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Contents

I   Introduction .......................................................................................................

1

II   Symbols used in this manual ...........................................................................

2

III   Cautions when undertaking service operations - Part 1 ................................. 3

IV   Cautions when undertaking service operations - Part 2 .................................

4

1  General ..............................................................................

7

1 - 1  Differences from the PC-P43 ....................................................................

8

1 - 2  Adjusting the Angle and the Height of the Knife ........................................

9

1 - 3  Machine Safety Features ........................................................................

11

2  Troubleshooting ...............................................................

15

2 - 1  System Errors ......................................................................................... 16
2 - 2  Monitor LEDs Do Not Light .....................................................................

19

2 - 3  The Machine Does Not Start by Pressing the Cutting Buttons ...............

20

2 - 4  The Machine Stops (System error 8 or 9) ...............................................

21

2 - 5  The Machine Stops Without a Beeping Sound .......................................

22

2 - 6  The Last Few Sheets Are Left Uncut ...................................................... 23
2 - 7  Cut Size Is Not Accurate .........................................................................

24

2 - 8  Skew Cut .................................................................................................

25

2 - 9  The Book Spine Is Crashed / The Book Is Contaminated ....................... 26
2 - 10  Vague Cut Line .....................................................................................

27

3  Descriptions of Mechanisms............................................ 31

3 - 1  Cutting and Clamp Section ..................................................................... 32
3 - 2  Backgauge Section ................................................................................. 33
3 - 3  Safety Cover Section .............................................................................. 34

3 - 4  Removing the Back Table ...........................................................................35
3 - 5  Removing the Front Table ...........................................................................36
3 - 6  Removing the Clamp ...................................................................................38
3 - 7  Removing the Knife Holder .........................................................................39
3 - 8  Removing the Cam .....................................................................................

40

3 - 9  Removing the Backgauge Drive Section .....................................................

41

3 - 10  Removing the Motor ..................................................................................

42

3 - 11  Replacing the Knife ...................................................................................43

4  Electrical Parts Location .....................................................

51

4 - 1  PC-P430 Electrical Parts List ......................................................................

52

4 - 2  Motor and Switch Locations and Names .....................................................

54

4 - 3  Other Electrical Parts Locations and Names ..............................................

55

5  Circuit Boards .....................................................................

59

5 - 1  Board Locations and Names .......................................................................60
5 - 2  QPW-968 (P115811) Control Board ...........................................................61

5 - 2 - 1   QPW-968 Board Diagram ...................................................................................... 61
5 - 2 - 2   QPW-968 LED Location ......................................................................................... 62

5 - 3  QPW-959 (P114711) Cut Line LED Current Control Board ........................63
5 - 4  QPW-969 (P115911) LED Board ................................................................64
5 - 11  ROM Version History ................................................................................65

6  Electrical Circuits ................................................................69

6 - 1  SD Circuit ....................................................................................................

70

6 - 1 - 1   SD1 AC Power Circuit ............................................................................................

70

6 - 1 - 2   SD2 Input and Output System Circuit ....................................................................

71

END SHEET ...............................................................................................

74

Summary of Contents for PC-P430

Page 1: ...icates additional information which will help you to operate the machine efficiently Attention This explains functional limitations and restrictions on the operation of the machine Edited and Published by Horizon International Inc 140927 PC P430 00E HN KJ US504013 00 001 I Introduction This service manual is for the following product Paper Cutter PC P430 Prior consent This service manual is intend...

Page 2: ...er code BRN Brown Brown RED Red Red GRY Grey Grey YEL Yellow Yellow GRN Green Green BLU Blue Blue VIO Violet Violet WHT White White BLK Black Black ORN Orange Orange PNK Pink Pink LBLU Light blue Light blue MOD Module connector NC Normal closed contact terminal NO Normal open contact terminal SSR Solid state relay VR Volume SIG Signal voltage S N Machine number BSD Block schematic diagram X Connec...

Page 3: ...one by one person When turning the power back on wait for approximately ten seconds after turning the power off before turning it on again When replacing parts use the parts shown in the parts book unless commercially avail able parts with exactly the same functions and performance can be obtained Special screws are used to mount the safe ty switches which detects that the cover is opened or close...

Page 4: ... La batterie doit être conservée dans un endroit où la température ne dépasse pas 60 degrés Celsius 140 degrés Fahrenheit Ne pas jeter la batterie usagée avec les déchets ménagers Jeter ou recycler la batterie conformément à la réglementation et ou aux décrets des autorités locales A battery is mounted inside the digital counter Dispose of or recycle the battery according to the regulations and or...

Page 5: ...criptions of Mechanisms 31 3 1 Cutting and Clamp Section 32 3 2 Backgauge Section 33 3 3 Safety Cover Section 34 3 4 Removing the Back Table 35 3 5 Removing the Front Table 36 3 6 Removing the Clamp 38 3 7 Removing the Knife Holder 39 3 8 Removing the Cam 40 3 9 Removing the Backgauge Drive Section 41 3 10 Removing the Motor 42 3 11 Replacing the Knife 43 4 Electrical Parts Location 51 4 1 PC P430...

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Page 7: ...General 1 PC P430 7 1 General PC P430 ...

Page 8: ...the original mechanical lock guard two inter lock contactors K01 and K02 are added to have a redundant circuit The fault self checking function is also equipped See below for details The Knife Lower Limit switch is mounted on the P C board 404018 1_1_1D The knife is set by the Toggle switch on the QPW 968 control board to stop at the lower limit See page 61 for details The fault self checking devi...

Page 9: ...s The knife will lower and stop at the lower limit 4 Turn off the Key switch 5 Adjust the height Fig 3 Loosen the lock nut and adjust the height by turning the adjusting screw so that the knife edge touches the top sheet of the four sheets on the left side 6 Adjust the angle Fig 4 Loosen the locking screw and adjust the angle by turn ing the eccentric pin so that the knife edge touches the sheet o...

Page 10: ... of the knife the LEDs on the QPW 968 control board are lit as shown in the table of Fig 7 Fig 6 Lowering the knife Fig 5 Point to be checked Fig 7 LEDs Lighting Condition 404018 1_2_1E LEDs on the QPW 968 control board on off Lighting Condition L2 L1 L3 L6 When the Toggle switch on the board is set to ADJ When S05 Left Cutting button and S06 Right Cutting button are pressed at the same time When ...

Page 11: ... direction The machine is equipped with a lever which moves the cut sheets forward The opera tor can remove the cut sheets safely by pulling the lever to the operator side The operator does not need to put the hands under the knife The machine cuts the sheets only when both Cutting buttons are pressed within 0 5 seconds While the machine is cutting the operator is using the two hands to press the ...

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Page 15: ...Troubleshooting 2 PC P430 15 2 Troubleshooting PC P430 ...

Page 16: ...at the contact points on K11 are not damaged If the contact points are not damaged check the wiring connection between terminals 13 and 14 on K11 and CON2 on the QPW 968 control board If these are OK the board is defective Replace it Function Error of K11 Contactor for Reverse Rotation Check whether the L4 on the QPW 968 control board is lit while the knife is running in reverse direction If the L...

Page 17: ...Relay 2 Check whether the L7 on the QPW 968 control board is lit while the safety cover is closed If the LED is lit go to 1 If not go to 2 1 The LED is lit The correct signals are input from K02 to the board but the signals are not being processed correctly Replace the board 2 The LED is not lit Check the wiring connection between terminals 21 and 22 of K02 and CON3 on the QPW 968 control board If...

Page 18: ...2 Troubleshooting PC P430 18 This page is intentionally left blank ...

Page 19: ...e on the output terminal of G00 Switching Power Supply Check that 24VDC is output If 24VDC is output go to 3 If 24VDC is not output go to 4 3 Check the wiring connection between G00 switching power supply and the QPW 968 control board If it is normal replace the QPW 968 4 Check the wiring connection between G00 switching power supply and Z00 noise filter Are power cable connection and Key switch O...

Page 20: ...LED flashes go to 1 If the LED does not flash go to 2 1 Check the Cutting buttons Go to the right column 2 You should hear a click sound from the actuators of S07 S08 S10 when the safety cover or the door is closed If not S07 S08 S10 is not mounted in the correct posi tions Check electric continuity of S07 S08 S10 If this is normal Check the wiring connection between S07 S08 S10 and CON3 on the QP...

Page 21: ...ht column is defective system error 8 or 9 occurs and the machine stops Even after the machine stops the machine keeps beeping until the cause is corrected Turn off the power wait 10 seconds and turn it on again to stop the beeping sound The LED on the monitor remains lit Are Cam switches A and B OK S04 S03 NO NO COM COM NC NC NC NC 404018 2_4_1C Check how the Cam switches A and B S03 and S04 are ...

Page 22: ...ife go up and stop when you released the Cutting buttons If the knife went up and stopped go to 1 If the knife did not move go to 2 1 Check the screws on the knife holding plate If the mounting screws on the knife holding plate are loos ened the bottom of the holding plate may come off from the knife during the cutting operation If the bottom of the knife holding plate hit the sheets the machine m...

Page 23: ...se width is the same as the cutting stick If the knife edge is worn the dull knife causes the louder cutting noise and the last few sheets are left uncut Replace the knife Service technicians should bring back the used knife The wear of the knife can not be seen by the eyes The repeated operation with the dull knife may result in machine malfunction The knife needs to be replaced earlier Is the kn...

Page 24: ...cator to read the value correctly Does the backgauge plate stick out 2 3 1 4 6 7 3 5 404018 2_7_1A The backgauge plate 3 is pressed against the frame 4 by the spring If there is a gap between the backgauge plate and the frame the cut size differs from the length indicated by the indicator If there is a gap check the following The three slide shafts 1 are locked on the backgauge plate The two beari...

Page 25: ...e knife Is the backgauge plate is tilted 404018 2_8_1A If the backgauge plate does not move smoothly it makes a gap as shown in the drawing above In this case skew cut will occur The backgauge plate is always pressed against the frame by the spring See the left column on the previous page If the backgauge cannot be moved smoothly us ing the sheet pusher lever check the following The three slide sh...

Page 26: ... using tissue paper Instruct also not put hands and fingers under the knife Is the book placed in the center 404018 2_9_1A The book spine is thicker than the sheets because of the spine glue If the book is in the center the clamp crashes the spine when cutting the book The clamp has a cutout on the left end as shown in the drawing above If the book spine is placed under the cutout the book spine i...

Page 27: ...ils 2 Loosen the locking screws and adjust the position of the LED boards for the sharp cut line Are paper chips stuck on the rear of the knife 404018 2_10_1A There is a slight gap between the knife and the clamp The light from the LEDs go through this gap and make the cut line If a part of the cut line is vague remove the knife and check that no paper chips are stuck on the rear of the knife If t...

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Page 31: ...Descriptions of Mechanisms 3 PC P430 31 3 Descriptions of Mechanisms PC P430 ...

Page 32: ...Fig 6 37 S03 S04 Actuator Normal Direction Crank Ring Fig 6 7 Clamp Fig 6 1 Drive Cam Knife Holder Cutting Stick M01 Main Motor Fig 6 41 This spring presses down the clamp The clamp is hooked on the knife holder The edge of the clamp is always below the edge of knife The cut line is the light from this space Part B is eccentric to part A Insert the screw driver to the straight slot and turn the pi...

Page 33: ... of the backgauge plate using the shims so that the projections on the backgauge plate do not rub the grooves on the table Mounting Screw Mechanism Shims Fig 3 22 Tension Backgauge Feed Screw Guide Shaft Feed Block The backgauge should be parallel to the knife Make the parallel adjustment using the allowance of the screw holes If the backgauge is skew too much adjust the backgauge using the timing...

Page 34: ...cover is opened the detect cam presses the actuator of S07 S10 and break the circuit Position the detect cam so that the S07 S10 is activated when you lift the safety cover by 5 to 8 mm 0 2 to 0 3 When the safety cover is closed the tip of the link plate is not projecting from the bracket so the knife holder is able to move When the safety cover is open the tip of the link plate is projecting from...

Page 35: ...t outward You do not need to remove the screws 4 Remove the backgauge Fig 3 Shims to adjust the height may be under the bracket Be careful not to lose the shims 5 Remove the back table Fig 4 6 Lower the knife holder to the lower limit Go through step 2 to 4 in page 9 Lower the knife holder to the lower limit so that the clamp can be removed easily afterward Turn off the power and disconnect the po...

Page 36: ... pull out the lower cover in a horizontal direction 3 Remove the cutting stick removing lever Fig 3 Remove the snap ring and pull out the cutting stick removing lever unit 4 Remove the counter Fig 4 Remove the counter so that you can remove the body of the Key switch in step 6 on the next page 1 Push the claws on the white case outward and push out the counter from the inside of the machine 2 Remo...

Page 37: ...ver switches Fig 5 6 Remove the body of the Key switch Fig 6 1 Press the white part on the body and pull out the body 2 Put the removed body under the front table through the square window below the Key switch 7 Disconnect the connectors of S05 S06 Right and Left Cutting buttons Fig 7 8 Remove the whole front table Fig 8 There are eight mounting screws Front Table Unit Key Switch Safety Cover Swit...

Page 38: ...nife is already lowered to the lower limit you can remove the spring holder easily There are six mounting screws The two screws on the front is shorter than the other four screws When you mount the holder spring afterward pay atten tion to the length of the screws and use the screws correctly 3 Remove the clamp Fig 3 Grease is applied on the guide sections on the both ends of the clamp Before you ...

Page 39: ...nife holder See Fig 4 for details Be careful not to drop the rings 3 Remove the crank Fig 3 The knife pin is just inserted from the front You can push it out from the rear Pay attention to the mounting direction The knife pin has a flange on the front side 4 Pull out the pins Fig 4 The left pin has the hole for the set screw sharp point When you mount the left pin again insert the tip of the set s...

Page 40: ...r plate Fig 2 Remove the screws for the side frame Open the side frame slightly and remove the rear plate 4 Remove the cam Fig 3 Loosen the two set screws SS5 20 using a 2 5 mm Allen wrench When you cannot pull out the cam use a tool to pull out a pulley How to mount the front plate Fig 4 1 Mount the collars on the lower two screws and turn each screw until the first thread groove goes into the re...

Page 41: ...ting screws 3 Remove the timing pulley Fig 3 1 Lower the tension pulley 2 Remove the timing belt 3 Remove the timing pulley 4 Remove the feed screw and the guide shaft Fig 4 You need to remove the side frame before replacing the motor You need to broaden out the front of the side frame when you remove the side frame Remove the feed screw and the guide shaft so that you can broaden the side frame a...

Page 42: ...t the connector for Z00 noise filter 2 Disconnect the connector for the Q00 circuit breaker 3 Disconnect the ground terminal When you connect these parts again connect the parts correctly 3 Remove the side frame Fig 3 Broaden out the front of the frame and then remove the frame by pushing it to the rear 4 Remove the M01 main motor Fig 4 1 Disconnect the connector for the motor 2 Remove the key on ...

Page 43: ... Cutting Height and the Service Life of the Knife Removing the knife 1 Turn off the Key switch Fig 2 2 Unlock the knife Fig 3 Use the supplied Allen wrench and loosen the four screws on the knife holder counterclockwise by a half turn WARNING Do not remove the screws The knife drops when the screws are removed completely The knife is designed so that it will not drop when the screws are just loose...

Page 44: ...ement tool and pull the knife out of the machine by about 30 through 35 mm 1 19 through 1 37 5 Insert the edge of the knife into the sheath Fig 7 6 Push the knife into the sheath completely Fig 8 Push the knife into the sheath until the pin is inserted into the hole in the stopper completely CAUTION Keep the sheath level or keep its edge with the stopper lower until the pin is inserted into the ho...

Page 45: ...he knife and in the sheath and insert the tie 2 Twist the tie by two or three turns so that it will not be loosened Ask the local dealer to dispose of the old knife Installing the new knife 8 Prepare a new knife Fig 10 Remove the tie 9 Push out the knife from the sheath by about 100 mm 3 94 Fig 11 WARNING The knife is very sharp Be careful when you handling 10 Fit the knife edge with the cutout of...

Page 46: ...the door Fig 14 Tighten the locking knob completely 13 Lock the knife Fig 15 Tighten the four screws on the knife holder clockwise using the Allen wrench Insert the Allen wrench into the head of screw com pletely WARNING Be sure to tighten the screws completely Otherwise the machine may malfunction or cause injury Store the Allen wrench into the hole as shown below 14044 20702G1 14 Press the Reset...

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Page 51: ...Electrical Parts Location 4 PC P430 51 4 Electrical Parts Location PC P430 ...

Page 52: ...W 968 p 71 S04 Cam Switch B S05 Left Cutting Button S06 Right Cutting Button S07 Safety Cover Switch Right S08 Door Switch S10 Safety Cover Switch Left Other Electrical Parts Reference ID No Name Location Board Circuit A10 Counter p 55 p 71 A20 Brake Pack p 70 C01 Capacitor 1 25μF C02 Capacitor 2 25μF C03 Capacitor G00 Switching Power Supply p 70 p 71 K01 Interlock Relay 1 QPW 968 K02 Interlock Re...

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Page 54: ...ig 6_41 3 phase 90W p 70 2 S00 Key Switch Fig 1_9 1 S03 Cam Switch A Fig 6_29 QPW 968 CON2 L2 p 71 S04 Cam Switch B Fig 6_29 CON2 L3 2 S05 Left Cutting Button Fig 2_20 CON2 L1 S06 Right Cutting Button Fig 2_20 CON2 L1 S07 Safety Cover Switch Right Fig 2_11 CON3 S08 Door Switch Fig 1_7 CON3 S10 Safety Cover Switch Left Fig 2_11 CON3 A10 Knife Front Table Mechanism Knife Mechanism S04 S03 S07 S05 S1...

Page 55: ... 115V Capacitor 1 25μF 230V C02 Capacitor 2 25μF 100V Fig 8_16 Capacitor 2 25μF 115V Capacitor 2 25μF 230V C03 Capacitor Fig 8_2 G00 Switching Power Supply Fig 8_7 p 70 p 71 K01 Interlock Relay 1 Fig 8_5 QPW 968 CON3 L6 9 K02 Interlock Relay 2 Fig 8_5 CON3 L7 8 K10 Contactor for Normal Rotation Fig 8_3 CON2 L5 K11 Contactor for Reverse Rotation Fig 8_3 CON2 L4 Q00 Circuit Breaker 100 115V Fig 8_11...

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Page 59: ...Circuit Boards 5 PC P430 59 5 Circuit Boards PC P430 ...

Page 60: ...the current for the QPW 960 cut line LED board 1 and 2 p 63 QPW 960 P114811 Cut Line LED Board 1 2 Their LEDs indicate the cut line p 63 QPW 968 P115811 Control Board Board to control the whole machine p 61 QPW 969 P115911 LED Board Board to indicate the state of machine by the LEDs p 64 5 1 Board Locations and Names 5 1 1 Board List QPW 959 QPW 969 QPW 968 QPW 960 ...

Page 61: ...5 1 12 CON 4 12 1 CON 3 14 1 FIDU2 1 2 FIDU1 Bar Code P No RY1 RY2 RY3 FL 1 L1 L2 5V 24V L3 L4 L5 L9 L8 L7 L6 SW1 NORMAL ADJ SW1 QPW 968 P115811 Control Board ADJ NORMAL 404018 5_2_1A Toggle Switch ADJ For adjusting the lower limit The knife stops temporarily at the lower limit while the cutting buttons are being pressed NORMAL Normal Operation QPW 968 ...

Page 62: ... Cam Switch A is pressed This LED goes off when the knife is at upper limit L3 S04 When the knife is at just before the lower limit and until it reaches the upper limit While the Cam Switch B is pressed This LED goes off when the knife is at upper limit L4 K11 When Contactor for Reverse Rotation works Monitor of normal open auxil iary contact L5 K10 When Contactor for Normal Rotation works Monitor...

Page 63: ...1 CON 4 DC24V_OUT QPW 960 P114811 Cut Line LED Board 1 QPW 968 P115811 Control Board CON 2 1 12 CON 1 4 1 QPW 960 P114811 Cut Line LED Board 2 2 1 4 3 2 1 FIDU1 FIDU1 FIDU2 FIDU2 1 3 2 1 3 2 CON 1 4 1 FIDU1 FIDU2 QPW 959 P114711 LED Current Control Board QPW 959 P114711 LED Current Control Board 404018 5_3_1A QPW 959 QPW 960 Cut Line LED Board 2 QPW 960 Cut Line LED Board 1 ...

Page 64: ... 3 2 4 6 5 L1 L2 L3 QPW 969 P115911 Panel LED Board QPW 969 P115911 Panel LED Board 404018 5_4_1A LED No ID No Lighting Condition L1 When the machine is ready to run L2 While the machine is running L3 When there is a problem inside the machine This LED flashes when the safety cover or the door is open QPW 969 404018 5_4_1B Monitor ...

Page 65: ...Circuit Boards 5 QPW 969 P115911 LED Board PC P430 65 5 11 ROM Version History 5 11 1 ROM Version Main Control Board Serial Number Related Bulletin Date of issue QPW 968 Upgrade Contents ...

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Page 69: ...Electrical Circuits 6 PC P430 69 6 Electrical Circuits PC P430 ...

Page 70: ...00 115V 1A 230V SD1 00 Z00 Noise Filter Inlet S00 Key Switch Q00 Circuit Breaker Switching Power Supply G00 K01 K02 Interlock Relay 1 Interlock Relay 2 A20 Brake Pack M01 Main Motor M01 Main Motor K10 K11 Contactor for Normal Rotation Contactor for Reverse Rotation XS00 X00 X00 X00 X00 X00 X00 C02 C01 C03 Capacitor 2 25μF Capacitor 1 25μF Capacitor Bottom Top Bottom Top Bottom Top Bottom Top Botto...

Page 71: ...t Cutting Button Contactor for Reverse Rotation Auxiliary Contact Contactor for Normal Rotation Auxiliary Contact S04 Cam Switch B K10 Contactor for Normal Rotation K01 Interlock Relay 1 K02 Interlock Relay 2 Attached with Surge Protector Attached with Surge Protector K11 Contactor for Reverse Rotation S05 Left Cutting Button S06 Right Cutting Button S07 Safety Cover Switch Right S08 Door Switch S...

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Page 74: ...You can download the latest manual http hip horizon co jp Anytime and Anywhere END SHEET ...

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