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

Challenge CMT-330TC Installation And Operator's Manual

Three-knife trimmer
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THE CHALLENGE MACHINERY COMPANY
CMT-330TC
Three-Knife Trimmer
Installation and
Operator's Manual
Serial Numbers: 330TC-A-161000 and up
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441 USA
SERIAL No.: ____________________
ChallengeMachinery.com
F.033TCA / APR 2018
CMT-330TC Three-Knife Trimmer

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  • Page 1 THE CHALLENGE MACHINERY COMPANY CMT-330TC Three-Knife Trimmer Installation and Operator's Manual Serial Numbers: 330TC-A-161000 and up The Challenge Machinery Company 6125 Norton Center Drive Norton Shores, MI 49441 USA SERIAL No.: ____________________ ChallengeMachinery.com F.033TCA / APR 2018 CMT-330TC 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

    2.1 Shipping Claims ........2-2 3.6.6 Hydraulic/Air ........3-10 2.2 Unpacking ..........2-2 3.6.7 Accuracy Adjust......... 3-11 2.3 Moving ............2-2 3.7 Diagnostics ..........3-11 2.4 Infeed Setup ..........2-3 2.4.1 Tilt Conveyor + Elevator...... 2-3 APR 2018 CMT-330TC Three-Knife Trimmer Introduction...
  • Page 4 Notes: APR 2018 CMT-330TC Three-Knife Trimmer Introduction...

  • Page 5: Introduction

    1.10.12 Hand Feeder + Exit Ramp .... 1-23 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-330TC Three-Knife Trimmer 1. Introduction...

  • Page 6: Warranty Information

    Follow all precautions and instructions. For mined for this machine at the factory: ord at Challenge. Copy this page, fill in the in- parts and service contact the Authorized Chal- formation and send it care of The Challenge Service Department, 6125 Norton Center Drive ...

  • Page 7: Warning Label Definitions

    Do not operate with covers re- tions remain, contact your Authorized if not strictly observed, could result in injury moved. Challenge Dealer. Failure to understand or loss of life. Do not disable safety devices. the operating instructions may result in personal injury.

  • Page 8: Power Lockout Procedure

    Make sure all applicable accessories are securely bolted to the main machine. Tip hazards may result from unsecured acces- sories.  If the machine operates abnormally, con- sult a Challenge authorized service agent. Figure 1-1. Main Power Disconnect APR 2018 CMT-330TC Three-Knife Trimmer 1. Introduction...

  • Page 9: Packing List

    1.7.1 Base Machine/Options This parts list includes the base machine and any accessories that may have been ordered with it. CMT-330TC Shown with Tilt Conveyor, Elevator, Pile Feeder, and Vertical Stacker Part Number Description Qty. CMC-330TCA-SW...

  • Page 10: Standard Accessories

    1.7.2 Standard Accessories The following list contains the supplied, standard Part Number Description Qty. accessories for the CMT-330TC. 56248 Knives (HSS) - Set of 3 56275 Knife Height Spacer 56028 Knife Lifter 5064 Cut Stick Puller W-164 5/16" T-Handle Hex Wrench...

  • Page 11: Optional Items

    Spare Parts Kit – CMT-330TC K-56030-3 K-56040 Oil Change Kit K-56031 Oil Change Tool Kit S-1991-3 Hydraulic Fluid (5 Gal.) 1.7.4 Consumables The CMT-330TC uses the following consumable items: Part Description Qty. Frequency 56569 UHMW Tape (Joggers) 2 x 14 in. 1 yr.

  • Page 12: Specifications

    Height x Width x Depth 5 x 10 x 15 in. 13 x 25 x 38 cm Note: See Section 1.10 for floor space requirements of the CMT-330TC with various option configurations APR 2018 CMT-330TC Three-Knife Trimmer 1. Introduction...

  • Page 13: Book Size Chart

    (See 1.8 Specifica- tions). The CMT-330TC software will not allow a book to be cut outside this range. The operator should be aware of these size constraints before Figure 1-2. Book Size Charts books are printed.

  • Page 14: General Locations

    Remember these references while reading instructions in this manual. Refer back to this figure as neces- sary. Figure 1-3 Locations APR 2018 CMT-330TC Three-Knife Trimmer 1-10 1. Introduction...

  • Page 15: Floor Space Requirements

    Note the air and power hook-up locations. Air and power lines should be dropped from the ceiling in order to have clear access to the waste bins using a rolling cart. APR 2018 CMT-330TC Three-Knife Trimmer 1-11 1. Introduction...

  • Page 16: Tilt + Elev. + Stacker

    1.10.1 Tilt + Elev. + Stacker Figure 1-4 In-line Tilt Conveyor with Elevator and Stacker Configuration APR 2018 CMT-330TC Three-Knife Trimmer 1-12 1. Introduction...

  • Page 17: Tilt + Elev. + Pile Feeder + Stacker

    1.10.2 Tilt + Elev. + Pile Feeder + Stacker Figure 1-5 In-line Tilt Conveyor with Elevator, In-Line Pile Feeder and Stacker Configuration APR 2018 CMT-330TC Three-Knife Trimmer 1-13 1. Introduction...

  • Page 18: Pile Feeder + Stacker

    1.10.3 Pile Feeder + Stacker Figure 1-6 Pile Feeder and Stacker Configuration APR 2018 CMT-330TC Three-Knife Trimmer 1-14 1. Introduction...

  • Page 19: Hand Feeder + Stacker

    1.10.4 Hand Feeder + Stacker Figure 1-7 Hand Feeder and Stacker Configuration APR 2018 CMT-330TC Three-Knife Trimmer 1-15 1. Introduction...

  • Page 20: Tilt + Elevator + Exit Conveyor

    1.10.5 Tilt + Elevator + Exit Conveyor Figure 1-8 In-line Tilt Conveyor with Elevator and Exit Conveyor Configuration APR 2018 CMT-330TC Three-Knife Trimmer 1-16 1. Introduction...

  • Page 21: Tilt + Elev. + Pile Feed. + Exit Conv

    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 APR 2018 CMT-330TC Three-Knife Trimmer 1-17 1. Introduction...

  • Page 22: Pile Feeder + Exit Conveyor

    1.10.7 Pile Feeder + Exit Conveyor Figure 1-10 Pile Feeder and Exit Conveyor Configuration APR 2018 CMT-330TC Three-Knife Trimmer 1-18 1. Introduction...

  • Page 23: Hand Feeder + Exit Conveyor

    1.10.8 Hand Feeder + Exit Conveyor Figure 1-11 Hand Feeder and Exit Conveyor Configuration APR 2018 CMT-330TC Three-Knife Trimmer 1-19 1. Introduction...

  • Page 24: Tilt + Elev. + Exit Ramp

    1.10.9 Tilt + Elev. + Exit Ramp Figure 1-12 In-line Tilt Conveyor with Elevator and Exit Ramp Configuration APR 2018 CMT-330TC Three-Knife Trimmer 1-20 1. Introduction...

  • Page 25: Tilt + Elev. + Pile Feeder + Ramp

    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 APR 2018 CMT-330TC Three-Knife Trimmer 1-21 1. Introduction...

  • Page 26: Pile Feeder + Exit Ramp

    1.10.11 Pile Feeder + Exit Ramp Figure 1-14 Pile Feeder and Exit Ramp Configuration APR 2018 CMT-330TC Three-Knife Trimmer 1-22 1. Introduction...

  • Page 27: Hand Feeder + Exit Ramp

    1.10.12 Hand Feeder + Exit Ramp Figure 1-15 Hand Feeder and Exit Ramp Configuration APR 2018 CMT-330TC Three-Knife Trimmer 1-23 1. Introduction...
  • Page 28 NOTES APR 2018 CMT-330TC Three-Knife Trimmer 1-24 1. Introduction...

  • Page 29: Installation Guide

    2.8 Main Air Hookup ........2-19 2.9 Cleaning ..........2-20 Introduction The installation guide provides information and instructions essential to the proper setup of each of the CMT-330TC and its accessory options. APR 2018 CMT-330TC Three-Knife Trimmer 2. Installation Guide...

  • Page 30: Shipping Claims

    2.1 Shipping Claims 2.3 Moving 1. Remove the four screws from each of the The CMT-330TC has been packed to prevent Once the machine is near its final location, it can two lower front side doors using a 1/8" hex- damage during shipment.

  • Page 31: Infeed Setup

    2.4 Infeed Setup 2.4.1 Tilt Conveyor + Elevator of the tilt infeed conveyor should be set to The CMT-330TC can be used either in-line with about 13-7/8" (35.2 cm) from the floor and a perfect binder or as a stand-alone three-knife level (Figure 2-6).
  • Page 32 1/32” (1mm) below the trimmer's infeed rate communication cables that were sup- conveyor belt. plied with the infeed/outfeed options. Figure 2-11. Elevator Attachment to Trimmer 5. Connect the communication cables as shown in Figure 2-13. APR 2018 CMT-330TC Three-Knife Trimmer 2. Installation Guide...
  • Page 33 Also locate any separate air tubing sections that may have been supplied with the infeed/out- feed options. 7. Connect the air tubing as shown in Figure 2-14. APR 2018 CMT-330TC Three-Knife Trimmer 2. Installation Guide...

  • Page 34: Tilt Conv. + Elevator + Pile Feeder

    Figure 2-17. inside the trimmer that is labelled with the number that corresponds to the label on the elevator near the input connectors. The APR 2018 CMT-330TC Three-Knife Trimmer 2. Installation Guide...
  • Page 35 Figure 2-18. Air Tubing Connections Now go to Section 2.5 Trimmer Height Setup to continue the setup process. APR 2018 CMT-330TC Three-Knife Trimmer 2. Installation Guide...

  • Page 36: Pile Feeder (Stand Alone)

    Figure 2-21. number that corresponds to the label on the pile feeder near the input connectors. The power cables are the larger diameter cables with 7-pin connectors on the end. APR 2018 CMT-330TC Three-Knife Trimmer 2. Installation Guide...
  • Page 37 Figure 2-22. Air Tubing Connection Now go to Section 2.5 Trimmer Height Setup to continue the setup process. APR 2018 CMT-330TC Three-Knife Trimmer 2. Installation Guide...

  • Page 38: Standard Hand-Feed Conveyor

    2. Route the power cable under the hydraulic unit and out of the left side of the trimmer. 3. Connect the power cable as shown in Figure 2-25. APR 2018 CMT-330TC Three-Knife Trimmer 2-10 2. Installation Guide...

  • Page 39: Long Hand-Feed Conveyor

    It may be necessary to adjust the Hand- APR 2018 CMT-330TC Three-Knife Trimmer 2-11 2. Installation Guide...

  • Page 40: Trimmer Height Setup

    5. Lock all (6) leveling pads in place by tighten- ing the jam nuts against the inside of the machine's base as shown in Figure 2-30. The nuts are accessed from below the ma- chine. Figure 2-30. Tighten Jam Nuts APR 2018 CMT-330TC Three-Knife Trimmer 2-12 2. Installation Guide...

  • Page 41: Outfeed Setup

    2.6 Outfeed Setup 2.6.1 Vertical Outfeed Stacker outfeed stacker near the input connectors. There are (3) available CMT-330TC outfeed op- The power cables are the larger diameter tions: cables with 7-pin connectors on the end.
  • Page 42 7. Connect the air tubing as shown in Figure 2-34. APR 2018 CMT-330TC Three-Knife Trimmer 2-14 2. Installation Guide...

  • Page 43: Exit Conveyor

    Figure 2-38. Comm. Cable Connections 3. Connect the power cable as shown in Figure Now go to Section 2.7 Main Power Hookup to 2-37. continue the setup process. APR 2018 CMT-330TC Three-Knife Trimmer 2-15 2. Installation Guide...

  • Page 44: Exit Ramp

    Exit Ramp as shown in Figure 2-39 below using the hardware provided. Figure 2-39. Exit Ramp Placement Now go to Section 2.7 Main Power Hookup to continue the setup process. APR 2018 CMT-330TC Three-Knife Trimmer 2-16 2. Installation Guide...

  • Page 45: Main Power Hookup

    This section describes how to hookup main and remove the door. 6. Fasten the ground lead to the ground termi- power to the CMT-330TC. These procedures nal lug as shown in Figure 2-41. should be performed by a licensed electrician that is familiar with the local electrical codes in your area.
  • Page 46 16. Remove the power panel door at the right- hand side of the machine. 17. Exchange any two of the main power leads at the terminals L1, L2, or L3. 18. Repeat steps 8-13. APR 2018 CMT-330TC Three-Knife Trimmer 2-18 2. Installation Guide...

  • Page 47: Main Air Hookup

    Compressed Air Requirements Figure 2-43). Failure to use dry, non-lubricated compressed The CMT-330TC requires 80 – 90 PSI (550 – air that meets or exceeds the preceding require- 620 kPa) regulated, dry, non-lubricated com- ments may cause damage to the machine and pressed air at a minimum of 9 cfm at 90 PSI will result in THE WARRANTY BEING VOIDED.

  • Page 48: Cleaning

    Do not use petroleum or acid-based cleaners or solvents to clean the console or any part of the trimmer and accessories. Doing so may result in permanent damage. APR 2018 CMT-330TC Three-Knife Trimmer 2-20 2. Installation Guide...

  • Page 49: Operator's Guide

    3.4.8 Job Options ......... 3-5 3.5 Barcode Mode .......... 3-6 3.5.1 Bar Code Specifications ...... 3-7 Introduction The operator's guide provides instructions es- sential to operating the CMT-330TC, including programming instructions and trimming options. APR 2018 CMT-330TC Three-Knife Trimmer 3. Operator's Guide...

  • Page 50: The Tc Console

    3.1 The TC Console Figure 3-1. CMT-330TC Console APR 2018 CMT-330TC Three-Knife Trimmer 3. Operator's Guide...

  • Page 51: Power Up

    Once the machine is initialized, the Run screen 3.2 Power up will appear and display the installed infeed and To switch the power on to the CMT-330TC, turn outfeed accessories (Figure 3-5). the main power switch clockwise. Figure 3-3. Start Up Screen The startup screen lists the detected installed peripherals (infeed/outfeed options).

  • Page 52: Jobs

    There are sensors in the machine that will determine the thickness and the starting width of Figure 3-9. Job Run Screen the book, however if you wish to enter in these dimensions manually, change the pull down APR 2018 CMT-330TC Three-Knife Trimmer 3. Operator's Guide...

  • Page 53: Editing An Existing Job

    Start button next to the console. (Figure 3-6) by pressing the “Job” button. If us- ing a USB drive, make sure the drive is inserted before going to the Job List screen. APR 2018 CMT-330TC Three-Knife Trimmer 3. Operator's Guide...

  • Page 54: Barcode Mode

    The cut options determine which sides of the extended while the side joggers retract and the book will be trimmed. The following diagram When using the CMT-330TC in barcode mode, book leaves the registration area. This results in shows the different sides of the book:...

  • Page 55: Bar Code Specifications

    When the job options have been set, press the page. “SAVE” button to save the settings. To start the job, press the green Start button next to the con- sole. This will bring up the Barcode Run screen (Figure 3-14). APR 2018 CMT-330TC Three-Knife Trimmer 3. Operator's Guide...
  • Page 56 Figure 3-15. Barcode Specifications APR 2018 CMT-330TC Three-Knife Trimmer 3. Operator's Guide...

  • Page 57: Setup Options

    3.6 Setup Options default job option settings for new jobs. knife changes and machine lubrication. It also The setup options on the CMT-330TC can be gives knife counts and total cycle counts for the accessed from by pressing the “Setup” button lo- Spine Offset –...

  • Page 58: Color Settings

    Load Software and Program Flash – Used to correctly, or else damage to machine could 3.6.5 Options & Updates update the CMT-330TC software. The latest result! Use caution when editing. software version as well as step-by-step updat- ing instructions can be found at: Knife Cushion Value –...

  • Page 59: Accuracy Adjust

    Caution: When testing the jog pressure, make To adjust the accuracy, follow the instructions CMT-330TC Service Manual available at: sure to place a book in the jogger area first! displayed on the screen.
  • Page 60 NOTES APR 2018 CMT-330TC Three-Knife Trimmer 3-12 3. Operator's Guide...

  • Page 61: Routine Tasks

    This section will describe these tasks and more. Performing as many of these tasks before a shift begins prevents down time while a job is in progress and ensures safe oper- ation of the machine. APR 2018 CMT-330TC Three-Knife Trimmer 4. Routine Tasks...

  • Page 62: Book Underside Air Lift

    2. Locate the red locking ring and unlock it by pulling it toward you (away from the ma- chine). 3. To increase the amount of lift, such as for thicker books, adjust the valve counter- Figure 4-2. Stop Button Location clockwise. APR 2018 CMT-330TC Three-Knife Trimmer 4. Routine Tasks...

  • Page 63: Cut Plates

    If only one side of the plate is New cut plates can be purchased from your au- used, turn the plate over and reinstall it with thorized Challenge dealer. The part number is the smooth side up. Replace the cut plate listed in Section 1.7.4 Consumables.

  • Page 64: Knife Change

    If a surface has been used twice, rotate the stick to an unused surface before reinstalling (Figure APR 2018 CMT-330TC Three-Knife Trimmer 4. Routine Tasks...

  • Page 65: Knife Removal

    7. When the knife is free, move it down and clear of the knife bar. 8. Hold the knife lifter with knife at a safe dis- Figure 4-11. Knife Replacement Supplies tance from the body. Other people should APR 2018 CMT-330TC Three-Knife Trimmer 4. Routine Tasks...

  • Page 66: Knife Installation

    Figure 4-14. Knife Adjustment Knobs 10. Hold the knife lifter with knife at a safe dis- tance from the body. Other people should not be nearby. Carry the lifter to the installa- tion location. APR 2018 CMT-330TC Three-Knife Trimmer 4. Routine Tasks...

  • Page 67: Knife Life And Sharpening Info

    16. Place two knife bolts into the holes from significantly affect knife blade sharpness. Also, if which the knife lifter handles were removed the knife depth is set too deep, the knife will cut APR 2018 CMT-330TC Three-Knife Trimmer 4. Routine Tasks...

  • Page 68: Knife Spacers

    Sharpening Specifications A worn cut plate or cut stick can affect the cut quality of the bottom sheets. When this Knives for the CMT-330TC are shipped from happens, rotate or change the cut plate Challenge with a 20° bevel angle. Challenge and/or cut stick, even if it’s not time to...
  • Page 69 10. Open the doors and check each book. If the bottom cover of either book is not fully cut through, set the knife depth deeper by turn- ing the appropriate knife adjustment knob APR 2018 CMT-330TC Three-Knife Trimmer 4. Routine Tasks...

  • Page 70: Safety Systems Check

    1. Switch on the main power. All motors should stop running. 2. Press the green start button on the front 7. Close the door. console and wait for the trimmer to initialize. APR 2018 CMT-330TC Three-Knife Trimmer 4-10 4. Routine Tasks...

  • Page 71: 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 4-10 of the Installation and Operator's Manual. TESTER DATE TESTER DATE TESTER DATE APR 2018 CMT-330TC Three-Knife Trimmer 4-11 4. Routine Tasks...
  • Page 72 NOTES APR 2018 CMT-330TC Three-Knife Trimmer 4-12 4. Routine Tasks...

  • Page 73: Book Quality

    Most quality issues are resolved by changing the knives and cut plates/stick. Other quality issues such as accuracy and squareness should be re- ferred to an authorized service technician. APR 2018 CMT-330TC Three-Knife Trimmer 5. Book Quality...

  • Page 74: Burr Marks

    (see Section 4.3 Cut Plates   Replace the knives (see Section 4.5 Replace the knives (see Section 4.5 and/or 4.4 Cut Stick). Knife Change). Knife Change).  Replace the knives (see Section 4.5 Knife Change). APR 2018 CMT-330TC Three-Knife Trimmer 5. Book Quality...

  • Page 75: Rectangular Crease Lines

     Reduce the clamp pressure until crease crease lines disappear on test books lines disappear on test books. Use the Solutions (see CMT-330TC Service Manual to ad- clamp pressure adjustment knob located just).  Adjust the spine offset amount (see inside the lower back door (if equipped).

  • Page 76: Draw

    (see Section 4.3 Cut Plates ment knob located inside the lower back and/or 4.4 Cut Stick). door.  Replace the knives (see Section 4.5 Knife Change). APR 2018 CMT-330TC Three-Knife Trimmer 5. Book Quality...

  • Page 77: Books Not Square

    Adjust the binder such that glue will not be applied past the end of the binding.  If normal wear has forced the cutting or registration mechanisms out of square, refer the problem to an authorized ser- vice technician. APR 2018 CMT-330TC Three-Knife Trimmer 5. Book Quality...
  • Page 78 0.328 21/64 8.33 0.984 63/64 25.00 0.656 21/32 16.67 1.000 64/64 25.40 APR 2018 © 2018 by The Challenge Machinery Company. All rights reserved. Printed in the USA F.033TCA / CMT-330TCA / APR 2018 CMT-330TC Three-Knife Trimmer 5. Book Quality...

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