ABC Balance Hydraulic full Head

Cutting Machine
Machine ABC-E100

INSTRUCTION BOOK

1. Safety .................................................................................... 1-1

1.1. General safety considerations ...................................................... 1-1
1.2. Safety considerations during start up .......................................... 1-1
1.3. Safety considerations during operation ........................................ 1-1
1.4. Emergency stop ........................................................................... 1-3
1.5. Danger area ................................................................................ 1-4
2. Technical specifications ......................................................... 2-1
2.1. System drawing ........................................................................... 2-1
2.2. System specifications .................................................................. 2-2
2.3. Spare parts ................................................................................. 2-2
2.4. System overview .......................................................................... 2-4
2.5. Conversion of cutting pressure .................................................... 2-6
2.6. Recommended hydraulic oil ......................................................... 2-7
3. Installation ............................................................................ 3-1
3.1. Placing the machine in position ................................................... 3-1
3.2. Installation ................................................................................. 3-1
3.3. Connecting to the main power supply .......................................... 3-1
4. Operation instruction ............................................................ 4-1
4.1. Control panel .............................................................................. 4-1
4.2. Starting the machine ................................................................... 4-5
4.3. Die heibht setting ........................................................................ 4-5
4.4. Cutting mode .............................................................................. 4-6
5. Electrical schemes ................................................................. 5-1
5.1. Main connection to power supply ................................................ 5-1
5.2. AC control circuit ....................................................................... 5-2
5.3. DC control circuit ....................................................................... 5-3
5.4. Pause control circuit ................................................................... 5-4
5.5. Emergency control circuit ........................................................... 5-5
5.6. Mitsubishi PLC Ax2n-48MR ........................................................ 5-6
5.7. Mitsubishi inverter .................................................................... 5-10
5.8. Location drawing ....................................................................... 5-11
5.9. Inverter parameter setting ......................................................... 5-12
6. Hydraulic & pneumatic ........................................................ 6-14
6.1. Pneumatic circuit ....................................................................... 6-14
7. Alarms & maintenance .......................................................... 7-1
7.1. Maintance ................................................................................... 7-1
7.2. Trouble shooting ......................................................................... 7-1
7.2.1. Trouble shooting ................................................................ 7-2
8. Assembly drawing .................................................................. 8-1

1-1

1. Safety
1.1. General safety considerations
This machine is designed for use in accordance with all existing CE plant safety regulations.
This machine is equipped with a number of safety devices to protect both the operator and the
machine itself from the dangers posed by accidents.
However, operators should not rely solely on the safety equipment.

Unless thoroughly familiar

with all machine safety precautions, no attempt should be made to operate the machine.
Attention
Improper usage could cause injury to personnel in and around the machine.

1.2. Safety considerations during start up

Before you begin any application, it is important to always check thoroughly that the machine is
functioning properly, and that all the safety features are in place.
be made every time you start up the machine.

The following checks should

Before powering up the machine, make the following checks

Perform the daily inspections as outlined in the Chapter 7.1: Maintenance.

Confirm that the safety door has been closed.

Confirm that all of the operation switches are functioning properly.

Once the machine is running

Be particularly careful in confirming that all the motors are running in the proper direction.
Make sure to check the direction during machine installation as well as after the power
source has been rewired.

Make sure all of the lamp indicators on the panel are functioning.

Check the safety devices

Confirm that all safety devices, such as safety guards, safety switches, emergency buttons
and ground wires are properly installed.

1.3. Safety considerations during operation

Be certain any change in conductor wire matches the original route and color.
With any high performance machine there is a degree of danger that accompanies its efficiency.
The many fast moving parts, the powerful hydraulic cutting ram, and the high voltage wiring all
carry the potential for danger if the machines operator does not rigorously follow the safety
instructions.
To better utilize all the functions of the machine, and, more importantly, to do so safely, each
person who works with the machine should carefully read the following safety instructions as
well as the operating information provided in this manual.

1-2

Safety instructions
Operators should fully understand the entire range of this machines function and operating
sequence.
Do not remove any safety devices from the machine. The safety guard, safety switch,
emergency button and ground wire must all be kept secured in their proper places.
Do not remove any warning indications from the machine.
Please make sure you know how to stop the machine before you start it.
Do not try to stop any machine operation by hand; always wait until moving parts are
completely motionless before attempting to handle them.
Never allow two or more people to operate the control panel or other button switches at the
same time.
Only qualified technicians should perform any electrical or mechanical servicing.
Before opening the control box door, turn the power off.
Before dismounting or replacing electric components, make sure the power source has been
turned off.
Pay attention to all warning indications before operation and read the section on electric
circuitry carefully. It is important that the circuitry match the needs of your site.
Use only insulated tools: ie., plastic casing around metal handles.
Never use a fuse of a higher voltage than the designated specification.

Never substitute a

fuse with any other kind of connecting wire.

Be certain any change in conductor wire matches the original route and color.
After doing maintenance, make sure the safety windows are replaced and restored to their
original position.
Be careful to check that no one is doing any work on the machine before giving the machine
any electricity.
If there is no electricity delivery system grounding area, please be sure to bury the brass
stick underground (to keep the resistor under 100 ohm), and connect at the Earth Ground
point inside the control box.
It is prohibited to put anything (food, clothing, scrap material, etc.) on top of the control box
or the operating box.
Make certain that the high voltage pins inside the control box, transformer, motor, relay box
etc., never touch.

1-3

1.4. Emergency stop

This machine is equipped with a locking EMERGENCY STOP button. In case of accident, or
if you wish to quickly stop the machine for any other reason, press the EMERGENCY STOP
button. Power to the machine is immediately cut, and all parts stop moving. This button locks
when you press it. To release the button, turn it and pull it out.
Note: Pressing the emergency stop button resets all values to zero (batch counter, etc.). To
resume operation after pressing the EMERGENCY STOP button, restart the machine as you
normally would after turning on the MAIN SWITCH. See Chapter 4 for details.
Pause button
If you wish to PAUSE machine operation, but not cut the power, press PAUSE. All machine
parts will immediately stop moving. To resume machine operation, press RESET or SET
ORIGIN (note: pressing SET ORIGIN resets all values such as batch counter, etc. to zero). See
Chapter 4 for detail
To prevent serious bodily injury

DANGER
Always operate machine in a normal fashion by standing in front and facing machine
Do not leave hand or other parts of body on block, material, or die when turning away from
machine or bending down
Do not allow other personnel to approach the machine from the side or rear while the motor
is on
Do not place any part of your body under the beam or within the die area while the motor is
on
Do not operate, install dies, or maintain this machine without proper instruction
Do not install dies or service this machine with the motor on
Shut off power whenever leaving the machine or making any kind of adjustments
If light curtain is used to activate cutting stroke (not recommended by us) additional hazards
require extra operator precaution
Inform your foreman or supervisor of any possible malfunction, so that prompt repairs can
be made
It is the employers responsibility to implement the above and also to provide proper dies,
guards, devices, or means that may be necessary or required for any particular use,
operation, set-up, or service

1-4

1.5. Danger area

2-1

2. Technical specifications
2.1. System drawing

2-2

2.2. System specifications

(mm)
(kg)

(ton)
(mm)
(mm)
(mm)
(bar)
(Hp)
((Hp)

ABC-E100 Model
188007 Serial number
Material type
Control Panel
W2529D3508H1670 Machine size (mm)
7000 Weight (kg)
Machine color
380V x 3x50 Hz Power supply
100 Cutting force (ton)
W1450D1150 Effective cutting area (mm)
110 Cutting stroke (mm)
50-160 Open daylight (mm)
6 Compressed air (bar)
10HPx4P Main motor (Hp)
1Hpx4P Feeder motor (Hp)

()

(mm)
(mm)

ABC-E100
188007
Sheet
Button
W2529D3508H1670
7000
Standard Blue
380V x 3x 50Hz
100
W1450D1150
110
50-160
6
10HPx4P
1Hpx4P
185138(90%)

W1600D1200
W1450D1150

(ton)
(mm)
&

(mm)
P.P.(mm)

()
PLC InputOutput
()

ABC-100_W1600D120
100
110
10HP4P+QT43+ 60+
Abc +QVD1

W1600D1200
W1600D1200T20
1HP
CE
,

2-3

2.3. Spare parts

Free spare parts
Item

Description

Fuse

Qty

Parts Number

10

EFU-006

HC Relay

ERL-3128

Button (22mm)

ESE-30DN-BS

Cutting head top limit switch.

ESL-8104

Tool box

H-T01

Adjustable wrench

H-T02

Hexagonal head wrench

H-T03

+ Driver

H-T05

Driver

H-T06

Instruction book

185041

10

Recommend charged spare parts

Item

Qty

Parts Number

Fuse

ERL-5532P7

HC Relay

ESE-30DN-BS

Button22MM

ESL-8104

Cutting head top limit switch

H-T01

Tool box

H-T02

Adjustable wrench

H-T03

Hexagonal head wrench

H-T05

+Driver

H-T06

-Driver

ERL-5532P7

Description

2-4

2.4. System overview

The ABC series is designed to cut any kind of soft material. In order to perform a cutting
operation, the operator must first place the material and blade-downward cutting die onto the
cutting pad. Then, using both hands, the operator must manually push the sliding table into the
cutting area. Again using two hands, the operator must then press the two START buttons
simultaneously to command the cutting head to automatically execute the cutting operation.
For cutting mode information, please refer to Chapter 4.4.
This machine can be used to cut a wide range of materials, such as cardboard, paper, textiles,
plastics, sponge, leather, rubber, floor covering, carpeting, fiberglass, cloth, and cork. These
materials can be used to produce items for the automotive upholstery industry, as well as other
items, such as foams, vacuum forming products, baby carriages, balls, brassieres, labels,
envelopes, paper tubes, floor tiles, garments, gaskets, plastic novelties, raincoats, umbrellas,
rubber products, shoes, furniture, leather goods, luggage, cork products, toys and so on.
Basic machine structure
This ABC series has a twin cylinders, four-column construction, which utilizes an internal
mechanical balancing system to ensure a plane-parallel cutting stroke and uniform cutting
pressure over the entire cutting bed. A parallel cutting stroke is essential for obtaining accurate
cut parts, as well as for extending the life of both cutting die and pad.
The speed of the cutting head slows to 10mm/sec just before touching the cutting die. This
minimizes the size difference between the top and bottom layers of material. This function
allows the ABC-40 to cut a thicker material stack than single-speed machines. The slower speed
at the moment of cutting impact has the added benefit of reducing noise associated with the
cutting process. Because the cutting head ascends and descends very quickly before and after the
actual cutting, the cutting cycle time is also reduced. The adjustable open daylight can also
reduce cutting cycle time. Thus, the working capacity of the ABC-40 is twice that of singlespeed machines. Normally, it takes 2 to 4 seconds per cutting stroke and about 6 to 12 seconds
per complete cutting cycle, including sliding the table, cutting the material, moving the die, and
removing the cut parts.
For safety considerations, this machine has an EMC stop device; two side safety guards; a
simultaneous two-hand trip, hold, and anti repeat system, and other devices necessary for safe
and efficient operation. It is operated by pressing two start buttons, which are linked by a 0.5
sec time interlock, ensuring that the operator is safely away from danger.
This is a user-friendly machine, and its well-constructed frame guarantees accurate cutting and
low risk for safe and successful long-term use.

2-5

Performance reference
At the time this manual was written, there were thousands of ABC machines being successfully
used by companies all around the world, including the following corporations.
ABC-E2563 to LIM-KOREA since Sep., 1989.
ABC-E2563 to COX-ENGLAND since Oct., 1989.
ABC-E2550 to HUMA-U.S.A. since Sep., 1990.
ABC-E2563 to Dorey-FRANCE since Dec., 1990.
ABC-E2550 to APMC-U.S.A. since Nov., 1991.
ABC-E2563 to Top Line-INDONESIA since Nov., 1992.
ABC-E2550 to W-H-L-HONG KONG since Dec., 1992.
ABC-E2563 to Wah Kui-HONG KONG since Mar., 1993.
ABC-E2550 to A.H.-MALAYSIYA since Oct., 1993.
ABC-E2563 to UNIP-MALAYSIYA since Nov., 1994.
ABC-E2550 to SDCS-KOREA since Sep., 1995.
ABC-E2550 to Shontel-SINGARPORE since Jan., 1996.
ABC-E2563 to A.H.-MALAYSIYA since Sep., 1996.

2-6

2.5. Conversion of cutting pressure

Reading at
manometer
kg/cm2

40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
285
290
300

HSC-12

2.8
3.5
4.3
5.0
5.7
6.4
7.1
7.8
8.5
9.2
10.0
10.6
11.3
12.0
12.8
13.5

THNC-20
HSC-20

2.8
3.5
4.3
5.0
5.7
6.4
7.1
7.8
8.5
9.2
10.0
10.6
11.3
12.0
12.8
13.5
14.2
14.9
15.6
16.3
17.0
17.7
18.4
19.1
19.8
20.2

THNC-25
CPC-25
HSC-25

3.8
4.8
5.7
6.7
7.6
8.6
9.5
10.5
11.4
12.4
13.3
14.3
15.2
16.2
17.1
18.1
19.0
20.0
20.9
21.8
22.8
23.7
24.7
25.6

Metric Tons
ABC-E25
ABC-30
ABC-25
RBC-30
HBC-30
MBC-30
4.0
5.0
6.0
7.0
8.0
9.0
10.1
11.1
12.1
13.1
14.1
15.1
16.1
17.1
18.1
19.1
20.1
21.1
22.1
23.1
24.1
25.1

5.7
7.1
8.5
9.9
11.3
12.8
14.2
15.6
17.0
18.4
19.8
21.3
22.7
24.1
25.5
26.9
28.4
29.8
31.2

CPC-30
HSC-30

HSC-40

ABC-40
CPC-40
RBC-40
MBC-40

5.3
6.6
8.0
9.3
10.6
11.9
13.3
14.6
15.9
17.2
18.6
19.9
21.2
22.6
23.9
25.2
26.5
27.9
29.2
30.5

5.3
6.6
8.0
9.3
10.6
11.9
13.3
14.6
15.9
17.2
18.6
19.9
21.2
22.6
23.9
25.2
26.5
27.9
29.2
30.5
31.8
33.2
34.5
35.8
37.1
37.8
38.5
39.8

7.6
9.5
11.4
13.3
15.2
17.1
19.0
20.9
22.8
24.7
26.6
28.5
30.4
32.3
34.2
36.1
38.0
39.9
41.8

2-7
Metric Tons
Reading at
manometer
kg/cm2

ABC-60
RBC-60
HBC-60

ABC-70
MBC-70
CPC-70

ABC-100
RBC-100
HBC-100

40
50

MBC-60
MRC-60
10.6
13.3

RBC-70
MRC-70
10.6
13.3

15.9
18.6
21.2
23.9
26.5
29.2
31.9
34.5
37.2
39.8
42.5
45.1
47.8
50.4
53.1
55.8
58.4
61.1

15.9
18.6
21.2
23.9
26.5
29.2
31.9
34.5
37.2
39.8
42.5
45.1
47.8
50.4
53.1
55.8
58.4
61.1
63.7
66.3
69.0
71.6

60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
285
290

ABC-150
CPC-150

ABC-200

ABC-300
MBC-300

CAR-5

MBC-100
MRC-100
14.1
17.7

20.3
25.4

27.6
34.6

40.6
50.8

1.5
1.9

21.2
24.7
28.3
31.8
35.3
38.9
42.4
45.9
49.5
53.0
56.6
60.1
63.6
67.2
70.7
74.2
77.8
81.3
84.8
88.4
91.9
95.4
98.9

30.5
35.6
40.6
45.7
50.8
55.9
61.0
66.1
71.2
76.3
81.3
86.4
91.5
96.6
101.7
106.8
111.9
116.9
122.0
127.1
132.2
137.3
142.4

41.5
48.4
55.3
62.3
69.2
76.1
83.0
90.0
96.9
103.8
110.7
117.7
124.6
131.5
138.4
145.3
152.3
159.2
166.1
173.0
180.0
186.9
193.8

61
71.2
81.2
91.4
101.6
111.8
122
132.2
142.4
152.6
162.6
172.8
183
193.2
203.4
213.6
223.8
233.8
244
254.2
264.4
274.6
284.8

2.3
2.6
3.0
3.4
3.8
4.2
4.6
5.0

100.7

147.5
152.6

200.7

295
305.2

300

2.6. Recommended hydraulic oil

BP---------------- ----------- ENERGOL HP 46
CASTROL ----------------- HYSPIN AWS 46
CHEVRON ---------------- EP hydraulic oil 46
ESSO ----------------------- NUTO HP 46
Q8 --------------------------- HARMONY AW 46
SHELL --------------------- Tellus oil 46
TEXACO ------------------ Regal oil R & O 46

3-1

3. Installation
3.1. Placing the machine in position
After the machine has been unpacked, either a forklift or a crane must be used to move the
machine to its permanent position. No matter which method is used, please note the weight of
the machine (found in Chapter 2.1) in relationship to the lifting capacity of your lifting device.
If a crane is used to move the machine, please choose a suitable sling, jib, and boom. Pay special
attention to the strength specifications of sling, jib, and boom. Also, be sure to the take the
following points into consideration:
Do not decline the machine too much. The sling may slide off from the hook, and the boom
may slide off from the machine.
The horizontal force of the sling may damage the covers or the parts of the machine.
A forklift is strongly recommended to avoid the above risks.
The following picture is an example of using a forklift to move a machine.

3.2. Installation
The feeding system must be mounted to the cutting machine in accordance with the layout
drawing in Chapter 2.1 All the safety covers can be assembled at this time.
Use a level gauge to adjust the horizontal leveling of the machine body and the feeding system.
The machine and the feeding system can be clamped to the floor if desired, but it is not
necessary. The screws for clamps both are available.
Removal oil tank cover, fill in hydraulic oil as recommended in Chapter 2.6. Please make sure
the hydraulic oil is clean enough. If the machine needs compressed air, connect the air inlet
tube to the compressor air supply.

Regular compressed air pressure is 6 kg/cm2.

3.3. Connecting to the main power supply

Warning
Only qualified technicians should work on the power source connection. Power supply voltage
is usually greater than 220v; contact with this high a voltage may lead to death.
Match voltage

3-2

There are some secondary electric distribution boxes on the machine and feeding system. These
wires must be connected according to the drawing shown in Chapter 5.1. Once the wiring is
completed, you should connect the main electric power cable, making sure the local voltage
matches the voltage indicated on the machines nameplate.
Check motor rotation
With power engaged, the motor will begin rotating. It is important to check that the direction
of the rotation matches the direction of the arrow sign embossed or stuck onto the outer casing
of the motor.
Press SYSTEM ON to start the motor.
Press EMERGENCY to stop the motor. Once the blade slows down enough, you can see
if the direction of the blades spin matches that of the direction arrow on the machine.
If the motor is running opposite the direction of the arrows, then the machine is not wired
properly. Cut all power and make the necessary corrections.
Any change in wire arrangement, in any part of the circuit sequence, can change the direction of
the motor. In the example below, we see the final circuit connection to the X-axis motor.
Should the wires be mismatched at this point (ex. wire A switched with wire B) the entire
sequence will be inverted, affecting also the wire arrangement of the Y-axes. To solve the
problem, you must rearrange the wire formation from the originating connection.
to Chapter 5.2 for a more detailed schematic.
Again
Only qualified technicians should perform electrical servicing.
qualifications or training, please contact a certified technician.

Please refer

If you do not possess the proper

Warning
Never run the motor in the wrong direction for over one minute.
This machine must be correctly grounded to protect against electrical shock hazards. Proper
grounding also helps to reduce electrical noise by isolating induced noise voltages to individual
ground wires and shunting them to ground. The recommended earth ground copper bar is 1
meter by 3/8 inch in diameter.
Warning
Do not share the grounding wire with any other machine.
.

4-1

4. Operation instruction
4.1. Control panel

4-2

Button or selector
MAIN SWITCH

MOTOR ON

Function
Powers up the control console.

MOTOR ON button.
It starts the main hydraulic motor, and doubles as a signal
light to indicate that the main hydraulic motor is running.

MOTOR OFF

MOTOR OFF button.

It stops the main hydraulic motor, and doubles as a signal
light to indicate that the main hydraulic motor is not
running.

CUTTING DEPTH

CUTTING DEPTH timer.

The greater the value of the CUTTING DEPTH timer, the
deeper the head will penetrate the die.
NOTE:
The scale should set zero at the beginning of the operation,
then adjust to bigger scale gradually until the right depth
scale is reached.

LIFT HEIGHT

LIFT HEIGHT timer.

The greater the value of the LIFT HEIGHT timer, the
higher the head will move upward after completed the
cutting.

4-3

Button or selector

Function

DIE SETTING

DIE SETTING light (yellow).

It flashes throughout the die height setting process, until the
die height has been completely and properly set.

OPERATION

OPERATION light (green).

It lights to indicate that the machine is currently
functioning in OPERATION mode.

COUNTER

It is for counting cutting strokes.

SELECTION SW.1

For selecting execute DIE SETTING or OPERATION.

FEED FORWARD

FEEDING FORWARD button.

It means the feeding is

forward. It is a signal light, too. If this light is on, the

machine is under feeding forward.

4-4

Button or selector

Function

FEED BACKWARD

FEEDING BACKWARD button.

It means the feeding is

backward. It is a signal light, too. If this light is on, the

machine mode is under feeding backward.

START

EMC

START buttons. The START buttons must be pressed

simultaneously to begin most machine operations.

EMERGENCY STOP button. If the EMC is pressed, the

cutting head moves up, all moving parts stop, and power is
immediately cut to the machine.

4-5

4.2. Starting the machine

Check voltage and motor direction
After ensuring the power supply voltage matches the needs of the machine (see 3.3 for further
instructions) and the hydraulic pump motor is rotating in the proper direction (see also 3.3), then
the machine is ready for operation.
Power up the machine:
Located on the side electrical cabinet is a large black knob labeled MAIN SWITCH.
this to ON.

Turn

Press the RESET button and the machine will automatically check to see if the initial
conditions are normal. If there is no problem, the power light will switch on. If the
power light does not switch on, then there is some problem with the safety or electric relay.
Warning:
Make sure the cutting die height is properly set before beginning any cutting operation.
Careless die height setting could damage the cutting die, pad, or other machine parts.

4.3. Die heibht setting

This mode is designed for the important task of setting the cutting die height.

Accurate die

height setting guarantees quality cutting, and extends the life of both cutting die and pad. The
ABC series provides a fast and accurate die height setting method, detailed as follows.
Place the die on the cutting pad.
Be sure the top selection switch is set to DIE SETTING. The yellow light will flash.
Simultaneously press the two START BUTTONS, which are located on the panel at the
front edge of the cutting table. The cutting head will move slowly downward until it touches
the cutting die.
Loosen the setting handle, move it up and down once or twice, and then press it downward
to touch the cutting stroke end limit switch; meanwhile, the yellow die setting light goes off
and the green operation light comes on. Now tighten the setting handle.
Change the top selection switch to OPERATION mode. The cutting head will move
upward, completing the die setting process.

Note
The START BUTTONS operate on a time interlock device. The two buttons must be
pressed and held simultaneously (within 0.5 seconds of each other) in order to begin the
setting process.
The two START BUTTONS must be pressed and held until the remaining stroke distance is
less than 23 mm; otherwise, the cutting head will move upward, causing the die setting to

4-6

fail. For best results, hold the START buttons down until the head has touched the cutting
die.
If the emergency button is pressed during the setting process, the cutting head will move
upward and cause the die setting to fail.
Make sure the cutting die height is set completely and correctly before beginning a cutting
operation. Careless die height setting could result in breakage of the cutting die and pad,
mechanical parts damage, or other unpredictable damage.
It is important to toggle the setting handle up and down to check that the spring is working
properly. If there is no tension when the handle is moved up and down, there may be a
problem with the spring. Do not operate the machine with a faulty spring. Contact a
technician.

4.4. Cutting mode

Before beginning any CUTTING operation, please be sure that the height of the cutting die has
been properly set. (Refer to 4.3 SETTING MODE). This will avoid any unnecessary damage to
the machine.

The procedure for performing a CUTTING operation is detailed as follows.

After the die height has been set, place the material onto the cutting table.
Place the cutting die onto the material
Push the sliding table into the cutting area.
Simultaneously press both START buttons. The cutting head moves quickly downward until
it reaches the slow-speed sensor. Upon reaching the slow-speed sensor, the head slows
down, but continues its descent until it touches the stroke end limit switch. According to the
setting of the CUTTING DEPTH timer, the cutting head will maintain pressure for a short
period of time.
After completing the cut, the head will move upward according to the setting of the LIFT
HEIGHT timer.
Note
The greater the value of the CUTTING DEPTH TIMER, the deeper the die will penetrate
the pad. To avoid damaging the die, pad, or other machine parts, the scale should be set to
zero at the beginning of the operation, then gradually adjusted until the desired depth scale
is reached.
The LIFT HEIGHT TIMER design theory is the same as that of the CUTTING DEPTH TIMER,
so follow the directions as previously indicated.
2. Refer to Chapter 1.4 for more information about the emergency button.
If regardless of the CUTTING DEPTH timer, the cutting head stops at the bottom position,
is unable to cut through the material, and causes the motor to make abnormal noise, it may
be due to one of the following reasons. The cutting die is too large; or, the cutting force has
exceeded its range of capacity.

5-1

5. Electrical schemes
5.1. Main connection to power supply
Main connection to power supply

Z2703

5-2

5.2. AC control circuit

AC control circuit

Z0558k

5-3

5.3. DC control circuit

DC control circuit

Z0039

5-4

5.4. Pause control circuit

Pause control circuit

Z0560

5-5

5.5. Emergency control circuit

Emergency control circuit

Z1062

5-6

5.6. Mitsubishi PLC Ax2n-48MR

Mitsubishi PLC Ax2n-48MR input 1

Z2704

5-7

Mitsubishi PLC Ax2n-48MR input 2

Z1494k

5-8

Mitsubishi PLC Ax2n-48MR output 1

Z0564

5-9

Mitsubishi PLC Ax2n-48MR output 2

Z0565

5-10

5.7. Mitsubishi inverter

Mitsubishi inverter

Z1495

5-11

5.8. Location drawing

Location drawing of control cabinet

185041

G9D-301

5-12

5.9. Inverter parameter setting

A : Feeding inverter parameter (FR-A540-0.75K)
B
C
D
E

: No use
: No use
: No use
: No use

No. Description

00

Torque boost (manual)

01

Upper limit frequency.

60

60

60

60

60

02

Lower limit frequency.

03

Base frequency.

60

60

60

60

60

04

3-speed setting (high speed)

60

60

60

60

60

05

3-speed setting (mid speed)

30

30

30

30

30

06

3-speed setting (low speed)

07

Acceleration time

0.3

0.3

0.3

0.3

0.3

08

Deceleration time

0.3

0.3

0.3

0.3

0.3

09

Electronic thermal overload relay

1.2

3.8

3.8

3.8

3.8

10

DC injection braking frequency

11

DC injection braking time

0.5

0.5

0.5

0.5

0.5

12

DC injection braking voltage

13

Starting frequency

0.5

0.5

0.5

0.5

0.5

14

Selection of applied

15

Jog frequency

16

Jog acceleration deceleration time

0.5

0.5

0.5

0.5

0.5

17

External thermal relay input

18

Upper limit frequency for high speed operation

60

60

60

60

60

19

Base frequency voltage

9999

9999

9999

9999

9999

20

Reference frequency for acceleration/deceleration

60

60

60

60

60

21

Acceleration/deceleration time increments

22

Stall prevention function operation level

150

150

150

150

150

9999

9999

9999

9999

9999

23

Stall prevention function operation level offset coefficient

for double speed operation

24

Multiple-speed setting (speed 4)

9999

9999

9999

9999

9999

25

Multiple-speed setting (speed 5)

9999

9999

9999

9999

9999

26

Multiple-speed setting (speed 6)

9999

9999

9999

9999

9999

27

Multiple-speed setting (speed 7)

9999

9999

9999

9999

9999

29

Selection of acceleration/deceleration pattern

30

Selection of regeneration brake duty ratio

31

Frequency jump 1A 0 - 400Hz

9999

9999

9999

9999

9999

32

Frequency jump 1B 0 - 400Hz

9999

9999

9999

9999

9999

5-13
No. Description

33

Frequency jump 2A 0 - 400Hz

9999

9999

9999

9999

9999

34

Frequency jump 2B 0 - 400Hz moment.

9999

9999

9999

9999

9999

35

Frequency jump 3A 0 - 400Hz

9999

9999

9999

9999

9999

36

Frequency jump 3B 0 - 400Hz

9999

9999

9999

9999

9999

37

Speed display

38

Frequency at 5v (10v) input

60

60

60

60

60

39

Frequency at 20mA input

60

60

60

60

60

41

Up-to-frequency sensitivity

6%

6%

6%

6%

6%

42

Output frequency detection

43

Output frequency detection for reverse rotation

9999

9999

9999

9999

9999

nd

44

2 acceleration/deceleration

45

2nd deceleration time

46
47

9999

9999

9999

9999

9999

nd

9999

9999

9999

9999

9999

nd

9999

9999

9999

9999

9999

nd

150

150

150

150

150

2 torque boost
2 V/F (base frequency)

48

2 electronic over current protection

52

Output signal selection 1.

0000

0000

0000

0000

0000

79

Operation mode selection

180 RL terminal function selection

181 RM terminal function selection

182 RH terminal function selection

183 MRS terminal function selection

190 RUN terminal function selection

191 SU terminal function selection

192 IPF terminal function selection

232 Multi-speed setting (speed 8)

9999

9999

9999

9999

9999

233 Multi-speed setting (speed 9)

9999

9999

9999

9999

9999

234 Multi-speed setting (speed 10)

9999

9999

9999

9999

9999

235 Multi-speed setting (speed 11)

9999

9999

9999

9999

9999

236 Multi-speed setting (speed 12)

9999

9999

9999

9999

9999

237 Multi-speed setting (speed 13)

9999

9999

9999

9999

9999

238 Multi-speed setting (speed 14)

9999

9999

9999

9999

9999

239 Multi-speed setting (speed 15)

9999

9999

9999

9999

9999

250 Stop selection

9999

9999

9999

9999

9999

900 FM terminal calibration

902 Frequency setting voltage bias

903 Frequency setting voltage gain

60

60

60

60

60

904 Frequency setting current bias

905 Frequency setting current gain

60

60

60

60

60

922 Built-in frequency setting potentiometer bias

----

----

----

----

----

923 Built-in frequency setting potentiometer gain

----

----

----

----

----

990 Parameter for FR-PU04

----

----

----

----

----

991 Parameter for FR-PU04

----

----

----

----

----

6-14

6. Hydraulic & pneumatic

6.1. Pneumatic circuit
Connection of motors & solenoid vales

7-1

7. Alarms & maintenance

7.1. Maintance
Period

Maintenance

Daily

Clean the machine after finishing the operation.

Let pump motor run for at least 5 minutes before running the machine at full capacity.
Clean the outer surface of the machine.

Monthly

Check the hydraulic system for leakage.

Tighten up the fittings, if necessary.

Check that the cutting results are even over the whole cutting area.
Grease the outer surface between traveling head and upper beam.
Check that the electric cable connection is not loose.
Check and clean the air filter unit, removing any accumulated dust.
Yearly

Change fresh hydraulic oil into the hydraulic tank.

Change or clean the hydraulic oil filter.
Check or replace the top and bottom limit switches.
Tighten up all safety covers and replace missing screws.
Test the machine pressure.

Check the relief valve function and the pump performance.

Note
Yearly means max. 2000 hours of operation.
For new machine, first hydraulic change should be made after 6 months or 1000 hours of
operation.

7.2. Trouble shooting

Please refer to Chapter 4.1 OPERATION PANEL, Chapter 5 ELECTRICAL DRAWING,
Chapter 6 HYDRAULIC DRAWING, and Chapter 8 MACHINE ASSEMBLY DRAWING
such associated chapters when you do trouble shooting.

7-2

7.2.1. Trouble shooting

Symptom

Remedy

No matter motor runs or not, head

Check valve V03 stuck with dust

slowly go down when machine is

Relief valve V06 is loosen or abnormal

not in cutting down operation

* Spool of SV1, SV4 stuck with dust

* Hydraulic pipe or joints are loosened or broken
Packing of hydraulic cylinder is broken

Motor runs loudly

Motor rotation direction is incorrect (arrow direction on motor)

* Rubber coupling between pump and motor is broken
* Motor or pump fixing screws are loosened
* Hydraulic oil is not enough
* Oil filter is dirty
Motor or pump is broken
Bearing between motor and pump run out of grease or broken

Motor runs, but no cutting

No hydraulic oil flowing inside oil tank; it means pump is broken or

operation

coupling between pump and motor is broken

Motor rotation direction is incorrect (arrow direction on motor)
Emergency switch is abnormal
Setting handle wheel is loosen
Two hand trip buttons are abnormal
Hydraulic pipe or joints are loosened or broken
Spool of SV1 is stuck with dust or not activated
Bottom limit switch is out of order
Overcut protect limit switch is loosened

Do setting, but head is not slowly

SV 4 coil is not activated

down

Spool of SV4 stuck with dust

Improper stuck of four column mechanical balance mechanism
Four column mounting nuts are loosened
Hydraulic cylinder mounting nuts are loosened
If head is quick down during setting, flow control plug on SV4 is loosened
Two hand trip buttons are abnormal

Head go down with slow speed at

Logic valve V01 is stuck with dust

the starting of operation

Spool of SV3A, SV3B stuck with dust

Spool of SV1 stuck with dust

Head quickly cutting down

Head slow down sensor position is too low or mounting screw is loosened

without slow speed before cutting

Head slow down sensor is out of order

SV1 stuck with dust and do not return to neutral
Relief valve V06 is loosened or dust inside
Check valve V03 is abnormal

7-3
Symptom
Cutting depth is not even

Remedy
Thickness of cutting pad is not even.
Head slow down sensor is broken
Spool of SV2 is stuck with dust
Bottom limit switch is loosened or broken or position is too low
Cutting depth timer is broken
Four column mounting nuts are loosened
Hydraulic cylinder mounting nuts are loosened
Hydraulic oil is not enough
Oil filter is dirty
Head slow down sensor position is too low or mounting screw is loosened

Cutting force is not enough

Packing of hydraulic cylinder is broken

Cutting depth timer is out of order
Hydraulic pipe or joints are loosened or broken
Cutting die is too big or not sharp
SV2 spool is stuck with dust
Hydraulic oil is not enough
Oil filter is dirty
Motor or pump is broken
Head slow down sensor is broken
Relief valve V07 is loosened or dust inside
Logic valve V01 stuck with dust
V03 spool do not return t neutral

Cutting depth is too much

Setting mechanism is stuck with dust

Bottom limit switch is loosened or broken or position is too low
Cutting depth timer is broken
Die height setting process is incorrect
Spool of SV12 is stuck with dust

Head do not go up after cutting

Top limit switch is out of order

Lift height timer is broken
Cutting depth timer is broken
Coil SV3 is not activated
Spool of SV3, V01 are stuck with dust
Hydraulic pipe or joints are loosened or broken
Relief valve V06 is loosened or dust inside
Packing of hydraulic cylinder is broken

8-1

8. Assembly drawing
Machine frame

8-2
Machine frame
Part no.

Description

Qty Part no.

Description

Qty

82277

Top cover

70945

Upper frame

84236

Column

70946

Lower frame

10120

Upper frame

S-M06010

Screw

16

81138

Bush

R-LBH80906

Ring

81139

Bush

S-M08085

Screw

16

94013

Cover

B-DU8060

Bearing

93890

Top cover

S-M08035

Screw

16

95531

Cover plate

S-M06012

Screw

16

81099

Front cover

S-M08020

Screw

40

94089

Nut

S-M06012

Screw

10

S-N08X

Loose proof nut

S-N08X

Loose-proof nut

8-3

Balance machanism

8-4

Balance mechanism
Part no.

Description

Qty Part no.

Description

Qty

93995

Pin

12

81054

Horizontal bar

93994

Rocker arm

00654

Cross support

93997

Bush

JCU-02E02

Fitting

00652

Support

JNL-01L02

Fitting

12

00653

Transverse shaft

JNL-01R02

Fitting

94094

Seat support

S-M24180

Screw

93952

Bolt

12

B-SOB354430

Bearing

93892

Stop block

S-M08060

Screw

81105

Oil distribution

S-M06025

Screw

94174

Oil pipe fixed block

S-M06030F

Screw

S-N06

Nut

JNL-03S12

Fitting

S-W06

Washer

JPT-03S03

Fitting

JNL-01L02

Fitting

S-M04016

Screw

12

JNL-01S02

Fitting

JNL-03S12

Fitting

8-5

Cylinder

8-6

Cylinder
Part no.

Description

Qty Part no.

Description

Qty

82442

Connector

3891

Tie bar

19106

Cover

93954

Drain pipe

19107

Cover

81033

Cylinder front cover

19105

Piston

93893

Connector

19108

Bush

R-BRT130

Back-up ring

93894

Cover

R-OSI130

Packing

81000

Top cover

R-WR130123153 Ring

93986

Cylinder

S-M10025

Screw

12

80998

Oil tank

R-IS-I1201359

Ring

93953

Pipe

S-M08030

Screw

14

QVL-LV32-D02

Logic valve

R-P009

O-Ring

R-BRT85

Back-up ring

R-P014

O-Ring

R-G080-90

O-Ring

R-P020

O-Ring

R-G145

O-Ring

S-M10045

Screw

S-M12070

Screw

16

S-M10055

Screw

JST-15-0X-2.0

Pipe

S-P01

Screw

JST-UE15

Elbow union

S-N20

Nut

S-M24140

Screw

16

JST-04SM15

Steel elbow union

JSF-04SM15

Connector

R-P014

O-Ring

QVD-101

Directional valve

S-M08050

Screw

R-G105

O-Ring

R-P145

O-Ring

S-M06016

Screw

16

8-7

Pump unit

8-8

Pump unit
Part no.

Description

Qty Part no.

Description

Qty

94140

Bush

10516

Connection

93339

Washer

81043

Fly wheel

93030

Magnetic seat

99245

Unloading valve cover

99246

Locked block

83837

Unloading valve cover

81044

Pump seat

93993

Pump cover

93992

Shaft coupling

99247

Rear cover

93898

Bush

21495

Fixed block

93956

Dead plate

21494

Oil pipe fixed block

93991

Shaft coupling

H-N1006

Nipple

93955

Dead plate

JFL-10

Female elbow union

JPT-12S10

Iron connection

S-M10030

Screw

MVC-07H4P

Motor

S-M12030

Screw

QSF-N12

Filter net

R-P022A

O-Ring

S-M14040

Screw

S-M06012

Screw

S-M18050

Screw

94140

Bush

S-SW14

Spring washer

S-M08020

Screw

S-M06025

Screw

R-P042

O-Ring

JST-06LM22

Cooper joint

S-M06012

Screw

QPV-006

Pump

S-M06016

Screw

QSF-N12

Filter net

QVD-101-VS

Vlave

S-P01

Screw

R-G030

Ring

H-N0605

Nipple

R-P009

O-Ring

H-X058C

Connector

S-M10085

Screw

JCM-06S08

Fitting

S-PZ2

Plug

JFL-06

Female joint

S-M06012

Screw

12

JNL-04L12

Fitting

S-M06012

Screw

10

JPF-06L06

Pipe fitting

S-M08025

Screw

P-06L0650

Hose

S-M08045

Screw

QVL-LV25-C02

Logical valve

8-9

Hydraulic unit

8-10

Hydraulic unit
Part no.

Description

Qty Part no.

Description

Qty

93958

Bush

JFL-02

Iron joint

11873

Muffler

JST-02LM6

Steel joint

83930

Direction valve seat

JST-02SM6

Steel elbow union

93983

Raising block

QGA-400IN

Pressure gauge

81023

Seat

S-M04040

Screw

96001

Oil pipe fixed block

JST-UE15

Elbow union

95315

Plate

QVD-102-VS

Valve

97948

Oil pipe fixed block

QVF-SV12

Check valve

70278

Hydraulic plate

R-P012

O-Ring

H-VL450

ISI-1101259

S-M06060

Screw

JFL-03

Fitting

JSF-04LM15

Elbow union

JPT-03S03

Fitting

JSF-04SM15

Connector

JSF-06SM22

Steel connector

JST-04LM15

Steel joint

JST-UE22

Elbow union

JST-04SM15

Steel elbow union

S-M08025

Screw

JST-15-0X-2.0

Pipe

JNL-03S12

Fitting

JST-22-0X-2.5

Pipe

S-M08045

Screw

QVC-CA02C-03

Check valve

S-M06012

Screw

16

QVD-308-

Radio tube

3C4VS
S-M08060

Screw

QVS-DR02C-HL

Relief valve

H-X058D

Connector

QVS-DR02C-M

Relief valve

S-P02

Plug

S-P04

Plug

S-P03

Plug

S-PZ2

Plug

8-11

Enactment mechanism

8-12

Enactment mechanism
Part no.

Description

Qty Part no.

Description

Qty

10124

Back-up block

93766

Stroke adjust rod

94057

Fixed seat

80935

Cover plate

94157

Adjusting wheel

80940

Side control box

92208

Handle

94019

Locked block

92193

Locking block

93957

Top block

93901

Protecting piece

92192

Contact block

81064

Rail

93765

Support

91323

Roof bar

93767

Contact block

94017

Plate

94096

Adjustable seat

94018

Plate

S-M08020

Screw

S-M08045

Screw

S-M08020

Screw

S-M08025

Screw

S-M08016

Screw

S-M08035

Screw

S-M04025

Screw

SC-1009450141

Spring

S-M08050

Screw

S-F06025C

Screw

S-W04

Washer

S-M06010

Screw

S-M08025

Screw

8-13

Feeding systems

8-14

Feeding systems
Part no.

Description

Qty Part no.

Description

Qty

94714

Bearing seat

89457

Steadier

97667

Spring seat

25514

Guide rod

91697

Spring seat

88131

Left support

94112

Shaft

88130

Steadier

89456

Shaft

31019

Steadier

26628

Spring support rod

20765

Block

22476

Fixed seat

89563

Press rungs

97031

Fixed seat

16374

Screw bolt

94030

Lock block

29309

Bush

94035

Contact block

82242

Support frame

97665

Wheel

31062

Control gainer

89651

Stealer

36427

Slat

26119

Clip block

00659

Cover

94031

Adjusting seat

00661

Cover

36423

P.P Pad

00658

Cover

00656

Slide plate

00660

Cover

36432

P.P pad

97088

Buffer board

32081

P.P pad

94064

Roller chain sprocket

94166

Stop block

92652

Roller chain sprocket

00657

Safety cover

93858

Shaft seat

36425

Plate

H-R80

C-Retaining

36430

Plate

S-M08025

Screw

20737

Bush

H-S20

C-Retaining

94353

Connecting chip

S-H10065X

Screw

20234

Connector

10

SC-4034100009

Spring

97087

Buffer board

S-M10030

Screw

16

18098

Fixed block

H-S25

Circle

94047

Fixed plate

NWG-BH70X20

Gear reducer

36424

Mat block

S-N16

Nut

B-UCC205

Bearing

S-M08030

Screw

S-M08030

Screw

S-N20

Nut

S-M08040

Screw

S-M08045

Screw

S-M08040

Screw

S-M08025

Screw

S-M05016

Screw

B-6904ZZ

Bearing

S-M06016

Screw

B-DU1212

Bearing

S-M08016

Screw

S-H08040

Screw

8-15

Feeding systems
Part no.

Description

MVX-01H4P

Motor

Qty Part no.

Description

Qty

S-M08025

Screw

NWG-BH70X20 Gear reducer

S-H12090FX

Hex head steel screw

B-LM30UU

Linear bearing

S-M08040

Screw

H-R45

Ring

S-N12

Nut

S-M06025

Screw

16

ESL-8104

Limit switch

S-M08025

Screw

ESL-8104

Limit switch

S-M06040

Screw

S-F05020FH

Screw

S-M06040

Screw

S-M05012

Screw

S-M06100

Screw

S-M05020

Screw

S-M06100

Screw

S-M08016

Screw

B-6005ZZ

Bearing

S-M08016

Screw

S-M06020

Screw

S-M08045

Screw

S-M08020

Screw

Screw