SB-15 Operation Manual

SYSTEM BINDER SB-15
Important Information
- This manual is designed to help you to install, operate and maintain the SB-15 System
Binder. Please read and understand this manual and keep it in a safe and convenient place.
- Do not operate the SB-15 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 modifi-
cation 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.
061212/SB15/14E/HS
I UM205007-14
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 damage to the machine. It may also be used to warn against unsafe practices.
- Please read and understand all safety instructions which include the terms WARNING
and CAUTION. If these safety instructions are ignored, personal injury may result.
- Horizon International Inc. cannot anticipate every possible situation that might involve
a potential hazard. Therefore, the instructions in this manual and the warning labels on the
machine are not all-inclusive.
- All equipment shall be locked out or tagged out to protect against accidental or inad-
vertent operation when such operation could cause injury to personnel. Do not attempt to
operate any switch, valve, or other energy isolating device where it is locked or tagged out.
- Do not operate the machine when any covers are removed.
- Some of the drawings in this manual show the machine uncovered to allow for explana-
tions of the details or inside the machine.
II
Perfect Binding
Perfect binding is the process of binding book blocks to wraparound covers
through the use of hot melt (or cold) glue.
The three basic steps of perfect binding are as follows:
1. The spine of the binding edge of the sheets is prepared by a milling and notch-
ing process which breaks down the paper fibers to be bound by the glue.
2. Hot melt glue is applied to the spine of the book block.
3. Wrap around covers are presented to the book block with the appropriate
upward force and front and back nipping pressure to ensure a strong binding
and a clean professional finish.
Milling Gluing Nipping
Other methods of binding, such as saddle stitching or mechanical binding, may

fasten the sheets more permanently or allow for the easy removal of individual
sheets. However, perfect binding is quite often the binding of choice for a
number of good reasons. Perfect binding provides a strong, long lasting
binding which is generally more professional and appealing in appearance.
The square even profile of the binding edge provides superior stacking and
packing. It also provides a printing surface for a title or reference numbers so
that a book or document can be easily identified and retrieved from a book-
shelf.
To maintain the integrity of the binding and minimize the potential for sheets
becoming loose it is recommend that the spine of the book not be broken.
This occurs when the book is opened and pressed completely flat or folded
back in a manner so as to expose the adhesive between the sheets.
Good Bad
III
For optimum binding strength and the highest quality finish, the following
conditions are recommended:
1. The sheets should have a grain direction

parallel to the binding. (See illustration.)
2. The cover stock thickness should match the

book block thickness (e.g., thin book / thin
cover, thick book / thick cover).
3. Apply the correct glue in an amount

appropriate to the book thickness.
4. Ensure the quality of the glue. (Use the

glue recommended in the machine specifi-
cations.)
Perfect binders are designed to provide strong, quality-finished books ranging

from a very thin book up to a 2" book. It is common for the corners of a
thicker book to be slightly less sharp in appearance because of the thicker
application of glue and the heavier weight cover stock required to ensure
binding strength.
Corner is round.
Cautions to observe during perfect binding.

-Use the paper with the grain direction as shown in the drawing below.
-Use a cover that is suitable for the thickness of the book block.
-Notice the curl of the cover when using a laminated cover.
IV
Hot Melt Glue
WARNING
- Hot melt glue is inedible. Keep this glue away from children. If chil-
dren eat any glue, call a doctor immediately.
Hot melt glue is solid at room temperatures. It becomes softer when the tempera-
ture is above 100 ˚C (212 ˚F), and turns liquid as the temperature rises. Liquid
glue permeates the sheets and turns solid again and adheres to sheets after the
temperature falls. This glue is different from starch glue and chemical synthetic
glue that adhere as they dry.
Hot melt glue will deteriorate if it is heated over a long period, even if new glue is
continuously added to the tank. It will also deteriorate if overheated. Melted glue
will turn to gel after it has been heated for 50 hours.
If this glue is exposed to ultraviolet light for 6 to 12 months, it becomes fragile,

but the binding strength does not change. Finished books with covers prevent the
glue from being exposed to the ultraviolet rays directly.
Deteriorated glue becomes darker. Replace the deteriorated glue with a new
supply before doing any binding.
V
CONTENTS
Important Information ............................................................................ I
Safety Precautions .................................................................................. II
Perfect Binding ..................................................................................... III
Hot Melt Glue ......................................................................................... V
1. Before You Begin

1-1 Machine Description ......................................................................... 2
1-1-1 Safety Covers And Switches ................................................. 2

1-1-2 Unit Location ......................................................................... 3
1-2 Control Panel Description ................................................................ 4
1-2-1 Main Screen ........................................................................... 4

1-2-2 Book Size Input Screen ......................................................... 5
1-2-3 Binding Condition Screen ..................................................... 6
1-2-4 Function Screen ..................................................................... 7
1-2-5 Optional Device Set Up Screen ............................................. 8
1-2-6 Error Screen ........................................................................... 9
1-2-7 Fine Adjustment Screen ........................................................ 11
1-2-8 Memory Screen ..................................................................... 12
1-2-9 Cover Feed Test Screen ......................................................... 12
1-2-10 Milling Cutter Replacing Screen ......................................... 13
1-2-11 Motor Driver Error Screen .................................................. 14
2. Checks Before Operating

2-1 Turn On The Power ........................................................................ 16
2-2 Rotate The Clamps ......................................................................... 17
2-3 Emergency Stop Button Check ...................................................... 19
2-4 Stop Bar Check ............................................................................... 21
2-5 Cover Interlock Check ................................................................... 22
3. Binding Operation
3-1 Binding Operation Outline ............................................................ 24
3-2 Confirming The Settings ................................................................ 26
3-3 Binding Procedure .......................................................................... 29
VI
3-4 Finishing Binding ............................................................................ 36
3-5 If A Problem Occurs ....................................................................... 37
3-5-1 Pole Lamp................................................................................... 37

3-5-2 Buzzer ......................................................................................... 37
3-5-3 Using The Remote Control......................................................... 38
3-5-4 Using The Manual Operation Handle ........................................ 38
4. Machine Set Up And Adjustment
4-0 Outline -Setting Each Section ....................................................... 40
4-1 Automatic Setting And Book Size Input Interface ...................... 42
4-2 Setting The Machine Functions ..................................................... 44

4-3 Setting The Optional Devices ......................................................... 45
4-4 Setting The Infeed Section ............................................................. 46
4-5 Setting The Level Plate (Hand Feed Section) ............................... 50
4-6 Setting The Clamp Section ............................................................. 54
4-7 Setting The Milling Section ............................................................ 56
4-8 Setting The Glue Tank Section ...................................................... 59
4-9 Setting The Side Gluing Section .................................................... 68
4-10 Setting The Cover Feeder ............................................................ 74
4-11 Setting The Scoring Rollers ......................................................... 82
4-12 Setting The Cover Sheet Transport Section ............................... 87
4-13 Setting The Cover and Book Registering Section ...................... 89
4-14 Setting The Nipping Section ........................................................ 91
4-15 Setting The Delivery Section ........................................................ 94
4-16 Setting The Twisting Conveyor Section ...................................... 96
VII
5. Maintenance
5-1 Adding The Spine Glue ...................................................................... 100
5-2 Adding The Side Glue ........................................................................ 101
5-3 Cleaning ............................................................................................... 102
5-3-1 Cleaning The Clamp Track ........................................................ 102

5-3-2 Cleaning The Book Block Track ................................................ 103
5-3-3 Cleaning The Cover Feeder ........................................................ 104
5-3-4 Cleaning The Sensors ................................................................. 105
5-3-5 Cleaning The Air Pump Filters .................................................. 106
5-4 Lubrication .......................................................................................... 107
5-5 Replacing The Milling Cutter ............................................................ 113
5-6 Replacing The Roughening Cutter .................................................... 117
5-7 Replacing A Suction Cup ................................................................... 118
5-8 Replacing The Shear Pin .................................................................... 119
5-9 Replacing The Spine Glue .................................................................. 121
5-10 Replacing The Side Glue .................................................................. 123
5-11 Description of The Weekly Timer .................................................. 125
5-12 Replacing the carbon Blades of Pump ........................................... 128
6. Troubleshooting
6-1 Poor Binding Quality .......................................................................... 129
The Corners Of The Spine Are Too Round

The Corners Of The Spine Are Too Sharp
The Spine Is Scratched
Prints On The Spine Is Not In The Center
The Book Block And The Cover Sheet Are Shifted In The Top Bottom Direction
The Book Block And The Cover Sheet Are Shifted Diagonally
Too Much Spine Glue Extends From The Top Or Bottom Of The Book Block
When Glue Is Not Applied To The Part Of The Book Block Spine
When A Part Of The Book Block Fore-edge Is Bent
6-2 When The Pole Lamp Lights And The Machine Stops ................... 145
Error Screen Indications

6-3 Clearing Errors ................................................................................. 148
VIII
Clearing A The Book Block Jam In A Clamp
Resetting The Torque Limiter In The Infeed Section
Resetting The Torque Limiter In The Clamp Section
Resetting After A Melt Tank Overheat
If Double Feeding Occurs Frequently
If Misfeeding Occurs Frequently
If The Shear Pin In The Nipping Section Breaks
Resetting The Torque Limiter In The Delivery Section
6-4 Problems In The Cover Feeder ......................................................... 156
When The Cover Sheets Are Not Fed Properly

When The Cover Sheets Are Loaded In The Wrong Direction.
6-5 When a Bad Booklet Is Not Detected ................................................ 158
7. Accessories And Specifications
7-1 Accessories ........................................................................................... 160
7-1-1 Accessaries And Tools ............................................................... 160

7-1-2 Consumptions ............................................................................. 163
7-2 SB-15 Specification ............................................................................. 164
8. Optional Devices
IX
This page is intentionally left blank.
X
1. Before You Begin
1. Before You Begin

This chapter explains some points that the operator should know before
starting the binding operation.
1-1 Machine Description ..........................................................................................2
1-1-1 Safety Covers And Safety Devices ........................................................... 2

1-1-2 Unit Location............................................................................................. 3
1-2 Control Panel Description ................................................................................. 4
1-2-1 Main Screen............................................................................................... 4

1-2-2 Book Size Input Screen ............................................................................. 5
1-2-3 Production Information Screen ................................................................. 6
1-2-4 Function Screen ......................................................................................... 7
1-2-5 Optional Device Set Up Screen ................................................................. 8
1-2-6 Error Screen............................................................................................... 9
1-2-7 Manual Setup Screen ................................................................................. 11
1-2-8 Memory Screen ......................................................................................... 12
1-2-9 Cover Feeding Test Screen........................................................................12
1-2-10 Milling Cutter Replacing Screen ............................................................. 13
1-2-11 Motor Driver Error Screen ......................................................................14
1
1. Before You Begin
1-1 Machine Description

1-1-1 Safety Covers And Safety Devices
Milling On/Off Lever
Hand Feed Melt Tank Cover
Milling Section Cover Section Cover The binding operation cannot start when
This also includes the this cover is opened. The guide can still be
milling section cover. moved using the remote control.
Stop Button
Pole Lamp
Infeed Section Front The machine stops when
This shows the
Cover this button is pressed.
operating condition of
the machine. Refer to
Sect. 3-5-1 for details.
Book Block Feed

Section Front Cover
Stop Button
The binding operation stops
when this button is pressed. Manual Operation
Handle Door
Milling Section Door Window For Spine
The binding operation stops Gluing End Adjustment Power Section Cover
when this cover is opened. Melt Tank Section Cover
Nipper Section Cover Delivery Section Cover
The binding operation cannot start The binding operation stops when this cover is opened.
when this cover is opened. The The guide can still be moved using the remote control.
guide can still be moved using the
remote control. Stop Button
The machine stops when this
button is pressed.
Twisting Conveyor Door

The machine stops when this
door is opened.
Delivery Section Door
Stop Button Nipping Section Lubrication Window
The machine stops when this Nipping Section Door
button is pressed.
Cover Sheet Transport
Section Door
Misfeed Receiving Tray
2
1. Before You Begin
1-1 Machine Description (Continued)

1-1-2 Unit Locations *Option
Milling Section (M)
Side Gluing Section
Milling This mills the spine of the book. Clamp Section (C) This applies side glue to the
Blower Unit Refer to Sect. 4-7 for details. This clamps the book book block. Refer to Sect. 4-9
DB-15W block and transports for details. Book Size Input
it. Refer to Sect. 4-6
for details. Interface
Input the book size
by measuring the
actual book block.
Refer to Chapter 8.
Infeed Section
This section receives the book Total Counter
block from the connecting unit This counter gives
and place it in a clamp. Refer Glue Tank Section tentative criteria for
to Sect. 4-4 for details. Apply glue to the book spine. supplying.
Hand Feed Section (L) Refer to [4-8] for details.
The pages in the book block are arranged Electrical Box (E)
neatly by a jogging mechanism. The book Power Section
block can be fed manually. Refer to Sect. 4- Open the cover and turn the
5 for details. manual operation handle to
Control Panel (T) run the machine manually.
This indicates the binding Cover Sheet Trans-
conditions (the number of port Section (Q) Delivery Section (D)
bound booklets, faulty booklets This transports the The clamp releases the book here
and production speed). cover sheet to the and it is delivered to the twisting
This is also used to set up each cover and book regis- conveyor section.
part of the machine. Refer to tering section. Refer to
Sect. 1-2 for details. Sect. 4-12 for details. Twisting Conveyor Section
Weight Checker
Sorter
Nipper Section (N)

Cover and Book The nipper holds the cover
Cover Feeder (H) Registering Section and the book block together to
This feeds covers to the This attaches a cover to form the book spine. Refer to
cover and book regis- the book block spine. Sect. 4-14 for details.
tering section. Refer to Refer to Sect. 4-13 for
Sect. 4-10 for details. details.
3
1. Before You Begin
1-2 Control Panel Description
1-2-1 Main Screen
Book Size Indicator Screen

See Sect. 1-2-2 for details.
0.394 inch 12 0 book(s)

(mm) 3
8.268 inch 7.874 inch 0 book(s)
(mm)
(mm)
1400
5.906 inch
(mm) 5200 books/h
1000 rpm Production Information Screen
9.055
7.087 inch
(mm)
Production information is displayed
15.748 inch here.
1 2 Error Screen
The error icon and the location of the
problem are displayed here.
Optional Device Set Up Screen

Icons for any optional devices being
used are displayed here. Icon for Manual Setup screen
Icon for Memory screen
Function Screen Icon for Cover Feeding Test

Icons for any functions in use are dis- screen
played here. Icon for Service screen
Icon for Closing screen
4
1. Before You Begin
1-2 Control Panel Description (Continued)

1-2-2 Book Size Input Screen
12
3
0 book(s)
0 book(s)
1400 books/h
5200
1000 rpm
1 2
Main Screen
Press at the upper left side of the main screen to display the Book Size Input
screen. There are two different displays which can appear on the Book Size Input
screen.
This section explains the screen displays. Refer to Section 4-1 to actually input the
book size.
Input using the center line or the center of the print on the spine
1 Input the book block thickness.
1
10.0 2 Input the top-bottom length of the book block.
inch
(mm)
3 Input the fore-edge length of the book block.

2inch
(mm)
4 Input the length from the edge of the cover to
3 200.0 inch
(mm)
120.0 inch
(mm)
the center of the spine.
5 Input the top-bottom length of the cover sheet.
4 230.0 6 Input the cover sheet width.
5 inch
(mm)
6
400.0 inch
(mm)
OK
The new setting is saved and

Return to the main the Cover Transport Guide
screen without saving Check screen is displayed.
the new setting.
Input using the book block thickness
1 Input the book block thickness.
1 (mm)
10.0 inch 2 Input the top-bottom length of the book block.
3 Input the fore-edge length of the book block.
inch
2
(mm)
3 200.0 inch
(mm) 4 Input the length from the edge of the cover to
inch
(mm)
the near edge of the book block spine.
4 5 Input the length from the edge of the cover to
230.0
6 inch
(mm)
the far edge of the spine.
5 inch
130.0 (mm)
6 Input the top-bottom length of the cover sheet.

7 (mm)
400.0 inch
7 Input the cover sheet width.
OK
The new setting is saved

Return to the main and the Cover Transport
screen without saving Guide Check screen is
the new setting. displayed.
5
1. Before You Begin

1-2-3 Production Information Screen
Bound Books: The number of

0.394 inch 12 0 book(s)
acceptable books (This value
8.268 inch
(mm)
7.874 inch
3
0 book(s) 12 is not cleared until the is
(mm) (mm) 3
5.906 inch
(mm)
1400 books/h pressed.)
5400
1000 rpm
5.511 inch 9.055
(mm)
Bad Books: The number of bad
7.087 inch
(mm)
15.748 inch
books (This value is not cleared
(mm)
until the is pressed.)
1 2
Production Speed: The number
of books produced in one hour.
Main Screen Milling Cutter Rotation Speed:
The speed of the milling cutter
12
3
0 book(s) rotation for one minute.*
0 book(s) Clear: Clears the indicated
1400 books/h numbers for Bound Books and
Bad Books.
5200
1000 rpm
*The milling cutter rotating speed automatically
Producing changes with the production speed, so the pitch of
Information the roughening cutter is kept constant. The upper
Screen limit is 2500 rpm.
Upper Limit Of Production Speed
The production speed should be set less
than the speed of the Three-Knife
Trimmer.
The performance of the Three-Knife
Trimmer changes according to the sheet
size and stack height.
When the glue is solidified before the
cover is sticked, the booklet can be
produced with production speed over
the upper limitation with manual bind-
ing. When the maximum production
speed (5200) is pressed on the screen,
the box color is reversed and the upper
limitation of production speed is re-
leased. However you should operate the
machine with the manual feeding to
check that the three-knife trimmer is
operated smoothly.
6
1. Before You Begin

1-2-4 Function Screen
Function Screen 3 54 5
6 7
6
0.394 inch
(mm)
8.268 inch
12
3
0 book(s) 1 ON ON ON
(mm)
7.874 inch 0 book(s)
2
(mm)
HT
5.906 inch 1400 books/h
(mm)
5200 OFF OFF OFF
1000 rpm
7.087 inch
(mm)
5.511 inch 9.055
(mm)
4
2 MG MG+HT
15.748 inch
OK 80%
8
7 ON
OFF
ON
OFF
ON
OFF
1 2
Main Screen OK
Return to the Main

9 10 11 12 13
New setting is saved and the system
screen returns to the Main screen
1 Use the SB-15 as a stand alone unit.
2 Use the SB-15 as a system with the Three-Knife Trimmer. Start to bind at the binder.
HT
Use the SB-15 as a system with the gatherer. When this icon appears, the binding opera-
3 tion can not be started at the binder.
MG Start the operation at the gatherer.
Use the SB-15 as a system with the gatherer and the trimmer.
4 When this icon appears, the binding operation can not be started at the binder.
MG+HT Start the operation at the gatherer.
5
Side Glue ON/OFF: Press ON when using the side glue feature.
6 Fore-edge Glue ON/OFF: Press ON when using the fore-edge glue feature.
Partial gluing ON/OFF: Press ON when using the partial gluing feature.
7 Press OFF when gluing the spine normally. Caution-When ON is selected, wiper adjust-
ment of the spine is needed. Refer to step 9 in Section 4-8-2.
Double Feed Detection ON/OFF and Sensitivity: Press ON when using the double feed
8 detect function for the cover sheets. Adjust the detecting sensitivity using the level bars.
9 Cover Misloading Detection ON/OFF and Sensitivity: Press ON when using the cover
misloading detect function. Adjust the detecting sensitivity using the level bars.
10 OK80% Compare the scanned standard cover 11 with the actual cover scan 12 and shows the
relationship in %.
11 Write: Scan an image of the cover and use it as a standard.
12 Test Start: Perform the cover scan test.
Book Length Detection ON / OFF: Press ON when using the faulty book detect function
13 which detects the top-bottom length of the book.
7
1. Before You Begin

1-2-5 Optional Device Set Up Screen
This icon appears when the machine is operated from the touch
panel. When using the remote control, the icon for the remote con-
This icon appears when trol appears here. This means that the machine can be operated by
the book size input inter- the remote control.
face is available. This icon appears when the sorter is available.
Optional Device Set Up Screen
0.394 inch 12 0 book(s)
(mm) 3
(mm)
(mm)
ON
1 2 3
(mm)
5200 ON ON ON
1000 rpm
OFF OFF OFF OFF
5.511 inch 9.055
(mm)
7.087 inch
6
5
(mm)
15.748 inch
(mm)
1 2
ON ON
1 2
5 SEC
4 OFF
5 SEC
5 OFF
10 SEC 3 SEC
OK
Main Screen
Return to the Main The new setting is saved and
screen then return to the Main screen
Weight Checker: Detects a faulty book by measuring the weight of the book.
1
Select On when using this device.
Infeed Section Blowing Air: Blows air to separate the book block from the guide
2
against the resistance of static electricity. Select On when using this device.
1 Pre-melt tank 1: When using the pre-melter for tank 1, select On.
3
4
2 Pre-melt tank 2: When using the pre-melter for tank 2, select On.
5 Side Glue Supply Unit: Supplies side glue automatically. Select On when using this
device.
8
1. Before You Begin

1-2-6 Error Screen Error Screen
12
3
0 book(s)
20 19 18 17 16 15
0 book(s)
1400 books/h
5200
14
1000 rpm
22 13
23
21
1
1 2
1 2 3
Main Screen
: 2 1
1
2
2
3
7
The setting of each 10
section is still not
completed. 11
Perform the automatic 12
setting of each section. 4 3 5 6 8 9
(See Section 4-1, Step 3 Error screen is explained at 6-2. Refer to 6-2
for details.) for details.
The torque limiter for the clamp

1 Collator MG-60H has an error. 13
rotation is operating.
The stop button on the infeed

2 14 The nipper section cover is open.
section is pressed.
The torque limiter at the book 15
The shear pin in the nipping
3 section is broken.
block insert section is operating.
The milling section cover is 16
The delivery section cover is
4 open.
open.
The torque limiter at the deliv-
5 The stop bar is operating. 17
ery section is operating.
The stop button on the hand A book remains in the delivery
6 18
feed section is pressed. section.
The hand feed section cover is Inverter error at twisting conveyor
7 19
open. section.
8
Book jammed in level plate The twisting conveyor section
section. 20
cover is open.
Level plate is lowered too A book block remains in the
9 21
much. clamp.
The stop button on the twist-
10 The milling section door is open. 22 ing conveyor section is
pressed.
The milling section can not be
11
operated. 23 Finisher Error
The milling slide lock lever is
12
released.
9
1. Before You Begin

1-2-6 Error Screen (Continued)
Error Screen
47 48
49
46 44
12 0 book(s)
43
3
0 book(s)
1400 books/h
28 45
5200
1000 rpm
24 32 42
41
25 1 2 3
40
30
29
3
39
30
1 2 1 2
1 2
Main Screen 26 38
30 37
27 31 34 35 33 36
The Error screen is explained in Section 6-
2. Refer to Section 6-2 for details.
The glue in the melt tank is not

24 hot enough to perform the bind- 37 Milling motor driver error
ing operation.
There are not enough glue in the 38 Clamp rotating inverter error
25 1
melt tank 1.
Application drum 1 glue tem- 39 Power switch is turned OFF.
26 1
perature error The stop switch on the control
40
Pre-melter error for application panel is pressed.
27
drum 1 The standard cover image has not
41
28 The melt tank cover is open. been saved.
There are not enough glue in the 42 No covers left

29 2
melt tank 2.
Application drum 2 glue tem- 43 The supply of covers is low.
30 2
perature error
2 Pre-melter error for application 44 Cover is left on the cover feeder.
31
drum 2 and 3
45 A cover sheet is loaded in the
The glue in the melt tank is not wrong direction.
32 high enough to perform the
binding operation. Double feeding at the cover
46
feeder
There is not enough glue in melt
33 3
tank 3. 47 Misfeeding at the cover feeder
Side gluing drum temperature The stop button on the cover

34 3 48
error feeder is pressed.
35
Side glue supply unit has a prob- Sheet jam at the cover feeder
49
lem
Low air pressure at side gluing
36
mechanism
10
1. Before You Begin

1-2-7 Manual Setup Screen
12
3
0 book(s)
0 book(s)
8
9 7 5
1400 books/h
5200
1000 rpm
6
1
1 2
2 3 4 Fine Adjustment
Main Screen
Return to the Main screen Screen
1
The Infeed Section Manual Setup screen
appears.
The Clamp Section Manual Setup screen

2
appears.
3 The Milling Section Manual Setup screen

appears.
4 The Melt Tank Section Manual Setup

screen appears.
The Cover Feed / Cover Sheet Transport

5
Section Manual Setup screen appears.
The Fore-edge Glue Section Manual Setup

6 screen appears if the optional fore-edge
gluing device is used.
7 The Nipping Section Manual Setup screen

appears.
8 The Delivery Section Manual Setup screen

appears.
11
1. Before You Begin

1-2-8 Memory Screen
Memory Screen
12
3
0 book(s)
0 book(s)
1400 books/h
5200
1000 rpm
Write
1 2
Read
1 2 3 4 5 6 7 8 9 10
Main Screen
11 12 13 14 15 16 17 18 19 20
Delete
Return to the Main screen Grey = Empty
Green = Data in use
White = Data saved here
1-3-9 Cover Feeding Test Screen
12
3
0 book(s)
0 book(s)
3200 sheets/h
1400 books/h
5200
1000 rpm
1
10 sheets
2
OK OK OK
1 2
0% 98% 96% 80% 80%
Main Screen
OK OK
4
OK OK
86% 92% 93% 88% 98%
OK
3
Return to the Main screen
1 Cover Feed Speed Feeding Test Results
OK Cover Fed Properly

2 Number Fed
Double Feed
3
Test Start
Misfeed
OK OK OK
Result of the
4 0% 98% 96% 80% 80%
feeding test
OK OK OK OK OK
86% 92% 93% 88% 98%
12
1. Before You Begin

1-2-10 Milling Cutter Replacement Screen
12 0 book(s)
3
0 book(s)
1400
5200
1000
books/h
Service Screen
rpm
1 2
Clamp Removing Screen
Confirmation Screen
remove the clamp

press the "next" button after removing the clamp.
OK?
NEXT
Clamp Moving Screen
Press the start button.

Milling Guide Moving Screen
rotating the clamp
This takes about 30 seconds.

moving the milling guide
Milling Cutter Replacing Screen
This takes a maximum of 70 seconds.

Clamp Attach Sreen
replace the cutter referring the operation manual

press the "next" button after replacing the clamp.
NEXT
Replace the milling cutter

when this screen appears on restore the clamp
the control panel. press the "OK" button after restoring the clamp.
OK
Press OK after replacing the

clamp. The Service screen
appears.
13
1. Before You Begin

1-2-11 Motor Driver Error Screen
Motor Driver Error Screen 2 3 4

?
6
1
5
8
7
9 15
10
11
12 13 14
Motor Driver Error Screen
This screen appears if one of the
motor drivers has a problem when
the power switch is turned on.
1 Book Block Length Detect 9 Connecting Unit Guide Width
2
Infeed Section Entrance Guide
Delivery Section Guide Width 10 Width
Nipper Width Infeed Section Slope Guide

3 11
Width
Cover Sheet Transport Guide
4 12 Level Plate Height
Width
5 Cover Feeder Side Guide-Left 13 Milling Guide Width
6 Cover Feeder Side Guide-Right 14 Glue Length
7 Cover Feed Table Height 15 Side Glue Width
8 Clamp Width
14

This chapter explains how to check the safety functions
before starting the binding operation.
2-1 Turn On The Power........................................................................................... 16
2-2 Rotate The Clamps ............................................................................................17
2-3 Emergency Stop Button Check......................................................................... 19
2-4 Stop Bar Check ..................................................................................................21
2-5 Cover Interlock Check ......................................................................................22
15
2-1 Turn On The Power
Turn On The Power

Z
1. There are switches which control the
power on this machine. Turn on the J B
U W D N A Q H
main switch first and then turn on the C
power switch. MG-60H R S L M G Y
All sections of the machine receive

power. An error screen (“Glue is not
completely nelted”) appears on the Main
control panel. Switch
The pole lamp turns red to show that the Red Pole Lamp Power
melt tank is heating up. Lights Switch
The melt tank can be heated up before- Initial Screen

hand using the weekly timer. See
Section 5-11 for instructions on setting
up the weekly timer.
CAUTION
When using the weekly timer,
turn on the main switch Main Screen
beforehand. If the main 0.394 inch
(mm)
12
3
0 book(s) Press to go to
switch is turned off, the heater 8.268 inch
(mm)
5.906 inch
7.874 inch
(mm)
1400
0 book(s)
the error screen
5200 books/h
in the melt tank will not (mm)
1000 rpm
operate at the set time. 7.087 inch

(mm)
9.055 inch
(mm)
15.748 inch
(mm)
The optional devices listed below have

their own switches. Turn on each 1 2
switch. (If a switch is turned on before-

hand, it will turns on along with the
SB-15.)
Weight Checker
Pre-melt tank
2. Wait until the melt tank has heated up Error Screen

enough to melt the glue. (The glue is not completely melted yet)
The glue in the melt tank is melted and

the machine is ready to operate when
the pole lamp turns from red to yellow.
16
2-2 Rotate The Clamp
Rotate The Clamps
Run the machine using the jog button to

check or adjust it.
WARNING CAUTION
Do not put your hand into the If the guides are adjusted tighter
clamp section while it is than the automatic setting, the
operating. A moving clamp lower part of the clamp may hit
can cause severe personal the adjusted guide and break.
injury. Refer to Section 4-7-2 and
increase the spacing between the
guides.
Clamp Rotation Switch
1. Turn on the clamp rotation switch on the Production Speed
control panel.
0.394 inch 12 0 book(s)
(mm) 3
(mm)
(mm)
5.906 inch 1400
(mm) 5200 books/h
1000 rpm
9.055
7.087 inch
(mm)
15.748 inch
(mm)
1 2
Symbol for
2. Turn on the remote control box activa- Remote Control
tion switch on the remote control box for
clamp rotation.
- The symbol for the remote control J B

W D N A Q H
U
appears on the control panel. At this
S B - 1 5
point, the machine can not be operated MG-60HaL
from the control panel. R S L M G Y
- The reset button on the remote control

box lights.
- If a cover is opened, the remote control
box can not be used. Close all covers.
- There are two remote control boxes. If
one of the remote control boxes is Remote Control Box
being used, the other one can not be Activation Switch ON
OFF
used.
t
Rese
Reset Button
3. Press the reset button.
g
Inchin
- A warning buzzer sounds and the
inching operation button lights. Now Inching
the jog can be performed by pressing Operation
the inching operation button. Button Remote Control
Box For Clamp
Rotation
17
2-2 Rotate The Clamps (Continued)
4. Press the inching operation button.
- The machine moves as long as the Remote Box ON OFF

inching operation button is pressed. The Activation Switch
machine stops when it is released.
Reset
- The operation speed is same as the
speed set on the control panel. Reset Button
- To perform the inching operation again, Inching
press the reset button, and then press the Inching
inching operation button again. Operation
Button 05SB08A20
Any booklet delivered using the inching

operation button will be ejected as a
faulty book by the sorter.
CAUTION
If you press the reset button
and the jog button quickly and
repeatedly, this may make the
clamp vibrate and damage the
clutch. Do not use the controls
on the remote control box
frequently in a short periods of
time.
18
2-3 Emergency Stop Button Check
Check the Emergency Stop Button
WARNING CAUTION
Do not put your hand into the If the guides have been
clamp section while it is manually set narrower than
operating. The moving clamp the automatic setting, the
can cause severe personal injury. lower part of the clamp may
hit the guide and break. Refer
to Section 4-7-2 and increase
the distance between the
1. Turn off the remote control box activation guides.
switch on the remote control box.
Remote Control Box

Activation Switch ON OFF
Reset
Reset Button
Inching
2. Turn on the clamp rotation switch on the Inching

control panel. Operation
Button 05SB08A20
3. Press the start button. Clamp Rotation Switch

- The warning buzzer sounds and the
clamp starts to move. 0.394 inch
(mm)
12
3
0 book(s)
(mm) (mm)
1400
5.906 inch
(mm) 5200 books/h
1000 rpm
9.055
7.087 inch
(mm)
15.748 inch
(mm)
Start
4. Press the stop button on the control panel 1 2
Button
and check the following:
- The machine stops

- appears on the control panel Stop Button
Error Screen
- Pole lamp turns red.
- Press in the lower left corner of

the Error screen. The Main screen ap-
pears.
WARNING
If the machine does not stop,
turn off both the main switch
and power switch and call
your local dealer.
shows that the
stop button is pressed.
19
2-3 Emergency Stop Button Check (Continued)
5. Also check the stop function of all stop Z

buttons shown in the figure to the right.
W D N A Q H
S B - 1 5
WARNING R S L M G Y

turn off both the main switch Stop Button Locations
your local dealer.
- There are five stop buttons.

1. Control Panel
2. Cover Feeder
3. Level Plate Section
4. Twisting Conveyor Section
5. Infeed Section
20
2-4 Stop Bar Check
Check the stop bar function
The "Stop Bar" is a safety function designed

to stop the machine when the hand of the
operator touches the bar while feeding manu-
ally.
1. Rotate the clamp following steps 1-3 in

Section 2-2.
Stop Bar
2. Touch the stop bar and check for the
following:
- The machine stops Error Screen (Stop Bar Is Operating)
- appears on the Error screen on the
control panel.
- Pole lamp turns red.
- Press in the lower left corner

of the Error screen. The Main screen
appears.
WARNING
and power switch and call Red
your local dealer. Lamp
The stop bar functions not only during

manual feed operation, but also during
automatic binding. The automatic
binding operation stops if this stop bar
is touched.
21
2-5 Cover Interlock Check
Check the cover interlock
The "Interlock" is a safety function designed Nipper Section Delivery Section Cover
to stop the machine when any cover is opened Cover
while the machine is operating.
1. Rotate the clamp following steps 1-3 in

Section 2-2.
Twisting Conveyor Door
Milling Section
Cover Melt Tank Section Cover
2. When opening one of the covers shown
in the figure to the right, check for the
following:
- the machine stops
- appears on the touch panel display
- Pole lamp turns red. Milling Section

Door
- The Main screen appears when
in the lower left corner of the
Error screen is pressed.
Error Screen
3. Check the interlock function for the (Cover Open)
following covers also:
- Nipper section cover
- Delivery section cover
- Melt tank section cover
- Milling section cover
- Milling section door
- Twisting conveyor door
WARNING
your local dealer. shows that a
cover is opened.
22
This chapter explains the steps in the binding operation. The proce-
dures for setting up or adjusting the machine are explained in the
next chapter. If you are using this machine for the first time, or you
are not used to this machine, please read the next chapter (“Machine
Set Up And Adjustment”) first, and understand the outline of the
binding procedure first.
3-1 Binding Operation Outline ............................................................................... 24
3-2 Confirming The Settings ................................................................................... 26
3-3 Binding Procedure ............................................................................................. 29
3-4 Finishing Binding ............................................................................................... 36
3-5 If A Problem Occurs ..........................................................................................37
3-5-1 Pole Lamp....................................................................................................... 37

3-5-2 Buzzer ............................................................................................................. 37
3-5-3 Using The Remote Control............................................................................. 38
3-5-4 Using The Manual Operation Handle ............................................................38
23
3-1 Binding Operation Outline

This section explains the general procedures
included in the binding operation. Under-
stand the outline of the binding procedure
first, then go to the next chapter to start the
operation.
Initial Screen
1. Turn ON the power.
2. Wait until the glue is completely melted 0.394 inch

8.268 inch
(mm)
7.874 inch
12
3
0 book(s)
0 book(s) Waiting Screen
in the melt tank.
(mm) (mm)
5.906 inch 1400
(mm) 5200 books/h
- This takes about one hour. 9.055

1000 rpm
7.087 inch
(mm)
15.748 inch
(mm)
1 2
3. Perform the safety checks.

- Once the safety functions have been
Follow Chapter 2.
checked as described in Chapter 2, go
to the next step.
4. Input the book block size. 10.0 inch

(mm)
Block Size Input
- Input the size of the book block. inch
Screen
(mm) 200.0 (mm)
inch
inch
(mm)
230.0 inch
(mm)
130.0 (mm)
inch
400.0 (mm)
inch
OK
5. Perform the automatic setting.

- Set each part of the machine automati-
cally according to the input book block Automatic Seting
Screen
size.
setting to the moving away

home position setting position
returning to the restoring
home position complete to set
not complete
to set
24
3-1 Binding Operation Outline (Continued)
6. Set the functions.

- This section controls spine glue partial HT
ON ON
OFF
ON
OFF Function Screen
OFF
gluing, off-line or system operation, MG MG+HT
double feed detect function, side glu- ON ON OK 80% ON
ing, misloading prevention function, OFF OFF OFF
and the sheet length detect function.

OK
7. Set the optional devices.

ON ON ON ON
- Turn the optional devices On/Off OFF OFF OFF OFF

Optional Device
including the Weight Checker, Sorter, 1 2
Set Up Screen
ON ON
Pre-melt Tank, Side Glue Supply Unit, OFF OFF
10 SEC 3 SEC
Infeed Section Air Assist Blower etc. 5 SEC 5 SEC
OK
8. Confirm the set up of each part of the

machine.
- Check the set up conditions of each
part of the machine by following the
instructions in Section 3-2.
9. Test the cover sheet feeding. 3200 sheets/h Test Feeding

Screen
- Input the cover sheet feed speed using 10 sheets
the screen shown to the right. OK OK OK
- Decide how often the test should be 0% 98% 96% 80% 80%
OK OK OK OK OK
performed. (Maximum 10 times) 86% 92% 93% 88% 98%
10. Press the start button.

- Perform a test binding.
- Check the quality of the bound book
block.
11. Make any manual adjustments.

Fine Adjustment
- Make any necessary manual adjust- Screen
ments depending on the quality of the
bound book block.
25
3-2 Confirming the Settings
This section explains the check lists used to

confirm that the each part of the machine
has been set properly.
Check Items Subject Reference

See Section 4-1,
Book block size is set Check the book block size on the block size
Inputting the book
correctly input screen.
block size
Chck to see that the spine glue partial
gluing, off-line or system operation, double
Function settings have See Section 4-2,
feed detect function, side glue supply unit,
been done Setting the functions
mis-load prevention function, and sheet
length detect functions are set properly.
Check that the settings for the weight
Optional device settings checker, sorter, side glue supply unit, pre- See Section 8 and set
have been done melt tank, infeed section air assist blower the optional devices
are correct.
The distance between the guides on the
Connecting unit setting is See Section 8, Setting
connecting unit is 0.039" (1 mm) less than
correct the connecting unit
the book block thickness.
The distance between the guide plates on the See Section 4-4,
Book block entrance
book block entrance section is 0.039" (1 Setting the book block
section setting is correct
mm) less than the book block thickness. entrance section
The milling width is decided by changing the See Section 4-5,
Milling width is set
thickness of the level plate. The level plate Setting the level plate
correctly
setting must be correct. section
The clamp opening in the level plate section See Section 4-6,
Clamp opening is set
is wide enough for the book block to pass Setting the clamp
correctly
through. section
See Section 4-7,
Milling section setting is When performing the milling operation,
Setting the milling
correct check that the milling On/Off lever is raised.
section
The glue in the melt tank is heated up to the See Section 4-8,
Spine gluing section
setting temperature. There is no icon on the Setting the spine
setting is correct
Error screen. gluing section
There is enough glue in the melt tank.
When using separate tanks, the separation
valve is closed.
The height setting for each drum is correct.
The spine glue application length is set
correctly.
The wiper opening is set correctly.
See Section 4-9,
Side gluing section setting The glue in the melt tank is heated up to the
Setting the side gluing
is correct target temperature.
section
There is enough glue in the melt tank.
When using the side glue supply unit, there
is glue in the hopper.
The side glue application length is set
correctly
The side glue application width is set
correctly
The optional side glue supply unit is set up
correctly.
26
3-2 Confirming the Settings (Continued)

See Section 4-10,
Cover feed section setting is
The position of the side guide is correct Setting the cover
correct.
feeder
The height of the table is correct
The positions of the suction cups are correct
The projecting length of the double feed stop
screw is correct
The amount of blower air is correct
Each unused suction cup is covered
The scoring roller position is correct.
Double feed detect function

See Section 4-10-2-
The sensitivity setting is correct 8, Setting the double
setting is correct.
feed detect function
See Section 4-10-2-
Mis-loading prevention 9, Setting the mis-
The sensitivity setting is correct
function setting is correct. loading prevention
function
The detector can see the patterns on the sheets.
The pattern used by the detector has been
saved.
Cover feeding test is See Section 4-10-3,
The covers are being fed properly.
performed. Cover Feed Test
See Section 4-12-2,
Cover sheet transport There are no foreign objects in the way of the
Setting the cover
section setting is correct. cover sheets.
sheet holder
The guide width is same as the cover width
The cover sheet holder is set.
27
3-2 Confirming the Settings (Continued)
See Section 4-13,

The register adjustment between the
Cover sheet register section setting is Setting the cover and
book block and the cover sheet is
correct book registering
correct
section
See Section 4-14,
The distance between the nippers is
Nipping section setting is correct Setting the nipping
correct
section
The nipper height adjustment is correct
There are no foreign object stuck to the

surface of the nippers
The gap between the conveyor guides
is set to 1.4" (35 mm) when the book
See Section 4-15,
block thickness is less than 1.4" (35
Delivery section setting is correct Setting the delivery
mm), or to the same thickness as the
section
book block when the book block
thickness is more than 1.4" (35 mm).
See Section 4-16,
Twisting conveyor section setting is
The book block guide setting is correct Setting the twisting
correct
conveyor section
See Chapter 8, Setting
The settings on the optional weight
The power switch is turned on. the weight measuring
checker are correct
device
If the weight measuring device is turned
off on the function screen, go to the The book character is selected.
next box.
The standard weight and limits are
entered
The settings on the optional sorter are See Chapter 8, Setting
The power for the sorter is turned on.
correct the sorter
If the sorter is turned off on the The stopper guide is set to the book
function screen, go to the next box. block dimension + 3.9" (100 mm).
The settings on the optional delivery The position of fore-edge guide is See Chapter 8, Setting
stacker are correct correct the delivery conveyor
The settings for the top-bottom guide

and the entrance roller are correct
The number of books in each stack is

set
The delivery speed setting is correct
The settings on the optional milling See Chapter 8, Setting
The power switch is turned on.
blower unit are correct the milling blower
The trim box is not full.
28
3-3 Binding Procedure
This section describes the procedure used to

produce the book. Details of setting up or ad-
justing the machine may be explained in other
chapters.
1 Turn on the power
1. There are two switches which control the

power on this machine. Turn on the main Z
switch first then turn on the power switch. J B

U Q
W D N A H
S B - 1 5
MG-60HaL R S L M G Y
- Electricity is supplied to the machine and
the Initial screen changes to the Error Main Switch
screen. An error icon is displayed (Glue is
not completely melted.)
- The red part of the pole lamp lights. This Weekly
indicates that the melt tank is starting to Power Timer
warm up. Switch
- If the air pressure is low, appears on
the Error screen.
2. The melt tank can be warmed up ahead of Initial Screen

time, using the weekly timer. Refer to
Section 5-11 for instructions on setting the
weekly timer.
When using the weekly timer, be sure to

turn on the main switch. If the main
Error Screen (Glue is not melted)
switch is not turned on, the heater for the
melt tank will not heat up at the pre-set
time.
3. There are power switches on the optional

devices listed below. Turn on the power
switch on each unit. (Once the power Press here to go to the
switch has been turned on, the unit will Main screen
power-up along with the SB-15.)
Main Screen
0 book(s)
- Weight Checker 12
3
0 book(s)
- Pre-melt Tank 1400 books/h

5200
1000 rpm
Error
Indication
1 2
(Glue is not
melted)
29
2 Wait until the glue is melted completely
- This usually takes about one hour, Red = Melt tank is heating up
although the time changes according to Yellow = Tank temperature
the room temperature and the amount has reached as to the
of glue. setting temperature
- During melting, the red light on the
pole lamp is lighted. The yellow lamp
lights when the temperature of the melt Pole Lamp
tank reaches the pre-set temperature. Present
Temperature
- The temperature of the melt tank is
indicated on the display on the side of
the electrical box as shown in the figure
to the right.
- To change the temperature setting for
the melt tank, press on the
Pre-Set
Error screen. An error symbol should
Temperature
be showing. (Glue is not melted com-
pletely.) The Main screen appears. See
Section 4-8-4 for instructions.
3 Perform the preparation check
- Check the following items according

to the instructions in Chapter 2.
1. Check that each part of the machine

operates correctly by doing the inching
operation.
- Use the inching operation button on
the remote control.
2. Check that the machine starts to operate

when you press the start button, and
stops when you press the stop button.
3. Check that the machine starts to operate

when you press the start button, and
stops when you push the stop bar.
4. Check that the machine stops when any

of the covers is opened.
30
4 Input the book block size

Main Screen
12 0 book(s)
- There are two ways to input the book 3
0 book(s)
block size. 1400 books/h

5200
1000 rpm
1. Input the book block size using the

Block Size Input screen.
- Input the size by following the instruc- 1 2
tions in Section 4-1.

Block Size Input Screen
0.394 inch
(mm)
8.268 inch
- or - 5.906 inch
(mm) 7.874 inch
(mm)
(mm)
9.055 inch
(mm)
7.087 inch
(mm)
15.748 inch
(mm)
OK
2. Input the book block size using the

optional book size input interface. Input
MAX
C
Optional Book Size

E
the size by using the original book block

Input Interface
and a cover sheet.
- For instructions see Chapter 8.
5 Perform the automatic setting

Block Size
- Perform the automatic setting accord- 0.394 (mm)
inch Input Screen
ing to the input book block size. 8.268 (mm)
inch
7.874 inch
(mm)
5.906 (mm)
inch
9.055 inch
(mm)
7.087 inch
1. Press OK on the Block Size Input 15.748

(mm)
inch
(mm)
screen. OK
1
- The Automatic Setting Confirmation
screen appears. Confirmation Screen
OK?
2. Press the start button on the control

panel.
- The Automatic Setting screen appears Start Button

and each part of the machine is set
automatically. 2
31
3. It takes 2 to 3 minutes to automatically Auotmatic Setting Screen

set all sections of the machine.
- The touch panel indicates the condi-

tion of each part of the machine using
icons during the automatic setting
procedure.
=Machine is stopped, has reached

to the home position home position
setting to the
setting position
moving away

not complete
= Moving to the home position to set
= Moving to the pre-set position

Autmatic Setting Finished Screen
= Setting is complete
- Once all parts have been set correctly,

the Automatic Setting Finished screen
appears.
4. Press OK . The Main screen ap- OK

pears.
4 Press here to go to
the Main screen
6 Perform the function settings

Function Screen
- There are seven functions on this
machine ON ON ON
1 Off-line use/System use

1
MG
HT
MG+HT
2 OFF
3 OFF
4 OFF
2 Side glue supplier On/Off ON ON OK 80% ON

3 Fore-edge gluing On/Off
4 Spine glue partial gluing On/Off 5 OFF OFF
6 7
OFF
5 Double feed detect function On/Off

6 Mis-loading function On/Off OK
7 Sheet length detect function On/Off

2
Press here to go to
1. Set each by following the instructions in the Main screen
Section 4-2.
2. Press OK .
- The function is input and the Main
screen appears.
32
7 Set up the optional devices

- The optional devices listed below may
Optionl Device Set Up Screen
be installed. Set these optional devices
ON or OFF.
ON ON ON ON
1) Weight Checker 1 OFF 2 OFF 3 OFF OFF
2) Infeed Section Air Assist Blower 1

ON
2
ON
6
3) Pre-melt Tank for Melt Tank 1
4) Pre-melt Tank for Melt Tank 2 5 SEC
4 OFF
5
5 SEC
OFF
10 SEC 3 SEC
5) Side Glue Supply Unit OK
2
1. Perform the set ups as described in Save the new setting and
Section 4-3. return to the Main screen
2. Press OK .
- The optional device setting is input There may be other optional devices
and the Main screen appears. such as the delivery conveyor, or the
milling blower unit. Since these are not
usually installed with the SB-15, they
are treated as user options.
8 Set up the cover feeder

- Set up the cover feeder.
1. Set up the following parts. See the

1) Side guide adjustment

2) Feed table height adjustment
3) Suction cups positioning adjustment
4) Double feed stop screw projecting
length adjustment
5) Blower air adjustment
6) Plugging unused suction cups
7) Scoring roller adjustment Test Feed Screen
2. Perform a test binding. See Section 4-10- 3200 sheets/h

3.
10 sheets
OK OK OK
0% 98% 96% 80% 80%
OK OK OK OK OK
86% 92% 93% 88% 98%
33
9 Confirm the setting for each part
- Run the following test and check that

each part of the machine is set up
correctly.
- Check using the tables in Section 3-2.
10 Perform a test binding
1. For testing, select on the Function Main Screen

screen to check the binding quality.
12
(mm) 3
(mm) (mm)
5.906 inch 1400
(mm) 5200 books/h
1000 rpm
- Using the SB-15 only 7.087 inch

(mm)
9.055 Function Screen
15.748 inch
(mm)
(Single)
- Using the SB-15 in a system 1 1 2
ON ON ON
HT with the three-knife trimmer. HT

OFF OFF OFF
1 MG MG+HT
ON ON OK 80% ON
- Using the SB-15 in a system OFF OFF OFF
MG
with the gatherer.
OK
- Using the SB-15 in a system

MG+HT
with the gatherer and the
three-knife trimmer Start Button
2. Press the start button on the control

panel. 2
3. Insert the book block into the clamp.

- Check the binding quality by repeating
these procedures for several books.
4. If there is a problem with the binding

quality, go to Chapter 4 and make the
necessary manual adjustments.
34
11 Start the binding operation

Function Screen
(Selecting system configuration)
1. Select the correct system configuration
on the Function screen shown in the ON ON ON
figure to the right, and press the start HT
OFF OFF OFF
button on the collator. MG MG+HT
ON ON OK 80% ON
OFF OFF OFF
OK
35
3-4 Finishing Binding
Error Screen
1. Press the finishing icon shown in the 0.394 inch
(mm)
12
3
0 book(s)
figure to the right. 8.268 inch

(mm) 7.874 inch
(mm)
0 book(s)
1400
5.906 inch
(mm) 5200 books/h
1000 rpm
- Press the finishing icon in the lower 9.055
7.087 inch
right corner of the touch panel. (mm)
15.748 inch
(mm)
- The Finishing screen appears.
1 2
Finishing Screen
1
2. Press OK on the Finishing screen.
- The hourglass appears on the screen.

OK?
- If you want to interrupt the binding
operation, press on the Finish-
ing screen. The Main screen appears. OK
Hourglass Screen
2
0.394 inch 12 0 book(s)
3.
(mm) 3
Wait until the hourglass on the screen 8.268 inch

(mm) 7.874 inch
(mm)
0 book(s)
1400
disappears. 5.906
5200 books/h
1000 rpm
230.0
- While the hourglass is indicated on the 7.087
15.748
screen, the binding conditions and the inch
information about the adjustments is (mm)
input. After all of this information has 1 2
been input, the OK screen appears.
OK Screen
OK
Main
4. Turn OFF the switches controlling the Switch
power.
- When using the weekly timer, do not Weekly

turn off the main switch. If the main Timer
switch is turned off, the timer function Power
can not be used. Switch
- If you are not using the weekly timer,
will not be using this machine for a
long time, turn off the main switch too.
36
3-5 If A Problem Occurs

3-5-1 Pole Lamp
Appears if the cover is opened

Red Appears if stop button is pressed
Appears if a problem occurs
Appears while melt tank is heating up
Appears when the machine is stopped

Yellow
Appears while the clamp is rotating
Appears when the machine is running without
producing books
Green = Appears when the machine is producing books
Yellow and
Green = Appears when the machine is stopped and
ready to begin binding
3-5-2 Buzzer
When the supply of book blocks is less than 0.78" (20mm) thick, buzzer
Automatic Stop
Pattern 1 pattern 1 sounds from the moment the 18th clamp clamps until the clamp
Notice
rotation stops.
Not Enough Buzzer pattern 2 sounds when the stack of cover sheets on the cover feeder
Pattern 2
Cover Sheets becomes less than 0.78" (20 mm)
Buzzer pattern 2 sounds when the surface of the glue in the melt tank
Not Enough Glue
becomes lower than the minimum line.
During
Automatic After the book block size is input, each part of the machine is set
Pattern 3 Setting automatically to the correct position. During automatic setting, buzzer
During Milling pattern 3 sounds.
Cutter Operation
When the start button is pressed to start binding, buzzer pattern 4 sounds to
Pattern 4 Start Binding
warn people around the machine.
37
3-5 If A Problem Occurs (Continued)

3-5-3 Using The Remote Control
- The remote controls can not be used if
There are two kinds of remote controls lo- any safety cover is opened.
cated at the positions shown in the figure - The remote controls can be used even
below. if the melt tank is not heated up to the
pre-set temperature.
J B
W D N A Q H
U
S B - 1 5
MG-60
Collator R S L M G Y
Remote Control For

Guide Width
Remote Control For

Clamp Rotation
Open the guides to
the maximum width Control Box
Activation Switch
Guide returns to
ON
the pre-set position OFF
When this button is Reset

pressed, the guides Rese
t
Inching
open to the home Operation
position, then close to Button
g
the pre-set position. Inchin
3-5-4 Using The Manual Operation Handle
CAUTION
Be sure to turn off the power
before doing this. Otherwise, a
sudden start of the machine
can cause severe personal
injury.
- The clamp can be rotated manually.

- Turn the manual operation handle Manual
counterclockwise. The clamp will Operation
rotate clockwise. Handle
38

This section explains how to set and adjust the machine.
4-0 Outline - Setting Each Section ......................................................................... 40
4-1 Automatic Setting And Book Size Input Interface ......................................... 42
4-2 Setting The Machine Functions ........................................................................44
4-3 Setting The Optional Devices ............................................................................45
4-4 Setting The Infeed Section ................................................................................46
4-5 Setting The Level Plate (Hand Feed Section) ..................................................50
4-6 Setting The Clamp Section ................................................................................54
4-7 Setting The Milling Section ............................................................................... 56
4-8 Setting The Glue Tank Section ......................................................................... 59
4-9 Setting The Side Gluing Section ....................................................................... 68
4-10 Setting The Cover Feeder ............................................................................... 74
4-11 Setting The Scoring Rollers ............................................................................82
4-12 Setting The Cover Sheet Transport Section ..................................................87
4-13 Setting The Cover and Book Registering Section ......................................... 89
4-14 Setting The Nipping Section ........................................................................... 91
4-15 Setting The Delivery Section ........................................................................... 94
4-16 Setting The Twisting Conveyor Section ......................................................... 96
39
4-0 Outline - Setting Each Section

4-0-1 Setting parts automatically
The actual binding operation is performed automatically by this machine. For automatic
binding, each part of the machine must be set according to the following procedure.
Some critical parts must be set every time the binding size changes. These are set automatically
when the binding size is input. These sections are indicated by AUTO in the figure below. The
other parts must be set manually. These sections are indicated by in the figure below.
Whole System Overview Twisting Con- Milling Blower Unit (option) AUTO
veyor Section Cover
AUTO
Bad Book Sorter (option) Sheet
AUTO Z Cover and Transport
Delivery
Delivery Book Section Cover
Conveyor Weight AUTO
Section Nipping Registering Feeder
Checker Section
(option) Section
J B
Delivery H
U W D N A Q
Conveyor
C
S B - 1 5 Book Size
MG-60H Input
Gatherer R S L M G Y Interface
Glue Side
Connecting Level Plate Tank
Book Block Height Gluing
Unit Infeed Section Section
Detect Sensor Milling Section
AUTO AUTO
Section Clamp Section AUTO
AUTO AUTO
Section
AUTO Electrical
Control Panel Box
Parts Adjusted Manually
Section Code
L Level Plate Section Level Plate Height, Milling Width, Support Plate Position
M Milling Section Milling On/Off
G Spine Gluing Section Glue Temperature, Gluing Roller Height, Wiper Opening
H Cover Sheet Air Pressure, Suction Cup Position, Double Feed Stop Screw Extension Length
Transport Section
Scoring Roller Position, Blower Air Position, Press Roller Balance
A Cover Sheet
Register Section Cover Register Position
N Nipping Section Parallel, Tilt, Height
Twisting Conveyor
Section Guide Position, Angle
Book Block Height
Detect Sensor Detecting Sensor Position
Book Block
S Entrance Section Guide Position
Y Side Gluing Section Gluing Roller Height
40
4-0 Outline - Setting Each Section (Continued)

4-0-2 Input from the touch panel screen
Set the following parts on the touch panel

display: 1. Book Size Input Screen
1. Input the block size
2. Set the machine functions inch
10.0 (mm)
3. Set the optional devices
inch
(mm) 200.0 inch
(mm)
0.394 inch 12 0 book(s) 120.0 (mm)
inch
(mm) 3
1
(mm) (mm)
1400
5.906 inch 230.0
(mm) 5200 books/h inch
(mm)
1000 rpm
9.055
8.087 inch 400.0 mm
(mm)
15.748 inch
10.0 inch
(mm)
(mm) OK
inch
(mm) 200.0 inch
2
(mm)
1 3 2
inch
(mm)
230.0 inch
(mm)
130.0 (mm)
inch
400.0 (mm)
inch
OK
Input the size of the book block and cover

sheet.
ON ON ON
HT There are two kinds of screen used to input the
OFF OFF
OFF
book size according to the relation between the
MG MG+HT
book block and the cover sheet. Refer to Sect.
ON ON OK 80% ON
4-1 for details.
OFF OFF OFF
The block size can be input using the optional
book size input interface. (Refer to Chapter 8.)
OK
ON ON ON ON
2. Function Screen OFF OFF OFF OFF
This screen indicates the functions on the

machine. Press in the upper left part of this 1
ON
2
ON
screen to go to the Function screen. OFF OFF
10 SEC 3 SEC
5 SEC 5 SEC
OK
Set the machine functions from the list below:
See Sect. 4-2 for details. 3. Optional Device Screen
- Use the SB-15 as part of a system, or This screen indicates the optional devices
as a single binder connected to the SB-15. Press in the
- Side glue supply unit ON/OFF upper left part of this screen to go to the
- Partial gluing function ON/OFF Optional Device screen.
- Double feed detect function ON/OFF Set the optional devices mentioned below
- Misloading prevention function ON/ Refer to Sect. 4-3 for details.
OFF - Weight checker, Sorter
- Sheet length detect function ON/OFF - Infeed section air assist blower
- Pre-melt tank
- Side glue supply unit
41
4-1 Automatic Setting And Book Size Input Interface
Input the block size

Press in the upper left on the touch
panel screen. The Block Size Input screen
appears. 1
10.0 ch
m)
inch
(m 2
0.394 inch
(mm)
12
3
0 book(s) 3 200.0 inch
(mm)
8.268 inch 7.874 inch 0 book(s) 120.0 (mm)
inch
(mm) (mm)
(mm)
5200 6 4
1000 rpm 230.0 inch
mm)
5.511 inch 9.055
(mm)
5.070 inch
(mm)
15.748 inch
1
400.0 mm10.0
ch
m)
(mm)
in
(m) 3 2 200.0 (mm)
inch
OK
inch
(mm)
When entering
1 2
5 the book block
230.0
4 inch
7
130.0 inch
(mm)
(mm) size based on
1. Select the input screen.
400.0 inch
the center line.
- There are two different ways to input 8 (mm)
the book block size depending on the OK
presence of a center line on the book When entering the book block size
spine. based on the book block thickness.
- Press either icon shown in the figure to
the right to select the input screen. When entering the book block
size based on the center line.
2. Input the size.
- Press the number for the value you When entering the book block size
want to input. The number input key- based on the book block thickness.
pad screen appears.
- Input the value on the number input Value
keypad screen and press OK. (The any Setting
0.394 Keypad inch
(mm)
value which is out of range will not be
used.) 8.268 inch
Screen
(mm) 7.874 inch
- The value is entered. 5.906 inch

(mm)
CAUTION
230.0 mm
5.070 inch
The value of the fore-edge length (mm)
15.748 (mm)
is used for trimming. So if you are inch
using the SB-15 as a stand-alone OK
binder, skip step 3. OK
Input Items
Item Substance Range of Setting Value
1 Book Block Thickness Input the book block thickness 0.000"~ 1.969" (1mm~ 50mm)
Top-bottom Length
2 Of The Book Block Input the top-bottom length of the book block 5.315"~ 15.748" (135mm~ 400mm)
Fore-edge Length
3 Of The Book Block Input the fore-edge length of the book block 4.134"~ 12.992" (105mm~ 330mm)
Top-bottom Length
4 Of The Cover Sheet
Input the top-bottom length of the cover sheet 5.315"~ 15.748" (135mm~ 400mm)
Cover Sheet Left Side Of The Input the length from the left side of the cover sheet to the
5 Book Spine left side of the book spine 4.331"~ 12.205" (110mm~ 310mm)
Input the length from the left side of the cover sheet to the
6 Cover Sheet Center Frame center frame 4.331"~ 13.189" (110mm~ 335mm)
Cover Sheet Right Side Of The Input the length from the left side of the cover sheet to the
7 Book Spine right side of the book spine 4.331"~ 14.173" (110mm~ 360mm)
8 Cover Sheet Length Input the cover sheet length 9.055"~ 25.984" (230mm~ 660mm)
42
4-1 Automatic Setting And Book Size Input Interface (Continued)
0.394 inch
(mm)
3. Save the settings. 8.268 inch

(mm)
7.874 inch
(mm)
5.906 inch
(mm)
- After inputting the all of the items,

9.055 (mm)
inch
press OK in the lower right part of 7.087 inch

(mm)
the screen. The Transport Guide Con- 15.748 (mm)

inch
firmation screen appears. OK
Transport Guide Confirmation Screen

Press to go to the previous
screen.
Any value just input will not be memo-
rized.
Check that the cover sheet holder does not

4. Check the transport guide in the cover hit the transport guide while it is operating.
sheet transport section. OK
- Remove the cover sheet holder so that Automatic Setting Confirmation Screen
the cover sheet holder does not hit the
transport guide during the automatic
setting operation.
- Press OK on the Transport Guide OK?
Confirmation screen. The Automatic

Setting Confirmation screen appears.
Press the start button

5. Perform the automatic set-up. Confirms the on the control panel.
automatic setting
- Confirm the automatic settings after
the value have been input.
Automatic Setting Screen
- To perform the automatic set-up, press
the start button. The Automatic Setting
screen appears and the clamp starts to
rotate.
setting to the moving away

home position setting position
not complete
6. Automatic setting is completed. to set
Positioning Completed Screen

- When automatic setting is started, the
screen shown to the right appears. After
the set-up is complete, the Positioning
Completed screen appears.
OK
43
4-2 Setting The Machine Functions
Set the machine functions

Functions used for the previous binding operation are indicated in the lower left part of the
Main screen. Press in the upper left part of that screen. The following screen (the Func-
tion Screen] shows whether each function will be used. Turn each function ON or OFF
according to the table below. Then press OK to save the settings.
Function Screen
0.394 inch 12 0 book(s)
(mm) 3
8.268 inch 7.874 inch 0 book(s) ON ON ON
2
(mm)
1 3 4
(mm)
HT
5.906 1400 books/h OFF OFF
OFF
5200
1000 rpm MG MG+HT
5.511 inch 9.055
(mm)
7.087 (mm)
inch
ON ON 80 ON
15.748 (mm)
inch
5 OFF
6
5
OFF
7
5 OFF
1 2
OK
Functions used for the previ- The settings are not saved and The new settings are
ous binding operation are the previous screen appears. saved and the previous
indicated. screen appears.
Icon Subject Explanation
Set Single Use / Press if using the SB-15 in stand-alone mode .
System Use Press if using the SB-15 as a system including the
1 HT
HT
three-knife trimmer.
MG
Press MG if using SB-15 as a system including the gatherer.
MG+HT
Press MG+HT
if using SB-15 as a system including the
gatherer and the three-knife trimmer.
ON Side Glue Supply Unit Press ON when using the side glue supply unit.
2 OFF
Setting
3 This setting can not be changed by the operator.
Press ON to use the partial gluing function.

Partial Gluing Setting
ON Press OFF to use normal gluing.
4 OFF [CAUTION] When ON is selected, lower the milling ON/OFF lever
and adjust the glue cut wiper opening.
ON Double Feed Detect Press ON to use the double feed detect function.
Function Setting
OFF When ON is pressed, adjust the detecting sensitivity by pressing
5
and , low high.
ON OK80% Cover Sheet Press ON to use cover sheet mis-loading detect function.
OFF
Mis-loading Prevention When ON is selected, adjust the detecting sensitivity by pressing
6 Sensor Setting and , low high.
If ON is pressed, refer to Section 4-10-2 for details.
This function is used to detect a cover sheet shift or book block

ON shift by comparing the top-bottom length of the book block with
OFF Book Block Height the pre-set value.
7 Detect Sensor Setting Press ON to use this function.
When ON is pressed, adjust the detecting sensitivity by pressing
and , low high.
44
4-3 Setting The Optional Devices
Set the optional devices

"Optional device" means a device which is not
Optional devices used for the previous bind-
included with the standard machine.
ing operation are indicated in the lower part
of the Main screen. Press in the upper -Weight Checker, Sorter (1)
left part of that screen. The next screen - Infeed Section Air Pump (2)
(Optional Device Screen) shows which op- - Pre-melt Tank 1 (3)
tional device will be used. Turn each device - Pre-melt Tank 2 (4)
ON if necessary by following the table below. - Side Glue Supply Unit (5)
Then press OK and save the new settings.
Optional Device Screen
0.394 inch 12 0 book(s)
(mm) 3
(mm) (mm) ON
1
ON ON ON
5.906 inch
(mm)
5.511 inch 9.055

1400 books/h
5200
1000 rpm OFF 2 OFF 3 OFF OFF
(mm)
7.087 inch
(mm)
15.748 inch
(mm)
1
ON
2
ON
6
5
5 SEC
4 OFF
5 SEC
5 OFF
10 SEC 3 SEC
1 2
OK
Optional devices used for the previ- The setting is not saved and The setting is saved and the
ous binding operation are indicated. the previous screen appears. previous screen appears.
Icon Subject Explanation
This section measures the book block weight and
Weight Checker delivers the faulty book automatically at the sorter.
1 ON OFF Sorter Setting* Press ON to use these devices.
Refer to [Weight Checker], [Sorter] on chapter 8.
This device blows air from the guide plate on book block
In-feed Section entrance section to transport the book block delivered from the
ON
2 Air Assist Blower collator smoothly to the clamp.
OFF Setting Press ON to use this device.
This device jogs the book block being transported on the In-feed section.
ON Press OFF not to use this device when the small sheets are jogged
In-feed Section
3 OFF and are not arranged.
Jog Setting
Press ON to use this device.
1
ON Press ON when using the pre-melt tank at first tank while
the tank is separated into two section.
4 OFF Pre-melt Tank 1 Setting
Press to adjust the glue supplying start time.
5 SEC Refer to [Pre-melt Tank] on chapter 8.
2 Press ON when using the pre-melt tank at second tank while

ON
the tank is separated into two section.
Pre-melt Tank 2 Setting
5 OFF
5 SEC Refer to [Pre-melt Tank] on chapter 8.
ON Press ON to use the side glue supply unit which applies

OFF the side glue into the glue tank automatically.
Side Glue Supply Unit Press to adjust the glue supplying time.
6 Setting
10 SEC 3 SEC
While the is pressed, the glues continue to apply.
Refer to [Side Glue Supply Unit] on chapter 8.
45
4-4 Setting The Infeed Section

4-4-1 Parts Description Z
J B
U W D N A Q H
MG-60 R L M G Y
S
Lift Assist Section
Guide
Slope Transport
Section
Level Transport
Section
Lift Lever
This lever helps the book
block to transport onto the
level plate by lifting the
Hand Feed Mechanism On Level Transport Section rear edge of the book
The book block can be bound from here if it is a standard block.
binding operation. (5.827"- 4.134", 13.780"- 10.236")
(148 - 105, 350 - 260 mm)
Book Block Flow Diagram
Book
Block Lift Assist
Section
Level Transport Section Slope Transport Section

Connecting Infeed Section Level Plate
Unit Section
46
4-4 Setting The Infeed Section (Continued)

4-4-2 Setting the infeed section
This section receives the book block trans-

ported from the connecting unit and moves it
to the clamp.
Set the following parts:

(1) Set the transport section guide width.
(2) Adjust the transport guide width.
(3) Turn the infeed section air pump ON.
(4) Turn the jog ON.
1 Setting the transport section guide width

- The transport section guide width Book Block Guide (Fixed) Guide Width
(level transport section and slope trans-
port section) is set automatically to
match the book block thickness. Adjusting
- The guide width is set to the book Width
block thickness +0.197" (+ 5 mm). The Guide
width adjustment can be changed (Adjustable)
according to the book block condition.
NOTE
If a book block is damaged, it can not
be transported properly. In this case,
follow the instructions in the next
section and adjust the width. When the book block is curled
2 Adjusting the transport guide width
Main Screen
1. Press (manual adjustment) on the 0.394 inch 12 0 book(s)
control panel. 8.268 inch
(mm)
(mm)
7.874 inch
(mm)
3
0 book(s)
- The Manual Adjustment screen ap- 5.906 (mm)

inch 1400
5200 books/h Manual
1000 rpm
pears. 7.087 inch
9.055 Adjustment
(mm)
15.748 inch
(mm)
Screen
2. Press (transport section).
- The Transport Section Manual Adjust- 1 2
ment screen appears.

1
3. Press on the section and
adjust the guide width for the level 2
transport section.
- The value can be set from 0.390" to -
0.390" (10.0 to -10.0).
+0.000 +0.000 +0.000 +0.000
If the guide width in the level transport

section is set narrower than the guides 3
OK
on the connecting unit, a jam may

Transport Section Manual Adjustment Screen
occur.
47
4. Press on the section and

adjust the guide width for the slope
transport section.
- The value can be set from +0.390" to - +0.000 +0.000 +0.000 +0.000
0.390" (+10.0 to -10.0).
OK
4 5
- If the guide width is set too narrow Transport Section
compared to the guides in the level Manual Adjustment
transport section, a jam may occur. Screen
- If the width is set wider than the
clamp opening, a jam may occur.
5. Press OK.
- The new settings are saved and the
previous screen appears.
3 Turning the infeed section air assist blower on

Main Screen
The machine can be set to provide air from 0.394 inch
(mm)
12
3
0 book(s)
the guide on the infeed section. This will 8.268 inch

(mm)
5.906 inch
7.874 inch
(mm)
0 book(s)
1400
5200 books/h
prevent the book block from sticking to the (mm)
1000 rpm
guide section because of static electricity. 7.087 (mm)

inch
9.055
Optional Device
15.748 inch
(mm)
Screen
1. Press on the Main screen.
- The Optional Device screen appears. 1 1 2
ON ON ON ON
OFF OFF OFF OFF
2. Turn on the air section. 2

- The air comes from the guide on the 1
ON
2
ON
10 SEC 3 SEC
infeed section. OFF OFF
5 SEC 5 SEC
3. Press OK . OK
- The setting is saved and the previous 3

screen appears.
4 Turning the jog on

Main Screen
The machine can be set to provide the book 10.0 12
3
0 book(s)
block with the jog. When the small sheets are 210.0
150.0
200.0 0 book(s)
1400
5200 books/h
jogged and are not arranged, turn off the jog. 1000 rpm
230.0
180.0
400.0 Optional Device
1. Press on the Main screen. Screen
ON ON ON ON
2. Turn on the jog. OFF OFF OFF OFF
- The book block is jogged.

1 2
2
ON ON
3. Press OK . OFF OFF

10 SEC 3 SEC
- The setting is saved and the previous 5 SEC 5 SEC
screen appears. OK
48 3

Book
4-4-3 Bottom-up Section Block Clamp
A book block delivered from the slope trans-

port section is clamped by the clamp in the
level plate section. If the book block is short,
it may not be level when this happens. In this
case, the lift assist section helps the book
block to enter into the clamp by lifting the Level Plate
end of the book block. When the machine is Section
connected to the collator, the final lift func- Lift Assist
tion operates automatically. Section
1 When doing the manual binding
- When doing the manual binding (SB- Main Screen

15 is not connected to the collator), 0.394 inch
(mm)
12
3
0 book(s)
press on the Function screen. 8.268 inch

(mm)
5.906 inch
7.874 inch
(mm)
0 book(s)
1400
(mm) 5200 books/h
1000 rpm
9.055
7.087 inch
(mm)
15.748 inch
(mm)
1 2
Function Screen
ON ON ON
HT
OFF OFF OFF
MG MG+HT
ON ON OK 80% ON
OFF OFF OFF
- When doing the manual binding, the OK
lift assist section becomes level auto-

matically as shown in the figure to the
right.
Level Plate
Section
2 Adjusting the guide position

Guide Guide Set Screw
1. Loosen the guide set screw and adjust
the guide width.
- When using soft sheets, this adjust-
ment is necessary.
49
4-5 Setting The Level Plate (Hand Feed Section)

Automatic Binding J B
U W D N A Q H
MG-60 R S M G Y
Hand Feed L
Section Cover
Stop Bar
Clamp
Stop Button
Book
Block
Manual Feed Table
Level Plate
Place the bottom of the
book block here.
Manual Binding
Set the cover to this posi-

tion when doing the manual
feeding.
Manual Feed
Table
50
4-5 Setting The Level Plate (Hand Feed Section) (Continued)

4-5-2 Setting the level plate section
Clamp
Each book block transported to the clamp is
arranged in the level plate section, and then Book
clamped to be transported to the milling Block
section.
Level Plate
1 Adjust the height of the level plate

1. If there is a problem with the quality of
the book, change the milling width by
adjusting the level plate height. Follow
procedure 2. Book Milling
Block
The height of the milling cutter can not
be changed. Instead, change the milling
depth by lowering the level plate section Milling Level Plate
and the position of the book block as Width
shown in the figure to the right.
2 Manual adjustment of the level plate height
1. Press (manual adjustment) on the

control panel. Main Screen
- The Manual Adjustment screen ap- 0.394 inch
8.268 inch
(mm)
12
3
0 book(s)

pears. (mm)
5.906 (mm)
inch
(mm)
1400
5200 books/h Manual
2. Press (transport section). 9.055
1000 rpm
Adjustment
- The Transport Section Manual Adjust- 7.087 inch
(mm)
15.748 inch Screen
(mm)
3. Press for the section to 1 2
adjust the level plate height.

1
- The value can be set from +0.000" to 2
0.195" (+0.0 to 5.0 mm).
- Amount to lower the level plate will be
the milling depth.
- When you press or , the press plate
raises or lowers directly to the upper or +0.000 +0.000 +0.000 +0.000
lower limit so that it becomes easier to
take out a jammed sheet. OK
4. Press OK . 3
- The new setting is saved and the Transport Section
Manual Adjustment 4
previous screen appears.
Screen
51
4-5-3 Setting the hand feed section
This section explains how to feed the book Book

block into the clamp manually when not Block
using this binder as a part of system.
Clamp
Level Plate
Set Hand Feed

1. Set the hand feed section cover. Screw Section Cover
- Loosen the set screw and push the Stop Bar
hand feed section cover to the end.
Tighten the set screw again.
2. Lower the torque limiter release lever.

- The transport hook in the transport
section is locked.
3. Set the milling width.

- Set the milling width as described in
procedure 2. Follow steps 1 through 4
on the previous page.
Torque Limiter Release Lever
52
4-5-4 When using thin book blocks Manual

Feed Table
When binding a thin book block (a few mm)
including heavy sheets such as coated paper,
the bottom of the book block may be bent on the
level plate. If this happens, attach the support
plate.
Backing Backing Support

Plate Plate Plate
If the support plate is not used when
binding a thin book block with heavy
sheets, the milling can not be performed
properly, and the binding quality will be Without With Support
poor. Support Plate Plate
1. Open the milling section cover.

- The level plate section can be seen from
the bottom of the hand feed section.
Backing
Plate
2. Attach the support plate.
- Attach the support plate so that there is a

distance of +0.197" (+ 5 mm) between
the backing plate and the support plate.
Support
- Adjust the space between the backing Level Plate Plate
plate and the support plate depending on
the book block thickness and the sheet
weight.
53
4-6 Setting The Clamp Section

4-6-1 Parts Description
Z
J B
U W D N A Q H
MG-60 R S L M G Y
C
Clamp Locating Hole

This hole is used to
attach the clamp to
the main body.
Support Plate
Attach this plate when
binding soft sheets.
Connecting Brace
Press this mechanism Front Frame
using the cam plate (Adjustable)
to open the clamp. The opening of this
section is adjusted
automatically accord-
Lock ing to the book block
width.
Positioning Hole
Gear Guard
Bottom View
Grease Nipple
Apply grease here to
lubricate the lock section. Pressed Plate
This part is pressed during
the milling operation.
54
4-6 Setting The Clamp Section (Continued)
4-6-2 Setting the clamp section
This section clamps the book block which is

arranged in the level plate section, and trans-
ports it to the milling section.
1 Setting the clamp width

- The clamp width is set automatically
according to the book block thickness.
- You can fine-tune the setting for the
clamp width.
NOTE
If the book block is bent, it can not be
transported properly. In this case, go to
the next procedure and increase the
clamp width.
When the sheets are curled

2 Adjusting the clamp width
1. Press (manual adjustment) on the Main Screen

Touch Panel screen. 0.394 inch 12 0 book(s) Manual
- The Manual Adjustment screen ap-
(mm) 3
Adjustment
(mm) (mm)
5.906 inch 1400
(mm) 5200 books/h
pears. 7.087 inch

(mm)
9.055
1000 rpm
Screen
inch
15.748 (mm)
1 2
2. Press (clamp section).

1
- The Clamp Width Manual Adjustment
2
screen appears.
3. Press and increase the clamp width.
= Wide = Narrow +0.0
OK
- 3
The width can be set from 0.390" to - Clamp Width Manual
0.390" (10 to -10 mm). Adjustment Screen
NOTE
When rotating the clamp after this
adjustment, you may hear the clamp
opening and closing during first rota-
tion, but this is normal.
55
4-7 Setting The Milling Section

J B
U W D N A Q H
C
MG-60 R S L G Y
M
Milling Guide (Fixed)
Cutter
Press Rollers
These press the lower part Milling Box
of the clamp to perform the
milling operation correctly. Milling Guide (Adjustable)
Milling ON/OFF Lever

When not doing milling,
turn this to the right to
lower the milling cutter.
Upper Knife
The milling
operation is Press Roller Lock Lever
performed by the When removing the cutter, turn
cutter and the this lever to the right to release
upper knife. the lock on the press roller.
Milling Width Adjusting Shaft

This shaft moves the milling guide
and the press roller on the
operator's side of the machine.
Manual Handle
Slide Lock Lever

Lock the milling unit at the
bottom position using this lever.
Release this lever and insert the Milling Unit Removal Shaft
manual handle to pull out the Insert the manual handle to pull
milling unit when replacing the out the milling unit. Use this
cutter. shaft when replacing the cutter.
56
4-7 Setting The Milling Section (Continued)

4-7-2 Setting the milling section
A book block which has been clamped at the

correct height over the level plate section is
held by the press roller. It is then milled on the
bottom by the milling cutter and the roughen-
ing cutter.
Set the following functions: Press Roller

(1) Set the milling guide plate width [AUTO]
(2) Milling cutter rotation speed
(3) Milling on/off
1 Setting the milling guide width [Auto]
- The press roller and the guide plate are
set automatically according to the book
block size. Press Guide
- You can fine-tune the milling width Roller Plate
adjustment.
Clamp Milling
Guide
Width
Press Roller
Milling Cutter
2 Adjusting the milling guide width
Main Screen
1. Press (manual adjustment) on the 0.394 inch
(mm)
12
3
0 book(s)
Main screen. 8.268 (mm)

inch
5.906 inch
7.874 inch
(mm)
1400
0 book(s)
5200 books/h
- The Manual Adjustment screen appears. (mm)
1000 rpm Manual

7.087 inch
(mm)
9.055
Adjustment
2. Press (milling section). 15.748 inch
(mm)
Screen
- The Milling Section Manual Adjustment
screen appears. 1 2
3. Adjust the milling guide width by pressing 1

and .
- The value can be set in increments of 2
0.004" (0.1 mm)
- The value can be set from 0.390" to -
0.390" (10 to -10 mm).
= Wide = Narrow
+0.000
4. Press OK to save the setting.

3 OK
4
Milling Section Manual Adjustment Screen
57
4-7 Setting The Milling Section (Continued)
3 Setting the milling cutter rotation speed
- There are two roughening cutters Roughening

attached to the milling cutter. (Up to 4 Cutter
roughening cutters may be installed.)
- The roughening cutters make grooves
on the book spine. When these grooves
are glued, they reinforce the spine.
- The pitch of the groove can be ad-
justed separately from the milling cutter
Milling
rotating speed. If this is necessary,
Cutter
follow the procedures listed below.
0.394 inch 12 0 book(s)
(mm) 3
NOTE 8.268 (mm)
inch 7.874 inch
(mm)
0 book(s)
Once the milling cutter rotating speed 5.906 (mm)
inch 1400 books/h
5200
has been set, it corresponds to the 1000 rpm
55.118 (mm)
production speed and keeps the pitch of 7.087 inch
(mm)
inch 9.055
the grooves uniform, even if the pro- 15.748 inch

(mm)
duction speed is changed.
1. Look at the Operating Condition screen 1 2
in the upper right part of the Main

screen.
- This screen indicates the present Main Screen
operating conditions.
12
3
0 book(s)
- The number next to shows the
milling cutter rotating speed. 0 book(s)
2. Press and at the section to 1400 books/h

change the milling cutter rotating speed. 5200
1000 rpm
- The rotating speed can be changed
from 1000 to 2500 rpm in increments Operating Condition
Screen Milling Cutter Rotating
of 100. Speed/(RPM).
4 Turning the milling operation off
-When doing the binding without mill-

ing, lower the milling lever 180 degrees.
This lowers the milling cutter so that the
book block will not be milled. Milling On
NOTE
When the milling operation is turned
Off, the level plate height is set zero
automatically.
Milling Off
58
4-8 Setting The Glue Tank Section

Z
J B
U W D N A Q H
C
MG-60 R S L M Y
Application Drum 2 G
Wiper 2
Application Drum 1 Wiper 3 Application Drum 3

Scrape Roller
Wiper 1
Wiper 1 Side Gluing
Adjust Section
Section
Wiper 2
Adjust
Section
Scale Label
Wiper 3 Adjust Section
Drain
(inside) Connection To The
Drain the glue Pre-melt Tank (Inside)
from the tank
using this
outlet.
Melt Tank Up/Down Handle

This handle is used when replac-
ing the glue in the melt tank.
Scrape Roller
Height
Application Drum 3 Adjustment
Handles
Application Drum 2
Application Drum 1
59
4-8 Setting The Glue Tank Section (Continued)

4-8-2 Setting the Glue Tank Section
Application Drum
- This section applies glue to the book Book Wiper Scrape Roller
spine using three application drums, Block
and levels the glue using a scrape roller.
- The timing used to apply glue to the
book block is set automatically for each
wiper.
Set the following items: Separation wall (The melt tank

(1) Select the glue can be separated into two
(2) Select the tank sections using the separation
(3) Decide whether to use the pre-melt tank wall.)
(4) Do the temperature setting for each tank
(5) Do the height setting for each tank
when necessary, set the following items
also:
(6) Glue application length
(7) Wiper opening
(8) Bottom edge adjustment
1 Select the glue

- Two different kinds of glue can be
used on the book spine. - The glue listed below is put inside the
- Remove the value when the sections of tank at the factory:
the melt tank are not separated. (The Spine Glue: Horizon [HM-220]
value is not in place when the machine Side Glue: Horizon [HM-403]
is first installed.) Select the glue ac-
cording to the book size, sheet quality,
and required spine strength.
2 Select the tank to use

- Insert the optional valve into the gate
when using two kinds of glue.
- On the first drum, use a glue which
penetrates the book spine quickly. If
desired, you may use a different kind of
glue on the second and third drums.
CAUTION
Do not touch the melt tank.
The melt tank is heated up to
Valve
approximately 200 ˚C (400˚F).
It can cause severe skin burns.
The figure indicates the closed position
60
3 Using the pre-melt tank
When using the optional pre-melt tank, refer to

Chapter 8 for instructions on the setting up the
pre-melt tank. Pre-melt Tank
Main Screen Setting
1. Press on the control panel. 0.394 inch
(mm)
12
3
0 book(s)
(mm) (mm)
5.906 inch
(mm)
1400
5200 books/h Optional Device
- The Optional Device screen appears. 9.055
1000 rpm
Screen
7.087 inch
(mm)
15.748 (mm)
inch
ON ON ON ON
2. Press the ON button for the pre-melt tank. 1 1 2
OFF OFF OFF OFF
- The ON section turns green, and the pre-

melt tank is ready for use. 1
ON
2
ON
10 SEC 3 SEC
OFF OFF
5 SEC 5 SEC
OK
If the pre-melt tank is not installed, you 4

cannot do the pre-melt tank setting. 1 ON
2
3. Press or and set the glue supply- OFF
ing start time (in seconds). 20 S
- Set the waiting time from pressing the
binding start button. The glue is not 3
supplied during the waiting time although Pre-melt Tank Set
the glue amount is less. Screen
- This is set to 10 seconds at the factory.
- The value can be set between 10 to 60
sec.
4. Press OK .
- The setting is saved and the previous
screen appears.
61
4 Temperature setting for each tank
1. Press (manual adjustment) on the touch Main Screen

panel screen. 0.394 inch 12 0 book(s)
(mm) 3
8.268 (mm) 0 book(s)
Manual
inch 7.874 inch
(mm)
5.906 inch 1400
(mm) 5200 books/h
- The Manual Adjustment screen ap- 9.055
1000 rpm
Adjustment
pears. 7.087 inch
(mm)
15.748 inch
(mm) Screen
2. Press (glue tank section). 1 2
- The Glue Tank Section Manual Adjust- 1

ment screen appears. 2
3. Press or beside 180 .
- This inputs the temperature for melt +0.000 +0.000 +0.000 +0.000
tank 1.
- The temperature can be set between 1
0 180
150˚ and 200 ˚C (300 to 400 ˚F). 2 0 180

3
3 0 170
- The temperature of each tank during

the binding operation is shown this way: OK
1 4
Glue Tank Section Manual
180 Adjustment Screen
- The pre-set temperature is indicated on
the side of the electrical box. (The Set Temperature
temperature can not be set from the
panel on the electrical box).
4. Press OK .

screen appears.
62
5 Setting the drum height for each tank
- Set the height of each drum and the Scrape Roller

scrape roller separately.
- If the height of a drum is low, there
will be a large gap between the book
spine and the drum and the glue appli-
cation will be thick.
CAUTION
Set the drum height
adjustment when the glue in
the tank is melted completely. Drum Height Set Dials
Do not turn the tank up/down
knob while the glue is cool.
This can damage the machine.
Scrape Roller
1. Loosen the locking knob.
- Loosen the locking knob on the drum Tank Up/Down
height set dial to change the drum Knob
height. Scale
- The drum height set dials are arranged Locking
in the same order as the drums. Knob
2. Turn the tank up/down knob. Milling Cutter The number of the scale
- Each division on the scale is equal to 1
mm (0.04").
S
- The larger the number on the scale
(up/down knob is turned clockwise),
the lower the drum height and the more
glue is applied.
- Refer to the table below for some
normal settings.
Scale Role
Drum 1 0 to 0.5 Rub the glue into the book spine
Drum 2 1 to 1.5 Apply the glue on the book spine
Drum 3 1.5 to 2 Apply more glue on the book spine
Scrape Roller 1.5 to 2 Scrape the excess glue off of the book spine
When the scale is set higher than 2,

applied glue may drip, depending on the
glue type. In this case, the setting does
not correspond with actual amount of
glue applied.
63
6 Setting the glue application length (Start position)

- The glue application length is set
automatically according to the book
block size, but this can be adjusted if
necessary.
- The glue application length is set by Wiper
the wiper open/close timing. The timing
to start applying glue is set on the Glue Application
control panel. The end position is set by Length Drum
changing the mechanical settings. Refer
to procedure 4-8-8. (Normally, it is not
necessary to change this.)
Main Screen
0.394 (mm)
inch 12 0 book(s)
3
8.268 (mm)
inch 7.874 (mm)
inch 0 book(s)
5.906 (mm)
inch 1400
1. Press (manual adjustment) on the 5200 books/h

1000 rpm Manual
touch panel screen. 7.087 (mm)
inch
9.055
Adjustment
- The Manual Adjustment screen ap- 15.748 (mm)
inch
Screen
pears.
1 2
2. Press (glue tank section).

- The Glue Tank Section Manual 1
Adjustment screen appears.
2
3. Press or .
+0.000 +0.000 +0.000 +0.000
- The start position for the glue applica-

tion changes. The end position does not
1
change. 3 178 180
- The value can be changed from 0.390" 2 182 180
to -0.390" (10.0 to -10.0 mm). Check
168 170
the binding condition and adjust the 3
value if necessary.
OK
Glue Tank Section

Manual Adjustment
Screen
64
7 Adjusting the wiper opening

- Adjust the wiper opening width for Dials Attached To The Adjusting Screws
each drum separately. This sets the glue
application thickness for each drum.
- Turn the gap adjusting screw to adjust
the wiper opening.
CAUTION
Set the drum height adjustment Point the correct
when the glue in the tank is setting at the notch
melted completely. 0.8
Do not turn the tank up/down
0.4
1.2
knob while the glue is cool. 1.6
This can damage the machine.
1. Set the drum height to 0. Clamp Rotation Switch

- Set the scale for each drum to 0. See
Section 4-8-5, "Setting The Height For
0.394 inch 12 0 book(s)
(mm) 3
(mm) (mm)
1400
5.906 inch
5200 books/h
Each Tank". (mm)
9.055
1000 rpm
2. Move the clamp.

7.087 inch
(mm)
15.748 inch
(mm)
- Turn on the clamp rotation switch on

the control panel.
1 2
- Press the start button. The clamp will

move into position.
3. Insert the Allen wrench into the hole in Stop Button
the end of the adjusting screw, and turn Drum
the gap adjusting screw. Wiper
- Insert the Allen wrench (supplied) into Allen
the hole on the screw shown as in the Wrench
figure to the right. Gap Adjusting
- The more the gap adjusting screw is Screw
turned clockwise, the smaller the gap
between the drum and the wiper, and the
less glue is applied.
- The scale is used for setting the wiper
adjustment. Stopper
CAUTION
Clockwise
When turning the Allen wrench
clockwise, do not turn it further Narrow
than the point where the wiper
touches the drum. Otherwise, the Wiper
drum may be damaged or the
mechanism may be broken. Scale Drum
NOTE
One rotation of the gap adjusting screw
changes the wiper opening by 0.063"
(1.6 mm). One rotation makes the wiper opening 1.6 mm
(0.063") narrower.
65
8 Adjusting the bottom edge
- The bottom edge setting (standard

position) to apply glue does not change
according to the book block size. The Book
bottom edge will not need to be ad- Block
justed for normal operations.
- If necessary, adjust the bottom edge by
following the procedures listed below. Bottom Cover Sheet
This will move the cover sheets out in Edge
relation to the book block.
1. Insert the Allen wrench into the lower

hole shown in the figure to the right.
- Loosen the set screw using the sup-

plied Allen wrench. It is not necessary
to remove the set screw. Just turn it one 2
half of a turn. 1
2. Turn the adjusting screw.

- Insert a standard screwdriver into the
slot in the center of the adjusting dial,
and turn the screwdriver.
- Turn the screw clockwise to move
back the bottom edge. Mounting
Block
CAUTION
The adjusting screw has no
stop. Do not tighten it too
much. Rotating it 90 degrees
will be enough.
66
9 Turning the partial gluing function on or off
1. Lower application drums 2 and 3.
1) Loosen the set screw.

- Loosen the set screw of the drum
height set dial to change the drum
height.
- The drum height set dials are arranged
in the same order as the drums.
2) Turn the up/down knob.

- 1 scale (division) is equal to 1 mm Drum Height Set Dial
(0.04"). Section
- The larger the number on the scale
(up/down knob is turned clockwise),
the lower the drum height and the more
glue is applied. Up/Down
- Refer to the table below to set up for Knob
normal operations.
Set
Drum 2 Drum 3 Scrape Roller Scale Screw
2 2 2 Drum
Wiper
2. Close wipers 2 and 3. Allen
Wrench
- Insert the supplied Allen wrench into Gap Adjust
the adjusting screw shown in the figure Screw
to the right.
- Turn it clockwise to decrease the gap
between the wiper and the drum and
reduce the glue application thickness.
Stopper
CAUTION
When turning the Allen Clockwise
wrench clockwise, do not turn
Narrow
it further than the point where
the wiper touches the drum. Wiper
Otherwise, the drum may be
damaged or the mechanism
may be broken. Drum
3. Perform the binding operation using tank

1 only.
One rotation makes the wiper opening 1.6 mm
(0.04") narrower.
67
4-9 Setting The Side Gluing Section

J B
U W D N A Q H
C
MG-60 R S L M G
Side Gluing Tank Y
Fixed Roller
This applies glue on
the bottom of the
book block using an
adjustable roller on
the operator side.
Scrape Roller
Side Glue Application Side Gluing Wiper Adjust Knob

Guide
This transports the glue
from the side glue supply Drain
unit to the side gluing
tank. Sensor
Fixed Roller Adjusting

Knob
Height Adjusting Handle

This moves the side gluing
section up or down.
68
4-9 Setting The Side Gluing Section (Continued)

4-9-2 Setting the side gluing section
- Apply glue to the spine area using a pair

of side gluing drums.
- The gap between the side gluing drums,
and the side gluing length are set auto-
matically.
Set the following functions:
(1) Decide whether to use the side gluing Side Gluing
function or not. Drum
(2) Select the glue being used
(3) Set the side glue supply unit ON/OFF
(4) Set the glue tank temperature Height
(5) Adjust the side gluing length
(6) Adjust the gap between the side gluing drums
(7) Adjust the side gluing height
- When using the side glue supply unit, it Length
should be set up using the control panel.
Refer to Section 4-3 "Setting The Op- Width
tional Devices".
1 Using the side gluing function
Main Screen
- Applying the side glue makes it easier to 0.394 inch
(mm)
12
3
0 book(s)
build the spine. 8.268 inch

(mm)
5.906 inch
(mm)
7.874 inch
(mm)
0 book(s)
1400
5200 books/h
1000 rpm
9.055
1. 7.087 (mm)
inch
Press on the touch panel screen. 15.748 inch

(mm)
- The Function screen appears.

1 1 2
2. Press ON on the (side gluing section). ON ON ON
- The [ON] section turns green and the HT

OFF OFF OFF
side glue supply unit is ready to be used. MG MG+HT 2

ON ON OK80% ON
OFF OFF OFF
3. Press OK .
screen appears. OK
3
Function Screen
2 Select the glue to use
- The glue is scraped and applied by the - Glue type Horizon HM-403 is filled
lower sections of the two drums. Select a in the tank when the machine is
glue which flows easily. shipped.
In summer time, if the glue does not
harden immediately and the spine of
CAUTION the book is torn, use the glue type
Do not use spine glue. Horizon HM-401 by itself or blend
with HM-403. The open time of the
HM-401 will be shorter than that of
HM-403.
69
3 Turning the side glue supply unit on or off

- The side glue supply unit detects the
glue level in the side gluing tank and
adds side glue automatically.
Side Glue
1. Press on the Main screen. Supply Unit
- The Optional Device screen appears.
2. Press ON on the section on the

Optional Device screen.
- [ON] turns to green and the side glue Main Screen
supply unit is ready. 0.394 inch
(mm)
12
3
0 book(s)
(mm)
Optional Device
(mm)
1400
5.906 inch
5200 books/h
3.
(mm)
Press or to set the glue supply- 1000 rpm

Screen
9.055
ing time. 7.087 inch
(mm)
15.748 inch
(mm)
- When the sensor detects that the glue ON

ON ON
level in the side glue tank is lower than
1 OFF OFF
OFF
2
the set-point, the side glue supply unit 1 2
supplies more glue. Set the side glue 1

ON
2
ON
10 SEC 3 SEC
supply unit operating time. OFF OFF
5 SEC 5 SEC
- A setting of 3 seconds is loaded when
OK
the machine is shipped.
- The value can be set between 1 sec. and 10 SEC 3 SEC 5
5 sec.
4 3
4. Press or and set the glue sup-
plying start time.
- Set the waiting time by pressing the
binding start button. The glue is not
supplied during the waiting time, even if
the glue amount is less than the set-
point.
- 10 sec. is loaded when the machine is
shipped.
- The value can be set between 10 sec.
and 60 sec.
While the is pressed, the glue

continues to be applied.
5. Press OK .
screen appears.
70
4 Setting the glue tank temperature

Main Screen
1. Press (manual adjustment) on the 0.394 (mm)
inch
8.268 (mm)
inch 7.874 (mm)
inch
12
3
0 book(s)
0 book(s)
control panel. 5.906 (mm)
inch 1400
5200 books/h Manual
- The Manual Adjustment screen appears. 9.055
1000 rpm
Adjustment
7.087 (mm)
inch
15.748 (mm)
inch Screen
- The Melt Tank Manual Adjustment 1 2
screen appears.
1
2
3. Press or to set the temperature.
- The value can be adjusted between 150 ˚
and 200 ˚C (300 to 400 ˚F).
- The temperature of the glue tank during +0.000 +0.000 +0.000 +0.000
binding is shown this way:

3 170 1
180 180
2 180
180
3 170 170
4. Press OK .
- The setting is saved and the previous OK
3
screen appears. 4
5 Adjusting the side gluing length
- The glue application length is set Main Screen

automatically according to the book 0.394 (mm)
inch 12
3
0 book(s)
8.268 (mm)
inch 7.874 (mm) 0 book(s)
block size, but it can be adjusted if 5.906 (mm)
inch
inch
1400
there are problems with the binding.

5200 books/h
1000 rpm
Manual
7.087 (mm)
inch
9.055
Adjustment
15.748 (mm)
inch
Screen
control panel.
- The Manual Adjustment screen ap- 1 2
pears.
1
2
- The Melt Tank Manual Adjustment
screen appears.
3. Press or on the section and
adjust the gluing length. +0.000 +0.000 +0.000 +0.000
- The value can be changed in steps of

0.004" (0.1 mm). Press + to increase 1
3 0 180
the gluing length. 2 0 180
- The value can be adjust 1.180" to - 3 0 170
1.180" (30 to - 30 mm).

4. Press OK . OK

screen appears.
71
6 Adjusting the gap between side gluing drums
Main Screen
- The gap between the side gluing drums is
0.394 (mm) 0 book(s)
set automatically according to the book inch
8.268 (mm)
inch 7.874 (mm)
inch
12
3
0 book(s)
block size, but it can be adjusted if there 5.906 (mm)

inch 1400
5200 books/h
Manual
1000 rpm
are problems with the binding. 9.055 Adjustment
7.087 (mm)
inch
15.748 (mm)
inch
Screen
control panel.
1 2
- The Manual Adjustment screen appears.
2. Press (glue tank section). 1

- The Melt Tank Manual Adjustment 2
screen appears.
3. Press or on the section and

adjust the gap.
- The value can be changed in steps of +0.000 +0.000 +0.000 +0.000
0.004" (0.1 mm). Press + to increase the

gap. 1
0 180
- The value can be adjusted from 0.195" to 2 0 3180

-0.195" (5 to -5 mm). 3 0 170
4. Press OK . OK

screen appears.
72
7 Adjusting the side gluing height
The side glue application height can be

adjusted from 0.118" to 0.276" (3 to 7 mm)
by moving the side gluing section up and Height
down. 0.118" to
0.276"
(3-7 mm)
1. Loosen the locking screw.

- Loosen the locking screw one rotation. Cover
Feeder
2. Turn the height adjusting handle.
- Turn the height adjust handle clock-

wise to lower the side gluing section.
- The height can be adjusted from

0.118" to 0.276" (3 to 7 mm) as shown
in the figure to the right. Locking
Screw
CAUTION
Height
Do not set the height above 6 Adjusting
mm. Otherwise, the side gluing Handle
tank may hit the clamp.
8 Adjusting the side gluing wiper opening

Side Gluing Wiper Adjust Knob
1. Turn the side gluing wiper adjust knob
on rear side and adjust the glue amount. Close
- The wiper closes and glue reduces
when turning the knob clockwise. Open
- The wiper opens and glue increases
when turning the knob counterclock-
wise.
2. Loosen the smaller screw on operation Rear Side
side once and tighten it little.
3. Loosen the bigger screw. Operation Side
4. Position the driver to cutout of the set Set Plate
plate and adjust the wiper by moving the
set plate. Bigger Screw
- Move the driver to right, and the wiper
closes and glue reduces. Smaller Screw
- Move the driver to left, and the wiper Cap Screw
opens and glue increases.
73
4-10 Setting The Cover Feeder

Whole Unit Z
H
J B
U W D N A Q
C
MG-60 R S L M G Y
Transport
Roller Pressure
Adjusting Knob
Pen Head Switch
Cover Sheet Hold-Down

Weight Pressure
Use this weight when there Release
are not many cover sheets Lever
Air Pump
Mis-feeding Receiving Tray

Mis-fed cover sheets enter here.
Side Guide AUTO
Stop Button
Cover Sheet Table
AUTO
Scoring Roller Shaft Blower Air Adjusting Knobs
A B
74
4-10 Setting The Cover Feeder (Continued)

Double Feed
Vacuum Parts Stop Screw
Separating
Adjustable Separating Part Parts
When the cover sheets are curled, both
side of the sheet can be held.
Blower Air Adjusting Section

Separation Hooks
These hooks separate the
sheets which have been
picked up by the suction
cups.
Separation Air Blower

This section blows air so
that the last sheet does not
Press Rollers
stick to the feed table.
This mechanism
Mis-loading transports the
Prevent Section cover sheet
This device reads which have been
the printing on the Feed Roller picked up by the
cover sheets and suction cups.
prevents mis- Suction Cup
loading. Grips the cover sheet from the
bottom
Blower Separation
Air Cover Hook
Nozzle Sheets Press Roller
Feed Roller
Suction
Cup
75

4-10-2 Setting Up The Cover Sheets
- The cover sheet is pasted to the glued book
block by adjusting the timing.
- The side guide and the feed table are set
automatically according to the cover sheet size.
- The cover sheet can be scored.
- The cover fed during the test operation is
Misfeed
delivered to the misfeed receiving tray. If Scoring
Cover Receiving
double feeding occurs, the cover sheets are Rollers Tray
also delivered to the misfeed receiving tray.
Side Guides
Set up the following functions:
(1) Adjust the side guides. Cover Feed
(2) Set the cover feed table height Table
adjustment.
(3) Adjust the position of the suction
cups.
(4) Adjust the projecting length of
the double feed stop screw.
(5) Adjust the blower air.
(6) Remove any unused suction cups.
(7) Set up the double feed detect function.
(8) Set up the mis-feed detect function.
1 Adjusting the side guides

Main Screen
The side guides are set automatically accord- 0.394 inch 12 0 book(s)
ing to the book block size, but they can be

(mm) 3
(mm) (mm)
5.906 inch 1400
(mm) 5200 books/h
adjusted if there is a problem with the bind- 9.055

1000 rpm
7.087 inch
ing. (mm)
15.748 inch
(mm)
Manual
Adjustment
1 2
Screen
control panel. 1
- The Manual Adjustment screen ap-
pears. 2
2. Press .
- The Cover Feeder Manual Adjustment
screen appears. +0.000
Cover Sheet
Width
3. Adjust the position of the side guides.
+0.000
3 +0.000 Adjustment
- Press or to adjust the position.
- Press or to adjust the width. +0.000
3
+0.000
- The value can be set between 0.390"
and 0.390" (10 to -10 mm). OK
Cover Sheet Width 4

4. Press OK . Adjustment
screen appears.
76
2 Adjusting the height of the feed table

Main Screen
- The feed table height is adjusted auto- 0.394 inch
(mm)
12
3
0 book(s)
matically according to the size of the (mm)
5.906 inch
(mm)
(mm)
1400
5200 books/h
1000 rpm
cover sheet, but sometimes it should be 7.087 inch

(mm)
9.055
adjusted manually depending on the

15.748 inch
(mm)
Manual
quality of the cover sheet and the feed- 1 2
Adjustment
ing conditions. Screen
1
2
Main screen.
2. Press .
- The Cover Feeder Manual Adjustment
screen appears. +0.000
3. Press or and adjust the feed table +0.000 +0.000

height.
- Press + to lower the table
+0.000
- The value can be adjusted from 0.390" +0.000
to 0.390" (10 to -10 mm).

4. Press OK . OK
3
- The setting is saved and the previous Height 4
screen appears. Adjustment
3 Adjusting the positions of the suction cups
- Adjust the upper limit of travel for the

Suction Cup
suction cups where they come closest to
the cover sheet.
1. Turn on the clamp rotation switch on the

control panel.
- The clamp will rotate.

- The suction cups move, but they don't
pull on the cover sheet. Suction Cup
Position
2. Load the cover sheets. Adjusting
Knob
3. Adjust the position of each suction cup
using the suction cup position adjusting
knob.
- Turn the knob counterclockwise to

bring the suction cup closer to the cover
sheet.
- Stop turning the knob at the position
where the suction cup almost touches
the cover sheet.
77
4 Setting the projecting length of the double feed stop screw

Double
- The double feed stop screw is used to
Feed Stop
separate the active cover sheet from the
Screw
cover sheets. Adjust the projecting length
of the double feed stop screw according Stop Block
to the type of sheet.
- If the top of the stack of cover sheets is
pressed against the stop block, or there is This part allows
a wide gap between the top of the stack only the active
and the stop block, adjust the projecting sheet to be trans-
length by following Section 4-10-2, ported
"Adjusting the feed table height".
1. Turn the manual operation handle.
- Turn the manual operation handle.
(Refer to Section 3-5-4) and release the
suction cups. Projecting
2. Adjust the projecting length of the double Length
feed stop screw.
- Turn the double feed stop screw using an
Allen wrench. Turn it clockwise to in-
crease the projecting length.
- When using thin cover sheets, set the
projecting length to 0.039" to 0.079" (1 to Mis-feeding may occur if the projecting
2 mm). When using thick cover sheets, length is set too long while using thick
set the projecting length to 0.000" to sheets.
0.039" (0 to 1 mm).
5 Adjusting the blower air
- The blower air blows from the upper

part of the cover feeder so that the cover Set Blower Air
sheet is fed from the bottom of the stack Screw Nozzle
of sheets.
1. Adjust the position of each nozzle.

- Loosen the set screw and blow some air,
then adjust the position and the direction
of the air nozzle to match the cover sheet
size. Blower Air
2. Adjust the blower air pressure. Adjust
- Check the cover sheet condition and Knobs
adjust the blower air pressure using the
blower air adjusting knob.
- If desired, turn each knob to the left to
stop the blower air.
78
6 Dealing with unused suction cups
- There are six suction cups which grip

the cover sheet. When using small
cover sheets, the outer suction cups are Cap
not used. The vacuum pressure de-
creases when there are unused suction
cups, so cover any unused suction cups
using cap.
7 Setting the double feed detect function

When using the double feed detecting func- Main Screen
tion, any cover sheets which are fed incor- 0.394 inch
8.268 (mm)
inch
(mm)
7.874 (mm)
inch
12
3
0 book(s)
0 book(s)
rectly will be delivered to the misfeed receiv- 5.906 (mm)

inch
1400
5200 books/h
1000 rpm
ing tray and the machine will stop. This 7.087 (mm)
inch
9.055
section includes set-up instructions for the 15.748 (mm)

inch
double feed detect function. Function Screen

1 1 2
1. Press on the Main screen. HT

ON ON
OFF
ON
OFF
OFF
- The Function screen appears. MG MG+HT
ON ON 80 ON
2. When using the double feed detecting OFF OFF OFF
function, press ON on the Function 2

screen as shown in the figure to the right. OK
- The ON indicator turns green and the 4

double feed detecting function is ready
to be used.
3. When ON has been pressed, press or

ON
to select the detecting sensitivity.
= Low sensitivity OFF
= Normal sensitivity
= High sensitivity
3
4. Press OK . Cover Sheet Double Feed
- The setting is saved and the previous Prevention Screen
screen appears.
When using embossed cover sheets or

when the ink is applied thickly, the
detecting function becomes unreliable.
Turn off the detecting function and the
detecting sensitivity adjustment depend-
ing on the printing conditions.
79
8 Setting the mis-loading prevention function

Main Screen
Set up the mis-loading prevention function. 0.394 inch
(mm)
8.268 inch
(mm) 7.874 inch
(mm)
12
3
0 book(s)
0 book(s)
This detects when the wrong cover sheets 5.906 inch

(mm)
1400
5200 books/h
1000 rpm
have been loaded. 7.087 (mm)

inch
9.055
15.748 inch
(mm)
Function
1. Press on the control panel. 1 1 2 Screen
- The Function screen appears.
2. Press ON on the Mis-loading Prevention HT
ON
OFF
ON
OFF
ON
OFF
Function Set-Up screen shown in the MG MG+HT
figure to the right. ON ON OK 90% ON
- The ON indicator turns green and the OFF OFF OFF
mis-loading prevention function is 2

ready to be used. OK
5
3. Press or to set the detecting
sensitivity.
4. Scan and save an image of the cover
sheet. ON OK 90%
(1) Load a cover sheet at the correct
position. OFF
(2) Press . OK appears over the
symbol. The image of the cover
sheet has been saved. If a cover sheet
which a different image is fed, the 3
sensor detects mis-loading and stops Mis-loading Prevention Function Set Up Screen
the collator. The binder keeps operating
until all of the bad books have been
delivered to the sorter.
NOTE
If only one cover sheet was mis-loaded,
a good book may be delivered as if it
was bad. Check each book in the sorter.
Mis-loading detection function can not

be used when there is no image on the Sensor
cover sheet, or the sheet is not within
the detection range of the sensor. Load
the cover sheets upside-down and check
to see if the image is detected before
beginning the binding operation. If the If the correct image of the cover sheet
image is not detected, the mis-loading has not been saved, the mis-loading
detection function can not be used. Be prevention function will not work even
careful when loading the cover sheets. if it has been turned ON on the control
panel.
5. Press OK .
screen appears.
80

4-10-3 Cover sheet test feeding
Main Screen
- Perform a test feed to check the settings for 0.394 inch
(mm)
12
3
0 book(s)
the cover feeder on the control panel. 8.268 (mm)

inch 7.874 inch
(mm)
0 book(s)
1400
5.906 (mm)
inch
- When using the double feed detection 5200 books/h

1000 rpm
function, measure the cover sheet thickness 7.087 (mm)

inch
9.055
and save it. 15.748 (mm)

inch
- The result of the test feeding will be indi-

cated on the touch panel screen. Make any 1 2
necessary adjustments after the test.

1
1. Press (cover sheet test feeding) on the Test Feeding Screen
control panel.
- The Test Feeding screen appears.
3200 sheets/h
2. Press 0000 3200 sheets/h and use or

to set the feeding speed. 2
10 sheets
- Set to the actual feeding speed.

- The value can be set from 1400 to 5200
OK OK OK
3
0% 98% 96% 80% 80%
book/h in steps of 100. OK OK OK OK OK
86% 92% 93% 88% 98%
4
The feeding speed corresponds to the clamp
speed. The cover sheets are fed at the same
speed as the book block production speed.
3. Press 1000 sheets and use or to Result Of Test Feeding

set the number of test feeds.
- The maximum value is 10. OK OK OK
0% 98% 96% 80% 80%
4. Press the start button on the control panel.
OK OK OK OK OK
- The machine starts to operate.
86% 92% 93% 88% 98%
5. Press (start). (Ex.) Result for ten test feeding
- The test feeding starts.
When the machine has made the correct OK = The cover sheet was fed
number of test feeds, the results will be properly
indicated on the touch panel. = The cover sheet was not fed
- The cover sheets will be delivered to the
misfeed receiving tray.
= Double feeding has occurred
86% = percentage of the test feed

CAUTION compared with the memory
Do not press before pressing
the start button on the control
panel. Otherwise, the fed sheet
will not be detected properly.
81
4-11 Setting The Scoring Rollers

(Upper)
Standard
Scoring
Rollers Locked Roller
(Drive Side)
(White Circle Mark)
Do not move.
Adjusting
Screw (Lower)
1 mm (0.039") of
(Upper)
opening is set at
the factory.
Adjusting
Movable Screw
Scoring Rollers
(Lower)
Mounting
Screw
(White Circle Mark)
Do not move.
rd
n da am 1 mm (0.039") of
t a tre
=S Side wn
s
a b opening is set at
Do ble
S rive
va the factory.
e
D
o
id
=M Side
r
e to
C A B D
id ra
S pe
O
This length "a" can be This length "b" can be

changed by loosening changed by loosening
the adjusting screw the adjusting screw
and moving the roller. and moving the roller.
Book Block Fixed Side Movable Side

Scoring Position Scoring Position
Cover Do not change the position This position changes to
of this roller, because it match the book block
aligns with the fixed side thickness. The position can
(rear side) of the clamp. be fine-adjusted.
The adjustable range
of "a" and "b" is from a b
5 to 9 mm
(0.197" to 0.354").
6 mm (0.039") is set
at the factory.
82
4-11 Setting The Scoring Rollers (Continued)

4-11-2 Setting the scoring rollers Standard
Scoring Roller Position
- The eight scoring rollers make four
scoring lines. The set of the movable
scoring rollers are set automatically to
match the book block thickness.
The set of the standard scoring rollers
are fixed to align with the clamp fixed
side.
CAUTION
Movable Side
Press the emergency stop Scoring Roller Position
button before performing the Drive Side Operator Side
operation. Otherwise, a sud- =Fixed Side =Movable Side
den start of the machine due
to the mis-operation can cause
severe personal injury. Pressing Knob
When the upper and lower rollers are

separated not to score the sheets, loosen Lock Knob
the lock knob, turn the "pressing knob"
as shown in the figure at right and raise
Scoring Roller
the scoring roller shaft so that the
Shaft
scoring rollers meet each other.
Set the following items of the scoring

roller section:
(1) Adjust the scoring distance
(Position B, AUTO)
(2) Adjust the fixed scoring position
(Position A)
(3) Adjust the length of "a" and "b".
1 Adjust the scoring distance (Position B)

a b
- The scoring distance (A-B) is set
automatically to match the book
block thickness. The position of B C A B D
can be adjusted according to the Main Screen
binding quality. 0.0
0.0 0.0
12
3 0 book(s)
0 book(s)
0.0 0 books/h
0.0 4000
0 rpm
0.0
0.0
1. Press (manual adjustment) on 0.0

Manual
the control panel. Adjustment
- The "Manual Adjustment Screen" Screen
1
appears.
2. Press . 2
- The "Cover Feeder Manual

Adjustment Screen" appears. 83

Cover Feeder
3. Adjust the position of B.
Manual Adjustment Screen
- Press in the figure to the right to +0.0 +0.0
adjust the distance.
- The value can be set between 10 and +0.0
+0.0 3
-10 mm (0.390" and -0.390").
+0.0
4. Press OK . +0.0
- The setting is saved and the previous OK
screen appears. 4
2 Adjust the fixed scoring position (Position A)
- The position A should not be changed, a b

because it aligns with the fixed side
(rear side) of the clamp. However, the
scoring position A on the cover sheet C A B D
can be moved by changing the position
of the cover sheet guide and cover side
guide.
Scoring Roller
control panel. Cover Side
- The "Manual Adjustment Screen" Guides
appears. The position changes
without changing the
width. Therefore, the
2. Press . length between cover
- The "Cover Feeder Manual Adjust- sheet edge and scoring
ment Screen" appears. line changes.
+0.0 +0.0
3. Adjust the position of A.
- Press in the figure to the right to +0.0
+0.0
adjust the distance.
- The value can be set between 10 and
+0.0
-10 mm (0.390" and -0.390"). 3 +0.0
OK
4. Press OK . 4
- The setting is saved and the previous If this position is adjusted,
screen appears. both the cover sheet guide
and cover side guide move.
Therefore, the scoring
position changes relatively.
84
3 Adjust the length "a" and "b"
1. Adjust the length "a" and "b".

- Although this length is set to 6mm
(0.039") at the factory, to change it,
Book Block
insert some sheets for the desired length
+ 1 mm (0.039") between lower scoring Cover
rollers and lock them.
The adjusting
Loosen this Insert sheets for the range of a and b is
screw and desired thickness from 5 to 9.0 mm
adjust. + 1 mm (0.039"). (0.197" to 0.354"). a b
6 mm (0.039") is
set at the factory.
Locked
(Do not loosen.)
Lower
Scoring Roller
(Standard Side)
Move these rollers.

The position of the upper scoring roll- (Upper Side)
ers is set to match the position of the
lower scoring rollers. Fixed
Upper scoring rollers are not locked to (Do not move.) Standard
Side
the shaft. Slide the upper scoring roller Scoring
while the upper and lower scoring Roller
rollers meet each other. (Lower Side)
Adjusting Screw Move these rollers.
(Upper Side)
Adjusting Screw
Movable
Side Mounting Screw
Scoring
Roller
(Lower Side)
Automatic
Adjustment
85

4-11-3 Scoring Roller Pressure Adjustment
- The sheets can be scored deeply by Checking Hole

pressing down the scoring roller shaft. The knob should be turned
- The lowering amount of the scoring only a little. Use it just for
roller depends on the cover sheet thick- reference to memorize the
ness. current position.
1. Loosen the lock knob and tighten the
pressing knobs.
- Tighten the right and left pressing
knobs evenly. If they are not tightened
evenly, the cover cannot be straightly
transported when passing it between the
scoring rollers.
Pressing Knobs
The pressing knob should be turned

within 30 degrees. If they are turned
more to increase the pressure, the cover
Lock Knob
sheet may be smeared with ink.
Scoring
Roller
Shaft
Use the checking hole on pressing knob
to check the tightened amount. The
checking hole can be turned to the
desired position after loosening the
screw on the top.
2. Fasten the lock knob.
Transport Rubber Roller
The scoring rollers meet each

other by their own weight.
86
4-12 Setting The Cover Sheet Transport Section

Z
Q
J B
U W D N A H
Chain
C
MG-60 R S L M G Y
Transport Hooks Cover Sheet Holder For

The cover sheets are Small Cover Sheets
transported by these Use this holder when using
hooks. small sheets and the stan-
dard cover sheet holder can
not be used. Move the
release lever to the right to
release the grip.
Release Lever
Cover Sheet
Register Section
Cover Sheet Holder
Transport Guide
Transport Guide (operator side)
(drive side)
Cover Sheet Holder (S)
Cover Sheet Holder (L)

Transport Guide
Entrance Section
87
4-12 Setting The Cover Sheet Transport Section (Continued)

4-12-2 Setting the cover sheet transport section
Fore-edge Glue
This mechanism receives the cover sheets
delivered from the cover feeder and transports
them to the cover and book registering sec-
tion.
Set up the following functions: Guide

(1) Adjust the guide position
(2) Set the cover sheet holder Scoring
1 Adjusting the guide positions

- The guide width is set automatically Main Screen
according to the cover sheet size, but it 0.394 inch
(mm)
12
3
0 book(s)
can be adjusted if the cover sheets are 8.268 inch

(mm) 7.874 inch
(mm)
0 book(s)
1400
not fed properly or the relation between 5.906 inch
(mm) 5200 books/h
1000 rpm
the book block and the cover sheet is not 7.087 inch
(mm)
9.055
correct. 15.748 inch

(mm)
1. Press (manual adjustment) on the Manual

control panel. 1 2
Adjustment
- The Manual Adjustment screen ap- Screen
pears. 1
2. Press on the Manual Adjustment
screen. 2
- The Cover Sheet Position Adjustment
screen appears.
3. Press or to adjust the guide position.
- The cover sheet position to the book block
changes, but the width does not change.
+0.000
+0.000 +0.000
When changing the guide position, the
position of the cover feed section should
be adjusted as well. If the relationship 3 +0.000
between the position of the cover feeder +0.000
and the cover sheet transport section
changes, jams may occur. 4 OK
4. Press or to adjust the guide width. Cover Sheet Position Adjust Screen 5
- Press to increase the guide width.
5. Press OK .
screen appears.
2 Setting the cover sheet holders

- Set the cover sheet holder so the cover
sheet can be transported to the cover
and book registering section properly. Cover Sheet Holder (S)
- Attach the weight into the cover sheet
holder (L) if the cover sheets bind and
shift when the stopper block on the Cover Sheet Holder (L)
cover and the book registering section
receives the cover sheet. 88
4-13 Setting The Cover and Book Registering Section

Z
A
J B
U W D N Q H
C
MG-60 R S L M G Y
Bottom Of The Clamp

The adjusting plate hits here
Adjusting Plate
Cover Stopper Block

Book Adjust the alignment between the
Block book block and the cover sheet
position by changing the stopper
block position. Use the stopper block
adjusting screw.
Stopper Block
Adjusting Adjusting Screw
Plate This screw adjusts
the stopper block
Clamp position.
Book
Block
The Relation Between The

Book Block, Cover Sheet, and
Adjusting Plate
89
4-13 Setting The Cover and Book Registering Section (Continued)
4-13-2 Setting the cover and book

registering section
This section receives the cover sheets trans-

ported from the cover sheet transport section.
Then this section combines the covers and
the book blocks before gluing.

(1) Adjust the position relationship between
the book block and the cover sheet.
(2) Adjust the tilt of the cover sheet.
1 Adjusting the relationship between the book block and the cover
- Adjust the position by turning both
adjusting screws in the same direction
by the same amount. Book
- Turn the adjusting screws clockwise to Block
delay the timing of the cover sheet.
- Turn the adjusting screws counter-
clockwise to advance the timing of the Play
cover sheet. Cover
- If an adjusting screw will not turn, turn Sheet
it using the supplied ball-point driver
(0.157")(4 mm).
The position relationship changes with Adjusting Stopper

the position of the cover sheet holder, Screw Block
or the weight on it. When binding more
than 4500 book blocks, use spine glue
which has a short open time.
2 Adjusting the tilt of the cover sheet
- If only the stopper block adjusting

screw on the operation side is turned
clockwise, the stopper block on the
operation side will move back and the
operation side of the cover sheet will be
delayed.
CAUTION
The adjustment for the cover
sheet tilt is limited because it
is corrected by the cover sheet
transport guides.
90
4-14 Setting The Nipping Section

N
J B
U W D A Q H
C
Tilt Adjust Section MG-60 R S L M G Y
(Base Side)
Lubrication Points
Fixed Nip Plate
Apply grease to the nip cam here.
Nip Plate Parallel

Adjustment
Nip Cam
Cover Sheet
Register Section
Tilt Adjust Section
Slide Rail
Adjustable Nip Plate
Shear Pin
91
4-14 Setting The Nipping Section (Continued)

4-14-2 Setting the nipping section
This section forms the spine of the book block

with the cover sheet attached to the cover by
the book registering section.

(1) Adjust the nip width.
(2) Adjust the nip height.
(3) Make the nip section tilt adjustment (height).
(4) Set the nip section parallel adjustment.
1 Adjusting the nipping width

The nip width is set automatically according Main Screen
to the book block size, but it can also be 0.394 inch
(mm)
8.268 inch
(mm)
7.874 inch
(mm)
12
3
0 book(s)
0 book(s)
1400
adjusted if the spine is not formed properly. 5.906 inch

(mm) 5200 books/h
1000 rpm
9.055
7.087 inch
(mm)
1. Press (manual adjustment) on the 15.748 inch

(mm)
touch panel screen. 1 2

Manual Adjustment
- The Manual Adjustment screen appears. Screen
1
2. Press .
2
- The Nip Section Manual Adjustment
screen appears.
3. Press or to adjust the nip width.
- The value can be input from 0.195" to
0.195" (5 to -5 mm).
CAUTION
When the nip width is set too
tight, the shear pin may break in 0.040 0.040
order to protect the machine.
4. Press OK . 3 OK
- The setting is saved and the previous Nip Width Adjustment 4

screen appears. Screen
2 Adjusting the nipping height
The nip height is adjusted according to the
type of spine.
1. Press on the touch panel display.
2. Press .
- The Nip Section Manual Adjustment
screen appears.
3. Press or to adjust the nip height. 0.040 0.040
- The value can be input from 0.010" to
0.055" (0.3 to 1.5 mm). 3
4. Press OK . OK
- The setting is saved and the previous Nip Height Adjustment 4

screen appears. Screen
92
4-14 Setting The Nipping Section (Continued)
3 Nipping section tilt adjustment (height)
If the nip condition is different at the top and

bottom of the book block, adjust the tilt to The nip plate is
correct the nip height. not parallel
1. Loosen the locking screw.
The spine be-

2. Move the adjusting block. comes round
- Move the adjusting block to the right Adjusting
to raise the right side of the nipper so Block
that the spine becomes sharper.
NOTE
Set the adjusting block in the best
position by adjusting the nip height as
described earlier.
3. Tighten the locking screw.

Locking Screw
4 Nipping section parallel adjustment

Nipping Plate
When the nip plates are not parallel, the
(operation side)
binding quality of the spine is different at the
top and bottom of the spine.
1. Loosen the locking screw and the bear- Locking

ing screw. Screw
2. Adjust the nip plate position by turning
the adjusting screw.
- Put a coin or an adjusting driver into Bearing
the slot on the adjusting screw to turn
the adjusting screw. Adjusting
Screw
NOTE
Adjust the nip plate so that it is per-
fectly parallel. A little play affects the
binding quality.
Do not adjust the nip plate on the drive
3. Tighten the locking screw and attach the side. This will change the relationship
nip plate. between the nip section and other parts
of the machine.
93
4-15 Setting The Delivery Section

Z
D
J B
U W N A Q H
C
MG-60 R S L M G Y
Fixed Conveyor Guide Plate
Adjustable Conveyor Guide

Delivery Conveyor This guide is adjusted auto-
The books are dropped matically to match the book
on this conveyor and block thickness
delivered. Detecting Slit
The sensors detect
the book length
through this slit.
Sensor
The book
length is
detected by
these two
sensors.
Top-bottom Length
Detect Section
Manual Drive Section

Electrical If there is a problem, turn off the
Section power and insert the handle here.
Turn the handle to change the
guide width.
94
4-15 Setting The Delivery Section (Continued)

4-15-2 Setting the delivery section Top-bottom
Length Detect
The book block is nipped in the nipping sec- Sensor
tion and delivered onto the delivery section
conveyor. Each book block dropped and
delivered onto the conveyor is checked to see if
there has been a shift between the book block
and the cover sheet. If the cover sheet and the Guide
book block have shifted, the sorter receives the Width
signal and delivers the book block as a bad
book.
Conveyor
See the following section:
Guide
(1) Adjusting the conveyor guide width
(screen)
1 Adjusting the conveyor guide width (screen)

- The width of the conveyor guide in the Main Screen
delivery section is adjusted automati- 0.394 inch
(mm)
8.268 inch 7.874 inch

12
3
0 book(s)
0 book(s)
(mm)
cally according to the book block thick- 5.906 inch

(mm)
(mm)
1400
5200 books/h
1000 rpm
ness. The minimum setting is 1.375" (35 7.087 inch
9.055
mm).
(mm)
15.748 inch
(mm)
- The conveyor width can be adjusted Manual

depending on the way the book block is 1 2 Adjustment
transported. Screen
1
Main screen. 2
2. Press .
- The Delivery Section Manual Adjust-

+0.0
OK
3. Press or to adjust the width. 3
- This can be set from 0.390" to - 0.390" Delivery Section 4
(10 to -10 mm). Manual Adjustment
Screen
4. Press OK .
screen appears.
95
4-16 Setting The Twisting Conveyor Section

Z
2
HD 1
J B
U W D N A Q H
C
MG-60 R S L M G Y
Delivery Section
Stop Button
View 1
Conveyor Section Door
Book Block Guide Section

Adjust the guide width so that
the delivered book block moves
smoothly on the twisting con-
veyor.
View 2
Twisting Conveyor
This section lowers and
delivers the book block.
To Weight Checker
96
4-16 Setting The Twisting Conveyor Section (Continued)

4-16-2 Setting the twisting conveyor
This section lowers the book block transported

from the delivery section using three
conveyors. Then the mechanism transports the
book block to the weight checker (optional
device) or to the book block delivery stacker.
2 Adjusting the book block guide

- Open the cover of the twisting con-
veyor and adjust the guide bar accord-
ing to the delivery condition of the
book block.
See the following section:
(1) Adjusting the book block guide
97
This page is intentionally left blank.
98
5. Maintenance
5. Maintenance
This chapter explains how to maintain the machine.
5-1 Adding The Spine Glue ..................................................................................... 100
5-2 Applying The Side Glue ....................................................................................101
5-3 Cleaning ..............................................................................................................102
5-3-1 Cleaning the Clamp Track ..............................................................................102

5-3-2 Cleaning The Book Block Track ....................................................................103
5-3-3 Cleaning The Cover Feeder ............................................................................104
5-3-4 Cleaning The Sensors ..................................................................................... 105
5-3-5 Cleaning The Air Pump Filters ......................................................................106
5-4 Lubrication ......................................................................................................... 107
5-5 Replacing The Milling Cutter ........................................................................... 113
5-6 Replacing The Roughening Cutter................................................................... 117
5-7 Replacing A Suction Cup ..................................................................................118
5-8 Replacing The Shear Pin ................................................................................... 119
5-9 Replacing The Spine Glue ................................................................................. 121
5-10 Replacing The Side Glue ................................................................................. 123
5-11 Description of The Weekly Timer ................................................................. 125
99
5. Maintenance
5-1 Adding The Spine Glue
Adding the spine glue
If you are using the optional pre-melt tank, the

procedures listed below are not necessary.
WARNING
The melt tank is heated to about
200 ˚C (392 ˚F). Keep your hands
and fingers away from the melt
tank. Otherwise, the hot tank can
cause severe skin burns.
- When adding glue manually, do this

when the glue tank is raised.
1. Open the cover on the melt tank.
2. Add spine glue to the spine glue supplying

section of the melt tank. Red
- Do not add glue above the red line. Line
- We recommend the glue type Horizon
HM-401 (Only in the winter, the glue
type Horizon [HM-403]). Spine Glue
Supplying
Section
CAUTION
The level of the glue becomes
lower when the drum is rotating.
Keep the glue below the red
line when the drum is not
rotating.
3. The melt tank can be separated into two

parts. When using different glue for the
spine, separate the two sections.
- Use glue which penetrates easily for

drum 1, and use normal spine glue for
drum 2 and 3. This will make the spine
stronger.
100
5. Maintenance
5-2 Adding The Side Glue
Adding the side glue
If you are using the optional side glue supply

unit, the procedures listed below are not neces-
sary.
WARNING
200 ˚C (392 ˚F). Keep your hands
Left Fin
tank. Otherwise, the hot tank can
cause severe skin burns. Side Glue
Supplying
Section
1. Add glue to the side glue supplying
section. Right Fin
- When the drum is not rotating, the level

of the glue should be higher than the left
fin and lower than the right fin.
05SB08B73
- Glue type Horizon HM-403 is filled in

the tank when the machine is shipped.
harden immediately and the spine of the
book is torn, use the glue type Horizon
HM-401 by itself or blend with HM-403.
The open time of the HM-401 will be
shorter than that of HM-403.
101
5. Maintenance
5-3 Cleaning
5-3-1 Cleaning The Clamp Track
Cleaning the clamp track (Once a week)
WARNING
Turn off the power switch
before cleaning this mechanism.
Otherwise, a sudden start of the
machine can cause severe
personal injury.
200 ˚C (392 ˚F). Keep your
hands and fingers away from
the melt tank. Otherwise, the
hot tank can cause severe skin
burns.
1. If there is any trim around the hand feed

section, milling section or melt tank
section, remove the trim using a vacuum Hand Feed
cleaner. Section
Milling Melt Tank
- Be careful not to put the trim into the Section Section
melt tank.
2. If necessary, remove any glue stuck to

the cover sheet register section, nipping
section, or delivery section. Cover Sheet Nipping Delivery
Register Section Section
Section
102
5. Maintenance
5-3 Cleaning (Continued)

5-3-2 Cleaning The Book Block Track
Cleaning the book block Track (Once a week)
WARNING
personal injury.
200 ˚C (392 ˚F). Keep your
hands and fingers away from
the melt tank. Otherwise, the
hot tank can cause severe skin
burns.
1. Remove any stains and dust from the slot
on the infeed section.
Hand Feed
Section Milling
Section Clamp
2. If necessary, remove any glue or stains Section
inside the clamp.
3. If necessary, remove any paper dust on

the milling section.
4. If necessary, remove any glue on the

cover sheet transport section.
Delivery
5. If necessary, remove any glue or stains Cover Nipping
Section Section
on the nipping section. Sheet
Transport
Section
6. If necessary, remove any glue or stains
on the conveyor section.
NOTE
Apply silicone spray to make cleaning
easier next time. (Do not do this if the
spray will stain the book block.)
103
5. Maintenance

5-3-3 Cleaning The Cover Feeder
Clean the rollers on the cover feeder (Once a month)
WARNING
personal injury.
1. Turn the manual operation handle and Cover Feeder

rotate the roller. Wipe off any stains on
the roller using a cloth moistened with
alcohol.
Roller
Press
Roller
2. Also clean the feed roller and the press
roller.
Feed Roller
104
5. Maintenance

5-3-4 Cleaning The Sensors
5-3-4-1 Clean the sensor for the cover feeder
Clean the six sensors for the cover feeder (Once a month)
WARNING
Turn off the power switch before
cleaning these sensors.
personal injury.
1. Use compressed air to clean the six sen-

sors listed below and remove any dust or
the paper chips.
1) Cover sheet detect sensor

2) Cover sheet detect sensor
3) Window of the mis-loading prevention
camera
4) Misfeed detect sensor
5) Double feed detect sensor
6) Jam detect sensor
5-3-4-2 Clean the sensors for the delivery section
Clean the sensors for the delivery section (Every 6 months)
WARNING
cleaning this sensor. Otherwise,
a sudden start of the machine can
cause severe personal injury.
1. Open the delivery section cover.
2. Use compressed air to clean the two Delivery

sensors shown in the figure to the right. Section
Remove any dust or the paper dust. Sensors
105
5. Maintenance

5-3-5 Cleaning The Air Pump Filters
Cleaning the air pump filters (every 6 months)
- Perform this operation only after

turning off the power switch. Pressure
Adjusting
Knob
1. Remove the two mounting screws shown
in the figure to the right.
2. Remove the filter cover.
Filter Cover
Mounting
Screws
3. Remove the three filter elements from

the cover. If an element is clogged, clean
it using compressed air. It may help to
tap on the filter element.
Filter Element
05SB08B43
There are two filter elements inside the

pressure adjusting knobs and one under
the filter cover.
4. If a filter element is still clogged, or the

element has been contaminated with
grease or oil, replace the filter element.
5. Place the filter elements inside the air

pump.
6. Attach the filter cover and tighten the

mounting screws.
NOTE
Replace the filter elements once a year.
106
5. Maintenance
5-4 Lubrication
There are eight lubrication points. The application method

and the type of grease used will vary, depending on the appli-
cation point. Refer to the table below.
Lubrication Point Application Method Grease Type Color Frequency

1 Sprocket Brush Normal Grease Green
2 Bevel Gear Brush Normal Grease Green Every three mil-
3 Clamp Slide Rail Section Brush Normal Grease Green lion books, or
4 Cover Sheet Transport Section Brush Normal Grease - every six months.
5 Bottom Of The Clamp Grease Gun High Temperature Grease Yellow
6 Melt Tank Section Grease Gun High Temperature Grease Yellow
7 Side Gluing Roller Grease Gun Normal Grease Green
8 Nipping Cam Section Grease Gun Normal Grease Green
1 Apply grease to the sprocket
WARNING
Work alone when you perform
this operation.
Jog the machine using the
remote control.
Moving the machine
continuously or letting someone
else operate the machine may
cause severe personal injury.
1. Remove the top cover shown in the figure

to the right.
Sprocket Teeth
2. Apply grease to the rotary blade of the
sprocket as shown in the figure to the
right.
- Apply grease to the rollers on the chain

as the sprocket rotates.
107
5. Maintenance
5-4 Lubrication (Continued)
2 Apply grease to the bevel gear
WARNING 1 24 23
2 22
21
- Work alone when you perform
20 19
this operation.
18
- Jog the machine using the
40
45
manual operation handle.
9
13 12 11 10
- Moving the machine

continuously or letting
someone else operate the
machine may cause severe
personal injury.
Rotary Blade of Bevel Gear
1. Remove two covers shown in the figure
to the right.
2. Apply grease to the rotary blade of the

bevel gear as shown in the figure to the
right.
Manual Operation
Handle
3 Apply grease to the clamp slide rail section
WARNING
- Work alone when you perform
this operation.
remote control.
someone else operate the Grease
machine may cause severe Application
personal injury. Point
1. Turn the manual operation handle and

rotate the clamp. Apply grease to the
eight grease application marked by green
tapes.
Green Tape
Apply a thin, even coat of grease. If

there is too much grease, it can stain the
book block.
108
5. Maintenance
4 Lubricate the cover sheet transport section chain
WARNING Chain With

Hook
- Work alone when you
perform this operation.
remote control.
personal injury.
1. Apply grease to the chain in the cover

sheet transport mechanism.
- Apply a thin, even coat of grease. Too
much grease may stain the book block.
5 Lubricate to the bottom of each clamp
1. Move each clamp by jogging until the Clamp

clamp stops between the side gluing tank
and the cover feeder.
WARNING
Press the stop button before
performing this operation.
machine can cause severe Grease
personal injury. Lever Grease Nipple
2. Apply grease to the grease nipples marked

with the yellow labels under the clamp. Use High Yellow Mark
the grease gun with the yellow mark. Temperature
- There are two grease nipples on each Grease
clamp. Apply
- Lubricate all of the clamps. Grease
- One shot from the grease gun is enough.
After lubrication, excess grease may stain

the book block. Wipe away any extra
grease using a clean cloth.
109
5. Maintenance
6 Apply grease to the glue cut section of the melt tank
1. Open the cover on the melt tank.
2. Apply grease to two grease nipples

marked with the yellow labels shown in
the figure to the right. Use the grease
gun with the yellow mark.
- One shot from the grease gun is
enough.
Grease Nipples
3. Close the cover on the melt tank.
7 Apply grease to the gears for the side gluing roller
WARNING
Press the emergency stop
button before performing this Grease Nipples
operation. Otherwise, a
injury.
1. Apply grease to the two grease nipples

shown in the figure to the right. Use the
grease gun with the green mark.
- Apply one shot from the grease gun.
Then turn the manual operation handle
for two rotations and apply the grease
again.
Side Gluing
Section
110
5. Maintenance
8 Apply grease to the nipping cam section
1. Bring the nipper up to the delivery

section using the remote control. Delivery Section
Side
WARNING
- Work alone when you
perform this operation.
remote control.
personal injury.
2. Apply grease inside the gutter cam

WARNING
Press the emergency stop
button before performing this
operation. Otherwise, a
injury.
Cover Sheet
Register
3. Bring the nipper up to the cover sheet Section Side
register section using the remote con-
trol.
4. Apply grease inside the cam shown in

the figure to the right.
111
5. Maintenance
5. Remove the nipping section lubrication A

window. (There are four mounting
screws.)
6. Apply grease with a brush to the position

- Apply grease to the edge and front of

the cam plate as shown in the figure to
the right.
B
7. Apply grease to four grease nipples (A
and B) shown in the figure to the right
using a grease gun. Grease
- One shot from the grease gun is Nipple
enough.
- When applying the grease to the two
grease nipples at A, use two shots from
the grease gun. Rotate the cam plate 60˚
using the remote control, and add two
more shots. Repeat the process around
the rest of the cam plate.
8. Attach the nipping section lubrication

window.
112
5. Maintenance
5-5 Replacing The Milling Cutter
Replacing a dull milling cutter

Milling Cutter
WARNING Replacing Button
Service Screen
- Wear thick gloves, and do
not touch the edge of the
milling cutter or the
roughening cutter. A sharp
cutter can cause severe personal
injury.
1. Press the milling cutter replacing button.

Clamp Removing Screen
- Press the milling cutter replacing button
on the Service screen.
- The Clamp Removing screen appears.
2. Remove the clamp.

- When replacing the milling cutter, the
clamp interferes with the replacing opera-
tion. Remove one of the clamps over the
remove the clamp
cover sheet transport section. Choose a press the "next" button after removing the clamp.
clamp which can be removed easily. NEXT
(1) Press the inching button and move the Z Milling Cutter
clamp over the cover sheet transport Replacing Range
section. Stop the clamp in the area marked
by the yellow tape. D N A Q H
(2) Turn off the power switch and remove

R S L M G Y
the clamp. (There are four mounting
screws.) C
- If you cannot reach a mounting screw,
remove the support plate.
(3) Close the cover and turn on the power
switch.
(4) Press the "next" button on the clamp
removing screen. The Confirmation screen
appears.
(5) Press the start button.
- The area where the clamp was removed
moves over the milling cutter.
- The Clamp Moving and Guide Moving Clamp
screens appear on the touch panel.
NOTE
- If the guide was adjusted narrower than
the automatic setting, the bottom of the
clamp may hit the guide. Press the start
button after returning the guide to the
113
5. Maintenance
5-5 Replacing The Milling Cutter (Continued)
original position.
Milling Cutter Replacing Screen
- After the clamp stops, the Cutter
Replacing screen is appears.

press the "next" button after raplacing the clamp.
NEXT
Guide Roller
(Operator Side)
3. Pull out the milling unit.
1. Turn off the power switch.

(1) The control panel will indicate a
Power Switch Off error.
(2) Remove the milling section door. Press Roller

Fixing Lever
(3) Turn the slide locking lever clock-
wise.
(4) Insert the support handle in the Support

position shown in figure to the right Slide Handle
and turn it clockwise. The milling Locking Slide Motion
mechanism will move forward. Lever Screw
Upper
4. Remove the milling cutter. Knife
(1) Remove the milling guide.
(2) Remove the upper knife.
(3) Release the press roller by turning
the press roller locking lever to the left. Milling
Then move the guide roller. Guide
(4) Attach the milling cutter handle.
114
5. Maintenance
Handle
(5) Remove four mounting screws on the
milling cutter.
(6) Remove the milling cutter. Mounting Milling
Screw Cutter
5. Attach the new cutter.
(1) Attach the handle to the new milling

cutter.
(2) Attach the milling cutter with the

handle using the four mounting screws.
(3) Remove the handle.
(4) Attach the milling guide and the upper

knife.
- After attaching the milling guide and the

upper knife, check that there is 0.004”
(0.1 mm) gap between the upper knife
and the milling cutter. Use a thickness
gauge. (This is the thickness of one 64 Upper Knife
gsm sheet.) Check that the milling cutter 0.004” (0.1 mm)
does not hit the upper knife when you
turn the milling cutter counterclockwise.
Milling Cutter
- Do not re-sharpen the surface of the
milling cutter. Re-sharpen only the side
of the milling cutter.
CAUTION Roughening Cutter

Stack of
Adjustment Gauge
Sheets Thickness
When the surface of the milling
cutter is sharpened, the cutter Spacer
becomes thinner. To compensate,
install a spacer between the
milling cutter and the milling Milling
holder as shown in the figure to Cutter
the right. The roughening
cutter should also be lowered. To Milling Holder
do this, make up a stack of sheets
equal to the thickness of the
spacer. Place this between the
roughening cutter and the If you are also replacing the roughen-
roughening cutter adjustment ing cutter, see Section 5-6 on the next
gauge. page.
115
5. Maintenance
6. Return the milling unit.

Guide Roller
(1) Push back the guide roller on the

operator side.
(2) Lock the press roller by raising the
press roller locking lever.
(3) Turn the slide locking lever to the left.
(4) Turn the support handle counterclock-

wise and move the milling mechanism
backwards.
(5) Close the milling section door.
Support
Handle
7. Replace the clamp. Milling Cutter Replacing Screen
(1) Press the "next" button on the Milling

Cutter Replace screen. The Confirmation
screen appears.
(2) Press the start button.

press the "next" button after raplacing the clamp.
- The clamp returns to the position where NEXT
it was removed, and the milling guide

plate returns to the original position.
- The Clamp Moving and Guide Moving Clamp Attachment Complete Screen
screens appear on the touch panel.
(3) Open the nipping section cover and

attach the clamp.
(4) Press the OK button on the Clamp restore the clamp

press the "OK" button after restoring the clamp.
Attachment Complete screen.
- The Service screen appears. OK
116
5. Maintenance
5-6 Replacing The Roughening Cutter

Replace the roughening cutter when the
cutter is worn out.
WARNING
- Wear thick gloves, and do not
touch the edge of the milling
cutter or the roughening cutter. A Mounting
sharp cutter can cause severe Screw
personal injury.
- Keep your hands and fingers away
from the melt tank. Otherwise, it
can cause severe skin burns.
1. Press the stop buttons.
2. Remove the four mounting screws shown
in the figure to the right. Also remove the Milling Guide
milling guide on the operator side. Operator Side
3. Remove the roughening cutter.
- If the roughening cutter is difficult to Roughening Cutter
reach, or if you are replacing the rough- Cloth
ening cutter on the other side, turn the
milling cutter clockwise.
(1) Press the roughening cutter downward
using a thick cloth.
Set
- There is a spring under the roughening
Screw
cutter. The cutter can pop once the set
Allen
screw has been loosened.
Wrench Spring
(2) Loosen the set screw on the roughen-
ing cutter using 0.098” (2.5 mm) Allen
wrench.
(3) Remove the roughening cutter. Direction of
Rotation
4. Install the new roughening cutter.
(1) Insert the new roughening cutter so SB-15
that the top of the cutter is even with the Roughening Cutter
highest part of the milling cutter.
There are cutter blades on both ends of
each roughening cutter. This means that
each roughening cutter can be used twice. Attachment
- Do not use the standard SB-08 roughen-
ing cutter. Use only the special roughen- Allen Wrench Roughening Cutter
ing cutter for the SB-15. 2.5 mm Adjustment Gauge
(2) Push down the edge of the roughening Milling Cutter
cutter using the roughening cutter adjust-
ment gauge and tighten the set screw.
(3) Remove the adjustment gauge.
(4) Rotate the milling cutter counterclock-
wise for one rotation and check that the Set Screw
roughening cutter does not hit the upper
knife.
5. Attach the milling guide plate. Roughening
Cutter
117
5. Maintenance
5-7 Replacing A Suction Cup

Replace any suction cup in the cover feeder if
it is worn out and the suction vacuum is
reduced. Suction Cup
Which Is Worn Out
WARNING
Press the stop button before
personal injury.
1. Locate the suction cup which is worn New Suction Cup

out. Pull the part out to remove it.
2. Attach the new suction cup.
118
5. Maintenance
5-8 Replacing The Shear Pin
If the nipper width is set narrower than the

book block thickness, the nipper plate can be
overloaded during the nipping operation.
This may cause a shear pin to break to pro-
tect the mechanism. If the shear pin breaks,
the binding operation stops and the control
panel indicates a "Safety Pin Break" error as
WARNING
- Work alone when replacing
the shear pin. Error Screen
remote control.
personal injury.
Nipper Section Cover

1. To make the process easier, bring the
nipper up to the delivery section, using
the remote control.
2. Press the stop button and open the nipper

section cover.
3. Loosen the mounting screw using an

Allen wrench, and move the block.
Allen
Block Wrench
119
5. Maintenance
5-8 Replacing The Shear Pin (Continued)
4. Turn the remaining part of the shear pin

using a standard screwdriver, and re-
move it.
5. Install a new shear pin and tighten it

using the standard screwdriver.
Shear Pin
6. Cover the safety pin with the block and

tighten the mounting screw.
Mounting
Screw
Block
7. Check that the error icon on the Main
screen has disappeared.
Error
Screen
0.394 inch
10.0 (mm) 00 book(s)
8.
11 22 3 book(s)
Close the nipper section cover.

3
8.268 inch
(mm)
7.874 inch
200.0 (mm) 00 book(s)
book(s)
120.0 1400
(mm) 5200 books/h
1000
1000 rpm
rpm
1400 9.055
230.0
7.087 inch
(mm)
15.748 inch
400.0 (mm)
9. Correct the problem which caused the 1 2
shear pin to break.
120
5. Maintenance
5-9 Replacing The Spine Glue

Drain the old glue from the bottom of the melt
tank, and add new glue.
WARNING
Wear good cotton gloves when
replacing the glue. The melt tank
is heated up to around 392 ˚F
(200 ˚C). Keep your hands and
fingers away from the melt tank.
Otherwise, the hot tank can cause
severe skin burns.
- Check that the power is turned on and Front

the glue is melted. Cover
WARNING
replacing the glue.
1. Remove the four mounting screws and

remove the top cover.
2. Turn the melt tank up/down handle coun-

terclockwise. (See the next page.) Lower
the melt tank completely. Drain
3. Place a container which can hold the

melted glue under the melt tank. (You can
use a cardboard box.)
- Use a container which can hold more
than 3.6 pt or 0.45 gal (1.7 liter) for melt Cardboard
tank 1 and more than 7.0 pt or 0.87 gal Box Drain Stub
(3.3 liter) for the melt tank 2.
4. Loosen the drain plug with a wrench.

Plug
Drain
5. Attach the drain. Assembly
- Fit the end of the drain assembly over Drain
the drain stub. Holder
6. Turn on the main switch.
121
5. Maintenance
5-9 Replacing The Spine Glue (Continued)
7. Remove the plug and drain the glue.

- Check that the temperature of the glue is
326 ˚F (180 ˚C) or higher. If the glue
temperature is not high enough, the glue
will become hard when cooled by the
drain, and may plug the drain.
- Wipe off the glue on the plug while it is
hot and soft.
- Any glue stuck to the drain should be Plug
removed after it sets.
- Be careful not to drop the plug.
- Add a little new glue and drain it out
again with the old glue.
- To drain the glue completely, remove the
clamp and scrape the glue with a wooden
scraper.
CAUTION
Stay beside the machine while
draining the glue.
8. The temperature sensor will turn off the

main switch. If the glue hardens and can
not be drained, turn on the power and heat
the glue again. In this case, be careful the
glue does not overheat, because the tem-
perature is not controlled.
- If the glue begins to melt, the melt tank Thermocouple
is too hot. Sensor
9. Remove the drain.
WARNING Plug
Watch out for the melted glue Drain

when removing the drain. Assembly
Drain
Holder
10. Install the plug and turn on the main
switch. Then add new glue.
- Tighten the plug when the tank is heated
up enough to melt the glue.
11. Turn the melt tank up/down handle clock-

wise and raise the melt tank.
12. Attach the front cover.
122
5. Maintenance
5-10 Replacing The Side Glue

Drain the old glue from the side of the side
gluing section and apply new glue.
WARNING
Wear good cotton gloves when
replacing the glue. The melt
tank is heated up to around 392
˚F (200 ˚C). Keep your hands
tank. Otherwise, the hot tank
can cause severe skin burns.
- Check that the power is turned on and

the glue is melted completely.
NOTE
Remove the clamp before performing
this operation. This way, the paper dust
does not enter to tank and the replace-
ment operation is simpler. Cardboard
Box
Drain Stub
1. Place a container which can hold the Drain Plug
melted glue under the side gluing sec- Assembly
tion. (You can use a cardboard box.)
- Use a container which can hold more
than 5.9 pt or 0.73 gal (2.8 liter).
2. Loosen the plug.

- The plug may be tight. Check that the Drain
plug can be loosened. Holder
3. Attach the drain. Drain

- Fit the end of the drain assembly over
the drain stub.
4. Remove the plug and drain the glue.

- Apply a little new glue and drain it out
again with the old glue.
123
5. Maintenance
5-10 Replacing The Side Glue (Continued)
5. Turn off the main power when the

surface of the glue gets near the bottom.
If the glue starts to set and can not be
drained, turn on the power and heat the
glue again. In this case, be careful not to
overheat the glue because the tempera-
ture is not controlled.
Main Switch
- It the glue begins to smoke, the glue is
too hot.
6. Install the plug and remove the drain.

Then tighten the plug more harder.
7. Turn on the main switch and add new

glue.
- Glue type Horizon HM-403 is filled in
the tank when the machine is shipped.
harden immediately and the spine of the
book is torn, use the glue type Horizon
HM-401 by itself or blend with HM-
403. The open time of the HM-401 will
be shorter than that of HM-403.
124
5. Maintenance
5-11 Description of The Weekly Timer

NOTE
5-1-2 Description of the Control Panel
- If the starting time for the melt tank
heating is set before the start of produc-
tion, the binding operation can be
started without waiting for the glue to
be melted.
- When using the weekly timer, leave
the power switch on the SB-15 turned
on.
- If the power switch for the machine is
not turned on for over 300 hours, the
Sunday (S) lamp may blink when the Weekly Timer
power switch is turned on. In this case,
set the current time and day. (Refer to
the next page.)
Setting Scale
This scale is used to set the Continuous / Normal Switch
time to turn the SB-15 ON or Set this switch to "CONTINU-
OFF. One rotation takes a day OUS" when the time between
and the indexes can be set turning the machine on and off is
every 15 minutes. over 24 hours. Normally, set this
switch to NORMAL.
CON-
NORMAL
A-TB72CQ TINUOUS
OUTPUT
Output Lamp
Current Time Setting Knob OFF AUTO
This lamp lights when the
This knob is used to set the S
M timer function is active.
current time. One rotation of T
this knob takes an hour. W Day Lamps

T
These lamps are used to
F
Minute Scale S indicate the current day. A
DAY lighted lamp indicates the
SETTING
PRESENT
current day.
TIME
OFF ON
AUTO Current Day Setting
Button
This button is used to select
Day Select Switch
the current day.
For each day on which the melt
tank will be heated automatically,
set the switch for that day to ON, AUTO, and OFF Switch
AUTO. ON-When the power switch of the SB-15 is
turned on, the melt tank is always heated
OFF ON up, independently of the timer function.
AUTO AUTO-The timer function is available.
OFF-Although the power switch of the SB-15
is turned on, power is not supplied to the
BQ-460.
NOTE
- When using the weekly timer, turn the
ON / AUTO / OFF switch to the
"AUTO" position.
125
5. Maintenance
5-11 Description of The Weekly Timer (Continued)

5-1-3 Weekly Timer Set Up
Set the current time and the auto-start-up Current Time
time. 2
1 24 23
22 Setting Knob
WARNING
21
20 19
1. Remove the transparent cover.
18
40
45
9
13 12 11 10
2. Set the current time as follows:

Turn the current time setting knob clock-
wise to set the hour index first, then set
the minute index.
Index Hour Minute
3. Set the current day as follows:
Press the day setting button using the tip
NORMAL CON-
of a screwdriver. Each time you press TINUOUS
the current day setting button, the current OUTPUT
day indicators advance a day. Stop when OFF AUTO

S
they indicate the current day. M
T
W
4. Set the auto-start-up time for the melt T
Current Day Lamps
tank by following the examples below: F
S
DAY
NOTE SETTING
Current Day Setting
- Set the time to heat up the melt tank
OFF ON Button
by shifting the appropriate index tabs to AUTO
the center of the dial.
A. Setup within a day

(1) Set the normal/continuous switch to Normal/Continuous Switch
NORMAL. NORMAL CON-
TINUOUS
(2) Set the day select switches to the OUTPUT
AUTO side only for the days when the
OFF AUTO
melt tank will be heated automatically. S
19 17
M
T Day Select
- For example, when the time switch is
8
W
12 Switch
set as shown in the figure to the right, T
F
the machine will operate according to S
the program from Monday to Friday, and Time Switch DAY
SETTING
will not operate on Saturday and Sunday.
ON/Auto/OFF
OFF ON
AUTO Switch
Monday (A) 8:00-12:00 (ON) (Output)

to Friday (B) 17:00-19:00 (ON) SUN MON TUE WED THU FRI SAT
Saturday
and All Day OFF A B A B A B A B A B
Sunday
126
5. Maintenance
5-11 Description of The Weekly Timer (Continued)

B. Setup over a break between days
This is used to control the machine auto-start- NORMAL CON- Normal/
TINUOUS
up over a period which includes two days. Continuous
OUTPUT
Switch
(1) Set the normal/continuous switch to OFF AUTO
20
S
NORMAL.
6
M
(2) Set the day select switches as de-
16
8
T
W
Day Select
scribed for the setup within a day. T Switches
NOTE F
S
- When controlling the machine auto- Time Switch DAY
start-up over a break between days, the SETTING
Manual ON,
program continues from the previous Auto, Manual
OFF ON
day. Therefore, the machine is powered AUTO
OFF Switch
up until it reaches the off setup time,
even though the day select switch for (Output)
the day is turned off.
SUN MON TUE WED THU FRI SAT
Mon, Tue, (C) 8:00-16:00 (ON)

Thu, Fri (D) 8:00-16:00 (ON) C D C D C D C D
(over a date)
Sun All Day OFF
Wed, Sat, OFF after 6:00
C. Setup through a series of days

This is used when the period that the machine NORMAL CON- Normal/
TINUOUS
is continuously on or off is over 24 hours. Continuous
OUTPUT
Switch
OFF AUTO
(1) Set the normal/continuous switch to S
CONTINUOUS. M
T Day Select
W Switch
17
8
(2) Set the day select switches by T

F
referring to the example below: S
05SB06B80
DAY
The machine is powered on at the on setup Time Switch SETTING
time of the first day when the day select switch ON, Auto, and
OFF ON
is set to AUTO. The machine is powered off AUTO OFF Switch
at the off setup time of the first day when the
day select switch is set to OFF. (Output)
(Example) SUN MON TUE WED THU FRI SAT
Monday 8:00 to Friday 17:00 8:00 17:00

(through a series of days)
Sat and Sun All Day OFF
127
5. Maintenance
5-12 Replacing the Carbon Blades of Pump

5-1-3 Weekly Timer Set Up
The Pump does not work correctly if the car-
bon blade in the pump are worn out. After
5,000 hours of use, follow the procedure Cover
below and check if the blades are worn. If
necessary, replace the blades.
1. Turn off the main power.
2. Remove the cover of pump.
3. Remove the end cover.
4. Pull the carbon blades out and check

them.
NOTE
End Cover
- If the length of the carbon blade is
24 mm or less, replace the blades.
- Replace all seven blades together.
IMPORTANT
- When inserting the new blade, make
sure to fit the end of the blade to the
innner wall of the cylinder.
5. Attach the cover in the reverse order of

removal.
24mm
or longer The dimension
of new one is
39 mm.
Blades
Insert the blade

so that the end of
blade fits on the
inner wall of
cylinder.
128
6. Troubleshooting
6. Troubleshooting
This chapter explains how to deal with some possible problems.
6-1 Poor Binding Quality ......................................................................................... 129

The Spine Is Scratched
Prints On The Spine Is Not In The Center
The Book Block And The Cover Sheet Are Shifted In The Top Bottom Direction
The Book Block And The Cover Sheet Are Shifted Diagonally
Too Much Spine Glue Extends From The Top Or Bottom Of The Book Block
When The Spine Glue Laps To The Side
When Glue Is Not Applied To Part Of The Book Block Spine
When A Fore-edge Part Of The Book Block Is Bent
6-2 When The Pole Lamp Lights And The Machine Stops ..................................145

6-3 Clearing Errors ................................................................................................148
Clearing A Book Block Jam In A Clamp

Resetting After A Temperature Error Occurs in the Spine/Side Glue Tank
When The Cover Sheets Are Loaded In The Wrong Direction
6-4 Problems In The Cover Feeder ........................................................................156
6-5 When A Bad Booklet Is Not Detected ..............................................................158
129
6. Troubleshooting
6-1 Poor Binding Quality

Description Of The Book Block
Top
In this section, each part of the book block is Spine
described using the name shown in the figure to
the right.
Print On
NOTE Spine
The quality of the bound book changes a
lot according to the production speed.
Perform a test binding using the actual
production speed setting. Bottom
Check that the grain direction of the cover

sheet is not at a right angle to the book block
spine as shown in the figure to the right.
- If the grain line of the cover sheet is at a right

angle to the book block spine, the spine Book
becomes round, especially when using a thick Block
cover sheet. Use a cover sheet with a grain
direction which is parallel to the book block
Grain Direction
spine.
Main Screen
Check that the nipping height is correct 0.394 inch
(mm) 12
3
0 book(s)
(mm) (mm)
1400
5.906 inch
(mm) 5200 books/h
- The nipping height can be changed according 7.087 inch

(mm)
9.055
1000 rpm
to the book block size. Increase the nipping 15.748 inch

(mm)
Manual
height by following step 2 in Section 4-14- 1 2
Adjustment
2. Screen
OK
Nipping Height Adjust Screen

130
6. Troubleshooting
6-1 Poor Binding Quality (Continued)

Main Screen
0.394
(mm) 11 22 3 book(s)
3
Check that the nipping width is correct 8.268 inch

(mm)
120.0inch
5.906 (mm)
7.874
200.0 inch
(mm)
00
1400
1400
5200
book(s)
book(s)
books/h
books/h
-The nipping width is set automatically 7.087

130.0 inch
(mm)
1400 9.055
230.0
230.0
1000
1000 rpm
rpm
according to the book block size. If the nipping 15.748

400.0 inch
(mm)
width is not input properly, the book quality 1 2

0.394 (mm)
inch
will not be as good. 8.268 (mm)

inch 7.874 inch
(mm)
- Check that the thickness of the book block 5.906 inch
(mm)
input on the Block Size Input screen matches
the actual book block thickness. If it does not 55.118 inch 9.055
(mm)
match, input the correct value on the Block 7.087 inch
(mm)
Size Input screen or use the book size input 15.748 inch
(mm)
interface. See Chapter 8.

Block Size Input Screen
Reduce the nipping width 0.394 inch
(mm)
12
3
0 book(s)
- Set the nipping width by following step 1 in (mm)
5.906 inch
(mm)
7.874 inch
(mm)
1400
5200 books/h
1000 rpm
Section 4-14-2. 7.087 inch

(mm)
9.055
15.748 inch
(mm)
1 2
The maximum amount that the nipping

width can be reduced is +0.197” (+5.0
mm). But do not reduce it too much in
one step. Check the bound book and
adjust the nipping width in small steps.
- If you reduce the nipping width too

much, the nipping section will be over-
loaded and the shear pin will break.
OK
Nipping Width Adjust

Check that the glue temperature is not set
Screen
too high
-If the glue temperature is set too high, the
corners of the spine may become rounded after
the nipping operation. Lower the temperature +0.000 +0.000 +0.000 +0.000
setting.
1
0 180
2 0 180
Check that there is enough glue 3 0 170
- If enough glue is not applied to the corner of
the spine, the corners of the spine may become OK
rounded. Adjust the wiper opening following Melt Tank Section Manual
the step 7 in Section 4-8 in order to increase the Adjustment Screen
amount of glue applied. Check the glue height
level in the melt tank.
131
6. Troubleshooting
- If the spine is not improved when you

try the steps listed previously, change the a
nipping timing.
2 2
- There are two patterns (a or b) for the
nipping timing. 1 Raises,then
1 2 closes.
a : The spine becomes sharper
b : The spine becomes rounder
1. Remove the nipping section lubrication

b
window. 1 1
2. Rotate the timing cam to the position

shown in the figure to the right. Both close at
- Set the position using the operation by 1 the same time.
inches button on the remote control.
- Position the timing cam so that two of Mounting Screws
the mounting screws on the timing cam
can be seen from the two holes on the
front of the side plate.
WARNING
The nip timing is adjusted by
changing the cam position as
follows.
Make sure to turn off the power
switch on the machine.
3. Turn off the power switch. Timing Cam
4. Loosen the mounting screws on the timing

cam.
- Loosen the three mounting screws using
an Allen wrench. It is not necessary to
remove the screws.
5. Rotate the timing cam clockwise.

- When the cam comes to the position
shown in the figure to the right, the spine
When the cam is moved to this position,
becomes sharper.
the spine becomes sharper.
- The cam is set to the "normal" (center)
position when the machine is shipped.
- Tighten the mounting screws and attach
the cover.
6. Turn on the power switch.
132
6. Troubleshooting

Main Screen
Check that the nipping height is correct 0.394
10.0 inch
(mm) 11 22 3
3
00 book(s)
book(s)
- The nipping height can be changed 8.268 inch

(mm)
120.0inch
5.906 (mm)
7.874
200.0 inch
(mm) 00
1400
1400
5200
book(s)
book(s)
books/h
books/h
according to the book block size. Reduce the

1000
1000 rpm
rpm
1400 9.055
230.0
7.087
130.0 inch
(mm)
nipping height by following the step 2 in 15.748

400.0 inch
(mm)
Manual
Section 4-14-2. 1 2
Adjustment
Screen
OK
Nipping Height Adjust Screen

Check that the nipping width is correct
- The nipping width is set automatically 0.394
10.0 inch
(mm)
8.268 inch
(mm) 7.874
200.0 inch
(mm)
11 22 3
3
00
1400
00 book(s)
book(s)
book(s)
book(s)
120.0inch
according to the book block size. If the 5.906 (mm) 1400

5200
1000
1000
books/h
books/h
rpm
rpm
1400 9.055
230.0
230.0
nipping width is not input properly, the book 7.087
130.0 inch
(mm)
15.748
400.0 inch
(mm)
quality will not be as good. 0.394 (mm)

inch
- Check that the thickness of the book block 1 2
8.268 (mm)
inch 7.874 inch
input on the Block Size Input screen matches (mm)
5.906 inch
the actual book block thickness. If it does not (mm)
match, input the correct value on the Block

Size Input screen or use the block size input 55.118 inch 9.055
(mm)
7.087 inch
device. See Chapter 8. (mm)
15.748 inch
(mm)
Block Size Input

Screen
Increase the nipping width
- Set the nipping width by following step 1 in
Section 4-14-2.
NOTE
The maximum amount that the nipping
width can be increased is +0.390”
(+10.0 mm). But do not increase it too OK
much in one step. Check the bound
Nipping Width Adjust
book and adjust the nipping width in
Screen
small steps.
133
6. Troubleshooting
- If the spine is not improved when you try a

the steps listed previously, change the
nipping timing. 2 2
- There are two patterns (a or b) for the
nipping timing.
1 Raises,then
a : The spine becomes sharper 1 2 closes.
b : The spine becomes rounder
b
1 1
1. Remove the nipping section lubrication
window. Both close at
1 the same time.
2. Rotate the timing cam to the position shown
in the figure to the right.
- Position the timing cam using the operate Mounting
by inches button on the remote control. Screws
- Position the nipping cam so that two of
the mounting screws on the timing cam
can be seen from the two holes on the
front of the side plate.
WARNING
The nip timing is adjusted by
changing the cam position as
follows.
Make sure to turn off the power
switch on the machine.
Timing Cam
3. Turn off the power switch.
4. Loosen the mounting screws on the timing

cam.
- Loosen the three mounting screws using
an Allen wrench. It is not necessary to
remove the screws.
5. Rotate the timing cam counterclockwise.

- When the cam comes to the position
shown in the figure ti the right, the spine
becomes rounder. When the cam is moved to this posi-
- The cam is set to the "normal" (center) tion, the spine becomes rounder.
position when the machine is shipped.
- Tighten the mounting screws and attach
the cover.
6. Turn on the power switch
134
6. Troubleshooting
When binding a thin booklet made of

coated paper
- When binding a thin booklet (under 0.197 or
5 mm) of soft and heavy paper such as a coated
paper, the lower part of the book block may be
bent inside the clamp. If this happens, the milling
operation can not be performed correctly, result-
ing in poor binding quality. Attach the support
plate as described in Section 4-5-4.
Without Support With Support Plate

Plate
When there is too much spine glue or side

glue
- When too much glue is applied, the glue
layer becomes too thick, and extra glue
reaches up between the sheets. If this happens,
the spine of the booklet can not be formed
correctly.
- Reduce the amount of glue applied by Normal Too Much Glue
following step 5 and 7 in Section 4-8 and step Milling Cutter
6 and 7 in Section 4-9.
When the milling cutter is tipped or worn

out
- If the milling cutter is tipped , worn out, or
the upper knife is worn out, the milling
quality becomes poor and the outer sheets are
pulled away. When binding the sheets which
have been cut by a dull cutter, one corner of
the book block becomes rounded.
Outer
sheets are
pulled
away
Normal Cutter Is Worn Out
135
6. Troubleshooting
If the problem continues after replacing the Milling Cutter

milling cutter Cutter Spacer
-When the upper surface of the milling cutter is
re-sharpened, it becomes thinner. When the
replaced milling cutter is too thin, it does not
mill the book spine enough and it causes the
same situation as when the nipping section is
raised. When replacing a re-sharpened milling
cutter, place a spacer under the milling cutter.
Adjust the gap between the milling cutter Upper 0.004”
and the upper knife to be about 0.004” (0.1 Knife (0.1 mm)
mm).
0.004”
(0.1 mm)
136
6. Troubleshooting
The spine is scratched
Check the cover and book registering section

and the nipping plate
- If there is a mass of glue on the cover sheet
register section or the nipping section, every
book block will have a scratch in the same
place. Check the cover and book registering
section and the nipping plate section.
Nipping Plate
Check inside the clamp.
- If there is a mass of glue inside the clamp, all
ve of the book blocks clamped by this clamp will
have a scratch in the same place. Check inside
the clamp.
Check that there are no bubbles in the glue Application Drum

inside the melt tank.
- Check the glue on the application drum
carefully. If there are bubbles in the glue and
the glue on the application drum is not even,
glue will not be applied to some part of the
spine. That section will be dented after the
nipping operation. Check for any foreign
object inside the melt tank and the wiper, and
check the glue level in the melt tank.
Check the transport route for the cover

sheets
- If there is a foreign object in the way of the
cover sheets, the cover sheets will be
scratched.
137
6. Troubleshooting
The printing on the spine is not centered

Main Screen
Check that the position of the printing on 0.394
10.0 inch
(mm) 11 22 3
3
00 book(s)
book(s)
8.268 inch 7.874
book(s)
the spine does not vary

(mm) (mm)
120.0inch
5.906 1400
(mm) 1400 books/h
5200 books/h
1000
1000 rpm
rpm
- If the printing on the spine varies, the 7.087

130.0 inch
(mm)
15.748
1400 9.055
230.0
230.0
400.0 inch
binding machine can not correct for this. Use

(mm)
0.394 (mm)
inch
cover sheets which have printing in the center 1 2
of the spine. 8.268 (mm)

inch 7.874 inch
(mm)
5.906 inch
(mm)
Check that the input data is correct

- Check that the actual thickness of the book 55.118 inch 9.055
(mm)
7.087 inch
block matches the setting on the Block Size (mm)
Input screen. If an incorrect book block size is 15.748 inch

(mm)
input, input the correct value on the Block

Size Input screen or use the book size input Block Size Input Screen
interface. See Chapter 8.
0.394
(mm) 11 22 3 book(s)
3
8.268 inch
(mm) 7.874
200.0 inch
(mm) 0 0 book(s)
book(s)
1400
5.906 inch
(mm) 1400 books/h
5200 books/h
1000 rpm
1000 rpm
1400 9.055
230.0
Check that the loading position for the 7.087

130.0 inch
(mm)
15.748
400.0 inch
(mm)
cover sheets has not changed

- The guide position for the cover loading 1 2
position is set automatically according to the

cover sheet size, but is also adjustable using
the Manual Adjustment screen. Check that the
cover sheet loading position is set to the
correct setting.
- When performing the readjustment, follow
the guide adjustment procedure.
+0.000
+0.000 +0.000
Check that the guide position for the cover

sheet transport section has not changed +0.000
+0.000
- The guide position is set automatically
according to the cover sheet size, but is also OK
adjustable using the Manual Adjustment

Cover Feeder Manual
screen. Check that the guide position has not
Adjustment Screen
changed on the Manual Adjustment screen.
- To readjust, follow the guide positioning Guide
procedure in Section 4-13-2.
Check that the cover sheets are trimmed to

the same size
- The guide plate will only work correctly if
cover sheets are all same size. If the cover
sheets are not the same size, re-adjust the
guide position for each new batch of cover
sheets using the Cover Feed Section Manual
Adjustment screen.
138
6. Troubleshooting
The book block and the cover sheet are shifted in the top-bottom direction
Check that the stopper block is adjusted

properly.
- If the stopper block in the cover sheet
register section is not adjusted properly, the
book block and cover sheets will not be
aligned properly.
- Follow the instructions for “Positioning Top-bottom
Adjustment of Book Block and Cover Sheet“ Direction
in Section 4-14-2.
Gap
Check that the production speed is not too Stopper Block

fast
- When the production speed is too fast, the
cover sheets can be delayed. Reduce the
production speed.
- When using hard folded sheets, the book
block may hit the base of the clamp when it is
inserted into the clamp.
This causes the center of the book block to Down-
shift downstream. Reduce the production stream
speed.
The cover sheet holder is necessary Cover Sheet

- The holding pressure (adjusted by weight) Delays
produced by the cover sheet holder prevents
the cover sheets from being embossed. If this
pressure is too light, the cover sheet shifts to Down-
Middle Of The Book stream
the top when it hits the stopper block. The Block Shifts
faster the production speed, the more the Weights
cover sheet will shift. Reduce the production
speed or adjust the weight of the cover sheet
holder so that the cover sheet does not shift.
Cover Sheet
Holder
139
6. Troubleshooting
The book block and the cover are shifted diagonally
Check that the stopper block is adjusted

properly
- If the two stopper blocks on the cover sheet
register section are not adjusted equally, the
book block and the cover sheet will be shifted
diagonally.
- Adjust the stopper blocks so that they are
straight by following the instructions in
“Positioning Adjustment of Book Block and Book block and the cover is
the Cover Sheet” in Section 4-14-2. shifted diagonally
NOTE
The function of the stopper block is to
prevent the cover sheet from being
diagonally in relation to the book block.
The stopper blocks can correct skewing
of the cover sheets, as long as this can
be done within the space allowed by the
cover sheet guides.
Stopper Block
140
6. Troubleshooting
Too much spine glue extends from the top or bottom of the book block
Check that the input data is correct Production

- Compare input length of the book block Flow
and the actual book block length. If an
incorrect length has been input, the glue timing
on the application drum will not match the
book block, and too much glue will extend Bottom
from the top or bottom of the book block.
Top
0.394 inch
(mm)
4.724 inch
7.874 inch
(mm)
(mm)
9.055 inch
(mm)
5.118 inch
(mm)
15.748 inch
(mm)
OK
Shorten the spine glue application length Block Size Input Screen
- The spine glue application length can be
adjusted according to the condition of the Main Screen
binding. Shorten the spine glue application 0.394 (mm)
inch
8.268 (mm)
inch 7.874 (mm)
inch
12
3
0 book(s)
0 book(s)
length by following step 6- “Setting the Glue 5.906 (mm)
inch 1400
5200 books/h Manual
Applying Length” in Section 4-8-2. 9.055
1000 rpm
Adjustment
7.087 (mm)
inch
15.748 (mm)
inch
Screen
1 2
1
2
+0.000 +0.000 +0.000 +0.000
1
179 180
2 181 180
3 169 170
OK
Spine Glue Manual

Adjustment Screen
141
6. Troubleshooting
When the spine glue laps to the side
- This section explains why the spine glue can

lap to the side after the nipping operation. The
figure to the right is shown without the cover
sheet in order to point out the glue pattern.
- When the spine glue laps to the side, this can
be caused by incorrect glue application
thickness or incorrect nipper height. Any extra
glue laps to the side.
Spine Glue
Spine Glue Lap (without cover sheet)
Drum 3
When the spine glue is too thick Drum 2
- The spine glue thickness is set by the height Drum 1
of each drum and by the wiper opening.
The lower each drum is set, the thicker the Scrape Roller
spine glue becomes. The extra glue is removed
when the spine is nipped by the nipping
section. Check the height of each drum and the
wiper opening.
- Refer to step 5, “Adjusting the Height of Scale
Each Drum” in Section 4-8. Drum1 0.5
- Refer to step 7, “Adjusting the Wiper
Drum2 1.0
Opening” in Section 4-8.
Drum3 1.5
Scrape Roller 1.3
Main Screen
Lower the nipper height 0.394
10.0 inch
(mm)
8.268 inch 7.874

200.0 inch
11 22 3
3
00 book(s)
book(s)
0 0 book(s)
(mm) (mm) book(s)
- Lowering the nipper height prevents the 5.906

1400
1400 books/h
5200 books/h
1000 rpm
1000 rpm
spine glue from lapping. This makes the spine 7.087

130.0 inch
(mm)
15.748
400.0 inch
1400 9.055
230.0
rounder.
(mm)
- Lower the nipper height. See step 2 in 1 2
Section 4-14-2.
OK
Nipping Height Adjusting Screen
142
6. Troubleshooting
When glue is not applied to part of the book block spine
Glue is not applied to the top of the book spine

- Compare the input length for the book block
Book Line
with the actual book block length. If the input
Block
length is shorter than the actual book block, glue
will not be applied to the top of the book block. Top
Lengthen the spine glue application length Glue

- The spine glue applying length can be adjusted No glue is applied
according to the condition of the binding.
Lengthen the spine glue application length by
following step 6, “Setting the Glue Application
Length” in Section 4-8-2.
Glue is not applied to the bottom of the book

spine
Book Line
Adjust the bottom edge of the spine Block
- The bottom edge of the book block rests at a Bottom
standard position, so it need not be adjusted. If Edge
the glue is not applied to the bottom edge of the Glue
spine, even if the book block size is changed,
adjust the bottom edge of the spine by following No glue is applied
step 8, “Adjusting The Bottom Edge Of The
Spine” in Section 4-8-2.
Glue is not applied to the middle of the book

spine
Check that there is enough glue in the melt

tank.
- When there is not enough glue inside the melt
tank, the rotation of the application drum can Book Line
catch some air. The bubble can then break out Block
when it reaches the application drum.
Check that there is no foreign object inside the Glue

melt tank No glue is applied
- If there is milling dust inside the melt tank, the
glue will not flow smoothly, and the glue on the
application drum will become uneven. In this
case, check inside the tank and the wiper.
143
6. Troubleshooting
Check that the book block is not swelled Fore-edge

- When binding a thick book block using Part
folded sheets, and the folded sheets have not
been completely creased, the whole book
block swells. When this swelled book block is
inserted into the clamp, the upper corner of
the book block (fore-edge) may be bent when
it hits the clamp. Use folded sheets which
have been completely creased.
The fore-edge of the
book block is bent.
Clamp
144
6. Troubleshooting
6-2 When The Pole Lamp Lights And The Machine Stops

If a problem occurs, the sensors in each area detect
the trouble and stop the machine. The red warning Pole Lamp (red)
lamp is lighted to indicate that there is a problem. 12
3
book(s)
book(s)
books/h
rpm
The monitor displays an error icon to show the 1 2 3
cause of the error. This section describes the error

icons.
16
15 :
14 The changeover
Error Indication : of each section
13 Press to go to the is still not
error screen. completed.
Perform the
1 1 2 3
0.394 (mm)
inch
8.268 (mm)
inch 7.874 (mm)
inch
12
3
0 book(s)
0 book(s) automatic
1400
5.906 (mm)
inch
3
7
5400 books/h
changeover of
2 1 2 1000 rpm
1 2
7.087 (mm)
inch
9.055
each section.
10 15.748 (mm)
inch
(See Section
11 4-1, Step 3 for
1 2
details.)
Error Screen 12
4 3 5 6 8 9 Main Screen
This figure shows the all error icons. Actually, only the icon
which indicates a current error will appear on the monitor.
Collator MG-60H has an error. Level plate is lowered too much.

1 Check the collator. 9
Raise the level plate.
The stop button in the infeed section The milling section door is open.
2 has been pressed. Pull it up to clear 10
Close the door to clear the error.
the error.
The torque limiter at infeed section has
3 tripped. (Refer to Section 6-3(3) for 11 The milling operation is not working.
details about the torque limiter.)
4
The transport section cover is opened. The milling slide locking lever is not
12
Close the cover to clear the error. locked.
The stop bar on the hand feed mecha- The torque limiter in the clamp
5 13 rotation section has tripped. Refer to
nism has been pushed.
Section 6-3(13) to clear the error.
The stop button on the manual feed The nipping section cover is open.
6 tray has been pressed. Pull it up to 14
Close the cover to clear the error.
clear the error.
The hand feed section cover is open. The shear pin in the nipping section has
Pull it forward when doing the 15 broken. Refer to Section 6-3(15) to
7
automatic binding. clear the error.
Book jam at level plate section. The delivery section cover is open.
8 Restart after removing the jammed 16 Close the cover to clear the error.
book block.
145
6. Troubleshooting
6-2 When The Pole Lamp Lights And The Machine Stops (Continued)
Error Screen Indications (Continued)
20 19 18 17 Glossary
When the binding operation at high speed, a lot
of spine glue is needed. The pre-melt tank can
22 provide the increased amount of melted glue to
the melt tank automatically.
23 28
24
21 Glossary
25 3
32 When some of the moving parts of the machine
1 2
lock up for some reason, moving those parts by
29 1 2
3
force may damage the machine. A torque limiter
1 2
is a safety device which is attached on the power
transmission linkage to prevent this kind of
26 problem.
30
27 31 33
The torque limiter at the delivery A temperature error occurs in the spine
17 section is operated. Refer to 6-3(17) to 26 1
glue tank 1.
release the error. Refer to Section 6-3(25) to clear the error.
Book block jam at delivery section. 1 There is a problem with the pre-melt
18 Restart after removing the jammed 27
book block. tank for melt tank 1.
Twisting conveyor section cover is The melt tank cover is open.

19 open. Close the cover to clear the 28 Close the cover to clear the error.
error.
The twisting conveyor section cover is There are not enough glue inside the melt
20
open. 29 2 tank 2. Apply glue to release the error.
There is a book block left inside the A temperature error occurs in the spine
21 clamp. Refer to Section 6-3(21) to 30 2 glue tank 2.
clear the error. Refer to Section 6-3(25) to clear the error.
The stop button on the twisting
conveyor section is pressed. Pull it 2 There is a problem with the pre-melt
22 31
to release. tank for melt tank 2.
There is an error on the finisher The whole melt tank has been lowered.
23 (three-knife trimmer). Check the 32
three-knife trimmer Raise the melt tank.
The glue in the melt tank is not hot A temperature error occurs in the side
24 enough yet. The error will be released 33 gluing tank .
3
when the glue is heated up to the setting Refer to Section 6-3(25) to clear the error.
teperature.
There are not enough glue inside the
25 1
melt tank 1. Apply glue to release the
error.
146
6. Troubleshooting
6-2 When The Pole Lamp Lights And The Machine Stops (Continued)
Error Screen Indications (Continued)
47 48
49
46 44
45 43
42
41
1 2 3
3
40
30
1 2
1 2
39
30
38
37
34 35 36
The temperature error occurs in the There are no cover sheets on the feed
34 3 side gluing tank. Refer to 6-3(25) to 42
release the error. table. Load more cover sheets.
The side glue supply unit has a prob- 43 There are just a few cover sheets on the
35
lem. Check the side glue supply unit. feed table. Load more cover sheets.
36
The side gluing air pressure is not 44
Automatic setting function can not be
correct. used because of the loaded cover sheets.
Remove the cover sheets to release the
error.
There is an alarm from the driver for The cover sheets have been loaded
37 the milling motor. 45 incorrectly. Check the direction and the
Turn off the power, wait 10 seconds, orientation of the cover sheets.
and turn it on again. Refer to Section 6-4 for details.
There is an alarm from the driver for Double feeding occurred. Refer to
38 the clamp drive motor. 46 Section 6-4 to correct the problem.
Turn off the power, wait 10 seconds Refer to Section 6-3(46) to clear the
and turn it on again. error.
Misfeeding occurred. Refer to Section
39 Power switch is turned OFF. 6-4 to correct the problem.
47
Refer to Section 6-3(47) to clear the
error .
The stop button on the control panel The stop button on the cover feeder
40 has been pressed. 48 has been pressed. Pull it out to clear
Pull it forward to clear the error. the error.
The cover sheet image has not been There has been a sheet jam.
41 saved. Save the image again. Refer to 49
Restart after removing the jammed sheet.
Section 4-10.
147
6. Troubleshooting
6-3 Clearing Error (3)
Check the cause
- The book blocks are transported by the

chain shown in the figure to the right. If a
problem occurs in the drive mechanism for
this chain, a torque limiter will operate in
order to protect the machine. Chain Torque Limiter
Mechanism
Check that there is no book block jammed

inside the infeed section.
- When the machine locks up because a book
block is jammed in the infeed section, the torque
limiter between main body of the SB-15 and the
infeed section has operated in order to protect the
machine. Remove the jammed book block.
Torque Limiter
Reset the torque limiter
Release Lever
- When torque limiter has operated, the

lever in the figure to the right moves down.
1) Correct the problem which caused the

torque limited to trip. Torque Limiter Release
Lever
ON OFF
2) Lift the torque limiter release lever and
turn on the remote control for the clamp
rotation. Press the reset button and then Reset
keep pressing the operate by inches button.

Stop when you hear a click and the chain is Inching
engaged.
- If the lever is not lowered, it means that

the torque limiter has reset.
Remote Control For
Clamp Rotation
148
6. Troubleshooting

Check the cause
Check to see if a clamped book block has hit

something Book
- If a clamped book block slips and hits Block Clamp
something, this can place too much load on
the clamp. The torque limiter will operate in order
to protect the machine.
- If the book block has slipped, check the number
of sheets in that book block. If the number of
sheets is correct, there is something wrong with
the clamp.
Check that the guide rollers on the clamp are

OK
- There are nine rollers on each clamp. If there is a
problem with these rollers, the clamp movement Guide Rail
becomes sluggish and the torque limiter trips.
Check that the guide rail of the clamp is OK Guide Roller

- When there is a foreign object on the upper or Guide Rail
lower clamp guide rail, the clamp movement
becomes sluggish and the torque limiter trips.
Guide Roller
- Correct the problem that caused the torque Guide Section Of The
limiter to trip, then rotate the clamp clockwise by Clamp
hand. The limiter will reset and the clamp will
become hard to rotate by hand.
149
6. Troubleshooting
Check the cause
- When nipping the book block which is

wider than the width, the mechanism of the
nipping section may be overloaded. To
prevent this problem, the shear pin will break
to protect the mechanism.
Safety
Pin

- The nipping width is set automatically
according to the book block thickness. If
the incorrect book block size is input, the
nipping action may be incorrect.
- Check that the actual thickness of the book Main Screen
block matches the setting on the Block Size 0.394
10.0 inch
(mm)
8.268 inch 7.874

200.0 inch
11 22 3
3
00 book(s)
00
book(s)
book(s)
(mm) book(s)
Input screen. If the incorrect book block size

(mm)
120.0inch
5.906 1400
(mm) 1400 books/h
5200 books/h
1000
1000 rpm
rpm
has been input, input the correct value on the 7.087

130.0 inch
(mm)
15.748
400.0 inch
1400 9.055
230.0
230.0
Block Size Input screen or by using the book

(mm)
0.394 (mm)
inch
size input interface. See Chapter 8. Also 1 2
8.268 (mm)
inch
check the value on the Manual Adjustment 7.874 inch
(mm)
screen. 5.906 inch

(mm)
Check the number of the sheets in the book 55.118 inch 9.055
(mm)
7.087 inch
block when the shear pin was broken. (mm)
- If a book block with many more sheets 15.748 inch

(mm)
than the setting is delivered to the nipping

section, the shear pin will be broken by the Block Size Input Screen
force of the nipping operation. Find out why
too many sheets were transported to the
nipping section.
Replacing the shear pin

- Replace the shear pin by following the
150
6. Troubleshooting
Check the cause
Check that the book block is not jammed

inside the delivery conveyor.
- When the conveyor locks up because of a
book block jam in the delivery conveyor, the
torque limiter will operate to protect the
machine. (The torque limiter is located in the
connecting section between the main body and
the delivery section.)
Remove the jammed book block. Delivery
Conveyor
Check the drive section of the delivery con-

veyor.
- If there is a problem in the drive section of the
conveyor, the torque limiter will operate. Check
the belt pulley and the shaft.
- Remove the cause of the conveyor

overloading, and repeat the binding operation
again. The torque limiter will reset
automatically.
151
6. Troubleshooting
Clearing A Book Block Jam In A Clamp
If there is already a book block inside the

clamp, a sensor detects the book block and
stops the machine. U
Check that there is a book block inside the Book Block Inspection
clamp. Window
- Open the door for the twisting conveyor

section and see if there is a book block still in
the clamp. If there is a book block, remove it.
If it is difficult to remove the book block,
open the book block inspection window and Twisting
remove it. After removing the book block, Conveyor
return the detector bar and close the book Section Door
block inspection window.
Check that the inside of the clamp is not

fouled
- When the inside of the clamp is fouled with Detector

glue and you are binding thin book blocks, Bar
the cover sheet may become stuck inside the
clamp. Clean inside the clamp.
CAUTION
Press the stop switch or open
an upper cover before
removing the book block.
152
6. Troubleshooting
1 2 3 Resetting After A Temperature Error Occurs In The Spine/Side Glue Tank
Check the cause
Error appears when the tank temperature CAUTION

is different 50 degrees Celsius or more from
the setting temperature. The melt tank is heated up to
about 392 ˚F (200 ˚C). Keep your
Check that the temperature fuse is not hand and fingers away from the
blown melt tank. Otherwise, the high
- There are two temperature fuses for the temperature can cause severe
spine gluing section and one on the side skin burns.
gluing section. When the temperature of one
of the melt tanks becomes too high, a fuse
blows and prevents overheating and ignition.
If a fuse is bad, an error icon appears on the
error screen.
Resolving an Overheating Problem
- Each thermo-fuse should be installed in the

bottom of the glue tank through the white insu-
lating tube. If the white insulating tube moves or
comes off, the temperature can be transmitted to
the thermo-fuse directly and the blow the fuse.If
the thermo-fuse is not fit to the bottom of the
glue tank correctly, the fuse cannot prevent Temperature
overheating when the glue tank temperature Sensor
becomes too high.
- If the overheating problem is not corrected

although the thermo-sensor and fuse are installed
properly, call your local dealer.
WARNING
Temperature
Do not the short-circuit the Fuse
thermo fuse. This can cause a fire.
Attach the round part of the Bottom Of The Melt Tank
thermo fuse to the bottom of the
glue tank inside the white insulat-
ing tube. If this is not installed, Fit
the fuse cannot function properly
and this may cause a fire.
Thermo-fuse
White Insulating Tube
153
6. Troubleshooting

Double
Feed Stop
Check that the projecting length of the
Screw
double feed stop screw is OK
- When the projecting length of the double
feed stop screw is too short, the cover sheets
can not be separated correctly. Increase the
projecting length by following step 4 in
Section 4-10-2, “Setting The Projecting
Length Of The Double Feed Stop Screw”.
Projecting
Length
Check that the blower air is OK

- Cover sheets are fed one by one from the
bottom of the stack. In order to separate the Blower Air
cover sheets, blower air is supplied from the
top of the stack. If the air pressure or the
blower air position is not correct, double
feeding can occur.
Reset the blower air setting by following step
5, “Adjusting The Blower Air” in Section 4-
10-2.
Check that the air pressure produced by the

pump is OK
- Increase the blower air pressure produced by
the pump within the range of 4.3 psi to 8.6 psi
(30 KPa - 60 KPa).
Check that the cover sheets are fanned

correctly
- See the same item on the next page.
Blower Air
Adjusting
Knobs
154
6. Troubleshooting
Check that any suction cup which is not used Suction

is covered Cup
- When using small cover sheets, one suction Which Is
cup on each side is not used. If these two Not Used
suction cups are not covered, the vacuum going
to the other suction cups is reduced and the
cover sheets can not be fed. Follow step 6 in
Section 4-10-2.
Check that the double feed stop screw does

not extend too far Double
- If the double feed stop screw extends too Feed Stop
far, it becomes difficult to separate the cover Screw
sheet which is gripped by the suction cups. Set
it correctly by following step 4 in Section 4-10-
2.
Check that the cover sheets are fanned cor-

rectly
- If the ink on the printed sheet is not dried
completely, or the sheets are trimmed by a dull
cutter, the sheets can be difficult to separate. Cover
Fan the sheets well before binding. Sheets
Glossary
To “fan” means to fan through the stack of sheets.
This leaves some air between the sheets so they
can be separated easily.
Check that the vacuum provided by the air

pump is OK
- Increase the vacuum provided by the pump
within the range of 40 KPa to 60 KPa.
- Adjust the vacuum while the cover sheet is
attached to the suction cups.
155
6. Troubleshooting
6-4 Problems In The Cover Feeder
When The Cover Sheets Are Not Fed Properly
If a cover sheet is not fed properly, the red light

of the pole lamp illuminates and an error
screen indicates the trouble. See the sections
“When Double Feeding Occurs Frequently”,
and “When Misfeeding Occurs Frequently”.
Restarting
The collator and the binder stop operating

when an error occurs. Deal with the booklets
which have stopped “in process” using the
following procedures:
1. Take out any gathered book blocks, which

have not entered the clamp yet.
- Bind each book block by feeding manu-
ally or replace it in the bin of the gath-
erer.
2. Any book block which is bound with an

extra cover sheet should be rejected as a
bad book.
ON OFF
(1) If a cover sheet jam occurred, remove

the jammed sheet. Reset
Inching
(2) Operate the binder using the inching Inching

operation button on the remote control. Operation
- Press the reset button and inching Button 05SB08A20
operation button.
- At this time, glue is applied to the spine
of the next book.
156
6. Troubleshooting
6-4 Problems In The Cover Feeder (Continued)
3. Bind the next book block by inching NOTE

operation. - Continue inching until all the book
- Repeat step 2. Glue is applied to the blocks in the binder are delivered to the
spine of the next book block. sorter.
- If the feeding problem was temporary, - Book blocks which are bound by
the cover sheet will be fed properly inching will be sorted as bad books. But
next time. Check to see if the cover if step 2 and 3 can be done quickly, the
sheet is fed properly using the window book block can be bound before the
in the cover sheet transport section and spine glue can harden. This produces a
keep operating the machine by inches. good book even though it is sorted as a
bad book. Check for this.
- If the cover is not fed correctly, repeat
step 2.
When the cover sheets are loaded in the wrong direction
- When the book block enters the clamp,

the cover feeder feeds the cover corre- NOTE
sponding to the clamp movement. - All of the books bound after detecting
misloading are sorted as bad book
- At this point, the mis-loading preven- blocks.
tion sensor checks the direction of the - If there is only one cover sheet which
cover sheet. If misloading is detected, was loaded on the wrong direction, the
the sensor stops the gatherer. The book block with that cover sheet is a
binder continues operating until all the defective product. Therefore there may
book blocks which have been bound be good quality books sorted as faulty
with misloaded cover sheets are sorted books. Check the bound books.
as bad books.
- Reload the cover sheets with the

correct orientation and start the binding
operation again.
157
6. Troubleshooting
6-5 When A Bad Booklet Is Not Detected

The SB-15 detects a bad booklet using the
three sensor functions listed below.
1. Cover Sheet Mis-Loading Prevention

Sensor
2. Book Block Height Detect Sensor
2. Book Block Height Detect Sensor
3. Weight Checker (Option) By comparing the top-bottom length of
the book block with the pre-set value,
the SB-15 detects a booklet of which
1. Cover Sheet Mis-Loading Prevention cover or book block shifts, as a bad
Sensor booklet.
If the sensor misdetects a correct book-
let with the correctly set cover, as a bad If the SB-15 misdetects a booklet as a
booklet, decrease the detecting sensitiv- bad booklet even though the amount of
ity. the shift between the cover and book
block is permissible, decrease the
NOTE detecting sensitivity.
If a cover is set in wrong direction, it
makes one bad booklet. The booklets NOTE
which are made after that bad booklet At the Max. sensitivity, a booklet with
are also delivered with the bad booklets the pre-set value of book block + 1.5
even though they are OK. This is not an mm is detected as a correct.
detection error. By each level you decrease the detecting
10.0
210.0
Main Screen
200.0
12
3
0 book(s)
0 book(s)
1400
sensitivity, it adds 1.5 mm to detect a
150.0
230.0
5200 books/h
1000 rpm booklet as a correct (At the Min. sensi-
180.0
400.0
tivity, +7.5 mm.)
d3
1 2
ON ON ON
Function Book Block
MG MG+HT
HT
OFF OFF OFF
Screen ON Height Detect
ON ON OK 90% ON Sensor Setting
OFF OFF OFF OFF
Screen
OK
Mis-loading Book Block Size + 1.5 mm

ON OK 90%
Prevention is detected as correct
OFF Function Book Block Size + 7.5 mm
Set Up Screen is detected as correct
To the contrary, if an bad booklet

To the contrary, if a bad booklet is not ejected, check the ON icon is
with a misloaded cover is not ejected, pressed on the Book Block Height
check the followings. Detect Sensor Setting screen.
- On the Mis-loading Prevention Func- If the setting is ON, increase the
tion Set Up screen, the ON icon is detecting sensitivity.
pressed.
- The image of the cover is saved
correctly. (Refer to page 80 for details.) 3. Weight Checker (Option)
If the settings are OK, increase the
detection sensitivity. See Chepter 8 “Optional Devices”.
158

This chapter lists the accessories and specifications for the SB-15
7-1 Accessaries ..........................................................................................................160
7-1-1 Accessaries And Tools ................................................................................... 160

7-1-2 Consumptions ................................................................................................. 163
7-2 SB15 Specification ............................................................................................. 164
159
7-1 Accessories
7-1-1 Accessories And Tools
Operation Manual 1 pc Tool Box 1 pc
Op
era
tio
nM
an
ua
l
This box includes

tools.
Hand Feed Guide 15 pcs Cover Sheet Holder Weights 2 pcs

Use this guide when using large covers
Use these weights
with lighter cover
sheets.
Fuses 2 pcs each Chain Joint 2 pcs

For the transport chain in the book
block transport section
For Tank 1 and 2 For Side Gluing
Grease Guns 1 pc each Roughening Cutter Setting Gauge 1 pc
Yellow
Green
Leveling Mounts 5 pcs Jogger Plate 1 pc
160
7-1 Accessories (Continued)
Milling Cutter Handle 1 pc Milling Cutter Handle Mounting Screws 2 pcs
Allen Wrench Set BL X 6 1 pc Allen Wrench (0.55”)(14 mm) 1 pc
Wrench (Small) 1 pc Wrench (Large) 1 pc
5 mm x 7 mm 19 mm x 24 mm
Wrench (Medium) 1 pc Wrench (Small) 1 pc
13 mm x 17 mm 8 mm x 10 mm
Ball Point Driver (0.16”) ( 4 mm) 1 pc Socket Wrench (0.95”)(24 mm) 1 pc
161
Ball Point Driver (0.12”)(3 mm) 1 pc Wrench (1.8”)(46 mm) 1 pc
Handle 1 pc Cutter Spacer 5 sheets
Drain Assembly 1 pc Belt 1 pc each
150L050
124L050
Drive belt for twisting conveyor section
Chute (M102172-01) 1 pc
Attach at side gluing chute (spare).
162

7-1-2 Consumables
Spine Glue (HM-220) 5 Kg Side Glue (HM-403) 5 Kg
Suction Cups For Cover Feeder / Caps 10 pcs each Shear Pins 5 pcs
[M052010-00]
Spare Cover Screws 5 pcs each Milling Cutter (M101486-00) 1 pc
Roughening Cutter 2 pcs Grease Cartridges 1 pc each

These are only for the SB-15. Do not use for
other types of binding machines. [A933225-00]
[A933224-00]
163
7-2 SB15 Specifications
Model SB-15
Clamps 15
Landscape (1) (2) Remarks
(1)
Max. 330 mm (12.99") 320 mm (12.59")
(2)
Hand Feed Only
Min. 135 mm (5.32") 185 mm (7.29")
Portrait
When feeding the sheet
330 mm (12.99") 250 mm (9.84")
Book Size blocks from the gatherer
(1) Max. When feeding the sheet

350 mm (13.77") 260 mm (10.23") blocks into the infeed
(2) section
400 mm (15.74") 280 mm (11.02") Hand Feed into the Clamp
*1
Min. 148 mm (5.83") 105mm (4.14")*1
Book Thickness 2 mm to 50 mm (0.08" to 2")
Max. 400 mm x 660 mm (15.74" x 25.98")
Cover Size (Top-Bottom x Fore Edge)
Min. 135 mm x 230 mm (5.32" x 9.06")
81.2 to 290 gsm (30 to 120 lb) (Normal Paper)
Cover Weight Range
104.4 to 348 gsm (40 to 128 lb) (Coated Paper)
Cover Pile Height Max. 130 mm (5.1")
Tank Temperature 150 to 200 degrees Celsius (302 to 392 degrees Fahrenheit)
Application Drums 3 (The tank can be divided into two sections)
Milling Cutter Maximum Trim Depth 5 mm (0.2") (Depends on the sheet weight)
Milling Cutter Diameter 220 mm (8.66")
Milling Cutter Rotation Speed 1000-2500 rpm
Available Collator MG-60H
Cover sheet double feeding, No feeding, Mis-loading*2
Detecting Functions
Sheet length, Cover sheet jam
Production Speed Max. 5200 books / hr.
3 Phase, 200-230 V, 50/60 Hz
Voltage/Frequency
3 Phase, 380-415 V, 50 Hz
Heat Out Put 26,860 kJ (6,430 kcal)
Machine Dimensions 6,250 (W) x 1,700 (D) x 1,130 (H) mm (246.5"x 67.0" x 44.5")
Machine Weight 4,100 kg (9039 lb)
Book Size Input Interface, Connecting Unit, Weight Checker, Sorter,

Delivery Stacker (SC-15), Delivery Conveyor (RC-15), Stack Orientator
Optional Equipment (PP-100), Milling Blower Unit, Pre-melt Tank, Side Glue Supply Unit, Book
Block Sensor, Infeed Air Assist Blower, Power Supply Box, Chip Extractor
(TB-100)
*1 When feeding the A6 (148 mm x 105 mm) from the gatherer,

the optional attachment is necessary for the gatherer.
*2 When using A6 or smaller sheets, or there is no printing on the
sheets, the detection function can not be used.
164
8. Optional Devices
8. Optional Devices
This chapter explains how to operate the optional devices for
the SB-15.
165
8. Optional Devices
8 Book Size Input Interface

1 Parts description
This unit measures and inputs the book

block size using the original bound book
block. This makes it unnecessary to input
the book block size using the touch panel
Control Panel
Hooks
MA
X
C
Slider
E
Slide this unit to measure

the book block or cover
sheet.
Measuring Length
This value is input to the SB-15.
Input Items
MAX
= Zero point input
= Maximum point input
= Book block thickness
= Book block top-bottom length
= Cover sheet top-bottom length
= Cover sheet width
C = Spine 1
= Spine 2
= Book block fore-edge length
= Data transfer
Clear the measured value

E The input item and the measured value are indicated.
Enter the measured value
Control Skip the input item and go to the next item

Panel
166
8. Optional Devices
8 Book Size Input Interface (Continued)

2 Setting the book size input interface
1 Connect the power cable and the signal cable
- The service representative will take care of this.
Book Size Input Interface

2 Input the book block size using the original book
1. Go to the Block Size Input screen on the
MAX
C
Slider
E
monitor.
- Press in the upper left corner of
the Main screen. Block Size Input
screen appears.
If the touch panel is not presenting the Main Screen

Block Size Input screen, the data from 0.394 inch
(mm) 12
3
0 book(s)
the book size input interface can not be 8.268 inch

(mm) 7.874 (mm)
inch 0 book(s)
1400
5.906 (mm)
inch
received. 5200 books/h

1000 rpm
230.0
5.118 inch
(mm)
15.748 (mm)
inch
0.394 inch
(mm)
If the value out of range is input, the 8.268 (mm)

inch
7.874 (mm)
inch
Out Of Range screen appears. You can 1 2 5.906 inch

(mm)
not bind the book with the size which is

9.055 inch
out of range. Refer to page 42 for the 7.087 inch
(mm)
(mm)
value range which you can bind the inch

15.748 (mm)
book. OK
2. Initialize the settings. Block Size Input Screen

- After turning on the power, initialize
the book size input interface so that it
will perform correctly.
(1) The " " symbol appears on the

panel. OK
Move the slider to the left end and press

the "E" button (Input). The zero point is Out Of Range Screen
Panel
saved.
(2) The " " symbol appears on the

panel.
Move the slider to the right end and
press "E" button (Input). Maximum
reading is saved.
Now the initialization of the device is E

complete. It is not necessary to repeat
these procedures unless the power is
turned off.
167
8. Optional Devices

3. Input the book block thickness.
MA
X
- The " " symbol appears on the panel. Book
C
Clamp the book block as shown in the Block
E
figure to the right and press the "E"
button (Input).
NOTE
- Clamp the thinnest part of the book
block. The folded part is larger and the
thickness of the book block can not be
measured correctly there.
MA
X
- Press the slider firmly against the
C
book block and press the "E" button
E
(Input).
4. Input the top-bottom length of the book

block. Top-bottom
- The " " symbol appears on the panel. Direction
Clamp the book block in the top-
bottom direction as shown in the figure
to the right and press the "E" button
(Input).
5. Input the fore-edge length of the book

MA
X
block.
C
- The " " symbol appears on the panel.

E
Clamp the book block in the fore-edge

direction and press the "E" button
(Input). Fore-edge
Direction
This value is necessary when using the Hook

unit in a system including a three-knife
trimmer.
If you are not using the three-knife
trimmer, press the Skip button and go
to the next procedure.
6. Input the top-bottom length of the cover
sheet. Cover
- The " " symbol appears on the panel. Sheet
Clamp the cover sheet in the top-
bottom direction (short direction) and
press the "E" button (Input).
7. Input the cover sheet width.

Clamp the cover sheet along the width
dimension (long direction) and press
the "E" button (Input).
168
8. Optional Devices
8. Input the measurement for spine position

1.
Move the slider to the position for
Spine Position 1, as shown in the figure
to the right, and press the "E" button
Book Size Input Interface

(Input).
NOTE
- The book size input determines the
position of the printing on the spine
using the measurements for spine 1 and
2. If the printing on the spine is not cen-
- You can also set the spine position tered, this can be adjusted. See Section
using just a single measurement to the 6-1, "The printing on the spine is not
center of the spine. To do this, move the come centered."
hook to the center of the spine and
press the "E" button (input). Skip step
9 ("F"- Spine Position 2) by pressing ing
int
Pr
the Skip button. ine

Sp
on
9. Input the measurement for spine position

2.
Move the slider to the position for
Spine Position 2, as shown in the figure
to the right, and press the "E" button
(Input). Panel
- When the center frame or the center of
the spine is input on procedure 8, press
[skip] and skip this procedure.
10. Enter the data.

E
Press the "E" button (Input). The book
size input interface will send the book
data which have been input in steps 2-9
to the binder.
169
8. Optional Devices
8 Connecting Unit
1 Parts description Z
This section receives each book
block transported from the gath- J B
erer, then raises and delivers it to U W D N A Q H
the infeed section C
MG-60 S L M G Y
R
CAUTION
Viewpoint
If the guide width is set
automatically, and then the position
is changed manually, the machine
will not remember the new setting.
If you reset the power switch (Off,
then On again), the connecting unit
will move to the previous position.
Adjustable Guide Belt
Infeed Section [S] This section is set automatically according
This is described in Section 4-4. to the book block thickness.
Fixed Guide Belt
The book blocks are clamped
between this belt and the
adjustable guide belt, then
transported to the infeed
section.
Hole For A Handle
The guide width can be adjusted
manually by inserting the attached
handle here. When removing a
book block, use the remote control
for the guide width adjustment.
Collator
Mount
These adjust the height of the
connecting unit.
170
8. Optional Devices
8 Connecting Unit (Continued)
2 Setting the connecting unit
(1) Set the transport section width (AUTO)
Connecting Unit
(2) Adjust the guide width of the transport
section
1 Setting the transport section width

Book Block Fixed Guide Belt
- The guide belt width in the transport
section is set automatically according to
the book block width. Adjusting
Width
- The guide belt width in the transport Adjustable Guide Belt
section is set to be 0.0394" (1.0 mm)
narrower than the book block width. The
guide position can be fine-tuned depend-
ing on the condition of the book block.
Sheets Are Curled
2 Adjusting the guide width of the transport section
1. Press (manual adjustment) on the Main Screen

touch panel. 0.394 inch
(mm)
12
3
0 book(s)
(mm)
(mm)
5.906 (mm)
inch 1400
5200 books/h Manual
- The Manual Adjustment screen appears. 1000 rpm
9.055
Adjustment
7.087 inch
(mm)
15.748 inch
(mm)
Screen
2. Press (transport section).
1 2
- The Transport Section Manual Adjust-

ment screen appears. 1
2
3. Adjust the transport section width by

pressing or under the symbol.
- The setting range is from +0.390" to -
0.390" (+10.0 to -10.0 mm). +0.000 +0.000 +0.000 +0.000
4. Press OK. OK
- The new setting is entered and the previ- 3

ous screen appears. Transport Section Manual 4
Adjustment Screen
171
8. Optional Devices
8 Weight Checker
1 Parts description
This section explains how to identify a

bad book using the electrical scale. Z
Read the operation manual of the W
electrical scale for details. J B
U D N A Q H
C
MG-60 R S L M G Y
Control Panel
See the next
page.
SELECT
ITEM
OVER DYNAMIC
CALIBRATE
Sensor
SET EXIT
UP
PROPER NET
CONVEYOR
INFO
Power Switch
UNDER
ENTER
PRINT C
This sensor checks each

Keep this power switch
book block. Normally,
turned on. The weight
both the green and red
checker will turn on and
LED's are lighted. When
off along with the SB-15.
the sensor sees a book
block, only the green
LED will light.
Sorter
Transport Conveyor
This receives the book
blocks transported
from the delivery
conveyor.
Conveyor Cover
This cover prevents small air
flow from affecting the weight
measurements.
Weight Measuring Conveyor (The small air flow can affect
This conveyor measures the book the accuracy of measurement.)
weight while the book is being
transported across.
172
8. Optional Devices
8 Weight Checker (Continued)

2 Control panel description
(17) (1) (2) (3) (4) (7)
Weight Checker
Control Panel
This indicates the
condition and setting
of the device.
(10)
(14)
SELECT
(11)
OVER DYNAMIC ITEM
(15) CALIBRATE
SET (12)
EXIT
PROPER NET UP
CONVEYOR
INFO
(16) UNDER (13)
ENTER
PRINT C
Keypad
(18) (5) (6) (8) (9) Input the condition and
setting of the device.
Number Code Description Number Code Description

Pressing when the device is
SELECT ITEM The item on the control panel is
(1) StartKey on stand by, the conveyor (10)
Key* selected.
starts to drive.
Pressing when the device is The current setting finishes and
(2) Stop Key operated, the conveyor (11) EXIT Key the screen changes to the
stops. previous one.
Pressing when the device is
(3) Calibration Key on stand by, the calibration (12) Triangle Key The cursor is moved.
starts.
Pressing when the device is The cursor is moved.
ENTER
(4) SET UP Key on stand by, the setting (13) When inputting value, the value
Triangle Key
indication appears. is entered.
When pressing, the screen
Illuminates when the book is
(5) INFO Key on the control panel (14) OVER Lamp
overweight.
changes.
When pressing, the print Illuminates when the weight of

(6) PRINT Key* (15) PROPER Lamp
indication appears. the book is proper.
Illuminates when the book is

(7) Number Key The number is input. (16) UNDER Lamp
underweight.
DYNAMIC
Desimal Point Illuminates when performing a
(8) The decimal point is input. (17) CALIBRATE
Key fine adjustment.
Lamp
Illuminates when subtracting the

(9) Clear Key The input value is cleared. (18) NET Lamp
weight of tare.
* These keys are not used normally.
173
8. Optional Devices

3 Setting up the weight checker
- You must measure the weight of the Main Screen

book block so that the machine can
0.394 inch
detect mis-collating or misfeeding of the (mm) 12
3
0 book(s)
8.268 (mm)
inch 7.874 (mm)
inch 0 book(s)
covers, and can identify bad books. 5.906 (mm)
inch
1400
5200 books/h
- The weight checker is always used with 1000 rpm
the sorter. Therefore the set-up for the 7.087 (mm)
inch
9.055
sorter is performed at the same time as 15.748 inch

(mm)
the set-up for the weight checker.
1 1 2
1. Press of the optional device on the

Main screen.
- The Optional Device screen appears.
Optional Device Screen
2. Press ON on the control panel for the
weight checker. ON ON ON ON
- The weight checker is ready to operate. OFF OFF OFF OFF
2
1 2
ON ON
3. Press OK . OFF OFF

10 SEC 3 SEC
- The new setting is saved and the previ- 5 SEC 5 SEC

ous screen appears. OK
3
4 Preparing the weight checker
- The conveyor of the weight checker is

composed of an electrical scale. This
conveyor measures the weight of each
book while it is transported over the
conveyor. OVER DYNAMIC
SELECT
ITEM
CALIBRATE
SET EXIT
PROPER NET UP
CONVEYOR
INFO
UNDER
ENTER
PRINT C

- The calibration is performed automati-
cally. Check that the control panel indi-
cates "0 g"and go to the next step.
- If the control panel does not indicate
"0 g", press the Key" to calibrate the
weight checker.
CAUTION
Set up the weight checker
without placing book. If the
weight indication varies because
of air flow, keep the air flow
away from the weight checker.
174
8. Optional Devices
2. Press and ENTER

buttons and input the
value of the "REF WT", "UPPER +",
"LOWER -" and "LENGTH" by moving
the cursor and set the value by pressing ENTER
button.
Weight Checker
- After the calibration of the step 1, place a
book to be measured on the conveyor to
measure the weight of the book. Input the
weight to the "REF WT." REF WT 110 g
UPPER + 5.0 g
- Measure the weight of the lightest signa- LOWER - 5.0 g
ture on the conveyor and input the half LENGTH 230 mm 0.0 g
value of the signature weight to the
"UPPER +" and "LOWER -." If the
setting value is 3 g or below, the weight 7 8 9 SELECT
OVER DYNAMIC ITEM
may not be judged correctly because of CALIBRATE
measuring error of the weight checker.

- Input the length of the book in the trans-
port direction to the "LENGTH."
If the length is 350 mm (13.7") or above,
change the value of "IF Speed" and "WT LOWER - 5.0 g
LENGTH 230 mm
Speed" to 39 m/min from 54 m/min. IF Speed 54 m/min
If the length is below 350 mm (13.7"), set WT Speed 54 m/min 0.0 g
the value of "IF Speed" and "WT Speed"
to 54 m/min.
SELECT
OVER DYNAMIC
7 8 9 ITEM
CALIBRATE
3. Press button and activate the weight

checker.
- The weight checker is ready to measure.
5 Cleaning the weight checker sensor
- If the sensor shown in the figure at right

is smeared with dust or the paper chips,
the sensor cannot detect the book. Clean
the sensor regularly (once a month).
Weight Check Sensor
WARNING
Press the emergency stop button
before performing this opera-
tion.
machine can cause severe per-
sonal injury.
1. Remove any dust or the paper chips from

the sensor shown in the figure at right using
the compressed air or wiping it with a clean
cloth.
175
8. Optional Devices
8 Sorter
1 Parts Description
Z
The sorter is used with the weight
U
checker. J B
W D N A Q H
C
MG-60 R S L M G Y
Book Supporting Bar

A book on the bad book delivery conveyor may be
scratched by another book which falls from the
transport conveyor. Adjust the position of the bar to
Transport Conveyor prevent scratching.
The sorter drops a bad book to the
bad book delivery conveyor by Book Block Delivery Section
opening the transport conveyor
when a bad book is detected.
Usually, this conveyor is closed
and transports a good book to the
book block delivery section.
Reflecting Plate
Weight Checker
Stopper Guide
Locking Handle
Bad Book Delivery

Conveyor Button Stopper Guide
The bad book delivery conveyor Adjust the guide
moves only while this button is according to the
being pressed. book block length.
Misfeed Button Bad Book Delivery Conveyor
The conveyor for the sorter opens only This advances a short distance
while this button is being pressed. when a bad book is delivered.
176
8. Optional Devices
8 Sorter (Continued)
2 Setting The Sorter
- When a bad book block detected by the

weight checker comes to the sorter, the con-
veyor opens and drops the bad book onto the
bad book delivery conveyor.
Sorter
1 Adjusting the stopper guide
- If you are working with small books,

adjust the stopper guide position so that Locking Handle
the bad books are placed correctly on
the bad book delivery conveyor.
1. Change the stopper guide position.

- Loosen the locking handle and set the
stopper guide in a position equal to the Stopper Guide
book block +0.394" (+10 mm) as Stopper Guide
Boo
kB
NOTE 0.39lock
4 inc
When setting the stopper guide, lift the h
guide and mount it so that the roller Roller
under the stopper guide does not press
against the conveyor belt. Surface Of The
Conveyor Belt
Cleaning the sorter sensor
WARNING
Turn off the power before Sensor On Sorter
personal injury.
1. Wipe the sensor shown in the figure to the

right and remove any dust or paper chips.
177
8. Optional Devices
8 Delivery Stacker (SCH-15) And Delivery Conveyor (CVC-101)

Z
1 Parts Description
J B
When the unit is not used as part of a system U W D N A Q H
including a three-knife trimmer, the delivery C
stacker collects a set number of books into a MG-60 R S L M G Y SI-15
stack, and then pushes the stack onto the
delivery conveyor.
Emergency Stop Jog
Button Button
01
Fore-edge Guide 0 100
Adjust this guide

Book Delivery Set Counter
to match the book
Speed Adjusting This sets the
size.
Knob number of
Pusher Set the delivery books in each
This part pushes speed of the books stack.
the book out. here.
Fore-edge Guide Top-bottom Guide

Locking Screw Adjust this guide to
match the book size.
Entrance Roller
Sensor
This sensor detects a
delivered book.
WARNING
Keep your hands and fingers away from the pusher. Otherwise, the moving
pusher can cause personal injury.
The pusher moves when the number of stacked books reaches the preset
number of books set at the set counter. If you bring your hand near the
sensor, the sensor may react. Therefore, the pusher may move even if the
preset number of books has not been stacked.
178
8. Optional Devices
8 Delivery Stacker (SCH-15) And Delivery Conveyor (CVC-101) (Continued)
2 Setting the Stacker and the Conveyor
In this section, the transported books are

stacked and delivered.
Delivery Stacker (SCH-15) and Delivery Conveyor (CVC-101)

(1) Set the guides.
(2) Set the number of books in each stack.
(3) Set the book delivery speed.
1 Set the guides
- Adjust the guides and the rollers to match 3. Entrance Roller

the book size. See the figure to the right.
2. Top-bottom Guide
1. Adjust the fore-edge guide. 1. Fore-edge
- Adjust the fore-edge guide position so it Guide
fits against the side of the transported
book.
2. Adjust the top-bottom guide.
- Place the book against the center of the
fore-edge guide. Then adjust the top-
bottom guide by placing the top-bottom Base
guide against the book.
3. Adjust the entrance rollers.
- Adjust the entrance rollers when the Sensor
book is in the position described in step 2. Mechanism
Always install the first entrance roller
(with the sensor on the right end) up
against the book. If the remaining gap is
too large, install one or two additional
entrance rollers.
2 Set the number of books in each stack

- Set the number of books in each stack
using the setting buttons on the control
panel on the conveyor. Less than
100 mm Maximum
- The maximum stack height, not including Stack Height
the book on top of the stack, should be less (3.9")
than 100 mm (3.9").
3 Set the book delivery speed
- Set the book delivery speed. Turn the NOTE
delivery speed adjusting knob clock- The books can be delivered with more
wise to increase the speed. power if the delivery speed is slower, as
- Operate the pusher by moving a hand long as the next book block does not
near the sensor mechanism. Notice arrive while the pusher is still deliver-
how fast the pusher operates, and ing the previous stack.
adjust the book delivery speed if neces-
sary.
179
8. Optional Devices
8 Delivery Stacker (SCH-15) And Delivery Conveyor (CVC-101) (Continued)

3 Cleaning the stacker sensor
Cleaning the stacker sensor (Once a month)
WARNING
Turn off the power before per
forming this operation.
personal injury.
1. Remove any dust or paper chips on the

sensor shown in the figure to the right
using compressed air or wiping it with a Stacker Section
clean cloth. Sensor
180
8. Optional Devices
8 PP-100 Rotating Conveyor Section (CC)
This unit rotates the book blocks

through 90 degrees, and then transports
PP
it to the slope conveyor section.
LD
1. Parts Description CC
PP-100 Rotating Conveyor Section (CC)

Viewpoint
Guide 5
Guide 4
Book Block Drop

Guide Locking Screw
Loosen this screw to tilt
Book Block the book block drop
Drop Guide guide.
181
8. Optional Devices
8 PP-100 Rotating Conveyor (CC) (Continued)

2. Setting the rotating conveyor
The transported book hits the top-bottom

guide, drops from the drop guide and is
transported by the conveyor.
1 Adjusting the tilt of the drop guide

Drop Guide
- When binding a small book, the book
may be transported diagonally because Locking
the gap between the drop guide and the Screw
belt is too big. In this case, loosen the
locking screw of the drop guide and tilt
the drop guide, so that the book drops
firmly.
2 Adjusting the guide finely

Book Drop Guide
When the books are not dropped cor-
rectly, or when opening the top-bottom
guide, adjust the drop guide and the
top-bottom guide position using the
control panel on the stack orientator
(PP).
See Chapter 8, "Stack Orientator (PP)."
NOTE Drop
- Normally, the positions of the drop Guide
guide and the top-bottom guides are set
automatically according to the informa-
tion from the three-knife trimmer.
- When the book is transported diago-
nally, the drop guide may be too close to
the fore-edge guide.
- When the drop guide is extended Top-bottom
along the line of the spine, the book Guide
block may not drop, causing jamming.
In this case, move the drop guide in the
fore-edge direction using the manual
adjustment function on the stack
orientator.
182
8. Optional Devices
8 PP-100 Slope Conveyor Section (LD)

The slope conveyor raises the book block
transported from the rotating conveyor PP
(CC) compresses the book, and delivers it

to the stack orientator (PP). LD
Viewpoint
CC
SB-15
1. Parts Description
PP-100 Slope Conveyor Section (LD)

Pole Lamp*
Guide 6
Book Count Sensor

This counts the books transported to
the accumulating section (PP-100).
When the set number of books has
been stacked, the stack orientator
delivers the books to the next
device.
* Description Of Pole Lamp

Red : This lights when the conveyor can not be operated because an error or
because the stop button has been pressed.
Yellow + Green : When the conveyor can be used with the in-line system including the
three-knife trimmer. (When the three-knife trimmer is operating, only the
green lamp illuminates.)
Yellow : This lights when using the slope conveyor in a system including a rotation
conveyor + slope conveyor + stack orientator. The yellow lamp also
illuminates while in the guide manual adjustment mode.
183
8. Optional Devices
8 PP-100 Slope Conveyor (LD) (Continued)
2. Setting the slope conveyor
1 Height Adjustment Of Holding Rollers
- Adjust the height of the holding rollers

so that the gap between the holding
rollers and the transport belt is a little
larger than the book thickness (including
the fold at the binding). The holding roller
is set automatically according to the
information from the HT-100 when it is
part of the system. There should be a little
resistance between the book block and the
belt. To increase the height of the holding
roller, do a manual adjustment using the Book Thickness
control panel on the accumulating section. + 0.039" (1 mm)
Book
Slope
- Check the height of the holding rollers Conveyor
before running a new size of book. Oth-
erwise, a book jam may occur or the book
may not be delivered to the stack
orientator.
- If the books are soft and thin, they may
not drop on the stack orientator correctly.
In this case, the height of the holding
rollers may be too great. Adjust the height
of the holding rollers using the control
panel on the stack orientator.
184
8. Optional Devices
8 Stack Orientator (PP-100)
This section accumulates the books trans- Z

ported from the slope conveyor (LD). The
unit collects a pre-set number of books J B
Viewpoint
U W Q H
into a stack, then delivers the stack to the D N A
three-knife trimmer. C
MG-60 R S
Stack Orientator (PP-100)

L M G Y
1. Parts description
Guide 3 Guide 2
Guide 1 Top-bottom Guide

(Fixed Side)
Power Switch
Emergency Stop Switch Off-line Stop Button.
This button is used when performing
Off-line Start Button off-line binding.
Display and Set Buttons Single Cycle Button

These control the manual adjustment of This button initiates a complete accumu-
the accumulating section guide and the lating sequence. This button can only be
rotating conveyor guide, and the height used when the machine is stopped.
adjustment of the holding roller.
185
8. Optional Devices
8 Stack Orientator (PP) (Continued)

2 Setting the stack orientator
1 Turn on the power switch

Turn on the power for the stack orientator
(PP). The power for the rotating conveyor Manual adjustment of the guide on the stack
(CC) and the slope conveyor (LD) will be orientator
turned on too. Spine Guide 0.000" to 0.195" (by 0.039")
- The yellow and green lamps on the pole lamp (0 mm to +5 mm by 1 mm)
for the slope conveyor section will light. This Fore-edge Guide 0.000" to 0.195" (by 0.039")
means that the stack orientator is ready to (0 mm to +5 mm by 1 mm)
operate. When starting the three-knife trimmer, Top-bottom Guide 0.000" to 0.195" (by 0.039")
only green lamp illuminates. (0 mm to +5 mm by 1 mm)
- The display of the stack orientator presents the Manual adjustment of the guide on the
Main screen shown in the figure to the right. rotating conveyor
- When E (Error) appears in the upper left Drop Guide 0 to 5 stage (1 stage 0.195")
part of the Main screen, clear the error (5 mm)
by referring to the following table. Top-bottom Guide 0.000" to 0.195" (by 0.039")
(0 mm to +5 mm by 1 mm)
NOTE Slope conveyor holder rollers manual adjustment
Usually, the rotating conveyor (CC), the 0.000" to 0.195" (by 0.039")
guide position of the stack orientator (0 mm to +5 mm by 1 mm)
(PP), and the height of the holding
rollers on the slope conveyor (LD) are set - If all parts of the stack orientator do not
automatically according to the book size move to the home position once the power
information from the HT-100. switch is turned on, the manual adjustment of
the guide can not be performed. (The guide in
- When adjusting the guide or the rollers the stack orientator moves to the home
because the book is difficult to transport position when the book size information is
or accumulate, make the adjustment using the sent to the stack orientator.)
control panel on the stack orientator. (Refer to
the next page.)
Main Screen Total Counter
The guide can be extended only.
Error
Indication
Please call your local dealer if the error

does not disappear even after you
Error Indica- Current Number In Stack
follow the procedure described in the
tion Button
table below. The number of
the books to
collect in each
stack
186
8. Optional Devices
Error Table
Error No. Indication Explanation Clearing the Problem
E02 Guide Set Error Guide Set Error Reset the PP-100.
(The motion of the guide When on-line: Stop the HT-100 and
and the transport hook is not restart it.
Stack Orientator (PP)

complete.) When off-line: Reset the PP-100 (To
reset, follow the setting procedure
mentioned on another sheet.)
E04 Emergency Stop The stop button is pressed Release the stop button and press the
cycle button.
E05 Inverter Error Inverter Error Call your local dealer.
(There is a problem with the
inverter inside the stack
orientator.)
E06 Cooling Belt Cooling Belt Conveyor Just press the error indication button
Error and wait about 3 seconds.
Conveyor Error Motor Driver Error
E07 Motor Driver Error Motor Driver Error 1. Press the stop button and release it
after one minute.
2. Press the cycle button.
3. Stop the HT-100 and restart it.
Note: If the book is jammed in the PP-
100, remove the book and follow
above mentioned procedure.
E08 Sensor Error Book Block Detect Sensor Remove the remaining book in the LD-
(LD) Error 15.
(The book detect sensor on
the slope conveyor has been
blocked for more than 5
seconds.)
187
8. Optional Devices
2 Adjusting the guide position finely
(1) Press the Next button on the Main screen.

Main Screen
NOTE
Use this screen to increase the book block
thickness when not using the holding Guide Fine Adjust
rollers on the slope conveyor.
OR Size Set From HT-100
Size Is Not Received
LD Roller Adjust Change
(2) Press the Set button on the Guide Adjust The Book
screen. Thickness
NOTE
To finish the manual adjustment of the
guide, press the Next button and go to
step B. LD Thick 0.0" to 21.7"
by 0.1 inch
(0 to 500
- When the Off-line? Button is pressed, mm)
the off-line setting mode is selected. (by 0.1 mm)
Usually the stack orientator is used in the
production line, so do not press this
button. When using only the rotating
conveyor, slope conveyor, and the stack
orientator, press the Off-line? button.
- The setting cam be changed during the Extend The
accumulating operation. Guide Adjust
Roller And
The Guide A
Bit
(To the Main Screen When

The Machine Is Operating)
188
8. Optional Devices
Main Screen
After the power switch is turned on and Set the size at the HT-100
the binding size is input from the HT-
100 (three-knife trimmer), the guide of Now Setting
the stack orientator, the rotating con-
veyor and the height of the hold rollers

on the slope conveyor are set automati-
cally. When these settings are finished,
press start on the HT-100, and the
machine will operate with the rest of the Completed
system.
When Esc
is pressed
or an error
To Guide Adjust Panel occurs.
Not Completed
Return to the Main Screen and

input the size from the HT-100 again.
189
8. Optional Devices
(3) Press the Next button to go to the screen The Value (0.000"~0.195" : by 0.039")
for the guide you want to adjust. To Change (0~5mm : by 1mm)
Guide 1
Current
(4) Every time you press the value change Setting
button, the width changes. Next Set Button
Button Cursor Value Changing
Move Button
Button
(0.000"~0.195" : by 0.039")
(0~5mm : by 1mm)
Guide 2
NOTE
The maximum opening of the CC top-
bottom guide is 15.678"(402 mm). There- (0.000"~0.195" : by 0.039")
(0~5mm : by 1mm)
fore when binding a book which measures
Guide 3
15.600" (400 mm) (B4W) in the top-
bottom direction, the guide extends only
0.078" (2 mm).
(5) Input the new setting value and save (0.000"~0.195" : by 0.039")
that setting by pressing the Set button. (0~5mm : by 1mm)
Guide 4
Now Setting
Normally Completed
(0.000"~0.195" : by 0.039")
(0~5mm : by 1mm)
Guide 5
Completed When Esc is

pressed or
the machine
stops incor- (0.000"~0.195" : by 0.039")
rectly. (0~5mm : by 1mm)
To Guide Adjust Panel
Guide 6
Not Completed
Guide Adjust
C-2
Return to the Main Screen and

input the size from the HT-100 again.
(While oprating, return to the Main screen.)
190
8. Optional Devices
(6) After completing the manual adjustment of

the affected guide, press the Next button
until the Off-line? Screen appears.
(7) Press the ESC button to go back to the

Main screen.

Main Screen for Main Screen for
On Line Operation Off Line Operation
When the Off-line? button is pressed,
the off-line setting mode is selected.
(See the next page) If you are using
only the rotating conveyor, slope con-
veyor, and the stack orientator, press
the Off-line? button.
191
8. Optional Devices
3 Using In Off-line Mode
- When you press the Off-line? button on

the Off-line? screen, the stack orientator
is disconnected from the three-knife
trimmer (Off-line setting mode). The
yellow lamp on the pole lamp lights.
- Set the number of book blocks in each Off-line
stack, the book block size, guide posi-
tion adjustment, and the settings of the Main Screen
parameters here when using the rotating
conveyor (CC) and the slope conveyor
(LD) and the stack orientator (PP).
Normally, each part of the machine is

set automatically according to the infor-
mation coming from the three-knife
trimmer.
If the setting for any part of the machine
is changed while in this mode, the new
setting is effective even if operation is
changed to the in-line mode.
If you are using stack orientator in the
in-line mode, set the book size and the
number of books in each stack from the
three-knife trimmer again.
192
8. Optional Devices
[Adjusting Thickness Setting] Main Screen of

Off Line
(1) Go to the Books screen by pressing the
Next button.

Accumulate
(2) Input the new value by pressing the value Number Set
change button.
Set button
Value Change
Button
(3) Press the Set button to enter the change.
Book Size Set Book Size Set
LD Roller Adjust LD Roller

- Use these screens to change the thick- Height Adjust
ness (the height of the hold roller). The
thickness can not be reduced from the
value already input for the book thick-
ness.
(Ex.) If the hold roller height is 4.724" (120 Thick LD Roller

Height Input
mm), the value can be set between
21.654" (550 mm), which is the maxi-
mum roller height, to 4.724" (120 mm).
The hold roller height can be fine-tuned
using the Guide Adjust screen.
The adjustment range is 0.039" to Guide Adjust Off-Line Guide
Adjust
0.197" (0 to 5 mm).
Parameter Set
Parameter Set
Connect HT?
Main Screen
193
8. Optional Devices

Length in steps of 0.1 inch (by 0.1 mm)
Setting The Book Block Size
Length
(1) Press the Set button on the Book Size
Set screen.
(2) Input the book size (top-bottom dimension) Set

using the value change button and the
cursor move button. Cursor Move Value Change
Button Button
- The value is input in steps of 0.1" (0.1 Width in steps of 0.1
mm). To set a value of 7.8" (200 mm), inch (by 0.1 mm)
input the numbers 78.7. Width
(3) Enter the setting by pressing the Set

button.
(4) Also input the block size (fore-edge-spine Thickness

dimension), and press the Set button. Thick
(5) Next, input the block size (thickness

dimension) and press the Set button.
Start to set?
(6) Press the Set button again.
(7) Each guide will move to the home position,

then move to the setting position.
When Esc
is pressed
or the
Now Setting machine
stops
incorrectly.
Not Completed
194
8. Optional Devices
8 Stack Orientator (PP-100) (Continued)
Manual Adjustment Of The Guide The Value Current

(1) Press the Set button on the Guide Guide 1 To Change
Manual Setting
Adjust screen. (0.000"~0.195")
(0~5mm)
Adjustment
Screen Guide 1
(2) Press the Next button to go to the screen of
the guide you want to adjust. Set

Next Button
(3) Every time you press the value change Button Cursor Value Change
button, the width changes. Move Button
Button
Guide 2 (0.000"~0.195")
(0~5mm)
Manual
Guide 2
Adjustment
Screen
NOTE
Guide 3 (0.000"~0.195")
The maximum opening of the CC top- (0~5mm)
Manual
bottom guide is 15.826" (402 mm). Guide 3
Adjustment
Therefore when binding a book block
Screen
which measures 15.748" (400 mm)
(B4W) in the top-bottom direction, the
guide extends only 0.078" (2 mm).
(4) Input the new setting value and save Guide 4 (0.000~0.195 : by 0.039 inch)
(0~5 : by 1mm)
that setting by pressing the Set button. Manual Guide 4
Adjustment
Screen
Now Setting
(0.000"~0.195")
Guide 5 (0~5mm)
Manual
Adjustment
Completed Screen
(0.000"~0.195")
(0~5mm)
To Guide Adjust Panel Guide 6
Exit Guide 6
Manual
Adjustment
Not Completed
Screen
195
8. Optional Devices
8 Stack Orientator (PP-100) (Continued)
CAUTION
If the parameter setting is
incorrect, the whole system will
not operate correctly. It is Parameter Set
necessary to change this setting,
please call your local dealer.
Main Screen
Vsb : production speed (1400 to 5200 books)
Default Value : 0 Vsb
VSB
Main Screen
A : Intervals between the books on the cooling
belt conveyor. A
0.039" to 3.861"(1 to 99 mm) A
Default Value : 60
Main Screen
196
8. Optional Devices
8 Milling Blower Unit (DB-15W)

1 Parts Description
This unit vacuums up the milling dust and

collects it in dust bags. The figure to the right
shows the milling blower unit with two dust
bags. There is also a milling blower unit with
just one dust bag. Filter Bags
Milling Blower Unit

These collect the dust and allow the air
to escape.
Shift Lever
Turn this lever left to
used the right dust bag.
Turn this lever down
to use right dust bag.
107.0" Turn this lever to the
(2720 mm) middle to use both dust
bags.
Dust Bag
The milling dust is
collected here.
Diameter = 22.8" x
31.5" (580 mm x 800
mm) ( Plastic)
Parts number of the
dust bag is 4700378-00
38.6"
(980 mm)
Vacuum Nozzle
The milling dust is vacuumed here.
The nozzle has a diameter of 5.8" (148
mm), and connects to a hose with a
diameter of 5.9" (150 mm).
197
8. Optional Devices
8 Milling Blower Unit (DB-15W) (Continued)
2 Setting The Milling Blower Unit
1 Connect the power cable of the milling blower unit
1. Connect the blower cable to the binder.

- The milling blower unit will operate
along with the binder. (Refer to the
installation manual.)
2. Check the direction of rotation.
- Press the Start button on the binder,
and the milling blower unit will start to
operate also.
- Check the back of the milling blower
unit. The motor of the milling blower
unit should be rotating clockwise.
- If it is rotating counterclockwise,
change the position of any two cables
out of three. See the installation
manual.
If the three phase power cable is con-

nected incorrectly, the filter bag will fill
but there will not be enough vacuum.
2 Connect the vacuum hose
- The hose coming from the binder has a

diameter of 3.937" (100 mm). Install an
adapter between the hose from the Milling
binder and the hose to the milling Section
blower unit. Diameter 3.937" (100
mm)
Adapter
Diameter 5.906" (150 mm)

3 Turn the diverter lever down.
(When using the single type milling
blower unit, skip this procedure.)
- Turn the diverter lever down. The trim
will be collected in the left dust bag.
- When the left dust bag becomes full,
damp the milling dust in the dust bag
by turning the diverter lever to the left.
The unit will fill the dust bag on the
right. Refer to the next page for the
procedure for replacing.
198
8. Optional Devices

3 Replacing the dust bag (Double type milling blower unit)
Remove the full dust bag
1. Turn the diverter lever and change the
Milling Blower Unit

dust bag being filled.
2. On the full dust bag, pull the blue loop Diverter

inward and pull in on the locking ring Lever
from the outside.
3. Carefully separate the ring from the dust

bag and remove the dust bag.
Attach the new dust bag (Parts number of dust bag : 4700378-00)
1. Drape the upper end of the new dust bag

over the ring as shown in the figure to
the right. Fit the assembly inside the
milling blower unit.
2. Check that the ring fits into the groove

on the milling blower unit. Groove
Dust Bag
3. Check that the lip on the dust bag ex-
tends down at least 0.787" (20 mm) 0.787"
below the ring.

(20mm) Ring
199
8. Optional Devices

4 Replacing the dust bag (Single type milling blower unit)
Remove the full dust bag
1. Press the stop button and stop the milling

blower unit.
2. Pull the blue loop inward and pull in on

the locking ring from the outside.
3. Carefully separate the ring from the dust

bag and remove the dust bag.
Attach the new dust bag (Parts number of dust bag : 4700378-00)
1. Drape the upper end of the new dust bag

over the ring as shown in the figure to
the right. Fit the assembly inside the
milling blower unit.
2. Check that the ring fits into the groove

on the milling blower unit.
Groove
3. Check that the lip on the dust bag ex-
tends down at least 0.787" (20 mm) Dust Bag
0.787"
below the ring. (20mm)
Ring
200
8. Optional Devices
8 Pre-melt Tank
The pre-melt tank melts the spine glue before

use and supplies glue to the spine gluing tank
automatically when the glue level in the spine
gluing tank drops. The capacity is 10.6 gal-
lons or 42.2 quarts (40 liter). It takes about
60 minutes to melt all of the glue in the tank.
Pre-melt tank
1 Parts Description
WARNING Handle
Do not allow your face to get too close Pull here to open the cover.
to the tank when the cover is open. Lid Hot
Keep your hands and fingers away A glue tank with a capacity of
from the pre-melt tank. Otherwise, the 10.6 gallons or 42.2 quarts (40
high temperatures can cause severe liters) is located below this
skin burns. cover. Add more glue here.
Control Panel Glue Level Scale
Power Switch CAUTION
Signal Cable Do not supply
Power Cable glue beyond
The pre-melt tank requires 6 the upper
KW. Connect the power cable limit of the
to a dedicated circuit breaker. glue level scale
Hose in the tank.
This hose includes a heating Hose Guard 5 pcs
element.
Spine Glue Tank Glue
Level Sensor
Temperature Fuse 2 pcs
Warm-up Lamp
This lamp lights while the unit is warm-
ing up.
Power Switch Lamp
Automatic Pump Operation
The unit will supply glue auto- Lamp
matically when the glue in the This lamp lights when
spine gluing tank drops and the the pump is operating or
pump operation lamp is lighted. the pump is allowed to
Jog operate. This lamp blinks
The unit will supply glue while the when there is enough
pump operation lamp is lighted or glue in the melt tank.
blinking.
Pump Shift Switch Error Lamp
This lamp blinks or
lights when there is a
problem with the
Tank Temperature
Glue Level Sensor Temperature circuit breaker for
This indicates the tank temperature
This indicates the temperature around the pump, or with a
and the target setting temperature. The
the glue level sensor. fuse.
available setting range is 160-170 ˚C.
201
8. Optional Devices
8 Pre-melt Tank (Continued)

2 Basic Cautions
When using the pre-melter, apply sufficient pellet inside the tank
up to the "glue level scale."
Apply
- Heater of the Pre-melter is installed at the bottom of the tank. Glue in the tank is heated
sufficient from the bottom, so the glue in the upper part of the tank will not become high temperature.
pellet - Glue in the upper part is not heated and deteriorated. It also prevents the heated glue at
lower part from oxidizing by exposing the air. Even if not using a lot of glue for the binding
operation, fill the tank with glue up to the "glue level scale."
- Glue is deteriorated rapidly when it is heated over 200 degrees Celsius (392 Fahrenheit).
Replace the As it is deteriorated, it turns yellow and becomes sticky. The sticky glue may stack inside
the pump or the nozzle, and the glue will not be supplied.
old glue - Drain the deteriorated glue to the melt tank of the binder switching to the [Manual] on the
mode select switch to replace the glue.
Glue level inside the melt tank changes when the application
drum rotates.
- When the application drum rotates, glue inside the melt tank is pulled by the drum and the
glue level changes. Install the glue level sensor and the nozzle in the correct position
The glue depending on the machine model. First, set the sensor so that it comes out 40 mm (1.57")
level sensor from the connecting plate and set the connecting plate on the center of the hole. Then,
position is check that glue is supplied up to the glue level scale correctly and adjust the position while
checking the glue level.
important to
supply the WARNING
glue stably
Do not touch the melt tank.
The melt tank is heated up to
approximately 200 ˚C (400˚F).
It can cause severe skin burns.
Pulled
Watch out for the glue level sensor
when the melt tank is lowered.
- If the melt tank is lowered when the top of the

glue level sensor positions lower than the hard-
ened glue surface, the cable of the glue levels
sensor is pulled. Melt the glue before lowering the
melt tank.
202
8. Optional Devices
Do Not Place Any Do Not Drop Anything

Flammables without Glue
Side cover is heated to 40 Be careful not to drop anything
to 50 degrees Celsius (104 inside the tank when applying the
to 122 Fahrenheit). pellet. It may cause the pump or
Pre-melt tank
Do Not Select nozzle breakdown.
[Manual]
[Manual] can be Fill the Tank with Pellet
selected only when the Up to the "Glue Level
glue is melted. If the Scale"
[Manual] is selected
when the glue is not Even if not consuming a lot of
melted, the pump may glue, fill the tank with glue to
be damaged. prevent the glue deterioration.
Do not place
Close the Rid Normaly
anything in front of
the cooling window. Do not Approach Your
Face with the Rid Opened
Inside of the tank is heated
to 160 degrees Celsius (320
Fahrenheit). Heated air and
steam comes while the rid
is opened. Do not ap-
proach your face, other-
wise, heated air can cause
severe skin burn.
Glue Level Scale
Do Not Place Anything

on the Hot Hose.
If something is placed on the hose, it
becomes hot and can be danaged or
cause fire. Also do not touch the hose
to each other by winding it. It becomes
hot and can be danaged or cause fire.
Sensor
Nozzle
Install Nozzle in Correct Position
Refer [Watch out for the glue level sensor when

the melt tank is lowered] in the previous page.
Do Not Bend
Do Not Approach Hose to Cover If the hose is bent
when the glue is not
Do not approach the hot hose to the cover. melted, heater inside
The cover will become hot. may be damaged
203
8. Optional Devices

3 Setting The Pre-melt Tank
1. Connect the power cable.

- Connect the power cable for the pre- WARNING
melt tank. (See the installation manual).
Do not allow your face to get too
close to the tank when cover is
open. Keep your hands and
The heater on the pre-melt tank requires fingers away from the pre-melt
5.7 to 6.3 KW. tank. Otherwise, the high
Connect the power cable to a circuit temperatures can cause severe
breaker which can provide this current. skin burns.
2. Connect the signal cable.
- Connect the signal cable which carries
signals from the binder to the pre-melt
tank.
3. Connect the supply hose.

- Connect the melted glue supply hose to
the melt tank.
Supply
There is a heater element inside the Hose
hose. Do not step on or bend the hose.
CAUTION
The hose will be very hot. Do not
place anything which can be
damaged by heat near the hose.
4. Connect the glue level sensor. Supply Hose Sensor Bracket

- Connect the glue surface sensor with
the sensor bracket.
Keep the cable of the glue level sensor

away from the terminal of heater.
5. Connect the air hose. Terminal of

-Connect the air hose to the branch from heater
SB-15 side glue blower hose. Sensor Speed Controller
cooling air is supplied through this hose.
Air Hose From
Branch HT-101 compressor
6. Set the binder.
- Set the pre-melt tank by following step
3 in Section 4-8 "Using the pre-melt
tank".
204
8. Optional Devices

3 Setting The Pre-melt Tank (Continued)
8. Set the pump shift switch to the automatic

position.
- After the glue in the pre-melt tank has
Pump Shift Switch
Side Glue Supply Unit

melted, the glue is supplied to the melt
tank when requested by the binder.
205
8. Optional Devices
8 Side Glue Supply Unit
1 Machine description
Z
J B
U W D N A Q H
C
MG-60 R S L M G Y
Opening for Supplying

Side Glue
Bucket Conveyor
Hopper
Put the side glue here.
Move the unit

forward to
open the melt
tank section
cover
Base
Melt Tank Section Cover
Locking Handle
206
8. Optional Devices
8 Side Glue Supply Unit (Continued)
2 Setting the side glue supply unit
This device includes a sensor which detects Main Screen

the glue level in the side gluing tank and 0.394 inch
(mm)
8.268 inch
(mm)
7.874 inch
(mm)
12
3
0 book(s)
0 book(s)
supplies glue to the tank automatically. 5.906 inch

(mm)
1400
5200 books/h Optional Device
1000 rpm
9.055 Screen
Side Glue Supply Unit

7.087 inch
-1.
(mm)
Press on the Optional Device 15.748 inch

(mm)
screen. ON ON
ON

OFF OFF
OFF
2
1 2
ON ON
2. Press ON in the section on the OFF OFF
10 SEC 3 SEC
Optional Device screen. 5 SEC 5 SEC
- ON section turns to the green and the OK
side glue supply unit is ready for use. 10 SEC 3 SEC 5

3. Press or to set the glue sup-
plying time (in seconds). 4 3
- The sensor checks if the glue level in
the side glue tank becomes lower than
the pre-set lomot, and operate the side
glue supply unit. Set the side glue
supply unit operation time.
sec.
4. Press or and set the glue sup-

plying start time (in seconds).
- Set the waiting time from pressing the
binding start button. The glue is not
supplied during the waiting time al-
though the glue amount is less.
sec.
While the is pressed, the glue

continues to apply.
5. Press OK .
screen appears.
207
8. Optional Devices
8 Side Glue Supply Unit (Continued)
3. Moving the side glue supply unit
1. Close the melt tank section cover and

push the side glue supply unit forward. Locking
Then lock the side glue supply unit by Lever
turning the locking lever down.
- To open the melt tank section cover,
turn the lever up and pull the side glue
supply unit out.
2. Add glue to the hopper. Side Glue Supply Unit
The material used as the side glue is

different from spine glue. Do not mix
these two kinds of glue.
208
8. Optional Devices
8 Book Block Height Detect Sensor
This sensor detects any bent or raised sheets

Z
and stops the binding operation.
J B
U W D N A Q H
1. Parts description
C
MG-60 R S L M G Y
Book Block Height Detect Sensor

Viewpoint
Reflecting
Plate
Steady Lamp (Green)

Error Lamp (Red)
2. Setting the book block height detect sensor
1. Adjust the detecting height.

- Adjust the detecting height according to
the book block size.
(1) Place the book block between the reflect-

ing plate and the sensor, and set the
sensor 0.0394" to 0.079" (1 to 2 mm)
above the point where the sensor detects
the book block (where error lamp lights).
NOTE
- When the sensor does not detect a book
block, only the steady lamp (green) will
light.
When the sensor does detect a book
block, the error lamp (red) will light also.
- The higher the sensor is set, the more
difficult it becomes to detect a problem.
209
8. Optional Devices
8 Chip Extractor (TB-100)
HT-101
The Chip Extractor vacuums and
collects the trim.
J B
U W D N A Q H
1. Parts description C
MG-60 R S L M G Y
Circuit Breaker
Keep this breaker
turned On. The
blower will operate
automatically
when the trimming Trim Collector
operation begins to
produce trim.
Power Cable
Delivery
Section
Delivery Air
Adjusting Knob
This adjusts the amount of
delivery air. Turn this knob Hose
clockwise to increase the
delivery air. The delivery air
is turned off when this knob Delivery Stand
is turned counterclockwise.
210
CABS5000 Optional Devices List
CABS5000 Optional Devices

1 2 3 4
19
12 15 15 15 22 Three-knife HT-101
17 Trimmer
Book Block Connecting Belt In-feeder Air
Pier KB-15 Sensor MG-CH Unit R-15 Assist Blower AP-15
12 18 21 This pier is used to cross When the book block delivered This unit connects the collator and This blower blows air from the side
from the collator is not arranged, the binder. This unit clamps the of the in-feeder so that the
the machine.
16 this sensor detects the error and
stops the binding operation.
book block delivered from the
collator by roller belt and transport
transported book blocks are
delivered smoothly.
14 20 it to the in-feed section.
24
9 5 6 7 8
13 12 11 10
Binder
Connect Unit S B - 1 5
Collator Collator 1 MG-60HL 3 8
MG-60H MG-60H 2
4 7
23 Milling Blower Side Glue Book Size Input
6 Unit DB-15W Supply Unit TM-5 Pre-melt Tank PM-40 Interface SI-15
5 This unit vacuums and This unit supplies the glue into the This tank melts thespine This interface is used to measure the
side glue tank automatically when size of the actual binding book block
collects the trimmings. the glue level in the tank lowers glue previously and keep and read that value by the binder.
There are single type (DB- and keeps the glue level. the glue level in the melt Input from the operator console is not
15) and double type. tank. necessary.
9 10 11 12 Book Block holder 13 14 15 16 17

UC-15
Cover Sheet Side-lay Delivery Roller Cooling Belt Delivery Roller

Adjustment Handset RA-15 Weight Checker CH-09 Sorter DU-15 Stack Orientator PP-100 Delivery Stacker SC-15 Conveyor
RC-15 Conveyor Conveyor CV-100 Power Supply Box BP-100
This remote control is used to This device is used to find the bad This section recveives the signal Accumulate This section stacks the This conveyor is used by
adjust the position of the prints on book by checking the weight of the from the binder or the weight
Rotating Conveyor Slope Conveyor Section predetermined number of book connecting to the stacker when not
This conveyor is used to cool
down and harden the spine glue
Trimmed book blocks are This box is a power source of
bound book while transportation. delivered on this the cooling belt conveyor.
spine by checking it's position in checker, and pick out the poor This section accumulates the predetermined number of book blocks and blocks and deliver it to the delivery using three-knife trimmer. while transportation. Connect
hand. quality book block. Then delivers it roller conveyor when HT-100 is not several cooling belt conveyors. conveyor.Take out the This box is controled from the
deliveras it to the cooling belt conveyor.
to the faulty book ejecting unit. connected. book blocks here. HT-100 side.
18 19 20 21 22 23 24
ON OFF
10.0 12 0 book(s)
3
200.0 0 book(s)
120.0 1400
5200 books/h
1000 rpm
230.0
130.0
400.0
1 2
Compressor CM-15 Manual Feed HC-100 Delivery Extension

CVA-100 TB-100 Guide
Manual Feed
HCG-100 Extra Monitor MD-15 Curve Conveyor
Conveyor Conveyor Chip Extractor
Guide
CCG-100
This compressor is used This conveyor is used to Delivered book blocks are This unit vacuums and This guide is used when This nmonitor indicates the same This guide is needed when
place trimming book blocks informationn as the operator using the curve conveyor
when the binder is not put on this conveyor. collects the trimmings. performing thebook block console of the SB-15. Input can
connected to the three- when three-knife trimmer is (3m stretch) manual feeding. This guide not be performed. between SB15 and HT100.
knife trimmer. used as a single trimmer. can be used on line.
CAB System Installing Figure
CAB System Installing Size
Installation size is shown in the figure below.

Install the CAB system based on the standard
position. Refer to the referrance page shown
below on the installation manual.
Stack Orientator
Refer to P.38
801.58" (20,360)
35.18" (8,935) 441.15" (11,205)
48.75"(1,238) 79.38" (2,016) 118.75" (3,016) 118.75" (3,016) 76.54" (1,944)
29.73" (755)
105.00" (2,667)
Cooling Belt Conveyor Refer to P.44

46.46" (1,180)
Three Knife Trimmer
74.34" (1,888)
HT-101
53.47" (1,358)
70.40"(1,788)
18.12"(460)
Milling Blower Unit
143.78" (3,652)
Refer to P.31
163.15" (4,144)
67.60" (1,717)
Sorter Twisting Conveyor Section Refer to P.25 2.68"(68)

Refer to P.28 Standard Point
Weight Checker Refer to P.27
(1,138)
44.81"
5'-3.779"(1,620)
63.78"(1,620)
SB-15 Refer to P.11 Cover Feeder
Refer to P.20
Chip Extractor
63.78
1,620
MG-60H X3 Refer to P.49
Electrical Box
33.71"(856) 105.00"(2,667) 105.00"(2,667) 105.00"(2,667) 43.86"(1,114) 44.93" 17.13" 217.05" (5,513) Refer to P.17
(1,141) (435)
348.71" (8,857) 331.58" (8,422)
680.28" (17,279)
( mm )
Side Guide Supply Unit
Connecting Unit Refer to P.15 In-Feed Section Refer to P.13 Refer to P.53 Pre-Melt Tank Refer to P.51

SB-15 Operation Manual

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SB-15 Operation Manual

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SYSTEM BINDER SB-15

- Horizon International Inc. pursues a policy of continuing improvement in design and

- Do not operate the machine when any covers are removed.

The three basic steps of perfect binding are as follows:

2. Hot melt glue is applied to the spine of the book block.

Milling Gluing Nipping

Other methods of binding, such as saddle stitching or mechanical binding, may

1. The sheets should have a grain direction

2. The cover stock thickness should match the

3. Apply the correct glue in an amount

4. Ensure the quality of the glue. (Use the

Perfect binders are designed to provide strong, quality-finished books ranging

Cautions to observe during perfect binding.

If this glue is exposed to ultraviolet light for 6 to 12 months, it becomes fragile,

Safety Precautions .................................................................................. II

Perfect Binding ..................................................................................... III

Hot Melt Glue ......................................................................................... V

1. Before You Begin

1-1-1 Safety Covers And Switches ................................................. 2

1-2-1 Main Screen ........................................................................... 4

2. Checks Before Operating

2-2 Rotate The Clamps ......................................................................... 17

2-3 Emergency Stop Button Check ...................................................... 19

2-4 Stop Bar Check ............................................................................... 21

2-5 Cover Interlock Check ................................................................... 22

3-2 Confirming The Settings ................................................................ 26

3-3 Binding Procedure .......................................................................... 29

3-5 If A Problem Occurs ....................................................................... 37

3-5-1 Pole Lamp................................................................................... 37

4. Machine Set Up And Adjustment

4-0 Outline -Setting Each Section ....................................................... 40

4-1 Automatic Setting And Book Size Input Interface ...................... 42

4-2 Setting The Machine Functions ..................................................... 44

4-4 Setting The Infeed Section ............................................................. 46

4-5 Setting The Level Plate (Hand Feed Section) ............................... 50

4-6 Setting The Clamp Section ............................................................. 54

4-7 Setting The Milling Section ............................................................ 56

4-8 Setting The Glue Tank Section ...................................................... 59

4-9 Setting The Side Gluing Section .................................................... 68

4-10 Setting The Cover Feeder ............................................................ 74

4-11 Setting The Scoring Rollers ......................................................... 82

4-12 Setting The Cover Sheet Transport Section ............................... 87

4-13 Setting The Cover and Book Registering Section ...................... 89

4-14 Setting The Nipping Section ........................................................ 91

4-15 Setting The Delivery Section ........................................................ 94

4-16 Setting The Twisting Conveyor Section ...................................... 96

5-2 Adding The Side Glue ........................................................................ 101

5-3 Cleaning ............................................................................................... 102

5-3-1 Cleaning The Clamp Track ........................................................ 102

5-5 Replacing The Milling Cutter ............................................................ 113

5-6 Replacing The Roughening Cutter .................................................... 117

5-7 Replacing A Suction Cup ................................................................... 118

5-8 Replacing The Shear Pin .................................................................... 119

5-9 Replacing The Spine Glue .................................................................. 121

5-10 Replacing The Side Glue .................................................................. 123

5-11 Description of The Weekly Timer .................................................. 125

5-12 Replacing the carbon Blades of Pump ........................................... 128

6-1 Poor Binding Quality .......................................................................... 129