning a name to a printing machine operated in
the network. Change the machine name before you
create a new work step.
Change the parameter Machine name with the PC-
keyboard.
All printing machines of the network must
have different names.
The modification will take effect after switch-
ing the printing machine off and on.
Menu 06 Menu configuration

Locking the creation of new work steps at the cent-
ral control console / Selecting the ink zone presetting
method.
Deactivate the parameter with the key [ w ].
Creating jobs +: At the central control console you can
create new work steps.
Creating jobs w: At the central control console you
cannot create new work steps.
Select the ink zone presetting method.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Presetting method LCS1: Possibility of selection LCS

from inking unit to inking units
Presetting method w: The ink slides are set without
considering LCS.
Menu 08 CCI-menu
Selection of a Multi-CCI measuring console, if at least
2 Multi-CCI measuring consoles are connected to the
network.

Select the measuring console with the keys [ + ] or

[ w ].
Measuring console Standalone: Not designed as a
measuring console.
Measuring console Multi measuring console: Designed
as a measuring console.
Menu 10 Characteristic curve menu

Determination of the machine speed up to which the
blast frame is to work with a min. air quantity.
Enter the machine speed starting from which the
blast frame is to work with the max. air quantity.
Speed air (+) blast frame: 0 to 12 000 Sh/h
Preset value: 50 (5000 s/h).
Enter the air quantity of the blast frame in % which
is to be effective below the blast frame switching
speed.
Blast frame min. value: 0 to 100 %
Preset value: 70 %
Menu 11 Machine setting I

Setting of an alternative starting signal on two neigh-
boring printing machines.
Set the starting signal with the keys [ + ] or [ w ].
For the safety of the personnel on the printing
machine it is absolutely necessary to have
different starting signals in order to avoid
confusion and, thus, danger to the person-
nel.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Menu 15 Step width menu

Changing the setting path of stepping motors
Set the step width with the keys [ + ] or [ w ].
Step width: 0 to 10 mm (0 to 0.394 in)
The step width must never be below 1.0
since otherwise the pile supporting plate will
no longer automatically align the pile.

11.9.4 RSD REMOTE SERVICE DIAGNOSIS (option)

Making a modem connection between the printing ma-
chine and a service computer for the remote diagnosis
of trouble.
Conditions
ISDN-connection
Procedure
K58-1

After completion of the tasks, immediately K67-1
take out the shop supervisor disk and keep it

in a safe place, inaccessible for unauthorized
persons.
Activate the RSD function using the [ F1 ] key.

F1
K41
The screen mask RSD will be displayed. At the DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
lower screen edge you see the telephone number DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
called last.
RSD
DDDDD DDDDDDD :
DDDDDDDD : DD DDDDDD DDDDDD :
F1 F7 F8
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1038-1
Start the dialing procedure with the key [ F6 ].

A soon as the connection is made, the correspond-
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
ing symbol will be displayed in the status range.

The text on the keys changes to Abort.
By means of the modem connection, the MAN
ROLAND Service can copy data to the hard disk,
view stored data there and, thus, locate and identify
trouble..
Terminate the connection with the key [ F6 ].
The connection will be disconnected auto-
matically, if no data is transferred within 20
minutes.

Activate the Call number function using the [ F7 ]

key.
The stored telephone numbers will be displayed. DD DDDDDD

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
DDDD DD DDD DDDDDD
1234 DDD
333484 DDDDDD
DDDDD DDDDDDD : DDDDDD

333484
DDDDDDDD : DD DDDDDD DDDDDD :
F7 F8 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1039-1
Create a new telephone number by pressing the

key [ F8: New ].
Admissible signs: Digits from 0 to 9. Slash, hyphen,
comma and blanks are allowed, too. These signs serve
to present a clear list, but during the dialing procedure
they are ignored.
Change the stored telephone number with the key
[ F9: Change ].
Delete a stored telephone number by pressing the
key [ F10: Delete ].
11.9.5 Resetting parameters for ink presetting (PR only)

Resetting the correction values for ink slides after an
ink slide zero setting. Resetting parameters
(self-learning option) to MAN ROLAND values.
DISK)
Conditions
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Procedure
K58-1
K77


PERVISOR DISK)
LS-03696-1

key.

D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
DDDDDD 1 2 3 4 L
3 Correcting calculation DDDDDDD B C M Y /
F6 Function Start
DDDDDD + + + +
1
F7 Presetting function DDDDD 2 Auto Auto Auto Manu
DDDDDDDD
F6 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1147-1

button.
inking unit.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

11 Post Mortem Dump
Resetting parameters for ink presetting

Press the [ F2: MRB values ] key. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
The stored preset ink values are automatically reset DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
to the MAN Roland values.
DDDDDD 1 2 3 4 L
DDDDDDD B C M Y /
DDDDDD + + + +
DDDDD Auto Auto Auto Auto

DDDDDDDD 100 100 100 100
F2 F3 F6 F7 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1152-1
Resetting correction of the ink slide

Resetting the correction values after an ink slide zero
setting.
Press the [ F3: Slide adjustment ] key. DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
The correction values stored individually for the ink DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
slide are automatically reset.
DDDDDD 1 2 3 4 L
After completion of the tasks, immediately DDDDDDD B C M Y /
take the shop supervisor disk out of the drive

DDDDDD + + + +
and keep it in a safe place, inaccessible for DDDDD Auto Auto Auto Auto
unauthorized persons. DDDDDDDD 100 100 100 100
F2 F3 F6 F7 F9 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1152-1
11.10 Post Mortem Dump

11.10.1 Description
After a fatal error in the program, a message is dis-
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
played on the screen:POST MORTEM DUMP

the automatic production stops.
The printing machine can only be jogged now.

Post Mortem Dump 11
11.10.2 Measures to be taken after a POST MORTEM DUMP (PMD)

POST MORTEM DUMP PMD COPY PROGRAM
disk
Key for switch cabinet
Procedure
Label the delivered diskPMD COPY PROGRAMM.
PMD COMPANY ADDRESS: Name of the customer
PMD DATE: Date of the POST MORTEM DUMP
PMD MACHINE TYPE: Machine type, e.g. R 700
PMD MACHINE NUMBER: Machine number
PMD PROGRAM VERSION: - see display on the screen PMD copy programm
PMD TERMINATION ADDRESS (CS IP): - see 8-digit display

on the screen CS IP XXXX:YYYY - company address date
POST MORTEM DUMP PMD COPY PROGRAM disk machine type machine number
program version termination address(CS IP)

MAN Roland 2004
LS-06010-1
Remove the cover from the disk drive.

Insert the PMD -disk into the drive.
LS-03696-1

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
OFF
N
O
LS-03432-1

11 Emergency operation
Switch on the printing press using the [ main

switch ] - see chapter Printing press -.
OFF
ON
02-03087-1
Carry out the work steps displayed on the screen of

the central control console.
Take the disk out of the drive.
Close the cover of the disk drive.
Send the disk to MAN ROLAND, Dept.
ELEKTROSERVICE.
11.11 Emergency operation

11.11.1 Emergency disk
If the central control console program does not start
after the printing machine has been switched on, the
EMERGENCY-Disk offers you the possibility to oper-
ate the central control console program using the last
back-up copy. 0 35 D 4239 35 V01.00
In case of emergency operation, all changes, EMERGENCY Disk

Tools
work steps and protocols since the last
back-up will be lost.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
LS-06011-1

Emergency operation 11
11.11.2 Working with the back-up copy of the central control console
program
Emergency diskEMERGENCY-DISK
Procedure
If the central control console program does not start
automatically when you switch on the printing ma-
chine, immediately inform your MAN ROLAND sales /
service partner.
Only use the emergency disk in compliance
with the instructions given by yourMAN
ROLAND sales / service partner.
Remove the cover from the disk drive.

Insert the emergency disk EMERGENCY-DISK into
the drive.
LS-03696-1

OFF
N
O
LS-03432-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

11 Matching desk
Switch on the printing press using the [ main

switch ] - see chapter Printing press -.
OFF
ON
02-03087-1
Carry out the work steps displayed on the screen of

the central control console.
The emergency disk must remain in the drive while
you are working with the central control console
program.
The emergency disk must remain in the drive
until the MAN ROLAND sales / service partner
has terminated the emergency operation and
the problem is solved.
During emergency operation, you cannot
activate the function TOOLS.
11.12 Matching desk

11.12.1 Matching desk
1 Control keys
2 ColorPilot color control system (option)
3 Color matching lamp 3
4 Ambient light guard (Option)
5 Profile indication, ink slide position (option) 4
6 Setting keys: Angle of inclination of the area
where the sheet is placed
7 Setting keys: Contrast of the profile display 2 5
(option)
1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
7 6
LS-03155-2

Matching desk 11
11.12.2 Overview of the operating panels

Control keys at the matching desk
3 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
2
1 5 6 7
14 %
15 8 7 6 5 4 3 2 1 12 10 9
13 11 8
LS-02673-2
1 Ink slide keys 9 Brief increase of dampening solution

2 7-segments indicator: ink slide position 10 Ink stripper / ink spatula
3 Display: Ink zone number 11 Group of buttons [ Percent ]
4 Display: Ink zone block 12 Key : locking
5 DUCTOR STRIP 13 Printing module keys
6 Water fountain roller 14 Display: mode "Preparation"
7 Release 15 Preparation
8 Circumferential / side / diagonal register
Group of buttons [ Percent ]

1 Status indicators
%
2 LED-display: Ink slide position (%)
3 UP (to increase the value) 1 2 3 5
4 DOWN (to decrease the value)
5 Enter (to confirm the entry) 4
LS-03144-1
11.12.3 Presettings
Forming a block of ink zones at the matching desk
Form blocks of ink zones, if you want to change the
ink slide positions of the adjacent ink zones accord-
ing to the set percentage or if you want to carry out
Ink stripper / Ink spatula in several ink zones at the
same time.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Press and hold down both [ ink slide keys ] of the 24

first ink zone of the block.
LS-03141-1

11 Matching desk
Press both [ ink slide keys ] of the last ink zone of 24

the block.
LS-03141-1
The LED Ink zone block (1) above the selected ink 1 1
zones is on.
19 20 21 22 23 24
The ink slide block also remains active when
you choose another printing module.
LS-03142-1
To cancel the ink zone block, press both [ ink slide 24

keys ] in any ink zone of the block.
The LED Ink zone block goes out.
LS-03141-1

Procedure
Setting the ink zone status "locked"
Press both [ Ink slide key ] twice. 24
LS-03141-1
The ink zone is marked with a dash (see picture, 19 20 21 22 23 24

ink zone 21).
Ink zone status locked: A change of the current ink
slide position is not possible. The ink slide keys are
locked.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
LS-03143-1

Matching desk 11
Setting the ink zone status "inkfree"

Important! 24
Danger of damage to ink fountain roller

and ink slides during the zero setting. The
ink slides may be pressed against the ink
fountain roller. In this case, the ink foun-
tain roller will be deformed. This will in-
fluence the ink dosage of the adjacent ink
slides. The ink slide front edges will be LS-04595-1
worn excessively.
Constantly observe the ink fountain roller
during the zero setting. When the ink slide
is in zero position there must still be a
very thin film of ink on the ink fountain
roller. The ink slides should NEVER strip
off the ink completely from the ink foun-
tain roller.
Close the ink slides with the lower [ ink slide key ].
The 7-segments indicator [ Slide position ] shows
000.
Press both [ Ink slide key ] twice. 24
LS-03141-1
The ink zone is marked with a dash (see picture, 19 20 21 22 23 24

ink zone 21).
Ink zone status ink-free: The ink slides are closed. The
ink slide keys are locked.
The [ ink slide keys ] in the zones marked as "ink-
free" or "locked" are without function.
LS-05145-1
Setting the ink zone status "uncontrolled"

- only in connection with a COLORPILOT ink control sys-
tem -
Press both [ Ink slide keys ] three times. 24
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
LS-03141-1

11 Matching desk
ONLY with the optionCOLORPILOT: The ink zone will 19 20 21 22 23 24

be marked with a u (in the picture, ink zone 23).
Ink zone status uncontrolled: The ink zone is excluded
from the automatic control (option). A manual change
of the ink slide position is possible.
LS-03143-1
Canceling the ink zone status

Press both [ ink slide keys ] of the desired ink zone. 24
The symbol for the ink zone status goes out.

You have to cancel the ink zone status for
each ink zone or for each ink zone block sep-
arately.
LS-03141-1
Locking the buttons on the matching desk to protect the settings against being
changed unintentionally
Press the key [ Lock ].
K87
The ink zones are marked with dashes ---- (1). 19 20 21 22 23 24
The keys are locked to protect the settings against 1

being changed unintentionally.
LS-03267-1
To unlock the [ ink slide keys ], press the corres-

ponding [ printing module key ].
The locking of the keys is released. 11 10 9 8 7 6 5 4 3 2 1
LS-02841-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Selecting the printing module at the matching desk

Press the desired [ Printing module key ].
The LED on the key is on.
11 10 9 8 7 6 5 4 3 2 1
LS-02841-1

Matching desk 11
Changing over the matching desk to the mode "Preparation"

K89
The LEDs (1) under the ink slide keys are flashing. 19 20 21 22 23 24
As long as the LEDs are flashing, the connection

between printing machine and matching desk is
interrupted. You can work at the matching desk
without influencing the running production. 2
You can change over to the mode Job Pre-
paration (JP) only, if the program level Job
Preparation (JP) is preselected on the cent- 1 1
ral control console. LS-03145-1
Setting the contrast of the ink slide profile display (option)

The block of keys is on the underside of the matching
desk.
Change the contrast of the ink slide profile display

with the keys [ Contrast + / w ].
K908
Setting the inclination of the area where the sheet is placed

The block of keys is on the underside of the matching
desk.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

11 Matching desk
Change the inclination of the area where the sheet is

placed with the keys [ Inclination + / w ].
K907
11.12.4 Inking corrections

Setting the inking at the matching desk
You have different ways to influence the inking at the
matching desk.
Procedure
Select a printing module with the [ Printing module
keys ].
11 10 9 8 7 6 5 4 3 2 1
LS-02841-1
Changing individual ink slide positions at the matching desk

Press the upper or lower [ Ink slide key ]. 24
K95
The 7-segments indicator (1) over the [ ink slide 24

keys ] provides information on the selected ink slide 1
position.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
LS-03140-1
Always coordinate the ink slide openings with

the ductor roller strip width.

If no ink zone block is selected, the change applies to
all ink zones.

Matching desk 11
Press the [ Up ] (2) or [ Down ] (3) button until the

LED (1) shows the desired percentage value.
%
Changing the ink slide position (%): -25 to 25 %, Step 1
width: 1 % 2
Confirm the entries with the [ Enter ] key. 3
LS-03410-1
The blue status indicator (1) next to the 7-segments

indicator is on.
%
Once the ink slides have been set to the new value,
1
the status indicator will go out.
LS-05149-1
Always coordinate the ink slide openings with

the ductor roller strip width.
Changing the ink ductor roller strips on the matching desk

Press the upper or lower [ Ductor roller strip width ]
button until the 7 segments display shows the de-
sired percentage value.
Always coordinate ductor roller strip width
with the ink slide opening.
K245
Executing the function "Ink stripper / ink spatula" at the matching desk
Brief removing of ink or creating of an ink surplus in
several or all ink zones of an inking unit.
Procedure
Select a printing module with the [ Printing module
keys ].
Starting the function "Ink stripper / ink spatula" at the matching desk
Press the button [ Ink stripper / Ink spatula ].
The LED under the key is on.
The LED under the key is on.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
K79

11 Matching desk
Carrying out the function "Ink stripper / ink spatula" in all ink zones by changing the ductor roller strip
width
Press the upper or lower [ Ductor roller strip width ]
button until the LED shows the desired percentage
value.
K245
Carrying out the function "Ink stripper / Ink spatula" in adjacent ink zones
Form an ink zone block.
%
For stripping of the ink press the [ Down ] button (3)
until the 7-segments-indicator (1) shows the desired 1
2
slide position.
3
For increasing the ink supply, press the [ Up ] but-
ton (2) until the 7-segments indicator (1) shows the LS-03410-1
desired ink slide position.

In locked ink zones, the selected ink slide position
remains stored.
You can select a further printing module,
even if the function Ink stripper / Ink spatula
in another printing module is not yet termin-
ated.
Carrying out the function "Ink stripper / Ink spatula" in one ink zone
Press the upper or lower [ Ink slide key ]. 24
K95
The 7-segments indicator (1) over the [ ink slide 24

keys ] provides information on the selected ink slide 1
position.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
LS-03140-1
Terminating the function "Ink stripper / ink spatula" at the matching desk
Press the button [ Ink stripper / Ink spatula ].
The LED under the key goes out.
The LEDs under the keys go out.
Thereafter all ink slides will automatically be reset to
the original value.
K79

Matching desk 11
11.12.5 Register corrections

Setting the registers
Conditions
Printing plates are mounted in the printing modules.
The printing plate change is terminated.
The machine turns at basic speed or production
speed.
Procedure
Select a printing module.
11 10 9 8 7 6 5 4 3 2 1
LS-02841-1
Activate the keys [ Register ] with the key [ Release ] 2

(7). 3
The LED is flashing. 1
7 4
Set the circumferential register with the keys [ Cir-
cumferential register ] (2) (6).
0.039 in), Step width: 0.01 mm (0 in) 6 5
Circumferential register: Coating module: -0.5 to 2 mm
(-0.02 to 0.079 in), Step width: 0.01 K914
Set the side register with the keys [ Side register ] (1)
(4).
Step width: 0.01 mm (0 in)
Set the diagonal register with the keys [ Diagonal
register ] (3) (5).
To set the diagonal register, proceed from the right
sheet edge.
Diagonal (Cook) register: -0.15 to 0.15 mm (-0.006 to
The LEDs show the change of the setting.
LS-05133-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
A blue status indicator over the keys Register is lit as

long as the registers are set.
You can also set the register at the central K974
control console program level Production,

main menu Register.

11 JobCard Reader
11.12.6 Dampening corrections

Setting the water fountain roller speed at the matching desk
Press and hold down the upper or lower key [ Water
fountain roller ].
Water fountain roller speed (color matching desk): 15
to 100 %, Step width: 1 %
The water fountain roller speed will change as long
as you press the key.
K93
Briefly increasing the quantity of dampening solution from the matching desk
Press the key [ Overdampening ].
The LED is on.
Brief overdampening, duration: 3 s
After a few seconds the brief overdampening will be
stopped automatically. K71
Thereafter, the previous water fountain roller

values will be reset automatically.
11.13 JobCard Reader

11.13.1 JobCard Reader
1 Green LED: Function indicator. No JobCard
inserted. You can insert a JobCard.
1, 2 Green LED + Red LED: A JobCard is inser-
ted. You can press the key Eject (3). 1 2
2 Red LED: The JobCard is being read or writ-
ten. You must not press the key Eject (3).
3 Ejecting key for removing a JobCard.
3
LS-02553-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

JobCard Reader 11
11.13.2 Description
The JOBCARD READER (1) is integrated into the central
control console.
The JOBCARD READER reads stored data from a
JOBCARD or stores data on a JOBCARD.
LS-02948-3
The JOBCARD is the storage medium for the JOBCARD

READER.
You can read the following information from a
JOBCARD or store it on a JOBCARD:
Surface areas in % of the printing plate (determined by
the EPS plate scanner or the PrePress Link);
Ink slide positions and ductor roller strip width of a
work step.
On a JOB CARD you can only store the data of one
work step.
11.13.3 Handling the JobCard Reader

1
2
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
LS-03036-1

11 Notes concerning printing

JOBCARD READER.
1
3
LS-03036-1
11.14 Notes concerning printing

11.14.1 Ink slide presetting, based on surface areas
Entering the correcting value (F7: Presettings)
If the ink slide positions calculated from the surface DD DDDDDD
D
DD
DD DDD D
DD 0
DD
0 DDD
DDDD DDDD DDD
DDDD
DD
area data are generally too high or too low, the result DDDDDDD DD D DD DDDD DDDD DDDD DDDD
can be corrected in either direction, up or down, by
entering a correcting factor (2). DDDDDD 1 2 3 4
DDDDDDD B C M Y
Recommended procedure:
DDDDDD + + + + 1
1. Read the surface area data (see program level Job DDDDDDD 2 100 100 100 100
Preparation (JP), main menu Damp / Ink) and start the

automatic calculation without changing the preset cor-
recting value (100 %).
2. Evaluate the printing result.
3. With the next, similar printing job, enter a correcting
F7 F10
value for calculating the ink slide positions, if you are F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
not satisfied with the printing result in some or all print- B-897-1
ing modules.
A modification of further parameters ([ key
F8 ]) is recommended only if the calculated
ink slide position cannot be optimized any
further by manipulating the correcting value.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Notes concerning printing 11
Modifying parameters (F8: Parameter)

The mask Parameter contains 2 zones: DD DDDDDD
D DD DDD D
DD DD 0
DD DDDD
0 DDD DDDD
DDD DD
The upper zone (1) displays the max.surface areas of DDD / DDD
printing plates read from the JobCard as well as the
DDDDDD 1 2 3 4 L
correcting values (2) for the calculation. DDDDDDD B C M Y /
DDDDD DDDDD D 0.0 0.0 0.0 0.0 1
The surface areas read are assigned to the preset val- DDDDDD + + + +
ues for low, mean and high surface areas (3). The lim- DDDDDDD 100 100 100 100 2
its for low and mean surface areas can be edited. The
max. value for high surface areas is fixed to 100 %. DD
3 DDDDDD D
DDDDDD D 4
20
20
50
30
100
50
The following settings can be preselected for the indi- DD DDDD
vidual zones: 5 DDDDDDDDD 10 8 7
Ink ductor roller strip (4)

F7 F8 F10
Characteristic curve F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1021-1
The selection of characteristic curve (5) depends on
whether the ink slide openings for the corresponding
surface areas are to be larger or smaller.
Higher characteristic curve: larger ink slide opening
Lower characteristic curve: smaller ink slide opening
Try to find a good coordination between ink ductor

roller strip and ink slide opening.
Input instructions - see main menu Ink /
Damp., chapter Converting surface area
data into ink slide positions.
Ink presetting using the "Self-learning" function (option)

A good ink presetting considerably reduces the make-
ready time. The Self-learning function automatically
optimizes the parameter values of scale inks; these val-
ues can be used for subsequent jobs as preset values.
Requirement for application:
The Self-learning function is only suitable for scale
inks.
The current job is a standard job, i.e. similar jobs are
also expected in future.
The operator activates the Self-learning function as
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
soon as a good sheet is obtained.
Process:
From the ink slide positions and the ink ductor roller
strips at the time of the attainment of a good sheet,
the system automatically identifies a set of paramet-
ers for the optimum ink presetting.
An individual correction value is calculated for each
ink slide where necessary.

11 Notes concerning printing
The preset ink values thus obtained are automat-

ically set for the next job if the same scale inks are
printed and the AUTO procedure is set.
11.14.2 Low Coverage Stabilization (LCS )

With LCS you reach a stabilization of the printing pro-
cess in case of printing images with a low ink accept-
ance.
A correct dosing of the inking is usually difficult in ink
zones with very low ink acceptance. The ink slides are
almost completely closed. The inking unit reacts only
slowly to inking corrections. The ink emulsifies.
When you work with LCS, only every second ink slide DD DDDDDD
D
DD
DD DDD D
DD 0
DD DDDD
0 DDD DDDD
DDD DD
is opened for better control of the inking. The ink slide DDDDDDD DD D DD DDDD DDDD DDDD DDDD DDDD
position is the same across the entire sheet width. DDDDD
DDDD
250
200
150
100
50
DDD
48
0
DDDDD 3 5 10 15 20 25 30 35 40 45 50 55 60
F1 F2 F3 F4 F5 F6 F7 F10
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
B-1026-1
The closed ink slides strip off the excessive ink from
20 21 22
15 16 17 18 19
10 11 12 13 14
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
LS-02852-2

Care of the central control console 11
The max. set ductor roller strip promotes a constant

return flow to the ink fountain. In ink zones with open
ink slides, the available ink quantity is higher. The ink-
ing unit reacts faster to inking corrections. Fine correc-
tions of the inking are possible.
When you work with LCS, the ink slides must be ad-
justed. A zero setting of the ink slides therefore be-
comes necessary at regular intervals.
LS-02849-1
11.15 Care of the central control console

11.15.1 Cleaning the central control console
Soft, lintfree cloth
Soft brush
Antistatic cleaning agent
Glass cleaning agent
Procedure
Attention!:
Aggressive cleaning agents, scouring
agents and solvents damage sensitive
surfaces.
For cleaning the surfaces, use a soft and
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
slightly moist cloth only.
Use a soft, slightly damp cloth to clean the screen,

the foil keyboard and the surfaces of the central
control console.
Antistatic cleaning agent
Use a soft brush to clean the keyboard of the
matching desk and the PC keyboard.
Soft brush LS-05604-1

11 Care of the central control console
Clean the covering pane of the matching lamp.

Glass cleaning agent
LS-05604-1
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Equipment
Transport aids 12
12 Equipment
12.1 Transport aids
Covering for forwarder suckers
Height: 8 mm (0.315 in)
Inner diameter: 17 mm (0.669 in)
Outer diameter: 22.5 mm (0.886 in)
Ref.no.:: 021F047330
Auxiliary forwarder sucker: Cardboard
Ref.no.:: 021F017715
Spray bottle
Volume: 1 L (0.26 gal(US))
Material: Polyethylene, soft
Ref.no.:: 094Z901140
Ink spatula
Width: 70 mm (2.756 in)
Material: Plastic
Ink: red
Ref.no.:: 094M042040

Width: 25 to 70 mm (0.984 to 2.756 in)
Material: Plastic
Ref.no.:: 094M042750
Width: 40 to 70 mm (1.575 to 2.756 in)
Material: Plastic
Ref.no.:: 094M042350
Lintfree cloth
Soft brush
Shop supervisor disk (SAALMEISTERDISKETTE / SHOP SUPERVISOR DISK)
POST MORTEM DUMP PMD COPY PROGRAM disk

06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Protective gloves
Width of the test strip: Reference value: 50 mm (1.968 in)
Length of the test strip: Reference value: 200 mm (200 in)

Equipment
12 Tools
12.2 Tools
Torque: 40 to 200 Nm (4.08 to 20.4 kpm)
Drive: 1/2 "
Ref.no.:: 094L188940
Socket wrench insert 1/2", width across flats 17 (DIN 3124)

Drive: 1/2 "
Width across flats: 17 mm
Ref.no.:: 094L057140
Socket wrench insert 1/2", hexagon, width across flats 17, 250L
Drive: 1/2 "
Extension: 250 mm (9.842 in)
Material: 31CrV3
Property of material: chrome-plated
Ref.no.:: 094L025950
Socket wrench insert 1/2", width across flats 24, hexagon
Drive: 1/2 "
Material: 31CrV3
Ref.no.:: 094L026140
Screwdriver insert 1/2", width across flats 10, hexagon 140L

Drive: 1/2 "
Length of shaft: 140 mm (5.512 in)
Extension: 250 mm (9.842 in)
Form: Hexagon
Material: 31CrV3
Ref.no.:: 094L026240
Eccentric wrench
Length: 280 mm (11.024 in)
Diameter: 10 mm (0.394 in)
Eccentric radius: 6 mm (0.236 in)
Length of lever: 200 mm (7.874 in)
Ref.no.:: 013A066713

Drive: 1/2 "
Ref.no.:: 094L026340
Double open-end combination spanner, width across flats 8 (DIN 3113)

Material: 31CrV3
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Form: short
Ref.no.:: 094L116040

Material: 31CrV3
Form: short
Ref.no.:: 094L116240

Equipment
Tools 12

Material: 31CrV3
Form: short
Ref.no.:: 094L116540

Material: 31CrV3
Form: short
Ref.no.:: 094L116840

Phillips screwdriver
Size: PH1
Shape of the screwdriver tip: Phillips
Property of material: magnetized
Ref.no.:: 094L204040
Slot screw driver

Thickness of blade: 0.8 mm (0.031 in)
Width of blade: 5.5 mm (0.216 in)
Material: Steel
Ref.no.:: 094L205340

Material: Chrome-vanadium-steel
Ref.no.:: 094L014250
Lever RD4x240
Diameter, round material: 4 mm (0.157 in)
Material: 42CrMo4
Property of material: phosphated
Ref.no.:: 094L250850

Ref.no.:: 094L082640

Material: Chrome-vanadium-steel
Ref.no.:: 094L022340
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Ref.no.:: 094L082713
Setting device for ink slide

Star handle, Order no. Stegmann: 88000001
Ref.no.:: 007C428030

Equipment
12 Testing devices
Rod
Ref.no.:: 002A301813
12.3 Testing devices

Feeler gauge 0.1x25x200
Width: 25 mm (0.984 in)
Thickness: 0.1 mm (0.004 in)
Material: CK67
Ref.no.:: 094P015545
12.4 Wearing parts

12.4.1 Feeder
Designation Technical specifica- Packaging unit Ref.no.:
tions
Sheet separator for lightweight 1 units 021F178313
cardboard and cardboard
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Directories
Technical specifications 13
13 Directories
13.1 Technical specifications
13.1.1 Technical specifications
Machine speed
Production speed R 702 to R 709: 3 000 to 16 000 Sh/h
Printing material data

Sheet length: 340 to 740 mm (13.386 to 29.134 in)
Sheet width: 480 to 1 040 mm (18.898 to 40.945 in)
Pressure setting: 0.04 to 1 mm (0.002 to 0.039 in)
Printing area
Length of the area to printed: max. 715 mm (max. 28.15 in)
Width of the area to be printed: max. 1 020 mm (max. 40.157 in)
Sheet edge to leading edge of print: 9 to 11 mm (0.354 to 0.433 in)
Printing plate (standard size)

Length (standard): 785 mm (30.905 in)
Width (standard): 1 030 mm (40.551 in)
Front edge of plate up to start of printing: 43 mm (1.693 in)
Plate cylinder
Undercut: 0.5 mm (0.02 in)
Packing sheet
Length (standard size): 730 mm (28.74 in)
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
with printing plate length: 785 mm (30.905 in)

Width (standard size): 1 030 mm (40.551 in)
Blanket (with rail)

Length: 910 mm (35.827 in)
Width: 1 060 mm (41.732 in)
Thickness: 1.9 mm (0.075 in)
Bottom packing sheet

Length: 770 mm (30.315 in)

Directories
13 Technical specifications
Width: 1 030 mm (40.551 in)
Top packing sheet

Length: 780 mm (30.709 in)
Width: 1 030 mm (40.551 in)
Blanket cylinder
Undercut: 3.25 mm (0.128 in)
Impression cylinder
Noise level dB (A)

Feeder: 84 dB(A)
Delivery: 81 dB(A)
between feeder and printing module 1: 84 dB(A)
Compressed air supply

Operating pressure without reversing device: max. 9 bar
Operating pressure with reversing device: max. 10 bar
Feeder: Pile weight (without pallet)

Pile weight: main pile (without pallet): max. 1 300 kg (max. 2 866.5 lb)
Residual pile: max. 450 kg
Main pile with base: [ 275 mm / 10.827 in ]: max. 1 300 kg
Residual pile with base: [ 275 mm / 10.827 in ]: max. 450 kg
Residual pile with base: [ 550 mm / 21.653 in ]: max. 450 kg
Delivery unit: Pile weight (without pallet)

Main pile: max. 1 300 kg
Intermediate pile: max. 280 kg
Intermediate pile with base: [ 275 mm / 10.827 in ]: max. 280 kg
Main pile with base [ 550 mm / 21.653 in ]: max. 1 300 kg
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Intermediate pile with base [ 550 mm / 21.653 in ]: max. 280 kg
Feeder: pile height (without pallet)

Pile height: main pile (without pallet): max. 1 180 mm (max. 46.457 in)
Residual pile: max. 500 mm (max. 19.685 in)
Main pile with base: [ 275 mm / 10.827 in ]: max. 1 455 mm (max. 57.283 in)
Residual pile with base: [ 275 mm / 10.827 in ]: max. 500 mm (max. 19.685 in)
Residual pile with base: [ 550 mm / 21.653 in ]: max. 500 mm (max. 19.685 in)

Directories
Roller plan 13
Delivery unit: pile height (without pallet)

Main pile: max. 1 080 mm (max. 42.52 in)
Intermediate pile: max. 100 mm (max. 3.937 in)
Intermediate pile with base: [ 275 mm / 10.827 in ]: max. 100 mm (max. 3.937 in)
Intermediate pile with base: [ 550 mm / 21.653 in ]: max. 100 mm (max. 3.937 in)
Pallet height
13.2 Roller plan

13.2.1 Strip prints of rollers in inking unit
The contact pressure of the unmarked rollers is permanently set by MAN Roland.
Measuring unit of strip prints: mm (see illustration).
No. Designation 3
61 Ink fountain roller 110 mm
(4.331 in) 61
71 Ink ductor roller 71
0.5
mm 71 3
(2.795+0.02
-0.019 in)
94
514 Ink vibrator rollers 103.5 mm
(4.075 in) 514
513 Ink vibrator rollers 103.5 mm 82
(4.075 in)
511 Ink vibrator rollers 103.5 mm 93
(4.075 in) 4
512 Ink vibrator rollers 103.5 mm 91 513
(4.075 in)
512 92
83 Intermediate roller 60 mm 83 4
(2.362 in) 4- 5
453
451 Ink form roller 711.2 mm 454
511
4-5 452
(2.795+0.047
-0.047 in) 4-5
452 Ink form roller 1.2 4-5
73 mm 4
(2.874+0.047
-0.047 in) 4 4 451
453 Ink form roller 69 1.2
mm 4
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
(2.716+0.048
-0.047 in) 06-05930-1
454 Ink form roller 781.2 mm

(3.071+0.047
-0.047 in)

Directories
13 List of abbreviations
13.2.2 Strip prints of rollers in dampening unit

The contact pressure of the following rollers is permanently set by MAN Roland: Intermediate roller
11.5 - ink form roller 451; Transition roller 11.5 - water form roller 402; Vibrator roller 11.4 - water form
roller 402
Measuring unit of strip prints: mm (see illustration).
No. Designation
31 Water metering roller 850.5 mm 451
(3.346+0.02
-0.019 in) 11.5
21 Water fountain roller 100 mm
(3.937 in) 11.4
6-8
402 Water form roller 120.50.5 mm 402
(4.744+0.02
-0.02 in)
11.4 Vibrator roller 78 mm 6

(3.071 in)
31
11.5 Transition roller 60 mm 21
(2.362 in)
451 Ink form roller 6
711.2 +0.047
mm
(2.795-0.047 in) 07-05931-1
13.3 List of abbreviations

A-side Drive side
B-side Operating side
ANL Side facing the feeder
AUSL Side facing the delivery unit
APL Automatic plate loading
JP Program level preliminary operations
PDA Operational data acquisition
PR Program level production
LE Leading edge
TE Tail edge
PM Printing module
ICB Impression cylinder blowing device
AID Impression cylinder washing device
AFD Form cylinder washing device
IRB Ink roller blowing device
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
ARD Ink roller wash-up device

ABD Blanket washing device
in inch
LCS Low coverage stabilization
PL Program level
PPL Power plate loading (semi-automatic plate change)
PPS Production planning system
RSD Remote service diagnosis
Hex Hexagon
SSP Sales / service partner

Directories
Glossary 13
13.4 Glossary
AUPASYS Product designation: AUtomatic PAllet handling SYStem;? automatic pallet hand-
ling system combined with non-stop operation on feeder and delivery unit.
Surface area Percentage coverage of printing surfaces compared to total surface of the print-
ing plate.This is measured along the circumference of the printing plate and per ink
zone.
InlineSheeter Element of the feeder that cuts the printing material off from the reel and passes it
to the feeder (reel-to-sheet feeder ).
InlineSorter (Sheet distributor): Device for the automatic ejection of waste sheets so that only
the good sheets are deposited on the main pile.
Ionization A module preventing the electrostatic charging of printing materials.
JobCard Reader Device installed in the central control console or plate scanner for reading and writ-
ing a JobCard.
Remote service diagnosis Remote service diagnosis. Product designation for a piece of software for remote
diagnosis of faults in MAN Roland sheet offset printing presses.
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Directories
13 Glossary
06.09.2004 10:35:31 - 747 - 80 95A EN 6778

Index
14
14 Index
- Blast tube
- if side edge control detector reacts (feed Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
register) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-84 Shutting off air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30 Blast-suction rail . . . . . . . . . . . . . . . . . . . . . . . 11-42, 11-111
Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30
Brief increase of dampening solution . . . . . . . . . . . 11-196
A C
APL plate change
Cardboard guiding device
Mounting the printing plate . . . . . . . . . . . . . . . . . . . . 7-10
Feed register drum . . . . . . . . . . . . . . . . . . . . . 6-30, 6-32
Removing the printing plate . . . . . . . . . . . . . . . . . . . . 7-9
Feed register drum (QuickChange
Starting (several printing modules) . . . . . . . . . . . . 11-66 option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34,
Area data 6-35
Calculate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45 Side guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Presetting . . . . . . . . . . . . . . . . . . . . . . . . . . 11-46, 11-114 Cardboard guiding roller . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
Presetting (self-learning) . . . . . . . . . . . . . . . . . . . 11-119 CCI
READ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44, 11-45 Deleting protocols . . . . . . . . . . . . . . . . . . . . 11-15, 11-19
VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45, 11-114 Changing the machine name . . . . . . . . . . . . . . . . . . 11-177
Automatic functions: Start . . . . . . . . . . . . . . . . . 3-6, 11-70 Changing the printing plate . . . . . . . . . . . . . . . . . . . . 7-5, 7-9
Automatic pile control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Characteristic dampening curve . . . . . . . . . . . . . . . . 11-102
Automatic production . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-63 Characteristic inking curve . . . . . . . . . . . . . . . . . . . . 11-102
Continuing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Coating (emptying time) . . . . . . . . . . . . . . . . . . . . . . . 11-157
Interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Coating module:
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7, 11-63 Preselecting (JP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24
Terminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Preselecting (PR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-76
Automatic zero setting of the position and Preselecting the coating application
stepping motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-171 (JP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26,
Auxiliary blast nozzles . . . . . . . . . . . . . . . . . . . . . . . . . 11-110 11-77
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Preselecting the coating control (PR) . . . . . . . . . . 11-78
Auxiliary forwarder sucker Presetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-156
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Rinse coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-157
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 Collecting blade
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Emptying time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-157
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Color assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-23, 11-75
B Entering the name of the printing plate . . . . . . . 11-22,

11-74
Basic functions . . . . . . . . . . . . . . . . . . . . . . . . . 11-10, 11-11
Interchange . . . . . . . . . . . . . . . . . . . . . . . . 11-35, 11-104
Basic speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-96
Preselecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-74
Blanket washing device . . . . . . . . . 11-68, 11-142, 11-152
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Control console
Changing the presetting . . . . . . . . . . . . . . . . . . . 11-139
Restarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Cloth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-141, 11-151
Cover guide height . . . . . . . . . . . . . . . . . . . . . . 11-27, 11-79
Parameter . . . . . . . . . . . . . . . . . . . . . . . . . 11-143, 11-153
Sheet edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-140
D
Washing programs . . . . . . . . . . . . . . . . . 11-140, 11-150
Dampening
Blast air upstream of reversing device
(option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-107 Integrated . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32, 11-94
Blast frame Presetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32
blast tubes . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31, 10-32 Setting the basic dampening . . . . . . . . . . . . . . . . . 11-96
Ventilators . . . . . . . . . . . . 10-27, 10-29, 11-40, 11-109 Dampening solution refrigerator . . . . . . . . 11-137, 11-138,
11-139

Index
14
Dampening unit F
Controlling dampening . . . . . . . . . . . . . . . . . . . . . . . 8-28 Feed register
Decalcifying . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4, 11-147 Presetting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28, 11-83
Preselecting (JP) . . . . . . . . . . . . . . . . . . . . . 11-25, 11-77 Setting the air pressure . . . . . . . . . 6-8, 6-9, 6-10, 6-11
De-coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-97 Setting the detector . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Delivery drum Setting the sheet thickness . . . . . . . . . . . . . 6-20, 6-22
Sheet guiding rods . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Sheet guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21, 6-23
Delivery unit
Sheet hold-down . . . . . . . . . . . . . . . . . . . . . . 6-17, 6-18
Access protection . . . . . . . . . . . . . . . . . . . . 10-37, 10-39
Side guide . . . . . . . . . . . . . . . . . . . . . . . 6-12, 6-13, 6-14
Changing pile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Suction plate . . . . . . . . . . . . . . . 6-14, 6-15, 6-16, 6-17
Deselecting the ventilators . . . . . . . . . . . . . . . . . . . 10-28
Feed register drum
Gripper opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Cardboard guide (QuickChange
Inserting the pallet . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Inspection sheet removal mechanism . . . . . . . . 10-22,
Cardboard guiding device . . . . . . . . . . . . . . . . . . . . . 6-30
10-24
Moving out the pile . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16 QuickChange . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34, 6-35
Nonstop with rake . . . . . . . . . . . . . . . . . . . . . . . . . . 11-89 Setting gripper pad bar . . . . . . . . . . . . . . . . . . . . . . . 6-29
Preselecting the ventilators . . . . . . . . . . . . . . . . . . . 10-28 Standard printing materials . . . . . . . . . . . . . . 6-32, 6-35
Presetting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-31, 11-87 Feeder
Size correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Changing pile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Suction roller . . . . . . . . . . . 10-19, 10-33, 10-34, 10-35 Changing pile (option: base) . . . . . . . . . . . . . . . . . . . 4-7
Disengaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Ventilators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Make-ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Waste sheet removal . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Making ready (after a size change) . . . . . . . . . . . . . . 4-9
Delta effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-94
Unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33 Presetting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28, 11-83
Diagnosis messages . . . . . . . . . . . . . . . . . . . . . . . . . . 11-164 Feeder timing . . . . . . . . . . . . . . . . . . . . . . 4-62, 11-86, 11-87
Distribution insert . . . . . . . . . . . . . . . . . . . 8-18, 11-35, 11-97 Foil printing
Doctor blade collecting pan Suction air at the suction tapes feed
board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Foreign object barrier
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Double sheet control . . . . . . . . . . . . . . . . . . . . . . 4-57, 4-58
Forwarder sucker
Checking the mechanical function . . . . . . . . . . . . . 4-56
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30, 4-31
Checking the printing material . . . . . . . . . . . . . . . . . 4-57
Setting the height. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Electronically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Suction disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Setting to paper or cardboard . . . . . . . . . . . . . . . . . 4-59
Forwarder wheels
Drive motor
Releasing brake electrically . . . . . . . . . . . . . . . . . . . . . 5-9 Check the distance ! . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
Releasing brake manually . . . . . . . . . . . . . . . . . . . . . 5-10 Checking position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Dry sprayer. . . . . . . . . . . . . . . . . . . 11-153, 11-154, 11-155 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Powder vacuuming (option) . . . . . . . . . . . . . . . . 11-160 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Front edge detector . . . . . . . . . . . . . . . . . . . . . 11-29, 11-83

FRONT GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
E
Basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Emergency disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-185
Loading profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-135
EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . 11-168
Setting individually . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
emergency stop
Setting the profile . . . . . . . . . . . . . . . . . . 11-133, 11-134
Stopping the machine in dangerous
situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Setting to zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-135
Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Storing the profile . . . . . . . . . . . . . . . . . . . . . . . . . 11-136
Executing test programs . . . . . . . . . . . . . . . . . . . . . . 11-172

Index
14
G Ink fountain
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Gas pressure spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Gripper opening cam . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Ink fountain separator (option) . . . . . . . . . . . . . . . . . . 8-8
Gripper pad bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-82
Feed register drum . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Ink fountain roller
Activating the reverse rotation . . . . . . . . . . . . . . 11-103
Swing gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Transferter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Preselecting (JP) . . . . . . . . . . . . . . . . . . . . . 11-25, 11-76
Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
I
Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Idle running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-64
Ink pre-setting
Idle running speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-62
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-198
Image pos. correct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-80
Description of LCS . . . . . . . . . . . . . . . . . . . . . . . . 11-200
Off-center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-80
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-182
Impression cylinder blowing device . . . . . . . . . . 7-28, 7-34
Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-180
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Ink roller blowing device . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Loading values . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-106
Ink roller washing program . . . . . . . . . . . . . . 11-67, 11-148
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Changing the presetting . . . . . . . . . . . . . . . . . . . 11-143
Storing values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-106
Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-149
Impression cylinder washing device . . . . . . . . . . . . 11-69,
11-142, Re-washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-146
11-152 Re-washing (special cleaner) . . . . . . . . . . . . . . . 11-146
Changing the presetting . . . . . . . . . . . . . . . . . . . 11-149 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6, 9-7
Cloth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-141, 11-151 Washing programs . . . . . . . . . . . . . . . . . 11-144, 11-145
Sheet edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-150 Ink slides
Washing programs . . . . . . . . . . . . . . . . . 11-140, 11-150 Activating the zero setting . . . . . . . . . . . . . 8-15, 11-173
Infeed register Calling the profile "Before zero" . . . . . . . . . . . . . 11-129
basic setting of front guides . . . . . . . . . . . . . . . . . . . 6-24 Changing according to the set
Displacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-133 percentage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-51,
11-128
Individual setting of the front guides . . . . . . . . . . . . 6-26
Close . . . . . . . . . . . . . . . . . . . . . . 8-4, 8-5, 8-11, 11-129
Parallel displacing . . . . . . . . . . . . . . . . . . . . . . . . . 11-133
Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-134 Copying the profile . . . . . . . . . . . . . . . . . . . . . . . . . . 11-52
Skewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 LCS (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-121
Ink ductor roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-65 Parallel setting . . . . . . . . . . . . . . . . . . . . . . 11-50, 11-127
Ink ductor roller cycle Parameter . . . . . . . . . . . . . . . . . . . . . . . . . 11-116, 11-117
Presetting . . . . . . . . . . . . . . . . . . . . . . . . . . 11-47, 11-123 Preselecting correction value . . . . . . . . . . . . . . . 11-121
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48, 11-123 Reading data from the JobCard . . . . . . . . . . . . 11-167
Ink ductor roller strip Resetting correction values (shop
supervisor disk) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-182
Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-116
Resetting ink slide correction (shop
Presetting . . . . . . . . . . . . . . 8-11, 11-47, 11-48, 11-123 supervisor disk) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-180
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Storing (intermediate storage) . . . . . . . . . . . . . . 11-125 Resetting presetting (shop supervisor

Storing (job storage) . . . . . . . . . . . . . . . . . . . . . . . 11-124 disk) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-180
Ink flow Self-learning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-122
Front-heavy . . . . . . . . . . . . . . . . . . . . . . . . . 11-34, 11-96 Setting . . . . . . . . . . . . . . . . . . . . . . 11-49, 11-50, 11-127
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34, 11-96 Storing the profile (intermediate
Symmetric . . . . . . . . . . . . . . . . . . . . . . . . . . 11-33, 11-95 storage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-125
Ink form roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23, 11-65 Storing the profile (job storage) . . . . . . . . . . . . . 11-124
Axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 Viewing profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-118
Working position . . . . . . . . . . . . . . . . . . . . . . . . . . 11-122
Writing data on a JobCard . . . . . . . . . . . . . . . . . 11-167
Zero setting . . . . . . . . . . . . . . . . . . . . 8-10, 8-15, 11-173

Index
14
Ink vibrator rollers Low Coverage Stabilization (LCS ) . . . . . . 11-115, 11-117,

Distribution path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 11-121
Ink zone block . . . . . . . . . . . . . . . . . . . . . . . . . 11-49, 11-126 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-200
Ink zone status . . . . . . . . . . . . . . . . . 11-48, 11-49, 11-125 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-47
Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Inking unit M
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Main switch
Decalcifying . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4, 11-147 Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8, 3-3
Distribution path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7, 3-3
Preselecting (JP) . . . . . . . . . . . . . . . . . . . . . 11-24, 11-76 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
InlineSheeter Make-ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-59
Reel-to-sheet feeder (option) . . . . . . . . . . . . . . . . . 11-86 Setting the sheet thickness . . . . . . . . 6-28, 6-29, 7-36
InlineSorter Matching desk . . . . . . . . 11-187, 11-188, 11-189, 11-192,
Presetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-92 11-193
Inspection sheet removal mechanism . . . . . . 10-22, Changing over to the mode
10-23, "Preparation" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-191
10-24, 10-25 Changing the zone status . . . . . . . . . . . . . . . . . . 11-188
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 Ink stripper / ink spatula . . . . . . . . . . . . 11-193, 11-194
Intermediate drier Locking the keys . . . . . . . . . . . . . . . . . . . . . . . . . . 11-190
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Setting the inclination of the area
Ionization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-160 where the sheet is placed . . . . . . . . . . . . . . . . . . 11-191
Setting the inking . . . . . . . . . . . . . . . . . . . . . . . . . 11-192
J Missing sheet detector . . . . . . . . . . . . . . . . . . . . . . . . . . 11-98
Job
copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15, 11-18 N
Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15, 11-18 NONSTOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-91
Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . 11-91
Managing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15 Pile change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-88
NEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13 Pile height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-92
Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13, 11-14 Preselecting "Small piles" . . . . . . . . . . . . . . . . . . . . 11-88
Search . . . . . . . . . . . . . . . . . 11-15, 11-16, 11-53, 11-55 Stacking small piles . . . . . . . . . . . . . . . . . . . . . . . . . 11-91
VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17, 11-57 Starting (manual) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Wrong job number . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14 NONSTOP manual
Job Papers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20, 11-58 Inserting the pile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19, 11-57 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Notes concerning printing . . . . . . . . . . . . . . 11-198, 11-200
JobCard
Eject . . . . . . . . . . . . . . . . . . . . . . 11-45, 11-167, 11-198
Insert . . . . . . . . . . . . . . . . . . . . . . 11-44, 11-166, 11-197 O
READ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-45 Oil circulation lubrication . . . . . . . . 11-99, 11-100, 11-101
RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-167
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Jog: P
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Packing sheet
Forward, limited travel . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
PDA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-161, 11-162
Reverse, limited travel . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Permanent dampening
JP (Job Preparation)
Preselecting (JP) . . . . . . . . . . . . . . . . . . . . . 11-25, 11-77
Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21
Pick-up sucker
Interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21
Changing nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
L
Loading ventilator values . . . . . . . . . . . . . . . . . . . . . . 11-106

Index
14
Pile Printing plate

Changing: delivery unit . . . . . . . . . . . . . . . . . . . . . . 10-16 Gumming . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3, 11-147
Changing: Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Removing the ink . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-63
Changing: feeder (option: base) . . . . . . . . . . . . . . . . 4-7 Printing press
Pile height detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-83 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Select mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29 Switching off . . . . . . . . . . . . . . . . . . . . . 2-7, 3-3, 11-170
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Pile lowering/raising . . . . . . . . . . . . . . . . . . . . . 11-31, 11-87
Printing pressure adjustment . . . . . . . . . . . . . . . . . . . . 11-81
Pile supporting plate: . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-79
Lowering . . . . . . . . . . . . 4-5, 4-40, 4-53, 10-15, 10-33, Printing with bearer ring contact . . . . . . . . . . . . . . . . 7-2
10-34, 10-35
Procedure of automatic functions . . . . . . 3-13, 3-14, 3-15
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4, 10-14
Production
Pile: Stop-Secure
Continuing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Stopping and locking . . . . . . . . . . . 2-8, 2-9, 4-5, 10-15 Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-59
Unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7, 11-59
Plate cylinder Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Register correction, LE . . . . . . . . . . . . . . . . . . . . . . . 7-18 Terminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Register correction, tail edge . . . . . . . . . . . . 7-20, 7-22 Production speed . . . . . . . . . . . . . . . . . . . . . . . . . 3-5, 11-62
Post Mortem Dump
Measures to be taken . . . . . . . . . . . . . . . . . . . . . 11-183
Q
PP sheet decurler (option) . . . . . . . . . . . . . . . . . . . . . 11-110
PPL Quick start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-64
Closing the LE tensioning bar manually . . . . . . . . . . 7-8 QuickChange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Emergency program . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Mounting the printing plate . . . . . . . . . . . . . . . . . . . . . 7-8 R
Removing the printing plate . . . . . . . . . . . . . . . . . . . . 7-6 Rainbow printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Start (a printing module) . . . . . . . . . . . . . . . . . . . . . . 7-17 Reel-to-sheet feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-86
Starting (several printing modules) . . . . . . . . . . . . 11-66 Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-130
Pre-coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-98 Before zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-132
Preparing the machine run . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Circumferential register . . . . . . . . . . . . . . . . . . . . 11-131
Preselecting coating return flow . . . . . . . . . . . . . . . . 11-157 Printing "off-center" . . . . . . . . . . . . . . . . . . . . . . . . . 11-80
Preselecting coating supply . . . . . . . . . . . . . . . . . . . 11-156 Setting (during production) . . . . . . . . . . . . . . . . . . . 11-80
Preselecting make-ready mode . . . . . . . . . . . . . . . . 11-174 Setting (matching desk) . . . . . . . . . . . . . . . . . . . . 11-195
Preselecting the pumps and blowers . . . . . . . . . . . . . 11-63 Setting the circumferential register . . . . . . . . . . 11-130
Presetting Damp. / Ink . . . . . . . . . . . . . . . . . . . . . . . . . . 11-93 Setting the diagonal register. . . . . . . . . . . . . . . . 11-130
Presetting the color data . . . . . . . . . . . . . . . . . . . . . . . . 11-32 Setting the side register . . . . . . . . . . . . . . . . . . . . 11-130
Presetting the machine run . . . . . . . . . . . . . . . . . . . . . . 11-61 Setting to zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-132
Pressure Side (lat.) register . . . . . . . . . . . . . . . . . . . . . . . . . 11-131
Throw on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-64 Reversing device . . . . . . . . . . . . . . . . . . . . . . . . 11-72, 11-73
Pressure foot Change-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-72
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Setting the working height . . . . . . . . . . . . . . . . . . . . 4-19 Printing sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-78

Printing material
Change data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26 Size correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-81
Changing the size . . . . . . . . . . . . . . . . . . . . 11-27, 11-79 Rinse coating . . . . . . . . . . . . . . . . . . . . . . . . . 11-158, 11-159
Printing module Run up ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-71, 11-72
Preselecting (JP) . . . . . . . . . . . . . . . . . . . . . 11-23, 11-24
Running sheets out of the machine . . . . . . . . . . . . . . . . . 3-8
Preselecting (PR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-76 running the residual sheets out of the
Select mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-190 machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
S
Safety (access protection) . . . . . . . . . . . . . . . . . . . . . . . 10-39

Index
14
Screen button Small pile

Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10, 11-11 Select mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-88
SEARCH Starting speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-62
Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16, 11-55 Stop-Secure
Self-cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 11-141, 11-151 Stopping and locking . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Separating blast nozzle Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 Storage capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-171
Setting date and time . . . . . . . . . . . . . . . . . . . . . . . . . 11-165 Storing the base job . . . . . . . . . . . . . . . . . . . . . . . . . . 11-169
Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . 11-165 Storing ventilator values . . . . . . . . . . . . . . . . . . . . . . . 11-106
Setting the measuring unit . . . . . . . . . . . . . . . . . . . . . 11-165 Suction air upstream of reversing device
Setting the temperature unit . . . . . . . . . . . . . . . . . . . 11-165 (option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-107
Sheet Suction bar
Removing the JobCard . . . . . . . . . . . . . . . . . . . . . . . 4-73 Lightweight paper printing (option) . . . . . . . . . . 11-107
Sheet counter Sheet guide in front of front guides
and cover guides . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-85
Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-65
Suction head
Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-65
Adjusting pick-up suckers . . . . . . . . . . . . . . . . . . . . 4-38
Sheet decurler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-110
Auxiliary blast nozzles . . . . . . . . . . . . . . . . . . 4-23, 4-44
Sheet distributor
Auxiliary forwarder sucker . . . . . . . . . . . . . . . 4-28, 4-29
Opening time . . . . . . . . . . . . . . . . . . . . . . . . 11-90, 11-92
Forwarder sucker . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Presetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-92
Height adjustment: sheet separators
Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-110
and separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-110
Pick-up suckers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Sheet guide
Pile height detector . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
air . . . . . . . . . . . . . . . . . . 11-39, 11-41, 11-108, 11-110
Preselecting blast air . . . . . . . . . . . . . . . . 11-42, 11-111
Air for feeder / feed register . . . . . . . . . . 11-42, 11-111 Preselecting suction air . . . . . . . . . . . . . . 11-42, 11-111
Sheet guiding rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53 Separating blast nozzle . . . . . . 4-23, 4-41, 4-42, 4-43
Carrier rods . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67, 4-68
Setting forward or backward . . . . . . . . . . . . . . . . . . 4-19
Sheet guiding rolls . . . . . . . . . . . . . . 4-64, 4-65, 4-66, 6-20
Setting the height. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Pneumatic (option) . . . . . . . . . . . . . . . . . . . . . . . . . . 11-86
Sheet separator elements . . . . . . . . . 4-45, 4-46, 4-47,
Sheet hold-down . . . . . . . . . . . . . . . . . . . . . 4-51, 4-52, 4-69 4-48
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68 Suction disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Sheet joggers Working height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Suction plate . . . . . . . . . . . 6-14, 6-15, 6-16, 6-17, 11-110
Sheet separator element Suction roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-112
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19, 10-33
Sheet stop Size change . . . . . . . . . . . . . . . . . . . . . . . . . 10-34, 10-35
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51 Suction tape
Sheet travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-63 Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-112
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Setting the characteristic curve of the
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
Terminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 suction air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-103

Sheet trend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Suction tapes feed board
Shop supervisor disk . . . . . . . . . . . . . . . . . . . . . . . . . 11-175 Adjusting the suction air . . . . . . . . . . . . . . . . . . . . . . 4-72
Changing the machine configuration . . . . . . . . 11-176 Foil printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
Side blower . . . . . . . . . . . . . . . . . . . . 11-42, 11-111, 11-112 Folding down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
Side guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-112 Folding up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Side guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-84 Removing the JobCard . . . . . . . . . . . . . . . . . . . . . . . 4-73
Pulling or pushing (option) . . . . . . . . . . . . . . . . . . . 11-85 Surface area
Select mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-29 Changing a characteristic curve . . . . . . . . . . . . 11-117
Selecting (pulling, pushing) . . . . . . . . . . . . . . . . . . . 11-30 Ink slide correction value . . . . . . . . . . . . . . . . . . . 11-121
Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Parameters: preselecting limit values . . . . . . . . 11-116

Index
14
Swing gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-112 Terminating (JP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21

Setting gripper pad bar . . . . . . . . . . . . . . . . . . . . . . . 6-28 VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17, 11-57
T
Transferter
Gripper pad bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
V
Ventilator track . . . . . . . . . 11-36, 11-37, 11-39, 11-41,
11-42, 11-105, 11-106, 11-108,
11-110, 11-111
Loading values . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-106
Setting (delivery unit) . . . . . . . . . . . . . . . . . . . . . . 11-108
Setting (whole machine) . . . . . . . . . . . . . . . . . . . 11-105
Storing values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-106
Viewing the machine park . . . . . . . . . . . . . . . . . . . . . 11-168
W
Washing agent container
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Washing programs
Blanket wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-139
Impression cylinder . . . . . . . . . . . . . . . . . . . . . . . . 11-149
Ink rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-143
Preselecting printing modules . . . . . . 11-141, 11-145,
11-151
Washing agent container . . . . . . . . . . 11-142, 11-143,
11-152
Waste sheet removal mechanism . . . . . . . . . . . . . . . . 10-25
Water form roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-65
Throwing off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Water fountain roller speed
Presetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-123
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-124, 11-196
Storing (intermediate storage) . . . . . . . . . . . . . . 11-125
Storing (job storage) . . . . . . . . . . . . . . . . . . . . . . . 11-124
Work step
Completing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
06.09.2004 10:35:31 - 747 - 80 95A EN 6778
copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15, 11-18

Delete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15, 11-18
Delete (shop supervisor disk) . . . . . . . . 11-175, 11-176
Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
Inserting data . . . . . . . . . . . . . . . . . . . . . . . . 11-15, 11-54
Interrupting (JP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21
Managing . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15, 11-55
NEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13, 11-14
Search . . . . . . . . . . . . . . . . . 11-15, 11-16, 11-53, 11-55

Eng 99C6778 PDF

Uploaded by

Copyright:

Available Formats

Eng 99C6778 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Eng 99C6778 PDF

Uploaded by

Copyright:

Available Formats

ROLAND 700

HKS Warenzeichenverband e.V.: HKS is a registered trademark of the HKS association.

MAN Roland Druckmaschinen AG

Copyright by MAN Roland Druckmaschinen AG 2004

All parts of this documentation are protected by copyright.

2.3 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Roland 700 - Operation I

2.5.4 Safety-relevant operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3 Printing machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

4.3.3 Stopping the pile hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

II Roland 700 - Operation

4.5.3 Pile loading during manual NONSTOP operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

5 Printing module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2.4 Printing module, delivery B-side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

6 Feed register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Roland 700 - Operation III

6.2.2 Control panel DM1, feed register B-side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

IV Roland 700 - Operation

6.10 Swing gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

7 Printing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.5.2 Impression cylinder blowing device (ICB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Roland 700 - Operation V

8 Inking unit and dampening unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9 Washing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.3 Washing devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

VI Roland 700 - Operation

9.5.2 Removing the doctor blade collecting pan: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

10.6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21

Roland 700 - Operation VII

10.7.5 Deselecting all ventilators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29

11 Central control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.5 Program level Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-53

VIII Roland 700 - Operation

11.6 Program level Production Data Acquisition (PDA) (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-161

11.12.6 Dampening corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-196

Roland 700 - Operation IX

11.15 Care of the central control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-201

06.09.2004 10:35:31 - 747 - 80 95A EN 6778

X Roland 700 - Operation

1 Documentation of your press

1.2 Components of the instructions manual

Safety measures to be taken by the operating per- Safety on

Roland 700 - Operation 1-1

1.2.2 Products for maintenance and care

R700 Produkte zur Bed+Wart

1.2.4 Putting into operation

Putting into operation (printing)

1-2 Roland 700 - Operation

1.3 Guideline indications

handling the press.

Roland 700 - Operation 1-3

Expected system reaction

Unexpected system reaction

1.3.2 Meaning accentuated words or passages in a text

(1) Reference to a position number in a picture.

1.4 Your opinion is important to us

Post office box 101264

1-4 Roland 700 - Operation

1.5 Using the operating manual