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Horizon Fitness BQ-270 Manual

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• 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.
040425/BQ270/10E/HS, TM, HH, HS
PERFECT BINDER
PERFECT BINDER
Important Information
BQ-270
UM202048-10

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Summary of Contents for Horizon Fitness BQ-270

  • Page 1 PERFECT BINDER 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.

  • Page 2: Safety Precautions

    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.

  • Page 3: Safety Operation Precautions

    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.

  • Page 4: Table Of Contents

    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 ................... 2 1-3-2 Level Plate Section....................2 1-3-3 Milling Section ......................3 1-3-4 Melt Tank Section.....................
  • Page 5 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................
  • Page 6 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...

  • Page 7: Machine Description

    1. Machine Description 1-1 Machine Description Milling Section Touch Screen Mills the book spine. Used to input necessary information and operate the machine. 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 Registers the bottom of the...

  • Page 8: Parts Descriptions

    1-3 Parts Descriptions 1-3-1 Carriage Clamp Section Grease Nipples Lubricate with grease here. 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.

  • Page 9: Milling Section

    1-3 Parts Descriptions 1-3-3 Milling Section Rear Milling Guide Upper Knife This guide holds the book spine while the milling operation is done. Brake Release Button Front Milling Guide This button is used when replacing the milling cutter. This guide holds the book spine This button works only after while the milling operation is done.

  • Page 10: Melt Tank Section

    1-3 Parts Descriptions 1-3-4 Melt Tank Section Glue Temperature Adjusting Knob The glue temperature can be adjusted from 120 to 180 . (248 to 356 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.

  • Page 11: Nipping Section

    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 Registration Stopper front side guide before the Transport Belts...

  • Page 12: Cover Feed Section

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

  • Page 13: Delivery Section

    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...

  • Page 14: Screen Descriptions

    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.) Memory Screen Setting Screens This screen is used to save or recall the These screens are used to input the job settings.

  • Page 15: Job Settings On Touch Screen

    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 Binding Mode Screen Start Mode Screen Book Block Size Screen...

  • Page 16: Binding Mode Screen

    Entering the Job Information Using the Setting Screens Binding Mode Screen : 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.

  • Page 17: Start Mode Screen

    Entering the Job Information Using the Setting Screens Start Mode Screen 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.

  • Page 18: Book Block Size Screen

    Entering the Job Information Using the Setting Screens 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”).

  • Page 19: Cover Sheet Size Screen

    Entering the Job Information Using the Setting Screens Cover Sheet Size Screen 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).

  • Page 20: Function Screen

    Entering the Job Information Using the Setting Screens 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.

  • Page 21: Milling And Nipping Screen

    Entering the Job Information Using the Setting Screens 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...

  • Page 22: Gluing Screen Part 1

    Entering the Job Information Using the Setting Screens 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.

  • Page 23: Gluing Screen Part 3

    Entering the Job Information Using the Setting Screens Gluing Screen Part 3 P. 3 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.

  • Page 24: Bind The Books Using The Binding Screens

    2-2 Bind the Books Using the Binding Screens The Binding Screens can cover the following three functions: Binding Screens Main Binding Screen Test Milling and Gluing Screen Clamp and Milling Fine-Adjust Screen P. 1 Glue Fine-Adjust Screen, Part 1 Glue Fine-Adjust Screen, Part 2 P.

  • Page 25: Binding Screens

    2-2 Bind the Books Using the Binding Screens Main Binding Screen The current job information and the production conditions are displayed here. Binding Counter Pre-set Counter 00000 0000 0030 Binding Counter/Pre-set Counter. Press 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.

  • Page 26: Test Milling And Gluing

    2-3 Test Milling and Gluing Test Milling and Gluing Screen The test milling and test gluing operations can be performed using this screen. 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.

  • Page 27: Fine Adjustment

    2-4 Fine Adjustment 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. Adjust the carriage clamp opening amount so that the book block is inserted smoothly.

  • Page 28: Glue Fine-Adjust Screen Part 1

    2-4 Fine Adjustment Glue Amount Adjustment Glue Fine-Adjust Screen Part 1 P. 1 This screen allows for fine adjustment of the spine glue. This adjusts the spine glue thickness in increments of 0.1mm (0.005”). The adjust- ment range is 0 to +4.0 mm (0.155”). This adjusts the starting point for the spine glue.

  • Page 29: Glue Fine-Adjust Screen Part 3

    2-4 Fine Adjustment Glue Amount Adjustment Glue Fine-Adjust Screen Part 3 P. 3 This adjusts the wiper opening for application drum 1. Press once, and the opening increases by 0.1 mm (0.005”). More glue will pen- etrate into the spine of the book. The adjustment range is +0.1 to +2.0 mm (+0.005” to +0.080”).

  • Page 30: Nipping Fine-Adjust Screen

    2-4 Fine Adjustment Nipping Operation Adjustment Nipping Fine-Adjust Screen This allows for adjustment of the nipping delay time, nipping time and nipper width. 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 nip- per until the nipping operation starts.

  • Page 31: Scoring Fine-Adjust Screen

    2-4 Fine Adjustment Scoring Operation Adjustment Scoring Fine-Adjust Screen : 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.

  • Page 32: Cover Sheet Fine-Adjust Screen Part 1

    2-4 Fine Adjustment Cover Feed Position Adjustment Cover Sheet Fine-Adjust Screen Part 1 P. 1 This allows for fine adjustment of the nipper against the cover sheet. Registration Position Cover Sheet Original Position 3mm (0.12") 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.

  • Page 33: Cover Sheet Fine-Adjust Screen Part 2

    2-4 Fine Adjustment Cover Pile Position Adjustment Cover Sheet Fine-Adjust Screen Part 2 P. 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”).

  • Page 34: Cover Sheet Fine-Adjust Screen Part 4

    2-4 Fine Adjustment Cover Feed Function Adjustment Cover Sheet Fine-Adjust Screen Part 4 P. 4 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 .

  • Page 35: Saving Or Recalling Or Deleting Job Settings

    2-5 Saving or Recalling Job Settings The Memory Screen is used to save or recall job settings. Milling Operation ON Nipping with Milling This area indicates the job settings saved for the selected job number. (In this exam- ple, the screen shows that job number 10 includes : milling operation ON and nipping with milling.) This shows the status of each job number.

  • Page 36: Using The Single Operation Screen

    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 Single Operation Screen Part 2 P.

  • Page 37: Single Operation Screen Part 2

    2-6 Using the Single Operation Screens Single Operation Screen Part 2 P. 2 CAUTION The upper adjustable scoring roller will not move if it presses too tightly against the lower adjustable scoring roller. : The nipper moves up. : The nipper moves down. The nipper moves down and opens completely.

  • Page 38: Home Positioning Screens

    2-6 Using the Single Operation Screens 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 posi- tion.) Milling Brake Release Screen This is the brake release button for the milling motor.

  • Page 39: Information Screen

    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.

  • Page 40: Error Screen

    2-8 Error Screen 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.

  • Page 41: Starting The Binding Operation

    Screen appears. for the application drum to rotate. 3-2 Safety Function Check The BQ-270 includes safety functions which protect the user from dangerous situations. Check these safety Area Sensor functions: Left Safety Cover...

  • Page 42: Enter The Job Information Using The Setting Screens

    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 Select the binding type. changeover, and the starting mode. - Select the binding type on the Binding Mode Screen.
  • Page 43 3-3 Enter the Job Information Using the Setting Screen Select the spine gluing and side Input the milling and nipping set- gluing settings. tings. - Input the spine glue and side glue settings - Select the type of milling and nipping using using the Glue Screen.
  • Page 44 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.
  • Page 45 3-3 Enter the Job Information Using the Setting Screen This screen appears when there is a cover sheet This screen appears when milling function ON/OFF left on the nipper and the cover table while is changed. If the level plate height is set correctly, changeover.

  • Page 46: Setting The Main Binding Screen

    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 Go to the Main Binding Screen. Sheet Fine-adjust Screen Part5.

  • Page 47: Setting The Scoring Rollers

    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 Open the left safety cover. for the scoring roller on the Single Operation Screen Part 2.
  • Page 48 3-5 Setting the Scoring Rollers Lower the upper scoring roller. Press the (Setting Position) button on the Single Operation - Turn the knob clockwise to lower the upper Screen. scoring roller. - To reach the standard setting, turn the knob - The adjustable scoring rollers move to the set- one rotation counterclockwise from the stop.

  • Page 49: Setting The Scraper (For Padding Only)

    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.

  • Page 50: Setting The Side Glue Rollers

    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 The screen will tell you to dislocate the side glue roller screen with the message reminding you to set or release on the far side.

  • Page 51: Start Binding

    3-8 Start Binding When 10 minutes has passed after the drum is stopped, message to rotate the drum appears. Press Press both start buttons to rotate button on the Single Operation Screen Part the milling cutter. 1 to check that the glue is heated to the setting temper- - The drum motor starts turning.
  • Page 52 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.

  • Page 53: Adding More Cover Sheets

    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 Bind- ing Screen. Press both Start buttons.

  • Page 54: Removing The Bound Booklets

    3-10 Removing the Bound Booklets Remove the booklet before the stacker is full. 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. Pull the stopper to the front. Remove the stacked booklets.

  • Page 55: Saving And Recalling The Job Information

    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.
  • Page 56 3-11 Saving, Recalling, Deleting the Job Information Recalling the Job Information Recall the job information. - Press the (Read Out) button. Select the Memory Screen. - The Read Out OK Screen appears. Press the button for the job number Press OK. you want to recall.
  • Page 57 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.

  • Page 58: Adding More Glue

    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.

  • Page 59: Finishing The Binding Operation

    (option), the binding oper- ation 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 opera- tion.

  • Page 61: Parts Adjustments

    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 Glu- ing Screen Part 3.

  • Page 62: Changing The Nipping Setting

    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, nip- ping time and the nipper width using the Nipping Screen. Refer to page 24.

  • Page 63: Changing The Cover Feeding Settings

    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 posi- tions (left/right, and front/rear) and the side guide width using the Cover Sheet Screen Part 1.

  • Page 64: Changing The Scoring Position

    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 Adjustable Scoring Rollers not be used.

  • Page 65: Milling Depth Adjustment

    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 mill- ing is overloaded, adjust the milling depth to 1.5mm (0.06”) or 1mm (0.04”).
  • Page 66 4-7 Milling Depth Adjustment Change the number of shims. There are three kinds of shims. Use just - Increase or decrease the number of shims on one shim or two shims together. Do not each side equally to adjust the level plate use three shims together.

  • Page 67: Glue Temperature Adjustment

    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. Measure the glue temperature when the application drum are rotating. If there are not enough glue, the measured Adjust the glue temperature using temperature tends to become low.

  • Page 68: Side Glue Amount Adjustment (Far Side)

    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.
  • Page 69 4-9 Side Glue Amount Adjustment (Far Side) Lock the mounting screws on the WARNING glue amount adjusting plate and Wear thick gloves during this operation. close the left safety cover. 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.

  • Page 70: Nipper Height Adjustment

    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 coun- terclockwise. If the spine is too sharp, turn the ring clockwise.

  • Page 71: Nipper Angle Adjustment

    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 Lock the adjusting block and close angle on both sides. the lower nipper door. Turn off the power switch and open the lower nipper door.

  • Page 72: Cover Sheet Angle Adjustment

    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 Adjust the angle of the cover sheet. doing this adjustment. If the cover sheets for the current - Turn the adjust knob clockwise, and the cover job are not square, make a temporary adjustment to fin- sheet will rotate to the left.

  • Page 73: Blower Air Adjustment

    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.

  • Page 74: Feed Table Height Adjustment

    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 Adjust the height as you check the is frequent double-feeding or mis-feeding.

  • Page 75: Maintenance

    5. Maintenance 5-1 Cleaning the Book Block Path Press the button (Carriage WARNING Clamp Move) on the Single Opera- Do not touch the melt tank. The melt tank is tion Screen Part 1. heated to 200 degrees Celsius (400 Fahren- - Press both Start buttons twice.
  • Page 76 5-1 Cleaning the Book Block Path Clean the delivery area. Press the button (Nipper - Pull the stopper to the front. Cleaning) on the Single Operation Screen Part 2 while the safety cover is closed. - The nipper will open to make cleaning easier. WARNING Turn off the power switch before cleaning this area.

  • Page 77: Cleaning The Sensors

    5-2 Cleaning the Sensors Frequency Symbol Cleaning Tool Symbol The number in front of the letter indicates the = Cotton Swab = Every Day multiple number. Choose the tool Example: = Once every week = Brush according to where = Once every 2 weeks you are cleaning = Once every month = Air...

  • Page 78: Lubrication

    5-3 Lubrication Lubrication Symbols Frequency Symbol The number in front of the letter indicates the = Lubricate using a lubrication brush = Every Day multiple number. Example: = Once every week = Lubricate using an oil applicator = Once every 2 weeks = Once every month = Once every 6 months = Lubricate using a grease gun...

  • Page 79: Book Support Plate Replacement

    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 Remove the side cover. following the procedure listed below. - Remove the two monting screws shown in the illustration below.
  • Page 80 5-4 Book Support Plate Replacement Attach the new book support plate. Attach the side cover. Turn the Emergency Stop button clockwise to release.

  • Page 81: Milling Cutter Replacement

    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 Enter a book block thickness of 20 the spine quality will suffer. The milling cutter may be mm (0.8”) on the Book Block Size worn, and may need to be replaced.
  • Page 82 5-5 Milling Cutter Replacement Remove the four mounting screws Remove the front milling guide. on the milling cutter. - 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 clock- wise until a mounting screw of the milling cut- Front Milling Guide...
  • Page 83 5-5 Milling Cutter Replacement Attach the rear milling guide using CAUTION the two mounting screws. 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 sharpened, insert spacer...

  • Page 84: Roughening Cutter Replacement

    5-6 Roughening Cutter Replacement If the roughening cutter does not cut the spine properly, Press the button (Brake the glue will not be evenly applied on the book spine and the spine quality will be reduced. The roughening Release) on the Milling Brake cutter may be worn.
  • Page 85 5-6 Roughening Cutter Replacement Remove the two roughening cut- (5) Loosen the mounting screw of the roughen- ters. ing 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.
  • Page 86 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 counterclock- wise. - If the roughening cutter hits the upper knife, reposition the upper knife referring to step 16 on page 77.

  • Page 87: Glue Replacement

    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 Hook the drain guide on the attach- before beginning this operation, and then ing screws on the melt tank.
  • Page 88 5-7 Glue Replacement Remove the plug using the sup- After the glue is drained, attach the plied long screwdriver. (There are plug. three mounting screws.) - Remove lower two screws first. - The glue will begin to drain. Remove the drain guide. WARNING Be careful not to touch the melted glue.

  • Page 89: Double Feed Stop Pad Replacement

    5-8 Double Feed Stop Pad Replacement If double feeding occurs often, replace the double feed stop pads. Double feeding can occur for several rea- sons. Refer to pages 67, 68 and 71. Turn off the power switch. Remove the two mounting screws on the double feed stop pads.

  • Page 90: Transport Belt Replacement

    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.

  • Page 91: Troubleshooting

    6. Troubleshooting 6-1 Problems with Booklet Quality Gluing Problems Problem Cause Remedy See page There are glue strings hanging from Too much spine glue is Decrease the amount of spine Page 22 the nipper unit. being applied. glue. The spine glue is leaking Decrease the amount of spine Page 22 There is a lump of glue on the nipper.
  • Page 92 6-1 Problems with Booklet Quality Problems with the Booklet Spine Condition Cause Remedy See page There is a lump of glue Clean the nipping section. Page 70 on the nipping mecha- The spine of the booklet is nism. dented. There is a lump of the Clean the delivery section Page 70 glue on the delivery...
  • Page 93 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 Make the pressure from the trans- Page 27 belts is too strong. port belts weaker. The registration stopper is out of Adjust the angle of the registration Page 66...
  • Page 94 6-1 Problems with Booklet Quality Problems with Scoring Condition Cause Remedy See page The cover sheet is cut by The scoring roller pres- Decrease the scoring roller Page 68 the scoring operation. sure is too strong. pressure. The scoring line is not The scoring roller pres- Increase the scoring roller Page 68...
  • Page 95 6-1 Problems with Booklet Quality Other Problems Condition Cause Remedy See page The feature for home Turn ON the feature for Home Page 10 positioning every changeover positioning every on the [Setting]-[Binding set- changeover is turned OFF The booklet quality deteriorates ting]-Binding Mode Screen.

  • Page 96: Error Codes

    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”...
  • Page 97 6-2 Error Codes Cause Remedy See page Error Codes 1123 Carriage clamp open/close, book- Check that the breaker corre- Page 94 sponding to the error code is not let delivery mechanism error tripped. If the breaker trips repeatedly, please call your local dealer.
  • Page 98 6-2 Error Codes Cause Remedy See page Error Codes 1401 Nipper width home positioning error If the nipping operation is done Page 12 twice, check that the thickness of the book is set correctly. Or widen the nipping width. Check that the stepper motor Service Call moves, and the home positioning sensor is active.
  • Page 99 6-2 Error Codes Cause Remedy See page Error Codes 0801 Delivery error Check that the breaker corre- Page 94 sponding to the error code is not tripped. If the breaker trips repeatedly, please call your local dealer. Check the delivery motor stop Service Call position sensor B70 and the motor rotation.

  • Page 100: If A Circuit Breaker Trips

    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.

  • Page 101: If A Message Screen Appears

    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 When the clamp stops above the milling section by minutes, this screen appears.

  • Page 103: Optional Device

    - 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 fin- ished.
  • Page 104 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.
  • Page 105 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 [NOR- MAL]. (2) Set the day select switches to the "Auto" side only for the days when the melt tank will be heated automatically.
  • Page 106 Weekly Timer B. [Setup over a break between days] C. [Setup through a series of days] (When controlling the machine auto-startup (When the period that the machine is over a period which includes two days.) continuously on or off is over 24 hours) - When controlling the machine auto-star- - The machine is powered on at the on tup over a break between days, the pro-...

  • Page 107: Installation

    Place three feet under the leveling bolts shown in the illustration CAUTION below. 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.
  • Page 108 8-1 Installation Place a foot under the fourth level- Install the touch panel. ing bolt shown in the illustration - Remove the top plate and install the panel below. 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.
  • Page 109 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. Do not check the rotating direction by 1) Turn on the main power.

  • Page 110: Installation Of Extractor (Option)

    8-2 Installation of Extractor (Option) Turn off the power switch and 2) Attach the hose ufsing the hose band on the remove the rear cover. extractor. Hose Band Remove the cover at the electrical Install the duct. box. Duct Attach the rear cover and install the flange.
  • Page 111 8-2 Installation of Extractor (Option) Change the current setting on the breaker Q80 from 9A to 10A using the driver. Q01Q80 Q80Q11Q12 Q60Q70 Q30 Q40Q50 A30 A40 A50 Check the rotating direction of the fan inside the extractor. Check that the fan rotates to the direc- tion shown in the illustration above.

  • Page 112: Installation Of Weekly Timer (Option)

    8-3 Installation of Weekly Timer (Option) Accessory for the Weekly Timer (T-270) Kit Power Switch for main body of BQ-270 used for BQ-270 Weekly Timwer and Relay...
  • Page 113 (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...
  • Page 114 No.21, No.22 and No.23 are connected. To Power Switch for main body of BQ-270 To Relay White Relay Connector Arrange the wires and attach the front cover. (2) Connect the wire No.99 on Q80.

  • Page 115: Appendix

    9. Appendix 9-1 Specifications Binding Type Binding with milling, Binding without milling and Padding Number of Clamper Book Block Size Max. 320 mm x 320 mm (12.5” x 12.5”) (Top-Bottom x Fore-edge) Min. 135 mm x 105 mm (5.4” x 4.2”) Binding Thickness 1 to 50 mm (0.04”...

  • Page 116: Accessories

    9-2 Accessories Tool Box (4-003344) 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. Adjusting Pin (M011117) 1 pc Roughening Cutter Setting Gauge (M011118) 1 pc Hexagon Allen Wrench 1 pc each Heat-resistant Oil (A930179) 1 pc 6 mm (0.24")(4001744)
  • Page 117 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) 4 pcs Delivery Chute (M126208) 1 pc Trimmings Bag (M005285) 1 pc Use this chute when binding very small or large booklets.
  • Page 118 9-2 Accessories Fuse (E319737) 2 pcs Glue (HM-220) 1 pack Grease (4017229) 1 pc Digital Caliper (4012395) 1 pc 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)

  • Page 119: Consumable Parts

    9-3 Consumable Parts Glue (HM-220) 1 box Milling Cutter (M011440) 1 pc - 2 2 Trimmings Bag (M005285) 2 pcs Roughening Cutter (M051609) 1 pc Double Feed Stop Pad (A924697) 1 pc Grease (4017229) 1 pc (Violet) Heat-resistant Oil (A930179) 1 pc Book Support Plate (M005395) 1 pc...

  • Page 120: Option

    9-4 Option Extractor (VS-270) 1 pc Weekly Timer 1 pc...

  • Page 121: Index

    9-5 Index 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 Carriage Clamp Section .......................
  • Page 122 Level Plate Section ........................2 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 ......................

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