D85 Operating Instructions PDF

Operating instructions
EXPERTCUT 106 PER 3.0
D85
BSA05571401_D85 052 − => 1641 / <=
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
 Bobst Mex SA 2017 055714 8552 0100 00211424 18.05.2017 A00 00 1

D85 D85 D85
BSA05571401_D85
<=
052 −
BSA05571401_D85 BSA05571401_D85
=> 1641 /
052 − 052 −
=> 1641 / <= => 1641 / <=

MANUAL NUMBER
BSA05571401_D85
052 −
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Summary
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety and environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Machine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Machine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Maintenance - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Maintenance - After the first month . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Maintenance - Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Maintenance - Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Maintenance - Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Maintenance - Half-yearly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Maintenance - Yearly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Maintenance - Every 2 years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Maintenance - Non-periodic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Various information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Summary
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Preface
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Reader’s comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Abreviations and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preface
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General
We reserve all rights in this document and in the subject Reserve
thereof. By acceptance of the document the recipient Some of the items shown in this manual are available as
acknowledges these rights and undertakes not to publish the options. Only those items will be supplied which figure in the
document nor the subject thereof in full or in part, nor to make order confirmation of Bobst Mex SA.
them available to any third party without our prior express
written authorization, nor to use it for any purpose other than Reader’s comments
for which it was delivered to him. Please submit any remarks or suggestions that might help us
to improve this manual.
Safety
When applying to us, please do not omit to mention the
The instructions regarding the safety are described in a chap- manual number.
ter printed on yellow paper. Before proceeding to any opera-
m Make a photocopy of each page concerned, noting your
tion on or with the machine, operators, operator helpers,
remarks or suggestions.
mechanics, electricians, persons responsible of the machine
and its production or anyone else who comes into physical m Send these pages together to the address indicated
contact with the machine are imperatively asked to read this below.
chapter. Abreviations and symbols
cc Operator’s side (os)
coc Opposite operator’s side (oos)
Bobst Mex SA Tel.: +41 21 621 21 11

Document Management Support FAX: +41 21 621 43 95
PO Box E-mail: doctech.bobst@bobst.com
CH-1001 Lausanne WEB: http://www.bobst.com
Preface
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Safety and environment

General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Manuals and directions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General rules for all users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Switch cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fluidic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Excerpt from the EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Precautions against magnetic fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Warning pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Prohibition pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Danger pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Obligation pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Rescue and help pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Personnel protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Main circuit-breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Key selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Acoustic warning device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Alarm lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Movable guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Safety light curtains at the feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Upper chase locking bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Stops on the lower cutting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Gripper bar chain locking device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Manual drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Safety instructions for operators and for operators’ helpers . . . . . . . . . . . . . . . . . . . 35
Conditions prior to any intervention from the outside of the machine . . . . . . . . . . . . . . . . . . 35
Conditions prior to any intervention inside the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Safety instructions for maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Conditions prior to any intervention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Telemaintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Protection of the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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Easy reconditioning of feedstock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Environmental concerns during the design stage of our machines . . . . . . . . . . . . . . . . . . . . . 43
Economic use of feedstock thanks to the technology of our machines . . . . . . . . . . . . . . . . . 44
Life cycle of our machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Flexo printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Rotogravure printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Box gluing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Waste management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Noise levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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General safety instructions

Introduction Manuals and directions for use
You should read and understand these instructions if you are The manuals supplied by the manufacturer with the machine
an operator, set-up person, mechanic, maintenance person, or after its delivery contain directions for use and must be
a helper or assistant to any of these people, or anyone else made available to any person working with the machine or
who comes into physical contact with the machine and if you having any responsibility with regard to it.
have administrative or supervisory responsibilities for the Anyone who will be working with the machine must read and
operation, maintenance, and use of the machine. understand the directions before beginning work on the
If there is anything about the instructions or about the machine. The directions must be followed by all workers.
machine that you do not understand, speak to your The manuals must be kept in a clean location and available
supervisor before you touch the machine. to anybody dealing with the machine. Everybody dealing with
YOUR FAILURE TO FOLLOW THESE INSTRUCTIONS the machine must be notified of all revisions.
MAY CAUSE SERIOUS INJURIES TO YOU OR TO To prevent injuries to people or damage to the machine,
SOMEONE ELSE. make sure that the whole machine receives regular
maintenance as described in the manual.

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General rules for all users

To prevent injuries, you must:
m read and comply with the directions supplied with the m never put your hands, feet or any other part of your body
machine. Make sure the machine is operated only by inside the machine or near moving parts while the
people who have been trained according to manufactur- machine is in operation.
er’s directions. m never climb onto the machine while the machine is in
m not use the machine unless it is in good working condition operation.
and unless all safety guards and devices as well as all m make sure the work area around the machine and the
machine functions work properly. machine itself are clean and neat. Grease, oil, and other
m check whether safety devices are working properly. slippery substances are dangerous and should be
m never void any safety device and never prevent or stop cleaned up immediately. Do not leave any tools or other
a safety device from doing what it is supposed to do. objects on the floor, platform or in other working areas.
m immediately report any trouble compromising safety at m make sure that the machine is serviced according to
work to your supervisor and warn any person likely to manufacturer’s directions given in the maintenance
work with the machine of the trouble. manual.
m make sure before every start-up, that no one is inside the m make sure that the worker is not putting himself in such
machine, that everybody is standing away from the a state (alcohol, narcotics, etc.) that he might put himself
machine, and that no one is touching the machine. or other workers in danger.
Switch cabinets
Only a qualified person is authorized to intervene inside the
switch cabinets.

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Fluidic equipment
Only a qualified person is authorized to intervene on the
fluidic equipment of the machine.
In fluidics, flexible conduits have a limited service life. A regu-
lar visual control, under the responsibility of the users, is nec-
essary to determine whether or not conduits must be
replaced.

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Excerpt from the EC Declaration of Conformity

Identification plate
We, Bobst Mex SA / Route de Faraz 3 / CH - 1031 Mex, declare on our own
responsibility that the machine:
Trademark: ..........................................
Type: ..........................................
Serial Number: ..........................................
Year of construction: ..........................................
Print date of document: ..........................................
is in conformity with the provisions of:

- the ”Machinery” directive 2006 / 42 / CE,
- the ”Electromagnetic Compatibility” directive 2014 / 30 / EU,
- the ”Low Voltage” directive 2014 / 35 / EU,
- the ”ATEX” directive 2014 / 34 / EU.
The legal person authorized to establish the ”Technical File” is:
Bobst Mex SA
Address: Route de Faraz 3
CH - 1031 Mex

EDT 01
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Precautions against magnetic fields

Certain motors with which the machines are equipped emit
more or less intense magnetic fields. Machine areas where
such fields occur are indicated by the plate on the right.
Persons with cardiac pacemakers must imperatively take all
possible precaution measures inside and close to these
areas. They have to be taken in accordance with operating
instructions of their device.

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Warning pictograms
Description
Various pictograms are put on the machine where a warning Important: These pictograms exist in form of self-adhesive
is required. Persons intervening on the machine have to pay stickers or attachable plates. They must not be removed.
attention to these warnings. To do so, it is indispenable to Check that they are always legible. If this is not the case,
know the meaning of these pictograms in order to take pre- replace them.
cautions to prevent any body harm.
Standard pictograms and machine-specific pictograms exist.
Standard pictograms are distinguished as follows:
1. Prohibition pictograms.
2. Danger pictograms.
3. Obligation pictograms.
4. Rescue and help pictograms.
Machine-specific pictograms are a compliment to standard
pictograms and in general refer to the machine zone con-
cerned by the warning.

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Prohibition pictograms No access with metallic objects or a

These pictograms are represented by a disk with a circular watch.
strip and an oblique red bar on a white background.
Meaning of the prohibition pictograms which can be put on Do not touch.
the machines:
General prohibition. No reaching in.
No smoking. No stepping on surface.
No open flame or any other ignition Do not walk or stand here.

source, no fire and no smoking.
No entry. No magnetic field.
No access with cardiac devices. Only for authorised personnel.
No access with a prosthesis.

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Do not take by hand.
Do not step on the belt.

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Danger pictograms Floor-level obstacle.

These pictograms are represented by a triangle with a black
edge on a yellow background.
The danger pictograms are in general used to warn from Risk of falling.
residual risks. These are the risks, which inevitably persist,
even if the safety devices required by the safety rules are cor-
rectly installed and operational. Slippery surface.
Meaning of the danger pictograms, which can be put on the
machine:
Electricity.
General warning.
Hot surface.
Light beam.
Automatic start-up.
Non-ionising radiation.
Crushing risk.
Magnetic field.
Overhead obstacle.

EDT 01
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Inflammable material. Sharp element.
Sharp element. Risk of crushing hands (rotating ele-

ments).
Optical radiation.
Crushing hands by tools.
Sudden loud noise.
Crushing risk.
Risk of crushing feet.
Hot materials. Counterrotating rollers.

EDT 01
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Risk of crushing hands (elements in

translational movement).

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Obligation pictograms
Wear safety footwear.
These pictograms are represented by a blue disk.
Meaning of the obligation pictograms, which can be put on
the machine:
Wear protective gloves.
General obligation.
Wear protective clothing.

Refer to instructions manual.
Wear head protection.

Wear ear protection.
Wear a mask.
Wear eye protection.
Wear a safety harness.

Disconnect mains plug.
Disconnect all energy sources.

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Verify that protection is in place.
Take here by hand.

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Rescue and help pictograms

These pictograms are represented by a green square for the
rescue pictograms and by red for the help pictograms.
Meaning of the rescue and help pictograms, which can be put
on or around the machine:
Emergency exit on the left.
Emergency exit on the right.
First aid station.

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Personnel protection
Main circuit-breaker
Before carrying out repairs, maintenance work or any other
intervention requiring acces to the inside of the machine,
switch off circuit-breaker A001D.Q1 and lock it using pad-
lock(s) 1.
WE DECLINE ALL RESPONSIBILITY IN THE EVENT
OF NON-OBSERVANCE OF THIS INSTRUCTION.
A001D.Q1
P10979

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To lock a circuit-breaker, proceed as follows:

m Rotate the circuit-breaker handle until white plate 2 is
opposite the green part 3 of the dial.
m Pull black plate 4 in order to clear an opening for clamp 5.
m Insert padlock(s) 1 according to local prescriptions.
ON ON
I I
5
D10999
O
OFF
O
OFF
1
D11000 D11001
3 2
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Key selector
Machine must not be able to be started up if the key is not in
the selector S50D and turned to pos. 2.
In order to interlock the machine controls, turn key of key
selector S50D to pos. 0, remove the key and keep it on you.
Important:
1. The key must not be attached to the machine by means
of a chain or any other means.
2. Only one key must be used on each machine.
S50D

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Emergency stop
The emergency stop push-button is a mushroom-type
push-button with locking device. There is one on:
m on the os control panel of the feeder (S55D).
m on the os control panel of the platen press (S51D).
m on the os control panel of the delivery (S52D).
m on the oos control panel of the platen press(S53D).
m on the oos control panel of the pallet conveyor (S54D).
S52D S51D S55D
S53D S54D

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Important
Check that each emergency stop push-button operates as
described below.
Operation
When an emergency stop push-button is pressed, the
machine is stopped immediately.
Once the push-button has been pressed, all the controls are
inoperative.
Restarting
After an emergency stop push-button has been pressed, pro-
ceed as follows to put the machine back into operation:
m Remedy the cause of the emergency stop.
m Unlock the pressed push-button. To do so, turn in the
direction indicated by the arrow.
m Proceed with the machine start-up.

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Acoustic warning device Alarm lamps

The acoustic warning device may sound in three different Orange light: Signals movements of a pallet conveyor.
ways: White light: Signals opening of the automatic door while
Continuous tone machine is running.
—————————
To signal a machine start-up.
Changing tone
— — — — —
Low-pitched:
m Non-stop cycle in operation at delivery.
m End of pile reached at delivery.
High-pitched:
m Non-stop cycle in operation at the feeder.
m Automatic lowering of pile supporting plate at the feeder
(if the machine is running).
Intermittent tone
SSS SSS SSS SSS SSS
Signals a trouble which is not causing machine stop.
The noise around the machine must not drown out the
acoustic warning device.

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Movable guards
The machine is equipped with the following movable guards:
m One transparent guard 1 at the platen press inlet.
m One transparent guard 2 on the os of the platen press.
m One transparent guard 3 on the os of the stripping station.
m One transparent guard 4 on the os of the delivery.
m One transparent guard 5 on the os of the residual waste
remover.
m One door 6 on the binder sheet inserter. 2
3
m One transparent guard 7 on the oos of the stripping 4
5
station.
6
m One transparent guard 8 on the oos of the delivery.
m One door 9 on the oos of the stripping station.
m One automatic door 10 on the oos of the delivery.
m One door 11 oos under the feed table.
7 10 8
9
1
11

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If one of the guards 1 to 10 is open, the HMI indicates a fault.

In this case, the machine stops or cannot be started up. HMI
If guard 2 is open and the machine is stopped between Notifications
195-215°MP (programmed stop) the diecutting equipment is
unclamped.
If one of the guards 3, 4, 7 and 8 is open and the machine
stopped between 195-215°MP (programmed stop) the upper
stripping and blank separating equipments are unclamped.
If door 11 is opened, the HMI signals a fault. In this case, the
machine including the main motor stops or cannot be started
up. 2
3
When closing one of the doors 6,9 or 11, make sure nobody 4
is inside the machine and press reset button S122D, S123D 5
6
or S124D.
Monitoring the function
Each movable guard has to go through one opening and
closing cycle once every 8 hours. If not, the HMI signals a
trouble.
10 8
9 7
1
11
S122D S123D
S124D

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Safety light curtains at the feeder When a beam 3 is interrupted:

When a beam is interrupted: m The Matic movements at the feeder and feed table are
m The HMI signals a problem and the telltale lamp S75D interrupted (format setting of the suction group and lateral
lights up. blowers, tools of the feed table).
m Acoustic warning device sounds. m The movement of the feed table frame is interrupted.
When beam 1 is interrupted: Give an impulse on S75D or S31D to reset the guard.
m Pile supporting plate descent is interrupted.
Give an impulse on S75D or S91D to reset the guard.
When a beam 2 is interrupted:
m The horizontal movement of the non-stop rack is
interrupted.
3
m The Matic movements at the feeder and feed table are
interrupted (format setting of the suction group and lateral
blowers, tools of the feed table).
ÓÓÓÓ
ÓÓÓÓ ÓÓÓÓ
ÓÓÓÓ
ÓÓÓÓ
Give an impulse on S75D to reset the guard.
ÓÓÓÓÓ ÓÓÓÓ
2
ÓÓÓÓÓ ÓÓÓÓ ÓÓÓÓ

ÓÓÓÓÓÓÓÓÓ ÓÓÓÓ 1
ÓÓÓÓ ÓÓÓÓ
ÓÓÓÓ
HMI ÓÓÓÓ
ÓÓÓÓ
S91D
Notifications ÓÓÓÓ
S31D S75D
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Upper chase locking bolts Stops on the lower cutting equipment

There are two locking bolts 210 (1 x platen press inlet side / If supporting rollers 211 (1 x platen press inlet side / 1 x
1 x platen press outlet side) situated on the outside guides of platen press outlet side) are not lowered, stops 1 prevent the
the platen press. These bolts prevent the chase from being lower cutting equipment from being taken out.
turned if it is not locked. The axle 212 is usefull to lock lower cutting equipment out of
In the intermediate position, they serve as a stop for the machine.
chase when pulling it out of the platen press.
Important: Check that the bolt on platen press inlet side puts
itself automaticallly into intermediate position when not
manually kept in withdrawn position.
210
212 1 211
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Gripper bar chain locking device

This device consists of claws 1 which prevent any ill-timed
movement of the gripper bar chains as soon as the machine
is stopped.

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Manual drive
When the manual drive axle 1 is engaged, the HMI signals
a fault. In this case the machine cannot be started up.
HMI
Important: Stop the main motor and wait for complete stand- Notifications
still of the flywheel before engaging the drive axle.

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Safety instructions for operators and for operators’ helpers

Conditions prior to any intervention from the outside
of the machine
These interventions refer mainly to a job change. Before
intervening on the machine, make sure it is stopped with the
movable platen in the lower dead center (190-260°MP). Two
cases are possible:
1. If the machine is running, give an impulse on one of the
programmed stop push-buttons, as for example S30D.
2. If the machine is stopped, place the movable platen in the
lower dead center using one of the inching push-buttons,
as for example S29D.
S30D S29D

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Note: For accessibility reasons some interventions cannot

be carried out with the movable platen in lower dead centre.
In such a case stop the machine at the machine position
(°MP) allowing the intervention.
Once the machine is stopped, proceed as follows:
m Wait until the locking claws 1 are engaged in the gripper
bar chain (approx. 6 seconds).
m Open movable guard, then proceed to the intervention.

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Conditions prior to any intervention inside the

machine
Certain interventions require operators to gain access inside
the machine. If so, before entering the machine, proceed as
follows:
m Stop the machine with the movable platen in the lower
dead center (190-260°MP). To do so, proceed as
described above in the section ”Conditions prior to any
intervention from the outside of the machine”.
Note: For accessibility reasons some interventions can-
not be carried out with the movable platen in lower dead
center. In such a case stop the machine at the machine 1
position (°MP) allowing the intervention.

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m Switch off the main motor (HMI).

m Open movable guard to enable intervention. HMI
m Interlock machine controls. To do so, turn the key of
selector S50D to pos. 0, remove the key and keep it on
you.
m Switch off main circuit-breaker A001D.Q1 and lock it
using padlock(s).
m Proceed to the intervention.
A001D.Q1
P10979
S50D

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Safety instructions for maintenance personnel

Conditions prior to any intervention
Before intervening on the machine to carry out repairs or
maintenance operations, make sure the machine is stopped
with the movable platen in lower dead center (190-260°MP).
Two cases are possible:
1. If the machine is running, give an impulse on one of the
programmed stop push-buttons, as for example S30D.
2. If the machine is stopped, place the movable platen in the
lower dead center using one of the inching push-buttons,
as for example S29D.
Note: For accessibility reasons some interventions cannot
be carried out with the movable platen in lower dead center.
In such a case stop the machine at the machine position
(°MP) allowing the intervention.
S30D S29D

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Once the machine is stopped, proceed as follows:

m Open movable guard to enable intervention.
m Interlock machine controls. To do so, turn the key of
selector S50D to pos. 0, remove the key and keep it on
you. 1
HMI
S50D

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m Close the compressed air feed hose of the machine. To

do this, turn the stop valve 215 clockwise and lock it using
a padlock.
m Switch off main circuit-breaker A001D.Q1 and lock it
using padlock(s).
m Wait until all moving elements, especially the main motor
flywheel, come to a complete stop.
m Proceed to the intervention.
A001D.Q1
Note: It is sometimes necessary to have a source of energy
available to carry out certain maintenance operations. If so,
special precautions have to be taken to ensure personal
safety. For more details, please refer to the instructions given
in the manual ”General maintenance”.
215
P18836

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Telemaintenance
Telemaintenance consists in troubleshooting, changing As far as possible, it is important to close all movable safety
parameters or performing checks from a place other than guards of the machine before any distant intervention is car-
where the machine is located. These operations are per- ried out on the machine. Moreover, safety prescriptions indi-
formed by Bobst technicians. cated in the ”Safety and environment” chapter of the
In order to perform a telemaintenance operation, technicians machine’s technical documentation have to be observed.
require the authorization of a person in charge and being Telemaintenance is an unexpected situation which requires
present on the production site. This person takes the entire persons involved to be very careful as it is impossible to
responsibility for safety on and around the machine. The per- define all observation conditions enabling to establish con-
son has to be physically near the machine and have it in his textual limits.
field of view.

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Protection of the environment

Introduction Environmental concerns during the design stage of
The packaging industry which we supply has the duty to take our machines
environmental questions into consideration. For this reason, Already during the design stage particular attention is given
we invite it to be committed to a voluntary environmental to the choice of materials and components used for manufac-
protection policy, in accordance with the legislation in force turing our machines. Whenever possible, they are chosen
and by the spirit of the ISO 14001 certification. with regard to their low impact on the environment, be it dur-
With this in mind, Bobst published a charter on its policy ing production or during their use and elimination.
regarding health, safety at work and environmental protec- The questions related to ergonomics and energy-saving are
tion (http://www.bobst.com). The various actions undertaken also part of our considerations. Furthermore, special atten-
as well as the results already obtained are listed in the busi- tion is paid to reduce the number of interventions, which often
ness report. produce various waste materials.
Easy reconditioning of feedstock

Packagings produced by our machines are made from paper,
flexible materials, solid and corrugated board. All these
materials can easily be recovered in order to be recycled and
revaluated.

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Economic use of feedstock thanks to the technology Flexo printing

of our machines Solvent-free water-based inks can be used efficiently in flexo
Machine precision and reliability of Bobst machines are printing. In this case the cleaning of the printing units and the
essential to the economic use of feedstock throughout a pro- inking elements is mainly done with water. Washing systems
duction run. with different programmes are also provided. They enable an
All our present machines are equipped with state-of-the-art economical use of ink and water.
electronics enabling to rapidly obtain ideal settings for each
Rotogravure printing
job to be created. This results in savings in time, energy and
materials when starting these jobs. The same goes for the Volatile organic compounds (VOCs) resulting from the
MATIC machines, since settings can be stored for repetitive evaporation of solvents contained in rotogravure inks have
jobs. to be recovered at their source. They can be recycled on-site
as supplementary heat sources representing further energy
The REGISTRON control devices warn (quality control) and
saving.
react (register control) immediately in case of irregularities,
which reduces waste production. They can be used together Box gluing
with an automatic waste ejection device. It is advisable to be in favour of using solvent-free glues in the
Life cycle of our machines folding box field, since they can be easily washed off with
warm water.
After renovation in our plants, our machines can enjoy a sec-
ond lease of life with customers wishing to have an accurate
and durable means of production at an attractive price at their
disposal.

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Waste management
The packaging industry does not only produce feedstock
waste. It also produces waste materials related to:
m production (tooling, printing plates, inks, glues, etc.)
m cleaning (cloths, dust, water, solvents, etc.)
m maintenance (oil changes, filters, etc.)
m repair works (replacing mechanical, electrical, electroni-
cal elements, etc.).
Within the framework of our commitment in favour of the
protection of the environment, an optimal waste manage-
ment system has to be put in place in order to analyse waste
types and quantities. Waste has to be collected, sorted and
stored by recycling specialists with regard to its recyclability
and elemination. These operations have to be carried out for
all types of waste materials in accordance with the local regu-
lations in force and with the directives of the manufacturers
concerned.

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Noise levels
Physical quantity
The level of noise measured below is the A-weighted
emission sound pressure level (LpA) expressed in dB(A).
Conditions
Measurements of the A-weighted emission sound pressure
level were carried out according to the ISO 11202 and the EN
13023 standards. They were carried out in a free sound field
environment, without sound reflection.
In the case of reflections on nearby walls and/or the ceiling,
the A-weighted emission sound pressure level is higher than
that measured in a free sound field.
The A-weighted emission sound pressure level can vary
depending on the hourly output, type, size and quality of the
material.
Individual guards
If the noise level is higher than standards in force in the coun-
try where the machine is used, the user’s personnel has to
be provided with adequate individual guards.

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Parameters for carrying out the measurements

Fig. 1. This table indicates the characteristics of the material
used for carrying out the measurements of the equivalent 1000
continuous sound A-weighted level. It also indicates the
0,42
hourly output at which these measurements were carried out.
Results of the measurements
Fig. 2. This table indicates the equivalent continuous sound 700
A-weighted levels in dB(A) and the places where these mea-
surements were carried out.
Number of dies 20
Stamping force 1,1 MN
P Q R S T U
1 Hourly output 6400 sheets/hour
F G
Points measured from a height of 1.6m and a dis-

O E A H
tance of 0.5m.
Points measured from a height of 1.6m and a dis-
tance of 0.5m.
D C B
N M L K J I
A B C D E F G H I J K L M N O P Q R S T U
2 85 81 80 80 84 81 85 83 78 80 79 79 78 77 83 79 83 84 81 83 82
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General
Designation of the machine subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
General
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Designation of the machine subassemblies

1 Feeder
2 Feed table
3 Platen press
4 Stripping station
5 Delivery
6 Residual waste remover and binder sheet inserter
6
5
4
3
2
1
General
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Machine controls
101
51
98
77
63
53
Machine controls
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Switch cabinet
A001D.Q1
P10979
Machine controls
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A001D.Q1 General power supply of the machine

When the white plate of the circuit-breaker is pointing:
m up, to ON: The cabinet is switched on.
m down, to OFF: The cabinet is switched off.
In this position, the circuit-breaker can be locked using padlock(s).
m to TRIPPED: After the circuit-breaker has been tripped by an overload or a short-cir-
cuit, the circuit-breaker moves automatically to this position.
Note: To reset, turn the circuit-breaker to OFF (RESET).
Important: It is imperative to switch off the main circuit-breaker and to lock it using pad-
lock(s):
m before any intervention of maintenance staff.
m before intervening to the inside of the machine of operators and operators’ helpers.
Machine controls
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Feeder
54
60
Machine controls
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Control panels
S38D S81D
S96D S7D
S92D S91D
S9D S8D
H16D S33D
S12D
S75D S74D
S73D S57D
S55D
Machine controls
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H16D Immaterial safety guard

Lights up when a luminous beam has been interrupted (see chapter ”Safety and environ-
ment”).
S7D Vertical movement of suction unit

Held to left: Raising.
Held to right: Lowering.
S8D Vertical movement of non-stop device

This function is locked when the machine is running.
S9D Automatic withdrawal and lowering of non-stop device

Case 1: Manual non-stop:
An impulse: Controls the lowering of the non-stop device.
Case 2: Automatic non-stop:
Held pressed: Activates the withdrawal of the non-stop rack.
As soon as the rack is withdrawn, lowering continues until the lower position is reached.
S12D Lateral shifting of pile supporting plate

Held to the left: Shifting towards os.
Held to the right: Shifting towards oos.
Machine controls
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S33D Sheet suction

1st impulse on pos. 1: Activation of air pumps; blower operating.
2nd impulse on pos. 1: Suction activated to take only one sheet. Telltale lamp flashes
until suction is activated, remains lit up during sheet suction.
2nd extended impulse on pos. 1: Suction activated. Telltale lamp flashes until suction
is activated, then it remains lit.
1st impulse on pos. 0: Suction interrupted at next cycle.
2nd impulse on pos. 0: Air pumps switched off.
Condition: Air pump running (HMI).
Notes:
1. Machine stopped. One minute after pos. 1 has been pressed for the first time, the air
pumps will stop.
2. When a sheet is sucked and the machine stops, keep this selector for more than 3
seconds on pos. 0 in order to stop the pumps.
3. For operation outside of non-stop mode, sheet suction is interrupted before the pile
supporting plate reaches the top. Hold this selector on pos. 1 to transport the remain-
der of the sheets in the pile.
Machine controls
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S38D Motorized shifting of the suction unit in running direction

Held to the left: Forward shifting.
Held to the right: Backward shifting.
S55D Emergency stop

Immediately stops the machine and all functions.
The main motor is switched off and all controls are locked.
S57D Normal stop

Stops the machine.
S73D Continuous run

To put the machine into continuous running, press the push-button twice.
1st impulse: Acoustic warning device.
2nd impulse: Continuous run.
Condition: The icon ”Machine ready” is displayed in green on the HMI.
Note: Does not operate if platen press is stopped in pressure zone (20-80_MP). In such
a case, begin by actuating inching run S74D.
Machine controls
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S74D Inching run

Press this push-button twice to set the machine to inching run.
2nd impulse: The machine runs as long as this button is pressed.
S75D Reset
An impulse on this push-button:
m resets the control circuits.
m cancels fault indicator in the HMI once fault has been remedied.
m cancels the programmed stop and the converting control functions.
m resets the immaterial safety guards at the feeder.
S81D Blocking / releasing of longitudinal movement of suction unit

An impulse on the left: Telltale lamp lit, unlocks the suction unit and enables to roughly
set its longitudinal position.
An impulse on the right: Telltale lamp lit, unlocks the suction unit and enables to refine
the setting of its longitudinal position by using flywheel 106.
After 20 seconds without a 2nd impulse on either the left or the right, the telltale lamp goes
out and the suction unit is blocked.
Condition: Machine stopped.
Machine controls
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S91D Slow supporting plate raising / lowering

Held to the lelft: Slow raising.
Held to the right: Slow lowering.
Note: When machine is running, an impulse on pos. 2 stops supporting pile raising and
sheet suction.
S92D Quick pile supporting plate raising / lowering

S91D held to the left + S92D pressed: Quick raising.
S91D held to the right + S92D pressed: Quick lowering.
When S91D and S92D are simultaneously kept pressed for more than two seconds, pile
supporting plate goes down to the ground.
S96D Angular correction of the sheet

Held on pos. 1: Counter clockwise rotation.
Held on pos. 2: Clockwise rotation.
Machine controls
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Various controls
102 101
112
111
103 106
104
105
108
110
113
109
Machine controls
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101 Adjusting suction pressure

The value is displayed on pressure gauge 102.
102 Suction pressure display

Cock 101 is used for adjustment.
103 Adjustment of flow rate of the press foot
104 Air flow adjustment of rear blowers
105 Locking handle for longitudinal positioning of suction unit
106 Longitudinal positioning of suction unit

Condition: Handle 105 tightened and handle 112 loosened.
108 Vertical adjustment of carrier suction cups
Machine controls
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109 General adjustment of lateral blower air supply
110 Adjustment of lateral blower air supply os and oos
111 Vertical movement of suction unit
112 Locking handle for longitudinal suction unit shifting
113 Front pile guides

Position the pile guides os and oos against the pile edge.
Machine controls
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Platen press
64
64
75
71
Machine controls
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Control panels
H22D H25D
H23D
H21D H24D
S122D S25D
S61D S141D
S53D
S37D S44D
S83D S34D
S31D S28D
S26D S58D
S51D
Machine controls
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H21D Front register os

m The sheet is not in position.
m The system cannot determine whether the sheet is advanced or delayed.
H22D Front register oos

m The sheet is not in position.
m The system cannot determine whether the sheet is advanced or delayed.
H23D Two-sheet sensor

Lights up when several sheets reach the infeed at the same time and flashes when it is
deactivated.
H25D Lateral register oos and os

m The system cannot determine whether the sheet is too much on os or too much on
oos.
m The sheet is too offset to be corrected.
Note: H24D and H25D light up simultaneously when the sheet has not been detected and
H24D
flash when the camera is deactivated.
Machine controls
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S25D Brake release

The brake is released as long as this push-button is held pressed.
Conditions:
m No normal or emergency stop push-button pressed.
m Key selector S50D on pos. 2.
m Main motor stopped (HMI).
m Safety guards closed, apart from door under the feed table.
m Confirmation lever 216 not pressed against the compressed air power supply of the
clutch.
Notes:
1. In order to drive the machine manually, refer to the procedure described in the manual
dealing with the machine operation.
2. The telltale lamp lights up if the conditions mentioned above are fulfilled.
3. The telltale lamp flashes if one of the first 4 conditions is not fulfilled and goes off if the
last is not fulfilled.
Machine controls
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S26D Continuous run

S28D Inching run

S31D Reset
Press the push-button once to:
m reset the control circuits.
m cancels the programmed stop and converting control functions.
Machine controls
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S34D Sheet suction

until suction is activated, remains lit up during sheet suction and flashes then again.
Notes:
pumps will stop.
S37 Lifting of pressing devices of lateral register

Hold pressed to remove a misaligned sheet.
Condition: Machine at standstill.
Machine controls
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S44 Driving of feed table belts

Hold this push-button pressed to empty the feed table.
Condition: Machine at standstill and feed table frame lifted.
S51D/S53D Emergency stop

Causes machine and all functions to be stopped immediately.
Main motor is switched off and all controls are locked.
S58D Ordinary stop

Stops machine.
S61D Platen press transparent guard os

One impulse on pos. 1: Safety guard opens.
If the machine was stopped by means of a programmed stop (195-215°MP), the upper
and lower diecutting equipment will be unlocked.
Held on pos. 2: Safety guard closes.
If the machine was stopped by means of a programmed stop (195-215°MP), the upper
and lower diecutting equipment will be locked.
Machine controls
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S83D Programmed stop

Controls the slow-down of the machine and then its stop between 195 and 215_MP.
The telltale lamp lights up as soon as the push-button is pressed and goes out after the
machine has stopped.
Pressed for more than two seconds, controls the slow-down of the machine and then its
stop between 195 and 215_MP, the os guard of the platen press opens. The acoustic
warning device sounds.
The telltale lamp lights up likewise when the machine is brought between 195 and
215_MP in inching run (S28D / S29D / S74D).
S122D Reset
m resets the door oos under the feed table.
S141D Raising and lowering of feed table frame

When the frame is not in its lower position, the telltale lamp lights up.
Machine controls
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Various controls
216
217
215
218
209 208 207 210
212
211
Machine controls
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207 Blocking the swivelling of the chase on outer guides

Latch engaged: Corrects the clearance, when the chase is swivelled by 180° (cutting die
upwards).
208 / 209 Pivoting the chase on the exterior guides

To pivot the chase through 180°, set the two pins 210 to the “chase locked” position and
then remove the bolts 208 and 209.
Once the upper bolt 209 is engaged, the chase cannot be pivoted.
Once the lower bolt 208 is engaged, the chase cannot be pivoted once it has pivoted
through 180°.
210 Locking of chase on outer guides

Latches engaged in chase: Locks travel movement and allows upper chase to swivel
on outer guides.
Intermediate position: Locks swivelling. The latches serve as a stop for the chase when
pulling it out of the platen press.
Latches disengaged in chase: Locks swivelling and enables the shifting movement.
This position enables to remove or put in place a chase on the exterior guides.
Machine controls
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211 Lower cutting equipment supports on outer guides

m Swivel the two supports in the horizontal position before withdrawing the lower cutting
equipment on the outer guides.
m Swivel the two supports in the vertical position before turning over the chase.
212 Locking of lower cutting equipment on outer guides

Latch engaged: Prevents shifting of lower cutting equipment on outer guides.
Latch pulled: Allows shifting of lower cutting equipment on outer guides.
Machine controls
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215 Main supply of compressed-air

Clockwise: Closed.
Counterclockwise: Open.
216 Setting of main compressed-air supply

Value = 6 bar.
Important: Never lower this value.
217 Compressed-air supply setting of air clutch

Value = 4.1 bar.
Important: Do not alter this setting.
218 Compressed-air supply of platen press blower
Machine controls
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Chase loader
231
230
P15885
P15876
Machine controls
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230 Unlocking the chase loader

To unlock the loader, press the push-button. Once it has been unlocked, the loader may
be manually pivoted, provided that pin 231 is in the “chase locked” position.
231 Locking the chase in the loader

To lock, engage the pin in the chase.
Machine controls
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Stripping station / delivery
78
88
92
Machine controls
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Control panels
S16D S6D S14D S79D S85D S35D S32D S29D
S52D
S50D S19D S23D S63D S30D S27D S59D

Machine controls
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S6D Raising the pile supporting plate of the delivery

Case 1: Machine stopped:
Pile supporting plate rises as long as the push-button is pressed.
Case 2: Machine running:
One impulse on the push-button activates automatic raising of pile supporting plate.
Conditions:
m Conveyor stopped, but not in intermediate position.
m If the pile supporting plate is on the ground, there must be a pallet on it which is cen-
tered transversely in the delivery. A pallet must be on the second plate under the plat-
form or out of the machine.
m All stripping station, delivery and waste remover safety guards must be closed.
m Tool protection photocell not obstructed.
m Binder sheet inserter withdrawn.
m Lower tool height test brush withdrawn.
Machine controls
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S14D Lifting / lowering of the upper stripping frame and the blank separator
Case 1: Machine at standstill and movable safety guard of the stripping station and
the delivery closed:
Impulse on the left: Lifting.
Impulse on the right: Lowering.
Note: The telltale lamp lights up when the frame is in the upper position.
Impulse on the left: Keeps the upper frames of the stripping station and of the delivery
in the upper position, for one machine cycle.
The sheet is delivered on the waste removal apron in order to be checked.
Note: The telltale lamp lights up when the frame is in the upper position and the dynamic
blocking piston is engaged.
Machine controls
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S16 Manual binder sheet insertion

Impulse to the right: Manual sheet insertion.
m Pile supporting plate positions itself vertically and sheet inserter carriage is inserted
into the delivery.
Impulse to the left: Withdrawal of sheet inserter carriage.
m A binder sheet is placed on the pile and the pile supporting plate rises under the lower
delivery tool.
Conditions:
m Machine stopped.
m All stripping station, delivery and waste remover safety guards closed.
S19 Non-stop rack

Withdrawal of non-stop rack.
Conditions:
m If machine is running, the pile must be present under the rack.
m If there is no pile under the rack, hold the button over two seconds to order the with-
drawal.
Machine controls
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S23D Lowering of delivery pile supporting plate

The pile supporting plate is lowered as long as the push-button is pressed.
After about 2 seconds, the plate continues to lower until it reaches the floor.
Conditions:
m Machine stopped.
m Conveyor without pallet waiting, second plate outside the machine or under the plat-
form.
Note: When the machine is running and there are sheets on the pile supporting plate, an
impulse on this push-button causes a 0,2 seconds descent.
S27D Continuous run

Press this push-button twice to set the machine to continuous run.
Note: Does not operate if the platen press is stopped in the pressure zone. In such a case
start by actuating inching run S29D.
Machine controls
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S29D Inching run


S32D Reset
An impulse on this push-button:
m resets the control circuits.
Machine controls
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S35D Sheet suction

Notes:
pumps will stop.
Machine controls
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S50D Key selector

Pos. 0: Machine out of operation.
Pos. 1: Standby. Switching-on of lighting inside the machine. This position does not allow
start-up of machine.
Pos. 2: Working position.
On positions 0 and 1, key can be pulled out.
S52D Emergency stop

Causes machine and all functions to be stopped immediately.
Main motor is switched off and all controls are locked.
S59D Ordinary stop

Stops the machine.
Machine controls
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S63D Transparent safety guards on stripping station and delivery os

Impulse on pos. 1:
m Unlocks upper equipment of stripping station and delivery if upper frame is in upper
position or machine is in position (223-243°AM) for accessing equipment.
m Controls opening of stripping station and delivery safety guards os.
Held on pos. 2:
m Controls closing of stripping station and delivery safety guards os.
m Locks upper equipment of stripping station and delivery.
S79D Checking of blanks

Press this button to:
m Bring the pallet into position outside the machine when the pile supporting plate is on
the ground.
m Activates a non-stop cycle if the machine is running.
The non-stop cycle interrupts suction to allow the pile supporting plate to be lowered;
controls introduction of non-stop rack and the exit from pile.
Machine controls
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S85D Checking the converting and the positioning of the tools

An impulse on pos.1 or pos. 2:
m slows the machine down to 5000 s/h.
m controls the infeed of one sheet into the machine.
The impulse on pos. 1:
D stops the sheet at 320°MP when it is in the stripping station.
If the machine is equipped with grippers pneumatic opening in the stripping
station, a second impulse on pos.1 opens the grippers.
The machine stops at 0°MP with this option. These angles can be edited in the
customer menu of the HMI.
The impulse on pos. 2:
D stops 2 sheets when they are in the delivery and the stripping station.
Note: The orange telltale lamp lights up after the impulse and goes out after the machine
has stopped.
Machine controls
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Various controls of the stripping station
308
301
P17689
302 303 308 309 305
310
325 304
306 307
322
321
328
324
323 330
329
P18837
342 344 341 345
343
Machine controls
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Position indicators
The position indicators a enable the machine operator to cor- 1 Upper tool (die or pull-out frame).
rect the position of the tools in the machine. 2 Upper pull-out frame.
Increasing the numerical value = movement in the ”+” direc- 3 Central pull-out frame.
tion. One unit on the counter represents a movement of 0.1
4 Lower pull-out frame.
mm. The medium position is at 005.0.
304
1
2
302
a
303 305
307
325
323
324
344
4
342
345
343
Machine controls
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Upper equipment
301 Unlocking of CENTERLINE centring

Os: Keep rod pushed to release tool.
Oos: Keep rod pulled to release tool.
306 Transverse locking / unlocking of pull-out frame
308 Loosening the upper equipment

Hold pressed to release the upper equipment.
309 Setting to the size of the upper tool
310 Blocking/releasing the reinforcing piece of the upper device with quick locking
Allows to remove the reinforcing piece for attaching an upper stripping pull-out frame.
m Hold the reinforcement and loosen handle to its stop.
m Remove the reinforcement by pulling it towards you.
m Tighten the handle.
Machine controls
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Central equipment (continued)
321 Locking / unlocking of central stripping pull-out frame
322 Longitudinal shifting of the braking tablet

Machine between 10-40_ MP. Release handle 322 and bring the tablet near the central
board, leaving enough room for the descent of the upper tool and the fall of the rear waste.
328 Modifying the stroke of the central stripping board rear support
To be used only when changing the length of the central stripping board.
Push crank 329 oos to free the knurled button.
329 Quick-lock clamping device of the central stripping board

Clockwise: Locking.
Counterclockwise: Loosening.
330 Locking / unlocking crank 329

Lock this crank after clamping the central stripping board.
Lower equipment
341 Locking / unlocking the pull-out frame
Machine controls
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Various controls of the delivery
408 404 403 408 409 405
401
402
416 418 414 406

407
421
413
411
412 417 415 419
Machine controls
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Full sheet frame

435
436
P19876
431 432
434
436
P19875
433 434
Machine controls
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Position indicators
The position indicators a enable the machine operator to cor- 5 Upper tool (die or pull-out frame).
rect the position of the tools in the machine. 6 Upper pull-out frame.
Increasing the numerical value = movement in the ”+” direc- 7 Lower pull-out frame.
tion. One unit on the counter represents a movement of 0.1
mm. The medium position is at 005.0.
404
5
6
402
a 405
403 407
414
7
412
413
Machine controls
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Upper equipment
401 Unlocking of CENTERLINE centring

Os: Keep rod pushed to release tool.
Oos: Keep rod pulled to release tool.
406 Transverse locking / unlocking of pull-out frame
408 Loosening the upper equipment

Hold pressed to release the upper equipment.
409 Setting to the size of the upper tool
Machine controls
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Lower equipment
411 Locking / unlocking the pull-out frame
415 / 416 Longitudinal shifting os and oos of the b

pile settling and jam detection
photocells
m Pull the lower drawer out of the machine.
m Place photocell a cc facing an opening.
m Align photocell b oos with photocell a.
The green LED on the photocell b sig-
nals a correct alignment.
417 / 418 Vertical shifting os and oos of the pile settling and jam detection photocells
419 Longitudinal shifting of the jam detection photocells

When the machine is equipped with photocells for jam detection c, have them face the
openings of the tool.
421 Longitudinal shifting of braking tablet

Release handle 421 and bring the tablet up against the lower tool.
Machine controls
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Full sheet frame
431 Locking / unlocking the full sheet frame
432 Setting of the position of the rear jogger of the full sheet frame
433 Setting of the position of the lateral joggers of the full sheet frame
434 Offset of the position of the lateral joggers of the full sheet frame os / oos
435 Pneumatic supply of the vibrating joggers
436 Locking of the front vibrating jogger of the full sheet frame oc / oos
Machine controls
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Residual waste remover and binder sheet inserter
S124D
S46D S20D
505 502 501
504 503
506
P20345 P203353
Machine controls
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S20D Releasing the brake of the non-stop rack and binder sheet inserter
1st impulse: Non-stop rack released, telltale lamp lit.
Held pressed more than 3 sec.: Pneumatic unlocking of the non-stop bars, tell-tale lamp
blinks.
2nd impulse: Non-strop rack braked, telltale lamp off.
Note: When the telltale lamp is lit, inching run only is possible.
S46D Vertical movement of non-stop rack

Held to left: Raising non-stop rack.
Held to right: Lowering non-stop rack.
Condition: Lower safety guard of waste remover open and other safety guards of the
stripping station and delivery closed.
S124D Reset
m reset the back door
Machine controls
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501 Insert-sheet centring wheel

Allows sideways centring of insert sheets in storage drawer.
502 Rear jogger of the binder sheets
503 Compressed-air supply of the binder sheet separation blower

Reference value: 2 bar.
504 Binder sheet separation blower

For setting the air flow from binder sheet separating nozzles.
Horizontal position: Open (maximum air flow).
Vertical position: Closed (no air flow).
505 Suction of binder sheets

For setting the suction force of sheet inserter suction cups according to thickness of binder
sheets.
Horizontal position: Open (maximum suction force).
Vertical position: Closed (no suction).
506 Setting the force of the vibrating joggers

Reference value: 2 bar.
Machine controls
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Conveyor
S72D S78D
H58D S77D
S108D S68D
S76D S22D
S71D S70D
H15
S64D S24D
S69D S60D
S123D
S54D
Machine controls
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H15 Alarm lamp

Orange light: Signals movements of pallet conveyor.
m Off: No movement.
m Flashing: Movement.
White light: Signals opening of the automatic door while machine is running.
m Off: Automatic door closed.
m On: Automatic door open while the machine is running.
H58D Pallet change

Flashing:
m each time a pallet, loaded or not, has moved into position outside the machine.
m if no empty pallet has been brought under the platform.
On: in case of trouble, for example an interrupted pallet exchange cycle.
Machine controls
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S22D Raising the pile supporting plate of the delivery

Case 1: Machine stopped:
Pile supporting plate rises as long as the push-button is pressed.
One impulse on the push-button activates automatic raising of pile supporting plate.
Conditions:
m Conveyor stopped, but not in intermediate position.
m If the pile supporting plate is on the ground, there must be a pallet on it which is cen-
tered transversely in the delivery. A pallet must be on the second plate under the plat-
form or out of the machine.
m All stripping station, delivery and waste remover safety guards must be closed.
m Tool protection photocell not obstructed.
Machine controls
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S24D Lowering of delivery pile supporting plate

The pile supporting plate is lowered as long as the push-button is pressed.
After about 2 seconds, the plate continues to lower until it reaches the floor.
Conditions:
m Machine stopped.
m Conveyor without pallet waiting, second plate outside the machine or under the plat-
form.
Note: When the machine is running and there are sheets on the pile supporting plate, an
impulse on this push-button causes a 0,2 seconds descent.
S54D Emergency stop

Immediately stops the machine and all functions.
The main motor is switched off and all controls are locked.
S60D Normal stop

Stops the machine.
Machine controls
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S64D Automatic delivery door oos

Impulse on pos. 1: Opening.
Held pressed on pos. 2: Closing.
S68D Sheet suction

Notes:
pumps will stop.
Machine controls
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S69D Continuous run

Condition: The icon ”Machine ready” is displayed on the HMI.
S70D Inching run

Condition: The icon ”Machine ready” is displayed on the HMI.
S71D Reset
Machine controls
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S72D Lifting / lowering of the upper stripping frame and the blank separator
Held to left: Lifting.
Conditions:
m Machine at standstill.
m No ordinary stop push-button on the stripping station and on the delivery pressed.
m Movable guards of the stripping station and of the delivery closed.
Note: Telltale lamp is:
D off, when frames are in the lower position. Machine can produce.
D flashing when frames are in the upper position. Machine can run, but stripping is
out of operation.
D lit, when frames are in the intermediate position. Machine cannot start up.
S76D Introduction of pallet

Press this button to send an empty pallet under the platform after removal of a full pallet.
Condition: The pile supporting plate is sufficiently high.
Machine controls
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S77D Pallet removal

Case 1: Plates stopped in the intermediate position:
As long as the button is pressed, the pile supporting plate is moved outside the machine.
Case 2: Pile supporting plate up:
As long as the button is pressed, the pile supporting plate below the platform is moved
outside the machine.
Case 3: Machine at standstill, one plate on floor in the delivery, the other one below the
platform:
An impulse on this push-button causes the pallet removal and resets the counters for the
next pile.
S78D Checking of blanks

Impulse to the right:
m Brings the pile supporting plate outside the machine.
m Activates a non-stop cycle if the machine is running.
The non-stop cycle interrupts suction to allow plate to be lowered; controls introduc-
tion of rack and the exit of pile.
Held to the left more than two seconds: Places pile supporting plate in machine and
controls its raising under lower tool.
Machine controls
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S123D Reset
m reset the oos door of the stripping unit.
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Machine operation
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Setting the production rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Stopping the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Stop at the end of the day or for an extended period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Sheet travelling control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Setting the operating threshold sensibility of the photocells . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Adjusting the photocells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Manual drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Machine immobilised under pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Repositioning of the clutch of gripper bar chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Job change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Non-stop device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Suction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Sheet separating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Mini format 400 x 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Machine operation
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Feed table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Two-sheet sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Initialization procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Braking tablets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Platen press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Cutting force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Upper chase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Lower diecutting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Position of the grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Stripping station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Upper pull-out frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Centerline centring pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Lower equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Residual waste evacuation comb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Non-stop rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Non-stop rack with adjustable height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Machine operation
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Binder sheet inserter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Positioning of plates on the conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Machine operation
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Start-up
m Switch on main power supply (Q1D).
m Turn the key selector S50D to pos. 2. Wait approximately P10788
1 minute while the HMI initialises.

m Reset by pressing push-buttons S122D, S123D and
S124D.
m Make sure that no fault is signalled on the HMI. If neces-
sary, locate faults by means of the HMI and remedy them. S50D S123D S122D A001D.Q1
m Switch on the main motor (HMI). S124D
HMI
Machine operation
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m Press a push-button S28D / S29D / S70D / S74D for inch-

ing run. Acoustic warning device sounds for 3 seconds.
m Press a second time on the inching push-button, then on
a continuous run button S26D / S27D / S69D / S73D.
m Control the lifting of the pile supporting plate with selector
S91D or S92D.
m Sheet suction can be switched on from several control
panels (selectors S33D / S34D / S35D / S68D).
S28D S26D S33D

S92D S91D
S29D S27D S34D
S70D S70D S35D
S74D S73D S68D
Machine operation
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Setting the production rate

The production rate (or machine speed) is expressed as a
number of sheets per hour (sheets/hour).
1. Press the ”Production” key to access the general
information. HMI
2. Set the reference value 1.
3. When the machine is in continuous run, the production 2
rate 2 automatically adapts to match the reference value.
1
Machine operation
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Stopping the machine

Programmed stop
By pressing the programmed stop push-button 1, the
machine slows down and stops in the right position for fitting
or withdrawing the cutting equipment.
Ordinary stop
To stop the machine outside the pressure zone, press one of
the ordinary stop push-buttons 2. 1
Emergency stop
When an emergency stop push-button (mushroom head) 3
is pressed, the machine stops immediately. It can therefore
remain blocked under pressure. If so and if inching is
ineffective, the machine has to be unblocked manually (see
manual drive).
2
Machine operation
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Stop at the end of the day or for an extended period

m Stop the machine with programmed stop (S30D) or
manually between 190-260°MP and open the safety
guard.
m Remove the supporting plate and the chase on the
guides and secure them by pushing the bolts.
m Clean the makeready protection plate and the bottom
surface of the supporting plate with a dry rag.
m Lower the pile supporting plates.
m Turn selector S50D to position 0.
m Switch off the main circuit-breaker A001D.Q1.
S30D S50D
HMI A001D.Q1
P16905 P9630
Machine operation
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Sheet travelling control

Sheet travelling is controlled by an electronic device. If a Setting the operating threshold sensibility of the
sheet is missing, torn or incomplete or if there is a jam, the photocells
machine stops. Selection in the HMI depending on the opacity of the
m A fault at the platen press outlet and the stripping station convertible stock.
outlet is signalled by the HMI.
Monitoring principle
Sheet travelling is monitored in two ways:
m Sheet presence control checks that the sheet travelling HMI
through is whole. Notifications
m After sheet control checks that the space between the
sheet and the following gripper bar is free.
Notes:
1. The range over which sheet presence control is active
can be set in the HMI. It must be adjusted whenever there
is a job (size) change. Jobs / Job Data / Seeting
2. When the machine starts, sheet presence control starts
up as soon as sheets arrive below the infeed photocell.
3. After sheet control is on permanently.
Machine operation
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Adjusting the photocells

m Convert one sheet and stop the machine when the beam
from the photocell at the stripping station outlet is
between 2 and 5 cm from the rear edge of the sheet. This
position is the end of sheet presence control.
If necessary, adjust the lateral position of the photocell so
that the beam does not fall in an opening while the control
is on.
m Validate the position and duration of monitoring in the
HMI.
m If necessary, adjust the lateral position of the platen press
outlet photocell so that the beam does not fall on a HMI
longitudinal cut while the control is on. Producing / Stripping Station / Sheet
Notes:
1. By default the control is active over a range of 10°. This
is the value that we recommend for most jobs.
2. The machine may stop even if the photocells are properly
adjusted. If this happens, clean the photocells and the
reflectors.
Machine operation
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Manual drive
Manual drive is principally used to reengage the gripper bar
chains or release the machine if it is immobilised under pres-
sure.
Procedure
HMI
m Switch off the main motor (HMI), and wait until the fly-
wheel has completely stopped.
m Open the safety guard 1 on the feed table oos.
Note: All the other safety guards must be closed and no
stop push-buttons must be pushed in.
Machine operation
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Mandatory actions: To drive the machine clockwise or anti-

clockwise by hand, it is essential to retract the blocking
claws 2 from the chains and release the brake by pressing
push-button S25D. To prevent serious damage to the
machine, it is vital to look at the chains and check that the
claws 2 have been retracted.
CAUTION: Keep your head and feet out of range of the
ratchet wrench. When push-button S25D is pressed, the
movable platen is released and can suddenly take the
ratchet wrench and the whole machine with it. If this hap-
pens, release push-button S25D immediately. 2
When the machine is in a position between 275° and 40° MP,
the wrench will be driven clockwise and when it is between
45° and 180° MP, the wrench will be driven anticlockwise.
m Engage the manual drive shaft 3. Engage the ratchet
wrench 4.
m Press push-button S25D to release the brake and oper-
ate the ratchet wrench:
Anticlockwise: The machine runs forwards.
Clockwise: The machine runs in reverse. 4
m Remove wrench 4 and disengage shaft 3. 3
m Close the safety guard.
S25D
Machine operation
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Machine immobilised under pressure

When the machine is immobilised under pressure, use
manual drive to release it. Manual drive is described in the
preceding pages.
Procedure
HMI
m Turn the main motor off and wait until the flywheel has
stopped completely.
Producing / Stripping Station / Sheet
m Note down the machine position on the HMI.
m Use manual drive as follows:
D Before 53°MP, i.e. before top dead centre, turn the
ratchet wrench anticlockwise.
D After 53°MP, i.e. after top dead centre, turn the
ratchet wrench clockwise.
Machine operation
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Repositioning of the clutch of gripper bar chains

In case of displacement of the clutch of gripper bar chains,
the machine and the main motor stop immediately (even if
under pressure). The display shown on the opposite side
appears in the HMI. HMI
Note: It is recommended that two persons carry out this work Notifications
together.
To reposition the clutch, use manual drive as described on
the previous pages.
Procedure
m Wait until the motor’s flywheel has come to a complete
standstill.
m Press on the Reset push-button.
m Determine the cause of displacement.
m Lift upper frame of the stripping station.
m Drive machine manually to set it between 190-260°MP,
then try to free the equipment.
Note:
D Before 53°MP, i.e. before top dead centre, turn the
ratchet wrench anticlockwise.
D After 53°MP, i.e. after top dead centre, turn the
ratchet wrench clockwise.
Machine operation
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m Remedy the reason for displacement.

m Drive the machine backward until it is possible to insert
locking finger 1 in the hole A (bored) of the os chain
wheel.
m Drive the machine backward until the clutch of the gripper 1
bar chains engages.
m Press Reset push-button.
m Remove locking finger. If it is difficult to remove, move the A
ratchet wrench slightly (by ±1°MP).
m Remove the wrench and disengage the manual drive
axle.
m Put the locking finger 1 back in its holding device.
Machine operation
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Job change
A = old job
B = new job
A Reduce cutting force. 147

A Stop the machine (programmed stop: 195-215°MP). 116
A Retract non-stop rack and release it. 168
Remove chase. Report the value of the cutting force on the patch sheet.Remove the
A 148
patch sheet and the cutting die.
B Insert chase with cutting die and patch sheet.
A Remove supporting plate. Remove the thin plate
B Secure thin plate to supporting plate. 150
B Insert supporting plate.
A Retract braking tablet. 91
A Remove stripping tools. 88
B Insert stripping board.
B Set position of braking tablet. 91
Machine operation
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A = old job
B = new job
A Retract braking tablet. 96

A Remove upper and lower tools. 92
B Fit the lower tool. Set position of pile settling and jam photocells. Insert the frame. 158
B Set position of braking tablet. 96
Bring non-stop racks in position. Check passage throough tool and put the brake on
B 168
the rack.
B Set the suction unit and the side blowers. 136 / 62
B Insert a pile into the feeder, center it and raise it. 130
B Set feed table elements. 143
B Set two-sheet sensor. 144
Machine operation
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A = old job
B = new job
B Machine running
Make sure the rollers and brushes are correctly placed. The feed table elements must
B 142
always be placed above a belt.
Set cutting force until it starts increasing sensibly. If the job has already been run
B before, align the counterparts before re-using the cutting force indicated on 147
makeready sheet.
Pass a sheet into the platen press, then remove it from the stripping station or the
B 87
waste evacuation station.
B Check the position of the counterparts. If necessary, set the position of the thin plate. 150
Check the register between the diecutting and the printing. If necessary, correct the
B D26 / D93
parameters of the Power Register.
Machine operation
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A = old job
B = new job
Increase the cutting force until a sufficient number of rules cut, for starting the
B 147
diecutting makeready.
B Proceed with the diecutting makeready. D34
B Convert one sheet and stop it in the stripping station. 87
B Check the position of the central board.
B Insert the upper tool and check its position.
Advance the diecut and stripped sheet to the delivery. Set the photocell position as
B 87 / 119
it passes the stripping station outlet.
B Check the position of the lower tool.
B Insert the lower tool and check its position.
Set the counters and selectors according to the pile delivery mode and reset the
B D26
totalizer to zero.
B Put the pallets in place on the conveyor. 172
B Put binder sheets into the store drawer. 170
Machine operation
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A = old job
B = new job
B If necessary make a manual insertion. 171

Convert approx. one hundred sheets, check registering and finish the diecutting
B
makeready.
B Proceed to production and set:
m Force of braking tablet. D26
m Force of braking tablet. D26
m The blower. D26
m Pile settling level. D26
m Speed of waste removal apron. D26
Machine operation
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Feeder
General
Position of the pile on the pallet
The sheets must not be allowed to stick to each other and
they must be properly arranged and centred on the pallet.
It is possible to use a prepiling device independently of the
machine.
Height of the pile on the pallet
The height of the pile varies depending on the machine con-
figuration. Please refer to the technical specifications of the
machine in the ”General notes” chapter.
P15899
= =
10
Machine operation
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Non-stop device
Automatic non-stop
m Put the non-stop device into operation by means of the
HMI. HMI
The non-stop rack is positioned vertically depending on the
Producing / Feeder / Non-Stop
thickness of the material and the height of the pile support
entered in the HMI.
When the pallet arrives at the rack infeed level, the acoustic
warning device sounds and the automatic non-stop cycle
starts. The rack is centered laterally in relation to the pallet
and enters. The pile supporting plate descends to the floor.
m Remove the pallet and introduce a new pile into the
feeder.
m Keep S91D turned to the left to raise the pile.
The new pile is centered laterally in relation to the preceding
one. When the rack reaches its upper position, it retracts and
is repositioned for the next non-stop cycle.
S91D
Machine operation
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Manual non-stop
m Put bar 1 into supports 2.
m Put the non-stop device into operation by means of the
HMI. HMI
During production, the bar 1 is in lower position, waiting for Producing / Feeder / Non-Stop
the next non-stop cycle.
2 1 2
P19015
Machine operation
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m As soon as the pile supporting plate gets close to bar 1

the operator is informed by the acoustic warning device
that a new pile can be introduced.
m As soon as the pile bottom exceeds the top line of bar 1,
put in non-stop bars 3; handles upwards. Arrange them
so that pile top remains as flat as possible.
m Check that all non-stop bars 3 are pushed all the way
against their seat.
Note: Openings on bar 1 indicate the possible positions for
the non-stop bars 3.
1
1
P15909
1 3
D2878 D2870
Machine operation
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m Raise carrying bar 1 (S8D to the left) until the non-stop

bars 2 is in contact with the pile. From this moment
onward, the non-stop system will take over and ensure
further pile hoist.
m Lower pile supporting plate (S91D to the right) and with-
draw the pallet.
S91D
S8D
D2879 D2880 D2881
Machine operation
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m Insert the new pile into feeder and raise it under the
non-stop bars 3, without touching them (S91D to the left).
m Correct laterally if required (S12D).
m Give an impulse to the left on S91D and make sure the
new pile is pressed under the non-stop bars.
m Maintain S8D to the right for more than a second. Bar 1
goes down to its waiting position until next non-stop S8D
cycle.
m Withdraw all non-stop bars 3, starting with those in the
centre under the press foot. Proceed towards outside, S12D
holding the pile with the hand.
S91D
D2882 D2883 D2884 D2885
Machine operation
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Suction unit
Checking of pile top
For a correct sheet feed, it is important to make sure that the
pile is always at the right height in relation to the alignment
flap 1 and infeed belts, at the feed table inlet. The ideal
position is 5 to 15 mm lower than alignment flap.
In automatic mode:
The pile height is controlled by photocell 2 in the front and /
or by press foot 3 in the back. 3
2 1 5 - 15 mm 3
Machine operation
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Pile height, detection at the front:

m In the HMI, set the selector to pos. Front and enter the
distance 1 between the pile top and the alignment flap. HMI
m Raise the suction unit (S7D).
Producing / Feeder / Pile
m Hold S91D to the right until the pile is 50 mm under the
photocell.
m When the pile is at the top stop, lower the suction
unit (S7D).
m In production, automatic correction of the height of the
suction unit is controlled by the photocell.
Pile height, combined detection:
m In the HMI, set the selector to pos. Combined and enter
the distance 1 between the pile top and the alignment
flap.
m Hold S91D to the left until the pile is 50 mm under the 1
photocell.
m The pile rises until it is stopped by the photocell; the
suction unit descends until it is stopped by the press foot.
m In production, the height of the pile is controlled by the
photocell and the height of the suction unit is controlled S7D
by the press foot.
S91D
Machine operation
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Pile height, detection at the rear

m In the HMI, set the selector to pos. Rear.
m Lower the suction unit to its bottom stop (S7D).
HMI
m Raise the pile up to the press foot (S91D to the left).
Producing / Feeder / Pile
m Raise the suction unit (S7D) until the pile is 5-15 mm
under the alignment flap.
m In production, the pile height is controlled by the press
foot.
Note: Since the scanning by the two sensors (photocell and
press foot) is carried out at a given angle, it is important to
carry out the settings while the machine is running, whatever
the chosen positioning is.
S7D
S91D
Machine operation
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Sheet separating elements
Light
70-200 g/m 2
3-4 mm
Standard 0,8 mm
200-1000 g/m 2
6-10 mm
Heavy 0,5 mm
1000−2000 g/m 2
Corrugated
0,8-4 mm
Machine operation
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Suction cups 2
The lifitng suction cups must be parallel to the sheet.
Tilt in the running direction: Knurled screws 1.
The carrier suction cups must be parallel to the sheet when
the sheet is grasped and must not rub against it during the
return motion.
Vertical setting of the outer cups: Knurles screws 2 / buttons
108. 1
P???
108
Machine operation
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Mini format 400 x 350

m Replace the two outer blade separators with pile-
guides 1 (BSA0306307400).
m Cut the supply of the outer transport suction cups 2 and
of the side blowers 3. Blower 4 remains active.
1 1 2 3 4
Machine operation
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Feed table
Infeed rollers
Must always be adjusted with identical contact forces to
ensure that the sheets are properly aligned on the feed table.
Loosen screws 1a and position the infeed rollers on knurled
shaft 1d for paper and solid board or belts 1e for micro-flute.
Adjusting the contact force:
m Loosen screws 1b so that the rollers rest on knurled shaft
1d. Secure the lock nuts leaving a 0.1 mm clearance
between screws 1b and the levers.
m Screws 1c allow the contact force to be adjusted. Check
that the sheets are not marked. Secure the lock nuts.
1e
1b 1c
1c
1a
1b
0,1 mm
1 1d
1
P16912 P17346
Machine operation
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Standard format Mini format 400 x 350

Important: Replace rollers 1 in in position before returning
to the standard format.
Machine operation
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Two-sheet sensor
This device stops the machine if two sheets arrive together
in the Power Register.
The trouble is signalled by red LED H23D as well as on the
HMI.
Initialization procedure H23D
m At the end of the learning sequence of the detection sys-
trem (see above), one sheet is in the sheet gripper, the
machine stopped between 300 and 20° MP. The machine
position is shown by the arrow a positioned above index S37D
mark b. 2
m Confirm to initialize the distance between detector SQ71
and the blade 1 with a sheet.
m Enter board thickness.
This distance is monitored during each sheet passage. The
machine stops if the distance is equivalent to two or more SQ71
sheets. Press push-button S37D to release the sheets in the
Power Register. HMI
Note: A metallized substrate can cause a production stop Producing / Platen Press / Sheet
while there is only one sheet in the sheet gripper. Repeat the
initialization procedure putting two sheets in the sheet grip-
per.
Machine operation
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Braking tablets
These devices, placed at the entrance to the stripping station
or of the delivery enable:
m the sheet to be kept perfectly flat as it is conveyed, by a
vacuum effect.
m a bridge to be created between the platen press outlet
and the central stripping board, then between the strip-
ping station outlet and the lower blanking tool.
Machine operation
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Adjusting the operating mode and the braking force

The braking force must be sufficient to prevent the sheet HMI
buckling but not so strong that the nicks are broken. Producing / Stripping Station or Delivery /
Use manual mode to obtain a constant braking force Sheet
whatever the production rate.
Use automatic mode to obtain a braking force that is
proportional to the machine speed. Depending on the
specifications of the convertible stock, this mode avoids
breaking the nicks when the machine speeds up or slows
down.
Machine operation
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Platen press
Cutting force
The cutting force is set in the HMI.
When the machine is running, the cutting force can be
brought down to its neutral value (position of the keys, corre-
sponding to a null theoretic cutting force in standard cutting
conditions) by activating icon 1.
The cutting force 2 is displayed on the HMI header. The
cutting force 3 can then be increased. 2
HMI
A safety device stops the machine in the event of an
Producing / Platen Press / Cutting Force
overload. It should be set to 0.1 MN above the cutting force
required for the current job 4.
Example: If the force required is 1.40 MN, set the switch-off
limit to 1.50 MN. 3 4
Note: The maximum cutting force of the machine is 2.6 MN
(260 t).
Machine operation
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Upper chase
Fastening the cutting die
Cutting dies of the following dimensions can be locked in the
chase:
1. Size 106 (1070 x 770)
2. Size 104 (full size 1050 x 744)
3. Standard size IIIB (1040 x 725)
m Locate the form under plates 4 and in the Centerline
4
1070
block 5.
m Lock the die in the running direction by turning screws 6
os/oos with a suitable screwdriver. The mark on the 1 770
screw must be between the two dots. 6
m Screw the die into the bottom plate of the chase (see D34
guide).
Additional lockings can be added, depending on the type of
job. 5
Note: For full size 104 and standard IIIB cutting dies, the
1050
position of the locking blocks in the running direction must be
changed.
2 744
3 725
1040
Machine operation
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Lower diecutting equipment

Possible variants
Fig. 1. For diecutting and cold embossing
1
(counterparts: approx. 0.8mm thick)
4
Supporting plate with:
0,8
17
12
m Compensating plate 4mm thick
1
m Thin plate 1mm thick
Fig. 2. For diecutting (long jobs)
5
Supporting plate with:
17
m Cutting plate 5mm thick
12
2
Fig. 3. For cold embossing only
3
(counterparts: approx. 2.8mm thick)
Embossing plate 3mm thick
15
12
3 2,8
Machine operation
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Fastening the thin plate

First secure the compensating plate with 4 screws 1 and then
fit the thin plate.
m Check the condition of the thin plate and clean the
surfaces.
m Locate the plate in the centring devices and engage it
under bar 2.
m Press the plate against edges A of the centring devices
and clamp it with the quick locking system 2 os and 3 oos.
Fastening the cutting or embossing plates
A
The method for fastening the cutting or embossing plates is
exactly the same as for the thin plate.
3 2
P18824
1
Machine operation
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Adjustable centring
The adjustable centring devices allow the position of the sup-
porting plate in the machine to be adjusted so that the coun-
terparts are precisely aligned with the cutting die.
Setting range: ±0.9mm (1 scale division = 0.05mm). Position-
ing between two scale divisions is possible. After setting, P15841
return the graduated ring to the locked position. +/− 0,9
+/− 0,9
+/− 0,9 P15832
Machine operation
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Compatibility of thin plates SP 102/103/104

Thin plates made for Autoplatine SP 102/103/104 presses
can be mounted on the supporting plate. They are positioned
using two movable shims placed on the supporting plate, os
and oos.
The direction of the shim depends of the size of plate used.
Push the plate up against edges A of the shims. Use
screws 1 os and oos for clamping.
A
A
SP 104 SP 103 SP 102-E/SE/C
1 1 1
A
A A
A
A
A
Machine operation
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Position of the grippers

0 represents the Centerline of the machine.
Notes:
m Do not stick any rubber on the cutting die at the gripper
positions.
m Do not shift the outer grippers.
22 118
228
346
456
Machine operation
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Stripping station
Upper pull-out frame
The upper pull-out frame can be mounted in the quick locking
device of the stripping station or delivery as shown on the a
plate.
m Position the frame with the grooves running in the correct
direction for the job concerned.
m If necessary, loosen screws a and rotate the front bar b
through 180°.
b
1
2
2
Machine operation
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Centerline centring pin

Purpose
In certain circumstances, to be able to strip waste located in ÄÄÄÄÄÄ
ÄÄÄÄÄÄ
the Centerline centring zone, it is not possible to fit the
Centerline block onto the central board. It may even be nec- ÄÄÄÄÄÄ
ÄÄÄÄÄÄ
essary to move the centring notch (15 x 8 mm) sideways.
This means that it is no longer possible to use Centerline
ÄÄÄÄÄÄ
ÄÄÄÄÄÄÄÄÄÄ
locking to position and lock the board laterally.
It is therefore necessary to use the centring pin 1 on the front
bar of the frame. ÄÄÄÄÄÄÄÄÄÄ
Machine operation
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Fitting
The stripping tools must be out of the machine.
The centring pin 1 and M6 securing screw are kept on the
frame oos. It is advisable to stock them here after use.
Remove the Centerline locking device 2 (two M6 screws).
Insert the board and center it.
Fit centring pin 1 under the front bar according to the position
of the centering notch.
2 1
1
P18993
Machine operation
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Delivery
Lower equipment
Fixing the lower tool on the pull-out frame
m Fig. 1 Place tool 1 on pull-out frame 2.
m Fig. 2 Lateral tool centering.
m Fig. 3 Os and oos. Tool positioning and tool fastening in
sheet travelling direction.
m Fig. 4 Os and oos. Rear fastening of tool. 2
Note: Please refer to the D23 guide ”Design and manufactur-
ing” for blank separating tools for further details on manufac-
turing these tools.
3 1 2
Machine operation
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Photocells for pile settling and jam detection

The lower tool has to have lateral openings for the light 416
beams of the photocells to pass.
The final positions of the photocells are found during produc-
tion because they depend on the behaviour of the convertible
stock.
Positioning the photocells:
m Open stripping station and delivery safety guards
m Place photocell 415 cc facing an opening.
m Align photocell 416 oos with photocell 415. The green
LED on the photocell 416 signals a correct alignment.
m When the machine is equipped with photocells for jam
detection 419, have them face the openings of the tool.
415 419
Machine operation
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Putting into operation: Pile settling control:

Photocell 415 is operating permanently. Pile settling with the upper tool can be set by means of pile
The HMI enables putting the photocells for jam detection into height; photocell 415. This setting is controlled by the HMI
operation or out of operation. and can be adjusted during production, depending on the
behaviour of the convertible stock.
A small value means less settling.
A high value means more settling.
HMI
Producing / Delivery / Sheet
415
Machine operation
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Delivery device for entire sheets

Mounting the device on the pull-out frame:
m Stop the machine with programmed stop S30D or bring
it between 195-215°MP using inching run S29D.
m Open the safety guard.
m Open guides 1.
S30D S29D
m Pull out the pull-out frame and remove the blank
separating tool.
m Place the device in the pull-out frame.
m Fasten the device with the 4 screws 2.
m Lock 431 in lower position. Push pull-out frame into
machine until lock bar slides into centering hole.
m Vibrating joggers: Connect air supply 3, open vane 435
and set pressure 506.
m Close guides 1. P17722
m Check the Non-Stop bars passage. 1 2 431

435
3
506 1
Machine operation
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Putting into operation:

m Bring a sheet by inching run in the tool S29D (for vibrating
jogger: stop the machine between 43 and 63°MP).
m Open the safety guard.
m Align the front jogger a of the device os and oos with the
gripper counterplates b by using the position indicators
413 and 414.
m Close the safety guard and feed a sheet into the delivery.
m Open the safety guard and set the lateral and the rear
joggers (cranks 433 and 432).
m Check the passage of the non-stop bars.
S29D
414
413 433 432

Machine operation
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Residual waste evacuation comb

Set the position of comb 1 according to the thickness of the
sheets:
m Thick board and corrugated, upper position.
m Medium board, middle position. 1
m Fine material, lower position.
Loosen screws 2 and remove bolts 3 (screw, washer, nut) os
and oos.
Position the comb, fit bolts 3 and fasten screws 2.
Note: The comb shown here is in middle position.
Machine operation
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Non-stop rack
The purpose of the non-stop rack is to receive the blanks in
the beginning of a run, during binder sheet inserting or while
the pallet is changed.
The machine can be equipped with the following two non-
stop racks:
m one with two positions.
m one with adjustable height.
Note: The machine is supplied with standard non-stop
bars a. For blanks smaller than 140 mm, as ”flip-top” packag- P2345
ing for example, special non-stop bars b are available as an

option.
Machine operation
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Jogger guides
Depending on the jobs, it is necessary to design the lower tool
with jogger guides of which the length depends on the pro-
cessed material.
Three types of jogger guides with different lenghts exist:
m Fig. 1. Short telescopic jogger guide (short tool) for solid
board.
m Fig. 2. Long non-telescopic jogger guide (long tool) for
E-flutes.
76
m Fig. 3. Extra-long non-telesopic jogger guide (extra-long
tool) for corrugated board. 151
251
Machine operation
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Non-stop rack with 2 positions

Depending on the use of a lower tool with short or long jogger
guides, the same non-stop bars can be fitted in the upper or
lower position.
m Fig. 1. Upper position with short tool.
max. 30
m Fig. 2. Lower position with long tool.
max. 151
max. 100
P20352
Machine operation
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Non-stop rack with adjustable height

With this device the non-stop device is shifted vertically. The
result of this is the building of a higher pile on the non-stop
rack enabling to carry out binder sheet insertings and pile
changes without additional interruption of the sheet suction.
It is possible to use the short, long or extra-long jogger guides
with regard to the processed material. max. 200
With an extra-long tool, the pile height on the non-stop rack
is maximally 200 mm.
Machine operation
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Positioning tool of the non-stop bar for a

custom-made lower tool
This wooden tool is cut by laser. It allows quick and precise
repetitive positioning of the non-stop bars with regard to the
position of the jogger guides of the lower tool.
The icons engraved on the bosses define the position and
types of bars to be used.
Note: Please refer to the D23 guide ”Design and manufactur-
ing” of blank separating tools for further details on manufac-
turing this tool.
Fitting in the machine
The wooden tool 1 is positioned on the support 2.
Important: Remove the positioning tool before putting the P15865
machine into operation.
P20349
1 2 1 2
Machine operation
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Fitting of non-stop bars

m Stop the machine, programmed stop S30D.
m Lower the pile supporting plate (S23D).
m Withdraw the non-stop rack (S19D).
m Open the door of the waste remover.
m Give an impulse on S20D. The telltale lamp lights up. The
brakes of the non-stop rack and the sheet inserter car-
riage are released.
m Fit the lower blank separating tool.
m Place the non-stop bar positioning tool 1.
m Choose the type of bars according to the engraved icon.
S30D S23D S19D
S20D P20352
Machine operation
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m Center each bar relating to the bosses:

D With a two position non-stop rack, place the bars in 3
the upper or lower position with regard to the length
of the tool and lock it with screw 3.
D With an adjustable height non-stop rack, hold S20D
pressed until the tell−tale lamp blinks.
m Remove the positioning tool.
m Push the non-stop rack as far as the stop into the delivery
in order to check passage of the bars through the lower
tool 4.
m Give an impulse on S20D. The telltale lamp goes off.
Non-stop rack and sheet inserter carriage are braked
again.
m Close the door of the waste remover.
Note: Without a positioning tool, fit at least two bars per S20D
P20346
blank. Align them with regard to the jogger guides of the blank
separating tool. 4
P20347
Machine operation
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Binder sheet inserter

m Unlock drawer by pushing it in and pull it out.
m Push sheets against stop by turning handwheel 501.
Then turn backwards by a quarter turn to leave a slight
clearance.
m Press the rear jogger 502 gently against the inserts.
Note: A photocell checks sheet stack in drawer. Make sure
to have a sufficient number of binder sheets throughout the
run. if the drawer is empy, the trouble is signalled on the HMI
and the machine stops when inserting should take place.
m Set the suction force by means of cock 505 in relation to
binder sheet thickness. 505
m Nozzles blow air in between the binder sheets to facilitate
their separation. The air pressure can be set by means
of button 503 and the flow rate with cock 504.
504 503
502
P18838
HMI
P20353
501
Machine operation
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Placing the first binder sheet on the sheet inserting

carriage
m Machine stopped.
m The safety guards of stripping station, delivery station
and waste remover must be closed.
m Binder sheets in place.
m Cocks for air supply and vacuum generation open.
Place the first sheet on the inserter carriage as follows:
m Give an impulse to the right on S16D:
D Pile supporting plate is positioned vertically. S16D
D The inserter carriage without binder sheet is
introduced into the delivery.
m Give an impulse to the left on S16D:
D The inserter carriage withdraws into the waste
remover and the first binder sheet is laid onto the
carriage.
Machine operation
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Conveyor
Positioning of plates on the conveyor Notes:
One plate is located in the delivery and the other one under- 1. A disturbed functioning of the pallet conveyor arises gen-
neath the platform. erally from a displacement of the plates due to oil traces,
m Give an impulse to the right on selector S78D to remove cardboard wastes or excessive dust between plates and
the first plate. rollers. It is important to clean this conveyor regularly.
Red tell-tale lamp H58D flashes. 2. Maximum size pallets must be centered very accurately.
Use the plate notches as reference points.
m Put a pallet on the plate and centre it with regard to the
plate.
m Hold selector S78D to the left to move plates to their
respective position: the first into its upper position under-
neath the non-stop rack, the second to stand-by position
underneath the platform.
m Keep the push-button S77D pressed to remove the sec-
ond plate. H58D S78D
m Put a pallet on the plate and centre it with regard to the
plate.
m Give an impulse on push-button S76D to move the sec-
ond plate back underneath the platform. S76D S77D
Machine operation
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Maintenance - General
How to use the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Explanation of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Commercial elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Control and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Electric motor maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
External supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Maintenance products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Belt and apron tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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How to use the manual
E4
Maintenance work according to symbols, see

What
list at the end of the manual
Cut and lock the different sources of energy according

to the instructions of chapter Safety
Link icon
A Illustrated machine side
Number of machine components to be serviced
Where 4 x cc
Components to be serviced Link to list of

symbols
Comments
Link to list of fluids
How
A
Use small grease gun for concave grease nipples

Maintenance interval When Daily
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Commercial elements Explanation of maintenance intervals

The machine is equipped with various commercial elements. The maintenance intervals depend on the machine running
Only routine maintenance of these elements are described hours.
in this manual. Other more specific operations can be recom- The correspondance between these intervals and the hour
mended by the manufacturer. In this case, refer to the counter is established based on a 2-shift operation. The run-
manufacturer’s documentation for the necessary informa- ning time being estimated at 5 hours for 8 working hours, it
tion. This documentation is not the responsibility of Bobst. results in:
❍ Daily = 10 hours
❍ Weekly = 50 hours
❍ Monthly = 200 hours
❍ Half-yearly = 1200 hours
❍ Yearly = 2400 hours
With machines equipped with an hour counter, carry out the
various periodic maintenances according to the above indi-
cations.
With machines equipped with a MSS, the latter will indicate
when the different periodic maintenances will have to be car-
ried out.
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Control and cleaning

Photocells
All photocells and reflectors of the machine have to be
cleaned regularly with a smooth and dry rag.
Note: A dirty photocell may cause a machine stop.
Electrostatic assist devices
Refer to the documentation of the supplier in order to carry
out the maintenance of the devices.
Plastics
Machine elements made of plastic such as sight glasses and
Warning transparent safety guards have to be cleaned with a smooth
All elements requiring a control or a specific cleaning are rag slightly soaked with water and detergent.
periodically mentioned in this manual. For all others, proceed
according to the indications given below. For this reason, it Conveyor belts
is very important to observe the safety instructions which are Conveyor belts have to be cleaned with a brush.
to be found in the documentation.
Waste
Waste which could impair the operation of the machine has
to be removed regularly.
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Seal gaskets and bellows

Seal gaskets and bellows have to be checked regularly.
When defective, they have to be exchanged by a person hav-
ing received the necessary instructions from Bobst.
Exhaust air gaskets
The status of the exhaust air gaskets must be checked regu-
larly. If one of these gaskets is defective, replace it immedi-
ately.
Flexible pneumatic and hydraulic pipes
The status of the pipes has to be checked regularly. If one of
these pipes is clogged or damaged, clean it or change it
immediately.
Gas spring
Correct gas spring operation has to be regularly checked. No
alignment fault due to ill-timed shocks should occur. Further-
more, check both the surface state of the piston rod and the
state of the seal gaskets which keep the gas pressure in the
interior. A defective gas spring has to be replaced immedi-
ately.
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Lubrication
Lubricators and oilers
Pay attention to the following when lubricating:
❍ Clean lubricators and oilers with a rag first to avoid the
penetration of impurities.
❍ Lubricate moderately.
❍ Remove surplus grease or oil from the lubricator or oiler.
Important: Excess grease, particularly in bearings can
Warning cause heating.
All elements requiring a specific lubrication are periodically Sliding rails and shifting spindles
mentioned in this manual. For all others, proceed according Keep sliding rails and spindles in perfect condition enabling
to the indications given below. For this reason, it is imperative them to assure the displacement of related elements.
to respect the safety prescriptions described in the chapter Elements with plastic counterparts:
”Safety and environment”. ❍ Clean with a rag and do not lubricate.
Reduction gears, angular gear boxes and oil Elements with bronze, brass or steel counterparts:
reservoirs
❍ Clean with a rag and oil slightly.
Maintenance-free elements are not mentioned in this manual
and any intervention has to be performed according to the Roller running surfaces
prescriptions of the manufacturer. In general, roller running surfaces are cleaned with a rag.
Do not lubricate.
Elements to be lubricated are treated separately in this
manual.
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Racks
Clean toothed racks and lubricate slightly.
Lugs and fixations of traction springs
Check lugs and fixations of traction springs and oil regularly.
Oil recovery basins
Empty and clean oil recovery basins regularly.
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Electric motor maintenance

Brake motors
Maintenance consists of checking whether the brake motors
are in good working order.
Wear of the brake linings can cause trouble. Remedial mea-
sure:
❍ Adjust air gap and spring elasticity. Exchange brake lin-
ings if necessary respecting the manufacturer’s prescrip-
tions.
Asynchronous motors
Warning The asynchronous motors do not need any particular mainte-
Interventions on electric motors may exclusively be carried nance.
out by qualified persons.
WE DECLINE ALL RESPONSIBILITY IN THE EVENT
OF NON-OBSERVANCE OF THIS INSTRUCTION.
Some operations of general nature are to be carried out on
the electric motors as described hereafter. According to the
motor suppliers, other more specific operations have also to
be carried out. In this regard refer to the manufacturer’s docu-
mentation as well as to the indications given on the motor
identification plates.
For motor types as well as their location in the machine, refer
to the Bobst electric documents.
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External supplies
Warning
The machine is equipped with various elements from other
suppliers. Only current maintenance operations of these ele-
ments are described in this manual. Other more specific
operations may be recommended by the supplier. In this
case, refer to the product documentation in order to get the
required information. This documentation is not under the
responsibility of Bobst.
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Maintenance products
Warning
Some products which are used for the maintenance of our
machines require special precautions. To do so, carefully
read the safety data sheet of the product. This sheet contains
information about the danger probabilities, the precautions to
be taken, first aid measures, effects on the environment and
the elimination of the product used.
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Belt and apron tension

Example: For a desired tension of 2%, the distance between
both marks has to be 1020 mm (or 510 mm or 255 mm):
❍ Have the belt or apron turn a couple of revolutions to
distribute the tension evenly and check the distance
between both marks. Tighten further or slacken again if
necessary.
Case 1
To obtain the correct belt or apron tension, proceed as fol-
lows:
❍ Slacken belt or apron.
❍ On the belt or apron mark two division marks at a distance
of 1000 mm (or 500 mm or 250 mm according to belt or
apron length).
❍ Tighten belt or apron with tightener to desired tension
(nl in %). 1000 mm
1020 mm
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Case 2 Case 3
Check the belt tension with a measurement device 1. To do Check the belt tension with a measurement device 2. To do
so, apply a force F and measure deflection x. so, apply a force F and measure deflection y.
1 2
F (N)
F (N)
x (mm)
P13196
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Case 4
It is also possible to verify the belt tension by using a device 3
to measure the frequency f (Hz).
3
P20336
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Maintenance - After the first month

General check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Oil reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

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General check
After one month of operation the following has to be done:

❍ make sure the machine is running perfectly. This check
can be carried out in collaboration with a Bobst techni-
cian.
❍ carry out all operations described in the maintenance
intervals over one month.
❍ check the equipment for any water, air or oil leakages.

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Oil reservoirs
Change the oil in the platen press oil tank after 500 operating
hours. To do so, refer to the procedure described in Chapter
”Yearly-Maintenance” in this manual.

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Maintenance - Daily
Upper chase and lower diecutting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Maintenance - Daily
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Upper chase and lower diecutting equipment
In case of heavy dirt marks use only the following products:

❍ Cyclohexan C6H12
❍ Ethanol C2H5 OH
❍ Ether (C2H5)2 O
❍ Isopropanol (CH3)2 CHOH
After use of above-mentioned products treat surfaces by pro-
ceeding as follows:
❍ Vaporize the different contact surfaces with a lubricating
❍ Every evening or on the occasion of a prolonged stop,
pull upper chase and lower diecutting equipment out. spray, for example Molykote 321 R, Rocket WD40 or
OKS 471 (BSA921900025).
❍ Open or remove the makeready protection plate(s).
❍ Wipe the treated surfaces with a clean cloth.
❍ Clean them with a dry cloth.
Maintenance - Daily
EDT 01
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Maintenance - Weekly
Oil reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Central lubrication of gripper bar chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Upper and movable platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Optical sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Optical sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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Oil reservoirs
A
A1
1 x coc
Check the oil level with the machine stopped and the main
motor in operation. The oil level has to be in the middle of the
sight glass.
2
A
1/
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ESSO ATF LT 71141
3
2/
B
P000
1 x cc / 1 x coc
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Central lubrication of gripper bar chains
1 x coc
C4
If there is not enough oil in the tank, the HMI signals a trouble.
max.
min.
HMI A
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Air filters
1 x coc KDT 3.80

B
C
A
1
❍ Remove filters 1 and clean with compressed air. Blow A
from the inside to the outside. P14890
❍ Clean cooling ducts 2 with compressed air. 2
1 x cc VT 4.25
1 x coc VT 4.40
2 x coc SV 8.130
B C P10602
P14847
2
2 1
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Upper and movable platen
Cleaning intervals depend on environmental and weather

conditions (levels of humidity), and machine working condi-
tions. Clean using a dry cloth, taking care not to remove the
”greasy” coating on the surfaces, as this is an anti-corrosion
product.
If removing this coating is unavoidable, the anti-corrosion
must be reapplied. To do so, refer to the procedure described
in chapter non-periodic maintenance in this manual.
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Optical sensors
❍ Open the guard and push the sheet gripper 1 in the oppo-
site direction to the sheet passage.
❍ Shift the lateral sensor(s) 2 towards os.
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Optical sensors
❍ Use cleaning brush 3 to remove the dust on the scanning

zone 4 of all upper and lower front sensors 5 and lateral
sensors 2.
❍ Wrap brush 3 in a alcohol dampened tissue 6 and clean
the scanning zones 4 again.
Notes:
1. Make sure the brush is clean and in good shape in order
to avoid any scratches.
2. BOBST disclaims all responsibility for any damage or dis-
functioning of a sensor following the use of the cleaning
kit.
4
2
3
4
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Maintenance - Monthly
Power Register central lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Water reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Grease nipples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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Power Register central lubrication
Power Register 1 x coc

B A
E8
max.
Fill up Power Register grease in order to always be on maxi-
mum level. min.
A
If there is not enough grease in the tank, the HMI signals a
trouble.
Check that the grease reaches the slides (9 transparent
hoses 1).
HMI
1 B
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Air filters
# x coc
For each filter proceed as follows:

❍ Remove air filter 4 and clean it with hot water. 4
Note: In case of heavy dirt, clean filter by using hot water with
added detergent. Rinse with clear water. Do not use corro- A
sive products.
❍ Carefully dry filter after cleaning. Put it on an angle in
order to drain off the water completely.
❍ Put the filter back in place.
Note: The shape and number of filters depend on the config-
uration of the machine.
A
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Water reservoirs
1 x coc
❍ 2/
Fill up the reservoir with a solution of 3 of demineralised
or distilled water and 1/3 of Glattol 9244
(4 l: BSA1162000700 / 20 l: BSA1162000800).
min.
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A B
Power Register
Note: The shape and number of condensers depend on the

configuration of the machine. A
P18355
A
P18356
B B
P16879 P17548
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E4
Grease nipples
B 2 x cc / 2 x coc
A
1 x cc 1 x coc
B B A
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Maintenance - Half-yearly
Flexible hydraulic conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Central lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Power Register central lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Rotor of the suction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Toothed belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Grease nipples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Gripper bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Braking tablets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
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Flexible hydraulic conduits
If one of the following situations occurs, replace conduit

immediately:
❍ Fitting slides on the conduct.
❍ Leakage on fittings or conduit.
❍ Fittings are cracked, damaged or present severe corro-
sion traces.
❍ Outer sleeve of the conduit is damaged, deteriorated,
swollen, soft or unstuck.
Check state of hydraulic conduits and correct functioning of ❍ Conduit is hard, stiff, crazed or burnt.
driven elements. The maintenance program must include at
❍ Conduit is crushed, squashed or twisted.
least the following checkings.
Important: Within the framework of a preventive mainte-
If one of the following situations occurs, act quickly on the
nance, flexible conduits must be replaced every 5 years
conduit:
since the installation date of the machine.
❍ Leakage on couplings. In this case, tighten according to
suppliers prescriptions.
❍ Blocked or dirty conduit.
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Central lubrication
A
P17377
Lubrication control of gripper bar chains

❍ Insert a strip of cardboard 1 between nozzles os / oos and 1
the gripper bar chains.
❍ Order a few lubrication cycles (HMI) and check that the
strips of cardboard have traces with the same amount of
oil from each nozzle.
If this is not the case, check the distributor or the nozzles
concerned and if necessary replace the defective pieces.
HMI
Setting / Test
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Checking a distributor
When a part is not lubricated:
❍ Unscrew the dosing device 3 of the part concerned. This
dosing device is on a distributor 4.
❍ Take out the distributor components. 3
❍ Check that the pintle 5 slides freely into part 6.
❍ Also check the seals.
❍ If necessary, replace faulty parts.
❍ Reassemble in the reverse order to removal.
P16055
4
5 6
P15479
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Bleeding
When replacing a hose, distributor or dosing device, the cir-
cuit concerned needs to be bled. Proceed as follows:
❍ Unscrew cap 7 on the most remote distributor of the cir-
cuit concerned.
❍ Order a few lubrication cycles (HMI) and check that oil
7
runs out through the cap opening. As soon as the oil
starts running, screw cap 7 back in. P10776
❍ Order a few more lubrication cycles (HMI) and check that

oil is running out at the end of the hose or at the nozzles.
HMI
Setting / Test
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Power Register central lubrication
2
A
To top up the level, proceed as follows:

3
❍ Put down basin 1 by releasing hooks 2.
❍ Fill up basin 1 with new grease to maximum.
❍ Mix the grease to obtain a uniform consistence as well as 1 A
a flat surface (no vacuum cone around suction body 3).
Do not ”beat” the grease to avoid the formation of air
bubbles.
❍ Fit basin 1 again.
max.
E8
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Rotor of the suction unit 2
A
3 1x
❍ Remove retaining flange 1.

❍ Extract rotor 2.
❍ Clean the rotor with a cleaning petrol soaked rag.
P17376
Important: Never dip the rotor into cleaning petrol as it
contains a bearing lubricated for life.
❍ If necessary, clean the rotor housing with a cleaning pet- 2
rol soaked rag.
❍ Put the rotor back into its housing, turning it around its
own axis to make sure it engages.
❍ Put the retaining flange 1 back into place. Place notch 3
at noon.
A
P7475
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Toothed belts
C A B Note: Only a person having been trained by Bobst will be

able to replace the belts.
D
1 x coc 1 x coc
A B
P16857 P16857
1x 1x
A B
C D
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Note: Only a person having been trained by Bobst will be

able to replace the belts.
1 x cc
E F
E
P16857
1 x cc
E F
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❍ Check the belt tension with a measurement device. To do

so, apply a force F and measure deflection x according
to the opposite table.
Note: Refer to chapter ”General / Tension of belts and F (N) x (mm) f (Hz)
aprons”. A 29 6 80 ± 2
B 34 12 34 ± 2
C
D 145 ± 2
E 137 ± 2
F 37 ± 2
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Chains
B A 2 x coc 1 x cc / 1 x coc
D
A C
P16857
1 x coc 1 x coc
B
A
B D
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1 x coc / 1 x cc
E F
1 x coc / 1 x cc
E
P17701
1 x cc
F
P17702
G
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1 x cc
H I
H
1 x cc
2-3 mm
I
P17703
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V-belts
Belt tension
❍ Unscrew the four screws 1.
❍ Act on the two screws 2 to tighten belts.
2
P15546
1
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Belt tension (cont’d)

❍ Check the belt tension with measurement device 3. A
force F of 35 N has to cause a sag of 7 mm.
Note: It is possible to verify the belt tension by using a fre-
quency measurement device. Frequency f has to be
44 Hz.
❍ Block the screws.
Important: Make sure that the pulley 4 of the main motor is
aligned and parallel with pulley 5 of wheel 6.
3
F = 35 N
5
6
F
4 x = 7 mm
P15547 P13196
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Replacing belts
❍ Slacken belts by unscrewing the four screws 1 and the
two screws 2.
2
P15546
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Replacing belts (cont’d)

❍ Disconnect the compressed air supplies 3. ❍ Disconnect the hydraulic tubes 5.
❍ Disconnect connectors 4. ❍ Remove spacers 6 (three M8 screws).
3 4 3
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Replacing belts (cont’d)

❍ Unscrew bracket 7 from the support of the pneumatic unit
(one M8 screw, one M6 screw). 7
❍ Remove shims 8 (four M16 screws) and 9 (one M8
screw).
❍ Remove the worn belts by pulling them through the gaps.
❍ Replace the new belts and reassemble in reverse order.
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E4
Grease nipples
B
A
1 x cc 2 x coc 3x
A A B
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E4
C D
C
1 x cc 1 x cc 1 x coc
C C D
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E4
2 x cc / 2 x coc 1 x cc / 1 x coc 3 x coc
F F F
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E4
G 3 x cc / 3 x coc 3 x cc / 3 x coc
I H
H I
1 x cc 1 x cc 1 x coc 1 x coc
G G G G
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E4
L K
J M
4 x cc / 4 x coc 3 x cc / 3 x coc 1 x cc / 1coc 3 x cc
L K J M
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E4
P O
1 x coc 1 x coc
P O
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E4
R Q
4 x cc / 4 x coc
5 x cc / 5 x coc
R Q
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E4
S T
2 x cc / 2 x coc 4 x cc / 4 x coc
S T
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Gripper bars 230°
Use a lubricant spray such as Molykote 321 R or OKS 471

(BSA921900025).
#x9
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Braking tablets
2x
Putting the tablets into service

❍ Put the braking tablets cleaning into service (HMI). A
HMI
Setting / Test
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Cleaning procedure
This cleaning is done with the os and oos guards open.
❍ Clean all holes 1 with compressed air.
❍ Feel by hand which tablet holes 1 reject air.
Note: Make sure no air flows out from holes 1.If this should
happen, introduce cleaner 2 into hole 1 and move it through
channel 3 in order to remove dust.
P10775
P2931
1 2
1 1
3 P11103
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Checking procedure
Put a piece of cardboard on tablet and pull it by hand to check
braking efficiency.
Note: Satisfactory operation of the braking tablets depends
on the cleanliness of the compressor filters and the tubes.
P11103
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Maintenance - Yearly
Metal surfaces without coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Flat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Oil reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Water separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Pumps vanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Dust separators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Reduction gears with level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Waste removal apron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
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Metal surfaces without coating

H1
These surfaces are protected by a water-repellent product

that forms a very thin, strong coating, which is non-stick and
does not attract dust. P15802 P15588
Wipe the surfaces with a clean, dry cloth and then apply the
anti-corrosion, water-repellent product H1 (BSA932400007)
to the surfaces.
Drying time is approximately 30 minutes.
Important: The anti-corrosion product is flammable. No
smoking or naked flames during the procedure. Ensure that
the area is well-ventilated.
P15917 P15804
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Flat belts
2x
A
P18489
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Oil reservoirs
A A
Analysis
Oil degrades gradually over a period of time. This degrada- 2
tion process depends on several factors. An analysis allows
oil degradation times to be assessed, and the analysis
results allows the appropriate oil change intervals to be
applied.
Draining
In order to drain, proceed as follows:
❍ Put down and check the sector membrane.
❍ Unscrew cap 1 and drain the reservoir.
❍ Remove the cover 2 from sector casing.
1
❍ Check condition and tension of chain 3. 3
❍ Clean the bottom of the gear case and tank 4 with a clean
cloth. 4
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Draining (cont’d)
❍ Clean magnetic filter 5.
❍ Refit cap 1.
Filling
❍ Refit the cover 2 of sector casing.
❍ Fill the tank.
❍ Check the oil level with the machine stopped and the
main motor in operation. The oil level has to be in the
middle of the sight glass.
❍ Fill up if necessary.
❍ Refit the sector membrane. A1
75 l
2
1/
1
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Oil filters
A
A 1 x coc
4
5
12
6
Replace the filter once a year or before the pressure reaches

7
1,8 bar (BSA1260040001).
❍ Close inlet 1 and outlet 2 valves. 8
❍ Open valve 3 and drain the system. 9
❍ Unscrew nut 4 and remove o-ring 5, housing 6 and 3 2 1
o-ring 7. 10
❍ Unscrew nut 8 and remove spring 9 and spring guide 10.
❍ Remove filter 11 and clean inside of filter base 12.
❍ Replace the filter and refit all parts taking care not to dam-
age o-ring 13.
❍ Screw nut 8 until it touches the collar of the spring guide
10 and fasten four additional turns.
11
❍ Fasten nut 4 to 70 Nm.
13
EDT 01
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Water separators
Reassembly
A
❍ Proceed in reverse order.
Dismantling
❍ Push locking guide 1 downwards, simultaneously turn
cup 2 and remove it from the device. 1 4
❍ Unscrew centring disk 3.
❍ Remove and replace filter cartridge 4. 2 3
BSA1260037100. P18144
Cup cleaning A 5
P18146
❍ Clean cup 2 only with water, soap water (+ 60° C max.)

or white spirit (non-aromatic).
❍ Check operation of automatic drain 5.
4
P18145
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Chains
1 x cc
A
P18148
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4 x cc
4 x coc
2 x cc
2 x coc
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Pumps vanes
1 x coc KDT 3.80 4x
B A
A
Blow cylinder with dry compressed air. P14889
P10938
Minimum width of vanes for KDT 3.80:

x = min. 26mm.
Minimum width of vanes for VT 4.25 / 4.40:
x = min. 28mm.
1 x cc VT 4.25
1 x coc VT 4.40 7x
X
B
P14847 P3282
P3106
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Dust separators
1x
KDT 3.80
A
P14890
A
P10935
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Reduction gears with level check
C B A
A1
A1
B
P16865
A C
P16864
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Waste removal apron
1 x cc / 1 x coc
A
P17699 A
2
Tension of the apron
❍ Set springs by means of screws 1 at 47mm.
❍ When starting up the machine, check and adjust if
required the centering of the apron:
D Loosen screws 2. 1 x cc / 1 x coc
P17698
D Set by using screws 3.

3
D Tighten screws 2 again. A2
3,5 l 1
P17716
47
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Channels
B A
P18909
1 x cc / 1 x coc 1 x cc / 1 x coc
2 x cc / 2 x coc
A B
P18882
P18883
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Maintenance - Every 2 years

Reduction gears with level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Water reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

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Reduction gears with level check
C B A
A1
0,9 l
1x
A1
1,4 l
2x
B
P16865
A C
P16864

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Water reservoirs
3 1x
Cleaning
❍ Unscrew plug 1 and open the valve 2 in order to drain the
reservoir and the hoses.
❍ Close the valve 2 and screw on plug 1.
❍ Fill up the reservoir with water through the opening 3.
A
P19117
1
P19929

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Cleaning (cont’d)
❍ Put the cooling unit into operation.
❍ Let the cooling unit run for 1 hour in order to rinse the sys-
tem.
❍ Stop the cooling unit.
❍ Unscrew plug 1 and open the valve 2 in order to drain the

reservoir and the hoses.
❍ Close the valve 2 and screw on plug 1.
2
1
P19929

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Filling
❍ Fill up the reservoir with a solution of 2/3 of demineralised
or distilled water and 1/3 of Glattol 9244 1x
30 l
(4 l: BSA1162000700 / 20 l: BSA1162000800).
❍ Put the cooling unit into operation.

❍ Check the level.
min.
P19117

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Maintenance - Non-periodic
Supporting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Upper and movable platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Suction cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Brakes and clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
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Supporting plate
While dismounting the lower cutting equipment, clean the

contact surfaces between supporting plate 1 and cutting
plate or compensating plate:
❍ Clean them with a dry cloth.
❍ Vaporize the different contact surfaces with a lubricating
spray, for example Molykote 321 R, Rocket WD40 or
OKS 471 (BSA921900025).
❍ Wipe the treated surfaces with a clean cloth.
In case of heavy dirt marks use only the following products,
then treat the surfaces as described above.
❍ Cyclohexan C6H12
❍ Ethanol C2H5 OH
❍ Ether (C2H5)2 O
❍ Isopropanol (CH3)2 CHOH
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Upper and movable platen 2 H1
Basic anticorrosive treatment. Proceed as follows:

❍ Clean the surfaces with cleaning petrol.
❍ Wipe with a clean and dry cloth (after possible oiling).
❍ Apply grease ”OKS 260” (BSA921200023) with a clean
cloth by making intensive circular movements. Use 25 g
of grease per square metre.
A lubricating spray OKS 471 equivalent with OKS 260
can be obtained from BSA921900025.
❍ Treat the surfaces with the waterproof anticorrosive pro-
duct H1 (BSA932400007).
❍ Drying time is about 30 minutes.
Important: Since anticorrosive product is inflammable, do
not smoke during this procedure. The room also has be prop-
erly ventilated.
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Suction cups 2
A 9x
If the suction cups are not moving correctly in vertical direc-

tion, clean them as follows:
❍ Remove suction cups. A
❍ Remove rubber washers.
❍ Degrease outer and inner sliding surfaces with cleaning 5x
petrol.
❍ Dry with compressed air.
❍ Fit cups again without oiling them.
B
P17700
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Brakes and clutches
When the ”Maintenance” key signals a trouble and the ”Bra- HMI
king” icon is indicated on the HMI screen, proceed described
as follows.
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Setting the brake

Checking the wear on the brake linings:
❍ Check the cleanness and the degree of wear of the lin-
ings before proceeding with the brake setting.
❍ The linings 1 are screwed onto the jaws. They have to be
replaced once the thickness reaches a minimum of 5mm.
Setting the piston:
❍ In the braking position, use a screwdriver to push piston P16874
2 to the bottom of its housing.

❍ Check that there is a distance y of 2 to 3mm between the
head of screw 3 and the jaw. If not, loosen screw 3 and 1
set the required distance. Lock the screw.
y = 2 - 3 mm
2 3
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Setting the brake (continued)

Setting the lateral stop:
❍ Switch on the machine so that the push-button S25 for
releasing the brake manually is once again operational.
❍ Press the brake release push-button S25 and check that
the clearance x between brake drum 4 and brake linings 1
1 is equal on either side. If not, adjust with screw 5. 1
4
S25
x x
P18880
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Setting the brake (continued)

Braking check:
❍ Make sure the ”Declutching of the feeder” function is out
of operation (HMI). HMI
❍ Run the machine at max. speed and cover the photocell
at the infeed with a piece of cardboard. The machine has
to come to a standstill between 270-290_MP:
D If the machine stops ahead of 270_MP, slacken the
springs of the air brake progressively.
D If the machine stops after 290_MP, compress the
springs of the air brake progressively.
Note: On a new air brake the prestressing distance of the
springs is 110mm.
110
055714 8552 0100 00211470 18.05.2017 X05 00 4  Bobst Mex SA 2017 261
EXPERTCUT 106 PER 3.0 => 1641 / <=
7 3 x 0,8 mm
Setting the clutch
The distance between armatures 6 is given by spacers 7 and
washers 8. The minimum distance is given by studs 9.
ÉÉ
ÉÉÉÉ
ÉÉÉÉ
ÉÉ
8
ÉÉÉÉ
ÉÉ
ÉÉÉÉ
ÉÉ ÇÇÇÇÇÉÉÉ
ÇÇÇÇÇ
❍ Measure distance b between the friction disks 10 and the
ÉÉÉÉ
ÉÉ
ÉÉÉÉÇÇÇÇÇÉÉÉ
armatures 8 (measure on the radius passing through the
ÉÉ ÉÉÉ
nuts 11). The normal operating distance b (0,25 -
0.45mm) has to be equal on both sides. If it is unequal,
ÉÉÉÉ
ÉÉ
ÉÉÉÉ
ÉÉ ÉÉÉ
correct the centering and the parallelism of the disks with
in relation to the armatures by using nuts 11.
6
ÉÉÉÉ
ÉÉ ÉÉÉ
ÉÉÉ
6
❍ When the maximally tolerated distance b reaches or

exceeds 0.7mm, remove a washer 8 and remount it on
ÉÉÉÉ
ÉÉ ÉÉÉ
the outer side of the armature in order to obtain again a
distance b = 0.25 - 0.45mm. 10
b b
❍ Then adjust the centering and the parallelism of disks 10
in relation to the armatures 6 using nuts 11. 9
Note: Washers 8 may be ordered from BOBST.
0.8mm thick: 1106 0776 00
11
P16681
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Checking the programmed stop

After checking and setting air brake / clutch, proceed to check
the programmed stop:
❍ In the HMI customer menu, set back brake compensation
to its default value.
❍ Run the machine at maximum speed, then control
programmed stop with push-button S30. Repeat this
operation several times until machine learning device
can be initialized. The machine has to stop between
S30
195-215_MP.
If this is not the case, contact the BOBST customer service.
HMI
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Fluids
Use of charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Required brands and quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Fluids
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Use of charts
Important
Only use fluids referenced in handbook D51 ”Fluids refer-
ences”. Bobst accepts no lability in case of use of any other Oil changing
fluids, even if they comply with the same DIN and ISO stan-
dards as the fluids mentioned in this handbook.
BOBST
reference
coc A2
1,5 l
A Quantity of
oil
Required brands and quantities

Periodic maintenance BOBST
0,5 l
Reduction gear 0,35 l A2
0,95 l
DocSearch
FTP
Fluids
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Required brands and quantities
Periodic maintenance BOBST
Oil reservoirs 75 l
1,4 l
A1
Reduction gears 1,4 l
0,9 l
Oil reservoirs (*:ESSO ATF LT 71141) 0,5 l *
Waste removal apron 3,5 l A2
Central lubrication unit 2,7 l
C4
Oil for various elements ----
Grease for various elements ---- E4
Grease for various elements ---- E11
Power Register central lubrication unit 2,5 l E8
Metal surfaces without coating ---- H1
Glattol 9244 (4 l: BSA1162000700 / 20 l: BSA1162000800) ---- ----
The quantities are indicated for information only.

Fluids
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Various information
List of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Various information
055714 8552 0100 00211474 18.05.2017 Z00 01 1  Bobst Mex SA 2017 267
EXPERTCUT 106 PER 3.0 => 1641 / <=
List of symbols
Cut and lock the different sources of energy Check condition + operation
according to the instructions of chapter
Safety Check chain tension
Pull out key Check belt tension
Put in key
Check level
Clean Oil level in the sight glass
1 Water + detergent Change
2
Cleaning petrol * Fill in here
3
Petroleum (kerosene) Drain here
Clean with compressed air Grease
Use vacuum cleaner Oil
Lubricate with spray
* Flash point higher than 55°C. Fire protection class FE 3 Lubricate with spray for chains
according to EUR. INSUR. COMM. Do not use solvents
such as thinner or trichlorethylene. Do not oil
Various information
055714 8552 0100 00119508 30.09.2004 Z99 00 1E  Bobst Mex SA 2017 268
EXPERTCUT 106 PER 3.0 => 1641 / <=
Intervention: see text Part to be maintained
Remove to reach the element

# On each printing unit
Exchange / Replace
C4 See oil and grease charts
Replace if necessary
cc Operator’s side (os)
Measure
coc Opposite operator’s side (oos)
320_
Machine position (°MP)
Board travel direction
Various information
055714 8552 0100 00076592 08.01.2001 Z99 00 2C  Bobst Mex SA 2017 269

D85 Operating Instructions PDF

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Operating instructions

EXPERTCUT 106 PER 3.0

TRANSLATION OF THE ORIGINAL INSTRUCTIONS

 Bobst Mex SA 2017 055714 8552 0100 00211424 18.05.2017 A00 00 1

D85 D85 D85

=> 1641 / <= => 1641 / <=

EXPERTCUT 106 PER 3.0

EXPERTCUT 106 PER 3.0

055714 8552 0100 00211425 18.05.2017 A00 00 2A  Bobst Mex SA 2017 2

Bobst Mex SA Tel.: +41 21 621 21 11

Safety and environment

Safety and environment

Safety and environment

Easy reconditioning of feedstock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Safety and environment

General safety instructions

Safety and environment

General rules for all users

Safety and environment

Safety and environment

Excerpt from the EC Declaration of Conformity

is in conformity with the provisions of:

Safety and environment

Precautions against magnetic fields

Safety and environment

Safety and environment

Prohibition pictograms No access with metallic objects or a

General prohibition. No reaching in.

No smoking. No stepping on surface.

No open flame or any other ignition Do not walk or stand here.

No entry. No magnetic field.

No access with cardiac devices. Only for authorised personnel.

No access with a prosthesis.

Safety and environment

Do not take by hand.

Do not step on the belt.

Safety and environment

Danger pictograms Floor-level obstacle.

Safety and environment

Inflammable material. Sharp element.

Sharp element. Risk of crushing hands (rotating ele-

Crushing hands by tools.

Sudden loud noise.

Risk of crushing feet.

Hot materials. Counterrotating rollers.

Safety and environment

Risk of crushing hands (elements in

Safety and environment

Wear protective clothing.

Wear head protection.

Wear a safety harness.

Disconnect all energy sources.

Safety and environment

Verify that protection is in place.

Take here by hand.

Safety and environment

Rescue and help pictograms

Emergency exit on the left.

Emergency exit on the right.

First aid station.

Safety and environment

Safety and environment