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Horizon Fitness APC-61 Manual

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

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Summary of Contents for Horizon Fitness APC-61

  • Page 1 APC-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).

  • Page 3: Important Information

    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.
  • Page 4 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.

  • Page 5: Necessary Tools For Maintenance And Repair

    2. The following abbreviation represent electronic and electri- I. Necessary Tools for Maintenance and Repair cal parts. Use the following tools for maintenance and repair. Abbreviation Meaning 1. Screw Driver No. 2 Clutch 2. Screw Driver 6 to 7 mm Brake 3.

  • Page 6: Table Of Contents

    FOREWORD ................1 2-3 Knife Does Not Lower (Clamp Does Not Lower Either) Paper Cutter ................1 Part 1 ................. 2-8 Model APC-61 ................. 1 Part 2 ................. 2-9 Important Information ............1 Part 3 ................. 2-10 I. Necessary Tools for Maintenance and Repair ....3 2-4 Knife Does Not Lift II.
  • Page 7 4-6 Replacing Clamp Link A and B........4-11 3.Adjustment 4-7 Replacing Joint (For Clamp) ........... 4-13 3-1 Fine Adjustment of Cut Size 4-8 Replacing Joint (For Knife) ..........4-14 (Different is about 0.1 mm) ....3-2 4-9 Replacing Rod End ............4-16 3-2 Adjustment of Cut Size 4-10 Replacing Rod ..............
  • Page 8 5.Hydraulic Parts 7-4 Control Board (QPW-153D), LED and Main Parts ..7-5 5-1 Hydraulic Parts Description 7-5 Control Board (QPW-153D) Connector Layout .... 7-6 (For S/N 100001 or above) ..........5-2 7-6 Foot Switch Control Board (QPW-155A) ...... 7-7 5-2 Hydraulic Circuit .............. 5-3 7-7 Foot Switch Control Board (QPW-155A) ......

  • Page 9: Machine Parts Descriptions

    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...

  • Page 10: General View

    1-1 General View Knife Angle Adjust Lever Fix Screw Knife angle adjust lever is fixed with this screw. Clamp This clamp holds sheets not to move the sheets Knife Angle Adjust Lever when they are cut. The knife angle adjusted with this lever. (500 to 1,700kg/cm ) Cutting Depth Adjust Dial Cutting Knife...
  • Page 11 1-1 General View Light Switch When turning up the lever, the table is Control Box lightened up, but it becomes difficult to see the cut line. Backgauge This backgauge is the back stop of sheets to be cut. Back Table Pressure Support Plate Side Guides These guides are register plates for...
  • Page 12 1-1 General View Key Switch Photoelectric Guard When there is a foreign object on the optical line between photoelectric guards, the ray is blocked and safety function 7 8 9 APC-T 61 APC-T 61 4 5 6 HYDRULIC CUTTER HYDRULIC CUTTER 1 2 3 operates.

  • Page 13: Operation Panel Descriptions (T61)

    1-2 Operation Panel Descriptions (T61) Full Memory Lamp This lamp lights when input memory is full. Push-out Memory Lamp Operation Error Lamp Repeat/Setup Lamp Put-out No More Repeat Setup Memory Memory Opar Error Power Lamp Current position Presetting Program No. Step.No.
  • Page 14 1-2 Operation Panel Descriptions (T61) Step Number Display Program Number Display Numeric Keypad Presetting Size Display Current Position Display This display shows the backgauge current position. Put-out No More Setup Repeat Memory Memory Opar Error Current position Presetting Program No. Step.No.

  • Page 15: Operation Panel Descriptions (M61)

    1-3 Operation Panel Descriptions (M61) Step Number Display Program Number Display Presetting Size Display Step Forward Button Current Position Display This display shows the backgauge Size Memory Button current position. Hydraulic Pressure Lamp Push-out Memory Button Memory Current Position Display Replacing Knife Power Lamp Presetting...

  • Page 16: Cover Descriptions

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

  • Page 17: Entering Service Screen (61Ii)

    1-5 Entering Service Screen "Numeric Keypad" Screen "Service" Screen "Normal Cutting" Screen 6 1 2 Press the buttons. "Maintenance" Screen Total Count Input 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 Motor Home Position Display When the...

  • Page 18: Calibration Of Home Position (61Ii)

    1-6 Calibration of Home Position 1. Set the cutting length to 100.0mm. 6. Check. - This is the temporary value for comparing the - Follow the steps 1 through 3 and check that the set value with the actual cut length. set value matches the actual cut length.

  • Page 19: Checking Motor Home Position Distance (61Ii)

    1-7 Checking Motor Home Position Distance Explanation of "Home Positioning" Checking the Motor Home Position Distance 1. At first, the backgauge moves backward and B21 home position sensor (Fig.2) detects the - The Z-phase cannot be detected correctly sensor plate and turns on. around the area that the B21 home position 2.
  • Page 20 This page is intentionally left blank. 1-12...

  • Page 21: Troubleshooting

    2. Troubleshooting blinks on the Display (Backgauge Does Not Operate) ..2-2 2-2 Cut Size is Not Equal ..............2-6 2-3 Knife Does Not Lower (Clamp Does Not Lower Either) ..2-8 2-4 Knife Does Not Lift ..............2-11 2-5 Clamp Lowers but Knife Does Not Lower ....... 2-13 2-6 Clamp Does Not Lower Though Foot Pedal Is Stepped On.

  • Page 22: Blinks On The Display (Backgauge Does Not Operate) Part 1

    blinks on the Display (Backgauge Does Not Operate) Part 1 Why does blink on the display ? Backgauge is traveled by the screw shaft which is driven by motor. Encoder is installed directly at the back end of the screw shaft, and the operation distance of backgauge is controlled by counting the number of pulse from the encoder.
  • Page 23 blinks on the Display (Backgauge Does Not Operate) Part 2 Phase of power is lacking. There is problem in control board. Backgauge belt is cut. Even if one of the three-phases AC power results in open phase, motor does not operate and blinks on the display.
  • Page 24 blinks on the Display (Backgauge Does Not Operate) Part 3 Coupling of encoder unit is broken Adjust knob is heavy There is problem in encoder. Gauge Rail Encoder is very delicate. When its shaft bends Screw Shaft Coupling because of external shock, it does not operate correctly, even if it is connected with coupling.
  • Page 25 blinks on the Display (Backgauge Does Not Operate) Part 4 Motor has burned out Brake surface smuts. Backgauge is moved by 2 motors. Above all, Brake high speed motor repeats driving in the normal and reverse direction according to using condi- tion.

  • Page 26: Cut Size Is Not Equal

    2-2 Cut Size is Not Equal Part 1 Backgauge position is determined only by Set screw of coupling is loose. Backgauge driving belt is loose. high speed for- and backward buttons. When backgauge is operated only using the high speed forward or backward button, the backgauge can not stop in the correct position because of overrun.

  • Page 27: Cut Size Is Not Equal Part 1

    2-2 Cut Size Is Not Equal Part 2 24VDC is not output from power supply. Gap of clutch or break is not correct. Operation Side 0.15 to 0.30 0.2 to 0.3 Clutch Brake PW-24 Gap of brake should be 0.15 to 0.30 mm. Gap of clutch should be 0.2 to 0.3 mm.

  • Page 28: Knife Does Not Lower (Clamp Does Not Lower Either) Part 1

    2-3 Knife Does Not Lower (Clamp Does Not Lower Either) Part 1 Cutting button A and B are not pressed Knife is not at the upper limit position. Clamp is not at the upper limit position. simultaneously. The cutting operation does not start when either knife or clamp is not at the upper limit For safety, when the timing to press cut but- Control Box...
  • Page 29 2-3 Knife Does Not Lower (Clamp Does Not Lower Either) Part 2 There is an obstruction between beam Some of switches on operation panel remains There is problem in control board. guards. Beam Guards (APC-M61) Memory Current Position Display Presetting Program No.
  • Page 30 2-3 Knife Does Not Lower (Clamp Does Not Lower Either) Part 3 Hydraulic valve does not operate correctly. Grease on clamp rails is not enough to move There is problem in clamp link. the clamp. [Valve Section] Link A Clamp lifts and lowers guided by right and left rails.

  • Page 31: Knife Does Not Lift Part 1

    2-4 Knife Does Not Lift Part 1 When cut buttons are pressed, first clamp lowers. Second, knife lowers to cut . After that, knife stops and does not lift again. (Clamp does not lift either.) Or when you release your hands from cut buttons, knife lifts again. However, Step does not proceed automati- cally.

  • Page 32: Knife Does Not Lift

    2-4 Knife Does Not Lift Part 2 Knife lower limit position sensor does not operate correctly. WARNING Turn off the switch of hydraulic pressure Knife Exchange before the following operation. Other- Position Sensor wise heavy accident will result. Lower Limit Position Sensor When knife is at the upper limit position, measure the voltage between 4 and 5 of CON1...

  • Page 33: Clamp Lowers But Knife Does Not Lower

    2-5 Clamp Lowers but Knife Does Not Lower WARNING When pressed cut buttons, clamp lowers Clamp operates only and knife never at first and knife begins to lower. But Turn off the switch of hydraulic pressure operates, though cut buttons are pressed. knife lifts before it is reached to the before the following operation.

  • Page 34: Is Stepped On

    2-6 Clamp Does Not Lower Though Foot Pedal Is Stepped On. Joint or rod has problem. Stepping Position Detecting Micro switches are out of order (For T-58.) Rod End For machines of S/N 010999 or below, the drawing of rod is as follows. Micro Switch Foot Pedal Check 2 micro switches detecting the position...

  • Page 35: Backgauge Does Not Operate Part 1

    2-7 Backgauge Does Not Operate Part 1 Power is distributed to each motor. Motor coil is burnt out. There is problem with control board, Remove the motor terminals from each termi- nal board and check continuity among 3 Control Box cables.

  • Page 36: Backgauge Does Not Operate

    2-7 Backgauge Does Not Operate Part 2 Adjust knob remains pressed. Any of switches on operation panel remains When any of the switches is out of order or remains pressed, the machine determines setting mode is operated. Therefore, backgauge (APC-M61) does not operate.

  • Page 37: Backgauge Does Not Come Forward

    2-8 Backgauge Does Not come Forward (But goes backward) Limit switch remains ÒONÓ. There is problem with high speed motor. Check of limit switch: See Ò7-5 Control Board, Connector LayoutÓ. Power is supplied to the high speed motor. Coil of high speed motor is burnt out. High speed belt is cut.

  • Page 38: Backgauge Operates By Itself

    2-9 Backgauge Operates By Itself Check knife lower limit position sensor. The voltage of power supply (PW-05) declines. WARNING Turn off the switch of hydraulic system before the following operation. Other- CON7 wise heavy accident will result. View A Control Box Output Sensor Shield...

  • Page 39: Nothing Is Shown On Displays

    2-10 Nothing Is Shown on Displays Fuse for electronic circuit is blown. Distributor does not operate. There is problem with power switch. Check whether the breaker in the distributor is Control Box Check whether the fuse in the distributor is blown.

  • Page 40: Hydraulic Pressure Does Not Operate

    2-11 Hydraulic Pressure Does Not Operate Thermal relay trips. Contactor can not cut electricity because of Any of Phases is Open. heat. The voltage 200V is not supplied among Thermal Relay contactor output terminals 1, 3, and 5. Control Box Thermal Relay 14 6 4 2 Contactor...

  • Page 41: Knife Is Down Before Operation

    2-12 Knife Is Down before Operation After finishing operation of the day before and C spring to return the knife is cut. Oil is leaking at hydraulic hose joint. turning off hydraulic pressure, the oil in Touch the joint between hydraulic hose and hydraulic circuit return to the tank because of each hydraulic parts.

  • Page 42: Knife Lower Limit Position Varies

    2-13 Knife Lower Limit Position Varies [Cause 1: Oil temperature variation] [Cause 2: The timing of lower limit position detection] When this machine is operated for a long time, The oil suited to ISO VG32 should be used. oil temperature rises and viscosity weakens. The signal is sent with about 10msec cycle in Therefore, the speed of hydraulic cylinder this machine.

  • Page 43: Backgauge Does Not Move (61Ii)

    2-14 Backgauge Does Not Move - Check that the drive mechanism of the - Check that grease is applied. - Check that the electrical wiring is correct. machine is not damaged. 200V Block To SD1 (on the page 7-16) Spindle 200V 500VA Servo Motor 504007...
  • Page 44 2-15 Error Code - If an error code which is not included in the following table is displayed, it can be a communication error. Causes and Solutions Error Code Error Details 【Cause】 The knife lower limit sensor B11 did not turn on, although a specific time has passed after the knife started to lower. Check if the lower limit was set too low using the knife up and down adjusting dial.
  • Page 45 2-15 Error Code Error Code Error Details Causes and Solutions 【 Cause 】 When B51L projector of the safety light beam sensor does not light, the B51R receiver turns on. 【 Additional The APC-61II checks the B51 safety light beam sensor every time the cutting operation is done. It checks that the B51R receiver Information1】...

  • Page 46: Error Code (61Ii)

    2-15 Error Code Causes and Solutions Error Code Error Details 【Cause】 The control P.C.B. QPM-195 received an alarm signal from A24 amplifier of M20 servo motor. Turn off the main power switch for 10 seconds and then turn it on again. If this error still appears, refer to the alarm numbers A** below which is displayed on the screen of A24 amplifier.
  • Page 47 2-15 Error Code Causes and Solutions Error Code Error Details 【 Cause 】 Regenerative energy causes the main circuit DC voltage or current inside A24 to excess the specified value. Alarm A30 【 Solution 】 Check if the backgauge is not moved forward or backward in a short period. If it is not moved, check the set value of the parameter P00 on A24.
  • Page 48 2-15 Error Code Caus es and Solutions Error Code Error Details 【 Cause 】 B21 h ome p osition s enso r did n ot turn o n within the s pecific time a fte r hom e po sitioning o pera tion of the backgau ge is sta rted. Hom e po sition of the backgau ge;...

  • Page 49: Adjustment

    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...

  • Page 50: Fine Adjustment Of Cut Size

    3-1 Fine Adjustment of Cut Size (Different is about 0.1 mm) 1. Remove the upper cover. (3 screws on the Upper Cover Screw operation panel) 2. Switch the position of the two switches on the upper left side of the operation panel according to the error condition and the following chart.

  • Page 51: Adjustment Of Cut Size (Different Is About Between 0.1 And 0.2 Mm)

    3-2 Adjustment of Cut Size (Different is about between 0.1 and 0.2 mm) 1. To clarify the difference of the size between 3. Loosen the screws of encoder coupling (2 5. Tighten screws of encoder coupling. indicate size and actual cut size, for example, screws on operation side).

  • Page 52: Rough Adjustment Of Cut Size

    3-3 Rough Adjustment of Cut Size (Different is about 0.5 mm) When the position of the limit switch for 1. Turn off the power switch. 4. Turn on the power switch and check the gap homeposition is shifted, the gap between dis- between actual cut size and indicated size.

  • Page 53: Adjustment Of Electromagnetic Brake Gap

    3-4 Adjustment of Electromagnetic Brake Gap 3. Loosen the nut with wrench between 25 and The gap should be between 0.15 and 0.3mm 28mm. Shim For easier loosening the nut, fit an allen wrench into the screw (SS6-8) fixing large pulley to the shaft.

  • Page 54: Adjustment Of Electromagnetic Clutch Gap

    3-5 Adjustment of Electromagnetic Clutch Gap 3. Remove the snap ring. Do not lose shims at The gap should be between the back of snap ring. (These are for remov- 0.2 and 0.3mm ing the play because of thrust.) 4. Pull out low speed pulley. Armature is fixed at the back of low speed pulley.

  • Page 55: Adjustment Of Knife Replacement Position

    3-6 Adjustment of Knife Replacement Position When replacing knife replacement position 2. Turn cutting depth adjust dial to the left to 4. Loosen 2 hexagon head bolts pointed by the detecting sensor or knife hydraulic cylinder, lower the knife lower limit position detect- arrows and adjust the position of knife the adjustment is needed to keep the position of ing sensor.

  • Page 56: Adjustment Of Knife Lower Limit Position

    3-7 Adjustment of Knife Lower Limit Position When replacing knife lower limit position 3. Remove the paper dust from the cutting stick detecting sensor or the lower limit position of groove and set a new cutting stick. Cutting Depth Adjust Dial new knife is shifted from dial scale “3”...

  • Page 57: Adjustment Of Cutting Line Width

    3-8 Adjustment of Cutting Line Width 2. When double cutting line appears, adjust the When double cutting line appears or after 3. To make the cutting line clear, so that the position of the socket for- and backwards. replacing the lamp, adjust as follows. filament is horizontal.

  • Page 58: Release Of Locked Knife

    3-9 Release of Locked Knife Cause for knife locking To check whether knife is locking To release knife (When washer is not set in the left screw) Knife Holder Clamp Valve Clamp Knife Valve Screw Washer Upper Limit Position Sensor Knife Detection Part [Electromagnetic Valve]...
  • Page 59 3-9 Release of Locked Knife 3. Next, operate the electromagnetic valve by 4. Put washer to the left most screw of the hand to lower the knife holder. knife. For electromagnetic valve [Top view of electromagnetic valve] When pressing 4, clamp lowers. 5.

  • Page 60: Pressure Adjustment Of Hydraulic Pump

    3-10 Pressure Adjustment of Hydraulic Pump The hydraulic pump of this machine is adjust- 3. Press cut buttons and lower knife. Knife able. The pressure can be adjusted with the still remains at the lower limit position even Machine up to serial number pressure adjust screw shown in the following though cut buttons are released.

  • Page 61: Right Angle Adjustment Of Backgauge To The Table

    3-11 Right Angle Adjustment of Backgauge to the Table 1. Loosen lock lever. Backgauge is fixed as the gap between square 2. Loosen lock nut for backgauge angle adjust on the table and backgauge should be under screw for a half turn. 0.1mm.

  • Page 62: Horizontal Adjustment Of Backgauge To The Table

    3-12 Horizontal Adjustment of Backgauge to the Table Backgauge is fixed as it should be horizontal 1. Loosen lock lever. to the table. When the gap is not less than 1.5 Backgauge needs also right angle to the table mm because of parts replacement or use for 2.

  • Page 63: Parallel Adjustment Of Backgauge To The Knife

    3-13 Parallel Adjustment of Backgauge to the Knife Backgauge is fixed as the gap between square 2. Loosen lock lever. on the knife and backgauge should be less 3. Loosen lock nuts of parallel adjust screws - Point for adjustment than 0.1mm.

  • Page 64: Backgauge Drive Section Mechanism (61Ii)

    3-14 Backgauge Drive Section Mechanism Fig 11- Spindle Shims Bearing Fig 11- Servo Motor Fig 11- Timing Pulley (Spindle Pulley) SS5-10 Fig 11- Idle Pulley Fig 11- Servo Amplifier Timing Belt SS5-5 Fig 11- Timing Pulley (Motor Pulley) 404007 3_14_1A 3-16...

  • Page 65: Spindle Section Mechanism (61Ii)

    3-15 Spindle Section Mechanism Backgauge Block Sensor Plate These three pairs of a screw Fig 10- and a nut adjust the gap between the block and the Nut for Spindle gauge rail. Backgauge Home Position Sensor Fig 10- Fig 10- When the backgauge moves backward, B21 detects the sensor plate and turns on.
  • Page 66 This page is intentionally left blank. 3-18...

  • Page 67: Repair

    4.Repair 4-1 Replacing Knife Holder ..............4-2 4-16 Replacing Motor (For High Speed)........... 4-23 4-2 Replacing Clamp ................4-5 4-17 Replacing VC Relay and Contactor.......... 4-24 4-3 Replacing Backgauge ..............4-8 4-18 Replacing Sensors (Detecting Knife Replacement Position, 4-4 Replacing Backgauge Block ............4-9 Knife Lower Limit Position) ..

  • Page 68: Replacing Knife Holder

    4-1 Replacing Knife Holder Frame Hole Upper Cover WARNING During this operation, hydraulic pres- Bridge Joint Part sure is turned on and off. If operated Rear Cover R with wrong order, the machine will be heavily damaged or severe personal Front Cover injury will result to operator.
  • Page 69 4-1 Replacing Knife Holder 14. Remove pin B. This pin is fixed with snap Pin B Pin E ring STW-20. There is a hole on the frame of main body at the back of this pin B. Remove the snap ring at the back from this Pin C Pin D hole and push out this pin from the back side...
  • Page 70 4-1 Replacing Knife Holder [Fixing a new knife holder] 25. Fix pin C with the screw at the upper left 18. Grease the surface (polished part) of the new side of the bridge (section B). knife holder sliding with the main frame. 26.

  • Page 71: Replacing Clamp

    4-2 Replacing Clamp [Remove some parts around clamp] Control Box WARNING 9. Loosen 2 screws of dumper to remove it During this operation, hydraulic pres- dumper. sure is turned on and off. If operated with wrong order, the machine will be 10.
  • Page 72 4-2 Replacing Clamp [Remove clamp] 17. Determine the position of new clamp ac- Rail 14. Turn the power switch and the hydraulic cording to the removal position of step 15 pressure on. Only upper parts combined with and fix right and left rails with 3 screws for clamp lift and clamp remains on the table.
  • Page 73 4-2 Replacing Clamp 20.Turn the power switch and the hydraulic pressure on. Press cut buttons and lift and lower clamp several times. Grease Nipple Rail Lock Nut Hexagon Bolts M5 Screw Rail Frame 21. Turn the hydraulic pressure and power switch off.

  • Page 74: Replacing Backgauge

    4-3 Replacing Backgauge Backgauge is fixed with one handle and a ball 4. Stick 20 blocks on backgauge with a tape so Backgauge on the block under the table. The ball func- that blocks do not come out when turning tions as fulcrum and vertical and horizontal over backgauge.

  • Page 75: Replacing Backgauge Block

    4-4 Replacing Backgauge Block 4. Lift the tip of backgauge about 20mm and pinch something so that it does not fall. Backgauge Handle Lock Nut About 20 mm Angle Adjustment 5. Remove blocks to be replaced and replace Screw them with new ones. Parallel Adjustment Screw 6.

  • Page 76: Replacing Knife Link A And B

    4-5 Replacing Knife Link A and B 2. (This step is not necessary for link B. Go to WANING the next.) During this operation, hydraulic pres- Fix the hook to link A sure is turned on and off. If operated Hook with wrong order, the machine will be Link A...

  • Page 77: Replacing Clamp Link A And B

    4-6 Replacing Clamp Link A and B 1. Remove rear cover, pull up control box on 6. Loosen 3 screws at the end of friction joint Control Box 6 and remove friction joint 6 . (Loosen the machine and screw it. each screw little by little and repeat this Clamp Link A 2.
  • Page 78 4-6 Replacing Clamp Link A and B 11. Insert pin H 10 in joints and fix it with set 17. Pull out the stick inserted in the step 2. screw. 18. Check that clamp is from 100 to 103mm 12. Put joint plate 9 in the shafts of joint A and above the table.

  • Page 79: Replacing Joint (For Clamp)

    4-7 Replacing Joint (For Clamp) 1. Remove parts up to plate according to “4-6 3. Remove snap ring at the bottom of hydraulic Replacing Clamp Link A, B, from the step 1 cylinder and remove cylinder from the to 7”. machine.

  • Page 80: Replacing Joint (For Knife)

    4-8 Replacing Joint (For Knife) Frame Hole When joint can not be removed as follows, do WARNING not remove forcibly but replace the whole During this operation, hydraulic pres- cylinder. Bridge sure is turned on and off. If operated Joint Part with wrong order, the machine will be 1.
  • Page 81 4-8 Replacing Joint (For Knife) 16. Remove joint. 13. Remove hydraulic hose. Hole Link A Joint Hydraulic Pin B When removing hose, oil leaks from hydraulic Cylinder cylinder. Put receiver under the cylinder before removing. Fix elbow with other wrench Cylinder Rod and loosen hydraulic hose with wrench.

  • Page 82: Replacing Rod End

    4-9 Replacing Rod End [Rod Positon seen from the rear of machine] 1. Loosen nuts under rod and pull out washers 7. Insert rod to lower rod end. Step down from and rubber. (Wrench 19mm) foot pedal, insert washer, rubber, nuts and fix them.

  • Page 83: Replacing Rod

    4-10 Replacing Rod 6. Adjust the position of lower nut so that the [Rod Positon seen from the rear of machine] 1. Loosen nuts under rod and pull out washers play (the distance of pedal until clamp starts and rubber. (Wrench 19mm) to lower) when stepping on foot pedal is 2.

  • Page 84: Replacing Encoder

    4-11 Replacing Encoder 1. Remove back cover of the machine. 2. Loosen 4 screws 1 of coupling. (Allen There are two different encoders depending wrench 1.5mm) on S/N of the machine. But these are interchangable each other. 3. Remove 2 screws 2 and pull out encoder unit.

  • Page 85: Replacing Electromagnetic Brake

    4-12 Replacing Electromagnetic Brake The gap should be between 0.15 and 0.3mm 3. Loosen the nut with wrench between 25 and Electromagnetic Brake (Coil) 28mm. Shim For easier loosening the nut, fit allen wrench into the screw (SS6-8) of large pulley to the shaft.

  • Page 86: Replacing Electromagnetic Clutch

    4-13 Replacing Electromagnetic Clutch 3. Replace snap ring. Do not lose shims (to The gap should be between remove the play) at the back of snap ring. 0.2 and 0.3mm 4. Pull out low speed pulley. Armature is fixed at the back of low speed pulley. Handle them together.

  • Page 87: Replacing Belt (For High Speed)

    4-14 Replacing Belt (For High Speed) 6. Put low speed belt and adjust so that the 1. Remove encoder unit according to “4-11 flexure of belt is between 3 and 4mm with Replacing Encoder”. idle pulley when applying the load of 1 kgf to belt.

  • Page 88: Replacing Belt (For Low Speed)

    4-15 Replacing Belt (For Low Speed) 1. Remove encoder according to “4-11 Replac- 6.Fix encoder unit. ing Encoder”. 7.Because encoder was once removed, adjust 2. Remove bracket. the gap between actual cut size and indicated Idle Pulley size according to “Adjustment of Cut Size, 3.

  • Page 89: Replacing Motor (For High Speed)

    4-16 Replacing Motor (For High Speed) 1. Remove encoder according to “4-11 Replac- 9. Adjust tension of belts. ing encoder”. Idle Pulley High Speed Belt Idle Pulley 2. Remove bracket. 3. Loosen idle pulley and remove low speed belt. 3 to 4mm Low Speed Belt 2 to 3mm 4.

  • Page 90: Replacing Vc Relay And Contactor

    4-17 Replacing VC Relay and Contactor Generation First Generation Second Generation Third Generation (Presence) Thermal Relay Control Box B 20 16 14 12 6 4 2 5 4 3 2 1 5 4 3 2 1 VC-1 TYPE FKT-15E (Separative) FKT-15N A 19 15 13 11 PW-05...

  • Page 91: Replacing Sensors

    4-18 Replacing Sensors (Detecting Knife Replacement Position, Knife Lower Limit Position) Before this operation, check each sensor is out 7. Adjust the position of sensor according to Top Cover Knife Angle Adjust Lever of order. “3-6 Adjustment of Knife Replacement Front Position“...

  • Page 92: Replacing Power Supply

    4-19 Replacing Power Supply 1. Remove the cover of control box. 2. Disconnect all the connectors connected with control P.C.B. Let cables connected PW-05(DC5V) PW-24(DC24V) with terminal board TAN-1 remain. 100V 3. Remove 6 screws fixing control board. Control P.C.B Input Ourput Rotate control board in the direction of the...

  • Page 93: Replacing Operation Panel

    4-20 Replacing Operation Panel 5. Disconnect the connector at the back of Lower Cover Upper Cover CPU Board panel and remove panel unit. Display Board 6. Loosen 4 screws of 5 and remove panel. 7. Loosen screw 6 and remove the small Panel board at the back (CPU board).

  • Page 94: Replacing Control Board

    4-21 Replacing Control Board See “7-5 Control Board, Connector Plan“ for Contrl Box connection to terminal board (TAN-1). Terminal Board (TAN-1) Control Board 1.Loosen 4 screws of table cover 1 and 4. Pull out cables connected to terminal board remove table cover. (TAN-1) on the right end of control board.

  • Page 95: Replacing Fuse And Resetting Thermal Relay

    4-22 Replacing Fuse and Resetting Thermal Relay To replace fuse To reset thermal relay Control Box Thermal Relay Control P.C.B For Board For High Speed Motor Tip Bar Reset Button For Low Speed Motor 1. Turn hydraulic pressure and power switch 1.

  • Page 96: Replacing Limit Switches

    4-23 Replacing Limit Switches To replace front limit detection limit switch To replace original detection limit switch To replace backgauge adjust knob detection limit switch Table Table Table SW4 Original Detection SW2 Front Limit Detection 1 SW1 Backgauge Adjust Knob Detection SW3 Front Limit Detection 2 1.

  • Page 97: Replacing Knife Holder Upper Limit Position Sensor

    4-24 Replacing Knife Holder Upper Limit Position Sensor Rear Cover L Front Cover Sensor Detection Part Bracket Upper Limit Position Sensor 1. Remove front cover and rear cover L so that 3. Remove bracket and replace sensor with a upper limit position sensor can be seen. new one.

  • Page 98: Replacing Limit Switch

    4-25 Replacing Limit Switch for Clamp Upper Limit Position Control Box Bracket Actuator Dock Clamp Upper Limit Position Limit Switch Dock Clamp Upper Limit Position Limit Switch 1. Remove transparent table cover. 4. Remove bracket and replace limit switch. 2. Remove rear covers A and B and pull up control box so that clamp upper limit posi- Fix limit switch so that actuator is still tion limit switch can be seen.

  • Page 99: Replacing Cutting Line Bulb

    4-26 Replacing Cutting Line Bulb 1. Pull up control box at the back of the ma- chine and put it on the machine. 2. Bulb holder can be seen at the position of Control Box left drawing. Remove screw and hold bulb attachment knob.

  • Page 100: Replacing Electromagnetic Valve

    4-27 Replacing Electromagnetic Valve 1. Remove apron cover under the table so that 5. Fix a new electromagnetic valve. hydraulic unit can be seen. There are 2 electromagnetic valves. Seen from front If there is dust on attaching side, oil leak will side, right one is valve for clamp, left one is result or it will influence hydraulic operation for knife.
  • Page 101 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).........

  • Page 102: Hydraulic Parts Description (For S/N 100001 Or Above)

    5-1 Hydraulic Parts Description (For S/N 100001 or above) It prevents hydraulic pressure from increasing and makes the lower limit position of knife stable. Spark Killer It absorbs abnormal voltage from elec- tromagnetic valve. Compensator Electromagnetic Valve for Clamp It adjusts the pressure from It lifts or lowers clamp by changing hydraulic pump.

  • Page 103: Hydraulic Circuit

    5-2 Hydraulic Circuit (For S/N 100001 to 122899) High Pressure Hose High Pressure Hose High Pressure Hose High Pressure Hose Pressure Gauge High Pressure Hose Elbow Adapter High Pressure Elbow (MG) High Pressure Nipple Hose Adapter With Different Diameters High Pressure Male and Female Elbow (B2) With Nut And Bolt (A2) Elbow Adapter...

  • Page 104: (For S/N 123001 Or Above)

    5-2 Hydraulic Circuit (For S/N 123001 or above) High Pressure Hose High Pressure Hose High Pressure Hose High Pressure Hose Pressure Gauge High Pressure Hose Elbow Adapter High Pressure Elbow (MG) High Pressure Nipple Hose Adapter With Different Diameters High Pressure Male and Female Elbow (B2) With Nut And Bolt (A2) Elbow Adapter...

  • Page 105: Hydraulic Parts Descriptions (For S/N 099999 Or Below)

    5-3 Hydraulic Parts Descriptions (For S/N 099999 or below) Spark Killer Filter It absorbs error voltage from electro- It filters oil returning to magnetic valve. hydraulic tank. Electromagnetic Valve for Clamp Compensator It lifts and lowers clamp by changing It adjusts the pressure from the direction of oil to clamp hydraulic hydraulic pump.

  • Page 106: Hydraulic Circuit (For S/N No.099999 Or Below)

    5-4 Hydraulic Circuit (For S/N No.099999 or below) High Pressure Hose High Pressure Hose High Pressure Hose High Pressure Hose Pressure Gauge High Pressure Hose Elbow Adapter High Pressure Elbow (MG) High Pressure Nipple Hose Adapter With Different Diameters High Pressure Male and Female Elbow (B2) With Nut And Bolt (A2) Elbow Adapter...

  • Page 107: Electrical Parts Description

    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 Parts 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...

  • Page 108: Identification And Location Of Motors And Encoder

    6-1 Identification and Location of Motors and Encoder Gear Head N o . Names/Roles Capacity Parts No. Parts book M1 Low Speed Geared Motor Three Phase 40W 4002971-00 Fig No.5 M2 High Speed Motor Three Phase 200W 4002990-00 Fig No.5 M3 Hydraulic Motor Three Phase 2.2KW 4003059-00 Fig No.12...

  • Page 109: Identification And Location Of Sensors And Switches

    6-2 Identification and Location of Sensors and Switches SW10 SW11 Names/Roles Parts No. Parts book Manual Operation Knob Detection Switch 4002632-00 Fig No.4-26 Front Limit 1 Detection Switch 4002994-00 Fig No.4-9 SW12 Front Limit 2 Detection Switch 4002995-00 Fig No.4-12 Back Limit and Original Detection Switch 4002994-00 Fig No.4-15...

  • Page 110: Identification And Location

    6-3 Identification and Location of Components in the Control Box Filter Board Noise Filter QPP213 AP3124K View from here Contactor Thermal Relay Spark Killer B 20 16 14 12 6 4 2 3 2 1 5 4 3 2 1 VC-1 A 19 15 13 11 PW-05...
  • Page 111 6-4 Location and Name of Parts in Control Box Code Name Parts Book Circuit Circuit Breaker for Inverter of M10 Fig-13_15 7-14-1 Contactor for M10 Fig-13_13 7-14-1 Circuit Breaker for T20 Transformer Fig-13_23 7-14-1 Circuit Breaker for Lamp Fig-13_12 7-14-1 Circuit Breaker for Switching Power Supply Fig-13_12 7-14-1...

  • Page 112: Panel Internal Layout And Name (61Ii)

    6-5 Panel Internal Layout and Name Code Name Parts Book Circuit Hydraulic Pressure Key Switch Fig-3_7 7-13-1(1/2) P071811 P071811 Touch panel control P .C.B. (QPM-157) Fig-3_9 7-13-1 (QPM-157) Inverter P.C.B. for Backlight Fig-3_3 4012462 6-5-1 Touch Panel Fig-3_10 4012434 6-5-1 4012462 To Main Power and Control P.C.B.
  • Page 113 6-6 Hydraulic Pressure and Motor Unit Layout and Name Code Name CON/LED Circuit Parts Book Related P.C.B. Photo Area Guard 7-14-1 Hydraulic Motor Fig-12_6 (Area Sensor) B50R 7-14-1 Oil Cooling Fan Fig-12_4 Receiver 7-13-1(1/2) Cutting Button B (Right) Fig-4_12 QPM-195 CON17 7-13-1(1/2) Cutting Button A (Left)
  • Page 114 6-7 Backgauge Motor Section Layout and Name Code Name CON/LED Parts Book Related P.C.B. Circuit Operator-Side View Fig-11_10 QPM-195 CON9 7-14-1 Servo Motor Fig-2_10 QPM-195 CON17 7-13-1(2/2) Paper Clamp Supporting Plate SW Fig-8_2 QPM-195 CON5 7-13-1(1/2) Paper Clamp Upper Limit Sensor Fig-6_5 QPM-195 CON5...

  • Page 115: Parameter Settings Of Amplifier

    6-8 Parameter Settings of Amplifier for Servo Motor Setup Procedure For Parameters of the Parameter Numbers and Set ameter Numbers and Set Values Amplifier for Servo Motor Name Value Amplifier for Servo Motor Regenerative Option MITSUBISHI 1. Disconnect the CN1 cable (WHT) of the Auto Tuning uning amplifier for the servo motor.
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  • Page 117: System Wiring And Connections

    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.....................

  • Page 118: Board Connections

    7-1. Board Connections CPU Board It controls the operation of QPW-162 backgauge. APC-T 61 APC-T 61 7 8 9 HYDRULIC CUTTER HYDRULIC CUTTER 4 5 6 1 2 3 [10 keys type, for T-61 only] Panel Board It receives and indicates QPW-176B input.

  • Page 119: Cpu Board (Qpw-162)

    7-2. CPU Board (QPW-162) P-ROM ROM Version Label To PW05-1 To PW05-2 To Panel Board PW-05: 5V Power supply PW-24: 24V Power supply...

  • Page 120: Cpu Board Qpw-162

    7-3 Display Board M61•••QPW-175 T61•••QPW-176 To Flat Cable 40P Control Board CON2 Power Supply Lamp CPU Board RED 12 Back Side WHT 9 QPW-162 GRN 4 ORN 3 CON2 BRN 1 Key Switch CON1 To Control Board CON5-10 To Control Board CON5-7 To Control Board CON5-4 Micro Switch for Clamp support plate To Control Board CON5-1...

  • Page 121: Control Board (Qpw-153D), Led And Main Parts

    7-4. Control Board (QPW-153D), LED and Main Parts CON3 CON5 Surge absorber SSR1 (Varistor) Knife lowering CON4 SSR2 Knife lifting SSR3 Hydraulic Pump Clamp lowering SSR4 Front Limit Clamp lifting SSR5 and SSR6 Phases Change Back Limit SSR6 200V Backgauge forward operation High Speed Motor Input Power Supply SSR7...

  • Page 122: Control Board (Qpw-153D) Connector Layout

    7-5 Control Board (QPW-153D) Connector Layout To CPU Board-CON1-1 To CPU Board-CON1-4 To CPU Board-CON1-7 To CPU Board-CON1-10 GRN in 58 SSR1 CON3 CON5 To Foot Switch Control Board CON2-5 SSR2 To Foot Switch Control Board CON2-6 100V To TAN-1/8 To Foot Switch Control Board CON2-3 To VC-1/13 To Thermal Relay-96...

  • Page 123: Foot Switch Control Board (Qpw-155A)

    7-6. Foot Switch Control Board (QPW-155A) Connector Wirings CON3 CON5 Empty Empty Empty Empty CON2 To Control Board TAN1-14 GRN 5 To Control Board TAN1-13 To Control Board TAN1-12 WHT 3 To Control Board TAN1-11 To Control Board TAN1-10 BLK 1 To Control Board TAN1-8 Empty To Hydraulic Valve, Knife Valve A (Lowering)
  • Page 124 7-7. Foot Switch Control Board (QPW-155A) Relay Locations CON3 CON5 CON2 CON4 CON1 N o . Names/Roles Parts No. Producers No. Parts book Ry1 Knife lowering relay 4001190-06 AP-3124 Fig No.6 Ry2 Clamp lowering relay 4001190-06 AP-3124 Fig No.6 Ry3 Clamp lowering relay 4001190-06 AP-3124 Fig No.6 Clamp lowering relay 4001190-06 AP-3124...

  • Page 125: Control Box Schematic Diagram

    7-8 Control Box Schematic Diagram Lighting Bulb 24V12WX3 Cutline Bulb IL-6P 5V3A 24V12W RS-8-5 Control Board CON-7 5V Power Supply SSKD Control Board 100A OPW-153 24V0.5A RS-8-24 R" 24V Power Supply R" S" S" Fuse VC-2 BNK122101N F3321-6P Toggle SW 100V S-421T Light ON/OFF Switch...

  • Page 126: Wiring Diagram

    7-9 Wiring Diagram (Up to S/N 116899) Terminal-1 TAN-1 The color in ( ) is the old wiring. Clamp Support Plate Shield 7-10...
  • Page 127 7-9 Wiring Diagram (From S/N 117007) Clamp Lamp Relay S/N117001 or above Toggle Switch Terminal-1 TAN-1 The color in ( ) is the old wiring. Clamp Support Plate Shield 7-11...

  • Page 128: Terminal-1

    7-10 Terminal-1 MC-1=Connector 1 MC-2=Connector 2 MC-2 To Control Board CON3-1 View from here To Control Board CON3-4 MC-1 Shield To Control Board CON3-5 Control Board CON6-1 Shield To Control Board CON3-6 Control Board CON6-3 Shield To Control Board CON3-2 Control Board CON6-2 To Control Board CON3-3 4 5 6 7 8...

  • Page 129: Terminal-2 Wiring Diagram (Inside Of Control Box)

    7-11 Terminal-2 Wiring Diagram (Inside of Control Box) To Fuse U To TAN1-9 To Contactor A To Fuse V' To TAN1-8 View from here To VC Relay A To PW24-4 To Control Board CON4-10 To PW24-5 To Control Board CON4-13 To Cut line Table Light To Transformer 24V To Fuse U...

  • Page 130: Led And Dsw Of Control P.c.b. P083411(Qpm-195) (61Ii)

    7-12. LED and DSW of Control P.C.B. P083411(QPM-195) Lighting Condition B10 paper clamp upper limit sensor is ON DSW1 Remarks B12 knife upper limit sensor is ON Not Used B13 knife replacement position sensor is ON DSW1 Used Not Used Safety Light Beam Sensor B11 knife lower limit sensor is ON Used...
  • Page 131 7-13. LED and DSW of Panel P.C.B. P071811(QPM-157) QPM-157 Board Name P071811 (QPM-157) Panel Control P.C.B. SW1 Setting Set the switch to down. DSW1 1 2 3 4 When using the touch panels 1: 3 CON 5 manufactured by SHARP CON 4 CON 10 CON 3...

  • Page 132: P083411(Qpm-195) Connector Connection (61Ii)

    7-14. P083411(QPM-195) Connector Connection X100 CON3 CON1 SM-8P P071811 Output (To Panel) Input (To Panel) Touch Panel Knife lowering Valve Control P.C.B. CON8 (QPM-157) CON19 SIG (Y10) Knife Raising Valve CON4 + 24V GND(Y10) GND (24V) SIG (Y11) GND(Y11) CON11 Paper Clamp Lowering Valve SIG (Y12) GND(Y12)
  • Page 133 7-14. P083411(QPM-195) Connector Connection (Continued) With Photo Area Guard CON13 X101 CON1 SL-04 BLU/BRN CON16 Panel SW1 BLU/RED Photo Area Guard B50R Panel SW2 Receiver BLU/ORN Panel SW3 BLU/YEL QPW-553 XS20 CON14 CON17 P083411 BLU/BRN BLU/RED Paper Clamp Photo Area Guard B50P BLU/ORN Main Control P.C.B...

  • Page 134: New Circuit (Power System) (61Ii)

    7-15. New Circuit (Power System) Power System SD4 24V 12W X 4 Cutting Line Lamp 24V 12W BL Connector BL Connector Toggle SW 415V 200V ( 240V ) 400V ( 220V ) 380V ( 208V ) To SD1 (5A) XM21 Oil Cooling Fan BLU/RED AC400V...

  • Page 135: Safety Circuit Performance (61Ii)

    7-16. Safety Circuit Performance Knife and Paper Clamp Control Circuit Raising and lowering of a knife and paper clamp are controlled Half-Second Circuit on Cutting Buttons by this control circuit. 1. The condenser charges electricity when either S10 or S11 cutting button is not pressed. 1.
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