MBO K8RS Operational manual

Folding machine
Translation of the original operating manual
Keep for future reference!
K8RS

Copyright Thisdocumentationissubject tocopyright law.The claimed copyrightincludes
all forms and types of copyright-protected materials and information that are
currently permitted. No part of the documentation may be copied, otherwise
duplicated,editedortranslatedintootherlanguages,regardlessofthe manner
in which or with which tools this takes place.
Electronically-stored information provided by the manufacturer (CD-ROM, In-
ternet) may be printed out by the user if the created print medium serves the
purpose of use or service of the product described.
Type of machine: Folding machine
Model: K8RS
Type of document: Translation of the original operating manual
Version: V2.2 Author: Wolfgang Matzner
Dated: 06/08/2016 Machine no.:
Language: English File name: BA_K8RS_M1-BF- Standard_Automatik_
V2.2_en
Manufacturer:
MBO Maschinenbau Oppenweiler Binder GmbH & Co. KG
PO Box 1169
71567 Oppenweiler
GERMANY
Tel.: [phone]
Fax: [phone]
http://www.mbo-folder.com
[e-mail]
Subject to alterations!

Folding machine K8RS
Name plate and
CE marking For all questions relating to your machine, please contact your MBO agen- cy.
You can find the address on our home page: www.mbo-folder.com.
For the identification of the machine and the most important machine data,
see the name plate on the machine.
Always specify these details for inquiries, service and spare parts orders:
• Commission number
• Type of machine
1 CE marking
2 Type of machine
3 Commission number
4 Year of manufacture
5 Name plate
Figure 1: Name plate
1
2
3
54

Folding machine K8RS
EC/EU Declaration of Conformity
according to EC Machine Directive 2006/42/EC, Annex II, No. 1 A.
The manufacturer
MBO Maschinenbau Oppenweiler Binder GmbH & Co. KG
Grabenstraße 4-6
71570 Oppenweiler
GERMANY
Oppenweiler, 06/08/2016
hereby declares that the machine described below
Designation Folding machine
Type K8RS
Commissioning no.
complies with the provisions of the following EC/EU directives
Machinery Directive 2006/42/EC
EMC Directive 2014/30/EU
Harmonized standards applied:
DIN EN ISO 12100:2010
DIN EN 1010-1:2004+A1:2010
EN 1010-4:2004+A1:2009
EN ISO 60204-1:2006
EN ISO 13849-1:2008
Authorized representative for compiling the technical file:
Name Wolfgang Matzner
Address Grabenstrasse 4-6
71570 Oppenweiler
GERMANY
_________________________________
Frank Eckert- Managing Director

Falzmaschine K8RS 1
Table of contents
Table of contents
1 About this manual
1.1 Additional documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1.1 Supplier documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Structure of the operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Signs and symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 Description of safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4.1 Signal words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4.2 Structure of safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4.3 Safety sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4.4 Marking of danger spots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5 User assessment of the operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Basic safety instructions
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Reasonable foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Obligation and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5.1 Transport, interim storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5.2 Set-up, commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5.3 Adjustment and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5.4 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5.5 Decommissioning, storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.5.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6 Product-specific hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6.1 Entanglement hazard and crushing hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6.2 Cutting hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6.3 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7 Life time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7.1 Life time of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7.2 Service life of the control-technical safety components . . . . . . . . . . . . . . . . . . . . . . . 27
2.8 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.8.1 Transport, interim storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.8.2 Set-up, commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.8.3 Normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.8.4 Adjustment and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2Falzmaschine K8RS
Table of contents
2.8.5 Maintenance and repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.8.6 Work on electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.9 Personnel, qualifications and duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2.9.1 Qualification of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.9.2 Duties of the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.9.3 Duties of the operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.9.4 Duties of the maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.10 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2.10.1 Operation and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.10.2 Operational maintenance (cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.11 Work areas and workstations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
2.11.1 Variants S-KTL, S-KTLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.11.2 Model S-KTZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.12 Markings on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
2.12.1 Position and meaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.13 Directions for emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
2.13.1 Emergency call numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.13.2 Behavior in case of accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3 Product description
3.1 Important notices about the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3.1.1 Overall view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.1.2 Standard equipment for K8RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
3.2.1 Floor plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.2.2 Performance characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2.3 Shipping and transport data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2.4 Electrical supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2.5 Compressed air supply, control air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.2.6 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.2.7 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4 Structure and function
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
4.1.1 What is folding?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.1.2 Folding principles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.2 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
4.2.1 Views of the palletized feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.2.2 Views of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.3 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
4.3.1 Pallet feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.3.2 Combi folding machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Falzmaschine K8RS 3
Table of contents
4.3.3 Register table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.3.4 Parallel folding unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.3.5 Cross fold folding unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.3.6 Waste paper deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.3.7 Threefold folding unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.3.8 Sheet monitoring of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.3.9 Delivery systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.4 Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.4.1 FP800_130 RS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.4.2 Model S-KTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.4.3 Model S-KTLT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.4.4 Model S-KTZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.5 Machine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.5.1 M1 Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.5.2 RAPIDSET automation (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.5.3 DATAMANAGER (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.5.4 MBO-RAS (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.6 Protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.6.1 Explanation of the term "guards" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.6.2 Explanation of the term "protective devices" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.6.3 Overview of protective devices on the palletized feeder . . . . . . . . . . . . . . . . . . . . . . 72
4.6.4 Overview of protective devices on the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.6.5 Main switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.6.6 Noise damping safety hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.6.7 Safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.6.8 Operating the safety handwheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.6.9 Fixed guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.6.10 Faulty protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.6.11 Checking protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.6.12 Checklists for protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5 Operating and display elements, operating modes
5.1 Operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.1.2 Main switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.1.3 EMERGENCY STOP palm button on the FP130 feeder . . . . . . . . . . . . . . . . . . . . . . 97
5.1.4 Main control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.1.5 <Machine functions> key field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.1.6 Touchscreen handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
5.1.7 Touchscreen structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.1.8 Info box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.1.9 Entering the password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.1.10 Displaying machine status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.1.11 Description of the function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.1.12 Switching the help on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4Falzmaschine K8RS
Table of contents
5.1.13 Selecting favorite pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.1.14 Switching on the large-scale display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.1.15 Numeric input keyboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.1.16 <Diagnosis> page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5.1.17 Displaying alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.1.18 Control panel in the cross fold and threefold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.2 Compressed air nozzle with manometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
5.2.1 FP feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.2.2 Combi area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.3 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
5.3.1 Switching the operating mode of the folding knives . . . . . . . . . . . . . . . . . . . . . . . . 125
5.3.2 Set-up mode with open protective device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.3.3 Creating production readiness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.3.4 Machine control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.3.5 Self-control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.3.6 Adapter box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6 Transport, interim storage
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
6.1.1 Qualification of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.1.2 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
6.2.1 Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.2.2 Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.2.3 Buckle plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.2.4 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.2.5 Pressure vacuum pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.2.6 Unpacking accessories/options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.2.7 Performing an incoming inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.2.8 Reporting a damage situation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.3 Transporting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
6.4 Interim storage of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
6.4.1 Outdoors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.4.2 In a storage room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7 Installation, commissioning
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
7.1.1 Qualification of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.1.2 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.2 Setting up the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
7.3 Making the stationary mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
7.3.1 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Falzmaschine K8RS 5
Table of contents
7.3.2 Heed network prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.3.3 Observe the design of the stationary mains connection. . . . . . . . . . . . . . . . . . . . . . 142
7.3.4 Making the stationary mains connection on the main control cabinet . . . . . . . . . . . 143
7.3.5 Connecting the protective equipotential bonding conductor. . . . . . . . . . . . . . . . . . . 144
7.3.6 Checking the protective conductor connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.4 Removing transport locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.4.1 On the threefold unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.4.2 Threefold, variant KTZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.5 Connecting the compressed air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.7 Conducting a final check of the protective devices . . . . . . . . . . . . . . . . . . . . . . 148
7.8 Conducting an inspection after commissioning . . . . . . . . . . . . . . . . . . . . . . . . 148
8 Operation and adjustment
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.1.1 Qualification of personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.1.2 Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8.2 Operating the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
8.2.1 Switching the main switch on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
8.2.2 EMERGENCY STOP palm button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
8.2.3 Raising/lowering the pile plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
8.2.4 Switching the Feeder Loading System (FLS) on/off. . . . . . . . . . . . . . . . . . . . . . . . . 156
8.2.5 Switching the air supply on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
8.2.6 Starting/stopping the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
8.2.7 Starting/stopping the sheet infeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
8.3 Brief instructions for adjusting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.4 Adjusting the M1 control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.4.1 Activate "Setup" machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.4.2 Main page structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
8.4.3 Beginning a new job. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8.4.4 Beginning a new signature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
8.4.5 Beginning a new shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.4.6 Making the counter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8.4.7 Selecting a folding imposition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.4.8 Start buckle plate positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
8.4.9 Positioning of the fold rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
8.4.10 "Setup" machine, manual activation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
8.4.11 Changing the infeed data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
8.4.12 <FP130 settings> page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
8.4.13 <PB1 settings> page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
8.4.14 <KB settings> page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
8.4.15 <DB settings> page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

6Falzmaschine K8RS
Table of contents
8.5 Setting the feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
8.5.1 Pivoting the feeder head upwards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
8.5.2 Set the right-hand pile stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
8.5.3 Loading the feeder with a pallet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
8.5.4 Align the paper pile laterally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
8.5.5 Position the feeder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
8.5.6 Set the left-hand pile stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
8.5.7 Inserting the smoothers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
8.5.8 Adjusting the pressure vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
8.5.9 Adjusting the feeder head, VACULIFT RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
8.5.10 Setting the paper pile level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8.5.11 Setting the lateral ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8.5.12 Setting the small sheet-size device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8.5.13 Adjusting the front ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8.5.14 Adjusting the dual suction belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
8.6 Setting the standard register table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
8.6.1 Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
8.6.2 Adjusting the conveyor table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.6.3 Switch ultrasonic double sheet detector on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
8.6.4 Adjusting the manual double sheet detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
8.6.5 Adjusting for the sheet format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
8.6.6 Adjusting the angle for the fold rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
8.6.7 Adjusting the vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
8.7 Adjusting the parallel fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
8.7.1 Adjusting the roller pressure (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
8.7.2 Changing the fold roller setting (automatic). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
8.7.3 Buckle plate positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
8.7.4 Inserting the buckle plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
8.7.5 Pull back/remove the buckle plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
8.7.6 Adjusting the buckle plates (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
8.7.7 Adjusting the buckle plates (automatic). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
8.7.8 Adjusting the FTK combination buckle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
8.7.9 Correcting skewed perforation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
8.7.10 Installing/dismounting slitter shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
8.7.11 Creasing, cutting and perforating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
8.8 Adjusting the crossfold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
8.8.1 Set-up of transport brushes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
8.8.2 Adjusting the cross fold stop (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
8.8.3 Adjusting the cross fold stop (automatic). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
8.8.4 Open/close crossfold stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
8.8.5 Opening/closing the pneumatic crossfold stop (option). . . . . . . . . . . . . . . . . . . . . . 260
8.8.6 Adjusting the folding knife in the lengthwise position (standard). . . . . . . . . . . . . . . 261
8.8.7 Adjusting the folding knife in the lengthwise position (automatic) . . . . . . . . . . . . . . 262
8.8.8 Opening/closing the crossfold table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
8.8.9 Adjusting the fold rollers and slitter shafts (standard) . . . . . . . . . . . . . . . . . . . . . . . 264

Falzmaschine K8RS 7
Table of contents
8.8.10 Adjusting the fold rollers and slitter shafts (automatic). . . . . . . . . . . . . . . . . . . . . . . 265
8.8.11 Installing/removing slitter shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
8.8.12 Adjusting the KLT buckle plate (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
8.8.13 Adjusting the KTL buckle plate (automatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
8.9 Adjusting the threefold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
8.9.1 Set-up of transport brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
8.9.2 Adjusting the threefold stop (standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
8.9.3 Adjusting the threefold stop (automatic). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
8.9.4 Open/close threefold stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
8.9.5 Pull out the three fold carriage.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
8.9.6 Adjusting the fold rollers (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
8.9.7 Adjusting the fold rollers (automatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
8.9.8 Installing/removing slitter shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
8.9.9 Special procedure with threefold work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
8.9.10 Adjusting the KTLT buckle plate (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
8.9.11 Adjusting the KTLT buckle plate (automatic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
8.10 Adjusting the folding knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
8.10.1 Adjusting the height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
8.10.2 Adjusting the angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
8.10.3 Enter additional steadying distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
8.11 Adjusting outfeed transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
8.12 Turning the threefold folding unit (variant S-KTZ). . . . . . . . . . . . . . . . . . . . . . . 291
8.13 Removing the paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
8.14 Identification and handling of malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
8.14.1 Palletized feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
8.14.2 Register table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
8.14.3 Parallel fold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
8.14.4 Double fold in the first fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
8.14.5 Edges/dog ears at letter fold, gatefold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
9 Maintenance
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
9.1.1 Qualification of personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
9.1.2 Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
9.2 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
9.2.1 Ordering spare and wear parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
9.3 Operational maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
9.3.1 Checking protective devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
9.3.2 Checking the pneumatic springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
9.3.3 Cleaning the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
9.3.4 Cleaning/replacing air filter of the pressure vacuum pump . . . . . . . . . . . . . . . . . . . 326
9.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
9.4.1 Checking the feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

8Falzmaschine K8RS
Table of contents
9.4.2 Checking the register table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
9.4.3 Checking the parallel fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
9.4.4 Checking the fold rollers and slitter shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
9.4.5 Checking the buckle plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
9.4.6 Checking the slitter shaft cassette. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
9.4.7 Checking the folding knives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
9.4.8 Checking the crossfold table and threefold carriage . . . . . . . . . . . . . . . . . . . . . . . . 353
9.4.9 Maintaining the pressure vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
9.4.10 Lubricating the safety handwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
9.4.11 Checking the fan in the control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
9.5 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361
9.6 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .364
10 Shutdown, storage
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365
10.1.1 Qualification of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
10.1.2 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
10.2 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365
10.2.1 Temporary shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
10.2.2 Final decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
10.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .366
11 Disposal
11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .367
11.1.1 Qualification of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
11.1.2 Safety messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
11.2 Disposal/recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .367

Folding machine K8RS 9
About this manual
1 About this manual
This operatingmanual must be readby everybodywho transports,sets up,
connects, commissions, adjusts, operates, maintains, repairs and
dismantles this machine.
Safe use of the machine is only possible once everybody has understood
the content of and follows all points of the operating manual. This applies
especially to the chapter on safety.
This operating manual contains important notes on how to operate the
machine safely, correctly, and economically.
Following these
notices helps • To avoid hazards.
• To minimize repair costs and downtimes.
• To increase the reliability and service life of the machine.
Supplementation • The operator must add instructions regarding national regulations for
accident prevention to this operating manual.
Retention • This operating manual forms part of the machine. It must be available
on the machine throughout the machine's entire service life.
If you sell
the machine • Give this operating manual to any subsequent owner or user of the machine.
We reserve the right to make technical changes to improve the machine,
even if these changes are not taken into account in this operating manual.

10 Folding machine K8RS
About this manual
Additional documents
1.1 Additional documents
In addition to this operating manual, there are these documents about the
machine:
1.1.1 Supplier documentation
1.2 Structure of the operating manual
The table lists the chapters of the operating manual. It also describes the
essential content of these chapters as well as the target groups at whom
the chapters are directed.
Designation Type
MBO part number Use
Wiring diagram with pneumatic diagram
Spare parts list
Knife catalog
Supplier documentation
Table 1: Additional documents
Manufacturer Designation Type
MBO part number Use
Elmo-Rietschle Pressure vacuum pump C-KLR 140
4006527 Compressed air generation Vacuum generation
Table 2: Supplier documentation

Folding machine K8RS 11
About this manual
Structure of the operating manual
No. Chapter Contents Target group
Table of contents The detailed table of contents serves
as a search tool •Operator • Operating personnel
• Maintenance personnel
• Service technicians
1 About this manual Important notes about this operating
manual •Operator • Operating personnel
• Maintenance personnel
• Service technicians
2 Basic safety
instructions Details about: • Residual risks and hazards with
intended use.
• Foreseeable misuse.
• Avoidance of the risks.
•Operator
• Operating personnel
• Maintenance personnel
• Service technicians
3 Product description • Important notices about the product
• Technical data •Operator • Operating personnel
• Maintenance personnel
4 Structure and function Description of:
• Structure and function
• Protective devices
• Operating personnel
• Maintenance personnel
• Service technicians
5 Operating and display
elements,
operating modes
Description of the:
• Operating and display elements
• Operating modes
• Operating personnel
• Maintenance personnel
• Service technicians
6 Transportation, interim
storage Details about: • Packaging
• Transportation
• Interim storage
• Transport personnel
• Maintenance personnel
• Service technicians
7 Set-up and
commissioning Details for: •Set-up
• Commissioning
• Maintenance personnel
• Service technicians
8 Adjustment and
operation Details for: •Operation
• Adjustment
• Operating personnel
• Maintenance personnel
• Service technicians
9 Maintenance Details for the:
• Operational maintenance
• Maintenance
• Repair
• Operating personnel,
• Maintenance personnel
• Service technicians
10 Decommissioning,
storage and putting the
machine back into
operation
Details for the:
• Decommissioning
•Storage
• Recommissioning
•Operator
• Operating personnel
• Maintenance personnel
• Service technicians
11 Disposal Details for the environmentally friendly
disposal •Operator • Maintenance personnel
• Service technicians
Table 3: Structure of the operating manual

12 Folding machine K8RS
About this manual
Signs and symbols used
1.3 Signs and symbols used
The signs and symbols in this manual should help you to use the manual
and the machine quickly and safely.
Symbol Explanation
Indicates an instruction for action.
The sequence is not specified.
1) ...
2) ...
3) ...
Numbered instructions for action.
The defined sequence of the instructions for action
makes it easier for you to use the machine correctly and
safely.
Here you will find the result of a sequence of
instructions for action.
<STOP> Push button with the label between the brackets (e.g.
Stop).
Additional information for use of the machine.
Important notice, please observe.
Table 4: Symbols, terms, and abbreviations

Folding machine K8RS 13
About this manual
Description of safety messages
1.4 Description of safety messages
Safety messages are marked by a safety sign and a signal word.
1.4.1 Signal words
Thesignalwords drawyourattentiontothe severityofthe hazard. Theyare
structured according to a classification system.
.
1.4.2 Structure of safety messages
Each safety message is structured as follows:
• Safety sign
• Signal word to identify the hazard level
• Type and source of the hazard
• Possible consequences of the hazard
• Measure(s) for avoiding the hazard
Example:
Signal word Meaning
DANGER Signal word to indicate a hazardous situation with
high risk level which, if not avoided, will result in
death or serious injury.
WARNING Signal word to indicate a possible hazardous
situation with medium risk level which, if not
avoided, could result in death or serious injury.
CAUTION Signal word to indicate a possible hazardous
situation with minor risk level which, if not avoided,
could result in minor or moderate injury or property
damage.
Table 5: Signal word meanings
DANGER! WARNING! CAUTION! (Signal word)
Type and source of the hazard.
Possible consequences of the hazard.
Measure(s) for avoiding the hazard

14 Folding machine K8RS
About this manual
Description of safety messages
1.4.3 Safety sign
1.4.3.1 Prohibition sign
Depiction Meaning
Prohibition sign
Red border, white background, black symbol.
Safety symbol that forbids a behavior that could
cause a hazard.
Warning sign
Yellow background, black symbol.
Safety sign that warns about a hazard.
Mandatory sign
Blue background, white symbol.
Safety sign that prescribes a particular
behavior.
Rescue sign
Green background, white symbol.
Safety sign that identifies the rescue path or
the path to a place where you can get help or
find rescue equipment in case of an
emergency.
Fire protection sign
Red background, white symbol.
Safety sign, which in case of hazard marks the
location of fire alarm and fire extinguishing
equipment and/or the path to this equipment.
Table 6: Safety sign
Depiction Meaning
Entry of the area forbidden.
This prohibition sign indicates that it is
forbidden to enter the area.
Table 7: Prohibition sign

Folding machine K8RS 15
About this manual
Description of safety messages
1.4.3.2 Warning sign
Depiction Meaning
Warning about a general hazard.
You will see this warning-triangle next to
activities during which several causes can
create hazards.
Warning of hazardous voltage.
You will see this warning-triangle next to
activities during which there is a hazard of
electrical shock, possibly with deadly
consequences.
Warning of crushing of body parts
You will see this warning triangle next to
activities during which there is a hazard of
crushing, possibly with deadly consequences.
Warning of rotating rollers.
You will see this warning triangle next to
activities during which there is a hazard of
crushing, possibly with deadly consequences.
Warning of crushing of hand.
You will see this warning-triangle next to
activities during which there is a hazard of
crushing the hand.
Warning of crushing by noise dumping
hood.
You will see this warning triangle next to
activities during which there is a hazard of
crushing by the noise dumping hood, possibly
with deadly consequences.
Warning against rotating knives.
You will see this warning-triangle next to
activities during which there is a hazard of
cutting injuries, possibly with deadly
consequences.
Warning of lifting heavy machine parts.
You will see this warning triangle next to
activities during which there is a hazard of
overloading due to lifting heavy loads.
Table 8: Warning sign

16 Folding machine K8RS
About this manual
Description of safety messages
Warning of tipping machine parts.
You will see this warning-triangle next to
activities during which there is a hazard of
crushing due to tipping loads.
Warning of entanglement zones.
You will see this warning triangle next to
activities during which there is an
entanglement hazard.
Warning of sharp knives.
You will see this warning-triangle next to
activities during which there is a hazard of
cutting injuries, possibly with deadly
consequences.
Warning of substances harmful to health.
You will see this warning-triangle next to
activities during which there is a hazard of
substances harmful to health, possibly with
deadly consequences.
Warning of oxidizing substances.
You will see this warning-triangle next to
activities during which there is a hazard of
oxidizing substances, possibly with deadly
consequences.
Warning of hot surfaces.
You will see this warning-triangle next to
activities during which there is a danger of
burns, possibly with long-term consequences.
Warning of stumbling points.
You will see this warning-triangle next to
activities during which there is a tripping
hazard, possibly with deadly consequences.
Depiction Meaning
Table 8: Warning sign