BQ270 Operator Manual PDF

PERFECT BINDER BQ-270
Important Information
• This manual is designed to help you to install, operate and maintain the BQ-270 Perfect Binder.
Please read and understand this manual, and keep it in a safe and convenient place.
• Do not operate the BQ-270 until you read and understand the instructions in this manual.
• Horizon International Inc. shall not be liable for incidental consequential damages resulting from:
improper or inadequate maintenance by the customer unauthorized modification or misuse, or
operation outside of the environmental specifications for the product.
• Horizon International Inc. pursues a policy of continuing improvement in design and performance
of the product. Therefore, the product design and specifications are subject to change without prior
notice and without our legal obligation.
• All rights are reserved. No part of this manual may be photocopied, reproduced or translated to
another language without the prior written consent of Horizon International Inc.
061031/BQ270/11E/HS, TM, HH, HS UM202048-11

Safety precautions are indicated in this manual as follows:
Safety Precautions
• The term WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
• The term CAUTION indicates a potentially hazardous situation which, if not avoided, may
result in serious injury, or damage to the machine.
• This symbol indicates a note which includes important information. Follow the note to
operate the machine safely.
• This symbol indicates a prohibited action. Do not perform any prohibited action.
• This symbol indicates an essential procedure. Follow the procedure to operate the machine
safely.
This lists the range of acceptable values and operating conditions.

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

Note
This explains a mechanism in the machine.

Additional
Information
Safety Operation Precautions
WARNING
Do not touch the melt tank while the power switch is turned on. Melt tank is heated to 200
degrees Celsius (400 Fahrenheit), and may cause severe skin burn.
Work alone when you maintain and lubricate the machine. Letting someone else operate the
machine may cause severe personal injury.
Do not touch the moving part. Otherwise it may cause severe personal injury.
Turn off the power switch before adjusting the machine. If the start button is pressed, it may
cause severe personal injury.
Do not touch the milling cutter and roughening cutter. Otherwise it may cause severe personal
injury.
Be careful not to pinch your hands when inserting the book block into the clamp.
Disconnect the power cable from the socket when recovering the breaker.
BQ-270 weighs 900 kg (1,980 lb). Transport and install the machine safely, and keep the weight
of the unit in mind.
CAUTION
When turning off the power switch and on again, wait a dozen of seconds. Otherwise, the board
may be damaged.
When the milling guide and the nipper are set narrower than the clamp width, do not move the
clamp. Otherwise, the lower part of the clamp may hit the guide and be damaged.
Do not insert book block into clamp and drive the machine while chanover. Otherwise, tha
machine may be damaged.
Make sure to tighten the lock screw of milling cover brush. Otherwise the brush may fall out
when the clamp passes over.
Do not drive the application drum when the glue is not melted completely. Othewise, the
machine may be damaged.
When using optional weekly timer, the melt tank is heated up in the set up day, at the set up time.
Check the machine when the melt tank is heated up for safe.
Use the lubrication grease recommended by Horizon. If the ingredient of the grease changes, the
life of the machine may be shortened or the machine may be damaged.
CONTENTS
Important Information
Safety Precautions
Safety Operation Precautions
1. Machine Description .................................................................................... 1

1-1 Machine Description............................................................................................... 1
1-2 Safety Functions .................................................................................................... 1
1-3 Parts Descriptions .................................................................................................. 2
1-3-1 Carriage Clamp Section ........................................................................................... 2
1-3-2 Level Plate Section................................................................................................... 2
1-3-3 Milling Section .......................................................................................................... 3
1-3-4 Melt Tank Section..................................................................................................... 4
1-3-5 Nipping Section ........................................................................................................ 5
1-3-6 Cover Feed Section.................................................................................................. 6
1-3-7 Delivery Section ....................................................................................................... 7
1-3-8 Touch Screen ........................................................................................................... 7
1-4 Screen Descriptions ............................................................................................... 8
2. Job Settings on Touch Screen ................................................................... 9

2-1 Entering the Job Information Using the Setting Screens ....................................... 9
Binding Mode Screen ...................................................................................................... 10
Start Mode Screen............................................................................................................ 11
Book Block Size Screen .................................................................................................. 12
Cover Sheet Size Screen ................................................................................................ 13
Function Screen............................................................................................................... 14
Milling and Nipping Screen ............................................................................................... 15
Gluing Screen Part 1 ....................................................................................................... 16
2-2 Bind the Books Using the Binding Screens.......................................................... 18
Binding Screens............................................................................................................... 19
2-3 Test Milling and Gluing.......................................................................................... 20
Test Milling and Gluing Screen........................................................................................ 20
2-4 Fine Adjustment .................................................................................................... 21
Clamp and Milling Fine-Adjust Screen............................................................................. 21
Glue Fine-Adjust Screen Part 1 ....................................................................................... 22
Nipping Fine-Adjust Screen ............................................................................................. 24
Scoring Fine-Adjust Screen ............................................................................................. 25
Cover Sheet Fine-Adjust Screen Part 1........................................................................... 26
2-5 Saving or Recalling or Deleting Job Settings. ...................................................... 29
2-6 Using the Single Operation Screen...................................................................... 30
Single Operation Screen Part 1 ....................................................................................... 30
Home Positioning Screens .............................................................................................. 32
Milling Brake Release Screen.......................................................................................... 32
2-7 Information Screen............................................................................................... 33
2-8 Error Screen......................................................................................................... 34
2-9 Numeric Keypad Screen ...................................................................................... 34
3. Starting the Binding Operation ................................................................. 35

3-1 Turn On the Power Switch ................................................................................... 35
3-2 Safety Function Check ......................................................................................... 35
3-3 Enter the Job Information Using the Setting Screens .......................................... 36
3-4 Setting the Main Binding Screen.......................................................................... 40
3-5 Setting the Scoring Rollers................................................................................... 41
3-6 Setting the Scraper (For Padding Only) ................................................................ 43
3-7 Setting the Side Glue Rollers ............................................................................... 44
3-8 Start Binding......................................................................................................... 45
3-9 Adding More Cover Sheets .................................................................................. 47
3-10 Removing the Bound Booklets........................................................................... 48
3-11 Saving and Recalling the Job Information.......................................................... 49
3-12 Adding More Glue .............................................................................................. 52
3-13 Finishing the Binding Operation ......................................................................... 53
4. Parts Adjustments ..................................................................................... 55

4-1 Changing the Spine Glue Amount and Position................................................... 55
4-2 Adjusting the Side Glue Amount .......................................................................... 55
4-3 Changing the Nipping Setting .............................................................................. 56
4-4 Changing the Cover Feeding Settings ................................................................. 57
4-5 Changing the Scoring Position............................................................................. 58
4-6 Changing the Carriage Clamp Opening and Milling Guide Width ........................ 58
4-7 Milling Depth Adjustment ..................................................................................... 59
4-8 Glue Temperature Adjustment ............................................................................. 61
4-9 Side Glue Amount Adjustment (Far Side) ............................................................ 62
4-10 Nipper Height Adjustment .................................................................................. 64
4-11 Nipper Angle Adjustment ................................................................................... 65
4-12 Cover Sheet Angle Adjustment .......................................................................... 66
4-13 Blower Air Adjustment........................................................................................ 67
4-14 Double Feed Stop Pad Height Adjustment ........................................................ 67
4-15 Feed Table Height Adjustment........................................................................... 68
4-16 Scoring Roller Pressure Adjustment .................................................................. 68
5. Maintenance ............................................................................................... 69
5-1 Cleaning the Book Block Path.............................................................................. 69
5-2 Cleaning the Sensors........................................................................................... 71
5-3 Lubrication............................................................................................................ 72
5-4 Book Support Plate Replacement ........................................................................ 73
5-5 Milling Cutter Replacement .................................................................................. 75
5-6 Roughening Cutter Replacement......................................................................... 78
5-7 Glue Replacement ............................................................................................... 81
5-8 Double Feed Stop Pad Replacement................................................................... 83
5-9 Transport Belt Replacement ................................................................................ 84
6. Troubleshooting ......................................................................................... 85
6-1 Problems with Booklet Quality ............................................................................. 85
6-2 Error Codes.......................................................................................................... 90
6-3 If a Circuit Breaker Trips ...................................................................................... 94
6-4 If a Message Screen Appears .............................................................................. 95
7. Optional Device .......................................................................................... 97

7-1 Weekly Timer ....................................................................................................... 97
8. Installation ................................................................................................ 101
8-1 Installation .......................................................................................................... 101
8-2 Installation of Extractor (Option).......................................................................... 104
8-3 Installation of Weekly Timer (Option) ................................................................. 106
9. Appendix................................................................................................... 109
9-1 Specifications ..................................................................................................... 109
9-2 Accessories........................................................................................................ 110
9-3 Consumable Parts.............................................................................................. 113
9-4 Option................................................................................................................. 114
9-5 Index ................................................................................................................... 115
1. Machine Description
1-1 Machine Description

Touch Screen Milling Section
Used to input necessary Mills the book spine.
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
book spine and forms the spine.
sheet block.
Cover Feed Section

Feeds the cover sheet
to the nipping section.
PERFECT BINDER
BQ-270
Trimmings Bag
Collects the trimmings.
Glue Temperature Adjusting Knob

Adjusts the glue temperature
from 120 to 180 (248 to 356 ).
Power Switch
Delivery Section
Stacks the bound booklets Milling ON/OFF Lever
vertically. Turns the milling operation ON or
OFF. Turn the lever to the right
to select milling ON.
Turn to the left to select milling
OFF.
1-2 Safety Functions

Safety Cover (left)
The machine stops if
this cover is opened.
Safety Cover (right)
Area Sensors The machine stops if
The machine stops if this cover is opened.
this light between the
sensors are cut.
PERFECT BINDER
BQ-270
Emergency Stop Button
this button is pressed.
Lower Nipper Door

this door is opened.
1
1-3 Parts Descriptions
1-3-1 Carriage Clamp Section
Grease Nipples
PERFECT BINDER
BQ-270
Lubricate with
grease here.
Book Block Insert Section

Insert the book blocks
here, aligning to the right.

Press this button to stop
the machine.
Turn the button clockwise
to release the emergency
stop.
Start Buttons
When using the manual starting mode, press
both buttons to start the binding operation.
1-3-2 Level Plate Section

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

Regularly lubricate with grease.
Delivery Section
Each booklet is delivered here.
2
1-3-3 Milling Section
PERFECT BINDER
BQ-270
Rear Milling Guide
NING
WAR
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
This guide holds the book spine replacing the milling cutter.
while the milling operation is done. This button works only after
pressing the brake release
Guide Block button on Touch Panel Screen.
This block transports the power
from the motor to the front milling
guide.
Milling Select Lever

When milling the book spine,
this lever is used to turn the milling
operation ON or OFF. Set the lever
to the left to turn off the milling operation.
3
1-3-4 Melt Tank Section
Glue Temperature Adjusting Knob

The glue temperature can be adjusted from
PERFECT BINDER
BQ-270 120 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.
Wiper 2
Side Glue Roller Lubrication Point Glue Level Upper Limit

This drum is used to apply the glue Refer to [5-3] for details. Keep the glue level lower
on the lower side of the book block. than this line.
The lower limit of the glue level
Glue Amount Adjusting Plate is 8 mm (0.31") lower position
below the upper limit line.
If too little glue is applied to the
side glue roller, or too much glue is Application Drum 2
applied, adjust the glue amount by This drum is used to put the
moving this plate. glue on the book spine.
Scrape Roller
This roller scrapes the extra
glue off of the spine.
Adjust according to the glue Glue Supply Section

amount applied here. Add more glue here when
the glue level is low.
Wiper 1
The distance of glue penetration
into the spine depends on the wiper 0
opening.
Application Drum 1
This drum is used to provide the
glue that penetrates into the spine. Positioning Plate - Side Glue Roller (far side)
This plate is used to adjust the position of the side
glue roller on the far side of the machine. Turn the
plate counterclockwise, and the roller moves
forward to approach to the book block. (Normally
set to 0.)
4
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
nipping operation. Registers the cover
Transport the cover sheets. sheets to the right.
Rear Nipper
This forms the book
spine with the front
nipper.
Front Nipper
7 0
Q-2
DE
R B
Front Jog Guide IN
TB
Before the cover sheet is fed, the side EC
guide waits 3 mm (0.12") away from the RF
edge of the sheet. It registers the cover
PE
with the rear side guide before the nipping
operation.
Angle Adjusting Lever
This lever is used to adjust
the cover sheet angle.
Refer to [4-12] for details.
Nipper Angle Adjusting Block Nipper Height Adjusting Ring

Refer to [4-11] for details. This ring is used to adjust the
book spine sharpness.
5
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
on the feed table.
End Guide
Feed Table
Pad Height Adjusting Lever

This adjusts the height of the double Positioning Guide
feed stop pads. If the pad is worn or
double feeding occurs
frequently, raise the pads. Feed Rotor
Refer to [4-14] for details. This feeds the cover sheets
using suction and friction.
Double Feed
Detect Sensor
This detects double
feeding by measuring
Blower Air Adjusting Lever the light that penetrates
the sheet.
Double Feed Stop Pads
6
1-3-7 Delivery Section
Push Plate
This plate pushes the
delivered booklets forward.
Stopper
Set this stopper next to the push
plate. The stopper will be pushed
forward as the booklets are stacked.
1-3-8 Touch Screen
Touch Screen
Refer to Section 2 for details on
the screens.
BQ-270
7
1-4 Screen Descriptions
The BQ-270 has five kinds of screens. Refer to Section 2 [Job Settings on Touch Panel] for details. (See page 9.)
Setting Screens Memory Screen

These screens are used to input the This screen is used to save or recall the
necessary job information. Refer to [2-1]. job settings. Refer to [2-5].
Binding Screens Single Operation Screens

These screens are used to display the current These screens are used during maintenance
job information during the binding operation. (cleaning or parts replacement). They can also
The can also be used to make fine be used to check the function of each section.
adjustments. Refer to [2-2]. Refer to [2-6].
Information Screen
Service Screen This screen is used to show the ROM version
and the total binding number. Refer to [2-7].
Function Setting Screen

This screen is used to select the table
movement when the double feeding occurs,
milling function, and the delivery section full
detection ON/OFF.
8
2. Job Settings on Touch Screen
2-1 Entering the Job Information Using the Setting Screens
Input the necessary job information such as the binding type, sheet size and other
functions. The Setting Screen can cover the following seven functions:
Setting Screens
1 Binding Mode Screen

2 Start Mode Screen
3 Book Block Size Screen
4 Cover Sheet Size Screen
5 Function Screen
6 Milling, Nipping Screen
P. 1 7 Gluing Screen Part 1

Press the box, and the Numeric Keypad

Screen appears. Input the setting value
on the Numeric Keypad Screen in
increments of 0.1mm (0.004").
9
1 - - Binding Mode Screen
3
1 2
1 : Binding with cover sheets.

Select when binding with cover sheets.
When this button is selected, the side glue rollers should be moved into their working
positions. Refer to [3-6] on page 44. The side glue roller on the near side is controlled
by the computer. The side glue roller on the far side must be set manually.
2 : Binding without cover sheets.

Select when binding without cover sheets.
When this button is selected, the side glue rollers should be moved out of their work-
ing positions. Refer to [3-6] on page 44. The side glue roller on the near side is con-
trolled by the computer. The side glue roller on the far side must be set manually.
Also, when this button is selected, the support plate should be installed. Refer to [3-3]
on page 36.
OK button. Each of the Setting Screens has an OK button. Press this button to input
3 the setting and go to the next screen.
10
2 - - Start Mode Screen
1 Return to the home position during every changeover. Normally, select .

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

2
: Normal Start mode. Binding operation starts with start buttons.
: Auto Start mode. Binding operation starts after the time set in 3 .
Start waiting time

3 Input the time after the book block is inserted into the carriage clamp till the bind-
ing operation starts in increments of 0.1. Input range is 0.0 to 9.9.
11
3 - Book Block Size Screen
1
2
1 Input the book block thickness. Measure the actual book block thickness using the
attached caliper and input the value. The input range is 0.3 to 50 mm (0.010” to
2.000”).
Input the book block length. Measure the actual book block length and input the
2 value. The input range is 135.0 to 320.0 mm (5.315” to 12.600”).
12
4 - - Cover Sheet Size Screen
3 1
2
1 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
2 edge, or the center of the spine). The input range is shown in illustration below.
or : Either edge of the spine Fixed Side Downstream Movable Side
Scoring Scoring
(Rear Side) (Front Side)
(5.32" to 12.60")
135 to 320
110 to 310 120 to 350

(4.33" to 12.20) (4.72" to 13.77")
230 to 660 (9.05" to 25.98")

mm(inch)
If the dimension is out of this range, the front

or rear guides may not reachthe cover sheet edge.
: Center of the spine.
Input the cover sheet width in increments of 0.1 mm (0.005”). The input range is
3 135.0 to 320.0 mm (5.315” to 12.600”).
When measuring the distance to the center of the spine, use the accessory
alignment plate.
4 5
2 3
1
8 9 20
6 7
4 5
2 3
1
8 9 10
6 7
4 5
thin
2 3 on.
1 tomati
0 think au
ka
uto
ma
tion
Alignment Plate
.
Center of the Spine
13
5 - - Function Screen
1 (ON): Use the double feed detecting function.

(OFF): Do not use the double feed detecting function.
If the machine produces false indications of double-feeding because of an

image on the cover sheet, turn this function OFF.
14
6 - Milling and Nipping Screen
2-1
Nipping with milling
1 2-2
Nipping without milling

2 2-1 2-2 2-3
2-3
Nipping without cover
1 Turn the milling operation ON or OFF.

: Milling ON : Milling OFF
- If the milling set lever is set incorrectly, an error message screen will
appear.
- When Milling OFF is selected, the “Insert Shim” message appears.
Insert the shims, referring to the message screen and [4-7] on page 59.
Select this when doing milling. The nipper raises, then closes.
2 : 2-1
Select this when nipping without milling. The nipper closes as it raises to pre-
2 : 2-2 vent the spine from swelling.
If this mode is selected when the milling operation is done, the spine
will become round.
Select this when binding without cover sheets. The nipper will not operate. The
2 : 2-3 machine will wait until the glue on the spine hardens, then the booklet will be
delivered.
15
7 - - P. 1 Gluing Screen Part 1
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.
2 : Side glue will be applied. If you select , set the glue amount using the
Gluing Screen Part 3.
: Side glue will not be applied.

(Available when selecting on Gluing Screen Part 1)
1
2
3
1 Adjust the spine glue thickness in increments of 0.1mm (0.005”). The adjustment
range is 0 to +4.0 mm (0.155”).
Adjust the starting point to apply the spine glue. The adjustment range is -20.0 mm to
2 +20.0 mm (-0.785” to +0.785”).
Adjust the end point for the spine glue. The adjustment range is -20.0 mm to +20.0
3 mm (-0.785” to +0.785”).
16
CAUTION
The side gluing roller distance should not
be used for adjustment of the side glue
amount. This adjust the side gluing roller to
1 correct position depending on the booklet
thickness.
1 Adjust the side gluing roller distance in increments of 0.1 mm (0.005”). The input
range is -1.0 mm to +5.0 mm (-0.040” to +0.195”).
1
2
1 Adjust the wiper opening of application drum 1.

Press once, and the opening increases by 0.1 mm (0.005”). The glue will pene-
trate farther into the spine. The adjustment range is +0.1 to +2.0 mm (+0.005” to
+0.080”).
Adjust the wiper opening of application drum 2.
2
Press once, and the opening increases by 0.1 mm (0.005”). More glue will be
applied to the spine. The adjustment range is +0.1 to +2.0 mm (+0.005” to +0.080”).
CAUTION
The wiper opening adjustment should not
be used to adjust the spine glue thickness.
But when the opening is set 0.5 mm (0.02”)
or less, glue may not be applied to the book
spine at all.
17
2-2 Bind the Books Using the Binding Screens
The Binding Screens can cover the following three functions:
Binding Screens
1 Main Binding Screen
2 Test Milling and Gluing Screen
3 Clamp and Milling Fine-Adjust Screen
P. 1 4 Glue Fine-Adjust Screen, Part 1
7 Nipping Fine-Adjust Screen
8 Scoring Fine-Adjust Screen
P. 1 9 Cover Sheet Fine-Adjust Screen, Part 1
Press the box and the Numeric Keypad

Screen appears. The value can be input
using the Numeric Keypad Screen.
18
2-2 Bind the Books Using the Binding Screens
1 - Main Binding Screen

The current job information and the production conditions are displayed here.
30
1
10
2
Binding Counter Pre-set Counter
3 00000 C 0000 0030

6
4
0
5 9 8 7
1 Binding Counter/Pre-set Counter. Press C to clear the counter. To change to the pre-set counter,
press the counter box and input the new pre-set number using the Numeric Keypad Screen. Press the
right part of the pre-set counter ( ) and input 0 to return to the binding counter. See figure above.
This adjusts the production speed (carriage clamp moving speed) in five steps.
2
: Slow down : Speed up
This indicates the book block thickness already entered on the Setting Screen.
3
This indicates the distance between the cover sheet edge and the spine already entered on the Setting
4 Screen.
When using a saved job, the job number appears here. When not using a saved job or the read memory
5 has been changed, 0 is indicated here.
This area displays the production conditions.

6
Press this button to lower the feed table.

7
Press this button to feed one cover sheet. The machine memorizes the cover sheet thickness in order to
8 detect the double feeding.
This button is used to stop the motor on each unit after the binding operation. (Before the motor drives,
9 start icon is indicated.) Press this button before switching the power off.
Status Monitor
10 : This symbol will appear when the cover sheet is fed to the nipping section, and the book block is
put in the carriage clamp.
:This symbol will appear if a cover sheet is not fed automatically to the nipping section. Feed a cover
sheet by pressing both start buttons.
Booklet is not delivered within 2 seconds after the carriage clamp has opened.
Double feeding Misfeeding In operation Delivery section full
No cover sheet on the feed table. Set the cover sheets. Insert Book Block
###
OK
Pre-set number of binding is finished.
Milling ON/OFF lever Error Press start button to drive the motor.
Remove cover sheet on nipper. Remove cover sheet at double feed detect sensor.
19
2-3 Test Milling and Gluing
2 - Test Milling and Gluing Screen

The test milling and test gluing operations can be performed using this screen.
2 2 3
5 6 7
1 Test Milling Button. Press this button, and only the milling operation is performed and
the booklet is delivered from the delivery section. Use this function to check milling
depth.
Test Gluing Button. Press this button to perform milling and gluing operation. The
2 booklet stops above the nipping section with no cover sheet and stays there until the
start button is pressed. Wait until the glue hardens, and check the applied glue
amount. Press start buttons to deliver the booklet. Use this function to check the glue
amount on the booklet.
Test Binding Button. Press this button to perform a single binding with a cover sheet.
3 The machine does not feed the next cover sheet.
4 Condition Monitor. When appears here, the test milling or the test gluing opera-
tions can be started.
This button is used to stop the motor on each unit after the binding operation. (Before
5 the motor drives, start icon is indicated.) Press this button before switching the power
off.
Press this button to feed one cover sheet. The machine memorizes the cover sheet
6 thickness in order to detect the double feeding.
Press this button to lower the feed table.
7
20
2-4 Fine Adjustment Clamp, Milling Width Adjustment
3 - - Clamp and Milling Fine-Adjustment Screen

You can use this screen to make fine adjustments to the carriage clamp width and the
milling guide width.
1 Adjust the carriage clamp opening amount so that the book block is inserted
smoothly. Unless you make this adjustment, the carriage clamp opens just the same
amount as the book block thickness. Increase the opening to match the type of the
book block. The input range is 0 to +15.0 mm (+0.590”).
: Makes the carriage clamp width wider. (Use this when using signatures.)
: Makes the carriage clamp width narrower. (Use this when using sheets which
crease or tear easily.)
Adjust the opening so that the book block can move into the carriage clamp easily
without being disturbed. After the adjustment, check that there is enough carriage
clamp pressure by pressing the Carriage Clamp Close button on the Single Operation
Screen.
Adjust the milling guide width. The input range is 0 to +10. 0 mm (+0.395”).
2 This adjustment may be necessary when using signatures. (Signatures can cause the
spine of the book block to swell and hit the milling guide.)
: Make the milling guide wider.
: Make the milling guide narrower.
When using signatures, make the milling guide wider to give the spine a good finish.
However, if the guide is set too wide, the spine will be allowed to expand too much.
21
2-4 Fine Adjustment Glue Amount Adjustment
4 - - - P. 1 Glue Fine-Adjust Screen Part 1

This screen allows for fine adjustment of the spine glue.
1
2
3
1 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. The adjustment range is -20.0 mm to
2 +20.0 mm (-0.785” to +0.785”).
This adjusts the end point for the spine glue. The adjustment range is -20.0 mm to
3 +20.0 mm (-0.785” to +0.785”).
1 This adjusts the side gluing roller distance in increments of 0.1 mm (0.005”). The
adjustment range is -1.0 mm to +5.0 mm (-0.040” to +0.195”).
CAUTION
The side gluing roller distance should not
be used for adjustment of the side glue
amount. This adjust the side gluing roller to
correct position depending on the booklet
thickness.
22
2-4 Fine Adjustment Glue Amount Adjustment
1
2
1 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”).
This adjusts the wiper opening for application drum 2.
2
Press once, and the opening increases by 0.1 mm (0.005”). More glue will be
applied. The adjustment range is +0.1 to +2.0 mm (+0.005” to +0.080”).
CAUTION
The wiper opening adjustment should not
be used to adjust the spine glue thickness.
But when the opening is set 0.5 mm (0.02”)
or less, glue may not be applied to the book
spine at all.
23
2-4 Fine Adjustment Nipping Operation Adjustment
7 - - Nipping Fine-Adjust Screen

This allows for adjustment of the nipping delay time, nipping time and nipper width.
1 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. If the glue squeezes out, set the nipping delay time longer
so that the glue will harden before the nipping operation. If the glue squeezes out even if the nip-
ping delay time is increased, decrease the spine glue thickness.
When binding with cover sheet

2 Nipping operating time.
When binding a thick book block, make this longer.
When binding without cover sheet

The carriage clamp is returned after waiting above the nipper during the nipping oper-
ating time.(The glue on the spine hardens well, and then the booklet will be deliv-
ered.)
The adjustment range is 0 to 30.0 sec. with either binding mode.
3 : Increase the nipper width

: Decrease the nipper width
Usually, the squareness of the spine depends on the nipper height. If the spine quality
is poor even if the nipper height has been adjusted, adjust the nipper width. If the
spine is too round, make the nipper width narrower. If the spine is too sharp, make it
wider. The adjustment range is -0.5 to +1.0 mm (-0.020” to +0.040”).
24
2-4 Fine Adjustment Scoring Operation Adjustment
8 - - Scoring Fine-Adjust Screen
1 : The fixed scoring rollers move to the rear (far side).
: The fixed scoring rollers move to the front (operator side).

The adjustment range is - 1.0 mm to +1.0 mm (-0.040” to +0.040”).
The fixed rollers actually do not move. If the fixed scoring roller position is
adjusted on the screen, the stack of cover sheets actually moves to com-
pensate.
2 : The adjustable scoring rollers move to the rear (far side).
: The adjustable scoring rollers move to the front (operator side).

The adjustment range is -10.0 mm to +10.0 mm (-0.395” to +0.395”).
Fixed Scoring Rollers

Adjustable Scoring Rollers
25
2-4 Fine Adjustment Cover Feed Position Adjustment
9 - - - P. 1 Cover Sheet Fine-Adjust Screen Part 1

This allows for fine adjustment of the nipper against the cover sheet.
Registration Position
Cover Sheet
3 Original Position
3mm (0.12")
4
Cover Sheet
1
3mm (0.12")
1 Press this button to move the nipper against the cover sheets.
Normally, step 2 through 4 cannot be performed because the jog guides are
not pressed against the cover sheet. Before doing the other adjustments
(step 2 through 4), press button 1 to bring the jog guides up against the
cover sheet. After the adjustments, press the button again to return the jog
guides to their original positions.
2 Press the button to move the stack of sheets position to the right (cover feeder
side) by 0.2 mm (0.008”). The input range is -3.0 mm to +3.0 mm (-0.110” to +0.110”).
This changes the jog guide spacing by 0.1 mm (0.005”). The input range is -10.0 mm
3 to + 10.0 mm (-0.395” to +0.395”).
4 Press the button to move the cover sheet position to the rear by 0.1 mm
(0.005”). The input range is -10.0 mm to +10.0 mm (-0.395” to +0.395”)
If you make this adjustment, make sure to adjust the position of the stack of
cover sheets by the same amount.
26
2-4 Fine Adjustment Cover Pile Position Adjustment

This allows for fine adjustment of the cover sheet stack position.
1 : This increases the positioning guide spacing on the feed table.

: This decreases the positioning guide spacing on the feed table.
These can be set by 0.1 mm (0.005”). The input range is -10.0 mm to +10.0 mm
(-0.395” to +0.395”).
Transport Belt
1 Registration Stopper
1 This sets the pressure produced by the transport belts. After the cover sheets are fed
by the feed rotor, the transport belts feed the covers back to the registration stopper.
The pressure of the transport belt is adjustable in five steps. Normally, use a loose
setting when using thin sheets and use a tight setting when using thick sheets. The
standard setting is .
This adjusts the vacuum to the feed rotor when feeding the stacked sheets. If double-
2 feeding occurs often, make the vacuum weaker. If mis-feeding occurs often, make the
vacuum stronger. The standard setting is .
27
2-4 Fine Adjustment Cover Feed Function Adjustment
1 This sets the light strength of the sensor using and .

Select for normal use. If using thick or dark cover sheet, or if fault detection of
double feeding occurs, select . Oppositely, if fault detection of mis-feeding occurs,
select .
2 This sets the sensitivity of the double feeding detect sensor using (high),
(middle), and (low).
- - - P. 5 Cover Sheet Fine-Adjust Screen Part 5
Cover Sheet
Sensor
Rear Registration
58mm
1
1 This sets the number of the window (hole) on the cover sheets.
The sensor which detects the window on the cover is located 58 mm rear side from
the rear registration position.
When not entering the number of the window, reposition the cover sheet and the book
block so that the window does not pass over the sensor.
Input range is 0 to 9.
28
2-5 Saving or Recalling Job Settings
The Memory Screen is used to save or recall job settings.
1 2
6 Milling Operation ON
Nipping with Milling
3 4 5
1 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.
2
White ( 1 ): empty Gray ( 5 ): saved job Black ( 10 ): now selected
This is the save button. Press this button to save the present settings to memory.
3 Select the job number, then press the save button. Press OK on the Write OK Screen,
and the present setting will be stored to the selected job number.
This is the read out or recall button. Press the job number you want to read out, the
4 press this button. Press OK on the Read Out OK Screen and go back to the Binding
Screen. Press OK on the Changeover OK Screen, and all parts of the machine will
move to the set (read out) positions.
This is the Delete button. Select the job number to delete and press this button. The
5 selected memory will be deleted.
This is the Current Settings button. Press this button to indicate the current settings.
6
29
2-6 Using the Single Operation Screens
These screens are used to maintain the machine and to check the function of each section.
The Single Operation Screen can cover the following four functions:
Single Operation Screens
P. 1 1 Single Operation Screen Part 1
4 Home Positioning Screen
5 Milling Brake Release Screen
1 - - P. 1 Single Operation Screen Part 1
1 2
3 4 5 6
7
8
1 Press to rotate the glue application drums.
2 This is the Application Drum button. Press to lower the right side of the melt tank
when draining the glue. The tank returns to the original position when changeover is
performed.
Jammed Booklet Delivery Button. Press this button to open the clamp to release the
3 jammed booklet.
Carriage Clamp Close
4
Carriage Clamp Open
5
This triggers the booklet delivering motion: the level plate moves back and the car-
6 riage clamp opens.
This is the Carriage Clamp Move button. Press this button and then press the Start
7 buttons. The carriage clamp rail rises and the carriage clamp moves above the nip-
per. This button is used when setting the milling depth, or when replacing the carriage
clamp support plate.
8 Instruction for the next step to move the carriage clamp. is shown while the car-
riage clamp is moving.
30
1 2
CAUTION
3 4 The upper adjustable scoring roller will not
move if it presses too tightly against the
lower adjustable scoring roller.
5
1 : The nipper moves up.

: The nipper moves down.
The nipper moves down and opens completely. This button is used when cleaning the
2 nipping section.
The lower adjustable scoring roller moves next to the fixed scoring rollers.
3 This button is used to bring the upper and lower adjustable scoring rollers together.
This moves the lower adjustable scoring roller to the set position.
4
5 : Opens the milling guide to the limit.

: Moves the milling guide to the set position.
1 : Press this button once, and the carriage clamp opens by 10 mm (0.395”).
Use this button when the book block is caught on the carriage clamp.
2 :Press this button to reposition the delivery section after cleaning.

:The delivery section moves back. This button is used when cleaning the
delivery section.
31
4 - Home Positioning Screen
1 1
1 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.)
5 - Milling Brake Release Screen
1 This is the brake release button for the milling motor. The milling motor can not be
released by pressing the brake release button on the machine until this button is
pressed. Use this button when replacing the milling cutter or the roughening cutter.
32
2-7 Information Screen
These screens are used to set some machine operating functions. And also you can access
the Information Screen which shows the ROM version and the total binding number from this
screen. When you call your local dealer to service the machine, our operator may ask the
ROM version or total binding number. In that case, refer to the Information Screen.
4 7
The control ROM version is indicated here.

1
The panel ROM version is indicated here.

2
The total binding number is indicated here.
3
4 : The feed table is lowered when double feeding is detected.

: The feed table is not lowered when double feeding is detected.
5 : When changing the binding mode, the milling operation is set automatically
depending on the selected binding mode.
: When changing the binding mode, the milling operation is set manually
by operator.
The full detection function is use/ is not use at delivery section.
6
7 : The jog guides are opened when the cover sheet is moved back to the registration stopper.
: The jog guides are closed when the cover sheet is moved back to the registration stopper.
33
2-8 Error Screen
1
3
4 5
1 The cover is open. Close the cover.
The emergency stop button is pressed. Turn the emergency stop button clockwise.
2
Light between area sensors is blocked. Remove the hand or object between sensors.
3
An error code may appear here. See Section 6 [Troubleshooting] on page 90.
4
This is the OK button. Use this to recover from an error condition. Press this button to
5 go back to the Binding Screen.
2-9 Numeric Keypad Screen
This screen is used to enter or input values. Input the value, then press ent (“enter”).
If you enter an improper value, the value will not be accepted, and an “E” will appear
on the screen.
Press to return to the previous screen without entering a new value.
34
3. Starting the Binding Operation
3-1 Turn On the Power Switch

Turn on the power switch.
WARNING
Do not touch the melt tank after the power is The glue inside the tank melts 40 to 50 minutes
turned on. The melt tank is heated to 200 after the power is turned on. Press while
degrees Celsius (400 Fahrenheit), and may
cause severe skin burns. Warm-Up Screen is indicated. The Warm-Up
Also be careful of the melt tank cover. Screen disappears after the glue is melted com-
pletely, then the Changeover Confirmation
Screen appears.
Turn on the power switch.
PERFECT BINDER
B
Warm-Up Screen
Power Switch CAUTION

When the warm up has completed, the glue tem-
- Turn the power switch to the right. perature does not necessarily rise to the set
- After the Initial Screen appears, the Warm-Up temperature, therefore it can be warm enough
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:
Emergency Left Safety Cover
- Emergency stop button Stop Button Right Safety Cover
- Right safety cover

- Left safety cover
- Lower nipper door
All of these must work properly. Operate the cover, or
press the button, and check the error icons on the Error
Screen. If the Error Screen appears, the safety function
is working properly. If the Error Screen does not
appear, there is a problem with the safety circuit. Stop
Lower Nipper Door
using the machine and call your local dealer.
35
3-3 Enter the Job Information Using the Setting Screens
This section explains the steps necessary to input the
job information.
Decide whether the machine
should home all parts on every
Select the binding type. changeover, and the starting mode.
- Select the binding type on the Binding Mode
Screen.
: Binding with cover sheets
: Binding without cover sheets
- Turn the home positioning feature ON or OFF

on the Start Mode Screen.
: Reset the guides to the home

position on every changeover.
: Reset the guides to the home

position on the first changeover.
The guide moves directly to the set
- If you select binding without cover sheets, the position from the second changeover.
side glue rollers should be moved out of the
working positions. Refer to page 44. The side - Select the operation starting mode on the
glue roller on the operator side is controlled by Start Mode Screen.
the computer. The side glue roller on the far : Binding operation starts with start
side must be set manually. buttons.
- If you select binding without cover sheets, the : Binding operation starts when the
support plate and the shims (1 mm) should be time which has been set on the box
installed. (Refer to page 59 to install the shim.) passes after the book block is
If the support plate is not installed, the bound inserted into the carriage clamp.
book will fall on the stacker and separate. When selecting, input the start
waiting time.
Input the book block size.

- Input the book block size using the Book
Block Size Screen. Refer to page 12.
36
3-3 Enter the Job Information Using the Setting Screen
Select the spine gluing and side 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. Refer to page 16. the Milling, Nipping Screen. Refer to page 15.
- If you are using spine glue or the side glue,
adjust the glue amount using Part 2, 3 and 4
of the Gluing Screen. Refer to pages 16 and
17. (The glue amounts can also be adjusted
using the Fine-adjust Screens.)
- To select milling OFF, select . Also

check that the milling ON/OFF lever is set to
Input the cover sheet size. the left (OFF).
- Input the cover sheet length and width, and - To select milling OFF, select . Also
the distance between the cover edge and the check that the milling ON/OFF lever is set to
spine. Refer to page 13. the right (ON).
- When using saved job information, go to

page 49.
PERFECT
Milling Select Lever
Turn the double feeding detect

function ON or OFF.
- Turn the double feeding detect function ON or
OFF using the Function Screen. Refer to page Without Milling With Milling
14.
37
Select the Binding Screen. Message Screens shown while changeover

- Changeover OK Screen appears.
This screen appears when there is a cover sheet

left on the nipper while changeover. Remove the
Press OK to start the changeover. cover sheet and press OK. If is pressed, the
changeover is canceled and the previous screen
- Press , and the changeover is canceled appears.
and the previous screen appears.
- While the changeover, Changeover Screen
appears.
This screen appears when there is a book block left

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

changeover is canceled and the previous screen
appears.
This screen appears when there is a cover sheet

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

the changeover is canceled and the previous
screen appears.
38
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. Remove the cover sheet and press press OK. If the level plate height is not set cor-
OK. If is pressed, the changeover is can- rectly, press to move the clamp and set the
celed and the previous screen appears. level plate height correctly referring to page 59, then
press OK. If is pressed, the changeover is

canceled and the previous screen appears.
These screens appear when the binding mode

which is set on the screen and the milling lever set-
ting does not match. Refer to page 37 to set the
milling lever correctly and press OK. If is

pressed, the changeover is canceled and the previ-
ous screen appears.
39
3-4 Setting the Main Binding Screen
This section explains the steps necessary to set the
production speed and the counter function.
When using the cover sheet with
window or hole, enter the number
of the window (hole) using Cover
Go to the Main Binding Screen. Sheet Fine-adjust Screen Part5.
Binding counter
This area can display both the
binding counter and the pre-set counter.
- There is a sensor which detects the window

When using the pre-set counter, (hole) at 58 mm rear side from the rear regis-
trating position.
press .
- Enter the number of the window (hole) or
- The Numeric Keypad Screen appears. Input reposition covers and book block so that the
the pre-set number and press ent. window (hole) on the cover does not pass
over the sensor.
- Press the right part of to change
the pre-set number using the Numeric Keypad sensor
Screen.
Window
When the machine reaches the pre-set
number of bindings, it will stop feeding 58mm
the next cover sheets. This prevents the
machine from scoring additional cover
sheets once it reaches the pre-set num- Cover Sheet
ber.
The settings on this screen are now complete.
Go to the [Scoring Roller Setting] on next page.
Select the production speed.
- The production speed can be selected from
five steps.
- When binding thick book blocks, use a slower
setting.
If you are binding a thick book block

and the production speed is set too
fast, the milling can not be completed
properly. On the other hand, if the pro-
duction speed is set too slow, the side
glue will dry and the binding quality will
deteriorate.
40
3-5 Setting the Scoring Rollers
Adjust the gap between the upper and lower scoring
rollers by turning the scoring roller pressure knob.
Binding without Scoring Binding with Scoring
Open the left safety cover. Press the (standard) button

for the scoring roller on the Single
Operation Screen Part 2.
- The lower adjustable scoring roller moves
next to the fixed scoring rollers.
Loosen the scoring roller pressure
knob.
- Turn the knob counterclockwise until the

upper adjustable scoring roller is free.
CAUTION
Adjustable Scoring If the safety cover is opened while the scor-
Roller ing roller is moving, the scoring roller will
stop at the wrong position. Check that the
scoring roller has finished moving before
opening the cover.
Scoring Roller
Pressure Knob
Upper Adjustable
Open the right safety cover.
Scoring Roller
Fixed
Roller
Move the upper adjustable scoring
roller by hand until it touches the
Lower Adjustable
Scoring Roller fixed scoring roller.
- The upper scoring roller should be set above
the lower scoring roller.
41
3-5 Setting the Scoring Rollers
Lower the upper scoring roller. Press the (Setting Position)

- Turn the knob clockwise to lower the upper button on the Single Operation
scoring roller. Screen.
- To reach the standard setting, turn the knob - The adjustable scoring rollers move to the set-
one rotation counterclockwise from the stop. ting positions.
Adjust so that there is a small gap

between the upper and lower adjustable
scoring rollers. You should be able to
move the upper adjustable roller a bit
with your finger.
Upper Adjustable Scoring Roller
Standard Gap
Lower Adjustable Scoring Roller
CAUTION
If the scoring pressure is so strong so
that the scoring roller does not rotate,
the machine may be damaged when
performing a changeover. Before each
changeover, check with your finger to
ensure that the scoring rollers rotate
smoothly.
Close the right safety cover.
42
3-6 Setting the Scraper (For Padding Only)
Set the scraper manually if you select padding. The
scraper levels the glue even. [How to adjust]
- Loosen the lock screw using the wrench, and
CAUTION move the scraper holding the lever.
- First begin at the lower position. Raise it grad-
- The set position differs depending on
ually.
the spine glue thickness set on the
- Tighten the lock screw after adjustment.
screen. Select (Manual) on the
Gluing Screen Part 1, and raise the
scraper gradually checking the glue If the spine glue thickness is set to
scraping condition. Do not raise the 1.2mm, and when the scraper hits the
scraper too much, otherwise the stopper, glue will be actually left a little
scraper hits the booklet and be dam- on the spine after scraping. (It differs
aged. depending on each machine or other
- Scraper is very hot. Wear thick gloves settings.)
when setting the scraper.
Set the desired glue thickness on
the Gluing Screen Part 2.
Gluing Screen Part 2
Press on the Gluing Screen
Part 2 and set the glue thickness to
1.0 mm.
Open the safety cover (right).
Find the lowest position where the

scraper can level the glue even by Perform the binding operation.
repeating the test padding.
CAUTION
- When performing the binding with
Scraper cover sheets, make sure to reposition
the scraper at lowest position. Other-
Lever wise, the scraper hits the booklet and
be damaged.
Lock Screw
- If the glue is burned, the scraper can
not be smoothly adjusted. Make sure to
wipe off the extra glue on the scraper
after the operation, so that it can be
Stopper
adjusted in anytime.
43
3-7 Setting the Side Glue Rollers
When you change the binding type, (binding with covers or When binding without covers
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.
the side glue rollers will appear. Set or dislocate the side
guide rollers according to the binding type.
When binding with covers

The screen will tell you to set the side glue roller on the
far side.
Before dislocating the roller, make sure to

memorize the original setting position.
Turn off the power switch and open

the left safety cover.
the left safety cover.
CAUTION
CAUTION Wear thick gloves during this opera-
tion. The melt tank may be heated to
Wear thick gloves during this opera-
200 degrees Celsius (400 Fahrenheit)
tion. The melt tank may be heated to
and may cause severe skin burns.
200 degrees Celsius (400 Fahrenheit)
and may cause severe skin burns.
To adjust the side gluing roller on

To adjust the side gluing roller on the far side, loosen the locking
the far side, loosen the locking screw on the positioning plate and
screw on the positioning plate and
turn the plate counterclockwise to turn the plate clockwise to the stop.
the memorized position. Side Gluing Roller (far side)
Side Gluing Roller (far side)
Allen Wrench
Allen Wrench
0
0
Locking Screw
Locking Screw Positioning Plate
Positioning Plate
Tighten the locking screw.

Tighten the locking screw.
- The pre-sets for the binding operation are
complete. Start the binding operation, refer-
ring to [Start Binding] on next page.
44
3-8 Start Binding
When 10 minutes has passed after the drum is
stopped, message to rotate the drum appears. Press
Press both start buttons to rotate
the 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.
ature and melted completely.
WARNING
- Do not put your hand inside the machine
when the carriage clamp is operating. This
part can cause severe personal injury. Insert a book block in the carriage
- When feeding a book block, remove your clamp and push it to the right.
hand from the carriage clamp before it
moves. This part can cause severe per-
sonal injury.
Binding Operation Flow

Start the binding operation.
Insert book block - Press both Start buttons.
inside the carriage clamp.
If the milling operation

is turned ON, the book
spine is milled here.
Glue is applied to the

book block by the melt
tank.
The nipping section presses

the book spine and the
cover sheet.
After the carriage clamp

comes back above the
level plate, the booklet is
delivered to the delivery
section and stacked.
45
3-8 Start Binding
Stop Binding
Press the (Stop) button on

the Binding Screen.
- The machine stops.
- If a cover sheet has been fed, open the right
safety cover and remove the cover, and clear
the error. Prepare for the next job.
46
3-9 Adding More Cover Sheets
As the stack of cover sheets is reduced during the job,
add more cover sheets.
Move the end guide against the
right edge of the stack.
Press the Stop button on the Bind-

ing Screen.
- The machine stops and the feed table lowers. Press both Start buttons.
- The milling cutter rotates, and the feed table
rises.
Restart the binding operation.
Move the end guide to the right.
End Guide
Feed Table
Stack more cover sheets on the

feed table.
- Separate the cover sheets well before stack-
ing. If the cover sheets are not separated, this
can cause double feeding, or the cover sheets
may be partially fed.
- If it is difficult to stack the cover sheets,
remove the end guide on the right.
- Place the sheets in the correct orientation.
47
3-10 Removing the Bound Booklets
Remove the booklet before the stacker is full.
WARNING •How to use the delivery chute

Press the Emergency Stop button before
removing the booklets. If you do not do -Use the chute when the book spine is
this, the machine may start suddenly and scratched or bound book size is very large
cause severe personal injury. or small.
-Hook the chute on the delivery section.
-Place a suitable box at the exit to receive
Pull the stopper to the front. the delivered book without scratch or stain.
•How to install the delivery chute
1.Move the stopper back.

Remove the stacked booklets.
Stopper
Stopper
2.Hook the chute.
Push the stopper to the rear. -Hook the chute on the three square holes of
the delivery guide.
Delivery Guide
Delivery Chute
48
3-11 Saving, Recalling, Deleting the Job Information
The BQ-270 has a memory function which can save
and recall the job information. This section explains the
procedures necessary to write and read out the job
information using the Memory Screen.
Saving the Job Information
Select the Memory Screen. Press the button.

- The selected job number turns black and the
Write OK Screen appears.
Select the job number on which you

want to write the job information.
- When selecting the memory with saved job
- White ( 1 ): Empty (Gray), Replace OK Screen appears.
- Gray ( 5 ): Saved job
- Black ( 10 ): Now selected
Press OK
.
- The present settings are saved in the selected
job number.
49
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. Refer to page - The Memory Screen appears.
29.
- Each job number which is gray already has
saved information.
- Press the job number, and the saved job infor-
mation will be shown in the left part of the
screen.
Select the Binding Screen if you

want the machine to start the
changeover right now.
- The Changeover OK Screen appears.
- Press OK, and the machine performs the

changeover and the Binding Screen appears.
The recall of the job information is now complete.
50
Deleting the Job Information
Select the Memory Screen.
Press the button for the job number

you want to delete.
- Number with gray scale has saved job.
Press (delete).
- Selected memory number turns black and the
Delete OK Screen appears.
Press OK.
- Selected memory will be deleted.
51
3-12 Adding More Glue
This section explains how to refill the glue in the melt
tank.
The lower limit of the glue level is 8 mm (0.31”) lower

position below the upper limit line.
Do not run the machine in the condition that the glue
level is under the lower limit line.
.
WARNING
Do not touch the melt tank after the power
CAUTION
is turned on. The melt tank is heated to 200 The glue level lowers while the application
degrees Celsius (400 Fahrenheit) and may roller is rotating. Check the glue amount
cause severe skin burn. when the application roller stops.
Open the left safety cover.

Close the left safety cover.
Add glue into the melt tank.

- Add glue when the glue level come to the
lower edge of the glue level plate. If the glue
level comes lower than the plate, it may dam-
age the gluing mechanism.
- Be careful that the glue level will not go over
the upper limit line when the glue is melted.
This will cause the glue to overflow.
Glue Level Upper Limit
Glue Feed Section
Use type HM220 glue, made by Horizon.
52
3-13 Finishing the Binding Operation
Turn off the power switch
Press the (Stop) button on

the Binding Screen.
Turn off the power switch.

- Turn the switch to left to turn off the power.
PERFECT BINDER
B
Power Switch
When the power is turned on the next time, the

machine will recall the information from the pre-
vious job.
-If the starting time for the melt tank

heating is set beforehand using the
weekly timer (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.
53
54
4. Adjustments
4-1 Changing the Spine Glue Amount and Position

If too much or too little spine glue is applied, you can
adjust the amount of spine glue and the starting and
ending position.
Adjust the spine glue amount and

the starting/ending positions using
the Gluing Screen Part 1 and Glu-
ing Screen Part 3. Refer to pages
22 and 23.
4-2 Adjusting the Side Glue Amount

If too much or too little side glue is applied, adjust the
distance between the side glue rollers to adjust the side
glue amount.
Adjust the distance between the
side glue rollers using the Gluing
Screen Part 2. Refer to page 22.
CAUTION
In case the nipper position is too
high for the spine glue amount, the
spine glue may comes aside and Gluing Screen Part 2
increase the side glue amount.
55
4-3 Changing the Nipping Setting
If the spine quality is poor, adjust the nipping delay
time, nipping time and the nipper width.
Adjust the nipping delay time, nip-

ping time and the nipper width
using the Nipping Screen. Refer to
page 24.
Nipping Delay Time
Nipper Width Nipping Time
- If the spine sharpness does not improve, refer

to [Nipper Height Adjustment] on page 64.
56
4-4 Changing the Cover Feeding Settings
If the cover sheet is out of position on the book block or
is not fed correctly, change the cover feeding settings.
Transport Belts
Adjust the cover registration posi-
tions (left/right, and front/rear) and
the side guide width using the Cover
Sheet Screen Part 1. Refer to page
26.
Cover Sheet
Registration Button
Adjust the cover sheet stack posi-

tion to match the settings made in
step 1. Feed Rotor
- Increase or decrease the values to match the
settings made in step 1.
- Adjust the cover sheet stack position and the
positioning guide width using the Cover Sheet Vacuum
Screen Part 2. Refer to page 27. Cover Sheet
When mis-detecting the double

feeding or mis-feeding, adjust the
light strength or the detecting sensi-
tivity.
Guide Width - Adjust the light project amount and the
detecting sensitivity using the Cover Sheet
If any of the problems listed below Screen Part 4. Refer to page 28.
occurs, adjust the vacuum to the
feed rotor and the pressure of the
transport belts.
- After feeding, the cover sheets are wrinkled.
- The cover sheets double-feed or misfeed. 1
- The feeding actiton is not stable.
2
- Adjust the vacuum to the feed rotor and the
pressure of the transport rollers using the
Cover Sheet Screen Part 3. Refer to page 27.
57
4-5 Changing the Scoring Position
If the scoring line is out of position, adjust the scoring
position.
Adjust the position of the fixed and

adjustable scoring rollers using the
Scoring Screen. Refer to page 25.
Fixed Scoring Rollers
- A cover sheet which has already been fed can
Adjustable Scoring Rollers
not be used. Remove the cover sheet and
feed a new one.
Fixed Side
Adjustable Side
4-6 Changing the Carriage Clamp Opening and Milling Guide Width
If the book block escapes when the machine is per-

forming a milling or nipping operation, decrease the
opening of the carriage clamp.
If the book block moves when it hits the milling guide,
increase the milling guide width.
Adjust the opening of the carriage

clamp or the milling guide width
using the Carriage Clamp/Milling
Fine-Adjustment Screen. Refer to
page 21.
- When using sheets which can bent easily, do
not open the carriage clamp too far.
58
4-7 Milling Depth Adjustment
The milling depth changes depending on the shims
under the level plate.
The milling depth is set to 2 mm when the machine is
shipped. When binding a thick book block, or if the mill-
ing is overloaded, adjust the milling depth to 1.5mm
(0.06”) or 1mm (0.04”).
Press the Carriage Clamp Move

button on the Single Operation
Screen.
Press the Start buttons twice with

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

- The touch screen presents the Error Screen.
59
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. Othewise the
height.
level plate height becomes too high and
- The level plate can be pushed up by pushing the booklet detect sensor can not detect
the pin on the bottom.
the booklet correctly.
Shim
- Insert each shim completely.
Level Plate 3
Shim
The level plate and book block are raised

by the increased shim thickness, and the
1 milling depth decreases by the same
3 amount. The less the milling depth, the less
the load on the milling mechanism.
Turn the Emergency Stop button

2
clockwise to release.
- The Single Operation Screen appears.
Press the Carriage Clamp Move

button on the Single Operation
Screen.
- There are three thicknesses of shims: 1, 1.5

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

Thickness (mm)
0 3 mm (0.12”) Press the Start buttons twice.

1 2 mm (0.08”) - Press the start button once and the carriage
clamp returns to the left side. Press it again
1.5 1.5 mm (0.06”) and the clamp rail lower and the carriage
clamp opens.
2 1 mm (0.04”)
1 and 1.5 0.5 mm (0.02”)
1 and 2 0
60
4-8 Glue Temperature Adjustment
The glue will perform best if is heated to the correct
temperature. Adjust the glue temperature according to
the type of glue which is being used.
Adjust the glue temperature using

the glue temperature adjusting
knob.
Thermometer
The best temperature for HM-220 Hot
Application Drums
Melt glue made by Horizon is 170
degrees Celsius (350 Fahrenheit).
CAUTION Measure the glue temperature when the

application drum are rotating.
Adjust the glue temperature under
If there are not enough glue, the measured
180 degrees Celsius. Otherwise the
temperature tends to become low. Fill the
glue alteration accelerates, and the
glue so that the thermometer soaks into
glue does not apply on the applica-
the glue by 40 mm (1.57”).
tion drums.
PERFECT BINDER
BQ-270
120 140 C
160
180
- Use the temperature scale shown

above just for reference. The glue tem-
perature changes depending on the
room temperature.
- Use a thermometer in the melt tank to
make an accurate check of the glue
temperature.
61
4-9 Side Glue Amount Adjustment (Far Side)
If the side glue is not applied on the far side even there
is glue on the side gluing roller, you should adjust the
position of the side gluing roller on the far side.
CAUTION
Wear thick gloves during this operation.
The melt tank may be heated to 200
degrees Celsius (400 Fahrenheit) and may
cause severe skin burns.
Turn off the power and open the left

safety cover.
Loosen the locking screw of the

positioning plate and turn the plate
counterclockwise.
- Insert an Allen wrench into the hole on the
plate and rotate the plate.
- The side gluing roller on the far side will move
out.
Side Gluing Roller (far side)
Allen Wrench
Locking Screw
Positioning Plate
- After adjustment, tighten the locking screw.

If there is still not enough glue on the side gluing roller,
adjust the glue amount on the side gluing roller. See
the instructions which follow.
62
4-9 Side Glue Amount Adjustment (Far Side)
WARNING Lock the mounting screws on the

glue amount adjusting plate and
Wear thick gloves during this operation.
The glue amount adjusting plate is very
close the left safety cover.
hot, and may cause severe skin burns.
Loosen the two mounting screws

on the glue amount adjusting plate.
- The illustration below shows the glue amount
adjust plate on the far side.
Mounting Screws
Glue Amount Adjusting Plate
Adjust the position of the glue

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

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

amount of glue applied.
63
4-10 Nipper Height Adjustment
If the booklet spine is too sharp, or too round, or some
bubbles are caught in the spine glue, adjust the nipper
height.
- If the spine is round, turn the ring coun-
terclockwise. If the spine is too sharp, turn
the ring clockwise.
Turn off the power switch and open - Usually the ring is set between 3 and 6.
the lower nipper door. - The ring is set to 4.5 at the factory.
Adjust the nipper height.

- Insert the adjusting pin into the nipper height
adjusting ring so you can turn the ring.
The nipper is too low-
The nipper is too high-
- Turn the ring counterclockwise (decrease the turn the ring to the right.
turn the ring to the left.
number) to raise the nipper, or turn it clock-
wise (increase the number) to lower the nip- -If there are bubbles on the spine, raise the
per. nipper height, or increase the spine glue
- The height changes by 0.2 mm (0.01”) for amount.
each step on the scale.
Nipper Height Adjusting Ring
2 6 Higher (Spine
3 4 5
becomes
sharp)
(Spine
becomes
round) Lower
Adjusting Pin
64
4-11 Nipper Angle Adjustment
If the sharpness of the spine is incorrect (too sharp, or
too round) on either side of the spine, adjust the nipper
Lock the adjusting block and close
angle on both sides.
the lower nipper door.

the lower nipper door. Test the binding.
- Check that the spine sharpness is the same
on both sides of the spine.
- When using signatures, the corners may
become sharper.
Loosen the locking screw on the
nipper angle adjusting block.
- Refer to the illustration below.
Nipper Angle Adjusting Block
Nipper
Locking Screw
Rotate the nipper angle adjusting

block left or right to adjust the nip-
per angle.
- When you turn the nipper angle adjust block
to the right, the left side (melt tank side) of the
nipper lowers and the left (melt tank side) side
of the spine becomes more round.
65
4-12 Cover Sheet Angle Adjustment
When the cover sheet is out of position, adjust the
angle of the registration stopper.
Check that the cover sheets are cut correctly before Adjust the angle of the cover sheet.
doing this adjustment. If the cover sheets for the current
job are not square, make a temporary adjustment to fin- - Turn the adjust knob clockwise, and the cover
ish the job. Remember to reset the angle adjustment sheet will rotate to the left.
when the job is finished. - To move the lever to the left, push the lever to
the adjust knob and turn the adjust knob
counterclockwise.
Open the lower nipper door.
Loosen the locking nut on the angle

adjusting lever.
Loosen the locking knob.

- Loosen the locking knob on the registration
stopper angle adjusting lever. Adjust Knob
Registration
Stopper Angle
Adjusting Lever
Cover
Tighten the locking knob and the

locking nut, then close the lower
nipper door.
Locking Nut Locking Knob
Angle Adjusting Lever
66
4-13 Blower Air Adjustment
The blower air is used to separate the cover sheets
when they are fed. When the blower air is too weak or
too strong, double feeding or mis-feeding can occur. If
necessary, adjust the amount of blower air.
Blower Air Adjusting Lever
Adjust the air pressure.

- Pull out on the blower air adjusting lever to
reduce the blower air. Press the lever in to
increase the blower air. Strong
- If the blower air flow is too weak, the cover

sheets will not be separated. If the blower air
Weak
is too strong, the cover sheets will flap.
4-14 Double Feed Stop Pad Height Adjustment

If there is frequent double feeding or mis-feeding
although the blower air is set properly, adjust the height
Feed a cover sheet by pressing the
of the double feed stop pad.
Start buttons. Check that there is
no double feeding.
Adjust the pad height. If double feeding still occurs:
- Lower the pad height adjusting lever to raise - Check that the cover sheets are not stuck to
the pad. As the pad is raised, the gap each other.
between the feed rotor and the pad is reduced - “Fan” or separate the cover sheets before
to help prevent double feeding. loading them.
- Raise the pad a little more.
- Lower the feed table height. Refer to [Feed
Table Height Adjustment] on page 68.
Pad Height
Adjusting Lever
- If the pad is raised too high, the
machine will not feed at all.
- If there are frequent mis-feeds, reduce
the blower air.
Double Feed Stop Pad
67
4-15 Feed Table Height Adjustment
When using thin sheets, set the table height a little
lower. When using thick sheets, set it a little higher than
the center position. Aiso adjust the table height if there
is frequent double-feeding or mis-feeding. Adjust the height as you check the
scale.
Loosen the feed table height lock- - Read the scale at the center of the screw.
ing knob. - After the adjustment, lock the screw.
Feed Table Height - When using thin sheets, set the table
Locking Knob height just above the point where the
table will not feed at all.
- If there is frequent double feeding, the
vacuum may be too strong. In this case,
reduce the vacuum or lower the feed
table. If there are frequent mis-feeds,
raise the feed table.
Feed Table Height

Locking Knob
Feed Table
4-16 Scoring Roller Pressure Adjustment

If a cover sheet is cut by the scoring roller, or no scor-
ing line is produced, adjust the scoring roller pressure.
Scoring Roller
Pressure Knob
Open the right safety cover.
Adjust the scoring roller pressure.

Adjustable Scoring Roller
- Turn the scoring roller pressure knob counter-
clockwise to make the scoring line more shal-
low. Turn it clockwise to make the scoring line
deeper.
- To get the standard settings, turn the knob
one rotation counterclockwise from the stop. CAUTION
If the scoring pressure is so strong that the
scoring rollers do not turn, the machine
may be damaged during the changeover.
Before each changeover, check that the
scoring rollers rotate smoothly by turning
them by hand.
68
5. Maintenance
5-1 Cleaning the Book Block Path
WARNING Press the button (Carriage

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-
heit), and may cause severe skin burns. - Press both Start buttons twice. The carriage
clamp closes by first press and clamp rail
Do not touch the milling and the roughen-
raises. Then the carriage clamp will move to
ing cutters. These can cause severe per- the right and stop by second press.
sonal injury.
Open the left safety cover.
Clean the milling section.

- If there are paper chips, remove them using a Press the Emergency Stop button
vacuum cleaner. and clean the level plate mecha-
- If the cutter cover does not return quickly to nism.
the original position when sliding it to the right - If there are paper chip, remove them using a
and releasing, there are paper chips under the vacuum cleaner.
cover links. Remove the paper chips. If the
cutter cover does not move smoothly, paper
chips may be scattered heavily.
Vacuum Cleaner
Press the button (Carriage

Clamp Move) on the Single Opera-
tion Screen Part 1.
- Press both Start buttons twice. The carriage
clamp will move back to the left side by first
press. Then the clamp rail lowers by second
Cover Links press and carriage clamp opens.
Cutter Cover
Close the left safety cover.
69
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. The machine may start suddenly,
causing severe personal injury.
Open the safety cover and Clean

the nipper.
- Remove any glue. Stopper
- Apply a little silicon spray to the nipper, so that
the glue will not stick to the nipper.
Wipe away any glue or dust on the
Press the button (Nipper delivery section.
Cleaning) again.
- The nipper will return the previous position.
70
5-2 Cleaning the Sensors
Cleaning Tool Symbol Frequency Symbol

The number in front of
= Cotton Swab the letter indicates the
Choose the tool

1d = Every Day multiple number.
= Brush according to where 1w = Once every week Example:

2w = Once every 2 weeks
you are cleaning 1m = Once every month
= Air 6m = Once every 6 months
(Horizon Air Duster)
1y = Once every year
(One day = 4 hours use)
There are four kinds of sensors which need cleaning.

1m 1m Cover Sheet 1m
Detect Sensor
on Feed Table
Compressed
Air
Cover Sheet Detect

Book Block Detect Sensors Sensor on Nipper
1m
Double Feed
Detect Sensor
PERFECT BINDER
BQ-270
If the carriage clamp is in the way,

press or on the Single Operation Screen.
71
5-3 Lubrication
Lubrication Symbols Frequency Symbol

The number in front of
the letter indicates the
= Lubricate using a lubrication brush 1d = Every Day multiple number.
= Lubricate using an oil applicator 1w = Once every week Example:

2w = Once every 2 weeks
1m = Once every month
= Lubricate using a grease gun 6m = Once every 6 months
1y = Once every year
(One day = 4 hours use)
There are four mechanisms which need to be lubricated.

3m 1m 20 drops
Grease Nipples
3m
1m
CAUTION
After applying grease, run the
application drums for at least 10
minutes before binding.
PERFECT BINDER
BQ-270
Level Plate
1m
The carriage clamp is in the way,

press or on the Single Operation Screen
to remove or return the clamp.
CAUTION
Use the lubrication grease recommended by Horizon. If the
ingredient of the grease changes, the life of the machine
may be shortened or the machine may be damaged.
72
5-4 Book Support Plate Replacement
If the book support plate hits the machine and is bent, it
must be replaced. Replace the book support plate by
Remove the side cover.
following the procedure listed below.
- Remove the two monting screws shown in the
illustration below.
Enter a block thickness of 50 mm

(2”) on the Book Block Size Screen. Side Cover
Carriage Clamp
Remove the book support plate.

- Insert your hand between the carriage clamp
and the frame and remove the four mounting
Check that the other items for the screws shown in the illustration below. Use
job have been entered. the supplied screwdriver.
Open the carriage clamp as far as

possible.
- Select the Binding Screen to do the
changeover.
Carriage Clamp
Book Support Plate
The book support plate is an option.

Press the Emergency Stop button.
Please purchase and replace.
73
5-4 Book Support Plate Replacement
Attach the new book support plate.
Attach the side cover.

74
5-5 Milling Cutter Replacement
If the milling cutter does not cut the spine properly, the
glue will not be evenly applied to the book spine and
Enter a book block thickness of 20
the spine quality will suffer. The milling cutter may be
worn, and may need to be replaced. mm (0.8”) on the Book Block Size
Screen and perform the
CAUTION changeover.
- When loosening the mounting screws of the
milling cutter, turn off the power switch. Oth-
erwise, the machine may start suddenly and The mounting screws on the milling
cause severe personal injury. guide will be removed in a later step.
- Wear thick gloves during this operation, and
do not touch the edges of the milling or
roughening cutters. Otherwise, the sharp cut-
ters can cause severe personal injury.
- The melt tank is very hot for a while after the
power is turned off. Do not touch the tank.
Turn off the power switch and

remove the milling section front
cover.
- Remove the four mounting screws shown in Press the button (Brake
the illustration below.
Release) on the Milling Brake
Release Screen.
Milling Section Front Cover
Remove the milling section safety

cover.
- Remove the four mounting screws shown in
the illustration below. Open the left safety cover.
- Be careful not to drop the screws.
- After removing the covers, turn on the power
switch.
Milling Section Safety Cover
Press the brake release button on
the frame.
Brake
Release
Button
75
Remove the four mounting screws Remove the front milling guide.
on the milling cutter. - Turn the pulley shown in the illustration below
(1) Keep pressing the brake release button on and slide out the front milling guide.
the machine and rotating milling cutter clock-
wise until a mounting screw of the milling cut- Front Milling Guide
ter moves into the center of the 20 mm (0.8”)
gap.
(2) Turn off the power switch.
(3) Remove the mounting screw from the mill-
ing cutter using the supplied hexagon Allen
wrench. The screw will be very tight.
(4) Turn on the power switch.
(5) Repeat steps (1) to (4) to remove all four
mounting screws.
Milling Cutter Guide Block Pulley

Mounting Screw
Remove the milling cutter.

Loosened
Clockwise
CAUTION
Wear thick gloves during this operation. Do
not touch the edges of the milling or rough-
ening cutters. Otherwise, the sharp cutters
can cause severe personal injury.
Replace the rear milling guide and
the upper knife.
- Check that the power is turned off, and
Attach the new milling cutter.
remove the two mounting screws on each - Wipe off the grease on the surface of the cut-
side shown in the illustration below. Remove ter before attaching it.
the rear milling guide and the upper knife. - Mount the new milling cutter and temporarily
tighten the four mounting screws.
Rear Milling Guide
Attach the front milling guide.
- Reverse the instructions listed above. Insert
the screws from the rear and turn the pulley
by hand.
Place the front milling guide in a posi-

tion where the rear milling guide can be
attached.
Upper Knife
76
Attach the rear milling guide using

the two mounting screws. CAUTION
In general, do not sharpen the top surface
of the milling cutter. This will reduce the
height of the milling cutter. If the milling
cutter is sharpened, insert a spacer
Move the front milling guide 20 mm between the milling cutter and the milling
from the rear milling guide. holder. This will raise the milling cutter as
- Turn the pulley by hand to leave a 20 mm shown in the illustration below. The rough-
(0.8”) opening. ening cutter should also be lowered. Make
a stack of sheets which has a thickness
equal to the amount removed from the mill-
Fasten the mounting screws on the ing cutter during sharpening. Insert this
milling cutter as follows. stack between the roughening cutter and
the roughening cutter setting gauge.
(1) Turn on the power switch.
(2) Keep pressing the brake release button on
the machine and rotating the milling cutter
clockwise until a mounting screw of the milling Roughening Cutter
Setting Gauge
cutter moves into the center of the 20 mm Spacer
(0.8”) gap.
(3) Turn off the power switch.
(4) Tighten each mounting screw of the milling Milling Cutter
cutter using the supplied hexagon Allen
wrench.
(5) Repeat steps (1) to (4) to install all four Milling Holder
mounting screws.
Attach the upper knife using the Attach the milling section safety
two mounting screws. cover.
- Mount the upper knife temporarily.
- After mounting the upper knife temporarily,
check that there is 0.1 mm (0.004”) gap
between the upper knife and the milling cutter Attach the milling section front
using the thickness gauge. (This is the thick- cover.
ness of one 64 gsm sheet.)
Upper Knife
0.1 mm (0.04")
Close the left safety cover and turn
0.1 mm Milling Cutter on the power switch.
(0.04")
- Rotate the milling cutter counterclockwise

slowly to check that the milling cutter does not
hit the upper knife.
77
5-6 Roughening Cutter Replacement
If the roughening cutter does not cut the spine properly,
the glue will not be evenly applied on the book spine Press the button (Brake
and the spine quality will be reduced. The roughening
cutter may be worn. If it is worn, replace the roughening
Release) on the Milling Brake
cutter. Release Screen.
WARNING
Turn off the power switch before perform-
ing this operation. A sudden start of the
machine can cause severe personal injury.
Wear thick gloves and do not touch the
edge of the milling or roughening cutter.
Otherwise, a sharp cutter can cause severe
personal injury.
Turn off the power switch and

remove the milling section front Open the left safety cover.
cover.
- Remove the four mounting screws shown in
the illustration below.
Slide the milling section safety

cover to the right and hold it with
gummed tape.
- After holding the cover, turn on the power
switch.
Milling Section Front Cover
Set the book block thickness to 50 Gummed

Safety Cover Tape
mm (1.97”) on the Book Block Size
Screen and perform the
changeover.
The roughening cutters will be removed Cover Gummed

in a later step. Tape
Cover
Safety Cover
78
Remove the two roughening cut- (5) Loosen the mounting screw of the roughen-
ters. ing cutter using a 2.5 mm (0.098”) Allen
(1) Press the brake release button on the wrench.
machine. (6) Remove the roughening cutter.
Brake (7) Turn on the power switch.
Release
Button (8) Repeat steps (1) to (7) and remove the
other roughening cutter.
Mount the new roughening cutters

when the power is turned OFF.
(1) Mount each new roughening cutter so that
the top of the cutter is in line with the rotating
direction of the milling cutter.
(2) Keep pressing the brake release button on Rotating Direction

the machine and rotate the milling cutter
clockwise until the roughening cutter you want
to remove comes to the right side of the open-
ing (shown below).
Roughening Cutter
Roughening Cutter
(2) There are cutters on both sides of each

roughening cutter. One roughening cutter can
Clockwise be used twice.
(3) Push down the edge of the roughening cut-
ter using the roughening cutter setting gauge
and tighten the set screw.
Roughening Cutter
(3) Turn off the power switch. Milling Cutter
(4) Press the roughening cutter down using a Roughening
thick cloth. Cutter Setting
Gauge
Allen Wrench
Spring
Roughening Cutter Set Screw
Cloth
(4) Remove the roughening cutter setting
gauge.
Spring
Allen Close the left safety cover and turn
Wrench
Set on the power switch.
Screw
(There is a spring under the roughening cutter.

It will pop up when the set screw is loosened.)
79
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.
Reset the milling section safety

cover.
Attach the milling section front

cover.
80
5-7 Glue Replacement
If the glue becomes brown or sticky, the glue is getting
old. Replace the glue by following the procedure below.
Check that the glue is melted completely

before beginning this operation, and then Hook the drain guide on the attach-
turn off the power switch. Drain the glue ing screws on the melt tank.
quickly before it hardens.
WARNING
The melt tank may be heated to 200
degrees Celsius (400 Fahrenheit), and may
cause severe skin burns. Wear tightly-
woven cotton gloves when draining the
glue.
Attaching
Find a container for the drained Screws
glue (capacity 4 liters or 1.25 gal-
lons). Get the drain guide and a
cloth to wipe up the glue.
Drain Guide
Press the button on the Single
- The attaching screws should already be
Operation Screen Part 2 to lower installed on the melt tank.
the melt tank.
Turn off the power switch and open Place the container for the drained
the lower nipper lower. glue under the drain guide.
WARNING
For the box to catch the glue, use a
durable one against the heat. It is
dangerous when the box is broken
or cracks.
81
5-7 Glue Replacement
Remove the plug using the 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. Otherwise, it may cause the
severe skin burn.
Mounting
Screws
Leave the attaching screws in place.
Close the lower nipper lower.

Drain Guide
- Wipe off any glue on the plug immediately.
Turn on the power switch and add

Do not walk away from the machine new glue immediately.
when draining the glue. Old glue is very
sticky and not all of it can be removed.
The small amount of old glue left over
will mix with the new glue.
Do not pick the glue in fine part of the

tank. Picked glue may be left inside the
tank and may not melt. It stucks
between the roller and the wiper and
causes the problems.
82
5-8 Double Feed Stop Pad Replacement
If double feeding occurs often, replace the double feed
stop pads. Double feeding can occur for several 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.
- Now the pads can be removed.
Double Feed Stop Pads
Mounting Screws
Attach new pads.

- Check that the mounting screws fit completely
into the recesses in the pad assembly, then
push down in on the assembly and tighten the
screws.
- Attach each pad using the screws removed in
step 2.
83
5-9 Transport Belt Replacement
When the cover sheet position changes, replace the
transport belt. Perform this operation after tring all the
operation at the troubleshooting (Refer to page 87).
Open the safety cover(right). Move the spare transport belt to the
former position.
- Do not pull the belt strongly when moving it
over the upper cover guide.
Cut the transport belt using a scis-

sors. Upper Cover Guide
Transport Belt
Transport Belt
Cut the tyton which fixes the spare

transport belt shown in the illustra- - Replace two transport belts together.
tion below.
Spare Transport Belt
Nylon Tie
84
6. Troubleshooting
6-1 Problems with Booklet Quality

Gluing Problems
Problem Cause Remedy See page

There are glue strings hanging from 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. from the cover sheets. glue.
Decrease the length of the Page 22

spine glue.
The side glue is turned Turn the side glue ON. Page 16
OFF.
Not enough side glue is being The side glue roller dis- Make the distance wider. Page 22
applied. tance is too narrow.
The gap between the side Widen the gap. Page 55

glue roller and the glue
amount adjusting plate is
too small.
The spine glue is turned Turn the spine glue ON. Page 16
OFF.
Not enough spine glue is being
applied. The setting for spine glue Increase the spine glue Page 22
is too low. amount.
The wiper opening is too Increase the wiper opening. Page 23

narrow.
The side glue roller dis- Make the distance narrower. Page 22
tance is too wide.
The nipper height is too Reduce the nipper height. Page 64

Too much side glue is applied. high, and the spilled glue
leaks to the side.
The gap between the side Reduce the gap. Page 55

glue roller and the glue
amount adjusting plate is
too wide.
The setting for spine glue Decrease the spine glue Page 22
is too high. amount.
Too much spine glue is applied.
The wiper opening is too Reduce the wiper opening. Page 23
wide.
Glue is not melted. Breaker of the heater is Check if the breaker is not Page 94
tripped. tripped. If the breaker trips
repeatedly, please call your
local dealer.
The booklet is delivered before the The waiting time above Adjust the nipping operating Page 24
glue on the spine hardens when bind- the nipper is not set up. time.
ing without cover sheet.
85
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
mechanism.
The carriage clamp Make the carriage clamp Page 21

opening is too narrow. opening amount larger.
One edge of the spine is dented. When the booklet falls
down to the delivery
section, the booklet
falls down at a tilt.
The nipping delay time Increase the nipping Page 24

The spine of the booklet is wrin- is too short. delay time.
kled (especially, a thick booklet).
The nipping mode with Select nipping without Page 15
milling is selected. milling.
The nipper height is Lower the nipper height. Page 64

too high.
The spine of the booklet is too
sharp. The nipping time is too Make the nipping time Page 24
long. shorter.
The nipping mode with Select nipping without Page 15

milling is selected. milling.
The nipping mode Select nipping with mill- Page 15

without milling is ing.
selected.
Booklet spine is rounded.
The nipper height is Increase the nipper Page 64
too low. height.
The nipping time is too Make the nipping time Page 24

short. longer.
The nipper width is too Make the nipper width Page 24

wide. narrower.
Too much spine glue is Decrease the spine glue Page 22

applied. amount.
The sharpness of the spine is The nipper is inclined Adjust the nipper angle. Page 65
different at the top and bottom. to the right or left.
The rear spine is too round and The rotation of the mill- Switch two black cabels Page 103
the front spine is too sharp. ing cutter is opposite. out of three which supply
the power to the machine.
86
Problems with the Cover Sheets

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
The cover sheet is applied diag- position. stopper.
onally.
The cover sheet is not cut at the Use cover sheets which have been -
correct angle. correctly trimmed.
The cover sheet is not trans- Increase the amount to transport the Service
ported to the registration stop- cover sheet backward.
per.
Jog guides interrupts the cover Select [Guide Open] at the Informa- Page 33
sheet moving back to the regis- tion screen.
tration stopper.
The jog guides on the nipper are Adjust the positions of the jog Page 26
The cover sheet is shifted paral- not set correctly. guides.
lel to the book block toward the
fore-edge. The scoring position is not cor- Adjust the position of the scoring Page 25
rect. roller.
The cover sheet is shifted paral- Cover sheet detect sensor is Clean the sensor. Page 71
lel to the book block in the top- stained.
bottom direction.
The registration stopper position Adjust the position of the registration Page 26
is not correct. stopper.
Upper cover guide hits the regis- Make some space between the -
tration stopper. upper cover guide and registration
stopper.
The pressure from the transport Adjust the pressure from the trans- Page 27
belts is too strong, or too weak. port belts.
The transport belts are stained. Wipe the transport belts using a dry Page 5
cloth.
A transport belt is missing. Install the missing transport belt. Page 5

The position of the cover sheet The jog guide width on the nip- Adjust the jog guide width. Page 26
changes. per is too wide, or too narrow.
The positioning guide width is Adjust the positioning guide width. Page 27
too wide, or too narrow.
Transport belt is worn. Replace with spare belts. Page 84
The production speed is too Increase the production speed. Page 19

slow.
The glue temperature is too low. Increase the glue temperature using Page 61
The cover sheet is not glued to the glue temperature adjusting
the book block spine. knob.
The glue which is being used Use the correct glue or talk to the -
hardens too quickly. dealer.
The nipping delay time is too Decrease the nipping delay time. Page 24
long.
The cover is not fed. Breaker of the cover feed blower Check if the breaker is not tripped. If Page 94
is tripped. the breaker trips repeatedly, please
call your local dealer.
87
Problems with Scoring
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
produced. sure is too weak. pressure.
The upper and lower scor- Align the upper and lower Page 41
ing rollers do not meet scoring rollers properly.
each other.
The transport roller is Wipe the transport roller Page 6

The scoring line moves. stained. using a dry cloth.
The positioning guide Adjust the positioning guide Page 27

width is too wide, or too width on the feed table.
narrow.
The scoring line is created The scoring position is not Adjust the scoring position. Page 25
in the wrong place. set correctly.
Problems with Stack
Bound books cannot be Used sheets are too Push the stopper to the end Page 111
stacked correctly. large, or too small. and attach the accessory
delivery chute.
88
Other Problems
The feature for home Turn ON the feature for Home Page 10
positioning every positioning every changeover
on the [Setting]-[Binding set-
The booklet quality deteriorates changeover is turned OFF ting]-Binding Mode Screen. If
during the binding operation. on the [Setting]-[Binding the booklet quality is still bad,
setting]-Binding Mode return the appropriate section
Screen. of the machine to the home Page 32
position using the [Single Oper-
ation]-Home Positioning
Screen.
The jog guides and the posi- Adjust the jog guide and the Page 26
tioning guides are not aligned positioning guides for a clear- Page 27
with each other. ance of 3 mm (0.12”).
The cover sheets jam. The cover sheets are curled. Uncurl the cover sheets. -
The position of the upper cover Set the upper cover guide at Page 5
guide is not correct. the edge of the cover sheet.
A transport belt is missing. Install the missing transport Page 5

belt.
The milling cutter is worn. Replace the milling cutter. Page 75
The milling depth is too large. Add shims under the level plate Page 59
The carriage clamp slows down to decrease the milling depth.
during the milling operation.
The production speed is too Slow the production speed. Page 10
fast.
Excess glue sticks to the delivery Too much spine glue is applied. Decrease the spine glue Page 22
mechanism. amount.
The trimmings bag is full or Remove the paper chip from -

clogged. the bag.
The hose is clogged with trim- Remove the trimmings from the -
mings. hose.
There are a lot of paper chips
around the milling section. Trimmings are clogged inside Clean the milling unit. Page 69
the milling unit.
Breaker of the milling blower is Check if the breaker is not Page 94

local dealer.
The double feed detect sensor Clean the sensor. Page 71

is dirty.
There is false detection of double
feeding. Setting on the Cover Sheet Increase the detecting sensitiv- Page 27
Fine-Adjustment Part 4 Screen ity or light strength.
is not suitable.
There is false detection of mis- Setting on the Cover Sheet Decrease the detecting sensi- Page 27
feeding. Fine-Adjustment Part 4 Screen tivity or light strength.
is not suitable.
Book block hits the milling section. Breaker of the milling motor is Check if the breaker is not Page 94
local dealer.
The power does not power on. The main breaker is tripped. Check if the breaker is not Page 94
tripped. If the breaker trips
local dealer.
89
6-2 Error Codes
If an error occurs, an error code will appear on the Error Screen. There are some problems only a service person
can handle. (These are inidicated by the gray shading in the table below.) If an Error code with [Service call] in the
column for “See page” comes up repeatedly, please call your local dealer and report the error code.
Error Codes Cause Remedy See page

0001 Emergency Stop switch is pressed. Release the Emergency Stop -
switch.
0002 Left safety cover is open. Close the cover. -
0003 Right safety cover is open. Close the cover. -
0004 Lower nipper door is open. Close the door. -
0501 Cover sheet left on the nipper. Remove the cover sheet and -
check the last booklet.
0601 Cover sheet jam Remove the cover sheet and -
check the last booklet.
1001 Emergency stop error If this error code appears Service call
repeatedly, check the covers
and the brake release button.
Check that there are no prob- Service call
lems with the interlock relay.
1101 Carriage clamp opening amount Check that the stepper motor Service call
home positioning error moves, and that the home posi-
tioning sensor is active.
1111 Carriage clamp home positioning Check that the carriage clamp Service call
error moves smoothly. If this error
code appears repeatedly,
replace the inverter A20.
1112 Carriage clamp moving error Check that the carriage clamp Service call
moves smoothly. If this error
replace the inverter A20.
1113 Carriage clamp moving home posi- Check the carriage clamp home Service call
tioning error position sensor B42.
1121 Carriage clamp open position error Check that the breaker corre- Page 94
sponding to the error code is not
repeatedly, please call your local
dealer.
Check the level plate position Service call
detect sensor B51. If this error
replace the inverter A50
1122 Carriage clamp close position error Check that the breaker corre- Page 94
dealer.
90
6-2 Error Codes
1123 Carriage clamp open/close, book- Check that the breaker corre- Page 94
let delivery mechanism error sponding to the error code is not
dealer.

1131 Rail up motion error Check that the breaker corre- Page 94
dealer.
Check the rail up/down position Service Call

sensor B44 and the lower limit
sensor B45. If this error code
appears repeatedly, replace the
inverter A40.
1132 Rail down motion error Check that the breaker corre- Page 94
dealer.
Check the rail up/down position Service Call

sensor B44. If this error code
appears repeatedly, replace the
inverter A40.
1201 Milling guide home positioning error Check that the stepper motor Service Call
moves, and the home position-
ing sensor is active.
1301 Side gluing roller home positioning Check that the stepper motor Service Call
error moves, and the home position-
1302 Spine glue thickness home posi- Check that the stepper motor Service Call
tioning error moves, and the home position-
1303 Wiper 1 home positioning error Check that the stepper motor Service Call
1304 Wiper 2 home positioning error Check that the stepper motor Service Call
91
6-2 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.
1411 Nipper up motion error Check that the breaker corre- Page 94
tripped. If the breaker trips repeat-
edly, please call your local dealer.
Check the nipper stop position Service Call

sensor B31 and nipper upper
position detect sensor B32. If this
error appears repeatedly, replace
the inverter A30.
1412 Nipper down motion error Check that the breaker corre- Page 94
tripped. If the breaker trips repeat-
edly, please call your local dealer.
Check the nipper stop position Service Call

sensor B31 and nipper upper
position detect sensor B32. If this
error appears repeatedly, replace
the inverter A30.
1501 Jog guide home positioning error Check that the stepper motor Service Call
moves, and the home positioning
sensor is active.
1502 Scoring roller width home positioning Check that the stepper motor Service Call
error moves, and the home positioning
sensor is active.
1503 Stopper adjust cam home positioning Check that the stepper motor Service Call
sensor is active.
1601 Positioning guide home positioning Check that the stepper motor Service Call
sensor is active.
1611 Feed table up motion error Check the feed table upper posi- Service Call
tion sensor B63 and the motor
rotation.
1612 Feed table down motion error Check the feed table lower posi- Service Call
tion sensor B64 and the motor
rotation.
92
6-2 Error Codes
0801 Delivery error Check that the breaker corre- Page 94

dealer.
Check the delivery motor stop Service Call

position sensor B70 and the
motor rotation.
Check that the delivery section Page 48

is not full of bound books.
1801 Thermo-Fuse error Check that the breaker corre- Page 94

dealer.
Check that the power cable is -

connected to the power source
properly.
93
6-3 If a Circuit Breaker Trips
If a specific part of the machine does not work, check the
circuit breaker(s) for that part. If the breaker is tripped,
turn it ON.
WARNING
Turn off the power switch before turning
ON the breaker. Otherwise, it can cause an
electrical shock.
Check the error code on the Error

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

spond to the error code.
1
2
5 3
6 4
7
8
9
10
70
DER
BQ-2
T BIN
PER
FEC A50
A40
A30
A20
Error No. Location Code No. Trouble

1121,1122,1123 1 Q50 Clamp, Level Plate Open/Close Motor M50 has trouble.
1131,1132 2 Q40 Clamper Rail Up/Down Motor M41 has trouble.
1411,1412 3 Q30 Nipper Motor M31 has trouble.
1123 4 Q20 Application Drum Motor M21, Clamp Motor M22 has
trouble.
0801 5 Q70 Delivery Motor M70 has trouble.
1801 9 Q80 Melt Tank Heater E80 has trouble.
No Error No. 6 Q60 Cover Feeder Blower Motor M61 has trouble.
No Error No. 7 Q12 Chip Extractor Motor M12 has trouble.
No Error No. 8 Q11 Milling Motor M11 has trouble.
No Error No. 9 Q01 Main Circuit Breaker has trouble.
94
6-4 If a Message Scrren Appears
When message screens below appears, operate the
machine by following the message.
Glue Drum Rotation OK Screen Clamp Manual Move Screen
When the glue drum is stopped for more than 10 When the clamp stops above the milling section by
minutes, this screen appears. Press OK, and the the emergency stop, this screen appears. Open the
Glue Drum Rotating Screen appears and the drum safety cover and move the clamp by hand to the
rotates for 3 minutes. original position (above the level plate). The previ-
ous screen appears.
This screen appears to prevent the clamp from hit-
Glue Drum Rotating Screen ting the milling section safety cover.
Manual Setting OK Screen
When is pressed, the drum stops rotating.

And the previous screen appers. After another 10
minutes has passed, Glue Drum Rotation OK
Screen appears again. This screen appears when one or some settings out
This screen appears for preventing the glue from of the spine glue thickness, wiper opening, nipping
hardening. delay time and nipping time were tried to be
changed manually although the settings are set to
“Auto”.
When the spine glue thickness, wiper opening, nip-
ping delay time, and nipping time should be
changed manually, press OK and change the set-
ting.
Press to set each part automatically and
show the previous screen.
95
96
7. Optional Device
7-1 Weekly Timer

Two power switch operation
ON Main Power Switch: ON
Power switch for main body of

BQ-270
OFF
BQ-270: OFF
PERFECT BINDER
Main Power Switch
Power Switch for

main body of BQ-270
- When the weekly timer is used, turn on the

main power switch all the time.
- Even if the power switch for main body of BQ-

270 is turned off, the weekly timer works and
the melt tank will be heated according to the
weekly timer setting.
- Turn on the power switch for main body of

BQ-270 before performing the the binding
operation.
- Turn off only the power switch for main body

of BQ-270 after the binding operation is fin-
ished.
97
7-1 Weekly Timer
Weekly Timer Operation Procedures
Switch Description
- If the starting time for the melt tank heat-

ing is set beforehand, the binding opera-
tion can be started without waiting for the
glue to be melted.
- When using the weekly timer, leave the
main power switch turned ON.
- If the power switch for the main body of
BQ-270 is not turned on for over 300 hours,
the Sunday (S) lamp may blink when the
power switch is turned on. In this case, set
the current time and day. (Refer to the next
page)
Reset Lamp
When this timer does not work correctly
according to setting, reset lamp illuminates.
Continuous / Normal Switch
Setting Scale Set this switch to "CONTINUOUS" when
This scale is used to set the time to the time between turning the machine on
turn the BQ-270 ON or OFF. One and off is over 24 hours.
rotation takes a day and the indexes Normally, set this switch to [NORMAL].
can be set every 15 minutes. Set the
CON-
tabs inside to turn on the setting. A-TB72CQ NORMAL TINUOUS Output Lamp
RESET OUTPUT This lamp lights when the timer function
Current Time Setting Knob is active.
OFF AUTO
This knob is used to set the current
S
time. One rotation of this knob takes 2
1 24 23
22 Day Lamps
M
an hour.
3
These lamps are used to indicate the

21
T
20 19
W current day. A lighted lamp indicates

18
T the current day.

40
Minutes Scale 45
F
9
13 12 11 10
S Current Day Setting Button
Hours Scale DAY This button is used to select the current day.
SETTING
PRESENT
TIME
OFF ON
AUTO
Day Select Switch ON, Auto, and OFF Switch

For each day on which the melt tank ON: When the main power switch of the BQ-270
will be heated automatically, set the is turned on, the melt tank is always heated
switch for that day to [AUTO]. up, independently of the timer function.
For each day on which the melt tank OFF ON AUTO: The timer function is available.
will not be heated automatically, set the AUTO
OFF: Although the main power switch of the
switch for that day to [OFF].
BQ-270 is turned on, power is not supplied
to the BQ-270.
98
7-1 Weekly Timer
Setting the present time and the day Setting the time switches
A. [Setup within a day]

Set the weekly timer.
(1) Set the normal/continuous switch to [NOR-
MAL].
2
1 24 23
22
(2) Set the day select switches to the "Auto"
side only for the days when the melt tank will
3
21
20 19
be heated automatically.
18
40
45
NORMAL CON-
Normal/Contin-
9
13 12 11 10 TINUOUS
RESET OUTPUT uous Switch
OFF AUTO
S
Scale M
Minute T
Day Select
Hour W
T Switch
F
S
CAUTION DAY
SETTING
Weekly timer heats up the melt tank at the ON/Auto/OFF Switch
set time on the set date. For safety, check OFF ON
the machine in the set time. AUTO
(3) Set the time to heat up the melt tank by

shifting the appropriate index tabs to the cen-
ter of the dial.
- For example, when the time switch is set
Remove the transparent cover. as shown in the figure at right, the machine
will operate according to the program from
1. Set the current time as follows: Monday to Friday, and will not operate on
Saturday and Sunday.
- Turn the current time setting knob clockwise
to set the [hour] index first, then set the
[Minute] index. Monday- ON OFF
Friday
(A) 8:00 - 12:00
2. Set the current day as follows:
- Press the day setting button using the tip of a (B) 17:00 - 19:00
screwdriver. Each time you press the current
day setting button, the current day indicators Saturday, All Day OFF
advance a day. Stop when they indicate the Sunday
current day.
NORMAL CON-
TINUOUS
RESET OUTPUT
19 17
OFF AUTO
S
8
M 12
T
Current Day
W
T Lamp
F
S Output Time Switch
DAY
SETTING Current Day SUN MON TUE WED THU FRI SAT
Setting Button
OFF ON
AUTO A B A B A B A B A B
99
7-1 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- setup time of the first day when the day
gram continues from the previous day. select switch is set to "AUTO." The
Therefore, the machine is powered up until machine is powered off at the off setup
it reaches the off setup time, even though time of the first day when the day select
the day select switch for the day is turned switch is set to "OFF."
off.
(1) Set the normal/continuous switch to [CON-
(1) Set the normal/continuous switch to [NOR- TINUOUS].
MAL]. (2) Set the day select switches by referring to
(2) Set the day select switches as described for the example below:
the setup within a day. (3) Set the time to heat up the melt tank by
(3) Set the time to heat up the melt tank by shifting the appropriate index tabs to the cen-
shifting the appropriate index tabs to the center of the dial.
ter of the dial.
Monday 8:00 to Friday 17:00
Monday- ON OFF (through a series of days)
Friday
(A) 8:00 - 16:00 Satu All Day OFF
(B) 20:00 - 6:00 rday, Sun-
day
Saturday, All Day OFF
Sunday
CON-
NORMAL
TINUOUS Normal/Continuous
RESET OUTPUT Switch
NORMAL CON- OFF AUTO
TINUOUS Normal/Continuous S
RESET OUTPUT
Switch M
OFF AUTO T
W
Day Select
S
M T Switches
T Day Select F
S
W
T Switches DAY
SETTING
F
S
DAY OFF ON
SETTING AUTO
OFF ON
AUTO
Time Switch
17
20
8
6
Time Switch
16
8
Output
Output SUN MON TUE WED THU FRI SAT
SUN MON TUE WED THU FRI SAT
8:00 17:00
C D C D C D C D
100
8. Installation
8-1 Installation
This section includes procedures that can be performed
only by our service engineer.
Place three feet under the leveling
bolts shown in the illustration
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.
Move the carriage clamp. Top View
- Move the chain 1 shown below by hand,

about 5 cm (19.68”) along the arrow direction.
PERFECT BINDER
BQ-270
Adjust the leveling bolts and lift up
the machine so that the machine
Chain
1
Carriage Clamp
becomes level.
2 - Place a water level on the nipper in two direc-
tions (shown in the illustration below) to check
for level.
- Lift up the machine so that the casters do not
touch the floor.
- Push the carriage clamp at its end 2 and
move it to the left end.
- Remove the foam polystyrene below the car-
riage clamp.
2 7 0
Q-
DER
B
T BIN
FEC
P ER
101
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.
Top View
Lock each leveling bolt using the

lock nut. Wire the touch panel.
- Install the ground from the touch panel to the
position as shown below.
- Connect the cables shown below to the CON3
Lock Nut and CON4 on the touch panel P.C.Board.
Leveling Bolt
Ground
Foot CON3
CON4
Attach the spacer and the adapter.

- Attach the spacer and the adapter on the right
side of the machine and fix with the screw.
Spacer
Mouth
Attach the trimmings bag.

- Attach the trimmings bag on the adapter and
tie it with the string.
102
8-1 Installation
Wire the machine. - Seeing the milling cutter from top, the knife
should turn clockwise.
- Connect the machine main power.
- Follow the procedure described below. Check
the milling cutter rotate direction.
1) Turn on the main power. Do not check the rotating direction by
2) Enter the service mode. slowing down the cutter using the
3) Slide the milling section safety cover and button. The milling cutter may be
hold it using the gummed tape.
seen rotating backward by sudden
Safety Cover
Gummed
Tape
braking. It is useful if you tape a string
of paper on the sheet guide and touch
the other side of the paper to the knife
edge. Press on the screen and
the edge of the paper will be drawn to
Cover
the rotating direction.
Gummed
Tape
Cover
Safety Cover
Sheet Guide
4) Press button (Milling Cutter Rotation

Button) on the Information - Single Operation -
Milling Screen. Clockwise Tape
WARNING
5) If the milling cutter rotates counterclock-
Keep your hands away from the wise, exchange the two black cables (out of
rotating milling cutter. It may cause three) each other at the power box, which
severe personal injury. supply the power to the machine.
Black
Ground
U V W
6) Rotate the milling cutter again by the single

operation and ensure that the cutter rotates
clockwise.
103
8-2 Installation of Extractor (Option)
Turn off the power switch and 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.
Connect the power cord of the

This procedure is for connecting the
hose on the machine. Attach the flange
extractor.
where you want to connect the hose.
Small Cover Q01 Q80Q11Q12Q60Q70 Q20 Q30 Q40Q50
Small Cover
K82 A22
A20 A30 A40 A50
Flange
1 3 6 13 A1
K82
2 4 6 14 A2
BLK
RED
1) Attach the hose on the flange. WHT
GRN
104
8-2 Installation of Extractor (Option)
Change the current setting on the

breaker Q80 from 9A to 10A using
the driver.
Q01Q80
Q80Q11Q12Q60Q70 Q20 Q30 Q40Q50
K82 A22
A20 A30 A40 A50
Q80
10
9
6
9A 10A
Check the rotating direction of the

fan inside the extractor.
Check that the fan rotates to the direc-

tion shown in the illustration above. If
the fan rotates backward, switch the
position of two wires out of three.
Prepare the delivery hose and

install it on the delivery vent using
the hose band.
- Delivery hose is not included in the optional
extractor.
Use the hose which has smooth texture

inside, and also which has diameter
over 100 pi.
105
8-3 Installation of Weekly Timer (Option)
Accessory for the Weekly Timer
(T-270) Kit
Power Switch for main body of BQ-270
99
RED
WHT
BLK
Not
used for
BQ-270
RED
WHT
BLK
100
Weekly Timwer and Relay
61
95
WHT
WHT
BLK
WHT
73
BLK
BLK
WHT
98
106
Turn off the power switch and dis- Install the weekly timer.
connect the power cable from the (1) Remove the lock screw and the fixing plate
customer power source. from the weekly timer.
Remove the front cover and the ter- Wires

minal board cover. Lock Screw
Fixing Plate
PERFECT BINDE
R BQ-270
(2) Insert the weekly timer to the hole.

(3) Fix the weekly timer using the lock screw
and the fixing plate.
Front Cover
Plate Install the power switch (black) for
the main body of BQ-270.
(1) Remove the handle and the bracket from
the switch.
Switch
Bracket
Handle
Terminal Board Cover (2) Insert the power switch for the main body of
BQ-270 to the hole.
(3) Attach the bracket and fix it with the screw.
(4) Attach the handle.
Remove the plate under the power
switch.
Screw
99
Make some space to install the 100
weekly timer by loosening the

wires. Bracket
Handle
107
Install the relay. Wire the terminal board.

- Hook the upper part on the rail and push the (1) Reconnect the heater wire which is con-
lower part in. nected on the terminal No.4, to the terminal
No.9.
Only when the

area sensor is
used
Relay
Terminal Board
K01 1 1
K02 2 2
WHT 3 RED WHT 3 WHT
26
4 26
4
5 5
BLK RED BLK RED
6 6
7 7
8 BLK
8 RED
9 9
98
Wire the breaker.
(1) Remove three wires No.18 which is con-
nected between Q01 and Q80. (2) Connect the wire No.98 from the relay, to
the terminal No.4 and No.9.
Connect the wire No.61 from the

weekly timer, to the white relay con-
nector which wire No.21, No.22 and
5 5 5 No.23 are connected.
BLK
BLK
BLK
18
18
18
Q01 Q80
To Power K11
Switch for 5 5 K20 K10
5
K60
BLK
BLK
BLK
main body
99 K83
of BQ-270 100
WHT
RED
WHT
BLK
RED
BLK
To Relay 73
BLK KO1
WHT KO2
White Relay Connector
Q01 Q80
Arrange the wires and attach the

(2) Connect the wire No.99 on Q80. front cover.
(3) Connect the wire No.100 and wire No.73 on
Q01.
108
9. Appendix
9-1 Specifications
Binding Type Binding with milling, Binding without milling and Padding
Number of Clamper 1
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” to 2.00”)
Cover Sheet Size Max. 320mm x 660mm (12.5” x 25.9”) Fixed Side Downstream
Scoring
Movable Side
Scoring
Min. 135mm x 230mm (5.4” x 9.0”) (Rear Side) (Front Side)
Cover Sheet Quality 82 to 302 gsm (22 to 80 lb)
(5.32" to 12.60")
135 to 320
Cover Pile Height Max. 70 mm (2.7”)
110 to 310 120 to 350
Warm up Time 40 min. (4.33" to 12.20) (4.72" to 13.77")
230 to 660 (9.05" to 25.98")

mm(inch)
Glue Temperature 120 to 180 degrees Celsius (248 to 356 degrees Fahr-
enheit)
Maximum Milling Depth 3 mm (0.12”)
Production Speed Without Milling: Max. 500 cycles/hr.
With Milling: Max. 500 cycles/hr.
Padding: Max. 500 cycles/hr.
Voltage/Frequency AC220V/230V/240V/400V 50Hz/60Hz
(3 phases 3 wires plus PE)
Rated Current AC220V/230V/240V 50Hz 9.7A (Max.12.8A)

AC220V/230V/240V 60Hz 8.5A (Max.12.8A)
AC400V 50Hz/60Hz 5.6A/5.1A (Max. 9A/6.4A)
Power Consumption 220V/230V/240V 50Hz 2.9kW

220V/230V/240V 60Hz 2.78kW
400V 50Hz/60Hz 3.1kW/3.16kW
Heat Out Put 7,870 kJ (1,880 kcal)
Machine Dimensions 2,300 (W) x 860 (D) x 1,250 (H) mm (90.6” x 33.9” x 49.3”)
Noise Level L A peak: 83.3 dB

L A eq: 74.0 dB
Machine Weight 900 kg (1,984.5 lb)
109
9-2 Accessories
Tool Box (4-003344) 1pc Shim 2 pcs each
1.0mm (0.04")(M011601)
1.5mm (0.06")(M049499)
2.0mm (0.08")(M011602)
1.0 mm thim is attached on the machine.
Roughening Cutter Setting Gauge (M011118) 1 pc Adjusting Pin (M011117) 1 pc
Hexagon Allen Wrench 1 pc each Heat-resistant Oil (A930179) 1 pc
6 mm (0.24")(4001744)
5 mm (0.2") (4000968)
4 mm (0.16")(4001439)
3 mm (0.12")(4001438)
2.5 mm (0.1") (4001437)
2 mm (0.08")(4001320)
Single Open-End Wrench (M127498) 1 pc Double Open-End Wrench (4010556) 1 pc
30 mm (1.18") 7 x 8 mm (0.28"x 0.31")
Support Plate (A931959-00) 1 pc
110
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. Hook the chute onto the delivery section.
Place suitable box to receive the delivered booklets.
Spacer (M127359-00) 1 pc Adapter (M127356-01) 1 pc
111
9-2 Accessories
Fuse (E319737) 2 pcs Glue (HM-220) 1 pack
Grease (4017229) 1 pc Digital Caliper (4012395) 1 pc
10
Only for mm version of
70
80
BQ-270
90
10
0
Spare battery SR1130
Small Book Block Insertion Guide 1 pc Book Block Insertion Guide 1 pc
Drain Guide (M126530) 1 pc Grease Gun (4004391) 1 pc
Alignment Plate (M027079) 1 pc Thermometer (4017505) 1 pc
80
100 Concave
120
60 140
40
20 160
0 180
200
When measuring the glue temperature,

check that the application drum is rotating
and the glue reaches the concave of the
thermometer.
112
9-3 Consumable Parts
Glue (HM-220) 1 box Milling Cutter (M011440) 1 pc
HM
-22
0
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
113
9-4 Option
Extractor (VS-270) 1 pc Weekly Timer 1 pc
114
9-5 Index
B
Binding Counter ......................................................................................................................... 19
Binding Mode Screen ................................................................................................................. 10
Binding Screens ......................................................................................................................... 18
Blower Air Adjustment ............................................................................................................... 67
Book Block Length Setting......................................................................................................... 12
Book Block Size Screen ............................................................................................................. 12
Book Block Thickness Setting .................................................................................................... 12
Book Support Plate Replacement .............................................................................................. 73
C
Carriage Clamp Section ............................................................................................................... 2
Clamp and Milling Fine-Adjustment Screen................................................................................ 21
Clamp Opening Amount Adjustment .......................................................................................... 21
Cover Feed Section ..................................................................................................................... 6
Cover Feeding Settings ............................................................................................................. 57
Cover Sheet Angle Adjustment .................................................................................................. 66
Cover Sheet Fine-Adjust Screen Part 1 ..................................................................................... 26
Cover Sheet Length Seting......................................................................................................... 13
Cover Sheet Size Screen ........................................................................................................... 13
Cover Sheet Width Setting ......................................................................................................... 13
D
Delete Button ............................................................................................................................. 29
Delivery Section ........................................................................................................................... 7
Double Feed Detecting Function ............................................................................................... 14
Double Feed Stop Pad Adjustment ............................................................................................ 67
Double Feed Stop Pad Replacement ......................................................................................... 83
E
Error Screen................................................................................................................................ 34
Extractor ................................................................................................................................... 104
F
Feed Rotor Vacuum Adjustment ................................................................................................ 27
Feed Table Height Adjustment .................................................................................................. 68
Function Screen......................................................................................................................... 14
G
Glue Amount Adjusting Plate ..................................................................................................... 63
Glue Fine-Adjust Screen Part 1 ................................................................................................. 22
Glue Replacement ..................................................................................................................... 81
Gluing Screens .......................................................................................................................... 16
H
Home Positioning Screen .......................................................................................................... 32
I
Information Screen ..................................................................................................................... 33
115
L
Level Plate Section ...................................................................................................................... 2
M
Main Binding Screen ............................................................................................................ 19, 40
Melt Tank Section ........................................................................................................................ 4
Memory Function ....................................................................................................................... 49
Memory Screen.......................................................................................................................... 29
Milling and Nipping Screen ........................................................................................................ 15
Milling Brake Release Screen.............................................................................................. 32, 75
Milling Cutter Replacement ........................................................................................................ 75
Milling Depth Adjustment ........................................................................................................... 59
Milling Guide Width Adjustment ................................................................................................. 21
Milling Section .............................................................................................................................. 3
N
Nipper Angle .............................................................................................................................. 65
Nipper Height ............................................................................................................................. 64
Nipping Delay Time .................................................................................................................... 24
Nipping Fine-Adjust Screen ....................................................................................................... 24
Nipping Section ............................................................................................................................ 5
Numeric Keypad Screen ............................................................................................................ 34
P
Pre-set Counter .......................................................................................................................... 19
R
Read Out Button ........................................................................................................................ 29
Registration Stopper Angle Adjustment ..................................................................................... 66
Roughening Cutter Replacement ............................................................................................... 78
S
Safety Function Check............................................................................................................... 35
Scoring Fine-Adjust Screen ....................................................................................................... 25
Scoring Position Change ........................................................................................................... 58
Scoring Roller Pressure Adjustment ........................................................................................... 68
Scoring Roller Setting ................................................................................................................ 41
Setting Screens ...................................................................................................................... 9, 36
Shim Installation.......................................................................................................................... 60
Side Glue Amount Adjustment ............................................................................................. 55, 62
Side Gluing Roller (Far Side) Positioning Plate ......................................................................... 62
Side Gluing Roller Settings .................................................................................................. 22, 44
Single Operation Screens .......................................................................................................... 30
Single Operation Screen Part 1 ................................................................................................. 30
Spine Glue Amount Adjustments ............................................................................................... 55
Start Mode Screen ..................................................................................................................... 11
T
Touch Screen ............................................................................................................................... 7
Transport Belt Pressure Adjustment .......................................................................................... 27
W
Weekly Timer ..................................................................................................................... 97, 106
Wiper Opening Adjustment ......................................................................................................... 23
Write Button ............................................................................................................................... 29
116

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PERFECT BINDER BQ-270

061031/BQ270/11E/HS, TM, HH, HS UM202048-11

This lists the range of acceptable values and operating conditions.

Refer to this note when you operate the machine.

This explains a mechanism in the machine.

1. Machine Description .................................................................................... 1

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

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

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

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

1-1 Machine Description

Cover Feed Section

Glue Temperature Adjusting Knob

1-2 Safety Functions

Lower Nipper Door

Book Block Insert Section

Emergency Stop Button

1-3-2 Level Plate Section

Level Plate Slide Guide

Rear Milling Guide

Brake Release Button

Milling Select Lever

Glue Temperature Adjusting Knob

Side Glue Roller Lubrication Point Glue Level Upper Limit

Adjust according to the glue Glue Supply Section

Upper Cover Guide

Rear Jog Guide

Nipper Angle Adjusting Block Nipper Height Adjusting Ring

Scoring Roller Pressure

Cover Sheet Detect

Pad Height Adjusting Lever

1-3-8 Touch Screen

Setting Screens Memory Screen

Binding Screens Single Operation Screens

Function Setting Screen

2-1 Entering the Job Information Using the Setting Screens

1 Binding Mode Screen

P. 1 7 Gluing Screen Part 1

P. 2 8 Gluing Screen Part 2

Press the box, and the Numeric Keypad

1 - - Binding Mode Screen

1 : Binding with cover sheets.

2 : Binding without cover sheets.

2 - - Start Mode Screen

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

Select the start mode.

Start waiting time

3 - Book Block Size Screen

4 - - Cover Sheet Size Screen

Input this setting first on this screen.

110 to 310 120 to 350

230 to 660 (9.05" to 25.98")

If the dimension is out of this range, the front

: Center of the spine.

Center of the Spine

1 (ON): Use the double feed detecting function.

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

6 - Milling and Nipping Screen