Horizon Fitness Bookletmaker SPF-200A User manual

i
• This manual is designed to help you to install, operate and maintain the
SPF-200A/SPF-200L or FC-200A/FC-200L Bookletmaker. Please read and
understand this manual, and keep it in a safe and convenient place.
• Do not operate the SPF-200A/SPF-200L or FC-200A/FC-200L until you read and
understand the instructions in this manual.
• Horizon International Inc. shall not be liable for incidental consequential
damages resulting from: improper or inadequate maintenance by the customer,
unauthorized modification or misuse, or operation outside of the environmental
specifications for the product.
• Horizon International Inc. pursues a policy of continuing improvement in design
and performance of the product. Therefore, the product design and
specifications are subject to change without prior notice and without our legal
obligation.
• All rights are reserved. No part of this manual may be photocopied, reproduced
or translated to another language without the prior written consent of Horizon
International Inc.
This manual explains on the basis of the SPF-200A/FC-200A.
The operating instructions for the SPF-200L/FC-200L are added
as necessary.
In case that the sheet length is longer than 500 mm (19.68”),
some functions may not available in the upstream and down-
stream devices of the SPF-200L.
Important Information
BOOKLETMAKER
BOOKLETMAKER
SPF-200A / FC-200A
SPF-200L
/ FC-200L
160218/SPF200A/FC200A/SPF200L/FC200L/20E/HN,TM,AT/F7/ICS5/PXI UM201102-20(000)
*UM201102*

ii
Safety Precautions
Safety precautions are indicated in this manual as follows:
The term WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
The term CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in serious injury, or damage to the machine.
This symbol indicates a note which includes important information. Follow
the note to operate the machine safely.
This symbol indicates a prohibited action. Do not perform any prohibited
action.
This symbol indicates an essential procedure. Follow the procedure to
operate the machine safely.
Important • This lists the range of acceptable values and operating
conditions.
Attention • This information will help you to avoid problems with the
machine or help you learn how to operate the machine.
Note • Refer to this note when you operate the machine.
Additional
Information
• This explains a mechanism in the machine.

iii
Operating Safety Precautions
WARNINGS for Operation
This machine must be operated by just one person at a time.
Work alone when you maintain and lubricate the machine. Letting someone else operate the
machine may cause severe personal injury.
Do not remove or bypass any safety features. Moving parts can cause severe personal
injury.
Some adjustments must be made with some of the machine covers opened.
Keep your hands and fingers outside of the safety cover and away from any moving parts
while the machine is running. Otherwise moving parts can cause severe personal injury.
The machine will not stop immediately if the Emergency Stop switch on an upstream device
is pressed. After all in-process booklets are delivered, the machine will stop.
Do not allow anyone else near the machine when you are moving the main section of the
SPF forwards or backwards.
When replacing the knife, wear gloves and do not touch the edge of the knife directly. The
knife is extremely sharp, and may cause severe personal injury.
Press the Emergency Stop button before turning the handwheel. A sudden accidental start
of the machine can cause severe personal injury.
Do not operate the fore-edge trim section separately from the SPF main unit.
CAUTIONS for Operation
After turning off the power switch, wait ten seconds before turning it on again. Otherwise, a
circuit board may be damaged.
The fold knife and roller may strike each other if the fold knife is lifted too far. Turn the fold
knife height adjustment knob in small amounts.
Remove the cable connected to the SPF main unit before moving the fore-edge trim section
away.

iv
WARNINGS for Maintenance
Turn off the power switch before beginning any maintenance operation. If the machine acci-
dentally starts suddenly, this can cause severe personal injury.
Turn off the power switch before clearing a jam. If the machine accidentally starts suddenly,
this can cause severe personal injury.
When working inside the machine, be careful to keep your hands away from nearby parts.
Be sure to press the Emergency Stop button before opening the fold section cover. The
machine may start suddenly, causing severe personal injury.
Turn off the power switch before resetting a circuit breaker. Otherwise, the machine may
start suddenly, causing severe personal injury.
Fuse replacement must be done under the supervision of a maintenance administrator.
Turn off the power switch and unplug the power cable before replacing a fuse.
When the booklet thickness detector is installed, evacuate the laser unit.
Otherwise the sensor may be damaged.
CAUTIONS for Maintenance
Use the types of lubrication oil and grease which are recommended by HORIZON. Other oil
or grease may reduce the life of the machine or cause damage.
WARNINGS for Installation
Turn off the main power or circuit breaker in the factory before connecting the power cord to
the machine. High voltage electricity can cause severe personal injury.
CAUTIONS for Installation
Be sure to install the floor mounting plates to keep the machine level. Otherwise, vibration
may cause the machine to move. The binding quality may deteriorate, or the machine may
be damaged.
The SPF-200A ＋the FC-200A weigh about 720 kg (1590 lb). The SPF-200L ＋the FC-200L
weigh about 750 kg (1653 lb). Transport and install the machine safely, and keep the weight
of the unit in mind.
Install the machine correctly, referring to the installation manual or installation instructions in
the user’s manual before starting the machine. Otherwise, the binding quality cannot be
guaranteed.

v
CONTENTS
Important Information ............................................................................................................... i
Safety Precautions ...................................................................................................................ii
Operating Safety Precautions .................................................................................................iii
1 Machine Description
1-1 Automatic and Manual Settings ................................................................................. 1
1-2 Machine Descriptions .................................................................................................. 2
1-2-1 Safety Device / Safety Functions ......................................................................... 2
1-2-2 Overall Machine ................................................................................................... 3
1-2-3 Manual Feed / Infeed Conveyor Section ............................................................. 5
1-2-4 Infeed Section ...................................................................................................... 6
1-2-5 Jog Section .......................................................................................................... 7
1-2-6 Stitch Section ....................................................................................................... 8
1-2-7 Fold Section ......................................................................................................... 9
1-2-8 Fore-edge Trim Section ..................................................................................... 10
1-2-9 Delivery Conveyor ............................................................................................. 11
1-2-10 Control Panel ................................................................................................... 12
1-3 Screen Descriptions .................................................................................................. 13
1-3-1 Setting-Binding Pattern Screen ......................................................................... 13
1-3-2 Setting-Sheet Size Screen ................................................................................ 13
1-3-3 Setting-Finishing Size Screen ........................................................................... 14
1-3-4 Setting-Instruction Screen ................................................................................. 15
1-3-5 Setting-Confirmation Screen ............................................................................. 19
1-3-6 Binding-Operation Screen ................................................................................. 20
1-3-7 Binding-Fine Adjust Screen ............................................................................... 22
1-3-8 Binding-Status Setting Screen ........................................................................... 24
1-3-9 Memory Screen................................................................................................ 28
1-3-10 Information-Main Screen................................................................................ 29
1-3-11 Information-Monitor/Single Operation Screen................................................ 30
1-3-12 Information-Administrator Screen .................................................................... 31
1-3-13 Error Screen .................................................................................................... 34
2 Checks before Operating
2-1 Checking the Emergency Stop Function ................................................................. 35
3 Operating Procedures
3-1 Overview of Operating Procedures .......................................................................... 37
3-2 Setting Up a Job Using the Setting Screen ............................................................. 39
3-3 Doing a Changeover .................................................................................................. 44
3-3-1 Removing Parts Before the Changeover ........................................................... 44
3-3-2 Attaching Parts After Changeover ..................................................................... 49
3-3-3 Confirmation After Changeover ......................................................................... 52
3-4 Doing a Test Binding ................................................................................................. 53
3-4-1 Preparing the Upstream Device ........................................................................ 53
3-4-2 Binding a Booklet as a Test ............................................................................... 55
3-4-3 Do a Test Binding and Check the Settings ........................................................ 56
3-4-4 Perform the Test Stitching ................................................................................. 59
3-5 Confirming the Status Settings............................................................................... 60

vi
3-6 Start Binding .............................................................................................................. 62
3-7 Manual Feeding .......................................................................................................... 65
3-8 Saving, Loading and Deleting Jobs ......................................................................... 70
3-8-1 Saving a Job ...................................................................................................... 70
3-8-2 Loading a Job .................................................................................................... 71
3-8-3 Deleting a Job .................................................................................................... 73
3-9 Power Saving Mode ................................................................................................... 74
3-10Reversing the Stitcher Heads ................................................................................... 75
4 Adjustments
4-1 Stitch Adjustments................................................................................................... 77
4-2 Infeed Section Adjustments ...................................................................................... 79
4-3 Jog Section Adjustments .......................................................................................... 81
4-4 Fold Section Adjustments ......................................................................................... 83
4-5 Fore-edge Trim Section Adjustments ...................................................................... 84
5 Troubleshooting
5-1 If an Icon Is Displayed on the Error Screen ............................................................. 87
5-1-1 If An Error Icon Is Displayed .............................................................................. 87
5-1-2 If a System Error Occurs ................................................................................... 90
5-2 Removing Jammed Sheets ....................................................................................... 99
5-3 Stitch-Related Problems ......................................................................................... 101
5-3-1 The Stitches Are Moved Parallel to the Fold Line ........................................... 101
5-3-2 The Distance Is Not Correct........................................................................... 101
5-3-3 The Stitches Are Angled................................................................................. 101
5-3-4 The Stitch Position Varies............................................................................... 102
5-3-5 The Stitches Are Curved................................................................................. 102
5-3-6 There Are Problems With The Stitch Length.................................................. 102
5-3-7 The Sheets Are Not Stitched.......................................................................... 103
5-3-8 The Wire Jams................................................................................................ 103
5-3-9 The Shape of the Stitch is Incorrect................................................................ 104
5-4 Poor Sheet Arrangement ......................................................................................... 107
5-5 Folding-Related Problems ...................................................................................... 109
5-5-1 Fold Skewing.................................................................................................. 109
5-5-2 The Folding Position Varies............................................................................ 109
5-5-3 Failed to Fold at Correct Position................................................................... 110
5-5-4 Jog Error Not Detected................................................................................... 111
5-5-5 The Sheets Are Bent...................................................................................... 111
5-6 Fore-edge Trimming-Related Problems ................................................................. 112
5-6-1 The Sheets Are Trimmed Incorrectly.............................................................. 112
5-6-2 Incorrect Trim Position.................................................................................... 112
5-7 Scratched Sheets ..................................................................................................... 113
5-8 Specific Symptom-Related Problems .................................................................... 114
5-8-1 The Buzzer Beeps at an Interval of Two Seconds.......................................... 114
5-8-2 Fine Adjustment from the Touch Panel Does Not Work................................. 114
5-8-3 The Delivery Conveyor Does Not Move......................................................... 114
5-8-4 The Trim Is Not Collected (The pump does not operate) ................................ 114
5-8-5 The Touch Panel Does Not Light Up.............................................................. 115
5-8-6 A Stitcher Head is Jammed............................................................................ 115

vii
5-9 Other Problems ........................................................................................................ 116
5-9-1
The Booklets Overlap Each Other at the Delivery Conveyor though They are Offset  .... 116
6 Maintenance
6-1 Loading Stitch Wire................................................................................................ 117
6-2 Threading the Wire Through the Stitcher Head .................................................... 118
6-3 Attaching the Transport Pusher ............................................................................. 119
6-4 Lubrication ............................................................................................................... 120
6-4-1 Top and Bottom Guide Slide Shaft .................................................................. 120
6-4-2 Stitcher Vertical Slide Shaft ............................................................................. 120
6-4-3 Fold Knife Section ........................................................................................... 120
6-4-4 Stitcher Head ................................................................................................... 121
6-4-5 Clincher Drive Cam ......................................................................................... 121
6-5 Cleaning ....................................................................................................................122
6-5-1 Around the Stitcher Heads .............................................................................. 122
6-5-2 Transport Belts / Transport Rollers .................................................................. 122
6-5-3 Sensors ........................................................................................................... 123
6-6 Replacing the Fore-edge Trim Knife ...................................................................... 125
6-6-1 Upper Knife Replacement ............................................................................... 125
6-6-2 Lower Knife Replacement ............................................................................... 127
6-7 Clincher Point Replacement ................................................................................... 130
6-8 Guide Sheet Replacement ....................................................................................... 131
6-9 Stitcher Head Removal / Attachment ..................................................................... 132
6-9-1 Stitcher Head Removal .................................................................................... 132
6-9-2 Stitcher Head Attachment ................................................................................ 132
6-10Resetting the Circuit Breakers ............................................................................... 136
6-11Replacing the Fuses ................................................................................................ 137
7 Installation
7-1 Installing the Main Unit ............................................................................................ 139
7-2 Installing the Fore-edge Trim Section .................................................................... 141
7-3 Attaching the Accessories ...................................................................................... 143
7-4 Installing the Delivery Conveyor ............................................................................ 145
7-4-1 SC-200 Short Conveyor .................................................................................. 145
7-4-2 LC-200 Long Conveyor ................................................................................... 146
7-5 Connecting to an Upstream Device ....................................................................... 147
7-6 Checking ROM Versions of Connected Devices ................................................... 150
7-7 Connecting the Main Unit Power Cable ................................................................. 152
7-8 Setting the System Configuration .......................................................................... 153
7-9 Setting Up for Optional Devices ............................................................................. 154
7-10Synchronizing Between the Devices ..................................................................... 155
8 Options
8-1 Preset Kicker PK-30 ................................................................................................. 157
8-1-1 Installation of Preset Kicker ............................................................................. 157
8-1-2 Operation ......................................................................................................... 158
8-2 Paper Insertion Kit PN-200 ...................................................................................... 159
8-2-1 Operation ......................................................................................................... 159
8-2-2 Installation of Paper Insertion Kit ..................................................................... 161
8-3 Four Stitching Kit FST-200 ...................................................................................... 166

viii
8-3-1 Accessories for Four Stitching Kit................................................................... 166
8-3-2 Installation of Clincher ..................................................................................... 168
8-3-3 Installation of Stitcher Head ............................................................................. 169
8-3-4 Wire Attachment .............................................................................................. 171
8-3-5 Option Setup .................................................................................................... 173
8-3-6 Limitation for Use ............................................................................................. 174
8-4 Side/Corner Stitch Kit SSK-200/SSK-200L ............................................................ 175
8-4-1 Installation of Side/Corner Stitch Kit............................................................... 175
8-4-2 Option Setup................................................................................................... 178
8-5 Mis-stitch Detector SDS-200 ................................................................................... 179
8-5-1 Installation of Mis-stitch Detector ..................................................................... 179
8-5-2 Operation........................................................................................................ 182
8-6 Thickness Detector TD-200 ..................................................................................... 183
8-6-1 Installation of Thickness Detector .................................................................... 183
8-6-2 Calibrating the TD-200.................................................................................... 185
8-6-3 Operation ......................................................................................................... 187
8-7 Chip Extractor TB-200 ............................................................................................. 189
8-7-1 Operation ......................................................................................................... 189
8-7-2 Installation of Chip Extractor ............................................................................ 190
8-8 Loop Stitching .......................................................................................................... 192
8-8-1 Loop Stitcher Head Replacement .................................................................... 192
9 Appendix
9-1 Specifications ........................................................................................................... 195
9-1-1 SPF-200A....................................................................................................... 195
9-1-2 FC-200A......................................................................................................... 198
9-1-3 SPF-200L........................................................................................................ 199
9-1-4 FC-200L.......................................................................................................... 203
9-2 Accessories .............................................................................................................. 204
9-2-1 SPF-200A/SPF-200L ....................................................................................... 204
9-2-2 FC-200A/FC-200L.......................................................................................... 206
9-2-3 IFU-200 ............................................................................................................ 207
9-3 Consumables ........................................................................................................... 208

Automatic and Manual Settings / Machine Description
1
1
s1 Machine Description
This chapter explains how to use the automatic and manual settings, and describes the
parts of the machine and their functions.
1-1 Automatic and Manual Settings
Automatic: This indicates a setting which is performed automatically to match the sheet size and
binding pattern. The setting can be changed using the touch panel.
Manual: This indicates a setting which is performed manually using a knob or lever.
11119
10101A1
Front Transport Belt Gap Adjustment
Transport Belt Height Adjustment
Stopper Position
Fold Roller Gap
Jog Pusher
Fold Section Top and Bottom Guide Width
Fold Section Top and Bottom Guide Stroke
Forward Roller Position
Delivery Roller Position
Saddle Stitch Stopper Replacement
(Large / Small)
Saddle Stitch Stopper Position
Guide Bar Attachment
Transport Pusher Speed
Corner Stitch Guide Replacement
Top and Bottom Guide Width
Top and Bottom Guide Stroke
Jogging Frequency
Manual Feed Guide Width
Fore-edge Trim Section
Alignment for a Small Booklet
Buckle Gap Adjustment
Fold Skew Correction
Fold Knife Height Adjustment
Infeed Section Direction
Stitcher Head Drive Block Attachment
Stitch Angle
Stitch Distance
Stitch Length

2
1-2 Machine Descriptions
1-2-1 Safety Device / Safety Functions
The whole system stops when a safety cover is opened or the Emergency Stop bottom is pressed dur-
ing operation.
11119
10201A1
Jog Section
Cover
Fore-edge Trim Section
Cover
Infeed Section
Cover
Emergency Stop Button
Press
Release
Fold Section
Cover
1-2-1
Safety Device / Safety Functions

3
1
Machine Descriptions / Machine Description
1-2 Machine Descriptions
1-2-2 Overall Machine
This explains how to use the system configuration including the optional IFU-200 infeed conveyor, FC-
200A/200L fore-edge trim section, and the SC-200 delivery conveyor.
21102
10202A1
11119
10202E1
11119
10202J1
11119
10202D1
11119
10202B1
Fold Section
Connectors for Upstream Devices
2. The sheet is pushed up by the fold knife, then is
caught in the fold roller and folded. Next the press
rollers crease the folded sheet.
Power Switch
Control Panel
Refer to 1-2-10.
Horizontal Transport
Section
The unfolded sheets are
transported through this sec-
tion.
Stitch Section
Control Panel
1. The sheet is squared-up in the top-bottom and
fore-edge directions before folding. (This hap-
pens if the top and bottom guide jog function is
turned on.)
Infeed Section
The sheets are trans-
ported from this section to
the jog section.
Manual Feed Sec-
tion
The sheets can be manu-
ally fed when the stopper
opens in this section.
Press
Rollers
Fold Rollers
Fold Knife
Air Line from the Collator
Not Used
Signal Connectors for Collator
Signal Connector for
IFU-200 Infeed Conveyor
Stitch Section
The sheets are stapled here.
11119
10202C1
Jog Section
The sheet is squared-up in
the top-bottom and fore-edge
direction before stitching.
Connectors for
Downstream Device
Power Connector
for Fore-edge Trim
Connector for Deliv-
ery Conveyor
Signal Connector
for Fore-edge Trim
Section
Arcnet Communi-
cation Connector
Optional IFU-200
Infeed Conveyor
The collated sheets are transported
from the collator to the infeed section
of the SPF-200A/200L.
1-2-2
Overall Machine

4
1-2 Machine Descriptions
11119
10202G1
11119
10202H1
11119
10202I1
11119
10202F1
Fore-edge Trim
Section
The transport belts com-
press the booklets, and
then the fore-edge of
each booklet is trimmed.
Connectors for Downstream
Devices
Connector
for TB-200
Chip
Extractor
Fore-edge Trim Section
Control Panel
Transport
Belt
Not Used
Hole for MKU-
54, MKU-54T or
PST-40 Com-
munication
Cable
Delivery Conveyor
(Option)
This illustration shows a short con-
veyor.
Connector
for PK-30
Preset
Kicker
Power Con-
nector for
Delivery Con-
veyor
Faulty Set Ejecting Section
A faulty set is ejected to the faulty set
ejecting tray.
Good
Set
Bad
Set
Gate
Faulty Set Ejecting Tray
Trim Chute
The trim is ejected from this chute.
Not Used (for
Short Circuit
Connector)
1-2-2
Overall Machine

5
1
Machine Descriptions / Machine Description
1-2 Machine Descriptions
1-2-3 Manual Feed / Infeed Conveyor Section
11119
10203A1
Manual Feed Stopper
Sheets can be fed manually if the stopper is lowered.
Manual Feed Sheet Sensor
This sensor detects any sheets placed on the manual
feed table.
Manual Feed Guide
This guide can be set to match the width of the sheet
being fed.
Guide Position Scale
Sheet Sensor
This sensor detects a sheet as it feeds from the colla-
tor and triggers the manual feed.
Upper Transport Section Lifting
Handle
1-2-3
Manual Feed / Infeed Conveyor Section

6
1-2 Machine Descriptions
1-2-4 Infeed Section
Infeed Section Direction
Adjusting Knob
There are five possible settings. To make an adjust-
ment, pull the knob and turn it.
Sheet
Length Short Long
Knob
Position
Infeed
Direction
11119
10204E1
In the ideal setting, the sheet is directed toward the cor-
ner of the stopper.
11119
10204F1
11119
10204G1
11119
10204H1
11119
10204B1
Low
11119
10204C1
Middle
11119
10204D1
High
(Horizontal)
11119
10204A1
Weights
The transport roller pressure can be
adjusted by changing the positions of
these weights. To move a weight, turn
the top to loosen it.
Hold-down Guides
These guides help to control sheets
which are bent or rolled.
Fore-edge Jog Plate
This squares up the sheet in the fore-
edge direction.
Jam Sensor
Sheet Holder
If the tail of the sheet remains at
the exit of the infeed section and
is not transported completely, the
sheet can be pushed to the belt
using this holder. (If the holder
pushes too strongly, the sheet
may be scratched.)
1-2-4
Infeed Section

7
1
Machine Descriptions / Machine Description
1-2 Machine Descriptions
1-2-5 Jog Section
21102
10205A1
Transport Pusher for
Paper Insertion (Option)
Transport Pusher
This pusher transports the flat
sheet when it is inserted into the
center page of a stitched book-
let.
The sheet is pushed and trans-
ported by this pusher. The
pusher may be removed if there
are paper jams. (Remember to
re-install the pusher for normal
setups.)
The waiting position for the transport pusher can be adjusted using
the touch panel screen. Refer to page 25 for details.
11119
10205C1
11119
10205D1
11119
10205E1
Saddle Stitch Stopper
Install large or small stoppers to match the sheet
width. (The instruction screen is displayed on the
touch panel.)
Side Stitch Stopper
This stopper is used for side stitching and corner
stitching.
Top and Bottom Guides
- These guides jog the sheets from the top and bot-
tom sides before stitching.
- The settings listed below can be done using the
touch panel.
- Jogging frequency before stitching
- Stroke (Guide opening when the sheet comes in)
- Delivery Stroke (Guide opening when the sheet
goes out)
- When you are doing corner stitching, these guides
are replaced by the corner stitch guide.
- This guide assembly consists of three parts. When
you are running small booklets, you may have to
remove these guides. (The instruction screen is
displayed on the touch panel.)
Side Stitch Sheet Hold-Down Plate
This plate prevents the sheets from floating.
Long type and short plates are available.
Guide Bar
This bar prevents the sheets from being bent
down. You must remove this bar before doing a
changeover. (The instruction screen is displayed
on the touch panel.)
11119
10205B1
Parallel Adjusting Bolt
This bolt is used as a gauge to adjust the
top-bottom guide so that it is parallel.
1-2-5
Jog Section

8
1-2 Machine Descriptions
1-2-6 Stitch Section
The operation of the stitcher head is explained in Section 4-1.
11119
10206B1
11119
10206A1
11119
10206D1
11119
10206E1
11119
10206C1
Wire Feeding
Detection Sensor
As the wire is feeding, the
wire guide bends down and
immediately returns to its
original position. This sensor
watches the movement of the
wire guide to see that the
wire is feeding properly. The
sensor is turned on (red LED
lights) when the wire guide is
bent down.
Clincher Lever
This allows you to remove a stitch which remains in
the clincher section.
Stitcher Head Drive Block
When one of these blocks is removed, the machine
does not make stitches on that side. The block on
the non-stitched side should be removed when you
are doing corner stitching. (The instruction screen
is displayed on the touch panel.)
Coil Brake
This brake prevents the coil from turning too easily and tangling
the wire. If the brake is pressed harder against the coil, it becomes
harder to turn the coil.
Stitch Angle Adjusting Knob
The stitch angle can be adjusted using this knob if one
stitch is not lined up.
Wire Coil
Standard wire is No.25 (0.5 mm in diameter)
Optional wire No.26 (0.45 mm in diameter) is
available.
Wire
Guide
Red LED
This lamp lights
when the sensor
detects the wire
guide.
There are circuit breakers inside this cover. See Section 6-10.
These holes allow for
installation of two
optional stitcher heads.
The positions of these
two stitchers are fixed.
Sheet Holder
This holder prevents the sheet from
floating. Long, short, and side stitch-
ing holders are available. Select the
holder to match the binding pattern
and sheet size. To change the holder,
loosen the locking knob. Set the
position of the holder to match
the thickness of the book-
let.
Locking Knob
1-2-6
Stitch Section

9
1
Machine Descriptions / Machine Description
1-2 Machine Descriptions
1-2-7 Fold Section
11119
10207A1
11119
10207B1
Fold Knife Height Adjusting Knob
The fold knife lifts when you turn this knob clock-
wise. (If you lift the fold knife too far, it may hit the
fold roller.)
Press
Rollers
These rollers
compress the
booklets.
Fold Rollers
The gap between the rollers
is automatically set to match
the booklet thickness
entered on the touch panel.
Fold Section Top and Bottom Guides
-These guides jog the sheets before folding.
-The settings listed below can be done using the touch panel.
- Distance between guides when jogging sheets
- Stroke (Guide opening when the sheet comes in)
- Delivery stroke (Guide opening when the sheet
goes out)
Fold Section Jog Pushers
-These pushers jog the sheets
before folding.
-The positions of these pushers
when jogging the sheets can be
adjusted on the touch panel.
(Refer to 1-3-7.)
Sheet Hold-Down Plate
These plates prevent the sheets from
floating.
Sheet Guide Locking Knobs
If sheets jam between the fold rollers and press rollers, remove the sheet guide by loosening these knobs.
Fold Skew Correction
Knob
As shown in the illustration, any
fold skewing can be corrected
by turning this knob clockwise.
Buckle Gap Adjusting Knob
The buckle gap can be adjusted in three levels
to match the sheet thickness.
The fold section stopper can be reached by opening this cover.
Press the Emergency Stop button before
turning the handwheel. A sudden acciden-
tal start of the machine can cause severe
personal injury.
WARNING
Do not open this cover while the machine
is running. Otherwise, moving parts can
cause severe personal injury.
WARNING
Forward Rollers
These rollers transport the sheets to
the fold section and prevent the sheets
from bouncing.
Handwheel
The fold roller and press rollers can be turned by hand for clean-
ing.
11119
10207E1
11119
10207F1
11119
10207D1
1-2-7
Fold Section

10
1-2 Machine Descriptions
1-2-8 Fore-edge Trim Section
11119
10208B1
11119
10208C1
11119
10208A1
Booklet Stopper
This stopper is automatically
set to match the finishing size
of the booklet.
Transport Belts
The sheet is transported by these belts.
The gap between the upper and lower
belts is automatically set up to match the
book thickness entered on the touch panel.
Locking
Lever
Front Transport Belt Height
Adjusting Knob
If the booklets do not move correctly, adjust
this knob. To reduce the gap at the front of the
transport belts, loosen the locking lever and
turn the knob clockwise.
Jam Sensor
Trim Knife (Upper Knife)
Infeed Belts
These belts move the sheet into the fore-
edge trim section.
Fore-edge Trim Section Locking Lever
If you are trimming small booklets (smaller than B5), the booklet may not move correctly if the pressure is
different at the front and rear transport belts.
Transport Belt
Transport Belt
Lift the locking lever up and
move the fore-edge trim mech-
anism to the front.
When the fore-edge trim mechanism is moved to the front, the stopper holds the far side of the booklet,
and the booklet should stop straight against the stopper.
(The instruction screen for this is displayed on the touch panel when binding sheets smaller than B5.)
Position for Small Booklet
Normal Position
Stopper
1-2-8
Fore-edge Trim Section

11
1
Machine Descriptions / Machine Description
1-2 Machine Descriptions
1-2-9 Delivery Conveyor
11119
10209A1
Faulty Set Ejecting Gate
If the machine detects a faulty set, this
gate moves and the faulty set is deliv-
ered to the faulty set ejecting tray.
Delivery Conveyor
When a booklet is delivered, the belts
move for a moment. The running time
for the belts can be set on the touch
panel.
Delivery Rollers
These rollers hold the delivered booklet. These
rollers should be placed about 30 mm (1.2")
from the end of the booklet.
Locking Knob
Locking Knob
Jog Button
The conveyor belts move when this
button is pressed.
Faulty Set Ejecting Tray
When the faulty set eject function is activated on the touch
panel, faulty sets are delivered to this tray.
The possible causes of faulty sets are:
- Mis-feed / double feed / Jam in upstream device
- Fold section jog error
- Missed stitch detection (option)
- Fore-edge trim section thickness detection (option)
If the operation starts with a sheet remaining in the machine,
the sheet is delivered to this tray.
Trim Chute
The trim is ejected through this chute.
Trim Full Sensor
This sensor detects the trim full error.
Mirror
1-2-9
Delivery Conveyor

12
1-2 Machine Descriptions
1-2-10 Control Panel
11119
10210A1
11119
10210B1
11119
10210C1
11119
10210D1
Fore-edge Trim
Section Power LED
Trim Knife
Reverse Jog
Button
When this button is
pressed and held, the trim
knife operates once and
then stops at the top posi-
tion. If the knife is locked,
the trim knife can be
returned to the top posi-
tion using this button.
When some screens are displayed on
the touch screen, these buttons will not
work.
Stop Button
This button stops the binding
operation. Feeding from the
upstream device stops when
this button is pressed. All book-
lets in-process are delivered,
and the transport rollers keep
moving. When this button is
pressed again, the machine
stops completely.
Main Machine Power
LED
This LED lights when the
power switch is turned On.
The LED blinks if the machine
is using the power saving
mode.
Transport Belt
Inching Button
The transport belt at
the fore-edge trim sec-
tion drives only while
this button is pressed. Start Button
This button starts the binding oper-
ation. If there are sheets remaining
inside the machine, they will be
ejected. While this is happening,
the button blinks. When the
machine is ready, the button lights
and feeding from the upstream
device (collator) starts.
Machine Jog Button
This jogs the jog section and the fold section. Jog-
ging is stopped when this button is pressed again.
This button will work even if a cover is opened.
Stitch Jog Button
Operating the stitcher heads in the normal direction
Press and hold this button to make one stitch in the normal
direction while the cover is closed and the Emergency Stop
button is not pressed.
Reversing the stitcher heads
The stitcher heads will return to the original position by
reverse movement if you press this button while pressing
the Machine Jog button when the cover is closed and the
Emergency Stop button is not pressed. See page 75 for
details.
Releasing the top and bottom guides
The top and bottom guides move outward if this button is
pressed while the cover is opened or the Emergency Stop
button is pressed. Any sheets remaining at the jog section
can be removed easily. (The top and bottom guide returns to
its setting position when the jog button is pressed.)
When the power is first turned on,
these buttons will not work until the
first changeover has been done.
1-2-10
Control Panel