Horizon Fitness APC-61 II User manual

I
APC-61II
Important Information
- This manual is designed to help you to install, operate and maintain the APC-61II
Hydraulic Paper Cutter. Please read and understand this manual and keep it in a
safe and convenient place.
- Do not operate the APC-61II until you have read and understood the instructions in
this manual.
- Horizon International Inc. shall not be liable for incidental consequential damages
resulting from: improper or inadequate maintenance by the customer, unauthorized
modification or misuse, or operation outside of the environmental specifications for
the product.
- Horizon International Inc. follows a policy of continuing improvement in design
and performance of this product. Therefore, the product design and specifications
are subject to change without prior notice and without our legal obligation.
- All rights are reserved. No part of this manual may be photocopied, reproduced or
translated to another language without the prior written consent of Horizon Interna-
tional Inc.
080409/APC-61II/03E/HN/TM/HO/P65/I9/P7 UM204018-03

II
Safety Precautions
- The term WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
- The term CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in damage to the machine. It may also be used to warn
against unsafe practices.
- Please read and understand all safety instructions which include the terms
WARNING or CAUTION. If these safety instructions are ignored, personal
injury may result.
- Horizon International Inc. cannot anticipate every possible situation that might
involve a potential hazard. Therefore, the instructions in this manual and the
warning labels on the machine are not all-inclusive.
- All equipment shall be locked out or tagged out to protect against accidental or
inadvertent operation when such operation could cause injury to personnel. Do
not attempt to operate any switch, valve, or other energy isolating device when it
has been locked or tagged out.
- Do not operate the machine when any covers are removed.
- Some of the drawings in this manual show the machine with the covers removed
to explain some of the details inside the machine. Never operate the machine the
covers removed.

III
Operating Precautions
WARNING
This machine must be operated by just one person at a time.
When this machine is not in use, remove the key.
An authorized person should keep the key so that
other people can not run the machine.
Various safety devices are installed on this machine. If any of
these are bypassed or removed, this may cause severe acci-
dent and personal injury.
Each operator should be familiar with the safety instructions,
be aware of the potential dangers, and have sufficient knowl-
edge of how to manage an accident. Anyone who does not
have this training should not operate the machine.
Before starting the machine, be sure to perform the checks
described in Chapter 2: Safety Checks.
When loading the sheets on the table and setting the sheet
position, get your foot off from the foot pedal.
WARNING
Maintenance Precaution
When replacing the knife, wear gloves and do not touch the
edge of the knife directly. The knife is extremely sharp, and
may cause severe personal injury.
OFF
ON
CAUTION
Install this machine on a firm surface that sill support the
weight of the machine.
If you turn the power switch Off, wait 10 seconds or more
before turning it On again.
Do not cut anything besides paper. This may damage the
machine.
Do not place anything in front of the cooling fan. This may
damage the machine.

IV
Contents
Important Information .......................................................................................... I
Safety Precautions .............................................................................................. II
1. Machine Description ....................................................1
1-1 Machine Description ................................................................................. 1
1-2 Control Panel Screen Descriptions ........................................................... 3
1-2-1 Mode Descriptions ..................................................................................3
1-2-2 Cutting - Normal Cutting Screen ............................................................4
1-2-3 Cutting - Key Switch Screen ..................................................................4
1-2-4 Cutting - Program Cutting Screen .........................................................5
1-2-5 Memory- Programming Screen ..............................................................6
1-2-6 Memory- Even Divide Cutting/Total Cutting Screens ...........................7
1-2-7 Memory - Program Select Screen ...........................................................8
1-2-8 Compression Mode Screen .....................................................................9
1-2-9 Maintenance - Knife Replacement Screen ...........................................10
1-2-10 Maintenance - Lubrication Screen ........................................................11
1-2-11 Maintenance - Push-out Length Setting Screen....................................12
1-2-12 Maintenance - Clamp Pressure Adjustment Screen..............................13
1-2-13 Maintenance - Sensor/Switch Signal Monitor Screen ..........................14
1-2-14 Maintenance - Backgauge Calibration Screen ......................................15
1-2-15 Maintenance - Properties Screen ..........................................................16
2. Safety Checks.............................................................17
2-1 Oil Check ................................................................................................ 17
2-2 Power Switch Check ............................................................................... 18
2-3 Hydraulic Pressure Unit Check ............................................................... 19
2-4 Cutting Button Check.............................................................................. 21
2-5 Backgauge Check.................................................................................... 23
3. Basic Operation.......................................................... 25
3-1 Selecting the Control Panel Screen ......................................................... 25
3-2 Entering a Value...................................................................................... 27
3-3 Moving the Backgauge ........................................................................... 28
3-4 Lowering the Clamp and Knife ............................................................... 29

V
4. Operating Procedures ...............................................31
4-1 Cutting Operation on the Cutting Line ................................................... 31
4-2 Cutting Operation by Entering a Value................................................... 33
4-3 Creating a Cutting Program .................................................................... 35
4-3-1 Entering the Values to Create a Program .............................................35
4-3-2 Cutting the Sheets to Create a Program ................................................39
4-3-3 Copying a Program ...............................................................................42
4-3-4 Inserting a Step .....................................................................................44
4-3-5 Deleting a Step ......................................................................................45
4-3-6 Deleting a Program ...............................................................................46
4-3-7 Even Divide Cutting Program ..............................................................47
4-3-8 Total Cutting Program ..........................................................................50
4-4 Using a Cutting Program......................................................................... 53
4-5 Compression Operation........................................................................... 54
4-6 Clamp Support Plate ............................................................................... 55
4-7 Changing the Push-out Length ................................................................ 57
5. Troubleshooting.........................................................59
5-1 The Bottom Sheet Is Longer Than the Top Sheet................................... 59
5-2 There Is a Scratched Line On the Cutting Face ...................................... 59
5-3 The Sheets Are Not Cut Parallel ............................................................. 60
5-4 The Top Sheet Is Marked By the Clamp................................................. 60
5-5 The Sheets Are Contaminated With Grease ........................................... 60
5-6 A Sheet Remains Partly Uncut................................................................ 61
5-7 Some Sheets Remain Uncut .................................................................... 61
5-8 Some Sheets Are Bent Down .................................................................. 61
5-9 An Error Code Appears........................................................................... 62
6. Maintenance ...............................................................63
6-1 Cutting Stick Replacement...................................................................... 63
6-2 Knife Replacement .................................................................................. 64
6-2-1 Precautions for Knife Replacement ......................................................64
6-2-2 Outline and Notes on Knife Replacement ............................................65
6-2-3 Removing the Knife ..............................................................................66
6-2-4 Installing the Knife ...............................................................................69
6-3 Knife Angle and Cutting Depth Adjustments ......................................... 72
6-4 Clamp Pressure Adjustment .................................................................... 74
6-5 Backgauge Home Position Calibration ................................................... 75
6-6 Backgauge Angle Adjustment ................................................................ 76
6-7 Backgauge Parallel Adjustment .............................................................. 77
6-8 Lubrication .............................................................................................. 78
6-9 Oil Replacement...................................................................................... 79
6-10 Cleaning the Cooling Fan ....................................................................... 80

VI
7. Installation Procedures.............................................. 81
7-1 Installation ............................................................................................... 81
7-2 Installing the Control Panel..................................................................... 82
7-3 Connecting the Power Cable ................................................................... 83
7-4 Adjusting the Hydraulic Pump to Match the Frequency (Only for
Machines Used in 400 V Area) .............................................................. 85
8. Appendix ....................................................................87
8-1 Intended Use ........................................................................................... 87
8-2 Specifications ........................................................................................... 87
8-3 Accessories and Tools ............................................................................ 88
8-4 Consumables ........................................................................................... 90
8-5 Index ........................................................................................................ 91

(1)
Machine
Description
OFF
1. Machine Description
1-1 Machine Description
This section describes the machine and the screens on the control panel.
Cutting Button A
Cutting Button B
The knife operates when
both the A and B buttons
are pressed at the same
time. If either the A or B
button is released, the
clamp and knife retract.
Control Panel
Backgauge Motion Buttons
Forward Button
Each time this button is pressed, the backgauge moves
forward by 0.1 mm. When this button is pressed and
held, the backgauge keeps moving forward.
Backward Button
Each time this button is
pressed, the backgauge
moves backward by 0.1 mm.
When this button is pressed
and held, the backgauge
keeps moving backward.
High Speed Motion Button
When this button is pressed and held, and
the backward or forward button is pressed,
the backgauge moves at a higher speed.
Key Switch
When this switch is ON,
it turns on the hydraulic
pump.
Machine Description
Cutting Buttons
Safety Light Beam (Option)
Machine which is equipped with the safety light beam
Cut Line Indicator

(2)
ON
OFF
0
Electrical Box
Side Guide
This aligns to the side edges
of the sheets being cut.
Work Area
Light Switch
Backgauge
This aligns to the rear edges
of the sheets being cut.
Paper Clamp
This keeps the sheets
from moving when
they are cut.
Knife
Power Switch
Clamp Pressure Indicator
Adjusting Knob for
Clamp Pressure
Locking Screw for
Knife Angle Adjusting Lever
The knife angle adjusting lever can
be locked using this screw.
Knife Angle Adjusting Lever
The knife angle can be adjusted with
this lever to get an even cut.
Foot Pedal
Step on this pedal to lower
the paper clamp.
Cutting Depth Adjusting Dial
The cutting depth can be adjusted
using this dial.
1-1 Machine Description
Rear View
Cooling Fan
Do not place anything in front of this.
Cleaning is regularly necessary.
See Section 6-10 for details.
Oil Gauge
The oil level can
be checked here.
- The motor which moves the
back gauge is installed here.
- While the power is ON, this
always vibrates. This is
normal.
Backgauge Cover

(3)
Machine
Description
1-2 Control Panel Screen Descriptions
"Cutting" Mode
Use this mode during a cutting operation.
- Normal Cutting: Enter the cutting length manually for
each cut.
- Program Cutting: The position of the backgauge is set
automatically by a saved program.
See pages 4 and 5 for details.
"Memory" Mode
Use this mode to create a cutting program, including the
length and other settings, and store it as a sequence of
steps.
See pages 6 through 8 for details.
"Compression" Mode
Use this mode to do a compression operation, and
reduce the bulk of the booklet using the clamp pressure.
See page 9 for details.
"Maintenance" Mode
Use this mode to do maintenance (lubrication, knife
replacement and clamp pressure adjustment, etc.), and
to check the condition of the machine.
See pages 10 through 16 for details.
1-2-1 Mode Descriptions
There are four modes for the control screens on the APC-61II.
Control Panel Screen Descriptions

(4)
1-2 Control Panel Screen Descriptions
1 2
3
1
2
3
Cutting Length Input
When this is pressed, the numeric keypad screen appears.
Enter the cutting length using the numeric keypad screen and then press .
The value is entered and the backgauge moves to that position.
Unit Select Button
Each time this button is pressed, the units used on the machine changes: or .
Push-Out Button
When the button is pressed, the sheets are pushed out by the backgauge after each cut.
The backgauge then returns to the set position.
mm inch
ent
=
The key switch must be ON to enter the value.
1-2-2 Cutting - Normal Cutting Screen
Use this screen to enter the cutting length manually and cut the sheets to
that length.
1-2-3 Cutting - Key Switch Screen
This screen appears when the power switch is ON but the key switch is OFF.
This screen indicates that the key switch is
OFF and the machine can not run. When the
key switch is turned ON, the screen changes to
the Normal Cutting Screen which allows the
machine to operate.
This should be used only by service personnel

(5)
Machine
Description
1-2 Control Panel Screen Descriptions
1 2 3
4 5 6 7
8
Current Length Indicator
The current position of the backgauge is indicated here.
Program Start Button
After a program is recalled, when this button is pressed, the machine starts the program cutting
operation from the step displayed in the middle of the list.
Step Heading Button
When this button is pressed, the first step in the program is displayed in the middle of the list.
Step Forward Button
Each time this button is pressed, the next step is displayed.
Step Backward Button
Each time this button is pressed, the previous step is displayed.
Calibration Value /Push-out - Repeat Select Button
Each time this button is pressed, the function changes: (calibration) and (push-out/repeat.)
Step Indicator
These indicate the type of information displayed below: step number, cut length, and push-out distance.
Calibration Value Input
When the value saved by the program needs to be calibrated, enter the calibration value here.
(The adjustable range is 9.9 mm (0.390"). A value beyond the max. or min. cutting length can not be entered.)
1
2
3
4
5
6
7
8
9
Program Number Input
When this is pressed, the Program Select Screen appears. (See Page 8.)
On that screen, press the program number you want to recall, and press the button. The program
will be recalled.
9
1-2-4 Cutting - Program Cutting Screen
This screen is used to cut the sheets using a stored program.
The backgauge is set automatically by the program, so a cutting
operation can be repeated.
Control Panel Screen Descriptions

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1-2 Control Panel Screen Descriptions
1 2 3
5 6 7 8 9
10 11 12
13 14 15 16
4
Step Delete Button
When this button is pressed, the step displayed in the middle of the list is deleted.
Step Insert Button
When this button is pressed, the step displayed in the middle of the list moves down and a new step is
inserted into the program.
Cut Memorizing Button
After setting the backgauge to teh desired position, press this button (image reverses to black), and then cut
the sheets. The cutting length will be entered into memory for the step. By doing this for each step, a cutting
program can be created automatically.
Read Button
When this button is pressed, the current position of the backgauge is entered into the step.
Start Button
After the setup is complete, press this button. The Program Cutting Screen appears and the program can be
used.
Step Number Input
When this is pressed, the Numeric Keypad Screen appears. Enter the
number of the step you want to show, and that step will be displayed.
Cutting Length Input
Enter the cutting length for the step. If you are using the repeat function, enter the cutting width here.
Push-out Button
: After the sheets are cut, they will be pushed out by the backgauge.
: After the sheets are cut, they will not be pushed out.
Repeat Button
: After cutting the sheets, the program does not proceed to the next step, and the backgauge moves into
position to cut the sheets again by the same cutting width.
: After cutting the sheets, the cutting operation proceeds to the next step.
Repeat Frequency Input
If repeat has been selected , enter the number of times the step should be repeated.
If "0" is entered, the machine will continue to repeat the same cut.
Program Number Input
When this is pressed, the Program Select Screen appears.
(See page 8.) On that screen, select the program number
you want recall or save.
Current Length Input
The current cutting length is indicated here. When this
area is pressed, the Numeric Keypad Screen appears.
When the value of the cutting length is entered, the
backgauge moves to that position.
Unit Select Button
Each time this button is pressed, the units used on the
machine change: or
1
2
3
Refer to numbers through in Section 1-2-4 "Cutting Mode - Program Cutting Screen."
Cutting Line
Cutting
Length
Cutting Width
4
5
6
7
8
9
13
~
10 12
4 6
14
15
16
mm inch
Described on the next page
1-2-5 Memory - Programming Screen
This screen is used to create a cutting program, including settings such as cutting
length and other functions, and store them as a program sequence.

(7)
Machine
Description
1-2 Control Panel Screen Descriptions
17
18
19
22
23
25
25
24
21 20 21 20
Even Divide Cutting Screen Total Cutting Screen
Even Divide Cutting/Total Cutting Button
When this button is pressed, the "Even Divide Cutting" or the "Total Cutting" Screen is displayed.
Total Length Input
Enter the total length of the sheets after trimming.
Divide Number Input
Input the number of divisions (more than 2)
Enter Button
When this button is pressed, the current value is entered and the backgauge position for each step is
calculated automatically. Then the display goes back to the "Memory - Programming" Screen.
Screen Back Button
When this button is pressed, the setting is canceled and the display goes back to the "Programming" Screen.
Constant Width 1 Input
Enter the first constant width.
Constant Width 2 Input
Enter the second constant width.
Number of Pieces
Use with the Total Cutting feature. (must be 2 or more)
Clear Button
When this button is pressed, the entered value returns to "0."
17
18
19
20
21
22
23
24
25
1-2-6 Memory - Even Divide Cutting/Total Cutting Screens
Control Panel Screen Descriptions

(8)
1-2-7 Memory - Program Select Screen
This screen is used to select a saved cutting program.
2
3
1
6
4 5
Program Number Button
(White) : This program is empty.
(Gray) : This program has already saved some settings.
(Black) : This program is currently selected.
Screen Back Button
When this button is pressed, the screen goes back to the "Programming" Screen.
Program Select Button
This recalls the selected program.
Program Delete Button
This deletes the selected program.
Program Store Button
This stores the current settings into the selected program. If the selected program
number has already saved other settings, the Overwrite OK Screen appears. Press
OK to replace the old data.
Page Buttons
Use these buttons to see the rest of the programs (up to 99).
1
2
3
4
5
6
Delete OK Screen Overwrite OK Screen
09
03
01
1-2 Control Panel Screen Descriptions

(9)
Machine
Description
1-2-8 Compression Mode Screen
This screen is used to perform a compression operation.
The paper clamp pressure can be used to press the spine of the stitched and folded
booklets and reduce their bulk.
1-2 Control Panel Screen Descriptions
Operation of the cutting buttons in the Compression Mode
1. When the both cutting buttons are pressed, only the clamp lowers.
(After one second or more, even if the cutting buttons are released,
the clamp remains lowered. )
2. When both cutting buttons are pressed again, the clamp lifts.
To release the Compression Mode, display the Cutting Mode Screen on the
control panel, and press both cutting buttons. Now the knife and clamp will
move at the same time.
Control Panel Screen Descriptions

(10)
1-2-9 Maintenance - Knife Replacement Screen
This screen is used when replacing the knife.
If this screen is displayed on the control panel, the machine changes
automatically into the knife replacement mode.
1-2 Control Panel Screen Descriptions
1
2
3
4
1
2
3
4
Cutting Total Counter
This indicates the total number of cutting cycles since the machine was new. This number can not
be cleared.
Clear Button
After replacing the knife, press this button. This clears the Knife Cut Counter.
Screen Back Button.
The screen goes back to the "Maintenance" Mode Screen.
Knife Cut Counter
This indicates the number of cutting cycles counted since the knife was last replaced.
"Knife Replacement" Screen
"Maintenance" Mode Screen
Operation of the cutting buttons in the Knife Replacement Mode
1. When both cutting buttons are pressed, the knife and clamp lower.
2. When both cutting buttons are pressed again, only the knife lifts.
The clamp remains lowered.
3. After that, when both cutting buttons are pressed, just the knife
continues to raise and lower.
To release the Knife Replacement Mode, display the Cutting Mode Screen on
the control panel and press both cutting buttons. Now the knife and clamp will
move at the same time.

(11)
Machine
Description
1-2-10 Maintenance - Lubrication Screen
This screen is used when lubricating the machine.
The positions which require lubrication are shown on this screen.
1-2 Control Panel Screen Descriptions
Maintenance Mode Screen
Lubrication Screen Page 1 Lubrication Screen Page 2
Back Button
Goes back to the Maintenance
Mode Screen
Control Panel Screen Descriptions

(12)
1-2-11 Maintenance - Push-out Length Setting Screen
This screen is used to change the push-out length.
The "push-out" function sets the distance the sheets are pushed forward after they
are cut, so that they can be removed easily.
This is set to 50 mm (1.970") at the factory. The setting is adjustable within the range
of 20 mm (0.785") to 150 mm (5.905").
1-2 Control Panel Screen Descriptions
1
2
1
2Back Button
The display goes back to the "Maintenance" Mode Screen.
Push-out Length Input
This is adjustable from 20 mm (0.785") to 150 mm (5.905").
"Push-out Length Setting" Screen
"Maintenance" Mode Screen

(13)
Machine
Description
1-2-12 Maintenance - Clamp Pressure Adjustment Screen
This screen is used to adjust the paper clamp pressure.
If this screen is displayed on the control panel, the machine changes
automatically into the pressure adjustment mode.
1-2 Control Panel Screen Descriptions
Back Button
Goes back to the Maintenance
Mode Screen
Clamp Pressure Adjustment Screen
Maintenance Mode Screen
Operation by the cutting buttons in the Pressure Adjustment Mode
1. When both cutting buttons are pressed, only the clamp lowers.
Keep pressing both cutting buttons and read the pressure indicator.
- If either button is released, the pressure indicator returns to "0."
- If the pressure gauge returns to "0", press both cutting buttons again to raise the
clamp. Then, press both cutting buttons again to lower the clamp and check the pressure.
To release the Pressure Adjustment Mode, display the Cutting Mode Screen on the control
panel and press both cutting buttons. Now the knife and clamp will move at the same time.
Control Panel Screen Descriptions