Challenge CMT-330 Installation And Operator's Manual
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Challenge CMT-330 Installation And Operator's Manual

Challenge CMT-330 Installation And Operator's Manual

Three-knife trimmer
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CMT-330
Three-Knife Trimmer
Installation and
Operator's Manual
Serial Numbers: 12040256 through 15999999,
330T-C-150000 and up
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441 USA
ChallengeMachinery.com
CMT-330 Three Knife Trimmer
THE CHALLENGE MACHINERY COMPANY
SERIAL No.: ____________________
F.033C / APR 2018

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  • Page 1 CMT-330 Three-Knife Trimmer Installation and Operator's Manual Serial Numbers: 12040256 through 15999999, 330T-C-150000 and up The Challenge Machinery Company 6125 Norton Center Drive Norton Shores, MI 49441 USA SERIAL No.: ____________________ ChallengeMachinery.com F.033C / APR 2018 CMT-330 Three Knife Trimmer...
  • Page 2 Attempting these procedures without proper training may cause machine damage or operator injury! Prepared by: Products may be unsupported by The Challenge Machinery Company due to age or the unavail- ability of parts from their original manufacturer. No parts or product support will be available to The Challenge Machinery Company repair or maintain unsupported products.

  • Page 3: Table Of Contents

    3.6 Example Job ........... 3-13 4. Routine Tasks Contents ............4-1 Introduction ............. 4-1 4.1 Book Underside Air Lift ......4-2 4.2 Waste Bins ..........4-2 4.3 Cut Stick / Cut Plates ........ 4-3 APR 2018 CMT-330 Three Knife Trimmer Introduction...
  • Page 4 Notes: APR 2018 CMT-330 Three Knife Trimmer Introduction...

  • Page 5: Introduction

    1.8.2 Site Specifications ......1-13 Introduction The introduction section of this manual is in- tended to provide installers and operators with basic information. Safety recommendations are made and machine options and specifications are listed. APR 2018 CMT-330 Three Knife Trimmer 1. Introduction...

  • Page 6: Warranty Information

    Copy this page, fill in the information and Follow all precautions and instructions. For this manual and return it DIRECTLY TO send it care of The Challenge Service Depart- ment, 6125 Norton Center Drive  Norton parts and service contact the Authorized Chal- CHALLENGE.

  • Page 7: Warning Label Definitions

    Author- Cut / Crush Hazard! nance procedure, practice, or condition that, ized Challenge Dealer. Failure to un- Do not operate with covers re- if not strictly observed, could result in injury derstand the operating instructions may moved.

  • Page 8: Power Lockout Procedure

    Tip hazards may result from un- secured accessories.  If the machine operates abnormally, consult a Challenge authorized service agent. Figure 1-1. Main Power Disconnect APR 2018 CMT-330 Three Knife Trimmer 1. Introduction...

  • Page 9: Packing List

    1.6 Packing List APR 2018 CMT-330 Three Knife Trimmer 1. Introduction...
  • Page 10 Compare the contents of the crate against the CMT-330 Shown with Tilt In-Feed Conveyor, Cooling Elevator, and Vertical Stacker Part Number Description Qty. CMC-330C CMT-330 Basic Machine Infeed Options – In-Line 56600B & 56421B Tilt In-Feed Conveyor and Cooling Elevator Infeed Options –...

  • Page 11: Basic Machine/Options

    1.6.1 Basic Machine/Options This parts list includes the basic machine and any accessories that may have been ordered with the machine. APR 2018 CMT-330 Three Knife Trimmer 1. Introduction...

  • Page 12: Standard Accessories

    1.6.2 Standard Accessories The following list contains pre-installed, standard accessories for the CMT-330. Item Part Number Description Qty. 5064 Cut Stick Puller 56028 Knife Lifter 56143 Waste Bin 56246 Knife Set of 3 (scabbard not shown) 56275 Knife Height Spacer...

  • Page 13: Optional Items

    1.6.3 Optional Items 1.6.4 Consumables The following items and accessories are op- The CMT-330 uses the following consumable tional. items. 56246-2 Super HSS 5X Knives (3) Part Description Qty. Frequency 56246-1 Tungsten Carbide Knives (3) E-967-1 Lamp 10,000 hrs 41058...

  • Page 14: Specifications

    Height x Width x Depth 5 x 10 x 12 in. 13 x 25 x 30 cm isting units. Note: See Section 1.8.2 for floor space requirements of the CMT-330 with various option configurations. APR 2018 CMT-330 Three Knife Trimmer 1-10...

  • Page 15: Book Size Chart

    The book size must fall within the shaded region of the chart but never exactly on the sloped line. The CMT-330 software will not allow a book to be cut outside this range. The operator should Figure 1-2. Trimmable Book Sizes...

  • Page 16: General Locations

    Remember these references while reading instructions in this manual. Refer back Figure 1-5. Left Rear View to these figures as necessary. Figure 1-4. Right Front View APR 2018 CMT-330 Three Knife Trimmer 1-12 1. Introduction...

  • Page 17: Site Specifications

    1.8.2.1 Hand Feeder and Stacker Configura- tion Figure 1-6 Hand Feeder and Stacker Configuration APR 2018 CMT-330 Three Knife Trimmer 1-13 1. Introduction...
  • Page 18 1.8.2.2 Pile Feeder and Stacker Configura- tion Figure 1-7 Pile Feeder and Stacker Configuration APR 2018 CMT-330 Three Knife Trimmer 1-14 1. Introduction...
  • Page 19 1.8.2.3 In-line Tilt Conveyor with Elevator and Stacker Configuration Figure 1-8 In-line Tilt Conveyor with Elevator and Stacker Configuration APR 2018 CMT-330 Three Knife Trimmer 1-15 1. Introduction...
  • Page 20 1.8.2.4 Hand Feeder and Exit Conveyor Con- figuration Figure 1-9 Hand Feeder and Exit Conveyor Configuration APR 2018 CMT-330 Three Knife Trimmer 1-16 1. Introduction...
  • Page 21 1.8.2.5 Pile Feeder and Exit Conveyor Con- figuration Figure 1-10 Pile Feeder and Exit Conveyor Configuration APR 2018 CMT-330 Three Knife Trimmer 1-17 1. Introduction...
  • Page 22 1.8.2.6 In-line Tilt Conveyor with Elevator and Exit Conveyor Configuration Figure 1-11 In-line Tilt Conveyor with Elevator and Exit Conveyor Configuration APR 2018 CMT-330 Three Knife Trimmer 1-18 1. Introduction...
  • Page 23 1.8.2.7 Hand Feeder and Exit Ramp Configu- ration Figure 1-12 Hand Feeder and Exit Ramp Configuration APR 2018 CMT-330 Three Knife Trimmer 1-19 1. Introduction...
  • Page 24 1.8.2.8 Pile Feeder and Exit Ramp Configu- ration Figure 1-13 Pile Feeder and Exit Ramp Configuration APR 2018 CMT-330 Three Knife Trimmer 1-20 1. Introduction...
  • Page 25 1.8.2.9 In-line Tilt Conveyor with Elevator and Exit Ramp Configuration Figure 1-14 In-line Tilt Conveyor with Elevator and Exit Ramp Configuration APR 2018 CMT-330 Three Knife Trimmer 1-21 1. Introduction...
  • Page 26 Notes: APR 2018 CMT-330 Three Knife Trimmer 1-22 1. Introduction...

  • Page 27: Installation Guide

    2.8.1 Compressed Air Requirements ... 2-8 2.8.2 Air Hookup Procedure ......2-9 2.9 Cleaning ............ 2-9 Introduction The installation guide provides information and instructions essential to the proper setup of the CMT-330 and its accessory options. APR 2018 CMT-330 Three Knife Trimmer 2. Installation Guide...

  • Page 28: Shipping Claims

    2.4 In-feed Setup The CMT-330 can be used either In-Line with a perfect binder or as a Stand-Alone three knife trimmer. The following table lists the in-feed op- tions for each application.

  • Page 29: In-Line In-Feed Option Setup

    Figure 2-9. Position such that the lower surface of the bracket opening is 1/32” (1mm) below the trimmer's in- feed conveyor belt. Figure 2-5. Height Adjustment APR 2018 CMT-330 Three Knife Trimmer 2. Installation Guide...

  • Page 30: Pile Feeder Option Setup

    For the Book Pile Feeder option setup, consult through the front door panel. until the trimmer height is set (Section the instructions and parts manual supplied with In-feed Conveyor the Book Pile Feeder. APR 2018 CMT-330 Three Knife Trimmer 2. Installation Guide...

  • Page 31: Standard Hand-Feed Option Setup

    2. Remove (4) sets of screws and washers Figure 2-16. Hand-feed Mounting Brackets fastened to the center of the door on the 5. Fasten the conveyor to the trimmer us- ing the hardware from step 1. APR 2018 CMT-330 Three Knife Trimmer 2. Installation Guide...

  • Page 32: Trimmer Setup

    Figure 2-17. Tighten Jam Nuts 2.5 Trimmer Setup 2.6 Out-feed Setup With the trimmer positioned in its final loca- The available CMT-330 out-feed options (3) are tion, follow these steps to complete the trim- Figure 2-18. Exit Conveyor as follows:...

  • Page 33: Power Hookup

    380/415 2.7.1 Power Hookup Procedure The following procedure describes how to hookup main power to the CMT-330. After power is hooked up, running the machine will verify if wires are correctly connected to the ter- minal block on the power panel.

  • Page 34: Air Hookup

    Figure 2-24. The hy- 2.8.1 Compressed Air Requirements draulic motor should turn on. The ma- The CMT-330 requires 80-90 PSI regulated, dry, chine was shipped with all three knives non-lubricated compressed air at a minimum of in the down position. If power is hooked 5 cubic feet per minute (at 80-90 PSI).

  • Page 35: Cleaning

    3/8 NPT port. A facilities maintenance chine. Damage may result. technician should connect shop air using a male 3/8 NPT fitting using either Teflon thread tape or a liquid, pipe sealing compound. APR 2018 CMT-330 Three Knife Trimmer 2. Installation Guide...
  • Page 36 Notes: APR 2018 CMT-330 Three Knife Trimmer 2-10 2. Installation Guide...

  • Page 37: Operator's Guide

    3.5 Status Messages ........3-10 3.6 Example Job ........... 3-13 Introduction The operator's guide provides instructions es- sential to operating the CMT-330 with each ac- cessory option. These instructions include pro- gramming instructions and book size changeo- ver tasks. APR 2018 CMT-330 Three Knife Trimmer 3.

  • Page 38: Control Console

    3.1 Control Console Interfacing with the CMT-330 is accomplished by use of the control console. 3.1.1 Console Descriptions The console is found on the front of the ma- chine. General areas of the console are shown in Figure 3-1. The specific function of each key on the console is given in this section.

  • Page 39: Key Descriptions

    The plus key is used to add numbers in the dis- play. The clear key is used to clear an entry value or clear an status message. APR 2018 CMT-330 Three Knife Trimmer 3. Operator's Guide...

  • Page 40: Using The Keypad

    Down Arrow Key Entering Math Rather than using a separate calculator, the CMT-330's computer can calculate lengths as you enter values. However, you should be fa- miliar with the order of numerical operations if The enter key selects items in menu screens The down arrow key is used to move the screen you intend to use this feature.

  • Page 41: User Interface Map

    3.2 User Interface Map The following chart illustrates the organization of user interface screens encountered in the CMT- 330 software. Figure 3-2. CMT-330 User Interface Map APR 2018 CMT-330 Three Knife Trimmer 3. Operator's Guide...

  • Page 42: Power Up

    3.4 Jobs B ) J o b 3.3.1 Initialization The CMT-330 uses jobs to do all of its book trim- Press and hold the green start button until the Figure 3-5. Example Job Run Screen ming. A job is a set of trim dimensions and set- hydraulic motor starts.

  • Page 43: Creating A Job

    Numbers APR 2018 CMT-330 Three Knife Trimmer 3. Operator's Guide...

  • Page 44: Lock/Unlock A Job

    Use the “Face & Side On” setting to trim all sides of the book (top, bottom, and face). Use “Side Cut Off” to trim only the APR 2018 CMT-330 Three Knife Trimmer 3. Operator's Guide...

  • Page 45: Running A Job

    Or if you are ready to start feeding and trimming books, simply press APR 2018 CMT-330 Three Knife Trimmer 3. Operator's Guide...

  • Page 46: Status Messages

    F a i l u r e The slow down proximity sensor did not respond before the down proximity sensor. The face knife slow down proximity sensor is either misadjusted or faulty. APR 2018 CMT-330 Three Knife Trimmer 3-10 3. Operator's Guide...
  • Page 47 The side knife latch proximity sensor did not activate. This can be caused by a faulty or d i s e n g a g e misadjusted proximity sensor. The air cylinder may have failed to pull in. APR 2018 CMT-330 Three Knife Trimmer 3-11 3. Operator's Guide...
  • Page 48 Either a stop button is pressed or one is faulty. U p p e r d o o r O p e n One of the upper doors is open. APR 2018 CMT-330 Three Knife Trimmer 3-12 3. Operator's Guide...

  • Page 49: Example Job

    Figure 3-17. Job Selection Screen Create a new job number by typing an un-used job number, then press the enter key. The screen will then look similar to Figure 3-18. APR 2018 CMT-330 Three Knife Trimmer 3-13 3. Operator's Guide...
  • Page 50 A ) M a i n t . C ) O p t i o n s B ) J o b Figure 3-19. Job Name Figure 3-21. Completed Job Run Screen APR 2018 CMT-330 Three Knife Trimmer 3-14 3. Operator's Guide...
  • Page 51 APR 2018 CMT-330 Three Knife Trimmer 3-15 3. Operator's Guide...
  • Page 52 Notes: APR 2018 CMT-330 Three Knife Trimmer 3-16 3. Operator's Guide...

  • Page 53: Routine Tasks

    Per- forming as many of these tasks before a shift begins prevents down time while a job is in pro- gress and ensures safe operation of the ma- chine. APR 2018 CMT-330 Three Knife Trimmer 4. Routine Tasks...

  • Page 54: Book Underside Air Lift

    When the waste bins are is located at the back of the machine. of lift may require adjustment depending on the near capacity during a job run, the CMT-330 Figure 4-3 and Figure 4-4 show the thickness of books being trimmed.

  • Page 55: Cut Stick / Cut Plates

    4-3. The cut stick puller has a finger hold before disposal. To use a surface twice, and hook as shown in Figure 4-5. reinstall the cut stick by turning it such APR 2018 CMT-330 Three Knife Trimmer 4. Routine Tasks...

  • Page 56: Knives

    3. The knives are located behind the doors may result if knives are not from the same set. 8. Securely close the double doors at the shown in Figure 4-9 and Figure 4-10. back of the machine. APR 2018 CMT-330 Three Knife Trimmer 4. Routine Tasks...
  • Page 57 16. Repeat steps 4 through 15 with the re- and fifth bolts from either end of the mainder of the knives. knife. Set the bolts aside and save for knife installation. WARNING APR 2018 CMT-330 Three Knife Trimmer 4. Routine Tasks...
  • Page 58 25. Turn the handles counterclockwise 1/2 not move down as the handles are tight- (Figure 4-13) and Turn both knobs turn so the ends of the handles will not ened. clockwise until they stop. APR 2018 CMT-330 Three Knife Trimmer 4. Routine Tasks...

  • Page 59: Knife Adjustment

    If the bot- ing the inside of the machine. Face Knife Adjustment tom cover and binding of the book are 8. Securely close the set of double doors. APR 2018 CMT-330 Three Knife Trimmer 4. Routine Tasks...

  • Page 60: Knife Spacers

    The knives should not be sharpened to less than 2.50 in. (63.5 mm). Each time a set of knives are sharpened, a small amount of material is removed. Once the knife APR 2018 CMT-330 Three Knife Trimmer 4. Routine Tasks...

  • Page 61: Check Pressure Switch

    Make photo- 2. Press the green start button at the con- sole to start the hydraulic motor. copies of the check-off sheet as necessary. sole to start the hydraulic motor. APR 2018 CMT-330 Three Knife Trimmer 4. Routine Tasks...

  • Page 62: Safety Check-Off Sheet

    Use this sheet to sign tester's initials and test Serial Number: _________________________ dates for performing the Safety Systems Check on page 4-9 of the Installation and Operator's Manual. TESTER DATE TESTER DATE TESTER DATE APR 2018 CMT-330 Three Knife Trimmer 4-10 4. Routine Tasks...

  • Page 63: Book Quality

    Other quality issues such as accuracy and square should be referred to an authorized tech- nician because they involve service repairs or adjustments, which are outside the scope of an operator's training. APR 2018 CMT-330 Three Knife Trimmer 5. Book Quality...

  • Page 64: Burr Marks

    If the problem is on the top or bottom Rotate or replace the cut plates. knives sharpened separately. faces of the book, the cut plates may need rotation or replacement. The knives may also require replacement. APR 2018 CMT-330 Three Knife Trimmer 5. Book Quality...

  • Page 65: Rectangular Crease Lines

    Solutions Solutions sure for the stock being cut.   Check clamp pressure and/or system Consult the CMT-330 Technical Manual Solutions pressure. Clamp pressure and system for this adjustment.  Turn or change the cut plates. pressure should be 80-90 PSI. Turn ...

  • Page 66: All Sheets Not Cut

     If normal wear has forced the cutting or  Replace the cut stick or cut plates. transport mechanisms out of square, re- fer the problem to an authorized service agent. APR 2018 CMT-330 Three Knife Trimmer 5. Book Quality...
  • Page 67 Notes APR 2018 CMT-330 Three Knife Trimmer 5. Book Quality...
  • Page 68 41/64 16.27 0.984 63/64 25.00 0.656 21/32 16.67 1.000 64/64 25.40 APR 2018 © 2002-2018 by The Challenge Machinery Company. All rights reserved. Printed in the USA F.033C / CMT-330C / APR 2018 CMT-330 Three Knife Trimmer 5. Book Quality...

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