Itoh 432 Cutter 4110-121-4

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Overview SOP Instructions & Explanations

1 Operating Modes 
1.1 Four basic operating modes are available: MANUAL for basic drive operations, PROGRAM to create new jobs,
REVIEW to look up old jobs and AUTOMATIC to sequence position to position as described by a selected job.

1 1.1, 3.1, 6.1,7.1, 8.1, 9.1 Control panel touchscreen 2 2.1 Help mode display

2 Making choices at the selection screens

2.1 Several features have been built into microcut. These appear on the display. Each feature is preceded with F1 …
F9. Press the corresponding key set (feature key and then the number) to make the selection.

3 Backgauge Movement
3.1 Press FORWARD or REVERSE to move the backgauge. To move to a specific position, use NUMBERS and +, -
, / to display the target value and press MOVE. In the case of the FORWARD or REVERSE keys, auto correction
will remain off allowing the hand wheel to be used. Auto correction will engage after any move to a specific
location (automatic operation or with MOVE).

4 Getting Started
4.1 Make sure everyone is clear of the machine and that all guards are in place. Flip the switch in the lower right side
of the display console to the on position. Microcut will check the electronics.
4.2 The display will show:
4.2a “YES; Press this key when all guards are in place”
4.2b Make sure all the machine guards are in place. Press YES. The display will then show:
4.2c “YES; Press this key when everyone is clear of the machine”
4.2d Look around the machine to make sure that no one is near any of the moving parts and that nothing has been
left on the table surface which could be damaged.
4.3 Press YES to continue. Microcut will:
4.3a Check the circuits, and continue only if everything is OK. If there are any errors microcut will display the
problems so that they can be corrected.
4.3b If full power has been removed from the control since the last use, then the backgauge will move slowly to
the rear of the cutter to calibrate. Note: If microcut is already at the rear of the table it will move the backgauge
forward before going back.
4.3c Microcut is now ready to use.
 Itoh 432 Cutter Work Instructions 4110-121-4
3 5.1 Manual mode display and codes 4 4.1 Microcut On & Off switch 5 4.2a Display

8 5.2, 4.4 Oil lube system under the

6 4.2c Display 7 4.3a Display table and main power switch

Oil lube system

Main power switch

4.4 Oil lubrication system located on the backgauge and under the front cutting table. When starting the shift, give
the oil system one pump.

5 Manual Mode
5.1 MANUAL is the basic operating mode. The backgauge can be moved by pressing the FORWARD and
REVERSE keys or by pressing NUMBERS and the MOVE key. Auto correcting will stay off unless the MOVE
key is used.
5.2 The main power switch is located under the cutting table next to the Bejur oiling system. Turn that switch on and
then go to the secondary power switch, located on the front right side of the cutter. Ensure that the lock out key is
vertical and then push the green button. This will power up the main unit including the hydraulics.
5.3 The table light switch is located below and to the left of the secondary power switch. This can be used in either
the full light or a light stripe position.

6 Program Mode
6.1 Program mode is used to define a series of targets so microcut can operate in automatic mode. These stops (and
pushes and load points) can proceed without limitations of direction or motion. Press PROGRAM. Use
NUMBERS, LETTERS, and F1 to enter a job title or press F2 and the lowest unused number will be found.
Letters can be entered by using the ARROW keys and pressing YES. Use NUMBERS and LETTERS to show a
description if desired. Press F1 to continue. Programming can now be done by pressing NUMBERS to display the
desired position and YES to record it, or by moving the backgauge and cycling the knife. The +, -, /, * keys can
be used to enter fractions or blind program from the previously programmed position. The ARROW keys can be
used to scroll up and down the job to make adjustments or corrections. Once programming is completed, press
AUTOMATIC and microcut will drive the backgauge to the highlighted position. Once in automatic mode, the
backgauge will move to the next position after each cut, or whenever MOVE is pressed.
6.2 Features in Program Mode:
6.2a Several features are available to help create the job and facilitate easier cutting. To select a feature press the
corresponding F key.
6.3 Features Screen 1:

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 Itoh 432 Cutter Work Instructions 4110-121-4
6.3a F1 Cut options: Allows stock pushes, load points, or cuts to be programmed.
6.3b Note: On OEM applications other cut options may be available such as CLAMP ONLY or AUTO TRIM.
6.3c Additionally, the clamp pressure can be adjusted by turning the pressure adjustment handle on the front lower
left side of the cutter.
6.3d F2 Comments: Allows comments to be entered alongside each programmed position.
6.3e F3 Insert cut: Adds a cut in front of the one that is highlighted on the display.
6.3f F4 Delete cut: Removes the cut that is shown on the display. Press YES to confirm.
6.3g F5 Change cut: Allows an already programmed cut to be adjusted.
6.3h F6 Next screen: Offers additional features of the program mode.
6.4 Features Screen 2
6.4a F1 Label mode: Programs cut values for a step and repeat sequence. A worksheet for entering values will
appear and a graphical “picture” of the cuts will be drawn as information is entered. microcut will automatically
fill in the missing pieces of information if you do not know the first cut position or the gutter trim size.
6.4b F2 Sheet divide: Calculates stop values that will cut the sheet into equal sizes. A worksheet for entering
values will appear and a graphical “picture” of the cuts will be drawn as information is entered.
6.4c F3 Change units: Shifts the position to the next allowed unit of measurement.
6.4d F4 Copy job: Allows you to copy a job to a new job with a different number. The description can also be
changed. A protected job (see below) can be copied and will not be protected in case changes are required and
the original owner does not want his job to reflect those changes. A copied job will start with zero lifts run and
show the current date as the creation date. Note: This feature can be used to change just the job description if
the job number is not altered.
6.4e F5 Job protect: This prevents unauthorized modification or erasure of special jobs. The owner’s access code
(or the management code, or, if the access codes are off then the universal operator’s code 2 9 8 4) must be
entered before changes are allowed. The protection is re-enabled any time manual mode is commenced. The job
can be copied without the access code (see above) if changes are required.
6.4f F6 Previous screen: Allows you to display FEATURES SCREEN 1.

10 6.1 First Program mode display; 11 6.1 Second Program mode display;
9 17.2 Calculator mode give the job a name and number give a description

7 Review Mode
7.1 Press REVIEW to review an existing job. The jobs will be sorted and displayed. Press the ARROWS to highlight
the desired job. Press YES to recall the job (this allows you to view the job in the same manner as PROGRAM—
see the previous pages). Press AUTOMATIC to use the job or MANUAL to exit.
7.2 Features in Review Mode:
7.2a Several features are available to help find, copy, read, or delete jobs. To select a feature press the
corresponding F key:
7.2b F1 Page up: Moves up a full screen of jobs.
7.2c F2 Page down: Moves down a full screen of jobs.
7.2d F3 Options: Allows you to sort or search the jobs by date, number, or description. Also allows you to delete
or copy jobs, zero the lifts run counter, print jobs, or switch to the floppy disk drive. Follow the on-screen
instructions for details.
7.3 Notes:
7.4 The NO key can be pressed from the entry screen to delete the highlighted job directly.

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 Itoh 432 Cutter Work Instructions 4110-121-4
7.5 If a diskette containing a CIP4 compatible file (extension is .PPF) is placed in the floppy drive and pulled up a job
will be created automatically using the job number and description contained in the CIP4 file. Push out, clamp
only, and load point values will not be programmed. The operator will need to insert those while running the job.

8 Automatic Mode
8.1 While in automatic operation microcut will read programmed locations from job memory and position the
backgauge sequentially from one value to the next as the knife (or clamp if the target is a clamp only) is cycled,
MOVE is pressed, or the location is reached (push out). Program a new job or press REVIEW to select the
desired job. Press AUTOMATIC and microcut will move to the highlighted value.
8.2 Press the ARROW keys to move the display to a previous or future value. Press MOVE to go there.
8.3 Use FORWARD, REVERSE, or NUMBERS and MOVE to move the backgauge to adjust a cut for this lift only.
8.4 Press any MODE key to exit automatic mode. Press AUTOMATIC to go back to automatic mode at the same
place you exited.

9 Features in Automatic Mode

9.1 The same features available in program mode are available in automatic mode with the features screen 2 addition
of:
9.1a F4 Lay compensate this lift only: Adjusts all forward moving backgauge targets up to the end job or the next
load point for only this lift.
9.1b F5 Lay compensate all lifts: Adjusts all forward moving backgauge targets up to the end job or the next load
point for all lifts.
9.1c The lay comp feature allows an operator to program a label job with the convenience of the label mode
regardless of the quality of the layout. On the first lift use the lay comp feature to adjust each trim out. All
finished label sizes will be maintained but each trim will be adjusted.
9.1d Note that copy job and job protect options are not available in AUTOMATIC operation.

12 7.1 Review mode display 13 10.3 Throttle valve 14 11.9a Back gauge manual turn handle

Knife support bolts

Air table on/off

Back gauge handle

10 Knife Removal
10.1 When handling the blade always use Kevlar Gloves!
10.2 Bring the blade to the lowest position and remove 2 bolts from the left side. Return the blade to the top position.
10.3 Turn the throttle valve to the right completely then back of half a turn. (in this state, the main motor and
hydraulic pump motor keep running, but the vertical motion of the clamp will slow down with the throttle valve.
10.4 Remove the knife support bolts from under the front cutting table.
10.5 Lower the clamp by pushing the clamp pedal; then fit two knife support bolts on both sides of the clamp.
10.6 When the clamp pedal is released slowly, the clamp will gradually go up, and will reach a position where the
knife is supported by the bolts on its cutting edge.
10.7 Remove the remaining knife fixing bolts.
10.8 Set the blade handles into the holes of the blade which will meet the grooved portions of the blade holder.
10.9 SET THE BLADE HOLDERS just under the blade handles.
10.10 Press the clamp pedal, slowly lower down the clamp, so as to fit the blade handles just into the grooved
portions of the blade holders.

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 Itoh 432 Cutter Work Instructions 4110-121-4
10.11 Fasten the blade handles, and blade will be fixed on the holders.
10.12 Press the clamp pedal to lower the clamp and remove the blade.
10.13 Pull out the blade by the handles to the front side of the machine.
10.14 Release the clamp pedal slowly, and the clamp will move up slowly.
10.15 Loosen the blade handle a little and lift up the blade, removing it from the blade holders.
10.16 Place the blade by its handles to the Storage container and remove the handles.

15 10 Knife fixing bolts 16 11.8 Ratchet wrench for knife bolts 17 10.8 10.12 Blade holders and handles

Knife fixing bolts

Knife carriage Blade holders

Blade handles

Knife support bolt holders

11 Replacing the Knife

11.1 Put the new blade flatly on the machine table. Fix the blade handles upright softly on to the blade with their
fixing holes on the blade.
11.2 This is a good time to clean the blade and spray the blade with silicone.
11.3 Lay the holder down on the blade.
11.4 Keep the throttle valve in the same position as it was when the knife was removed.
11.5 Let the blade holders with their blade and blade handles stand upright on the table, then move it toward the knife
holder. Place it just under the position where the blade handles can get into the grooved portion of knife holder.
11.6 Loosen Blade handle a little.
11.7 Release the clamp pedal slowly and it will move up. Knife Support bolts which are fitted on the clamp front face
will move up catching the blade on its edge.
11.8 Using the wrench, fix the blade with knife fixing bolts to the knife holder.
11.9 Let the clamp down by pressing the clamp pedal, then remove the two knife support bolts.
11.9a These supporting bolts have to be restored to the right positions under the front cutting table. If not the knife
will never move.
11.9b Remove the blade handles from the blade, and carry them with the blade holders to the prescribed storage
place.
11.9c Move the throttle valve knob to the left side to its initial setting position.

18 10.16 Knife storage unit 19 11.10a Blade height adjuster 20 5.2, 5.3 Control buttons
Start Lock out
Stop

Blade height adjuster

Locking pin

Table light switch

11.10 The marks on the clamp show if the new blade is larger or smaller than the previous blade.

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 Itoh 432 Cutter Work Instructions 4110-121-4
11.10a By releasing the locking pin and rotating the blade height adjuster, the blade can be raised or lowered
according to the proper cutting level.

12 Trouble Shooting and Maintenance 

12.1 In case the blade does not complete a full cycle and will not re-engage to complete the cycle:
12.1a Turn the secondary switch off and power down the main unit.
12.1b Once the main unit is powered down, turn the “lock out’ key to horizontal.
12.1c A clicking sound will indicate the clutch has disengaged.
12.1d Use the hand crank on the manual gear turner (located on the back right side), turn counter-clockwise until
the blade has reached the top of the cycle (when the lines on the clamp appear).
12.1e Remove the handle and store it on top of the vacuum system door.
12.1f Turn the “lock out” key to vertical and push the green start button to restart the main unit.
12.1g Try to cycle the knife. If it does not cycle then the blade has not been moved into the top cycle position;
repeat.
12.2 After changing the blade, grease the machine (4 zerk fittings)
12.3 Every 24 hours of operation, pump the oil system; one on the backgauge and the other under the table next to the
main power switch. Check the fluid level.
12.4 Check back gauge oil reservoir; pump once every 24 hrs. of operation

13 Maintaining Squareness of Cuts:

13.1 To ensure that the backgauge is parallel to the knife:
13.1a Place 4 or 5 full size sheets in the cutter.
13.1b Trim off an inch of stock.
13.1c Flip the sheets so that the right side is now on the left side of the cutter.
13.1d Try cutting again without moving the backgauge.
13.1e If more is trimmed off, one side of the backgauge is closer than the other.
13.1f If you don’t trim any off, try trimming one more inch off and flipping the stock the other direction. If there is
no trim this time than the backgauge is in line with the blade.
13.2 To check if the side-guide is square with the blade:
13.2a Ensure that the backgauge and blade are in line.
13.2b Place 4-5 sheets into the cutter against the side wall.
13.2c Four-side trim the sheets turning 90° each cut.
13.2d After trimming the sheets, set them against the back gauge and slide them to the side wall. If they lay against
both the backgauge and side wall, they are square. If not then an adjustment must be made to the machine.
13.2e Try this on the other side of the cutter to ensure it is also square.

21 12.1d Crank handle 22 4.4, 12.3 Oil reservoir 23 12.2 Zerk fittings

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 Itoh 432 Cutter Work Instructions 4110-121-4

14 The Finishing Area will be provided with a list of jobs that will run in the Scripture Bindery area each
month.
15 The Finishing Scheduler will schedule jobs into the normal cutting schedule.
16 Operators will run jobs to the exact counts listed in the job ticket only

17 HELP:
17.1 A variety of options are available directly from any operating mode. Press HELP and the screen shows:
17.2 F1 Standard Calculator: A desk top type calculator for doing standard (non-dimensional) math.
17.3 F2 Waste Calculator: Displays a worksheet to enter height of stock cut, number of sheets per unit of height, and
the number of signatures per sheet. There are also options to put in waste quantity. The display will then show the
total good signatures, total waste, and the % yield.
17.4 F3 Status Screen: Allows the operator to monitor the status of many components in the microcut electronic
control system. Software versions, factory set up data, and other information can be viewed as well.
17.5 F0 Exit: Goes back to where you entered this routine.
17.6 Microcut contains several user selectable features:
17.7 F1 Change operator: microcut will request that a new operator access code be entered. Press YES after the
correct code is entered. The operating limitations, preferences, and colors for that operator will be automatically
installed.
17.8 F2 Change language: This allows a new language to be selected. If only one language is installed this key will
be ignored. Press 3 1 7 5 at the GUARDS screen (power on) to access SERVICE ROUTINES to install additional
languages.
17.9 F3 Maintenance log: This shows (and allows changes to) the dates that maintenance was last performed.
17.10 →F1 Knife change: Perform this when the knife is dull. The cut strokes will be returned to 0 and the date will
be changed to the current date.
17.11 →F2 Calibrate gauge: This should be verified any time the knife is changed or accuracy is in question. Square
the back gauge. Trim a lift of stock. Move the gauge to one half the last cut size value and cut the stock. Remove
the top half of the pile in the cutter. Slide the top half of the front pile onto the bottom half of the back pile. Check
the pile for smoothness. The top half is an exact size. If the bottom half is shorter, the cutter is cutting short. If the
bottom half is longer, the cutter is cutting long. Use NUMBERS and YES to enter the true position. Check and
repeat if necessary.
17.12 →F3 Next screen: A list of standard maintenance items will appear showing the last done date as well as the
next due date. Press the corresponding F key after the maintenance has been done to enter the current date. If any
due date is passed without the maintenance being performed, a warning reminder will appear each time
MANUAL mode is entered.
17.13 →F0 Exit: Press this to record your new values and exit.
17.14 F4 Operating preferences: This allows the operator to adjust several of the system parameters. If access codes
are enabled (see below) these selections will be saved individually for each operator—
17.15 →F1 Inch units: Toggles these units between available and locked out.
17.16 →F2 Centimeter units: Toggles these units between available and locked out.
17.17 →F3 Millimeter units: Toggles these units between available and locked out.
17.18 →F4 Sun units: Toggles these units between available and locked out.
17.19 →F5 Decimal entry: Limits number entry to whole numbers or allows decimals.
17.20 →F6 Show all digits: Controls the position display to 12.345 or 12.34.
17.21 →F7 Auto push out: Controls the auto push out feature so that if the gauge must move backwards after Manual
Mode a cut in automatic mode, it will push forward a specified distance first.
17.22 →F8 Screen color selection: Allows color selection for each part of the display.
17.23 →F9 Next screen: Advances to the second screen of operating preferences.
17.24 →F0 Exit: Returns to the manual mode of operation.
17.25 Next screen (F9):
17.26 →F1 Side loading: Drives the gauge to the maximum rear of the table at the end of each job sequence in
automatic operation if this is on. Side loading requires an optional sensor to avoid potential collisions.

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 Itoh 432 Cutter Work Instructions 4110-121-4
17.27 →F2 Auto advance after load: Advances the gauge to the first stop value after the stock load is complete
without any operator request. Note: Sensor required.
17.28 →F3 Screen saver: Turns the screen saver mode on or off in the event that no operation is seen for a specified
amount of time.
17.29 →F4 Gauge power meter: This shows the required power to operate the back gauge.
17.30 →F5 Change backgauge tolerance: Used to adjust the required accuracy.
17.31 →F6 Change time: Adjusts the time clock value and selects display on or off.
17.32 →F7 Change date: Adjusts the date value and selects display on or off.
17.33 →F8 Change backgauge speed: Used to adjust the top speed for the gauge in forward, reverse, and push
operations. The deceleration can also be set between 1 (most gradual) and 100 (quickest).
17.34 →F9 Previous screen: Goes back to screen one.
17.35 →F0 Exit: Returns to the manual mode of operation.
17.36 F5 microfacts: This opens the options list for setting up the security and time management system.
17.37 F6 Change units: This allows enabled units of measurement to be selected. Refer to the OPERATING
PREFERENCES section for units.

24 Light guards with infrared sensors

The protruding light

guards have built-in
infrared sensors that
automatically stop the
machine if the beam is
broken

Hazards Document Control Information

1 Clamp can crush Effective: 2016-09-15
Control: Keep hands out of clamp drop area. When the Created/Revised by: Dennis Horne
foot pedal is operated approx. 500 lbs is activated.
Document Owner: Pete Hoyne
When the cutter buttons are engaged, 1000-4000 psi is
activated. The light curtain machine guard protects an Document Controller: Scott Walker
operator from this recognized hazard. Approved by: Steven Lewis, Director:
2 Knife blade is very sharp and will cut easily. File name: Itoh 432 Cutter
Control: Keep hands and fingers away from the blade The official image of this document is located on the ISO
and cutting area. If the infrared light beam between the Document Management System. These documents are
light guards is broken, the machine will automatically available to employees on terminals throughout the facility.
stop. All other electronic or printed copies are considered
-Know where any E-Stops on this machine are located. uncontrolled and may not be the latest approved version.
Doc Revisions:
 Quality Checks 9/18/2020 – reviewed with line 10.1 added;
 See Cutter Quality Standards sheet.
 Check output product against the Product Acceptance
Standards. If nonconformances are found, follow the Zero
Defects process.

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 Itoh 432 Cutter Work Instructions 4110-121-4
Learning Assessment Guide
 Key Learning/Performance Points Initials indicate that the trainee has
demonstrated proficiency in all
initialled steps.
C Step Trainee Trainer
Initial Initial
1. Demonstrate each step of the Itoh cutter procedure.
2.
Trainee Name:______________________Trainer Name:
Completion Date Time AM/PM Trainee Signature Trainer Signature
1st Solo Set up
2nd Solo Set up
3rd Solo Set up

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