Challenge CMT-130, Service Manual

Page: 43 / 226

FEB 2017
CMT 130 Book Trimmer 2-33 2. Status Indicator RAPs
RAP 2.25 Jogger Cylinder
Outputs 9 and 18
To register each book, an air cylinder pushes
the book into the registration plate during the jog
cycle. The jogging cylinder is located across
from the registration assembly, Figure 2-35.
The jogger pressure valve increases or de-
creases the pressure to the jogger cylinder de-
pending on the thickness of the books.
Possible Fault Indicators

Jogger fails to extend

Crushed covers, books out of square,
wrong side knife cut locations

Jogger not fully extending

Jogger out when it should
have been in
is displayed

Jogger in when it should have
been out
is displayed
Initial Actions
Check for air leaks and disconnected or pinched
air hoses.
Check for loose or broken wires 67 and 61 at the
power panel.
Check that the wire connector for valve number
1 is connected properly.
Procedure
1. Switch off power to the machine.
2. Switch off the main air.
3. Move the jogger plate in and out by hand.
Does the cylinder move freely?
Y N
Replace jogger cylinder (PL 5.9 Main As-
sembly 59000 (9/12))
4. Inside the power panel area, disconnect the
air hose labeled “P” from the pressure con-
trol valve and re-route as 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).
Does the jogger extend?
Y N
Disconnect main power and replace valve
number 1 (PL 5.21 Pneu. Manifold Asm.
59012-1).
8. Electrically activate valve number 1 by short-
ing wire 67 to 74. Does the jogger extend?
Y N
Disconnect main power and replace valve
number 1 (PL 5.21 Pneu. Manifold Asm.
59012-1).
9. Is there 24 VDC between wires 61 and 74
while in idle state and 7-12 VDC during a jog
cycle?
Y N
Disconnect main power and replace the
main PWB (REP 4.22 Main PWB Replace-
ment).
10. Is there 24 VDC between wires 67 and 74
while in idle state and 0 VDC during a jog
cycle?
Y N
Disconnect main power and replace the
main PWB (REP 4.22 Main PWB Replace-
ment).
11. Switch off main air.
12. Re-
connect air hoses “P” and “1P” to their
initial configuration as shown in Figure 2-36.
13. In the
Maint>Service>Jogging Pres-
sure
screen, significantly increase the jog-
ging pressure. Run the trimmer through a
cycle. Does the jogger extend fast?
Y N
Disconnect main power and replace the pro-
portional valve (PL 5.2 Main Assembly
59000 (2/12)).
14. In the
Maint>Service>Jogging Pres-
sure
screen, readjust the minimum jogging
pressure such that it will not crush a 12 page
book.
Figure 2-35. Jogger Cylinder
Figure 2-36. Air Re-routing