Challenge CMT-330TC, Installation And Operator'S Manual

Page 1: ...r F 033TCA APR 2018 The Challenge Machinery Company 6125 Norton Center Drive Norton Shores MI 49441 USA ChallengeMachinery com SERIAL No ____________________ CMT 330TC Three Knife Trimmer Installation...

Page 2: ...of the product owner and user Older products may not comply with current safety procedures guidelines or regulations and it is the product owner s and user s responsibility to evaluate the suitability...

Page 3: ...2 6 Outfeed Setup 2 13 2 6 1 Vertical Outfeed Stacker 2 13 2 6 2 Exit Conveyor 2 15 2 6 3 Exit Ramp 2 16 2 7 Main Power Hookup 2 17 2 8 Main Air Hookup 2 19 2 9 Cleaning 2 20 3 Operator s Guide 3 1 C...

Page 4: ...APR 2018 CMT 330TC Three Knife Trimmer iv Introduction Notes...

Page 5: ...uirements 1 11 1 10 1 Tilt Elev Stacker 1 12 1 10 2 Tilt Elev Pile Feeder Stacker 1 13 1 10 3 Pile Feeder Stacker 1 14 1 10 4 Hand Feeder Stacker 1 15 1 10 5 Tilt Elevator Exit Conveyor 1 16 1 10 6 Ti...

Page 6: ...chine CAUTION The CMT 330 requires 80 90 psi 5 5 6 2 bar regulated dry non lubricated compressed air that meets or exceeds ISO 8573 1 Class 2 4 2 Failure to do so may cause damage to the machine and w...

Page 7: ...cates an operating or mainte nance procedure practice or condition that if not strictly observed could result in damage to or destruction of equipment Note Definition Note A regular note indicates an...

Page 8: ...will fall into the size range described in the specifications on page 1 8 Make sure all applicable accessories are securely bolted to the main machine Tip hazards may result from unsecured acces sorie...

Page 9: ...cker Part Number Description Qty CMC 330TCA SW CMT 330TC Basic Machine Internal Waste 60HZ 1 CMC 330TCA EW CMT 330TC Basic Machine External Waste 60HZ CMC 330TCA SW 015 CMT 330TC Basic Machine Interna...

Page 10: ...d standard accessories for the CMT 330TC Part Number Description Qty 56248 Knives HSS Set of 3 2 56275 Knife Height Spacer 3 56028 Knife Lifter 1 5064 Cut Stick Puller 1 W 164 5 16 T Handle Hex Wrench...

Page 11: ...8 2 Super HSS 5X Knives set of 3 1 25 000 50 000 books 56248 1 Tungsten Carb Knives set of 3 1 25 000 80 000 books 56303 Cut Stick 1 rot 1 000 change 8 000 books 56317 Cut Plate 2 rot 1 000 change 4 0...

Page 12: ...7 cm 58600TCLA Book Pile Feeder 430 lb 195 kg net 500 lb 227 kg ship 15 2 PSI kPa load Height x Width x Depth 56 x 22 x 57 in 142 x 56 x 145 cm 59230TCLA Standard Hand Feed Conveyor 50 lb 23 kg net 80...

Page 13: ...ollated form of a book that does not include the cover It contains all front and end matter as well as the text block Untrimmed book An untrimmed book is a book block that has been bound with a cover...

Page 14: ...In order to understand the instructions pre sented it is necessary to have a working knowledge of machine locations Figure 1 3 helps to locate the front back right and left sides of the machine as we...

Page 15: ...ly of compressed air and electricity Refer to Section 1 8 Specifica tions on page 1 8 to verify that the site can ac commodate these requirements Use the follow ing figures to determine floor space re...

Page 16: ...APR 2018 CMT 330TC Three Knife Trimmer 1 12 1 Introduction 1 10 1 Tilt Elev Stacker Figure 1 4 In line Tilt Conveyor with Elevator and Stacker Configuration...

Page 17: ...APR 2018 CMT 330TC Three Knife Trimmer 1 13 1 Introduction 1 10 2 Tilt Elev Pile Feeder Stacker Figure 1 5 In line Tilt Conveyor with Elevator In Line Pile Feeder and Stacker Configuration...

Page 18: ...APR 2018 CMT 330TC Three Knife Trimmer 1 14 1 Introduction 1 10 3 Pile Feeder Stacker Figure 1 6 Pile Feeder and Stacker Configuration...

Page 19: ...APR 2018 CMT 330TC Three Knife Trimmer 1 15 1 Introduction 1 10 4 Hand Feeder Stacker Figure 1 7 Hand Feeder and Stacker Configuration...

Page 20: ...APR 2018 CMT 330TC Three Knife Trimmer 1 16 1 Introduction 1 10 5 Tilt Elevator Exit Conveyor Figure 1 8 In line Tilt Conveyor with Elevator and Exit Conveyor Configuration...

Page 21: ...APR 2018 CMT 330TC Three Knife Trimmer 1 17 1 Introduction 1 10 6 Tilt Elev Pile Feed Exit Conv Figure 1 9 In line Tilt Conveyor with Elevator In line Pile Feeder and Exit Conveyor Configuration...

Page 22: ...APR 2018 CMT 330TC Three Knife Trimmer 1 18 1 Introduction 1 10 7 Pile Feeder Exit Conveyor Figure 1 10 Pile Feeder and Exit Conveyor Configuration...

Page 23: ...APR 2018 CMT 330TC Three Knife Trimmer 1 19 1 Introduction 1 10 8 Hand Feeder Exit Conveyor Figure 1 11 Hand Feeder and Exit Conveyor Configuration...

Page 24: ...APR 2018 CMT 330TC Three Knife Trimmer 1 20 1 Introduction 1 10 9 Tilt Elev Exit Ramp Figure 1 12 In line Tilt Conveyor with Elevator and Exit Ramp Configuration...

Page 25: ...APR 2018 CMT 330TC Three Knife Trimmer 1 21 1 Introduction 1 10 10 Tilt Elev Pile Feeder Ramp Figure 1 13 In line Tilt Conveyor with Elevator In line Pile Feeder and Exit Ramp Configuration...

Page 26: ...APR 2018 CMT 330TC Three Knife Trimmer 1 22 1 Introduction 1 10 11 Pile Feeder Exit Ramp Figure 1 14 Pile Feeder and Exit Ramp Configuration...

Page 27: ...APR 2018 CMT 330TC Three Knife Trimmer 1 23 1 Introduction 1 10 12 Hand Feeder Exit Ramp Figure 1 15 Hand Feeder and Exit Ramp Configuration...

Page 28: ...APR 2018 CMT 330TC Three Knife Trimmer 1 24 1 Introduction NOTES...

Page 29: ...one 2 8 2 4 4 Standard Hand Feed Conveyor 2 10 2 4 5 Long Hand Feed Conveyor 2 11 2 5 Trimmer Height Setup 2 12 2 6 Outfeed Setup 2 13 2 6 1 Vertical Outfeed Stacker 2 13 2 6 2 Exit Conveyor 2 15 2 6...

Page 30: ...shown in Figure 2 1 3 Open the two lower rear side doors and re move the waste bins 4 Remove the two rear lag screws from the two rear locations shown in Figure 2 1 5 Reinstall the waste bins and clo...

Page 31: ...etup Procedure 1 Position the Tilt Infeed Conveyor in front of the binder such that height adjustable por tion of the conveyor is centered on the exit chute of the binder Figure 2 5 Tilt Infeed Convey...

Page 32: ...Setup attach the eleva tor to the trimmer using supplied mounting hardware Figure 2 11 Figure 2 11 Elevator Attachment to Trimmer Cable and Air Tubing Connections 1 Remove the lower front panel of the...

Page 33: ...nd that is labelled with the numbers that correspond to the labels on the elevator and tilt conveyor near the input connectors Also locate any separate air tubing sections that may have been supplied...

Page 34: ...on the elevator near the input connectors The power cables are the larger diameter cables with 7 pin connectors on the end 2 Route the power cable under the hydraulic unit and out of the left side of...

Page 35: ...APR 2018 CMT 330TC Three Knife Trimmer 2 7 2 Installation Guide Figure 2 18 Air Tubing Connections Now go to Section 2 5 Trimmer Height Setup to continue the setup process...

Page 36: ...e feeder near the input connectors The power cables are the larger diameter cables with 7 pin connectors on the end 2 Route the power cable under the hydraulic unit and out of the left side of the tri...

Page 37: ...APR 2018 CMT 330TC Three Knife Trimmer 2 9 2 Installation Guide Figure 2 22 Air Tubing Connection Now go to Section 2 5 Trimmer Height Setup to continue the setup process...

Page 38: ...ting Hardware 4 Fasten the conveyor to the trimmer using the hardware from step 2 Cable Connections 1 Remove the lower front panel of the trimmer and locate the yellow power cable coiled up inside the...

Page 39: ...r such that the slots in the conveyor mounting brackets line up with the holes in the trimmer s left hand side It may be necessary to adjust the Hand Feed Conveyor s leveling pads in order for the mou...

Page 40: ...to right 2 Open the rear doors and raise the rear end of the machine by adjusting the rear two lev eling pads until the trimmer table is level 3 Check the front end of the machine with the level to m...

Page 41: ...ting brackets line up with the holes in the side of the trimmer 4 Fasten the Outfeed Stacker to the trimmer using the hardware from step 2 Cable and Air Tubing Connections 1 Remove the lower front pan...

Page 42: ...e of blue air tub ing with a red and white connector on the end that is labelled with the number that cor responds to the label on the outfeed stacker near the input connectors 7 Connect the air tubin...

Page 43: ...panel of the trimmer and locate the yellow power cable coiled up inside the trimmer that is labelled with the number that corresponds to the label on the exit conveyor near the input connectors The po...

Page 44: ...Guide 2 6 3 Exit Ramp Setup Procedure To install the Exit Ramp option simply attach the Exit Ramp as shown in Figure 2 39 below using the hardware provided Figure 2 39 Exit Ramp Placement Now go to S...

Page 45: ...ower at main disconnect switch before working on the trimmer Lock it out to prevent acci dental power up See Power Lockout Proce dure on page 1 4 1 Locate the electrical panel door at the lower right...

Page 46: ...tart button is pressed If power is incor rectly connected the mechanism will remain in the down position If power was correctly connected skip steps 14 18 and go to Section 2 8 Main Air Hookup 14 Swit...

Page 47: ...50 OIL Including Liquid and Vapor ISO QUALITY CLASS Mg m3 ppm 1 0 01 0 008 2 0 1 0 08 3 1 0 8 4 5 4 5 25 21 6 CAUTION Failure to use dry non lubricated compressed air that meets or exceeds the precedi...

Page 48: ...sary to clean the trimmer and accessories after installation If so use a mild non abrasive soap and water solution and a moist cloth Do not use petroleum or acid based cleaners or solvents to clean th...

Page 49: ...Job 3 4 3 4 3 Editing an Existing Job 3 5 3 4 4 Lock Unlock a Job 3 5 3 4 5 Deleting a Job 3 5 3 4 6 Storing Jobs on a USB Drive 3 5 3 4 7 Copying Jobs 3 5 3 4 8 Job Options 3 5 3 5 Barcode Mode 3 6 3...

Page 50: ...APR 2018 CMT 330TC Three Knife Trimmer 3 2 3 Operator s Guide 3 1 The TC Console Figure 3 1 CMT 330TC Console...

Page 51: ...tialized the Run screen will appear and display the installed infeed and outfeed accessories Figure 3 5 Figure 3 5 Run Screen The trimmer is now ready to trim books to the di mensions shown on the rig...

Page 52: ...key in the desired dimensions of the fin ished book The graphic on the left side of the screen will show which dimension you are enter ing There are sensors in the machine that will determine the thic...

Page 53: ...ghlighted click on the Lock Save button A star will appear next to the job name to indicate that it is locked Click the button again to unlock the job 3 4 5 Deleting a Job Deleting a job will permanen...

Page 54: ...this parameter correctly in order to obtain the best results Failure to do so may prevent books from being registered properly 3 4 8 4 Finish Cut The finish cut option turns on a sequence where each s...

Page 55: ...mming was suc cessful for the selected barcode format When the job options have been set press the SAVE button to save the settings To start the job press the green Start button next to the con sole T...

Page 56: ...APR 2018 CMT 330TC Three Knife Trimmer 3 8 3 Operator s Guide Figure 3 15 Barcode Specifications...

Page 57: ...This sets the minimum thickness of books that will trigger a finish cut when finish cut is set to Auto Input Offset This adjusts how far an incoming book travels on the conveyors before it is clamped...

Page 58: ...Software and Program Flash Used to update the CMT 330TC software The latest software version as well as step by step updat ing instructions can be found at www challengemachinery com software Load Par...

Page 59: ...e 6125 is entered into the Enable Tabs Code input box on the Service Info tab Note Settings on this screen must be set correctly or else damage to machine could result Use caution when editing To adju...

Page 60: ...APR 2018 CMT 330TC Three Knife Trimmer 3 12 3 Operator s Guide NOTES...

Page 61: ...Depth Adjustment 4 8 4 7 Safety Systems Check 4 10 4 7 1 Safety Check Off Sheet 4 11 Introduction Certain tasks should be performed on a regular basis For example the safety systems check should be do...

Page 62: ...ock it in place 4 2 Waste Bins The three waste bins may require emptying in the middle of a shift but it is a good idea to do it before a shift begins Sensors detect when a waste bin is full If any on...

Page 63: ...l it slides off the four pins in the table If nec essary slide the end of a flat blade screw driver between the slot in the table and the cut plate Figure 4 5 Carefully pry the plate up with the screw...

Page 64: ...installing Figure 4 8 If all 4 surfaces have been used twice replace the stick with a new one Figure 4 8 Cut Stick Rotation 8 Firmly press the new or rotated cut stick all the way down into the slot T...

Page 65: ...gning each lifter handle with the holes from which the two knife bolts were removed in the pre vious step Turn the handles clockwise until the lifter is securely fastened to the knife bar Figure 4 13...

Page 66: ...dis connect switch is locked out as described in Section 1 6 Power Lockout Procedure on page 1 4 2 Turn both knife depth adjustment han dles counterclockwise until they stop Figure 4 14 This will set...

Page 67: ...with screws tight ened You are aware of the dangers but oth ers may not be Never attempt to hone polish or service the knife in any way Fail ure to follow safety procedures may result in severe lacera...

Page 68: ...ned to less than 2 50 in 63 5 mm 4 5 5 Knife Care Tips WARNING Knives are DANGEROUS They are heavy and very sharp even after use Keep the edge away from your body and keep the area clear of others whe...

Page 69: ...nt of trim off the face of the book The spine should be facing the front of the ma chine 7 Place a scrap book under the side knives such that the knives will cut a small amount of trim off the top and...

Page 70: ...the door Left Rear Sliding Door Interlock 1 Switch on the main power 2 Press the green start button on the front console and wait for the trimmer to initialize 3 Open the left rear sliding door All m...

Page 71: ...ks 4 7 1 Safety Check Off Sheet Use this sheet to sign tester s initials and test dates for performing the Safety Systems Check on page 4 10 of the Installation and Operator s Manual Machine Model CMT...

Page 72: ...APR 2018 CMT 330TC Three Knife Trimmer 4 12 4 Routine Tasks NOTES...

Page 73: ...ll Sheets Not Cut 5 4 5 9 Books Not Accurately Trimmed 5 4 5 10 Books Not Square 5 5 Introduction Occasionally it may be necessary to trouble shoot book quality issues The sections that fol low provid...

Page 74: ...ur when deep score marks develop in the cut stick The cover is pushed into the score mark folded over and torn Figure 5 2 Jagged Cover Possible Causes The cut plates and or stick may be worn The knive...

Page 75: ...t books Use the clamp pressure adjustment knob located inside the lower back door if equipped Note Reducing the clamp pressure too much will cause other quality problems such as draw Only reduce clamp...

Page 76: ...Cutting Through Possible Causes The knives are not adjusted deep enough The cut plates and or cut stick may be worn Solutions Adjust the knife depth see Section 4 6 Knife Depth Adjustment Rotate or re...

Page 77: ...the binding leav ing a knob like protrusion The protru sion interfered with the trimmer s regis tration and squaring process Normal wear has forced the cutting or registration mechanisms out of square...

Page 78: ...16 11 11 0 453 29 64 11 51 0 469 15 32 11 91 0 484 31 64 12 30 0 500 1 2 12 70 0 516 33 64 13 10 0 531 17 32 13 49 0 547 35 64 13 89 0 563 9 16 14 29 0 578 37 64 14 68 0 594 19 32 15 08 0 609 39 64 1...