Page 1 SPF-200A/FC-200A BOOKLETMAKER BOOKLETMAKER SPF-200L/FC-200L Important Information • This manual is designed to help you to install, operate and maintain the SPF-200A/SPF-200L or FC-200A/FC-200L Bookletmaker. Please read and understand this manual, and keep it in a safe and convenient place. • Do not operate the SPF-200A/SPF-200L or FC-200A/FC-200L until you read and understand the instructions in this manual.
Page 2 Safety Precautions Safety precautions are indicated in this manual as follows: 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.
Page 3 Operating Safety Precautions WARNINGS for Operation This machine must be operated by just one person at a time. Work alone when you maintain and lubricate the machine. Letting someone else operate the machine may cause severe personal injury. Do not remove or bypass any safety features. Moving parts can cause severe personal injury.
Page 4 WARNINGS for Maintenance Turn off the power switch before beginning any maintenance operation. If the machine acci- dentally starts suddenly, this can cause severe personal injury. Turn off the power switch before clearing a jam. If the machine accidentally starts suddenly, this can cause severe personal injury.
Page 5: Table Of Contents
CONTENTS Important Information ....................... i Safety Precautions ........................ii Operating Safety Precautions ....................iii 1 Machine Description 1-1 Automatic and Manual Settings ................. 1 1-2 Machine Descriptions ....................2 1-2-1 Safety Device / Safety Functions ................. 2 1-2-2 Overall Machine ....................3 1-2-3 Manual Feed / Infeed Conveyor Section .............
Page 6 3-6 Start Binding ......................62 3-7 Manual Feeding ......................65 3-8 Saving, Loading and Deleting Jobs ................. 70 3-8-1 Saving a Job ...................... 70 3-8-2 Loading a Job ....................71 3-8-3 Deleting a Job ....................73 3-9 Power Saving Mode ....................74 3-10Reversing the Stitcher Heads ...................
Page 7 5-9 Other Problems ......................116 5-9-1 The Booklets Overlap Each Other at the Delivery Conveyor though They are Offset ..116 6 Maintenance 6-1 Loading Stitch Wire ....................117 6-2 Threading the Wire Through the Stitcher Head ............ 118 6-3 Attaching the Transport Pusher ................119 6-4 Lubrication .......................
Page 8 8-3-1 Accessories for Four Stitching Kit ..............166 8-3-2 Installation of Clincher ..................168 8-3-3 Installation of Stitcher Head ................169 8-3-4 Wire Attachment ....................171 8-3-5 Option Setup ....................173 8-3-6 Limitation for Use ..................... 174 8-4 Side/Corner Stitch Kit SSK-200/SSK-200L ............175 8-4-1 Installation of Side/Corner Stitch Kit ...
Page 9: Machine Description
1 Machine Description This chapter explains how to use the automatic and manual settings, and describes the parts of the machine and their functions. Automatic and Manual Settings Automatic: This indicates a setting which is performed automatically to match the sheet size and binding pattern.
Page 10: Machine Descriptions
1-2-1 Machine Descriptions Safety Device / Safety Functions 1-2-1 Safety Device / Safety Functions The whole system stops when a safety cover is opened or the Emergency Stop bottom is pressed dur- ing operation. Fore-edge Trim Section Cover Fold Section Cover Jog Section Cover...
Page 11: Overall Machine
1-2-2 Machine Descriptions Overall Machine 1-2-2 Overall Machine This explains how to use the system configuration including the optional IFU-200 infeed conveyor, FC- 200A/200L fore-edge trim section, and the SC-200 delivery conveyor. Fold Section Connectors for Downstream Device 1. The sheet is squared-up in the top-bottom and fore-edge directions before folding.
Page 12 1-2-2 Machine Descriptions Overall Machine Fore-edge Trim Connectors for Downstream Section Devices Power Con- The transport belts com- nector for press the booklets, and Delivery Con- then the fore-edge of veyor each booklet is trimmed. Connector Transport Connector for PK-30 Belt for TB-200 Preset...
Page 13: Manual Feed / Infeed Conveyor Section
1-2-3 Machine Descriptions Manual Feed / Infeed Conveyor Section 1-2-3 Manual Feed / Infeed Conveyor Section Manual Feed Stopper Sheets can be fed manually if the stopper is lowered. Manual Feed Sheet Sensor This sensor detects any sheets placed on the manual feed table.
Page 14: Infeed Section
1-2-4 Machine Descriptions Infeed Section 1-2-4 Infeed Section Weights The transport roller pressure can be adjusted by changing the positions of these weights. To move a weight, turn the top to loosen it. Hold-down Guides These guides help to control sheets which are bent or rolled.
Page 15: Jog Section
1-2-5 Machine Descriptions Jog Section 1-2-5 Jog Section Saddle Stitch Stopper Parallel Adjusting Bolt Install large or small stoppers to match the sheet This bolt is used as a gauge to adjust the width. (The instruction screen is displayed on the top-bottom guide so that it is parallel.
Page 16: Stitch Section
1-2-6 Machine Descriptions Stitch Section 1-2-6 Stitch Section The operation of the stitcher head is explained in Section 4-1. Wire Coil Standard wire is No.25 (0.5 mm in diameter) Wire Feeding Optional wire No.26 (0.45 mm in diameter) is Detection Sensor available.
Page 17: Fold Section
1-2-7 Machine Descriptions Fold Section 1-2-7 Fold Section Press Fold Section Top and Bottom Guides Fold Section Jog Pushers Fold Rollers Rollers -These guides jog the sheets before folding. -These pushers jog the sheets The gap between the rollers -The settings listed below can be done using the touch panel. before folding.
Page 18: Fore-Edge Trim Section
1-2-8 Machine Descriptions Fore-edge Trim Section 1-2-8 Fore-edge Trim Section Transport Belts Front Transport Belt Height Booklet Stopper Adjusting Knob The sheet is transported by these belts. This stopper is automatically The gap between the upper and lower set to match the finishing size If the booklets do not move correctly, adjust of the booklet.
Page 19: Delivery Conveyor
1-2-9 Machine Descriptions Delivery Conveyor 1-2-9 Delivery Conveyor Delivery Rollers These rollers hold the delivered booklet. These rollers should be placed about 30 mm (1.2") from the end of the booklet. Locking Knob Faulty Set Ejecting Gate If the machine detects a faulty set, this gate moves and the faulty set is deliv- ered to the faulty set ejecting tray.
Page 20: Control Panel
1-2-10 Machine Descriptions Control Panel 1-2-10 Control Panel Stitch Jog Button Operating the stitcher heads in the normal direction Press and hold this button to make one stitch in the normal When the power is first turned on, direction while the cover is closed and the Emergency Stop these buttons will not work until the button is not pressed.
Page 21: Screen Descriptions
1-3-1 Screen Descriptions Setting-Binding Pattern Screen 1-3-1 Setting-Binding Pattern Screen Binding Pattern Screen - After the power is turned on, the Initial Screen and Binding Pattern Screen are displayed. - The binding pattern can be selected on this screen. Press one of the icons, and the Sheet Size screen shown below is displayed.
Page 22: Setting-Finishing Size Screen
1-3-3 Screen Descriptions Setting-Finishing Size Screen 1-3-3 Setting-Finishing Size Screen Finishing Size-Saddle Stitch Screen Finishing Size Press one of these buttons for standard size sheets, and the dimensions are entered automatically. Stitch Type Select a stitch type from one of the five styles. Depending on the sheet size, some stitch types may not be available.
Page 23: Setting-Instruction Screen
1-3-4 Screen Descriptions Setting-Instruction Screen 1-3-4 Setting-Instruction Screen The following screens are displayed after the If you press , the following instruction changeover. screens appear: Instruction-Remove Screen Instruction-Attachment Screen 11119 11119 10304A1 10304E1 Remove the upper and lower parts for the top and Attach the upper and lower parts for the top and bottom guides.
Page 24 1-3-4 Screen Descriptions Setting-Instruction Screen The following screens below are displayed after If you press , the following instruction the changeover. screens appear: 11119 11119 10304D1 10304G1 Remove two stitcher head assemblies, including Attach two stitcher head assemblies, including the the mounting block and the clincher inside.
Page 25 1-3-4 Screen Descriptions Setting-Instruction Screen If you press , the following instruction The following screens below are displayed after screens appear: the changeover. 11119 11119 10304L1 10304K1 Remove the stitch detection sensor. Install the stitch detection sensor.
Page 26 1-3-4 Screen Descriptions Setting-Instruction Screen If corner stitching has just been selected, or if you are stopping corner stitching and using another binding pattern, the following instruction screens are displayed. (Corner stitching is an option.) 11119 10305F1 11119 10305G1 Replace the rear top and bottom guides Remove the front stitcher head drive block.
Page 27: Setting-Confirmation Screen
1-3-5 Screen Descriptions Setting-Confirmation Screen 1-3-5 Setting-Confirmation Screen Stitcher Head Position Confirmation Screen This screen confirms the stitcher head position. Check the position of the stitcher head in relation to the corner stitch guide. 11119 10305R1 Hollow Area Under Corner Stitch Guide If the stitcher head is positioned in the hollow area of the corner stitch guide, the stitcher head can interfere with the guide during changeover.
Page 28: Binding-Operation Screen
1-3-6 Screen Descriptions Binding-Operation Screen 1-3-6 Binding-Operation Screen Operation Screen Job Information The job name and the job number are displayed after the job is saved. Upstream/Downstream Device Information = The SPF-200A/200L or FC-200A/200L has a problem. Press to learn about the problem. = The collator has a problem.
Page 29 1-3-6 Screen Descriptions Binding-Operation Screen Operation Screen = Only manual feeding = Using the HMU (Hand Marry Unit on the collator) = Feeding starts from the collator after sheets are loaded into the manual feed section. = Feeding the sheets manually to match the feed from the collator.
Page 30: Binding-Fine Adjust Screen
1-3-7 Screen Descriptions Binding-Fine Adjust Screen 1-3-7 Binding-Fine Adjust Screen Fine Adjust-Stitch Section Screen Distance between jog plate and the stopper: (-10.0 to +10.0mm)(-0.400 to 0.400") These areas can be changed when sheets are being jogged. Top and bottom guide width: (-10.0 to +10.0mm) (-0.400”...
Page 31 1-3-7 Screen Descriptions Binding-Fine Adjust Screen Transport Belt Height Fine Adjust-Fore-edge Trim Section Screen Maximum fine adjust value: 7.0mm (0.275")- (booklet thickness) This area can be changed when the transport belts are raised. 11119 10307H1 Finishing fore-edge dimension: (-10.0 to +10.0) (-0.400”...
Page 32: Binding-Status Setting Screen
1-3-8 Screen Descriptions Binding-Status Setting Screen 1-3-8 Binding-Status Setting Screen Items marked like this are default settings. Collator/Faulty Set Detect/Manual Transport Speed Feed/Stitch Screen This indicates the operating speed of the belt or roller. It can be adjusted in six steps. VAC Support Guide (Used for sheets with a width smaller than 148 mm (5.83”).) = Guide is not used.
Page 33 1-3-8 Screen Descriptions Binding-Status Setting Screen Items marked like this are default settings. Collator/Faulty Set Detect/Manual Feed/Stitch Screen Stitch Section Jogging Frequency This indicates the number of jogs done before stitching. Press if the sheets are not squared up. (This will slow down the production speed.) Stitch Delay Time This indicates the delay from the moment the sheets are transported from the jog section until the...
Page 34 1-3-8 Screen Descriptions Binding-Status Setting Screen Items marked this way are default settings. Fold Section Jog Direction = The sheets are jogged by the jog pusher and the top and bottom guides. Fold/Fore-edge Trim/Conveyor Screen = The sheets are jogged only by the jog pusher. Using the default setting, the sheets are jogged only by the jog pusher.
Page 35 1-3-8 Screen Descriptions Binding-Status Setting Screen Items marked this way are default settings. Stitch Detection Option Screen This function detects if the stitching has been done correctly. It can be selected only if the optional SDS-200 is connected. = Off = On Paper Insertion This selects whether the paper insertion function is used.
Page 36: Memory Screen
1-3-9 Screen Descriptions Memory Screen 1-3-9 Memory Screen The detailed information for the selected job is dis- played. Detailed Information Screen 21102 10309B1 Scroll Buttons = Screen Scrolling (5 previous jobs) 21102 10309A1 = Scrolling (up) Job No. Input Enter the number of the job to be displayed using the numeric key- = Scrolling (down) pad screen which appears when...
Page 37: Information-Main Screen
1-3-10 Screen Descriptions Information-Main Screen 1-3-10 Information-Main Screen Administrator Mode Screen Information-Main Screen A Password is required to display this screen. Password Input Screen Enter the password and then press 11119 10310F1 21102 10310A1 See [1-3-12] See next page. This button is used by the service person only.
Page 38: Information-Monitor/Single Operation Screen
1-3-11 Screen Descriptions Information-Monitor/Single Operation Screen 1-3-11 Information-Monitor/Single Operation Screen = Single Operation Each section of the machine Stepper Motor Lock Release can be operated separately If the is displayed you can using these screens. move each guide and stopper by hand. 21102 10311A1 2110210311F1...
Page 39: Information-Administrator Screen
1-3-12 Screen Descriptions Information-Administrator Screen 1-3-12 Information-Administrator Screen Administrator-Password Screen Press after the pass- word is entered. Trim Count 11119 10312B1 The same trim count as on the Informa- 21102 10312A1 tion-Counter screen is displayed here. Information-Counter Administrator Mode Screen Screen Power Saving Mode When...
Page 40 1-3-12 Screen Descriptions Information-Administrator Screen = Home Position Calibration If you find yourself making the same fine adjustment every time, the home position can be calibrated so that no adjustment is required. This is available only when saddle stitch is selected. Enter the correction or offset value here.
Page 41 1-3-12 Screen Descriptions Information-Administrator Screen = Option Use this to selected the optional devices installed with the SPF-200A/200L. 21102 10312N1 21102 10312T1 = System Configuration SSK-200A Horizontal Transport Use this to select the upstream/down- /SSK-200L stream devices connected to the SPF- 200A/200L.
Page 42: Error Screen
1-3-13 Screen Descriptions Error Screen 1-3-13 Error Screen This section explains the function of the error screen and how to interpret the error icons. See Section 5-1-1 for instructions on recovery after an error. = A jog error has occurred in the fold section. = The feed interval between the booklets is too short, and the booklets are not trimmed correctly.
Page 43: Checks Before Operating
2 Checks before Operating This chapter explains the safety checks you must make before beginning the binding operation. Checking the Emergency Stop Function This machine has many safety functions designed to protect customers from possible risk during oper- ation. Before operating the machine, check that all of the safety functions are working normally. The Emergency Stop circuit is activated after the power switch is turned On and all sec- tions of the machine have returned to their...
Page 44 Checking the Emergency Stop Function Check the safety interlocks on the safety covers. - Check that the correct icon is displayed on the screen when you open each of the fol- lowing covers: 1. Infeed Section Cover 2. Stitch Section Cover 3.
Page 45: Operating Procedures
3 Operating Procedures This chapter describes the procedure for doing a regular bookbinding job. Overview of Operating Procedures This section provides an outline of the procedure for the bookbinding job. Refer to Section 3-2 for details. Turn On Power Refer to page 35 Chapter 2, “Check Before Operating.”...
Page 46 Overview of Operating Procedures Test Binding Refer to page 53 Prepare the upstream device. Produce one booklet, or do a test binding and check all of the settings. Do some test stitching, if necessary. 11119 30101G1 21102 30101H1 21102 21102 30101J1 30101L1 21102...
Page 47: Setting Up A Job Using The Setting Screen
Setting Up a Job Using the Setting Screen The following sections include detailed Fold Only instructions for each part of the machine. Side Stitch and Fold Saddle Stitch Side Stitch (Option) Select the binding pattern. - Select the icon which indicates the required binding pattern.
Page 48 Setting Up a Job Using the Setting Screen When doing saddle stitching - Enter each dimension. Sheet Size Screen - Enter in steps of 0.1 mm (0.005"). A: Sheet Length B: Sheet Width Saddle Stitch/Fold Only/Pass Through Select one of these if you are using a Sheet Size A=Length...
Page 49 Setting Up a Job Using the Setting Screen When doing saddle stitching - Sheet Size-Saddle Stitch Screen - Press The Finishing Size screen is displayed. When doing binding patterns Sheet Size-Other Binding Pat- except saddle stitching - tern Screen - Press - If the HOF error icon is displayed, there is a problem with the HOF-20/30.
Page 50 Setting Up a Job Using the Setting Screen Enter all of the dimensions. Finishing Size Screen Select one of these - Enter the finishing size for saddle stitch or if you are using a standard sheet fold only. size. - Enter in steps of 0.1 mm (0.005"). A: Finishing Size Finishing size Top and...
Page 51 Setting Up a Job Using the Setting Screen Press The Setting-Instruction screen is dis- played. - If the HOF error icon is displayed, there is a problem with the HOF-20/30. Clear the error on the HOF-20/30 before doing the changeover. - Go to the next page.
Page 52: Doing A Changeover
3-3-1 Removing Parts Before Doing a Changeover the Changeover This section explains how to remove or attach the guides and stoppers before and after the changeover by referring to the Instruction screen. Guide Bar 3-3-1 Removing Parts Before the Changeover After removing the specified parts, press Remove the guide bars in the...
Page 53 3-3-1 Removing Parts Before 3-3-1 Removing Parts Before Doing a Changeover the Changeover the Changeover - Replace the large saddle stitch stopper to the small one. - Loosen the locking screws to remove the stopper. Lock by pressing the stopper down. 11119 30301F1 If the stopper is located in a place where it is hard...
Page 54 3-3-1 Removing Parts Before Doing a Changeover the Changeover If you press , the following instruction screens appear: 11119 10304K1 Remove the stitch detection sensor. Refer to Section 8-4.
Page 55 3-3-1 Removing Parts Before Doing a Changeover the Changeover - When you stop doing corner stitching and go to another binding pattern, or - When you select corner stitching for the first time, The stitch section moves to the left end, the top and bottom guides open, then the machine stops before doing the changeover.
Page 56 3-3-1 Removing Parts Before Doing a Changeover the Changeover - The screen shown to the right may be displayed before you begin the changeover for corner stitch- Stitcher Head Position Confirmation Screen ing. - This screen is used to confirm the stitcher head positions.
Page 57: Attaching Parts After Changeover
3-3-2 Attaching Parts After Doing a Changeover Changeover 3-3-2 Attaching Parts After Changeover - After required parts are attached, press the display. Lower Part of Attach the upper the Guide and lower sections of the top and bot- tom guides. 3.
Page 58 3-3-2 Attaching Parts After Doing a Changeover Changeover -Attach stitcher head assemblies with the clinchers. Refer to Section 8-3-2 through 8- 3-5 for instruc- tions. 11119 30302A1 Lever 11119 30302D1 If the stitches on the booklet hit the stopper and the trim posi- Move the fore-edge tion varies, adjust the position of the fore-edge trim section.
Page 59 3-3-2 Attaching Parts After Doing a Changeover Changeover The following screens below are displayed after the changeover. 11119 10304L1 Install the stitch detection sensor. Refer to Section 8-4. - Attach the sheet hold-down plates in the fold sec- tion if necessary. (There are no instructions on the screen telling you to attach the sheet hold-down plates.) - Mount each plate on the guide and tighten the lock-...
Page 60: Confirmation After Changeover
3-3-3 Confirmation After Doing a Changeover Changeover 3-3-3 Confirmation After Changeover After the required parts are attached, the Setting Confirmation Screen screen shown to the right may be displayed. - This screen shows function that have been turned off. - Press if the correct functions have been turned off.
Page 61: Doing A Test Binding
3-4-1 Doing a Test Binding Preparing the Upstream Device 3-4-1 Preparing the Upstream Device Turn on the power switch on the upstream device. 1 2 3 1 2 3 Stitch - It does not matter which machine is turned (Lamp On) on first.
Page 62 3-4-1 Doing a Test Binding Preparing the Upstream Device VAC-100/1000/60H/600H Binding-Status Setting-Collator/Faulty Set Detect/Manual 1. Set up the support guide. Feed/Stitch Screen - If the sheet width is 148 mm (5.830") or less, be sure to install the support guide. (Refer to Section 2-2-2 in the user's manual for the VAC.) - When the support guide is used, select the Collator/Faulty Set Detect/Manual Feed/Stitch...
Page 63: Binding A Booklet As A Test
3-4-2 Binding a Booklet as a Test Doing a Test Binding 3-4-2 Binding a Booklet as a Test * This function is not available when you are using the manual feeding function. Binding-Operation Screen Press The sheets for one set are fed from the upstream device, then one booklet is deliv- ered.
Page 64: Do A Test Binding And Check The Settings
3-4-3 Do a Test Binding and Check Doing a Test Binding the Settings 3-4-3 Do a Test Binding and Check the Settings In the example used in this section, we will Binding-Operation Screen describe a job with saddle stitching with fore- edge trimming.
Page 65 3-4-3 Do a Test Binding and Check Doing a Test Binding the Settings Adjusting the fold section Press Binding-Fine Adjust-Fold Section Screen The sheets will be jogged. - Open the cover and check if there is a gap between the sheets and the guides or the jog pusher.
Page 66 3-4-3 Do a Test Binding and Check Doing a Test Binding the Settings Adjusting the fore-edge trim section The booklet which has been transported to the Binding-Fine Adjust-Fore-edge Trim Section Screen fore-edge trim section stops. It is held by the transport belt.
Page 67: Perform The Test Stitching
3-4-4 Doing a Test Binding Perform the Test Stitching 3-4-4 Perform the Test Stitching This section explains how to do multiple test stitching. Place the sheets in the jog section. - Use the size of sheets the machine is set to run.
Page 68: Confirming The Status Settings
Confirming the Status Settings This section only describes the status set- tings you must make before every binding operation. There may also be other status set- tings which are not mentioned here. Display the Binding-Status Setting screen. 11119 30501A1 Select if the support guide Caution Screen is used in the VAC.
Page 69 Confirming the Status Settings Select the Status Setting-Option Status Setting-Option Screen screen. Select the optional devices to use. - The default is for all of the optional devices to be turned off. To restore to the default settings 21102 30501D1 1.
Page 70: Start Binding
Start Binding Set up the offset function. Operation Screen Non-offset delivery is selected as a default setting. = Offset the last booklet when it reaches the preset count number. (This icon is available only if the optional PK-30 Preset Kicker is connected.) 21102 30601A1...
Page 71 Start Binding Settings which can be changed during the binding operation - Production speed - Delivery Conveyor Run Distance This indicates how far the conveyor will move each time a booklet is delivered. 21102 - Delivery Conveyor Run Distance for Offset Function 30601H1 When you use the offset function, this indi- cates how long the conveyor runs between...
Page 72 Start Binding Stopping the binding operation Press the Stop Button. 1 2 3 11119 30601C1 - The binding operation can be stopped using any of the following stop buttons: - SPF: Stop button next to the touch panel 11119 - VAC: Stop button on the remote control 30601P1 - VAC: Stop button on the Main screen - HOF-20/30: Stop button on the control panel...
Page 73: Manual Feeding
Manual Feeding This section explains how to do manual feed- IFU-200 Manual Feed ing. Complete the changeover beforehand. Guide Manual Feed Set up the manual feed section. Sheet Guide Width Set These for When the IFU-200 is connected: Half the Sheet Width - Set the manual feed guide to match the sheet size.
Page 74 Manual Feeding Select the manual feed mode. = When only doing manual feeding Status Setting-Collator/Faulty Set Detect/Manual (*1) Feed/ Stitch Screen = Feeding using the HMU (optional Hand Marry Unit of the collator). This function cannot be selected on the screen. This function can only selected using a switch on the HMU.
Page 75 Manual Feeding Start Binding Insert sheets after has been selected, you hear the "beep." 1. Press the Start button. The machine prepares for manual feeding. When it is ready, the machine will “beep.” 2. Insert the sheets for one set in the manual feed section.
Page 76 Manual Feeding has been selected, 1. Press the Start button. The machine will prepare for manual feeding. When it is ready, the machine will “beep.” 2. Insert a sheet in the manual feed section. - Push the sheet toward the manual feed stopper and hold it.
Page 77 Manual Feeding has been selected, 1. Press the Start button. The machine will prepare for manual feeding. When it is ready, the machine will “beep.” 2. Insert a sheet in the manual feed section. - Push the sheet toward the manual feed stopper and hold it.
Page 78: Saving, Loading And Deleting Jobs
3-8-1 Saving, Loading and Deleting Jobs Saving a Job A job which is used frequently should be saved Binding-Operation Screen and loaded using the Memory screen. This sec- tion explains how to save, load, and delete a job. 3-8-1 Saving a Job Memory-Main Screen Before saving a job, finish the changeover and fine adjustments so that the machine is neces-...
Page 79: Loading A Job
3-8-2 Saving, Loading and Deleting Jobs Loading a Job 3-8-2 Loading a Job Press Binding-Operation Screen The Memory-Main screen is displayed. Memory-Main Screen Select the number for the job you want to load. - There are two ways to select the job number: 1.
Page 80 3-8-2 Saving, Loading and Deleting Jobs Loading a Job Do the changeover. Setting-Finishing Size Screen All parts of the machine start to move to the saved positions. - If this is the first changeover since the power was turned on, press All the job information is loaded - not just the binding pattern and size data, but also the fine 21102...
Page 81: Deleting A Job
3-8-3 Saving, Loading and Deleting Jobs Deleting a Job 3-8-3 Deleting a Job Binding-Operation Screen Press The Memory-Main screen is displayed. Memory-Main Screen Select the number of the job you want to delete. - There are two ways to select the job number: 1.
Page 82: Power Saving Mode
Power Saving Mode Select the power saving mode if the machine will not be operated for a long time. This Binding-Operation Screen decreases standby power consumption and saves energy. When returning from the power saving mode, always save the current settings to the job memory before entering the power saving mode.
Page 83: 3-10Reversing The Stitcher Heads
3-10 Reversing the Stitcher Heads If you are stitching a very thick booklet, or if the stitch jams because of overstitching, the stitcher heads may be locked. If this happens, reverse the stitcher heads. Clincher Lever Press the Stitcher Jog button while pressing the Machine Jog button.
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Page 85: Adjustments
4 Adjustments This chapter explains how to adjust each section as needed. Stitch Adjustments This section explains how to change the Shorten Lengthen appearance of the stitch. Wire Length Wire Length After you make an adjustment, the first stitch may not be made correctly. Check the second stitch.
Page 86 Stitch Adjustments Wire Straightening Adjustment The wire is supplied in a coil, so it is not straight. Adjust the wire so that it comes out straight. Wire Adjusting Lever 11119 40101I1 11119 40101M1 Move the leaf spring to the right and remove the former.
Page 87: Infeed Section Adjustments
Infeed Section Adjustments Weight Adjustment - The "drive" provided by the transport rollers can be adjusted by changing the positions of the weights. (Normally the weights are positioned in the mid- dle.) - Move each weight toward the stitcher when feeding thick papers or multiple sheets.
Page 88 Infeed Section Adjustments Lifter Attachment - Attach lifter if thin sheets are folded as they move. - Remove lifter if thick sheets do not move smoothly. - Attach the lifter to the lower guide in the infeed sec- tion. 11119 40201G1 11119 40201H1...
Page 89: Jog Section Adjustments
Jog Section Adjustments Sheet Holder Attachment - This holder helps to control the sheet if a thin sheet floats and goes beyond the stopper. 11119 40301A1 - Three types of sheet holders are available. Use the correct type to match the binding pattern and sheet size.
Page 90 Jog Section Adjustments Top and Bottom Guide Parallel Adjustment Administrator Mode Screen - Check that the top and bottom guides are parallel to the frame of the machine. If the machine is installed with the casters touching on the floor, the frame itself may be distorted.
Page 91: Fold Section Adjustments
Fold Section Adjustments Fold Skew Adjustment - Fold skewing can be corrected by changing the angle of the fold section stopper. - Correct for fold skewing by turning the fold skew correction knob. To find the standard setting, turn the knob clockwise as far as possible.
Page 92: Fore-Edge Trim Section Adjustments
Fore-edge Trim Section Adjustments Transport Belt Gap Adjustment Booklet Stopper Transport Belt - If the booklet bounces when it hits the stopper, it may not be trimmed to the set finishing size. - If this happens, reduce the gap at the transport belts to prevent the booklet from flipping over.
Page 93 Fore-edge Trim Section Adjustments Infeed Belt Pressure Adjustment - Adjust the pressure of the infeed belts to match the booklet weight. - Increase the pressure of the infeed belts if the booklet stops at the entrance of the fore-edge trim section.
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Page 95: Troubleshooting
5 Troubleshooting This chapter explains how to correct some typical problems. If an Icon Is Displayed on the Error Screen 5-1-1 If An Error Icon Is Displayed If a problem occurs, a sensor will detect the problem and stop the machine. Icons which indicate the error status are displayed on the touch panel.
Page 96 If an Icon Is Displayed on the Error Screen Icon Explanation Icon Explanation A jog error has occurred in the fold section. Press An error has occurred in the upstream If the sheets are not arranged correctly in device. the stitch section, increase the jogging fre- Clear the error in the upstream device, and quency using the Binding Status Setting press...
Page 97 If an Icon Is Displayed on the Error Screen Last set If the faulty set ejecting function is turned on and a faulty set is delivered to the faulty set ejecting tray correctly, the icons indi- cate the cause of the problem. If the same error is displayed repeatedly, follow the procedure listed below to correct the problem.
Page 98: If A System Error Occurs
If an Icon Is Displayed on the Error Screen 5-1-2 If a System Error Occurs If a system error icon is displayed on the screen, check the error code next to the icon, and clear the cause of the error. See the tables shown below. This icon indicates that the machine has a system error.
Page 99 If an Icon Is Displayed on the Error Screen 100 to 199 SPF Section Jam Cause and Solution There were no sheets in the jog section when the stitching operation was done. The sheets enter into the jog section before the stopper rises. Therefore, the sheets No Sheet at Jog Section may not stop at the correct position.
Page 100 If an Icon Is Displayed on the Error Screen 200 to 299 HP-200A Jam Cause and Solution Punch Cover Open Close the punch section cover. Infeed Error to Infeed The booklet is transported from the upstream device. However, the HP-200A Section entrance sensor did not detect the booklet.
Page 101 If an Icon Is Displayed on the Error Screen 800 to 899 SPF Option Error Cause and Solution Front Stitch Detection The machine did not make a front stitch. Error Check if the wire has run out, or if the wire is jammed. Rear Stitch Detection The machine did not make a rear stitch.
Page 102 If an Icon Is Displayed on the Error Screen 1200 to 1299 HP-200A System Error Cause and Solution 1200 Interlock Contactor Fault There is a problem with the interlock contactor K00. Please call your local dealer. Turn off the power switch, and wait about 10 minutes, then turn it on again. 1201 Inverter Alarm If the problem occurs again, please call your local dealer...
Page 103 If an Icon Is Displayed on the Error Screen SPF Section Home 4100 to 4199 Cause and Solution Positioning Error After you press OK to correct the error, the machine will do a changeover. At this point, the forward/back position of the main part of the machine is not correct. (This error will not be displayed again as long as the machine is homed again.) Check if the main part of the machine moves forward or back by pressing the button M02 Body Fore/Back...
Page 104 If an Icon Is Displayed on the Error Screen SPF Section Home 4100 to 4199 Cause and Solution Positioning Error Please call your local dealer. After you press OK to correct the error, the machine will do a changeover. At this M42 Fold Section For- point, the fold section forward roller is not at the correct position, and it may interfere 4142...
Page 105 If an Icon Is Displayed on the Error Screen HP-200A 4200 to 4299 Cause and Solution Home Positioning Error M13 Transport Belt Up/ Please call your local dealer. After you press OK to correct the error, the machine will 4213 Down Motor Home Posi- do a changeover.
Page 106 If an Icon Is Displayed on the Error Screen HP-200A 7200 to 7299 Cause and Solution Communication Error Control Board Commu- 7200 Please call your local dealer. nication Error Fore-edge Trim Section 7300 to 7399 Cause and Solution Communication Error Control Board Commu- 7300 Please call your local dealer.
Page 107: Removing Jammed Sheets
Removing Jammed Sheets A small size sheet stops at the entrance of the SPF-200A/200L and cannot be removed. Sheet - Lift the upper transport section by holding the han- dle, and remove the sheet. - Press the Jog button on the remote control for the VAC to move the sheets.
Page 108 Removing Jammed Sheets Sheets jam between the fold rollers and the press rollers. Horizontal Transport 1. Open the cover and lift the horizontal transport Section section. 11119 50201C1 Sheet Guide Lock- ing Knob 2. Remove the sheet guide locking knob and remove the sheet guide.
Page 109: Stitch-Related Problems
Stitch-Related Problems 5-3-1 The Stitches Are Moved Parallel to the Fold Line Related Where to Check Cause and Solution Item Make a fine - Adjust the stitch position using the Binding-Fine Adjust-Stitch screen. adjustment using the Fine Adjust screen. 21102 50301B1 3-4-3 When doing sad-...
Page 110: The Stitch Position Varies
Stitch-Related Problems 5-3-4 The Stitch Position Varies Related Where to Check Cause and Solution Item There are no - See if the sheets move while they are being jogged. If the sheets move, there is a gap. gaps between the sheets and - Adjust the following items to match the sheet the top and bot- size using the Binding-Fine Adjust-Stitch Sec-...
Page 111: The Sheets Are Not Stitched
Stitch-Related Problems 5-3-7 The Sheets Are Not Stitched Related Where to Check Cause and Solution Item The wire feed On/ - Turn the wire feed On/Off knob and close the gap shown by arrow on the illustration to the left. Off knob may be set to the Off position.
Page 112: The Shape Of The Stitch Is Incorrect
Stitch-Related Problems 5-3-9 The Shape of the Stitch is Incorrect Related Stitch Pattern Where to Check Cause and Solution Item The clincher - If the clincher points are worn, the stitch will not be bent completely. points may be worn out. - Replace the clincher points.
Page 113 Stitch-Related Problems 5-3-9 The Shape of the Stitch is Incorrect (Continued) Related Stitch Pattern Where to Check Cause and Solution Item The wire - Use a different type of wire. may be too fragile. The wire - For a standard bender, use wire No.26 to No.28. thickness - Use the wire No.26 (diameter 0.5 mm [0.02"]) to No.28 (diam- 11119...
Page 114 Stitch-Related Problems 5-3-9 The Shape of the Stitch is Incorrect (Continued) Related Stitch Pattern Where to Check Cause and Solution Item The wire - Adjust the angle of the eccentric shaft so that the wire is fed straight. must be straight.
Page 115: Poor Sheet Arrangement
Poor Sheet Arrangement Related Where to Check Cause and Solution Item There should be - Move the sheets while they are being jogged. If the sheets move, there is a gap. no gaps between the sheets and - Adjust the following items to match the sheet the top and bot- size using Binding-Fine Adjust-Stitch Section tom guides, or...
Page 116 Poor Sheet Arrangement Related Where to Check Cause and Solution Item The jogging fre- - Increase the jogging frequency using the Bind- ing-Status Setting-Collator/Faulty Set Detect/ quency setting is Manual Feed/Stitch screen. too small. Page 24 21102 50401G1 The stitch delay - Increase the stitch delay time using the Binding- Status Setting-Collator/Faulty Set Detect/Man- time is too short.
Page 117: Folding-Related Problems
Folding-Related Problems 5-5-1 Fold Skewing Related Where to Check Cause and Solution Item The sheets are - Turn on the stitch section top and bottom guide delivery stroke using the Binding-Status Setting- not straight when Collator/Faulty Set Detect/Manual Feed/Stitch they are trans- screen.
Page 118: Failed To Fold At Correct Position
Folding-Related Problems 5-5-2 The Folding Position Varies (Continued) Related Where to Check Cause and Solution Item The buckle gap - Uneven folding can occur if the buckle gap is too wide, or if it is too narrow. must be set cor- rectly.
Page 119: Jog Error Not Detected
Folding-Related Problems 5-5-3 Failed to Fold at Correct Position (Continued) Related Where to Check Cause and Solution Item A piece of paper - Press the Emergency Stop button, remove the fold section cover, and lift the buckle gap adjust- may be left inside ing knob and check inside the machine.
Page 120: Fore-Edge Trimming-Related Problems
Fore-edge Trimming-Related Problems 5-6-1 The Sheets Are Trimmed Incorrectly Related Where to Check Cause and Solution Item The sheets may - Select for the fold section jog direction not be straight on the Binding-Status Setting-Fold/Fore-edge when they are to Trim/Conveyor screen. the fore-edge Page 25 - The default setting for the fold section top and...
Page 121: Scratched Sheets
Scratched Sheets Related Where to Check Cause and Solution Item Sheets may be - The sheet holders are angled downward too much, causing the sheet to be scratched. Angle scratched by the the sheet holders upward a little. sheet holders in the infeed sec- tion.
Page 122: Specific Symptom-Related Problems
Specific Symptom-Related Problems 5-8-1 The Buzzer Beeps at an Interval of Two Seconds Related Where to Check Cause and Solution Item The trim chute is - Remove the trim from the trim chute. full. - If the binding operation continues for another minute after the alarm sounds, feeding will stop.
Page 123: The Touch Panel Does Not Light Up
Specific Symptom-Related Problems 5-8-5 The Touch Panel Does Not Light Up Related Where to Check Cause and Solution Item A circuit breaker - Check whether the main circuit breaker (Q00) has tripped. If the circuit breaker has tripped, on the SPF- wait a few minutes, and then turn on the circuit 200A/200L has breaker.
Page 124: Other Problems
Other Problems 5-9-1 The Booklets Overlap Each Other at the Delivery Conveyor though They are Offset Related Where to Check Cause and Solution Item The delivery - Increase the delivery conveyor run distance for offset function using the Binding - Status Setting conveyor run - Fold/Fore-edge Trim/Conveyor screen (press distance for offset...
Page 125: Maintenance
6 Maintenance This chapter describes how to clean the machine, replace the consumables and lubricate the parts. Loading Stitch Wire Place the wire coils on the rods. - Be aware of the wire direction when attach- ing the coils. - The standard accessory wire is No.26 (0.5 mm in diameter).
Page 126: Threading The Wire Through The Stitcher Head
Threading the Wire Through the Stitcher Head This section shows how to thread the wire Open Close through the stitcher heads. Turn the wire feed On/Off knob to the Off position. 11119 60201A1 Off: No wire feed On: Wire feed turned on Thread the wire along the path as shown in the figure to the right.
Page 127: Attaching The Transport Pusher
Attaching the Transport Pusher The pusher may be removed if there are paper jams. If this happens, mount the transport pusher. Turn off the power switch. Attach the transport pusher. 11119 60301A1 - The transport belt can be moved freely when the power is turned off.
Page 128: Lubrication
6-4-1 Top and Bottom Guide Slide Shaft Lubrication 6-4-2 Stitcher Vertical Slide Shaft 6-4-3 Fold Knife Section Lubricate the following parts in specified fre- These icons show how to lubricate] quency. The icons to the right show how to lubricate the parts. = Apply grease with a brush.
Page 129: Stitcher Head
6-4-4 Stitcher Head Lubrication 6-4-5 Clincher Drive Cam 6-4-4 Stitcher Head Wire Lubrication This section explains how to lubricate the Felt stitcher heads. Lack of regular lubrication Slide causes the stitcher heads to wear more Groove quickly so that they must be replaced more often.
Page 130: Cleaning
6-5-1 Around the Stitcher Heads Cleaning 6-5-2 Transport Belts / Transport Rollers WARNING Turn off the power switch when cleaning the inside of the machine. Otherwise, the machine can start suddenly, causing severe personal injury. 6-5-1 Around the Stitcher Heads - If pieces of wire and paper dust collect around the stitcher heads, vacuum them up.
Page 131: Sensors
6-5-3 Sensors Cleaning 6-5-3 Sensors If a sensor is fouled with paper dust, the machine will not work properly. Every month, remove any dust on the sensors shown in the figure below with a cloth or a brush. Infeed Conveyor Sensors Stitch Section Sheet Detect Fold Section Delivery Sensor...
Page 132 Cleaning Faulty Set Detect Sensor Loosen the two screws to remove the sensor attachment support before cleaning. Clean the sensor using a brush. Reflector 11119 60503I1 Sensor Attachment Faulty Set 11119 60503I1 Support Detect Sensor 11119 60503A1...
Page 133: Replacing The Fore-Edge Trim Knife
6-6-1 Replacing the Fore-edge Trim Knife Upper Knife Replacement WARNING - When replacing the knife, wear gloves and do not touch the edge of the knife directly. The knife is extremely sharp, and may cause severe personal injury. - Turn off the power switch before replac- ing the knife.
Page 134 6-6-1 Replacing the Fore-edge Trim Knife Upper Knife Replacement Remove the pipe bracket. Upper Knife Remove the upper knife. - Remove the four mounting screws. - Hold the knife using the handle. Pipe Bracket Remove the handle from the upper knife and install it on the new knife.
Page 135: Lower Knife Replacement
6-6-2 Replacing the Fore-edge Trim Knife Lower Knife Replacement 6-6-2 Lower Knife Replacement Adjuster Bolt Locking Nut Remove the upper knife. (Refer to the previous page.) Remove the lower knife. 21102 Trim Base 60602B1 Loosen the two inside mounting screws with the accessory ratchet wrench.
Page 136 6-6-2 Replacing the Fore-edge Trim Knife Lower Knife Replacement Lower the upper knife. - Press the Trim Knife Reverse Jog button and lower the upper knife as low as possi- ble. Lock the lower knife while lightly Trim Knife Reverse pressing against the upper knife.
Page 137 6-6-2 Replacing the Fore-edge Trim Knife Lower Knife Replacement Move the lower knife forward slightly. 1. Loosen the mounting screws at both ends with an Allen wrench. 2. Turn each adjuster bolt 60 degrees clockwise. - Turn the adjuster bolts evenly. 3.
Page 138: Clincher Point Replacement
Clincher Point Replacement If the clincher points are worn out, the stitch may not be bent enough. 11119 60701A1 Replace the clincher points when they are worn out. Remove the clincher. 11119 60701B1 Be careful not to drop the nut plate on the rear side.
Page 139: Guide Sheet Replacement
Guide Sheet Replacement - If the upper and lower sections of the top and bot- tom guides are not removed before changeover to a small size setting, the guide sheet may be dam- aged. If this happens, replace the guide sheet (accessory).
Page 140: Stitcher Head Removal / Attachment
6-9-1 Stitcher Head Removal / Attachment 6-9-2 6-9-1 Stitcher Head Removal Turn off the power switch. Cut the wire and stick the end of wire in the wire coil. T-Nut Loosen the locking screw for the T-nut on the stitcher head. - Loosen with a T-wrench.
Page 141 6-9-2 Stitcher Head Removal / Attachment Remove the head guide. - Just loosen the screws. Head Guide 11119 60902J1 Screws Turn the wire feed On/Off knob to Open Close the Off position. 11119 60201A1 Off: No wire feed On: Wire feed turned on Close the cover and press the stitch jog button to stop the bender at the lower position.
Page 142 6-9-2 Stitcher Head Removal / Attachment Fit the positioning gauge on the bender and push it down to fit it on Click Bender the clincher also. Positioning gauge Clincher Fasten the stitcher head. - Tighten the mounting screw for T-nut. T-nut 11119 60902K1...
Page 143 6-9-2 Stitcher Head Removal / Attachment Remove the stitcher head cover on the operator side. Timing Pulley - The cover can be removed by removing one mounting screw. ñÒ1mm 11119 60902E1 11119 60902F1 Move the stitcher head outward. Proximity Sensor - Rotate the timing pulley by hand so that the tip of the detection bar is next to the proxim- ity sensor shown in the figure to the right.
Page 144: 6-10Resetting The Circuit Breakers
6-10 Resetting the Circuit Breakers WARNING Turn off the power switch before resetting any circuit breaker. Otherwise, the machine may start suddenly, causing severe personal injury. Identify the tripped breaker by Error Screen checking the symptom of problem. - Any breaker may trip if the following error codes are displayed on the Error screen.
Page 145: 6-11Replacing The Fuses
6-11 Replacing the Fuses WARNING - Fuse replacement must be supervised by a maintenance administrator. - Turn off the power switch and unplug the power cord before replacing a fuse. Identify which fuse has blown by checking the machine. Spare Fuses Fore-edge Trim Knife Section 1102 11119...
Page 146 This page is intentionally left blank.
Page 147: Installation
7 Installation The steps in this section can be done only by authorized service personnel. Installing the Main Unit Lifting the SPF Main Unit Lifting the Fore-edge Trim Section Attach a rope to the four eyebolts on the corners and hoist the SPF. 11119 70101B1 11119...
Page 148 Installing the Main Unit If the main part of the SPF is con- nected directly to a collator, install the IFU-200 Infeed Conveyor. 1. Remove the rear cover on the SPF main unit 11119 70101K1 and the rear cover on the IFU-200. 2.
Page 149: Installing The Fore-Edge Trim Section
Installing the Fore-edge Trim Section Connect the wiring between the Rear View fore-edge trim section and the main part of the SPF. 1. Remove the terminating connector and con- nector for stand-alone machine from the SPF main unit. 11119 70201A1 11119 70201G1 Connector for Stand-...
Page 150 Installing the Fore-edge Trim Section Remove the locking parts on the fore-edge trim section. 11119 Locking 70101H1 parts Attach the leveling bolts. Leveling Bolt (Long) 1. Remove the front cover. 2. 1 long and 2 short leveling bolts are Mounting included.
Page 151: Attaching The Accessories
Attaching the Accessories Attaching the Touch Panel Stopper Attaching the Bracket for the Sheet Holder Stopper 11119 11119 70301B1 70301A1 Attaching the Wire Guides Place each wire guide over the end of the wire tube and lock it in place using knob.
Page 152 Attaching the Accessories Attaching the Faulty Set Ejecting Tray Hook the faulty set ejecting tray into the slot on the fore-edge trim section. Attach the supports to the faulty set ejecting tray. Attach the faulty set ejecting tray Support using the screws. 11119 70301F1 Stay...
Page 153: Installing The Delivery Conveyor
7-4-1 Installing the Delivery Conveyor SC-200 Short Conveyor 7-4-1 SC-200 Short Conveyor Attach the hanger bolts only if the delivery conveyor is connected to the SPF main unit. - This step is unnecessary for the fore-edge trim section because the hanger bolts are already attached.
Page 154: Long Conveyor
7-4-2 Installing the Delivery Conveyor LC-200 Long Conveyor 7-4-2 LC-200 Long Conveyor Attach the hanger bolts only when connecting the delivery conveyor with the SPF main unit. - This step is unnecessary for the fore-edge trim section because the hanger bolts are already attached.
Page 155: Connecting To An Upstream Device
Connecting to an Upstream Device Connecting the Collator Connecting the ST-40 No connec- tion here. Docking Plate Lower Cover 11119 70501G1 Connection to ST-40 Lower Cover 11119 70501E1 ST-40 Height Collator Height Collator Delivery Section Match the height. Match the height 111191 70501H1...
Page 156 Connecting to an Upstream Device Connecting the HOF-400 / AC-400 No connection here. Lower Cover 11119 70501J1 AC-400 Height Match the Match the height height. 16053 10201B1 AC-400 Refer to the user's manual for the HOF-400 for height adjustment of the AC-400 and installa- tion of the HOF-400.
Page 157 Connecting to an Upstream Device Connecting the HOF-30/HOF-20 Connecting the BC-20 No connec- tion here. No connection here. 11119 70501A1 Lower Cover 11119 70501C1 Lower Cover HOF Height BC-20 Height Match the Match the height. height. 111191 111191 70501B1 HOF-30/ 70501D1 BC-20 HOF-20...
Page 158: Checking Rom Versions Of Connected Devices
Checking ROM Versions of Connected Devices When the VAC-100/VAC-60H, ST-40, BC-20, or HOF-20/HOF-30 are connected with the SPF- S/N023899 200A/SPF-200L, check that the ROM versions or before for these devices are V.5.00 or above. QPM-157 VAC-60H QPM-120 ROM Name ROM Version Image Image Control ROM: VAC-60H...
Page 159 Checking ROM Versions of Connected Devices ST-40 ROM Name ROM Version Control ROM: ST-60 V.5.00 or above The machine which serial number is S/N364123 or above are shipped with ROM V.5.00 or above. QPM-139 11119 70601E1 BC-20 ROM Name ROM Version Control ROM: BC-20 V.5.00 or above The machine which serial number is S/N306003 or...
Page 160: Connecting The Main Unit Power Cable
Connecting the Main Unit Power Cable CAUTION Call an electrician when connecting the main unit power cable directly to the circuit breaker on the distribution panel in the building. Turn off the circuit breaker on the distribution panel. Connect the power cable for the main unit to the power source (dis- tribution panel).
Page 161: Setting The System Configuration
Setting the System Configuration Set up the system configuration using the Administrator Mode screen. Initial Screen Turn on the power switch. - If the icon is displayed on the Initial screen, press the button and go to Step 5. 11119 70701O1 Information Screen Password Entry Screen...
Page 162: Setting Up For Optional Devices
Setting Up for Optional Devices Set up the connected optional devices using the Administrator Mode screen. Administrator Screen Display the Service screen. Press the icon. The Option-Setting screen is displayed. Press the buttons for the optional devices which are connected. 21102 70801A1 = Horizontal Transport Unit...
Page 163: 7-10Synchronizing Between The Devices
7-10 Synchronizing Between the Devices The transport speeds for all of the devices are Information Service Screen set automatically so the sheets move smoothly between the units. Display the Transport Speed Adjustment screen screen. - Press the icon on the Service screen.
Page 164 7-10 Synchronizing Between the Devices Press the The settings are saved and the Transport Speed Adjustment screen is displayed. Press the icon and then press the icon. Press the icon. The Save screen is displayed. Press the The settings are saved and the Transport Speed Adjustment screen is displayed.
Page 165: Options
8 Options This chapter explains how to use optional devices. 8-1-1 Preset Kicker PK-30 Installation of Preset Kicker The Preset Kicker PK-30 can be installed only when the fore-edge trim section is connected. 8-1-1 Installation of Preset Kicker Install the preset kicker on the delivery conveyor as shown in the figure at right.
Page 166: Operation
8-1-2 Preset Kicker PK-30 Operation 8-1-2 Operation Set the preset kicker (PK-30) to match with a booklet width. Shorter Stopper Bar - Set the longer stopper bar outside of the Fore-edge Trim Section delivered booklet. - Set the shorter stopper bar, which is pushed down when kicking, so that it hits the side of the delivered booklet as shown in the figure at right.
Page 167: Paper Insertion Kit Pn-200
8-2-1 Paper Insertion Kit PN-200 Operation 8-2-1 Operation Load sheets to be inserted on the a Tawer m,c Tawer using lowest bins on the collator. 11119 80201A1 Sheets to be inserted The size of sheet which can be inserted - A inserted sheet is transported by the trans- port pusher for paper insertion.
Page 168 8-2-1 Paper Insertion Kit PN-200 Operation Set up the job on the Setting Binding-Status Setting-Option Screen Screen and do the changeover. - Refer to 3-2 to 3-5 for details. Turn on the PN-200 on the Status Setting-Option screen. - Press (PN-200) on the Binding-Sta- tus Setting-Option screen.
Page 169: Installation Of Paper Insertion Kit
8-2-2 Paper Insertion Kit PN-200 Installation of Paper Insertion Kit 8-2-2 Installation of Paper Insertion Kit This section explains how to install the paper insertion kit to the main unit. Remove the front and rear cover on the SPF main unit. Replace the fold knife.
Page 170 8-2-2 Paper Insertion Kit PN-200 Installation of Paper Insertion Kit 8-2-2 Installation of Paper Insertion Kit (continued) Remove the aluminum stay from the main unit. Aluminum Stay 11119 80202D1 Install the roller unit to the alumi- num stay. Mounting Screws - Fasten the mounting screws while the bracket is lifted up.
Page 171 8-2-2 Paper Insertion Kit PN-200 Installation of Paper Insertion Kit 8-2-2 Installation of Paper Insertion Kit (continued) Check if the roller pressure is appropriate. 1. Push the plunger up to the top. The rollers touch the belt. - If the rollers do not touch the belt, turn the aluminum stay to the direction "A"...
Page 172 8-2-2 Paper Insertion Kit PN-200 Installation of Paper Insertion Kit Set up on the Service screen. Information Screen 1. Enter into the service mode. 2. Press on the Service screen. 3. Press 4. Press to go back to the Informa- tion screen.
Page 173 8-2-2 Paper Insertion Kit PN-200 Installation of Paper Insertion Kit 8-2-2 Installation of Paper Insertion Kit (continued) Set up on the touch panel. 1. Display the Administrator Mode-Option Information Screen screen. 21102 80201H1 Administrator Mode Screen 21102 80201I1 Option Screen 2.
Page 174: Four Stitching Kit Fst-200
8-3-1 Four Stitching Kit FST-200 Accessories for Four Stitching Kit 8-3-1 Accessories for Four Stitching Kit Wire Attaching Bars 2 pcs Wire Brakes 2 pcs 11119 80301B1 11119 80301A1 Washers Each 2 Mounting Screws and Wing Nuts for Each 2 Wire Attaching Bar 11119 11119...
Page 175 8-3-1 Four Stitching Kit FST-200 Accessories for Four Stitching Kit 8-3-1 Accessories for Four Stitching Kit (continued) Head Guides 2 pcs Wire Feeding Detection Sensor 2 pcs Brackets Mounting Screws B4-8CRZP 4pcs 11119 80301H1 11119 80301G1 Gauges 2 pcs Relay Wire 1 pc This gauge is used to position the inside stitcher...
Page 176: Installation Of Clincher
8-3-2 Four Stitching Kit FST-200 Installation of Clincher 8-3-2 Installation of Clincher Nut Plate Install the clincher to the mounting block. Insert the pusher into the clincher. SB5-20 Pusher Face inside 11119 80302A1 Install the mounting block to the main unit. - The screws are still loosened.
Page 177: Installation Of Stitcher Head
8-3-3 Four Stitching Kit FST-200 Installation of Stitcher Head 8-3-3 Installation of Stitcher Head Install the head slider to the stitcher head. 1. Loosen the locking screw for T-shaped nut on the stitcher head. Use a T-wrench to T-shaped Head Slider loosen.
Page 178 8-3-3 Four Stitching Kit FST-200 Installation of Stitcher Head 8-3-3 Installation of Stitcher Head (continued) Adjust the Stitcher head position. 1. Press the stitch jog button to lower the bender. - Lock the bender where it is raised 0.2 to 0.5 mm from the lowest position.
Page 179: Wire Attachment
8-3-4 Four Stitching Kit FST-200 Wire Attachment 8-3-4 Wire Attachment Install the wire attaching bar on Wing Nut the main unit. Washer(Small) Attach the wire coil. Washer (Large) - Refer to 6-1. Washer (Medium) 11119 80304A1 Install the wire guide. Wire Guide 1.
Page 180 8-3-4 Four Stitching Kit FST-200 Wire Attachment 8-3-4 Wire Attachment (continued) 6. Install the relay wire for the sensor. Cable No. 136 Cable No. 137 - Connect the relay wire to the connector (8 pins) on the rear side of the stitcher head unit.
Page 181: Option Setup
8-3-5 Four Stitching Kit FST-200 Option Setup 8-3-5 Option Setup Display the Administrator Mode- Option screen. Information Screen 21102 80201H1 Administrator Mode Screen 21102 80201I1 Option Screen Press Press and go back to the Information screen. 21102 80305A1...
Page 182: Limitation For Use
8-3-6 Four Stitching Kit FST-200 Limitation for Use 8-3-6 Limitation for Use - Minimum sheet width for four stitching Minimum sheet width for four 270.0 mm (10.630") stitching 270.0 mm (10.630") 11119 80306A1 - Minimum distance of the outside stitch Finishing Size Screen 190 mm (7.485") for The distance for loop stitch...
Page 183: Side/Corner Stitch Kit Ssk-200/Ssk-200L
8-4-1 Installation of Side/Corner Stitch Kit SSK-200/SSK-200L Side/Corner Stitch Kit 8-4-1 Installation of Side/Corner Stitch Kit Remove the front and rear covers on the main unit. Bearing Remove the drive belt. Rear Remove the drive pulley shaft. Drive Belt 1. Remove the bearing on the operation side. 2.
Page 184 8-4-1 Installation of Side/Corner Stitch Kit SSK-200/SSK-200L Side/Corner Stitch Kit 8-4-1 Installation of Side/Corner Stitch Kit (continued) Install the horizontal transport unit to the main unit. - Match the screw with the ditch of the shaft to Bearing lock the bearing. Pulley Snap Ring...
Page 185 8-4-1 Installation of Side/Corner Stitch Kit SSK-200/SSK-200L Side/Corner Stitch Kit 8-4-1 Installation of Side/Corner Stitch Kit (continued) Install the lever. Lever 21102 80401J1 Install the solenoid only when the fore-edge trim section is installed. Guide Plate 1. Remove the front cover of the fore-edge trim section.
Page 186: Option Setup
8-4-2 Side/Corner Stitch Kit SSK-200/SSK-200L Option Setup 8-4-2 Option Setup Display the Administrator Mode- Option screen. Information Screen 21102 80201H1 Administrator Mode Screen 21102 80201I1 Option Screen Press Press and go back to the Information screen. 21102 80305B1...
Page 187: Mis-Stitch Detector Sds-200
8-5-1 Mis-stitch Detector SDS-200 Installation of Mis-stitch Detector 8-5-1 Installation of Mis-stitch Detector Four units of SDS-200 cannot be installed for the Four Stitching Kit FST-200. Only two units can be installed in the machine. Prepare for the wiring on the front. 1 Stitcher Head Left Cover 1.
Page 188 8-5-1 Mis-stitch Detector SDS-200 Installation of Mis-stitch Detector Install the mounting bracket to the clincher. 21102 21102 80501H1 80501G1 21102 80501E1 Fasten the cable on the cable bracket with nylon ties. - The mounting bracket moves laterally according to the stitch position. Fasten the cable so that it cannot be stretched.
Page 189 8-5-1 Mis-stitch Detector SDS-200 Installation of Mis-stitch Detector Install the sheet holding brush. 1. Remove the standard head guide and replace it with the head guide which is included in the SDS-200. Head Guide You can adjust the angle of brush by loosening this screw.
Page 190: Operation
8-5-2 Mis-stitch Detector SDS-200 Operation 8-5-2 Operation Set up the job on the Setting Screen and do the changeover. - The SDS-200 cannot be used in the corner stitching operation. The mis-stitch detector can be used in the range of sheet size as follows. - Saddle Stitch and Fold Only For the SPF-200A Max.
Page 191: Thickness Detector Td-200
8-6-1 Thickness Detector TD-200 Installation of Thickness Detector 8-6-1 Installation of Thickness Detector Turn off the power switch. Open the upper cover. Enter the short leg of a 5 mm Allen wrench into the hole of the middle clamp rod. 21102 80601B1 Hold the clamp rod with the Allen...
Page 192 8-6-1 Thickness Detector TD-200 Installation of Thickness Detector Take the TD-200 until and just Screws loosen 4 screws that fix the brack- Bracket ets to the bar. Put the TD-200 into the machine, Screws 11119 so that the Laser unit is located 80501J1 Bracket above the reflector nut.
Page 193: Calibrating The Td-200
8-6-2 Thickness Detector TD-200 Calibrating the TD-200 8-6-2 Calibrating the TD-200 Close all covers. Information Screen Turn on the power switch. Display the Administrator Mode- Option screen. 21102 80602A1 Administrator Mode Screen 21102 80602B1 Option Screen Press (TD-200). Press to go back to the Information screen.
Page 194 8-6-2 Thickness Detector TD-200 Calibrating the TD-200 If not then adjust the height of laser unit. - Adjust the brackets of the bar, or the mount- ing plate of the Laser unit until the value is within the correct range. Loosen Loosen - Point the laser beam in the center of the...
Page 195: Operation
8-6-3 Thickness Detector TD-200 Operation 8-6-3 Operation Set up the job on the Setting screen and do the changeover. This thickness detector function can be - Refer to 3-2 to 3-5 for details. used only when the "saddle stitch" or "fold only"...
Page 196 8-6-3 Thickness Detector TD-200 Operation Start binding. - After the start of binding, the first booklet thickness is stored in the machine. The sec- ond and later booklet thicknesses are deter- mined based on the stored thickness. - The reference thickness value is updated every four booklets during operation.
Page 197: Chip Extractor Tb-200
8-7-1 Chip Extractor TB-200 Operation 8-7-1 Operation Turn on the chip extractor function on the Status Setting-Option screen. 21102 80701A1 Set the panel on the chip extractor. 21102 80701B1 Air blows during Air blows while the Breaker operation. breaker is turned on. Power switch on the this unit...
Page 198: Installation Of Chip Extractor
8-7-2 Chip Extractor TB-200 Installation of Chip Extractor 8-7-2 Installation of Chip Extractor Install the chip extractor as shown in the figure at right. Connect the grounding wire. - The grounding wire is connected with the base plate of the trims container stand. - Clip the grounding wire with the wire-mesh part of the trim container.
Page 199 8-7-2 Chip Extractor TB-200 Installation of Chip Extractor 8-7-2 Installation of Chip Extractor (continued) Display the Administrator Mode- Option screen. Information Screen 21102 80201H1 Administrator Mode Screen 21102 80201I1 Option Screen Press Press and go back to the Information screen. 21102 80702B1...
Page 200: Loop Stitching
Loop Stitching 8-8-1 Loop Stitcher Head Replacement Remove the stitcher head. - See Section 6-9-1. Specifications of Loop Stitcher Head: - Inner diameter of loop: 6 mm (0.24") - Wire: thick type No 24 to 26 (diameter: 0.6 to 0.5 mm or 0.024"...
Page 201 Loop Stitching Install the adjusting block and guide. Standard Spring Install the spring for loop stitch- ing. - For loop stitchinng, the both two springs are Spring for Loop necessary to install. Stitching Install the former used for loop stitching. - Then, lower the spring plate.
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Page 203: Appendix
9 Appendix This chapter lists the specifications and accessories for this machine. Specifications 9-1-1 SPF-200A Saddle Stitch, Fold only and Top Stitch and Fold Functions (Option SSK-200A : Top/Side Stitch, Rear Corner Stitch, Front Corner Stitch, Pass Through) Saddle Stitch and Fold Only Max.
Page 204 Specifications 9-1-1 SPF-200A (Continued) 73 to 290 mm (2.875" x 11.400") Adjustable Stitch Distance When saddle stitching, the stitch distance can be limited by the fold knife Corner Stitching Position*2 6mm (0.24") Fired 3 to 15 mm (0.120" to 0.590") Adjustable Standard : No.26 (0.5 mm) Stitching Wire Option : No.27 (0.45 mm)
Page 205 Specifications 9-1-1 SPF-200A (Continued) SPF Main Body : 2,830 kJ (680 kcal) Heat Output Delivery Conveyor (SC/LC) : 10 kJ (4 kcal) SPF Main Body : 400 W x 1, 200 W x 1, 25 W x 1 Motors Delivery Conveyor (SC/LC) : 15 W x 1 1,625 (W) x 810 (D) x 1,250 (H) mm Machine Dimensions (64.0"...
Page 206: Fc-200A
Specifications 9-1-2 FC-200A Untrimmed Booklet Size Length Max. W 356.0 x L 254.0 mm (14.000" x 10.000") Min. W 120.0 x L 90.0 mm (4.725" x 3.545") Width 11119 90101C1 Max. W 356.0 x L 250.0 mm (14.000" x 9.840") Finished Booklet Size Min.
Page 207: Spf-200L
Specifications 9-1-3 SPF-200L Saddle Stitch, Fold only and Top Stitch and Fold Functions (Option : Top/Side Stitch, Rear Corner Stitch, Front Corner Stitch, Pass Through) Saddle Stitch and Fold Only Max. W 356.0 x L 610.0 mm (14.000"x 24.000") Min. W 120.0 x L 180.0 mm (4.725"x 7.090") Sheet Size*1 Top Stitch and Fold (Also sheet size for manual feed)
Page 208 Specifications 9-1-3 SPF-200L (Continued) 73 to 290 mm (2.875" x 11.400") Adjustable Stitch Distance When saddle stitching, the stitch distance can be limited by the fold knife. Corner Stitching Position*2 6mm (0.24") Fired 3 to 15 mm (0.120" to 0.590") Adjustable Standard : No.26 (0.5 mm) Stitching Wire Option : No.27 (0.45 mm)
Page 209 Specifications 9-1-3 SPF-200L (Continued) SPF-200L : Single Phase 200 to 220 V, 50 / 60 Hz, 4.3 A Rated Current Single Phase 230 to 240 V, 50 / 60 Hz, 4.3 A Leak Current Single Phase 200 to 240 V, 50 / 60 Hz, 4.2 mA SPF-200L : SPF Main Body : 2,830 kJ (680 kcal) Heat Output...
Page 210 Specifications 9-1-3 SPF-200L (Continued) Noise Level eq : 77.9 dB Machine Weight SPF-200L+SSK-200L : 492 kg / 1,083.8 lb VAC-2000 + IFU-200 + SPF-200L + FC-200L + SC-200 Unit :mm(inch) FC-200L : H 1,070(42.2") SPF-200L : H1,250(49.3") SC-200 : H 705(27.8") VAC-1000 : H1,962(77.3") LC-200 LC-200...
Page 211: Fc-200L
Specifications 9-1-4 FC-200L Untrimmed Booklet Size Length Max. W 356.0 x L 305.0 mm (14.000" x 12.000") Min. W 120.0 x L 90.0 mm (4.725" x 3.545") Width 11119 90101C1 Max. W 356.0 x L 305.0 mm (14.000" x 12.000") Finished Booklet Size Min.
Page 212: Accessories
Accessories 9-2-1 SPF-200A/SPF-200L Sheet Hold-Down Plates 1 pc Guide Bars 2 pcs Wires (No.26) 2 pcs for Side Stitching each 0.5 mm in diameter 11119 11119 11119 90201B1 90201C1 90201A1 Wire Guides 2 pcs Bracket for Sheet 1 pc Sheet Holder for Side 1 pc Holder Stitching...
Page 213 Accessories 9-2-1 SPF-200A/SPF-200L (Continued) Tool Box 1 pc Reversible Driver 1 pc Ball Point Driver 1 pc 3 mm 11119 11119 11119 90201N1 90201O1 90201P1 Allen Wrench Set 1 set Handwheel 1 pc Wrenches 1 pc each 11119 11119 11119 90201Q1 90201B2 90201S1...
Page 214: Fc-200A/Fc-200L
Accessories 9-2-1 SPF-200A/SPF-200L (Continued) Guide Sheets Terminating Connector 1 pc Stand-alone Connector 1 pc sheets This connector is plugged to the This connector is plugged to the SPF-200A/200L when shipped. SPF-200A/200L when shipped. 11119 11119 11119 90202K1 90202L1 90201C2 Positioning Gauge 2 pcs For aligning the stitcher head with the clincher...
Page 215: 207
Accessories 9-2-2 FC-200A/FC-200L (Continued) Terminating Connector 1 pc Signal Cable No.12 1 pc LAN Cable 1 pc This connector is plugged to the Connector on back of the FC-200A/ 200L when shipped. 14054 50203D1 11119 90202N1 This cable is explained in page 141. This cable is explained in page 141.
Page 216: Consumables
Consumables SPF-200A/SPF-200L Grease Wire 11119 11119 11119 90201T1 90201C1 90201U1 FC-200A/FC-200L Upper Knife Lower Knife 11119 21102 90202E1 90202F1...
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Page 218 Manufacturer: www.horizon.co.jp/ Phone:+81-75-934-6700, Fax:+81-75-934-6708,...

This manual is also suitable for:

Bookletmaker fc-200a Bookletmaker spf-200l Bookletmaker fc-200l

Horizon Fitness Bookletmaker SPF-200A Manual

1 Machine Description

Automatic and Manual Settings

Machine Descriptions

Screen Descriptions

2 Checks before Operating

Checking the Emergency Stop Function

3 Operating Procedures

Overview of Operating Procedures

Setting up a Job Using the Setting Screen

Doing a Changeover

Doing a Test Binding

Confirming the Status Settings

Start Binding

Manual Feeding

Saving, Loading and Deleting Jobs

Power Saving Mode

3-10Reversing the Stitcher Heads

4 Adjustments

Stitch Adjustments

Infeed Section Adjustments

Jog Section Adjustments

Fold Section Adjustments

Fore-Edge Trim Section Adjustments

5 Troubleshooting

If an Icon Is Displayed on the Error Screen

Removing Jammed Sheets

Stitch-Related Problems

Poor Sheet Arrangement

Folding-Related Problems

Fore-Edge Trimming-Related Problems

Scratched Sheets

Specific Symptom-Related Problems

Other Problems

6 Maintenance

Loading Stitch Wire

Threading the Wire through the Stitcher Head

Attaching the Transport Pusher

Lubrication

Cleaning

Replacing the Fore-Edge Trim Knife

Clincher Point Replacement

Guide Sheet Replacement

Stitcher Head Removal / Attachment

6-10Resetting the Circuit Breakers

6-11Replacing the Fuses

7 Installation

Installing the Main Unit

Installing the Fore-Edge Trim Section

Attaching the Accessories

Installing the Delivery Conveyor

Connecting to an Upstream Device

Checking ROM Versions of Connected Devices

Connecting the Main Unit Power Cable

Setting the System Configuration

Setting up for Optional Devices

7-10Synchronizing between the Devices

8 Options

Preset Kicker PK-30

Paper Insertion Kit PN-200

Four Stitching Kit FST-200

Side/Corner Stitch Kit SSK-200/SSK-200L

Mis-Stitch Detector SDS-200

Thickness Detector TD-200

Chip Extractor TB-200

Loop Stitching

9 Appendix

Specifications

Accessories

Consumables

Quick Links

Summary of Contents for Horizon Fitness Bookletmaker SPF-200A