INSTRUCTION MANUAL SYSTEM5000 Dynamic Booklet Maker DBM-500 [ for 120 V ] Be sure to read this manual prior to use. Please leave this manual at the site of use for easy reference.
Applicable to the 120 V machine This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.
INTRODUCTION Thank you for purchasing this Duplo equipment. To ensure correct usage, please read this instruction manual thoroughly, especially the section entitled "Safety Precautions". The aim of this instruction manual is to ensure safe and proper use of the equipment. For this reason, do not attempt to remodel, modify or adapt this equipment or to use it for any other purpose than that intended by the manufacturer. After reading, please keep this instruction manual handy for future reference. CONTENTS 1. SAFETY PRECAUTIONS... 2 2. USAGE PRECAUTIONS... 5 2-1. Power Supply... 5 2-2. Operating Environment... 5 2-3. Storage Conditions... 5 3. NAMES AND FUNCTIONS... 6 3-1. External Parts... 6 3-2. Internal Parts... 8 3-3. Downstream Unit (Optional)... 11 3-4. Accessories... 11 4. NAMES AND FUNCTIONS OF CONTROL PANEL (MAIN MENU)... 12 5. PREPARING FOR OPERATION... 14 5-1. Power ON... 14 5-2. Operations... 15 5-3. Settings... 19 6. SADDLE STITCHING PROCEDURE... 27 6-1. Settings... 27 6-2. Changing Size... 30 6-3. Adjustments Using the Step Mode... 30 6-4. Checking the Finished Set... 33 7. SIDE STITCHING/CORNER STITCHING PROCEDURE... 38 7-1. Settings... 38 7-2. Changing Size... 41 7-3. Adjustments Using the Step Mode... 42 7-4. Checking the Bound State... 45 8. NO-STITCHING FOLDING PROCEDURE... 46 8-1. Settings... 46 8-2. Changing Size... 48 8-3. Adjustments Using the Step Mode... 49 8-4. Checking the Finished Set... 52 9. VARIOUS SETTINGS... 56 9-1. Fine Adjustment Menu... 56 9-2. Option Menus... 61 9-3. Accessory Menus... 63 9-4. Adjusting the Press Pressure and Conveyance Pressure... 66 9-5. Adjusting the Saddle Stitching Guide/Side Stitching Guide... 66 10. ERROR MESSAGES... 67 10-1. Emergency Stop... 67 10-2. Covers... 67 10-3. Paper Jam... 68 10-4. Wire Feed Detection... 68 10-5. Paper Tray Full... 68 10-6. Motor Error... 69 10-7. Service Person Error... 69 10-8. Shutter... 69 11. CORRECTING PAPER JAMS... 70 12. STITCHER HEAD... 71 12-1. Names and Functions... 71 12-2. Wire... 72 12-3. Feeding the Wire... 73 12-4. Stitching Tests... 75 12-5. Removing Wire... 76 12-6. Adjustments... 77 12-7. Maintenance... 78 13. TROUBLESHOOTING... 79 14. CLEANING... 81 15. SPECIFICATIONS... 82 1
1. SAFETY PRECAUTIONS Always observe the cautions and warnings given below to prevent personal injury or property damage. The degree of danger and damage that could occur is indicated on two levels by the following marks. WARNING: CAUTION: Ignoring this mark could result in the possibility of serious injury or even death. Ignoring this mark could result in the possibility of injury or physical damage. The following graphic symbols indicate the various types of action to be performed or avoided. This graphic symbol indicates a forbidden action. means Do not disassemble. means Do not touch. This graphic symbol indicates actions that must be performed. means Disconnect the power plug. WARNING: Do not place metal objects or vessels containing liquids on top of the unit. The entry of any metal object or liquid could result in a fire or an electrical shock. Do not insert any metal or easily-combustible object inside this unit. This could result in a fire or an electrical shock. Do not touch or insert foreign objects into any rotating part during operation. This could result in injury. Do not remove the cover or back panel. This unit contains high-voltage components that could cause an electrical shock. Do not disassemble, modify or repair this unit. There is a danger of fire, electrical shock or injury. Contact your dealer when repairs are necessary. Use only the power supply voltage specified on the main nameplate. Using other voltages could result in a fire or an electrical shock. Keep this unit and the power cord away from heaters and heater vents. Excessive heat could melt the cover or power cord covering, and result in a fire or an electrical shock. 2
1. SAFETY PRECAUTIONS Do not use flammable sprays or solvent inside or near the unit (e.g. when cleaning the unit). Such flammable gas or solvent may ignite and cause a fire or combustion. Make sure that the combined power consumption of the appliances to be connected does not exceed the capacity rating of the power outlets or plug receptacles. Exceeding the capacity rating could cause the power outlets, plug receptacles, or power extension cords to overheat and catch a fire. Remove any dust that accumulates on the power plug prongs and the surface of the plug from which the prongs extend. Accumulated dust could result in a fire. If any foreign object such as metal or liquid should enter this unit, immediately turn the unit off at the power switch and disconnect the power plug from the power outlet. Failure to do so could result in a fire or an electrical shock. Contact your dealer immediately. Do not damage the power cord or power plug. (Do not scratch, alter, bend, twist, pull or place heavy objects on the power cord or power plug.) This could result in damage, a fire or an electrical shock. Always grip the plug when disconnecting the power plug from the power outlet. Forcibly pulling on the power cord could cause damage, resulting in a fire or an electrical shock. Do not touch the power plug or power switch with wet hands. This could result in an electrical shock. Before cleaning this unit, turn the unit off at the power switch and disconnect the power plug from the power outlet. Accidental operation of the unit during cleaning could result in injury. CAUTION: Always disconnect the power plug from the power outlet when the unit is not to be used for an extended period. Failure to do so could result in fire due to leakage current if the insulation should deteriorate. Install this unit on a level, stable stand or floor, with sufficient space around it. Failure to do so could result in the unit overturning and causing injury. Do not install this unit in a location where there is excessive humidity or where contact with water is possible. Poor choice of location could result in deterioration of the insulation, fire or electrical shock. Disconnect the power plug from the power outlet before attempting to move this unit. Failure to do so could result in power cord damage, fire or electrical shock. 3
1. SAFETY PRECAUTIONS Safety The following shows the location of the safety devices and warning/caution label. Top cover (Back) Top cover (Front) Emergency Stop Switch Shutter Note Labels are pasted to ensure the safety of users. Do not remove nor change them. If a label becomes dirty or missing, be sure to contact your dealer for a new one. The actual control panel and emergency stop switch of this machine may be located opposite to the locations shown in the above figure. 4
2. USAGE PRECAUTIONS 2-1. Power Supply This equipment shall be installed near the socket-outlet where the plug on the power supply cord is easily accessible. Make sure the power supply used is always within the following range. 220-240V AC 50Hz/120V AC 60Hz When you power other appliances from the same AC outlet, make sure that the combined power consumption does not exceed the power supply capacity. Rated power of this equipment : 3.8A/6.5A 2-2. Operating Environment Operate this unit in the following environment: where the temperature range is between 5 and 35 C/41 and 95 F, where the humidity range is between 10 and 85%RH (no dew condensation), which is not subject to direct sunlight, which is subject to little or no vibration, where there are no harmful chemicals, which is reasonably free from dust, which is free from air-borne salt, and where the equipment will not be exposed to water. 2-3. Storage Conditions Store this unit in the following environment: where the temperature range is between 10 and +50 C/14 and 122 F, where the humidity range is between 10 and 85%RH (no dew condensation), which is not subject to direct sunlight, which is subject to little or no vibration, where there are no harmful chemicals, which is reasonably free from dust, which is free from air-borne salt, and where the equipment will not be exposed to water. 5
3. NAMES AND FUNCTIONS 3-1. External Parts In this manual, the left side of the paper conveyance direction is indicated as L side and the right side as R side. 4 Paper direction L side 2 3 R side bl bm 1 bk 5 6 7 8 9 No. Name Function 1 Main power switch Refer to 5-1. Power ON. ( Refer to page 14.) 2 Emergency stop button Press to stop the machine in emergency. Paper being fed will stop halfway. To resume operations, remove this paper. To stop the machine normally, use the [Stop Key] on the upstream unit or this machine. To release this switch, rotate it to the right. 3 Front top cover Cover for ensuring user safety This machine will not operate if open. 4 Rear top cover Cover for ensuring user safety This machine will not operate if open. 5 Option connector Optional power connector 6 E port connector-1 Connects the E port cable from the upstream unit. 7 E port connector-2 Connects the E port cable to the downstream unit. 8 D port connector-1 Connects the D port cable from the upstream unit. 9 D port connector-2 Connects the D port cable to the downstream unit. bk Power cord Supplies power to this machine. bl Power switch Refer to 5-1. Power ON. ( Refer to page 14.) bm Stacker connector Connects the power cord of the belt stacker. 6
3. NAMES AND FUNCTIONS bn bo ck R side L side bt bp cl Paper direction cm bs br cn bq co cp cp No. Name Function bn Wire reel Stitches paper bo Control panel Refer to Description of Control Panel. ( Refer to page 12.) bp Folding stopper adjustment dial Adjusts the angle of the folding stopper to correct folding misalignment. bq Deflector strip Holds booklets sent to the side stitching stacker. br Side stitching stacker Receives booklets which are side stitched (corner stitched). bs Stacker plate Receives booklets which are saddle stitched, and folded. When stacked poor due to small booklet size, use it at upper position. bt Belt stacker Sends booklets folded into two to the stacker plate. Connect the power cord plug of the Belt Stacker Unit to the outlet of the DBM-500 ck Paper guide wheel Holds paper sent to the stacker and feeds to the stacker plate. cl Shutter Opening for inserting the handle Normally leave closed. This machine will not operate if the shutter is open. ( Refer to pages 70 and 81.) cm Handle Used to remove jammed paper and clean the folding stopper cn Side stitching stopper Stops booklets which have been side stitched (corner stitched). co Side stitching stopper adjustment Adjusts the position of the side stitching stopper. knob cp Ejection roller Ejects side stitched (corner stitched) booklets. 7
3. NAMES AND FUNCTIONS 3-2. Internal Parts Paper direction 3 3 1 1 4 2 2 5 5 6 8 7 When the conveyance roller open No. Name Function 1 Stitcher head Binds paper with wire. 2 Side jogger Aligns the sides of paper. 3 Side stitching stopper Rises during side stitching (corner stitching) to stop paper. 4 Side stitching guide Prevents paper from curling during side stitching (corner stitching). 5 Back jogger Aligns the leading and trailing edges of paper. 6 Conveyance driven roller Helps to convey paper to the paper alignment section. 7 Conveyance roller lifting handle Lift to remove paper jammed at the paper alignment section. 8 Conveyance roller Conveys paper to the paper alignment section. 8
3. NAMES AND FUNCTIONS bl Paper direction bn bo bl bm bk 9 bm No. Name Function 9 Saddle stitching stopper Rises to stop paper during saddle stitching. bk Ejection driven roller Helps to deliver stitched booklets to the folder. bl Saddle stitching guide Prevents paper from curling during saddle stitching. The height can be adjusted. ( Refer to page 66.) bm Folding side guide Holds both ends of booklets during folding. bn Ejection roller Ejects stitched booklets to the folder. bo Ejection roller stopper Solves the poor alignment of insert sheets in insert mode. 9
3. NAMES AND FUNCTIONS Paper direction bq bq bp Roller attaching position bt bp bs br bq bs br ck cl cl No. Name Function bp Folding roller Roller for folding booklets into two bq Press roller Presses booklets folded into two. br Pressure adjustment hook Adjusts the pressure of the press roller. bs Conveyance pressure adjustment Switches the conveyance pressure of booklets folded into two. hook bt Folding stopper Stops booklets during folding. ck Folding back guide lifting handle Lift to remove booklets when paper jams at the folding unit. cl Folding back guide Presses the ends of booklets during folding. 10
3. NAMES AND FUNCTIONS 3-3. Downstream Unit (Optional) DBM-500T (Optional) DBM-K (Optional) This machine DBM-LSI (Optional) 3-4. Accessories Paper guide wheel Adjusting handle Corner stitching paper holder 11
4. NAMES AND FUNCTIONS OF CONTROL PANEL (MAIN MENU) The control panel is composed of the touch panel and numerical pad. The following describes the main menu which is the standard screen displayed normally, and the numerical pad. 1 5 2 6 3 7 4 br bs MAINMENU ADJUST OPTION ACCESSOR 420. 0 x 297. 0 207. 0 x 277. 0 01 00000 8 9 bq bn bo bk bm bp bl bt cl cm ck [Touch Panel] [Numerical Pad] No. Name Function 1 Main menu tab Displays the main menu. 2 Fine adjustment menu tab Displays fine adjustment menus. ( Refer to page 56.) 3 Option menu tab Displays option menus. ( Refer to page 61.) 4 Accessory menu tab Displays accessory menus. ( Refer to page 63.) 5 Stitch setting display Displays the stitch setting of the memory number currently selected. Indicates that saddle stitching is selected. Indicates that side stitching (corner stitching) is selected. Indicates that Stitch Off is selected. 6 Fold setting display Displays the fold setting of the memory number currently selected. Indicates that Fold On is selected. Indicates that Fold Off is selected. 12
4. NAMES AND FUNCTIONS OF CONTROL PANEL (MAIN MENU) No. Name Function 7 Trim setting display Displays the trim setting of the memory number currently selected. Note: This is not displayed when not connected with the DBM-500T, or when Fold Off is selected. Indicates that Head/Foot Trim On is selected. Indicates that Fore-edge Trim On is selected. Indicates that Trim Off is selected. 8 Sheet size display Displays the paper size of the memory number currently selected in the following format. length x width 9 Finished size display Displays the finished size of the booklet processed by this machine. bk Memory number display Displays the memory number of the binding mode currently selected. bl Memory number selection key Selects the memory number. The selected memory number is displayed at bk Memory number display, and the settings are displayed at 5 to 9. bm Setting key Displays the setting menu of the memory number of the binding mode currently selected. bn Processed number display Displays the number of sets processed by this machine. bo Processed number clear key Clears the Processed number display to 0. Press for more than 1 second. bp Size change key Changes the settings of the memory number currently selected. Press for more than 1 second. bq Message display Displays messages. br Numerical keys Enters values such as paper size, etc. bs Clear key Clears the value entered using br Numerical keys to 0. bt Return key Confirms values entered using br Numerical keys to 0. ck Jog key Step-ejects paper forcibly. ( Refer to page 16.) Press for more than 1 second. cl Start key Starts the system. Press for more than 1 second. cm Stop key Stops the system including this machine. 13
5. PREPARING FOR OPERATION FOR OPERATION 5-1. Power ON This machine has a main power switch and a power switch. Operate the machine with the main power switch On, and the power switch " " The remote function allows this unit to turn on/off by pressing the power switch for DC-10/60,and the main power switch for DSF-2000. It means there is no need to touch the main power switch or the power switch of this unit. Power switch Note To turn the power of this machine On/Off by itself, set the power switch to I and the main power switch On. When operating the power switch, do so after turning Off the main power switch. If an upstream unit is connected, do not turn On/Off the power of this machine by itself. This may cause the machine to operate abnormally. Be sure to turn On/Off the main power switch or the power switch of the upstream unit instead. Main power switch Power switch DBM-LS1 DBM-500T This machine LUL-HM DC-10/60 When DC-10/60 is connected DBM-LS1 DBM-500T This machine DSF-2000 Main power switch When DSF-2000 is connected 14
5. PREPARING FOR OPERATION 5-2. Operations Memory No. Size change key Clear key MAINMENU ADJUST OPTION ACCESSOR 420. 0 x 297. 0 207. 0 x 277. 0 01 00000 Processed number display Processed number clear key Message Return key Start key Stop key Jog key Memory No. The memory number consists of 1 to 12 for registering binding setting (binding mode) such as paper size, stitching, and folding to each memory. Default settings at shipment are as follows. Memory No. Paper size (mm) (inch) Stitching Folding 1 420 x 297 (A3) (17.00 x 11.00 (Double letter)) Saddle stitching Folding 2 297 x 210 (A4) (11.00 x 08.50 (Letter)) Saddle stitching Folding 3 210 x 297 (A4) (08.50 x 11.00 (Letter)) Side stitching No folding 4 210 x 148 (A5) (08.50 x 05.83 (Letter)) Saddle stitching Folding 5 364 x 257 (B4) (08.50 x 05.83) Saddle stitching Folding 6 257 x 182 (B5) (10.12 x 07.17) Saddle stitching Folding 7 182 x 257 (B5) (07.17 x 10.12) Side stitching No folding 8 431.8 x 279.4 (17.00 x 11.00) Saddle stitching Folding 9 355.6 x 215.9 (14.00 x 08.50) Saddle stitching Folding 10 215.9 x 355.6 (08.50 x 14.00) Side stitching No folding 11 279.4 x 215.9 (11.00 x 08.50) Saddle stitching Folding 12 215.9 x 279.4 (08.50 x 11.00) Side stitching No folding Each memory number can be overwritten. Register the 12 settings usually used for convenience. Select the memory number of the binding mode to be used, change the size and begin binding. ( Refer to page 16.) Memory No. 1 to 12 can also be set so that settings are not overwritten. ( Refer to page 63.) About Memory No. 0 Use Memory No. 0 to set a binding mode that is slightly different from the pre-set settings for the current job only. The settings set at Memory No. 0 cannot be saved. Select a memory number from Memory No. 1 to 12, and change the size. Then select Memory No. 0. The same settings as the memory number for which size was changed will be displayed. Press the [Setting key] on the touch panel, and change the binding mode using Memory No. 0. Press the [Return key] on the touch panel to confirm the settings of Memory No. 0. Change the size again to proceed with the binding work. Settings of the previously selected memory number are not updated so that the original settings can be selected again. 15
5. PREPARING FOR OPERATION Size change Size change is the process of returning guides to their standard points once, and then moving them to the positions set according to the settings of the memory number selected. Pressing the [Size Change key] changes the size. This process is required after the power is turned on, and after the memory number is changed. When the message display shows Perform paper size change and the [Size Change key] blinks, size change is also required. Normally, the stitcher will not return to its standard point. But pressing the [Size Change key] while pressing the [Clear key] returns the stitcher to its standard position and moves it to the set position. Pressing the [Size Change key] while pressing numerical key 0 only returns all guides to their standard positions. Note While Perform paper size change is displayed, this machine will not operate. Processed number display Counts up the number of sets normally processed. The display can be reset to 0 using the [Processed number clear key]. The count is reset to 0 when the power is turned off. Starting/stopping processing Pressing the [Start key] of this machine or the upstream machine starts processing. Pressing the [Stop key] ejects all paper being processed, after which this machine stops. If an error occurs during processing, this machine will stop according to the situation. If an error of the emergency stop switch, top cover, or shutter occurs during processing, the machine will also stop immediately. Step-ejection Pressing the [Jog key] binds paper left in the machine and ejects them. Perform the following procedure using the [Jog key]. 1. This machine will keep running while the [Jog key] is held down. 2. When the [Jog key] is released, paper inside the machine will to be stitched or folded, and move to next step. The machine will then wait for the next jog key operation. When paper jams inside the machine, a paper jam message appears and the machine stops. However, visually check the machine because the machine will stop due to paper jam without displaying the paper jam message in some cases. In such cases, open the top cover and remove the paper. 3. When conveyance is being carried out continuously, press the [Jog key] several time to execute stitching or folding, and eject the processed sets. Note If paper is forcibly ejected by the upstream unit, this machine will also perform conveyance motion. The paper will stop at the stitching area but this machine will not advance the paper fed. Open the top cover and remove the paper conveyed to this machine. 16
5. PREPARING FOR OPERATION Aligning the paper passage lines After preparing this machine for binding operations, check that the paper passage line is aligned to that of the upstream unit. When paper conveyed from the upstream unit is conveyed to this machine, check that there is even space between the left and right side joggers and paper. If not even, adjust the position of this machine to avoid paper jams. Move this machine at other fine adjustment screens of the fine adjustment menu, until the space becomes even. ( Refer to page 60.) Side jogger Space Paper Side jogger Space Stitching range Saddle stitching Stitching is carried out at the positions indicated by the pointer. Normally, stitching is done at two positions. * This can be increased to four positions by factory options. Pointer Stitching position label When paper is more than 140 mm/5.51 inch wide, the standard stitching width is determined by the ratio of 1:2:1. Stitching width is the center to center distance between the two stitches. However, if the stitching position lies inside the stitch prohibited area, it will be set at a position avoiding this area. For example, if the paper width is 240 mm/9.45 inch, stitching is carried out at the 60 mm/2.36 inch and 180 mm /7.09 inch positions from the paper edge. Stitching position Paper conveyance direction Stitching position 1 : 2 : 1 60 (2.36) 60 (2.36) 60 (2.36) 60 (2.36) 180 (7.09) 240 (9.45) When less than 140 mm/5.51 inch, the stitching width is 70 mm/2.76 inch (minimum stitching width). Unit: mm (inch) The stitching width (the ratio) can be changed. ( Refer to page 58.) 17
5. PREPARING FOR OPERATION The stitching position cannot be within 14 mm/0.55 inch from both edges of the paper. The stitching width cannot be within 70 mm/2.76 inch. Stitching position 14 (0.55) 120 to 356 Paper conveyance direction Stitching position Center line of paper width Unstitchable area Unit: mm (inch) 35 (2.76) 35 (2.76) 14 (0.55) Side stitching (corner stitching) The stitching position is about 6 mm/0.24 inch from the leading edge of the paper, and cannot be changed vertically. The stitching position along the width of the paper is the same as saddle stitching. Paper width Paper conveyance direction 6 (0.24) Unit: mm (inch) Stitch prohibited area The position at which the folding knife and a stitch coincide is called the stitch prohibited area. During folding operations, the folding knife may bend the stitch if they touch. When a standard stitching position determined by the paper width entered is inside the stitch prohibited area, the position avoids this area automatically. Note When adjusting the stitching width, avoid the stitching prohibited area. Stitching position label Mark (Stitch prohibited area) A Pointer A Make sure the mark does not enter area A 18
5. PREPARING FOR OPERATION When paper is fed at an upstream unit (Refer to the instruction manual on upstream unit for details of manual feed) There is a need to enter values for processed sheets and number of jogs on the control panel. ( Refer to Option Menu 2 on page 60 for number of jogs and Option Menu 3 on page 61 for processed sheets.) Set the number of jogs to two or three times, and increase this number if paper alignment is poor. Manual feeding from DC-10/60, DC-8/32 Set only the number of sheets to be inserted at LUL-HM at " processed sheets". When the sets with many number of sheets frequently ride over the saddle stitching stopper, press the Hand Marry key 2 on the DC-10/60 or DC-8/32 collator control panel. Normally press the key 1. It runs fast to achieve higher productivity. Merging-collation mode with DC-10/60 or DC-8/32 Set the total number of sheets fed from the LUL-HM and the collator at processed sheets. Manual feeding from DSF-2000 Insert one set of paper into the machine, and press the [Jog key] of this machine. Binding operation starts. Automatic operations can also be performed. For details, refer to "Option Menu 4" on page 61. Precautions on connecting and using DSF-2000 When using DSF-2000 in the random mode or as a barcode kit or intelligent kit, there is a need to enter the processed sheets on the control panel of this machine beforehand. At this time, the processed sheets differ according to the set. Enter the minimum number of sheets of each set at processed sheets. 5-3. Settings Perform binding settings. Select the memory number whose setting is to be changed, and press the [Setting key]. The memory number to be used can be saved at the last. If not saving, use Memory No. 0. ( Refer to page 15.) Memory No. Memory number selection key MAINMENU ADJUST OPTION ACCESSOR 420. 0 x 297. 0 207. 0 x 277. 0 00250 01 Setting key <Main Menu> Screen 19
5. PREPARING FOR OPERATION Selecting the binding mode Select the stitchng and folding mode. Set the stitching mode. To perform saddle stitching, select 1 Saddle stitching, to perform side stitching, select 2 Side stitching, and if not performing stitching, select 3 Stitch Off. Select 2 Side stitching also for corner stitching. 4 1 2 5 3 Selecting Saddle stitching automatically sets the folding mode to Fold On. (Can be changed) Selecting Side stitching automatically sets the folding mode to Fold Off and the trimming mode to Trim Off. (Can be changed) Set the folding mode. To perform folding, select 4 Fold On. If not performing folding, select 5 Fold Off. Cancel key <Select Binding Mode> Screen Next key Selecting Fold Off sets the trimming mode to Trim Off. After setting the binding mode, press the [Next key] to proceed to the [Select trimming mode] screen. Pressing the [Cancel key] cancels the values entered, and then returns to the main menu. Select the trimming mode. 6 7 Set the Fore-edge trim. To perform trimming, select 6 Trim On. If not to perform trimming, select 7 Trim Off. (When DBM-500T is not connected, or when Fold Off is selected, Trim On cannot be selected.) Set the Head/Foot Trim. To perform trimming, select 8 Trim On. If not to perform trimming, select 9 Trim Off. (When 7 Fore-edge Trim Off is selected, 8 Trim On cannot be selected.) After setting the trimming mode, press the [Next key] to proceed to the [Enter paper size] screen. 8 9 Back key Next key <Select Trimming Mode> Screen 20
5. PREPARING FOR OPERATION Entering paper size Enter the paper length and width. Standard values for the stitching/folding positions and stitching width are displayed according to the paper size entered. Pressing inside the box showing a value resets the value to 0. Enter the desired values using the [Numerical keys], and press the [Return key] on the numerical pad to confirm. Pressing the box again before pressing the [Return key] returns the original value. Paper width Stitching position 297. 0 210. 0 420. 0 Paper conveyance direction 148. 5 Paper length Stitching width Back key Note The values in this screen are original figures you entered. They remain the same no matter how finely adjusted later according to binding conditions. Folding position 210. 0 <Enter Paper Size> Screen Next key Entering the paper length Entering the paper width Stitching position display Folding position display Stitching width display Enter the paper length. Range of input Saddle stitching: 178.0 to 508.0 mm/7.01 to 20.00 inch (When connect with DBM-2KT: 178.0 to 500.0 mm/7.01 to 19.69 inch) Stitch Off: 178.0 to 508.0 mm/7.01 to 20.00 inch Side stitching (Corner stitching): 140.0 to 364.0 mm/5.51 to 14.33 inch (Side stitchable length: Above 182.0 mm/7.17 inch) * When set to Fold On : 178.0 to 364.0 mm/7.01 to 14.33 inch Enter the paper width. Range of input Saddle stitching and Stitch Off: 120.0 to 356.0 mm/4.72 to 14.02 inch Side stitching (Corner stitching): 210.0 to 356.0 mm/8.27 to 14.02 inch Length from the paper leading edge to stitching position. When the paper length is entered, the standard stitching position will automatically be set. (Can be changed) * Standard stitching position: (Paper length 2) mm/inch Range of input Saddle stitching: 89.0 to 254.0 mm/3.50 to 10.00 inch (However, the difference with the paper length is in the range of 89 to 359 mm/3.50 to 14.24 inch) Length from the paper leading edge to stitching position. When the paper length is entered, the standard folding position will automatically be set. (Can be changed) * Standard folding position: (Paper length 2) mm/inch Range of input 89.0 to 254.0 mm/3.50 to 10.00 inch (However, the difference with the paper length is in the range of 89 to 254 mm/3.50 to 10.00 inch) The width between both stitches. When the paper width is entered, the standard width will automatically be set. (Can be changed) * Standard stitching position: (Paper length 2) mm/inch However, if the paper width is less than 140 mm/5.51 inch, the stitching width will be set to 70.0 mm/2.76 inch (minimum stitching interval). The stitching position will also avoid the stitch prohibited area. Range of input From 70.0 mm/2.76 inch to (Paper width 28.0 mm/1.10 inch) Stitching cannot be carried out within 14 mm/0.55 inch from the side edges. After entering the paper size, press the [Next key] to proceed to the next step. When the binding mode is set to Trim On, the Set Trimming Position screen will appear. If set to Trim Off, the [Confirm Settings] screen will appear. As paper size is restricted according to binding conditions, the machine will not proceed to the next step if the paper size entered is not appropriate. Pressing the [Back key] returns to the <Select Trimming Mode> screen. 21
5. PREPARING FOR OPERATION Setting the Fore-edge Trimming position (When DBM-500T is connected and [Trim On] is selected) 1 Displaying the trimming position This is the finished length after Fore-edge Trimming. When the paper length is entered, the standard stitching position will automatically be set. (Can be changed) * Standard trimming position: (Paper length 2) 3 mm/0.12 inch (MAX: 253 mm/9.96 inch) Pressing inside the box showing a value resets the value to 0. Enter the finished length using the [Numerical keys] on the numerical pad, and then press the [Return key] to confirm. Pressing the box again before pressing the [Return key] returns the original value. 1 207. 0 Trimming width Range of input: 75.0 to 253.0 mm/2.95 to 9.96 inch (Trimming width should be within 75 mm/2.95 inch) Back key Next key <Set Trimming Position> Screen After entering the Fore-edge Trimming position, press the [Next key]. When the trimming mode is set to Trim On, the Set Head/Foot Trimming Position screen will appear. If set to Trim Off, the [Confirm Settings] screen will appear. Pressing the [Back key] returns to the <Enter paper size> screen. Setting the Head/Foot Trimming position (Available only when [Trim On] is selected both in the Fore-edge trim, and Head/Foot Trim modes while DBM-2KT is connected. ) 1 Displaying the Head Trimming position 2 Displaying the Foot Trimming position Margin widths to be Head/Foot trimmed are displayed. When the paper width is entered, the standard stitching position will automatically be set. (Can be changed) * Standard trimming width: 10 mm/0.40 inch Pressing inside the box showing a value resets the value to 0. Enter the finished length using the [Numerical keys] on the numerical pad, and then press the [Return key] to confirm. Pressing the box again before pressing the [Return key] returns the original value. Range of input: 0 and 1.0 to 25.0 mm/0 and 0.04 to 0.98 inch When "0" is input, the machine does not operate. 3 1 10. 0 277. 0 10. 0 Back key Next key <Set Trimming Position> Screen 2 22
5. PREPARING FOR OPERATION 3 Displaying the Head/Foot trimming positions The finished width after Head/Foot trimming is displayed. When the paper width is entered, the standard trimming position will automatically be set. (Can be changed) Standard width after trimming = (Width - 20 mm/0.79 inch) Pressing inside the box showing a value resets the value to 0. Enter the finished width using the [Numerical keys] on the numerical pad, and then press the [Return key] to confirm. Pressing the box again before pressing the [Return key] returns the original value. Range of input: from a figure ( Sheet width - Margin width ) to specified Sheet width ( 120 to 356 mm/4.72 to 14.02 inch) After inputting the Head/Foot trimming positions, press the [Next key] to proceed to the [Confirm Settings] screen. Pressing the [Back key] returns to the <Enter Fore-edge trimming position> screen. Confirming settings Make sure that the values entered are all correct, and then press the [Return key] on the touch panel. Pressing the [Return key] saves the settings of the memory number and returns to the Main Menu screen. Pressing the [Back key] returns to; 1. the "Set Head/Foot Trimming Positions" screen, when the trimming mode is set to "Head/Foot Trim On", 2. the [Enter Fore-edge Trimming Positions] screen, when set to"head/foot Trimming Off", and "Fore-edge Trimming On", 3. the "Enter Paper Size" screen, when set to "Head/Foot Trimming Off", and "Fore-edge Trimming Off". 420. 0 x 297. 0 207. 0 x 277. 0 Back key <Confirm Setting> Screen Return key Adjusting the position of the paper guide wheel when the trimmer is not connected Where the fore-edge of booklets touches the outlet as shown, set the wheels at about 30 mm/1.18 inch from the book spine. Loosen the setscrew and move the paper guide wheel. Setscrew DBM-500 Outlet Note If the booklet is widely open, and cannot be conveyed properly, move the paper guide wheel closer to the outlet. Paper guide wheel Setscrew Booklet DBM-500 Book spine Fore-edge Stacker 30 mm (1.18 inch) Outlet 23
5. PREPARING FOR OPERATION Size change Press the [Size Change key] for more than one second to change the size. When size change completes, a beep sounds. MAINMENU ADJUST OPTION ACCESSOR Note This machine moves left and right. 420. 0 x 297. 0 01 207. 0 x 277. 0 00000 Perform paper size change Size change key <Main Menu> Screen Adjustments using the step mode <Fine adjustment menu> After changing the size, perform fine adjustments of each function in the step mode. When the step mode completes, the newly adjusted value is saved as the new setting of the memory number. Load actually bound paper into the upstream unit, and prepare to start adjustments. Note Values shown in the Main Menu screen are replaced by values adjusted not only in the fine adjustment screen but also in the step mode. However, the values shown in the setting screens of each Memory Number will remain the same. They show values originally entered. Starting the step mode When the DBM-500T is connected, select whether to trim sets bound in the step mode using the [Trim On/Off key]. Step Mode key Trim On/Off key MAINMENU ADJUST OPTION ACCESSOR On: Off: Trims. Set to trim booklets. No trimming. Set to check stitching and folding positions. The setting of the [Trim On/Off key] has priority during the step mode, regardless of whether trimming has been set or not at the memory number used. Pressing the [Step Mode key] in the fine adjustment menu proceeds to the <Stitcher Adjustment> screen. <Fine Adjustment Menu> Screen <Stitcher Adjustment> Screen 24
5. PREPARING FOR OPERATION Pressing the [Start key] of the upstream unit or this machine conveys one set of paper from the upstream unit to the stitching stopper. Paper direction To terminate the step mode halfway through, press the [Stop key] of this machine. Open the top cover and remove the paper remaining inside the machine. Side jogger Paper Side jogger Conveyance roller lifting handle Back jogger Back jogger Paper direction Conveyance roller lifting handle Opened state of conveyance roller Adjustments at the stitching section Adjust the positions of the side jogger and back jogger for aligning paper using the [Fine Adjustment key]. Adjust the position using keys 1 to 4 and 6 to 9. Perform jogging using keys 5 and bk. Adjust so that the joggers touch the paper edges lightly. After adjusting, press the bl [Stitch key]. Stitching is performed, and the booklet advances to the folding stopper. When set to Stitch Off, the set advances to the folding stopper without stitching. When set to Side stitching (corner stitching) or Fold Off, the booklet is ejected to the side stitching stacker. 1 2 3 4 5 bk 6 8 9 blstitch key 7 <Stitcher Adjustment> Screen 1 Fine adjustment of side jogger The side jogger moves inward by about 1 mm/0.04 inch. 2 Fine adjustment of side jogger The side jogger moves inward by about 0.2 mm/0.008 inch. 3 Fine adjustment of side jogger The side jogger moves outward by about 1 mm/0.04 inch. 4 Fine adjustment of side jogger The side jogger moves outward by about 0.2 mm/0.008 inch. 5 Side jogger operations Activates the side jogger once. 6 Fine adjustment of back jogger The back jogger moves backward by about 0.1 mm/0.004 inch. 7 Fine adjustment of back jogger The back jogger moves backward by about 1 mm/0.04 inch. 8 Fine adjustment of back jogger The back jogger moves forward by about 0.1 mm/0.004 inch. 9 Fine adjustment of back jogger The back jogger moves forward by about 1 mm/0.04 inch. bk Back jogger operations Activates the back jogger once. bl Stitch key Stitches the set. The booklet is conveyed to the folding stopper and stops. When set to Fold Off for side stitching (corner stitching), the booklet is ejected to the side stitching stacker, and the step mode ends. Note Fine adjustments can be performed only within the range of ±5 mm/±0.20 inch after size change. If the paper size entered and that actually used differ by more than 5 mm/0.20 inch, the difference is beyond adjustment. In this case, enter the correct paper size again, and perform the size change. 25
5. PREPARING FOR OPERATION Adjustments at the folding section (When [Fold On] is selected) Adjust the positions of the folding side guides and folding back guides using the [Fine Adjustment key]. Adjust the position using keys 1 to 4 and 6 to 9. Perform jogging using keys 5 and bk. Adjust so that the guides touch the booklet edges lightly. After adjusting, press the bl [Fold key]. The booklets are folded and ejected, and the step mode ends. If ON is selected using the [Trim On/Off key] at the start of the step mode, booklets are trimmed and ejected. 1 2 3 4 5 bk 68 blfold key <Folder Adjustment> Screen 79 Folding back guide Folding back guide Folding side guide Folding side guide Opened state of folding back guide 1 Fine adjustment of folding side guide The folding side guide moves inward by about 1 mm/0.04 inch. 2 Fine adjustment of folding side guide The folding side guide moves inward by about 0.2 mm / 0.008 inch. 3 Fine adjustment of folding side guide The folding side guide moves outward by about 1 mm/0.04 inch. 4 Fine adjustment of folding side guide The folding side guide moves outward by about 0.2 mm/0.008 inch. 5 Folding side guide operations Activates the folding side guide once. 6 Fine adjustment of folding back guide The folding back guide moves backward by about 0.1 mm/0.004 inch. 7 Fine adjustment of folding back guide The folding back guide moves backward by about 1 mm/0.04 inch. 8 Fine adjustment of folding back guide The folding back guide moves forward by about 0.1 mm/0.004 inch. 9 Fine adjustment of folding back guide The folding back guide moves forward by about 1 mm/0.04 inch. bk Folding back guide operations Activates the folding back guide once. bl Fold key Booklets are ejected after folding, and the step mode ends. 26
6. SADDLE STITCHING PROCEDURE 6-1. Settings Select the memory number whose settings are to be changed using the [Memory number selection key] and press the [Setting key]. The Select Binding Mode screen appears. Memory No. Memory number selection key MAINMENU ADJUST OPTION ACCESSOR The settings of the memory number selected are saved. If there is no need to save, use memory No. 0. ( Refer to page 15.) 420. 0 x 297. 0 207. 0 x 297. 0 00000 01 Setting key <Main Menu> Screen The following describes the procedure for the conditions: A3 vertical (length 420 mm/17.00 inch x width 297 mm/11.00 inch), saddle stitching, fold On, trimming On Step 1 Selecting the finishing mode Select and enter the stitching and folding mode. Saddle Stitching key 1 Setting the stitching mode. Press the [Saddle Stitching key] to set Saddle stitching. The folding mode is automatically set to Fold On. After setting the trimming mode, press the [Next key] to proceed to the [Select Tirmming mode] screen. Pressing the [Cancel key] cancels the values entered, and then returns to the main menu. 2 Set the trimming mode. Pressing the [Trim On key], set Trim On. Fold On key Cancel key Next key <Select Finishing Mode> Screen Note If DBM-500T is not connected, or when Fold Off is selected, Trim On cannot be selected. Fore-edge Trim On key Trim Off key After setting the trimming mode, press the [Next key] to proceed to the [Enter Paper size] screen. Head/Foot Trim On key Trim Off key Back key Next key <Select Trimming Mode> Screen 27
6. SADDLE STITCHING PROCEDURE Step 2 Entering the paper size Enter the paper length and width. Standard values for the stitching/folding position and stitching width are displayed according to the paper size entered. Pressing inside the box showing a value resets the value to 0. Enter the desired values using the [Numerical keys], and press the [Return key] on the numerical pad to confirm. Pressing the box again before pressing the [Return key] returns the original value. 2 1 5 297. 0 210. 0 210. 0 420. 0 148. 5 3 4 Back key Next key Return key Numerical keys <Enter Paper Size> Screen <Numerical Pad> 1 Enter the length of the paper. Press the box 1, and enter 4200/16.54. Press the [Return key] to confirm the value. Range of input: 178.0 to 508.0 mm/7.01 to 20.00 inch (When connect with DBM-2KT: 178.0 to 500.0 mm/7.01 to 19.69 inch) The stitching position is displayed. The value from the leading edge of the paper to the stitching position is displayed. When the paper length is entered, the standard stitching position will automatically be displayed. * Standard stitching position: (Paper length 2) mm/inch Here, it is displayed as 210.0/08.27 (420 2 = 210/16.54 2 = 8.27). To change the value, press the box 3, and enter the desired value. Range of input: 89.0 to 254.0/3.50 to 10.00 (Difference with the paper length should be within 89 to 359 mm/3.50 to 14.13 inch) Press the [Return key] to confirm the value. The folding position is displayed. The value from the leading edge of the paper to the folding position is displayed. When the paper length is entered, the standard folding position will automatically be displayed. * Standard folding position: (Paper length 2) mm/inch Here, it is displayed as 210.0/08.27 (420 2 = 210/16.54 2 = 8.27). To change the value, press the box 4, and enter the desired value. Range of input: 89.0 to 254.0/3.50 to 10.00 (Difference with the paper length should be within 89 to 254 mm/3.50 to 10.00 inch) Press the [Return key] to confirm the value. 28
6. SADDLE STITCHING PROCEDURE 2 Enter the width of the paper. Press the box 2, and enter 2970/11.69. Range of input: 120.0 to 356.0 mm/4.72 to 14.02 inch Press the [Return key] to confirm the value. The stitching width is displayed. The stitching position interval is displayed. When the paper width is entered, the standard stitching width will automatically be displayed. * Standard stitching width: (Paper width 2) mm/inch Here, it is displayed as 148.5/5.85 (297 2 = 148.5/11.69 2 = 5.85). When paper width is below 140 mm/5.51 inch, stitching width will always be 70 mm/2.76 inch. When the standard stitching width set by the paper width entered is inside a stitch prohibited area, a value avoiding this area will be displayed. Note When adjusting the stitching width, avoid the stitching prohibited areas. To change the value, press the box 5, and enter the desired value. Range of input: From 70.0/2.76 (Paper width 28.0 mm/1.10 inch) Press the [Return key] to confirm the value. After entering the paper size, press the [Next key] and proceed to the <Set Trimming Position> screen. As paper size is restricted according to binding conditions, the machine will not proceed to the next step if the paper size entered is not appropriate. Pressing the [Back key] returns to the <Select Binding Mode> screen. Step 3 Setting the trimming position The finished length after Fore-edge Trimming is displayed. When the paper length is entered, the standard trimming position will automatically be displayed. The standard trimming width is 3 mm/0.12 inch. * Standard trimming position: (Paper length 2) 3 mm/ 0.12 inch (MAX: 253 mm/9.96 inch) Here, it is displayed as 207.0/8.15 (420 2) 3 = 207/ (16.54 2) 0.12 = 8.15. If not changing this value, proceed onto the next step. To change the finished length, press the box 1 to reset the value displayed to 0, and enter the desired value. 1 207. 0 Trimming width Range of input: 75.0 to 253.0 mm/2.95 to 9.96 inch (Trimming width within 75 mm/2.95 inch) Press the [Return key] to confirm the value. Pressing the box again while entering the value returns the original value. After entering the trimming position, press the [Next key] to proceed to the Confirm Settings screen. Pressing the [Back key] returns to the <Enter Paper Size> screen. Back key Next key <Set Trimming Position> Screen 29
6. SADDLE STITCHING PROCEDURE Step 4 Confirming settings Make sure that the values entered are all correct, and then press the [Return key] on the touch panel. Pressing the [Return key] saves the settings of the memory number and returns to the <Main Menu> screen. Pressing the [Back key] returns to the <Set Trimming Position> screen. 420. 0 x 297. 0 207. 0 x 297. 0 Back key Return key <Confirm Settings> Screen 6-2. Changing Size Press the [Size Change key] for more than one second to change the size. When size change completes, a beep sounds. MAINMENU ADJUST OPTION ACCESSOR Note This machine moves left and right. 420. 0 x 297. 0 01 207. 0 x 297. 0 00000 Perform paper size change Size change key <MAIN MENU> Screen 6-3. Adjustments Using the Step Mode After changing the size, perform fine adjustments of each function in the step mode. When the step mode completes, the newly adjusted value is saved as the new setting of the memory number. Note Values shown in the Main Menu screen are replaced by values adjusted not only in the fine adjustment screen but also in the step mode. However, the values shown in the setting screens of each Memory Number will remain the same. They show values originally entered. 30
6. SADDLE STITCHING PROCEDURE Starting the step mode <Fine adjustment menu> If the DBM-500T is connected, select whether to trim sets bound in the step mode using the [Trim On/Off key]. ON: Trims. Set to trim booklets. OFF: No trimming. Set to check stitching and folding positions. Step mode key Trim On/Off key MAINMENU ADJUST OPTION ACCESSOR The setting of the [Trim On/Off key] has priority during the step mode, regardless of whether trimming has been set or not at the memory number. Pressing the [Step Mode key] in the fine adjustment menu proceeds to the <Stitcher Adjustment> screen. Pressing the [Start key] of the upstream unit or this machine conveys one set of paper from the upstream unit to the saddle stitching stopper. <Fine Adjustment Menu> Screen To terminate the step mode halfway through, press the [Stop key] of this machine. Open the top cover and remove the paper remaining inside the machine. <Stitcher Adjustment> Screen Adjustments at the stitching section Adjust the positions of the side jogger and back jogger for aligning paper using the [Fine adjustment key]. Adjust the position using keys 1 to 4 and 6 to 9. Perform jogging using keys 5 and bk. Adjust so that the joggers touch the paper edges lightly. After adjusting, press the bl [Stitch key]. Stitching is perfomed, and the booklet advances to the folding stopper. 1 2 3 4 5 bk bl Stitch key 6 8 7 9 <Stitcher Adjustment> Screen 31
6. SADDLE STITCHING PROCEDURE 1 Fine adjustment of side jogger The side jogger moves inward by about 1 mm/0.04 inch. 2 Fine adjustment of side jogger The side jogger moves inward by about 0.2 mm/0.008 inch. 3 Fine adjustment of side jogger The side jogger moves outward by about 1 mm/0.04 inch. 4 Fine adjustment of side jogger The side jogger moves outward by about 0.2 mm/0.008 inch. 5 Side jogger operations Activates the side jogger once. 6 Fine adjustment of back jogger The back jogger moves backward by about 0.1 mm/0.004 inch. 7 Fine adjustment of back jogger The back jogger moves backward by about 1 mm/0.04 inch. 8 Fine adjustment of back jogger The back jogger moves forward by about 0.1 mm/0.004 inch. 9 Fine adjustment of back jogger The back jogger moves forward by about 1 mm/0.04 inch. bk Back jogger operations Activates the back jogger once. bl Stitch key Stitches the set. The booklet is conveyed to the folding stopper and stops. Note Fine adjustments can be performed only within the range of ±5 mm/±0.20 inch after size change. If the paper size entered and that actually used differ by more than 5 mm/0.20 inch, the difference is beyond adjustment. In this case, enter the correct paper size again, and perform the size change. Adjustments at the folding section (When [Fold On] is selected) Adjust the positions of the folding side guides and folding back guides using the [Fine Adjustment key]. Adjust the position using keys 1 to 4 and 6 to 9. Perform jogging using keys 5 and bk. Adjust so that the guides touch the booklet edges lightly. After adjusting, press the bl [Fold key]. The booklets are folded and ejected, and the step mode ends. If ON is selected using the [Trim On/Off key] at the start of the step mode, booklets are trimmed and ejected. 1 2 3 4 5 bk Folding back guide Folding back guide Folding side guide blfold key 68 79 <Folder Adjustment> Screen Folding side guide Opened state of folding back guide 32
6. SADDLE STITCHING PROCEDURE 1 Fine adjustment of folding side guide The folding side guide moves inward by about 1 mm/0.04 inch. 2 Fine adjustment of folding side guide The folding side guide moves inward by about 0.2 mm/0.008 inch. 3 Fine adjustment of folding side guide The folding side guide moves outward by about 1 mm/0.04 inch. 4 Fine adjustment of folding side guide The folding side guide moves outward by about 0.2 mm/0.008 inch. 5 Folding side guide operations Activates the folding side guide once. 6 Fine adjustment of folding back guide The folding back guide moves backward by about 0.1 mm/0.004 inch. 7 Fine adjustment of folding back guide The folding back guide moves backward by about 1 mm/0.04 inch. 8 Fine adjustment of folding back guide The folding back guide moves forward by about 0.1 mm/0.004 inch. 9 Fine adjustment of folding back guide The folding back guide moves forward by about 1 mm/0.04 inch. bk Folding back guide operations Activates the folding back guide once. bl Fold key Booklets are ejected after folding, and the step mode ends. 6-4. Checking the Finished Set Check the sample booklets after adjustment. When paper alignment is poor Adjust the side jogger and back jogger again. ( Refer to page 31.) When the stitching position and folding position do not match Move the stitching position to the folding position Adjust the position using the [Stitch Position Fine Adjustment key]. ( Refer to page 57.) Move the folding position to the stitching position Adjust the position using the [Fold Position Fine Adjustment key]. ( Refer to page 57.) When the stitching position and folding position match, and both are to be moved Adjust the position using the [Stitch Position Fine Adjustment key] and [Fold Position Fine Adjustment key]. ( Refer to page 58.) To adjust the stitching width Adjust the position using the [Stitching Width Fine Adjustment key]. ( Refer to page 58.) 33
6. SADDLE STITCHING PROCEDURE When folded skewed During use, rotate the lock dial in the counterclockwise direction while holding the folding stopper adjustment dial to release the lock. Next, adjust the angle of the folding stopper using the folding stopper adjustment dial. After adjustment, rotate the lock dial in the clockwise direction while holding the folding stopper adjustment dial to lock it. Lock dial Folding stopper adjustment dial Rotate clockwise Rotate counterclockwise If the stitching position is inside the stitching prohibited area shown on the stitching position label ( refer to page 18), folding misalignment may occur. Change the stitching width using the [Stitching Width Fine Adjustment key] and adjust so that it is outside this area. ( Refer to page 58.) Folding misalignment may also occur if the folding side guides are set too narrow or wide. Perform adjustments in the step mode again, and check the position of the folding side guides. ( Refer to page 32.) If the booklet rides onto the folding side guide or jams, gradually increase the value of stitching side jogger open timing on the option menu. The standard value is 0. ( Refer to page 61.) However, paper may jam at the stitching section if too many sheets of paper are fed. Pointer Stitching position label Stitching position label Mark (Stitch prohibited area) Pointer 34
6. SADDLE STITCHING PROCEDURE Adjust the position of the folding back guide roller. Loosen the locknut, and move the folding back guide roller to the trail edge using the knobscrew. This holds down the booklet and prevents folding misalignment. If folding only a few sheets which are soft, decrease the gap between the folding stoppers. Loosen the four knob screws, and lower the top folding plate. Normally use this folding plate in the raised position. When processing many sheets of paper, using with this folding plate lowered will cause paper jams. Lock nut Knobscrew Folding back guide roller Booklet Trail edge Knobscrew Folding back guide roller Locknut Folding back guide roller Adjustment dial Top folding plate Knobscrew Lock plate Knobscrew When stitching position is not perpendicular to paper Adjust the angle of the saddle stitching stopper. Release the lock plate with the finger, and turn the adjustment dial. For the condition shown in the left figure A, rotate the adjustment dial in the counterclockwise direction. For the condition shown in the right figure B, rotate the adjustment dial in the clockwise direction. After adjusting, fit the lock plate into the groove on the lock dial. Figure A Figure B When booklet alignment is poor at the belt stacker Change the conveyance time of the belt stacker at accessory menu. ( Refer to page 65.) If there are too many sheets, or when paper is thick, set a long conveyance time. If booklet alignment is still poor after adjusting the conveyance time, replace the paper guide wheel with one for large size paper. (Not available for paper less than 121 mm/4.76 inch) If booklet alignment is still poor, loosen the knob screw and move the paper guide wheel to the main body. 35
6. SADDLE STITCHING PROCEDURE When there are conveyance belt marks on the booklet Use the belt guide kit for saddle-stitching binding. Replace the ejection roller unit. Release the knobscrew A so that the ejection roller unit stregth can be sdjusted using the knob. Strong Knob screw A Weak Ejection roller unit Tighten the knobscrew B. Normally, leave it loose. Knob screw B Attach the belt guide L or S. If the paper length is more than 170 mm and less than 297 mm, use belt guide S. If more than 297 mm to 500 mm, use belt guide L. Paper direction Belt guide L Belt guide L Paper direction Belt guide S Belt guide L 36
6. SADDLE STITCHING PROCEDURE Attach belt guide M. Belt guide M Belt guide M Attach filmed guides R and L. Filmed guide R Note Belt guides L, S, and M can be used for paper width above 190 mm. They cannot be used for paper less than 190 mm. After use, remove the belt guide kit and return it to its original state. Do not use it for side-stitching and cornerstitching. Filmed guide L 37
7. SIDE STITCHING/CORNER STITCHING PROCEDURE 7-1. Settings Select the memory number whose settings are to be changed using the [Memory number selection key] and press the [Setting key]. The <Select Binding Mode> screen appears. Memory No. Memory number selection key MAINMENU ADJUST OPTION ACCESSOR The settings of the memory number selected are saved. If there is no need to save, use memory No. 0. ( Refer to page 15.) 210. 0 x 297. 0 210. 0 x 297. 0 00000 03 Setting key <Main Menu> Screen The following describes the procedure for the conditions: A4 horizontal (length 210 mm/8.50 inch x width 297 mm/11.00 inch), side stitching, folding Off, trimming Off. Step 1 Selecting the finishing mode Select the finishing mode. The stitching position is about 6 mm/0.24 inch from the leading edge of the paper and cannot be changed vertically. 1 Setting the stitching mode. Press the [Side Stitching key] to set Side stitching. (Select side stitching even for corner stitching.) The folding mode is automatically set to Fold Off. (Can be changed.) When set to Fold Off, the trimming mode cannot be selected. Press the [Fold On key] to set Fold On. This allows selection of the trimming mode. To trim, press the [Trim On key] and set Trim On. Leading edge Front 6 mm (0.24 inch) Stitching position Side Stitching key Back Fold Off key Note If DBM-500T is not connected, or when Fold Off is selected, Trim On cannot be selected. After setting the finishing mode, press the [Next key] and proceed to the <Enter Paper Size> screen. Pressing the [Cancel key] cancels the values entered and returns to the main menu. Fold On key Cancel key Next key <Select Finishing Mode> Screen 38
7. SIDE STITCHING/CORNER STITCHING PROCEDURE Step 2 Entering the paper size Enter the paper length and width. Standard values for stitching width are displayed according to the paper size entered. Pressing inside the box showing a value resets the value to 0. Enter the desired values using the [Numerical keys], and press the [Return key] on the numerical pad to confirm. Pressing the box again before pressing the [Return key] returns the original value. 2 3 1 210. 0 297. 0 148. 5 Return key Numerical keys <Fold Off> Screen <Numerical Pad> 1 Enter the length of the paper. Press the box 1, and enter 2100/08.50. Press the [Return key] to confirm the value. Range of input: Fold Off : 140.0 to 364.0 mm/0.59 to 14.33 inch Fold On : 178.0 to 364.0 mm/7.01 to 14.33 inch (The foldable length is above 182.0 mm/7.16 inch.) The folding position is displayed when set to [Fold On]. The value from the leading edge of the paper to the folding position is displayed. When the paper length is entered, the standard folding position will automatically be displayed. Standard folding position: (Paper length 2) mm/ inch Here, it is displayed as 105.0/4.13 (210 2 = 105.0/ 8.27 2 = 4.13). To change the value, press the box 4, and enter the desired value. Press the [Return key] to confirm the value. 2 3 1 210. 0 297. 0 148. 5 105. 0 4 Back key Next key <Fold On> Screen Note The box 4 is not displayed when set to Fold Off. 2 Enter the width of the paper. Press the box 2, and enter 2970/11.00. Press the [Return key] to confirm the value. Range of input: 120.0 to 356.0 mm/4.72 to 14.02 inch (The foldable width is above 210.0 mm/8.50 inch.) 39
7. SIDE STITCHING/CORNER STITCHING PROCEDURES The stitching width is displayed. The stitching position interval is displayed. When the paper width is entered, the standard stitching width will automatically be displayed. Standard stitching width: (Paper width 2) mm/inch Here, it is displayed as 148.5/5.85 (297 2 = 148.5/11.69 2 = 5.85). When paper width is below 140 mm/5.51 inch, stitching width will always be 70 mm/2.76 inch. To change the value, press the box 3, and enter the desired value. For corner stitching, enter the value Paper width 30.0 mm/1.18 inch (stitches at the 15.0 mm/0.59 inch position from the side edge of the paper). Range of input: From 70.0/2.76 (Paper width 28.0 mm/1.10 inch) Press the [Return key] to confirm the value. After entering the paper size, press the [Next key] and proceed to the <Confirm Settings> screen. If set to Trim On, proceed to the Set Trimming Position screen. As paper size is restricted according to binding conditions, the machine will not proceed to the next step if the paper size entered is not appropriate. Pressing the [Back key] returns to the <Select Binding Mode> screen. Step 3 Setting the trimming position (When set to [Trim On]) This is the finished length after trimming. When the paper length is entered, the standard trimming position will automatically be displayed. The standard trimming width is 3 mm/0.12 inch. Standard trimming position: (Paper length 2) 3 mm/ 0.12 inch (MAX: 253 mm/9.96 inch) Here, it is displayed as 102.0/4.02 (210 2) 3 = 102.0/ (8.27 2) 0.12 = 4.02. If not changing this value, proceed onto the next step. To change the finished length, press the box 1 to reset the value displayed to 0, and enter the desired value. 1 102. 0 Trimming width Range of input: 75.0 to 253.0 mm/2.95 to 9.96 inch (Trimming width within 75 mm/2.95 inch) Press the [Return key] to confirm the value. Pressing the box again while entering the value returns the original value. Back key Next key <Set Trimming Position> Screen After entering the trimming position, press the [Next key] to proceed to the <Confirm Settings> screen. Pressing the [Back key] returns to the <Enter Paper Size> screen. Step 4 Confirming settings Make sure that the values entered are all correct, and then press the [Return key] on the touch panel. Pressing the [Return key] saves the settings of the memory number and returns to the <Main Menu> screen. Pressing the [Back key] returns to the <Set Trimming Position> screen if set to Trim On, and returns to the <Enter Paper Size> screen if set to Trim Off. 210. 0 x 297. 0 210. 0 x 297. 0 40 Back key Return key <Confirm Settings> Screen
7. SIDE STITCHING/CORNER STITCHING PROCEDURE 7-2. Changing Size Press the [Size Change key] for more than one second to change the size. When size change completes, a beep sounds. MAINMENU ADJUST OPTION ACCESSOR Note This machine moves left and right. 210. 0 x 297. 0 03 210. 0 x 297. 0 00000 Perform paper size change Main Menu Screen Size change key Corner-stitching Perform the following procedure after changing the size. Stitching at the R side When the stitching width is set above 220 mm/8.66 inch, loosen the knobscrew of the clamp L, move the clamp to the end of the R side, and secure. When the stitching width is set below 219 mm/8.62 inch, loosen the knobscrew of the clamp L, move the clamp to the end of the L side, and secure. Turn Off the wire feed detection unit of the L side. ( Refer to page 61.) Replace the corner stitching guide of the folding side guide. Knobscrew Clamp L Handle R side Clamp R L side Clamp L Paper conveyance direction Stitching at the L side Secure the clamp L at the back of the stitcher head with the knob screw. Move the clamp R to the L side by lifting the handle. Turn Off the wire feed detection unit of the R side. ( Refer to page 61.) Corner stitching guide Folding side guide 41
7. SIDE STITCHING/CORNER STITCHING PROCEDURE 7-3. Adjustments Using the Step Mode After changing the size, perform fine adjustments of each function in the step mode. When the step mode completes, the newly adjusted value is saved as the new setting of the memory number. Note Values shown in the Main Menu screen are replaced by values adjusted not only in the fine adjustment screen but also in the step mode. However, the values shown in the setting screens of each Memory Number will remain the same. They show values originally entered. Starting the step mode <Fine adjustment menu> If the DBM-500T is connected, select whether to trim sets bound in the step mode using the [Trim On/Off key]. ON: Trims. Set to trim sets. OFF: No trimming. Set to check stitching and folding positions. Step mode key Trim On/Off key MAINMENU ADJUST OPTION ACCESSOR The setting of the [Trim On/Off key] has priority during the step mode, regardless of whether trimming has been set or not at the memory number. Pressing the [Step Mode key] in the fine adjustment menu proceeds to the <Stitcher Adjustment> screen. ON cannot be selected when set to Trim Off. Pressing the [Start key] of the upstream unit or this machine conveys one set of paper from the upstream unit to the side stitching stopper. <Fine Adjustment Menu> Screen To terminate the step mode halfway through, press the [Stop key] of this machine. Open the top cover and remove the paper remaining inside the machine. <Stitcher Adjustment> Screen 42
7. SIDE STITCHING/CORNER STITCHING PROCEDURE Adjustments at the stitching section Adjust the positions of the side jogger and back jogger for aligning paper using the [Fine Adjustment key]. Adjust the position using keys 1 to 4 and 6 to 9. Perform jogging using keys 5 and bk. Adjust so that the joggers touch the paper edges lightly. After adjusting, press the bl [Stitch key]. Stitching is performed, and the set advances to the folding stopper. 1 2 3 4 5 bk 6 8 9 blstitch key 7 <Stitcher Adjustment> Screen 1 Fine adjustment of side jogger The side jogger moves inward by about 1 mm/0.04 inch. 2 Fine adjustment of side jogger The side jogger moves inward by about 0.2 mm/0.008 inch. 3 Fine adjustment of side jogger The side jogger moves outward by about 1 mm/0.04 inch. 4 Fine adjustment of side jogger The side jogger moves outward by about 0.2 mm/0.008 inch. 5 Side jogger operations Activates the side jogger once. 6 Fine adjustment of back jogger The back jogger moves backward by about 0.1 mm/0.004 inch. 7 Fine adjustment of back jogger The back jogger moves backward by about 1 mm/0.04 inch. 8 Fine adjustment of back jogger The back jogger moves forward by about 0.1 mm/0.004 inch. 9 Fine adjustment of back jogger The back jogger moves forward by about 1 mm/0.04 inch. bk Back jogger operations Activates the back jogger once. bl Stitch key Paper is stitched, ejected, and the step mode ends. When set to Fold On, the paper is conveyed to the folding stopper after stitching. ( Refer to page 44.) Note Fine adjustments can be performed only within the range of ±5 mm/±0.20 inch after size change. If the paper size entered and that actually used differ by more than 5 mm/0.20 inch, the difference is beyond adjustment. In this case, enter the correct paper size again, and perform the size change. 43
7. SIDE STITCHING/CORNER STITCHING PROCEDURE Adjustments at the folding section (When [Folding On] is selected) Adjust the positions of the folding side guides and folding back guides using the [Fine Adjustment key]. Adjust the position using keys 1 to 4 and 6 to 9. Perform jogging using keys 5 and bk. Adjust so that the guides touch the booklet edges lightly. After adjusting, press the bl [Fold key]. The sets are folded and ejected, and the step mode ends. 1 2 3 4 5 bk If ON is selected using the [Trim On/Off key] at the start of the step mode, sets are trimmed and ejected. bl Fold key 68 <Folder Adjustment> Screen 79 Folding back guide Folding back guide Folding side guide Folding side guide Opened state of folding back guide 1 Fine adjustment of folding side guide The folding side guide moves inward by about 1 mm/0.04 inch. 2 Fine adjustment of folding side guide The folding side guide moves inward by about 0.2 mm/0.008 inch. 3 Fine adjustment of folding side guide The folding side guide moves outward by about 1 mm/0.04 inch. 4 Fine adjustment of folding side guide The folding side guide moves outward by about 0.2 mm/0.008 inch. 5 Folding side guide operations Activates the folding side guide once. 6 Fine adjustment of folding back guide The folding back guide moves backward by about 0.1 mm/0.004 inch. 7 Fine adjustment of folding back guide The folding back guide moves backward by about 1 mm/0.04 inch. 8 Fine adjustment of folding back guide The folding back guide moves forward by about 0.1 mm/0.004 inch. 9 Fine adjustment of folding back guide The folding back guide moves forward by about 1 mm/0.04 inch. bk Folding back guide operations Activates the folding back guide once. bl Fold key Sets are ejected after folding, and the step mode ends. 44
7. SIDE STITCHING/CORNER STITCHING PROCEDURE Check the sample sets after adjustment. 7-4. Checking the Bound State When paper alignment is poor Adjust the side jogger and back jogger again. ( Refer to page 43.) Check the height of the side stitching guide. If the guide is too high, paper may ride onto the side stitching stopper. If too low, paper alignment may deteriorate due to resistance. When stitched sets are not ejected to the side stitching stacker smoothly Are the folding side guides properly positioned for the paper width? If too narrow, ejection defects or paper jam may occur. Perform adjustments using the [Folding Side Guide position fine adjustment key]. ( Refer to page 59.) Is the height of the saddle stitching guide appropriate? Adjust so that it is higher than the paper thickness. ( Refer to page 66.) If the sets stop in front of the saddle stitching stacker, move the folding back guide forward using the [Folding Back Guide position fine adjustment key]. ( Refer to page 60.) When stacking is uneven on the side stitching stacker Adjust the stacker guide position according to the paper size. If the leading edge of the set is caught by the stitches of the sets ejected first, adjust the position of the stopper smaller than the paper size. When side (corner) stitched sets frequently ride onto the stopper If side (corner) stitched sets frequently ride onto the stopper, slow down the feeding speed from the collator. 45
8. NO-STITCHING FOLDING PROCEDURE 8-1. Settings Select the memory number whose settings are to be changed using the [Memory number selection key] and press the [Setting key]. The <Select Binding Mode> screen appears. Memory No. Memory number selection key MAINMENU ADJUST OPTION ACCESSOR The settings of the memory number selected are saved. If there is no need to save, use memory No. 0. ( Refer to page 15.) 420. 0 x 297. 0 210. 0 x 297. 0 00000 01 Setting key <Main Menu> Screen The following describes the procedure for the conditions: A3 vertical (length 420 mm/17.00 inch x width 297 mm/11.00 inch), stitching Off, folding On, trimming Off. Step 1 Selecting the finishing mode Select the stitching and folding mode. Stitch Off key 1 Setting the stitching mode. Press the [Saddle Off key] to set Stitching Off. 2 Set the folding mode. Press the [Fold On key] and set Fold On. After setting the stitching/folding mode, press the [Next key] to proceed to the [Select trimming mode] screen. Pressing the [Cancel key] cancels the values entered, and then returns to the main menu. Select the trimming mode. 3 Set the Fore-edge Trimming mode. Press the [Trim Off key] to set Trim Off. To perform Fore-edge trimming, press the [Trim On key] to set Trim On. At this time, as the paper is not stitched, paper may deviate while trimming. Fold On key Cancel key Next key <Select Finishing Mode> Screen Fore-edge Trim On key Trim Off key Note If DBM-500T is not connected, or when Fold Off is selected, Trim On cannot be selected. After setting the trimming mode, press the [Next key] to proceed to the [Enter paper size] screen. 46 Head/Foot Trim On key Trim Off key Back key Next key <Select Trimming Mode> Screen
8. NO-STITCHING FOLDING PROCEDURE Step 2 Entering the paper size Enter the paper length and width. Standard values for the folding position are displayed according to the paper size entered. Pressing inside the box showing a value resets the value to 0. Enter the desired value using the [Numerical keys], and press the [Return key] on the numerical pad to confirm the value. Pressing the box again while entering the value returns to the original value. 2 297. 0 1 420. 0 210. 0 3 Back key Next key <Enter Paper Size> Screen Return key Numerical keys <Numerical Pad> 1 Enter the length of the paper. Press the box 1, and enter 4200/17.00. Press the [Return key] to confirm the value. Range of input: 178.0 to 508.0 mm/7.01 to 20.00 inch (When connect with DBM-2KT: 178.0 to 500.0 mm/7.01 to 19.69 inch) The folding position is displayed. The value from the leading edge of the paper to the folding position is displayed. When the paper length is entered, the standard folding position will automatically be displayed. * Standard folding position: (Paper length 2) mm /inch Here, it is displayed as 210.0/08.27 (420 2 = 210/16.54 2 = 8.27). To change the value, press the box 3, and enter the desired value. Range of input: 89.0 to 254.0/3.50 to 10.00) (Difference with the paper length should be within 89 to 254 mm/3.50 to 10.00 inch) Press the [Return key] to confirm the value. 2 Enter the width of the paper. Press the box 2, and enter 2970/11.00. Range of input: 120.0 to 356.0 mm/4.72 to 14.02 inch Press the [Return key] to confirm the value. After entering the paper size, press the [Next key] and proceed to the <Set Trimming Position> screen. As paper size is restricted according to binding conditions, the machine will not proceed to the next step if the paper size entered is not appropriate. Pressing the [Back key] returns to the <Select Binding Mode> screen. 47
8. NO-STITCHING FOLDING PROCEDURE Step 3 Confirming settings Make sure that the values entered are all correct, and then press the [Return key] on the touch panel. Pressing the [Return key] saves the settings of the memory number and returns to the <Main Menu> screen. Pressing the [Back key] returns to the <Set Trimming Position> screen when set to Trim On, and returns to the <Enter Paper Size> screen when set to Trim Off. 420. 0 x 297. 0 210. 0 x 297. 0 Step 4 Back key Return key <Confirm Settings> Screen Setting the trimming position (When set to Trim On ) (As the paper is not stitched, paper may deviate while trimming) This is the finished length after trimming. When the paper length is entered, the standard trimming position will automatically be displayed. Standard trimming position: (Paper length 2) 3 mm / 0.12 inch (MAX: 253 mm/9.96 inch) 1 Trimming width Here, it is displayed as 207.0/8.15 (400 2) 3 = 207.0/ (16.54 2) 0.12 = 8.15. If not changing this value, proceed onto the next step. To change the finished length, press the box 1 to reset the value displayed to 0, and enter the desired value. Range of input: 75.0 to 253.0 mm/2.95 to 9.96 inch (Trimming width within 78 mm/2.95 inch) Press the [Return key] to confirm the value. Pressing the box again while entering the value returns to the original value. After entering the trimming position, press the [Next key] to proceed to the <Confirming settings> screen. Pressing the [Back key] returns to the <Enter Paper Size> screen. 207. 0 Back key Next key <Set Trimming Position> Screen 8-2. Changing Size Press the [Size Change key] for more than one second to change the size. When size change completes, a beep sounds. MAINMENU ADJUST OPTION ACCESSOR Note This machine moves left and right. 420. 0 x 297. 0 210. 0 x 297. 0 01 00000 Perform paper size change 48 Size change key <Main Menu> Screen
8. NO-STITCHING FOLDING PROCEDURE 8-3. Adjustments Using the Step Mode After changing the size, perform fine adjustments of each function in the step mode. When the step mode completes, the newly adjusted value is saved as the new setting of the memory number. Note Values shown in the Main Menu screen are replaced by values adjusted not only in the fine adjustment screen but also in the step mode. However, the values shown in the setting screens of each Memory Number will remain the same. They show values originally entered. Starting the step mode <Fine adjustment menu> If the DBM-500T is connected, select whether to trim sets bound in the step mode using the [Trim On/Off key]. On: Off: Trims. Set to trim booklets. No trimming. Set to check stitching and folding positions. Step mode key Trim On/Off key MAINMENU ADJUST OPTION ACCESSOR The setting of the [Trim On/Off key] has priority during the step mode, regardless of whether trimming has been set or not at the memory number. Pressing the [Step Mode key] in the fine adjustment menu proceeds to the <Stitcher Adjustment> screen. Pressing the [Start key] of the upstream unit or this machine conveys one set of paper from the upstream unit to the side stitching stopper. <Fine Adjustment Menu> Screen To terminate the step mode halfway through, press the [Stop key] of this machine. Open the top cover and remove the paper remaining inside the machine. <Stitcher Adjustment> Screen 49
8. NO-STITCHING FOLDING PROCEDURE Adjustments at the stitching section Adjust the positions of the side jogger and back jogger for aligning paper using the [Fine adjustment key]. Adjust the position using keys 1 to 4 and 6 to 9. Perform jogging using keys 5 and bk. Adjust so that the joggers touch the paper edges lightly. After adjusting, press the bl [Stitch key]. Stitching is performed, and the booklet advances to the folding stopper. 1 2 3 4 5 bk bl Stitch key 6 8 7 9 <Stitcher Adjustment> Screen 1 Fine adjustment of side jogger The side jogger moves inward by about 1 mm/0.04 inch. 2 Fine adjustment of side jogger The side jogger moves inward by about 0.2 mm/0.008 inch. 3 Fine adjustment of side jogger The side jogger moves outward by about 1 mm/0.04 inch. 4 Fine adjustment of side jogger The side jogger moves outward by about 0.2 mm/0.008 inch. 5 Side jogger operations Activates the side jogger once. 6 Fine adjustment of back jogger The back jogger moves backward by about 0.1 mm/0.004 inch. 7 Fine adjustment of back jogger The back jogger moves backward by about 1 mm/0.04 inch. 8 Fine adjustment of back jogger The back jogger moves forward by about 0.1 mm/0.004 inch. 9 Fine adjustment of back jogger The back jogger moves forward by about 1 mm/0.04 inch. bk Back jogger operations Activates the back jogger once. bl Stitch key Stitches the set. The booklet is conveyed to the folding stopper and stops. Note Fine adjustments can be performed only within the range of ±5 mm/±0.20 inch after size change. If the paper size entered and that actually used differ by more than 5 mm/0.20 inch, the difference is beyond adjustment. In this case, enter the correct paper size again, and perform the size change. 50
8. NO-STITCHING FOLDING PROCEDURE Adjustments at the folding section (When [Fold On] is selected) Adjust the positions of the folding side guides and folding back guides using the [Fine Adjustment key]. Adjust the position using keys 1 to 4 and 6 to 9. Perform jogging using keys 5 and bk. Adjust so that the guides touch the booklet edges lightly. After adjusting, press the bl [Fold key]. The booklets are folded and ejected, and the step mode ends. If ON is selected using the [Trim On/Off key] at the start of the step mode, booklets are trimmed and ejected. 1 2 3 4 5 bk Folding back guide Folding back guide bl Fold key 6 8 7 9 <Folder Adjustment> Screen Folding side guide Opened state of folding back guide 1 Fine adjustment of folding side guide The folding side guide moves inward by about 1 mm / 0.04 inch. 2 Fine adjustment of folding side guide The folding side guide moves inward by about 0.2 mm / 0.008 inch. 3 Fine adjustment of folding side guide The folding side guide moves outward by about 1 mm / 0.04 inch. 4 Fine adjustment of folding side guide The folding side guide moves outward by about 0.2 mm / 0.008 inch. 5 Folding side guide operations Activates the folding side guide once. 6 Fine adjustment of folding back guide The folding back guide moves backward by about 0.1 mm / 0.004 inch. 7 Fine adjustment of folding back guide The folding back guide moves backward by about 1 mm / 0.04 inch. 8 Fine adjustment of folding back guide The folding back guide moves forward by about 0.1 mm / 0.004 inch. 9 Fine adjustment of folding back guide The folding back guide moves forward by about 1 mm / 0.04 inch. bk Folding back guide operations Activates the folding back guide once. bl Fold key Booklets are ejected after folding, and the step mode ends. 51
8. NO-STITCHING FOLDING PROCEDURE 8-4. Checking the Finished Set Check the sample booklets after adjustment. When folding position has deviated Adjust the position using the [Fold Position fine adjustment key]. ( Refer to page 57.) When folding deviates skewed Adjust the angle of the folding stopper using the folding stopper adjustment dial. When folding misalignment/wrinkles occur The pressure of the conveyance roller adjacent to the folding rollers is too strong. Rotate the dial clockwise until it stops. When inserts do not align with folded sheets in Insert mode Loosen the screws and slide the Ejection roller stopper in the arrow direction. Make sure to replace the Stopper when going back to normal operation and tighten the screws. Ejection roller stopper Screw Ejection Roller Folding stopper adjustment dial Dial Rotate clockwise Rotate counterclockwise 52
8. NO-STITCHING FOLDING PROCEDURE Folding misalignment may also occur if the folding side guides are too narrow or wide. Perform adjustments in the step mode again, and check the positions of the folding side guides. ( Refer to page 51.) If the booklet rides onto the folding side guide or jams, gradually increase the value of stitching side jogger open timing on the option menu. The standard value is 0. ( Refer to page 61.) However, paper may jam at the stitching section if too many sheets of paper are fed. Adjust the position of the folding back guide roller. Loosen the locknut, and move the folding back guide roller to the trail edge using the knobscrew. This holds down the booklet and prevents folding misalignment. Lock nut Knobscrew Folding back guide roller Booklet Trail edge Knobscrew Folding back guide roller Locknut When booklet alignment is poor at the belt stacker Change the conveyance time of the belt stacker at accessory menu. ( Refer to page 65.) If there are too many sheets, or when paper is thick, set a long conveyance time. If booklet alignment is still poor after adjusting the conveyance time, replace the paper guide wheel with one for large size paper. (Not available for paper less than 121 mm/4.76 inch.) If booklet alignment is still poor, loosen the knob screw and move the paper guide wheel to the main body. Single insertion binding Single insertion means single folding A3 (LD) paper and inserting one sheet of A4 horizontal (LT horizontal) paper during non-stitching binding. The single insertion binding procedure is as follows. 1 Replace the conveyance roller with the sponge roller unit provided. 2 Set the DC-10/60 overlap to 3 so that the inserted paper is transported to the DBM-500 in first. (Refer to the DC-10/60 instruction manual.) Remove the screw, pull out the conveyance roller unit in the arrow direction, and replace with the sponge roller unit. Remove screw Conveyance roller unit Remove in arrow direction Sponge roller unit Conveyance roller 53
8. NO-STITCHING FOLDING PROCEDURE 3 Remove the paper holder of the folding side guide. 4 Change the stitching side jogger open timing from 0 to about 5. ( page 61) 5 Set the folding side guides about 2 mm wider than normally done. ( page 51) Folding side guide Folding side guide 6 Adjust the dial so that the conveyance belt and sponge roller lightly touch when the conveyance roller solenoid is ON. Dial When there are conveyance belt marks on the booklet Use the belt guide kit for saddle-stitching binding. Replace the ejection roller unit. Release the knobscrew A so that the ejection roller unit stregth can be sdjusted using the knob. Strong Knob screw A Weak Ejection roller unit Tighten the knobscrew B. Normally, leave it loose. Knob screw B 54
8. NO-STITCHING FOLDING PROCEDURE Attach the belt guide L or S. If the paper length is more than 170 mm and less than 297 mm, use belt guide S. If more than 297 mm to 500 mm, use belt guide L. Paper direction Belt guide L Belt guide L Paper direction Belt guide S Belt guide L Attach belt guide M. Belt guide M Belt guide M Attach filmed guides R and L. Filmed guide R Note Belt guides L, S, and M can be used for paper width above 190 mm. They cannot be used for paper less than 190 mm. After use, remove the belt guide kit and return it to its original state. Do not use it for side-stitching and cornerstitching. Filmed guide L 55
9. VARIOUS SETTINGS 9-1. Fine Adjustment Menu The fine adjustment menu consists of the step mode and fine adjustment items. This section describes the fine adjustment items. For details of the step mode, refer to 5. Binding Preparations ( page 24). Values set for the fine adjustment menu are saved in the memory number used. 3 1 4 5 6 2 MAINMENU ADJUST OPTION ACCESSOR 7 8 9 bk <Fine Adjustment Menu> Screen 1 Step Mode key Press to set the mode which finely adjusts paper alignment at the stitching and folding sections. For details, refer to 5. Binding Preparations ( page 24). 2 Step Mode/Trimming On/Off key Press to determine whether to trim or not in the step mode. Trimming is carried out when On is displayed. Press to display On and Off. 3 Stitch Position fine adjustment key Press to move to the screen for finely adjusting the stitching position. 4 Fold Position fine adjustment key Press to move to the screen for finely adjusting the folding position. 5 Stitch Fold position fine adjustment Press to move to the screen for finely adjusting the stitching folding position. key 6 Stitching Width position fine Press to move to the screen for finely adjusting the stitching width. adjustment key 7 Side Jogger position fine Press to move to the screen for finely adjusting the side jogger position. adjustment key 8 Folding Side guide position fine Press to move to the screen for finely adjusting the folding side guide position. adjustment key 9 Folding Back Guide position fine Press to move to the screen for finely adjusting the folding back guide position. adjustment key bk Other setting position fine Press to move to the screen for other fine adjustments. adjustment key Adjustments of 3 to bk can be changed while the machine is running. However, poor booklets may result from the folding/stitching timing and the fine adjustment timing. 56
9. VARIOUS SETTINGS Stitching position fine adjustment screen Press the [Stitch position fine adjustment key]. The saddle stitching stopper and back jogger are moved to finely adjust the stitching position. They can be moved within ±5 mm/±0.20 inch from the position set at the memory number. To move outside this range, change the setting of the stitching position of the memory number, and perform the size change procedure. 1 Length from paper leading edge to stitching position. (A3/LGR example) 2 Stitching position moves forward by about 0.1 mm/ 0.004 inch. 3 Stitching position moves forward by about 1 mm/0.04 inch. 4 Stitching position moves backward by about 1 mm/ 0.04 inch. 5 Stitching position moves backward by about 0.1 mm/ 0.004 inch. Pressing the [Back key] returns to the fine adjustment menu. Front Leading edge 2 3 4 210. 0 1 5 Back key Back Stitching position Folding position fine adjustment screen Press the [Fold position fine adjustment key]. The folding stopper and folding back guide are moved to finely adjust the folding position. They can be moved within ±5 mm/±0.20 inch from the position set at the memory number. To move outside this range, change the setting of the stitching position of the memory number, and perform the size change procedure. 2 3 4 5 1 Length from paper leading edge to folding position. (A3/LGR example) 2 Folding position moves forward by about 0.1 mm/0.004 inch. 3 Folding position moves forward by about 1 mm/0.04 inch. 4 Folding position moves backward by about 1 mm/0.04 inch. 5 Folding position moves backward by about 0.1 mm/ 0.004 inch. Pressing the [Back key] returns to the fine adjustment menu. Front Leading edge 210. 0 1 Back key Back Folding position 57
9. VARIOUS SETTINGS Stitching/folding fine adjustment screen Press the [Stitch Fold position fine adjustment key]. The saddle stitching stopper, back jogger, folding stopper, and folding back guide are moved all together at the same time to finely adjust the stitching/folding position. They can be moved within ±5 mm/±0.20 inch from the position set at the memory number. To move outside this range, change the setting of the stitching position of the memory number, and perform the size change procedure. 1 Stitching/folding position moves forward by about 0.1 mm/0.004 inch together. 2 Stitching/folding position moves forward by about 1 mm/0.04 inch together. 3 Stitching/folding position moves backward by about 1 mm (0.04 inch). 4 Stitching/folding position moves backward by about 0.1 mm (0.004 inch). Pressing the [Back key] returns to the fine adjustment menu. Front 1 2 3 Leading edge 4 Back key Back Stitching/folding position Stitching width fine adjustment screen Press the [Stitching Width fine adjustment key]. Move the position of the stitcher to finely adjust the stitching width. Stitching width is the length between the centers of two stitches. The stitching positions are symmetrical with the paper width as the center. The stitcher can be moved within ±5 mm/±0.20 inch from the position set at the memory number. To move outside this range, change the setting of the stitching position of the memory number, and perform the size change procedure. 2 3 1 148. 5 1 Stitching width length (A3/LGR example) 2 Stitching width is about 1 mm/0.04inch narrower. 3 Stitching width is about 1 mm/0.04inch wider. Pressing the [Back key] returns to the fine adjustment menu. A B Back key Center of paper A=B 58
9. VARIOUS SETTINGS Side jogger position fine adjustment screen Press the [Side Jogger position fine adjustment key]. Finely adjusts the distance between the left and right side joggers. The side joggers can be moved within ±5 mm/±0.20 inch from the position set at the memory number. To move outside this range, change the setting of the stitching position of the memory number, and perform the size change procedure. 2 3 4 5 1 Distance between the left and right stitching side joggers. 2 Distance decreases by about 0.2 mm/0.008 inch. 3 Distance decreases by about 1 mm/0.04 inch. 4 Distance increases by about 1 mm/0.04 inch. 5 Distance increases by about 0.2 mm/0.008 inch. Pressing the [Back key] returns to the fine adjustment menu. 297. 0 1 Back key While the machine is running, this adjustment is not possible at a processing speed of 2 jog times and less. Make fine adjustments after stopping the machine, or after lowering the processing speed down to 3 jog times and more by controlling the upstream unit speed. Note During fine adjustment, a number of jogs temporarily turns less than a set number. Folding Side Guide position fine adjustment screen Press the [Folding Side Guide position fine adjustment key]. Finely adjusts the distance between the left and right folding side guides. 1 2 3 4 1 Distance decreases by about 0.2 mm/0.008 inch. 2 Distance decreases by about 1 mm/0.04 inch. 3 Distance increases by about 1 mm/0.04 inch. 4 Distance increases by about 0.2 mm/0.008 inch. Pressing the [Back key] returns to the fine adjustment menu. Back key 59
9. VARIOUS SETTINGS Folding Back Guide position fine adjustment screen Press the [Folding Back Guide position fine adjustment key]. Finely adjusts the position of the folding back guide. 1 2 1 The folding back guide moves forward by about 1 mm/ 0.04 inch. 2 The folding back guide moves backward by about 1 mm/0.04 inch. Pressing the [Back key] returns to the fine adjustment menu. Back key Front Leading edge Back Folding back guide Other setting position fine adjustment screen Press the [Other setting position fine adjustment key] to perform other fine adjustments. 1 1 Finely adjust the distance between folding rollers. Normally, as the distance is automatically adjusted according to the number of processed sheets, this setting is not required. Adjust within the 5 to +5 range using the [ / keys]. 0 is the standard setting, +5 is the maximum (the distance between rollers is wide), and 5 is the minimum (the distance is narrow). This setting is returned to 0 when size change is performed. The distance between folding roller changes by about 0.2 mm/0.008 inch with each gradation. 2 Finely adjust the position of this machine to the left and right to align with the paper passage line from the upstream unit. Pressing the [ / keys] moves this machine by about 1 mm as indicated in the figure. Pressing the [Back key] returns to the fine adjustment menu. This setting is available at each memory number. This setting still remains effective even though the power is shut off. 2 Paper direction Press key DBM-500 Press key Back key Upstream unit 60
9. VARIOUS SETTINGS 9-2. Option Menus The optional settings still remain effective even though the power is shut off. To memorize these settings, start this machine and stop once. The contents of each option setting is effective on all memory numbers. Option Menu 1 1 Changes the opening timing of the side joggers. Can be changed within 0 to 10 range using the [ / keys]. 0 is the standard setting. 0 is the fastest opening timing, and +10 the slowest. If stitched paper jams without being ejected from the stitching section, set to minus gradually. If stitched paper is ejected skewed, and jams at the folding section, set to plus gradually. 2 Set the folding conveyance belt to always On or Off. Pressing the [Switching key] switches between the On and Off display. Normally use Off. In the Stitch Off, Fold On mode, set to ON, because continuous belt running keeps pressing booklets against the folding stopper, resulting in stable operations. 3 Set the wire feed detection to On or Off. L1 is the left stitcher in respect to the paper conveyance direction, and R1 is the right stitcher. Pressing the [Switching key] switches between the On and Off display. Pressing the [Next key] proceeds to the option menu 2 screen. 1 2 3 Switching key MAINMENU ADJUST OPTION ACCESSOR Switching key Next key <Option Menu 1> Screen Option Menu 2 1 When connected with the sheet feeder DSF-2000, jog operations are performed once at the stitching section for every specified number of sheets during paper feed. This number of sheets can be set between 2 and 9 sheets only when the DSF-2000 is connected. 2 Set the number of jogs at the stitching section. ( Refer to page 19.) This can be set between 1 and 9 times. At start, the upstream unit compares the processing speed suitable for the number of jogs set on this machine and the processing speed set at the upstream unit, and starts operations with the slower processing speed. If the processing speed of the upstream unit is changed, the number of jogs of this machine will also be changed automatically. 3 Refer to Stitching Tests. ( Refer to page 75.) Pressing the [Next key] proceeds to the Option Menu 3. Pressing the [Back key] returns to the Option Menu 1. 1 2 3 MAINMENU ADJUST OPTION ACCESSOR 5 5 Stitch test key Back key Next key <Option Menu 2> Screen 61
9. VARIOUS SETTINGS Option Menu 3 1 Switches the oscillation stroke of the side jogger. The oscillation stroke consists of two types; 5 mm (0.20 inch) and 2 mm/0.08 inch. Normally use 5 mm/0.20 inch. Select 2 mm/0.08 inch when using DSF-2000 if paper moves skewed when conveyed and jams at the stitching section. Selects oscillation stroke 2 mm/0.08 inch. 1 2 3 MAINMENU ADJUST OPTION ACCESSOR 25 Selects oscillation stroke 5 mm/0.20 inch. 2 When feeding sheets by hand, or merging hand-fed sheets with the sheets from the collator, set the total number of sheets to be processed. Normally, this is automatically set based upon information from the upstream unit, and need not be set. ( Refer to page 19.) Pressing the box with a value displayed blinks the box and resets the value to 0. Enter the desired value using the [Numerical keys], and press the [Return key] on the numerical pad. The box stops blinking and the value is confirmed. Pressing the box while entering the value returns to the original value. The number of sheets can be set between 2 and 25 for Fold On and 2 and 50 for Fold Off. 3 Pressing the [Contrast key] displays the Brightness / Contrast Adjustment Screen. It sets it to the value that sees easily pushing "+" key or " " keys of Brightness and Contrast. When the adjustment ends, [OK key] is pushed. It ends pushing "X" key on the right of the screen. Contrast key Back key <Option Menu 3> Screen Next key Pressing the [Next key] proceeds to the Option Menu 4. Pressing the [Back key] returns to the Option Menu 2. <Brightness / Contrast Adjustment> Screen Option Menu 4 Sets the processing mode of this machine for hand feeding paper using DSF-2000. MAINMENU ADJUST OPTION ACCESSOR [ ] : Press the [jog key] to enable hand feeding. Insert one set of paper into the machine, and press the [jog key]. [1-3] : Binding operations are carried out automatically when paper is set for the number of binding times set. For instance, if set to [1], operations are carried out each time the paper is inserted. Set [2] if dividing a set of paper into two times and inserting separately. 62 Back key <Option Menu 4> Screen Next key
9. VARIOUS SETTINGS Option Menu 5 This menu locks settings of each memory number such as paper size, binding mode, etc. Settings of locked memory numbers cannot be changed. Pressing the key icon switches between the On/Off state. Pressing the [Back key] returns to the Option Menu 4. ON state MAINMENU ADJUST OPTION ACCESSOR Back key <Option Menu 4> Screen OFF state 9-3. Accessory Menus 1 Pressing the [Trimmer key] moves to the screen for setting the trimmer (DBM-500T). This can be selected only when the trimmer is connected. * The trimmer (DBM-500T) is optional. 2 Pressing the [Stacker key] moves to the screen for setting the belt stacker. * The stacker (DBM-LS1) is optional. 3 Pressing the [Kicker key] moves to the screen for setting the kicker. * The kicker (DBM-K) is optional. 4 Press the [option key] to shift to the options setting screen. * For details, refer to the instruction manual of the options packaged with this machine. Trimmer key Stacker key Kicker key MAINMENU ADJUST OPTION ACCESSOR <Accessory Menu> Screen 63
9. VARIOUS SETTINGS Trimmer Settings 1 Adjust the finished length (length from book spine to foreedge). Press the [Trimmer key]. 5 4 1 3 2 1 Finished length 2 Increases by about 0.1 mm/0.004 inch. 3 Increases by about 1 mm/ 0.04 inch. 4 Decreases by about 1 mm/0.04 inch. 5 Decreases by about 0.1 mm/0.004 inch. Pressing the [Back key] returns to the Accessory Menu. Pressing the [Next key] proceeds to the <Trimmer Setting 2> screen. 145. 5 Back key Next key <Trimmer Setting 1> Screen Trimmer stopper Spine Booklet Blade Short Finished length Long Fore-edge Trimmer Settings 2 The optional settings still remain effective even though the power is shut off. To memorize these settings, start this machine and stop once. The contents of each option setting is effective on all memory numbers. 64 1 Adjust the driving time of the conveyance belt. The standard setting is 1. Driving time can be selected between 0 and 10 using the [ / keys]. Increasing the value increases the driving time. If the trimming position is unstable because booklets bounce back, from the stopper or slip, these problems can be prevented by driving the belt longer. 2 Adjust the distance between the conveyance rollers. The standard setting is 0. The distance can be selected between 30 (minimum) to 30 (maximum) using the [ / keys]. If booklets cannot be conveyed smoothly due to the difference in paper quality, thickness of booklets, etc., adjust this distance. If booklets fail to enter the conveyance belts, the distance may be too narrow. Adjust larger. If booklets do not reach the stopper after entering the conveyance belts, or are not ejected smoothly after trimming, the distance may be too wide. Adjust smaller. Pressing the [Back key] returns to the <Trimmer Setting 1> screen. 1 2 Back key <Trimmer Setting 2> Screen
9. VARIOUS SETTINGS Stacker Settings The optional settings still remain effective even though the power is shut off. To memorize these settings, start this machine and stop once. The contents of each option setting is effective on all memory numbers. Press the [Stacker key]. ( Refer to 9-3. Accessory Menu on page 63.) 1 Adjust the start timing of the conveyance belt. The standard setting is 0. The start timing can be selected between 0 and 9 using the [ / keys]. Increasing the value sets a slower timing for conveyance to start. This applies also when the trimmer is connected. 2 Adjust the stacker conveyance time. The standard setting is 3. The stacker conveyance time can be selected between 1 and 9 using the [ / keys]. Increasing the value sets a longer conveyance time, and decreasing sets a shorter time. This applies also when the trimmer is connected. Pressing the [Back key] returns to the Accessory Menu. 1 2 Back key <Stacker Setting> Screen Kicker Settings (Kicker is Optional) The optional settings still remain effective even though the power is shut off. To memorize these settings, start this machine and stop once. The contents of each option setting is effective on all memory numbers. Press the [Kicker key]. ( Refer to page 63 9-3. Accessory Menus.) Switching key 1 Select the kicker operations On or Off. Pressing the [Switching key] switches between the On and Off display. 2 Enter the number of booklets to be sorted by the kicker. This can be selected between 0 and 999. Pressing the box with a value displayed blinks the box and resets the value to 0. Enter the desired value using the [Numerical keys], and press the [Return key] on the numerical pad. The box stops blinking and the value is confirmed. Pressing the box while entering the value returns to the original value. Pressing the [Back key] returns to the Accessory Menu. 1 2 999 Back key <Kicker Setting> Screen 65
9. VARIOUS SETTINGS 9-4. Adjusting the Press Pressure and Conveyance Pressure Adjusting the press pressure The standard setting for the press pressure is High. If booklets fail to enter the press rollers, or to be ejected skewed from the press rollers, set the press pressure adjustment hook to Medium or Low. Set the left and right hooks to the same settings. Adjusting the conveyance pressure The standard setting for the conveyance pressure is High. If booklets travel skewed and jam at the ejection rollers or cannot be ejected smoothly, set the conveyance pressure adjustment hooks to Low. Set the left and right hooks to the same settings. L Side R Side Low Press pressure adjustment hook High Conveyance pressure adjustment hook High Conveyance pressure adjustment hook Low High Low High Low Press pressure adjustment hook 9-5. Adjusting the Saddle Stitching Guide/Side Stitching Guide Set the saddle stitching guide and side stitching guide at high positions normally. However, set them at low positions if paper rides onto the saddle stitching or side stitching stoppers and jams. Set high when paper cannot be conveyed smoothly to the folding section. Fixing screw Saddle stitching guide Fixing screw Up Side stitching guide Side stitching stopper Up Down Down Fixing screw Saddle stitching stopper 66
10. ERROR MESSAGES When an error occurs, details of the error and its location are displayed on the touch panel, and the machine stops. Perform the appropriate procedures to correct the error. This machine will not operate while error messages are displayed. 10-1. Emergency Stop The moment the emergency stop switch is pressed, the machine stops and this error message appears on the touch panel. This machine will also stop when the emergency stop switches of the upstream or downstream unit is pressed. Likewise, the this error message will be displayed on the touch panel. [S01]Emergency stop Releasing the switch Turn the switch to the right to release it. If there is paper remaining inside the machine, open the top cover, remove it and resume operations. Turn to right Emergency stop switch 10-2. Covers This error message is displayed when the top cover is open. Opening the cover while the machine is running will stop the machine immediately, and the this error message will appear on the touch panel. If there is paper remaining inside the machine, open the top cover, remove it and resume operations. [C01]Safety cover (front) Note If RL VP Error is displayed, open the top cover again and close it properly. 67
10. ERROR MESSAGES 10-3. Paper Jam This error message is displayed when paper has jammed inside the machine. The jam location is displayed on the touch panel. For more details on correcting paper jams, refer to page 70. [J01]Jam 10-4. Wire Feed Detection This error message is displayed when the wire is not fed normally at the stitcher head. This machine stops after ejecting the booklets being processed. Be sure to check that these booklets have been stitched properly. Before resuming operations, set new wire if it has run out. If there is wire remaining, readjust the wire of the stitcher head and perform stitching tests. ( Refer to page 71.) The error message disappears when the top cover is opened and closed. This error detection can be switched On/Off at Option Menu 1. ( Refer to page 61.) [E01]Wire feed sensor (L1) 10-5. Paper Tray Full This error message is displayed when the side stitching stacker is full with booklets. The machine stops after all booklets being processed have been ejected out. Remove the booklets on the stacker. The error screen is cleared when the top cover is opened/ closed. After removing the booklets, pressing the [Start key] also resumes operations. [E05]Tray full 68