
The final print run for this would take a pressman around 3 days to run, and consider that the same job with 100 000 copies would also take the same time, with a lot less wasted paper in setup. You really want to print more than 10 000 copies to get the cost down, though I think Sony was able, because of the worldwide service centre network they had, to get to this level with ease. Bleeding expensive for a short press run, the costs of the plates are high, and the set up of the press is only doable with an experienced printer. Finally put the whole lot together and bind, then a final trim. Then slit to size, collate and fold using a folding machine. To print double sided simply turn over and print again, using talcum powder to keep the ink layers from sticking or transferring to the other pages. Big press for the long pages, using part of a very wide press, and doing all the other pages as sections along the wide paper. Colour was done with a second print head, which printed the red ink on the page at the same time as the black, using the blanket to transfer the image.
SONY DISCMAN DT4 MANUAL MANUAL
There they used these to make the final aluminium plates, and then printed the manual on the final paper using an offset press. The developed film was then carefully checked again, to ensure that the halftones were right ( a woven screen used during exposure to make dots) and sent finally as a set of positives to the printer. Then the final draft was signed off, and carefully placed in an exposure unit ( around 2m by 1m, using 2 1kW linear halogen lamps for light) and used to make a final lithographic film master.

The red was done with an acetate sheet overlay, which had the drawings made on it using a black Rotring pen, and a diagram on tracing paper placed under it, so you could see the placement to copy faithfully. Circuit diagrams hand drawn by a draughtsman on a large sheet of vellum paper, in pencil, then darkened with a Rotring pen afterwards to get the final diagram. That manual was produced the old fashioned way, using large sheets of white board, with the typewritten sections cut and pasted onto them, using glue to hold them down in position.
