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Challenge 130TC-A-160000, Service Manual

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Challenge 130TC-A-160000 Service Manual Download Page 3

 

 

 

 

MAY 2019 

 

CMT-130TC Book Trimmer

 

iii 

Introduction

 

SAFETY 

Before installing or operating any equipment, it 
is important to take precautions.  Read and thor-
oughly understand the safety precautions out-
lined below. 
 

 

This machine is designed for one-per-
son operation.  Never operate the ma-
chine with more than one person. 

 

Safe use of this machine is the respon-
sibility of the operator.  Use good judg-
ment and common sense when working 
with and around the machine and its ac-
cessories. 

 

Read and understand all instructions 
thoroughly before using the machine.  If 
questions remain, contact your Author-
ized Challenge Dealer.  Failure to un-
derstand the operating instructions may 
result in personal injury. 

 

Only trained and authorized individuals 
should operate this machine. 

 

Only trained and authorized service 
technicians should service this machine. 

 

Do not alter safety guards or devices.  
They are there for your protection.  Se-
vere laceration or dismemberment may 
result if safety devices are altered. 

 

Disconnect power and lock out before 
performing any maintenance.  See 
Power Lockout Procedure on page ix. 

 

Observe all caution and instruction la-
bels on this machine. 

 

Be extremely careful when handling and 
changing knives.  Severe lacerations or 
dismemberment could result from care-
less handling procedures. 

 

Perform the Safety System Check found 
in the 

CMT-

130TC Operator’s Manual

 

before each shift begins. 

 

 

 

 

 
 

 

 

Summary of Contents for 130TC-A-160000

Page 1: ...ile Feeder see manual F 501 For Vertical Stacker see manual F 502 CAUTION Certain components in the CMT 130TC are sus ceptible to damage due to electrostatic dis charge Observe all ESD procedures to a...

Page 2: ...ty of the product owner and user Older products may not comply with current safety procedures guidelines or regulations and it is the product owner s and user s responsibility to evaluate the suitabil...

Page 3: ...Challenge Dealer Failure to un derstand the operating instructions may result in personal injury Only trained and authorized individuals should operate this machine Only trained and authorized servic...

Page 4: ...MAY 2019 Introduction iv CMT 130TC Book Trimmer Page Rev Page Rev Revision Control List Page Rev Page Rev Page Rev Page Rev...

Page 5: ...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...

Page 6: ...L 5 48 Tilt Conv Pneumatics 56600TCA P 5 49 PL 5 49 Long Hand Feed 56413B 1 3 5 50 PL 5 50 Long Hand Feed 56413B 2 3 5 51 PL 5 51 Long Hand Feed 56413B 3 3 5 52 PL 5 52 Long Hand Feed Elec EE 2985 1 5...

Page 7: ...rimmer vii Introduction 8 1 Shipping Claims 8 2 8 2 Unpacking 8 2 8 3 Moving 8 2 8 4 Infeed Setup 8 3 8 5 Trimmer Height Setup 8 12 8 6 Outfeed Setup 8 13 8 7 Main Power Hookup 8 17 8 8 Main Air Hooku...

Page 8: ...s to its section number in this manual Section 6 General Procedures Information This section contains general procedures diag nostic information product specifications tag modification information and...

Page 9: ...re moved Do not disable safety devices Crush Hazard Do not operate with covers re moved Do not disable safety devices Crush Entanglement Hazard Do not operate with covers or guards removed Electrical...

Page 10: ...MAY 2019 Introduction x CMT 130TC Book Trimmer NOTES...

Page 11: ...2171 or 1 508 998 7502 Leave message with operator using au thorization number 3513 Include name telephone number with extension and time of call 5 C P Bourg Inc technical support engineer will troubl...

Page 12: ...spare parts kit for each site Customer must ensure adequate inven tory of spare parts are maintained on site at all times Customer reacts to parts usage data provided by Xerox CSE and contacts C P Bo...

Page 13: ...ok 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 Infe...

Page 14: ...nd back ON If the error message continues to display go to RAP 2 2 Error Messages and perform the applicable RAPs until no error messages show at this step Does a prob lem still exist Y N Go to Step 1...

Page 15: ...RAP 2 49 Book Thickness Sensor Book finish length outside limits See Installation and Operator s Manual for allowed dimensions Book finish width outside limits See Installation and Operator s Manual f...

Page 16: ...RAP 2 54 Elevator Tilt Infeed Motors RAP 2 55 Elevator Lift Motor Elevator Tilt Door Open RAP 2 52 Elevator Door Interlocks Elevator Tilt Error RAP 2 59 Book on Tilt Sensors RAP 2 58 Tilt Up Switch R...

Page 17: ...Cylinder RAP 2 39 Left Jogger Retract Sensor Linear Position Err Press Stop Then Green Start RAP 2 35 Gripper Transport Servo Motor Lubricate Machine and Clear Lube Counter ADJ 4 4 Lubrication Machin...

Page 18: ...inder RAP 2 42 Gripper Rotation Preset Sensor Sharpen Knife and Clear Knife Counter REP 4 2 Knife Replacement To clear counter see Installation and Operator s Manual Stacker Book Jam at Input RAP 2 73...

Page 19: ...move RAP 2 40 Registration Preset Sensor RAP 2 34 Registration Assembly Motor Gripper clamp will not clamp will not un clamp or is other wise stuck RAP 2 22 Gripper Clamp Cylinder Gripper never clamps...

Page 20: ...nds erratically RAP 2 60 Book Entering Elevator Sensor RAP 2 56 Elevator Pusher Cylinder RAP 2 64 Elevator Pusher Home Sensor RAP 2 65 Elevator Pusher Interlock A book jam is detected in Elevator when...

Page 21: ...Description of Fault Recommended Procedures Misc Accessory Faults Partner products get a signal that the trimmer is shut down when it is actually operating partner products get a signal that the trimm...

Page 22: ...embly 59000 1 14 6 Is there line voltage between wires 1 and 2 at the CB1 and CB2 circuit breakers Figure 2 2 Y N Reset circuit breakers CB1 and or CB2 if tripped If a circuit breaker continues to tri...

Page 23: ...MAY 2019 CMT 130TC Book Trimmer 2 11 2 Status Indicator RAPs Figure 2 3 T1 Transformer Figure 2 2 Input Power and Circuit Breaker Locations...

Page 24: ...ire at H5 7 and the blue yellow wire at H5 9 12VAC between the blue wire at H5 8 and the blue yellow wire at H5 9 24VAC between the blue wire at H5 7 and the blue wire at H5 8 Do all these voltages me...

Page 25: ...MAY 2019 CMT 130TC Book Trimmer 2 13 2 Status Indicator RAPs Figure 2 4 T2 T3 and BR1 Wire Connections...

Page 26: ...The touch screen display and the enclosure fans are powered from the same source 120 VAC Switch the main power ON to check if the touch screen display comes on If the enclosure fans also do not turn...

Page 27: ...Actions Check RAP 2 4 Input Power and RAP 2 5 DC Power Procedure 1 Switch the main power ON Is output LED 8 GP 6 3 Input Output LEDs switched on Y N Disconnect main power and replace the main PWB REP...

Page 28: ...is switched on Possible Fault Indicators The cooling fans will not switch on Initial Actions Switch the main power ON and check if all fans are running If the touch screen display also does not turn...

Page 29: ...AP 2 4 Input Power and RAP 2 5 DC Power Check and repair loose or damaged wires 93 97 99 at the electrical panel Procedure 1 Switch the main power ON Go to the diag nostic screen and enable outputs GP...

Page 30: ...n PWB REP 4 23 Main PWB Replacement Disconnect power and replace the Open Door Indicator PWB Figure 2 10 2 Check the operation of the indicated inter lock switch and make sure that the actuator key en...

Page 31: ...the contacts 4 Locate the normally open N O contacts Figure 2 12 and test continuity There should be no continuity at the normally open contacts Is this true Y N The switch is defective and should be...

Page 32: ...5 16 Power Panel EE 3503 1 2 4 Reconnect all wires to the interlock relay and switch the main power ON Short wire 89 at the IR relay to wire 74 at the main PWB Does the relay actuate Y N Disconnect p...

Page 33: ...nnect power and replace defective switch body PL 5 1 Main Assembly 59000 1 14 or PL 5 13 Main Assembly 59000 13 14 2 Switch the main power ON and go to the di agnostic screen GP 6 2 Input Output Diag...

Page 34: ...main power ON and go to the di agnostic screen GP 6 2 Input Output Diag nostics Are inputs Rear Stop and Front Stop both off Y N Disconnect wires 40 and 41 from the main PWB Does the diagnostic scree...

Page 35: ...An Interlock Relay error message is dis played on the screen A motor starter error message is dis played on the screen Initial Actions Check for loose wires at the HMR and IR relays Check for loose wi...

Page 36: ...2 3 Switch the main power ON Go to the diag nostic screen and enable outputs GP 6 2 Input Output Diagnostics Make sure all doors are closed then activate the Interlock Relay output Press the green sta...

Page 37: ...replace the main PWB REP 4 23 Main PWB Replacement If LED 26 does not come on disconnect power and replace the console PWB REP 4 24 Console PWB Replacement 3 Switch the main power OFF and remove the l...

Page 38: ...er supply Is the power supply okay Y N Disconnect power and repair the 24 VDC power supply Disconnect power and replace the main PWB REP 4 23 Main PWB Replacement 3 Switch the main power OFF 4 Short w...

Page 39: ...and replace the main PCB REP 4 23 Main PWB Replacement 2 Test continuity between the N C contact and Common contact Figure 2 23 Does the resistance measure less than 2 Y N Disconnect power and replac...

Page 40: ...air pres sure at 80 90 psi Y N Check and repair the hoses between the main air connection and the main pressure regulator inside the rear door and behind the main pressure gauge Adjust main regulator...

Page 41: ...power ON Place an A4 or 8 1 2 x 11 book in the jogging station 6 Manually activate valve 1 by pressing the button on the valve Figure 2 27 Does the jogger extend Y N Disconnect power and air then rep...

Page 42: ...r damaged wire 68 at the elec trical panel Check that the cable connector on valve 2 is connected properly Procedure 1 Switch the main power OFF 2 Switch the main air OFF 3 Attempt to actuate the grip...

Page 43: ...air leaks and disconnected or pinched hoses Check for loose or damaged wire 59 at the elec trical panel Check that the cable connector on valve 3 is connected properly Procedure 1 Switch the main air...

Page 44: ...rly Procedure 1 Open the rear door and fully open the flow control valves pertaining to the knife shift cylinders Figure 2 32 2 Switch the main air ON and main power ON 3 Manually activate valve 5 by...

Page 45: ...for air leaks and disconnected or pinched hoses Check for loose or damaged wire 69 at the elec trical panel Check that the cable connector on valve 6 is connected properly Procedure 1 Switch the main...

Page 46: ...6 14 Speed Control Air Valves Check for air leaks and disconnected or pinched hoses Check for loose or damaged wire 101 at the electrical panel Check that the cable connector on valve 7A is connected...

Page 47: ...rm ADJ 4 16 Book Underside Air Lift Check for a plugged air jet air leaks and dis connected or pinched hoses Check for loose or damaged wire 33 at the elec trical panel Check that the cable connector...

Page 48: ...rocedure 1 Switch the main air ON and main power ON 2 Press the green start button to initialize the trimmer This will raise the cutting mecha nism off of the knife latch if necessary 3 Open the rear...

Page 49: ...r pinched hoses Check for loose or damaged wire 72 at the elec trical panel Check that the cable connector on valve 9 is connected properly Procedure 1 Switch the main air ON and main power ON 2 Manua...

Page 50: ...nel Check that the cable connector on valve 10 is connected properly Procedure 1 Fully open the flow control valves on the book gate air cylinder Figure 2 44 2 Switch the main air ON and main power ON...

Page 51: ...ooks from the machine Check for air leaks and disconnected or pinched hoses Check for loose or damaged wire 96 at the elec trical panel Check that the cable connector on valve 11 is connected properly...

Page 52: ...ook causing the clamp to come down too far on the right side dur ing a cut sometimes causing excessive creasing in the book spine Initial Actions Perform RAP 2 20 Pneumatic Pressure Check for air leak...

Page 53: ...hort wire 26 to 37 at SSR1 Do both conveyor motors switch on Y N Disconnect power and replace the defective motor and or brake PL 5 11 Main Assembly 59000 11 14 4 Remove the short then go to the diagn...

Page 54: ...VAC Y N Disconnect main power and replace the EMI filter 1 PL 5 16 Power Panel EE 3503 1 2 5 Is there 5 VDC between wires 7 and 8 at the encoder cable connector Y N Check for loose or damaged wires 7...

Page 55: ...d then acti vate the Interlock Relay output Press the green start button to energize the IR relay The Interlock Relay IR input should switch on Is there 53 VAC between wires 79 and 80 at the bridge re...

Page 56: ...reen and enable out puts GP 6 2 Input Output Diagnostics Acti vate the Interlock Relay output Press the green start button to energize the IR relay The Interlock Relay IR input should switch on Is the...

Page 57: ...OFF Check that the knife latch is engaged cylinder is extended 2 Switch the main power ON and go to the di agnostic screen GP 6 2 Input Output Diag nostics Is input Knife Latch In off Y N Disconnect...

Page 58: ...y 59000 14 14 Check for loose or damaged wire 35 at the elec trical panel and at the terminal block Figure 2 60 Procedure 1 Make sure that both the sensor and the re flective strips are not obstructed...

Page 59: ...ostic screen GP 6 2 Input Output Diag nostics Does the diagnostic screen show input Left In on Y N Short wire 50 to 74 at the main PWB On the diagnostic screen does input Left In switch on Y N Disconn...

Page 60: ...e of fuses less than 2 Ohms Y N Replace blown fuses 3 Open the right door and rotate the registra tion drive pulley until the actuator tab is away from the sensor 4 Close the door and switch the main...

Page 61: ...up If not retract it by hand 3 Switch the main power ON and go to the di agnostic screen GP 6 2 Input Output Diag nostics Does the diagnostic screen show input Face Jog Rotary Down on Y N Short wire 1...

Page 62: ...that the rotator disk covers the sensor 3 Switch the main power ON and go to the di agnostic screen GP 6 2 Input Output Diag nostics Does the diagnostic screen show input Gripper Rotation Preset on Y...

Page 63: ...2 15 Starter Circuit 2 Is the knife bar assembly shifted to one side or the other such that the knife position sen sor is not inline with the sensor actuator bracket Y N Go to RAP 2 24 Knife Shift Cy...

Page 64: ...AP 2 15 Starter Circuit 2 Switch the main power OFF and then ON Go to the diagnostic screen GP 6 2 In put Output Diagnostics Does the diagnostic screen show input Knife Up on Y N Short wire 51 to 74 a...

Page 65: ...main power ON and go to the di agnostic screen GP 6 2 Input Output Diag nostics Does the diagnostic screen show input Knife Slowdown off Y N Disconnect wire 36 On the diagnostic screen does input Knif...

Page 66: ...electrical panel The following procedure must be performed with the knife up Procedure 1 Switch the main power ON and go to the di agnostic screen GP 6 2 Input Output Diag nostics Does the diagnostic...

Page 67: ...14 14 Check for loose or damaged wire 45 at the elec trical panel Check that the internal conveyor motors run If one or both never run go to RAP 2 33 Internal Conveyor Motor Procedure 1 Make sure tha...

Page 68: ...lled and not ob structed Replace if faulty PL 5 10 Main As sembly 59000 10 14 Check for loose or damaged wire 82 at the elec trical panel Procedure 1 Make sure that both the sensor and the re flector...

Page 69: ...N Is there 15VDC between wires 12 and 98 at the DI HS PWB Figure 2 75 Y N Is there 24VDC between wires 73 and 74 at the DI HS PWB Y N Go to RAP 2 5 DC Power Disconnect power and replace the DI HS PWB...

Page 70: ...or damaged cables and connec tions from the barcode scanner to the back of the display console Procedure 1 Switch the main power ON Is the yellow power light on the side of the barcode scan ner lit Y...

Page 71: ...or motor cover to access the Elevator electrical panel Is there 120 VAC between wires 25 at SSR1 and wire 22 at the electrical panel Figure 2 78 Y N Is there 120VAC at wires 120 and 22 at the Elevator...

Page 72: ...ck switch PL 5 33 Elevator 56421TCA 6 7 PL 5 34 Elevator 56421TCA 7 7 or PL 5 45 Tilt Conveyor 56600TCA 7 8 2 Check the operation of the indicated inter lock switch For Elevator interlocks make sure t...

Page 73: ...orm GP 6 14 Speed Control Air Valves Check that all air hoses inside the Tilt Infeed Conveyor are connected properly and not dam aged or pinched Check for loose or damaged wire 56 at the Ele vator s e...

Page 74: ...terminal block Is there 120VAC at all three SSR s Y N Is there 120VAC at wires 120 and 22 at the terminal block Y N Check for loose or damaged cables be tween the trimmer Elevator and Tilt In feed Co...

Page 75: ...k the lift plate position sensor RAP 2 62 Shelf Level Detect Sensor Procedure 1 Perform RAP 2 51 Elevator Input Power to make sure the Elevator is getting proper power 2 Switch the main power ON and p...

Page 76: ...the air valve is connected properly Procedure 1 Open the Elevator door and fully open the flow control valve on the left end of the pusher air cylinder Figure 2 83 2 Pull the Elevator away from the m...

Page 77: ...electrical panel Figure 2 86 Procedure 1 Switch the main power ON and go to the El evator diagnostic screen GP 6 2 Input Out put Diagnostics Make sure that the sensor is not obstructed Is input Book I...

Page 78: ...ut Tilt Cylinder Does the tilt table raise all the way up properly Y N Go to RAP 2 53 Elevator Tilt Table Cylin ders 2 On the diagnostic screen is input Tilt Up on Y N Short wire 41 to 74 On the diagn...

Page 79: ...ir loose or damaged wires 44 45 73 and 74 at the Elevator electrical panel Figure 2 90 Procedure 1 Switch the main power ON and go to the El evator diagnostic screen GP 6 2 Input Out put Diagnostics M...

Page 80: ...ires 59 73 and 74 at the Elevator electrical panel Procedure 1 Switch the main power ON and go to the El evator diagnostic screen GP 6 2 Input Out put Diagnostics Make sure that the sensor and reflect...

Page 81: ...ose or damaged wires 48 73 and 74 at the Elevator electrical panel Procedure 1 Switch the main power ON and go to the El evator diagnostic screen GP 6 2 Input Out put Diagnostics Make sure that the se...

Page 82: ...Is input Shelf Level De tect off Y N Disconnect wire 40 On the diagnostic screen does input Shelf Level Detect switch off Y N Disconnect power and replace the Ele vator I O PWB REP 4 26 Accessory PWB...

Page 83: ...ed wires 47 73 and 74 at the Elevator electrical panel Procedure 1 Switch the main power ON and go to the El evator diagnostic screen GP 6 2 Input Out put Diagnostics Make sure that the sensor is not...

Page 84: ...tor diagnostic screen GP 6 2 Input Output Diagnostics Is input Pusher Home on Y N Short wire 46 to 74 On the diagnostic screen does input Pusher Home switch on Y N Disconnect power and replace the Ele...

Page 85: ...on to initialize the trimmer Remove the Elevator motor cover to access the Elevator electrical panel Is there 120 VAC between wire 24 at circuit breaker CB1 and wire 22 at the electrical panel Y N Go...

Page 86: ...immer Does the trimmer s hydraulic motor come on Y N Go to RAP 2 15 Starter Circuit 2 Remove the Stacker s rear cover to access the Stacker s electrical panel Is there 120 VAC between wires 23 at SSR1...

Page 87: ...rd with each opening and clos ing Y N Disconnect power and replace the Stacker I O PWB REP 4 26 Accessory PWB Replacement Disconnect power and replace the defective interlock switch PL 5 62 Outfeed St...

Page 88: ...continuously check the Book In sensor RAP 2 74 Stacker Book In Tray Sensor Procedure 1 Perform RAP 2 66 Stacker Input Power to make sure the Stacker is getting proper power 2 Switch the trimmer power...

Page 89: ...electrical panel Check that cable 1 is connected to the air valve properly Procedure 1 Remove the rear panel on the Stacker and locate the tray up down cylinder Fully open the flow control valves loca...

Page 90: ...re 1 Remove the rear panel on the Stacker and locate the tray dump cylinder Fully open the flow control valves located at the air fit tings on the cylinder 2 Switch the main air ON and main power ON 3...

Page 91: ...open the flow control valves lo cated at the air fittings on the cylinder 2 Switch the main air ON and main power ON 3 Manually activate the pusher extend valve by pressing the actuator button on the...

Page 92: ...wer side panel on the Stacker and locate the finger lift cylinder Fully open the flow control valves near the ports on each end of the cylinder 2 Switch the main air ON and main power ON The fingered...

Page 93: ...etween the trimmer and Stacker are securely fastened and are not dam aged Check and repair loose or damaged wires 67 73 and 74 at the Stacker electrical panel Procedure 1 Switch the main power ON and...

Page 94: ...between the trimmer and Stacker are securely fastened and are not dam aged Check and repair loose or damaged wires 65 73 and 74 at the Stacker electrical panel Procedure 1 Switch the main power ON and...

Page 95: ...rimmer and Stacker are securely fastened and are not dam aged Check and repair loose or damaged wires 66 73 and 74 at the Stacker electrical panel Procedure 1 Switch the main power ON and go to the St...

Page 96: ...Pusher Cylinder 2 Go to the Stacker diagnostic screen GP 6 2 Input Output Diagnostics Is input Cyl Prox on Y N Short wire 69 to 74 On the diagnostic screen does input Cyl Prox switch on Y N Disconnect...

Page 97: ...ure 1 Remove all books from the Stacker and slide the back stop all the way forward away from the front end of the stacker 2 Switch the main power ON and go to the Stacker diagnostic screen GP 6 2 In...

Page 98: ...initialize the trimmer Does the trimmer s hydraulic motor come on Y N Go to RAP 2 15 Starter Circuit 4 Inside the conveyor case is there 120 VAC between wire 25 at SSR1 and wire 22 at the lower termi...

Page 99: ...ure 1 Switch the main power ON and go to the Exit Conveyor diagnostic screen GP 6 2 In put Output Diagnostics Make sure that the sensor is not obstructed Is input Tray Full off Y N Disconnect wire 47...

Page 100: ...and settings are as described in the installation manual 4 Run at least ten books through the machine Do the books feed through the machine cor rectly Y N Go to CMT 130TC Installation and Operator Man...

Page 101: ...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 Introduction The Book Quality section addresses issues per...

Page 102: ...Cover Rectangular shaped crease lines on cover BQ 3 5 Rectangular Crease Lines Linear crease lines on cover along cut edges BQ 3 6 Linear Crease Lines Bottom covers are scratched ADJ 4 16 Book Undersi...

Page 103: ...ply cut Tearing of the bottom sheets and cover occur when deep score marks develop in the cut stick The cover is pushed into the score mark folded over and torn Figure 3 2 Jagged Cover Possible Causes...

Page 104: ...s of the book Figure 3 5 Linear Crease Lines Possible Causes The clamp has too much clamp pres sure for the stock being cut Solutions Reduce the clamp pressure ADJ 4 19 Clamp Pressure Adjustment until...

Page 105: ...e most common cause of out of square Cover overhangs the book The over hang reduces the reliability of the squar ing process within the trimmer Glue was applied past the binding leav ing a knob like p...

Page 106: ...ks to be misaligned in the gripper when being trimmed Solutions Recalibrate the machine s accuracy set tings ADJ 4 5 Accuracy Adjustment Check function of left side jogging cylin der ADJ 4 20 Left Jog...

Page 107: ...4 14 Counterbalance Valve 4 19 ADJ 4 15 Knife Cushion Adjustment 4 20 ADJ 4 16 Book Underside Air Lift 4 21 ADJ 4 17 Knife Gib Adjustment 4 22 ADJ 4 18 Knife Latch 4 23 ADJ 4 19 Clamp Pressure Adjust...

Page 108: ...r hold and hook Figure 4 1 4 Hook the Cut Stick Puller over the right end of the cut stick Figure 4 2 with a finger in the loop of the puller Keep the Cut Stick Puller in line with the cut stick 5 Pul...

Page 109: ...aside and open the rear door 3 Place an empty scabbard on a nearby sta ble surface 4 Using the T handle hex wrench remove the two knife bolts that are in open slots in the knife bar Figure 4 5 They ar...

Page 110: ...RNING Even used knives are extremely sharp Use extreme care when handling new re ground and used knives Knife Installation Procedure 1 Make sure main power is still turned off and locked out 2 Turn th...

Page 111: ...e bolts into the holes from which the knife lifter handles were removed Use the T handle wrench to secure them Once the knife has been installed the cutting depth must be adjusted ADJ 4 3 Knife Depth...

Page 112: ...he knife adjustment knob counterclockwise ap proximately three full revolutions Proceed to step 5 5 Make sure the knife adjustment knob is turned all the way counterclockwise until it stops This will...

Page 113: ...g oil such as 3 in 1 SAE 20 electric motor oil 4 Squeeze four pumps of a 2 EP molyb denum grease such as Challenge part num ber SU 30 103 into each of the two bearing housings underneath the table Fig...

Page 114: ...uarely to the spine and with good quality spines that are straight not twisted and perpendicular to the rest of the book Procedure 1 Switch the main power ON and press the Setup button to bring up the...

Page 115: ...it was cut inside the machine 5 If the measurements vary from book to book repeat steps 1 and 2 until the meas urements are the same for all books It may be necessary to find different better books 6...

Page 116: ...t of the adjustment screw timing pulley Re engage the timing belt with the pulleys and tighten the belt as much as possible us ing the tensioning bracket 7 Measure the distances between the bottom of...

Page 117: ...tify which side is not cutting deep enough then locate the collar on that side Loosen the clamping screw on the collar then turn the collar clockwise 1 8 turn to lower it slightly Then tighten the cla...

Page 118: ...all new conveyor belt and re install all hardware and parts that were re moved i Perform ADJ 4 9 Conveyor Belt Track ing Adjustment 5 Inspect the drive timing belts Figure 4 21 Are they free of cracks...

Page 119: ...rimmer 4 13 4 Repair Adjustment Procedures Figure 4 20 Registration Timing Belt Figure 4 21 Conveyor and Timing Belts Figure 4 22 Accessory Conveyor Example Figure 4 23 Exit Conveyor Belts Figure 4 24...

Page 120: ...l the conveyor belt is ten sioned to meet the following conditions Internal Infeed Conveyor The belt can not be stopped by applying approxi mately 10 pounds of pressure to the top surface of the belt...

Page 121: ...should be checked for damage WARNING Disconnect and lockout power as described in the Power Lockout Procedure on page ix Procedure 1 Switch the main power OFF and lockout power to the machine 2 Acces...

Page 122: ...ota tion on the drill in order to transfer oil from the reservoir to the empty con tainer 6 Empty the contents of the shipping con tainer 7 Insert the suction hose into the filler breather hole and pu...

Page 123: ...e cylinder with the double lines on the filter head Pull the cylinder head down to remove the cylinder 6 Remove the black filter element retainer from the filter head Turn the retainer coun terclockwi...

Page 124: ...fo screen Click on the Enable Tabs Code text box enter in the code 6125 and press enter This will unlock all of the locked tabs 5 Press the Hydraulic Air tab to open the Hy draulic Air screen 6 Click...

Page 125: ...air ON 3 At the touch screen on the front console press the Setup button to bring up the setup options screen The Parameters tab should be active Now press the Enable Cut Cycle button near the lower...

Page 126: ...to open the Hy draulic Air screen 4 Press the green start button 5 The screen should now look similar to either Figure 4 31 or Figure 4 32 depending on software version of trimmer Does the screen hav...

Page 127: ...Book Underside Air output This will manually actuate the air valve 7B and start the underside air blast 4 Locate the book underside air lift adjustment knob at the front of the machine Figure 4 33 5...

Page 128: ...ide of the knife bar Stop tightening the screws when they begin to feel tight and the gib is visibly against the knife bar 5 Turn the screws counterclockwise enough to release any force on the knife b...

Page 129: ...cs This will assist in the adjusting of the sensor by emitting an audio beep whenever the sensor is activated or deactivated 3 Open the rear door to access the knife latch 4 Loosen the proximity senso...

Page 130: ...af fect the final cut quality of the books Initial Actions Check that the main air is switched ON Open the rear door Procedure 1 Open the rear door and locate the clamp pressure regulator Figure 4 36...

Page 131: ...r in the code 6125 and press enter This will unlock all of the locked tabs 3 Press the Hydraulic Air tab to open the Hy draulic Air screen Locate the minimum and maximum jog pressure slide bars Figure...

Page 132: ...clamp pressure to 0 2 to 0 3 MPa The gauge location is shown in Figure 4 39 Turning the screw clockwise will increase pressure Turning the screw counter clock wise will decrease the pressure 3 Actuat...

Page 133: ...nut on the valve 11 pres sure adjustment screw 2 Use a slotted screwdriver to set the gripper clamp pressure to 0 2 to 0 3 MPa The gauge location is shown in Figure 4 40 Turning the screw clockwise wi...

Page 134: ...Procedure on page ix 2 Remove the electrical panel door at the lower right side of the trimmer 3 Remove the two nuts that mount the high voltage shield to standoffs on the electrical panel Figure 4 41...

Page 135: ...to the machine WARNING Disconnect and lockout power as described in the Power Lockout Procedure on page ix 8 Remove the eight screws holding the display console in place 9 Pull the top of the console...

Page 136: ...panel door at the lower right side of the trimmer 3 Disconnect all cable connectors from the DI HS PWB 4 Remove the four nuts that mount the PWB to standoffs on the electrical panel Figure 4 43 5 Care...

Page 137: ...or panel that covers the accessory s electrical panel 3 Disconnect all cable connectors from the PWB 4 Remove the five nuts that mount the PWB to standoffs on the electrical panel Figure 4 44 5 Caref...

Page 138: ...o the trimmer 2 Switch the main air OFF 3 Open the top cover of the Elevator 4 Loosen the two screws that mount the pusher plate to the pusher bracket Figure 4 45 5 Push the plate to the edge of the l...

Page 139: ...e open hole in the sprocket hub 4 Turn the screw until the insert disengages from the sprocket hub 5 Remove the insert removal screw from the hub 6 Raise the Elevator lift plates on the free side unti...

Page 140: ...MAY 2019 4 Repair Adjustment Procedures 4 34 CMT 130TC Book Trimmer NOTES...

Page 141: ...v Electrical Panel EE 3523 5 38 PL 5 38 Elev Pneumatics 56421TCA P 5 39 PL 5 39 Tilt Conveyor 56600TCA 1 8 5 40 PL 5 40 Tilt Conveyor 56600TCA 2 8 5 41 PL 5 41 Tilt Conveyor 56600TCA 3 8 5 42 PL 5 42...

Page 142: ...REEN 1 15 E 3127 5 SWITCH RED STOP 1 16 E 3505 CAN CABLE JUMPER 1 17 EE 2971 SWITCH MAIN DISCONNECT 1 18 EE 3503 ELECTRICAL PANEL ASSEMBLY 1 19 H 6423 4 NUT 1 4 20 HEX KEP 4 20 H 6423 6 NUT 6 32 HEX K...

Page 143: ...32 X 2 SOC HD 4 17 H 7321 14 WASHER 7 8 SAE PLAIN 1 18 H 7321 5 WASHER 5 16 SAE PLAIN 2 19 H 7321 10 WASHER 10 SAE PLAIN 4 20 H 7327 10 WASHER 5 16 MEDIUM LOCK 2 21 H 7327 10 WASHER 10 MEDIUM LOCK 2 2...

Page 144: ...T HD 1 16 H 6915 1620 SCREW 1 14 X 2 1 2 SOC HD 2 17 H 6916 812 SCREW 1 2 20 X 1 1 2 FLT HD 4 18 H 6918 414 SCREW 1 4 20 X 1 3 4 SOC HD 2 19 H 6918 506 SCREW 5 16 18 X 3 4 SOC HD 2 20 H 6918 510 SCREW...

Page 145: ...NIFE UP U 1 30 H 5254 516 SCREW 5 16 X 2 SHSS 1 31 H 6410 16 NUT 1 14 SLOTTED HEX 1 32 H 6424 6 NUT 3 8 16 HEX JAM 2 33 H 6631 412 COTTER PIN 1 8 X 1 1 2 1 34 H 6909 405 SCREW 1 4 20 X 5 8 FLT HD 4 35...

Page 146: ...H 6423 4 NUT 4 40 HEX KEP 2 14 H 6424 6 NUT 3 8 16 HEX JAM 1 15 H 6428 4 NUT 1 4 28 HEX JAM 1 16 H 6909 102404 SCREW 10 24 X 1 2 FLT HD 1 17 H 6918 102408 SCREW 10 24 X 1 SOC HD 2 18 H 6918 412 SCREW...

Page 147: ...27 HOLE PLUG 4 23 EE 3270 PROX ASM REG FRONT LIMIT 1 24 H 5254 840 SCREW 1 2 X 5 SHSS 2 25 H 6417 6 NUT 3 8 16 HEX 2 26 H 6424 6 NUT 3 8 16 HEX JAM 6 27 H 6428 7 NUT 7 16 20 HEX JAM 4 28 H 6909 102404...

Page 148: ...0 24 HEX KEP 3 37 H 6423 4 NUT 4 40 HEX KEP 2 38 H 6423 8 NUT 8 32 HEX KEP 4 39 H 6424 4 NUT 1 4 20 HEX JAM 1 40 H 6428 4 NUT 1 4 28 HEX JAM 2 41 H 6432 10 NUT 10 24 ACORN NYLON 1 42 H 6909 83204 SCRE...

Page 149: ...1 7 59153 1 GRIPPER CLAMP PAD 2 8 59190 BUMPER 1 9 59313 SHIM GRIPPER 3 10 H 6909 102407 SCREW 10 24 X 7 8 FLT HD 2 11 H 6909 406 SCREW 1 4 20 X 3 4 FLT HD 2 12 H 6909 408 SCREW 1 4 20 X 1 FLT HD 2 1...

Page 150: ...20 H 6417 5 NUT 5 16 18 HEX 1 21 H 6909 44003 SCREW 4 40 X 3 8 FLT HD 6 22 H 6910 102402 SCREW 10 24 X 1 4 BUT HD 1 23 H 6910 622 SCREW 3 8 16 X 2 3 4 BUT HD 1 24 H 6910 624 SCREW 3 8 16 X 3 BUT HD 1...

Page 151: ...MAGNETIC SWITCH ASM REF 22 H 5254 403 SCREW 1 4 X 3 8 SHSS 2 23 H 6417 10 NUT 10 24 HEX 2 24 H 6909 405 SCREW 1 4 20 X 5 8 FLT HD 2 25 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 4 26 H 6913 606 SCREW 3 8 1...

Page 152: ...CITOR 1 18 E 2626 3 TERMINAL STRIP 3P 1 19 E 3522 THICKNESS SENSOR 1 20 H 6423 4 NUT 1 4 20 HEX KEP 8 21 H 6909 412 SCREW 1 4 20 X 1 1 2 FLT HD 8 22 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 4 23 H 6910...

Page 153: ...416 832 6 WELDNUT 8 32 TWIN PILOT 1 18 H 6423 10 NUT 10 24 HEX KEP 8 19 H 6423 8 NUT 8 32 HEX KEP 4 20 H 6888 83203 SCREW 8 32 X 3 8 TMPR PRF 2 21 H 6909 406 SCREW 1 4 20 X 3 4 FLT HD 4 22 H 6910 1024...

Page 154: ...STOP 1 24 E 3277 2 SWITCH RETROREFLECTIVE 1 25 E 3551 BAR CODE SCANNER 1 26 EE 3456 6 CONSOLE ASM 130 TC 1 27 EE 3502 1 LED LIGHT BOARD 3 28 H 6416 832 6 WELDNUT 8 32 TWIN PILOT 2 29 H 6417 5 NUT 5 16...

Page 155: ...72 24 SNAP IN BUSHING 1 13 E 3551 BAR CODE SCANNER 1 14 EE 3502 1 LED LIGHT BOARD 1 15 H 6423 4 NUT 1 4 20 HEX KEP 2 16 H 6423 8 NUT 8 32 HEX KEP 2 17 H 6909 102403 SCREW 10 24 X 3 8 FLT HD 2 18 H 690...

Page 156: ...R 180VDC 1 31 E 1736 2 QUENCHARC 1 32 E 2467 1 ENCODER 1 33 EE 2973 9 PROX ASM SIDE GUIDE PRESET REF 34 H 5254 405 SCREW 1 4 X 5 8 SHSS 2 35 H 5254 505 SCREW 5 16 X 5 8 SHSS 1 36 H 6417 10 NUT 10 24 H...

Page 157: ...38 S 1350 16 CABLE CLAMP PLASTIC 22 39 E 894 CABLE CLAMP METAL 4 40 E 2066 10 PLUG CONNECTOR P C B 10 PIN 10 41 E 2066 8 PLUG CONNECTOR P C B 8 PIN 3 42 E 2066 12 PLUG CONNECTOR P C B 12 PIN 1 43 P 29...

Page 158: ...77 EE 3531 1 1 PLUG ASM AIR SOL LEFT JOG OUT 1 78 EE 3531 2 2 PLUG ASM AIR SOL GRIPPER CLAMP ON 1 79 EE 3531 3 3 PLUG ASM AIR SOL GRIPPER ROT LOCKED 1 80 EE 3531 4 5 PLUG ASM AIR SOL KNIFE POSITION RI...

Page 159: ...EL ASM FRONT CONTROL TC 1 2 E 1584 LABEL ASM NO REV LEVEL 1 3 47701 6 TC PANEL INSERT CMT 130TC 1 5 E 1214 2 CONNECTOR 6 INS RING 1 6 E 1214 64 CONNECTOR 1 4 NON INS RING 1 7 E 2743 WIRE 18 GA YEL GRE...

Page 160: ...L 1 4 EE 2920 2 TRANSFORMER ASM 1 5 E 3215 BRACKET USB PORT 1 6 E 3203 1 CABLE BULKHEAD TO USB 1 7 43066 STRAIN RELIEF RIBBON CABLE 1 8 S 1781 42 LABEL GROUND SYMBOL 1 9 EE 3512 COPPER STRAP GROUNDING...

Page 161: ...art No Description Qty 1 P 303 1 4 O D P E TUBING SOLID BLUE 2 P 303 1 1 4 O D P U TUBING TRANS BLUE 3 P 303 2 3 8 O D P E TUBING SOLID BLUE 4 P 303 4 3 8 O D P U TUBING TRANS BLUE 5 56668 COLLET COVE...

Page 162: ...P 2 2 No Part No Description Qty 1 P 303 1 4 O D P E TUBING SOLID BLUE 2 P 303 1 1 4 O D P U TUBING TRANS BLUE 3 P 510 4 AIR FLOW REGULATOR 1 4 TUBE 9 4 P 508 4 UNION Y 1 4 TUBE DIA 1 5 P 318 PLUG 7...

Page 163: ...22 Pneu Manifold Asm 59012 1 No Part Number Description Qty 1 56009 VALVE 2 POSITION 11 2 56011 VALVE 3 POS EXH CENTER 1 3 56011 2 VALVE 3 POS PRESS CENTER 1 4 56012 REGULATOR MANIFOLD 2 5 56013 INDIV...

Page 164: ...4 ADAPTER O RING TO TUBE 1 12 H 238 4 STRAINER 1 13 H 242 60 HYD HOSE 1 14 H 248 1 ELBOW 90 STREET 1 15 H 248 2 ELBOW 90 STREET 1 16 H 270 8 PLUG NPT 1 17 H 287 2 BREATHER CAP 1 18 H 387 3 PUMP 1 19...

Page 165: ...TO TUBE 1 12 H 236 4 ADAPTER O RING TO TUBE 1 13 H 238 4 STRAINER 1 14 H 242 60 HYD HOSE 1 15 H 248 1 ELBOW 90 STREET 1 16 H 248 2 ELBOW 90 STREET 1 17 H 270 8 PLUG NPT 1 18 H 287 2 BREATHER CAP 1 19...

Page 166: ...1 7 H 568 CAVITY PLUG 1 8 H 200 2 SOLENOID VALVE DIRECTION 1 9 H 200 3 SOLENOID VALVE DUMP 1 10 H 230 3 ELBOW ORING TO TUBE 1 11 H 230 11 ELBOW ORING TO TUBE 1 12 H 230 12 ELBOW ORING TO TUBE 1 13 H 2...

Page 167: ...st PL 5 26 Hydraulic Schem 59010 S No Part Number Description Qty 1 H 203 26 SYSTEM RELIEF VALVE 1 2 56703 SOLENOID VALVE FLOW CTRL 1 3 E 1069 19 24V DC COIL 2 4 E 1069 23 COIL 1 8 H 200 2 SOLENOID VA...

Page 168: ...ate H 517 No Part Number Description Qty 1 H 203 26 SYSTEM RELIEF VALVE 1 2 8P 629 3 GAGE 0 3000 PSI 1 3 H 518 TUBE ASM PRESSURE GAGE 1 4 DTS 0345 4 MANIFOLD SUBPLATE 1 5 H 427 5 PLUG 6 O RING 9 16 18...

Page 169: ...56421TCA 1 7 No Part Number Description Qty 1 51036 FOOT 4 2 56456 THREADED ROD 4 3 56805 CASTER 4 4 56442 1 BASE 1 5 EE 3541 10 SWITCH RETROREFLECTIVE 1 6 H 6424 8 NUT 1 2 13 HEX JAM 4 7 H 6913 406...

Page 170: ...M TOP OF ELEV REF 12 H 6423 4 NUT 4 40 HEX KEP 2 13 H 6423 6 NUT 6 32 HEX KEP 4 14 H 6910 102403 SCREW 10 24 X 3 8 BUT HD 2 15 H 6918 44006 SCREW 4 40 X 3 4 SOC HD 2 16 H 6918 63203 SCREW 6 32 X 3 8 S...

Page 171: ...1 8 56435 2 SIDE FRAME LH 1 9 EE 3533 5 PROX ASM LIFT PLATE REF 10 H 6910 102403 SCREW 10 24 X 3 8 BUT HD 8 11 H 6913 404 SCREW 1 4 20 X 1 2 HEX HD 8 12 H 6913 407 SCREW 1 4 20 X 7 8 HEX HD 16 13 H 69...

Page 172: ...EE 3541 12 PROX ASM BOOK ENTER REF 11 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 2 12 H 6910 406 SCREW 1 4 20 X 3 4 BUT HD 8 13 H 6910 606 SCREW 3 8 16 X 3 4 BUT HD 4 14 H 6910 102404 SCREW 10 24 X 1 2 BUT...

Page 173: ...RIVE CHAIN 1 6 56478 TAPER LOCK SPROCKET 1 7 E 1165 7 BRAKE 1 8 E 1600 162 GEAR MOTOR 1 9 EE 3523 ELECTRICAL PANEL ASSEMBLY 1 10 H 6423 4 NUT 1 4 20 HEX KEP 4 11 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 4...

Page 174: ...STANDOFF 4 21 E 1152 124 STANDOFF 4 22 E 1886 2 CONNECTOR CORD GRIP REF 23 EE 3546 INTERLOCK SWITCH ASM REF 24 H 6416 832 6 WELDNUT 8 32 TWIN PILOT 1 25 H 6423 5 NUT 5 16 18 HEX KEP 2 26 H 6423 8 NUT...

Page 175: ...423 10 NUT 10 24 HEX KEP 3 12 H 6888 83204 SCREW 8 32 X 1 2 BUT HD T P 2 13 H 6910 406 SCREW 1 4 20 X 3 4 BUT HD 4 14 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 3 15 H 6910 102405 SCREW 10 24 X 5 8 BUT HD...

Page 176: ...0TC Book Trimmer PL 5 35 Idler 56446 No Part Number Description Qty 1 56444 IDLER BRACKET 1 2 56445 IDLER PIN 1 3 56447 IDLER SPROCKET 1 4 H 6424 8 NUT 1 2 13 HEX JAM 1 5 H 7324 16 WASHER 1 2 INT TOOT...

Page 177: ...ok Trimmer 5 37 5 Parts List PL 5 36 Pusher 56483 No Part Number Description Qty 1 56491 BRUSH HOLDER 2 2 56417 1 PUSHER PLATE 1 3 56484 303 BRUSH 2 4 H 6918 63203 SCREW 6 32 X 3 8 SOC HD 4 5 H 7324 6...

Page 178: ...3550 PLUG ASM 7 POS MALE POWER IN 1 24 EE 2397 6 SW ASM MAG POS RETRACT H 1 25 EE 3531 22 PLUG ASM AIR SOL PUSHER OUT 1 1 26 EE 3087 1 CABLE ASM MOTOR 1 27 EE 3546 CABLE ASM TOP DOOR INTLK TD 1 28 EE...

Page 179: ...0TC Book Trimmer 5 39 5 Parts List PL 5 38 Elev Pneumatics 56421TCA P No Part No Description Qty 1 P 303 1 4 O D P E TUBING SOLID BLUE 2 P 510 4 AIR FLOW REGULATOR 1 4 TUBE 2 3 59155 AIR TUBE ASM INFE...

Page 180: ...00TCA 1 8 No Part Number Description Qty 1 14050 SERIAL PLATE 1 2 56410 LEVELING PAD 4 3 56549 LEG 4 4 EE 3547 CONV CASE AND ELEC ASM 1 5 H 6910 604 SCREW 3 8 16 X 1 2 BUT HD 8 6 H 7324 12 WASHER 3 8...

Page 181: ...09 TIMING BELT 220XL037 1 2 56405 TENSIONER BLOCK 2 3 56613 DRIVE ASM 1 4 56614 IDLER ASM 1 5 56651 ENDLESS BELT TILT CONV 1 6 56606 1 WELDMENT TILT FRAME 1 7 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 6...

Page 182: ...ER BLOCK 2 2 56406 IDLER ASM 1 3 56602 FRAME 1 4 56180 REFLECTIVE TAPE 1 WIDE 1 5 56404 1 DRIVE ASM 1 6 56449 1 TIMING BELT 280XL037 1 7 56610 1 BELT BINDER CONVEYOR 1 8 H 6910 102404 SCREW 10 24 X 1...

Page 183: ...MICROSWITCH 1 12 H 5254 503 SCREW 5 16 X 3 8 SHSS 1 13 H 6423 6 NUT 6 32 HEX KEP 2 14 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 8 15 H 6910 605 SCREW 3 8 16 X 5 8 BUT HD 2 16 H 6918 63208 SCREW 6 32 X 1 S...

Page 184: ...26 3 TERMINAL STRIP 3P 1 11 EE 3541 14 PROX ASM TILT R T1 REF 12 EE 3541 15 PROX ASM TILT L T2 REF 13 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 2 14 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 5 15 H 6918 410 S...

Page 185: ...GUARD 1 11 E 1600 163 GEAR MOTOR 1 12 E 2181 4 CAPACITOR 1 13 E 2626 3 TERMINAL STRIP 3P 1 14 H 6423 8 NUT 8 32 HEX KEP 1 15 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 10 16 H 6918 63203 SCREW 6 32 X 3 8...

Page 186: ...EF 16 H 5254 405 SCREW 1 4 X 5 8 SHSS 2 17 H 5254 603 SCREW 3 8 X 3 8 SHSS 2 18 H 6424 8 NUT 1 2 13 HEX JAM 2 19 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 4 20 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 6 21 H...

Page 187: ...RH COVER 1 4 56648 GUARD 1 5 56649 FRONT COVER 1 6 56650 TOP COVER 1 7 56685 END COVER 1 8 13940 1 HANDLE 1 9 E 1152 61 STANDOFF 4 10 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 4 11 H 6910 102404 SCREW 10...

Page 188: ...V R 1 22 EE 3541 14 PHOTO SW ASM TILT CONV L 1 23 EE 3541 13 PHOTO SW ASM ENTERING TILT T 1 24 EE 3531 23 PLUG ASM AIR TILT CONV UP 1 25 E 2330 12 FUSE METRIC GLASS 8 10A SB 3 26 E 519 CONDUIT NUT 1 2...

Page 189: ...MAY 2019 CMT 130TC Book Trimmer 5 49 5 Parts List PL 5 48 Tilt Conv Pneumatics 56600TCA P No Part No Description Qty 1 P 303 1 4 O D P E TUBING SOLID BLUE 2 P 510 4 FLOW CONTROLLER 1 4 TUBE DIA 2...

Page 190: ...519 CONDUIT LOCKNUT 1 7 E 2450 1 CABLE PIGTAIL SPOOL MON 1 8 E 2626 6 TERMINAL STRIP 6P 1 9 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 8 10 H 6910 604 SCREW 3 8 16 X 1 2 BUT HD 8 11 H 6913 404 SCREW 1 4 20...

Page 191: ...ty 1 56404 DRIVE ASM 1 2 56405 TENSIONER BLOCK 2 3 56406 IDLER ASM 1 4 56544 ENDLESS BELT EXT CONV 1 5 56564 TIMING BELT 250XL037 1 6 56426 1 FRAME 1 7 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 6 8 H 691...

Page 192: ...T 2 4 56467 CONVEYOR COVER 1 5 56479 END COVER 1 6 59203 INFEED BOOK GUIDE 1 7 56426 1 FRAME 1 8 E 2196 11 HOLE PLUG 1 9 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 17 10 H 6910 102404 SCREW 10 24 X 1 2 BUT...

Page 193: ...N 1 4 FULLY INS Q D 2 6 E 1214 59 CONN 10 INS LOCK FORK 1 7 H 6918 63206 SCREW 6 32x3 4 SOC HD REF 8 H 7324 6 WASHER 6 INT TOOTH REF 9 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 1 10 H 7324 10 WASHER 10 I...

Page 194: ...OLE PLUG 4 18 E 2330 12 FUSE METRIC 8 10 AMP SB 1 19 E 2450 1 CABLE PIGTAIL SPOOL MON 1 20 E 2626 4 TERMINAL STRIP 4P 1 21 H 6910 102404SS SCREW 10 24 X 1 2 BUT SS 6 22 H 6910 102410 SCREW 10 24 X 1 1...

Page 195: ...MAY 2019 CMT 130TC Book Trimmer 5 55 5 Parts List PL 5 54 Std Hand Feed Elec EE 3342...

Page 196: ...029 1 REFLECTOR BRACKET 1 14 58539 TIE BAR 1 15 EE 3541 5 PROX ASM RLR STRT RS REF 16 H 6417 5 NUT 5 16 18 HEX 4 17 H 6423 4 NUT 1 4 20 HEX KEP 8 18 H 6424 8 NUT 1 2 13 HEX JAM 4 19 H 6910 510 SCREW 5...

Page 197: ...REF 3 E 3505 1 CAN CABLE JUMPER 1 4 EE 3460 3 PLUG ASM MALE CAN REF 5 EE 3518 ELECTRICAL PANEL ASM 1 6 EE 3550 PLUG ASM POWER IN REF 7 H 6918 102404 SCREW 10 24 X 1 2 SOC HD 4 8 H 6918 403 SCREW 1 4 2...

Page 198: ...F 5 58005 CROSS BRACKET REF 6 58026 AIR CYLINDER RODLESS 1 7 58027 FINGERED BOOK STOP PLATE 1 8 58037 WHEEL 2 9 58038 AXLE 2 10 58039 CONSTANT FORCE SPRING 2 11 H 6423 8 NUT 8 32 HEX KEP 2 12 H 6918 4...

Page 199: ...LINDER 1 6 58067 SENSOR BRACKET 1 7 A 11074 FOOT RUBBER 2 8 EE 3541 3 PROX ASM BOOK IN BI REF 9 EE 3541 4 PROX ASM PUSHER BP REF 10 H 5254 505 SCREW 5 16 X 5 8 SHSS 2 11 H 6918 102406 SCREW 10 24 X 3...

Page 200: ...2 19 EE 2952 9 PROX ASM TRAY FULL REF 20 H 5254 412 SCREW 1 4 X 1 1 2 SHSS 1 21 H 6423 4 NUT 1 4 20 HEX KEP 5 22 H 6423 4 NUT 4 40 HEX KEP 2 23 H 6442 10 NUT 10 24 NYLOC 2 24 H 6909 404 SCREW 1 4 20 X...

Page 201: ...K REF 3 58014 TILT CAGE 1 4 58015 CYLINDER END BLOCK 2 5 58016 AIR CYLINDER TRUNNION TYPE 1 6 58017 BEARING BLOCK 2 7 58018_ AIR CYLINDER 1 8 H 5254 412 SCREW 1 4 X 1 1 2 SHSS 1 9 H 5254 505 SCREW 5 1...

Page 202: ...IVE 5 15 58066 ROUND BELT MOTOR SHORT 1 16 58071 ROUND BELT MOTOR LONG 1 17 E 1600 163 GEAR MOTOR 1 18 E 2181 4 CAPACITOR 1 19 E 2626 3 TERMINAL STRIP 3P 1 20 H 5254 505 SCREW 5 16 X 5 8 SHSS 2 21 H 6...

Page 203: ...INGE ROD 1 3 58041 TOP COVER 1 4 E 866 9 POS ACTION MICROSWITCH 1 5 H 5254 402 SCREW 1 4 X 1 4 SHSS 1 6 H 6423 4 NUT 4 40 HEX KEP 2 7 H 6910 102404SS SCREW 10 24 X 1 2 BUT SS 6 8 H 6918 404 SCREW 1 4...

Page 204: ...VER 1 3 58051 UPPER SIDE COVER 1 4 58052 REAR COVER 1 5 58053 LOWER FRONT COVER 1 6 58054 TRANSPORT END COVER 1 7 58055 TRANSPORT SIDE COVER RH 1 8 58056 TRANSPORT SIDE COVER LH 1 9 E 1152 96 STANDOFF...

Page 205: ...FING S DN 4 1 19 EE 3531 19 PLUG ASM AIR PUSHER IN 5 1 20 EE 3541 3 SW ASM BOOK IN TILT BI 1 21 EE 3541 4 SW ASM BOOK PUSHER BP 1 22 EE 3541 5 SW ASM BOOK ENT STACKER 1 23 EE 2952 18 PROX ASM TRAY FU...

Page 206: ...er Pneumatics 58000TCA P No Part No Description Qty 1 P 303 1 4 O D P E TUBING SOLID BLUE 2 P 510 4 AIR FLOW REGULATOR 1 4 DIA 1 6 P 515 PUSH IN CONN 1 4 FEMALE REF 7 P 503 402 ELBOW 1 4 TUBE X 1 4 NP...

Page 207: ...19 CMT 130TC Book Trimmer 5 67 5 Parts List PL 5 66 Stacker Air Manifold 58008 No Part No Description Qty 1 56009 VALVE 2 POSITION 3 2 56011 1 VALVE 3 POS CLOSED CENTER 1 3 58008 M MANIFOLD BAR STOCK...

Page 208: ...56463 LEG BRACE 2 5 35126 4 KNOB 1 6 EE 3566 CASE ASM W ELEC COMP S 1 7 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 8 8 H 6910 604 SCREW 3 8 16 X 1 2 BUT HD 8 9 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 4 10 H...

Page 209: ...1 56404 DRIVE ASM 1 2 56405 TENSIONER BLOCK 2 3 56406 IDLER ASM 1 4 56544 ENDLESS BELT EXT CONV 1 5 56564 TIMING BELT 250XL037 1 6 56426 1 FRAME 1 7 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 6 8 H 6918...

Page 210: ...OVER 1 4 56467 CONVEYOR COVER 1 5 56479 END COVER 1 6 56503 ROLLER COVER 1 7 56426 1 FRAME 1 8 E 2196 11 HOLE PLUG 1 9 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 18 10 H 6910 102404 SCREW 10 24 X 1 2 BUT HD...

Page 211: ...LL CYL 1 13 E 1152 56 STAND OFF 1 4 HEX 1 2 LG 5 14 S 1781 42 LABEL GROUND 1 15 S 1781 105 LABEL SPEED SWOOP 1 16 S 1781 112 LABEL FUSE 8 10A 1 17 56340 2 CONVEYOR DRIVE ASM 1 18 E 1214 65 CONNECTOR 1...

Page 212: ...GEAR MOTOR 1 4 E 2181 4 CAPACITOR 1 5 E 2626 3 TERMINAL STRIP 3P 1 6 H 6918 44004 SCREW 4 40 X 1 2 SOC HD 1 7 H 6918 63206 SCREW 6 32 X 3 4 SOC HD 2 8 H 6918 102404 SCREW 10 24 X 1 2 SOC HD 2 9 H 6990...

Page 213: ...2181 4 CAPACITOR 1 5 E 2626 3 TERMINAL STRIP 3P 1 6 H 6918 44004 SCREW 4 40 X 1 2 SOC HD 1 7 H 6918 63206 SCREW 6 32 X 3 4 SOC HD 2 8 H 6918 102404 SCREW 10 24 X 1 2 SOC HD 2 9 H 6990 103204 SCREW 10...

Page 214: ...MAY 2019 5 Parts List 5 74 CMT 130TC Book Trimmer NOTES...

Page 215: ...er 6 10 GP 6 10 Micro Switches 6 11 GP 6 11 Keyed Interlock Switches 6 12 GP 6 12 Hirschmann Connectors 6 13 GP 6 13 Contact Blocks 6 14 GP 6 14 Speed Control Air Valves 6 15 GP 6 15 Principles of Ope...

Page 216: ...es The 5 most recent error messages can be viewed by performing the following pro cedure 1 Switch the main power ON and click on the Diagnostic button to bring up the diagnos tic screen Figure 6 1 2 A...

Page 217: ...tputs button Then press the checkbox next to the desired output to toggle it on or off Note Some outputs require the IR relay to be activated AND the green start button pressed before they can be acti...

Page 218: ...hts up whenever the corresponding input or output is on This can be helpful for troubleshooting input and output devices as well as the main PWB Certain status indicator RAPs refer to these The main P...

Page 219: ...ting Machine Software Machine software for the trimmer is stored on the console PWB It can be updated by in stalling an upgrade file from a USB drive Procedure 1 Go to www challengemachinery com soft...

Page 220: ...ctangular proximities are mounted on adjustable brackets Cylin drical proximities are mounted through holes and held in place with two nuts 5 Switch the main power ON and click the Di agnostic button...

Page 221: ...ector if damaged or peeling 4 Switch the main power ON Check the alignment of the sensor and reflector A red beam is emitted from the sensor that is visi ble on the reflector when aligned properly Rea...

Page 222: ...Clean the sensing surface with a dry cloth 2 Where possible adjust the position of the sensor such that the sensing surface is at least 1 25 4 mm away from where the books will pass 3 Switch the main...

Page 223: ...1 Switch the main power ON and press the Setup button to bring up the setup options 2 Press the Service Info tab to open the Ser vice Info screen Click on the Enable Tabs Code text box enter in the c...

Page 224: ...an be reset if necessary using the following procedure Procedure 1 Switch the main power ON and press the green start button to initialize the trimmer 2 Press the Job button then press the Bar Code bu...

Page 225: ...itch the main power OFF and lockout power to the machine WARNING Disconnect and lockout power as described in the Power Lockout Procedure on page ix There can be 120VAC at the micro switches 4 Loosen...

Page 226: ...n PWB Does the switch change state properly Y N Go to RAP 2 11 Interlock Test 3 Switch the main power OFF 4 Loosen the switch mounting and or bracket screws or actuator key mounting screws 5 Adjust th...

Page 227: ...the main power OFF and lockout power to the machine 2 Using a small screwdriver completely re move the mounting screw from the con nector 3 Remove the Hirschmann connector from the solenoid by pullin...

Page 228: ...wires from the contact block 4 Press and release the actuator Does the actuator return freely Y N The contact block is faulty and should be re placed Normally Open Contact 5 Check resistance between...

Page 229: ...to Table 6 1 5 Test the cylinder or item by manually actuat ing the corresponding pneumatic valve in the machine or accessory electrical panel area 6 Readjust speed control valve if necessary and tes...

Page 230: ...s power to the Elevator mo tor and does not rely on logic to stop the El evator from lifting Logic wiring is run be tween an additional switch on each interlock This logic data is communicated through...

Page 231: ...rolled by a DC motor with encoder feedback The registra tion plate is retracted by an air cylinder whenever the book moves in and out of the registration area It remains extended while the book is bei...

Page 232: ...vel 3 A second air cylinder lifts the side of the up per tray allowing the book to be ejected off from the upper tray and down onto the Verti cal Stacker delivery bed If the book is more than 1 2 5cm...

Page 233: ...edge trim 5 50 in 139 7 mm Max top head trim 6 00 in 152 4 mm Book thickness range 0 10 to 2 00 in 2 5 to 50 8 mm Min Trim 0 10 in 2 5 mm CMT 130TC Basic Machine Width 52 in 132 cm Depth 57 in 145 cm...

Page 234: ...collated pages of a book that does not include the cover It contains all front and end matter as well as the text block Untrimmed book An untrimmed book is a book block that has been bound with a cov...

Page 235: ...soap and water solution and a moist cloth 5 Remove the lower front door panel 6 Clean the hydraulic valves hoses fittings and manifold using a mild non abrasive soap and water solution and a moist cl...

Page 236: ...MAY 2019 6 General Procedures Information 6 22 CMT 130TC Book Trimmer GP 6 19 Change Tags There are no change tags at this time...

Page 237: ...ematic 120VAC 7 11 WD 7 11 Elevator Schematic 24VDC 7 12 WD 7 12 Tilt Schematic 120VAC 7 13 WD 7 13 Tilt Schematic 24VDC 7 14 WD 7 14 Long Infeed Schematic 120VAC 7 15 WD 7 15 Std Infeed Schematic 120...

Page 238: ...MAY 2019 7 Wiring Data 7 2 CMT 130TC Book Trimmer WD 7 1 Trimmer Schematic 230 VAC E 3496...

Page 239: ...MAY 2019 CMT 130TC Book Trimmer 7 3 7 Wiring Data WD 7 2 Trimmer Schematic 120 VAC E 3496...

Page 240: ...MAY 2019 7 Wiring Data 7 4 CMT 130TC Book Trimmer WD 7 3 Trimmer Schematic 53 VAC E 3496...

Page 241: ...MAY 2019 CMT 130TC Book Trimmer 7 5 7 Wiring Data WD 7 4 Trimmer Schematic 19 VAC E 3496...

Page 242: ...MAY 2019 7 Wiring Data 7 6 CMT 130TC Book Trimmer WD 7 5 Trimmer Schematic 9 VAC E 3496...

Page 243: ...MAY 2019 CMT 130TC Book Trimmer 7 7 7 Wiring Data WD 7 6 Trimmer Schematic 75 VDC E 3496...

Page 244: ...MAY 2019 7 Wiring Data 7 8 CMT 130TC Book Trimmer WD 7 7 Trimmer Schematic 24 VDC E 3496...

Page 245: ...MAY 2019 CMT 130TC Book Trimmer 7 9 7 Wiring Data WD 7 8 Trimmer Schematic 15 VDC E 3496...

Page 246: ...MAY 2019 7 Wiring Data 7 10 CMT 130TC Book Trimmer WD 7 9 Trimmer Schematic 5 VDC E 3496...

Page 247: ...MAY 2019 CMT 130TC Book Trimmer 7 11 7 Wiring Data WD 7 10 Elevator Schematic 120VAC E 3524...

Page 248: ...MAY 2019 7 Wiring Data 7 12 CMT 130TC Book Trimmer WD 7 11 Elevator Schematic 24VDC E 3524...

Page 249: ...MAY 2019 CMT 130TC Book Trimmer 7 13 7 Wiring Data WD 7 12 Tilt Schematic 120VAC E 3524...

Page 250: ...MAY 2019 7 Wiring Data 7 14 CMT 130TC Book Trimmer WD 7 13 Tilt Schematic 24VDC E 3524...

Page 251: ...MAY 2019 CMT 130TC Book Trimmer 7 15 7 Wiring Data WD 7 14 Long Infeed Schematic 120VAC EE 2985 1...

Page 252: ...MAY 2019 7 Wiring Data 7 16 CMT 130TC Book Trimmer WD 7 15 Std Infeed Schematic 120VAC EE 2985 1...

Page 253: ...MAY 2019 CMT 130TC Book Trimmer 7 17 7 Wiring Data WD 7 16 Stacker Schematic 120VAC E 3517...

Page 254: ...MAY 2019 7 Wiring Data 7 18 CMT 130TC Book Trimmer WD 7 17 Stacker Schematic 24VDC E 3517...

Page 255: ...MAY 2019 CMT 130TC Book Trimmer 7 19 7 Wiring Data WD 7 18 Exit Conv Schematic 120VAC E 3567...

Page 256: ...MAY 2019 7 Wiring Data 7 20 CMT 130TC Book Trimmer WD 7 19 Exit Conv Schematic 24VDC E 3567...

Page 257: ...MAY 2019 CMT 130TC Book Trimmer 7 21 7 Wiring Data WD 7 20 Exit Conv Schematic 5VDC E 3567...

Page 258: ...MAY 2019 7 Wiring Data 7 22 CMT 130TC Book Trimmer WD 7 21 Interconnection Diagram E 3504 Note This diagram is not intended to be an electrical schematic...

Page 259: ...MAY 2019 CMT 130TC Book Trimmer 7 23 7 Wiring Data WD 7 22 Fuse Circuit Breaker Chart S 1781 223 This label is located on the electrical panel cover...

Page 260: ...MAY 2019 7 Wiring Data 7 24 CMT 130TC Book Trimmer NOTES...

Page 261: ...Alone 8 8 Standard Hand Feed Conveyor 8 10 Long Hand Feed Conveyor 8 11 8 5 Trimmer Height Setup 8 12 8 6 Outfeed Setup 8 13 Vertical Outfeed Stacker 8 13 Exit Conveyor 8 15 Exit Ramp 8 16 8 7 Main Po...

Page 262: ...rench remove the lag screw from the front location shown in Figure 8 1 3 Open the rear door 4 Remove the belt guard near the bottom of the machine to reveal the rear lag screw 5 Remove the rear lag sc...

Page 263: ...Infeed Option 1 Tilt Conveyor Elevator Figure 8 4 Tilt Conv Elevator Setup Procedure 1 Position the Tilt Infeed Conveyor in front of the binder such that height adjustable por tion of the conveyor is...

Page 264: ...er Height Setup attach the eleva tor to the trimmer using supplied mounting hardware Figure 8 11 Figure 8 11 Elevator Attachment to Trimmer Cable and Air Tubing Connections Tilt Conveyor Elevator 1 Re...

Page 265: ...t is labelled with the numbers that correspond to the labels on the elevator and tilt conveyor near the input connectors Also locate any separate air tubing sections that may have been supplied with t...

Page 266: ...on the elevator near the input connectors The power cables are the larger diameter cables with 7 pin connectors on the end 2 Route the power cable under the hydraulic unit and out of the left side of...

Page 267: ...MAY 2019 CMT 130TC Book Trimmer 8 7 8 Installation Figure 8 18 Air Tubing Connections Now go to Section 8 5 Trimmer Height Setup to continue the setup process...

Page 268: ...feeder near the input connectors The power cables are the larger diameter cables with 7 pin connectors on the end 2 Route the power cable under the hydraulic unit and out of the left side of the trimm...

Page 269: ...MAY 2019 CMT 130TC Book Trimmer 8 9 8 Installation Figure 8 22 Air Tubing Connection Now go to Section 8 5 Trimmer Height Setup to continue the setup process...

Page 270: ...and Feed Mounting Hardware 4 Fasten the conveyor to the trimmer using the hardware from step 2 Cable Connections 1 Remove the lower front panel of the trimmer and locate the yellow power cable coiled...

Page 271: ...of the trimmer such that the slots in the conveyor mounting brackets line up with the holes in the trimmer s left hand side It may be necessary to adjust the Hand Feed Conveyor s leveling pads in ord...

Page 272: ...914mm from the floor Use a level to make sure the table is level from left to right 2 Open the rear doors and raise the rear end of the machine by adjusting the rear two lev eling pads until the trim...

Page 273: ...s in the outfeed stacker Cable and Air Tubing Connections 1 Remove the lower front panel of the trimmer and locate the yellow power cable coiled up inside the trimmer that is labelled with the number...

Page 274: ...lue air tub ing with a red and white connector on the end that is labelled with the number that cor responds to the label on the outfeed stacker near the input connectors 7 Connect the air tubing as s...

Page 275: ...anel of the trimmer and locate the yellow power cable coiled up inside the trimmer that is labelled with the number that corresponds to the label on the exit conveyor near the input connectors The pow...

Page 276: ...ed Option 3 Exit Ramp Setup Procedure To install the Exit Ramp option simply attach the Exit Ramp as shown in Figure 8 39 below using the hardware provided Figure 8 39 Exit Ramp Placement Now go to Se...

Page 277: ...disconnect switch before working on the trimmer Lock it out to prevent acci dental power up See Power Lockout Proce dure on page ix 1 Locate the power panel door at the lower right hand side of the ma...

Page 278: ...tton is pressed If power is incor rectly connected the mechanism will remain in the down position If power was correctly connected skip steps 14 18 and go to Section 8 8 Main Air Hookup 14 Switch off...

Page 279: ...L Including Liquid and Vapor ISO QUALITY CLASS Mg m3 ppm 1 0 01 0 008 2 0 1 0 08 3 1 0 8 4 5 4 5 25 21 6 CAUTION Failure to use dry non lubricated compressed air that meets or exceeds the preceding re...

Page 280: ...o clean the trimmer and accessories after installation If so use a mild non abrasive soap and water solution and a moist cloth Do not use petroleum or acid based cleaners or solvents to clean the cons...

Page 281: ...MAY 2019 CMT 130TC Book Trimmer 8 21 8 Installation NOTES...

Page 282: ...TC Book Trimmer 2002 2019 by The Challenge Machinery Company All rights reserved Printed in the USA FX 013B CMT 130B MAY 2019 2002 2019 by The Challenge Machinery Company All rights reserved Printed i...

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