Horizon Fitness APC-61 User manual

A
PC-61 Revision Control List
Manual No. Date Bulletin Code S/N applied History Page
US504004-00 Jan/17/2001 (First Edition)
1.Correcting the description of "2-11 Hydraulic Pressure Does not Operate." 2-20
2.Correcting the Hydraulic Circuit to (For S/N 100001 to 122899) and (For S/N
123001 or above). 5-3.4
US504004-01 Jun/4/2001 1.Adding precautions on P.C.board and ROM IV
2.Adding the relay in the control bo
x
6-4
3.Correcting producers No. for the rlay 7-8
4.Correcting wiring diagrams 7-6, 7-10, 7-11
US504004-03 Feb/27/2008 1. Adding the 61II-related pages.
2. Correcting the term "cut knife" to the "cutting knife". All Page
3. Correcting the term "back gauge" to the "backgauge". All Page
1
-
9
,
1
-
10
,
1
-
11
,
2
-
23,2-24,2-25,2-
26,2-27,2-28,3-
16,3-17,6-5,6-6,6-
7,6-8,6-9,7-14,7-
15,7-16,7-17,7-
18,7-19

1
Important Information
This service manual is designed to help you to repair and maintain the APC-61 in order to keep it in good operating condition.
Please read and understand the instructions in this service manual before performing any repair or maintenance.
- Horizon International Inc. shall not be liable for incidental or 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 the product. Therefore,
the product design and specifications are subject to change without prior notice and without our legal obligation.
- All rights are reserved. No part of the manual may be photocopied, reproduced or translated to another language without the
prior written consent of Horizon International Inc.
FOREWORD
Paper Cutter
Model APC-61
US504004-03080131/APC61/03E/KY/NT/P6/I9/P7

2
Safety Precautions
- Please read and understand all safety instructions which include the terms WARNING, and CAUTION. If these safety instruc-
tions are ignored, personal injury may result.
- The repair, maintenance and safety instructions in this manual are valid only when the repair or maintenance work is performed
according to the procedures described in this manual.
- 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 on machines. It may
also be used to alert against unsafe practices.
- Horizon International Inc. cannot anticipate every possible situation that might involve a potential hazard. The instructions in this
manual and the warning labels on the machine are therefore not all-inclusive.
- All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation when such operation, repair
or maintenance could cause injury to personnel. Do not attempt to operate any switch, valve, or any electrical device when it has
been locked or tagged out.
- Some of the drawings in this manual show the machine uncovered for explanations of the details inside the machine.

3
Use the following tools for maintenance and repair.
1. Screw Driver No. 2
2. Screw Driver 6 to 7 mm
3. Allen Wrenches 1.5, 2, 2.5, 3, 4, 5, and 6 mm
4. Open-ended Wrench 5.5 x 7, 8 x 10, 13 x 17 mm
5. Box Wrench 5.5 mm
6. Snap-ring Expander
1. The following abbreviations represent wire colors.
Abbreviation Color Abbreviations Color
BRN Brown PNK Pink
RED Red LBL Light Blue
ORN Orange YEG Yellow Green
YEL Yellow YEO Yellow Orange
GRN Green LYE Light Yellow
BLU Blue GND Ground
VIO Violet
GRY Gray
WHT White
BLK Black
2. The following abbreviation represent electronic and electri-
cal parts.
Abbreviation Meaning
CL Clutch
BK Brake
SW Switch
PS Proximity Switch
mSW Micro-switch
M Motor
LED Light Emitting Diode
VR Potentiometer
RY Relay
AS Assembly
I. Necessary Tools for Maintenance and Repair
II. Abbreviations in This Manual
1-
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4
Contents
FOREWORD........................................................................... 1
Paper Cutter ............................................................................ 1
Model APC-61 ......................................................................... 1
Important Information ........................................................... 1
I. Necessary Tools for Maintenance and Repair .................. 3
II. Abbreviations in This Manual .......................................... 3
1. Machine Parts Descriptions
1-1 General View ..................................................................... 1-2
1-2 Operation Panel Descriptions (T61)................................ 1-5
1-3 Operation Panel Descriptions (M61) .............................. 1-7
1-4 Cover Descriptions............................................................ 1-8
1-5 Entering Service Screen (61II)......................................... 1-9
1-6 Calibration of Home position (61II)................................ 1-10
1-7 Checking Motor Home Position Distance (61II)............ 1-11
2. Troubleshooting
2-1 blinks on the Display (Backgauge Does Not Operate)
Part 1 ................................................................................. 2-2
Part 2 ................................................................................. 2-3
Part 3 ................................................................................. 2-4
Part 4 ................................................................................. 2-5
2-2 Cut Size is Not Equal
Part 1 ................................................................................. 2-6
Part 2 ................................................................................. 2-7
2-3 Knife Does Not Lower (Clamp Does Not Lower Either)
Part 1 ................................................................................. 2-8
Part 2 ................................................................................. 2-9
Part 3 ................................................................................. 2-10
2-4 Knife Does Not Lift
Part 1 ................................................................................. 2-11
Part 2 ................................................................................. 2-12
2-5 Clamp Lowers but Knife Does Not Lower ..................... 2-13
2-6 Clamp Does Not Lower Though Foot Pedal
Is Stepped On................... 2-14
2-7 Backgauge Does Not Operate
Part 1 ................................................................................. 2-15
Part 2 ................................................................................. 2-16
2-8 Backgauge Does Not come Forward
(But goes backward) .......... 2-17
2-9 Backgauge Operates By Itself.......................................... 2-18
2-10 Nothing Is Shown on Displays ....................................... 2-19
2-11 Hydraulic Pressure Does Not Operate.......................... 2-20
2-12 Knife Is Down before Operation ................................... 2-21
2-13 Knife Lower Limit Position Varies ............................... 2-22
2-14 Backgauge Does Not Move (61II) ................................. 2-23
2-15 Error Code (61II)............................................................ 2-24

5
3.Adjustment
3-1 Fine Adjustment of Cut Size
(Different is about 0.1 mm) ................. 3-2
3-2 Adjustment of Cut Size
(Different is about between 0.1 and 0.2 mm)................. 3-3
3-3 Rough Adjustment of Cut Size
(Different is about 0.5 mm) ................. 3-4
3-4 Adjustment of Electromagnetic Brake Gap................... 3-5
3-5 Adjustment of Electromagnetic Clutch Gap .................. 3-6
3-6 Adjustment of Knife Replacement Position ................... 3-7
3-7 Adjustment of Knife Lower Limit Position.................... 3-8
3-8 Adjustment of Cutting Line Width ................................. 3-9
3-9 Release of Locked Knife................................................... 3-10
3-10 Pressure Adjustment of Hydraulic Pump .................... 3-12
3-11 Right Angle Adjustment of Backgauge to the Table....... 3-13
3-12 Horizontal Adjustment of Backgauge to the Table ..... 3-14
3-13 Parallel Adjustment of Backgauge to the Knife .......... 3-15
3-14 Backgauge Drive Section Mechanism (61II) ............... 3-16
3-15 Spindle Section Mechanism (61II)................................ 3-17
4.Repair
4-1 Replacing Knife Holder.................................................... 4-2
4-2 Replacing Clamp............................................................... 4-5
4-3 Replacing Backgauge........................................................ 4-8
4-4 Replacing Backgauge Block............................................. 4-9
4-5 Replacing Knife Link A and B......................................... 4-10
4-6 Replacing Clamp Link A and B....................................... 4-11
4-7 Replacing Joint (For Clamp) ........................................... 4-13
4-8 Replacing Joint (For Knife) ............................................. 4-14
4-9 Replacing Rod End ........................................................... 4-16
4-10 Replacing Rod ................................................................. 4-17
4-11 Replacing Encoder .......................................................... 4-18
4-12 Replacing Electromagnetic Brake................................. 4-19
4-13 Replacing Electromagnetic Clutch................................ 4-20
4-14 Replacing Belt (For High Speed)................................... 4-21
4-15 Replacing Belt (For Low Speed).................................... 4-22
4-16 Replacing Motor (For High Speed)............................... 4-23
4-17 Replacing VC Relay and Contactor .............................. 4-24
4-18 Replacing Sensors (Detecting Knife Replacement
Position, Knife Lower Limit Position) ..... 4-25
4-19 Replacing Power Supply ................................................ 4-26
4-20 Replacing Operation Panel ............................................ 4-27
4-21 Replacing Control Board ............................................... 4-28
4-22 Replacing Fuse and Resetting Thermal Relay ............. 4-29
4-23 Replacing Limit Switches............................................... 4-30
4-24 Replacing Knife Holder Upper Limit Position Sensor 4-31
4-25 Replacing Limit Switch
for Clamp Upper Limit Position.................. 4-32
4-26 Replacing Cutting Line Bulb ......................................... 4-33
4-27 Replacing Electromagnetic Valve.................................. 4-34

6
5.Hydraulic Parts
5-1 Hydraulic Parts Description
(For S/N 100001 or above) ............................................... 5-2
5-2 Hydraulic Circuit .............................................................. 5-3
(For S/N 100001 to 122899) .............................................. 5-3
(For S/N 123001 or above) ................................................ 5-4
5-3 Hydraulic Parts Descriptions
(For S/N 099999 or below) ................................................ 5-5
5-4 Hydraulic Circuit (For S/N No.099999 or below) .......... 5-6
6. Electrical Parts Description
6-1 Identification and Location of Motors and Encoder ..... 6-2
6-2 Identification and Location of Sensors and Switches .... 6-3
6-3 Identification and Location
of Components in the Control Box .... 6-4
6-4 Location and Name of Pairs in Control Box(61II) ........ 6-5
6-5 Panel Internal Layout and Name (61II) ......................... 6-6
6-6 Hydraulic Pressure and Motor Unit Layout and Name (61II) .. 6-7
6-7 Backgauge Motor Section Layout and Name (61II) ...... 6-8
6-8 Parameter Settings of Amplifier
for Servo Motor (61II) ........................ 6-9
7. System Wiring and Connections
7-1 Board Connections ............................................................ 7-2
7-2 CPU Board (QPW-162) .................................................... 7-3
7-3 Display Board M61:QPW-175, T61:QPW-176 .............. 7-4
7-4 Control Board (QPW-153D), LED and Main Parts ...... 7-5
7-5 Control Board (QPW-153D) Connector Layout ............ 7-6
7-6 Foot Switch Control Board (QPW-155A) ...................... 7-7
7-7 Foot Switch Control Board (QPW-155A) ...................... 7-8
7-8 Control Box Schematic Diagram ..................................... 7-9
7-9 Wiring Diagram ................................................................ 7-10
7-10 Terminal-1 ....................................................................... 7-11
7-11 Terminal-2 Wiring Diagram (Inside of Control Box) . 7-12
7-12 LED and DSW of Control P.C.B. P083411(QPM-195) (61II) .... 7-14
7-13 LED and DSW of Panel P.C.B. P071811(QPM-157) (61II).. 7-15
7-14 P083411(QPM-195) Connector Connection (61II) ...... 7-16
7-15 New Circuit (Power System) (61II) ............................... 7-18
7-16 Safety Circuit Performance (61II) ................................ 7-19

1-1
1.Machine Parts Descriptions
1-1 Machine Parts Descriptions ...........................................................................1-2
1-2 Operation Panel Descriptions (T61) ..............................................................1-5
1-3 Operation Panel Descriptions (M61) .............................................................1-7
1-4 Cover Descriptions ..........................................................................................1-8
1-5 Entering Service Screen (61II) .......................................................................1-9
1-6 Calibration of Home Position (61II) ............................................................1-10
1-7 Checking Motor Home Position Distance (61II) ........................................ 1-11

1-2
Cutting Depth Adjust Dial
This dial is used to adjust the knife lower limit
position only when Knife Operation Mode
Select Switch is turned off.
Knife Angle Adjust Lever Fix Screw
Knife angle adjust lever is fixed with this screw.
Knife Angle Adjust Lever
The knife angle adjusted with this lever.
Oil Tank
It can contain 40 liter of oil.
Power Switch
The type of this switch is the breaker.
Cutting Knife
Cutting Knife ON/OFF Switch and Lamp
When this switch is turned up, only clamping
will be performed with lamp lighting.
Clamp
This clamp holds sheets not to move the sheets
when they are cut.
(500 to 1,700kg/cm )
APC-T61
APC-T61
HYDRULICCUTTER
HYDRULICCUTTER
7 8 9
4 5 6
1 2 3
0
c
E
P
+-
P
S
+-
S
?
?
.
Paper Clamp Pressure Indicator
Paper Clamp Pressure Adjusting Knob
Backgauge Adjust Knob
This knob is used to adjust backgauge.
Foot Pedal
This pedal is used to lower clamp.
1-1 General View
2