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Horizon Fitness BOOK BINDER BQ-470 Important Information Manual

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BOOK BINDER
BOOK BINDER
Important Information
• This manual is designed to help you to install, operate and maintain the BQ-470/
BQ-470D Book Binder. Please read and understand this manual, and keep it in a
safe and convenient place.
• Do not operate the BQ-470/BQ-470D 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.
151210/BQ470/30E/HN,TM,HK/F7/IXI/PXI
BQ-470/BQ-470D
UM202064-30(000)
I

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Summary of Contents for Horizon Fitness BOOK BINDER BQ-470

  • Page 1 BQ-470/BQ-470D BOOK BINDER BOOK BINDER Important Information • This manual is designed to help you to install, operate and maintain the BQ-470/ BQ-470D Book Binder. Please read and understand this manual, and keep it in a safe and convenient place. •...

  • Page 2: Safety Precautions

    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 Keep your hands and fingers away from the tanks while turning the power on. The melt tanks are heated to a high temperature of about 200 degrees Celsius. The melt tank will remain hot for a while even after the power switch has been turn to Off. Keep your hands and fingers away from the tanks until the tanks cool off.
  • Page 4 WARNINGS for Maintenance Turn off the power switch before beginning any maintenance operation. A sudden acci- dental start of the machine can cause severe personal injury. Turn off the power switch before removing the cause of a jam. The machine may start suddenly, causing severe personal injury.
  • Page 5 Warning Label Locations and Meanings 22064 10101B1 There are electrical parts inside. Be careful when you open the cover. Otherwise, electrical shock may be caused. Do not step on or sit on the stacker. Otherwise, the machine may be damaged or fall down. Do not load the books over 40 kg (88 Ib).

  • Page 6: Table Of Contents

    CONTENTS Important Information ...................... I Safety Precautions ......................II Operating Safety Precautions ..................III Warning Label Locations and Meanings ................ V 1. Machine Description ..................1 1-1 Automatic and Manual Settings ................1 1-2 Machine Parts and Functions..................2 1-2-1 Overall Machine ....................2 1-2-2 Book Block Feed Section ..................
  • Page 7 3-13 Adjusting the Nipper Angle..................71 3-14 Adjusting the Cover Angle..................72 3-15 Adjusting the Blower Air ..................73 3-16 Adjusting the Double Feed Stop Pad Height............74 3-17 Adjusting the Cover Table Height ................. 75 3-18 Setting for the PUR glue ..................76 3-18-1 Changing the PUR glue after using the EVA glue.........
  • Page 8 4-5-3 The sheet of book block is torn or wrinkled........... 115 4-6 Scoring-Related Problems ..................116 4-6-1 The covers are cut during scoring..............116 4-6-2 No scoring ..................... 116 4-6-3 The scores shift out of position ..............116 4-6-4 The covers are scored diagonally ..............117 4-6-5 The cover stops at the scoring section............
  • Page 9 5-23 Replacing the Milling Brushes................181 5-24 Cleaning the Cover Sheet Waiting Position Sensor..........184 5-25 Cleaning the Cover Transport Belts ..............185 5-26 Teflon Recoating for PUR Glue Tank..............186 6. Optional Devices ..................187 6-1 T-470 Weekly Timer....................187 6-1-1 Operation Procedure..................
  • Page 10 This page is intentionally left blank.

  • Page 11: Machine Description

    1. Machine Description This chapter explains the automatic and manual settings, and describes the machine parts and their functions. Automatic and Manual Settings (Automatic) This indicates a setting which is performed automatically to match the size of the book blocks and covers. The setting can be changed using the touch panel. (Manual) This indicates a setting which is done manually using a knob, lever, etc.

  • Page 12: Machine Parts And Functions

    Machine Parts and Functions 1-2-1 Overall Machine Control Panel Safety Cover See section 1-3 for details. Use this to control the machine operation and enter Operation stops if these the necessary settings. covers are opened. Book Block Feed Section See section 1-2-2 for details. The book blocks are placed in the carriage clamp in this section.

  • Page 13: Book Block Feed Section

    Machine Parts and Functions 1-2-2 Book Block Feed Section Book Block Registering Shaft Area Sensor This shaft aligns the book blocks to the right after they If an operator puts his hand into the book Power Lamp have been fed into the carriage clamp. block feed section while the machine is operating, this is detected by the sensor, and Book Block Support Guide...

  • Page 14: Milling Section

    Machine Parts and Functions 1-2-3 Milling Section Milling Brush This brush removes the trim from the book blocks. The milling mechanism may be overloaded and the carriage clamp may be locked at the milling section depending on the sheet weight, the book thickness and the milling depth.

  • Page 15: Side Gluing Section

    Machine Parts and Functions 1-2-4 Side Gluing Section Oil Cup This lubricates the chain which turns the side gluing rollers. Side Gluing Roller Height Glue Level Upper Adjusting Bolt Limit When these bolts are turned, the tank Keep the level of the height (roller height) changes.

  • Page 16: Spine Gluing Section

    Machine Parts and Functions 1-2-5 Spine Gluing Section Glue Level Upper Limit Keep the surface of the glue lower than this line. The position of the lower limit is 15 mm (0.59”) lower than this line. Scraper Roller Height Adjusting Screw Use this screw to make an adjustment if you want to change just the height of the scraper roller.
  • Page 17 Machine Parts and Functions 1-2-5 Spine Gluing Section - continued Unlike with EVA, when the PUR glue is to be replaced, all the glue remaining in the tank must be removed. If any glue is left behind, it may find its way into the gaps between the wipers and the application rollers and cause unevenness in the amount of glue on the roller.

  • Page 18: Nipping Section

    Machine Parts and Functions 1-2-6 Nipping Section Cover Angle Adjusting Knob This is used to adjust the cover angle. See Section 3-14 for more details. Rear Cover Jog Guide Before the machine does the nipping, this jogs the cover together with the front cover jog guide to position the cover.

  • Page 19: Cover Feed Section

    Machine Parts and Functions 1-2-7 Cover Feed Section Scoring Roller Pressure Feed Rotor Transport Rollers Adjusting Knob This feeds the covers using vacuum These rollers feed the This is used to adjust the and friction. covers as far as the pressure of the scoring standby position.

  • Page 20: Delivery Section

    Machine Parts and Functions 1-2-8 Delivery Section Book Supporting Brush If a landscape book falls down and cannot be delivered smoothly, push in this brush to support a book. When the brush is not necessary, pull the brush to the operator side completely. Locking Lever Also, if the brush is used for a long term, it is gradually weighed down.

  • Page 21: Stacker

    Machine Parts and Functions 1-2-9 Stacker Book Detecting Arm Locking Knob -The height of the top book can be changed by setting the position of this plate. If the delivered book hits the books on the stacker and causes a jam, lower this plate.

  • Page 22: Screen Functions

    Screen Functions 1-3-1 Setup Screen When the power is turned on, the Initial screen appears first, followed by the Bookbinding Settings screen. Bookbinding Settings Screen Bookbinding modes Bookbinding with cover sheet Bookbinding without cover sheet Milling operation settings Level Angle No milling To Size Settings Screen Nipping operation settings...
  • Page 23 Screen Functions 1-3-1 Setup Screen - continued Size Settings Screen Book block size settings Book block length (145.0 to 320.0 mm) (5.710" to 12.600") Book block thickness (0.5 to 65.0 mm) (0.020" to 2.560") Cover sheet size settings Cover sheet width (135.0 to 320.0 mm) (5.315"...
  • Page 24 Screen Functions 1-3-1 Setup Screen - continued Glue Settings Screen Side gluing settings Side Gluing On/Off The side glue is applied. The side glue is not applied. To Check Screen Spine glue settings Thickness of glue on spine (This can be Automatic/manual switching changed only if Manual has been selected.)
  • Page 25 Screen Functions 1-3-1 Setup Screen - continued Check Screen Settings displayed Book block length (top to bottom) Book block thickness Cover sheet length (top to bottom) Cover sheet width (fore-edge) Dimension from cover rear edge Example of icons displayed Icons are used to indicate the bookbinding options which have been selected.

  • Page 26: Bookbinding Screens

    Screen Functions 1-3-2 Bookbinding Screens Test Bookbinding Screen This starts a bookbinding test for just one book. Fine Adjustment Screen Use this screen to make fine adjustments. Operation Screen Bookbinding counter Bookbinding counter This counter is not cleared until button is pressed. (This counter is not cleared even if the power is turned off.) Preset counter...
  • Page 27 Screen Functions 1-3-2 Bookbinding Screens - continued Maintenance Screen Milling section cleaning This opens the milling guide so you can clean the milling section. The milling guide opens. The milling guide returns to the pre-set width. Level plate height adjustment The carriage clamp moves out of the way and the nipper opens for cleaning.
  • Page 28 Screen Functions 1-3-2 Bookbinding Screens - continued Operation Screen Operation navigation - green icons Press the Bookbinding Start buttons. There is no cover at the standby position. Feed the book blocks. Bookbinding can be started. Bookbinding is now underway. Bookbinding of the preset number of books is complete.
  • Page 29 Screen Functions 1-3-2 Bookbinding Screens - continued Fine adjustment Screen Fine adjustments Clamp width: 0 to +20.0 mm (0" to +0.785") (in 0.5 mm or 0.020" increments) Milling guide width: 0 to +15.0 mm (0" to +0.590") (in 0.1 mm or 0.005" increments) Nipper width: –0.5 to +1.0 mm (–0.020"...
  • Page 30 Screen Functions 1-3-2 Bookbinding Screens - continued Fine Adjustment – Glue Screen Fine adjustments - glue Side glue roller width: 0.5 to +5.0 mm (+0.020" to +0.200") (in 0.1 mm or 0.005" increments) Thickness of glue on spine: EVA: 0 to 4.0 mm (0" to 0.160") (in 0.1 mm or 0.005"...
  • Page 31 Screen Functions 1-3-2 Bookbinding Screens - continued Fine Adjustment – Cover Screen Fine adjustments - cover Cover side guide width: .-10.0 to +10.0 mm (.0.395" to +0.395") (in 0.1 mm or 0.005" increments) The lower the feed table is, the wider the cover side guide width become than the set value for the cover width.
  • Page 32 Screen Functions 1-3-2 Bookbinding Screens - continued Changeover and Fine Adjustment Value    When you change either "bookbinding mode", "bool block length" or "cover sheet length" from current changeover, the fine adjustment values shown below return to the default settings. Bookbinding Setting Screen Bookbinding Modes Bookbinding with Cover Sheet...

  • Page 33: Memory Screens

    Screen Functions 1-3-3 Memory Screens Memory – Main Screen Press these icons to sort jobs by “job number”, “job name”, or “date”. B O O K 0 6 0 3 3 0 Detailed information button The Detailed Information screen for the selected job appears. * A beep sounds if a job has not been saved for the selected number.
  • Page 34 Screen Functions 1-3-3 Memory Screens - continued Job name Save date Memory – Detailed Information Screen B O O K 0 6 0 3 3 0 Detailed information Details of the selected job are displayed here. 423.6 Icons showing the bookbinding options selected To Memory –...

  • Page 35: Information Screens

    Screen Functions 1-3-4 Information Screens Information – Main Screen : Enter the current date. : Enter the current time. : Bookbinding total counter This indicates the total number of books bound over the life of the machine. (It cannot be reset.) : The serial number of the machine is displayed here.
  • Page 36 Screen Functions 1-3-4 Information Screens - continued Information – Monitor Screen When one of these buttons is pressed, one of the following Information – Monitor screens appears. Carriage clamp section Level plate section Milling section Side gluing section Spine gluing section Spine glue tank section To Information –...
  • Page 37 Screen Functions 1-3-4 Information Screens - continued Information – Single Operation Clamp Carriage clamp section Screen Clamp rotation Home position Set position Jog: Clamp rotates while the Bookbinding Start Buttons are pressed. Note: The carriage clamps must always be closed before they are moved.(They can be closed using the Single Operation Delivery screen.) See step 1 on Section 3-22 for details.
  • Page 38 Screen Functions 1-3-4 Information Screens - continued Information – Single Operation Cover Jog Screen Cover registering section Cover side guide Home position Set position Scoring roller Home position Set position Registering section guide width Home position Set position Close Open To Information –...
  • Page 39 Screen Functions 1-3-4 Information Screens - continued Information – Error history Screen This screen shows the dates, times and error codes of any system errors which have occurred in the past. (Information for the last 24 errors is saved.) To Information – Main Screen Use these to see other pages.
  • Page 40 Screen Functions 1-3-4 Information Screens - continued Information – Administrator Screen - Page 1 Enter adjustments for the home positions here. The values set on the current fine adjustment screen are displayed here. This rewrites all the adjustments for the home positions which have been entered.

  • Page 41: Error Screen

    Screen Functions 1-3-5 Error Screen Error Screen Error icons * These icons are described in more detail in Section 4-1-1. The area sensor of the book block feed section has detected something in the feed section. The Emergency Stop button has been pressed.
  • Page 42 This page is intentionally left blank.

  • Page 43: Checks Before Operating

    2. Checks Before Operating This chapter lists the safety checks which must be carried out on the machine before starting the bookbinding job. Turning On the Power Switch Turning the power switch on. • Turn the switch clockwise to turn on the power. The Start-Up screen appears on the touch panel followed by the Setup –...

  • Page 44: Checking The Emergency Stop Function

    Checking the Emergency Stop Function The BQ-470 is equipped with safety features which protect usersduring the bookbinding job. Check that the safety features are working by following the steps in this section. Delivery section Emergency Safety light beam left cover Stop button Right front Left front...
  • Page 45 Checking the Emergency Stop Function Check the safety functions of the Error Screen Emergency Stop buttons. • Press the Emergency Stop buttons. The Error screen is displayed. • Check that the correct error icons appear on the screen. • The Error screen is cleared when the Emergency Stop button is turned clockwise to release the emergency stop status.

  • Page 46: Checking The Glue Collection Tray

    Checking the Emergency Stop Function (8) Block the sensor using a sheet of paper or some other object during moving the carriage clamp. Do not use your hand. Check that the correct error icon appears on the screen. (9) Press The Error screen is cleared.

  • Page 47: Operating Procedures

    3. Operating Procedures This chapter describes the steps required for a normal bookbinding job. Overview of Operating Procedures This section provides an outline of the procedures for a normal bookbinding job. For more details on this type of job, refer to Section 3-2 and the following sections, and then proceed with the job. Start-Up Screen Turn on the power switch.
  • Page 48 Overview of Operating Procedures Setup - Bookbinding Settings Screen Do the job setups using the setup screens. Milling Set Lever (1) Select the “bookbinding mode.” (2) Select “milling.” • Manual – switch the milling set lever. (3) Select “nipping.” (4) Enter the bookbinding size. (5) Set the side glue.
  • Page 49 Overview of Operating Procedures Cover Table Set the covers. • For more details, see Section 3-4. Stack the covers on the cover table. • Place the cover front side down and check the Covers orientation of the covers. Tighten Locking Lever 22064 30101F1 Bookbiding - Operation Screen...

  • Page 50: Doing The Changeover

    Doing the Changeover 3-2-1 Replacing the tank unit If you need to change the type of spine glue, replace the glue tank and set the notching cutter and PUR chip cutter. This procedure explains how to exchange the EVA tank and PUR tank. WARNING Left Front Cover The melt tank will remain hot for a while...
  • Page 51 Doing the Changeover Remove the tank unit. (1) Insert the lifter (option) between the rails at the bottom of the tank unit. Check that pins on the lifter line up with the holes on the underside of the machine. Check that the pins on the lifter line up with the holes on the underside of the machine.
  • Page 52 Doing the Changeover Install the new tank unit. (1) Place the replacement tank unit on the lifter. Check that the hole positions on the Pedestal Positioning Pin lifter align with the holes on the underside of the tank unit. (2) Use the lifter to move the tank unit into the machine.
  • Page 53 Doing the Changeover Plug in the two connectors. Connector These connectors have different shapes so that they cannot be connected incorrectly. 22064 51401E1 Attach the front bottom cover on the tank unit. Tank Unit Front Bottom Cover 22064 51401F1 Return the tank unit to its original position. (1) Loosen the locking knob.

  • Page 54: Changing The Eva Glue After Using The Pur Glue

    Doing the Changeover 3-2-2 Changing the EVA glue after using the PUR glue When removing the PUR chip cutter WARNING For BQ-470 with PUR Tank: • Before loosening the mounting screws for the milling cutter, be sure to turn the power switch off. Also, place a piece of thick cloth over the cutter to PUR Chip Cutter ensure that your hands will not touch the cutter.
  • Page 55 Doing the Changeover When using the PUR chip cutter If you need to change the type of spine glue, replace the glue tank and set the notching cutter and PUR chip cutter. This procedure explain Adjust the height of the notching cutter. (1) Hold each notching cutter using a folded piece of thick cloth.

  • Page 56: Job Setup Using The Screens

    Doing the Changeover 3-2-3 Job setup using the screens The following sections include instructions on setting up different parts of the machine. Setup - Bookbinding Settings Screen Select the bookbinding mode. • Select either the “bookbinding with cover sheet” or “bookbinding without cover sheet.” •...
  • Page 57 Doing the Changeover Enter the book block dimensions. Setup - Size Screen • Measure the dimensions of the book block used for bookbinding. • Available range: 135.0 to 320.0 mm (5.315" to 12.600") (in 0.1 mm or 0.005" increments) • When is pressed, the Numeric Keypad screen appears.
  • Page 58 Doing the Changeover Setup - Size Screen Enter the cover sheet dimension. • Measure the length of the covers to be bound. • Available range: 225.0 to 660.0 mm (8.860" to 25.985") (in 0.1 mm or 0.005" increments) • When is pressed, the Numeric Keypad screen appears.
  • Page 59 Doing the Changeover Set the side glue. Setup - Glue Screen • Select whether the glue is to be applied. Apply: , Do not apply: • has been selected in this example. When side glue is turned off If the side glue will not be applied •...
  • Page 60 Doing the Changeover Setup - Check Screen Check the settings on the Setup – Check screen. (1) Check the settings. • The sizes of the book block and covers which Check have been entered are displayed. 423.6 • The “book binding settings” and “glue” settings are displayed by the icons at the bottom right of the screen.

  • Page 61: Manual Setup Procedures

    Manual Setup Procedures This section describes some settings which must be done manually. 3-3-1 With cover scoring The position of the lower scoring roller is Cover automatically adjusted to match the book Scoring block thickness. The upper scoring roller must be manually engaged with the lower scoring roller.

  • Page 62: Without Cover Scoring

    Manual Setup Procedures 3-3-2 Without cover scoring Disengage the scoring rollers so that they move freely. (1) Open the cover feed section cover. Cover Feed Section Cover (2) Turn the locking knobs on both sides to disengage the locks. (3) Loosen both of the pressure adjusting knobs by turning them counterclockwise.

  • Page 63: Setting The Stacker

    Manual Setup Procedures 3-3-3 Setting the stacker Set the stopper a point about 20 mm or Belt Speed 0.8” wider than the book. Control Knob If necessary, adjust the belt speed. • When a thin book is not transported to the stack tray, increase the belt speed using the belt Stopper speed adjusting knob.

  • Page 64: If The Side Glue Setting Has Been Changed From On To Off

    Manual Setup Procedures 3-3-4 If the side glue setting has been changed from on to off • If the side glue setting has been changed to Off on the Setup – Glue screen, the rear side glue Setup - Glue Screen roller must be pulled to the rear.

  • Page 65: Setting The Covers

    Setting the Covers Pull back the end stopper. End Stopper • Loosen the locking lever, and move the end stopper toward the edge of the cover table. Unlock Locking Lever 22064 30401A1 Covers (Place as shown) Fan the covers thoroughly. Side Guide After fanning the covers thoroughly, put them in place on the table.
  • Page 66 Setting the Covers Remove the cover lifting guide. • Remove the guide by lifting it up. Cover Lifting Guide 22064 30401E1 Set the cover transport guides to match the cover length. • Install each guide so that it is straight. •...

  • Page 67: Test Binding

    Test Binding Bind just one copy, and check the bookbinding quality and also whether the book is delivered smoothly. Bookbinding - Operation Screen Press on the Bookbinding – Operation screen. The display changes to the Bookbinding – Test screen. Bookbinding - Test Screen Set the production speed.
  • Page 68 Test Binding Book Block Feed the book block. • Insert the book block, and square it up against the right edge. 22064 30501B1 If the book block is difficult to insert Binding - Test Screen • Adjust the width of the carriage clamp. (1) Press The display changes to the Fine-Tune Binding - Operation Screen...

  • Page 69: Starting Bookbinding

    Starting Bookbinding Move through these operations by following the operation navigation icons. Bookbinding - Operation Screen Select the bookbinding start mode. • Select “manual start” or “timer start.” Start the bookbinding by pressing the Operation Bookbinding Start buttons. Navigation Icon After the safety light beam is unblocked, there will be a delay period, then the bookbinding will start automatically.
  • Page 70 Starting Bookbinding Operation Select Start the bookbinding job. navigation icon • If you selected Timer start in step , binding Bookbinding Start Buttons will start automatically after the set time has elapsed. • If you selected Manual start in step , press the Bookbinding Start buttons once more.

  • Page 71: Saving, Loading And Deleting Jobs

    Saving, Loading and Deleting Jobs On this machine, the settings for frequently performed binding jobs can be saved and loaded using the memory screens. This section describes how to save, load and delete these job settings. 3-7-1 Saving jobs Bookbinding - Operation Screen Before saving a job, first do the changeover and fine adjustments so the machine is set for the job which is to be saved.

  • Page 72: Loading Jobs

    Saving, Loading and Deleting Jobs 3-7-2 Loading jobs Press Bookbinding - Operation Screen The Memory – Main screen appears. Select the job number of the job to be Memory - Main Screen loaded. • This number can be selected either by entering the job number using the keypad or by touching the job number directly.
  • Page 73 Saving, Loading and Deleting Jobs Starting the changeover. Memory - Main Screen If there are covers at the cover standby position, remove them before initiating Setup - Bookbinding Settings Screen the changeover. B O O K 0 6 0 3 3 0 (1) Press The Setup –...

  • Page 74: Deleting Jobs

    Saving, Loading and Deleting Jobs 3-7-3 Deleting jobs Press Binding - Operation Screen The Memory – Main screen appears. Select the job number to be deleted. Memory - Main Screen • This number can be selected either by entering the job number using the keypad or by touching the job number directly.

  • Page 75: Adjusting The Milling Depth

    Adjusting the Milling Depth The milling depth changes depending on the number of Milling Depth spacers placed under the level plate. • If the book block is thick and the drag on the milling This is the part of the book block cutters is high, increase the number of spacers to reduce which is cut off by the milling Book Block...
  • Page 76 Adjusting the Milling Depth Lift the level plate, and insert the spacers to get the required height. 1 spacer (1) Put your fingers into the holes in the level plate, 2 spacers lift the plate, and change the spacers. Spacer Base plate (1 mm (2) Insert spacers with the same total thickness at...

  • Page 77: Adjusting The Scoring Position

    Adjusting the Scoring Position Adjust the scoring position if it is offset from the angle of the book block or if the distance between the scores is not correct for the thickness of the book block. Press on the Bookbinding – Bookbinding - Operation Screen Operation screen.

  • Page 78: Adjusting The Scoring Depth And Angle

    3-10 Adjusting the Scoring Depth and Angle If the scoring roller pressure is too high and the covers are cut, or if the scores are not deep enough, adjust the scoring pressure. And if the scoring angle is necessary to adjust, adjust the scoring pressure.

  • Page 79: Adjusting The Glue Amount For The Side Glue Rollers

    3-11 Adjusting the Glue Amount for the Side Glue Rollers WARNING Side Glue Roller Glue Wear gloves for this job. The adjusting plate is Amount Adjusting Plate very hot at this point, and you may burn yourself. Screws Side Glue Roller Open the left front cover.

  • Page 80: Adjusting The Nipper Height

    3-12 Adjusting the Nipper Height Adjust the nipper height if the book spine protrudes too much, if it is rounded, or if air bubbles enter the spine. Book spine protrudes Book spine is rounded The nipper height sets the shape of the finished too much spine.

  • Page 81: Adjusting The Nipper Angle

    3-13 Adjusting the Nipper Angle Adjust the nipper angle if the shape of the spine is different on the two ends, or if the spine on only one end protrudes too much or is rounded. The corners at this end are square. The corners at this end are round.

  • Page 82: Adjusting The Cover Angle

    3-14 Adjusting the Cover Angle The cover angle can be corrected by adjusting the angle of the cover tail edge positioner. Cover Angle Cover Only make this adjustment after checking that the covers have been trimmed Book Block accurately. If they have not been trimmed properly, adjust the angle, and after the job be absolutely sure to return to the original setting.

  • Page 83: Adjusting The Blower Air

    3-15 Adjusting the Blower Air The term “blower air” refers to the air which is blown out to loosen the stack of covers during feeding. Double feeding or mis-feeding may occur if the blower air is too weak or too strong. Adust the height of the feed table ( See the Section 3-17.), and then adjust blower air.

  • Page 84: Adjusting The Double Feed Stop Pad Height

    3-16 Adjusting the Double Feed Stop Pad Height Adjust the double feed stop pad height if there is double feeding or mis-feeding of the covers even though the pressure of the blower air is correct. Adjust the height of the double feed stop pad.

  • Page 85: Adjusting The Cover Table Height

    3-17 Adjusting the Cover Table Height The height should be set low for thin sheets and high for thick sheets. Also adjust the cover table height if double feeding or mis-feeding occurs often. Loosen the table height adjusting knob. If mis-feeding occurs frequently Table Height Adjusting Knob Adjust the height of the cover table.

  • Page 86: Setting For The Pur Glue

    3-18 Setting for the PUR glue 3-18-1Changing the PUR glue after using the EVA glue If you need to change the type of spine glue when the job is also changing, replace the glue tank and set the notching cutter and PUR chip cutter. WARNING •...
  • Page 87 3-18 Setting for the PUR glue Check the PUR chip cutter. When the PUR chip cutter is not installed Go to the step When the PUR chip cutter is installed Go to the step Install the PUR chip cutter and spacers. For BQ-470 with PUR Tank: (1) Perform the steps...

  • Page 88: Setting For The Pur Glue

    3-18 Setting for the PUR glue 3-18-2 Setting for the PUR glue Follow steps 3-2 through 3-4. • When handling PUR glue, make sure to order Glue Tank Fins the safety data sheet from the PUR glue supplier, then read and follow the instruction. 12 mm 3 mm •...
  • Page 89 3-18 Setting for the PUR glue Scraper Roller Height Setting of the spine glue thickness Adjusting Screw The spine glue thickness in PUR binding can be adjusted by changing the height of the scraper roller. At first, set the scraper roller to the standard position.

  • Page 90: Adding The Glue

    3-19 Adding the Glue Add the glue to the melt tanks for the side glue and the EVA spine glue from the opening. Add more glue before it drops to the level shown WARNING below. Upper limit of the Plate For Side Glue glue level Do not touch the melt tanks.

  • Page 91: Setting The Glue Tank Temperatures

    3-20 Setting the Glue Tank Temperatures Set the glue tank temperatures. • Set the temperature using the buttons on the temperature controller. Change the digits using the button. • The current temperature is indicated on the top Warm-Up Screen line and the temperature setting is displayed on the bottom line.

  • Page 92: Adjusting The Scraper Roller Height

    3-21 Adjusting the Scraper Roller Height The scraper roller scrapes off any excess glue applied to the book block spine to make the glue thickness uniform. If the scraper roller is lowered, the thickness of the glue applied to the spine will increase. WARNING The melt tanks are heated to a temperature of around 200°C (400°F).
  • Page 93 3-21 Adjusting the Scraper Roller Height Adjust the height of the scraper roller. • Turn the scraper roller height adjusting screw counterclockwise to lower the scraper roller. The scraper roller is lowered by 1 mm (0.04") if the scraper roller height adjusting screw is turned counterclockwise through 180 degrees.

  • Page 94: Rotating The Carriage Clamp Using The Handwheel

    3-22 Rotating the Carriage Clamp Using the Handwheel Turn the handwheel to move the carriage clamps if you want to move them a short distance. You can also use this if a book is caught in the milling section and you need to move the clamps backwards. Binding - Operation Screen CAUTION Close the carriage clamp before moving...
  • Page 95 3-22 Rotating the Carriage Clamp Using the Handwheel Align the thread in the handwheel with the Carriage Reducer groove on the shaft of the reducer, and Clamp insert. Insert Manual Handwheel Turn the handwheel to move the carriage clamps. • The clamps move in the forward direction when the handwheel is turned clockwise.

  • Page 96: Installing The Cover Lifting Guide

    3-23 Installing the Cover Lifting Guide Snap the left side of the cover lifting guide into the roller frame. • Make sure that the arrow labels line up. Screw Snap the right side of the guide onto the screws. Screw Roller Frame 22064 32301A1...

  • Page 97: Opening The Carriage Clamp Using The Handwheel

    3-24 Opening the Carriage Clamp using the Handwheel If book block jams inside the clamp and you want to open the carriage clamp manually, use the supplied handwheel to open the carriage clamp. It is recommnded to use the handwheel to open the cariage clamp manually when the book block jams between the nippers.

  • Page 98: Attaching The Cover Edge Lifting Guide

    3-25 Attaching the Cover Edge Lifting Guide Attach this guide if the cover edge drops after nipping and hits against the cover which is fed to the nipping section. Press the Emergency Stop button. Remove the cover lifting guide. • See page 86. Attach the supplied cover edge lifting guide.

  • Page 99: Removing The Jammed Cover Sheets Using The Handwheel

    3-26 Removing the jammed cover sheets using the Handwheel If the cover sheets jam while transported, use the supplied handwheel to remove the the jammed cover sheets. Press the Emergency Stop button. Right Safety Cover Open the right safety cover. Insert the handwheel into the hole shown in the drawing to the right.
  • Page 100 This page is intentionally left blank.

  • Page 101: Troubleshooting

    4. Troubleshooting This chapter describes how to correct the problem if an error icon is displayed on the screen. It also covers problems relating to bookbinding quality and machine operation. If an Icon Appears on the Error Screen 4-1-1 If an error icon is displayed If a problem occurs in the machine, it will be detected by one of the sensors.

  • Page 102: If An Alarm Icon Appears

    If an Icon Appears on the Error Screen 4-1-2 If an alarm icon appears If a problem occurs in the machine, it will be detected by one of the sensors. The machine is stopped, and the problem is indicated on the Bookbinding – Operation screen by an alarm icon. This section explains the meaning of each of these icons.

  • Page 103: If A System Error Occurs

    If an Icon Appears on the Error Screen 4-1-3 If a system error occurs Error Screen This icon indicates that a system error has occurred. Check the error code to the right of the icon, refer to the table below, and follow the instructions.
  • Page 104 If an Icon Appears on the Error Screen Error code Explanation Cause and solution Clamp width adjustment 1241 mechanism raising operation error Clamp width adjustment 1242 mechanism lowering operation There is a problem in the clamp width adjustment mechanism. Press the OK button on the screen. error Turn the power switch to Off, and wait 10 seconds before turning it back to On.
  • Page 105 If an Icon Appears on the Error Screen Error code Explanation Cause and solution Cover Sheet Sensor Double Feed When the Power switch is turned on, the sensor detects a cover sheet. Remove it. If there is no 1633 Detection Error sheet, the cover sheet sensor may be dirty.
  • Page 106 If an Icon Appears on the Error Screen Error code Explanation Cause and solution A problem has occurred during the return to home position. Press the OK button on the screen. Check whether something is blocking the return to home position. If the problem occurs again, Cover side guide rear home 4620 call the service technician.
  • Page 107 If an Icon Appears on the Error Screen Error Explanation Cause and solution code 6136 Servo watchdog error Excessive servo regeneration 6224 warning 6225 Servo overload warning Press the OK button on the screen. Turn the power switch to Off, and wait 10 seconds before Servo absolute position counter 6227 turning it back to On.
  • Page 108 If an Icon Appears on the Error Screen Error Explanation Cause and solution code There is a problem with machine serial number. Press the OK button on the screen. Turn the 9241 Serial number error power switch to Off, and wait 10 seconds before turning it back to On. If the problem occurs again, call the service technician.

  • Page 109: Glue-Related Problems

    Glue-Related Problems 4-2-1 If stringy glue sticks to the nipper Related Where to check Cause and solution item Too much spine glue. • Reduce the amount of spine glue using the Bookbinding - Fine-Tune Adjustment - Glue screen. 1-3-2 22064 4-2-2 If lumps of glue stick to the nipper Related Where to check...

  • Page 110: Spine Glue Is Not Applied

    Glue-Related Problems 4-2-3 Side glue is not applied - continued Related Where to check Cause and solution item The side glue rollers • The circuit breaker may have been tripped. • Try to turn the rollers using the single are not turning operation mode, and if they do not turn, check the circuit breaker.

  • Page 111: Too Much Side Glue Is Applied

    Glue-Related Problems 4-2-5 Too much side glue is applied Related Where to check Cause and solution item The clearance • Increase the clearance between the side glue rollers using the Bookbinding - Fine- between the side Tune Adjustment - Glue screen. glue rollers is too narrow.

  • Page 112: Spine Glue Is Protruding At The Sides

    Glue-Related Problems 4-2-7 Spine glue is protruding at the sides Related Where to check Cause and solution item There is too much • Reduce the amount of spine glue using the Bookbinding - Fine-Tune Adjustment - Glue spine glue. screen. You can also increase the height of the scraper roller.

  • Page 113: Spine Glue Is Only Partially Applied To The Book Blocks

    Glue-Related Problems 4-2-9 Spine glue is only partially applied to the book blocks Related Where to check Cause and solution item The amount of glue • If the glue level has dropped inside the tank, air will be sucked in when the roller turns, has dropped to a low leaving air bubbles on the roller.

  • Page 114: Spine Glue Is Not Applied To A Few Sheets On The Both Sides Of The Book Blocks

    Glue-Related Problems 4-2-12 Spine glue is not applied to a few sheets on the both sides of the book blocks Related Where to check Cause and solution item For EVA glue - • Reduce the production speed. This will reduce the notching pitch. The notching pitch is too large.

  • Page 115: Spine-Related Problems

    Spine-Related Problems 4-3-1 The spines on the covers are dented Related Where to check Cause and solution item There are some • Clean the nipping section. lumps of glue in the nipping section. 22064 40301A1 There are some • Clean the delivery section. lumps of glue in the delivery section.

  • Page 116: The Corners Of The Spines Are Too Sharp

    Spine-Related Problems 4-3-3 Thick books - spines are creased - continued Related Where to check Cause and solution item The amount of spine • Increase the amount of spine glue using the Bookbinding - Fine-Tune Adjustment - Glue glue is too low. screen.

  • Page 117: The Corners Of The Spines Are Too Round

    Spine-Related Problems 4-3-5 The corners of the spines are too round Related Where to check Cause and solution item The covers are set • The corners become rounded if the covers are folded in the cross grain direction in so they are folded relation to the book blocks.

  • Page 118: The Corners Are Formed Differently At The Top And Bottom

    Spine-Related Problems 4-3-5 The corners of the spines are too round - continued Related Where to check Cause and solution item The nipper is too low. • Increase the nipper height. Increase 3-12 22064 40305D1 The nipper width is • Reduce the nipper width using the Bookbinding - Fine-Tune Adjustment - too wide.

  • Page 119: The Spines Break When The Books Are Opened

    Spine-Related Problems 4-3-8 The spines break when the books are opened Related Where to check Cause and solution item Too little spine glue is • Try increasing the amount of spine glue using the Bookbinding - Fine-Tune being applied. Adjustment Glue screen. •...

  • Page 120: Cover-Related Problems

    Cover-Related Problems 4-4-1 The covers are skewed diagonally from the book blocks Related Where to check Cause and solution item The cover tail edge • Turn the cover angle adjusting knob to adjust the cover tail edge positioner angle. positioner is out of position.

  • Page 121: The Covers Move In The Top/Bottom Direction On The Book Blocks

    Cover-Related Problems 4-4-3 The covers move in the top/bottom direction on the book blocks 22064 40403A1 Related Where to check Cause and solution item The cover tail edge • Adjust the cover tail edge positioner in the left/right direction using the Bookbinding - positioner is set to Fine-Tune Adjustment - Covers screen.

  • Page 122: The Covers Do Not Stick To The Spines

    Cover-Related Problems 4-4-5 The covers do Not stick to the spines Related Where to check Cause and solution item The nipping delay • Reduce the nipping delay time using the Bookbinding - Fine-Tune Adjustment - time is too long. Clamp/Milling/Nipping/Delivery screen. 1-3-2 22064 40303A1...

  • Page 123: The Covers Do Not Stick To The Side Glue

    Cover-Related Problems 4-4-7 The covers do Not stick to the side glue Related Where to check Cause and solution item No spacer is installed • To hold the lower position of the book block, Spacer insert the spacer (accessory) between the with the carriage clamp and support plate.

  • Page 124: Wrinkle-Related Problems

    Wrinkle-Related Problems 4-5-1 The spines are wrinkled Related Where to check Cause and solution item The wipers are open • If the first wiper is open too far, large quantities of glue will be pushed into the too far. spines, and the spines will not open normally due to the amount of glue.

  • Page 125: The Spines Are Scratched Or Marked

    Wrinkle-Related Problems 4-5-2 The spines are scratched or marked Related Where to check Cause and solution item Some glue has stuck • If lumps of glue are stuck to the nipping plate, nicks or indentations will be made at to the nipping plate. the same locations in each of the spines.

  • Page 126: Scoring-Related Problems

    Scoring-Related Problems 4-6-1 The covers are cut during scoring Related Where to check Cause and solution item The scoring pressure • Reduce the scoring pressure. is too high. 3-10 22064 40601A1 4-6-2 No scoring Related Where to check Cause and solution item The scoring pressure •...

  • Page 127: The Covers Are Scored Diagonally

    Scoring-Related Problems 4-6-4 The covers are scored diagonally How to check whether the covers are scored perfectly straight • As shown in the figure to the right, any skewing is easier to see if the covers are folded in half. •...

  • Page 128: The Cover Stops At The Scoring Section

    Scoring-Related Problems 4-6-5 The cover stops at the scoring section Related Where to check Cause and solution item The scoring pressure • Reduce the scoring pressure. is too high. 3-10 22064 40601A1...

  • Page 129: Problems With The Main Part Of The Machine

    Problems with the Main Part of the Machine 4-7-1 Covers misfeeding Related Where to check Cause and solution item The feed table is too • If the feed table is too low, the covers cannot Cover Feed Height Adjusting Knob be picked up by the feed rotor.

  • Page 130: Cover Misfeeding Sensed Incorrectly

    Problems with the Main Part of the Machine 4-7-2 Cover misfeeding sensed incorrectly Related Where to check Cause and solution item The double feed • Clean the double feed detect sensor. detect sensor is dirty. Upper Sensor Lower Sensor 22064 40704A1 4-7-3 Covers double-feeding Related...

  • Page 131: Cover Double-Feeding Sensed Incorrectly

    Problems with the Main Part of the Machine 4-7-3 Covers double-feeding - continued Related Where to check Cause and solution item The double feed stop • When the edges of the double feed stop pads become worn, the braking force is pads are worn.

  • Page 132: Thick Books Are Not Delivered Smoothly

    Problems with the Main Part of the Machine 4-7-5 Thick books are not delivered smoothly Related Where to check Cause and solution item The delivery guide • Make it easier for the books to pass through by increasing width between the delivery width and delivery guides and the width between the delivery brush width are too...

  • Page 133: The Tank Temperature Does Not Rise

    Problems with the Main Part of the Machine 4-7-7 The tank temperature does not rise Related Where to check Cause and solution item The display • Check whether the circuit breaker for the tank heater has tripped. Circuit Breaker For on the The Tank Heater temperature...

  • Page 134: Scattered Trim

    Problems with the Main Part of the Machine 4-7-9 Scattered trim Related Where to check Cause and solution item The trim bag is full or • Throw out the trim. • If the filter bag is clogged, clean it. the filter bag is Clean clogged.

  • Page 135: The Carriage Clamp Slows Or Stops During Milling

    Problems with the Main Part of the Machine 4-7-10 The carriage clamp slows or stops during milling Related Where to check Cause and solution item The milling cutter is • Replace the milling cutter. worn. 5-11 22064 40709B1 The cutting depth is •...

  • Page 136: Some Parts Do Not Move

    Problems with the Main Part of the Machine 4-7-12 Some parts do not move Related Where to check Cause and solution item One of the circuit • Check whether the circuit breaker has tripped. breakers has tripped. • If the circuit breaker trips again, place a service call.

  • Page 137: If A Cover Sheet Or Book Block Jams

    If a Cover Sheet or Book Block Jams 4-8-1 If a cover sheet has jammed If a cover sheet has jammed after feeding, the alarm ▼Bookbinding - Operation screen icon is displayed on the Bookbinding - Operation screen. Alarm Icon 22064 40801A1 Right Safety Cover...
  • Page 138 If a Cover Sheet or Book Block Jams Clear the cause of the cover sheet jam. • Check to see that the cover transporting guide is correctly installed referring section 3- Press the button, and feed the ▼Bookbinding - Operation screen next cover sheet to the standby position.

  • Page 139: If The Book Block Has Jammed In Millimg Mechanism

    If a Cover Sheet or Book Block Jams 4-8-2 If the book block has jammed in millimg mechanism If the milling mechanism has been overloaded and the book block has jammed in the milling mechanism, remove the book block by following the procedures listed below. Move the carriage clamps in the reverse direction and position the clamp right above the level plate using the...
  • Page 140 If a Cover Sheet or Book Block Jams ▼Bookbinding - Operation screen Press (book drop) on the Information - Single Operation Delivery screen. ▼Information - Main screen The carriage clamp opens and the book block falls into the conveyor belt in the delivery section.

  • Page 141: If The Book Block Has Jammed In The Level Plate Section

    If a Cover Sheet or Book Block Jams 4-8-3 If the book block has jammed in the level plate section If books are not delivered properly and there are still some books inside the carriage clamp, the alarm icon is displayed on the Bookbinding - Operation screen. Alarm Icon 22064 40803A1...

  • Page 142: If The Book Block Has Jammed In The Delivery Section

    If a Cover Sheet or Book Block Jams 4-8-4 If the book block has jammed in the delivery section If the book block has jammed in the delivery section, the error ▼Error screen icon is displayed on the Error screen and the error codes 1871 through 1875 is displayed.

  • Page 143: Maintenance

    5. Maintenance This chapter describes how to clean the machine, replace the consumables and lubricate the parts. Regular Maintenance Remember the following maintenance points: Related Maintenance point If the machine is not maintained, the following may occur. items Clean the delivery •...

  • Page 144: Cleaning The Nipper Section

    Cleaning the Nipper Section Bookbinding – Operation Screen Open the nipper. (1) Press the button. The Binding - Maintenance screen appears. (2) Press the button. The nipper opens, and stops. The carriage clamp moves from above the nipper. Press the Emergency Stop button. Bookbinding –...

  • Page 145: Cleaning The Milling Section

    Cleaning the Milling Section Bookbinding - Operation Screen Open the milling guide. (1) Press the button. The Binding – Maintenance screen appears. (2) Press the button. The milling guide opens, and stops. Press the Emergency Stop button. Maintenance Screen Open the left front cover. 22064 50901F1 Remove the adjusting side brush.

  • Page 146: Cleaning The Delivery Section Conveyor

    Cleaning the Delivery Section Conveyor Bookbinding - Operation Screen Move the level plate to the rear. (1) Press the button. The Binding – Maintenance screen appears. (2) Press the button. The carriage clamp moves and the level plate moves to the rear. Press the Emergency Stop button.

  • Page 147: Cleaning And Replacing The Filter Bag

    Cleaning and Replacing the Filter Bag The air escapes from the filter bag, and the trim falls into the trim bag. Hit the outside of the filter bag regularly. When the trim bag is full, replace it. Cleaning the filter bag Hit the outside of the filter bag so that Hit the outside of the filter bag.

  • Page 148: Cleaning The Cover Sheet Sensor

    Cleaning the Cover Sheet Sensor The cover sheet sensor in the cover feed section will not work correctly if it is covered with paper dust or dust. Clean it periodically. Press the Emergency Stop button. Open the cover feed section cover. Cover Feed Section Cover 22064...
  • Page 149 Cleaning the Cover Sheet Sensor Clean the cover sheet sensor. • The sensor is located in a cramped space, so you should use compressed air to clean it. • Starting from the position shown in the figure to the right, use the air to blow off the paper dust. Cover Sheet Sensor Sensor Top...

  • Page 150: Cleaning The Book Block Sensor

    Cleaning the Book Block Sensor The book block sensor at the level plate section will not work correctly if it is covered with paper dust or dust. Clean it periodically. Move the carriage clamp away from the Bookbinding - Maintenance Screen level plate.

  • Page 151: Cleaning The Book Deliver Confirmation Sensor

    Cleaning the Book Deliver Confirmation Sensor The book deliver confirmation sensors will not work correctly if they are covered with paper dust or dust. If the delivery section jam error (error code 1873) is displayed even though the book is transported smoothly, the sensor or mirror may be dirty.

  • Page 152: Cleaning The Pur Tank

    Cleaning the PUR Tank With the glue melted, drain off the glue from the drain under the tank. Have the following items ready: • Drain for spine glue • Disposal container (with a capacity of at least 2 liters or 0.5 gal) WARNING •...
  • Page 153 Cleaning the PUR Tank Remove a strip of glue on each roller. Remove a strip of glue from each roller. After the glue hardens, this makes it easier to peel away the glue. WARNING Take care not to touch the glue stuck to the roller directly.
  • Page 154 Cleaning the PUR Tank Attach the drain for the spine glue. (1) Loosen the mounting screws for the spine glue drain. (These are attached to the frame.) Hang Mounting Screws the spine glue drain from the screws. (2) Tighten the mounting screws. Loosen the mounting screws and install the spine glue drain, and then tighten the screws.
  • Page 155 Cleaning the PUR Tank After the glue has hardened, peel away and remove the remaining glue. • After the tank temperature has dropped, use the scraper (supplied) to remove any bits of glue which are stuck to the walls of the tank. Use adhesive tape to completely remove any small particles of glue left behind.
  • Page 156 Cleaning the PUR Tank Install the wiper shafts. • Before installing, remove all the glue which is stuck to the wiper. Second Wiper • After installing the wiper shaft, tighten the mounting screws. The second wiper has a cutout. Be careful to install each wiper in the correct location.
  • Page 157 Cleaning the PUR Tank Return the tank unit to its original position. (1) Loosen the locking knob. (2) Push the tank unit back in. (3) Tighten the locking knob to secure the tank unit. Tighten Compared with EVA, PUR deteriorates more quickly, so supply fresh glue just before the next binding operation.

  • Page 158: Replacing The Support Plate

    5-10 Replacing the Support Plate Replace the support plate when it has become deformed by taking the steps below. Bookbinding – Operation Screen Move the carriage clamp to the position shown in the bottom figure. (1) Press the button. The “Binding – Maintenance” screen appears. (2) Press the button.

  • Page 159: Replacing The Milling Cutter

    5-11 Replacing the Milling Cutter If the milling cutter is dull, the glue will not stick properly to the spine of the book, and the spine will not be formed correctly. Replace the milling cutter using this procedure. WARNING • Before loosening the mounting screws for the milling cutter, be sure to turn the power switch off.
  • Page 160 5-11 Replacing the Milling Cutter Remove the right brush bracket and the left brush bracket. Right Brush Bracket Left Brush Bracket 22064 50701T1 Rear Milling Guide Remove the rear milling guide. 22064 50701U1 Remove the front milling guide. (1) Remove the mounting screws, and remove the left and right milling guide clamp blocks.
  • Page 161 5-11 Replacing the Milling Cutter Upper Knife Remove the upper knife and two upper knife shims. Upper Knife Shims 22064 50701D1 Removing the milling cutter. For BQ-470 with PUR Tank: (1) Place a piece of thick cloth over the milling cutter.
  • Page 162 5-11 Replacing the Milling Cutter Install the new milling cutter. Milling Cutter (1) Wipe off the grease on the cutter surface. (2) Install the milling cutter. • On a BQ-470 with a PUR tank, the chip cutter and spacers must be mounted on the milling Cutter Base cutter using four mounting screws.
  • Page 163 5-11 Replacing the Milling Cutter Check that the milling cutter and upper knife do not touch. (1) Turn the power switch on. (2) Press the Emergency Stop button. (3) While pressing the Brake Release button, turn the milling cutter counterclockwise by hand. Upper knife 22064 Brake Release button...
  • Page 164 5-11 Replacing the Milling Cutter Rear Milling Guide Install the rear milling guide. 22064 50701U1 Install the right brush bracket and the left brush bracket. Right Brush Bracket Left Brush Bracket 22064 50701T1 Adjusting Install the adjusting side brush. Side Brush 22064 50701W1 Register...

  • Page 165: Replacing The Pur Chip Cutter

    5-12 Replacing the PUR Chip Cutter If the chip cutter is dull, the glue will not be spread over the spine of the book, and the binding strength will be reduced. If this happens, replace the chip cutter. WARNING • Before replacing the cutter, be sure to turn the power switch off.
  • Page 166 5-12 Replacing the PUR Chip Cutter Install the new PUR chip cutter. Place a piece of thick (1) Place the cutter in place, and then put a piece cloth on top of the cutter to protect your hands. of thick cloth over it. •...

  • Page 167: Replacing The Eva Notching Cutters

    5-13 Replacing the EVA Notching Cutters If the notching cutters are dull, the glue will not be spread over the spine of the book, and the binding strength will be reduced. If this happens, replace the notching cutters. When changing the types of the notching cutters, replace the notching cutter by going through the same steps.
  • Page 168 5-13 Replacing the EVA Notching Cutters Remove the two EVA notching cutters. While pressing the Brake Release button, (1) Press the Brake Release button on the main turn the milling cutter clockwise. part of the machine. (2) With the Brake Release button held down, turn Brake Release Button the milling cutter clockwise by hand.
  • Page 169 5-13 Replacing the EVA Notching Cutters Place the set gauge here Install the new notching cutters. (1) Insert the new notching cutter so that the high end of the blade faces the direction of rotation. Each notching cutter has a blade at each Rotation direction end, so it can be used twice.
  • Page 170 5-13 Replacing the EVA Notching Cutters (2) Hold the edge of the notching cutter using the set gauge, and tighten the mounting screw. Align the height using the dedicated set Set Gauge gauge and then lock the cutter using SS5-25 as shown in Fig.4.

  • Page 171: Replacing The Glue

    5-14-1 5-14 Replacing the Glue Replacing the EVA spine glue 5-14-1 Replacing the EVA spine glue If the glue has turned yellow or its viscosity has increased, this means that the glue has deteriorated. With the glue melted, drain off the glue from the side panel of the spine glue tank unit, and add fresh glue. WARNING The melt tank is heated to a temperature of about 200°C (400°F).
  • Page 172 5-14-1 5-14 Replacing the Glue Replacing the EVA spine glue Attach the drain for the spine glue. (1) Loosen the twot glue drain mounting screws. (2) Hang the spine glue drain, and tighten both screws. Spine Glue Drain Loosen these screws and use it to hang the spine glue drain.
  • Page 173 5-14-1 5-14 Replacing the Glue Replacing the EVA spine glue Install the plug, and remove the spine glue drain. CAUTION Do not tighten the plug too tightly. If you tighten too tight, you will have difficulty removing the plug, or you will strip the screw thread and the plug cannot be installed.

  • Page 174: Replacing The Side Glue

    5-14-2 5-14 Replacing the Glue Replacing the side glue 5-14-2 Replacing the side glue With the side glue melted, drain off the glue from the lower front of the side glue tank, and add fresh glue. WARNING The side glue tank has a high temperature of about 200°C (400°F).
  • Page 175 5-14-2 5-14 Replacing the Glue Replacing the side glue Install the side glue drain. (1) Loosen the two drain mounting screws. (2) Insert the side glue drain on the screws, and Side Glue Drain tighten both the left and right screws. Place a disposal container under the glue drain.

  • Page 176: What To Do If The Glue Has Overflowed

    5-15 What to Do If the Glue Has Overflowed If the side glue or spine glue (EVA tank) has overflowed, it will collect in the glue collection tray. Dispose of the glue in this tray by following the steps listed below. WARNING The spine glue tank has a high temperature of about 200°C (400°F).

  • Page 177: Replacing The Double Feed Stop Pads

    5-16 Replacing the Double Feed Stop Pads If the covers double-feed frequently, the double feed stop pads may be worn. Follow the steps listed below to remove the double feed stop pads. If the pads are worn, replace them. Lower the cover table. Cover Table Up Button •...

  • Page 178: Resetting The Circuit Breakers

    5-17 Resetting the Circuit Breakers If any function or part of the machine is not working, check appropriate circuit breaker. WARNING Turn off the power switch before resetting any circuit breakers. Otherwise the machine may start suddenly, causing severe personal injury. Error Screen Check the error code.
  • Page 179 5-17 Resetting the Circuit Breakers Turn the power switch off. Wait a few minutes, and then turn the Removing the cover: circuit breaker on. For circuit breakers (1) Remove the cover. For circuit breakers (11) or (12) (1), (2), (3), (4) or (5) •...

  • Page 180: Lubrication

    5-18-1 5-18 Lubrication Melt tank chains Lubricate the parts indicated below at the periodic intervals indicated. The symbols in the figures show the lubrication method and frequency. Symbols indicating the lubrication method Lubrication interval symbols The following symbols show how often to Every day lubricate the part.

  • Page 181: Carriage Clamp Rails

    5-18-2 5-18 Lubrication Carriage clamp rails 5-18-2 Carriage clamp rails WARNING Before lubricating the sections, turn the power switch off. Turn the power switch off. Cover Lifting Guide Open the right front cover and cover feed section cover. Cover the cover lifting guide with a cloth, paper, etc.
  • Page 182 5-18-2 5-18 Lubrication Carriage clamp rails Information - Single Operation Move the carriage clamps so that the Delivery Screen grease is spread along them. (1) Turn the power switch on. (2) Close the cover. (3) Press the button. Delivery (4) Press the button.

  • Page 183: Level Plate Slide Rails

    5-18-3 5-18 Lubrication Level plate slide rails 5-18-3 Level plate slide rails WARNING Before lubricating these parts, turn the power switch off. Bookbinding – Operation Screen To set up for this procedure, turn the power switch on. Move the carriage clamp away from the level plate.

  • Page 184: Upper And Lower Nipper Shafts

    5-18-4 5-18 Lubrication Upper and lower nipper shafts 5-18-4 Upper and lower nipper shafts Open the nipping section bottom cover. Left Front Cover Nipping Section Bottom Cover 22064 51304A1 Two Mounting Screws Pull the lubricating lever out as far as it will go.

  • Page 185: Replacing The Thermal Fuses

    5-19 Replacing the Thermal Fuses Two thermal fuses are installed: one in the spine glue tank and another in the side glue tank. If the tank overheats, the thermal fuse will melt and prevent any damage. Replacing the fuse in the spine glue tank WARNING Before replacing the thermal fuse, turn the power switch off, and allow the tank to...
  • Page 186 5-19 Replacing the Thermal Fuses Replacing the fuse in the side glue tank WARNING Before replacing the thermal fuse, turn the power switch off, and allow the tank to cool off. Otherwise, the hot parts may cause burns. Turn the power switch off. Loosen Pull out the tank unit.

  • Page 187: Replacing The Upper Scoring Rollers

    5-20 Replacing the Upper Scoring Rollers Press the Emergency Stop button. Open the cover feed section cover. Cover Feed Section Cover 22064 50401A1 Remove the shaft for the upper scoring rollers. (1) Loosen the hex bolt at each end. (2) Turn the clamp block at each end, and remove the shaft.
  • Page 188 5-20 Replacing the Upper Scoring Rollers Remove the transport rollers and upper scoring rollers from the shaft. Transport Rollers • The transport rollers can be removed by loosening the locking screws. Install the transport rollers and upper Upper Scoring Rollers scoring rollers on the shaft.

  • Page 189: Cleaning And Replacing The Air Filter

    5-21 Cleaning and Replacing the Air Filter If the air filter in the cover feeder clogs, the blower air reduces and it can cause mis-feeding of cover. Remove the air filter following the procedures below, clean the air filter if necessary. If air filter does not clean off, replace it. See the parts No.

  • Page 190: Cleaning The Duct

    5-22 Cleaning the Duct The glue regin is stuck on the inside wall of the duct for the long-term use. Remove the glue regin once six months. If the glue regin is left unremoved, it may drop and stain the book. Turn the power switch off.

  • Page 191: Replacing The Milling Brushes

    5-23 Replacing the Milling Brushes If milling trim is scattered, the milling brushes may be worn out. Check the milling brushes, and if they are worn out, replace the milling brushes. Follow the steps listed below. WARNING •Wear work gloves for this job, and avoid touching the edge of the cutter blade.
  • Page 192 5-23 Replacing the Milling Brushes Install the new brush on the bracket. 12076 52401C1 • Install the right brush and the left brush in the positions shown in the drawing to the right. 9mm(0.37") 28mm(1.14") 22064 52401D1 Install the right brush bracket and the left Right Brush Bracket brush bracket on the milling unit.
  • Page 193 5-23 Replacing the Milling Brushes Register Side Brush Install the register side brush. Adjusting Side Brush Install the adjusting side brush. 22064 52401F1...

  • Page 194: Cleaning The Cover Sheet Waiting Position Sensor

    5-24 Cleaning the Cover Sheet Waiting Position Sensor The cover sheet waiting position sensor in the cover feed section will not work correctly if it is covered with paper chips or dust. Clean it periodically. Turn the power switch off. Right Safety Cover Open the right safety cover.

  • Page 195: Cleaning The Cover Transport Belts

    5-25 Cleaning the Cover Transport Belts If the cover transport belts are fouled, a cover may tilt and a sheet jam may occur during transporting a cover. Clean them periodically. Turn the power switch off. Right Safety Cover Open the right safety cover. 22064 52501A1 Remove the cover lifting guide.

  • Page 196: Teflon Recoating For Pur Glue Tank

    5-26 Teflon Recoating for PUR Glue Tank Some of the Teflon-coated parts must be recoated regularly. Contact your service technician for recoating. Type of Coating: PFA bilayer coating Coating Thickness: 40 to 50 microns from surface PUR Glue Remover: When PUR glue is stick too tightly, put Toluene on waste cloth and wipe PUR glue off surface. Glue manufacturers must have know-how to remove PUR glue.

  • Page 197: Optional Devices

    6. Optional Devices This chapter describes how to install and operate the optional devices of BQ-470. T-470 Weekly Timer 6-1-1 Operation Procedure Turn on the main power switch. Present time appears on the LCD of the weekly timer. When using the weekly timer, keep the main power switch turned on.
  • Page 198 T-470 Weekly Timer Set the current day and time. Entering Button • This explains the steps in case of setting 10:05 on Wednesday as an example. [1] Press MODE button until the display shows the MODE current time setting mode. (about 2 seconds) The indication of the day blinks.
  • Page 199 T-470 Weekly Timer Setting the timer off at 10:00 Entering Button [7] Press the + and - button to set “10”. [8] Press the entering button to enter the setting. The minites indication blinks. [9] Press the + and - button to set “00”. MODE [10] Press the entering button to enter the setting.

  • Page 200: Installation Procedure

    T-470 Weekly Timer This section explains how to install the T-470 with the BQ-470 with S/N 339899 or below. If the BQ-470 is S/N 340001 or above, see Section 6-1-3. 6-1-2 Installation Procedure T-470 WARNING • Make sure to disconnect the power cable of the transformer from customer power source.
  • Page 201 T-470 Weekly Timer 220/400 V BQ-470 For 220/400 VAC T-470 Power Cable Connect the T-470 power cable to the transformer. • Connect the T-470 power cable to the terminal board of the transformer where BQ-470 power cable was removed in step 1. T-470 Power Cable For 200 VAC Connect the T-470 power cable to the...
  • Page 202 T-470 Weekly Timer Install the T-470 to the BQ-470 using four mounting screws (TT4-8TPN). TT4-8TPN 22064 60101J1 Clamp three cables of T-470 using six cable clamps. • Install the cable clamps using the B4-12ZP. Cable Clamp 12076 B4-12ZP 60202E1...
  • Page 203 T-470 Weekly Timer Replace the head of the power switch. • Remove the red/yellow handle and install the black handle. WARNING • When T-470 is installed, current carrying part exists although the drive power switch is turned off. To prevent the electrical shock while maintenance opration, make sure to install the black handle to the drive power switch to...

  • Page 204: Installation Procedure

    T-470 Weekly Timer This section explains how to install the T-470 with the BQ-470 with S/N 340001 or above. If the BQ-470 is S/N 339899 or below, see Section 6-1-2. 6-1-3 Installation Procedure T-470 WARNING • Make sure to disconnect the power cable of the transformer from customer power source.
  • Page 205 T-470 Weekly Timer 220/400 V BQ-470 For 220/400 VAC T-470 Power Cable Connect the T-470 power cable to the transformer. • Connect the T-470 power cable to the terminal board of the transformer where BQ-470 power cable was removed in step 1. T-470 Power Cable For 200 VAC Connect the T-470 power cable to the...
  • Page 206 T-470 Weekly Timer Install the T-470 to the BQ-470 using four mounting screws (TT4-8TPN). TT4-8TPN 22064 60101J1 Clamp three cables of T-470 using six cable clamps. • Install the cable clamps using the B4-12ZP. Cable Clamp 12076 B4-12ZP 60203D1...
  • Page 207 T-470 Weekly Timer Remove the front cover feed section cover, and remove three short circuit bars from the terminal board shown in the drawing to the right. 22064 60203C1 Three Short Circuit Bars...
  • Page 208 T-470 Weekly Timer Replace the head of the power switch. • Remove the red/yellow handle and install the black handle. WARNING • When T-470 is installed, current carrying part exists although the drive power switch is turned off. To prevent the electrical shock while maintenance opration, make sure to install the black handle to the drive power switch to...

  • Page 209: Flap Cover Sheet Flp-470

    Flap Cover Sheet FLP-470 Disengage the upper scoring rollers so Cover Feed Section Cover that they move freely. (1) Open the upper cover feed section cover. (2) Turn the locking knobs on both sides to release the locks. (3) Loosen the pressure adjusting knobs on both sides by turning them counterclockwise.
  • Page 210 Flap Cover Sheet FLP-470 Adjust the position of the scoring rollers so that the scoring lines for the flap cover sheet are made in the right positions. Here are the positions where the scoring lines for the flap cover sheet can be made - Line on the far side: 128 mm to 250 mm (5.04”...
  • Page 211 Flap Cover Sheet FLP-470 Meet the upper and lower rollers. The scoring roller pressure for flap cover • The scoring pressure for flap cover sheet sheet is decreased. changes depending on the position where the rollers meet. The scoring roller pressure for (1) Meet the lower scoring roller with the upper flap cover...

  • Page 212: Extra Table Et-470

    Extra Table ET-470 The ET-470 is used when installing the SI-470A to the right side of the book block feed section. The ET-470 is also available as a work table. The ET-470 can be installed only to the BQ-470 with S/N 354001 or above. 6-3-1 Bundled Items B5-10ZP ×...
  • Page 213 Extra Table ET-470 Remove the front cover for the milling section. •This cover is not used. • The removed screws are used in step 5. 12076 60502E1 Install the table bracket. Install the front cover 2. 12076 Return the tank unit. •...
  • Page 214 Extra Table ET-470 Reinstall the milling set lever. SS6-6 12076 60502J1 Attach the packing. Install the table. 12076 60502I1...

  • Page 215: Wire Brush Wbc-470

    Wire Brush WBC-470 At the center of the milling cutter, the brush is installed to remove the trim from the book block. When the standard horsehair brush cannnot remove the trim enough, replace the standard brush with this brush. The end of the WBC-470 is stiff, and the height of the brush should be adjusted by inserting the shims under the brush.
  • Page 216 Wire Brush WBC-470 Brush Height Place the brush height gauge on the Gauge milling unit. Put this surface on the end of the milling cutter. 12116 60601B1 12116 60601B1 If the brush is high, the brush pushes up the center of the gauge and the gauge tilts left and right.

  • Page 217: Installation

    7. Installation The procedures in this section should only be done by authorized service personnel. Moving the Main Part of the Machine Have a cart ready before unloading the Space required for installation main part of the machine from the truck. Power : From customer's Power source 19.7”...
  • Page 218 Installing the Main Part of the Machine Dimensions and weight of each unit after disassembling are as below. Machine Dimensions Unit: mm (inch) Machine Weight About 2,000 kg (4,410 lb) Height 2,000 (78.8") Depth 1,090 (43.0") (Milling Lever included) Width 3,220 (126.8") 22064 70101M1 Dimensions after cover feed unit and clamp rail are removed...
  • Page 219 Installing the Main Part of the Machine Dimensions after upper and lower parts are disassembled Machine Weight About 980 kg (2,160 lb) Height 850 (33.5") ( Dimension not including the adjusting bolt ) Depth Depth 1,090 (43.0") (Milling Lever included) 1090( 22064 1,020 (40.2") (Milling Lever not included)

  • Page 220: Installing The Main Part Of The Machine

    Installing the Main Part of the Machine Place the mounts underneath the four Top view: setting bolts. Delivery Side Cover Feed Side Main Frame Place mounts underneath the four setting bolts. Setting Bolt (attached on the cover feed table) Mount 22064 70101B1 Remove the locking brackets for shipping.
  • Page 221 Installing the Main Part of the Machine Adjust the main part of the machine so Nipping Section that it is level. •Place the level on the plate in the nipping section, and check for level in two directions. •If the nipper needs to be wider, open the bottom cover of the nipping section, and turn Level the timing pulley of the stepper motor.
  • Page 222 Installing the Main Part of the Machine Attach the bracket for the milling trim bag. (1) Attach the bracket to the left side of the main part of the machine. (2) Remove the left rear cover. •Remove the four mounting screws. (3) Connect the duct hose, and secure it using a hose clamp Bracket For The...
  • Page 223 Installing the Main Part of the Machine Only you will want to change the tank - Tank Unit Remove the tank unit locking screws. (1) Remove the front cover on the tank unit. (2) Remove the two locking screws on the tank unit.

  • Page 224: Attaching The Stacker

    Attaching the Stacker Connect the power and signal cables for the stacker to the main part of the machine. Power Cable Signal Cable 22064 70301F1 Remove the lower cover and open the left cover. Left Cover Lower Cover 22064 70301G1 Right side Attach the stacker to the main part of the machine.

  • Page 225: Wiring Connections

    Wiring Connections WARNING If the machine’s power cable will be connected directly to a circuit breaker on the power distribution board at the building, ask a qualified contractor to do the job. For 200 VAC Input: Turn the circuit breaker on the power distribution board off.

  • Page 226: Installing The Smoke Extractor

    Installing the Smoke Extractor Connect the power cable for the smoke extractor to the main part of the machine. Connect the power cable for the smoke extractor. 22064 70401A1 Check the direction of rotation of the fan in Smoke Extractor the smoke extractor.

  • Page 227: Setting Up For Optional Devices

    Setting Up For Optional Devices Using the Service - Option screen , set up any optional devices which have been connected. Service Screen Display the Service screen. Press the icon. The Ootion - Setting screen is displayed. Press the buttons for the optional devices Option Screen which are connected.
  • Page 228 This page is intentionally left blank.

  • Page 229: Appendix

    8. Appendix This chapter lists the specifications and accessories for this machine. Specifications Binding Modes Binding with milling, Binding without milling and Pad binding Number of Carriage Clamps Book Block Size (Top-Bottom x Max. Top-bottom 320 x fore-edge 320 mm (12.59" x 12.59") Fore-edge) Min.

  • Page 230: Accessories

    Accessories 8-2-1 Accessories for BQ-470 The parts numbers are listed on the Fig.201 for 202 in the partsbook. Operation Manual 1 pc Parts Book 1 pc You are reading this now. 12076 12076 80201A1 80201B1 Tool Box 1 pc Caliper 1 pc Only for mm version of BQ-470...
  • Page 231 Accessories High Book Block Support Guides Book Block Support Guides (S) 4 pcs 4 pcs High 22064 22064 80201L1 80201M1 Hoisting Bars 2 pcs Eye-bolts 4 pcs 22064 22064 80201N1 80201O1 Allen Wrenches 1 each Allen Wrench (14mm) 1 pc 2.5mm 22064 22064...
  • Page 232 Accessories Screwdriver 1 pc Socket Wrench 1 set 22064 22064 80201V1 80201W1 Handle Allen Wrench 1 pc Drain for Side Glue 1 pc 22064 22064 80201X1 80201Y1 Side Glue (HM-403) 1 kg 1 set Glue Cups These are used to add glue to the tank.
  • Page 233 Accessories Adjusting Pin 1 pc 1 pc Cover Holder 22064 22064 80201J2 80201I2 Ring for Holding Scoring Roller 1 pc Transformer 1 pc One more is provided Only For 220V / 400V on the machine 22064 80201K3 22064 80202I1 Handle Allen Wrench 1 pc Long Screwdriver 1 pc...
  • Page 234 Accessories Hose Clamps 4 pc 4 pcs Mounts 22064 22064 80202F1 80202G1 1 pc Strap for Bag 2 pcs Cover Lifting Guide 22064 22064 80202K1 80202L1 Oil Container for 2 pcs 1 pc Hose for Smoke Extractor Nipper Lubrication Tank 22064 22064 80202O1...
  • Page 235 Accessories Keys for control box 2 pcs Cover Edge Lifting Guides 2 pcs 22064 12076 80202Q1 80202S1 Cable Bushing 1 pc Upper Knife Shim 1 pc Use this when you want increase the clearance This is used betwween the milling when installing cutter and the upper the optional...

  • Page 236: Accessories For Mu-470Eva

    Accessories 8-2-2 Accessories for MU-470EVA Set Gauge for Notching Cutter 1 pc Spine Glue (HM-221) 3 kg for EVA For EVA For EVA 12076 12076 80201H1 80201A2 Drain for Spine Glue 1 pc Thermal Fuse 1 pc For EVA For EVA tank 12076 12076 80201C2...

  • Page 237: Accessories For Mu-470Pur

    Accessories 8-2-3 Accessories for MU-470PUR The parts numbers are listed on the Fig.201 for 202 in the partsbook. 1 pc Cover Spacer 5 pcs For PUR For PUR When the BQ-470 is shipped with a MU- 470PUR, four spacers B3-6B 2 pcs are pre-mounted on the BQ-470.
  • Page 238 Accessories Installation Manual for Tank 1 pc Only if MU-470 PUR is shipped separately. 12076 80202W1...

  • Page 239: Consumables

    Consumables Glue Milling Cutter (M164401) HM-221 20kg = 4021840 HM-403 20kg = 4017857 HM-403 5kg = M790017 22064 22064 80301A1 80201I1 Filter Bag (M051747) Notching Cutter M164453 M051609 22064 80301B1 12076 80201F1 Double Feed Stop Pad Assembly Support Plate (M164104) (A924697) (Violet) 22064...
  • Page 240 Consumables Chip Cutter (M164404) Silicon Plug (4020191) For PUR For PUR 22064 22064 80201P2 80201R2 Air Filter for Cover Feeder Wiper (M164677) 3pcs (M072647) For PUR 22064 80401A1 Register Side Brush (M164443) Adjusting Side Brush (M204107) 12076 12076 80401Q1 80401P1 Delivery Section Book Supporting Brush Right and Left Milling Brush (M173612) (M165522)

  • Page 241: Options

    Options Description Model Remarks PUR Spine Glue Tank MU-470PUR With milling inverter. EVA Spine Glue Tank MU-470EVA Manual Simple Lifter L-470 This makes tank replacement easier. Fork for Lifter F-470 This is mounted on the lifter. Two stands are normally necessary when replacing Melt Tank Stand S-470 the tank.
  • Page 242 Options Notching Cutter Order these notching cutters when the spine glue is not applied to a few sheets on the both sides of the book block, or when you want to change the notching depth or condition. M051616-00 M051612-00 M164412-00 M051609-00 M164453-00 Double-Edge...

  • Page 243: Periodic Replacing Parts For Pur

    Periodic Replacing Parts for PUR 1 pc 1 pc Tank Screw Set (M166420) Roller Screw Set (M166421) 12076 12076 80401C1 80401D1 1 pc Wiper Screw Set (M166422) Glue Guide (M164799) 1 pc 12076 12076 80401E1 80401F1 Scrape Roller (A937945) 1 pc Drum AS (A937992) 1 pc M164653...
  • Page 244 Periodic Replacing Parts for PUR Spine Glue Tank (A937951) 1 pc 1 pc Drain (M164616) 12076 12076 80401M1 80401N1 1 pc Drain Guide (M164612) 12076 80401O1...

  • Page 245: Commissioning And Dismantling

    De-commissioning and Dismantling There is no specific hazardous materials and components for de-commisioning and dismantling the machine.
  • Page 246 Manufacturer: www.horizon.co.jp/ Phone:+81-75-934-6700, Fax:+81-75-934-6708,...

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