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Challenge CMT-130, Service Manual

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Challenge CMT-130 Service Manual Download Page 128

 

 

 

FEB 2017 

 

5. Parts List

 

5-16 

CMT 130 Book Trimmer 

PL 5.15 Power Panel EE-3306-1 (1/2) 

Components 

Item  Part 

Description 

Qty. 

1 

56864 

PANEL - POWER 

1 

2 

E-2742-5 

TRANS. - 120V PRIM., 16V & 24V SEC. (T2) 

1 

3 

E-2742-15 

TRANS. - 120V PRIM., 9V/19V/28V SEC.  (T3) 

1 

4 

E-2805-2 

STARTER - RELAYS, "PM" AND "IR" 

2 

5 

E-2376-2 

AUXILIARY CONTACT - STARTER, N.O. 

6 

6 

E-1429-21 

WIRE DUCT & COVER - 12" LONG 

1 

7 

E-1429-19 

WIRE DUCT & COVER - 23-1/2" LONG 

1 

8 

E-1977-26 

RAIL - TERMINAL - 4" LONG 

1 

9 

E-1977-15 

RAIL - TERMINAL - 9" LONG 

2 

10 

E-2068-3 

TERMINAL BLOCK - GROUNDING 

1 

11 

E-2068-9 

TERMINAL BLOCK - #10 AWG., UK 5 RETURN 

29 

12 

E-2068-7 

TERMINAL BLOCK - 3 AWG. 

5 

13 

E-3264-9 

CIRCUIT BREAKER - 8A, (CB1 THRU 4) 

4 

14 

E-1974-9 

TERMINAL BLOCK - FUSEHOLDER, GLASS 

8 

15 

E-2069-5 

END PLATE 

1 

16 

E-2070-1 

END BRACKET  

5 

17 

E-2864-1 

SEPERATOR PLATE - TERMINAL BLOCK 

2 

18 

E-1143 

BRIDGE RECTIFIER - PANEL MOUNT 

2 

19 

E-1599-11 

IC CHIP - 32 PIN PACKAGE (BLANK) 

1 

20 

E-2507-3 

FIXED BRIDGE - 3 POLE 

2 

21 

E-2507-8 

FIXED BRIDGE - 8 POLE 

2 

22 

E-2626-4 

TERMINAL STRIP - 4 POS. 

1 

23 

E-3145 

ANGLE BRACKET - TERMINAL RAIL 

2 

24 

E-1356-( ) 

MARKING STRIP - TERMINAL BLOCK 

2 

25 

EE-3318 

WIRE ASM - CUT LIST 

1 

26 

E-2064-2 

RELAY - SOLID STATE 

4 

28 

E-2232-4 

RELAY - SHUTDOWN (SD) (TL) 24VDC COIL 

2 

29 

EE-2939-2 

P.C.B. ASSEMBLY - CONTROLLER (RoHS) 

1 

30 

47157-7 

P.C.B. COVER - CLEAR 

1 

31 

E-1152-56 

STAND-OFF - 1/2" LONG 

10 

32 

E-1152-43 

STAND-OFF - 2" LONG 

2 

33 

E-2730-3 

FILTER - EMI/EFI, PANEL MOUNT (3EQ1) 

1 

34 

E-2730-5 

FILTER - EMI/EFI, PANEL MOUNT (6EQ1) 

1 

35 

E-1431-1 

CAPACITOR - 39000 uF ELECTROLYTIC (C1) 

2 

36 

E-2066-10 

PLUG CONNECTOR - P.C.B. 10 PIN 

6 

37 

E-2066-8 

PLUG CONNECTOR - P.C.B. 8 PIN 

1 

38 

E-2066-12 

PLUG CONNECTOR - P.C.B. 12 PIN 

4 

39 

P-294 

PRESSURE SWITCH - N.O. CLOSES @ 20 PSI 

1 

40 

P-295 

ADAPTOR - PRESSURE SWITCH BULKHEAD 

1 

41 

E-2709 

BRACKET - CAPACITOR 

2 

42 

E-894 

CABLE CLAMP - METAL 

3 

81 

E-889-5 

FUSE - 4A SLO-BLO GLASS, "F12" 

1 

83 

E-889 

FUSE - 1-1/4AMP SLO-BLO GLASS, "F5" 

1 

84 

E-889-9 

FUSE - 8AMP SLO-BLO GLASS, "F6,F7,F9 & F10" 

4 

85 

E-889-2 

FUSE - 2AMP SLO-BLO GLASS, "F8 & F11" 

2 

90 

EE-3289 

RESISTOR ASSEMBLY - IR RELAY COIL 

1 

91 

H-6918-63206 

SCREW, #6-32NC X 3/8" SOC HD CAP 

1 

92 

E-1584-52 

LABEL - TRANSFORMER, "T2" 

1 

93 

E-1584-53 

LABEL - TRANSFORMER, "T3" 

1 

94 

E-1584-( ) 

LABEL - ASM. NO./REV. LEVEL 

1 

95 

S-1781-35 

LABEL - CAUTION, ELEC. DANGER 

2 

96 

S-1781-42 

LABEL - GRND SYMBOL, SECONDARY 

1 

97 

H-6910-63203 

SCREW, #6-32NC X 3/8" BUT HD CAP 

16 

98 

H-6423-#6 

NUT, #6-32NC HEX (KEP STYLE) 

14 

99 

H-7324-#6 

WASHER, #6 INT. TOOTHLOCK 

17 

100 

H-6910-83203 

SCREW, #8-32NC X 3/8" BUT HD CAP 

30 

101 

H-7324-#8 

WASHER, #8 INT. TOOTHLOCK 

32 

102 

H-6910-102403 

SCREW, #10-24NC X 3/8" BUT HD CAP 

9 

103 

H-7324-#10 

WASHER, #10 INT. TOOTHLOCK 

9 

104 

H-6910-403 

SCREW, #1/4-20NC X 3/8" BUT HD CAP 

7 

105 

H-7324-8 

WASHER, 1/4 INT. TOOTHLOCK 

7 

106 

S-1694 

TY-WRAP - CABLE      (NOT SHOWN) 

10 

107 

S-1350-16 

STRAIN RELIEF - CABLE 

21 

108 

E-1453-6 

TUBING - SHRINK, 1/8 DIA. 1" LONG 

3 

110 

H-6915-103203 

SCREW, #10-32NC X 3/8" SOC HD CAP 

4 

111 

EE-2969-1 

CONDUIT ASSEMBLY - HYDRAULIC MOTOR 

1 

112 

E-1977-24 

RAIL - TERMINAL BLOCK, 2" LONG 

1 

113 

E-1736-4 

QUENCHARC - AUX. (QA2) 

1 

114 

E-2752-2 

COVER - TERMINAL BLOCK 

3 

121 

H-6910-83204 

SCREW - #8-32 X 1/2 BUT HD SOC CAP 

2 

122 

E-2441-11 

OVERLOAD RELAY - 13A TO 19A 

1 

126 

E-3292 

MOTOR CONTROL - STEPPER 

1 

127 

H-7324-#4 

WASHER - #4 INT. TOOTHLOCK 

2 

128 

H-6910-44003 

SCREW, #4-40NC X 3/8" BUT HD CAP 

2 

129 

EE-3311 

PCB ASSEMBLY - DOOR INDICATOR 

1 

131 

H-6910-44005 

SCREW, #4-40NC X 5/8" BUT HD CAP 

2 

132 

E-1736-5 

QUENCHARC - PANEL MOUNT, QA1 

1 

133 

S-1781-197 

LABEL - GROUND SYMBOL, PRIMARY 

1 

Summary of Contents for CMT-130

Page 1: ...al F 501 For Vertical Stacker see manual F 502 CAUTION Certain components in the CMT 130 are suscep tible to damage due to electrostatic discharge Observe all ESD procedures to avoid compo nent damage...

Page 2: ...lity 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 suitab...

Page 3: ...t 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...

Page 4: ...FEB 2017 Introduction iv CMT 130 Book Trimmer Page Rev Page Rev Revision Control List Page Rev Page Rev Page Rev Page Rev...

Page 5: ...2 RAP 2 45 Knife Latch Sensor 2 53 RAP 2 46 Book in Position Sensor 2 54 RAP 2 47 Jogger Retract Sensor 2 55 RAP 2 48 Registration Preset Sensor 2 56 RAP 2 49 Face Jog Sensors 2 57 RAP 2 50 Rotator Pr...

Page 6: ...Hand Feed Elec EE 3342 5 54 PL 5 54 Exit Conv 56420 1 3 5 55 PL 5 55 Exit Conv 56420 2 3 5 56 PL 5 56 Exit Conv 56420 3 3 5 57 PL 5 57 Exit Conv Elec EE 2979 3 5 58 PL 5 58 Conveyor Drive Asm 56340 1...

Page 7: ...o 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 ot...

Page 8: ...ate with covers or guards removed Electrical Shock Hazard Disconnect power before removing cover Electrical Shock Hazard Disconnect power before removing cover Other Symbols Become familiar with other...

Page 9: ...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 10: ...pare 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 Bour...

Page 11: ...rnal Conveyor Motor 2 47 RAP 2 40 Registration Assembly Motor 2 48 RAP 2 41 Rotary Gripper Motor 2 49 RAP 2 42 In Feed Motors 2 50 RAP 2 43 Elevator Motor 2 51 RAP 2 44 Out Feed Conveyor Motor 2 52 RA...

Page 12: ...Perform RAP 2 17 Starter Circuit 6 Once the gripper transport is in its home po sition the display should show the run screen which is a graphic of a book with di mensions displayed Does this happen Y...

Page 13: ...Run at least ten books through the machine by manually placing them on the in feed conveyor one at a time Do the books feed through the machine correctly Y N Go to CMT 130 Installation and Operator M...

Page 14: ...alance Valve Conveyor Stopped Out feed accessory is full or jammed DATA IS OUT OF RANGE This error message displays when the operator attempts to en ter a book dimension that is either too small or to...

Page 15: ...ife latch error OFF when it should be ON The knife latch sensor did not activate This can be caused by a misadjusted or faulty proximity sensor or the latch did not pull in RAP 2 33 Knife Latch Cylind...

Page 16: ...ted result is a negative value See Installation and Operator s Manual Send canceled This message is displayed when a key is pressed while the book positioner is moving Serial communication port failed...

Page 17: ...faulty RAP 2 16 E Stop Remote E Stop Buttons Upper door is Open The upper right hand door is open or the interlock is faulty or mis adjusted RAP 2 14 Interlock Relay RAP 2 11 Door Interlocks Waiting...

Page 18: ...17 Starter Circuit The internal conveyors do not run while the pump motor is on RAP 2 39 Internal Conveyor Motor The internal conveyors run while the pump motor is off RAP 2 39 Internal Conveyor Moto...

Page 19: ...Trimmer Book Quality Cuts appear scraped or rough BQ 3 1 Burr Marks Cut at bottom cover appears jagged or rough BQ 3 2 Jagged Bottom Cover Cut surfaces appear scraped or rough and bottom cover appear...

Page 20: ...tinuously lifts and stops after a timeout period RAP 2 43 Elevator Motor RAP 2 58 Elevator Lift Plate Sensor Book does not leave Elevator pusher remains ex tended never extends or extends erratically...

Page 21: ...nnect main power and replace the main power switch PL 5 1 Main Assembly 59000 1 12 6 Is there line voltage between wires 1 and 2 at the F1 and F2 fuses Figure 2 2 Y N Check continuity and replace blow...

Page 22: ...FEB 2017 2 Status Indicator RAPs 2 12 CMT 130 Book Trimmer Figure 2 3 Transformer Locations Figure 2 4 T1 Transformer 60Hz Figure 2 5 T1 T4 Transformers 50Hz Figure 2 2 Power Panel Item Locations...

Page 23: ...EE 3306 1 1 2 6 Is there 5 VDC between wires 7 and 8 Y N Disconnect main power and replace main PWB 7 Is there 12 VAC between wires pairs 50 51 and 51 52 and 24 VAC between 50 52 Y N Disconnect main...

Page 24: ...ep timer setting Initial Actions The enclosure lights and backlight are powered from the same source 9 VAC If the enclosure lights are also off go to RAP 2 5 Input Power and RAP 2 6 DC Power Procedure...

Page 25: ...ghts will not switch on Initial Actions Check RAP 2 5 Input Power and RAP 2 6 DC Power Procedure 1 Switch on the machine Is output LED 31 switched on Y N Disconnect main power and replace the main PWB...

Page 26: ...ys be on when the power is switched on Initial Actions Switch on the machine to check if all fans are running If the enclosure lights and the front console also do not turn on go to RAP 2 5 Input Powe...

Page 27: ...Check RAP 2 5 Input Power and RAP 2 6 DC Power Check and repair loose or broken wire 120 at the power panel Procedure 1 Switch on power to the machine Is output LED 1 on the main PWB switched on Y N...

Page 28: ...ose wires on all 3 door interlock switches because they are wired in series Procedure does not operate with doors closed 1 Does the Door Open Indicator display a door open Y N Cycle power press A to e...

Page 29: ...the machine and enter sensor data mode Does the sensor data display 13 1 Y N Short wire 126 to 64 at the main PWB Does the sensor data change to 13 1 Y N Disconnect main power and replace the main PWB...

Page 30: ...ure 1 Leave the door closed for the switch you are checking and examine the switch to make sure the plunger is not at all depressed 2 Check for continuity across the switch s ter minals see Figure 2 1...

Page 31: ...or tab is pressed Is continuity nor mal Y N Disconnect main power and replace the re lay IR PL 5 15 Power Panel EE 3306 1 1 2 5 Reconnect wires to the interlock relay 6 Short wire 89 at the IR relay t...

Page 32: ...d replace defec tive switch body PL 5 1 Main Assembly 59000 1 12 or PL 5 18 Control Console EE 3310 2 Switch on the machine and enter the sensor data screen at the console Does sensor data display 22...

Page 33: ...e machine and enter the sensor data screen at the console Does sensor data display 27 0 Y N Disconnect wire 41 from the main PWB Does the sensor data screen change to 27 0 Y N Disconnect main power an...

Page 34: ...elay error OFF when it should be on is displayed at machine startup Motor starter error ON when it should be off is displayed Motor starter error OFF when it should be on is displayed Initial Actions...

Page 35: ...re 88 and 89 were connected OLH Does the resistance measure less than 2 Y N Replace the overload relay OLH PL 5 15 Power Panel EE 3306 1 1 2 3 Switch on the machine Press A to enter sensor data mode M...

Page 36: ...solenoid connector from both the dump valve and the proportional flow control valve 5 Short wires 86 to 74 and 115 to 74 6 Place a Murr solenoid adapter Figure 2 25 between the Hirschmann connector an...

Page 37: ...FEB 2017 CMT 130 Book Trimmer 2 27 2 Status Indicator RAPs Figure 2 24 Proportional and Dump Valves Figure 2 25 Murr Adapter...

Page 38: ...e power supply okay Y N Disconnect main power and repair the 24 VDC power supply Disconnect main power and replace the main PWB REP 4 22 Main PWB Replace ment 3 Disconnect main power 4 Short wire 85 t...

Page 39: ...rocedure 1 Switch on the machine Is the output LED 14 switched off Y N Disconnect main power and replace the main PWB REP 4 22 Main PWB Replace ment 2 Press the green start button Does output LED 14 s...

Page 40: ...57 press and release the MODE button until P 54 appears in the display 11 Press and release the UP button until P 57 appears in the display 12 Press the SET button two times The display will flash 13...

Page 41: ...sensors GF POT and GR NOT are on Procedure 1 The servo drive is located in the upper right hand corner of the electrical panel Figure 2 31 2 Switch on the machine Do not press the green START button...

Page 42: ...oses between the air filter main pressure regulator and main sys tem pressure gauge Adjust control dial to 80 90 PSI 2 Check and repair hoses between the main air disconnect valve and the pressure swi...

Page 43: ...s shown in Figure 2 36 5 Switch on main air 6 Switch on power Place an A4 or 8 1 2 x 11 book in the jogging station 7 Manually activate valve number 1 by press ing the button on the valve Figure 2 36...

Page 44: ...r broken wire 68 at the power panel Check that the wire connector for valve number 2 is connected properly Procedure 1 Switch off main air at the main air valve 2 Attempt to actuate the gripper by han...

Page 45: ...d disconnected or pinched hoses Check for loose or broken wire 59 at the power panel Check that the wire connector for valve number 3 is connected properly Procedure 1 Manually activate valve number 3...

Page 46: ...he flow control valve on the left end of the pusher air cylinder Figure 2 41 2 Pull the elevator away from the machine to access the flow control on the right side of the elevator Fully open the flow...

Page 47: ...y Procedure 1 Open the rear door and fully open the flow control valves pertaining to the knife shift cylinders Figure 2 43 2 Manually activate valve number 5 by press ing the actuator button on the v...

Page 48: ...or loose or broken wire 69 at the power panel Check that the wire connector for valve number 6 is connected properly Procedure 1 Manually activate valve number 6 by press ing the actuator button on th...

Page 49: ...ontrol Air Valves Check for air leaks and disconnected or pinched hoses Check for loose or broken wire 116 at the power panel Check that the wire connector for valve number 7A is connected properly Pr...

Page 50: ...a plugged air jet air leaks and dis connected or pinched hoses Check for loose or broken wire 33 at the power panel Check that the wire connector for valve number 7B is connected properly Procedure 1...

Page 51: ...ose or broken wire 71 at the power panel Check that the wire connector for valve number 8 is connected properly Procedure 1 Using ADJ 4 17 Knife Latch check that the proximity switch is properly adjus...

Page 52: ...wer panel Check that the wire connector for valve number 9 is connected properly Procedure 1 Check that main air is switched on and that shop air is fully functional at 80 90 PSI 2 Manually activate v...

Page 53: ...is connected properly Procedure 1 Fully open the flow control valves on the book gate air cylinder Figure 2 55 2 Manually activate valve number 10 by press ing the actuator button on the valve Figure...

Page 54: ...e Figure 2 58 Does the face jog cylinder extend Y N Disconnect main power and replace valve number 12 PL 5 21 Pneu Manifold Asm 59012 1 2 Electrically activate valve number 12 by shorting wire 140 to...

Page 55: ...n off while trimming the bot tom of a book 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 Check for loose...

Page 56: ...at the power panel Check that the wire connector on the air valve is connected properly Procedure 1 Switch on the machine Is output LED 2 switched off Y N Disconnect main power and replace the main PW...

Page 57: ...er to preset Now there should be 120 VAC at both locations Are the volt ages okay Y N Go to RAP 2 14 Interlock Relay PL 5 15 Power Panel EE 3306 1 1 2 4 After the gripper has preset and the pump motor...

Page 58: ...on the machine and press the green start button to initialize 3 Check voltage between wires 28 and 29 Is there 208 230 VAC Y N Go to RAP 2 5 Input Power and check the 208 230 VAC circuit 4 Is there 5...

Page 59: ...and make sure they match settings shown in Figure 2 67 Procedure 1 Switch on the machine 2 Check the encoder wire connector Figure 2 66 Is there 5 VDC between wires 7 and 8 at the encoder wire connect...

Page 60: ...ine 2 Check fuses F1 F2 and F3 at the back side of the tilt conveyor Is the resistance less than 2 Ohms Y N Replace blown fuses 3 Switch on the machine and measure voltage between wire 22 and wire 123...

Page 61: ...move the motor cover and feed a book into the elevator Is there a click sound from the motor brake when the elevator should start lifting Y N Disconnect main power and replace the motor brake PL 5 31...

Page 62: ...57 Exit Conv Elec EE 2979 3 2 Replace the time delay relay PL 5 57 Exit Conv Elec EE 2979 3 Procedure conveyor never runs 1 Switch off the machine 2 Check fuse F11 Figure 2 2 Is resistance is less tha...

Page 63: ...machine Check that the knife latch is engaged 2 Switch on the machine and press A to enter sensor data mode Does the sensor data screen display 16 0 Y N Disconnect wire 13 from the main PWB Does the...

Page 64: ...de Place a white piece of paper over the sensing surface Gradually move the paper up and away from the sensing surface Is a beep heard from the main PWB at any time Y N Go to step 3 2 Go to GP 6 10 Re...

Page 65: ...the jogger is fully retracted 2 Switch on the machine and press A to enter sensor data mode Does the sensor data screen display 12 1 Y N Short wire 122 to 64 on the main PWB Does the sensor data chang...

Page 66: ...y Motor Procedure 1 Switch off the machine 2 Check fuses FA and FB on the main PWB Figure 2 2 Is the resistance of fuses less than 2 Ohms Y N Replace blown fuses 3 Open the right door and rotate the r...

Page 67: ...Short wire 119 to wire 64 at the main PWB Does the sensor data change to 18 1 Y N Disconnect main power and replace the main PWB REP 4 22 Main PWB Re placement Disconnect main power and replace the l...

Page 68: ...Procedure 1 Switch off the machine 2 Check replace fuses F12 FA F6 and F7 Figure 2 2 3 Manually move the rotator assembly such that the rotator disk covers the sensor 4 Switch on the machine 5 Does t...

Page 69: ...and repair loose wire 53 at the power panel Procedure 1 Switch on the machine and press the green start button Is the knife assembly up and is the knife bar assembly shifted all the way left or right...

Page 70: ...chine and press the green start button Is the knife assembly up all the way Y N Perform RAP 2 17 Starter Circuit 2 Switch off power and then back on Enter sensor data mode Does the screen display 32 0...

Page 71: ...damaged Check and repair loose or broken wire 36 at the power panel The following procedure must be performed with the knife up Procedure 1 Switch on the machine and enter sensor data mode Does the sc...

Page 72: ...lly damaged Check and repair loose or broken wire 46 at the power panel The following procedure must be performed with the knife up Procedure 1 Switch on the machine and enter sensor data mode Does th...

Page 73: ...cate 15 1 Y N Short wire 130 to 64 Does the sensor data change to 15 1 Y N Disconnect main power and replace the main PWB REP 4 22 Main PWB Re placement Go to GP 6 11 Diffuse Sensors PL 5 38 Tilt Conv...

Page 74: ...conveyor case Check that the reflective tape pieces are in place on the book stop Check and repair loose or broken wire 144 at the power panel Procedure 1 Check that the sensors are not blocked Does t...

Page 75: ...all cables are securely fastened to the connectors in the elevator base Check and repair loose or broken wire 54 at the power panel Procedure 1 Check that the sensor is not blocked Does the sensor dat...

Page 76: ...roximity Sensors PL 5 29 Elevator 56421 3 7 or PL 5 36 Elev Electrical EE 2980 1 Short wire 40 to 64 The sensor data screen displays 10 1 Y N Replace the main PWB REP 4 22 Main PWB Replacement Go to G...

Page 77: ...ator Check and repair loose or broken wire 127 at the power panel Procedure 1 Switch on the machine and press the green start button Press A to enter the sensor data screen Does the sensor data screen...

Page 78: ...flective tape on the shelf bracket is installed Check that the elevator is properly installed See the Installation and Operator s Manual Check for loose or broken wire 124 at the power panel Check tha...

Page 79: ...and repair wire 55 at the power panel Procedure 1 Output Conveyor Full message is al ways displayed The sensor data screen displays 3 1 Y N Short wire 55 to 64 The sensor data screen displays 3 1 Y N...

Page 80: ...FEB 2017 2 Status Indicator RAPs 2 70 CMT 130 Book Trimmer NOTES...

Page 81: ...Q 3 5 Linear Crease Lines 3 3 BQ 3 6 Draw 3 3 BQ 3 7 All Sheets Not Cut 3 4 BQ 3 8 Book Not Square 3 4 Introduction The Book Quality section addresses issues per taining to cut quality They are not in...

Page 82: ...g 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 The knife may...

Page 83: ...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 18 Clamp Pressure Adjustment until...

Page 84: ...ere the binding has had signifi cant time to harden 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 in...

Page 85: ...4 12 Air Filter Change 4 15 ADJ 4 13 Hydraulic System Pressure 4 16 ADJ 4 14 Counterbalance Valve 4 17 ADJ 4 15 Book Underside Air Lift 4 18 ADJ 4 16 Knife Gib Adjustment 4 19 ADJ 4 17 Knife Latch 4 2...

Page 86: ...er remove the waste bin and open the back door 2 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...

Page 87: ...k door 2 Place an empty scabbard on a stable rolling cart 3 Using the T handle hex wrench remove the two knife bolts that are in open slots in the knife bar Figure 4 5 They are the second and sixth bo...

Page 88: ...he knife depth adjustment handle clockwise until it stops The adjustment handle is located at the rear left corner of the machine 3 Place a scabbard containing a replacement knife on the cart Move the...

Page 89: ...g depth must be adjusted REP 4 3 Knife Depth Adjustment CAUTION The knives must be adjusted after every knife change Improper knife adjustment may cause damage to the machine Knife Sharpening Amount A...

Page 90: ...b clockwise approxi mately three full revolutions Proceed to step 5 4 Make sure the knife adjustment knob is turned all the way clockwise until it cannot turn clockwise any further 5 Move the waste bi...

Page 91: ...ricating oil such as 3 in 1 SAE 20 electric motor oil 3 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 ta...

Page 92: ...ger plates The tape should be checked for damage WARNING Disconnect and lockout power as described in the Power Lockout Procedure on page viii Procedure 1 Switch off main power and access the jog ging...

Page 93: ...the book has been trimmed Use a high resolution instrument such as Vernier calipers Enter the meas ured value into the width W dimension on the Accuracy Adj screen Typical values are 5 900 149 1 to 6...

Page 94: ...s 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 4 Subtract A from B B A If the result is pos itive t...

Page 95: ...no sag Y N a Loosen the four screws mounting the motor to the motor bracket b Pull the motor up until the sag is re moved from the timing belt c Re tighten all four mounting screws 4 Inspect the two c...

Page 96: ...e of holes tears or excessive edge fraying Y N Replace the conveyor belt PL 5 39 Tilt Conveyor 56600 2 8 PL 5 40 Tilt Con veyor 56600 3 8 PL 5 43 Tilt Con veyor 56600 6 8 or PL 5 55 Exit Conv 56420 2...

Page 97: ...pressure to the top surface of the belt Internal Out feed Conveyor Adjust this belt so that the gap between the belt and the belt guard or exit ramp is as small as possible without the belt touch ing...

Page 98: ...n the drill in order to transfer oil from the reservoir to the empty con tainer 5 Empty the contents of the shipping con tainer 6 Insert the suction hose into the filler breather hole and pump used oi...

Page 99: ...ove the cylinder 5 Remove the black filter element retainer from the filter head Turn the retainer coun terclockwise until it is freed from its mount ing rod 6 Remove the used filter element and clean...

Page 100: ...nt then select Service 3 Enter the service code 2 001 and press enter 4 Select Shipping Position and press en ter 5 Press the green start button The knife as sembly is forced up for 10 seconds at full...

Page 101: ...sen the lock nut on the counterbalance valve 2 Check that all doors are closed Switch on the power to the machine and press the green start button to initialize 3 Select A Maint then select Knife Ad j...

Page 102: ...en press enter This will manu ally actuate the air valve 7B and start the un derside air blast 4 Locate the book underside air lift adjustment knob Figure 4 26 5 Locate the red locking ring and unlock...

Page 103: ...and jam nuts 4 Tighten the middle gib screw on each side 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 count...

Page 104: ...en start button to initialize 2 Switch off the machine and switch off the main air valve 3 Access the knife latch through the rear door 4 Loosen the proximity sensor mounting screws 5 Push the latch b...

Page 105: ...essure may af fect the final cut quality of the books Initial Actions Check that the air supply is switched on Open the back door Procedure 1 Locate the clamp pressure regulator Figure 4 29 2 Lift up...

Page 106: ...the lock nut on the valve 2 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 30 Turning the screw cloc...

Page 107: ...ripper clamp pressure to 0 2 to 0 3 MPa The gauge location is shown in Figure 4 31 Turning the screw clockwise will increase pressure Turning the screw counter clock wise will decrease the pressure 3...

Page 108: ...ket perpendicular Y N a Loosen the block s clamp screw b Without rotating the cylinder shaft rotate the face jog block until the block and bracket are perpendicular to the table surface c Make sure th...

Page 109: ...5 12 Main Assembly 59000 12 12 7 Remove the two nuts that mount the high voltage cover to standoffs on the power panel 8 Use a small screwdriver to gently pry the PROM from its socket GP 6 7 Software...

Page 110: ...r at the main air dis connect valve at the back of the machine 2 Remove four screws from the elevator s top cover and remove the top cover 3 Loosen the two screws that mount the pusher plate to the pu...

Page 111: ...isengages from the sprocket hub 5 Remove the insert removal screw from the hub 6 Raise the elevator lift plates on the free side until they are level with the plates on the op posite side Figure 4 37...

Page 112: ...FEB 2017 4 Repair Adjustment Procedures 4 28 CMT 130 Book Trimmer NOTES...

Page 113: ...56421 2 7 5 29 PL 5 29 Elevator 56421 3 7 5 30 PL 5 30 Elevator 56421 4 7 5 31 PL 5 31 Elevator 56421 5 7 5 32 PL 5 32 Elevator 56421 6 7 5 33 PL 5 33 Elevator 56421 7 7 5 34 PL 5 34 Idler 56446 5 35...

Page 114: ...SHBUTTON SWITCH 1 19 E 3127 5 PUSHBUTTON SWITCH 1 20 E 3134 CONTROLLER SERVO AMP 1 21 EE 2971 SWITCH ASM MAIN DISC 1 22 EE 3306 1 ELECTRICAL PANEL ASSEMBLY 1 23 H 6423 4 NUT 1 4 20 HEX KEP 4 24 H 6423...

Page 115: ...2 16 H 6918 83216 SCREW 8 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 1...

Page 116: ...6918 404 SCREW 1 4 20 X 1 2 SOC HD 2 27 H 6918 414 SCREW 1 4 20 X 1 3 4 SOC HD 2 28 H 6918 44006 SCREW 4 40 X 3 4 SOC HD 2 29 H 6918 506 SCREW 5 16 18 X 3 4 SOC HD 2 30 H 6918 510 SCREW 5 16 18 X 1 1...

Page 117: ...NUT 4 40 HEX KEP 2 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 102410 SCREW 10 24 X 1 1 4 SOC HD 1 18 H 6918 102412 SCREW 10 24 X 1 1 2 SOC HD 1 19 H 6918 41...

Page 118: ...2196 27 HOLE PLUG 4 27 EE 3270 PROX ASSEMBLY 1 28 H 5254 840 SCREW 1 2 X 5 SHSS 2 29 H 6417 6 NUT 3 8 16 HEX 2 30 H 6424 6 NUT 3 8 16 HEX JAM 7 31 H 6428 7 NUT 7 16 20 HEX JAM 4 32 H 6909 102404 SCREW...

Page 119: ...6424 4 NUT 1 4 20 HEX JAM 1 42 H 6428 4 NUT 1 4 28 HEX JAM 2 43 H 6432 10 NUT 10 24 ACORN NYLON 1 44 H 6909 M620 SCREW M6 X 20MM FLAT HEAD CAP 2 45 H 6910 410 SCREW 1 4 20 X 1 1 4 BUTTON HEAD CAP 4 46...

Page 120: ...59083 GRIPPER MOUNTING BLOCK 1 7 59153 1 GRIPPER CLAMP PAD 2 8 59313 SHIM GRIPPER 3 9 H 6909 406 SCREW 1 4 20 X 3 4 FLT HD 2 10 H 6909 408 SCREW 1 4 20 X 1 FLT HD 2 11 H 6909 508 SCREW 5 16 18 X 1 FLT...

Page 121: ...16 WHIZ LOCK 1 13 H 6417 5 NUT 5 16 18 HEX 1 14 H 6423 10 NUT 10 24 HEX KEP 4 15 H 6424 4 NUT 1 4 20 HEX JAM 1 16 H 6909 44003 SCREW 4 40 X 3 8 FLT HD 6 17 H 6910 622 SCREW 3 8 16 X 2 3 4 BUT HD 1 18...

Page 122: ...2 35 H 6909 410 SCREW 1 4 20 X 1 1 4 FLT HD 8 36 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 4 37 H 6910 102408 SCREW 10 24 X 1 BUT HD 4 38 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 4 39 H 6913 606 SCREW 3 8 1...

Page 123: ...15 H 6423 4 NUT 4 40 HEX KEP 2 16 H 6423 8 NUT 8 32 HEX KEP 2 17 H 6909 406 SCREW 1 4 20 X 3 4 FLT HD 4 18 H 6910 102404 SCREW 10 24 X 1 2 BT HD 18 19 H 6910 102404SS SCREW 10 24 X 1 2 BT SS 6 20 H 69...

Page 124: ...R TRIM 24 13 E 866 9 POS ACTION MICROSWITCH 2 14 E 967 1 LIGHT BULB 3 15 E 1260 1 SOCKET LINE LIGHT 3 16 H 6417 5 NUT 5 16 18 HEX 2 17 H 6423 4 NUT 4 40 HEX KEP 4 18 H 6423 6 NUT 6 32 HEX KEP 7 19 H 6...

Page 125: ...COVER 3 4 59062 TOP COVER 1 5 59064 WINDOW PANEL 1 6 59157 ADJ HANDLE COVER 1 7 E 1152 61 STANDOFF 12 8 H 6423 4 NUT 1 4 20 HEX KEP 2 9 H 6910 102404SS SCR 10 24 X 1 2 BUT SS 32 10 H 6993 510 WASHER 5...

Page 126: ...OTOR 180VDC 1 31 E 1736 2 QUENCHARC 1 32 E 2467 1 ENCODER 1 33 EE 2973 9 PROX 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 HE...

Page 127: ...ENT 1 3 E 1165 7 BRAKE 1 4 E 1600 163 GEAR MOTOR 1 5 E 2181 4 CAPACITOR 1 6 E 2626 3 TERMINAL STRIP 3P 1 7 H 6918 44004 SCREW 4 40 X 1 2 SOC HD 1 8 H 6918 63206 SCREW 6 32 X 3 4 SOC HD 2 9 H 6990 1032...

Page 128: ...OR P C B 12 PIN 4 39 P 294 PRESSURE SWITCH N O CLOSES 20 PSI 1 40 P 295 ADAPTOR PRESSURE SWITCH BULKHEAD 1 41 E 2709 BRACKET CAPACITOR 2 42 E 894 CABLE CLAMP METAL 3 81 E 889 5 FUSE 4A SLO BLO GLASS F...

Page 129: ...G G 1 66 EE 2948 36 PLUG ASM AIR SOL JOG CYCLE 1 67 73 1 67 EE 2948 33 PLUG ASM AIR SOL TRANSP GRIP 2 68 73 1 68 EE 2948 34 PLUG ASM AIR SOL ROTAT LOCK 3 59 73 1 69 EE 2948 35 PLUG ASM AIR SOL ELEV PU...

Page 130: ...Description Qty 1 E 2742 16 TRANSF 380 415V PRIMARY T4 1 2 E 2441 13 RELAY OVERLOAD 7 5A TO 11A 1 5 H 6918 404 SCREW 1 4 20 X 1 2 SOC HD 4 6 H 7324 8 WASHER 1 4 INT TOOTHLOCK 4 7 H 7321 4 WASHER 1 4 F...

Page 131: ...ABLE ASM KEYPAD 1 8 EE 2967 1 CABLE ASM LITE START STOP SW 1 10 E 1152 58 STAND OFF 1 LONG 4 12 E 2066 2 CONNECTOR PLUG IN TERM BLK 1 13 E 1214 10 CONNECTOR 6 INS RING 2 14 E 1584 LABEL ASM NO REV LEV...

Page 132: ...Diag 59000 P 1 2 Item Part 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...

Page 133: ...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 3 6 P 516 PUSH IN CONN 1 4 MALE SHUT OFF 2 7 56492...

Page 134: ...21 Pneu Manifold Asm 59012 1 Item Part 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 INDIVIDUA...

Page 135: ...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 H 4...

Page 136: ...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 H 4...

Page 137: ...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 236 4...

Page 138: ...mer PL 5 25 Hydraulic Schem 59010 S Item Part 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 VALVE...

Page 139: ...Plate H 517 Item Part 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 1...

Page 140: ...2451 4 CABLE MINI LINE CONNECTOR 1 9 E 2626 12 TERMINAL STRIP 12P 1 10 H 6424 8 NUT 1 2 13 HEX JAM 4 11 H 6910 63204 SCREW 6 32 X 1 2 BUT HD 2 12 H 6913 406 SCREW 1 4 20 X 3 4 HEX HD 16 13 H 6918 632...

Page 141: ...7 H 6423 4 NUT 4 40 HEX KEP 2 8 H 6423 6 NUT 6 32 HEX KEP 4 9 H 6910 102403 SCREW 10 24 X 3 8 BUT HD 2 10 H 6918 44006 SCREW 4 40 X 3 4 SOC HD 2 11 H 6918 63212 SCREW 6 32 X 1 1 2 SOC HD 4 12 H 6918 M...

Page 142: ...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 6918 406 SCREW 1 4 20 X 3 4 SOC HD 2 14 H 6918 44006 SCREW 4 40 X 3 4 SOC HD 2 15 H 6918 63206 SCREW 6 32 X...

Page 143: ...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 HD 80 15 H 6913 404 SCREW 1 4 20 X 1 2 HEX HD 4 16 H 6913...

Page 144: ...6 56478 TAPER LOCK SPROCKET 1 7 56489 SIDE COVER BRACKET 2 8 E 1152 82 STANDOFF 2 9 E 1165 7 BRAKE 1 10 E 1600 162 GEAR MOTOR 1 11 H 6423 4 NUT 1 4 20 HEX KEP 4 12 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD...

Page 145: ...45 R H FRONT RETAINER 1 9 56546 L H FRONT RETAINER 1 10 56547 R H REAR RETAINER 1 11 56548 L H REAR RETAINER 1 12 56560 COVER 1 13 56180 1 REF TAPE 1 W X 1 1 2 L 1 14 56532 1 INFEED BRACKET STANDARD 1...

Page 146: ...406 SCREW 1 4 20 X 3 4 BUT HD 4 15 H 6910 83205 SCREW 8 32 X 5 8 BUT HD 2 16 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 3 17 H 6910 102405 SCREW 10 24 X 5 8 BUT HD 4 18 H 6910 102406 SCREW 10 24 X 3 4 BU...

Page 147: ...5 35 5 Parts List PL 5 34 Idler 56446 Item Part 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 TOOTH 1...

Page 148: ...List 5 36 CMT 130 Book Trimmer PL 5 35 Pusher 56483 Item Part Description Qty 1 56417 PUSHER PLATE 1 2 56491 BRUSH HOLDER 2 3 56484 303 BRUSH 2 4 H 6918 63203 SCREW 6 32 X 3 8 SOC HD 4 5 H 7324 6 WASH...

Page 149: ...0 E 1237 2 WIRE NUT 2 11 EE 3087 CABLE ASM TOWER MOT 1 12 H 6918 63206 SCREW 6 32x3 4 SOC HD REF 13 H 7324 6 WASHER 6 INT TOOTH REF 14 H 6910 404 SCREW 1 4 20 x 1 2 BUT HD 2 15 H 7324 8 WASHER 1 4 INT...

Page 150: ...7 5 Parts List 5 38 CMT 130 Book Trimmer PL 5 37 Elev Pneumatics 56421 P Item Part Description Qty 1 P 303 1 4 O D PE TUBING SOLID BLUE 14FT 2 P 510 4 AIR FLOW REG 1 4 TUBE 2 3 P 515 PUSH IN CONN 1 4...

Page 151: ...EE 2947 11 PROX ASM NEW BOOK 1 16 EE 2947 13 PROX ASM BOOK IN TILT T2 1 17 H 6910 604 SCREW 3 8 16 X 1 2 BUT HD 8 18 H 6913 404 SCREW 1 4 20 X 1 2 HEX HD 2 19 H 6918 63206 SCREW 6 32 X 3 4 SOC HD 2 2...

Page 152: ...MING 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 8 H 6...

Page 153: ...6405 TENSIONER BLOCK 2 3 56406 IDLER ASM 1 4 56449 TIMING BELT 290XL037 1 5 56602 FRAME 1 6 56180 2 REFLECTIVE TAPE 1 W X 1 L 1 7 56610 1 ENDLESS BELT BINDER CONV 1 8 H 6910 102404 SCREW 10 24 X 1 2 B...

Page 154: ...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 7 15 H 6910 605 SCREW 3 8 16 X 5 8 BUT HD 2 16 H 6918 63208 SCREW 6 32 X 1 SOC HD 2 17 H 6938 102408...

Page 155: ...9 E 2181 4 CAPACITOR 1 10 E 2626 3 TERMINAL STRIP 3P 1 11 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 2 12 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 5 13 H 6918 410 SCREW 1 4 20 X 1 1 4 SOC HD 12 14 H 6918 440...

Page 156: ...1 BELT GUARD 1 12 E 1600 163 GEAR MOTOR 1 13 E 2181 4 CAPACITOR 1 14 E 2626 3 TERMINAL STRIP 3P 1 15 H 6423 8 NUT 8 32 HEX KEP 1 16 H 6910 102404 SCREW 10 24 X 1 2 BUT HD 10 17 H 6918 63203 SCREW 6 32...

Page 157: ...N MICROSW 2 17 H 5254 405 SCREW 1 4 X 5 8 SHSS 2 18 H 5254 603 SCREW 3 8 X 3 8 SHSS 2 19 H 6424 8 NUT 1 2 13 HEX JAM 2 20 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 4 21 H 6910 102404 SCREW 10 24 X 1 2 BUT...

Page 158: ...COVER 1 3 56647 RH COVER 1 4 56648 GUARD 1 5 56649 FRONT COVER 1 6 56650 TOP COVER 1 7 56657 HANDLE W HDW 1 8 56685 END COVER 1 9 E 1152 61 STANDOFF 4 10 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 4 11 H 69...

Page 159: ...26 1 5 E 709 R WIRE 18 GA RED 16 26 1 6 E 709 R WIRE 18 GA RED 18 23 28 1 7 EE 3094 CABLE ASM TILT DOOR INT 1 8 EE 2949 3 CABLE ASM TILT CONV MOT 1 9 EE 2949 5 CABLE ASM RCVR CONV MOT 1 10 EE 2947 9...

Page 160: ...FEB 2017 5 Parts List 5 48 CMT 130 Book Trimmer PL 5 47 Tilt Conv Pneum 56600 P Item Part Description Qty 1 P 303 1 4 O D PE TUBING SOLID BLUE 7FT...

Page 161: ...9 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 X...

Page 162: ...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 163: ...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 H...

Page 164: ...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 IN...

Page 165: ...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 4 B...

Page 166: ...FEB 2017 5 Parts List 5 54 CMT 130 Book Trimmer PL 5 53 Std Hand Feed Elec EE 3342...

Page 167: ...6P 1 13 EE 2947 5 PROX ASM STACKER FULL 1 14 EE 2983 1 POTENTIOMETER ASSEMBLY 1 15 H 6910 404 SCREW 1 4 20 X 1 2 BUT HD 8 16 H 6910 604 SCREW 3 8 16 X 1 2 BUT HD 8 17 H 6910 63208 SCREW 6 32 X 1 BUT...

Page 168: ...404 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 10240...

Page 169: ...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 10 1...

Page 170: ...E REF 5 E 519 CONDUIT LOCKNUT 1 2 REF 6 EE 2947 5 PHOTO SWITCH ASM 1 7 E 1214 59 CONNECTOR 10 INS LOCK 1 8 E 709 R WIRE 18 GA RED MTW 8 3 9 EE 3124 1 CABLE ASM MOTOR 1 10 H 6918 63206 SCREW 6 32x3 4 S...

Page 171: ...R 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 10...

Page 172: ...1 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 32...

Page 173: ...10 Retro reflective Sensors 6 13 GP 6 11 Diffuse Sensors 6 14 GP 6 12 Micro Switches 6 15 GP 6 13 Hirschmann Connectors 6 16 GP 6 14 Contact Blocks 6 17 GP 6 15 Speed Control Air Valves 6 18 GP 6 16...

Page 174: ...may be helpful to see the most recent error messages If there are currently no error mes sages on the screen the 5 most recent error messages can be viewed by performing the fol lowing procedure 1 Swi...

Page 175: ...are the sensor data screen with the normal idle states shown in Figure 6 1 Does the sensor data screen match Y N 3 Perform the RAPs associated with each in put that does not coincide See the table on...

Page 176: ...put Door Interlocks 14 Book at top of elevator sensor 0 0 RAP 2 59 Book at Top of Elevator Sensor 15 In Feed Conveyor 1st feed sensor 0 0 RAP 2 55 In Feed Sleep Mode Sensor 16 Knife latch latch proxim...

Page 177: ...he Sensor Data Screen changes from zero to one Example If output number 10 is being actu ated the display will switch between 10 0 and 10 1 The output LED on the main circuit board switches on GP 6 4...

Page 178: ...RAP 2 32 Book Lift Air Blast 17 Registration cylinder extend 0 RAP 2 31 Registration Plate Extend Cylinder 18 Jogger cylinder valve 0 RAP 2 25 Jogger Cylinder 19 Rotary gripper motor enabled 0 RAP 2 4...

Page 179: ...main PWB has LED indicators for each in put and output Certain status indicator RAPs may refer to these The main PWB is located in the power panel area Figure 6 4 The location and numbering of these...

Page 180: ...anel Procedure 1 Go to the Sensor Data Screen GP 6 2 Input Diagnostics Sensor Data 2 Determine the expected state of the sensor GP 6 2 Input Diagnostics Sensor Data 3 Attempt to change the state of th...

Page 181: ...re are no mechanical binds in the output device Check that all connections air hydraulic and electrical are made Procedure 1 Observe the machine in operation or manu ally turn on the output GP 6 3 Out...

Page 182: ...scribed in the Power Lockout Procedure on page viii Procedure 1 Remove the power panel door PL 5 12 Main Assembly 59000 12 12 2 Use a small screwdriver to gently pry the PROM from its socket Pry by a...

Page 183: ...ss and hold the left and right arrow keys simultaneously and switch on the main power with the arrow keys pressed 3 Press and hold the blank black key and press the B key Release the keys 4 Type the f...

Page 184: ...6 9 Metal Sensing Proximities Procedure 1 Switch off the machine 2 Clean any debris from the actuator and switch 3 Inspect the switch for physical damage Re place switches with cracked housings 4 Loo...

Page 185: ...t the switch and tape for any physical damage Disconnect main power and re place sensor with cracked housings Re place damaged or peeling tape 4 Check for alignment of sensor and tape Realign as neces...

Page 186: ...bjects 1 4 sensing distance is recommended for sensing black cover Figure 6 11 Diffuse Sensor Procedure 1 Switch on the machine and enter sensor data mode 2 Clean the sensing surface with a dry cloth...

Page 187: ...6 12 Micro Switches Micro switches are small lever operated me chanical switches When the lever is actuated it either closes or opens the contacts within the switch Figure 6 12 Micro Switches The swit...

Page 188: ...e or shorted wires Procedure 1 Disconnect main power to the machine 2 Remove the Hirschmann connector from so lenoid using a small screwdriver Com pletely remove the mounting screw from the connector...

Page 189: ...ontact block then disconnect the wires from the contact block 4 Press and release the actuator Does the actuator return freely Y N The contact block is faulty if the actuator does not return freely No...

Page 190: ...6 1 5 Test the cylinder or item by manually actuat ing the corresponding pneumatic valve in the power panel area 6 Readjust speed control valve if necessary and test again 7 Tighten locking nut 8 Clo...

Page 191: ...hrough the ca ble connecting the elevator and in feed con veyor It is communicated to the trimmer through the cable connected between the el evator and the trimmer 5 The book is pushed across an inter...

Page 192: ...begins moving at 900 PSI The pressure increases under load of cutting and clamping The system relief pressure is set from 1800 2000 PSI Oil is sent back to tank at this pressure setting 7 The knife de...

Page 193: ...trimmer until the sensor is cleared of books Option 2 Exit Conveyor 1 As the book exits the trimmer the Exit Con veyor runs The length of time that the Exit Conveyor runs for each book is determined b...

Page 194: ...ness range 0 05 to 2 00 in 1 3 to 50 8 mm Min Trim 0 10 in 2 5 mm CMT 130 Basic Machine Width 52 in 312 cm Depth 57 in 145 cm Height 60 in 152 cm Net Weight 1 500 lb 680 kg Shipping Weight 1 800 lb 81...

Page 195: ...and collated form 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...

Page 196: ...manifold using a mild non abrasive de tergent and a moist cloth 7 Clean the fan covers using a dry cloth 8 Clean paper dust and shavings from the area underneath the table 9 Go to Section RAP 2 2 Fin...

Page 197: ...FEB 2017 CMT 130 Book Trimmer 6 25 6 General Procedures Information GP 6 20 Change Tags There are no change tags at this time...

Page 198: ...FEB 2017 6 General Procedures Information 6 26 CMT 130 Book Trimmer NOTES...

Page 199: ...8 Schematic 15 VDC E 3307 1 8 9 7 9 WD 7 9 Schematic 5 VDC E 3307 1 9 9 7 10 WD 7 10 Plug Connections to PWB EE 2939 2 7 11 WD 7 11 Schematic Elevator EE 2980 1 7 12 WD 7 12 Schematic Tilt Conv EE 29...

Page 200: ...FEB 2017 7 Wiring Data 7 2 CMT 130 Book Trimmer WD 7 1 Schematic 230 VAC E 3307 1 1 9...

Page 201: ...FEB 2017 CMT 130 Book Trimmer 7 3 7 Wiring Data WD 7 2 Schematic 120 VAC E 3307 1 2 9...

Page 202: ...FEB 2017 7 Wiring Data 7 4 CMT 130 Book Trimmer WD 7 3 Schematic 27 VAC E 3307 1 3 9...

Page 203: ...FEB 2017 CMT 130 Book Trimmer 7 5 7 Wiring Data WD 7 4 Schematic 18 VAC E 3307 1 4 9...

Page 204: ...FEB 2017 7 Wiring Data 7 6 CMT 130 Book Trimmer WD 7 5 Schematic 9 VAC E 3307 1 5 9...

Page 205: ...FEB 2017 CMT 130 Book Trimmer 7 7 7 Wiring Data WD 7 6 Schematic 35 VDC E 3307 1 6 9...

Page 206: ...FEB 2017 7 Wiring Data 7 8 CMT 130 Book Trimmer WD 7 7 Schematic 24 VDC E 3307 1 7 9...

Page 207: ...FEB 2017 CMT 130 Book Trimmer 7 9 7 Wiring Data WD 7 8 Schematic 15 VDC E 3307 1 8 9...

Page 208: ...FEB 2017 7 Wiring Data 7 10 CMT 130 Book Trimmer WD 7 9 Schematic 5 VDC E 3307 1 9 9...

Page 209: ...FEB 2017 CMT 130 Book Trimmer 7 11 7 Wiring Data WD 7 10 Plug Connections to PWB EE 2939 2...

Page 210: ...FEB 2017 7 Wiring Data 7 12 CMT 130 Book Trimmer WD 7 11 Schematic Elevator EE 2980 1...

Page 211: ...FEB 2017 CMT 130 Book Trimmer 7 13 7 Wiring Data WD 7 12 Schematic Tilt Conv EE 2993 3...

Page 212: ...FEB 2017 7 Wiring Data 7 14 CMT 130 Book Trimmer WD 7 13 Schematic Long In Feed EE 2985 1...

Page 213: ...FEB 2017 CMT 130 Book Trimmer 7 15 7 Wiring Data WD 7 14 Schematic Std In Feed EE 2985 1...

Page 214: ...FEB 2017 7 Wiring Data 7 16 CMT 130 Book Trimmer WD 7 15 Schematic Exit Conv EE 2979 3...

Page 215: ...2017 CMT 130 Book Trimmer 7 17 7 Wiring Data WD 7 16 Interconnection Diagram E 3308 1 This diagram can be used to help identifiy input and output devices It is not intended to be an electrical schema...

Page 216: ...FEB 2017 7 Wiring Data 7 18 CMT 130 Book Trimmer WD 7 17 Fuse Chart S 1781 193 This label is located on the power panel cover...

Page 217: ...2 8 3 Moving 8 2 8 4 In feed Setup 8 3 8 5 Trimmer Setup 8 6 8 6 Out feed Setup 8 6 8 7 Power Hookup 8 7 8 8 Air Hookup 8 9 8 9 Cleaning 8 9 Introduction The installation guide provides information an...

Page 218: ...e the lag screws from the two front locations shown in Figure 8 1 3 Open the rear door 4 Remove the two lag screws from the two rear locations shown in Figure 8 1 5 Close the rear door Use a forklift...

Page 219: ...t to about 13 7 8 35 2 cm from the floor Ad just the leveling pads as necessary Figure 8 5 Height Adjustment 2 The Tilt In feed Conveyor is set in front of the binder such that adjustable portion of t...

Page 220: ...ait until the trimmer height is set 8 5 Trimmer before attaching the elevator to the trimmer using mounting hardware as shown in Figure 8 11 Figure 8 11 Elevator Attachment to Trimmer 6 At this point...

Page 221: ...Route the cable behind the hydraulic power unit and under the left hand side of the ma chine base 6 Connect the cable to the socket on the back side of Hand feed Conveyor Lock into place by threading...

Page 222: ...the rear doors and raise the rear end of the machine by adjusting the rear two lev eling pads until the trimmer table is level 3 Check the front end of the machine with the level to make sure the fron...

Page 223: ...nt 8 7 Power Hookup This section describes how to hookup main power to the CMT 130 An adequate power supply must be provided to the machine See GP 6 17 Specifications for power requirements It should...

Page 224: ...Fasten the three power leads to the three terminals L1 L2 and L3 Figure 8 23 on the main power terminal block 9 Replace all panel doors 10 Make sure compressed air in connected to the machine and is...

Page 225: ...and will result in THE WARRANTY BEING VOIDED Procedure The main air connector shown in Figure 8 25 is a female 3 8 NPT port A facilities maintenance technician should connect shop air using a male 3 8...

Page 226: ...0 Book Trimmer 2002 2017 by The Challenge Machinery Company All rights reserved Printed in the USA FX 013B CMT 130B FEB 2017 2002 2017 by The Challenge Machinery Company All rights reserved Printed in...

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