Case Packer

Interactive Troubleshooting Guide Demo

Case Bottle Case
Metering Slug Feed
Infeed Infeed Slitting
Problems Problems
Problems Problems Problems

Click
for
Help

Case Top Case Turret /

To use this guide, click on any
of the highlighted boxes. Sealer Outfeed Packing Head
(Some functions are disabled Problems Problems Problems
on this demo.)

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 Bottle Infeed Bottle Infeed
Downed Bottles Click here if bottles are arriving
from Labeler at the packer are down.

Downed Bottles Click here if bottles are falling

in Lanes down in the bottle infeed lanes.

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 Bottle Infeed - Downed Bottles
Bottle Infeed
Downed Bottles
from Labeler from Labeler
Start

Check the Check for glass or

conveyor lube downed bottles under
bottle rails

NO
PROBLEMS NO DEBRIS
FOUND FOUND
Problems Identify where the
Debris found? Continue
found? bottles are falling

PROBLEMS DEBRIS
FOUND FOUND

Correct conveyor lube Clean out debris from

problem under bottle rails

Continued on next page.

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 Bottle Infeed - Downed Bottles
Bottle Infeed
Downed Bottles
from Labeler (Continued)from Labeler
Continue

Check for broken glass

Check bottle transfer
under the conveyor
points
chain

NO NO Contact maintenance to
Broken glass Problems
continue Continue
found? found?
troubleshooting

YES YES

Call maintenance to
Remove broken glass
correct the problems

Continued on next page.

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 Bottle Infeed - Downed Bottles
Bottle Infeed
Downed Bottles
from Labeler (Continued)from Labeler
Continue

Check conveyor wear Check the conveyor

strips chain sprockets

NO PROBLEMS NO PROBLEMS
FOUND FOUND Return to
Problems Problems
Bottle
found? found?
Infeed

PROBLEMS PROBLEMS
FOUND FOUND

Replace the conveyor

Replace the wear strips
chain sprockets

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Bottle Infeed - Downed BottlesDowned Check
Bottles
1. Verify that there is flow through the nozzles when Check Conveyor
the Conveyor Lube
the conveyor is running. Lube
2. Verify that conveyor lube is spraying evenly on all
conveyor chains.
3. Verify that the conveyor lube valves are open.
4. Verify that the conveyor lube concentration is correct.

Conveyor Lube
Spray Nozzles

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 Downed
Bottle Infeed - Downed Bottles Bottles
Identify Location
Identify Where Bottles Fall
Where Bottles Fall

1. Starting at the bottle infeed of

the packer, follow the full bottle
conveyors back to the labelers
and identify the location where
bottles are falling.

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 Check
Bottle Infeed - Downed BottlesDowned Bottles
Check for Bottles
for Bottles and Broken Glass
and Broken Glass

1. At the location where bottles

are falling, check for bottles
or broken glass wedged
under the bottle guide rails.
Remove any bottles or
broken glass found.

Conveyor Lube
Spray Nozzles

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 Check
Bottle Infeed - Downed BottlesDowned Bottles
1. At the location where bottles are falling, check the
Check the
the Bottle Transfer Points
transfer points from conveyor to conveyor and
across dead plates.
Transfer Points
Bottle transfer should be even or drop down
slightly. If bottles transfer up, they can be tripped.
Call maintenance to correct transfer problems.

Bottle
Transfer Point

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 Check
Bottle Infeed - Downed BottlesDowned Bottles
Check Conveyor
Conveyor Wear Strips Wear Strips

1. At the location where bottles are

falling, check the wear strips.
2. Replace wear strips that are:
Loose
Missing
Damaged.
3. Check wear strip for excessive
wear.
Replace if wear strip thickness is
Wear Strip
less than 0.725 inch.

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 Check
Bottle Infeed - Downed BottlesDowned Bottles
Check Conveyor
Conveyor Chain Sprockets
Chain Sprockets

1. At the location where bottles are

falling, check the conveyor chain
sprockets for the following:
Chips in teeth
Hooks
Sharp points
Loose set screws
Loose keys / keyway
2. Replace sprockets that are worn or
damaged.
Sprocket 3. Tighten / replace loose of missing
setscrews or keys.

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 Bottle Infeed - Downed Bottles
Bottle Infeed
Downed Bottles
In Lanes In Lanes
Start

Check if there is a Check the Check for crowns,

down bottle at the conveyor lube glass or other debris
down bottle sensors. under the lane guides

NO
PROBLEMS NO DEBRIS
YES FOUND FOUND
Down bottle Problems
Debris found? Continue
present? found?

PROBLEMS DEBRIS
NO FOUND
FOUND

Correct conveyor lube Clean out debris from

False Down Bottle
problem under bottle rails

Continued on next page.

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 Bottle Infeed - Downed Bottles
Bottle Infeed
Downed Bottles
In Lanes In Lanes
Continue

Check for broken glass

Check bottle transfer Check the lane guide
under the conveyor
points at infeed spacers
chain

NO NO NO
Broken glass Problems Problems
Continue
found? found? found?

YES YES YES

Call maintenance to Correct lane guide

Remove broken glass
correct the problems spacer problems

Continued on next page.

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 Bottle Infeed - Downed Bottles
Bottle Infeed
Downed Bottles
In Lanes In Lanes
Continue

Check for buildup on Check the conveyor

Check for label issues
lane guides chain

NO PROBLEMS NO PROBLEMS Conveyor NO PROBLEMS

FOUND FOUND FOUND Return to
Problems Label issues chain
Bottle
found? found? problems
found? Infeed

PROBLEMS PROBLEMS PROBLEMS

FOUND FOUND FOUND

Contact the labeler Contact the

Clean the lane guides operator to correct lmaintenace to correct
problems problems

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Bottle Infeed - Downed BottlesDowned Check
Bottles
Check for
for Downed Bottle Down Bottle
Down or missing bottle in this lane.

1. Check for a down or

missing bottle under the
downed bottle sensor flags.
2. If a down bottle is found,
remove it, and check the
flow of bottles upstream of
the packer to find the cause.
3. If bottles are missing. Look
upstream for bottle jams.

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Bottle Infeed - Downed BottlesDowned False
Bottles
False Down
Support Bars
Downed
Down Bottle
Flag Brackets
Bottle
Down Bottle
Proximity Switch Bottle

1. If a false down bottle is

detected, check the down
bottle mechanism for:
Down bottle flags
Bent support bars
Bent, sticking or
missing flag brackets
2. Call maintenance to
repair or replace missing
or damaged parts.

Continued on next page.

Down Bottle Flags

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 Bottle Infeed - Downed Bottles Downed FalseBottles
False Down
Down Bottle Downed
Down Bottle Bottle (Continued) Bottle
Flag Proximity Switch

3. Check the Down Bottle proximity

switch for the following:
Damage
Secure fastening of the
connector
Damage to the connector or
cable
4. Rotate the down bottle flag in front
of the proximity switch and verify
that the indicator light in the
proximity switch comes on.
Indicator Light Connector
5. Call maintenance to replace the
proximity switch if it is not working.

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Bottle Infeed - Downed BottlesDowned Check
Bottles
1. Verify that there is flow through the nozzles when Check Conveyor
the Conveyor Lube
the conveyor is running. Lube
2. Verify that conveyor lube is spraying evenly on all
conveyor chains.
3. Verify that the conveyor lube valves are open.
4. Verify that the conveyor lube concentration is correct.

Conveyor Lube
Spray Nozzles

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 Bottle Infeed - Downed Bottles Check for
Downed Bottles
1. At the location where bottles are falling, check for Check for Crowns
Crowns, Broken Glass, or
crowns, broken glass or other debris wedged under Other
andDebris
Broken Glass
the bottle lane guides.
Remove any crowns, broken glass or debris found.

Check for
debris under
lane guides.

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 Downed Bottles - Check theDowned
Lane Bottles
Check the Lane
Guide Spacers Guide Spacers

Lane Spacers

Lane Guides

1. Look for wrong, or missing lane spacers

(changeover parts).

Continued on next page.

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Downed Bottles Check theDowned
Lane Bottles
Check the Lane
Guide Spacers (Continued)
Guide Spacers

2. Look for loose lane spacers

(changeover parts).
3. Lane spacers should be pushed in
all the way.

Correctly
Installed
Loose Lane Spacer
Lane Spacer

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 Check
Bottle Infeed - Downed BottlesDowned Bottles
1. Check the bottle transfer points at the infeed to the
Check the Infeed
the Bottle Transfer Points
case packer.
Transfer Points
Bottle transfer should be even or drop down
slightly. If bottles transfer up, they can be tripped.
Call maintenance to correct transfer problems.

Bottle Transfer Points

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 Bottle Infeed - Downed Bottles Check for
Downed Bottles
1. Check the bottle lane guides for a buildup of labels Check Buildup
Buildup
or other residue. on Lane Guideson Lane Guides
Clean the bottle lane guides if any buildup is found.

Check for a buildup

of labels or other
residue on the
lane guides.

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Bottle Infeed - Downed Bottles Check the
Downed Bottles
Check the Chain
Chain Conveyor Conveyor

1. Check the bottle infeed

conveyor for broken conveyor
chain links.
2. If broken chain links are
found, contact maintenance
to repair the conveyor.

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 Metering
Click here if bottles are jamming
Metering
Stabilizer Jam in the bottle stabilizer.

Metering Module Click here if bottles are jamming

Jammed in the metering module.

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 Metering Stabilizer JamMetering
Stabilizer Jam
Start

Check the timing of Check for a missing Check slug feed

the bottle stabilizer metering pin bar timing

YES YES YES

Is timing Is timing Is timing Return to
correct? correct? correct? Metering

NO NO NO

Maintenance adjust
Adjust bottle Maintenance install
bottle stabilizer
stabilizer timing the metering pin bar
timing

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 Metering Stabilizer Jam Stabilizer Check Jam
1. Check the timing of the bottle stabilizer. Check Bottle
Bottle
The bottle stabilizerStabilizer Timing
should rotate in behind Stabilizer Timing
the sixth row of bottles just as the metering
pins rotate in behind the bottles.
The bottle stabilizer bar should be directly
over the metering pins.

Bottle Stabilizer Bar

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Metering Stabilizer Jam Stabilizer
Adjust Jam
Stabilizer Bar Adjust Bottle
Bottle Stabilizer Timing
Stabilizer Timing

If stabilizer timing is not correct:

1. Loosen the kip handle.
2. Adjust the bottle stabilizer
forward or back until the
timing pointer lines up with
the colored marker for the
scheduled product.
3. Tighten the kip handle.
Timing Pointer This adjustment moves the
stabilizer forward and back
so it catches the correct row
of bottles.
Colored Marker Kip Handle
Continued on next page.

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Metering Stabilizer Jam Stabilizer
Adjust Jam
Adjust Bottle
Bottle Stabilizer
Colored
Marker
Timing
Stabilizer Timing

If stabilizer timing is not correct:

4. Turn the stabilizer height
adjustment handwheel until
the height pointer lines up
with the colored marker for
the scheduled product.
The handwheel adjusts
Handwheel where on the bottle neck that
the stabilizer bar hits

Height Pointer

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Metering Stabilizer Jam Stabilizer
Check Jam
Check for Missing
for a Missing Metering Pin BarPin Bar
Metering

1. Look for missing metering pin bars.

2. If a missing bar is found, call maintenance to replace it.

Metering Pin Bar

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Metering Stabilizer Jam Stabilizer
Check
Check Slug
Slug Feed Timing Feed Timing
Bottles Centered
Under Grippers
Slug Feed Phase
Adjust Handwheel
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Jam
1. Check that the metering
pins align the bottles in the
bottle lanes with the
grippers.
The bottle grippers should
lower smoothly over each
row of bottles.
2. If gripper fingers jam on
bottles or knock bottles
over, adjust slug feed
timing.
Metering Stabilizer Jam Stabilizer
Adjust Jam
Adjust Slug
Slug Feed Timing Feed Timing
Maintenance perform the
following steps:

Bottles Centered
If slug feed timing is not
Under Grippers correct:
1. Jog machine until a
gripper head has lowered
down just above the tops
of the bottles.
The gripper head should
Slug Feed Phase be parallel with the bottle
Adjust Handwheel lane guides, but not
lowered onto the bottles.

Continued on next page.

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 Metering Stabilizer Jam Stabilizer
Adjust Jam
Adjust Slug
Handwheel
Slug Feed Timing Feed Timing
Pointer Gear Plate

2. Pull out the slug feed phase adjuster

handwheel to disengage the
metering pin chain from the drive.
3. Adjust the metering pin bars forward
or backward until the pointer on the
gear plate lines up with the marker
for the schedule bottle size.
The metering pins should align the
bottles with the grippers.
4. Push in on the phase adjuster
Markers handwheel to re-engage the
metering pin chain with the drive
Slug Feed Phase Adjuster system.

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 Case Outfeed Case Outfeed

Click here if cases

Flap Tucker
Are jamming in
Jam the flap tucker.

Click here if cases

Flap Plow
Are jamming in
Jammed the flap plow.

Click here if cases

Guide Arm
are jamming at
Jammed the case guide arm.

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 Case Outfeed Flap Tucker
Case Outfeed
FlapJam
Tucker
Jam
Continue

Check flap tucker Check flap tucker Check the flap

timing height hooks

NO PROBLEMS Return to
Flap tucker YES Flap tucker YES
Problems FOUND
timing timing Carton
found?
correct? correct? Outfeed

PROBLEMS
NO NO
FOUND

Adjust flap tucker Adjust flap tucker Call maintenance to

timing height correct problems

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Case Outfeed Flap Tucker
FlapJam
Tucker Jam
Check the
Check the Flap TuckerFlap Tucker
1. Check if the flap tucker is in
the jammed position.
When jammed, the flap
tucker will be turned out of
position.

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Case Outfeed False FlapFlap
Tucker
Tucker Jam
False Flap
Jammed Tucker Jammed

If this is a false flap tucker jammed:

1. Check the Flap Tucker Jammed
proximity switch for the following:
Damage
Secure fastening of the
connector
Damage to the connector or
cable
2. If the proximity switch, connector
or cable are damaged, call
Proximity Switch maintenance to repair or replace
the proximity switch.

Continued on next page.

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Case Outfeed False FlapFlap
Tucker
Tucker Jam
False Flap
Jammed Tucker Jammed

3. Check that when the flap tucker is in

its operating position the indicating
light is ON.
4. If the proximity switch indicator light
is not ON, call maintenance to adjust
or replace the proximity switch.

Indicating Light

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Case Outfeed Flap Tucker Jammed
Flap TuckerJam
Clear Jam,
Clear Jam, Reset, RestartReset, Restart

1. Remove the jammed case

from the flap tucker area.
2. Turn the flap tucker
clockwise until it drops back
into its detent.
3. Verify that the proximity
switch indicating light is ON.
4. Reset and restart the
machine.

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Case Outfeed Flap Tucker Jammed
Flap TuckerJam
Check Flap
Check Flap Tucker TimingTucker Timing

1. Jog the machine and verify

that the flap tucker catches
the trailing case flap just
after it is released by the
flap hooks.
2. Verify that the flap tucker
holds the trailing case flap
down until it is under the
flap plow.

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 Case Outfeed Flap Tucker Jammed
Flap TuckerJam
Adjust Flap
Adjust Flap Tucker TimingTucker Timing
Colored
Marker Pointer
If flap tucker timing is incorrect:
1. Lift the flap tucker up to
disengage the flap tucker
phase adjuster gear plate
from the position indicator
plate.
2. Turn the flap tucker until the
pointer lines up with the
colored marker for the
Pointer scheduled product.
3. Lower the flap tucker phase
adjuster gear plate into the
Gear Plate Indicator Plate indicator plate.

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Case Outfeed Flap Tucker Jammed
Flap TuckerJam
Check Flap
Check Flap Tucker HeightTucker Height

1. Jog the machine and verify

that the flap tucker catches
the trailing case flap half
way between the score and
the upper edge.

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 Case Outfeed Flap Tucker Jammed
Flap TuckerJam
Adjust Flap
Adjust Flap Tucker HeightTucker Height
Flap Tucker
Blade
If flap tucker height is incorrect:
1. Loosen the kip handle.
2. Raise or lower the flap tucker
Colored blade until the pointers line
Marker up with the colored mark.
3. Tighten the kip handle.

Kip handle is located

Indicator on the opposite side of
Plate Pointer the indicator plate.

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 Case Outfeed Flap Tucker Jammed
Flap TuckerJam
Check the
Check the Flap Hooks Flap Hooks
Spring Spring

1. Check that the flap hooks at

the front and rear of the carton
are present and not damaged.
2. Check that the springs hold the
flap hooks against the front
and back of the case.
3. Call maintenance to replace
broken flap hooks or springs.
4. Jog machine to check flap
Flap Hook Flap Hook hooks lift flaps all the way up
prior to the case passing under
the flap plow and the flap
tucker.

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Case Outfeed Flap PlowFlapJam
Case Outfeed
Plow
Jam
Start

Monitor machine for

Check the flap plow another flap plow jam

YES Remove jammed YES

Flap plow Does problem
cases, reset, and Continue
jammed? reoccur?
restart

NO NO

False Flap Plow

Continue Production
Jammed

Continued on next page.

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 Case Outfeed Flap Plow Jam
Case Outfeed
Flap Plow
(Continued) Jam
Continue

Check flap plow Check the flap

height hooks

NO PROBLEMS Return to
Flap plow YES
Problems FOUND
height Carton
found?
correct? Outfeed

PROBLEMS
NO
FOUND

Adjust flap plow Call maintenance to

height correct problems

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Case Outfeed Flap Plow Flap
Jam
Plow Jam
Check the
Check the Flap Plow Flap Plow
Flap Plow
Blade

1. Check if the flap plow is in the jammed

position.
When jammed, the flap plow will be
turned out of position. The indicating
light on the proximity switch will be
OFF.

Proximity
Switch

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Case Outfeed False FlapFlapPlow
Plow Jam
False Flap
Jammed Plow Jam

If this is a false flap plow jam:

1. Check the Flap Plow Jammed
proximity switch for the following:
Damage
Secure fastening of the
connector
Damage to the connector or
cable
2. If the proximity switch, connector
or cable are damaged, call
maintenance to repair or replace
Proximity Switch the proximity switch.

Continued on next page.

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Case Outfeed False FlapFlapPlow
Plow Jam
False Flap
Jammed Plow Jammed

3. Check that when the flap plow is in

its operating position the indicating
light is ON.
4. If the proximity switch indicator light
is not ON, call maintenance to adjust
or replace the proximity switch.

Indicating Light

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Case Outfeed Flap Plow Jammed Plow
Flap Clear
Jam
Clear Jam,
Jam, Reset, Restart Reset, Restart

1. Remove the jammed case

from the flap plow area.
2. Turn the flap plow clockwise
until it drops back into its
detent.
3. Verify that the proximity
switch indicating light is ON.
4. Reset and restart the
machine.

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Case Outfeed Flap Plow Jam Flap
Check
Plow Jam
Check Flap
Flap Plow Height Plow Height

1. Jog the machine and verify

that the flap plow catches
the leading case flap half
way between the score and
the upper edge.

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Case Outfeed Flap Plow Jam Flap
Adjust
Plow Jam
Adjust Flap
Pointer Flap Plow Height Plow Height
Kip
Handle
If flap plow height is incorrect:
1. Loosen the kip handle.
Colored 2. Raise or lower the flap plow
Markers blade until the pointers line up
with the colored mark.
3. Tighten the kip handle.

Indicator
Plate

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Case Outfeed Flap Plow JammedFlap
Plow
Check
Jam
Check the
the Flap Hooks Flap Hooks
Spring Spring

1. Check that the flap hooks at

the front and rear of the carton
are present and not damaged.
2. Check that the springs hold
the flap hooks against the front
and back of the case.
3. Call maintenance to replace
broken flap hooks or springs.
4. Jog machine to check flap
Flap Hook Flap Hook hooks lift flaps all the way up
prior to the case passing under
the flap plow and the flap
tucker.

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Case Outfeed Guide Arm
Case Outfeed
Case Outfeed Guide Arm
Guide Arm Jammed Jammed

1. Remove the jammed case.

2. Reposition the outfeed guide arm.
3. Reset and restart the machine.
4. If the problem occurs again, check
the flap tucker and the flap plow.

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 Welcome to the APS Troubleshooting
Troubleshooting Guide Demo Guide Help

This is a demo version of an interactive

Click the blue boxes for
troubleshooting guide.
detailed information on
how to perform the task. The functioning version runs as a web page on the
Continue users HMI or on a tablet computer.
Click on any of the colored boxes or icons to
proceed.
Check flap plow Check the flap
height hooks Flow charts will guide the user through the
troubleshooting process:
The flow charts are organized to have the
Flap plow YES
Problems
NO PROBLEMS
FOUND
Return to users check the most likely problems first,
height Carton
correct?
found?
Outfeed
then proceed to less likely issues.

PROBLEMS
Clicking on any blue box in a flow chart will
NO
FOUND provide more detailed information on how to
perform the task.
Adjust flap plow Call maintenance to
height correct problems
Note that in this demo version, many of the
selections are inactive (grayed-out).
Sample Flow Chart For more information, call Greg Pancerev at 610-
987-4054 or email us at info@aps-online.net

Proceed to the Demo Use browser return to exit this demo.

Case Outfeed Flap Plow Jam Flap
Check
Plow Jam
Check Flap
Pointer Flap Plow Height Plow Height
Kip
Handle
Check Flap Plow Height:
1. Pointer should be at the
correct colored marker for the
Colored
product being run.
Markers
If flap plow height is incorrect:
1. Loosen the kip handle.
2. Raise or lower the flap plow
blade until the pointers line
up with the colored mark.

Indicator 3. Tighten the kip handle.

Plate