Table Of Contents - Challenge CMT-130TC Service Manual

Table of Contents

Title
Introduction ...................................................... ii
NOTICE ................................................................... ii
SAFETY ................................................................. iii
Revision Control List .............................................. iv
Table of Contents .................................................... v
About this Manual ................................................. viii
Organization ......................................................... viii
Symbology and Nomenclature ............................. viii
Power Lockout Procedure ...................................... ix
1. Service Call Procedures .......................... 1-1
Contents .............................................................. 1-1
Introduction .......................................................... 1-1
Service Escalation Policy .................................... 1-1
How to Order Parts .............................................. 1-1
2. Status Indicator RAPs .............................. 2-1
Contents .............................................................. 2-1
Introduction .......................................................... 2-1
RAP 2.1 Fault Entry ............................................. 2-2
RAP 2.2 Error Messages ..................................... 2-3
RAP 2.3 Faults Without an Error Message .......... 2-7
RAP 2.4 Input Power ......................................... 2-10
RAP 2.5 DC Power ............................................ 2-12
RAP 2.6 Touch Screen Display ......................... 2-14
RAP 2.7 LED Enclosure Lights .......................... 2-15
RAP 2.8 Cooling Fans ....................................... 2-16
RAP 2.9 Status Light ......................................... 2-17
RAP 2.10 Door Interlocks - Trimmer ................. 2-18
RAP 2.11 Interlock Test..................................... 2-19
RAP 2.12 Interlock Relay .................................. 2-20
RAP 2.13 Start/Remote Cut Buttons ................. 2-21
RAP 2.14 E-Stop/Remote E-Stop Buttons......... 2-22
RAP 2.15 Starter Circuit .................................... 2-23
RAP 2.16 Hydraulic Motor Relay ....................... 2-24
RAP 2.17 Hydraulic Unload and Flow Valves .... 2-25
RAP 2.18 Cut Valve .......................................... 2-26
RAP 2.19 Shutdown Relay ................................ 2-27
RAP 2.20 Pneumatic Pressure .......................... 2-28
RAP 2.21 Left Jogger Cylinder .......................... 2-29
RAP 2.22 Gripper Clamp Cylinder ..................... 2-30
RAP 2.23 Gripper Rotator Lock Cylinder ........... 2-31
RAP 2.24 Knife Shift Cylinders .......................... 2-32
CMT-130TC Book Trimmer
Page Title
RAP 2.25 Gripper Lift Cylinder .......................... 2-33
RAP 2.26 Registration Plate Extend Cylinder .... 2-34
RAP 2.27 Book Lift Air Blast .............................. 2-35
RAP 2.28 Knife Latch Cylinder .......................... 2-36
RAP 2.29 Scrap Air Blast .................................. 2-37
RAP 2.30 Book Gate Cylinder ........................... 2-38
RAP 2.31 Face Jog Cylinder ............................. 2-39
RAP 2.32 Left and Right Clamp Cylinders ......... 2-40
RAP 2.33 Internal Conveyor Motor .................... 2-41
RAP 2.34 Registration Assembly Motor ............ 2-42
RAP 2.35 Gripper Transport Servo Motor ......... 2-43
RAP 2.36 Gripper Rotation Servo Motor ........... 2-44
RAP 2.37 Knife Latch Sensor ............................ 2-45
RAP 2.38 Book in Gripper Sensor ..................... 2-46
RAP 2.39 Left Jogger Retract Sensor ............... 2-47
RAP 2.40 Registration Preset Sensor ............... 2-48
RAP 2.41 Face Jog Sensor ............................... 2-49
RAP 2.42 Gripper Rotation Preset Sensor ........ 2-50
RAP 2.43 Knife Position Sensor ........................ 2-51
RAP 2.44 Knife Up Sensor ................................ 2-52
RAP 2.45 Knife Slow-Down Sensor ................... 2-53
RAP 2.46 Knife Down Switches......................... 2-54
RAP 2.47 Book Entering CMT Sensor ............... 2-55
RAP 2.48 Book Width Sensor............................ 2-56
RAP 2.49 Book Thickness Sensor ..................... 2-57
RAP 2.50 Barcode Scanner............................... 2-58
RAP 2.51 Elevator Input Power ......................... 2-59
RAP 2.52 Elevator Door Interlocks .................... 2-60
RAP 2.53 Elevator Tilt Table Cylinders ............. 2-61
RAP 2.54 Elevator Tilt Infeed Motors ................ 2-62
RAP 2.55 Elevator Lift Motor ............................. 2-63
RAP 2.56 Elevator Pusher Cylinder ................... 2-64
RAP 2.57 Book In From Binder Sensor ............. 2-65
RAP 2.58 Tilt Up Switch .................................... 2-66
RAP 2.59 Book on Tilt Sensors ......................... 2-67
RAP 2.60 Book Entering Elevator Sensor ......... 2-68
RAP 2.61 Elevator Book at Top Sensor ............ 2-69
RAP 2.62 Shelf Level Detect Sensor ................. 2-70
RAP 2.63 Elevator Empty Sensor ...................... 2-71
RAP 2.64 Elevator Pusher Home Sensor .......... 2-72
RAP 2.65 Elevator Pusher Interlock .................. 2-73
RAP 2.66 Stacker Input Power .......................... 2-74
RAP 2.67 Stacker Door Interlock ....................... 2-75
MAY 2019
v
Page Title
RAP 2.68 Stacker Roller Motor .......................... 2-76
RAP 2.69 Stacker Tray Up/Down Cylinder ........ 2-77
RAP 2.70 Stacker Tray Dump Cylinder ............. 2-78
RAP 2.71 Stacker Pusher Cylinder .................... 2-79
RAP 2.72 Stacker Finger Lift Cylinder ............... 2-80
RAP 2.73 Stacker Roller Start Sensor ............... 2-81
RAP 2.74 Stacker Book In Tray Sensor ............. 2-82
RAP 2.75 Stacker Book to Pusher Sensor ........ 2-83
RAP 2.76 Stacker Pusher Cylinder Sensor ....... 2-84
RAP 2.77 Stacker Tray Full Sensor ................... 2-85
RAP 2.78 Exit Conveyor Motor .......................... 2-86
RAP 2.79 Exit Conveyor Full Sensor ................. 2-87
RAP 2.80 Final Actions/System Checks ............ 2-88
3. Book Quality ..............................................3-1
Contents .............................................................. 3-1
Introduction .......................................................... 3-1
BQ 3.1 Book Quality Entry Rap ........................... 3-2
BQ 3.2 Burr Marks ............................................... 3-3
BQ 3.3 Jagged Bottom Cover .............................. 3-3
BQ 3.4 Burr Marks/Jagged Cover ........................ 3-3
BQ 3.5 Rectangular Crease Lines ....................... 3-4
BQ 3.6 Linear Crease Lines ................................ 3-4
BQ 3.7 Draw ........................................................ 3-4
BQ 3.8 All Sheets Not Cut ................................... 3-5
BQ 3.9 Books Not Square ................................... 3-5
BQ 3.10 Books Not Accurately Trimmed ............. 3-6
4. Repair/Adjustment Procedures ...............4-1
Contents .............................................................. 4-1
Introduction .......................................................... 4-1
REP 4.1 Cut Stick Replacement .......................... 4-2
REP 4.2 Knife Replacement ................................ 4-3
ADJ 4.3 Knife Depth Adjustment ......................... 4-6
ADJ 4.4 Lubrication ............................................. 4-7
ADJ 4.5 Accuracy Adjustment ............................. 4-8
ADJ 4.6 Squaring Adjustment .............................. 4-9
ADJ 4.7 Knife Down Switches Adjustment ........ 4-10
ADJ 4.8 Timing and Conveyor Belt Check/Repl. 4-12
ADJ 4.9 Conveyor Belt Tracking Adjustment ..... 4-14
REP 4.10 Slide Tape ......................................... 4-15
REP 4.11 Oil / Filter Change ............................. 4-16
REP 4.12 Air Filter Change ............................... 4-17
ADJ 4.13 Hydraulic System Pressure ................ 4-18
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Introduction