Challenge 130TC-A-160000, Service Manual

Page: 13 / 282

MAY 2019
CMT-130TC Book Trimmer 2-1 2. Status Indicator RAPs
Contents
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
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
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
Introduction
The status indicator, repair analysis procedures
(RAPs) provide in-depth troubleshooting
measures. They were designed for thorough
resolution of faults indicated by status messages
or controller board states.
WARNING
HIGH VOLTAGE! Nearly all RAPs require
that the machine have power while testing.
Use extreme caution at ALL times. Serious
injury or death may result from unsafe test-
ing practices. If replacing parts, lock out
main power at the source according to the
Power Lockout Procedure on page ix.
CAUTION
Standard precautions to prevent electro-static
discharge must be taken when working with
PWBs. Observe these practices whenever work
is being done in the electrical panel.
2. Status Indicator RAPs
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