Ishida Global Universal Auto Case Packer PM Training Manual

Ishida Global Universal

Auto Case Packer
Preventive Maintenance
Training Manual
Version 1.0
November 2012

Direct corrections/comments to Brian Klepp on MS Outlook.

2010 Frito-Lay, Inc.

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Ishida Global Universal Auto Case Packer PM Training Manual

Rev 1.0 Ishida Factory Pre-FAT 11-12-12

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Ishida Global Universal Auto Case Packer PM Training Manual

Table of Contents

CHAPTER 1 - INTRODUCTION ........................................................................................................... 6

INTRODUCTION ....................................................................................................................................... 6
DESCRIPTION OF MANUAL ...................................................................................................................... 6
TRAINING METHOD ................................................................................................................................ 6
OVERVIEW OF THE GLOBAL UNIVERSAL AUTO CASE PACKER ................................................................. 8
OVERVIEW ............................................................................................................................................. 8
CHAPTER 2 – CASE ERECTING .......................................................................................................... 9
COMPONENT OVERVIEW ......................................................................................................................... 9
INSPECTION POINT ? SHEET MAGAZINE CONVEYOR .............................................................................. 10
INSPECTION POINT ? SHEET MAGAZINE CONVEYOR PHOTO EYES B215, B216, B217, B218 AND B219 .. 11
INSPECTION POINT ? SHEET FEED WIDTH ADJUST ................................................................................. 13
INSPECTION POINT ? SHEET SPACER POSITION ADJUST .......................................................................... 15
INSPECTION POINT ? SHEET SUCTION POSITION ADJUST ........................................................................ 17
INSPECTION POINT ? SHEET LIFTER ....................................................................................................... 19
INSPECTION POINT ? CASE ERECTING CASE PUSHER ADJUST ................................................................. 21
INSPECTION POINT ? FLAP OPENER VERTICAL POSITION ADJUST ........................................................... 23
INSPECTION POINT ? PADDLE LENGTH ADJUST ...................................................................................... 25
INSPECTION POINT ? UPSTREAM PADDLE WIDTH ADJUST ...................................................................... 27
INSPECTION POINT ? DOWNSTREAM PADDLE WIDTH ADJUST ................................................................ 29
INSPECTION POINT ? SUB BASE POSITION ADJUST ................................................................................. 31
INSPECTION POINT ? BOTTOM FAN FOLDING-SHOE AIR CYLINDERS ...................................................... 33
INSPECTION POINT ? BOTTOM FAN FOLDING-MAJOR/MINOR FLAP GUIDES ........................................... 35
INSPECTION POINT ? BOTTOM FAN FOLDING-MAJOR/MINOR ARM MOVE .............................................. 36
INSPECTION POINT ? BOTTOM FOLDING- TAPE UNIT MOVE AND TAPE UNIT SHIFT ................................ 37
INSPECTION POINT ? TAPER-NO TAPE DETECT PHOTO EYE B437 .......................................................... 38
INSPECTION POINT ? CASE ERECTING TAPE UNIT POSITION ADJUST ...................................................... 39
INSPECTION POINT ? CASE TRANSFER MS8 ........................................................................................... 41
INSPECTION POINT ? CASE ERECTING ARM MS9 ................................................................................... 43
INSPECTION POINT ? MINOR FLAP PUSHER ............................................................................................ 45
INSPECTION POINT ? CASE CLAMP ........................................................................................................ 46
INSPECTION POINT ? MAJOR FLAP OPENER ........................................................................................... 47
INSPECTION POINT ? SHEET DETECT PHOTO EYE B227 .......................................................................... 49
INSPECTION POINT ? MAJOR FLAP BOTTOM AND SHIFT ......................................................................... 50
INSPECTION POINT ? BOTTOM FLAP PUSHER ......................................................................................... 51
INSPECTION POINT ? CASE ERECTING CASE PUSHER .............................................................................. 52
INSPECTION POINT ? LOWER FLAP PUSHER ........................................................................................... 53
INSPECTION POINT ? MINOR FLAP HOLDING.......................................................................................... 54
INSPECTION POINT ? CASE ERECTING CASE STOPPER ............................................................................ 55
INSPECTION POINT ? CASE DROP PUSHER .............................................................................................. 56
INSPECTION POINT ? CASE DROP GATE ................................................................................................. 57
INSPECTION POINT ? SHUTTER LENGTH ADJUST .................................................................................... 58
CHAPTER 3 – BAG SORTING ............................................................................................................ 59
INSPECTION POINT ? BAG INFEED INCLINE BELT MD1 .......................................................................... 61
INSPECTION POINT ? INFEED JAM DETECT PHOTO EYE B1011 ............................................................... 63
INSPECTION POINT ? BAG INFEED CONVEYOR MD1 .............................................................................. 64
INSPECTION POINT ? INFEED INNER SIDE BELT ...................................................................................... 65
INSPECTION POINT ? INNER SIDE BELT WIDTH ADJUST MT1 ................................................................ 66
INSPECTION POINT 7 OUTER SIDE BELT................................................................................................. 68
INSPECTION POINT ? OUTER SIDE BELT WIDTH ADJUST MT2 ............................................................... 69

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INSPECTION POINT ? DECLINE HEIGHT ADJUST ..................................................................................... 71

INSPECTION POINT ? SIDE GUIDE .......................................................................................................... 73
INSPECTION POINT ? SIDE GUIDE WIDTH ADJUST .................................................................................. 74
INSPECTION POINT ? DECLINE PE .......................................................................................................... 76
INSPECTION POINT ? BAG ROTATION ASSIST PUSHER ............................................................................ 77
INSPECTION POINT ? BAG ROTATION ASSIST PHOTO EYE B1012 ........................................................... 78
INSPECTION POINT ? SORT CONVEYOR #1 ............................................................................................. 79
INSPECTION POINT ? SORT CONVEYOR #2 ............................................................................................. 81
INSPECTION POINT ? SORT CONVEYOR #3 ............................................................................................. 82
INSPECTION POINT ? COMPRESS CONVEYOR .......................................................................................... 83
INSPECTION POINT ? COMPRESS CONVEYOR ADJUST ............................................................................ 85
INSPECTION POINT 21 REAR END GUIDES.............................................................................................. 87
INSPECTION POINT 22 SLIDER MS5 ....................................................................................................... 88
INSPECTION POINT 23 SLIDER WIDTH ADJUST ....................................................................................... 89
INSPECTION POINT ? UPSTREAM BAG LOADING AND DOWNSTREAM BAG LOADING PHOTO EYES
B613/B614........................................................................................................................................... 91
CHAPTER 4 – CASE LOADING .......................................................................................................... 92
COMPONENT OVERVIEW ....................................................................................................................... 92
INSPECTION POINT ? CASE LOADING GUIDE POSITION ADJUST .............................................................. 93
INSPECTION POINT ? CASE RECEIVING GATE ......................................................................................... 95
INSPECTION POINT ? CASE LOADING GUIDES ........................................................................................ 96
INSPECTION POINT ? CASE FLAP HOLDER .............................................................................................. 97
INSPECTION POINT ? MAJOR FLAP ASSIST ............................................................................................. 99
INSPECTION POINT ? CASE ELEVATOR MS4 ........................................................................................ 100
INSPECTION POINT ? CASE ROTATION LONG AND SHORT CYLINDERS .................................................. 101
INSPECTION POINT ? SHUTTER LENGTH ADJUST .................................................................................. 102
CHAPTER 5 – CASE CLOSING............................................................................................................... 104
INSPECTION POINT ? CASE CLOSING CASE PUSHER ............................................................................. 106
INSPECTION POINT ? CASE BASE PLATE .............................................................................................. 107
INSPECTION POINT ? CASE ACCEPT PUSHER ........................................................................................ 109
INSPECTION POINT ? INNER CASE CONVEYOR HEIGHT ADJUST MD5 .................................................. 110
INSPECTION POINT ? OUTER CASE CONVEYOR HEIGHT ADJUST MD6 ................................................. 111
INSPECTION POINT ? CASE CONVEYOR GUIDE ANTI-VIBRATION.......................................................... 112
INSPECTION POINT ? CASE CONVEYOR GUIDE ADJUST ........................................................................ 113
INSPECTION POINT ? MAJOR FLAP RAISE GUIDE .................................................................................. 115
INSPECTION POINT ? MINOR FLAP GUIDE ............................................................................................ 116
INSPECTION POINT ? MAJOR ARM POSITION ADJUST MT9 ................................................................... 117
INSPECTION POINT ? UPSTREAM MINOR ARM POSITION ADJUST MT8 ................................................. 119
INSPECTION POINT ? DOWNSTREAM MINOR ARM POSITION ADJUST MT10.......................................... 121
INSPECTION POINT ? CASE CLOSING-MAJOR/MINOR ARM MOVE ........................................................ 123
INSPECTION POINT ? CASE CLOSING MINOR AND MAJOR PADDLES...................................................... 124
INSPECTION POINT ? CASE CLOSING PE B651 ..................................................................................... 126
INSPECTION POINT ? CASE JAM DETECT PE B652................................................................................ 127
INSPECTION POINT ? MAJOR FLAP RAISE ............................................................................................. 128
INSPECTION POINT ? MINOR FLAP RAISE ............................................................................................. 129
INSPECTION POINT ? OUTER MAJOR FLAP RAISE AND SHIFT ................................................................ 130
INSPECTION POINT ? ANTI-BACK GUIDE SHIFT .................................................................................... 131
INSPECTION POINT ? FAN FOLD FLAP GUIDE ....................................................................................... 132
INSPECTION POINT ? MAJOR FLAP STOPPER POSITION ADJUST ............................................................ 133
INSPECTION POINT ? MINOR FLAP STOPPER POSITION ADJUST............................................................. 135
INSPECTION POINT ? CASE CLOSING TAPER UNIT POSITION ADJUST .................................................... 137
INSPECTION POINT ? CASE CLOSING TAPE UNIT VERTICAL ................................................................. 139
INSPECTION POINT ? MINOR FLAP SUB ARM ROTATION ...................................................................... 140
INSPECTION POINT ? MINOR FLAP SUB ARM SHIFT .............................................................................. 141
INSPECTION POINT ? LIFTER LOWER AND LIFTER UPPER ..................................................................... 142

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INSPECTION POINT ? LIFTER POSITION STOPPER .................................................................................. 143

INSPECTION POINT ? CASE EJECTING REJECT PUSHER ......................................................................... 144
INSPECTION POINT ? DOWNSTREAM/UPSTREAM LIFTER STOPPER ........................................................ 145
INSPECTION POINT ? REAR FLAP RAISE ............................................................................................... 146
INSPECTION POINT ? LIFTER ROTATION ............................................................................................... 147
INSPECTION POINT ? CASE EJECTING PE B817 .................................................................................... 148
INSPECTION POINT ? LIGHT CURTAIN REJECT PE B854 ....................................................................... 149
INSPECTION POINT ? LIGHT CURTAIN EXIT PE B855 ........................................................................... 150
INSPECTION POINT ? CASE EJECTING PE B817 .................................................................................... 151
INSPECTION POINT ? LIFTER ROLLERS MD 7 ....................................................................................... 152
INSPECTION POINT ? VACUUM PUMP AND FILTER ................................................................................ 153
CHAPTER 6 EXTERIOR CHECKS ........................................................................................................... 154
DOORS ............................................................................................................................................... 154
DOOR GUARD SWITCHES .................................................................................................................... 155
EMERGENCY STOP SWITCHES ............................................................................................................. 156
TOUCH SCREEN AND CABINET FILTERS ............................................................................................... 157
CYCLE MACHINE ................................................................................................................................ 158
CHAPTER 7 CERTIFICATION CHECKLIST ................................................................................. 159

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Ishida Global Universal Auto Case Packer PM Training Manual

Chapter 1 - Introduction
Introduction
This manual is designed for initial training of Maintenance Technicians on completing
a full PM of a Ishida Global Universal Auto Case Packer (GUACP).

Description of Manual
Each training section has a description of a particular section of the GUACP.
Components will be reviewed and then the details of each step of the PM will be
described. These components will be:

Inspection Point – A description of the specific point that will be inspected, including an
illustration of that point.

Inspection Procedure – These are specific instructions on how to complete the

inspection. They include what parts to remove if necessary and whether to inspect
visually of with some type of measuring device.

Specifications- Lists specific tolerances are acceptable for the component being
inspected, possibly including illustrations of examples of in and out of tolerance items.

Training Method

Sections should first be reviewed in a quiet location to allow for a full understanding
by the technicians being trained, then proceed directly to the floor for a practical
application of checking the inspection points for that area of the UACP. Trainees should
bring their text to the floor to review and take notes if needed.

All trainees should be certified on the PM by the trainer at the conclusion of the
course by completing a PM with that trainer one on one.

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Safety Precautions:

1. The machine must be locked out, both electrically and

pneumatically before beginning a PM.

2. Be aware of bump hazards while working in this

machine. There are several sharp points located
throughout.

3. DO NOT bypass any safety device at any time.

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Overview of the Global Universal Auto Case Packer

Overview
The Global Universal Auto Case Packer (GUACP) has four main areas:

Case Erecting
Bag Sorting
Case Loading
Case Closing

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Chapter 2 – Case Erecting

Component Overview
The Case Erecting section consists of a Sheet Feeder, Sheet Lifter, Sheet Spacer, Case
Transfer, and Case Erecting Arm. Blank cases are loaded in to the Sheet Feeder with the
bottom of the case facing the right hand side of the machine. A conveyor belt keeps the
blanks pulled close to the Sheet Lifter to insure the next case can be delivered to the Case
Erecting section. A Sheet Lifter will raise the Case to the Case Erecting Arm.

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Inspection Point ? Sheet Magazine Conveyor MD8

Description

The Sheet Magazine conveyor will move the Blank Cases to the Sheet Lifter. A
DC motor is used to drive this conveyor. The motor will cycle on and off based on a
photo eye B215. As the photo eye is unblocked by a blank case the conveyor will start
moving the stack of cases forward.

Sheet Magazine Conveyor

Inspection
Visually inspect belt for wear and proper tracking.
Inspect Tail Shaft for wear and smooth operation. Check internal bearings
for play or wear (2).
Inspect drive shaft for wear and smooth operation. Check internal bearings
for play or wear (2).
Inspect drive belt and pulleys for wear and tightness. Ensure belt is
running in center of pulleys.

Specifications

Belts in good repair

No wear on shafts and bearings in good condition.
Drive belt and pulleys are in good condition and centered.

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Inspection Point ? Sheet Magazine Conveyor Photo Eyes B215,

B216, B217, B218 and B219

Description

There are 4 photo eyes associated with the Sheet Magazine Conveyor. The B215
is a Send Receive style with an emitter and a collector on the opposite side of the
magazine. This photo eye is used to notify the Sheet Lifter that there is a case ready to be
moved to the erection section. It is also used to run the conveyor if B217 is blocked and
B216 is blocked in an attempt to satisfy B215. If this photo eye is not blocked and B217
is but B216 is not blocked, the machine will attempt to run 3 more sheets then fault. B216
is located at the end of the conveyor, prior to the drop off and is used to run the conveyor
if B215 and B217 are not blocked. If a certain amount of time passes without B217 and
B215 not being blocked the machine will fault. B217 is a retro reflective photo eye.
B218 is the photo eye closest the end of the machine and sends a warning of Low Cases
when not blocked. This is a diffused photo eye.
B219 is located at the top of the stroke of the Sheet lifter. If the Sheet lifter has made it
to the top and this photo eye is not blocked by a case the machine will fault. This is a
diffused photo eye.
B215

B216
B219
B217 B219

Sheet Magazine Conveyor Photo Eyes

Inspection
Inspect photo eyes for secure mounting and clean lenses and clean
reflector on B217.
Verify B216 and B218 for sensitivity. They should make at 6” from face
of photo eye.
Inspect cables for secure attachment and proper routing to avoid cables
getting hung on moving components.

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Specifications

Photo eyes clean and securely mounted.

B216 and B218 calibrated properly.
Cables secure and routed properly.

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Inspection Point ? Sheet Feed Width Adjust MT25/MT26

Description

The GUACP will handle many different case sizes and thus must be adjustable for
varying case widths and heights. The Sheet Feed has side guides that move in or out
independently. This movement is based on a value entered in to the recipe for the case
pack being run. The movements are driven by two stepper motors that are equipped with
photo interrupters that count the rotation of the screw shafts and thus can be accurately
moved to the desired location (B212 and B214). These two motors also have additional
photo interrupters to establish a Home position. As the GUACP is started, or after a
recipe change, the stepper motors will move the side guides to their widest position until
the Home photo interrupters are made (B211 and B213). Once the Home is established
the side guides will move the proper number of counts to achieve the recipe position.

Sheet Feed Adjust Top Plate Sheet Feed Adjust and screw shaft/Linear Shafts

Inspection
Inspect linear shafts for damage and clean. Lubricate with light oil and
wipe off excess.
Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screws with grease and wipe off excess.
Inspect fasteners attaching side guides to moveable carriages for secure
attachment.
Inspect drive belt and pulleys for wear and tightness. Ensure belt is
running in center of pulleys.
Inspect (4) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications

Linear shafts are clean, lubricated and not damaged.

No wear on screw shafts or bronze nuts, lubricated and clean.
All fasteners are tight and secure.
Drive belt and pulleys are in good condition and centered.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Sheet Spacer Position Adjust MT17

Description

As mentioned above, the GUACP will handle many different case sizes and thus
must be adjustable for varying case widths and heights. The Sheet Spacer Position
Adjust moves the Sheet Spacer up or down depending on the length of the case being run.
This movement is based on a value entered in to the recipe for the case pack being run.
The movement is driven by one stepper motor that is equipped with a photo interrupter
that counts the rotation of the screw shaft and thus can be accurately moved to the desired
location (B210). The motor drives a shaft that spans the width of the GUACP and drives
two screw shafts to move the entire structure up or down. The motor also has an
additional photo interrupter to establish a Home position. As the GUACP is started, or
after a recipe change, the stepper motor will move the Sheet Spacer to its highest position
until the Home photo interrupter is made (B209). Once the Home is established the Sheet
Spacer will move the proper number of counts to achieve the recipe position.

Sheet Spacer Position Adjust Sheet Spacer

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screws with grease and wipe off excess.
Inspect fasteners attaching Sheet Spacer to moveable carriage for secure
attachment.
Inspect drive belt and pulleys for wear and tightness. Ensure belt is
running in center of pulleys. Inspect bearings supporting horizontal drive
shaft for wear.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
All fasteners are tight and secure.
Drive belt and pulleys are in good condition and centered. Horizontal
shaft bearings not worn.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Sheet Suction Position Adjust MT16

Description
One other component that must move based on the case size being run is the
Sheet Suction cup. This cup is extend out to capture the highest part of the case so that
the Sheet Spacer can be placed behind the case that is being moved to the erection section
and the next case in the stack. The Sheet Suction Position Adjust moves the Sheet
Suction cup up or down depending on the length of the case being run. This movement is
based on a value entered in to the recipe for the case pack being run. The movement is
driven by one stepper motor that is equipped with a photo interrupter that counts the
rotation of the screw shaft and thus can be accurately moved to the desired location
(B208). The motor also has an additional photo interrupter to establish a Home position.
As the GUACP is started, or after a recipe change, the stepper motor will move the Sheet
Suction Cup to its highest position until the Home photo interrupter is made (B207).
Once the Home is established the Sheet Suction Cup will move the proper number of
counts to achieve the recipe position.

Sheet Suction Adjust Sheet Suction cup, cylinders and linear shafts and bearings

Inspection

Inspect Screw shaft and bronze nut for wear. Wipe off any build up on
face of nut. Lubricate screws with grease and wipe off excess.
Inspect fasteners attaching Sheet Suction to moveable carriage for secure
attachment.

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Inspect linear shafts and bearings for wear. Clean and lubricate shafts with
light oil and wipe off excess.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
All fasteners are tight and secure.
Linear shafts and bearings have no wear, clean and lubricated..
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Sheet Lifter MS7

Description

The Sheet Lifter carries the case blank from the magazine to the case erection
section. It is driven with a servo motor for speed and accuracy of placement of blank
case at case erection. A Home prox is used to tell the servo controller where to begin.
This prox is labeled B205. There is also an over limit prox located at the highest point of
the lifter and is on the operator side of the machine.

Sheet Lifter Servo Motor (Viewed from Top) Operator Side Drive Pulley

Sheet Lifter Servo Home Prox (Operator Side)

Inspection
Inspect two drive belts for wear and running in center of drive and idler
pulleys.
Inspect Drive Shaft bearings (2 bolt flange bearings) for wear and secure
attachment.
Inspect Idler shaft bearings and pulleys for wear.
Inspect drive belt and pulleys from servo motor and jack shaft for wear
and running in center of pulleys.

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Specifications

Belts in good condition and running in center of pulleys

No wear on shaft and bearings.
Idler bearings and pulleys are in good condition and centered.
Servo drive belt and pulleys in good condition and running in center of
pulleys.

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Inspection Point ? Case Erecting Case Pusher Adjust MT24

Description
Another component that must move based on the case size being run is the Case
Pusher. The Case once it is erected is pushed to the Case Loading section. This is
accomplished with an air cylinder; however depending on the folded case height the
entire pusher is moved. This movement is based on a value entered in to the recipe for
the case pack being run. The movement is driven by one stepper motor that is equipped
with a photo interrupter that counts the rotation of the screw shaft and thus can be
accurately moved to the desired location (B449). The motor also has an additional photo
interrupter to establish a Home position. As the GUACP is started, or after a recipe
change, the stepper motor will move the Case Pusher to its widest position until the
Home photo interrupter is made (B448). Once the Home is established the Case Pusher
will move the proper number of counts to achieve the recipe position.

Case Pusher Adjust

Inspection

Inspect Screw shaft and bronze nut for wear. Wipe off any build up on
face of nut. Lubricate screws with grease and wipe off excess.
Inspect fasteners attaching Case Pusher to the moveable carriage for
secure attachment.
Inspect linear shafts and bearings for wear. Clean and lubricate shafts with
light oil and wipe off excess.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
All fasteners are tight and secure.
Linear shafts and bearings have no wear, clean and lubricated..
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Flap Opener Vertical Position Adjust MT23

Description
Once the case has been opened, the top flaps must be captured so that they can be
held open until the top folding takes place. This is accomplished at case erecting Flap
Opener. The flap opener must be moved up and down based on the minor dimension of
the case. Thus another stepper motor is used to raise and lower the Vertical Flap Opener.
This movement is based on a value entered in to the recipe for the case pack being run.
The movement is driven by one stepper motor that is equipped with a photo interrupter
that counts the rotation of the screw shaft and thus can be accurately moved to the desired
location B229). The motor also has an additional photo interrupter to establish a Home
position. As the GUACP is started, or after a recipe change, the stepper motor will move
the Flap Opener Vertical to its highest position until the Home photo interrupter is made
(B228). Once the Home is established the Flap Opener will move the proper number of
counts to achieve the recipe position.

Flap Opener Vertical Adjust

Inspection

Inspect Screw shaft and bronze nut for wear. Wipe off any build up on
face of nut. Lubricate screws with grease and wipe off excess.
Inspect fasteners attaching Flap Opener to moveable carriage for secure
attachment.
Inspect linear shafts and bearings for wear. Clean and lubricate shafts with
light oil and wipe off excess.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
All fasteners are tight and secure.
Linear shafts and bearings have no wear, clean and lubricated..
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Paddle Length Adjust MT19

Description
Depending on the length of the case being run, the upstream minor folding shoe is
moved in the horizontal. Thus another stepper motor is used to move the entire flap
folding mechanism closer to the fixed downstream minor paddle or further away. This
movement is based on a value entered in to the recipe for the case pack being run. The
movement is driven by one stepper motor that is equipped with a photo interrupter that
counts the rotation of the screw shaft and thus can be accurately moved to the desired
location (B243). The motor also has an additional photo interrupter to establish a Home
position. As the GUACP is started, or after a recipe change, the stepper motor will move
the Paddle Length Adjust to its widest position until the Home photo interrupter is made
(B242). Once the Home is established the Paddle Length will move the proper number of
counts to achieve the recipe position.

Paddle Length Vertical Adjust

Inspection

Inspect Screw shaft and bronze nut for wear. Wipe off any build up on
face of nut. Lubricate screws with grease and wipe off excess.
Inspect fasteners attaching Paddle Length Adjust to moveable carriage for
secure attachment.
Inspect linear shafts and bearings for wear. Clean and lubricate shafts with
light oil and wipe off excess.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
All fasteners are tight and secure.
Linear shafts and bearings have no wear, clean and lubricated.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Upstream Paddle Width Adjust MT21

Description
Depending on the width of the case being run, the upstream major folding shoe is
moved in the vertical. Thus another stepper motor is used to move the entire flap folding
mechanism higher or lower than the fixed downstream minor paddle. This movement is
based on a value entered in to the recipe for the case pack being run. The movement is
driven by one stepper motor that is equipped with a photo interrupter that counts the
rotation of the screw shaft and thus can be accurately moved to the desired location
(B245). The motor also has an additional photo interrupter to establish a Home position.
As the GUACP is started, or after a recipe change, the stepper motor will move the
Paddle Width Adjust to its highest position until the Home photo interrupter is made
(B244). Once the Home is established the Paddle Width will move the proper number of
counts to achieve the recipe position.

Upstream Paddle Width Adjust

Inspection

Inspect Screw shaft and bronze nut for wear. Wipe off any build up on
face of nut. Lubricate screws with grease and wipe off excess.
Inspect fasteners attaching Upstream Paddle Width Adjustto moveable
carriage for secure attachment.
Inspect linear shafts and bearings for wear. Clean and lubricate shafts with
light oil and wipe off excess.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
All fasteners are tight and secure.
Linear shafts and bearings have no wear, clean and lubricated..
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Downstream Paddle Width Adjust MT20

Description
Depending on the width of the case being run, the downstream major folding shoe
is moved in the vertical. Thus another stepper motor is used to move the entire flap
folding mechanism higher or lower than the fixed downstream minor paddle. This
movement is based on a value entered in to the recipe for the case pack being run. The
movement is driven by one stepper motor that is equipped with a photo interrupter that
counts the rotation of the screw shaft and thus can be accurately moved to the desired
location (B247). The motor also has an additional photo interrupter to establish a Home
position. As the GUACP is started, or after a recipe change, the stepper motor will move
the Paddle Width Adjust to its highest position until the Home photo interrupter is made
(B246). Once the Home is established the Paddle Width will move the proper number of
counts to achieve the recipe position.

Downstream Paddle Adjust

Inspection

Inspect Screw shaft and bronze nut for wear. Wipe off any build up on
face of nut. Lubricate screws with grease and wipe off excess.
Inspect fasteners attaching Downstream Paddle Width Adjust to moveable
carriage for secure attachment.
Inspect linear shafts and bearings for wear. Clean and lubricate shafts with
light oil and wipe off excess.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
All fasteners are tight and secure.
Linear shafts and bearings have no wear, clean and lubricated..
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Ishida Global Universal Auto Case Packer PM Training Manual

Inspection Point ? Sub Base Position Adjust MT18

Description
Depending on the height of the case being run, the Sub Base Mechanism is moved
in the horizontal moving closer to the bottom folding shoes or farther away. Mounted on
the Sub Base are the cylinders and components for opening the top flaps of the case and
maintaining these until the case is transferred to the Case Loading. Another stepper
motor is used to move the entire Sub Base mechanism. This movement is based on a
value entered in to the recipe for the case pack being run. The movement is driven by
one stepper motor that is equipped with a photo interrupter that counts the rotation of the
screw shaft and thus can be accurately moved to the desired location (B241). The motor
also has an additional photo interrupter to establish a Home position. As the GUACP is
started, or after a recipe change, the stepper motor will move the Sub Base to its widest
position until the Home photo interrupter is made (B240). Once the Home is established
the Sub Base will move the proper number of counts to achieve the recipe position.

Sub Base Position Adjust

Inspection

Inspect Screw shaft and bronze nut for wear. Wipe off any build up on
face of nut. Lubricate screws with grease and wipe off excess. (This
requires removing the shields over the screw shaft)
Inspect fasteners attaching the Sub Base to moveable carriage for secure
attachment.
Inspect linear shafts and bearings for wear. Clean and lubricate shafts with
light oil and wipe off excess.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
All fasteners are tight and secure.
Linear shafts and bearings have no wear, clean and lubricated..
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Bottom Fan Folding-Shoe Air Cylinders

Description
The bottom fan folding is accomplished with several air cylinders. Here we will
describe five air cylinders, two that control minor shoes and two that control major shoes.
An additional air cylinder (Case Erecting Paddle Synchronizing) is used to tie the minor
and major cylinders together during retail fan folding so that one set will not lag behind
the other. Fan folding requires the minor and major shoes to close at exactly the same
time.
The minor paddles use the same two air cylinders and the major paddles use the same air
cylinders. Each has a short cylinder and a long cylinder ganged together. The short
cylinder will start the fan fold and then the long cylinder will complete the fan fold. The
motion of these air cylinders is transmitted by way of cables to the fan fold shoes.
Due to electric current available from the I/O being used by the Ishida, two outputs are
used for each long cylinder solenoid valve. The short cylinders do not require this.

Bottom Fan Folding Shoe Air Cylinders

Inspection

Inspect air cylinders for leaks and proper routing of air lines.
Inspect all cables, rod end clevis and adjustment nuts for secure
attachment.
Inspect linear shafts for wear. Clean and lubricate shafts with grease and
wipe off excess.
Inspect synchronizing cylinder and piston rod for proper engagement in
the bands.

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Specifications
No Leaks and air lines routed properly.
All fasteners are tight and secure.
Linear shafts and bearings have no wear, clean and lubricated.
Synchronizing cylinder and piston rod function properly.

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Inspection Point ? Bottom Fan Folding-Major/Minor Flap Guides

Description
The bottom fan folding is accomplished with several air cylinders. Here we will
describe eight air cylinders that are used to rotate the fan folding guides in to position
prior to the shoes actually folding the case flaps. These guides are designed to hold the
flaps in the proper position for folding by the shoes. The Major Flap Guides are
controlled by a single solenoid Y321. Each major guide has two cylinders, one to pivot
in to position and another to push the flap in to position.
The minors are also controlled by one solenoid valve Y322. Each minor guide
has two cylinders, one to pivot in to position and another to push the flap in to position.

Bottom Fan Folding Flap Guide Air Cylinders

Inspection

Inspect air cylinders for leaks and proper routing of air lines.
Inspect all cables, rod end clevis and adjustment nuts for secure
attachment.
Inspect pivots for wear.
Inspect Guides for damage.

Specifications
No Leaks and air lines routed properly.
All fasteners are tight and secure.
No wear in pivot points.
Guides not damaged..

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Inspection Point ? Bottom Fan Folding-Major/Minor Arm Move

Description
The bottom fan folding is accomplished with several air cylinders. Here we will
describe four air cylinders that are used to rotate the fan folding shoes in to position prior
to the shoes actually folding the case flaps. The Major Flap Arms are controlled by a
single solenoid Y316. Each major arm has one cylinder to pivot the shoe in to position
for fan folding.
The minors are also controlled by one solenoid valve Y317. Each minor shoe has
one cylinder to pivot in to position for folding.

Bottom Fan Folding Flap Shoe Air Cylinders

Inspection

Inspect air cylinders for leaks and proper routing of air lines.
Inspect all cables, rod end clevis and adjustment nuts for secure
attachment.
Inspect pivots for wear.
Inspect shoes for damage.

Specifications
No Leaks and air lines routed properly.
All fasteners are tight and secure.
No wear in pivot points.
Shoes not damaged.

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Inspection Point ? Bottom Folding- Tape Unit Move and Tape

Unit Shift

Description
The bottom of the cases can be taped when not fan folded, such as a Vend case.
When the taper is used, the fan fold will fold the minor flaps in first and then follow that
with the majors. The taper will tape the major flaps together where they join. There are
two air cylinders associated with the taping. The first is the Tape Unit Shift; this cylinder
moves the taper to or away from the case. It moves to the case during taping and away
while the Case Pusher moves the case to the loading area.
As the Case Transfer moves the case the taper will begin taping while the Tape
Unit Move will finish the taping. Once the taper has moved away from the case the Tape
Unit Move will return to its retracted position.

Shift

Move

Taper Unit Move and Taper Unit Shift Air Cylinders

Inspection

Inspect air cylinders for leaks and proper routing of air lines.
Inspect rod end clevis and adjustment nuts for secure attachment.
Inspect linear rails and bearing cassettes for wear, clean and lubricate
bearings.

Specifications
No Leaks and air lines routed properly.
All fasteners are tight and secure.
No wear on linear bearings, clean and lubricated.

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Inspection Point ? Taper-No Tape Detect Photo Eye B437

Description
The Roll of tape being used by the taper is constantly monitored to insure the
taper does not run out. The photo eye is a diffused style and reads the tape if present or
sends a signal to let the operator know that it is getting low.

B437

No Tape Detect

Inspection
Inspect photo eye for secure mounting and clean lense.
Verify B437 for sensitivity. The photo eye should read to the roll of tape.
Inspect cables for secure attachment and proper routing to avoid cables
getting hung on moving components.

Specifications

Photo eye clean and securely mounted.

B437 calibrated properly.
Cables secure and routed properly.

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Inspection Point ? Case Erecting Tape Unit Position Adjust

MT22

Description
Depending on the width of the case being run, the Taper is moved in the vertical.
Thus another stepper motor is used to move the entire Taper mechanism higher or lower
than the fixed downstream minor paddle. This movement is based on a value entered in to
the recipe for the case pack being run. The movement is driven by one stepper motor that
is equipped with a Barrel Prox that counts the rotation of the screw shaft and thus can be
accurately moved to the desired location (B436). The motor also has a photo interrupter
to establish a Home position. As the GUACP is started, or after a recipe change, the
stepper motor will move the Tape Unit Adjust to its lowest position until the Home photo
interrupter is made (B435). Once the Home is established the Taper Unit will move the
proper number of counts to achieve the recipe position.

Taper Unit Position Adjust

Inspection

Inspect Screw shaft and bronze nut for wear. Wipe off any build up on
face of nut. Lubricate screws with grease and wipe off excess.
Inspect fasteners attaching Taper Adjust to moveable carriage for secure
attachment.
Inspect linear shafts and bearings for wear. Clean and lubricate shafts with
light oil and wipe off excess.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
All fasteners are tight and secure.
Linear shafts and bearings have no wear, clean and lubricated..
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Case Transfer MS8

Description
Case Transfer from bottom folding to Case Pusher is accomplished with a servo
motor, drive belt, two linear bearings and an air cylinder. Once the case bottom flaps
have been folded the case transfer has an arm that will drop down on the upstream side of
the case (Case Transfer Plate Y336) and the servo will slide the case downstream until it
is near the bag loading section.
The servo has a home prox (B440) and an over limit switch (B441).

B440

B441

Case Transfer Servo, Drive belt and Idler Pulleys Home Prox and Over Limit Prox

Transfer
Plate

Case Transfer Plate Case Transfer Plate Air Cylinder and Linear Rail

Inspection

Inspect air cylinder (Case Transfer Plate) for air leaks, air lines routed
properly and secure mounting. Inspect linear rail and cassettes for wear.
Clean rail and lubricate cassettes, wipe of excess.
Inspect Dive belt and idler pulleys for wear and running in the center of
the pulleys.
Inspect Case Transfer linear rail and (2) bearing cassettes for wear. Clean
and lubricate, wipe off excess.
Inspect (2) barrel prox switches for damage and proper position.

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Specifications
No leaks, securely mounted and airlines routed properly. Clean and
lubricated.
No wear on drive belt and idler pulleys.
Linear rails and bearings have no wear, clean and lubricated..
No damage and proper position.

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Inspection Point ? Case Erecting Arm MS9

Description
The Case Erecting Arm is a servo driven arm with several vacuum cups that will move to
the vertical to capture the blank case from the Sheet Lifter and open the case for bottom
flap folding. The arm is articulated in the center so that as the case is unfolded the top
portion will support the downstream minor while the rest of the arm supports the lower
major flap. The arm will continue to support the case in this way until the bottom flaps
have been folded. There are two air cylinders associated with this arm one that
articulates the arm, it is called Sheet Tilting Head (Y308). The other air cylinder is called
Sheet Tilting (Y307) and it aligns the arm to the case at pick up and insures it is flat when
the case gets to folding.
The servo drives the Erecting Arm through a large gearbox, a crank arm and connecting
rod. The Home prox for this servo is B226. The servo is used to allow for the speed
needed and the smooth control of the case transition.

Case Erecting Arm Case Erecting Arm Gearbox and Crank Arm

Sheet Tilting
Sheet Tilting Head
Home Prox
B226

Case Erecting Arm Sheet Tilting and Sheet Tilting Head Air Cylinders Home Prox B226

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Inspection

Inspect Erecting Arm pivot bearings for wear. Arm should not move when
pushed side to side.
Inspect servo motor, gearbox, crank arm and connecting rod for wear and
secure attachment.
Inspect all hardware for secure attachment.
Inspect vacuum cups for wear or tears. (8 cups). Inspect vacuum lines for
damage and proper routing.
Inspect air cylinders (Sheet Tilting and Sheet Tilting Head) for air leaks,
air lines routed properly and secure mounting. Inspect pivot bearings on
Tilting head for wear.
Inspect Home barrel prox switch for damage and proper position.

Specifications
No wear on pivot bearing.
No wear on gearbox, crank arm and connecting rod.
All hardware secure.
No wear or cracks in vacuum cups.
No leaks and airlines routed properly. Pivot bearings in good condition.
Home prox has no damage and is in proper location.

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Inspection Point ? Minor Flap Pusher

Description
During the bottom flap closing the machine will capture the top flaps of the case so that
the flaps are open when the case finally gets to case loading. One of the devices used is
the Minor Flap Pusher. This pusher will push the downstream minor flap in to the open
position prior to the case transfer moving the case to the Case Pusher.

Minor Flap Pusher

Inspection

Inspect hinge joint for wear.

Inspect air cylinder for air leaks, air lines routed properly and secure
mounting.
Inspect rod clevis for wear.

Specifications
No wear.
No leaks and airline properly routed.
No wear in clevis.

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Inspection Point ? Case Clamp

Description
During the bottom flap closing the machine will capture the top flaps of the case so that
the flaps are open when the case finally gets to case loading. An arm is used as a back
stop for the upper major flap when the Major Flap opener completes its task. A single air
cylinder is used to drop the arm and raise it again after the case has been transferred by
the Case Transfer.

Case Clamp

Inspection

Inspect hinge joint for wear.

Inspect air cylinder for air leaks, air lines routed properly and secure
mounting.
Run unit and insure clamp is not banging up or down. Adjust flow
controls as necessary.
Inspect rod clevis for wear.

Specifications
No wear.
No leaks and airline properly routed.
Smooth operation of arm.
No wear in clevis.

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Inspection Point ? Major Flap Opener

Description
During the bottom flap closing the machine will capture the top flaps of the case so that
the flaps are open when the case finally gets to case loading. The upper major flap is
opened with three separate air Cylinders and associated components. First the Major
Flap Opener Turning cylinder will rotate the Major Flap Opener Shift from pointing
down to 90 degrees facing the case. At almost the same time the Major Flap Vertical
cylinder will raise the entire component straight up lifting the major flap. Then the Major
Flap Opener Shift will fire pushing the major flap against the Case Clamp mentioned
earlier. These cylinders will remain in this position until the Case Transfer has moved
the case to the Case Pusher.

*Major Flap Vertical Air Cylinder

*Major Flap Opener Turning Air

Cylinder

*Major Flap Opener Shift Air Cylinder

Minor Flap Pusher

*Major Flap Vertical Flow Controls

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Inspection

Major Flap Vertical Air Cylinder

 Inspect air cylinder for air leaks, air lines routed properly
and secure mounting.
 Inspect linear bearing rails and two cassettes for wear.
Clean and lubricate.
Major Flap Opener Turning Air Cylinder
 Inspect air cylinder for leaks, air lines routed properly.
 Inspect hinge for wear.
 Inspect rod clevis for wear.
Major Flap Opener Shift Air Cylinder
 Inspect air cylinder for leaks, air lines routed properly.
 Inspect linear shafts in cylinder for wear. Clean and
lubricate with light oil and wipe off excess.
 Inspect hardware for secure attachment.

Specifications
No leaks and airline properly routed.
Linear bearings clean and lubricated.
No wear on hinges or clevis.
Linear shafts clean and lubricated.
All hardware secure.

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Inspection Point ? Sheet Detect Photo Eye B227

Description
The Sheet Detect Photo eye is directly below the Case Erecting Arm. It points up
looking for a blank case at the bottom fan folding area. If no case is present when it is
supposed to be a fault will display. This photo eye is a diffused style and must be
calibrated to about 6” sensing distance.

Sheet Detect Photo Eye B277

Inspection

Inspect photo eye for secure mounting

Clean lens and calibrate to 6” from face.
Inspect cables for proper routing.

Specifications
Securely mounted.
Clean and calibrated.
Cables properly routed.

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Inspection Point ? Major Flap Bottom and Shift

Description
Prior to the fan folding of the bottom flaps two air cylinders and a metal hook are used to
retrieve the upper major flap. The hook is fired out and under the major flap, then the
Major Flap Bottom Shift will move the entire mechanism up carrying the major flap with
it. This hook will hold the upper major flap until the fan fold paddles begin the fan fold.
The Major Flap Stopper Bottom is Y309 and the Shift air cylinder is Y310.

Major Flap Bottom Air Cylinder/Hook and Shift Air Cylinder

Inspection

Inspect hook and mounting hardware for wear and secure attachment.
Inspect air cylinders for air leaks, air lines routed properly and secure
mounting.
Inspect Shift air cylinder linear rods for wear. Clean and lubricate with
light oil, wipe off excess.
Inspect pivot and clevis for wear.

Specifications
No wear and securely attached.
No leaks and airline properly routed.
No wear on linear rods. Clean and lubricated.
No wear in pivot or clevis.

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Inspection Point ? Bottom Flap Pusher

Description
After bottom flap closing an air cylinder and scissor mechanism will extend a sheetmetal
plate that insures the bottom flaps are completely folded.

Bottom Flap Pusher

Inspection

Inspect scissor joints for wear.

Inspect air cylinder for air leaks, air lines routed properly and secure
mounting.
Inspect all hardware for secure attachment.
Inspect air cylinder linear rods for wear. Clean and lubricate with light oil,
wipe off excess.

Specifications
No wear.
No leaks and airline properly routed.
Hardware secure.
No wear on linear rods, clean and lubricated.

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Inspection Point ? Case Erecting Case Pusher

Description
The Case Erecting Case Pusher is a large sheetmetal plate that takes the bottom folded
case from the Case Transfer and moves it to the outboard side of the machine so that it
will line up with the case loading section. It is air cylinder driven and is suspended off
two linear shafts and two large bearings. One air cylinder moves the Pusher and thus
moving the case to the loading area. The Pusher has two shocks at either end of its travel
to dampen the motion.

Case Erecting Pusher

Inspection

Inspect linear shaft and bearings for wear. Clean and lubricate.
Inspect air cylinder for air leaks, air lines routed properly and secure
mounting.
Inspect two shock dampers for proper operation and proper position. Air
cylinder should not bottom out.

Specifications
No wear, clean and lubricated.
No leaks and airline properly routed.
Shock dampers working and set correctly.

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Inspection Point ? Lower Flap Pusher

Description
The Case Pusher has two additional air cylinders mounted on the pusher. One is the
Lower Flap Pusher, this air cylinder and sheetmetal panel will move in to the vertical to
support the lower major flap during the pusher’s movement of the case to case loading.

Case Pusher Lower Flap Pusher

Inspection

Inspect hinge joint for wear, and sheetmetal structure for damage.
Inspect air cylinder for air leaks, air lines routed properly and secure
mounting.
Inspect rod clevis for wear.

Specifications
No wear.
No leaks and airline properly routed.
No wear in clevis.

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Inspection Point ? Minor Flap Holding

Description
The Case Pusher has two additional air cylinders mounted on the pusher. Another air
cylinder is the Minor Flap Holding, this air cylinder and sheetmetal panel will move
parallel to the Case Pusher to support the upstream minor flap during the pusher’s
movement of the case to case loading.

Minor Flap Holding

Inspection

Inspect hinge joint for wear.

Inspect air cylinder for air leaks, air lines routed properly and secure
mounting.
Inspect rod clevis for wear.

Specifications
No wear.
No leaks and airline properly routed.
No wear in clevis.

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Inspection Point ? Case Erecting Case Stopper

Description
The Case Erecting Case stopper is located directly above Case Loading, it is used to hold
the case in position as the case pusher pushes the case in to position for dropping to case
loading and holds the case in place prior to dropping to case loading.

Case Erecting Case Stopper

Inspection

Inspect sheetmetal stopper for damage.

Inspect air cylinder for air leaks, air lines routed properly and secure
mounting.
Inspect air cylinder linear rods for wear. Clean and lubricate with light oil
and wipe off excess.

Specifications
No damage.
No leaks and airline properly routed.
No wear n linear rods, clean and lubricated.

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Inspection Point ? Case Drop Pusher

Description
The Case Drop Pusher is a long air cylinder that has a round aluminum pad attached at
the end of the cylinder. This cylinder insures that the case has dropped to case loading
and did not get stuck somewhere in between.

Case Drop Pusher

Inspection

Inspect round aluminum plate for secure mounting.

Inspect air cylinder for air leaks, air lines routed properly and secure
mounting.

Specifications
Securely mounted.
No leaks and airline properly routed.

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Inspection Point ? Case Drop Gate

Description
The Case Drop Gate is two air cylinders being controlled from one solenoid. These gates
are directly above the case loading and hold the erected case until it is needed for loading.

Case Drop Gate

Inspection

Inspect sheetmetal gates for damage and for secure mounting. Gates
should be level when closed.
Inspect air cylinders for air leaks, air lines routed properly and secure
mounting.
Inspect hinge points and rod end clevis for wear.

Specifications
No damage and securely mounted.
No leaks and airline properly routed.
No wear in hinges or rod ends.

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Inspection Point ? Shutter Length Adjust MT5

Description
The Shutter is an air cylinder driven plate that will move in to the case being
loaded to assist with the placement of the bags in to the case. The shutter also is used to
compress the bags that are already in the case. This is accomplished by retracting the
shutter once the row is in the case, the case elevator then drops to a lower position and
the shutter extends again in to the case. With the shutter in the case the case elevator will
rise again and the bags that are below the shutter will be slightly compressed.
A rodless air cylinder is used to extend the shutter and the shutter is carried on two linear
bearing rails and four bearing cassettes.

Shutter Shutter Air Cylinder and Bearing Rails

Inspection

Inspect Shutter structure for damage or signs of rubbing.

Inspect rodless air cylinder for leaks and wear.
Inspect two linear rails and four bearing cassettes for wear. Clean and
lubricate.

Specifications
No damage or signs of rubbing.
No leaks or wear.
No wear on linear rails or bearing cassettes, clean and lubricated.

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Ishida Global Universal Auto Case Packer PM Training Manual

Chapter 3 – Bag Sorting

Component Overview
The Bag Sorting section consists of a Infeed Conveyor, Bag Turning, Decline, Sort Belts
1-3 and Compress Conveyor.

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Inspection Point ? Bag Infeed Round Belting

Description

The Bag Infeed Round Belting is a short section prior to the infeed belt. The
purpose for this section is to eliminate any chips that may have gotten past the Ishida
Inspector. By removing the chips, the GUACP will stay cleaner internally.

Bag Infeed Round Belt

Inspection
Visually inspect belts for wear and proper tracking.
Inspect Tail Shaft for wear and smooth operation. Check internal bearings
for play or wear (2).
Inspect drive shaft for wear and smooth operation. Check internal bearings
for play or wear (2).
Inspect drive belt and pulleys for wear and tightness. Ensure belt is
running in center of pulleys.

Specifications

Belts in good repair

No wear on shafts and bearings in good condition.
Drive belt and pulleys are in good condition and centered..

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Inspection Point ? Bag Infeed Incline Belt MD1

Description

The Bag Infeed Incline Belt is driven by a DC Brushless motor. Power from the motor is
transferred to the Bag Infeed Incline drive shaft by a timing belt and pulleys. This motor
also powers the Bag Infeed Round Belting Section.

Bag Infeed Incline Belt

Inspection Procedure

Visually inspect belt for wear fraying, holes, and tears. Visually inspect belt
vulcanized splice for damage.
Inspect Tail Shaft for wear and smooth operation. Check bearings for play or
wear (2).
Inspect drive shaft for wear and smooth operation. Check bearings for play or
wear (2).
Inspect Belt for tracking.
Inspect drive belt and pulleys for wear.
Inspect belt for proper tracking. Belt should ride in the center of all pulleys.
Inspect drive motor for vibration and overheating.
Inspect electrical wiring for damage and proper routing.

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Specifications

Belt is in good repair

No wear on shafts and bearings in good condition.
Belt is tracking on center of shafts.
No wear or damage on belt or pulleys.
Drive belt is tracking properly.
Motor is smooth and running cool.
No damage to electrical wiring.

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Inspection Point ? Infeed Jam Detect Photo Eye B1011

Description
The Infeed Jam Detect Photo Eye is used to detect any bags stuck in this location. If a
bag is stuck a fault will result and the machine will shut down. The operator will have to
clear the bags, reset and restart the machine.

Infeed Jam Detect Photo Eye

Inspection Procedure

Inspect photo eyes for secure mounting

Inspect cable for proper routing so that bags do not catch on the cable.
Clean photo eye and reflector with clean soft cloth.

Specifications

Secure mounted.
Properly routed.
Clean.

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Inspection Point ? Bag Infeed Conveyor MD1

Description
The Bag Infeed Belt is driven by a DC Brushless motor. Power from the motor is
transferred to the Bag Infeed drive shaft by a timing belt and pulleys. The Incline and
Infeed share the same DC motor MD1.

Bag Infeed Conveyor

Inspection Procedure

Visually inspect belt for wear fraying, holes, and tears. Visually inspect belt
vulcanized splice for damage.
Inspect Tail Shaft for wear and smooth operation. Check bearings for play or
wear (2).
Inspect drive shaft for wear and smooth operation. Check bearings for play or
wear (2).
Inspect Belt for tracking.
Inspect drive belt and pulleys for wear.
Inspect belt for proper tracking. Belt should ride in the center of pulleys.
Inspect drive motor for vibration and overheating.
Inspect electrical wiring for damage and proper routing.

Specifications

Belt is in good repair

No wear on shafts and bearings in good condition.
Belt is tracking on center of shafts.
No wear or damage on belt or pulleys.
Dive belt is tracking properly.
Motor is smooth and running cool.
No damage to electrical wiring.

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Inspection Point ? Infeed Inner Side Belt MD3

Description

The Bag Infeed Inboard Side Guide belt is driven by a DC Brushless motor. Power from
the motor is transferred to the Bag Infeed Inboard Side Guide drive shaft by a timing belt
and pulleys. This guide a can be moved in and out based on the bag size being run.

Infeed Inner Side Belt

Inspection Procedure

Visually inspect belt for wear fraying, holes, and tears. Visually inspect belt
vulcanized splice for damage.
Inspect Tail Shaft for wear and smooth operation. Check bearings for play or
wear (2).
Inspect drive shaft for wear and smooth operation. Check bearings for play or
wear (2).
Inspect Belt for tracking.
Inspect drive belt and pulleys for wear.
Inspect belt for proper tracking. Belt should ride in the center of all pulleys.
Inspect drive motor for vibration and overheating.
Inspect electrical wiring for damage and proper routing.

Specifications

Belt is in good repair

No wear on shafts and bearings in good condition.
Belt is tracking on center of shafts.
No wear or damage on belt or pulleys.
Dive belt is tracking properly.
Motor is smooth and running cool.
No damage to electrical wiring.

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Inspection Point ? Inner Side Belt Width Adjust MT1

Description
The GUACP can accommodate several different size bags, thus the inner side belt
needs to be moveable to accommodate the different bags. This movement is based on a
value entered in to the recipe for the bag size being run. The movement is driven by one
stepper motor that is equipped with a photo interrupter that counts the rotation of the
screw shaft and thus can be accurately moved to the desired location (B1004). The motor
also has an additional photo interrupter to establish a Home position (B1003). As the
GUACP is started, or after a recipe change, the stepper motors will move the Inner Side
Belt to its narrowest position until the Home photo interrupter is made. Once the Home
is established the Inner Side Belt will move the proper number of counts to achieve the
recipe position.

Inner Side Belt Adjust

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screws with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect fasteners attaching Inner Side Belt to moveable carriage for secure
attachment.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
All fasteners are tight and secure.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point 7 Outer Side Belt MD2

Description

The Outer Side Belt is driven by a DC Brushless motor. Power from the motor is
transferred to the Bag Infeed Outboard Side Guide drive shaft by a timing belt and
pulleys.

Outer Side Belt

Inspection Procedure

Visually inspect belt for wear fraying, holes, and tears. Visually inspect belt
vulcanized splice for damage.
Inspect Tail Shaft for wear and smooth operation. Check bearings for play or
wear (2).
Inspect drive shaft for wear and smooth operation. Check bearings for play or
wear (2).
Inspect Belt for tracking.
Inspect drive belt and pulleys for wear.
Inspect belt for proper tracking. Belt should ride in the center of all pulleys.
Inspect drive motor for vibration and overheating.
Inspect electrical wiring for damage and proper routing.

Specifications

Belt is in good repair

No wear on shafts and bearings in good condition.
Belt is tracking on center of shafts.
No wear or damage on belt or pulleys.
Dive belt is tracking properly.
Motor is smooth and running cool.
No damage to electrical wiring.

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Inspection Point ? Outer Side Belt Width Adjust MT2

Description
The GUACP can accommodate several different size bags, thus the outer side belt
needs to be moveable to accommodate the different bags. This movement is based on a
value entered in to the recipe for the bag size being run. The movement is driven by one
stepper motor that is equipped with a photo interrupter that counts the rotation of the
screw shaft and thus can be accurately moved to the desired location (B1006). The motor
also has an additional photo interrupter to establish a Home position (B1005). As the
GUACP is started, or after a recipe change, the stepper motors will move the Outer Side
Belt to its widest position until the Home photo interrupter is made. Once the Home is
established the Outer Side Belt will move the proper number of counts to achieve the
recipe position.

Outer Side Belt Adjust

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screws with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect fasteners attaching Inner Side Belt to moveable carriage for secure
attachment.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
All fasteners are tight and secure.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Decline Height Adjust MT3

Description

The Decline discharge is adjusted up and down to ensure the proper shingling of
bags on the sort conveyor. This movement is based on a value entered in to the recipe for
the bag size being run. The movement is driven by one stepper motor that is equipped
with a photo interrupter that counts the rotation of the screw shaft and thus can be
accurately moved to the desired location (B1008). The motor also has an additional
photo interrupter to establish a Home position (B1007). As the GUACP is started, or
after a recipe change, the stepper motors will move the Decline Height to its highest
position until the Home photo interrupter is made. Once the Home is established the
Decline Height will move the proper number of counts to achieve the recipe position.

Decline Height Adjustment

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screws with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect fasteners attaching Decline to moveable carriage for secure
attachment.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
All fasteners are tight and secure.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Side Guide

Description

The Side Guide Adjust is located on the Decline Conveyor and is used to guide the bags
off the end of the Decline Conveyor. The Side Guide is moved with a Stepper Motor and
jack screw. The weight of the Side Guide is carried on two linear guides.

Side Guide

Inspection Procedure

Inspect Entire Side Guide mechanism for loose hardware and proper position.
Inspect two guide rods for wear and lubricate

Specifications

No loose hardware.
No wear and lubricated.

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Inspection Point ? Side Guide Width Adjust MT4

Description

The Side Guide is located at the Decline and is moved to accommodate different
size bags. This movement is based on a value entered in to the recipe for the bag size
being run. The movement is driven by one stepper motor that is equipped with a photo
interrupter that counts the rotation of the screw shaft and thus can be accurately moved to
the desired location (B1010). The motor also has an additional photo interrupter to
establish a Home position (B1009). As the GUACP is started, or after a recipe change,
the stepper motors will move the Side Guide to its widest position until the Home photo
interrupter is made. Once the Home is established the Side Guide will move the proper
number of counts to achieve the recipe position.

Side Guide Width Adjust

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screws with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect fasteners attaching Decline to moveable carriage for secure
attachment.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
All fasteners are tight and secure.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Decline PE

Description

The Decline PE does the final count of bags prior to the bags making it to the case. This
photo eye is a Keyence that allows product to pass without counting it as a bag. This is
accomplished by setting the proper threshold in the PE controller.

Decline PE Decline PE Controller Threshold @ 58

Inspection Procedure

Inspect photo eyes for secure mounting

Inspect Emitter and collector for proper position and operation.
Clean emitter and collector with clean soft cloth.

Specifications

Secure mounted
Aligned
Clean.

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Inspection Point ? Bag Rotation Assist Pusher

Description

The Bag Rotation Assist Pusher is an air cylinder driven plate that is designed to help the
rotating of the bags. It is fired after PE B1012 sees the bag.

Bag Rotate Assist Pusher

Inspection Procedure

Inspect structure for damage and secure attachment.

Inspect air cylinder and airlines for leaks.
Inspect hinge for wear.
Inspect prox switches for secure mounting and proper position.
Inspect cables for damage and proper routing.

Specifications

Securely mounted.
No leaks.
No wear in hinge.
Proper position and securely mounted.
Wiring secure and routed properly.

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Inspection Point ? Bag Rotation Assist Photo Eye B1012

Description

The Bag Rotation Assist Photo Eye is a diffused photo eye. The photo eye is used to fire
the Bag Rotation assist if: 1.) The bag length is greater than 6.5” (16.5mm). 2.) If the
ration of width of bag and length of bag exceeds 1.9. 3.) Only used if bag speed is less
than 80 BPM.

Bag Rotation Assist PE

Inspection Procedure

Inspect mounting of photo eye for secure attachment.

Clean sensor with soft clean cloth.
Calibrate sensor

Specifications

Securely mounted
Clean
Calibrated

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Inspection Point ? Sort Conveyor #1 MS1

Description

The Sort Conveyor #1 receives the bags from the Decline and is servo driven so that bags
can be shingled properly. This conveyor also can be tilted in to 4 different tilt heights.
The tilting is accomplished with two air cylinders and a crank arm. There are four prox
switches to confirm movement of cylinders. B601 for up, B602 for down on
Y701…B603 for up, B604 for down on Y702.

Flat/Tilt Y701
Flat/Tilt
Y702

Sort Conveyor #1 Sort Conveyor Tilt Air Cylinders

Inspection Procedure
Visually inspect belt for wear fraying, holes, and tears. Visually inspect belt
vulcanized splice for damage.
Inspect Tail Shaft for wear and smooth operation. Check bearings for play or
wear (2).
Inspect drive shaft for wear and smooth operation. Check bearings for play or
wear (2).
Inspect Belt for tracking.
Inspect Servo for secure mounting.
Inspect wiring for damage and proper routing.
Inspect timing belts and pulleys for wear or damage.
Insure timing belts are running in center of pulleys.
Inspect belt tension, belt must be very snug.
Inspect air cylinder and airlines for leaks.
Clean cylinder rod
Inspect all mounting hardware
Inspect pivot point for wear and free movement
Inspect prox switches for secure mounting.
Inspect cable for damage and proper routing.

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Specifications
Belt is in good repair
No wear on shafts and bearings in good condition.
Belt is tracking on center of shafts.
Servo mounting secure.
Wiring not damaged and routed properly
No wear on drive belt or pulleys.
Belts tensioned proper with no wear or damage.
Belts running in center of pulleys.
No leaks in cylinder and air lines
Cylinder clean
All mounting hardware secure
No wear and free movement
Secure mounted
Wiring secure and routed properly.

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Inspection Point ? Sort Conveyor #2 MS2

Description

The Sort Conveyor #2 receives the bags from the Sort Conveyor #1 and is servo driven so
that bags that have been shingled on Sort Conveyor #1 can remain shingled.

Sort Conveyor #2

Inspection Procedure

Visually inspect belt for wear fraying, holes, and tears. Visually inspect belt
vulcanized splice for damage.
Inspect Tail Shaft for wear and smooth operation. Check bearings for play or
wear (2).
Inspect drive shaft for wear and smooth operation. Check bearings for play or
wear (2).
Inspect Belt for tracking.
Inspect Servo for secure mounting.
Inspect wiring for damage and proper routing.
Inspect timing belts and pulleys for wear or damage.
Insure timing belts are running in center of pulleys.
Inspect belt tension, belt must be very snug.

Specifications
Belt is in good repair
No wear on shafts and bearings in good condition.
Belt is tracking on center of shafts.
Servo mounting secure.
Wiring not damaged and routed properly
No wear on drive belt or pulleys.
Belts tensioned proper with no wear or damage.
Belts running in center of pulleys.

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Inspection Point ? Sort Conveyor #3 MS3

Description
The Sort Conveyor #3 receives the bags from the Sort Conveyor #2 and is servo driven so
that bags that have been shingled on Sort Conveyor #1 and #2 can remain shingled. This
conveyor is also where the shingled bags are moved to the Bag Loading section.

Sort Conveyor #3

Inspection Procedure

Visually inspect belt for wear fraying, holes, and tears. Visually inspect belt
vulcanized splice for damage.
Inspect Drive and Idler Shafts for wear and smooth operation. Check bearings for
play or wear (4).
Inspect Belt for tracking.
Inspect Servo for secure mounting.
Inspect wiring for damage and proper routing.
Inspect timing belts and pulleys for wear or damage.
Insure timing belts are running in center of pulleys.
Inspect belt tension, belt must be very snug.

Specifications
Belt is in good repair
No wear on shafts and bearings in good condition.
Belt is tracking on center of shafts.
Servo mounting secure.
Wiring not damaged and routed properly
No wear on drive belt or pulleys.
Belts tensioned proper with no wear or damage.
Belts running in center of pulleys.

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Inspection Point ? Compress Conveyor MD4

Description
The Compress Conveyor is part of Sort Conveyor #3. It is used to compress the row of
bags prior to entering the Load Section. This motion is associated with the bags being
shingled in to an up position also. The compress conveyor uses two air cylinders to
perform the compress. Depending on the case pack one or both cylinders are used. As
sort conveyor three brings bags to the load head area they are shingled but slightly spread
out. The compress conveyor will compress the bags against the Rear End Guide doors
prior to the slider pushing the bags in to the case.

Compress Conveyor Compress Conveyor Air Cylinders

Compress Conveyor

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Inspection Procedure

Visually inspect belt for wear fraying, holes, and tears. Visually inspect belt
vulcanized splice for damage.
Inspect Drive and Idler Shafts for wear and smooth operation. Check bearings for
play or wear (4).
Inspect Belt for tracking.
Inspect DC motor for secure mounting.
Inspect wiring for damage and proper routing.
Inspect timing belts and pulleys for wear or damage.
Insure timing belts are running in center of pulleys.
Inspect belt tension, belt must be snug.
Inspect UHMW plow for secure mounting, wear or damage.
Inspect air cylinders and air lines for leaks
Inspect mounting of air cylinders to Compress conveyor.
Inspect linear shafts and bearings for wear. Clean and lubricate.

Specifications
Belt is in good repair
No wear on shafts and bearings in good condition.
Belt is tracking on center of shafts.
Servo mounting secure.
Wiring not damaged and routed properly
No wear on drive belt or pulleys.
Belts tensioned proper with no wear or damage.
Belts running in center of pulleys.
No wear or damage.
No leaks
Securely mounted to conveyor.
No wear, clean and lubricated.

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Inspection Point ? Compress Conveyor Adjust MT15

Description

The GUACP is designed to handle many different case sizes thus the Compress
Conveyor must be capable of adjust its position from small cases to large case sizes. This
movement is based on a value entered in to the recipe for the case pack being run. The
movement is driven by one stepper motor that is equipped with a photo interrupter that
counts the rotation of the screw shaft and thus can be accurately moved to the desired
location (B656). The motor also has an additional photo interrupter to establish a Home
position (B655). As the GUACP is started, or after a recipe change, the stepper motors
will move the Compress Conveyor to its widest position until the Home photo interrupter
is made. Once the Home is established the Compress Conveyor will move the proper
number of counts to achieve the recipe position.

Compress Conveyor Adjust

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screws with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect fasteners attaching Compress Conveyor to moveable carriage for
secure attachment.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
All fasteners are tight and secure.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point 21 Rear End Guides

Description
The Rear End Guides are Lexan doors that will close to contain the shingled bags in the
load area. Two air cylinders are used both fed from a single solenoid valve (Y703).

Rear End Guide Short Cylinder

Inspection Procedure
Inspect Lexan doors and structure for damage and secure attachment.
Inspect two air cylinders and airlines for leaks.
Inspect prox switches for secure mounting.
Inspect cables for damage and proper routing.

Specifications

Securely mounted.
No leaks.
Secure mounted
Proper position
Wiring secure and routed properly.

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Inspection Point 22 Slider MS5

Description

The Slider is used to push the bags in to the case after being shingled and compressed A
servo is used to move the slider for speed and control of position. The Slider is suspended
on two large linear rails and four linear bearing cassettes. A photo interrupter is used for
the home position of the slider servo (B1016), there is also an over limit photo interrupter
(B1015).

Slider Servo

Inspection Procedure

Inspect Servo for secure mounting.

Inspect wiring for damage and proper routing.
Inspect timing belts and pulleys for wear or damage.
Insure timing belts are running in center of pulleys.
Inspect belt tension, belt must be snug.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

Specifications
Servo mounting secure.
Wiring not damaged and routed properly
No wear on drive belt or pulleys.
Belts tensioned proper with no wear or damage.
Belts running in center of pulleys.
No rubbing and clean.

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Inspection Point 23 Slider Width Adjust MT6

Description

The Slider Plate is designed to handle many different case sizes thus the slider must be
capable of adjust its width from small cases to large case sizes. This movement is based
on a value entered in to the recipe for the case pack being run. The movements is driven
by one stepper motor that is equipped with a photo interrupter that counts the rotation of
the screw shaft and thus can be accurately moved to the desired location (B1017). The
motor also has an additional photo interrupter to establish a Home position (B1016). As
the GUACP is started, or after a recipe change, the stepper motors will move the Slider
Width to its narrowest position until the Home photo interrupter is made. Once the Home
is established the Slider Width will move the proper number of counts to achieve the
recipe position.

Slider Width Adjust

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screws with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect fasteners attaching Slider to moveable carriage for secure
attachment.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
All fasteners are tight and secure.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Upstream Bag Loading and Downstream Bag

Loading Photo Eyes B613/B614
Description

The two photo eyes perform the same function. If a bag has become separated from the
shingled row and it blocks either photo eye sort conveyor #3 will run a little longer to
attempt to clear the bag in to the load area. If the recovery attempt does not clear the
photo eyes the machine will fault.

Upstream/Downstream Bag Loading Photo Eyes

Inspection Procedure

Inspect photo eyes for secure mounting

Inspect photo eyes and reflectors for proper position and operation.
Clean photo eyes and reflectors with clean soft cloth.

Specifications

Secure mounted
Aligned
Clean.

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Chapter 4 – Case Loading

Component Overview
The Case Loading section consists of a Case Loading Guide, Shutter, and Slider..

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Inspection Point ? Case Loading Guide Position Adjust MT7

Description
The GUACP can accommodate several different sizes of cases thus the loading
for these cases must be variable. The Case Loading guides are moved in or out based on
the major length of the case. This movement is based on a value entered in to the recipe
for the case pack being run. The movement is driven by one stepper motor that is
equipped with a photo interrupter that counts the rotation of the screw shaft and thus can
be accurately moved to the desired location (B1035). The motor also has an additional
photo interrupter to establish a Home position (B1034). As the GUACP is started, or
after a recipe change, the stepper motors will move the Case Loading Guides to its
narrowest position until the Home photo interrupter is made. Once the Home is
established the Case Loading Guides will move the proper number of counts to achieve
the recipe position.

Case Loading Guide Position Adjust

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screws with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect fasteners attaching Case Loading Guide to moveable carriage for
secure attachment.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
All fasteners are tight and secure.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Case Receiving Gate

Description
The Case Receiving Gates are two air cylinders being controlled from one solenoid
(Y707). These gates are located at case loading and hold the erected case until it begins
to fill. Once the case starts to fill the gates will retract and allow the Case Loading
Guides and Case Elevator to manage the position of the case.

Case Receiving Gates

Inspection

Inspect sheetmetal gates for damage and for secure mounting. Gates
should be level when closed.
Inspect air cylinders for air leaks, air lines routed properly and secure
mounting.
Inspect hinge points and rod end clevis for wear.

Specifications
No damage and securely mounted.
No leaks and airline properly routed.
No wear in hinges or rod ends.

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Inspection Point ? Case Loading Guides

Description
The Case Loading Guides are two air cylinders being controlled from one solenoid
(Y710). These guides are located at case loading and guide the case while the case is on
the Case Elevator and is being loaded.

Case Loading Guides

Inspection

Inspect sheetmetal guides for damage and for secure mounting. Guides
should be flush when closed.
Inspect air cylinders for air leaks, air lines routed properly and secure
mounting.
Inspect hinge points and rod end clevis for wear.

Specifications
No damage and securely mounted.
No leaks and airline properly routed.
No wear in hinges or rod ends.

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Inspection Point ? Case Loading Case Pusher

Description
The Case Loading Pushers are two air cylinders being controlled from one solenoid
(Y708). These guides are located at case loading and move the case in to the load head
for loading. The case is held tight to the load head during loading.

Case Loading Pusher Right Side Shown

Inspection

Inspect sheetmetal guides for damage and for secure mounting.

Inspect air cylinders for air leaks, air lines routed properly and secure
mounting.
Inspect linear rods for wear. Clean and lubricate with light oil, wipe off
excess.

Specifications
No damage and securely mounted.
No leaks and airline properly routed.
No wear, clean and lubricated..

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Inspection Point ? Case Flap Holder

Description
The Case Flap Holders are two air cylinders being controlled from one solenoid (Y709).
These guides are located at case loading and guides the case flaps as the case is moved in
to the load head.

Case Flap Holder Right Case Flap Holder Left

Inspection

Inspect sheetmetal guides for damage and for secure mounting.

Inspect air cylinders for air leaks, air lines routed properly and secure
mounting.
Inspect linear rods for wear. Clean and lubricate with light oil, wipe off
excess.

Specifications
No damage and securely mounted.
No leaks and airline properly routed.
No wear, clean and lubricated..

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Inspection Point ? Major Flap Assist

Description
The Major Flap Assist is one air cylinder that is part of the case loading and is integral to
the Case Flap Holder on the right side of the load area. It moves the right Case Flap
Holder downstream as the case is introduced to the load area. By doing this the top flaps
are controlled for loading. (Y734). .

Major Flap Assist

Inspection

Inspect sheetmetal guide for damage and for secure mounting.

Inspect air cylinder for air leaks, air lines routed properly and secure
mounting.
Inspect linear rods for wear. Clean and lubricate with light oil, wipe off
excess.

Specifications
No damage and securely mounted.
No leaks and airline properly routed.
No wear, clean and lubricated.

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Inspection Point ? Case Elevator MS4

Description
The Case Elevator is used to hold the case while loading and to move the case up
or down to accommodate different rows in the case. It is servo driven and the motion is
through a ball screw. The elevator moves very fast and quite often, it is imperative that
the components are kept clean and serviced regularly. There are six vacuum cups on the
elevator to assist in holding the case during loading. The metal plate around the vacuum
cups is spring loaded to compensate for irregular cases. Home prox is B629.

Case Elevator

Inspection

Inspect Screw shaft and ball nut for wear. Wipe off any build up on face of
nut and screw. Lubricate screws with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect fasteners attaching Case Elevator to moveable carriage for secure
attachment.
Inspect Home prox switch for damage and proper position.
Inspect drive belt and pulleys for wear or damage. Belt should ride in the
center of the pulleys.

Specifications
No wear on screw shaft or ball nut, lubricated and clean.
No wear on linear shafts, clean and lubricated.
All fasteners are tight and secure.
No damage and proper position
No wear or damage to belt and centered in pulleys..

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Inspection Point ? Case Rotation Long and Short Cylinders

Description
The Case Elevator rotates the filled case from horizontal to vertical with two air cylinders
mounted on each side of the elevator, for a total of four cylinders. The two long
cylinders are controlled by one solenoid (Y711) and the two short cylinders are
controlled by one solenoid (Y712). This combination of cylinders is used to gently roll
the case to vertical so that bags do not get dislodged.

`
Case Rotation Cylinders

Inspection

Inspect pivot points for wear.

Inspect air cylinders for air leaks, air lines routed properly and secure
mounting.
Inspect all mounting hardware for secure attachment.

Specifications
No wear in pivots.
No leaks and airline properly routed.
Hardware secure..

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Inspection Point ? Shutter Length Adjust MT5

Description
The GUACP can accommodate several different sizes of cases thus the loading
for these cases must be variable. The Shutter is moved in or out based on the major
length of the case. This movement is based on a value entered in to the recipe for the
case pack being run. The movement is driven by one stepper motor that is equipped with
a photo interrupter that counts the rotation of the screw shaft and thus can be accurately
moved to the desired location (B618). The motor also has an additional photo interrupter
to establish a Home position (B617). As the GUACP is started, or after a recipe change,
the stepper motor will move the Shutter Length to its narrowest position until the Home
photo interrupter is made. Once the Home is established the Shutter will move the proper
number of counts to achieve the recipe position.

Shutter Length Adjust

Inspection

Inspect Screw shafts and bronze nut for wear. Wipe off any build up on
face of nut. Lubricate screws with grease and wipe off excess. (The
Shutter guard will need to be removed to service this.)
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect fasteners attaching Shutter to moveable carriage for secure
attachment.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications

No wear on screw shaft or bronze nut, lubricated and clean.

No wear on linear shaft, clean and lubricated.
All fasteners are tight and secure.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Chapter 5 – Case Closing

The Ishida GUACP receives cases from the case erecting section; once the case has been
filled it moves to the case closing area.

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Inspection Point ? Case Conveyor MS6

Description

The Filled cases move through the case closing section by being pulled on a two rubber
flighted belts with lugs attached at specific intervals. The conveyor is powered by a servo
because of the precise positioning required to accomplish top flap folding. The case
conveyor receives the filled case from the Case Loading Case Pusher. The Case
Conveyor servo requires a home signal and this is done with a photo eye. It looks for a
flight and once it is seen, the conveyor is homed. (B641).

B641

Case Conveyor

Inspection Procedure

Inspect rubber belt and flights for secure attachment and no damage.
Inspect belts for wear and running in center of pulleys.
Inspect servo wiring for proper routing and no damage.
Inspect servo drive belt for wear and running in center of pulleys.
Inspect drive and idler shafts bearings for wear.
Inspect case conveyor home prox and flag for proper position.

Specifications

No damage and securely mounted.

No wear and aligned.
Properly routed and no damage.
Wiring secure and routed properly.
Drive belt not worn and aligned.
No wear in bearings.
Prox and flag in proper position.

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Inspection Point ? Case Closing Case Pusher

Description

After the filled case is discharged off the Case Elevator it is in a vertical position and
ready for top flaps closing. The case will be moved to the case conveyor by the Case
Closing Case Pusher (Y718). This air cylinder is a rodless air cylinder that has a small
sheetmetal plate attached that will catch the trailing minor edge of the case and push the
case to the case conveyor.

Case Closing Pusher Case Closing Pusher Rodless Air Cylinder

Inspection Procedure

Inspect air cylinder and airlines for leaks.

Inspect sheetmetal pusher for damage and wear.
Inspect linear rail and bearings cassettes for wear. Clean and lubricate.
Move pusher by hand looking for any binding.

Specifications

No leaks.
No damage or wear.
No wear, clean and lubricated.
No binding when moved

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Inspection Point ? Case Rotation Detect PE B653

Description

The Case Rotation Detect Photo Eye is a diffused photo eye. The photo eye is used to
sense when the case has been placed on the conveyor.

Case Rotation Detect PE

Inspection Procedure

Inspect mounting of photo eye for secure attachment.

Clean sensor with soft clean cloth.
Calibrate to 6”.
Inspect cables for proper routing.

Specifications

Securely mounted
Clean
Calibrated.
Properly routed.

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Inspection Point ? Case Base Plate

Description

After the filled case is discharged off the Case Elevator it is in a vertical position and
ready for top flaps closing. The case will be moved to the case conveyor by the Case
Closing Case Pusher. Another plate is involved in this push to the case conveyor; it is
called the Case Base Plate. The Case Base Plate will extend and support the inboard
bottom of the filled case while the pusher pushes the case.

Case Base Plate

Inspection Procedure

Inspect air cylinder and airlines for leaks.

Inspect sheetmetal for damage and wear.
Inspect linear shafts for wear. Clean and lubricate with light oil, wipe off excess.
Move Base Plate by hand looking for any binding.

Specifications

No leaks.
No damage or wear.
No wear, clean and lubricated.
No binding when moved

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Inspection Point ? Case Accept Pusher

Description

The Case Accept Pusher is wide open when the Case Elevator deposits the filled case to
the case closing area. Once the case is on the conveyor, the Case Accept Pusher will
push the case towards the center of the machine and against the inside conveyor rail. At
this time the Case Closing Pusher can push the case to the flighted conveyor. A single air
cylinder moves the pusher (Y719).

Case Accept Pusheer

Inspection Procedure

Inspect air cylinder and airlines for leaks.

Inspect air lines and cables for proper routing.
Inspect cylinder rod end clevis for wear.
Inspect (4) pivot bearings for wear and smooth motion.
Inspect pusher structure for damage and all hardware is secure.
Inspect actuator bearings and shaft for wear.
Inspect connecting linkage for secure mounting.

Specifications

No leaks.
Properly routed.
No wear.
No wear and smooth motion.
No damage and hardware is secure.
No wear on bearings or shaft..
Connect linkage secure.

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Inspection Point ? Inner Case Conveyor Height Adjust MD5

Description
The Case Conveyor will handle all case heights used by Frito-Lay/Sabritas/Walkers, etc.
thus the conveyor raises and lowers based on a recipe value. The Inner and Outer
conveyor halves are controlled and driven separately. The Inner Height Adjust has a
Low Limit prox (Home B647) and a prox to count pulses which translate to cm of height
(B645).
The mechanical portion is a chain wound over several of sprockets which drive screw
shafts. A DC motor is used to power this chain. The conveyor also has linear shafts and
bearings to support the weight and provide a stable platform for the conveyor.

Inner Case Conveyor DC Motor Inner Case Conveyor Screw Jack and Lower Limit

Inspection

Inspect screw jacks for wear. Clean and lubricate with light coat of grease.
Inspect linear shafts and bearings for wear. Clean and lubricate.
Inspect DC motor and cables for damage and cables are routed properly.
Inspect prox switches for secure mounting.
Inspect prox switch for signs of rubbing, misadjusted
Do Not lubricate chains.

Specifications

No wear, clean and lubricated.

No wear, clean and lubricated.
No damage and properly routed.
No rubbing and securely mounted

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Inspection Point ? Outer Case Conveyor Height Adjust MD6

Description
The Case Conveyor will handle all case heights used by Frito-Lay/Sabritas/Walkers, etc.
thus the conveyor raises and lowers based on a recipe value. The Inner and Outer
conveyor halves are controlled and driven separately. The Outer Height Adjust has a
Low Limit prox (Home B650) and a prox to count pulses which translate to cm of height
(B648). The outer also has a high limit prox (B649).
The mechanical portion is a chain wound over several of sprockets which drive screw
shafts. A DC motor is used to power this chain. The conveyor also has linear shafts and
bearings to support the weight and provide a stable platform for the conveyor.

Outer Case Conveyor DC Motor Outer Case Conveyor Low/High Limit

Inspection

Inspect screw jacks for wear. Clean and lubricate with light coat of grease.
Inspect linear shafts and bearings for wear. Clean and lubricate.
Inspect DC motor and cables for damage and cables are routed properly.
Inspect prox switches for secure mounting.
Inspect prox switches for signs of rubbing, misadjusted
Do Not lubricate chains.

Specifications

No wear, clean and lubricated.

No wear, clean and lubricated.
No damage and properly routed.
No rubbing and securely mounted

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Inspection Point ? Case Conveyor Guide Anti-Vibration

Description

The Outer Case Conveyor has a guide that extends to the Case Conveyor Accept Pusher.
This extension tends to move when it shouldn’t because of the distance without support.
A gear rack was added to stiffen this section while the machine is running. It is moved in
and out by a small air cylinder (Y720).

Case Conveyor Guide Anti-Vibration Rack

Inspection
Inspect air cylinder and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect gear rack for damage and secure mounting
Inspect prox switches for secure mounting.

Specifications

No leaks on cylinder or air lines

Properly routed.
No damage and securely mounted
Prox switches securely mounted..

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Inspection Point ? Case Conveyor Guide Adjust MT14

Description

The Case Conveyor is designed to handle many different case sizes thus the conveyor
must be capable of adjust its width from small cases to large case sizes. This movement is
based on a value entered in to the recipe for the case being run. The movements is driven
by one stepper motor that is equipped with a photo interrupter that counts the rotation of
the screw shaft and thus can be accurately moved to the desired location (B644). The
motor also has an additional photo interrupter to establish a Home position (B643). As
the GUACP is started, or after a recipe change, the stepper motors will move the Outer
Conveyor Guide Width to its narrowest position until the Home photo interrupter is
made. Once the Home is established the Case Conveyor Guide will move the proper
number of counts to achieve the recipe position.

Case Conveyor Width Adjust

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screws with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect two linear shafts and bearings for wear. Clean and lubricate.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
No wear on shafts or bearings, clean and lubricated.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Major Flap Raise Guide

Description

Once the filled case has been deposited on the case conveyor the outer major flap needs
to be raised to vertical to prepare it for fan folding. An air cylinder is used to push a
wedge shape sheetmetal guide down the outside of the case which raises the outer flap
and will keep the flap up until the case gets to case closing..

Major Flap Raise Guide

Inspection
Inspect air cylinder and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect two linear guide rods for wear and smooth movement. Clean and lubricate
with light oil, wipe off excess.
Inspect guide for damage and secure mounting

Specifications

No leaks on cylinder or air lines

Properly routed.
No wear on guide rods, clean and lubricated.
No damage and securely mounted

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Inspection Point ? Minor Flap Guide

Description

The Minor Flap Guide is an air cylinder fired arm that will assist in controlling the minor
flaps of the filled case as it is pushed to the Case Conveyor. The arm on the end of the
cylinder has a tab that will push the leading minor flap towards the discharge of the
machine but will also push the trailing minor flap out of the case and prepare the case for
closing.

Minor Flap Guide

Inspection
Inspect air cylinder and air lines for leaks and secure mounting.
Inspect air lines for proper routing.
Inspect arm for damage and secure mounting.

Specifications

No leaks on cylinder or air lines.

Properly routed.
No damage and securely mounted.

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Inspection Point ? Major Arm Position Adjust MT9

Description
Depending on the width of the case being run, the upstream major folding shoe is
moved in the proper place to successfully fold the major. A stepper motor is used to
move the entire flap folding mechanism in or out from the fixed downstream major
paddle. This movement is based on a value entered in to the recipe for the case pack
being run. The movement is driven by one stepper motor that is equipped with a photo
interrupter that counts the rotation of the screw shaft and thus can be accurately moved to
the desired location (B838). The motor also has an additional photo interrupter to
establish a Home position. As the GUACP is started, or after a recipe change, the stepper
motors will move the Major Arm Position Adjust to its widest position until the Home
photo interrupter is made (B837). Once the Home is established the Major Arm Position
Adjust will move the proper number of counts to achieve the recipe position.

Upstream Paddle Width Adjust

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screw with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Upstream Minor Arm Position Adjust MT8

Description
Depending on the size of the case being run, the upstream minor folding shoe is
moved upstream or downstream. Thus another stepper motor is used to move the entire
flap folding mechanism upstream or downstream from the fixed downstream major
paddle. The upstream major arm is also attached to this adjust so the upstream major and
minor will move when this adjustment is made. This movement is based on a value
entered in to the recipe for the case pack being run. The movement is driven by one
stepper motor that is equipped with a photo interrupter that counts the rotation of the
screw shaft and thus can be accurately moved to the desired location (B836). The motor
also has an additional photo interrupter to establish a Home position. As the GUACP is
started, or after a recipe change, the stepper motors will move the Minor Arm to its
highest position until the Home photo interrupter is made (B835). Once the Home is
established the Minor Arm will move the proper number of counts to achieve the recipe
position.

Upstream Minor Arm Position Adjust

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screw with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.
Inspect linear rail and bearing cassette on outer side of machine for wear.
Clean and lubricate.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
No rubbing (indicating flags are bent or out of position) and lens are clean.
No wear, clean and lubricated.

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Inspection Point ? Downstream Minor Arm Position Adjust MT10

Description
Depending on the width of the case being run, the downstream minor folding shoe
is moved in or out. A stepper motor is used to move the entire flap folding mechanism in
or out from the fixed downstream major paddle. This movement is based on a value
entered in to the recipe for the case pack being run. The movement is driven by one
stepper motor that is equipped with a photo interrupter that counts the rotation of the
screw shaft and thus can be accurately moved to the desired location (B2840). The motor
also has an additional photo interrupter to establish a Home position. As the GUACP is
started, or after a recipe change, the stepper motors will move the Minor Arm to its
highest position until the Home photo interrupter is made (B839). Once the Home is
established the Minor Arm will move the proper number of counts to achieve the recipe
position.

Downstream Minor Arm Adjust

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screw with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Case Closing-Major/Minor Arm Move

Description
The Case Closing is accomplished with several air cylinders. Here we will
describe four air cylinders that are used to rotate the fan folding shoes in to position prior
to the shoes actually folding the case flaps. The Major Flap Arms are controlled by a
single solenoid Y725. Each major arm has one cylinder to pivot the shoe in to position
for fan folding.
The minors are controlled by two solenoids valve, Case Closing Upstream Minor
Arm is Y726 and the Downstream Minor Arm is Y727. Each minor shoe has one
cylinder to pivot in to position for folding.

Case Closing Major/Minor Shoe Air Cylinders

Inspection

Inspect air cylinders for leaks and proper routing of air lines.
Inspect all cables, rod end clevis and adjustment nuts for secure
attachment.
Inspect pivots for wear.
Inspect shoes for damage.

Specifications
No Leaks and air lines routed properly.
All fasteners are tight and secure.
No wear in pivot points.
Shoes not damaged.

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Inspection Point ? Case Closing Minor and Major Paddles

Description
The Case Closing is accomplished with several air cylinders. Here we will
describe five air cylinders, two that control minor shoes and two that control major shoes.
An additional air cylinder (Case Closing Paddle Synchronizer) is used to tie the minor
and major cylinders together during retail fan folding so that one set will not lag behind
the other. Fan folding requires the minor and major shoes to close at exactly the same
time.
The minor paddles use the same two air cylinders and the major paddles use the same air
cylinders. Each has a short cylinder and a long cylinder ganged together. The short
cylinder will start the fan fold and then the long cylinder will complete the fan fold. The
motion of these air cylinders is transmitted by way of cables to the fan fold shoes.
Major Paddles Long Y728, Major Short Y729, Minor Long Y730, Minor Short Y731 and
Synchronizer Y732.

Case Closing Paddle Air Cylinders

Inspection

Inspect air cylinders for leaks and proper routing of air lines.
Inspect all cables, rod end clevis and adjustment nuts for secure
attachment.
Inspect linear shafts for wear. Clean and lubricate shafts with grease and
wipe off excess.
Inspect synchronizing cylinder and piston rod for proper engagement in
the bands.

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Specifications
No Leaks and air lines routed properly.
All fasteners are tight and secure.
Linear shafts and bearings have no wear, clean and lubricated.
Synchronizing cylinder and piston rod function properly.

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Inspection Point ? Case Closing PE B651

Description

The Case Closing Photo Eye is a reflective photo eye. The photo eye is used to start the
case closing. The machine knows there is a case present.

Case Closing PE

Inspection Procedure

Inspect mounting of photo eye for secure attachment.

Clean sensor and reflector with soft clean cloth.
Inspect cables for proper routing.

Specifications

Securely mounted
Clean
Properly routed.

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Inspection Point ? Case Jam Detect PE B652

Description

The Case Jam Photo Eye is a reflective photo eye. The photo eye is used to set a fault if
it is still blocked after the case should have left fan folding.

Case Jam Detect PE

Inspection Procedure

Inspect mounting of photo eye for secure attachment.

Clean sensor and reflector with soft clean cloth.
Inspect cables for proper routing.

Specifications

Securely mounted.
Clean.
Properly routed.

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Inspection Point ? Major Flap Raise

Description

The Major Flap Raise is a rotary air cylinder with a round rod attached to the rotary shaft.
When a case is present and just prior to folding the arm will raise the inner major flap
straight up.

Major Flap Raise

Inspection
Inspect air cylinder and air lines for leaks and secure mounting.
Inspect air lines for proper routing.
Inspect arm for damage and secure mounting.

Specifications

No leaks on cylinder or air lines.

Properly routed.
No damage and securely mounted.

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Inspection Point ? Minor Flap Raise

Description

The Minor Flap Raise is an air cylinder driving a pivoting arm. When a case is present
and just prior to folding the arm will raise the inner minor flap straight up.

Minor Flap Raise

Inspection
Inspect air cylinder and air lines for leaks and secure mounting.
Inspect air lines for proper routing.
Inspect arm for damage and secure mounting.
Inspect pivot for wear.

Specifications

No leaks on cylinder or air lines.

Properly routed.
No damage and securely mounted.
No wear.

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Inspection Point ? Outer Major Flap Raise and Shift

Description

The Outer Major flap is raised to vertical with two air cylinders working in conjunction.
The Outer Major Flap Raise cylinder is a rotary cylinder that rotates an arm from the
inner portion of the case to the outer side of the machine (Y1104). At the same time an
air cylinder moves the Outer Flap Raise cylinder and Arm to a lower position, this
cylinder is Outer Flap Raise Shift (Y1105).

Outer Major Flap Raise Outer Major Flap Shift

Inspection Procedure

Inspect air cylinders and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect guide rods for damage or wear. Clean and lubricate with light oil, wipe off
excess.
Inspect metal arm for secure attachment.

Specifications

No leaks on cylinder or air lines

Properly routed.
No damage or wear to guide rods. Clean and lubricated.
Secure attachment.

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Inspection Point ? Anti-Back Guide Shift

Description

The Anti-Back Shift has an arm that supports the downstream minor flap when it is raised
to vertical. This cylinder is only used for wide cases; it will move the Anti-Back out
further on the minor flap to insure it is above the minor lifter (Y1106).

Anti-Back Guide Shift

Inspection Procedure

Inspect air cylinders and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect guide rods for damage or wear. Clean and lubricate with light oil, wipe off
excess.
Inspect metal arm for secure attachment.

Specifications

No leaks on cylinder or air lines

Properly routed.
No damage or wear to guide rods. Clean and lubricated.
Secure attachment.

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Inspection Point ? Fan Fold Flap Guide

Description

The Fan Fold Flap Guide is a large air cylinder that raises and lowers the anti-backs, the
Anti-Back Guide Shift cylinder, and Case closing Flap Pushers (2). The unit drops down
when the flaps are being lifted to vertical and the anti-back brackets support the inside of
the flaps prior to folding. As the folding paddles start their folding this cylinder will raise
the anti-backs up and out of the case thus letting the paddles finish the folding. (Y1102).

Anti-Back Guide Shift

Inspection Procedure

Inspect air cylinders and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect guide rods for damage or wear. Clean and lubricate with light oil, wipe off
excess.
Inspect metal arm for secure attachment.

Specifications

No leaks on cylinder or air lines

Properly routed.
No damage or wear to guide rods. Clean and lubricated.
Secure attachment.

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Inspection Point ? Major Flap Stopper Position Adjust MT11

Description
Depending on the width of the case being run, the entire Fan Fold guide must be
moved inboard or outboard to align with the center of the case being run. A stepper motor
is used to move the entire Fan Fold Guide mechanism in or out from the fixed inboard
conveyor side rail. This movement is based on a value entered in to the recipe for the case
pack being run. The movement is driven by one stepper motor that is equipped with a
photo interrupter that counts the rotation of the screw shaft and thus can be accurately
moved to the desired location (B1060). The motor also has an additional photo
interrupter to establish a Home position. As the GUACP is started, or after a recipe
change, the stepper motors will move the Major Flap Stopper to its most inboard position
until the Home photo interrupter is made (B1059). Once the Home is established the
Major Flap Stopper will move the proper number of counts to achieve the recipe position.

Downstream Minor Arm Adjust

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screw with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Minor Flap Stopper Position Adjust MT12

Description
Depending on the length of the case being run, the entire Fan Fold guide must be
moved upstream or downstream to align with the center of the case being run. A stepper
motor is used to move the entire Fan Fold Guide mechanism forward or reverse from the
fixed inboard downstream major flap paddle. This movement is based on a value entered
in to the recipe for the case pack being run. The movement is driven by one stepper
motor that is equipped with a photo interrupter that counts the rotation of the screw shaft
and thus can be accurately moved to the desired location (B1058). The motor also has an
additional photo interrupter to establish a Home position. As the GUACP is started, or
after a recipe change, the stepper motors will move the Minor Flap Stopper to its most
outboard position until the Home photo interrupter is made (B1057). Once the Home is
established the Minor Flap Stopper will move the proper number of counts to achieve the
recipe position.

Minor Flap Stopper Adjust

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screw with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Case Closing Taper Unit Position Adjust

MT13

Description
Depending on the width of the case being run, the entire Taper Unit must be
moved in or out to align with the center of the case being run. A stepper motor is used to
move the entire Taper Unit mechanism in or out from the fixed inboard case conveyor
rail. This movement is based on a value entered in to the recipe for the case pack being
run. The movement is driven by one stepper motor that is equipped with a photo
interrupter that counts the rotation of the screw shaft and thus can be accurately moved to
the desired location (B1047). The motor also has an additional photo interrupter to
establish a Home position. As the GUACP is started, or after a recipe change, the stepper
motors will move the Taper Unit to its most inboard position until the Home photo
interrupter is made (B1046). Once the Home is established the Taper Unit will move the
proper number of counts to achieve the recipe position.

Taper Unit Adjust

Inspection

Inspect Screw shafts and bronze nuts for wear. Wipe off any build up on
face of nuts. Lubricate screw with grease and wipe off excess.
Inspect two linear shafts and bushings for wear, clean and lubricate with a
light coat of grease.
Inspect (2) photo interrupters for signs off flags rubbing and clean lens of
interrupters.

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Specifications
No wear on screw shafts or bronze nuts, lubricated and clean.
No wear on linear shafts, clean and lubricated.
No rubbing (indicating flags are bent or out of position) and lens are clean.

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Inspection Point ? Case Closing Tape Unit Vertical

Description

The Case Closing Tape Unit air cylinder will raise and lower the Tape Unit to the case
when running taped cases and stows the unit during retail runs Y1119).

Case Closing Tape Unit Vertical Air Cylinder

Inspection
Inspect air cylinder and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect two linear shafts and bushings for wear, clean and lubricate with a light
coat of grease. Wipe off excess.
Inspect prox switches for secure mounting.

Specifications

No leaks and secure mounted

Proper routing
No wear, clean and lubricated.
Securely attached.

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Inspection Point ? Minor Flap Sub Arm Rotation

Description

The Minor Flap Sub Arm Rotation air cylinder will lower the Sub Arms on to the case
just prior to taping. The arms will push down on the major flaps to insure the taper does
not catch the flaps (Y1120).

Minor Flap Sub Arm Rotation Air Cylinder

Inspection
Inspect air cylinder and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect pivot point for wear and secure attachment..
Inspect prox switches for secure mounting.

Specifications

No leaks and secure mounted

Proper routing
No wear securely attached.
Securely attached.

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Inspection Point ? Minor Flap Sub Arm Shift

Description

The Minor Flap Sub Arm Shift air cylinder will work in conjunction with the Sub Arm
cylinder. The Shift cylinder pushes the Sub Arms out so that the Sub Arms get to the top
of the case before the taper. (Y1121).

Minor Flap Sub Arm Shift Air Cylinder

Inspection
Inspect air cylinder and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect two linear shafts and bushings for wear, clean and lubricate with a light
coat of grease. Wipe off excess.
Inspect prox switches for secure mounting.

Specifications

No leaks and secure mounted

Proper routing
No wear, clean and lubricated.
Securely attached.

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Inspection Point ? Lifter Lower and Lifter Upper

Description

The Lifter is raised and lowered with two air cylinders that are ganged together. The
shorter cylinder is used because the Case Conveyor on tall boxes is below the level of the
discharge. The longer cylinder takes the lifter to whatever height the case conveyor is.
(Y1121).

Lifter Air Cylinders

Inspection
Inspect air cylinders and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect two linear shafts and bushings for wear, clean and lubricate with a light
coat of grease. Wipe off excess.
Inspect prox switches for secure mounting.

Specifications

No leaks and secure mounted

Proper routing
No wear, clean and lubricated.
Securely attached.

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Inspection Point ? Lifter Position Stopper

Description

The Lifter Position Stopper is used to insure the lifter is in the correct position to receive
a case from the Case Conveyor. It is a mechanical stop that will move up and down with
the case conveyor for different case heights.(Y1116).

Lifter Position Stopper Air Cylinder

Inspection
Inspect air cylinders and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect two linear shafts and bushings for wear, clean and lubricate with a light
coat of grease. Wipe off excess.
Inspect prox switches for secure mounting.

Specifications

No leaks and secure mounted

Proper routing
No wear, clean and lubricated.
Securely attached.

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Inspection Point ? Case Ejecting Reject Pusher

Description

The Case Ejecting Reject Pusher is used to reject cases that should not be palletized.
This might be because of open flaps or case purge. This air cylinder is a rodless cylinder
and utilizes a strong magnet in the cylinder to move the carrier. (Y1111).

Lifter Position Stopper Air Cylinder

Inspection
Inspect air cylinders and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect two linear shafts and bushings for wear, clean and lubricate with a light
coat of grease. Wipe off excess.
Inspect working surface of cylinder for signs of wear that may be caused by
misalignment.
Inspect prox switches for secure mounting.

Specifications

No leaks and secure mounted

Proper routing
No wear, clean and lubricated.
No wear and aligned.
Securely attached.

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Inspection Point ? Downstream/Upstream Lifter Stopper

Description

The Lifter has two cylinders mounted on the lifter that are used to stop the case on the
lifter until it is ready to discharge. (Y1112 and Y1113).

Downstream/Upstream Stopper Air Cylinder

Inspection
Inspect air cylinders and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect two linear shafts and bushings for wear, clean and lubricate with a light
coat of grease. Wipe off excess.
Inspect prox switches for secure mounting.

Specifications

No leaks and secure mounted

Proper routing
No wear, clean and lubricated.
Securely attached.

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Inspection Point ? Rear Flap Raise

Description

At the discharge of the Case Conveyor there is a rotary air cylinder with a straight rod
arm. This is called the Rear Flap Raise and is used to raise the upstream minor flap if the
fan folding did not complete the fold. The open flap will be seen by Fan Fold NG photo
eye B818. (Y1115).

Rear Flap Raise Air Cylinder

Inspection
Inspect air cylinder and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect mounting of cylinder and arm for secure attachment.
Inspect prox switches for secure mounting.

Specifications

No leaks and secure mounted

Proper routing
Securely mounted.
Securely attached.

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Inspection Point ? Lifter Rotation

Description

At the discharge of the GUACP the Lifter is designed to rotate the case so that a label can
be applied prior to discharging the case (Y1114).

Lifter Rotation Air Cylinder

Inspection
Inspect air cylinder and air lines for leaks and secure mounting
Inspect air lines for proper routing.
Inspect mounting of cylinder to lifter mechanism for secure attachment.
Inspect prox switches for secure mounting.

Specifications

No leaks and secure mounted

Proper routing
Securely mounted.
Securely attached.

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Inspection Point ? Case Ejecting PE B817

Description

The Case Ejecting Photo Eye is a reflective photo eye. The photo eye is used to signal
when a case is in the proper position to be ejected.

Case Ejecting PE

Inspection Procedure

Inspect mounting of photo eye for secure attachment.

Clean sensor and reflector with soft clean cloth.
Inspect cables for proper routing.

Specifications

Securely mounted
Clean.
Properly routed.

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Inspection Point ? Light Curtain Reject PE B854

Description

The Light Curtain Reject photo eyes are six photo eyes and reflectors wired in series, if
any one of them is blocked the machine will shut down. This is a safety feature to keep
people from reaching in to the machine while it is running. If a case is being rejected the
photo eyes will be turned off only long enough for the case to clear.
Test these photo eyes to insure they shut down the machine on every PM.

Light Curtain Reject PE’s

Inspection Procedure

Inspect mounting of photo eyes for secure attachment.

Clean sensors and reflectors with soft clean cloth.
Inspect cables for proper routing.

Specifications

Securely mounted
Clean.
Properly routed.

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Inspection Point ? Light Curtain Exit PE B855

Description

The Light Curtain Exit photo eyes are six photo eyes and reflectors wired in series, if any
one of them is blocked the machine will shut down. This is a safety feature to keep
people from reaching in to the machine while it is running. If a case is exiting the photo
eyes will be turned off only long enough for the case to clear.
Test these photo eyes to insure they shut down the machine on every PM.

Light Curtain Exit PE’s

Inspection Procedure

Inspect mounting of photo eyes for secure attachment.

Clean sensors and reflectors with soft clean cloth.
Inspect cables for proper routing.

Specifications

Securely mounted
Clean.
Properly routed.

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Inspection Point ? Fan Folding NG PE B817

Description

The Fan Folding NG Detect Photo Eye is a reflective photo eye. The photo eye is used
to signal when a case did not get folded properly; the case will then get rejected.

Fan Fold NG Detect PE

Inspection Procedure

Inspect mounting of photo eye for secure attachment.

Clean sensor and reflector with soft clean cloth.
Inspect cables for proper routing.

Specifications

Securely mounted
Clean.
Properly routed.

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Inspection Point ? Lifter Rollers MD7

Description

The Lifter has six rollers which are powered by a DC motor. The motor powers the end
roller through a cog belt and then the rest of the rollers are connected with another cog
belt.

Lifter Roller Motor

Inspection Procedure

Inspect motor mounting for secure attachment.

Remove the guard over the rollers and inspect the drive belt and driven belt for
wear and running in the center of the pulleys.
Inspect cables for proper routing.

Specifications

Securely mounted
No wear and running in center of pulleys.
Properly routed.

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Inspection Point ? Vacuum Pump and Filter

Description

The GUACP utilizes vacuum to hold cases during the erecting and closing. Poor vacuum
will result in many case faults. It is imperative that the vacuum pump runs well and the
filter is kept clean.

Vacuum Pump Vacuum Filter

Inspection Procedure

Inspect vacuum tubing for damage and proper routing.

Using compressed air, blow out vacuum pump removing cardboard dust that may
have been pulled in to fan.
Inspect vacuum filter and clean or replace.

Specifications

No damage and routed properly

Clean.
Clean or replaced.

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Chapter 6 Exterior Checks

Doors

Description

Doors prevent injury to technicians and keep foreign material from the machine interior.

Inspection Procedure

Physically inspect operation of all guard doors and handles.

Specifications

Hardware should move freely, Doors should be in good repair and not broken.

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Door Guard Switches

Description

The Door Guard Switches will cut electrical power, air pressure and stop all motion in the
machine when the doors are opened. This action will prevent technicians from getting
themselves caught in energized moving machinery. Non-functional or bypassed door
switches are a serious OSHA violation.

Inspection Procedure

Inspect door switches to ensure they are properly mounted and functioning.

Specifications

Door Switches should be operational. Switches shall not be bypassed.

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Emergency Stop Switches

control
Description

Emergency Stop Switches cut power, control air and stop motion in the machine to shut it
down quickly in an emergency. Non-functional or bypassed emergency stop switches
are a serious OSHA violation.

Inspection Procedure

Verify Emergency Stop Switches function by engaging stops and verifying proper
operation.

Specifications

E-Stops switches shall properly function and cannot be bypassed.

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Touch Screen and Cabinet Filters

Description

The Touch Screen is the Operator’s interface with the GUACP.

The cabinet filters keep contaminates out of the electrical components. It is critical that
these filters get cleaned or changed regularly.

Inspection Procedure

Visually inspect touch screen for defects. Reset all accumulated data at the
conclusion of the PM for an updated record to be saved for the next PM.
Remove cabinet filters and clean or replace.

Specifications

Screen shall be free of scratches and cracks.

Clean or replaced.

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Cycle Machine

Description

A final cycling of the machine will confirm that the PM is finished and that the machine
still functions optimally.

Inspection Procedure

Place all doors in proper position, and set machine in off-line operation. Let machine
cycle through 15 minutes of operation to visually inspect sequence of operation.

Specifications

Machine cycles easily.

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Chapter 7 Certification Checklist

The next page is a copy of the certification checklist for this Ishida UACP PM Training.
At the completion of training, the Trainer should certify each mechanic individually
using the checklist.

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Ishida GUACP PM Certification Checklist

Demonstration: Ishida GUACP Mechanic’s Name
Maintenance Expert Trainer’s Name

OPERATOR PERFORMANCE REQUIREMENTS

Successful completion of this Certification Checklist means the participant is able to:
(Indicate all requirements are met by initialing and dating on the appropriate lines.)
(Demonstrations should be completed in whole.)

Trainer Mechanic Date

Explain at what efficiency target the Ishida UACP should run.

Identify the Main Power cutoff on the Ishida GUACP .

With a trainer, complete a full PM of a Ishida GUACP

on the production floor in less than 240 minutes.

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