Horizon International BQ-P6 User manual

Service Manual
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SERVICE MANUAL
Kyoto,Japan
510 Kuze Ooyabu-cho Minami-ku, Kyoto 601-8206, Japan
Phone:[phone], Fax:[phone], URL http://www.horizon.co.jp/
BQ-P6 Perfect Binder

IUS502007-04060905/BQP6/04E/DV
FOREWORD
Perfect Binder
Model BQ-P6
Do not perform any maintenance until you read and
understand the instructions in this manual.
If you have questions regarding maintenance or this publication,
please contact our service division.
This manual is designed to help you to keep the machine in a good operating
condition. Read, study and keep this manual in a safe and convenient place.
The machine design and specifications are subject to
change without notice.

II
Safety Instruction
1. Read and understand all safety instructions with a signal WARNING,
and CAUTION. If safety instructions are ignored, personal injury will
result.
2. HORIZON INTERNATIONAL INC. cannot anticipate every possible situa-
tion that might involve a potential hazard. The instruction in this manual are
therefore not all inclusive.
3. Be sure to unplug the power cord when replacing the parts or repairing the
machine.
4. Take care with the rotating parts when the machine is operated with the covers
being opened.
5. Use the original HORIZON spare parts when replacing the parts.

III
I Necessary Tool for Maintenance and Repair
Use the following tools for maintenance and repair.
1. Screw Driver No. 2
2. Screw Driver 6 to 7 mm
3. Allen Wrenches 1.5, 2, 2.5, 3, 4, 5, and 6 mm
4. Open-ended Wrench 5.5 x 7 mm 8 x 10 13 x 17
5. Box Wrench 5.5 mm
6. Snap-ring Expander
II Signs and Abbreviations in This Manual
1. The following signs in this manual
represent wire color.
Sign Color
C Brown
RRed
O Orange
Y Yellow
G Green
B Blue
V Violet
H Gray
W White
D Black
S Transparent
DH Dark Gray
2. The following abbreviations in this manual
represent electronic and electrical parts.
Abbreviation Meaning
CL Clutch
BK Brake
SW Switch
mSW Microswitch
M Motor
LED Light Emitted Diode
VR Potentiometer
RY Relay

IV
Contents
FOREWORD .......................................................................................................................... I
Safety Instruction ................................................................................................................... II
I Necessary Tool for Maintenance and Repair ................................................................... III
II Signs and Abbreviations in this manual ........................................................................... III
1. Specifications ................................................................................................................... 1
2. Operation Procedure ...................................................................................................... 2
3. Leveling Adjustment for Glue Application ................................................................... 4
4. Drive Section Descriptions ............................................................................................. 5
5. How to Remove Cover .................................................................................................... 6
6. Troubleshooting ............................................................................................................... 7
7. Sensor and Electronic Parts Locations ......................................................................... 12
8. Switch Position Adjustment ........................................................................................... 13
9. Control P.C.B. LED Descriptions .................................................................................. 14
10. Electronic Circuit Diagram .......................................................................................... 15
11. Check Mode ................................................................................................................... 16
12. Melt Tank Replacement ............................................................................................... 17

MaximumBookSize
MaximumBookThickness
BindingType
ProductionSpeed



WarmingUpTime
PowerConsumption



MachineDimentions
(WxDxH)
MachineWeight
MeltTankCapacity
UptoA4Size
25mm(1")
CoverBinding,TapeBindingandPadding
Cover/TapeBindingMode:30seconds/book(50Hz)
27seconds/book(60Hz)
PadBindingMode:36seconds/book(50Hz)
33seconds/book(60Hz)
13minutes
100V-50/60Hz1050W
115V-60Hz1050W
230V-50Hz1050W

560x460280mm
(22"x18"x11")
32kg(64.8lb)
350g

2
2. Operation Procedure
Cover/Tape Binding Mode
Turn on power switch.
About 13 minutes
later.
Set sheets into
clamper.
Press start button.
Set cover sheet or tape
and press start button
again.
Take out book.
Press reset button.
- Heater begins to warm up.
- "Preparation" lamp illumi-
nates.
- "Cover/Tape Mode" lamp
illuminates.
- Alarm sounds.
- "Preparation" lamp goes out.
- "Insert stock. Depress start
button." lamp illuminates.
- Nipper lowers and clamper
moves to the rear side and
stops above melt tank while
"Operation" lamp is illuminat-
ing.
- "Operation" lamp goes out.
- "Place cover sheet. Depress
start button." lamp illuminates.
- "Operation" lamp illuminates.
- Clamper goes back to home
position and stops on nipper.
- Nipper rises to nip cover
sheet and stock.
- Alarm sounds and nipper
lowers.
- "Operation" lamp goes out.
- "Take out stock. Depress
reset button." lamp illuminates.
- "Operation" lamp illuminates.
- Nipper rises.
- "Operation" lamp goes out.
- "Insert stock. Depress start
button." lamp illuminates.
Operation Sensor or SwitchAction (Operation Panel LED)
1
2
3
4
5
6
7
- Clamper home position switch
ON
- Nipper upper limit
microswitch OFF
- Sheet presence microswitch
ON
- Nipper lower limit
microswitch OFF
- Clamper reverse switch ON
- Cover sheet sensor ON
- Clamper home position switch
ON
- Nipper lower limit
microswitch OFF
- Stock presence microswitch
OFF
- Nipper upper limit
microswitch OFF

3
1
2
3
4
5
6
7
Turn on power switch.
About 13 minutes
later.
Select binding mode.
Set sheets into
clamper.
Press start button.
Take out book.
Press reset button.
- Heater begins to warm up.
- "Preparation" lamp illumi-
nates.
- "Cover/Tape Mode" lamp
illuminates.
- Alarm sounds.
- "Preparation" lamp goes out.
- "Insert stock. Depress start
button." lamp illuminates.
- Lamp moves from "Cover/
Tape Mode" to "Padding
Mode".
- Nipper lowers and clamper
moves to the rear side and
stops above melt tank while
"Operation" lamp is illuminat-
ing.
- Alarm sounds
- "Operation" lamp goes out.
- "Take out stock. Depress
reset button." lamp illuminates.
- "Operation" lamp illuminates.
- Nipper rises.
- "Operation" lamp goes out.
- "Insert stock. Depress start
button." lamp illuminates.
Operation Sensor or Switch Action (Operation Panel LED)
- Clamper home position switch
ON
- Nipper upper limit
microswitch OFF
- Sheet presence microswitch
ON
- Nipper lower limit
microswitch OFF
- Clamper switch temporarily
ON
- Clamper home position switch
ON
- Stock presence microswitch
OFF
- Nipper upper limit
microswitch OFF
2. Operation Procedure
Padding Mode

4
Clamper
Operation Side
Lock Bolt (Black)
Lock Bolt (Yellow)
Bottom Plate
Lock Screw
Scrape Roller
Adjust Bolt
Level 0
Application Drum
Pivot
Bearing
Scrape Roller Nippers
Cam
(While stock is set.)
Nipper Base
3. Leveling Adjustment for Glue Application
Construction
Each section is adjusted based on the upper surface of application drum as the pivot of appli-
cation drum is fixed to the standard position.
1. Nipper Base Adjustment during Nipping Stocks
- Adjust nipper base with adjust bolt (Yellow) on the bottom of melt tank.
NOTE
- The clearance between the upper surface of application drum and the upper surface of
nipper must be 0.7 ~ 0.8 mm.
- Be sure to loose lock bolt (Black) before adjustment and fasten lock bolt (Black) after
adjustment.
2. Scrape Roller Adjustment
- Adjust scrape roller with scrape roller adjust bolt on melt tank.
NOTE
- It is easier to adjust scrape roller based on the upper surface of nipper which is adjusted
before.
- The clearance between the upper surface of scrape roller and the upper surface of nipper
must be 1.2 ~ 1.4 mm.
- Be sure to loose lock screw before adjustment and fasten lock screw after adjustment.
- Nipper base is lowered by cam while stock is nipped.

5
Clamper Home Position Switch
Clamper Reverse Position Switch
Clamper
A
A : Idler Pulley
Motor
Drive Chain
Torque Clutch
Drive Gear
Application Roller
Clamper Chain
A
A
Scrape Roller
B. Nipper
View from the Left Side
Nippers
Nipper Base Shaft
Nipper Arm Shaft (R)
Nipper Arm Shaft (L)
Nipper Chain
Motor
Nipper Arm
4. Drive Section Descriptions
A. Clamper and Melt Tank
View from the Right Side
1. While motor is rotating clockwise, drive chain and drive gear are activated, and application
roller rotates counterclockwise and scrape roller rotates clockwise in melt tank.
2. Motor rotation transmitts to torque clutch and then rotates clamper chain, and finally clamper
moves to the left.
1. While motor is rotating clockwise, nipper chain is activated, and nipper arm shaft (L) rotates
counterclockwise and nipper arm shaft (R) rotates clockwise to rotate nipper arm. Nipper
arms move nippers to nipping direction.
2. Cam fixed in nipper arm shaft (L) pivots nipper base on nipper base shaft.

6
Tool : Phillips Screwdriver
5. How to Remove Cover
A Right Cover M4 x 12 Tapping (Black) 2 pcs
M4 x 8 Bind 2 pcs
Nail 1 pcs
B Left Cover M4 x 14 Tapping (Black) 2 pcs
M4 x 8 Bind 2 pcs
C Clamper M3 x 8 Bind 4 pcs
D Front Cover M4 x 8 Screw 2 pcs
M4 x 8 Screw (Loosen) 2 pcs
CAUTION
- Be sure to turn power off before any
cover is removed.
- Melt tank is heated up to 180 ˚C.
Wait until melt tank is cooled down
before covers are removed.
Clamp Cover (C)
Right Cover (A)
Nail
Loosen
Control P.C.B.
Front Cover (D)
Melt Tank Cover
Left Cover (B)
A
A
A (Black)
A (Black)
D
D
D
D
B (Black)
B (Black)
B
B
C
C
C
C
Loosen

7
Clamper
Nipper Base
Operation Side
Lock Bolt (Black)
Ad
j
ust Bolt
(
Yellow
)
Bottom Plate
Nipper Cam
Nipper Base
Bearing
6. Troubleshooting
A. Glue is not applied on spine (partially).
View from the Left Side
(Cause)
Nipper base is too high.
(Remedy)
Lower nipper base.
Loosen two lock bolts (Black) on the operation side and
turn adjust bolt (Yellow) clockwise, and bearing will
lower and nipper base lower.
NOTE
- If nipper level is lowered too much, glue is not ap-
plied enough.
- Do not adjust adjust bolt more than 1/4 turn at one
time. Nipper base lowers by 0.1 mm with 1/4 turn.
- Turn both adjust bolts equally.

8
Melt Tank cover
Switch
Magnet
30
5
6. Troubleshooting
B. Enough glue is not applied on spine.
C. BQ-P6 stops suddenly during operation and not possible to start with any
button.
(Cause)
Nipper base is too low.
(Remedy)
Rise nipper.
- Loosen two lock bolts (Black) on the operation side and
turn adjust bolt (Yellow) counterclockwise, and bearing
will lower and nipper base lower. (Refer to page 7.)
NOTE
- If nipper level is raised too much, glue is not applied .
- Do not adjust adjust bolt more than 1/4 turn at one
time. Nipper base lowers by 0.1 mm with 1/4 turn.
- Turn both adjust bolts equally.
(Cause 1)
Safety switch for melt tank is
activated.
(Remedy 1)
- When melt tank switch is activated, check that the
clearance between magnet and switch is 0.5~1.0 mm.
- Check that magnet is set as shown in the drawing
below.
- Control P.C.B. tells whether switch is activated or not.
(Refer to page 14.)
Serial Number : 039 -, 049 -, 059 -, 010 -, 020 -, 022001 -
(Cause 2)
Clamper safety cover switch
is activated unnecessarily.
(Remedy 2)
Adjust switch so that switch will be activated when
safety cover for the front of clamper rises 5 ~ 10 mm
upward. (Refer to "Clamper Safety Cover Switch Ad-
justment" in page 13.)
Serial Number : from 03915 to 039 -, 049 -, 058 -,
059 -, 010 -, 020 -

9
(Cause 1)
Torque clutch is adjusted
improperly, and drive power
is not transmitted.
A : Idler Pulley
Motor
Drive Chain
Torque Clutch
Plunger
Lock Nut
View from the Left Side
6. Troubleshooting
D. Clamper stops during operation. (Motor is making noise and application
drum is rotating.)
E. Cover sheet is not perfectly bound.
Remedy 1)
Adjust torque again.
Serial Number : from 03915 to 03999, 049 -, 058 -,
059 -, from 01001
Move clamper to the far side by hand. Turn torque clutch
until click sound is heard from torque clutch. Then turn
further 60˚ and fasten plunger lightly. Turn back turque
clutch by 20 to 30˚ and then lock plunger with lock nut.
(Cause 2)
Clamper home position switch or clamper reverse switch is
broken. If clamper stops at the far side, clamper reverse
switch is broken. If clalmper stops at the operation side,
clamper home position switch is broken.
- Control P.C.B. tells whether switch is activated or not.
(Refer to page 15.)
(Remedy 2)
Replace switch.
(Cause 1)
Glue is not applied on spine
enough.
(Cause 2)
Glue is dried because of slow
set up of cover sheet.
(Remedy 1)
Refer to "Enough Glue is not applied on" in page 8.
(Remedy 2)
Set cover sheet quickly.

10
Nipper Center
Clamper Center
Clamper Fix Bolts
6. Troubleshooting
F. One side of spine corner is not bent.
G. All lamps on operation panel flash and BQ-P6 does not work.
(Cause)
Nipper center and clamper
center are not aligned.
(Remedy)
Adjust nipper center and clamper center by moving
clamper home position switch. (Refer to page 12.)
(Cause)
Nipper center and clamper
center are not parallel.
(Remedy)
Remove clamper cover, loosen clamper fix bolts and
adjust clamper so that nipper and clamper are parallel.
(Cause)
Nipper does not work properly.
(Remedy)
Adjust the positions of nipper highest and lowest
position microswitches. (Refer to page 12.)

11
I. Glue is not appeared on application drum because glue becomes gel.
J. The circuit protector trips when the power is turned on.
6. Troubleshooting
H. BQ-P6 does not work with "Preparation" LED illuminating.
(Cause 1)
Thermal fuse is blown.
(Cause 2)
Heater is blown.
(Remedy 1)
Replace thermal fuse. (167˚C)
NOTE
- Do not put excessive strength on terminal of thermal
fuse when replacing thermal fuse.
(Remedy 2)
Replace heater.
(Cause)
Hot melt glue is not good to use.
(Remedy)
Replace glue.
(Cause)
Internal circuit has a problem.
(Remedy)
Check the power circuit. Refer to the figure on page 15.

12
7. Sensor and Electronic Parts Locations
Drive Motor
Clamper Switch
Melt Tank Cover
Safety Switch
Clamper Home
Position Switch
Stock Presence
Microswitch
Nipper Lower Limit
Microswitch
Nipper Upper Limit
Microswitch
Power Supply
Nose Filter
Heater 1100W
Operation Panel P.C.B.QPW-417
EGO Sensor
Circuit Protector 8A/15A
Nipper Motor
Nipper Safety Switch
Power Switch
Clamper Safety Cover Switch
Clamper Safety Cover
Control P.C.B. QPW-416
Cover Sensor

13
Nipper Arms Nipper Arms
Touch
Fig. B
Fig. A
Stock Presence Switch
Clamper
Clamper Knob
Clamper Safety Cover
Nipper
Clamper Safety Cover Switch
Clamper Cover
8. Switch Position Adjustment
A. Nipper Upper / Lower Limit Microswitch Adjustment
Nipper upper limit microswitch :Adjust the position of switch cam so that microswitch is off
when the positions of nipper arms is either Fig. A or B.
(Refer to page 12.)
Nipper lower limit microswitch :Adjust the position of cam so that mcroswitch turns off
when nipper base is at the lower limit and also nipper up cam
is at the center of the lower limit.
B. Stock Presence Switch Adjustment
Adjust the position of stock presence switch
so that stock presence switch is stick out of
clamper by 0.5 to 0.7 mm while stock
presence switch is on.
C. Clamper Safety Cover Switch Adjustment
Adjust clamper safety cover switch so that
switch turns on when clamper safety cover
is raised by 5 to 8 mm.

14
L1 Nipper Up Nipper rises from nipping position.
L2 Nipper Down Nipper lowers to nip stock.
L3 Clamper Home Position Switch
L4 Clamper Reverse Switch
L5 Nipper Home Position Switch Illuminates at home position.
L6 Nipper Lowee Limit Switch Illuminates at lowest position.
L7 Stock Presence switch Illuminates when stock is not in clamper.
L8 Cover Sheet Sensor Illuminates when cover is used.
L9 Start Switch Illuminates by being pressed.
L10 Stop Switch Illuminates by being pressed.
L11 Reset Switch Illuminates by being pressed.
L12
Padding or Cover/Tape Binding Switch Illuminates by being pressed.
L13 Clamper at Home Position Illuminates at home position.
L14 Melt Tank Cover Illuminates when cover is closed.
L15 Clamper Illuminates at reverse position.
L16 Clamper Safety Cover Switch Illuminates when cover is closed.
CON6 CON1 CON2 CON3 CON4
L3
L2
L1
CON5
ROM
L4
L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16
9. Control P.C.B. LED Descriptions
S/N : from 03915 to 03999
049 -, 058 -, 059 -
010 -, from 02001 to 02047
S/N : from 03915 to 03999
049 -, 058 -, 059 -
from 01001