Challenge CMT-130TC User manual

THE CHALLENGE MACHINERY COMPANY
CMT-130 Book Trimmer FX.013B / MAY 2019
This manual covers: Hand-Feed Conveyor, Ad-
vanced Infeed Conveyor, Cooling Elevator, and
Exit Conveyor.
For Book Pile 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 avoid
component damage.
FX.013B
Issued: February 2016
Last Revised: 5/3/2019
SERIAL No.: ____________________
CMT-130TC
Book Trimmer
Service Manual
Serial Numbers: 130TC-A-160000 and up

MAY 2019
Introduction ii CMT-130TC Book Trimmer
NOTICE
Service documentation is supplied to Challenge
external customers for informational purposes
only. Service documentation is intended for use
by certified, product-trained personnel only.
Challenge does not warrant or represent that
such documentation is complete, nor does Chal-
lenge represent or warrant that it will notify or
provide to such customer any future changes to
this documentation. Customer performed ser-
vice of equipment may affect the warranty of-
fered by Challenge with respect to such equip-
ment. If the customer services this equipment,
modules, components or parts thereof, the cus-
tomer releases Challenge from any and all liabil-
ity for the customer actions, and the customer
agrees to indemnify, defend and hold Challenge
harmless from any third party claims which arise
directly or indirectly from such service.
Prepared by:
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441 USA
Phone: [phone] Fax: [phone]
ChallengeMachinery.com
©2019 by The Challenge Machinery Company.
All rights reserved.
Challenge® is a registered trademark of The
Challenge Machinery Company.
Introduction
The Challenge Machinery Company provides owner's manuals on its
products solely as a courtesy to its customers. See the information
below before using this manual.
These manuals are for reference only. These manuals include products which are noncurrent,
unsupported or no longer produced by The Challenge Machinery Company, and are provided
solely as an accommodation to our customers. By providing these manuals, The Challenge Ma-
chinery Company makes no representation or warranty as to the products, their current condition,
or their suitability or fitness for use in any particular application, which are the sole and independ-
ent responsibility 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 suitabilityand fitness
of the products in their current use and application. The Challenge Machinery Company
makes no representation, warranty or recommendation regarding any modifications which
may be required on non-current or unsupported products. The Challenge Machinery Com-
pany assumes no liability for any modification or alteration to any Challenge product, and
any such modification or alteration to any Challenge product is not authorized by The
Challenge Machinery Company. The availability of these manuals is solely for the purpose of
providing reference information for the products.
This manual may not be complete in all aspects of product maintenance and repair. All products
should be used only by qualified and properly trained personnel, following proper safety
procedures. All products should be regularly inspected and maintained, and their condition, ap-
plication and use should be periodically evaluated by qualified personnel. Only qualified and
properly trained technicians should perform maintenance, repair and replacement procedures.
Attempting these procedures without proper training may cause machine damage or operator
injury!
Products may be unsupported by The Challenge Machinery Company due to age or the unavail-
ability of parts from their original manufacturer. No parts or product support will be available to
repair or maintain unsupported products. Older products may not be UL listed (if the product does
not have a UL label it is not a listed product), and may not comply with applicable installation or
other regulations or requirements if relocated to a new facility. Many municipalities require a prod-
uct to be UL listed before an electrician will connect power to them. Often the cost of updating an
older product to comply with current safety regulations is greater than the value of the product.

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.

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

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

MAY 2019
Introduction vi CMT-130TC Book Trimmer
ADJ 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 Adjustment.............. 4-24
ADJ 4.20 Left Jog Pressure Adjustment............ 4-25
ADJ 4.21 Gripper Clamp Pressure.................... 4-26
ADJ 4.22 Face Jog Pressure............................. 4-27
REP 4.23 Main PWB Replacement................... 4-28
REP 4.24 Console PWB Replacement.............. 4-29
REP 4.25 DI/HS PWB Replacement................. 4-30
REP 4.26 Accessory PWB Replacement .......... 4-31
ADJ 4.27 Elevator Pusher Height...................... 4-32
ADJ 4.28 Elevator Shelf Synchronization.......... 4-33
5. Parts List ...................................................5-1
Contents.............................................................. 5-1
Introduction.......................................................... 5-1
PL 5.1 Main Assembly 59000 (1/14) ................... 5-2
PL 5.2 Main Assembly 59000 (2/14) ................... 5-3
PL 5.3 Main Assembly 59000 (3/14) ................... 5-4
PL 5.4 Main Assembly 59000 (4/14) ................... 5-5
PL 5.5 Main Assembly 59000 (5/14) ................... 5-6
PL 5.6 Main Assembly 59000 (6/14) ................... 5-7
PL 5.7 Main Assembly 59000 (7/14) ................... 5-8
PL 5.8 Main Assembly 59000 (8/14) ................... 5-9
PL 5.9 Main Assembly 59000 (9/14) ................. 5-10
PL 5.10 Main Assembly 59000 (10/14).............. 5-11
PL 5.11 Main Assembly 59000 (11/14).............. 5-12
PL 5.12 Main Assembly 59000 (12/14).............. 5-13
PL 5.13 Main Assembly 59000 (13/14).............. 5-14
PL 5.14 Main Assembly 59000 (14/14).............. 5-15
PL 5.15 Registration Asm. 56311-3................... 5-16
PL 5.16 Power Panel EE-3503 (1/2) ................. 5-17
PL 5.17 Power Panel EE-3503 (2/2) ................. 5-18
PL 5.18 Control Console EE-3456-6................. 5-19
PL 5.19 Panel Assembly EE-3471 .................... 5-20
PL 5.20 Pneu. Diag. 59000TCA-P (1/2)............ 5-21
PL 5.21 Pneu. Diag. 59000TCA-P (2/2)............ 5-22
PL 5.22 Pneu. Manifold Asm. 59012-1.............. 5-23
PL 5.23 Hydraulic Power Unit –60Hz 59010 .... 5-24
PL 5.24 Hydraulic Power Unit –50Hz 59010-1. 5-25
PL 5.25 Manifold Assembly 59011.................... 5-26
PL 5.26 Hydraulic Schem. 59010-S .................. 5-27
PL 5.27 Manifold Sub-Plate H-517.................... 5-28
PL 5.28 Elevator 56421TCA (1/7) ..................... 5-29
PL 5.29 Elevator 56421TCA (2/7) ..................... 5-30
PL 5.30 Elevator 56421TCA (3/7)......................5-31
PL 5.31 Elevator 56421TCA (4/7)......................5-32
PL 5.32 Elevator 56421TCA (5/7)......................5-33
PL 5.33 Elevator 56421TCA (6/7)......................5-34
PL 5.34 Elevator 56421TCA (7/7)......................5-35
PL 5.35 Idler 56446...........................................5-36
PL 5.36 Pusher 56483.......................................5-37
PL 5.37 Elev. 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 Tilt Conveyor 56600TCA (4/8)..............5-43
PL 5.43 Tilt Conveyor 56600TCA (5/8)..............5-44
PL 5.44 Tilt Conveyor 56600TCA (6/8)..............5-45
PL 5.45 Tilt Conveyor 56600TCA (7/8)..............5-46
PL 5.46 Tilt Conveyor 56600TCA (8/8)..............5-47
PL 5.47 Tilt Conv. Elec. Panel EE-3547............5-48
PL 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.......5-53
PL 5.53 Std. Hand-Feed Conv. 59200...............5-54
PL 5.54 Std. Hand-Feed Elec. EE-3342............5-55
PL 5.55 Outfeed Stacker 58000TCA (1/9).........5-56
PL 5.56 Outfeed Stacker 58000TCA (2/9).........5-57
PL 5.57 Outfeed Stacker 58000TCA (3/9).........5-58
PL 5.58 Outfeed Stacker 58000TCA (4/9).........5-59
PL 5.59 Outfeed Stacker 58000TCA (5/9).........5-60
PL 5.60 Outfeed Stacker 58000TCA (6/9).........5-61
PL 5.61 Outfeed Stacker 58000TCA (7/9).........5-62
PL 5.62 Outfeed Stacker 58000TCA (8/9).........5-63
PL 5.63 Outfeed Stacker 58000TCA (9/9).........5-64
PL 5.64 Stacker Elec. Panel EE-3518...............5-65
PL 5.65 Stacker Pneumatics 58000TCA-P........5-66
PL 5.66 Stacker Air Manifold 58008.................. 5-67
PL 5.67 Exit Conv. 56420TCA (1/3) ..................5-68
PL 5.68 Exit Conv. 56420TCA (2/3) ..................5-69
PL 5.69 Exit Conv. 56420TCA (3/3) ..................5-70
PL 5.70 Exit Conv. Elec. Panel EE-3566...........5-71
PL 5.71 Conveyor Drive Asm. 56340-1.............5-72
PL 5.72 Conveyor Drive Asm. 56340-2.............5-73
6. General Procedures/Information.............6-1
Contents..............................................................6-1
Introduction..........................................................6-1
GP 6.1 Retrieve Recent Error Messages ............6-2
GP 6.2 Input/Output Diagnostics .........................6-3
GP 6.3 Input/Output LEDs...................................6-4
GP 6.4 Updating Machine Software.....................6-5
GP 6.5 Proximity Sensors....................................6-6
GP 6.6 Retro-reflective Sensors..........................6-7
GP 6.7 Diffuse Sensors.......................................6-8
GP 6.8 Optical Distance Sensor..........................6-9
GP 6.9 Barcode Scanner...................................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 Operation ........................6-16
GP 6.16 Specifications ......................................6-19
GP 6.17 Book Size Chart...................................6-20
GP 6.18 Scheduled Maintenance......................6-21
GP 6.19 Change Tags.......................................6-22
7. Wiring Data ................................................7-1
Contents..............................................................7-1
Introduction..........................................................7-1
WD 7.1 Trimmer Schematic –230 VAC ..............7-2
WD 7.2 Trimmer Schematic –120 VAC ..............7-3
WD 7.3 Trimmer Schematic –53 VAC ................7-4
WD 7.4 Trimmer Schematic –19 VAC ................7-5
WD 7.5 Trimmer Schematic –9 VAC ..................7-6
WD 7.6 Trimmer Schematic –75 VDC ................7-7
WD 7.7 Trimmer Schematic –24 VDC ................7-8
WD 7.8 Trimmer Schematic –15 VDC................7-9
WD 7.9 Trimmer Schematic –5 VDC................7-10
WD 7.10 Elevator Schematic –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 –120VAC .......7-16
WD 7.16 Stacker Schematic –120VAC.............7-17
WD 7.17 Stacker Schematic –24VDC ..............7-18
WD 7.18 Exit Conv. Schematic –120VAC ........7-19
WD 7.19 Exit Conv. Schematic –24VDC..........7-20
WD 7.20 Exit Conv. Schematic –5VDC............7-21
WD 7.21 Interconnection Diagram.....................7-22
WD 7.22 Fuse/Circuit Breaker Chart .................7-23
8. Installation .................................................8-1
Contents..............................................................8-1
Introduction..........................................................8-1

MAY 2019
CMT-130TC Book Trimmer 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 Hookup.......................................... 8-19
8.9 Cleaning...................................................... 8-20

MAY 2019
Introduction viii CMT-130TC Book Trimmer
About this Manual
This Service Manual is part of a multinational
documentation system that includes service
training. It is intended to supplement service
training with specific procedures and necessary
reference information to efficiently service the
CMT-130TC Book Trimmer.
Organization
This manual is divided into 7 sections. The sec-
tions are outlined below:
Section 1 –Service Call Procedures
This section outlines the strategy for success-
fully completing a service call.
This section includes the following:
Initial Actions
System Checks
Scheduled Maintenance
Final Actions
Section 2 –Status Indicator RAPs
This section contains Repair Analysis Proce-
dures (RAPs) necessary to repair faults. Enu-
merated procedures are prefixed with RAP 2.x.
The "2" refers to section number in this manual.
Section 3 –Book Quality
This section contains procedures necessary to
correct book trim quality issues. Enumerated
procedures are prefixed with the letters BQ 3.x.
The "3" refers to the section number in this man-
ual.
Section 4 –Repairs/Adjustments
This section contains detailed procedures for the
repair and/or adjustment of mechanical and
electrical components. Enumerated procedures
are prefixed with the letters ADJ 4.x or REP 4.x.
The "4" refers to section number in this manual.
Section 5 –Parts List
This section contains exploded view drawings
and parts lists essential to the repair of the ma-
chine. Enumerated drawings are prefixed with
the letters PL 5.x. The "5" refers 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 other general infor-
mation. General procedures are prefixed with
the letters GP 6.x. The "6" refers to its section
number in this manual.
Section 7 –Wiring Data
This section contains Block Schematic Drawings
(BSDs) and wiring diagrams. Diagrams are enu-
merated with the prefix WD 7.x.
Section 8 –Installation Instructions
This section contains procedures necessary to
install the CMT-130 and its accessories.
Symbology and Nomenclature
The following reference symbols are used
throughout the documentation
Warnings, Cautions, and Notes
The formats of three specific types of notes
found throughout this manual indicate the level
of danger or importance associated with the task
presented. The format of warning notes, caution
notes, and regular notes imply a certain level of
danger. The following examples give a descrip-
tion. Associate the text format and symbol with
its level of danger or importance.
Warning Definition:
WARNING
A warning indicates an operating or mainte-
nance procedure that if not observed, could
result in injury or loss of life.
Caution Definition:
CAUTION
A Caution with this symbol indicates an operat-
ing or maintenance procedure that if not ob-
served, could result in damage to equipment.
ESD Caution Definition:
CAUTION
A Caution with this symbol indicates an operat-
ing or maintenance procedure that if not ob-
served, could result in damage due to electro-
static discharge.
Note Definition:
Note: A regular note indicates an operating,
maintenance procedure that can be helpful, yet
is not required.

MAY 2019
CMT-130TC Book Trimmer ix Introduction
Warning Label Symbols
Warning labels are posted throughout the ma-
chine to indicate areas where physical injury
may occur. The following symbols are used:
Read the instruction manual.
The instruction manual should be
read and understood before operat-
ing this machine.
Do not operate with more than
one person!
One person only should operate
this machine at a time.
Cut / Crush Hazard!
Do not operate with covers 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 Shock Hazard!
Disconnect power before removing
cover.
Electrical Shock Hazard!
Disconnect power before removing
cover.
Power Lockout Procedure
For maximum safety while making ADJUST-
MENTS or REPAIRS to your machine, lock out
the main power disconnect switch. The switch
should be moved to the OFF position and a pad-
lock securely fastened through the loop. The
person adjusting or servicing the machine
should hold the key.
On/Off Switch
Main Power Disconnect

MAY 2019
Introduction x CMT-130TC Book Trimmer
NOTES

MAY 2019
CMT-130TC Book Trimmer 1-1 1. Service Call Procedures
Contents
Title Page
Introduction.......................................................... 1-1
Service Escalation Policy .................................... 1-1
How to Order Parts.............................................. 1-1
Introduction
The Service Call Procedures section begins by
describing the technical support policy. Initial
Actions include collecting background infor-
mation regarding the service issue and retrieving
status messages from the machine's memory.
System Checks are made to identify faults and
direct the service technician to a resolution.
Regular Maintenance is performed after proper
machine operation is re-established.
Final Actions are taken to complete the service
call. Service log entries are made. If necessary,
tag modifications are made. The service issue
is closed.
Service Escalation Policy
Time and Material (T&M) is not supported by
Xerox Service
The following procedure should be used when
escalating a service call.
1. Before calling Xerox, the customer must
confirm system setup.
2. Customer contacts Xerox customer ser-
vice.
3. Xerox CSE responds to customer:
a. Review system setup
b. Troubleshoot problem
4. If problem is not identified within one hour,
Xerox CSE contacts C.P. Bourg, Inc. as
follows:
Normal Business Hours:
Monday-Friday, 8:00 am- 4:30 pm EST
Telephone: [phone]
Evenings, Weekends, Holidays:
Telephone: [phone]
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 troubleshoot via telephone with Xerox
CSE.
How to Order Parts
PFSMA
C.P. Bourg, Inc. will supply one CMT-
130TC spare parts kit for each machine.
Xerox CSE must contact C.P. Bourg,
Inc. at the following number to replenish
used parts:
Normal Business Hours:
Monday-Friday, 8:00 am- 5:00 pm EST
Telephone: [phone]
Fax: [phone]
1-508-998-2391
Evenings:
Monday-Thurs., 5:00 pm- 8:00 am EST
Phone: [phone]
1-508-998-2391
Weekends and Holidays:
Friday 5:00 pm- Sunday 5:00 pm
Fax parts order to 1-508-998-2391
Then call telephone: [phone]
or 1-617-730-3178
Leave message with operator using au-
thorization number 3513. Include name,
telephone number (with extension), and
time of call. Inform them you have
faxed in an emergency parts order.
Xerox CSE must emergency order
through C.P. Bourg, Inc. any parts not
included in the spare parts kit but re-
quired to complete a repair.
C.P. Bourg, Inc. will ship parts directly to
the customer site and will notify Xerox
CSE of expedited shipping method and
parts ETA.
Expedited shipping costs will be the re-
sponsibility of CP Bourg.
NOTE: C.P. Bourg, Inc. will supply the paper-
work for return of the failed part if required for re-
turn. The failed part will be returned to C.P.
Bourg, Inc. in the same box the new part was
shipped.
1. Service Call Procedures

MAY 2019
1. Service Call Procedures 1-2 CMT-130TC Book Trimmer
T&M
Time and Material (T&M) is not supported by
Xerox Service
Offline units only (not connected to printer)
Customer Responsibilities:
Customer must stock the CMT-130TC
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. Bourg, Inc. customer service at 1-
508-998-2171 to replenish inventory.
Customer must emergency order
through C.P. Bourg, Inc. customer ser-
vice at 1-508-998-2171 any parts not in
the spare parts kit but required to com-
plete a repair.

MAY 2019
CMT-130TC Book Trimmer 2-1 2. Status Indicator RAPs
Contents
RAP 2.1 Fault Entry............................................. 2-2
RAP 2.2 Error Messages..................................... 2-3
RAP 2.3 Faults Without an Error Message.......... 2-7
RAP 2.4 Input Power......................................... 2-10
RAP 2.5 DC Power............................................ 2-12
RAP 2.6 Touch Screen Display......................... 2-14
RAP 2.7 LED Enclosure Lights.......................... 2-15
RAP 2.8 Cooling Fans....................................... 2-16
RAP 2.9 Status Light......................................... 2-17
RAP 2.10 Door Interlocks –Trimmer................. 2-18
RAP 2.11 Interlock Test..................................... 2-19
RAP 2.12 Interlock Relay .................................. 2-20
RAP 2.13 Start/Remote Cut Buttons................. 2-21
RAP 2.14 E-Stop/Remote E-Stop Buttons......... 2-22
RAP 2.15 Starter Circuit.................................... 2-23
RAP 2.16 Hydraulic Motor Relay....................... 2-24
RAP 2.17 Hydraulic Unload and Flow Valves.... 2-25
RAP 2.18 Cut Valve .......................................... 2-26
RAP 2.19 Shutdown Relay................................ 2-27
RAP 2.20 Pneumatic Pressure.......................... 2-28
RAP 2.21 Left Jogger Cylinder.......................... 2-29
RAP 2.22 Gripper Clamp Cylinder..................... 2-30
RAP 2.23 Gripper Rotator Lock Cylinder........... 2-31
RAP 2.24 Knife Shift Cylinders.......................... 2-32
RAP 2.25 Gripper Lift Cylinder.......................... 2-33
RAP 2.26 Registration Plate Extend Cylinder.... 2-34
RAP 2.27 Book Lift Air Blast.............................. 2-35
RAP 2.28 Knife Latch Cylinder.......................... 2-36
RAP 2.29 Scrap Air Blast .................................. 2-37
RAP 2.30 Book Gate Cylinder........................... 2-38
RAP 2.31 Face Jog Cylinder............................. 2-39
RAP 2.32 Left and Right Clamp Cylinders......... 2-40
RAP 2.33 Internal Conveyor Motor.................... 2-41
RAP 2.34 Registration Assembly Motor ............ 2-42
RAP 2.35 Gripper Transport Servo Motor ......... 2-43
RAP 2.36 Gripper Rotation Servo Motor ........... 2-44
RAP 2.37 Knife Latch Sensor............................ 2-45
RAP 2.38 Book in Gripper Sensor..................... 2-46
RAP 2.39 Left Jogger Retract Sensor ............... 2-47
RAP 2.40 Registration Preset Sensor............... 2-48
RAP 2.41 Face Jog Sensor............................... 2-49
RAP 2.42 Gripper Rotation Preset Sensor........2-50
RAP 2.43 Knife Position Sensor........................2-51
RAP 2.44 Knife Up Sensor................................2-52
RAP 2.45 Knife Slow-Down Sensor...................2-53
RAP 2.46 Knife Down Switches.........................2-54
RAP 2.47 Book Entering CMT Sensor...............2-55
RAP 2.48 Book Width Sensor............................2-56
RAP 2.49 Book Thickness Sensor..................... 2-57
RAP 2.50 Barcode Scanner...............................2-58
RAP 2.51 Elevator Input Power.........................2-59
RAP 2.52 Elevator Door Interlocks....................2-60
RAP 2.53 Elevator Tilt Table Cylinders .............2-61
RAP 2.54 Elevator Tilt Infeed Motors ................2-62
RAP 2.55 Elevator Lift Motor.............................2-63
RAP 2.56 Elevator Pusher Cylinder...................2-64
RAP 2.57 Book In From Binder Sensor.............2-65
RAP 2.58 Tilt Up Switch....................................2-66
RAP 2.59 Book on Tilt Sensors.........................2-67
RAP 2.60 Book Entering Elevator Sensor.........2-68
RAP 2.61 Elevator Book at Top Sensor ............2-69
RAP 2.62 Shelf Level Detect Sensor.................2-70
RAP 2.63 Elevator Empty Sensor......................2-71
RAP 2.64 Elevator Pusher Home Sensor..........2-72
RAP 2.65 Elevator Pusher Interlock.................. 2-73
RAP 2.66 Stacker Input Power..........................2-74
RAP 2.67 Stacker Door Interlock.......................2-75
RAP 2.68 Stacker Roller Motor..........................2-76
RAP 2.69 Stacker Tray Up/Down Cylinder........2-77
RAP 2.70 Stacker Tray Dump Cylinder.............2-78
RAP 2.71 Stacker Pusher Cylinder....................2-79
RAP 2.72 Stacker Finger Lift Cylinder...............2-80
RAP 2.73 Stacker Roller Start Sensor...............2-81
RAP 2.74 Stacker Book In Tray Sensor ............2-82
RAP 2.75 Stacker Book to Pusher Sensor ........2-83
RAP 2.76 Stacker Pusher Cylinder Sensor .......2-84
RAP 2.77 Stacker Tray Full Sensor...................2-85
RAP 2.78 Exit Conveyor Motor..........................2-86
RAP 2.79 Exit Conveyor Full Sensor.................2-87
RAP 2.80 Final Actions/System Checks............2-88
Introduction
The status indicator, repair analysis procedures
(RAPs) provide in-depth troubleshooting
measures. They were designed for thorough
resolution of faults indicated by status messages
or controller board states.
WARNING
HIGH VOLTAGE! Nearly all RAPs require
that the machine have power while testing.
Use extreme caution at ALL times. Serious
injury or death may result from unsafe test-
ing practices. If replacing parts, lock out
main power at the source according to the
Power Lockout Procedure on page ix.
CAUTION
Standard precautions to prevent electro-static
discharge must be taken when working with
PWBs. Observe these practices whenever work
is being done in the electrical panel.
2. Status Indicator RAPs
Title Page Title Page

MAY 2019
2. Status Indicator RAPs 2-2 CMT-130TC Book Trimmer
RAP 2.1 Fault Entry
This RAP should be performed on every service
call in order to correctly diagnose and trouble-
shoot the problem being reported.
Initial Actions
Clear all books from the trimmer and accesso-
ries.
Check that all doors are closed completely.
Procedure
1. Ask the customer to describe the problem.
2. Check that a compressed air line is con-
nected to the trimmer, and is suppling com-
pressed air at least 80 psi (for compressed
air requirements and hookup, see Section
8.8 Main Air Hookup).
3. Check that the main air valve at the back of
the trimmer is switched on.
4. Switch the main power ON at the power
switch shown in Figure 2-1. Does the touch
screen display come on?
Y N
Perform RAP 2.4 Input Power and RAP 2.5
DC Power to confirm that all power sources
are working properly. Perform RAP 2.6
Touch Screen Display if necessary. Does a
problem still exist?
Y N
Go to Step 13.
5. Are there any error messages on the
screen?
Y N
Go to Step 7.
6. When possible, attempt to resolve and clear
the error message (for example, for an open
door message, close the door). It may be
necessary to switch the power OFF and
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 13.
7. Push the green start button. Does the hy-
draulic motor start?
Y N
Perform RAP 2.15 Starter Circuit
8. Are there any error messages on the
screen?
Y N
Go to Step 10.
9. When possible, attempt to resolve and clear
the error message (for example, for an open
door message, close the door). It may be
necessary to switch the power OFF and
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 13.
10. Do the gripper and other mechanical compo-
nents initialize properly?
Y N
Perform RAP 2.4 Input Power and RAP 2.5
DC Power to confirm that all power sources
are working properly. If the gripper does not
move, go to RAP 2.35 Gripper Transport
Servo Motor.
11. Is the problem a book quality problem?
Y N
Go to RAP 2.3 Faults Without an Error Mes-
sage and perform the applicable RAPs.
When complete, go to Step 13.
12. Go to BQ 3.1 Book Quality Entry Rap. When
complete, go to Step 13.
13. Go to GP 6.18 Scheduled Maintenance and
perform any necessary routine maintenance.
14. Perform RAP 2.80 Final Actions/System
Checks.
Figure 2-1. Start Up Controls

MAY 2019
CMT-130TC Book Trimmer 2-3 2. Status Indicator RAPs
RAP 2.2 Error Messages
An error message will appear on the display
screen often times when there is a fault. The fol-
lowing table contains the complete list of possi-
ble error messages. Always attempt to resolve
and clear the error message before performing
the recommended procedures in this list (for ex-
ample, for an open door message, close the
door). It may be necessary to switch the power
OFF and back ON in order to clear the mes-
sage. If the error message cannot be resolved
or continues to be displayed, follow the associ-
ated recommended procedures shown below.
Error Messages (in Alphabetical Order)
Recommended Procedures
Accuracy is out of range
ADJ 4.5 Accuracy Adjustment
Bar Code Error
RAP 2.50 Barcode Scanner
Book At Thickness Sensor Unexpectedly
RAP 2.47 Book Entering CMT Sensor
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 for allowed dimensions
Book in Elevator JAM Error
RAP 2.60 Book Entering Elevator Sensor
RAP 2.54 Elevator Tilt Infeed Motors
RAP 2.55 Elevator Lift Motor
Book Start length outside limits
See Installation and Operator's Manual for allowed dimensions
Book Start width outside limits
See Installation and Operator's Manual for allowed dimensions
Book Thickness value too large
See Installation and Operator's Manual for allowed dimensions
Book Length & Trim combination too large
See Installation and Operator's Manual for allowed dimensions
Book did not reach Width sensor in time
RAP 2.48 Book Width Sensor
Connection Lost to I/O Motor Controller!
RAP 2.6 Touch Screen Display
EE memory Read Fail
GP 6.4 Updating Machine Software
REP 4.24 Console PWB Replacement
EE memory Write failed
GP 6.4 Updating Machine Software
REP 4.24 Console PWB Replacement

MAY 2019
2. Status Indicator RAPs 2-4 CMT-130TC Book Trimmer
Error Messages (in Alphabetical Order)
Recommended Procedures
Elevator Book on Tilt Error
RAP 2.59 Book on Tilt Sensor
RAP 2.60 Book Entering Elevator Sensor
RAP 2.54 Elevator Tilt Infeed Motors
RAP 2.55 Elevator Lift Motor
Elevator Book Push Error
RAP 2.56 Elevator Pusher Cylinder
RAP 2.64 Elevator Pusher Home Sensor
RAP 2.65 Elevator Pusher Interlock
Elevator Door Open
RAP 2.52 Elevator Door Interlocks
Elevator Failed to Lift
RAP 2.62 Shelf Level Detect Sensor
RAP 2.55 Elevator Lift Motor
Elevator JAM Book on Top
RAP 2.61 Elevator Book at Top Sensor
Elevator JAM From the Binder
RAP 2.59 Book on Tilt Sensor
RAP 2.60 Book Entering Elevator Sensor
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
RAP 2.53 Elevator Tilt Table Cylinders
RAP 2.54 Elevator Tilt Infeed Motors
Elevator Top Door Open
RAP 2.52 Elevator Door Interlocks
Face Jog Failed to Rotate
RAP 2.31 Face Jog Cylinder
RAP 2.41 Face Jog Sensor
Flash file is corrupted! CheckSum failed
GP 6.4 Updating Machine Software
Interlock relay OFF when should be ON
RAP 2.12 Interlock Relay
RAP 2.15 Starter Circuit
JAM - Book Between Sensor Error
RAP 2.47 Book Entering CMT Sensor
RAP 2.33 Internal Conveyor Motor
Knife failed to leave down limit in time!
RAP 2.46 Knife Down
RAP 2.17 Hydraulic Unload and Flow Valve
RAP 2.18 Cut Valve
Knife failed to leave up limit in time
RAP 2.44 Knife Up Sensor
RAP 2.17 Hydraulic Unload and Flow Valve
RAP 2.18 Cut Valve

MAY 2019
CMT-130TC Book Trimmer 2-5 2. Status Indicator RAPs
Error Messages (in Alphabetical Order)
Recommended Procedures
Knife failed to reach down limit in time!
RAP 2.46 Knife Down Switches
RAP 2.17 Hydraulic Unload and Flow Valve
RAP 2.18 Cut Valve
RAP 2.44 Knife Up Sensor
Knife failed to reach Slow Down Prox
RAP 2.45 Knife Slow-Down Sensor
RAP 2.46 Knife Down Switches
Knife failed to reach up limit in time!
RAP 2.44 Knife Up Sensor
RAP 2.17 Hydraulic Unload and Flow Valve
RAP 2.18 Cut Valve
Knife Latch did not pull in!
RAP 2.28 Knife Latch Cylinder
RAP 2.37 Knife Latch Sensor
Knife Latch OUT when should be IN
RAP 2.28 Knife Latch Cylinder
RAP 2.37 Knife Latch Sensor
Left Jog Failed to Extend
RAP 2.21 Left Jogger 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
Machine Front Door Open
RAP 2.12 Interlock Relay
RAP 2.10 Door Interlocks
Machine Rear Door Open
RAP 2.12 Interlock Relay
RAP 2.10 Door Interlocks
Machine Side Door Open
RAP 2.12 Interlock Relay
RAP 2.10 Door Interlocks
Motor failed to move
RAP 2.35 Gripper Transport Servo Motor
Motor Starter off when it should be on!
RAP 2.15 Starter Circuit
RAP 2.55 Elevator Lift Motor
RAP 2.78 Exit Conveyor Motor
RAP 2.21 Left Jogger Cylinder
Motor Starter on when it should be off!
RAP 2.15 Starter Circuit
RAP 2.55 Elevator Lift Motor
RAP 2.78 Exit Conveyor Motor
No Air Pressure!
RAP 2.20 Pneumatic Pressure
Output is Full
RAP 2.79 Exit Conveyor Full Sensor
Pile Feeder Book Not Received
See Book Pile Feeder Instruction and Parts Manual

MAY 2019
2. Status Indicator RAPs 2-6 CMT-130TC Book Trimmer
Error Messages (in Alphabetical Order)
Recommended Procedures
Pile Feeder Book On Tilt
See Book Pile Feeder Instruction and Parts Manual
Pile Feeder Door Open
See Book Pile Feeder Instruction and Parts Manual
Pile Feeder Tilt Down Error
See Book Pile Feeder Instruction and Parts Manual
Registration Data Error
RAP 2.40 Registration Preset Sensor
RAP 2.34 Registration Assembly Motor
Registration Position Error
RAP 2.40 Registration Preset Sensor
RAP 2.34 Registration Assembly Motor
Rotation Error - Press Stop, Then Green
Start
RAP 2.36 Gripper Rotation Servo Motor
RAP 2.23 Gripper Rotator Lock Cylinder
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 Stacker Roller Start Sensor
RAP 2.68 Stacker Roller Motor
Stacker Book Jam Book to Pusher
RAP 2.75 Stacker Book to Pusher Sensor
RAP 2.70 Stacker Tray Dump Cylinder
Stacker Book Jam Start
RAP 2.74 Stacker Book In Tray Sensor
RAP 2.69 Stacker Tray Up/Down Cylinder
RAP 2.70 Stacker Tray Dump Cylinder
Stacker Door Open
RAP 2.67 Stacker Door Interlock
Stacker Output Full
RAP 2.77 Stacker Tray Full Sensor
Stacker Push Position Error
RAP 2.76 Stacker Pusher Cylinder Sensor
RAP 2.71 Stacker Pusher Cylinder
Stop Button is Pressed
RAP 2.14 E-Stop/Remote E-Stop Buttons
Target Position out of range
See Installation and Operator's Manual for allowed dimensions

MAY 2019
CMT-130TC Book Trimmer 2-7 2. Status Indicator RAPs
RAP 2.3 Faults Without an Error Message
Description of Fault
Recommended Procedures
Trimmer Faults
Machine will not switch on
RAP 2.4 Input Power
The status light is always on, or never on
RAP 2.9 Status Light
Console will not illuminate
RAP 2.6 Touch Screen Display
RAP 2.4 Input Power
Enclosure lights will not switch on or will not switch off
RAP 2.7 LED Enclosure Lights
Cooling fan(s) do not function
RAP 2.8 Cooling Fans
The hydraulic motor will not start
RAP 2.4 Input Power
RAP 2.15 Starter Circuit
The internal conveyors will not start and the gripper will not
move
RAP 2.12 Interlock Relay
RAP 2.15 Starter Circuit
The internal conveyors do not run while the pump motor is
on
RAP 2.33 Internal Conveyor Motor
The internal conveyors run while the pump motor is off
RAP 2.33 Internal Conveyor Motor
Registration assembly fails to 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 book and/or books are delivered to
outfeed accessory without being cut
RAP 2.38 Book in Gripper Sensor
Gripper freezes in registration area
RAP 2.31 Face Jog Cylinder
RAP 2.41 Face Jog Sensor
Registration stop plate is always extended, never extends,
or extends erratically
RAP 2.26 Registration Plate Extend Cylinder
The left side jogger fails to extend
RAP 2.21 Left Jogger Cylinder
The knife will not come down
RAP 2.17 Hydraulic Unload and Flow Valve
The knife stays down and hydraulic fluid passes over the
relief valve
RAP 2.17 Hydraulic Unload and Flow Valve
RAP 2.46 Knife Down Switches
Knife cuts with high impact at bottom of stroke even when
cushioning is set HIGH
RAP 2.17 Hydraulic Unload and Flow Valve
RAP 2.45 Knife Slow-Down Sensor
Paper scrap does not blow into waste bin
RAP 2.29 Scrap Air Blast
Start button or remote cut button does not work
RAP 2.13 Start/Remote Cut Buttons

MAY 2019
2. Status Indicator RAPs 2-8 CMT-130TC Book Trimmer
Description of Fault
Recommended Procedures
E-Stop button or remote E-Stop button does not work
RAP 2.14 E-Stop/Remote E-Stop Buttons
Pneumatics are sluggish or erratic
Check that input air pressure is 80-90 PSI.
RAP 2.20 Pneumatic Pressure
Machine never switches into/out of sleep mode
RAP 2.57 Book In From Binder Sensor
Knife mechanism drifts down while the machine is
switched off
RAP 2.28 Knife Latch Cylinder
Elevator Accessory Faults
Tilt Infeed Conveyor(s) do not run
RAP 2.54 Elevator Tilt Infeed Motors
Tilt Infeed conveyor tilt operation is faulty
RAP 2.53 Elevator Tilt Table Cylinders
RAP 2.59 Book on Tilt Sensor
RAP 2.54 Elevator Tilt Infeed Motors
The Elevator never lifts or continuously lifts and stops after
a timeout period
RAP 2.55 Elevator Lift Motor
RAP 2.62 Shelf Level Detect Sensor
Book does not leave Elevator, pusher remains extended,
never extends, or extends 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 there is no jam
RAP 2.60 Book Entering Elevator Sensor
RAP 2.47 Book Entering CMT Sensor
Elevator shelves are not synchronized
ADJ 4.28 Elevator Shelf Synchronization
Elevator pusher is not adjusted to proper height
ADJ 4.27 Elevator Pusher Height
Outfeed Stacker Accessory Faults
Outfeed Stacker rollers do not run
RAP 2.66 Stacker Input Power
RAP 2.67 Stacker Door Interlock
RAP 2.68 Stacker Roller Motor
Outfeed Stacker air cylinders do not operate
Check cable/air connections to Outfeed Stacker
RAP 2.67 Stacker Door Interlock
Book is not dropped onto output tray properly
RAP 2.69 Stacker Tray Up/Down Cylinder
RAP 2.70 Stacker Tray Dump Cylinder
RAP 2.71 Stacker Pusher Cylinder
Output tray is full but trimmer does not stop trimming books
RAP 2.77 Stacker Tray Full Sensor
Exit Conveyor Accessory Faults
Exit Conveyor does not run
RAP 2.78 Exit Conveyor Motor
Exit Conveyor doesn’t stop when full
RAP 2.79 Exit Conveyor Full Sensor