DBM-500 Instruction Manual -...

INSTRUCTION MANUAL

SYSTEM5000Dynamic 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 machineThis 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.

1

1. SAFETY PRECAUTIONS................................ 2

2. USAGE PRECAUTIONS ................................. 52-1. Power Supply .................................................. 5

2-2. Operating Environment ................................... 5

2-3. Storage Conditions ......................................... 5

3. NAMES AND FUNCTIONS ............................. 63-1. External Parts ................................................. 6

3-2. Internal Parts ................................................... 8

3-3. Downstream Unit (Optional) .......................... 11

3-4. Accessories ................................................... 11

4. NAMES AND FUNCTIONS OF CONTROLPANEL (MAIN MENU) ................................... 12

5. PREPARING FOR OPERATION................... 145-1. Power ON ..................................................... 14

5-2. Operations .................................................... 15

5-3. Settings ......................................................... 19

6. SADDLE STITCHING PROCEDURE ............ 276-1. 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 STITCHINGPROCEDURE ................................................ 387-1. Settings ......................................................... 38

7-2. Changing Size ............................................... 41


7-4. Checking the Bound State ............................ 45

8. NO-STITCHING FOLDING PROCEDURE ... 468-1. Settings ......................................................... 46

8-2. Changing Size ............................................... 48


8-4. Checking the Finished Set ............................ 52

CONTENTS

Thank you for purchasing this Duplo equipment. To ensure correct usage, please read thisinstruction 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 otherpurpose than that intended by the manufacturer.

After reading, please keep this instruction manual handy for future reference.

9. VARIOUS SETTINGS.................................... 569-1. Fine Adjustment Menu .................................. 56

9-2. Option Menus................................................ 61

9-3. Accessory Menus .......................................... 63

9-4. Adjusting the Press Pressure and ConveyancePressure ........................................................ 66

9-5. Adjusting the Saddle Stitching Guide/SideStitching Guide .............................................. 66

10. ERROR MESSAGES..................................... 6710-1. 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 .......................................... 7112-1. 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

INTRODUCTION

2

Always observe the cautions and warnings given below to prevent personal injury or propertydamage.

The degree of danger and damage that could occur is indicated on two levels by thefollowing marks.

WARNING: Ignoring this mark could result in the possibility of serious injuryor even death.

CAUTION: Ignoring this mark could result in the possibility of injury orphysical damage.

The following graphic symbols indicate the various types of action to be performedor 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 ofany 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 ina fire or an electrical shock.

Do not touch or insert foreign objects into any rotating part during operation. This couldresult in injury.

Do not remove the cover or back panel. This unit contains high-voltage components thatcould cause an electrical shock.

Do not disassemble, modify or repair this unit. There is a danger of fire, electrical shockor injury. Contact your dealer when repairs are necessary.

Use only the power supply voltage specified on the main nameplate. Using othervoltages could result in a fire or an electrical shock.

Keep this unit and the power cord away from heaters and heater vents. Excessive heatcould melt the cover or power cord covering, and result in a fire or an electrical shock.

1. SAFETY PRECAUTIONS

3


Do not use flammable sprays or solvent inside or near the unit (e.g. when cleaning theunit).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 connecteddoes not exceed the capacity rating of the power outlets or plug receptacles. Exceedingthe capacity rating could cause the power outlets, plug receptacles, or power extensioncords to overheat and catch a fire.

Remove any dust that accumulates on the power plug prongs and the surface of the plugfrom 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 theunit off at the power switch and disconnect the power plug from the power outlet. Failureto 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 orplace 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. Forciblypulling 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 anelectrical shock.

Before cleaning this unit, turn the unit off at the power switch and disconnect the powerplug from the power outlet. Accidental operation of the unit during cleaning could resultin injury.

CAUTION:

Always disconnect the power plug from the power outlet when the unit is not to be usedfor an extended period. Failure to do so could result in fire due to leakage current if theinsulation should deteriorate.

Install this unit on a level, stable stand or floor, with sufficient space around it. Failure todo 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 contactwith water is possible. Poor choice of location could result in deterioration of theinsulation, 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.

4


Emergency Stop Switch

Shutter

Top cover (Front)

Top cover (Back)

Safety

The following shows the location of the safety devices and warning/Caution label.

NoteNoteLabels 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 shownin the above figure.

5

2. USAGE PRECAUTIONS

2-1. Power Supply

• This equipment shall be installed near the socket-outlet where the plug on the powersupply 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 combinedpower 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.

6

3. NAMES AND FUNCTIONS

bm

9

7

8

6

bk

bl

5

4

3

2

1

L side

R side

Paper direction

3-1. External Parts

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 resumeoperations, remove this paper. To stop the machine normally, use the [Stop Key] onthe upstream unit or this machine.To release this switch, rotate it to the right.

3 Front top cover Cover for ensuring user safetyThis machine will not operate if open.

4 Rear top cover Cover for ensuring user safetyThis 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.

In this manual, the left side of the paper conveyance direction is indicated as L side and the right side as R side.

7


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.

cl

cn

bq

bnbo

bp

br

bs

bt

co

ck

cpcp

cm

L sideR side

Paper direction

8


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.

3-2. Internal Parts

4

5 6

2

8

7

5

2

113 3

� Paper direction

When the conveyance roller open

9


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.

bm

bm

bn

bk

9

bl

bl

bo

� Paper direction

10


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.

btbq

cl

Roller attaching position

ck

cl

bq

bq

br

br

bs

bp

bp

� Paper direction

bs

11


3-3. Downstream Unit (Optional)

3-4. Accessories

This machine

DBM-500T (Optional)

DBM-K (Optional)

DBM-LSI (Optional)

Adjusting handlePaper guide wheel Corner stitching paper holder

12

4. NAMES AND FUNCTIONS OF CONTROLPANEL (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.

[Numerical Pad][Touch Panel]

MAINMENU ADJUST OPTION ACCESSOR

01

00000

420. 0 x 297 . 0207. 0 x 277 . 0

9 bk bm bpbn bo

bs

btbq

br

ckcl cmbl8

1 5 2 6 3 7 4

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.

13

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 followingformat.

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 thesettings are displayed at 5 to 9.

bm Setting key Displays the setting menu of the memory number of the binding mode currentlyselected.

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.

14

5. PREPARING FOR OPERATION

5-1. Power ON

This machine has a main power switch and a powerswitch.Operate the machine with the main power switch On, andthe power switch " "The remote function allows this unit to turn on/off bypressing the power switch for DC-10/60,and the mainpower switch for DSF-2000.It means there is no need to touch the main power switchor the power switch of this unit.

NoteNote �� To turn the power of this machine On/Off byitself, set the power switch to “I” and the mainpower switch On.

�� When operating the power switch, do so afterturning Off the main power switch.

�� If an upstream unit is connected, do not turnOn/Off the power of this machine by itself.This may cause the machine to operateabnormally.Be sure to turn On/Off the main power switchor the power switch of the upstream unitinstead.

Main power switch

Power switch

DBM-LS1 DBM-500T This machine LUL-HM DC-10/60

DBM-LS1 DBM-500T This machine DSF-2000

When DC-10/60 is connected

When DSF-2000 is connectedMain power switch

Power switch


15


5-2. Operations

❊ Memory No.

The memory number consists of 1 to 12 for registering binding setting (binding mode) such as paper size, stitching, andfolding to each memory.Default settings at shipment are as follows.

01

00000

420. 0 x 297 . 0207. 0 x 277 . 0


Return keyProcessed number clear key

Start key Stop key

Clear keyMemory No. Size change key

MessageProcessed number display

Jog key

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 asthe 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.

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


10 215.9 x 355.6 (08.50 x 14.00) Side stitching No folding


12 215.9 x 279.4 (08.50 x 11.00) Side stitching No folding

16


❊ Size change

Size change is the process of returning guides to their standard points once, and then moving them to the positions setaccording 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 displayshows “Perform paper size change” and the [Size Change key] blinks, size change is also required. Normally, the stitcherwill 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 itto the set position.Pressing the [Size Change key] while pressing numerical key 0 only returns all guides to their standard positions.

NoteNote 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 allpaper being processed, after which this machine stops. If an error occurs during processing, this machine will stop accordingto the situation. If an error of the emergency stop switch, top cover, or shutter occurs during processing, the machine willalso 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 themachine because the machine will stop due to paper jam without displaying the paper jam message in some cases. Insuch 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, andeject the processed sets.

NoteNoteIf 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.

17


Stitching position label

Pointer

60(2

.36)

60(2

.36)

60(2

.36)

60(2

.36)

180

(7.0

9)

240

(9.

45)

Paper conveyance direction

Stitching position

Stitching position 1

:

2

:

1

Unit: mm (inch)

❊ Stitching range

Saddle stitching

Stitching is carried out at the positions indicated by thepointer.Normally, stitching is done at two positions.

* This can be increased to four positions by factoryoptions.

Paper

Space Space

Side joggerSide jogger

❊ Aligning the paper passage lines

After preparing this machine for binding operations, checkthat the paper passage line is aligned to that of theupstream unit.When paper conveyed from the upstream unit is conveyedto this machine, check that there is even space betweenthe left and right side joggers and paper.If not even, adjust the position of this machine to avoidpaper jams.Move this machine at other fine adjustment screens of thefine adjustment menu, until the space becomes even.( Refer to page 60.)

When paper is more than 140 mm/5.51 inch wide, thestandard stitching width is determined by the ratio of 1:2:1.Stitching width is the center to center distance betweenthe two stitches. However, if the stitching position liesinside the stitch prohibited area, it will be set at a positionavoiding 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.

When less than 140 mm/5.51 inch, the stitching width is70 mm/2.76 inch (minimum stitching width).

The stitching width (the ratio) can be changed. ( Referto page 58.)

18


Stitching position label Mark (Stitch prohibited area)

Pointer

Make sure the mark does not enter area A

A

A

❊ Stitch prohibited area

The position at which the folding knife and a stitchcoincide is called the stitch prohibited area.During folding operations, the folding knife may bend thestitch if they touch.When a standard stitching position determined by thepaper width entered is inside the stitch prohibited area, theposition avoids this area automatically.

NoteNote When adjusting the stitching width, avoid thestitching prohibited area.

120

to 3

56

14

(0.5

5)

14

(0.5

5)

35

(2.7

6)

35 (2.7

6)

Center line of paper width


Stitching position

Stitching position

Unstitchable area

Unit: mm (inch)

� The stitching position cannot be within 14 mm/0.55 inchfrom both edges of the paper.

� The stitching width cannot be within 70 mm/2.76 inch.

6 (0.24)


Pap

er w

idth

Unit: mm (inch)

Side stitching (corner stitching)

The stitching position is about 6 mm/0.24 inch from theleading edge of the paper, and cannot be changedvertically.The stitching position along the width of the paper is thesame as saddle stitching.

19


❊ 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-8/32Set 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 2on the DC-10/60 or DC-8/32 collator control panel.Normally press the key 1. It runs fast to achieve higher productivity.

5-3. Settings

Perform binding settings.Select the memory number whose setting is to bechanged, 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.)

01

00250

420. 0 x 297 . 0207. 0 x 277 . 0

Memory number selection key

Setting key

Memory No.

<Main Menu> Screen


� Merging-collation mode with DC-10/60 or DC-8/32Set the total number of sheets fed from the LUL-HMand the collator at “processed sheets”.

� Manual feeding from DSF-2000Insert 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 “processedsheets” 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 “processedsheets”.

20


❊ Selecting the binding mode

Select the stitchng and folding mode.

Set the stitching mode.To perform saddle stitching, select “1 Saddlestitching”, to perform side stitching, select “2 Sidestitching”, and if not performing stitching, select “3Stitch Off”.Select “2 Side stitching” also for corner stitching.

Selecting “Saddle stitching” automatically sets thefolding mode to “Fold On”. (Can be changed)Selecting “Side stitching” automatically sets thefolding mode to “Fold Off” and the trimming modeto “Trim Off”. (Can be changed)

Set the folding mode. To perform folding, select“4 Fold On”. If not performing folding, select “5Fold Off”.

Selecting “Fold Off” sets the trimming mode to“Trim Off”.

After setting the binding mode, press the [Next key] toproceed 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.

Set the Fore-edge trim. To perform trimming, select“6 Trim On”. If not to perform trimming, select “7Trim Off”.(When DBM-500T is not connected, or when “FoldOff” 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, “8Trim On” cannot be selected.)

After setting the trimming mode, press the [Next key] toproceed to the [Enter paper size] screen.

1 2 34 5

Next keyCancel key<Select Binding Mode> Screen

6 7

98 Next keyBack key

<Select Trimming Mode> Screen

21


Entering the paper length 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 inchSide 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

Entering the paper width 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

Stitching position display 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/inchRange 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 14.24inch)

Folding position display Length from the paper leading edge to stitching position.When the paper length is entered, the standard folding position will automatically be set. (Canbe changed)

* Standard folding position: (Paper length ÷ 2) mm/inchRange 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 10.00inch)

Stitching width display The width between both stitches.When the paper width is entered, the standard width will automatically be set. (Can bechanged)

* Standard stitching position: (Paper length ÷ 2) mm/inchHowever, if the paper width is less than 140 mm/5.51 inch, the stitching width will be set to70.0 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 [ConfirmSettings] screen will appear.As paper size is restricted according to binding conditions, the machine will not proceed to the next step if the paper sizeentered is not appropriate.Pressing the [Back key] returns to the <Select Trimming Mode> screen.

❊ Entering paper size

Paper width

Stitchingposition

Folding position

297. 0420. 0

210. 0

210. 0

148. 5

Next key

Back key

Stitching width

Paper length


<Enter Paper Size> Screen

Enter the paper length and width.Standard values for the stitching/folding positions andstitching width are displayed according to the paper sizeentered.Pressing inside the box showing a value resets the valueto 0. Enter the desired values using the [Numerical keys],and press the [Return key] on the numerical pad toconfirm. Pressing the box again before pressing the[Return key] returns the original value.

NoteNote The values in this screen are original figures youentered.They remain the same no matter how finelyadjusted later according to binding conditions.

22


❊ Setting the Fore-edge Trimming position (When DBM-500T is connected and [Trim On] is selected)

1 Displaying the trimming positionThis is the finished length after Fore-edge Trimming.When the paper length is entered, the standardstitching position will automatically be set. (Can bechanged)

* Standard trimming position: (Paper length ÷ 2) – 3mm/0.12 inch (MAX: 253 mm/9.96 inch)

Pressing inside the box showing a value resets thevalue 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 [Returnkey] returns the original value.

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)

After entering the Fore-edge Trimming position, press the[Next key].When the trimming mode is set to “Trim On”, the “SetHead/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.

207. 0

1

Next key

Trimming width

Back key

<Set Trimming Position> Screen

❊ Setting the Head/Foot Trimming position (Available only when [Trim On] is selectedboth 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 positionMargin widths to be Head/Foot trimmed are displayed.When the paper width is entered, the standardstitching position will automatically be set. (Can bechanged)

* Standard trimming width: 10 mm/0.40 inch

Pressing inside the box showing a value resets thevalue 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 [Returnkey] returns the original value.

Range of input: 0 and 1.0 to 25.0 mm/0 and 0.04 to0.98 inchWhen "0" is input, the machine does not operate.

3 1

277. 0

10. 0

10. 0 2

Next keyBack key<Set Trimming Position> Screen

23


Make sure that the values entered are all correct, and thenpress the [Return key] on the touch panel.Pressing the [Return key] saves the settings of thememory 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-edgeTrimming On",

3. the "Enter Paper Size" screen, when set to "Head/FootTrimming Off", and "Fore-edge Trimming Off".

❊ Confirming settings

DBM-500

Outlet

Setscrew

Stacker

Book spine

30 mm (1.18 inch)

Paper guide wheel

DBM-500Setscrew

Booklet

Outlet

Fore-edge

❊ Adjusting the position of the paper guide wheel when the trimmer is not connected

Where the fore-edge of booklets touches the outlet asshown, set the wheels at about 30 mm/1.18 inch from thebook spine.Loosen the setscrew and move the paper guide wheel.

NoteNote If the booklet is widely open, and cannot beconveyed properly, move the paper guide wheelcloser to the outlet.

3 Displaying the Head/Foot trimming positionsThe 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.

420. 0 x 297 . 0207. 0 x 277 . 0

Return keyBack key

<Confirm Setting> Screen

24


❊ Size change

Press the [Size Change key] for more than one second tochange the size.When size change completes, a beep sounds.

NoteNote This machine moves left and right.

❊ 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.

NoteNote Values shown in the Main Menu screen are replaced by values adjusted not only in the fine adjustment screen but alsoin 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 trimsets 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.

The setting of the [Trim On/Off key] has priority duringthe step mode, regardless of whether trimming has beenset or not at the memory number used.

Pressing the [Step Mode key] in the fine adjustmentmenu proceeds to the <Stitcher Adjustment> screen.

00000

01420. 0 x 297 . 0207. 0 x 277 . 0

Size change key<Main Menu> Screen


Perform paper size change

Step Mode key Trim On/Off key

<Fine Adjustment Menu> Screen

<Stitcher Adjustment> Screen


25


Pressing the [Start key] of the upstream unit or thismachine conveys one set of paper from the upstream unitto the stitching stopper.

To terminate the step mode halfway through, press the[Stop key] of this machine.Open the top cover and remove the paper remaininginside the machine.

Back jogger

Back jogger

Paper

Paper direction

Paper direction

Conveyance roller lifting handle


“Opened state of conveyance roller”

Side joggerSide jogger

8 9blStitch key 76

bk31 2 4 5


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 sidestitching stacker, and the step mode ends.

NoteNote Fine adjustments can be performed only within the range of ±5 mm/±0.20 inch after size change. If the paper sizeentered 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 stitching section

Adjust the positions of the side jogger and back jogger foraligning 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 thefolding 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.

26


�� Adjustments at the folding section(When [Fold On] is selected)

Adjust the positions of the folding side guides and foldingback 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 modeends.� If ON is selected using the [Trim On/Off key] at the

start of the step mode, booklets are trimmed andejected.

bk

9786blFold key

1 3 52 4

<Folder Adjustment> Screen

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.

Folding side guide

Folding back guideFolding back guide

“Opened state of folding back guide”

Folding side guide

27

6. SADDLE STITCHING PROCEDURE

00000

01420. 0 x 297 . 0207. 0 x 297 . 0

Setting key

Memory No.

<Main Menu> Screen



Selecting the finishing mode

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

6-1. Settings

Select the memory number whose settings are to bechanged using the [Memory number selection key] andpress the [Setting key]. The “Select Binding Mode”screen appears.

The settings of the memory number selected are saved.If there is no need to save, use memory No. 0. ( Referto page 15.)

Next keyCancel key

Saddle Stitching key

Fold On key<Select Finishing Mode> Screen

Select and enter the stitching and folding mode.

11111 Setting the stitching mode.

Press the [Saddle Stitching key] to set “Saddlestitching”.The folding mode is automatically set to “Fold On”.

After setting the trimming mode, press the [Next key] toproceed to the [Select Tirmming mode] screen.Pressing the [Cancel key] cancels the values entered,and then returns to the main menu.

22222 Set the trimming mode.

Pressing the [Trim On key], set “Trim On”.

NoteNote If DBM-500T is not connected, or when“Fold Off” is selected, “Trim On” cannotbe selected.

After setting the trimming mode, press the [Next key] toproceed to the [Enter Paper size] screen.

Next keyBack keyHead/Foot Trim On key

Fore-edge Trim On key Trim Off key

Trim Off key

<Select Trimming Mode> Screen

28


Entering the paper size

11111 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/inchHere, 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/3.50to 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/inchHere, 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/3.50to 10.00 inch)Press the [Return key] to confirm the value.

297. 0420. 0

210. 0

210. 0

148. 5297. 0

420. 0

210. 0

210. 0

148. 5

12 5

3 4 Return key Numerical keysNext keyBack key

<Enter Paper Size> Screen <Numerical Pad>

Step 2Enter the paper length and width. Standard values for the stitching/folding position and stitching width are displayedaccording 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. Pressingthe box again before pressing the [Return key] returns the original value.

29


Setting the trimming position

The finished length after Fore-edge Trimming is displayed.When the paper length is entered, the standard trimmingposition 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 resetthe 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 75 mm/2.95 inch)Press the [Return key] to confirm the value.Pressing the box again while entering the value returnsthe 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.

207. 0

1

Next keyBack key

Trimming width

<Set Trimming Position> Screen

Step 3

22222 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 inchPress 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/inchHere, 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 valueavoiding this area will be displayed.

NoteNote 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 sizeentered is not appropriate.Pressing the [Back key] returns to the <Select Binding Mode> screen.

30


00000

01420. 0 x 297 . 0207. 0 x 297 . 0

Size change key<MAIN MENU> Screen



Confirming settings

Make sure that the values entered are all correct, and thenpress the [Return key] on the touch panel.Pressing the [Return key] saves the settings of thememory number and returns to the <Main Menu> screen.Pressing the [Back key] returns to the <Set TrimmingPosition> screen. 420. 0 x 297 . 0

207. 0 x 297 . 0

Back key Return key<Confirm Settings> Screen

Step 4

6-2. Changing Size



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.


31


8 9bl Stitch key 76

bk31 2 4 5


Step mode key Trim On/Off key




❊ Starting the step mode <Fine adjustment menu>

If the DBM-500T is connected, select whether to trim setsbound 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.

The setting of the [Trim On/Off key] has priority duringthe step mode, regardless of whether trimming has beenset or not at the memory number.


Pressing the [Start key] of the upstream unit or thismachine conveys one set of paper from the upstream unitto the saddle stitching stopper.


❊ Adjustments at the stitching section

Adjust the positions of the side jogger and back jogger foraligning 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 thefolding stopper.

32


9786blFold key

1 3 52 4 bk


Folding side guide

Folding side guide













bl Stitch key Stitches the set. The booklet is conveyed to the folding stopper and stops.


❊ 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.

33



2 Fine adjustment of folding side guide The folding side guide moves inward by about 0.2 mm/0.008 inch.










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 positionAdjust the position using the [Stitch Position Fine Adjustment key]. ( Refer to page 57.)

� Move the folding position to the stitching positionAdjust 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.)

34


� If the stitching position is inside the stitchingprohibited area shown on the stitching position label( refer to page 18), folding misalignment mayoccur. Change the stitching width using the[Stitching Width Fine Adjustment key] and adjustso that it is outside this area. ( Refer to page58.)

� Folding misalignment may also occur if the foldingside guides are set too narrow or wide.Perform adjustments in the step mode again, andcheck the position of the folding side guides. ( Refer to page 32.)

� If the booklet rides onto the folding side guide orjams, gradually increase the value of “stitching sidejogger open timing” on the option menu.The standard value is 0. ( Refer to page 61.)However, paper may jam at the stitching section iftoo many sheets of paper are fed.

Folding stopper adjustment dial

Rotate clockwise

Rotate counterclockwise

Lock dial

Stitching position label Mark (Stitch prohibited area)

Pointer

Stitching position label

Pointer

�� When folded skewed

� During use, rotate the lock dial in the counterclockwise direction while holding the folding stopper adjustment dial torelease 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 dialto lock it.

35


� 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 thebooklet 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.

�� 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 adjustmentdial in the counterclockwise direction.For the condition shown in the right figure B, rotate the adjustmentdial in the clockwise direction.After adjusting, fit the lock plate into the groove on the lock dial.

�� 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 largesize 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.

Folding back guide roller


Locknut

KnobscrewLock nut


Booklet

Trail edge

Knobscrew

Top folding plate

Knobscrew

Knobscrew

Lock plate

Adjustment dial

Figure A Figure B

36


�� 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.

Belt guide L

Paper direction

Paper direction

Belt guide L

Belt guide L

Belt guide S

Knob screw B

Ejection roller unit

Knob screw A

StrongWeak

� Tighten the knobscrew B. Normally, leave it loose.

� Attach the belt guide L or S.If the paper length is more than 170 mm and lessthan 297 mm, use belt guide S. If more than 297mm to 500 mm, use belt guide L.

37


Belt guide M

Belt guide M

Filmed guide R

Filmed guide L

NoteNote �� Belt guides L, S, and M can be used for paperwidth above 190 mm. They cannot be used forpaper less than 190 mm.

�� After use, remove the belt guide kit and returnit to its original state.

�� Do not use it for side-stitching and corner-stitching.

� Attach belt guide M.

� Attach filmed guides R and L.

38

7-1. Settings

Select the memory number whose settings are to bechanged using the [Memory number selection key] andpress the [Setting key]. The <Select Binding Mode>screen appears.



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.

Select the finishing mode.The stitching position is about 6 mm/0.24 inch from theleading edge of the paper and cannot be changedvertically.


Press the [Side Stitching key] to set “Sidestitching”. (Select side stitching even for cornerstitching.)The folding mode is automatically set to “Fold Off”.(Can be changed.)When set to “Fold Off”, the trimming mode cannotbe 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 “TrimOn”.


After setting the finishing mode, press the [Next key] andproceed to the <Enter Paper Size> screen .Pressing the [Cancel key] cancels the values entered andreturns to the main menu.

00000

03210. 0 x 297 . 0210. 0 x 297 . 0


Setting key

Memory No.

<Main Menu> Screen


Stitching position

Lead

ing

edge

Fro

nt

Bac

k

6 mm (0.24 inch)

Next keyCancel key

Side Stitching key

Fold On key

Fold Off key

<Select Finishing Mode> Screen

Step 1

7. SIDE STITCHING/CORNERSTITCHING PROCEDURE

39


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], andpress the [Return key] on the numerical pad to confirm.Pressing the box again before pressing the [Return key] returns the original value.

<Fold Off> Screen <Numerical Pad>

297. 0 148. 5

210. 0

12 3

Return key Numerical keys

210. 0

105. 0

297. 0 148. 5

4 Back key Next key

12 3

<Fold On> Screen

Step 2


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 inchFold 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 thefolding position is displayed.When the paper length is entered, the standard foldingposition will automatically be displayed.∗ Standard folding position: (Paper length ÷ 2) mm/ inchHere, 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 thedesired value.Press the [Return key] to confirm the value.

NoteNote The box 4 is not displayed when set to “FoldOff”.


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.)

7. SIDE STITCHING/CORNER STITCHING PROCEDURE

40

Setting the trimming position (When set to [Trim On])

This is the finished length after trimming.When the paper length is entered, the standard trimmingposition 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 resetthe 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 75 mm/2.95 inch)Press the [Return key] to confirm the value.Pressing the box again while entering the value returnsthe 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.

102. 0

1

Next keyBack key<Set Trimming Position> Screen

Trimming width

Step 3

�� 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/inchHere, 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 positionfrom 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 sizeentered is not appropriate.Pressing the [Back key] returns to the <Select Binding Mode> screen.

Confirming settings

210. 0 x 297 . 0210. 0 x 297 . 0


Step 4Make sure that the values entered are all correct, and thenpress the [Return key] on the touch panel.Pressing the [Return key] saves the settings of thememory number and returns to the <Main Menu> screen.Pressing the [Back key] returns to the <Set TrimmingPosition> screen if set to “Trim On”, and returns to the<Enter Paper Size> screen if set to “Trim Off”.

7. SIDE STITCHING/CORNER STITCHING PROCEDURES

41

7-2. Changing Size

00000

03210. 0 x 297 . 0210. 0 x 297 . 0

Size change keyMain Menu Screen



❊ 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 tothe 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 tothe 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 sideguide.


Clamp L

Clamp R

Clamp L

Knobscrew

Handle

R side

L side

Corner stitching guide

Folding side guide



�� Stitching at the L side

Secure the clamp L at the back of the stitcher head withthe 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.)


42






ON: Trims. Set to trim sets.OFF: No trimming. Set to check stitching and folding

positions.



“ON” cannot be selected when set to “Trim Off”.

Pressing the [Start key] of the upstream unit or thismachine conveys one set of paper from the upstream unitto the side stitching stopper.







43


8 9blStitch key 76

bk31 2 4 5


Adjust the positions of the side jogger and back jogger foraligning 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 foldingstopper.











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.)



44

9786bl Fold key

1 3 52 4 bk


Folding side guide

Folding side guide



❊ Adjustments at the folding section (When [Folding On] is selected)

Adjust the positions of the folding side guides and foldingback 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.

� If ON is selected using the [Trim On/Off key] at thestart of the step mode, sets are trimmed and ejected.


2 Fine adjustment of folding side guide The folding side guide moves inward by about 0.2 mm/0.008 inch.









bl Fold key Sets are ejected after folding, and the step mode ends.


45

7-4. Checking the Bound State

Check the sample sets after adjustment.

�� 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 BackGuide 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.


46

8. NO-STITCHING FOLDINGPROCEDURE


00000

01420. 0 x 297 . 0210. 0 x 297 . 0


Setting key

Memory No.

<Main Menu> Screen


Fold On key

Stitch Off key

Cancel key Next key<Select Finishing Mode> 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

8-1. Settings

Select the memory number whose settings are to bechanged using the [Memory number selection key] andpress the [Setting key]. The <Select Binding Mode>screen appears.


Trim Off key

Trim Off key Back key Next key

<Select Trimming Mode> ScreenHead/Foot Trim On key

Fore-edge Trim On key

Select the stitching and folding mode.


Press the [Saddle Off key] to set “Stitching Off”.

22222 Set the folding mode.

Press the [Fold On key] and set “Fold On”.

After setting the stitching/Folding mode, press the [Nextkey] 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.

33333 Set the Fore-edge Trimming mode.

Press the [Trim Off key] to set “Trim Off”.To perform Fore-edge trimming, press the [TrimOn key] to set “Trim On”.At this time, as the paper is not stitched, paper maydeviate while trimming.


After setting the trimming mode, press the [Next key] toproceed to the [Enter paper size] screen.

47

8. NO-STITCHING FOLDING PROCEDURE



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 /inchHere, 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/3.50to 10.00 inch)Press the [Return key] to confirm the value.


Press the box 2, and enter “2970/11.00”.Range of input: 120.0 to 356.0 mm/4.72 to 14.02 inchPress 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 sizeentered is not appropriate.Pressing the [Back key] returns to the <Select Binding Mode> screen.

210. 0

420. 0

297. 0

12

3

<Enter Paper Size> Screen <Numerical Pad>

Return keyNext keyBack key Numerical keys

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.

Step 2

48


207. 0

1

Next key

Trimming width

Back key<Set Trimming Position> Screen

420. 0 x 297 . 0210. 0 x 297 . 0


00000

01420. 0 x 297 . 0210. 0 x 297 . 0

Size change key<Main Menu> Screen



Step 3

8-2. Changing Size



Confirming settings

Make sure that the values entered are all correct, and thenpress the [Return key] on the touch panel.Pressing the [Return key] saves the settings of thememory number and returns to the <Main Menu> screen.Pressing the [Back key] returns to the <Set TrimmingPosition> screen when set to “Trim On”, and returns to the<Enter Paper Size> screen when set to “Trim Off”.

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 trimmingposition will automatically be displayed.∗ 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” (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 resetthe 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 tothe 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 PaperSize> screen.

Step 4

49











On: Trims. Set to trim booklets.Off: No trimming. Set to check stitching and folding

positions.



Pressing the [Start key] of the upstream unit or thismachine conveys one set of paper from the upstream unitto the side stitching stopper.


50


8 9bl Stitch key 76

bk31 2 4 5



Adjust the positions of the side jogger and back jogger foraligning 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 thefolding stopper.











bl Stitch key Stitches the set. The booklet is conveyed to the folding stopper and stops.


51


8 9bl Fold key 76

bk31 2 4 5

<Folder Adjustment> Screen Folding side guide



❊ 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 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.


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.



52



Rotate clockwise

Folding stopper adjustment dial

Dial

Ejection roller stopper

Ejection Roller

Screw

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 whengoing back to normal operation and tighten the screws.

8-4. Checking the Finished Set

53


Lock nut

Trail edge

Booklet

Knobscrew


Locknut

Knobscrew


� 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.

�� 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 largesize 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 duringnon-stitching binding. The single insertion binding procedure is as follows.

1 Replace the conveyance roller with the sponge rollerunit provided.

2 Set the DC-10/60 overlap to 3 so that the insertedpaper 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

Sponge roller unit Conveyance roller

Remove in arrow direction

54


Knob screw B

Ejection roller unit

Knob screw A

StrongWeak

�� 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.

� Tighten the knobscrew B. Normally, leave it loose.

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)

6 Adjust the dial so that the conveyance belt and spongeroller lightly touch when the conveyance roller solenoidis ON.

Folding side guide

Folding side guide

Dial

55


Belt guide L

Paper direction

Paper direction

Belt guide L

Belt guide L

Belt guide S

� Attach the belt guide L or S.If the paper length is more than 170 mm and lessthan 297 mm, use belt guide S. If more than 297mm to 500 mm, use belt guide L.

Belt guide M

Belt guide M

Filmed guide R

Filmed guide L

� Attach belt guide M.

� Attach filmed guides R and L.

NoteNote �� Belt guides L, S, and M can be used for paperwidth above 190 mm. They cannot be used forpaper less than 190 mm.

�� After use, remove the belt guide kit and returnit to its original state.

�� Do not use it for side-stitching and corner-stitching.

56

9-1. Fine Adjustment Menu

The fine adjustment menu consists of the step mode andfine adjustment items. This section describes the fineadjustment items.For details of the step mode, refer to “5. BindingPreparations” ( page 24).Values set for the fine adjustment menu are saved in thememory number used.

987 bk<Fine Adjustment Menu> Screen


3 1 4 5 6 2

1 Step Mode key Press to set the mode which finely adjusts paper alignment at the stitching and foldingsections.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.

9. VARIOUS SETTINGS

57

9. VARIOUS SETTINGS

❊ Stitching position fine adjustment screen

210. 0

1

52 3 4

Back key

Lead

ing

edge

Fron

t

Bac

k

Stitching position

❊ Folding position fine adjustment screen

Press the [Fold position fine adjustment key].The folding stopper and folding back guide are moved tofinely adjust the folding position.They can be moved within ±5 mm/±0.20 inch from theposition set at the memory number.To move outside this range, change the setting of thestitching position of the memory number, and perform thesize change procedure.

1 Length from paper leading edge to folding position.(A3/LGR example)

2 Folding position moves forward by about 0.1 mm/0.004inch.

3 Folding position moves forward by about 1 mm/0.04inch.

4 Folding position moves backward by about 1 mm/0.04inch.

5 Folding position moves backward by about 0.1 mm/0.004 inch.Pressing the [Back key] returns to the fine adjustmentmenu.

210. 0

1

52 3 4

Back key

Folding position

Lead

ing

edge

Fron

t

Bac

k

Press the [Stitch position fine adjustment key].The saddle stitching stopper and back jogger are movedto finely adjust the stitching position.They can be moved within ±5 mm/±0.20 inch from theposition set at the memory number.To move outside this range, change the setting of thestitching position of the memory number, and perform thesize 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/0.04inch.

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 adjustmentmenu.

58

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 sametime to finely adjust the stitching/folding position.They can be moved within ±5 mm/±0.20 inch from theposition set at the memory number.To move outside this range, change the setting of thestitching position of the memory number, and perform thesize change procedure.

1 Stitching/folding position moves forward by about 0.1mm/0.004 inch together.

2 Stitching/folding position moves forward by about 1mm/0.04 inch together.

3 Stitching/folding position moves backward by about 1mm (0.04 inch).

4 Stitching/folding position moves backward by about 0.1mm (0.004 inch).Pressing the [Back key] returns to the fine adjustmentmenu.

41 2 3

Back key

Stitching/folding position

Lead

ing

edge

Fro

nt

Bac

k

Press the [Stitching Width fine adjustment key].Move the position of the stitcher to finely adjust thestitching width.Stitching width is the length between the centers of twostitches. The stitching positions are symmetrical with thepaper width as the center.The stitcher can be moved within ±5 mm/±0.20 inch fromthe position set at the memory number.To move outside this range, change the setting of thestitching position of the memory number, and perform thesize change procedure.

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 adjustmentmenu.

❊ Stitching width fine adjustment screen

148. 5

2 3 1

Back key

Center of paper

AB

A=B

59

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 sidejoggers.The side joggers can be moved within ±5 mm/±0.20 inchfrom the position set at the memory number.To move outside this range, change the setting of thestitching position of the memory number, and perform thesize change procedure.

1 Distance between the left and right stitching sidejoggers.

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 adjustmentmenu.

❊ Folding Side Guide position fine adjustment screen

Press the [Folding Side Guide position fine adjustmentkey].Finely adjusts the distance between the left and rightfolding side guides.

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 adjustmentmenu.

297. 0

1

2 3 4 5

Back key

1 2 3 4

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 bycontrolling the upstream unit speed.

NoteNoteDuring fine adjustment, a number of jogs temporarily turns less than a set number.

60

9. VARIOUS SETTINGS

❊ Folding Back Guide position fine adjustment screen

Press the [Folding Back Guide position fineadjustment key].Finely adjusts the position of the folding back guide.

1 The folding back guide moves forward by about 1 mm/0.04 inch.

2 The folding back guide moves backward by about1 mm/0.04 inch.Pressing the [Back key] returns to the fine adjustmentmenu.

1 2

Back key

Lead

ing

edge

Folding back guide

Fro

nt

Bac

k

❊ Other setting position fine adjustment screen

Press the [Other setting position fine adjustment key]to perform other fine adjustments.

1 Finely adjust the distance between folding rollers.Normally, as the distance is automatically adjustedaccording to the number of processed sheets, thissetting is not required.Adjust within the –5 to +5 range using the [ / keys].0 is the standard setting, +5 is the maximum (thedistance between rollers is wide), and –5 is theminimum (the distance is narrow).This setting is returned to 0 when size change isperformed.The distance between folding roller changes by about0.2 mm/0.008 inch with each gradation.

2 Finely adjust the position of this machine to the left andright to align with the paper passage line from theupstream unit.Pressing the [ / keys] moves this machine by about1 mm as indicated in the figure.Pressing the [Back key] returns to the fine adjustmentmenu.This setting is available at each memory number.This setting still remains effective even though thepower is shut off.

2

1

Back key

DBM-500 Upstream unit

Press key

Press key

Paper direction

61

9. VARIOUS SETTINGS

1

2

3

Next keySwitching key

Switching key

<Option Menu 1> Screen


❊ Option Menu 1

❊ Option Menu 2

55

1

2

3

Next keyBack keyStitch test key


MAINMENU ADJUST OPTION ACCESSOR1 When connected with the sheet feeder DSF-2000, jog

operations are performed once at the stitching sectionfor every specified number of sheets during paperfeed.This number of sheets can be set between 2 and 9sheets 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 processingspeed suitable for the number of jogs set on thismachine and the processing speed set at the upstreamunit, and starts operations with the slower processingspeed.If the processing speed of the upstream unit ischanged, the number of jogs of this machine will alsobe changed automatically.

3 Refer to “Stitching Tests”. ( Refer to page 75.)Pressing the [Next key] proceeds to the Option Menu3.Pressing the [Back key] returns to the Option Menu 1.

1 Changes the opening timing of the side joggers. Canbe changed within 0 to 10 range using the [ / keys].0 is the standard setting. 0 is the fastest openingtiming, and +10 the slowest.

If stitched paper jams without being ejected from thestitching section, set to minus gradually.If stitched paper is ejected skewed, and jams at thefolding section, set to plus gradually.

2 Set the folding conveyance belt to always On or Off.Pressing the [Switching key] switches between theOn and Off display.Normally use Off.In the Stitch Off, Fold On mode, set to ON, becausecontinuous belt running keeps pressing bookletsagainst the folding stopper, resulting in stableoperations.

3 Set the wire feed detection to On or Off.L1 is the left stitcher in respect to the paperconveyance direction, and R1 is the right stitcher.Pressing the [Switching key] switches between theOn and Off display.Pressing the [Next key] proceeds to the option menu 2screen.

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.

62

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 papermoves skewed when conveyed and jams at thestitching section.

Selects oscillation stroke 2 mm/0.08 inch.

Selects oscillation stroke 5 mm/0.20 inch.

2 When feeding sheets by hand, or merging hand-fedsheets with the sheets from the collator, set the totalnumber of sheets to be processed. Normally, this isautomatically set based upon information from theupstream unit, and need not be set. ( Refer topage 19.)Pressing the box with a value displayed blinks the boxand resets the value to “0”.Enter the desired value using the [Numerical keys],and press the [Return key] on the numerical pad. Thebox stops blinking and the value is confirmed.Pressing the box while entering the value returns to theoriginal 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 "+" keyor "–" keys of Brightness and Contrast.When the adjustment ends, [OK key] is pushed .It ends pushing "X" key on the right of the screen.

Pressing the [Next key] proceeds to the Option Menu 4.Pressing the [Back key] returns to the Option Menu 2.

25

1

2

3

Next keyContrast key Back key



❊ Option Menu 4

Sets the processing mode of this machine for handfeeding paper using DSF-2000.

[—] : Press the [jog key] to enable hand feeding.Insert one set of paper into the machine, and pressthe [jog key].

[1-3] : Binding operations are carried out automaticallywhen paper is set for the number of binding timesset.For instance, if set to [1], operations are carried outeach time the paper is inserted.Set [2] if dividing a set of paper into two times andinserting separately.


Next keyBack key<Option Menu 4> Screen

<Brightness / Contrast Adjustment> Screen

63

9. VARIOUS SETTINGS

9-3. Accessory Menus

1 Pressing the [Trimmer key] moves to the screen forsetting the trimmer (DBM-500T).This can be selected only when the trimmer isconnected.

* The trimmer (DBM-500T) is optional.

2 Pressing the [Stacker key] moves to the screen forsetting the belt stacker.

* The stacker (DBM-LS1) is optional.

3 Pressing the [Kicker key] moves to the screen forsetting the kicker.

* The kicker (DBM-K) is optional.

4 Press the [option key] to shift to the options settingscreen.

* For details, refer to the instruction manual of the options packaged with this machine.


<Accessory Menu> Screen

Trimmer key Stacker key Kicker key

❊ Option Menu 5

This menu locks settings of each memory number such aspaper 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.

OFF stateBack key<Option Menu 4> Screen


ON state

64

9. VARIOUS SETTINGS

❊ Trimmer Settings 2

1 Adjust the driving time of the conveyance belt. Thestandard setting is 1. Driving time can be selectedbetween 0 and 10 using the [ / keys]. Increasingthe value increases the driving time.If the trimming position is unstable because bookletsbounce back, from the stopper or slip, these problemscan be prevented by driving the belt longer.

2 Adjust the distance between the conveyance rollers.The standard setting is 0. The distance can beselected between –30 (minimum) to 30 (maximum)using the [ / keys].If booklets cannot be conveyed smoothly due to thedifference 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 smoothlyafter trimming, the distance may be too wide. Adjustsmaller.Pressing the [Back key] returns to the <TrimmerSetting 1> screen.

<Trimmer Setting 2> Screen

1

2

Back key

❊ Trimmer Settings 1

Adjust the finished length (length from book spine to fore-edge).Press the [Trimmer key].

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 AccessoryMenu.Pressing the [Next key] proceeds to the <TrimmerSetting 2> screen.

2345 1

Next keyBack key

Trimmer stopper BookletSpine

Fore-edge

Blade

Finished length

Short Long

145. 5

<Trimmer Setting 1> Screen


65

9. VARIOUS SETTINGS

❊ Kicker Settings (Kicker is Optional)

Press the [Kicker key]. ( Refer to page 63 “9-3.Accessory Menus”.)

1 Select the kicker operations On or Off.Pressing the [Switching key] switches between theOn and Off display.

2 Enter the number of booklets to be sorted by thekicker.This can be selected between 0 and 999.Pressing the box with a value displayed blinks the boxand resets the value to “0”. Enter the desired valueusing the [Numerical keys], and press the [Returnkey] on the numerical pad. The box stops blinking andthe value is confirmed. Pressing the box while enteringthe value returns to the original value.Pressing the [Back key] returns to the AccessoryMenu.

1

2

Back key

Switching key

999

<Kicker Setting> Screen

❊ Stacker Settings

1

2

Back key<Stacker Setting> Screen

Press the [Stacker key]. ( Refer to “9-3. AccessoryMenu” 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 9using the [ / keys].Increasing the value sets a slower timing forconveyance 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 between1 and 9 using the [ / keys]. Increasing the valuesets a longer conveyance time, and decreasing sets ashorter time.This applies also when the trimmer is connected.Pressing the [Back key] returns to the AccessoryMenu.



66

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 ejectedskewed from the press rollers, set the press pressureadjustment 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 rollersor cannot be ejected smoothly, set the conveyancepressure adjustment hooks to “Low”.Set the left and right hooks to the same settings.

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.

Side stitching guide

Fixing screw

Down

Up

Side stitching stopper

Press pressure adjustment hook


Conveyance pressure adjustment hook

L Side

R Side


Low

Low

Low

Low

High

High

High

High

Fixing screw

Down

Up

Fixing screw

Saddle stitching stopper

Saddle stitching guide

67

10. ERROR MESSAGESWhen an error occurs, details of the error and its location are displayed on the touch panel, and the machinestops.Perform the appropriate procedures to correct the error. This machine will not operate while error messages aredisplayed.

10-1. Emergency Stop

The moment the emergency stop switch is pressed, themachine stops and this error message appears on thetouch panel.This machine will also stop when the emergency stopswitches of the upstream or downstream unit is pressed.Likewise, the this error message will be displayed on thetouch panel.

�� Releasing the switch

Turn the switch to the right to release it.If there is paper remaining inside the machine, open thetop cover, remove it and resume operations.

Emergency stop switch

Turn to right

[S01]Emergency stop

10-2. Covers

This error message is displayed when the top cover isopen.Opening the cover while the machine is running will stopthe machine immediately, and the this error message willappear on the touch panel.If there is paper remaining inside the machine, open thetop cover, remove it and resume operations.

NoteNote If “RL VP Error” is displayed, open the top coveragain and close it properly.

[C01]Safety cover (front)

68

10. ERROR MESSAGES

This error message is displayed when paper has jammedinside the machine.The jam location is displayed on the touch panel.For more details on correcting paper jams, refer to page70.

[J01]Jam

10-4. Wire Feed Detection

This error message is displayed when the wire is not fednormally at the stitcher head. This machine stops afterejecting the booklets being processed. Be sure to checkthat 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 stitcherhead and perform stitching tests. ( Refer to page 71.)The error message disappears when the top cover isopened and closed.This error detection can be switched On/Off at OptionMenu 1. ( Refer to page 61.)

[E01]Wire feed sensor (L1)

10-5. Paper Tray Full

This error message is displayed when the side stitchingstacker is full with booklets.The machine stops after all booklets being processedhave 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 [Startkey] also resumes operations.

[E05]Tray full

10-3. Paper Jam

69

10. ERROR MESSAGES

10-6. Motor Error

This error message is displayed when an error occurs atthe motor.The machine stops immediately. To correct this error,open the top cover, or press the emergency stop switch.If the error cannot be cleared, or if the error occurs againafter resuming operations, contact our service person.

Motor error

[E∗∗]Motor error (∗∗∗)

10-7. Service Person Error

When errors starting with codes T01 are displayed, errorswhich the user cannot correct may have occurred.Turn off the power and then turn it on again, and resumeoperations from the beginning. If the same error occurs,contact our service person.

Inverter error Relay trouble

Memory data error

Communication error

10-8. Shutter

This error message is displayed when the shutter is open. Close the shutter

Shutter

[C05]Shutter

70

�� If booklets remain at the folding rollers.

Open the shutter, and rotate the rollers with the handle provided to remove the booklets.

HandleFolding roller

Booklet

11. CORRECTING PAPER JAMSThe machine stops when paper jams. The jams locationsare displayed on the touch panel.

Paper


�� If paper jams at the stitching section

Open the top cover, lift up the conveyance roller liftinghandle, and remove the jammed paper.

�� If paper jams at the folding section

Open the top cover, lift up the back guide handle, andremove the jammed paper.

Booklet

Back guide handle

NoteNote To remove jammed booklets (paper), be careful not to move the stitching side jogger and folding side guide whichhave been finely adjusted.If moved, perform size change and fine adjustments again.

71

12. STITCHER HEAD

12-1. Names and Functions

bl

bl

br

bq

br

2

2

1

4

6

7

8

99

bk

bk

bm bmbt

bn

bo

bo

bq

bp bp

bs

5

6

7

8

4

3

5

3

72

12. STITCHER HEAD

Wire measuring #27 (0.4 mm/0.02 inch) to #25 (0.5 mm/0.02 inch) in diameter can be used. The #25 (0.5 mm/0.02 inch)provides the best performance.

12-2. Wire

No. Name Function

1 Wire guide spring Feeds wire to the stitching section.

2 Wire guide Guides the wire.

3 Wire feed detection unit Detects wire feed amount and prevents stitching error.

4 Felt disks Cleans the wire surface and applies a small amount of oil.

5 Wire return lock Prevents the wire supplied from returning.

6 Release disk When lowered, releases the wire return lock.

7 Fixing knob Fixes the wire guide spring to the wire tube.

8 Wire tube upper Wire path

9 Stitch length adjustment knob Wire is cut short when rotated clockwise, and long when rotated counterclockwise.

bk Triangular handle For switching whether to stitch or not

bl Feed wheels Grip the wire when the triangular handle is set to the stitching position. When rotated,with the adjusting handle, wire is fed.

bm Wire tube lower Wire path

bn Mounting bolt Secures the stitcher head to the mounting block.

bo Balance adjustment wheel When rotated, adjusts the left and right leg length of a stitch.

bp Wire straightener Straightens the wire.

bq Leaf spring Holds the former.

br Former Cuts the wire and bends it into C shape.

bs Adjusting handle Used when feeding wire by hand. (Accessory)

bt Tenon block Secures the stitcher head to the mounting block.

73

12. STITCHER HEAD

33333 Pass the wire between the two felt disksand through the wire return lock.

44444 Insert the wire into the tip of the wire tubeupper.

Be careful not to bend the wire.

55555 Check that the triangular handle is at thestitching position where there is no clear-ance as shown right.

Wire

Wire return lock

Felt disks

Triangular handle

ClearanceNo clearanceStitching position Non stitching position

Wire

Roller

Bearing

Wire feed detection unit

22222 Pass the wire to the wire feed detectionunit.

Sandwich the wire between the bearing and roller.

12-3. Feeding the Wire

11111 Pass the wire through the wire guides.

Wire

Wire

Wire guideWire guide

Wire guide

74

12. STITCHER HEAD

Adjusting handle

Feed wheel

Wire tube lower

77777 Mount the adjusting handle onto the feedwheel, rotate to the right, so that thewheels grip the wire.

88888 Feed the wire with the handle.

Rotate the handle clockwise about two times.

NoteNote If the wire is bent, it will not enter the wiretube, and jam instead. Pull the wire, cut offthe bent part, and feed it again.

66666 Insert the wire into the tip of the wire tubeupper, and feed with pliers.

Be careful not to bend the wire.Feed until the wire reaches the feed wheels.

Wire tube upper

Wire

Pliers

Feed wheels

75

12. STITCHER HEAD


<Stitch Test Action> Screen

MAINMENU ADJUST ACCESSOROPTION

Stitch Test key

Stitch Test Action key

33333 Load the same size paper as the paper ofthe selected memory number on theupstream unit.

44444 Display the <Option Menu 2> by pressingthe option and [Next key] in order.

55555 Press the [Stitch Test key].

The <Stitch Test> screen appears.

66666 Press the [Start key] of this machine orupstream unit.

One set of paper is sent from the upstream unit tothe stitching stopper.

12-4. Stitching Tests

11111 Turn On the power of this machine.

( Refer to page 14 “5-1. Power On”.)

22222 Select a memory number that includes thesaddle stitching process from the mainmenu, and press the [Size Change key]. 01

00250

420. 0 x 297 . 0207. 0 x 277 . 0

<Select Binding Mode> Screen


Memory No.

Size Change key

76

12. STITCHER HEAD

77777 Press the [Stitch Test Action key].

After several stitching operations, the paper will beejected to the side stitching stacker.

Stitch Test Action key

<Stitch Test Action> Screen

12-5. Removing Wire

11111 Turn the triangular handle to the nonstitching position where there is a clear-ance as shown right.

Wire

Release disk

Triangular handle

ClearanceNo clearanceStitching position Non stitching position

22222 While holding down the release disk, pullout the wire.

33333 Return the triangular handle to the stitch-ing position where there is no clearance asshown right.

88888 Check the stitched state, and return to themain menu by pressing the MAIN MENU tab.

If the state is not satisfactory, adjust the stitcherhead and repeat stitching tests.( Refer to “12-6. Adjustments” on page 77.)

77

12. STITCHER HEAD

Stitch length adjustingknob

L RL R

U p ward

Balance adjustment wheel

Viewed from the paper feed inlet

Downward

Upward Downward

Wire is straight

Rotate clockwise


Counter-clockwise

Clockwise

Wire straightener

12-6. Adjustments

1. Adjusting the stitch length

� Rotate the stitch length adjusting knob clockwise to cutthe wire short.

� Rotate counterclockwise to cut it long.� The length changes by about 0.8 mm/0.03 inch with

each rotation.

2. Adjusting the left and right leg length

Adjust the left and right legs to the same length using thebalance adjustment wheel.� When this wheel is rotated upward, the L side leg

becomes longer.� When this wheel is rotated downward, the L side leg

becomes shorter.

3. Straightening the wire

Straight wire enables more stable stitching operations.

Remove the leaf spring and remove the former.Feed the wire with the adjusting handle.Rotating the wire straightener clockwise warps the wiredownward and rotating it counterclockwise warps itupward.Adjust until the wire runs out straight.After adjustment, pull the wire back inside with the handle,and then return the former to its original position.

NoteNote Factory adjusted at shipment.If not using the designated wires, adjustments arerequired.

78

12. STITCHER HEAD

Apply oil weekly to part A and monthly to part B withfew drops each time. Use the provided oil only.

12-7. Maintenance

A

B

NoteNote Excessive oil will drip and dirty the paper.

79

13. TROUBLESHOOTINGSymptom

Paper jams at the entrance of thismachine

Paper alignment is poor

Stitching position and folding positiondo not match

Folded crookedly

Paper rides onto the saddle stitchingstopper

Stitching problems

Paper stops at the folding rollers orpress rollers, or paper is ejectedskewed from the press rollers.

After folding, paper is not ejected tothe belt stacker or trimmer smoothly

Paper jams when conveyed to thefolding section

Paper alignment is poor at the

stacker unit

Cause

� The paper passage line of the upstreamunit and this machine do not match.

� Faulty adjustment of the stitching sidejogger

� Faulty adjustment of the back jogger� Incorrect position of the side stitching guide

� Faulty adjustment of the stitching positionand folding position

� Faulty adjustment of the folding stopperangle

� Poor paper alignmentStitch and folding blade tip are touching

� Faulty adjustment of the folding side guide

� Processing speed is too fast

� Paper is too thick or too many(When DC-10/60 is connected)

� Incorrect position of the saddle stitchingguide

� Faulty adjustment of the clearance at thefolding rollers and the press rollers

� Press roller pressure is too strong

� Faulty adjustment of the conveyancepressure.

� Paper rides onto the saddle stitching guide

� Narrow distance between the folding sideguides

� Paper is ejected skewed

� Incorrect position of the paper guide wheel

Solution

� Adjust this machine to the paper passageline of the upstream unit.

� Perform fine adjustment in the step mode(Refer to adjustments by the step mode foreach binding mode.)

� If paper rides onto the side stitchingstopper, set to a low position. If papercannot reach the stopper, set to a highposition (Refer to Figure 2 on page 80.)

� Refer to saddle stitching binding mode.

� Refer to saddle stitching binding mode.

� Set a slow processing speed for theupstream unit.

� Set a slow processing speed for thecollator. Adjust the overlap of the collator to2 or 4.(Refer to the instruction manual for thecollator.)

� Set the saddle stitching guide low.(Refer to Figure 1 on page 80.)

� Refer to the adjustments of each part fordetails of the stitcher head.

� If the clearance between the rollers is toowide for the paper thickness, set smaller. Iftoo narrow, adjust wider. (Refer to the fineadjustment menu, and other adjustmentkeys.)

� Adjust the press roller pressure adjustmentlower. (Refer to Figure 3 on page 80.)

� Clean the folding rollers and press rollers.

� Basically set a strong conveyancepressure. If paper is thick and stops beforethe ejection roller, set the conveyancepressure adjustment hook to weak. (Referto Figure 3 on page 80.)

� Set the position of the saddle stitchingguide to high.

� Widen the distance between the foldingside guides (Refer to fine adjustmentmenu/folding side guide position fineadjustment key.)

� Adjust the open timing of the stitching sidejogger at Option Menu 1 (Refer to OptionMenu 1).

� Adjust the position of the paper guidewheel. (Refer to “Adjusting the position ofthe paper guide wheel when the trimmer isnot connected” of Saddle Stitching BindingMethod.)

80

13. TROUBLESHOOTING

Symptom

Paper alignment on the side stitchingstacker is poor

Power On/Off is not linked to theupstream unit

The message display shows “pleasewait” and no further operations arepossible

Cannot start

The stitcher head is deviated fromthe specified position.

Display does not advance frompaper size input screen.

No adjustments is carried out whenany key is pressed at the FineAdjustment screen.

Cause

� Faulty adjustment of the side stitchingstopper position

� Incorrect settings of the main power switchand power switch

� Power On/Off is not linked to the upstreamunit

� Only the power of this machine was turnedON

� The upstream unit is not ready to start.

� Error message is displayed

� Size change is required(Error message is displayed)

� Cover was opened, or power was turnedOff while the stitcher head was movingduring size change.

� In the middle of entering values� The entered value is inappropriate.

� Fine adjustments not possible

Solution

� Adjust the position of the side stitchingstopper.

� Refer to “5-1. Power On” and set properly.

� Normally the power On/Off of this machineis operated at the upstream unit. Refer to“5-1. Power On” and set properly.

� Refer to the instruction manual for theupstream unit.

� Refer to “10. Error Messages” and correcterrors.

� Perform the size change.

� While pressing the [Clear key], press the[Size Change key]. The stitcher head willreturn to the home position first, and thenmove to the intended position.At this time, perform this operation again ifany motor error has occurred.

� Complete entering values.� The values which can be entered are

limited according to the selected bindingmode. Refer to “5-3. Binding Settings”.

� The adjustable range is limited to ± 5 mm/± 0.20 inch from the position set at thememory number. Enter the proper value,and perform the size change again. Andthen, carry out fine adjustments.

Fixing screw

Down

Up

Fixing screw

Saddle stitching stopper

Saddle stitching guide

Figure 1

Side stitching guide

Fixing screw

Down

Up

Side stitching stopper




L Side

R Side


Low

Low

Low

Low

High

High

High

High

Figure 3Figure 2

81

14. CLEANING

Shutter

Handle

To prevent accidents, be sure to turn OFF the power before cleaning.

❊ Cleaning the conveyance belt and rollers

� Wipe with a cloth moistened with alcohol.After cleaning, make sure that the alcohol has volatizedcompletely and dried before turning ON the power.

� To clean the belt and rollers, use the handle.Slide the shutter, mount the handle to rotate belts androllers.

NoteNote After cleaning, be sure to close the shutter.If left open, the safety switch functions, and thismachine will not operate.

❊ Cleaning the sensors (Ten spot)

Blow off dusts with air.

Sensor

Sensor

Sensor

Sensor

Sensor

Sensor

Sensor

Sensor

Sensor

Sensor

82

15. SPECIFICATIONSModel name

Model

Paper size

Paper quality

Maximum processingspeed

Stitching capacity

Folding capacity

Noise

Ratings

Size of machine

Weight

DBM-500

Stitcher folder

Saddle stitchingLength 178 to 508 mm/7.01 to 20.00 inchWidth 120 to 356 mm/4.72 to 14.02 inch

Side and corner stitchingB5 LEF, A4 (LTR) SEF/LEF, B4 SEF, LGL LEF

* Some sizes cannot be used. For best results, the length of a sheet should not be more than 2.2times its length.

Saddle stitching and foldingFine quality paper 64 to 127.9 GSM/17 to 33 lbArt and coated paper 84.9 to 157 GSM/ 24 to 41 lbThickness of one set : within 2.5 mm/0.10 inch for normal paper

within 1.5 mm/0.06 inch for heavy papersuch as 127.9 GSM/23lb

Cover sheet : Below 300 GSM/79 lbSide and corner stitching

Fine quality 64 to 127.9 GSM/17 to 33 lbThickness of one set : within 5.0 mm/0.20 inch for 81.4 GSM/22lb,A4/LTR paper

within 3.0 mm/0.12 inch for normal paper

5000 sets/hour (fine quality paper 178 (L) x 120 (W) mm/7.01 (L) x 4.72 (W) inch within five sheets)4500 sets/hour (fine quality 81.4 GSM/22 lb within 10 sheets A4 saddle stitching folding A5 finished)3900 sets/hour (fine quality 81.4 GSM/22 lb within 10 sheets A3 saddle stitching folding A4 finished)

No. of stitches 0 to 2 (Up to 4 possible with options)Stitch thickness Within 5 mm/0.20 inch (fine quality 81.4 GSM/22 lb 50 sheets equivalent)Wire Wire diameter #25 to #27

Below 25 sheets (cover x 1 (300 GSM/79 lb) + 24 sheets (81.4 GSM/22 lb) equivalent)

78 dB (Including scale A, peak)

120 V 60 Hz 6.5 A

When not used: 1610 (W) x 770 (D) x 1020 (H) mm (excludes stitcher head)63.39 (W) x 30.31 (D) x 40.16 (H) inch (excludes stitcher head)

When used: 2230 (W) x 865 (D) x 1300 (H) mm (includes belt stacker)87.80 (W) x 34.06 (D) x 51.18 (H) inch (includes belt stacker)

412 kg/908 lb

Specifications and external view are subject to change without prior notice.

SEF : Short Edge Feeding. Paper travels with its short edge leading.LEF : Long Edge Feeding. Paper travels with its long edge leading.GSM: g /m2

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12J-92804-008110012L

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