Horizon Fitness AFC-566F Manual Download Page 1 | Manualshive

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• This manual is designed to help you to install, operate and maintain the AFC-

566F Cross Folder. Please read and understand this manual, and keep it in a
safe and convenient place.

• Do not operate the AFC-566F 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 the customer,
unauthorized modification or misuse, or 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 this manual may be photocopied, reproduced

or translated to another language without the prior written consent of Horizon
International Inc.

Important Information

CROSS FOLDER

CROSS FOLDER

AFC-566F

170228/566F/32E/TI,TM,AT/F7/ICS5.5/PXI

UM203051-32(000)

*UM203051*

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Summary of Contents for AFC-566F

Page 1: ...zed modification or misuse or 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 this manual may be photocopied ...

Page 2: ...hich includes important information Follow the note to operate the machine safely This symbol indicates a prohibited action Do not perform any prohibited action This symbol indicates an essential procedure Follow the procedure to operate the machine safely Important This lists the range of acceptable values and operating conditions Attention This information will help you to avoid problems with th...

Page 3: ...e power switch before adjusting the machine unless instructed otherwise If the Start button is pressed the machine may move suddenly and cause severe per sonal injury Turn off the power switch before resetting the circuit breakers Otherwise the machine may start suddenly causing severe personal injury CAUTIONS for Operation Be sure to install the buckle chutes and conveyors correctly Otherwise the...

Page 4: ...IV WARNINGS for Installation Be sure to attach the cables hoses tubes in the areas where a foot cannot be caught ...

Page 5: ...your hands and fingers while the roller is rotating Other wise your hands and fingers may be caught by the rotating roller Do not insert your hands and fingers inside the cover There are gears inside and your hands and fingers may be caught by the gears When you lower the suction head bar be careful not to catch your finger Do not insert your fingers into the slit of the feed head while the feed t...

Page 6: ...ontrol Box 14 1 1 15 Pump Section 15 1 1 16 Control Panel 16 1 1 17 Sub Control Panel 17 1 1 18 Remote Controller 18 1 2 Touch Panel Description 19 1 2 1 Initial Screen 19 1 2 2 Main Function Screen 19 1 2 3 Main Condition Screen 20 1 2 4 Main Options Screen 21 1 2 5 Set Up Fold Pattern Screen 22 1 2 6 Set Up Guide Buckle Screen 23 1 2 7 Set Up Register Mark Position Entering Screen 24 1 2 8 Set U...

Page 7: ...s on Buckle Chute below Knife 81 4 11 Checking the Fold Quality 82 4 12 Other Adjustments 83 4 12 1 Feed rotor section adjustment 83 4 12 2 Buckle gate adjustment 85 4 12 3 Gap adjustments inside the buckle chutes 86 4 12 4 Gap adjustments between the buckle chutes and fold rollers 87 4 12 5 Stopper angle adjustment 88 4 12 6 Fold knife angle adjustment 89 4 12 7 Adjustment of the hold down roller...

Page 8: ...ivery conveyor does not run 114 6 8 3 The pump pressure does not increase when you turn the regulator knob 115 6 8 4 The pump does not run 115 6 8 5 The motor does not run when the Start button is pressed 115 6 8 6 The display does not appear when the main power is turned on 115 6 8 7 The gate fold buckle chute does not operate 116 6 8 8 Sheets cannot be fed continuously 116 6 9 General Folding Pr...

Page 9: ...ng the Conveyor and Accessories 144 8 6 Connecting the Power Cables 145 8 7 Pump Rotation Direction 145 8 8 Date and Time Setup 146 8 9 Checks After Installation 146 9 Appendix 9 1 Specifications 147 9 2 Accessories 148 9 3 Consumables 152 9 4 Options 153 9 5 De commissioning and Dismantling 154 9 6 Static and Dynamic Load Testing 155 ...

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Page 11: ...tion Suction Head Section The vacuum piston pulls up the top sheet and separates it from other sheets The suction head section changes position automati cally to match the sheet length Page 4 Power Switch Page 8 Control Panel LCD Register Guide This panel is used to control the folding operation Page 16 Page 15 Conveyor Section Page 13 Sub Control Panel Section Page 17 Feed Rotor Section This roto...

Page 12: ... in the roller is not engaged with the wheel Cross Folding Exit Section Buckle Chutes K1 and K2 Handwheel When the wheel is pulled out and rotated the fold rollers can be turned manually When the wheel is pressed in the rollers are not engaged with the wheel Feed Table The maximum stack height is 740 mm 29 1 Feed Table Knob This wheel moves the feed table to the front and rear The handwheel may tu...

Page 13: ...e 14 Door for Buckle Chute Below the Knife Open this door to remove buckle chute K2 If this cover is opened while operation the machine stops Control Box This contains the circuit breakers Page 14 Power Connector to Round Feeder option Power Connector to Gate Fold Buckle Chute option Conveyor Power Connector Communication Connector to Press Stacker option 1 1 3 Overall View 3 Top Cover If this cov...

Page 14: ...ght of the blower air nozzles Sheet Hold down Pres sure Adjusting Knob This knob adjusts the pressure produced by the sheet hold down bar against the sheet The higher the setting on this knob the greater the hold down pressure Sheet Hold down Bar This holds down the rear edge of the stack The suction head section adjusts position automatically during changeover to match the sheet length 1 1 4 Suct...

Page 15: ...ation Air Separation air is blown between the upper most sheet lifted by the vacuum piston and the lower sheet which is held by the separator Support Release Lever Suction Head Support Lifting Handle Suction Head Arm This supports the arm when it is raised Communication Connector for Round Feeder option Connector for Suction Head Lock Nut Piston Set Screw Vacuum Piston This piston catches the top ...

Page 16: ...he top sheet is about 9 to 11 mm Double Feed Stop Plate Adjusting Knob Table Sensor When the feed table Down button is pressed the table lowers until it reaches this sensor When there are sheets on the table and the Down button is pressed the table stops with the top of the stack even with the sensor Press Down again to lower the table all of the way Double Feed Stop Plate Normally you should not ...

Page 17: ...the feed table front or back When this wheel is turned clockwise the table moves to the rear The rear edge of the stack must be held by this guide This guide adjusts position automatically to match the sheet width 1 1 7 Side Air and Feed Table Front Side Air Adjusting Knob Side Air Hose When large and heavy sheets are used and sheets are not fanned using only the front air set the side air hose to...

Page 18: ... Guide Angle Adjusting Knob Adjust the guide angle using this knob so that the sheet is driven through the guide Turn the knob clockwise to move the right side of the guide to the front Register Guide Set this guide so that it supports the edge of the sheet This prevents the sheet edge from dropping and caus ing a sheet jam Transport Balls There are Nylon balls and steel balls The sheet is driven ...

Page 19: ...te release the buckle chute using this lever Buckle Stopper and Deflector This stopper is set automatically to match the sheet size and fold pattern The stopper setting position can be adjusted on the screen Buckle Stopper Adjusting Knob This knob moves only the end of the stopper on the operator side of the machine The angle of the stopper is adjustable Locking Knob for Buckle Stopper Adjusting K...

Page 20: ...all the blades with the correct orientation on the shaft facing the right way Each blade is split into two halves and is supplied this way Always use the two halves together Drive Rollers The sharp edges of the blades can cause severe personal injury Wear cutting proof gloves or wrap the blade with cloth when handling Also install remove the blades after pressing the Emergency Stop button WARNING ...

Page 21: ...his knob is driven by a motor Do not turn it by hand Buckle Stopper Adjusting Knob The angle of each stopper is adjust able This knob adjusts just the stopper on the operator side Jam Detect Sensor This triggers the fold knife and detects any sheet jams Hold Down Roller This roller holds the tail edge of the sheet Do not change the position The standard position is the middle of the scale Locking ...

Page 22: ...ear of the machine Buckle Chute K1 Stopper Adjusting Knob This part of the knob moves only the right end of the stopper Locking Knob for Buckle Stopper Adjusting Knob Buckle Chute Locking Knob If the sheet does not enter the buckle chute turn this knob to extend the gate Gate Scale The standard position is the middle of the scale Loosen the knob to remove the buckle chute Buckle Chute K1 Stopper D...

Page 23: ...justing Wheel Turn this wheel and match the conveyor section height to the exit section height Height Adjust Handle Locking Lever Catch Rollers Adjust the positions of these rollers to match the length of the delivered folded sheet Conveyor Switch Speed Control Knob The speed of the conveyor can be changed using the speed control knob Angle Adjustment Knob This side can be angled to deliver sheets...

Page 24: ...riginal position 23051 10114A1 Q10 Main Inverter Circuit Breaker Q12 Circuit Breaker for Drive Motor Below Knife Q20 Feed Table Motor Circuit Breaker Q21 Pump Circuit Breaker Q00 Main Power Circuit Breaker Q12 Knife Servo Amplifier Circuit Breaker Q30 Circuit Protector for Gate Fold Buckle Chute Q50 Circuit Protector for Conveyor Q11 Main Motor Circuit Breaker Q01 Circuit Protector 1 1 14 Power Bo...

Page 25: ... This gauge is used to check the air pressure Control the air pressure using the pressure regulator knob In normal use this is set to about 0 03 to 0 04 MPa 4 5 to 6 psi Do not set the air pressure higher than 0 07 MPa 10 psi Vacuum Regulator Knob Pressure Regulator Knob Vacuum Gauge This gauge is used to check the vacuum Control the vacuum using the vacuum regula tor knob In normal use this is se...

Page 26: ...heet Reverse Jog Button When this button is pressed the sheets move in the reverse direction Normal Jog Button When this button is pressed the sheets move in the normal direction Feed Table Down Button When this button is pressed the feed table starts to lower until it comes to the table sensor position Press the button again and the table lowers to the lowest point If the Down button is pressed w...

Page 27: ...utton Press this button to stop all machine operation 23051 10117A1 Motor Start Feed Start Button If the button is pressed once while the feed table Up button is lit the motor runs If the button is pressed again a sheet is moved into the fold section for the folding operation This button lights while the sheets are feeding and blinks in the Setup mode Motor Stop Feed Stop Button If this button is ...

Page 28: ...er is shown here Turn the jog dial to change the roller gap The roller gap which is currently selected on the remote controller is shown in blue Roller Gap Shown In Blue This is the item that is currently selected by the remote control ler Item Highlighted In Green The setting for the guides and stoppers can be changed Each jog 0 1mm The setting for the roller gaps can be changed Each jog 5 µm 0 0...

Page 29: ...culated based on the operation speed and the number of sheets and is displayed here Job Indicator The current job appears here Pause Time Enter the pause time here Preset Mode Select Buttons The sheets are fed continuously without using the preset function When the number of fed sheets reaches the preset count number the feeding action pauses for a set time This creates a gap between the sets on t...

Page 30: ... Double Multiple Feed Detection Knife Delay Time The feed interval is automatically made longer when the knife delay time is increased The taller the level bars on the display the longer the knife delay time When the delay time is set to the minimum the knife lowers at the moment when the sheet hits the knife stopper Belt Speed This sets the speed of the fold roller and transport belt Max 240 mete...

Page 31: ...e stacker connected to this machine is shown here The setting listed below is available only when the optional PST 40 press stacker is connected This displays the number of sheets included in each set Offset Mode Other Folders The folder connected to this machine is shown here Kick The stacker offsets one sheet when it reaches the preset set count number Shift The stacker offsets a batch of sheets...

Page 32: ...to match the fold pattern Sheet Length Width Press one of the sections and the Numeric Keypad screen appears Enter the dimension Sheet size Max 850 0 X 558 0 mm or 34 0 X 21 965 Min 148 0 X 128 0 mm or 5 830 X 5 040 OK Button Once this button has been pressed the fold pattern and sheet size are entered and the Guide Buckle screen appears Sheet Surface Reverse Select Button To reverse the sheet pre...

Page 33: ... adjusted automatically during changeover The manualcontrol function for the suction head and table guide is used when using the optional round feeder ON RegisterMark Position Entering Screen Press this button to open the Register Mark Position Entering screen See page 24 for details Roller Gap Locking Button When you change the value for number of sheets on the Setup Roller Gap screen and then en...

Page 34: ...not move tot match the changed register mark position Entering a Value When you want to change the value press this area to open the Numeric Keypad screen Enter a new value After entering a new value press to set the guides and buckle chutes automatically to match the new register mark position Default Button When you press this button the following screen is displayed O K O K Press this to return...

Page 35: ...nging the values of the roller gaps These areas indicate the buckle chutes and knives being used This opens the Roller Gap Fine Tune screen See the next page for details Increase the Gap Each time this button is pressed the roller gaps increase by one sheet Actually the roller gaps do not change until the button is pressed Send each roller to the home position then to the gap setting Send each rol...

Page 36: ...ness has been changed by adjusting knob press the Thickness Calibration button to update the displayed value To reflect this value to the roller gap press on the Roller Gap screen These select the rollers to be adjusted Press this button to return to the Roller Gap screen Thickness Zero Point Adjusting Button Press this button without a sheet on the sheet thickness detector The zero point will be ...

Page 37: ... If you will be doing knife folding install the knife stopper after the automatic setup 4 If the distance from the knife to the side edge of the sheet is less than 95 mm 3 8 install the front and rear side guides at the positions shown Remove the side guides before doing the auto matic setup If the distance from the knife to the side edge of the sheet is less than 95 mm 3 8 after the automatic set...

Page 38: ...h Panel Description 23051 10210A1 All Reset Button This button resets all fourteen mechanisms at the same time Single Function Reset Buttons Each button resets one of the mechanisms Condition Indicator After each reset function is completed the symbol appears If the reset is not completed for some reason the symbol appears OK OK If all section turns the Check Instruction screen appears ...

Page 39: ...Write Press here to store or memorize the job using the job number listed to the left If the same job number has been used before the older job information will be overwritten The job information will be stored and the Completion screen will appear Memory Recall Press here to recall the job you selected in the list The machine parts will not move to their set positions yet Job Number This section ...

Page 40: ...hine appears here T otal F eeding Counts The total n umber of the sheets run through the machine appears here T otal RunTime The total run time of the machine in hours appears here Time Setting This indicates the current time The time can be reset Date Setting This indicates the current data The data can be reset Press this area and the Numeric Keypad screen appears Input the date using the Numeri...

Page 41: ...ssage screen the count returns to zero Filter Cleaning Alarm for Pump Filter Cleaning Alarm for Cooling Fan This is used to set the time to display the alarm for cleaning the air filter of control box When the power on hours reach a set time a message screen will be displayed on the next power up See page 121 for details Use the screen as an indicator for frequency of a cleaning When you press on ...

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Page 43: ...etector Page 38 3 Setting the Fold Pattern Sheet Size and Job Name on the Touch Panel Screen Or recalling a saved job on the touch panel screen Page 38 4 Setting the Positions of the Guides and Buckle Chutes Page 41 5 Loading the Sheets on the Table Page 43 6 Setting the Suction Head Page 46 7 Setting the Register Guide Page 50 8 Setting the Perforation Blades Page 51 9 Setting the Knife Fold Sect...

Page 44: ...ng the Sheet Feeding Angle Page 59 4 Correct Fold Skew in Parallel Folding Page 60 2 2 Overview of Fine Tuning 23051 20201A1 Condiiton Screen Guide and Buckle Chute Screen 23051 20201B1 23051 20201C1 23051 20201D1 Roller Gap Screen Roller Gap Fine Tune Screen For Fine Tuning Adjustments ...

Page 45: ... Line to the Fold Knife Page 67 7 Setting the Perforation Blades and Scoring Blades Page 71 8 Setting the Knife Fold Section Page 75 2 2 Overview of Fine Tuning Guide and Buckle Chute Screen 23051 20201E1 23051 20201F1 Guide and Buckle Chute Screen 13071 20201G1 23051 20201H1 Knife Stopper Rear Side Guide Front Side Guide Operator Side ...

Page 46: ... 88 Fold knife angle adjustment 4 12 6 Page 89 Adjustment of the hold down roller pressure in the fold section 4 12 7 Page 90 9 Correct Fold Skew on Buckle Chute Below Knife Page 77 10 Correct Parallel Shifts on Buckle Chute Below Knife Page 81 11 Checking the Fold Quality Page 82 2 2 Overview of Fine Tuning 23051 20201I1 Roller Gap Screen Roller Gap Micro Adjusting Screen For Fine Tuning Adjustme...

Page 47: ...Power Switch 3 Basic Setup Turn on the power switch The LCD display presents the Initial screen Next the Fold Pattern screen is displayed 3 1 Turn On the Power Switch Initial Screen Setup Fold Pattern Screen 23051 30101A1 X Cross ...

Page 48: ...other custom fold pattern has been selected the Sheet Insertion Instruction screen appears on the display Go to step 5 on the next page Enter the register mark position 3 2 Setting the Fold Pattern and Sheet Size A Set the fold pattern and sheet size for a new job If the folding pattern you wish to start is not listed among the seventeen available patterns press on the screen If is pressed the she...

Page 49: ...ay If the custom fold pattern function has been selected see steps to If you are not using the custom fold pattern go to page 41 Do this only if you are using a custom fold pattern X button Enter the stop per positions for any buckle chutes which will be used 3 2 Setting the Fold Pattern and Sheet Size OK The keyboard screen does not appear in the following cases If the Zero Setup button is presse...

Page 50: ...want and press The Recall Confirmation Screen appears Press OK The job is recalled and the Completion Screen appears Press OK The Guide Buckle screen appears 3 2 Setting the Fold Pattern and Sheet Size The knife stopper is automatically moved to the maximum setting for knife folding The knife guides are automatically set to match the sheet width Setup Guide Buckle Screen 23051 30201E1 Setup Guide ...

Page 51: ...d the suction head is about 50 mm 2 Remove any sheets on the feed table The table guide may hit the sheets during the automatic setup 2 Remove the knife stopper 3 Remove the sheet guide in the knife fold sec tion 4 Remove the sheet holder in the register sec tion 3 3 Setting the Positions of the Guides and Buckle Chutes Setup Guide Buckle Screen Check Instruction Screen 1 23051 30301A1 CAUTION Do ...

Page 52: ...he sheet width is less than 95 mm 3 8 Remove the side guides for small sheet if the sheet width is 95 mm 3 8 or more 3 Install the sheet guides in the knife fold section 4 If a mechanism fails to reach to the home posi tion the Error Screen appears Use the error code to tell which mechanism did not reach the correct setting Fins out why the part could not move to the correct position Press OK on C...

Page 53: ...pped from lowering by pressing the Feed Table Up button while the table is moving 23051 30401A1 23051 Suction Head Bar Support Support Locking Bar Fan the sheets correctly Load the sheets so they are aligned with the table guide Align the head edge of the stack with the feed head The maximum stack height is 740 mm 29 1 The maximum stack weight is 250 kg 551 lb When you load the coated papers of 54...

Page 54: ...79 2 Adjust the position using Guide Buckle screen 3 Raise the feed table 3 4 Loading the Sheets on the Table 23051 30401D1 If the stack is not arranged correctly and the set register pin does not fit against the tail edge of the stack straighten the stack If the stack is not arranged correctly the feeding action may become uneven 23051 30401I1 Feed Standby Screen CAUTION Do not adjust the suction...

Page 55: ...eets to the front 1 Turn the feed table knob and move the sheet to the front 2 Decrease the value for the table guide by required amount using Guide Buckle screen The table guide moves to the front Position the sheet hold down bars If the sheets are thin or narrow move the bars inward If the sheets are thick or wide move the bars outward If necessary attach and adjust the air guides Set the guides...

Page 56: ...ld angle adjusting knob If double feeding occurs frequently increase the grip area direction shown by arrow 1 or loosen the locking screw first then increase the separator angle direction shown by arrow 2 For thin sheets reduce the sheet hold angle 1 1 2 4mm 23051 30501A1 2 1 Grip Area Width Adjusting Knob 2 Sheet Hold Angle Adjust ing Knob Separator Locking Screw If the vacuum piston feeds two sh...

Page 57: ...s and the blower pressure adjust ing knobs About 10 to 15 sheets at the top of the stack should be separated 3 5 Setting the Suction Head 23051 30501C1 23051 30501D1 Vacuum Regulator Knob Vacuum Gauge PressureRegulator Knob Pressure Gauge In normal use both of the blower pressure adjusting knobs are set evenly If the sheets are distorted on both sides of the suction cup because the sheets are curv...

Page 58: ... air 3 5 Setting the Suction Head MAX 0 0 23051 30501G1 Separation Air Pressure AdjustingKnob When the mark on the knob is moved upward as far as possible the air blowers produce the maximum output About 10 sheets at the top of the stack should be separated MAX 0 23051 30501I1 Front Air Adjusting Knob 10 sheets 23051 30501H1 Front Air Nozzles Front Air Nozzles ...

Page 59: ...because the air does not reach to the end of the sheet Use the side air to separate the edges of the sheets After adjusting the air press the Feed Stop button on the control panel 3 5 Setting the Suction Head 23051 30501J1 Front Side Air Adjusting Knob Front air Maximum Side air Off Front air Off Side air Maximum 23051 30501K1 ...

Page 60: ...ends on the stiffness of the sheet 23051 30601B1 Sheet Holder Arrange the steel and plastic balls to control the sheet smoothly See the drawing to the right When the top of the sheet is touching the stopper in the first buckle chute place plastic balls near the bottom of the sheet If the sheet is large or heavy replace these with steel balls If the sheets rise too close to the register guides redu...

Page 61: ...ring this operation Otherwise a sharp blade can cause severe personal injury Do not touch the blades WARNING Setup Roller Gap Screen 23051 30701B1 When you press this button this button turns orange The upper perforation shaft is lifted and the upper blade is separated from the lower blade The upper perforation shaft returns to the original height Return the perforation shaft after moving the uppe...

Page 62: ...rt by 10 mm 0 4 Move the upper drive rollers and lower drive rollers apart 3 7 Setting the Perforation Blades 23051 30701E1 Upper Drive Roller Lower Drive Roller If you are not doing perforating 13071 30701F1 Lower Blade Upper Blade More than 4 mm 0 4 23051 30701G1 Upper Drive Roller Lower Drive Roller ...

Page 63: ...performing knife folding Loosen the locking screw and remove the trans port roller 3 8 Setting the Knife Fold Section When the sheet width is less than 95 mm 3 8 attach the knife side guide for small sheets at the positions indicated on the Setup Guide Buckle Screen 95mm 23051 10209E1 Setup Guide Buckle Screen 23051 30801B1 23051 30801A1 Side Guide Match the arrow with the scale Only when the shee...

Page 64: ...n of the folded sheets Angle a conveyor table a little so that the tail end of the sheet falls and it is delivered smoothly without interrupted by the next sheet To adjust the angle of the conveyor table turn the angle adjusting knob lifting the table a little 3 9 Setting the Conveyor Section 23051 30901A1 Knife Folding 23051 30901B1 Parallel Folding 23051 30901C1 Height Adjusting Wheel Angle Adju...

Page 65: ... conveyor switch to Run If the speed adjusting knob is set to LOW fully counterclockwise the conveyor does not drive Turn the knob to the middle position at least Now the basic setup is complete See Chapter 4 for instructions on fine adjustments 3 9 Setting the Conveyor Section 23051 30901D1 13071 30901D1 Catch Roller Locking Knob 23051 30901E1 LOW HIGH RUN STAND BY SPEED CONTROL UNIT POWER ALARM ...

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Page 67: ...ly the perforation line will run straight Also if the speed is slow the delivered sheets will be arranged neatly If the belt speed is changed after the other sections of the machine have been adjusted the folding quality may deteriorate Set the belt speed first If you change the belt speed be sure to check the folding quality The belt speed may need to be changed depending on the paper quality pri...

Page 68: ... If double feeding or misfeeding occurs refer to section 6 1 If an Error Icon Appears on the Screen and adjust the feed section again See page 97 for details Feed a sheet by pressing the Normal Jog button and check that the sheet is aligned correctly with the register guide If the sheet is not aligned with the register guide replace the plastic balls with steel balls or increase the number of ball...

Page 69: ...e angle repeating step 4 in section 4 2 4 3 Checking the Sheet Feeding Angle If the reverse side of the sheet is fed bring the sheet up to the second buckle stopper When the sheet is very close to the buckle stopper feed the sheet using the handwheel 23051 40301A1 23051 40301B1 Rear Front Handwheel First Buckle Stopper 23051 40301C1 Register Guide Angle Adjusting Knob If the sheet is not trimmed c...

Page 70: ...e the first gap on the rear wider or make the first gap on the front narrower 2 Make the second gap on the rear narrower or make the second gap on the front wider 4 4 Adjusting Fold Skew in Parallel Folding In normal operation set the roller gaps on each side evenly If the gaps are not even this can cause the sheet to wrinkle and the scoring or perforation line will not run straight Only the first...

Page 71: ...lay the Roller Gap Fine Tune screen 2 Select the roller gap to be adjusted Touch the desired roller on the screen or press or buttons to select the roller gap The selected roller is displayed in blue 3 Change the gaps Increase by 5 µm Decrease by 5 µm After you press the or buttons the gaps are actually adjusted a few seconds later Adjusting one side only Adjusting both sides at once 4 4 Adjusting...

Page 72: ... value of the thickness of one sheet will change 4 Press on the Roller Gap screen All roller gap will be actually changed 4 4 Adjusting Fold Skew in Parallel Folding 23051 40401D1 300 5 m m 300 5 m m Setting the Roller Gap The roller gap is 305µm The roller gap is 295µm 23051 40401I1 80 Setup Roller Gap Fine Tune Screen 0 1 0 1 0 2mm 200 m 20351 40401J1 20351 40401K1 Setup Roller Gap Screen Thickn...

Page 73: ...ller 5 Press All roller gap are set for one sheet 6 Remove the sheet holders in the register guide section 7 Take the same type of paper you will run and tear it into strips Insert one strip into the roller gap 8 Adjust the roller gap on the screen so that the rollers turn slowly when you pull out the strip 9 Adjust the roller gap on both sides by the same amount 4 4 Adjusting Fold Skew in Paralle...

Page 74: ...is weak Increase the roller gap When the sheet is thick and the sheet grain is perpendicular 90 to the fold line The fold line may not be stable because the sheet is strong and is not folded tightly Decrease the roller gap When the roller gap in the middle is wider than at the ends When gap in the middle is wider because the rollers are worn out get the correct gap in the middle by tightening the ...

Page 75: ...er 5 When you will be doing knife folding go to section 4 1 4 5 Adjusting Parallel Shifts in Parallel Folding 23051 40501B Each time you press the or buttons the stopper position changes Once the value has been entered using the numeric keys press to adjust all the stoppers at once When changing the setting for buckle stopper after the sheet number in roller gap has been changed in Roller Gap scre...

Page 76: ... The cor rection value is the difference between the setting and the actual length of the last panel Enter the value using the Numeric Keypad screen When the last panel is shorter than the buckle enter a negative value Press The set values for the buckle 1 through 6 are automatically recalculate and the positions of the buckle stoppers are adjusted 4 5 Adjusting Parallel Shifts in Parallel Folding...

Page 77: ...Normal Jog button Check that the perforation line is aligned with the knife by viewing from point A as shown in the figure to the right Adjust the positions of the blades following the steps below if necessary 1 Adjust the position of the perforation blade Loosen the locking screw of the blade holder and adjust the position of the blade right and left 2 Adjust the position of the register guide so...

Page 78: ...oller is set evenly Also check if the sheet hits the side guides 4 6 Matching the Perforation Line to the Fold Press the Emergency Stop button before making this adjustment Otherwise the machine may start suddenly and cause severe personal injury Do not touch the blades Wear cutting proof gloves while making this adjustment Otherwise a sharp blade can cause severe personal injury WARNING 13071 406...

Page 79: ...position is aligned with the knife by viewing from point A as shown in the draw ing for step 2 Adjust the feeding position of the sheet using the screen 4 6 Matching the Perforation Line to the Fold Knife B If not doing perforating 3 1 2 23051 40601F 23051 40601G1 Knife Stopper Desired Fold Position Register Mark 23051 40601H1 If the fold line is shifted to parallel direction When the register gui...

Page 80: ... fine adjustments to rollers 3 4 5 6 and 7 4 6 Matching the Perforation Line to the Fold Knife When the desired fold line register mark is skewed in relation to the knife 23051 40601J1 Knife Guides Adjust the front knife guide first and then adjust the rear knife guide to match the sheet size If the or button for the front knife guide is pressed the rear knife guide is adjusted in the same directi...

Page 81: ...er guide section Press the Emergency Stop button Open the safety cover Move the sheet to a point just before the perforation shaft using the hand wheel 4 7 Setting the Perforation Blades and Scoring Blades If you perform the perforation or scoring with the unfolded sheet the perforation or scoring line may not run straight Press the Emergency Stop button before starting this operation Otherwise th...

Page 82: ...per foration shafts lifting levers The levers are installed on both the front and the rear 2 Loosen the upper scoring wheel and adjust the lower wheel holder to the operating position then tighten the holder using the set screw 3 Turn the handwheel so that locking screw comes to the position to be loosened 4 Loosen the lower scoring wheel and align the groove of the lower scoring wheel with the po...

Page 83: ...r so that the perforation line will run straight Attach the driver rollers evenly from the perfora tion blade 4 7 Setting the Perforation Blades and Scoring Blades Setup for optional center cut blade Each upper blade is made in two halves The position of the upper blade can be changed by loosening the holder and mov ing the spacers Before installing a new set of upper blades make sure the two halv...

Page 84: ...en the strips are pulled out Check that the wheels do not inter fere with each other Separate the upper and lower blades or wheels 4 7 Setting the Perforation Blades and Scoring Blades 23051 40701K1 13071 40701J1 Drive Roller If not doing perforation and scoring When not doing perforating or scoring the drive rollers are not used Separate the upper and lower drive rollers Scoring Blade Position Pe...

Page 85: ...e handwheel Check the gap between the sheet and the front knife guide Standard gap is 0 5 mm to 1 0 mm 0 02 to 0 04 If the gap is not within this range adjust the value for the front knife guide on the Setup Guide Buckle screen 4 8 Setting the Knife Fold Section 2 4 3 1 23051 40801A1 23051 40801B1 Handwheel If the or button for the front knife guide is pressed the rear knife guide is also adjusted...

Page 86: ...lding section 4 8 Setting the Knife Fold Section Set each knife guide so that the leaf springs on the knife guide push against the sheet a little Change the value for the rear knife guide to adjust the knife guide position When the or button for the rear knife guide is pressed only the rear knife guide is adjusted Sheet Sheet Sheet 23051 40801E1 Leaf Springs Setup Guide Buckle Screen 23051 40801F1...

Page 87: ...e right side 4 9 Adjusting Fold Skew on Buckle Chute below Knife Normally the roller gaps should be the same on each side If the gaps are uneven this can cause the sheet to wrinkle and the fold line will not run straight Even if the roller gaps are set the same on each side the folded side of the sheet may be delayed This depends on the sheet material the sheet thick ness and the sheet grain If th...

Page 88: ...screen or press or buttons to select the roller gap The selected roller is displayed in blue 3 Change the gaps Increase by 5 µm Decrease by 5 µm After you press the or buttons the gaps are actually adjusted a few seconds later Adjusting one side only Adjusting both sides at once 4 9 Adjusting Fold Skew on Buckle Chute below Knife Adjusting each roller gap Setup Roller Gap Screen Setup Roller Gap F...

Page 89: ...owly when the strip is pulled out 6 Increase the roller gap by the same amount on both sides 4 9 Adjusting Fold Skew on Buckle Chute below Knife WARNING Turn off the main power before checking the roller gap The relationship between sheet grain and roller pressure When the sheet is thin and the sheet grain is parallel to the fold line The sheet may not be folded correctly because the sheet is weak...

Page 90: ...e Adjust the buckle stopper angle referring to section 4 12 5 4 9 Adjusting Fold Skew on Buckle Chute below Knife 23051 41206A1 Fold Knife Angle Adjusting Knob Locking Knob The standard position is the middle of the scale 23051 41205B Knife Stopper Adjusting Knob Locking Knob Fixed Knob Buckle K1 Stopper Adjusting Knob Locking Knob Fixed Knob ...

Page 91: ...ime you press the or but tons the stopper position changes When a new value is entered using the numeric keys press to adjust the stopper When changing the setting for buckle stopper after the sheet number in roller gap has been changed in Roller Gap screen use the Micro Adjusting buttons If the value is changed using Numeric Keypad screen the roller gap is recalcu lated and the sheet number enter...

Page 92: ...tops feeding the sheet Press the Feed Stop button again to stop the transport motor Check the fold quality If the fold quality is satisfactory go to Chapter 5 Starting and Running the Job If the fold quality is poor go to Chapter 6 Trou bleshooting and resolve the problem 4 11 Checking the Fold Quality 23051 40701A1 23051 40701B1 23051 40411A1 If you press the Feed Stop button twice in a short per...

Page 93: ... the vacuum is not strong enough to separate the sheets move the sheets closer to the feed rotor If coarse or porous sheets are loaded provide more space between the sheet and the feed rotor Adjust the space using the feed table sensor adjust ing knob In normal operation the space is 8 mm 0 31 when the feed table reaches the upper limit point When the table sensor is raised the gap between the she...

Page 94: ...he posi tion using the set screw If using thick or curled up sheets Move the suction point 2 to 3 mm 0 07 to 0 12 to the right so that the sheet is not caught by the feed rotor or taken around the rotor The sheet should be straightened so that it will feed reliably 4 12 Other Adjustments Double feed stop plate adjustment Double Feed Stop Plate Adjusting Knob Suction point To Center Left Right 2305...

Page 95: ...gate adjusting knob There are gate adjusting knobs on front and rear Adjust both knobs evenly The center of the gate scale marks the standard gate position Thick sheets will not be folded correctly if the gate is extended too far 4 12 Other Adjustments 4 12 2 Buckle gate adjustment 23051 41202A1 Gate Adjusting Knob Gate Plate Gate Scale Standard Position Adjust the gate within the range of the gat...

Page 96: ...row Make the gap wider 4 12 Other Adjustments 4 12 3 Gap adjustments inside the buckle chutes Measure between the upper guide and the gate for the gap inside the buckle chute The standard gap setting and the adjustable range are as follows 1st buckle chute 0 5 mm 0 02 Adjustable between 0 5 1 5 mm 0 02 0 06 2nd buckle chute 0 8 mm 0 031 Adjustable between 0 5 1 5 mm 0 02 0 06 3rd and 4th buckle ch...

Page 97: ...e lock nut 4 12 Other Adjustments 4 12 4 Gap adjustments between the buckle chutes and fold rollers The gap can be reduced by turning the bolt in Allow a minimum gap between the lock nut and bolt of 1 mm 0 04 to prevent the buckle chute and roller from hitting CAUTION Make the same adjustment on each side If the gap between the buckle chute and fold roller is set too narrow and the buckle chute is...

Page 98: ...ustments 4 12 5 Stopper angle adjustment 23051 41205B Knife Stopper Adjusting Knob Locking Knob Fixed Knob Buckle K1 Stopper Adjusting Knob Locking Knob Fixed Knob 1 23051 40201G1 Align the deep groove to parallel the fold roller and the stopper Buckle Stopper Adjusting Knob Locking Knob Fixed Knob The fixed knob is rotated by a motor Do not turn it by hand This will change the home position for t...

Page 99: ...lowing the procedure listed below 1 Loosen the locking knob 2 Turn the knife angle adjusting knob to adjust the angle When the knob is turned in the direction shown by the arrow in the figure the left side of the fold knife moves down 3 Tighten the locking knob 4 12 Other Adjustments 4 12 6 Fold knife angle adjustment 23051 41206A1 23051 41206B1 Left Side Right Side Fold Knife Angle Adjusting Knob...

Page 100: ... pushing in turn the adjuster Pull out the adjuster so that the pin holds it in place 4 12 Other Adjustments 4 12 7 Adjustment of the hold down roller pressure in the fold section 23051 41207A1 Hold down Roller 23051 41207B1 Adjuster 23051 41207C1 Increase the roller pressure Increase the roller pressure 23051 41207D1 Pin ...

Page 101: ...ine remains stopped until the Feed Start button is pressed The machine stops and sounds the buzzer after feeding the preset num ber of sheets The machine resumes running the sheets after a short pre set time delay 2 If or is selected set the preset number If is selected 3 set the pause time The pause time can be set up to 9 9 sec 4 Set the batch counter The machine stops after completing the prese...

Page 102: ...Set the gap or distance between the sheets Set the interval according to the sheet intersection inside the buckle knife operation and the way the sheets are output on the delivery conveyor When Default is pressed the value is set to the default value The relation between the feed rotor suction time and the feed interval is illustrated in the figure below Initially select the function If you want t...

Page 103: ...heets Icons below are display only when photoelectric detec tion is selected Set the brightness of the double feed detecting lamp When detecting thick sheets 100 gsm or thicker or sheets with lots of dark printing use the brighter setting Set the sensitivity of the double feed detection The bigger the level bar is the higher the sensitivity If the sensor misdetects the correct feeding as dou ble d...

Page 104: ...r offsets a batch of sheets when it reaches the preset set count number Kick The stacker offsets one sheet when it reaches the preset set count number 5 1 Set up the Main Screen Main Options Screen 1 2 23051 50102G1 PST 40 5 1 2 3 4 5 5 1 5 2 3 4 1 5 2 3 4 1 5 2 3 4 1 2 3 4 1 2 3 4 KICK COUNT SHIFT COUNT 23051 50102H1 ...

Page 105: ...and the vacuum piston picks up a sheet The fold rollers and feed rotor start to run Press the Feed Start button again The sheet is fed into the register guide 5 2 Starting Folding 23051 50201A1 23051 50201B1 Adjust the drive speed of the conveyor according to the overlap length of the sheet LOW HIGH RUN STAND BY SPEED CONTROL UNIT POWER ALARM 23051 50201C1 Speed Control Knob 23051 50201B1 ...

Page 106: ...ing Folding The misfeeding icon appears on the Error screen and the machine stops when the last sheet on the table is fed Lower the table and reload the sheets on the table and raise the table again Press the button on the Error screen and repeat the process from step 2 OK Error Screen 23051 50201D1 23051 50201E1 Main Function Screen 23051 50201F1 Job Record Screen Working Time ...

Page 107: ...the feed rotor 48 5 Set the double feed stop plate in a lower position 84 6 Reduce the distance between the sheet hold down bars on the suction head 45 7 Adjust the air guides so that they do not hold the sheets as strongly 45 8 Set the blower air outlet in a lower position 47 9 Increase the pump vacuum using the vacuum regulator knob 47 10 Adjust the suction point of the feed rotor 84 11 Raise th...

Page 108: ...de 234 Sheet jam is detected by the sheet pass sensor Or double feed is detected by the double feed sensor while the motor is running When the machine is connected to RFU 54 sheet jam is detected by the rotor section sheet pass sensor or the gate section sheet pass sensor on RFU 54 Or double feed is detected by the double feed sensor on RFU 54 while the motor is running Sheet jam is detected by th...

Page 109: ...ck that the roller gap is adjusted correctly 61 4 If the sheet stops between the perforation scoring section and the knife fold section increase the pressure of the hold down roller nearest to the perforation scoring section 87 6 1 If an Error Icon Appears on the Screen 1 3 2 Description Jam Code 132 After a sheet entered the register guide the sheet did not reach the knife timing sensor within th...

Page 110: ...e error on the downstream device Check if the cable of the downstream device is connected cor rectly PSX 56 Error Error code 560 Clear the error on the PSX 56 Double Feed Sensor Cleaning Error code 238 Turn off the power switch and clean the double feed detect pho toelectronic sensor 135 Sheet Thickness Detection Error Error code 239 The sheet thickness has not been saved correctly Do the test fee...

Page 111: ...eck that the feed table lowers nor mally 500 Check that the cable for the optional press stacker is connected correctly If the optional stacker is not used install the short circuit connector 1000 Turn off the power switch for 30 seconds and then turn it on again If this system error occurs repeat edly call your local dealer 1001 to 1031 If this system error occurs repeatedly call your local deale...

Page 112: ...r occurs repeat edly call your local dealer 2080 to 2150 If this system error occurs repeatedly call your local dealer 3010 to 3150 This is an error of the RFU 54 Refer to the operation manual of the RFU 54 4000 Check that the cable for the optional press stacker is correctly connected If the optional stacker is not used install the short circuit connector If the cable is correctly connected turn ...

Page 113: ...eventing the 6th buckle chute stopper from moving to the home position Check if the optional gate fold buckle chute is installed instead of the 6th buckle chute 4109 Check if there are any objects preventing the K1 buckle chute stopper from moving to the home posi tion 4110 Check if there are any objects preventing the K2 buckle chute stopper from moving to the home posi tion 4111 Check if there a...

Page 114: ...Reduce the distance using the suction cup height adjusting knob Standard setting 1 mm or 0 04 page 46 The vacuum is too weak Increase the vacuum using the vacuum reg ulator knob page 47 The cylinder of the suction head is clogged with sheet dust Disassemble and clean the suction piston page 123 A suction cup is worn out Replace it with a new suction cup Thick or small sheets are used and the vacuu...

Page 115: ...14 Check Cause and Recovery Page The vacuum pis ton does not move smoothly Disassemble and clean the suction piston Do not over tighten the piston set screw page 123 Check Cause and Recovery Page The feed table motor circuit breaker Q20 is switched off Switch on the circuit breaker page 14 Check Cause and Recovery Page The suction length is too short Increase the suction length using the Main Cond...

Page 116: ...e feed table wheel page 45 The positions of the sheet hold down bars and the air guide are set incorrectly Adjust the positions of the sheet hold down bars depending on the sheet type Adjust the position of the air guide depend ing on the sheet width page 45 The sheets are sticky or the sepa ration air pressure is too weak Fan the sheets correctly and or increase the separation air pressure page 4...

Page 117: ...ended enough Extend the gate page 85 The gap of the buckle chute is too narrow Widen the gap page 86 Sheet is curled Flatten out the sheets When the first fold ing length is 30 mm to 50 mm 1 18 to 1 97 the edge of the sheet may get into under the stop per Curl the sheets upward slightly 6 5 Problems in the Buckle Chute Section 23051 60501A1 23051 60501B1 Gate 23051 60501C1 GAP 23051 60501D1 23061 ...

Page 118: ...e gap between the fold rollers is uneven Set the fold roller gap correctly so that it is even at both ends page 61 A buckle chute is installed incor rectly Reinstall the buckle chute page 130 The sheets are curled or the grain direction is not parallel to the fold roller Adjust the register guide angle If the sheet is still not folded correctly adjust the roller gap page 59 61 The sheets are not t...

Page 119: ...buckle chute is too strong Widen the roller gap page 61 The sheet floats in the register guide section Set the sheet holders so that they control the sheet page 50 Check Cause and Recovery Page The gap on the buckle chute is too wide Narrow the gap page 86 The roller pres sure is too strong Widen the roller gap page 61 The edge of the sheet hits the cor ner of the buckle chute stopper Loosen the b...

Page 120: ... Page The buckle chute gate is extended too far Pull back the gate page 85 The distance between the buckle chute and the fold roller is too wide Install the buckle chute closer to the fold roller page 87 6 5 Problems in the Buckle Chute Section 23051 60501B1 Gate 23051 60506A1 ...

Page 121: ...tely If the perforation shaft lifting levers have not been returned completely the upper and lower perforation shafts are separated and the scoring line is not correctly made page 10 The drive roller pressure is uneven Adjust the drive roller gap gap 8 page 74 Check Cause and Recovery Page The register guide position is incor rect Correct the register guide position page 67 6 6 Problems in the Sco...

Page 122: ... the knife roller gap gap 9 page 77 Check Cause and Recovery Page The perforation blade is not aligned with the knife 1 Align the perforation blade with the knife 2 Adjust the register guide to align the sheet with the perforation blade page 67 The knife guides are positioned incorrectly Feed one sheet in Setup Mode and adjust the knife guide positions page 70 The transport roll ers are removed Wh...

Page 123: ...de with the folds page 77 Check Cause and Recovery Page The knife func tion is turned off Turn on the knife function using the manual setup on the Setup Guide Buckle screen page 40 The knife servo amplifier circuit breaker Q40 is switched off Switch on the circuit breaker page 14 Check Cause and Recovery Page The motor circuit breaker below the knife Q12 is switched off Switch on the circuit break...

Page 124: ...ecovery Page The conveyor switch is set to Standby or the speed control knob is set to Low Turn the switch to Run Turn the knob to High page 55 The conveyor power cable is not connected Connect the power cable page 3 The circuit protec tor for the con veyor Q50 is switched off Switch on the circuit protector page 14 6 8 Other Problems 23051 60502B1 LOW HIGH RUN STAND BY SPEED CONTROL UNIT POWER AL...

Page 125: ...he pump filter is clogged Clean the filter page 125 Check Cause and Recovery Page The pump circuit breaker Q21 is switched off Switch on the circuit breaker page 14 Check Cause and Recovery Page The feed table is not raised Raise the feed table Check Cause and Recovery Page The main power circuit breaker Q00 or the cir cuit protector for 200V Q01 is switched off Switch on the circuit breaker or ci...

Page 126: ...les to the gate fold buckle chute power box are not fully connected Connect the cords See the user s man ual for GFB 56 The circuit protec tor for the gate fold buckle chute Q30 is switched off Switch on the circuit protector page 14 Check Cause and Recovery Page Double feed detect photoelec tronic sensor is dirty Clean the double feed detect photoelectronic sensor page 135 6 8 Other Problems 2305...

Page 127: ...olding problems The solutions for these problems are explained on the following pages 6 9 General Folding Problems and Remedies Z Shaped Folding Midstream Folding Dog Ears Double Step Folding Hitting the Deflector Rolling Wrinkles Crossing the Fold Line Wrinkles Spreading from the Fold Line ...

Page 128: ...eck that the pressure produced by roller A is not too strong Increase the gap inside the buckle chute page 86 Check to see whether there is paper dust in the buckle chute This can prevent a sheet from entering 6 9 General Folding Problems and Remedies Z Shaped Folding When folding thick sheets Z shaped folding might occur even if the gap at roller A is too loose A B A B A B Gate Midstream Folding ...

Page 129: ...e gate page 85 If a folding problem occurs as shown in the figure to the right If the corners of the sheet are curled upwards or the dis tance between the buckle chute and the roller is too narrow the sheet hits the buckle chute is folded up and cannot enter the clearance of the buckle chute Flatten out the sheets Increase the distance between the buckle chute and the roller page 87 Increase the g...

Page 130: ... escape easily Problem The sheet hits the edge of the deflector or the sheet is caught by a scratch on the deflector surface Increase the gap at roller A Increase the distance between the buckle chute and the roller page 87 Check that the deflector is not scratched 6 9 General Folding Problems and Remedies Double Step Folding Hitting the Deflector A ...

Page 131: ...the gate a little page 86 If a wrinkle occurs near the front edge of the sheet the sheet might be opening a bit as it moves through the register guide section Install the sheet holders page 50 Reduce the number of transport balls use lighter balls and rearrange the balls page 50 If the wrinkles spread from the fold line The gap pressure for the feeding roller is too strong Increase the gap 6 9 Gen...

Page 132: ...e within the range 89 It is time for cleaning the pump filter Press the OK button and clean or replace the pump filter See page 125 for details If you press the Return button this message icon is displayed again when the Power switch is turned on next time 90 It is time for cleaning the air filter for the control box Press the OK button and clean or replace the air fil ter for the control box See ...

Page 133: ...ency Stop button before doing any maintenance operation Otherwise a sudden start of the machine can cause severe personal injury or machine trouble 7 1 Cleaning the Vacuum Piston If the piston set screw breaks replace it with the accessory piston set screw in the same way Do not lubricate the piston The lubricating oil will catch more paper dust Do not hit or scratch the piston Keep the suction cu...

Page 134: ...set screw gradually and insert the screw into the groove on the piston Tighten the piston set screw slowly until it stops Do not tighten the set screw so much so that the piston is scratched 3 Loosen the set screw until the piston drops by itself 4 Fasten the lock nut 7 1 Cleaning the Vacuum Piston 23051 70101C1 Piston Set Screw Groove Lock Nut Turn the piston and insert the piston set screw into ...

Page 135: ...e three screws and the cover shown in the drawing to the right Remove the filters Remove any clogged dust in the filter using compressed air or a vacuum cleaner If the dust cannot be removed replace the filter Reinstall the filters in the original positions Install the filters and parts in the reverse order of removal 7 2 Disassembling and Cleaning the Pump Filter 23051 70201A1 Filter 23051 70201B...

Page 136: ...accessory cleaner or alcohol 7 3 Cleaning the Fold Roller Turn off the power switch before cleaning the rollers Otherwise a sudden start of the machine can cause severe personal injury WARNING Do not apply cleaner or alcohol to the roll ers directly The rollers may not dry com pletely and may contaminate the sheets Do not use blanket cleaner or recovery agents for printers They may cause dam age o...

Page 137: ...ed lubricate the grease nipple Frequency of Lubrication Once every 100 hours Specification of Grease Type Lithium complex soap grease Viscosity NL GI2 Add more grease into the grease nipple Use the accessory grease Add grease using the accessory grease gun 7 4 Lubrication Lubricating the Grease Nipple 23051 70401A1 Grease Nipple Grease Gun ...

Page 138: ...he conveyor drive chain regularly approximately once a month Remove the power connector for the conveyor Lubricate the drive chain Apply the accessory grease using a brush 7 4 Lubrication Lubricating the Con veyor Drive Chain 23051 70401C1 23051 70401D1 Chain ...

Page 139: ...Remove the perforation shaft Pull the perforation shaft to the operator side to remove the pin from the groove and lift the entire perforation shaft Install the perforation shaft in the reverse order of removal 7 5 Removing and Installing the Perforation Shaft Do not touch the blades Otherwise a sharp blade can cause severe personal injury WARNING Make sure to move any blades away from the lower b...

Page 140: ...nector Check that the buckle chute stop wire is attached There are wires on the front and rear Loosen the locking lever The buckle chute will slide down and be stopped by the wire Remove the wire Lift the buckle chute a little and unhook the wire Remove the buckle chute 7 6 Removing the Buckle Chute Turn off the power switch before removing the buckle chute Otherwise a sudden start can cause sever...

Page 141: ...on and loosen the locking knob Buckle Chute K2 Open the door for the buckle chute below the knife and loosen the locking knob Disconnect the cable connector Remove the buckle chute 7 6 Removing the Buckle Chute Buckle Chutes K1 and K2 23051 70601C1 23051 70601D1 Buckle Chute Locking Knob Cable Connector Buckle Chute Locking Knob Cable Connector Door for Buckle Chute Below the Knife Buckle Chute K1...

Page 142: ...ill sepa rate the upper scoring wheels from the lower blades 3 Remove the perforation shaft Loosen the locking screw using a 3 mm hex driver and move the shaft holder 7 7 Installing the Perforation Blade WARNING Turn off the power switch before replacing the blades Otherwise a sudden start of the machine can cause severe personal injury or machine trouble Do not touch a blade Otherwise a sharp bla...

Page 143: ...the holders yet 7 7 Installing the Perforation Blade Install each blade with the correct orientation Install each holder in the position shown in the drawing to the right Blade Holder A Blade Holder B Perforation Shaft 3 mm Upper Blade Upper Blade Drive Roller Lower Blade Lower Blade Set the upper blade so that the upper blade comes to outside of the lower blade Locking Screw for Upper Blade Holde...

Page 144: ...ation shaft lifting lever and align the scoring wheels Lock the roller to the perforation shaft 7 7 Installing the Perforation Blade 13071 70701B1 Shaft Holder 3 mm Hex Driver Locking Screw Perforation Shaft Pull the shaft holder out and insert the perforation shaft When installing the shaft insert it until it stops Pin 13071 40701Q1 Perforation Shaft Lifting Lever Return the upper perforation sha...

Page 145: ...wo locking screws 4mm Clean the projector and receiver of the double feed detect photoelec tronic sensor using soft cloth or brush Reinstall the projector of the double feed detect photoelectronic sensor Turn on the main power 7 8 Cleaning the Double Feed Detect Photoelectronic Sensor Use neutral detergent to clean the sensor lens Do not use blanket cleaner recovery agents for printer or any other...

Page 146: ...ir filter once a month Turn off the power switch Remove the filter case and the air fil ter Wash the filter with water If the filter is still contaminated replace it with a new filter Dry the filter completely and attach it 7 9 Cleaning and Replacing the Air Filter in the Control Box Turn off the power switch before cleaning the air filter WARNING 13071 70801C1 Filter Case Air Filter ...

Page 147: ...er shown in the drawing to the right Remove the rid Pull the carbon blades out and check them Attach the covers in the reverse order of removal 7 10 Replacing the Carbon Blades of Pump 23061 70901A1 Cover 23061 70901B1 Rid If the length of the carbon blade is 27 5 mm or less replace the blades Replace all seven blades together When inserting the new blade insert it to the direction shown in the dr...

Page 148: ... or recycle the battery according to the regulations and or ordinances of your local government Follow the precautions instructed on the bat teries Otherwise heat generation explosion and leackage of batteries may cause severe per sonal injury or damage or defile the sur rounding parts CAUTION Do not use rechargeable batteries They may cause heat generation or defective of batter ies CAUTION SELEC...

Page 149: ...s not solid enough place strong plywood on the floor for support Do not connect the power cable to your distri bution board until all the wiring connections in the machine are complete Otherwise an elec tric shock can cause severe personal injury Attach the ground wire WARNING Avoid direct sunlight Avoid hot and humid locations CAUTION 23051 80101C1 Center of Gravity Cross Folding 600 23 7 3 260 1...

Page 150: ...the fold rollers place a torpedo level on the side of the register guide section After making the leveling adjustments tighten the lock nuts to lock the level ing bolts 8 1 3 Installing the Delivery Section Front Cover Remove the knife fold section support on the operator side Remove the screw inside the cover support pin Install the delivery section front cover 8 1 Machine Installation 23051 8010...

Page 151: ... electrical box to the terminal board on the pump Refer to the illustration to the upper right Connect the cables 50 and 51 to the terminal board on the transformer as shown in the illus tration to the right Turn on the circuit breaker and set the volume to the maximum 8 2 Pump Power Cable Connection 23051 80201A1 Ground WHT RED BLK Pump Power Be sure to connect the ground Rear Transformer AFC 566...

Page 152: ...connecting the hoses fasten them using hose clamps Put the pump below the knife folding section Be sure to attach the cables and hoses in the areas where a foot cannot be caught as shown in the drawing below 8 3 Pump Power Cable Connection Rear 3 2 1 Suction Head Vacuum Piston Feed Rotor Front Air Suction Head Blower Separation 23051 80201B1 23051 80301F1 ...

Page 153: ...e the conveyor The exit direction of the sheets changes depending on the fold pattern Connect the conveyor power cable Turn the conveyor switch to Run Adjust the speed control knob to High 8 4 Installing the Conveyor and Accessories Cross Fold Parallel Fold LOW HIGH RUN STAND BY SPEED CONTROL UNIT POWER ALARM 23051 80301A1 Conveyor Power Connector ...

Page 154: ... When using more than one folder each folder needs its own remote controller Connect each remote controller to the corresponding folder to prevent interference See Section 1 6 3 and 5 15 1 in the Service Manual for details 8 5 Installing the Conveyor and Accessories 23051 80301B1 23051 80301C1 23051 80301D1 23051 80301E1 Delivery Section Guide Plates Air Guide Side Air Hose Sheet Edge Guide ...

Page 155: ...the pump If the fan rotates clockwise this is normal If it rotates counterclockwise press the Emergency Stop button immediately If you let the fan rotate counterclockwise for a long time the pump will be damaged If the fan rotates counterclockwise do the following 1 Turn off the power switch 2 Exchange the connections for the red and white wires connected to the terminal board 8 6 Connecting the P...

Page 156: ...led and the cover gaps are small 2 The interlocks operate 3 There are no strange noises or bad smells while the machine is running 4 The machine runs down when the Emergency Stop button is pressed while the motor is run ning 8 8 Date and Time Setup Properties Screen 23051 80501A1 8 9 Checks After Installation ...

Page 157: ...000 cycles per hour Knife 21 000 cycles per hour Standard Fold Roller Combination of soft polyurethane foam rubber and steel roller Optional side cut blades can be attached to the roller Perforation Parallel Fold Diameter 52 mm Cut 6 mm or 0 24 Blank 4 mm or 0 16 Perforation Cut 2 5 mm or 0 1 Blank 0 8 mm or 0 03 Option Cut 3 2 mm or 0 13 Blank 0 8 mm or 0 03 Cut 1 4 mm or 0 06 Blank 0 8 mm or 0 0...

Page 158: ...m 1 pc Hex Driver 3 mm 1 pc 30 mm 8 10 mm 13 17 mm Operation Manual and Parts Book A F C 5 6 6 F K T A F C 5 6 6 F A F C 5 6 6 F You are reading this now Remote Controller 1 pc SELECT 1 pc 12 14 mm Knob M6 15 1 pc To hold the shaft when the buckle chute motor is broken Transport Rollers 2 pcs ...

Page 159: ...Screwdriver 1 pc Guide Plates 3 pcs Mounts 4 pcs Sheet Hold down Bars 2 pcs Electrical Box Keys 5 pcs Pins 4 pcs Sheet Holders 4 pcs Install at exit of parallel fold section Grease Cartridge EP N0 2 1 pc Grease Gun 1 pc Side Air Hose 1 pcs 13092 90201E1 ...

Page 160: ... Sheet Guides 2 pcs Hose Clamps 3 pcs Thin Brown N5 10 pcs Thick Brown N8 For thick sheets 12 pcs Side Guides 1 Each A943018 A943019 T Handle Ball point Wrench 4 mm 1 pc 4 pcs Piston Set Screws 10 pcs Plastic Balls 20 pcs Steel Balls 20 pcs These are the replacement screws See page 123 for details ...

Page 161: ...Cover 1 pc Knife Stopper SS 2 pcs 400V Transformer 1 assy Sheet Holder PET 1 pc Lower Blades 2 pcs 2 5 X 0 8 Perforation Blade Holders AS Perforation Blades 2 pcs 1 pc Sheet Edge Guide 1 pc Perforation Guides 6 pcs When installing the machine a service tech nician mounts this cover ...

Page 162: ...Cups Parts Book Fig 81 Index 8 Parts Book Fig 81 Index 9 Parts Book Fig 68 Index 17 23061 10041A1 F1 Filter Element for Vacuum Pump F1 Parts Book Fig 68 Index 9 23061 10041C1 F3 Filter Element for Vacuum Pump F3 Parts Book Fig 68 Index 10 23061 10041B1 F2 Filter Element for Vacuum Pump F2 Parts Book Fig 68 Index 11 ...

Page 163: ...ter Blade Cut 3 2 mm x Blank 0 8 mm M174213 Cut 1 4 mm x Blank 0 8 mm M174212 Cut 2 5 mm x Blank 0 8 mm M174208 Diameter 51 mm M174214 Diameter 52 mm M174215 Diameter 54 mm M174710 Attach this guide when using the perforation blade below knife Scoring Wheel Diameter 51 mm M174711 Diameter 51 5 mm M174712 Diameter 52 mm M174716 ...

Page 164: ...154 There is no specific hazardous materials and components for de commisioning and dismantling the machine 9 5 De commissioning and Dismantling ...

Page 165: ...and Dynamic Load Testing We guanrantee that the feed table of this product has passed the static and dynamic load testing in accordance with 4 1 2 3 of the Machinery Directive 2006 42 EU 9 6 Static and Dynamic Load Testing ...

Page 166: ...Phone 81 75 934 6700 Fax 81 75 934 6708 www horizon co jp Manufacturer ...

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