Horizon Fitness SPF-9 User manual

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Standard
SPF9 Stapler-Folder
&
FC9 Trimmer
Service Manual

SERVICE MANUAL
Standard Horizon SPF-9/FC-9 Stapler-Folder
Fore-Edge Trimmer
Read this manual, and thoroughly
familiarize yourself with its
contents before operating or
servicing this equipment.
SM_SPF9/FC9

I
STAPLER & FOLDER
FORE-EDGE TRIMMER
US501009-01171808/SPF9FC9/01E/DV
Important Information
- This manual is designed to help you to maintain and repair Stapler & Folder SPF-9 and
Fore-edge Trimmer FC-9. Read, understand and keep this manual in a safe and convenient
place.
- Do not maintain or repair SPF-9/FC-9 until you read and understand the instructions in
this manual.
- Horizon International Inc. shall not be liable for incidental consequential damages
resulting from : improper or inadequate maintenance by customer; unauthorized modifica-
tion or misuse; operation outside of the environmental specifications for the product.
- Horizon International Inc. pursues 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.
SPF-9/FC-9

II
Safety Precautions
- The signal word WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
- The signal word 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.
- Read and understand all safety instructions with signal word such as WARNING and
CAUTION. If safety instructions are ignored, personal injury may result.
- Horizon International Inc. cannot anticipate every possible situation that might involve
a potential hazard. The instructions in this manual and warning labels on the machine are
therefore not all inclusive.
- Do not operate the machines when any covers are removed.
- Some of the drawings in this manual show the machine uncovered for explaining the
detail or inside of machine.

III
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 mm 8 x 10 13 x 17
5. Box Wrench 5.5 mm
6. Snap-ring Expander
1. The following signs in this manual
represent wire color.
Sign Color
BRN Brown
RED Red
ORN Orange
YEL Yellow
GRN Green
BLU Blue
VIO Violet
GRY Gray
WHT White
BLK Black
2. The following abbreviations in this manual
represent electronic and electrical parts.
Abbreviation Meaning
CL Clutch
BK Brake
SW Switch
mSW Microswitch
M Motor
LED Light Emitted Diode
VR Potentiometer
RY Relay
I. Necessary Tool for Maintenance and Repair
II. Signs and Abbreviations in This Manual

IV
Contents
Important Information ..........................................................................................................I
Safety Precautions ..................................................................................................................II
I. Necessary Tool for Maintenance and Repair.....................................................................III
II. Signs and Abbreviations in This Manual .........................................................................III
1. Specifications ...................................................................................................................1
2. Operation Overview ........................................................................................................3
3. Sheet Flow ........................................................................................................................4
4. Drive Section ....................................................................................................................7
5. How to Remove Covers...................................................................................................9
6. Knife Replacement ..........................................................................................................11
7. Troubleshooting...............................................................................................................13
8. Electronic Parts Layout ..................................................................................................21
9. Control Panel LED Descriptions ...................................................................................23
10. Line Diagram .................................................................................................................25

1
1. Specifications
1-1 SPF-9
Function Stapling and Folding, Side Stapling, Corner Stapling, Folding
Sheet Size Stapling and Folding : A3, A4 (11" x 17", 8.5" x 11")
Side Stapling/Corner Stapling : A4 (8.5" x 11")
Sheet Weight 64 gsm ~ 130 gsm (16# Bond to 36# Bond)
Stapling and Folding Thickness up to 20 sheets of 64 gsm / up to 10 sheets of 130 gsm
(14 sheets of 20# Bond)
Side Stapling Thickness up to 20 sheets of 130 gsm (36# Bond)
Corner Stapling Thickness up to 20 sheets of 130 gsm (36# Bond)
Production Speed 2,000 booklets / hour
Stacker Pile Height Stapling and Folding : 40 booklets (A3 - 64 gsm, 10 sheets)
Side Stapling : 100 booklets (A4 - 64 gsm, 10 sheets)
Staple Distance 120 mm (4.7") (Fixed)
Staple Cartridge type, 5,000 staples
Sensor No Staple, Sheet Jam, Misfeed on Collator
Counter 4 digits (No memory)
Machine Size (W x D x H) 1,240 x 621 x 796 mm (48.8" x 24.4" x 31.3")
Machine Weight 154 kg (339.2 lb)
Power 220-240 V 50 Hz, 115-120 V 60 Hz, 100 V 50/60 Hz
Power Consumption 60 Hz : 410 W 50 Hz : 375 W
Options Fore-edge Trimmer FC-9, Delivery Conveyor ED-9

2
1. Specifications
1-2 FC-9
Sheet Size A3, A5, 11" x 17", 5.5" x 8.5"
Trimmed Size Maximum : 323 x 225 mm (12.7" x 8.8")
Minimum : 180 x 105 mm (7" x 4.2")
trimming Thickness 64 gsm 40 sheets (16# Bond : 40 sheets)
Trimming Width Maximum : 13 mm (0.5")
Production Speed 2,000 books/hour
Detector Sheet Jam, Knife Lock, full Trimming
Counter Total Counter
Machine Size (W x D x H) 445 x 621 x 796 mm (17.6" x 24.5" x 31.4")
Machine Weight 101 kg (221 lb)
Power 220-240 V 50 Hz, 115-120 V 60 Hz, 100 V 50/60 Hz
Power Consumption 150 W
The machine design and specifications are subject to change without any notice.

3
2. Operation Overview
2-1 SPF-9
Connecting cable on SPF-9 is connected to collator.
1. Turn on power switch on SPF-9.
On operation panel,
- automatic mode lamp will illuminate.
- stapling & folding lamp will illuminate.
2. Turn on power switch on collator.
3. Pile sheets into collator and set required set up on SPF-9 following "2-1 Operation Procedure"
procedure 5 to 20 (page15 to 18) in SPF-9 Operation Manual.
4. Select automatic mode with function mode select button.
5. Press start button on collator.
- Sheets delivered from collator will be stapled automatically.
6. Press stop button on collator to stop SPF-9.
SPF-9 will stop without pressing stop button in the following cases.
- Sheet jam, misfeed, and double feed occur in collator. Collator lamp on SPF-9 illuminates.
- Sheets are jammed in SPF-9. Sheet jam lamp on SPF-9 illuminates.
- Sheet jam, misfeed and double feed occur
in collator.
- Sheets are jammed in SPF-9.
- Sheets are jammed in FC-9.
- Upper knife stops at the middle of cutting
process.
Cable on FC-9 is connected to SPF-9.
1. Turn on power switch on SPF-9.
2. Turn on power switch on collator.
3. Pile sheets into collator and set required set up on SPF-9 and FC-9 following "2-1 Operation
Procedure" 5 to 20 (page 15 to 18) in SPF-9/FC-9 Operation Manual.
4. Select automatic mode with function mode select button.
5. Press start button on collator.
- Sheet delivered from collator will be stapled and folded in SPF-9 and be cut in FC-9 auto-
matically.
6. Press stop button on collator to stop SPF-9.
SPF-9 will stop without pressing stop button in the following cases.
- Collator lamp in SPF-9 will illuminate.
- Sheet jam lamp on SPF-9 will illuminate.
- Jam lamp will illuminate.
- Knife lock lamp will illuminate.
2-2 FC-9

4
3. Sheet Flow
3-1 SPF-9
There are 2 ways in sheet flow.
I. When "stapling & folding" or "folding" mode is selected with operation mode select
button
1. Sheets enter and hit staple and fold stopper.
2. Sheets are jogged by jog plate and jog guide (F).
3. Sheets are stapled in staple & fold mode.
4. Transport roller (F) unit and transport roller (R) unit lower at the same time staple and fold
stopper rises, and transport belt transports sheets.
5. Sheets pass under gate and stop by hitting stopper in fold section.
6. Fold knife pushes fold part of sheets and fold roller nips sheets and then press rollers press
sheets and sheets are ejected.
II. When "side stapling" or "corner stapling" mode is selected with operation mode select
button
1. Sheets enter and hit side staple stopper.
2. Sheets are jogged by jog plate and jog guide (F).
3. Sheets are stapled.
4. Transport roller (F) unit and transport roller (R) unit lower at the same time staple and fold
stopper lowers, and transport belt transports sheets.
5. Sheets pass above gate and are ejected.

5
Top View from Operation Side
Transport Roller (F) Unit
Staple Unit
Jog Guide (R)
Jog Guide (F)
Jog Roller
Jog Plate
Jog Unit
Operation Side View
Press Roller
Fold Roller
Sheet Hold Roller
Staple & Fold Stopper Unit
Staple & Fold Stopper
Transport Roller (F) Unit
Transport Roller (R) Unit
Side Staple Stopper Unit
Staple Unit
Side Staple Stopper
Jog Roller
Jog Plate
Sheet Feed Guide A
Fold Knife
Gate
Stopper
Sheet Exit
Sheet Entrance
Transport Belt
3. Sheet Flow

6
Upper Transport Belt
3. Sheet Flow
3-2 FC-9
There are two ways in sheet flow.
I. When "stapling & folding" mode is selected with operation mode select button
1. Sheets from sheet entrance hit stopper.
2. Belt stops and sheets are trimmed.
3. Stopper lowers, belt rotates, and then sheets are ejected.
II. When "side stapling" or "corner stapling" mode is selected with operation mode select
button
1. Sheets from sheet entrance pass through FC-9.
Exit Side Entrance Side
Delivery Belt
Stopper Stopper Unit Lower Knife
Upper Knife
Lower Transport Belt
Hold Roller

7
4. Drive Section
4-1 SPF-9
1. Electricity is charged by turning on power switch. Motor will rotate with hand feed mode.
(In automatic mode, motor will rotate as soon as collator starts.)
2. Motor drives reduction belt and reduction pulley. At this point, speed of reduction pulley will
be 1/3 of motor speed.
3. Reduction pulley drives fold rollers and press rollers. When clutch is on, transport belt will be
rotated by clutch pulley.
4. When clutch is turned off, transport belt will stop.
Operation Side View
Timing Belt
Press Roller
Fold Roller
Clutch Pulley Reduction Pulley
Motor
Reduction Belt
Transport Belt
Transport Roller (9 pcs)

8
Delivery Belt
4. Drive Section
4-2 FC-9
1. Electricity is charged by turning on power switch. Motor will rotate with hand feed mode. (In
automatic mode, motor will rotate as soon as collator starts.)
2. Motor drives reduction belt and reduction pulley. At this point, speed of reduction pulley will
be 40 percent of motor speed.
3. Reduction pulley drives upper transport belt and lower transport belt with drive belt. And also
reduction pulley drives delivery belt.
Motor
Reduction Belt Lower
Transport Belt
Upper Transport Belt
Drive Belt
Reduction Pulley
Hold Roller

9
Bind Screw
(M4 x 6) (5 pcs)
Bind Screw
(M4 x 6) (4 pcs)
Bind Screw
(M4 x 6) (4 pcs)
Lower part of side
cover is placed
on two hook plates .
Lower part of side
cover is placed
on two hook plates .
5. How to Remove Covers
5-1 SPF-9
WARNING
- Turn power off before removing any
covers.

10
(1)
(2) (3)
(4)
(5)
WARNING
- Turn power off before removing any
covers.
5. How to Remove Cover
5-2 FC-9
Remove five covers as follows.
(1) Bind Screw M4 x 6 (2 pcs)
The lower part of rear cover is placed on
two hook plates.
(2) Bind Screw M4 x 6 (2 pcs)
(3) Bind Screw M4 x 6 (2 pcs)
The lower part of front cover (L) is placed
on two hook plates.
(4) Bind Screw M4 x 6 (2 pcs)
The lower part of cover (FL) is placed on
two hook plates.
(5) Bind Screw M4 x 6 (2 pcs)

11
6. Knife Replacement
6-1 Upper Knife
Fix Screw
WARNING
- Take care when replacing knife.
Sharp knife can cause severe personal
injury.
1.Remove two cables and slide FC-9 left to
access upper knife.
2.Turn air nozzle up. (2 fix screws)
3.Remove 3 fix screws and take out upper
knife from upper side.
4. Attach new/resharpened knife in the reverse
order of removal.
NOTE
- Apply a small amount of grease on mark
part of knife when upper knife is installed.
Air Nozzle
Fix Screw
Cables

12
6. Knife Replacement
6-2 Lower Knife
Align
1.Remove upper knife referring to page 6.
2.Remove entrance guide. (2 fix screws)
3.Re move 2 entrance lower belts.
Remove sensor connector and entrance
table (4 screws).
4.Remove 4 fix screws and take out lower
knife from lower side.
5.Install new/resharpened knife with reverse
order of removal.
NOTE
- Flash top surface of lower knife with trim
table with knife height adjust screws.
Knife Height Adjust Screw
Fix Screws
Sensor Connector
Entrance
Lower Belts
Entrance Table
Entrance Guide

13
Top View from Operation Side
Adjust Bolt C
Stopper must be
parallel with sheets.
Adjust Bolt B Adjust Bolt A
Rear Frame
Font Frame
Adjust Bolt C
Staple & Fold Stopper
Jog Guide (R)
Jog Guide (F)
Jog plate must be
parallell with sheets.
Jog Plate
Adjust Bolt D
Adjust Bolt D
7. Troubleshooting
7-1 Finishing quality is not good.
7-1-1 Sheets are not jogged neatly.
(Cause)
Jog guide (F), jog guide (R),
jog plate or staple & fold
stopper is (are) skewed.
(Remedy)
Adjust jog guide (F), jog guide (R), jog plate or staple &
fold stopper so that they are parallel with sheets.
1. Adjust jog guide (F) and jog guide (R) so that they
are parallel with front frame and rear frame respectively
with adjust bolts A and B.
2. Adjust staple & fold stopper so that it is parallel with
sheets with adjust bolt Cs.
3. Adjust jog plate so that it is parallel with sheets with
adjust bolt D.
- In case that sheets are still not jogged neatly, refer to
the next troubleshooting. (6-1-2 to 6-1-5)