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PERFECT BINDER

BQ-270

Important Information
This manual is designed to help you to install, operate and maintain the BQ-270 Perfect Binder.
Please read and understand this manual, and keep it in a safe and convenient place.
Do not operate the BQ-270 until you read and understand the instructions in this manual.
Horizon International Inc. shall not be liable for incidental consequential damages resulting from:
improper or inadequate maintenance by the customer unauthorized modification or misuse, or
operation outside of the environmental specifications for the product.
Horizon International Inc. pursues a policy of continuing improvement in design and performance
of the product. Therefore, the product design and specifications are subject to change without prior
notice and without our legal obligation.
All rights are reserved. No part of this manual may be photocopied, reproduced or translated to
another language without the prior written consent of Horizon International Inc.

061031/BQ270/11E/HS, TM, HH, HS

UM202048-11

Safety precautions are indicated in this manual as follows:

Safety Precautions
The term WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
The term CAUTION indicates a potentially hazardous situation which, if not avoided, may
result in serious injury, or damage to the machine.
This symbol indicates a note which includes important information. Follow the note to
operate the machine safely.
This symbol indicates a prohibited action. Do not perform any prohibited action.
This symbol indicates an essential procedure. Follow the procedure to operate the machine
safely.

This lists the range of acceptable values and operating conditions.


Important
Attention

This information will help you to avoid problems with the machine or help you
learn how to operate the machine.
Refer to this note when you operate the machine.

Note
This explains a mechanism in the machine.
Additional
Information

Safety Operation Precautions


WARNING
Do not touch the melt tank while the power switch is turned on. Melt tank is heated to 200
degrees Celsius (400 Fahrenheit), and may cause severe skin burn.
Work alone when you maintain and lubricate the machine. Letting someone else operate the
machine may cause severe personal injury.
Do not touch the moving part. Otherwise it may cause severe personal injury.

Turn off the power switch before adjusting the machine. If the start button is pressed, it may
cause severe personal injury.
Do not touch the milling cutter and roughening cutter. Otherwise it may cause severe personal
injury.
Be careful not to pinch your hands when inserting the book block into the clamp.

Disconnect the power cable from the socket when recovering the breaker.

BQ-270 weighs 900 kg (1,980 lb). Transport and install the machine safely, and keep the weight
of the unit in mind.

CAUTION
When turning off the power switch and on again, wait a dozen of seconds. Otherwise, the board
may be damaged.
When the milling guide and the nipper are set narrower than the clamp width, do not move the
clamp. Otherwise, the lower part of the clamp may hit the guide and be damaged.
Do not insert book block into clamp and drive the machine while chanover. Otherwise, tha
machine may be damaged.
Make sure to tighten the lock screw of milling cover brush. Otherwise the brush may fall out
when the clamp passes over.
Do not drive the application drum when the glue is not melted completely. Othewise, the
machine may be damaged.
When using optional weekly timer, the melt tank is heated up in the set up day, at the set up time.
Check the machine when the melt tank is heated up for safe.
Use the lubrication grease recommended by Horizon. If the ingredient of the grease changes, the
life of the machine may be shortened or the machine may be damaged.

CONTENTS
Important Information
Safety Precautions
Safety Operation Precautions
1. Machine Description .................................................................................... 1
1-1 Machine Description............................................................................................... 1
1-2 Safety Functions .................................................................................................... 1
1-3 Parts Descriptions .................................................................................................. 2
1-3-1 Carriage Clamp Section ...........................................................................................
1-3-2 Level Plate Section...................................................................................................
1-3-3 Milling Section ..........................................................................................................
1-3-4 Melt Tank Section.....................................................................................................
1-3-5 Nipping Section ........................................................................................................
1-3-6 Cover Feed Section..................................................................................................
1-3-7 Delivery Section .......................................................................................................
1-3-8 Touch Screen ...........................................................................................................

2
2
3
4
5
6
7
7

1-4 Screen Descriptions ............................................................................................... 8

2. Job Settings on Touch Screen ................................................................... 9


2-1 Entering the Job Information Using the Setting Screens ....................................... 9
Binding Mode Screen ...................................................................................................... 10
Start Mode Screen............................................................................................................ 11
Book Block Size Screen .................................................................................................. 12
Cover Sheet Size Screen ................................................................................................ 13
Function Screen............................................................................................................... 14
Milling and Nipping Screen ............................................................................................... 15
Gluing Screen Part 1 ....................................................................................................... 16
Gluing Screen Part 2 ....................................................................................................... 16
Gluing Screen Part 3 ....................................................................................................... 17
Gluing Screen Part 4 ....................................................................................................... 17

2-2 Bind the Books Using the Binding Screens.......................................................... 18


Binding Screens............................................................................................................... 19

2-3 Test Milling and Gluing.......................................................................................... 20


Test Milling and Gluing Screen........................................................................................ 20

2-4 Fine Adjustment .................................................................................................... 21


Clamp and Milling Fine-Adjust Screen.............................................................................
Glue Fine-Adjust Screen Part 1 .......................................................................................
Glue Fine-Adjust Screen Part 2 .......................................................................................
Glue Fine-Adjust Screen Part 3 .......................................................................................
Nipping Fine-Adjust Screen .............................................................................................
Scoring Fine-Adjust Screen .............................................................................................
Cover Sheet Fine-Adjust Screen Part 1...........................................................................
Cover Sheet Fine-Adjust Screen Part 2...........................................................................
Cover Sheet Fine-Adjust Screen Part 3...........................................................................
Cover Sheet Fine-Adjust Screen Part 4...........................................................................
Cover Sheet Fine-Adjust Screen Part 5...........................................................................

21
22
22
23
24
25
26
27
27
28
28

2-5 Saving or Recalling or Deleting Job Settings. ...................................................... 29


2-6 Using the Single Operation Screen...................................................................... 30
Single Operation Screen Part 1 .......................................................................................
Single Operation Screen Part 2 .......................................................................................
Single Operation Screen Part 3 .......................................................................................
Home Positioning Screens ..............................................................................................
Milling Brake Release Screen..........................................................................................

30
31
31
32
32

2-7 Information Screen............................................................................................... 33

2-8 Error Screen......................................................................................................... 34


2-9 Numeric Keypad Screen ...................................................................................... 34

3. Starting the Binding Operation ................................................................. 35


3-1 Turn On the Power Switch ................................................................................... 35
3-2 Safety Function Check ......................................................................................... 35
3-3 Enter the Job Information Using the Setting Screens .......................................... 36
3-4 Setting the Main Binding Screen.......................................................................... 40
3-5 Setting the Scoring Rollers................................................................................... 41
3-6 Setting the Scraper (For Padding Only) ................................................................ 43
3-7 Setting the Side Glue Rollers ............................................................................... 44
3-8 Start Binding......................................................................................................... 45
3-9 Adding More Cover Sheets .................................................................................. 47
3-10 Removing the Bound Booklets........................................................................... 48
3-11 Saving and Recalling the Job Information.......................................................... 49
3-12 Adding More Glue .............................................................................................. 52
3-13 Finishing the Binding Operation ......................................................................... 53

4. Parts Adjustments ..................................................................................... 55


4-1 Changing the Spine Glue Amount and Position...................................................
4-2 Adjusting the Side Glue Amount ..........................................................................
4-3 Changing the Nipping Setting ..............................................................................
4-4 Changing the Cover Feeding Settings .................................................................
4-5 Changing the Scoring Position.............................................................................
4-6 Changing the Carriage Clamp Opening and Milling Guide Width ........................
4-7 Milling Depth Adjustment .....................................................................................
4-8 Glue Temperature Adjustment .............................................................................
4-9 Side Glue Amount Adjustment (Far Side) ............................................................
4-10 Nipper Height Adjustment ..................................................................................
4-11 Nipper Angle Adjustment ...................................................................................
4-12 Cover Sheet Angle Adjustment ..........................................................................
4-13 Blower Air Adjustment........................................................................................
4-14 Double Feed Stop Pad Height Adjustment ........................................................
4-15 Feed Table Height Adjustment...........................................................................
4-16 Scoring Roller Pressure Adjustment ..................................................................

55
55
56
57
58
58
59
61
62
64
65
66
67
67
68
68

5. Maintenance ............................................................................................... 69
5-1 Cleaning the Book Block Path..............................................................................
5-2 Cleaning the Sensors...........................................................................................
5-3 Lubrication............................................................................................................
5-4 Book Support Plate Replacement ........................................................................
5-5 Milling Cutter Replacement ..................................................................................
5-6 Roughening Cutter Replacement.........................................................................
5-7 Glue Replacement ...............................................................................................
5-8 Double Feed Stop Pad Replacement...................................................................
5-9 Transport Belt Replacement ................................................................................

69
71
72
73
75
78
81
83
84

6. Troubleshooting ......................................................................................... 85
6-1 Problems with Booklet Quality .............................................................................
6-2 Error Codes..........................................................................................................
6-3 If a Circuit Breaker Trips ......................................................................................
6-4 If a Message Screen Appears ..............................................................................

85
90
94
95

7. Optional Device .......................................................................................... 97


7-1 Weekly Timer ....................................................................................................... 97

8. Installation ................................................................................................ 101


8-1 Installation .......................................................................................................... 101
8-2 Installation of Extractor (Option).......................................................................... 104
8-3 Installation of Weekly Timer (Option) ................................................................. 106

9. Appendix................................................................................................... 109
9-1 Specifications ..................................................................................................... 109
9-2 Accessories........................................................................................................ 110
9-3 Consumable Parts.............................................................................................. 113
9-4 Option................................................................................................................. 114
9-5 Index ................................................................................................................... 115

1. Machine Description

1-1 Machine Description


Touch Screen

Milling Section

Used to input necessary


information and operate the
machine.

Mills the book spine.

Melt Tank Section

Carriage Clamp

Applies glue to the book spine.

Clamps the book block.

Nipping Section

Level Plate

Pastes the cover sheet on the


book spine and forms the spine.

Registers the bottom of the


sheet block.

Cover Feed Section

PERFECT BINDER

Feeds the cover sheet


to the nipping section.

BQ-270

Trimmings Bag
Collects the trimmings.

Glue Temperature Adjusting Knob


Power Switch

Delivery Section

Adjusts the glue temperature


from 120 to 180 (248 to 356

).

Milling ON/OFF Lever

Stacks the bound booklets


vertically.

Turns the milling operation ON or


OFF. Turn the lever to the right
to select milling ON.
Turn to the left to select milling
OFF.

1-2 Safety Functions


Safety Cover (left)
The machine stops if
this cover is opened.

Safety Cover (right)

Area Sensors

The machine stops if


this cover is opened.

The machine stops if


this light between the
sensors are cut.

PERFECT BINDER

BQ-270

Emergency Stop Button


The machine stops if
this button is pressed.

Lower Nipper Door


The machine stops if
this door is opened.

1-3 Parts Descriptions


1-3-1 Carriage Clamp Section
Grease Nipples
PERFECT BINDER

Lubricate with
grease here.

BQ-270

Book Block Insert Section


Insert the book blocks
here, aligning to the right.

Emergency Stop Button


Press this button to stop
the machine.
Turn the button clockwise
to release the emergency
stop.

Start Buttons
When using the manual starting mode, press
both buttons to start the binding operation.

1-3-2 Level Plate Section


Level Plate
The level plate moves forward to hold
each book block as it is inserted.
It moves back when delivering the
booklet.

Level Plate Slide Guide


Regularly lubricate with grease.

Delivery Section
Each booklet is delivered here.

1-3 Parts Descriptions


1-3-3 Milling Section

PERFECT BINDER

BQ-270

Rear Milling Guide

NG

NI
WAR

Upper Knife
This guide holds the book
spine while the milling
operation is done.

Brake Release Button


Front Milling Guide
This guide holds the book spine
while the milling operation is done.

Guide Block

This button is used when


replacing the milling cutter.
This button works only after
pressing the brake release
button on Touch Panel Screen.

This block transports the power


from the motor to the front milling
guide.

Milling Select Lever


When milling the book spine,
this lever is used to turn the milling
operation ON or OFF. Set the lever
to the left to turn off the milling operation.

1-3 Parts Descriptions


1-3-4 Melt Tank Section
Glue Temperature Adjusting Knob
PERFECT BINDER

BQ-270

The glue temperature can be adjusted from


120 to 180 . (248 to 356 )

CAUTION

Wiper 2

Do not touch the melt tank after the power is turned on.
The melt tank is heated to 200 degrees Celsius (400
Fahrenheit) and may cause severe skin burn.

Side Glue Roller

Lubrication Point

Glue Level Upper Limit

This drum is used to apply the glue


on the lower side of the book block.

Refer to [5-3] for details.

Keep the glue level lower


than this line.
The lower limit of the glue level
is 8 mm (0.31") lower position
below the upper limit line.

Glue Amount Adjusting Plate


If too little glue is applied to the
side glue roller, or too much glue is
applied, adjust the glue amount by
moving this plate.

Application Drum 2
This drum is used to put the
glue on the book spine.

Scrape Roller
This roller scrapes the extra
glue off of the spine.

Glue Supply Section

Adjust according to the glue


amount applied here.

Add more glue here when


the glue level is low.

Wiper 1
The distance of glue penetration
into the spine depends on the wiper
opening.

Application Drum 1
This drum is used to provide the
glue that penetrates into the spine.

Positioning Plate - Side Glue Roller (far side)


This plate is used to adjust the position of the side
glue roller on the far side of the machine. Turn the
plate counterclockwise, and the roller moves
forward to approach to the book block. (Normally
set to 0.)

1-3 Parts Descriptions


1-3-5 Nipping Section
Upper Cover Guide
Set to match the
cover sheet size.

Rear Jog Guide


Before the cover sheet
is fed, the side guide
waits 3 mm (0.12") away
from the edge of the sheet.
It registers the cover with the
front side guide before the
nipping operation.

Transport Belts

Registration Stopper

Registers the cover


Transport the cover sheets. sheets to the right.

Rear Nipper
This forms the book
spine with the front
nipper.

Front Nipper

DE

IN
TB

Front Jog Guide


Before the cover sheet is fed, the side
guide waits 3 mm (0.12") away from the
edge of the sheet. It registers the cover
with the rear side guide before the nipping
operation.

EC

RF

PE

0
7
-2
Q
B

Registration Stopper
Angle Adjusting Lever
This lever is used to adjust
the cover sheet angle.
Refer to [4-12] for details.

Nipper Angle Adjusting Block

Nipper Height Adjusting Ring

Refer to [4-11] for details.

This ring is used to adjust the


book spine sharpness.
Refer to [4-10] for details.

1-3 Parts Descriptions


1-3-6 Cover Feed Section
Scoring Roller Pressure
Adjusting Knob
Adjust to produce the
correct scoring line.
Fixed Scoring Roller

Adjustable Scoring Roller


Transport Roller

Feed Table Height


Adjusting Knob
Adjusts the height to
feed the cover sheet.

Cover Sheet Detect


Sensor on Feed Table
Detects the cover sheets
on the feed table.

End Guide

Feed Table

Pad Height Adjusting Lever


Positioning Guide

This adjusts the height of the double


feed stop pads. If the pad is worn or
double feeding occurs
frequently, raise the pads.
Refer to [4-14] for details.

Feed Rotor
This feeds the cover sheets
using suction and friction.

Double Feed
Detect Sensor
This detects double
feeding by measuring
the light that penetrates
the sheet.

Blower Air Adjusting Lever


Refer to [4-13] for details.

Double Feed Stop Pads

1-3 Parts Descriptions


1-3-7 Delivery Section

Push Plate
This plate pushes the
delivered booklets forward.

Stopper
Set this stopper next to the push
plate. The stopper will be pushed
forward as the booklets are stacked.

1-3-8 Touch Screen


Touch Screen
Refer to Section 2 for details on
the screens.

BQ-270

1-4 Screen Descriptions


The BQ-270 has five kinds of screens. Refer to Section 2 [Job Settings on Touch Panel] for details. (See page 9.)

Setting Screens
These screens are used to input the
necessary job information. Refer to [2-1].

Binding Screens
These screens are used to display the current
job information during the binding operation.
The can also be used to make fine
adjustments. Refer to [2-2].

Service Screen

Memory Screen
This screen is used to save or recall the
job settings. Refer to [2-5].

Single Operation Screens


These screens are used during maintenance
(cleaning or parts replacement). They can also
be used to check the function of each section.
Refer to [2-6].

Information Screen
This screen is used to show the ROM version
and the total binding number. Refer to [2-7].

Function Setting Screen


This screen is used to select the table
movement when the double feeding occurs,
milling function, and the delivery section full
detection ON/OFF.

2. Job Settings on Touch Screen


2-1 Entering the Job Information Using the Setting Screens
Input the necessary job information such as the binding type, sheet size and other
functions. The Setting Screen can cover the following seven functions:
Setting Screens
1

Binding Mode Screen

Start Mode Screen

Book Block Size Screen

Cover Sheet Size Screen

Function Screen

Milling, Nipping Screen

P. 1

Gluing Screen Part 1

P. 2

Gluing Screen Part 2

P. 3

Gluing Screen Part 3

P. 4

10 Gluing Screen Part 4

Press the box, and the Numeric Keypad


Screen appears. Input the setting value
on the Numeric Keypad Screen in
increments of 0.1mm (0.004").

2-1 Entering the Job Information Using the Setting Screens


1

Binding Mode Screen

3
1

: Binding with cover sheets.


Select
when binding with cover sheets.
When this button is selected, the side glue rollers should be moved into their working
positions. Refer to [3-6] on page 44. The side glue roller on the near side is controlled
by the computer. The side glue roller on the far side must be set manually.

: Binding without cover sheets.


Select
when binding without cover sheets.
When this button is selected, the side glue rollers should be moved out of their working positions. Refer to [3-6] on page 44. The side glue roller on the near side is controlled by the computer. The side glue roller on the far side must be set manually.
Also, when this button is selected, the support plate should be installed. Refer to [3-3]
on page 36.

OK button. Each of the Setting Screens has an OK button. Press this button to input
the setting and go to the next screen.

10

2-1 Entering the Job Information Using the Setting Screens


-

Start Mode Screen

1
2
3

Return to the home position during every changeover. Normally, select

: Each part of the machine goes back to the home position before moving to
a new set position.
: Each part of the machine moves to the set position directly.

Select the start mode.


: Normal Start mode. Binding operation starts with start buttons.
: Auto Start mode. Binding operation starts after the time set in 3 .

Start waiting time


Input the time after the book block is inserted into the carriage clamp till the binding operation starts in increments of 0.1. Input range is 0.0 to 9.9.

11

2-1 Entering the Job Information Using the Setting Screens


3

Book Block Size Screen

Input the book block thickness. Measure the actual book block thickness using the
attached caliper and input the value. The input range is 0.3 to 50 mm (0.010 to
2.000).

Input the book block length. Measure the actual book block length and input the
value. The input range is 135.0 to 320.0 mm (5.315 to 12.600).

12

2-1 Entering the Job Information Using the Setting Screens


4

Cover Sheet Size Screen

1
2

Input the cover sheet length in increments of 0.1 mm (0.005). The input range is
230.0 to 660.0 mm (9.055 to 25.985).
Input this setting first on this screen.
Input the length between the cover sheet rear edge and the spine (using either
edge, or the center of the spine). The input range is shown in illustration below.
or
: Either edge of the spine Fixed Side Downstream Movable Side
Scoring
(Front Side)

135 to 320

Scoring
(Rear Side)

110 to 310

(5.32" to 12.60")

120 to 350

(4.33" to 12.20) (4.72" to 13.77")

230 to 660 (9.05" to

25.98")

mm(inch)

If the dimension is out of this range, the front


or rear guides may not reachthe cover sheet edge.

: Center of the spine.

Input the cover sheet width in increments of 0.1 mm (0.005). The input range is
135.0 to 320.0 mm (5.315 to 12.600).
When measuring the distance to the center of the spine, use the accessory
alignment plate.

1
9 10

.
tion
ma
uto
ka
thin

tomati
think au

1
9 20

on.

Alignment Plate

Center of the Spine

13

2-1 Entering the Job Information Using the Setting Screens


5

Function Screen

(ON): Use the double feed detecting function.


(OFF): Do not use the double feed detecting function.

If the machine produces false indications of double-feeding because of an


image on the cover sheet, turn this function OFF.

14

2-1 Entering the Job Information Using the Setting Screens


6

Milling and Nipping Screen


2-1

Nipping with milling

2-2

Nipping without milling

2-1

2-2

2-3
2-3

Nipping without cover

Turn the milling operation ON or OFF.


: Milling ON

: Milling OFF

- If the milling set lever is set incorrectly, an error message screen will
appear.
- When Milling OFF is selected, the Insert Shim message appears.
Insert the shims, referring to the message screen and [4-7] on page 59.

2 : 2-1
2 : 2-2

Select this when doing milling. The nipper raises, then closes.
Select this when nipping without milling. The nipper closes as it raises to prevent the spine from swelling.

If this mode is selected when the milling operation is done, the spine
will become round.

2 : 2-3

Select this when binding without cover sheets. The nipper will not operate. The
machine will wait until the glue on the spine hardens, then the booklet will be
delivered.

15

2-1 Entering the Job Information Using the Setting Screens


7

Gluing Screen Part 1

P. 1

: The glue amount, wiper opening, nipping time and the nipping delay time is
set automatically depending on the book block thickness.
: The spine glue amount is set on the Gluing Part 2 and Gluing Part 4 screens.

: Side glue will be applied. If you select


Gluing Screen Part 3.

, set the glue amount using the

: Side glue will not be applied.

Gluing Screen Part 2

P. 2

(Available when selecting

on Gluing Screen Part 1)

1
2
3

Adjust the spine glue thickness in increments of 0.1mm (0.005). The adjustment
range is 0 to +4.0 mm (0.155).

Adjust the starting point to apply the spine glue. The adjustment range is -20.0 mm to
+20.0 mm (-0.785 to +0.785).

Adjust the end point for the spine glue. The adjustment range is -20.0 mm to +20.0
mm (-0.785 to +0.785).

16

2-1 Entering the Job Information Using the Setting Screens


9

Gluing Screen Part 3

P. 3

CAUTION

10

The side gluing roller distance should not


be used for adjustment of the side glue
amount. This adjust the side gluing roller to
correct position depending on the booklet
thickness.

Adjust the side gluing roller distance in increments of 0.1 mm (0.005). The input
range is -1.0 mm to +5.0 mm (-0.040 to +0.195).

Gluing Screen Part 4

P. 4

1
2
1

Adjust the wiper opening of application drum 1.


Press
once, and the opening increases by 0.1 mm (0.005). The glue will penetrate farther into the spine. The adjustment range is +0.1 to +2.0 mm (+0.005 to
+0.080).

Adjust the wiper opening of application drum 2.


Press
once, and the opening increases by 0.1 mm (0.005). More glue will be
applied to the spine. The adjustment range is +0.1 to +2.0 mm (+0.005 to +0.080).

CAUTION
The wiper opening adjustment should not
be used to adjust the spine glue thickness.
But when the opening is set 0.5 mm (0.02)
or less, glue may not be applied to the book
spine at all.

17

2-2 Bind the Books Using the Binding Screens


The Binding Screens can cover the following three functions:
Binding Screens
1

Main Binding Screen

Test Milling and Gluing Screen

Clamp and Milling Fine-Adjust Screen

P. 1

Glue Fine-Adjust Screen, Part 1

P. 2

Glue Fine-Adjust Screen, Part 2

P. 3

Glue Fine-Adjust Screen, Part 3

Nipping Fine-Adjust Screen

Scoring Fine-Adjust Screen

P. 1

Cover Sheet Fine-Adjust Screen, Part 1

P. 2

10 Cover Sheet Fine-Adjust Screen, Part 2

P. 3

11 Cover Sheet Fine-Adjust Screen, Part 3

P. 4

12 Cover Sheet Fine-Adjust Screen, Part 4

P. 5

13 Cover Sheet Fine-Adjust Screen, Part 5

Press the box and the Numeric Keypad


Screen appears. The value can be input
using the Numeric Keypad Screen.

18

2-2 Bind the Books Using the Binding Screens


1

Main Binding Screen

The current job information and the production conditions are displayed here.
30
1
2

10
Binding Counter

00000

Pre-set Counter

0000 0030

0
5

Binding Counter/Pre-set Counter. Press C to clear the counter. To change to the pre-set counter,
press the counter box and input the new pre-set number using the Numeric Keypad Screen. Press the
right part of the pre-set counter (

2
3

) and input 0 to return to the binding counter. See figure above.

This adjusts the production speed (carriage clamp moving speed) in five steps.
: Slow down

: Speed up

This indicates the book block thickness already entered on the Setting Screen.

This indicates the distance between the cover sheet edge and the spine already entered on the Setting
Screen.

When using a saved job, the job number appears here. When not using a saved job or the read memory
has been changed, 0 is indicated here.

6
7

This area displays the production conditions.


Press this button to lower the feed table.

Press this button to feed one cover sheet. The machine memorizes the cover sheet thickness in order to
detect the double feeding.

This button is used to stop the motor on each unit after the binding operation. (Before the motor drives,
start icon is indicated.) Press this button before switching the power off.

10

Status Monitor
: This symbol will appear when the cover sheet is fed to the nipping section, and the book block is
put in the carriage clamp.
:This symbol will appear if a cover sheet is not fed automatically to the nipping section. Feed a cover
sheet by pressing both start buttons.
Booklet is not delivered within 2 seconds after the carriage clamp has opened.
Double feeding

Misfeeding

In operation

No cover sheet on the feed table. Set the cover sheets.


###

OK

Delivery section full


Insert Book Block

Pre-set number of binding is finished.


Milling ON/OFF lever Error

Press start button to drive the motor.

Remove cover sheet on nipper.

Remove cover sheet at double feed detect sensor.

19

2-3 Test Milling and Gluing


2

Test Milling and Gluing Screen

The test milling and test gluing operations can be performed using this screen.

4
2

Test Milling Button. Press this button, and only the milling operation is performed and
the booklet is delivered from the delivery section. Use this function to check milling
depth.
Test Gluing Button. Press this button to perform milling and gluing operation. The
booklet stops above the nipping section with no cover sheet and stays there until the
start button is pressed. Wait until the glue hardens, and check the applied glue
amount. Press start buttons to deliver the booklet. Use this function to check the glue
amount on the booklet.

Test Binding Button. Press this button to perform a single binding with a cover sheet.
The machine does not feed the next cover sheet.

Condition Monitor. When


tions can be started.

This button is used to stop the motor on each unit after the binding operation. (Before
the motor drives, start icon is indicated.) Press this button before switching the power
off.

Press this button to feed one cover sheet. The machine memorizes the cover sheet
thickness in order to detect the double feeding.

appears here, the test milling or the test gluing opera-

Press this button to lower the feed table.

20

2-4 Fine Adjustment


3

Clamp, Milling Width Adjustment

Clamp and Milling Fine-Adjustment Screen

You can use this screen to make fine adjustments to the carriage clamp width and the
milling guide width.

1
2

Adjust the carriage clamp opening amount so that the book block is inserted
smoothly. Unless you make this adjustment, the carriage clamp opens just the same
amount as the book block thickness. Increase the opening to match the type of the
book block. The input range is 0 to +15.0 mm (+0.590).
: Makes the carriage clamp width wider. (Use this when using signatures.)
: Makes the carriage clamp width narrower. (Use this when using sheets which
crease or tear easily.)
Adjust the opening so that the book block can move into the carriage clamp easily
without being disturbed. After the adjustment, check that there is enough carriage
clamp pressure by pressing the Carriage Clamp Close button on the Single Operation
Screen.

Adjust the milling guide width. The input range is 0 to +10. 0 mm (+0.395).
This adjustment may be necessary when using signatures. (Signatures can cause the
spine of the book block to swell and hit the milling guide.)
: Make the milling guide wider.
: Make the milling guide narrower.
When using signatures, make the milling guide wider to give the spine a good finish.
However, if the guide is set too wide, the spine will be allowed to expand too much.

21

2-4 Fine Adjustment


4

P. 1

Glue Amount Adjustment

Glue Fine-Adjust Screen Part 1

This screen allows for fine adjustment of the spine glue.

1
2
3

This adjusts the spine glue thickness in increments of 0.1mm (0.005). The adjustment range is 0 to +4.0 mm (0.155).

This adjusts the starting point for the spine glue. The adjustment range is -20.0 mm to
+20.0 mm (-0.785 to +0.785).

This adjusts the end point for the spine glue. The adjustment range is -20.0 mm to
+20.0 mm (-0.785 to +0.785).

P. 2

Glue Fine-Adjust Screen Part 2

This adjusts the side gluing roller distance in increments of 0.1 mm (0.005). The
adjustment range is -1.0 mm to +5.0 mm (-0.040 to +0.195).

CAUTION
The side gluing roller distance should not
be used for adjustment of the side glue
amount. This adjust the side gluing roller to
correct position depending on the booklet
thickness.

22

2-4 Fine Adjustment


6

P. 3

Glue Amount Adjustment

Glue Fine-Adjust Screen Part 3

1
2

This adjusts the wiper opening for application drum 1.


Press
once, and the opening increases by 0.1 mm (0.005). More glue will penetrate into the spine of the book. The adjustment range is +0.1 to +2.0 mm (+0.005 to
+0.080).

This adjusts the wiper opening for application drum 2.


Press
once, and the opening increases by 0.1 mm (0.005). More glue will be
applied. The adjustment range is +0.1 to +2.0 mm (+0.005 to +0.080).

CAUTION
The wiper opening adjustment should not
be used to adjust the spine glue thickness.
But when the opening is set 0.5 mm (0.02)
or less, glue may not be applied to the book
spine at all.

23

2-4 Fine Adjustment


7

Nipping Operation Adjustment

Nipping Fine-Adjust Screen

This allows for adjustment of the nipping delay time, nipping time and nipper width.

1
2
3

Nipping delay time


: Increase the nipping delay time.
: Decrease the nipping delay time.
Normally set to 0. The adjustment range is 0 to 30.0 sec.
Nipping Delay Time:
The nipping delay time is the delay from the moment the book block is transported above the nipper until the nipping operation starts. If the glue squeezes out, set the nipping delay time longer
so that the glue will harden before the nipping operation. If the glue squeezes out even if the nipping delay time is increased, decrease the spine glue thickness.

When binding with cover sheet


Nipping operating time.
When binding a thick book block, make this longer.
When binding without cover sheet
The carriage clamp is returned after waiting above the nipper during the nipping operating time.(The glue on the spine hardens well, and then the booklet will be delivered.)
The adjustment range is 0 to 30.0 sec. with either binding mode.

: Increase the nipper width


: Decrease the nipper width
Usually, the squareness of the spine depends on the nipper height. If the spine quality
is poor even if the nipper height has been adjusted, adjust the nipper width. If the
spine is too round, make the nipper width narrower. If the spine is too sharp, make it
wider. The adjustment range is -0.5 to +1.0 mm (-0.020 to +0.040).

24

2-4 Fine Adjustment


8

Scoring Operation Adjustment

Scoring Fine-Adjust Screen

1
2

: The fixed scoring rollers move to the rear (far side).


: The fixed scoring rollers move to the front (operator side).
The adjustment range is - 1.0 mm to +1.0 mm (-0.040 to +0.040).

The fixed rollers actually do not move. If the fixed scoring roller position is
adjusted on the screen, the stack of cover sheets actually moves to compensate.

: The adjustable scoring rollers move to the rear (far side).


: The adjustable scoring rollers move to the front (operator side).
The adjustment range is -10.0 mm to +10.0 mm (-0.395 to +0.395).

Fixed Scoring Rollers


Adjustable Scoring Rollers

25

2-4 Fine Adjustment


9

P. 1

Cover Feed Position Adjustment

Cover Sheet Fine-Adjust Screen Part 1

This allows for fine adjustment of the nipper against the cover sheet.
Registration Position

Cover Sheet

2
3

Original Position
3mm (0.12")

4
Cover Sheet

3mm (0.12")

Press this button to move the nipper against the cover sheets.

Normally, step 2 through 4 cannot be performed because the jog guides are
not pressed against the cover sheet. Before doing the other adjustments
(step 2 through 4), press button 1 to bring the jog guides up against the
cover sheet. After the adjustments, press the button again to return the jog
guides to their original positions.

3
4

Press the
button to move the stack of sheets position to the right (cover feeder
side) by 0.2 mm (0.008). The input range is -3.0 mm to +3.0 mm (-0.110 to +0.110).
This changes the jog guide spacing by 0.1 mm (0.005). The input range is -10.0 mm
to + 10.0 mm (-0.395 to +0.395).
Press the
button to move the cover sheet position to the rear by 0.1 mm
(0.005). The input range is -10.0 mm to +10.0 mm (-0.395 to +0.395)

If you make this adjustment, make sure to adjust the position of the stack of
cover sheets by the same amount.

26

2-4 Fine Adjustment


10

P. 2

Cover Pile Position Adjustment

Cover Sheet Fine-Adjust Screen Part 2

This allows for fine adjustment of the cover sheet stack position.

: This increases the positioning guide spacing on the feed table.


: This decreases the positioning guide spacing on the feed table.
These can be set by 0.1 mm (0.005). The input range is -10.0 mm to +10.0 mm
(-0.395 to +0.395).

11

P. 3

Cover Sheet Fine-Adjust Screen Part 3


Transport Belt

Registration Stopper

This sets the pressure produced by the transport belts. After the cover sheets are fed
by the feed rotor, the transport belts feed the covers back to the registration stopper.
The pressure of the transport belt is adjustable in five steps. Normally, use a loose
setting when using thin sheets and use a tight setting when using thick sheets. The
standard setting is
.
This adjusts the vacuum to the feed rotor when feeding the stacked sheets. If doublefeeding occurs often, make the vacuum weaker. If mis-feeding occurs often, make the
vacuum stronger. The standard setting is
.

27

2-4 Fine Adjustment


-

12

P. 4

Cover Feed Function Adjustment

Cover Sheet Fine-Adjust Screen Part 4

1
2

This sets the light strength of the sensor using


Select

for normal use. If using thick or dark cover sheet, or if fault detection of

double feeding occurs, select


select

and

. Oppositely, if fault detection of mis-feeding occurs,

This sets the sensitivity of the double feeding detect sensor using
(middle), and

(high),

(low).

P. 5

Cover Sheet Fine-Adjust Screen Part 5


Cover Sheet
Sensor
Rear Registration

58mm

This sets the number of the window (hole) on the cover sheets.
The sensor which detects the window on the cover is located 58 mm rear side from
the rear registration position.
When not entering the number of the window, reposition the cover sheet and the book
block so that the window does not pass over the sensor.
Input range is 0 to 9.

28

2-5 Saving or Recalling Job Settings


The Memory Screen is used to save or recall job settings.

2
6

Milling Operation ON

Nipping with Milling

This area indicates the job settings saved for the selected job number. (In this example, the screen shows that job number 10 includes
: milling operation ON and
nipping with milling.)

This shows the status of each job number.


White ( 1 ): empty
Gray ( 5 ): saved job

This is the save button. Press this button to save the present settings to memory.
Select the job number, then press the save button. Press OK on the Write OK Screen,
and the present setting will be stored to the selected job number.

5
6

Black ( 10 ): now selected

This is the read out or recall button. Press the job number you want to read out, the
press this button. Press OK on the Read Out OK Screen and go back to the Binding
Screen. Press OK on the Changeover OK Screen, and all parts of the machine will
move to the set (read out) positions.
This is the Delete button. Select the job number to delete and press this button. The
selected memory will be deleted.
This is the Current Settings button. Press this button to indicate the current settings.

29

2-6 Using the Single Operation Screens


These screens are used to maintain the machine and to check the function of each section.
The Single Operation Screen can cover the following four functions:

Single Operation Screens

P. 1

Single Operation Screen Part 1

P. 2

Single Operation Screen Part 2

P. 3

Single Operation Screen Part 3

Home Positioning Screen

Milling Brake Release Screen

Single Operation Screen Part 1

P. 1

6
7

Press

This is the Application Drum button. Press


to lower the right side of the melt tank
when draining the glue. The tank returns to the original position when changeover is
performed.

3
4
5
6
7

to rotate the glue application drums.

Jammed Booklet Delivery Button. Press this button to open the clamp to release the
jammed booklet.
Carriage Clamp Close
Carriage Clamp Open
This triggers the booklet delivering motion: the level plate moves back and the carriage clamp opens.
This is the Carriage Clamp Move button. Press this button and then press the Start
buttons. The carriage clamp rail rises and the carriage clamp moves above the nipper. This button is used when setting the milling depth, or when replacing the carriage
clamp support plate.
Instruction for the next step to move the carriage clamp.
riage clamp is moving.

30

is shown while the car-

2-6 Using the Single Operation Screens


2

P. 2

Single Operation Screen Part 2


2

CAUTION
The upper adjustable scoring roller will not
move if it presses too tightly against the
lower adjustable scoring roller.

3
5

: The nipper moves up.


: The nipper moves down.

The nipper moves down and opens completely. This button is used when cleaning the
nipping section.

The lower adjustable scoring roller moves next to the fixed scoring rollers.
This button is used to bring the upper and lower adjustable scoring rollers together.

4
5

This moves the lower adjustable scoring roller to the set position.
: Opens the milling guide to the limit.
: Moves the milling guide to the set position.

P. 3

Single Operation Screen Part 3

1
2

: Press this button once, and the carriage clamp opens by 10 mm (0.395).
Use this button when the book block is caught on the carriage clamp.
:Press this button to reposition the delivery section after cleaning.
:The delivery section moves back. This button is used when cleaning the
delivery section.

31

2-6 Using the Single Operation Screens


4

Home Positioning Screen

Press the
button for the section which you want to send to the home position.
(There are conditions which could cause part of the machine to lose its home position.)

Milling Brake Release Screen

This is the brake release button for the milling motor. The milling motor can not be
released by pressing the brake release button on the machine until this button is
pressed. Use this button when replacing the milling cutter or the roughening cutter.

32

2-7 Information Screen


These screens are used to set some machine operating functions. And also you can access
the Information Screen which shows the ROM version and the total binding number from this
screen. When you call your local dealer to service the machine, our operator may ask the
ROM version or total binding number. In that case, refer to the Information Screen.

1
2
3

4
5
6

1
2
3
4

The control ROM version is indicated here.


The panel ROM version is indicated here.
The total binding number is indicated here.

: The feed table is lowered when double feeding is detected.


: The feed table is not lowered when double feeding is detected.

: When changing the binding mode, the milling operation is set automatically
depending on the selected binding mode.
: When changing the binding mode, the milling operation is set manually
by operator.

6
7

The full detection function is use/ is not use at delivery section.

: The jog guides are opened when the cover sheet is moved back to the registration stopper.
: The jog guides are closed when the cover sheet is moved back to the registration stopper.

33

2-8 Error Screen


1
3
2

1
2
3
4
5

The cover is open. Close the cover.


The emergency stop button is pressed. Turn the emergency stop button clockwise.
Light between area sensors is blocked. Remove the hand or object between sensors.
An error code may appear here. See Section 6 [Troubleshooting] on page 90.
This is the OK button. Use this to recover from an error condition. Press this button to
go back to the Binding Screen.

2-9 Numeric Keypad Screen

This screen is used to enter or input values. Input the value, then press ent (enter).
If you enter an improper value, the value will not be accepted, and an E will appear
on the screen.
Press

to return to the previous screen without entering a new value.

34

3. Starting the Binding Operation


3-1 Turn On the Power Switch
Turn on the power switch.

WARNING
The glue inside the tank melts 40 to 50 minutes

Do not touch the melt tank after the power is


turned on. The melt tank is heated to 200
degrees Celsius (400 Fahrenheit), and may
cause severe skin burns.
Also be careful of the melt tank cover.

after the power is turned on. Press


while
Warm-Up Screen is indicated. The Warm-Up
Screen disappears after the glue is melted completely, then the Changeover Confirmation
Screen appears.

Turn on the power switch.

PERFECT BINDER

Warm-Up Screen

CAUTION

Power Switch

When the warm up has completed, the glue temperature does not necessarily rise to the set
temperature, therefore it can be warm enough
for the application drum to rotate.

- Turn the power switch to the right.


- After the Initial Screen appears, the Warm-Up
Screen appears.

3-2 Safety Function Check


The BQ-270 includes safety functions which protect the
user from dangerous situations. Check these safety
functions:

Area Sensor
Emergency
Stop Button

- Emergency stop button

Left Safety Cover


Right Safety Cover

- Right safety cover


- Left safety cover
- Lower nipper door
All of these must work properly. Operate the cover, or
press the button, and check the error icons on the Error
Screen. If the Error Screen appears, the safety function
is working properly. If the Error Screen does not
appear, there is a problem with the safety circuit. Stop
using the machine and call your local dealer.

Lower Nipper Door

35

3-3 Enter the Job Information Using the Setting Screens


This section explains the steps necessary to input the
job information.

Decide whether the machine


should home all parts on every
changeover, and the starting mode.

Select the binding type.


- Select the binding type on the Binding Mode
Screen.
: Binding with cover sheets

: Binding without cover sheets

- Turn the home positioning feature ON or OFF


on the Start Mode Screen.
: Reset the guides to the home
position on every changeover.
: Reset the guides to the home
position on the first changeover.
The guide moves directly to the set
position from the second changeover.

- If you select binding without cover sheets, the


side glue rollers should be moved out of the
working positions. Refer to page 44. The side
glue roller on the operator side is controlled by
the computer. The side glue roller on the far
side must be set manually.

- Select the operation starting mode on the


Start Mode Screen.
: Binding operation starts with start
buttons.

- If you select binding without cover sheets, the


support plate and the shims (1 mm) should be
installed. (Refer to page 59 to install the shim.)
If the support plate is not installed, the bound
book will fall on the stacker and separate.

: Binding operation starts when the


time which has been set on the box
passes after the book block is
inserted into the carriage clamp.
When selecting, input the start
waiting time.

Input the book block size.


- Input the book block size using the Book
Block Size Screen. Refer to page 12.

36

3-3 Enter the Job Information Using the Setting Screen


Select the spine gluing and side
gluing settings.

Input the milling and nipping settings.

- Input the spine glue and side glue settings


using the Glue Screen. Refer to page 16.

- Select the type of milling and nipping using


the Milling, Nipping Screen. Refer to page 15.

- If you are using spine glue or the side glue,


adjust the glue amount using Part 2, 3 and 4
of the Gluing Screen. Refer to pages 16 and
17. (The glue amounts can also be adjusted
using the Fine-adjust Screens.)

- To select milling OFF, select


. Also
check that the milling ON/OFF lever is set to
the left (OFF).

Input the cover sheet size.

- To select milling OFF, select


. Also
check that the milling ON/OFF lever is set to
the right (ON).

- Input the cover sheet length and width, and


the distance between the cover edge and the
spine. Refer to page 13.

- When using saved job information, go to


page 49.

Milling Select Lever

Turn the double feeding detect


function ON or OFF.
- Turn the double feeding detect function ON or
OFF using the Function Screen. Refer to page
14.

Without Milling

37

With Milling

PERFECT

3-3 Enter the Job Information Using the Setting Screen


Select the Binding Screen.

Message Screens shown while changeover

- Changeover OK Screen appears.

This screen appears when there is a cover sheet


left on the nipper while changeover. Remove the

Press OK to start the changeover.

cover sheet and press OK. If


is pressed, the
changeover is canceled and the previous screen
appears.

- Press
, and the changeover is canceled
and the previous screen appears.
- While the changeover, Changeover Screen
appears.

This screen appears when there is a book block left


in the clamp while changeover. Remove the book
block and press OK. If
is pressed, the
changeover is canceled and the previous screen
appears.

This screen appears when there is a cover sheet


left on the cover table while changeover. Remove
the cover sheet and press OK. If
is pressed,
the changeover is canceled and the previous
screen appears.

38

3-3 Enter the Job Information Using the Setting Screen

This screen appears when there is a cover sheet


left on the nipper and the cover table while
changeover. Remove the cover sheet and press

This screen appears when milling function ON/OFF


is changed. If the level plate height is set correctly,
press OK. If the level plate height is not set cor-

OK. If
is pressed, the changeover is canceled and the previous screen appears.

rectly, press
to move the clamp and set the
level plate height correctly referring to page 59, then
press OK. If
is pressed, the changeover is
canceled and the previous screen appears.

These screens appear when the binding mode


which is set on the screen and the milling lever setting does not match. Refer to page 37 to set the
milling lever correctly and press OK. If
is
pressed, the changeover is canceled and the previous screen appears.

39

3-4 Setting the Main Binding Screen


This section explains the steps necessary to set the
production speed and the counter function.

When using the cover sheet with


window or hole, enter the number
of the window (hole) using Cover
Sheet Fine-adjust Screen Part5.

Go to the Main Binding Screen.

Binding counter
This area can display both the
binding counter and the pre-set counter.

- There is a sensor which detects the window


(hole) at 58 mm rear side from the rear registrating position.

When using the pre-set counter,


press
.

- Enter the number of the window (hole) or


reposition covers and book block so that the
window (hole) on the cover does not pass
over the sensor.

- The Numeric Keypad Screen appears. Input


the pre-set number and press ent.
- Press the right part of
to change
the pre-set number using the Numeric Keypad
Screen.

sensor

Window

When the machine reaches the pre-set


number of bindings, it will stop feeding
the next cover sheets. This prevents the
machine from scoring additional cover
sheets once it reaches the pre-set number.

58mm

Cover Sheet

The settings on this screen are now complete.


Go to the [Scoring Roller Setting] on next page.

Select the production speed.


- The production speed can be selected from
five steps.
- When binding thick book blocks, use a slower
setting.

If you are binding a thick book block


and the production speed is set too
fast, the milling can not be completed
properly. On the other hand, if the production speed is set too slow, the side
glue will dry and the binding quality will
deteriorate.

40

3-5 Setting the Scoring Rollers


Adjust the gap between the upper and lower scoring
rollers by turning the scoring roller pressure knob.

Binding without Scoring

Binding with Scoring

Press the
(standard) button
for the scoring roller on the Single
Operation Screen Part 2.

Open the left safety cover.

- The lower adjustable scoring roller moves


next to the fixed scoring rollers.

Loosen the scoring roller pressure


knob.
- Turn the knob counterclockwise until the
upper adjustable scoring roller is free.

CAUTION
If the safety cover is opened while the scoring roller is moving, the scoring roller will
stop at the wrong position. Check that the
scoring roller has finished moving before
opening the cover.

Adjustable Scoring
Roller

Scoring Roller
Pressure Knob

Open the right safety cover.

Upper Adjustable
Scoring Roller

Fixed
Roller

Move the upper adjustable scoring


roller by hand until it touches the
fixed scoring roller.

Lower Adjustable
Scoring Roller

- The upper scoring roller should be set above


the lower scoring roller.

41

3-5 Setting the Scoring Rollers

- Turn the knob clockwise to lower the upper


scoring roller.

Press the
(Setting Position)
button on the Single Operation
Screen.

- To reach the standard setting, turn the knob


one rotation counterclockwise from the stop.

- The adjustable scoring rollers move to the setting positions.

Lower the upper scoring roller.

Adjust so that there is a small gap


between the upper and lower adjustable
scoring rollers. You should be able to
move the upper adjustable roller a bit
with your finger.

Upper Adjustable Scoring Roller


Standard Gap

Lower Adjustable Scoring Roller

CAUTION
If the scoring pressure is so strong so
that the scoring roller does not rotate,
the machine may be damaged when
performing a changeover. Before each
changeover, check with your finger to
ensure that the scoring rollers rotate
smoothly.

Close the right safety cover.

42

3-6 Setting the Scraper (For Padding Only)


Set the scraper manually if you select padding. The
scraper levels the glue even.

[How to adjust]
- Loosen the lock screw using the wrench, and
move the scraper holding the lever.

CAUTION

- First begin at the lower position. Raise it gradually.

- The set position differs depending on


the spine glue thickness set on the

- Tighten the lock screw after adjustment.

screen. Select
(Manual) on the
Gluing Screen Part 1, and raise the
scraper gradually checking the glue
scraping condition. Do not raise the
scraper too much, otherwise the
scraper hits the booklet and be damaged.
- Scraper is very hot. Wear thick gloves
when setting the scraper.

If the spine glue thickness is set to


1.2mm, and when the scraper hits the
stopper, glue will be actually left a little
on the spine after scraping. (It differs
depending on each machine or other
settings.)

Set the desired glue thickness on


the Gluing Screen Part 2.
Gluing Screen Part 2

Press
on the Gluing Screen
Part 2 and set the glue thickness to
1.0 mm.
Open the safety cover (right).

Find the lowest position where the


scraper can level the glue even by
repeating the test padding.

Perform the binding operation.

CAUTION
- When performing the binding with
cover sheets, make sure to reposition
the scraper at lowest position. Otherwise, the scraper hits the booklet and
be damaged.
- If the glue is burned, the scraper can
not be smoothly adjusted. Make sure to
wipe off the extra glue on the scraper
after the operation, so that it can be
adjusted in anytime.

Scraper

Lever
Lock Screw

Stopper

43

3-7 Setting the Side Glue Rollers


When binding without covers

When you change the binding type, (binding with covers or


binding without cover on the Binding Mode Screen, the
screen with the message reminding you to set or release
the side glue rollers will appear. Set or dislocate the side
guide rollers according to the binding type.

The screen will tell you to dislocate the side glue roller
on the far side.

When binding with covers


The screen will tell you to set the side glue roller on the
far side.

Before dislocating the roller, make sure to


memorize the original setting position.

Turn off the power switch and open


the left safety cover.

Turn off the power switch and open


the left safety cover.

CAUTION
CAUTION

Wear thick gloves during this operation. The melt tank may be heated to
200 degrees Celsius (400 Fahrenheit)
and may cause severe skin burns.

Wear thick gloves during this operation. The melt tank may be heated to
200 degrees Celsius (400 Fahrenheit)
and may cause severe skin burns.

To adjust the side gluing roller on


the far side, loosen the locking
screw on the positioning plate and
turn the plate clockwise to the stop.

To adjust the side gluing roller on


the far side, loosen the locking
screw on the positioning plate and
turn the plate counterclockwise to
the memorized position.

Side Gluing Roller (far side)

Side Gluing Roller (far side)

Allen Wrench
Allen Wrench

0
0

Locking Screw
Positioning Plate

Locking Screw
Positioning Plate

Tighten the locking screw.

Tighten the locking screw.

- The pre-sets for the binding operation are


complete. Start the binding operation, referring to [Start Binding] on next page.

44

3-8 Start Binding


When 10 minutes has passed after the drum is
stopped, message to rotate the drum appears. Press
the

Press both start buttons to rotate


the milling cutter.

button on the Single Operation Screen Part

1 to check that the glue is heated to the setting temperature and melted completely.

- The drum motor starts turning.

WARNING
- Do not put your hand inside the machine
when the carriage clamp is operating. This
part can cause severe personal injury.
- When feeding a book block, remove your
hand from the carriage clamp before it
moves. This part can cause severe personal injury.

Insert a book block in the carriage


clamp and push it to the right.

Binding Operation Flow


Start the binding operation.
Insert book block
inside the carriage clamp.

- Press both Start buttons.

If the milling operation


is turned ON, the book
spine is milled here.

Glue is applied to the


book block by the melt
tank.

The nipping section presses


the book spine and the
cover sheet.

After the carriage clamp


comes back above the
level plate, the booklet is
delivered to the delivery
section and stacked.

45

3-8 Start Binding


Stop Binding
Press the
(Stop) button on
the Binding Screen.
- The machine stops.
- If a cover sheet has been fed, open the right
safety cover and remove the cover, and clear
the error. Prepare for the next job.

46

3-9 Adding More Cover Sheets


As the stack of cover sheets is reduced during the job,
add more cover sheets.

Move the end guide against the


right edge of the stack.

Press the Stop button on the Binding Screen.


Press both Start buttons.

- The machine stops and the feed table lowers.

- The milling cutter rotates, and the feed table


rises.

Restart the binding operation.

Move the end guide to the right.


End Guide

Feed Table

Stack more cover sheets on the


feed table.
- Separate the cover sheets well before stacking. If the cover sheets are not separated, this
can cause double feeding, or the cover sheets
may be partially fed.
- If it is difficult to stack the cover sheets,
remove the end guide on the right.
- Place the sheets in the correct orientation.

47

3-10 Removing the Bound Booklets


Remove the booklet before the stacker is full.

How to use the delivery chute

WARNING
Press the Emergency Stop button before
removing the booklets. If you do not do
this, the machine may start suddenly and
cause severe personal injury.

-Use the chute when the book spine is


scratched or bound book size is very large
or small.
-Hook the chute on the delivery section.
-Place a suitable box at the exit to receive
the delivered book without scratch or stain.

Pull the stopper to the front.

How to install the delivery chute


1.Move the stopper back.
Remove the stacked booklets.

Stopper
Stopper

2.Hook the chute.


-Hook the chute on the three square holes of
the delivery guide.

Push the stopper to the rear.

Delivery Guide

Delivery Chute

48

3-11 Saving, Recalling, Deleting the Job Information


The BQ-270 has a memory function which can save
and recall the job information. This section explains the
procedures necessary to write and read out the job
information using the Memory Screen.

Saving the Job Information


Select the Memory Screen.

Press the

button.

- The selected job number turns black and the


Write OK Screen appears.

Select the job number on which you


want to write the job information.

- When selecting the memory with saved job


(Gray), Replace OK Screen appears.

- White ( 1 ): Empty
- Gray ( 5 ): Saved job
- Black ( 10 ): Now selected

Press

OK

- The present settings are saved in the selected


job number.

49

3-11 Saving, Recalling, Deleting the Job Information


Recalling the Job Information

Recall the job information.


- Press the

Select the Memory Screen.

(Read Out) button.

- The Read Out OK Screen appears.

Press OK.

Press the button for the job number


you want to recall. Refer to page
29.

- The Memory Screen appears.

- Each job number which is gray already has


saved information.
- Press the job number, and the saved job information will be shown in the left part of the
screen.

Select the Binding Screen if you


want the machine to start the
changeover right now.
- The Changeover OK Screen appears.

- Press OK, and the machine performs the


changeover and the Binding Screen appears.
The recall of the job information is now complete.

50

3-11 Saving, Recalling, Deleting the Job Information


Deleting the Job Information
Select the Memory Screen.

Press the button for the job number


you want to delete.
- Number with gray scale has saved job.

Press

(delete).

- Selected memory number turns black and the


Delete OK Screen appears.

Press OK.
- Selected memory will be deleted.

51

3-12 Adding More Glue


This section explains how to refill the glue in the melt
tank.
The lower limit of the glue level is 8 mm (0.31) lower
position below the upper limit line.
Do not run the machine in the condition that the glue
level is under the lower limit line.
.

WARNING

CAUTION

Do not touch the melt tank after the power


is turned on. The melt tank is heated to 200
degrees Celsius (400 Fahrenheit) and may
cause severe skin burn.

The glue level lowers while the application


roller is rotating. Check the glue amount
when the application roller stops.

Open the left safety cover.

Close the left safety cover.

Add glue into the melt tank.


- Add glue when the glue level come to the
lower edge of the glue level plate. If the glue
level comes lower than the plate, it may damage the gluing mechanism.
- Be careful that the glue level will not go over
the upper limit line when the glue is melted.
This will cause the glue to overflow.

Glue Level Upper Limit

Glue Feed Section

Use type HM220 glue, made by Horizon.

52

3-13 Finishing the Binding Operation


Turn off the power switch

Press the
(Stop) button on
the Binding Screen.

Turn off the power switch.


- Turn the switch to left to turn off the power.

PERFECT BINDER

Power Switch

When the power is turned on the next time, the


machine will recall the information from the previous job.

-If the starting time for the melt tank


heating is set beforehand using the
weekly timer (option), the binding operation can be started without waiting for
the glue to be melted.
- When using the optional weekly timer,
leave the power switch of the BQ-270
turned ON. Refer to page 97 for operation.

53

54

4. Adjustments
4-1 Changing the Spine Glue Amount and Position
If too much or too little spine glue is applied, you can
adjust the amount of spine glue and the starting and
ending position.

Adjust the spine glue amount and


the starting/ending positions using
the Gluing Screen Part 1 and Gluing Screen Part 3. Refer to pages
22 and 23.
Gluing Screen Part 3

Gluing Screen Part 1

4-2 Adjusting the Side Glue Amount


If too much or too little side glue is applied, adjust the
distance between the side glue rollers to adjust the side
glue amount.

Adjust the distance between the


side glue rollers using the Gluing
Screen Part 2. Refer to page 22.
CAUTION
In case the nipper position is too
high for the spine glue amount, the
spine glue may comes aside and
increase the side glue amount.

Gluing Screen Part 2

55

4-3 Changing the Nipping Setting


If the spine quality is poor, adjust the nipping delay
time, nipping time and the nipper width.

Adjust the nipping delay time, nipping time and the nipper width
using the Nipping Screen. Refer to
page 24.
Nipping Delay Time

Nipper Width

Nipping Time

- If the spine sharpness does not improve, refer


to [Nipper Height Adjustment] on page 64.

56

4-4 Changing the Cover Feeding Settings


If the cover sheet is out of position on the book block or
is not fed correctly, change the cover feeding settings.
Transport Belts

Adjust the cover registration positions (left/right, and front/rear) and


the side guide width using the Cover
Sheet Screen Part 1. Refer to page
26.
Cover Sheet

Registration Stopper

Registration Button

Adjust the cover sheet stack position to match the settings made in
step 1.

Feed Rotor

- Increase or decrease the values to match the


settings made in step 1.
- Adjust the cover sheet stack position and the
positioning guide width using the Cover Sheet
Screen Part 2. Refer to page 27.

Vacuum
Cover Sheet

When mis-detecting the double


feeding or mis-feeding, adjust the
light strength or the detecting sensitivity.
- Adjust the light project amount and the
detecting sensitivity using the Cover Sheet
Screen Part 4. Refer to page 28.

Guide Width

If any of the problems listed below


occurs, adjust the vacuum to the
feed rotor and the pressure of the
transport belts.
- After feeding, the cover sheets are wrinkled.
- The cover sheets double-feed or misfeed.
- The feeding actiton is not stable.
- Adjust the vacuum to the feed rotor and the
pressure of the transport rollers using the
Cover Sheet Screen Part 3. Refer to page 27.

1
2

57

4-5 Changing the Scoring Position


If the scoring line is out of position, adjust the scoring
position.

Adjust the position of the fixed and


adjustable scoring rollers using the
Scoring Screen. Refer to page 25.

Fixed Scoring Rollers

- A cover sheet which has already been fed can


not be used. Remove the cover sheet and
feed a new one.

Adjustable Scoring Rollers

Fixed Side
Adjustable Side

4-6 Changing the Carriage Clamp Opening and Milling Guide Width
If the book block escapes when the machine is performing a milling or nipping operation, decrease the
opening of the carriage clamp.
If the book block moves when it hits the milling guide,
increase the milling guide width.

Adjust the opening of the carriage


clamp or the milling guide width
using the Carriage Clamp/Milling
Fine-Adjustment Screen. Refer to
page 21.
- When using sheets which can bent easily, do
not open the carriage clamp too far.

58

4-7 Milling Depth Adjustment


The milling depth changes depending on the shims
under the level plate.
The milling depth is set to 2 mm when the machine is
shipped. When binding a thick book block, or if the milling is overloaded, adjust the milling depth to 1.5mm
(0.06) or 1mm (0.04).

Press the Carriage Clamp Move


button on the Single Operation
Screen.

Press the Start buttons twice with


both hands.
- Press the start button once and the carriage
clamp closes and the clamp rail raises. Press
it again and the carriage clamp moves to the
right and the level plate appears.

Press the Emergency Stop button.


- The touch screen presents the Error Screen.
Emergency Stop Button

59

4-7 Milling Depth Adjustment


Change the number of shims.

There are three kinds of shims. Use just


one shim or two shims together. Do not
use three shims together. Othewise the
level plate height becomes too high and
the booklet detect sensor can not detect
the booklet correctly.

- Increase or decrease the number of shims on


each side equally to adjust the level plate
height.
- The level plate can be pushed up by pushing
the pin on the bottom.
Shim

- Insert each shim completely.

Level Plate
Shim

The level plate and book block are raised


by the increased shim thickness, and the
milling depth decreases by the same
amount. The less the milling depth, the less
the load on the milling mechanism.

Turn the Emergency Stop button


clockwise to release.

- The Single Operation Screen appears.

Press the Carriage Clamp Move


button on the Single Operation
Screen.

- There are three thicknesses of shims: 1, 1.5


and 2 mm (0.04, 0.06, and 0.08). You can
add shims together to increase the thickness.
Total Shim
Thickness (mm)

Milling Depth (mm)

3 mm (0.12)

Press the Start buttons twice.

2 mm (0.08)

1.5

1.5 mm (0.06)

1 mm (0.04)

- Press the start button once and the carriage


clamp returns to the left side. Press it again
and the clamp rail lower and the carriage
clamp opens.

1 and 1.5

0.5 mm (0.02)

1 and 2

60

4-8 Glue Temperature Adjustment


The glue will perform best if is heated to the correct
temperature. Adjust the glue temperature according to
the type of glue which is being used.

Adjust the glue temperature using


the glue temperature adjusting
knob.

Thermometer

The best temperature for HM-220 Hot


Melt glue made by Horizon is 170
degrees Celsius (350 Fahrenheit).

Application Drums

CAUTION

Measure the glue temperature when the


application drum are rotating.
If there are not enough glue, the measured
temperature tends to become low. Fill the
glue so that the thermometer soaks into
the glue by 40 mm (1.57).

Adjust the glue temperature under


180 degrees Celsius. Otherwise the
glue alteration accelerates, and the
glue does not apply on the application drums.

PERFECT BINDER

BQ-270

120 140 C
160
180

- Use the temperature scale shown


above just for reference. The glue temperature changes depending on the
room temperature.
- Use a thermometer in the melt tank to
make an accurate check of the glue
temperature.

61

4-9 Side Glue Amount Adjustment (Far Side)


If the side glue is not applied on the far side even there
is glue on the side gluing roller, you should adjust the
position of the side gluing roller on the far side.

CAUTION
Wear thick gloves during this operation.
The melt tank may be heated to 200
degrees Celsius (400 Fahrenheit) and may
cause severe skin burns.

Turn off the power and open the left


safety cover.

Loosen the locking screw of the


positioning plate and turn the plate
counterclockwise.
- Insert an Allen wrench into the hole on the
plate and rotate the plate.
- The side gluing roller on the far side will move
out.

Side Gluing Roller (far side)

Allen Wrench

Locking Screw
Positioning Plate

- After adjustment, tighten the locking screw.


If there is still not enough glue on the side gluing roller,
adjust the glue amount on the side gluing roller. See
the instructions which follow.

62

4-9 Side Glue Amount Adjustment (Far Side)


Lock the mounting screws on the
glue amount adjusting plate and
close the left safety cover.

WARNING
Wear thick gloves during this operation.
The glue amount adjusting plate is very
hot, and may cause severe skin burns.

Loosen the two mounting screws


on the glue amount adjusting plate.
- The illustration below shows the glue amount
adjust plate on the far side.
Mounting Screws

Glue Amount Adjusting Plate

Adjust the position of the glue


amount adjusting plate.
- Move the glue amount adjust plate left or right
to adjust the glue amount on the application
roller.

- Move the plate to the left to increase


the glue amount.
- See the inside of the application roller
(shown in the illustration below) to
adjust the glue amount.
Mounting Screws

The gap here controls the


amount of glue applied.

63

4-10 Nipper Height Adjustment


If the booklet spine is too sharp, or too round, or some
bubbles are caught in the spine glue, adjust the nipper
height.

- If the spine is round, turn the ring counterclockwise. If the spine is too sharp, turn
the ring clockwise.
- Usually the ring is set between 3 and 6.
- The ring is set to 4.5 at the factory.

Turn off the power switch and open


the lower nipper door.

Adjust the nipper height.


- Insert the adjusting pin into the nipper height
adjusting ring so you can turn the ring.

The nipper is too lowturn the ring to the right.

- Turn the ring counterclockwise (decrease the


number) to raise the nipper, or turn it clockwise (increase the number) to lower the nipper.

-If there are bubbles on the spine, raise the


nipper height, or increase the spine glue
amount.

- The height changes by 0.2 mm (0.01) for


each step on the scale.
Nipper Height Adjusting Ring

The nipper is too highturn the ring to the left.

Higher (Spine
becomes
sharp)

(Spine
becomes
round) Lower

Adjusting Pin

64

4-11 Nipper Angle Adjustment


If the sharpness of the spine is incorrect (too sharp, or
too round) on either side of the spine, adjust the nipper
angle on both sides.

Lock the adjusting block and close


the lower nipper door.

Turn off the power switch and open


the lower nipper door.

Test the binding.


- Check that the spine sharpness is the same
on both sides of the spine.
- When using signatures, the corners may
become sharper.

Loosen the locking screw on the


nipper angle adjusting block.
- Refer to the illustration below.

Nipper Angle Adjusting Block

Nipper

Locking Screw

Rotate the nipper angle adjusting


block left or right to adjust the nipper angle.
- When you turn the nipper angle adjust block
to the right, the left side (melt tank side) of the
nipper lowers and the left (melt tank side) side
of the spine becomes more round.

65

4-12 Cover Sheet Angle Adjustment


When the cover sheet is out of position, adjust the
angle of the registration stopper.
Check that the cover sheets are cut correctly before
doing this adjustment. If the cover sheets for the current
job are not square, make a temporary adjustment to finish the job. Remember to reset the angle adjustment
when the job is finished.

Adjust the angle of the cover sheet.


- Turn the adjust knob clockwise, and the cover
sheet will rotate to the left.
- To move the lever to the left, push the lever to
the adjust knob and turn the adjust knob
counterclockwise.

Open the lower nipper door.

Loosen the locking nut on the angle


adjusting lever.

Loosen the locking knob.


- Loosen the locking knob on the registration
stopper angle adjusting lever.

Adjust Knob

Registration
Stopper Angle
Adjusting Lever

Cover

Tighten the locking knob and the


locking nut, then close the lower
nipper door.
Locking Nut

Locking Knob

Registration Stopper
Angle Adjusting Lever

66

4-13 Blower Air Adjustment


The blower air is used to separate the cover sheets
when they are fed. When the blower air is too weak or
too strong, double feeding or mis-feeding can occur. If
necessary, adjust the amount of blower air.
Blower Air Adjusting Lever

Adjust the air pressure.


- Pull out on the blower air adjusting lever to
reduce the blower air. Press the lever in to
increase the blower air.

Strong

- If the blower air flow is too weak, the cover


sheets will not be separated. If the blower air
is too strong, the cover sheets will flap.

Weak

4-14 Double Feed Stop Pad Height Adjustment


If there is frequent double feeding or mis-feeding
although the blower air is set properly, adjust the height
of the double feed stop pad.

Feed a cover sheet by pressing the


Start buttons. Check that there is
no double feeding.

Adjust the pad height.

If double feeding still occurs:

- Lower the pad height adjusting lever to raise


the pad. As the pad is raised, the gap
between the feed rotor and the pad is reduced
to help prevent double feeding.

- Check that the cover sheets are not stuck to


each other.
- Fan or separate the cover sheets before
loading them.
- Raise the pad a little more.
- Lower the feed table height. Refer to [Feed
Table Height Adjustment] on page 68.

Pad Height
Adjusting Lever

- If the pad is raised too high, the


machine will not feed at all.
- If there are frequent mis-feeds, reduce
the blower air.

Double Feed Stop Pad

67

4-15 Feed Table Height Adjustment


When using thin sheets, set the table height a little
lower. When using thick sheets, set it a little higher than
the center position. Aiso adjust the table height if there
is frequent double-feeding or mis-feeding.

Adjust the height as you check the


scale.

Loosen the feed table height locking knob.

- Read the scale at the center of the screw.


- After the adjustment, lock the screw.

- When using thin sheets, set the table


height just above the point where the
table will not feed at all.
- If there is frequent double feeding, the
vacuum may be too strong. In this case,
reduce the vacuum or lower the feed
table. If there are frequent mis-feeds,
raise the feed table.

Feed Table Height


Locking Knob

Feed Table Height


Locking Knob

Feed Table

4-16 Scoring Roller Pressure Adjustment


If a cover sheet is cut by the scoring roller, or no scoring line is produced, adjust the scoring roller pressure.
Scoring Roller
Pressure Knob

Open the right safety cover.

Adjust the scoring roller pressure.


Adjustable Scoring Roller

- Turn the scoring roller pressure knob counterclockwise to make the scoring line more shallow. Turn it clockwise to make the scoring line
deeper.
- To get the standard settings, turn the knob
one rotation counterclockwise from the stop.

CAUTION
If the scoring pressure is so strong that the
scoring rollers do not turn, the machine
may be damaged during the changeover.
Before each changeover, check that the
scoring rollers rotate smoothly by turning
them by hand.

68

5. Maintenance
5-1 Cleaning the Book Block Path
Press the
button (Carriage
Clamp Move) on the Single Operation Screen Part 1.

WARNING
Do not touch the melt tank. The melt tank is
heated to 200 degrees Celsius (400 Fahrenheit), and may cause severe skin burns.
Do not touch the milling and the roughening cutters. These can cause severe personal injury.

- Press both Start buttons twice. The carriage


clamp closes by first press and clamp rail
raises. Then the carriage clamp will move to
the right and stop by second press.

Open the left safety cover.

Clean the milling section.


Press the Emergency Stop button
and clean the level plate mechanism.

- If there are paper chips, remove them using a


vacuum cleaner.
- If the cutter cover does not return quickly to
the original position when sliding it to the right
and releasing, there are paper chips under the
cover links. Remove the paper chips. If the
cutter cover does not move smoothly, paper
chips may be scattered heavily.

- If there are paper chip, remove them using a


vacuum cleaner.

Turn the Emergency Stop button


clockwise to release.

Vacuum Cleaner

Press the
button (Carriage
Clamp Move) on the Single Operation Screen Part 1.
- Press both Start buttons twice. The carriage
clamp will move back to the left side by first
press. Then the clamp rail lowers by second
press and carriage clamp opens.

Cover Links
Cutter Cover

Close the left safety cover.

69

5-1 Cleaning the Book Block Path


Clean the delivery area.

Press the
button (Nipper
Cleaning) on the Single Operation
Screen Part 2 while the safety
cover is closed.

- Pull the stopper to the front.

- The nipper will open to make cleaning easier.

WARNING
Turn off the power switch before cleaning
this area. The machine may start suddenly,
causing severe personal injury.

Open the safety cover and Clean


the nipper.
- Remove any glue.

Stopper

- Apply a little silicon spray to the nipper, so that


the glue will not stick to the nipper.

Wipe away any glue or dust on the


delivery section.

Press the
button (Nipper
Cleaning) again.
- The nipper will return the previous position.

70

5-2 Cleaning the Sensors


Frequency Symbol

Cleaning Tool Symbol

The number in front of


the letter indicates the

= Cotton Swab

multiple number.
1d = Every Day
1w = Once every week Example:
2w = Once every 2 weeks
1m = Once every month
= Once every 6 months
6m
1y = Once every year

Choose the tool


according to where
you are cleaning

= Brush
= Air
(Horizon Air Duster)

(One day = 4 hours use)

There are four kinds of sensors which need cleaning.


1m

1m

Cover Sheet
Detect Sensor
on Feed Table

1m

Compressed
Air

Book Block Detect Sensors

Cover Sheet Detect


Sensor on Nipper

1m

Double Feed
Detect Sensor
PERFECT BINDER

BQ-270

If the carriage clamp is in the way,


press
or
on the Single Operation Screen.

71

5-3 Lubrication
Frequency Symbol

Lubrication Symbols
= Lubricate using a lubrication brush
= Lubricate using an oil applicator
= Lubricate using a grease gun

The number in front of


the letter indicates the
multiple number.

1d
1w = Once every week Example:
2w = Once every 2 weeks
1m = Once every month
= Once every 6 months
6m
1y = Once every year
= Every Day

(One day = 4 hours use)

There are four mechanisms which need to be lubricated.


3m

1m

20 drops

Grease Nipples

3m

1m

CAUTION
After applying grease, run the
application drums for at least 10
minutes before binding.

PERFECT BINDER

1m

BQ-270

Level Plate

The carriage clamp is in the way,


press
or
on the Single Operation Screen
to remove or return the clamp.
CAUTION
Use the lubrication grease recommended by Horizon. If the
ingredient of the grease changes, the life of the machine
may be shortened or the machine may be damaged.

72

5-4 Book Support Plate Replacement


If the book support plate hits the machine and is bent, it
must be replaced. Replace the book support plate by
following the procedure listed below.

Remove the side cover.


- Remove the two monting screws shown in the
illustration below.

Enter a block thickness of 50 mm


(2) on the Book Block Size Screen.

Side Cover

.
Carriage Clamp

Remove the book support plate.


- Insert your hand between the carriage clamp
and the frame and remove the four mounting
screws shown in the illustration below. Use
the supplied screwdriver.

Check that the other items for the


job have been entered.

Open the carriage clamp as far as


possible.
- Select the Binding Screen to do the
changeover.

Carriage Clamp

Book Support Plate

The book support plate is an option.

Press the Emergency Stop button.

Please purchase and replace.

73

5-4 Book Support Plate Replacement


Attach the new book support plate.

Attach the side cover.

Turn the Emergency Stop button


clockwise to release.

74

5-5 Milling Cutter Replacement


If the milling cutter does not cut the spine properly, the
glue will not be evenly applied to the book spine and
the spine quality will suffer. The milling cutter may be
worn, and may need to be replaced.

Enter a book block thickness of 20


mm (0.8) on the Book Block Size
Screen and perform the
changeover.

CAUTION
- When loosening the mounting screws of the
milling cutter, turn off the power switch. Otherwise, the machine may start suddenly and
cause severe personal injury.
- Wear thick gloves during this operation, and
do not touch the edges of the milling or
roughening cutters. Otherwise, the sharp cutters can cause severe personal injury.
- The melt tank is very hot for a while after the
power is turned off. Do not touch the tank.

The mounting screws on the milling


guide will be removed in a later step.

Turn off the power switch and


remove the milling section front
cover.
Press the
button (Brake
Release) on the Milling Brake
Release Screen.

- Remove the four mounting screws shown in


the illustration below.

Milling Section Front Cover

Remove the milling section safety


cover.
- Remove the four mounting screws shown in
the illustration below.

Open the left safety cover.

- Be careful not to drop the screws.


- After removing the covers, turn on the power
switch.
Milling Section Safety Cover

Press the brake release button on


the frame.
Brake
Release
Button

75

5-5 Milling Cutter Replacement


Remove the four mounting screws
on the milling cutter.

Remove the front milling guide.


- Turn the pulley shown in the illustration below
and slide out the front milling guide.

(1) Keep pressing the brake release button on


the machine and rotating milling cutter clockwise until a mounting screw of the milling cutter moves into the center of the 20 mm (0.8)
gap.

Front Milling Guide

(2) Turn off the power switch.


(3) Remove the mounting screw from the milling cutter using the supplied hexagon Allen
wrench. The screw will be very tight.
(4) Turn on the power switch.
(5) Repeat steps (1) to (4) to remove all four
mounting screws.
Guide Block

Milling Cutter
Mounting Screw

Pulley

Remove the milling cutter.


Loosened

CAUTION

Clockwise

Wear thick gloves during this operation. Do


not touch the edges of the milling or roughening cutters. Otherwise, the sharp cutters
can cause severe personal injury.

Replace the rear milling guide and


the upper knife.

Attach the new milling cutter.

- Check that the power is turned off, and


remove the two mounting screws on each
side shown in the illustration below. Remove
the rear milling guide and the upper knife.

- Wipe off the grease on the surface of the cutter before attaching it.
- Mount the new milling cutter and temporarily
tighten the four mounting screws.

Rear Milling Guide

Attach the front milling guide.


- Reverse the instructions listed above. Insert
the screws from the rear and turn the pulley
by hand.

Place the front milling guide in a position where the rear milling guide can be
attached.
Upper Knife

76

5-5 Milling Cutter Replacement


Attach the rear milling guide using
the two mounting screws.

CAUTION
In general, do not sharpen the top surface
of the milling cutter. This will reduce the
height of the milling cutter. If the milling
cutter is sharpened, insert a spacer
between the milling cutter and the milling
holder. This will raise the milling cutter as
shown in the illustration below. The roughening cutter should also be lowered. Make
a stack of sheets which has a thickness
equal to the amount removed from the milling cutter during sharpening. Insert this
stack between the roughening cutter and
the roughening cutter setting gauge.

Move the front milling guide 20 mm


from the rear milling guide.
- Turn the pulley by hand to leave a 20 mm
(0.8) opening.

Fasten the mounting screws on the


milling cutter as follows.
(1) Turn on the power switch.
(2) Keep pressing the brake release button on
the machine and rotating the milling cutter
clockwise until a mounting screw of the milling
cutter moves into the center of the 20 mm
(0.8) gap.

Roughening Cutter
Setting Gauge

Spacer

(3) Turn off the power switch.


(4) Tighten each mounting screw of the milling
cutter using the supplied hexagon Allen
wrench.

Milling Cutter

(5) Repeat steps (1) to (4) to install all four


mounting screws.

Milling Holder

Attach the milling section safety


cover.

Attach the upper knife using the


two mounting screws.
- Mount the upper knife temporarily.
- After mounting the upper knife temporarily,
check that there is 0.1 mm (0.004) gap
between the upper knife and the milling cutter
using the thickness gauge. (This is the thickness of one 64 gsm sheet.)

Attach the milling section front


cover.

Upper Knife
0.1 mm (0.04")

0.1 mm
(0.04")

Close the left safety cover and turn


on the power switch.

Milling Cutter

- Rotate the milling cutter counterclockwise


slowly to check that the milling cutter does not
hit the upper knife.

77

5-6 Roughening Cutter Replacement


If the roughening cutter does not cut the spine properly,
the glue will not be evenly applied on the book spine
and the spine quality will be reduced. The roughening
cutter may be worn. If it is worn, replace the roughening
cutter.

Press the
button (Brake
Release) on the Milling Brake
Release Screen.

WARNING
Turn off the power switch before performing this operation. A sudden start of the
machine can cause severe personal injury.
Wear thick gloves and do not touch the
edge of the milling or roughening cutter.
Otherwise, a sharp cutter can cause severe
personal injury.

Turn off the power switch and


remove the milling section front
cover.

Open the left safety cover.

- Remove the four mounting screws shown in


the illustration below.

Slide the milling section safety


cover to the right and hold it with
gummed tape.
- After holding the cover, turn on the power
switch.

Milling Section Front Cover

Set the book block thickness to 50


mm (1.97) on the Book Block Size
Screen and perform the
changeover.

Safety Cover

The roughening cutters will be removed


in a later step.

Cover

Gummed
Tape

Gummed
Tape

Cover
Safety Cover

78

5-6 Roughening Cutter Replacement


Remove the two roughening cutters.

(5) Loosen the mounting screw of the roughening cutter using a 2.5 mm (0.098) Allen
wrench.

(1) Press the brake release button on the


machine.

(6) Remove the roughening cutter.


(7) Turn on the power switch.

Brake
Release
Button

(8) Repeat steps (1) to (7) and remove the


other roughening cutter.

Mount the new roughening cutters


when the power is turned OFF.
(1) Mount each new roughening cutter so that
the top of the cutter is in line with the rotating
direction of the milling cutter.
(2) Keep pressing the brake release button on
the machine and rotate the milling cutter
clockwise until the roughening cutter you want
to remove comes to the right side of the opening (shown below).

Rotating Direction

Roughening Cutter

Roughening Cutter
(2) There are cutters on both sides of each
roughening cutter. One roughening cutter can
be used twice.

Clockwise

(3) Push down the edge of the roughening cutter using the roughening cutter setting gauge
and tighten the set screw.
Roughening Cutter

(3) Turn off the power switch.

Milling Cutter

(4) Press the roughening cutter down using a


thick cloth.

Roughening
Cutter Setting
Gauge
Spring

Roughening Cutter

Allen Wrench
Set Screw

Cloth
(4) Remove the roughening cutter setting
gauge.

Spring
Set
Screw

Close the left safety cover and turn


on the power switch.

Allen
Wrench

(There is a spring under the roughening cutter.


It will pop up when the set screw is loosened.)

79

5-6 Roughening Cutter Replacement


Check that the roughening cutter
does not hit the upper knife.
- Open the left safety cover, keep pressing the
brake release button on the machine and
rotate the milling cutter slowly counterclockwise.
- If the roughening cutter hits the upper knife,
reposition the upper knife referring to step 16
on page 77.

Reset the milling section safety


cover.

Attach the milling section front


cover.

80

5-7 Glue Replacement


If the glue becomes brown or sticky, the glue is getting
old. Replace the glue by following the procedure below.

Check that the glue is melted completely


before beginning this operation, and then
turn off the power switch. Drain the glue
quickly before it hardens.

Hook the drain guide on the attaching screws on the melt tank.

WARNING
The melt tank may be heated to 200
degrees Celsius (400 Fahrenheit), and may
cause severe skin burns. Wear tightlywoven cotton gloves when draining the
glue.

Attaching
Screws

Find a container for the drained


glue (capacity 4 liters or 1.25 gallons). Get the drain guide and a
cloth to wipe up the glue.
Drain Guide

Press the
button on the Single
Operation Screen Part 2 to lower
the melt tank.

- The attaching screws should already be


installed on the melt tank.

Turn off the power switch and open


the lower nipper lower.

Place the container for the drained


glue under the drain guide.

WARNING
For the box to catch the glue, use a
durable one against the heat. It is
dangerous when the box is broken
or cracks.

81

5-7 Glue Replacement


Remove the plug using the supplied long screwdriver. (There are
three mounting screws.)

After the glue is drained, attach the


plug.

- Remove lower two screws first.


- The glue will begin to drain.

Remove the drain guide.


WARNING
Be careful not to touch the melted
glue. Otherwise, it may cause the
severe skin burn.

Mounting
Screws

Leave the attaching screws in place.

Close the lower nipper lower.


Drain Guide

- Wipe off any glue on the plug immediately.

Turn on the power switch and add


new glue immediately.

Do not walk away from the machine


when draining the glue. Old glue is very
sticky and not all of it can be removed.
The small amount of old glue left over
will mix with the new glue.

Do not pick the glue in fine part of the


tank. Picked glue may be left inside the
tank and may not melt. It stucks
between the roller and the wiper and
causes the problems.

82

5-8 Double Feed Stop Pad Replacement


If double feeding occurs often, replace the double feed
stop pads. Double feeding can occur for several reasons. Refer to pages 67, 68 and 71.

Turn off the power switch.

Remove the two mounting screws


on the double feed stop pads.
- Now the pads can be removed.

Double Feed Stop Pads

Mounting Screws

Attach new pads.


- Check that the mounting screws fit completely
into the recesses in the pad assembly, then
push down in on the assembly and tighten the
screws.
- Attach each pad using the screws removed in
step 2.

83

5-9 Transport Belt Replacement


When the cover sheet position changes, replace the
transport belt. Perform this operation after tring all the
operation at the troubleshooting (Refer to page 87).

Open the safety cover(right).

Move the spare transport belt to the


former position.
- Do not pull the belt strongly when moving it
over the upper cover guide.

Cut the transport belt using a scissors.

Upper Cover Guide

Transport Belt
Transport Belt

Cut the tyton which fixes the spare


transport belt shown in the illustration below.

- Replace two transport belts together.

Spare Transport Belt

Nylon Tie

84

6. Troubleshooting
6-1 Problems with Booklet Quality
Gluing Problems
Problem

Cause

Remedy

See page

There are glue strings hanging from


the nipper unit.

Too much spine glue is


being applied.

Decrease the amount of spine


glue.

Page 22

There is a lump of glue on the nipper.

The spine glue is leaking


from the cover sheets.

Decrease the amount of spine


glue.

Page 22

Decrease the length of the


spine glue.

Page 22

The side glue is turned


OFF.

Turn the side glue ON.

Page 16

The side glue roller distance is too narrow.

Make the distance wider.

Page 22

The gap between the side


glue roller and the glue
amount adjusting plate is
too small.

Widen the gap.

Page 55

The spine glue is turned


OFF.

Turn the spine glue ON.

Page 16

The setting for spine glue


is too low.

Increase the spine glue


amount.

Page 22

The wiper opening is too


narrow.

Increase the wiper opening.

Page 23

The side glue roller distance is too wide.

Make the distance narrower.

Page 22

The nipper height is too


high, and the spilled glue
leaks to the side.

Reduce the nipper height.

Page 64

The gap between the side


glue roller and the glue
amount adjusting plate is
too wide.

Reduce the gap.

Page 55

The setting for spine glue


is too high.

Decrease the spine glue


amount.

Page 22

The wiper opening is too


wide.

Reduce the wiper opening.

Page 23

Glue is not melted.

Breaker of the heater is


tripped.

Check if the breaker is not


tripped. If the breaker trips
repeatedly, please call your
local dealer.

Page 94

The booklet is delivered before the


glue on the spine hardens when binding without cover sheet.

The waiting time above


the nipper is not set up.

Adjust the nipping operating


time.

Page 24

Not enough side glue is being


applied.

Not enough spine glue is being


applied.

Too much side glue is applied.

Too much spine glue is applied.

85

6-1 Problems with Booklet Quality


Problems with the Booklet Spine
Condition

Cause

Remedy

See page

There is a lump of glue


on the nipping mechanism.

Clean the nipping section.

Page 70

There is a lump of the


glue on the delivery
mechanism.

Clean the delivery section

Page 70

The carriage clamp


opening is too narrow.
When the booklet falls
down to the delivery
section, the booklet
falls down at a tilt.

Make the carriage clamp


opening amount larger.

Page 21

The nipping delay time


is too short.

Increase the nipping


delay time.

Page 24

The nipping mode with


milling is selected.

Select nipping without


milling.

Page 15

The nipper height is


too high.

Lower the nipper height.

Page 64

The nipping time is too


long.

Make the nipping time


shorter.

Page 24

The nipping mode with


milling is selected.

Select nipping without


milling.

Page 15

The nipping mode


without milling is
selected.

Select nipping with milling.

Page 15

The nipper height is


too low.

Increase the nipper


height.

Page 64

The nipping time is too


short.

Make the nipping time


longer.

Page 24

The nipper width is too


wide.

Make the nipper width


narrower.

Page 24

Too much spine glue is


applied.

Decrease the spine glue


amount.

Page 22

The sharpness of the spine is


different at the top and bottom.

The nipper is inclined


to the right or left.

Adjust the nipper angle.

Page 65

The rear spine is too round and


the front spine is too sharp.

The rotation of the milling cutter is opposite.

Switch two black cabels


out of three which supply
the power to the machine.

Page 103

The spine of the booklet is


dented.

One edge of the spine is dented.

The spine of the booklet is wrinkled (especially, a thick booklet).

The spine of the booklet is too


sharp.

Booklet spine is rounded.

86

6-1 Problems with Booklet Quality


Problems with the Cover Sheets
Condition

Cause

Remedy

See page

The cover sheet is wrinkled.

The pressure from the transport


belts is too strong.

Make the pressure from the transport belts weaker.

Page 27

The registration stopper is out of


position.

Adjust the angle of the registration


stopper.

Page 66

The cover sheet is not cut at the


correct angle.

Use cover sheets which have been


correctly trimmed.

The cover sheet is not transported to the registration stopper.

Increase the amount to transport the


cover sheet backward.

Service

Jog guides interrupts the cover


sheet moving back to the registration stopper.

Select [Guide Open] at the Information screen.

Page 33

The jog guides on the nipper are


not set correctly.

Adjust the positions of the jog


guides.

Page 26

The scoring position is not correct.

Adjust the position of the scoring


roller.

Page 25

Cover sheet detect sensor is


stained.

Clean the sensor.

Page 71

The registration stopper position


is not correct.

Adjust the position of the registration


stopper.

Page 26

Upper cover guide hits the registration stopper.

Make some space between the


upper cover guide and registration
stopper.

The pressure from the transport


belts is too strong, or too weak.

Adjust the pressure from the transport belts.

Page 27

The transport belts are stained.

Wipe the transport belts using a dry


cloth.

Page 5

A transport belt is missing.

Install the missing transport belt.

Page 5

The jog guide width on the nipper is too wide, or too narrow.

Adjust the jog guide width.

Page 26

The positioning guide width is


too wide, or too narrow.

Adjust the positioning guide width.

Page 27

Transport belt is worn.

Replace with spare belts.

Page 84

The production speed is too


slow.

Increase the production speed.

Page 19

The glue temperature is too low.

Increase the glue temperature using


the glue temperature adjusting
knob.

Page 61

The glue which is being used


hardens too quickly.

Use the correct glue or talk to the


dealer.

The nipping delay time is too


long.

Decrease the nipping delay time.

Page 24

Breaker of the cover feed blower


is tripped.

Check if the breaker is not tripped. If


the breaker trips repeatedly, please
call your local dealer.

Page 94

The cover sheet is applied diagonally.

The cover sheet is shifted parallel to the book block toward the
fore-edge.
The cover sheet is shifted parallel to the book block in the topbottom direction.

The position of the cover sheet


changes.

The cover sheet is not glued to


the book block spine.

The cover is not fed.

87

6-1 Problems with Booklet Quality


Problems with Scoring
Condition

Cause

Remedy

See page

The cover sheet is cut by


the scoring operation.

The scoring roller pressure is too strong.

Decrease the scoring roller


pressure.

Page 68

The scoring line is not


produced.

The scoring roller pressure is too weak.

Increase the scoring roller


pressure.

Page 68

The upper and lower scoring rollers do not meet


each other.

Align the upper and lower


scoring rollers properly.

Page 41

The transport roller is


stained.

Wipe the transport roller


using a dry cloth.

Page 6

The positioning guide


width is too wide, or too
narrow.

Adjust the positioning guide


width on the feed table.

Page 27

The scoring position is not


set correctly.

Adjust the scoring position.

Page 25

The scoring line moves.

The scoring line is created


in the wrong place.

Problems with Stack


Condition

Cause

Remedy

See page

Bound books cannot be


stacked correctly.

Used sheets are too


large, or too small.

Push the stopper to the end


and attach the accessory
delivery chute.

Page 111

88

6-1 Problems with Booklet Quality


Other Problems
Condition

Cause

Remedy

See page

Turn ON the feature for Home


positioning every changeover
on the [Setting]-[Binding setting]-Binding Mode Screen. If
the booklet quality is still bad,
return the appropriate section
of the machine to the home
position using the [Single Operation]-Home Positioning
Screen.

Page 10

The booklet quality deteriorates


during the binding operation.

The feature for home


positioning every
changeover is turned OFF
on the [Setting]-[Binding
setting]-Binding Mode
Screen.

The jog guides and the positioning guides are not aligned
with each other.

Adjust the jog guide and the


positioning guides for a clearance of 3 mm (0.12).

Page 26
Page 27

The cover sheets are curled.

Uncurl the cover sheets.

The position of the upper cover


guide is not correct.

Set the upper cover guide at


the edge of the cover sheet.

Page 5

A transport belt is missing.

Install the missing transport


belt.

Page 5

The milling cutter is worn.

Replace the milling cutter.

Page 75

The milling depth is too large.

Add shims under the level plate


to decrease the milling depth.

Page 59

The production speed is too


fast.

Slow the production speed.

Page 10

Too much spine glue is applied.

Decrease the spine glue


amount.

Page 22

The trimmings bag is full or


clogged.

Remove the paper chip from


the bag.

The hose is clogged with trimmings.

Remove the trimmings from the


hose.

Trimmings are clogged inside


the milling unit.

Clean the milling unit.

Page 69

Breaker of the milling blower is


tripped.

Check if the breaker is not


tripped. If the breaker trips
repeatedly, please call your
local dealer.

Page 94

The double feed detect sensor


is dirty.

Clean the sensor.

Page 71

Setting on the Cover Sheet


Fine-Adjustment Part 4 Screen
is not suitable.

Increase the detecting sensitivity or light strength.

Page 27

There is false detection of misfeeding.

Setting on the Cover Sheet


Fine-Adjustment Part 4 Screen
is not suitable.

Decrease the detecting sensitivity or light strength.

Page 27

Book block hits the milling section.

Breaker of the milling motor is


tripped.

Check if the breaker is not


tripped. If the breaker trips
repeatedly, please call your
local dealer.

Page 94

The power does not power on.

The main breaker is tripped.

Check if the breaker is not


tripped. If the breaker trips
repeatedly, please call your
local dealer.

Page 94

The cover sheets jam.

The carriage clamp slows down


during the milling operation.

Excess glue sticks to the delivery


mechanism.

There are a lot of paper chips


around the milling section.

There is false detection of double


feeding.

89

Page 32

6-2 Error Codes


If an error occurs, an error code will appear on the Error Screen. There are some problems only a service person
can handle. (These are inidicated by the gray shading in the table below.) If an Error code with [Service call] in the
column for See page comes up repeatedly, please call your local dealer and report the error code.

Error Codes

Cause

Remedy

See page

0001

Emergency Stop switch is pressed.

Release the Emergency Stop


switch.

0002

Left safety cover is open.

Close the cover.

0003

Right safety cover is open.

Close the cover.

0004

Lower nipper door is open.

Close the door.

0501

Cover sheet left on the nipper.

Remove the cover sheet and


check the last booklet.

0601

Cover sheet jam

Remove the cover sheet and


check the last booklet.

1001

Emergency stop error

If this error code appears


repeatedly, check the covers
and the brake release button.

Service call

Check that there are no problems with the interlock relay.

Service call

1101

Carriage clamp opening amount


home positioning error

Check that the stepper motor


moves, and that the home positioning sensor is active.

Service call

1111

Carriage clamp home positioning


error

Check that the carriage clamp


moves smoothly. If this error
code appears repeatedly,
replace the inverter A20.

Service call

1112

Carriage clamp moving error

Check that the carriage clamp


moves smoothly. If this error
code appears repeatedly,
replace the inverter A20.

Service call

1113

Carriage clamp moving home positioning error

Check the carriage clamp home


position sensor B42.

Service call

1121

Carriage clamp open position error

Check that the breaker corresponding to the error code is not


tripped. If the breaker trips
repeatedly, please call your local
dealer.

Page 94

Check the level plate position


detect sensor B51. If this error
code appears repeatedly,
replace the inverter A50

Service call

Check that the breaker corresponding to the error code is not


tripped. If the breaker trips
repeatedly, please call your local
dealer.

Page 94

Check the level plate position


detect sensor B52. If this error
code appears repeatedly,
replace the inverter A50

Service call

1122

Carriage clamp close position error

90

6-2 Error Codes


Error Codes

Cause

Remedy

See page

1123

Carriage clamp open/close, booklet delivery mechanism error

Check that the breaker corresponding to the error code is not


tripped. If the breaker trips
repeatedly, please call your local
dealer.

Page 94

Check the level plate position


detect sensor B51. If this error
code appears repeatedly,
replace the inverter A50

Service call

Check that the breaker corresponding to the error code is not


tripped. If the breaker trips
repeatedly, please call your local
dealer.

Page 94

Check the rail up/down position


sensor B44 and the lower limit
sensor B45. If this error code
appears repeatedly, replace the
inverter A40.

Service Call

Check that the breaker corresponding to the error code is not


tripped. If the breaker trips
repeatedly, please call your local
dealer.

Page 94

Check the rail up/down position


sensor B44. If this error code
appears repeatedly, replace the
inverter A40.

Service Call

1131

1132

Rail up motion error

Rail down motion error

1201

Milling guide home positioning error

Check that the stepper motor


moves, and the home positioning sensor is active.

Service Call

1301

Side gluing roller home positioning


error

Check that the stepper motor


moves, and the home positioning sensor is active.

Service Call

1302

Spine glue thickness home positioning error

Check that the stepper motor


moves, and the home positioning sensor is active.

Service Call

1303

Wiper 1 home positioning error

Check that the stepper motor


moves, and the home positioning sensor is active.

Service Call

1304

Wiper 2 home positioning error

Check that the stepper motor


moves, and the home positioning sensor is active.

Service Call

91

6-2 Error Codes


Error Codes

Cause

Remedy

See page

1401

Nipper width home positioning error

If the nipping operation is done


twice, check that the thickness of
the book is set correctly. Or widen
the nipping width.

Page 12

Check that the stepper motor


moves, and the home positioning
sensor is active.

Service Call

Check that the breaker corresponding to the error code is not


tripped. If the breaker trips repeatedly, please call your local dealer.

Page 94

Check the nipper stop position


sensor B31 and nipper upper
position detect sensor B32. If this
error appears repeatedly, replace
the inverter A30.

Service Call

Check that the breaker corresponding to the error code is not


tripped. If the breaker trips repeatedly, please call your local dealer.

Page 94

Check the nipper stop position


sensor B31 and nipper upper
position detect sensor B32. If this
error appears repeatedly, replace
the inverter A30.

Service Call

1411

1412

Nipper up motion error

Nipper down motion error

1501

Jog guide home positioning error

Check that the stepper motor


moves, and the home positioning
sensor is active.

Service Call

1502

Scoring roller width home positioning


error

Check that the stepper motor


moves, and the home positioning
sensor is active.

Service Call

1503

Stopper adjust cam home positioning


error

Check that the stepper motor


moves, and the home positioning
sensor is active.

Service Call

1601

Positioning guide home positioning


error

Check that the stepper motor


moves, and the home positioning
sensor is active.

Service Call

1611

Feed table up motion error

Check the feed table upper position sensor B63 and the motor
rotation.

Service Call

1612

Feed table down motion error

Check the feed table lower position sensor B64 and the motor
rotation.

Service Call

92

6-2 Error Codes


Error Codes

Cause

Remedy

See page

0801

Delivery error

Check that the breaker corresponding to the error code is not


tripped. If the breaker trips
repeatedly, please call your local
dealer.

Page 94

Check the delivery motor stop


position sensor B70 and the
motor rotation.

Service Call

Check that the delivery section


is not full of bound books.

Page 48

Check that the breaker corresponding to the error code is not


tripped. If the breaker trips
repeatedly, please call your local
dealer.

Page 94

Check that the power cable is


connected to the power source
properly.

1801

Thermo-Fuse error

93

6-3 If a Circuit Breaker Trips


If a specific part of the machine does not work, check the
circuit breaker(s) for that part. If the breaker is tripped,
turn it ON.

WARNING
Turn off the power switch before turning
ON the breaker. Otherwise, it can cause an
electrical shock.

Check the error code on the Error


Screen.
- Check the error code to find out which
breaker(s) have tripped.

Turn ON the breaker(s) which correspond to the error code.

DER

T BIN

10

70
BQ-2

A50

FEC

PER

A40
A30
A20

Error No.

Location

Code No.

Trouble

1121,1122,1123

Q50

Clamp, Level Plate Open/Close Motor M50 has trouble.

1131,1132

Q40

Clamper Rail Up/Down Motor M41 has trouble.

1411,1412

Q30

Nipper Motor M31 has trouble.

1123

Q20

Application Drum Motor M21, Clamp Motor M22 has


trouble.

0801

Q70

Delivery Motor M70 has trouble.

1801

Q80

Melt Tank Heater E80 has trouble.

No Error No.

Q60

Cover Feeder Blower Motor M61 has trouble.

No Error No.

Q12

Chip Extractor Motor M12 has trouble.

No Error No.

Q11

Milling Motor M11 has trouble.

No Error No.

Q01

Main Circuit Breaker has trouble.

94

6-4 If a Message Scrren Appears


When message screens below appears, operate the
machine by following the message.

Glue Drum Rotation OK Screen

Clamp Manual Move Screen

When the glue drum is stopped for more than 10


minutes, this screen appears. Press OK, and the
Glue Drum Rotating Screen appears and the drum
rotates for 3 minutes.

When the clamp stops above the milling section by


the emergency stop, this screen appears. Open the
safety cover and move the clamp by hand to the
original position (above the level plate). The previous screen appears.
This screen appears to prevent the clamp from hitting the milling section safety cover.

Glue Drum Rotating Screen

Manual Setting OK Screen

When

is pressed, the drum stops rotating.

And the previous screen appers. After another 10


minutes has passed, Glue Drum Rotation OK
Screen appears again.
This screen appears for preventing the glue from
hardening.

This screen appears when one or some settings out


of the spine glue thickness, wiper opening, nipping
delay time and nipping time were tried to be
changed manually although the settings are set to
Auto.
When the spine glue thickness, wiper opening, nipping delay time, and nipping time should be
changed manually, press OK and change the setting.
Press

to set each part automatically and

show the previous screen.

95

96

7. Optional Device
7-1 Weekly Timer
Two power switch operation

ON

PERFECT BINDER

BQ-270

Main Power Switch

Power Switch for


main body of BQ-270

- When the weekly timer is used, turn on the


main power switch all the time.
- Even if the power switch for main body of BQ270 is turned off, the weekly timer works and
the melt tank will be heated according to the
weekly timer setting.
- Turn on the power switch for main body of
BQ-270 before performing the the binding
operation.
- Turn off only the power switch for main body
of BQ-270 after the binding operation is finished.

97

OFF

Main Power Switch: ON

Power switch for main body of


BQ-270: OFF

7-1

Weekly Timer

Weekly Timer Operation Procedures


Switch Description

- If the starting time for the melt tank heating is set beforehand, the binding operation can be started without waiting for the
glue to be melted.
- When using the weekly timer, leave the
main power switch turned ON.
- If the power switch for the main body of
BQ-270 is not turned on for over 300 hours,
the Sunday (S) lamp may blink when the
power switch is turned on. In this case, set
the current time and day. (Refer to the next
page)

Reset Lamp
When this timer does not work correctly
according to setting, reset lamp illuminates.

Continuous / Normal Switch

Setting Scale
This scale is used to set the time to
turn the BQ-270 ON or OFF. One
rotation takes a day and the indexes
can be set every 15 minutes. Set the
tabs inside to turn on the setting.

Set this switch to "CONTINUOUS" when


the time between turning the machine on
and off is over 24 hours.
Normally, set this switch to [NORMAL].
A-TB72CQ

Current Time Setting Knob

NORMAL

CONTINUOUS

RESET

OUTPUT

OFF

This knob is used to set the current


time. One rotation of this knob takes
an hour.

AUTO

S
1 24 23

22

21
18
20 19

These lamps are used to indicate the


current day. A lighted lamp indicates
the current day.

T
W
T

40

Minutes Scale

45

This lamp lights when the timer function


is active.

Day Lamps

Output Lamp

Current Day Setting Button

13 12 11 10

Hours Scale

This button is used to select the current day.

DAY
SETTING
PRESENT
TIME
OFF

AUTO

ON

Day Select Switch

ON, Auto, and OFF Switch

For each day on which the melt tank


will be heated automatically, set the
switch for that day to [AUTO].
For each day on which the melt tank
will not be heated automatically, set the
switch for that day to [OFF].

ON: When the main power switch of the BQ-270


is turned on, the melt tank is always heated
up, independently of the timer function.

OFF

AUTO

98

ON

AUTO: The timer function is available.


OFF: Although the main power switch of the
BQ-270 is turned on, power is not supplied
to the BQ-270.

7-1

Weekly Timer

Setting the present time and the day

Setting the time switches


A. [Setup within a day]

Set the weekly timer.


(1) Set the normal/continuous switch to [NORMAL].
(2) Set the day select switches to the "Auto"
side only for the days when the melt tank will
be heated automatically.

1 24 23
22

21
18
20 19

40
45

NORMAL

CONTINUOUS

RESET

OUTPUT

13 12 11 10

AUTO

OFF

S
M
T
W
T
F
S

Scale
Hour

Normal/Continuous Switch

Minute

CAUTION

Day Select
Switch

DAY
SETTING

Weekly timer heats up the melt tank at the


set time on the set date. For safety, check
the machine in the set time.

OFF

ON/Auto/OFF Switch
ON

AUTO

(3) Set the time to heat up the melt tank by


shifting the appropriate index tabs to the center of the dial.

Remove the transparent cover.


1. Set the current time as follows:
- Turn the current time setting knob clockwise
to set the [hour] index first, then set the
[Minute] index.

- For example, when the time switch is set


as shown in the figure at right, the machine
will operate according to the program from
Monday to Friday, and will not operate on
Saturday and Sunday.

MondayFriday

ON

2. Set the current day as follows:


- Press the day setting button using the tip of a
screwdriver. Each time you press the current
day setting button, the current day indicators
advance a day. Stop when they indicate the
current day.
NORMAL

CONTINUOUS

RESET

OUTPUT

12:00

(B) 17:00

19:00

Saturday,
Sunday

All Day OFF

12

DAY
SETTING

AUTO

S
M
T
W
T
F
S

OFF

(A) 8:00

19 17

OFF

OFF

Current Day
Lamp
Output
Current Day
Setting Button

SUN

ON

Time Switch
MON

AUTO

99

TUE

WED

THU

FRI

SAT

7-1

Weekly Timer

B. [Setup over a break between days]


(When controlling the machine auto-startup
over a period which includes two days.)

C. [Setup through a series of days]


(When the period that the machine is
continuously on or off is over 24 hours)

- When controlling the machine auto-startup over a break between days, the program continues from the previous day.
Therefore, the machine is powered up until
it reaches the off setup time, even though
the day select switch for the day is turned
off.

- The machine is powered on at the on


setup time of the first day when the day
select switch is set to "AUTO." The
machine is powered off at the off setup
time of the first day when the day select
switch is set to "OFF."
(1) Set the normal/continuous switch to [CONTINUOUS].

(1) Set the normal/continuous switch to [NORMAL].

(2) Set the day select switches by referring to


the example below:

(2) Set the day select switches as described for


the setup within a day.

(3) Set the time to heat up the melt tank by


shifting the appropriate index tabs to the cen-

(3) Set the time to heat up the melt tank by


shifting the appropriate index tabs to the cen-

ter of the dial.

ter of the dial.

MondayFriday

ON
(A) 8:00

16:00

(B) 20:00

6:00

Saturday,
Sunday

Monday 8:00 to Friday 17:00


(through a series of days)

OFF

Satu
rday, Sunday

All Day OFF

NORMAL

CONTINUOUS

RESET

OUTPUT

NORMAL

CONTINUOUS

RESET

OUTPUT

S
M
T
W
T
F
S

S
M
T
W
T
F
S

Day Select
Switches

Normal/Continuous
Switch

AUTO

OFF

Normal/Continuous
Switch

AUTO

OFF

Day Select
Switches

DAY
SETTING
OFF

DAY
SETTING
OFF

All Day OFF

ON
AUTO

ON
AUTO

Time Switch
6

17

20

16

Time Switch

Output
Output
SUN

SUN
MON

TUE

WED

THU

FRI

MON

WED

THU

FRI

SAT
8:00

TUE

100

17:00

SAT

8. Installation
8-1 Installation
This section includes procedures that can be performed
only by our service engineer.

Place three feet under the leveling


bolts shown in the illustration
below.

CAUTION
The BQ-270 weighs about 900Kg (409 lb).
Be careful when moving the machine.

There are four leveling bolts. Place


three of them first to level the machine.

Move the carriage clamp.

Top View

- Move the chain 1 shown below by hand,


about 5 cm (19.68) along the arrow direction.

PERFECT BINDER

Chain

Adjust the leveling bolts and lift up


the machine so that the machine
becomes level.

BQ-270

Carriage Clamp

- Place a water level on the nipper in two directions (shown in the illustration below) to check
for level.

- Lift up the machine so that the casters do not


touch the floor.
- Push the carriage clamp at its end 2 and
move it to the left end.
- Remove the foam polystyrene below the carriage clamp.

ER

EC

F
ER

P
101

D
BIN

0
7
2
Q
B

8-1 Installation
Place a foot under the fourth leveling bolt shown in the illustration
below.

Install the touch panel.


- Remove the top plate and install the panel
with four screws as shown below.

- Lower the leveling bolt until it hits the foot.


- Turn the leveling bolt 90 degrees more after it
hits the foot.

Top View

Lock each leveling bolt using the


lock nut.

Wire the touch panel.


- Install the ground from the touch panel to the
position as shown below.
- Connect the cables shown below to the CON3
and CON4 on the touch panel P.C.Board.

Lock Nut
Leveling Bolt

Ground

Foot

CON3
CON4

Attach the spacer and the adapter.


- Attach the spacer and the adapter on the right
side of the machine and fix with the screw.

Spacer

Mouth

Attach the trimmings bag.


- Attach the trimmings bag on the adapter and
tie it with the string.

102

8-1 Installation
Wire the machine.

- Seeing the milling cutter from top, the knife


should turn clockwise.

- Connect the machine main power.


- Follow the procedure described below. Check
the milling cutter rotate direction.
1) Turn on the main power.
2) Enter the service mode.
3) Slide the milling section safety cover and
hold it using the gummed tape.
Safety Cover

Cover

Gummed
Tape

Do not check the rotating direction by


slowing down the cutter using the
button. The milling cutter may be
seen rotating backward by sudden
braking. It is useful if you tape a string
of paper on the sheet guide and touch
the other side of the paper to the knife
edge. Press
on the screen and
the edge of the paper will be drawn to
the rotating direction.

Gummed
Tape

Cover
Safety Cover

4) Press

Sheet Guide

button (Milling Cutter Rotation

Button) on the Information - Single Operation Milling Screen.

WARNING

Clockwise

Tape

5) If the milling cutter rotates counterclockwise, exchange the two black cables (out of
three) each other at the power box, which
supply the power to the machine.

Keep your hands away from the


rotating milling cutter. It may cause
severe personal injury.

Black
Ground

6) Rotate the milling cutter again by the single


operation and ensure that the cutter rotates
clockwise.

103

8-2 Installation of Extractor (Option)


Turn off the power switch and
remove the rear cover.

2) Attach the hose ufsing the hose band on the


extractor.

Hose Band

Remove the cover at the electrical


box.

Install the duct.

Duct

Attach the rear cover and install the


flange.
This procedure is for connecting the
hose on the machine. Attach the flange
where you want to connect the hose.
Small Cover

Connect the power cord of the


extractor.
Q01 Q80Q11Q12Q60Q70 Q20 Q30 Q40Q50

Small Cover

K82 A22

A20 A30 A40 A50

Flange

1 3 6 13 A1

K82
2 4 6 14 A2

BLK
RED
WHT

1) Attach the hose on the flange.

104

GRN

8-2 Installation of Extractor (Option)


Change the current setting on the
breaker Q80 from 9A to 10A using
the driver.
Q01Q80
Q80Q11Q12Q60Q70 Q20 Q30 Q40Q50

K82 A22

A20 A30 A40 A50

Q80

10
9

9A

6
10A

Check the rotating direction of the


fan inside the extractor.

Check that the fan rotates to the direction shown in the illustration above. If
the fan rotates backward, switch the
position of two wires out of three.

Prepare the delivery hose and


install it on the delivery vent using
the hose band.
- Delivery hose is not included in the optional
extractor.

Use the hose which has smooth texture


inside, and also which has diameter
over 100 pi.

105

8-3 Installation of Weekly Timer (Option)


Accessory for the Weekly Timer
(T-270) Kit
Power Switch for main body of BQ-270
RED
WHT
BLK

99

RED
WHT
BLK

Not
used for
BQ-270

100

Weekly Timwer and Relay

61
95

BLK

WHT

WHT

BLK

WHT

WHT
BLK

73

98

106

8-3

Installation of Weekly Timer (Option)


Turn off the power switch and disconnect the power cable from the
customer power source.

Install the weekly timer.


(1) Remove the lock screw and the fixing plate
from the weekly timer.

Wires

Remove the front cover and the terminal board cover.

Lock Screw
Fixing Plate

PERFECT BINDE

BQ-270

(2) Insert the weekly timer to the hole.


(3) Fix the weekly timer using the lock screw
and the fixing plate.

Front Cover
Plate

Install the power switch (black) for


the main body of BQ-270.
(1) Remove the handle and the bracket from
the switch.

Switch
Bracket
Handle

(2) Insert the power switch for the main body of


BQ-270 to the hole.

Terminal Board Cover

(3) Attach the bracket and fix it with the screw.


(4) Attach the handle.

Remove the plate under the power


switch.

Screw

Make some space to install the


weekly timer by loosening the
wires.

107

99

100

Bracket
Handle

8-3

Installation of Weekly Timer (Option)


Install the relay.

Wire the terminal board.

- Hook the upper part on the rail and push the


lower part in.

(1) Reconnect the heater wire which is connected on the terminal No.4, to the terminal
No.9.

Only when the


area sensor is
used
Relay

Terminal Board
K01
K02
WHT
26
BLK

1
2
3
4
5
6
7
8
9

RED

WHT
26
BLK

RED

BLK

(1) Remove three wires No.18 which is connected between Q01 and Q80.

BLK

Q01

BLK

18

BLK

18

18

RED

Connect the wire No.61 from the


weekly timer, to the white relay connector which wire No.21, No.22 and
No.23 are connected.

Q80

BLK

BLK

BLK

K11
K20
K60

K10

K83
BLK

WHT

BLK

RED

RED

WHT

BLK

RED

(2) Connect the wire No.98 from the relay, to


the terminal No.4 and No.9.

99
100
73

WHT

98

Wire the breaker.

To Power
Switch for
main body
of BQ-270
To Relay

1
2
3
4
5
6
7
8
9

KO1
KO2

WHT

Q01

White Relay Connector

Q80

Arrange the wires and attach the


front cover.

(2) Connect the wire No.99 on Q80.


(3) Connect the wire No.100 and wire No.73 on
Q01.

108

9. Appendix
9-1 Specifications
Binding Type

Binding with milling, Binding without milling and Padding

Number of Clamper

Book Block Size


(Top-Bottom x Fore-edge)

Max. 320 mm x 320 mm (12.5 x 12.5)


Min. 135 mm x 105 mm (5.4 x 4.2)

Binding Thickness

1 to 50 mm (0.04 to 2.00)

Cover Sheet Size

Max. 320mm x 660mm (12.5 x 25.9)


Min. 135mm x 230mm (5.4 x 9.0)

Cover Sheet Quality

82 to 302 gsm (22 to 80 lb)

Cover Pile Height

Max. 70 mm (2.7)

Warm up Time

40 min.

135 to 320

Movable Side
Scoring
(Front Side)

110 to 310

(5.32" to 12.60")

Fixed Side Downstream


Scoring
(Rear Side)

120 to 350

(4.33" to 12.20) (4.72" to 13.77")

230 to 660 (9.05" to 25.98")

mm(inch)

Glue Temperature

120 to 180 degrees Celsius (248 to 356 degrees Fahrenheit)

Maximum Milling Depth

3 mm (0.12)

Production Speed

Without Milling: Max. 500 cycles/hr.


With Milling: Max. 500 cycles/hr.
Padding: Max. 500 cycles/hr.

Voltage/Frequency

AC220V/230V/240V/400V 50Hz/60Hz
(3 phases 3 wires plus PE)

Rated Current

AC220V/230V/240V 50Hz 9.7A (Max.12.8A)


AC220V/230V/240V 60Hz 8.5A (Max.12.8A)
AC400V 50Hz/60Hz 5.6A/5.1A (Max. 9A/6.4A)

Power Consumption

220V/230V/240V 50Hz 2.9kW


220V/230V/240V 60Hz 2.78kW
400V 50Hz/60Hz 3.1kW/3.16kW

Heat Out Put

7,870 kJ (1,880 kcal)

Machine Dimensions

2,300 (W) x 860 (D) x 1,250 (H) mm (90.6 x 33.9 x 49.3)

Noise Level

L A peak: 83.3 dB
L A eq: 74.0 dB

Machine Weight

900 kg (1,984.5 lb)

109

9-2 Accessories
Tool Box (4-003344)

1pc

Shim

2 pcs each
1.0mm (0.04")(M011601)
1.5mm (0.06")(M049499)
2.0mm (0.08")(M011602)
1.0 mm thim is attached on the machine.

Roughening Cutter Setting Gauge (M011118)

Hexagon Allen Wrench

1 pc

1 pc each

Adjusting Pin (M011117)

Heat-resistant Oil (A930179)

1 pc

1 pc

6 mm (0.24")(4001744)
5 mm (0.2") (4000968)
4 mm (0.16")(4001439)
3 mm (0.12")(4001438)
2.5 mm (0.1") (4001437)
2 mm (0.08")(4001320)

Single Open-End Wrench (M127498)

1 pc

Double Open-End Wrench (4010556)

30 mm (1.18")

Support Plate (A931959-00)

7 x 8 mm (0.28"x 0.31")

1 pc

110

1 pc

9-2 Accessories
Installation Bolts

4 pcs

Stubby Screwdriver (4017228)

1 pc

Screwdriver (4000967)

1 pc

Long Screwdriver (4017233)

1 pc

Manual Wheel (A931965)

1 pc

Foot (M005374)

Delivery Chute (M126208)

1 pc

Trimmings Bag (M005285)

1 pc

Adapter (M127356-01)

1 pc

4 pcs

Use this chute when binding very small or large


booklets. Hook the chute onto the delivery section.
Place suitable box to receive the delivered booklets.

Spacer (M127359-00)

1 pc

111

9-2 Accessories
Fuse (E319737)

Grease (4017229)

2 pcs

1 pc

Glue (HM-220)

1 pack

Digital Caliper (4012395)

1 pc

Only for mm version of


BQ-270

10

70
80
90
10
0

Spare battery SR1130

Small Book Block Insertion Guide

1 pc

Book Block Insertion Guide

1 pc

Drain Guide (M126530)

1 pc

Grease Gun (4004391)

1 pc

Alignment Plate (M027079)

1 pc

Thermometer (4017505)

1 pc

Concave

100
80
60
40
20
0

120
140
160
200

180

When measuring the glue temperature,


check that the application drum is rotating
and the glue reaches the concave of the
thermometer.

112

9-3 Consumable Parts


Glue (HM-220)

1 box

Milling Cutter (M011440)

1 pc

Roughening Cutter (M051609)

1 pc

1 pc

Grease (4017229)

1 pc

1 pc

Book Support Plate (M005395)

1 pc

HM

-22

Trimmings Bag (M005285)

Double Feed Stop Pad (A924697)

2 pcs

(Violet)

Heat-resistant Oil (A930179)

113

9-4 Option
Extractor (VS-270)

1 pc

Weekly Timer

114

1 pc

9-5 Index
B
Binding Counter ......................................................................................................................... 19
Binding Mode Screen ................................................................................................................. 10
Binding Screens ......................................................................................................................... 18
Blower Air Adjustment ............................................................................................................... 67
Book Block Length Setting......................................................................................................... 12
Book Block Size Screen ............................................................................................................. 12
Book Block Thickness Setting .................................................................................................... 12
Book Support Plate Replacement .............................................................................................. 73

C
Carriage Clamp Section ............................................................................................................... 2
Clamp and Milling Fine-Adjustment Screen................................................................................ 21
Clamp Opening Amount Adjustment .......................................................................................... 21
Cover Feed Section ..................................................................................................................... 6
Cover Feeding Settings ............................................................................................................. 57
Cover Sheet Angle Adjustment .................................................................................................. 66
Cover Sheet Fine-Adjust Screen Part 1 ..................................................................................... 26
Cover Sheet Fine-Adjust Screen Part 2 ..................................................................................... 27
Cover Sheet Fine-Adjust Screen Part 3 ..................................................................................... 27
Cover Sheet Fine-Adjust Screen Part 4 ..................................................................................... 28
Cover Sheet Fine-Adjust Screen Part 5 ..................................................................................... 28
Cover Sheet Length Seting......................................................................................................... 13
Cover Sheet Size Screen ........................................................................................................... 13
Cover Sheet Width Setting ......................................................................................................... 13

D
Delete Button ............................................................................................................................. 29
Delivery Section ........................................................................................................................... 7
Double Feed Detecting Function ............................................................................................... 14
Double Feed Stop Pad Adjustment ............................................................................................ 67
Double Feed Stop Pad Replacement ......................................................................................... 83

E
Error Screen................................................................................................................................ 34
Extractor ................................................................................................................................... 104

F
Feed Rotor Vacuum Adjustment ................................................................................................ 27
Feed Table Height Adjustment .................................................................................................. 68
Function Screen......................................................................................................................... 14

G
Glue Amount Adjusting Plate ..................................................................................................... 63
Glue Fine-Adjust Screen Part 1 ................................................................................................. 22
Glue Fine-Adjust Screen Part 2 ................................................................................................. 22
Glue Fine-Adjust Screen Part 3 ................................................................................................. 23
Glue Replacement ..................................................................................................................... 81
Gluing Screens .......................................................................................................................... 16

H
Home Positioning Screen .......................................................................................................... 32

I
Information Screen ..................................................................................................................... 33

115

L
Level Plate Section ...................................................................................................................... 2

M
Main Binding Screen ............................................................................................................ 19, 40
Melt Tank Section ........................................................................................................................ 4
Memory Function ....................................................................................................................... 49
Memory Screen.......................................................................................................................... 29
Milling and Nipping Screen ........................................................................................................ 15
Milling Brake Release Screen.............................................................................................. 32, 75
Milling Cutter Replacement ........................................................................................................ 75
Milling Depth Adjustment ........................................................................................................... 59
Milling Guide Width Adjustment ................................................................................................. 21
Milling Section .............................................................................................................................. 3

N
Nipper Angle .............................................................................................................................. 65
Nipper Height ............................................................................................................................. 64
Nipping Delay Time .................................................................................................................... 24
Nipping Fine-Adjust Screen ....................................................................................................... 24
Nipping Section ............................................................................................................................ 5
Numeric Keypad Screen ............................................................................................................ 34

P
Pre-set Counter .......................................................................................................................... 19

R
Read Out Button ........................................................................................................................ 29
Registration Stopper Angle Adjustment ..................................................................................... 66
Roughening Cutter Replacement ............................................................................................... 78

S
Safety Function Check............................................................................................................... 35
Scoring Fine-Adjust Screen ....................................................................................................... 25
Scoring Position Change ........................................................................................................... 58
Scoring Roller Pressure Adjustment ........................................................................................... 68
Scoring Roller Setting ................................................................................................................ 41
Setting Screens ...................................................................................................................... 9, 36
Shim Installation.......................................................................................................................... 60
Side Glue Amount Adjustment ............................................................................................. 55, 62
Side Gluing Roller (Far Side) Positioning Plate ......................................................................... 62
Side Gluing Roller Settings .................................................................................................. 22, 44
Single Operation Screens .......................................................................................................... 30
Single Operation Screen Part 1 ................................................................................................. 30
Single Operation Screen Part 2 ................................................................................................. 31
Single Operation Screen Part 3 ................................................................................................. 31
Spine Glue Amount Adjustments ............................................................................................... 55
Start Mode Screen ..................................................................................................................... 11

T
Touch Screen ............................................................................................................................... 7
Transport Belt Pressure Adjustment .......................................................................................... 27

W
Weekly Timer ..................................................................................................................... 97, 106
Wiper Opening Adjustment ......................................................................................................... 23
Write Button ............................................................................................................................... 29

116