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-
9
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a page that is
related to
APC-61II.

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

1-3
Back Table
Light Switch
When turning up the lever, the table is
lightened up, but it becomes difficult to
see the cut line.
Backgauge
This backgauge is the back stop of
sheets to be cut.
Control Box
Side Guides
These guides are register plates for
preparing the sheets right angle
against cutting knife.
1-1 General View
Pressure Support Plate
Oil Gauge

1-4
Motor encoder Section
The high speed motor, low speed motor,
electromagnetic clutch, brake and en-
coder are housed.
Photoelectric Guard
When there is a foreign object
on the optical line between
photoelectric guards, the ray is
blocked and safety function
operates. Therefore, knife and
clamp does not lower.
Key Switch
APC-T61
APC-T61
HYDRULICCUTTER
HYDRULICCUTTER
7 8 9
4 5 6
1 2 3
0
c
E
P
+-
P
S
+-
S
?
?
.
Cutting Button A
Cutting Button B
This button and cutter A
button must be pressed
simultaneously to start
to cutting operation.
Oil Feed Cover For Backgauge
Backgauge Cover
1-1 General View

1-5
Repeat/Setup Lamp
Knife Operation Mode Select Switch
This switch is used select knife operation
mode, cutting mode or knife replace
mode. In normal operation, this switch
must be set to the cutting mode.
1-2 Operation Panel Descriptions (T61)
Current position
Replacing
knife
ON
Memory
Push-out
Step.No.
Presetting
Repeat Setup
Put-out
Memory
No More
Memory Opar Error
Program No.
APC-T61
HYDRULIC CUTTER
HYDRULIC CUTTER
Program
Setup
789
456
123
0cE
P
+- P
S
+- S
Delete
?
?
.
Push-out Memory Lamp Operation Error Lamp
Key Switch
Memory Button (for the Current Position)
Step Delete Button
Push-out Memory Button
Step Backward Button
Step Forward Button
Repeat/Setup Select Button
In normal operation, this switch must be set to the repeat
mode. (The above repeat lamp lights up.) The size memory
button must be set to the setup mode.(The above setup Lamp
lights up.)
High Speed Backward Button
This button is used to move backgauge
backward at high speed.
Low Speed Forward Button
This button is used to move backgauge
forward at low speed.
High Speed Forward Button
This button is used to move backgauge forward at
high speed.
Power Lamp
Full Memory Lamp
This lamp lights when input memory is full.
Hydraulic Pressure ON/OFF Switch
Hydraulic Pressure Lamp
Memory Button (for the Keypad Input)

1-6
Program Backward Button
Program Forward Button
Program Delete Button
Presetting Size Display
Current position
Replacing
knife
ON
Memory
Push-out
Step.No.
Presetting
Repeat Setup
Put-out
Memory
No More
Memory Opar Error
Program No.
APC-T61
HYDRULIC CUTTER
HYDRULIC CUTTER
Program
Setup
789
456
123
0
c
E
P
+- P
S
+- S
Delete
?
?
.
Program Number Display
Step Number Display
Current Position Display
This display shows the backgauge
current position.
Enter Key
When this key pressed after inputting the number,
the backgauge moves to the set position.
Decimal Point/Clear Key
The decimal point is input in the first press and
the number is deleted for the delete key in the
second press.
Numeric Keypad
1-2 Operation Panel Descriptions (T61)

1-7
Knife Operation Mode Select Switch
This switch is used to replace knife.
In normal operation, this switch must be set
to the cutting mode.
Program Forward Button
Memory Delete Button
High Speed Backward Button
This button is used to move
backgauge backward at high
speed.
Hydraulic Pressure OFF Button
Hydraulic Pressure ON Button
Hydraulic Pressure Lamp
Current Position Display
This display shows the backgauge
current position.
Replacing Knife
Be sure to set "knife Angle
Adjustmant" knob and "Knife
Operation Mode" select
switch to each "Replacing
Knife"Position
Cutting Operation & Knife
Vertical Adjustment
Be sure to set "knife
Operation Mode" select
switch to "cutting"
position
knife Operation
Mode
Memory
Current Position Display
Hydraulic
Backgauge Travel
Power
Repeat / Setup
Memory Delete Program Forward Program Extension
Replacing
Knife
Cutting
Push-out
Memory
Size
Memory
Step Forward
Step
Presetting Program No. Step No.
APC-M61
HYDRULIC CUTTER
1 2 3 4 5 6
1-3 Operation Panel Descriptions (M61)
Low Speed Forward Button
This button is used to move backgauge
forward at low speed.
High Speed Forward Button
This button is used to move backgauge
forward at high speed.
Repeat/Setup Select Button
In normal operation, this switch must be set to the
repeat mode. The above repeat/Setup Lamp lights up.
The size memory button must be set to the setup mode.
(The above setup Lamp lights up.)
Key Switch
Step Forward Button
Size Memory Button
Program Extension Button
Push-out Memory Button
Power Lamp
Step Number Display
Program Number Display
Presetting Size Display

1-8
1-4 Cover Descriptions
Front Cover L
Backgauge Cover
M013345-02
Back Cover B
Back Cover U
Back Cover L
Small Cover
Side Gauge R
Side Gauge L
Rear Cover R
Front Cover
Plate R
Upper Cover
Plate L
Small Cover
Back Cover A
Table R
Lower Cover
Table L
Rear Cover L
Control Box

1-9
612
"Normal Cutting" Screen
"Maintenance" Screen
"Information" Screen
"Numeric Keypad" Screen
Total Count Input
Press the buttons.
"Service" Screen
6
6 1 2
2
ent
ent
1
Motor Home Position Display
Special Functions - are not used.)
Press the button and the [OK] button. Saved cutting programs will be
deleted completely. Deleted cutting programs cannot be restored.
The total counts is memorized on the control P.C.B.
When replacing the control P.C.B.,
1. Write down the total counts before replacing the P.C.B.
2. Replace a new P.C.B.
3.
After replacement, press the button and the [OK] button to clear the total counts of a new P.C.B.
4. Press the button and input the total count number you wrote down.
Press the button and the [OK] button. Home positioning value will be
set to 620.0, and the push-out length will be set to 50.0.
Press the button and the [OK] button. Memorized total counts and
count after replacing knife will be set to zero.
Refer to 1-7 for details.
= Total Count Setting
= Cutting Program Clear
Resetting Home Position and
Push-out Length to Default
=
=
05
01
02
03
04
08
Total Count and Count after
Replacing Knife
When the button is pressed, the
numeric keypad screen appears.
CAUTION
Up to five digits can be entered using the
"numeric keypad" screen at once. Input the
numbers the first three digits and the last
four digits separately
.
04
02
03
04
(
01
1-5 Entering Service Screen

1-10
1. Set the cutting length to 100.0mm.
- This is the temporary value for comparing the
set value with the actual cut length.
2. Cut some sheets.
- Do not align the sheets on the side guide. Align the
sheets only on the backgauge properly, and cut.
3. Measure the dimension of cut sheets.
- Measure the dimension of the sheets by one
decimal place. 100.6mm is given for an ex-
ample here.
4. Obtain the correction value.
- Correction value is a half of the difference
between the set value and the actual cut length.
- The actual cut length is 100.6mm. Therefore,
the correction value is 0.3mm.
5. Enter a new home position. (Fig.2)
- Show the Backgauge Calibration screen.
(Fig.1, Fig2)
- Add or subtract the correction value which was
calculated in step 4 to or from the current home
position value, and enter the new home position
value. (When the actual cut length is larger than
the set value, substract the correction value.)
-
In the case of the example, enter the value which
is subtracted by 0.3 and press the button.
The backgauge will move to the new home
position.
1-6 Calibration of Home Position
504007
1_6_1A
504007
1_6_1B
504007
1_6_1C
The home position
sheet is attached to
the bottom of the
control panel box.
Fig.1 "Maintenance" Screen
Fig.2 "Backgauge Calibration" Screen
Fig.3 Location of the Home Position Sheet
6. Check.
- Follow the steps 1 through 3 and check that the
set value matches the actual cut length.
7. Rewrite the home position sheet.
- The home position sheet is attached to the
bottom of the control panel box shown in Fig.3.
Rewrite the new home position on it.

1-11
1-7 Checking Motor Home Position Distance
Explanation of "Home Positioning"
1. At first, the backgauge moves backward and
B21 home position sensor (Fig.2) detects the
sensor plate and turns on.
2. When B21 turns on, the servo motor M20
rotates in the reverse direction and moves the
backgauge forward, and B21 turns off.
3. The motor stops at the position where Z-phase
from the encoder is detected for the first time
in one rotation of M20. This position is the
home position.
- The encoder is housed in M20.
Explanation of "Motor Home Position
Distance"
- The motor home position distance is the
distance between the position which the B21
home position sensor turns off from on and
the position where the Z-phase from the
encoder is detected for the first time in one
rotation of M20. (steps 2 and 3 above).
- One rotation of M20 servo motor is set to 250
in APC-61II. The position of the home posi-
tion sensor B21 is set so that Z-phase will be
detected at the middle of the motor rotation.
Therefore, the motor home position distance
should be around 125. (Fig.1)
504007
1_7_1A
Fig.1 "Service" Screen
Fig.2 Home Position Sensor B21
404007
1_7_1B
Home Position Sensor
Sensor Plate
B21
Servo Motor
M20
Checking the Motor Home Position
Distance
- The Z-phase cannot be detected correctly
around the area that the B21 home position
sensor turned off from on, and the boundary
line of the first and second rotation of M20.
If the Z-phase appears at these areas, the
encoder may misread it, and detects the Z-
phase which appears next. This will set the
home position to the wrong position.
Therefore, checking the home position dis-
tance is necessary to make sure the encoder
reads Z-phase correctly in the stable area.

1-12
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