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MyBinding CMT 130 Instruction Manual

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CHALLENGE
CMT 130
BOOK TRIMMER
Instruction Manual
Provided By
http://www.MyBinding.com
http://www.MyBindingBlog.com

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  • Page 1 CHALLENGE CMT 130 BOOK TRIMMER Instruction Manual Provided By http://www.MyBinding.com http://www.MyBindingBlog.com...
  • Page 2 THE CHALLENGE MACHINERY COMPANY CMT 130 Book Trimmer Installation and Operator's Manual The Challenge Machinery Company 6125 Norton Center Drive Norton Shores, MI 49441 USA SERIAL No.: _____________ ChallengeMachinery.com F.013 / NOV 2009...
  • Page 3 The Challenge Machinery Company 6125 Norton Center Drive Norton Shores, MI 49441 USA Phone: 231.799.8484 Fax: 231.798.1275 ChallengeMachinery.com ©2009-2010 by The Challenge Machinery Company. All rights reserved. Challenge® is a registered trademark of The Challenge Machinery Company. 11/09 CMT 130 Book Trimmer...

  • Page 4: Table Of Contents

    4.1 Under Book Air Blast.........4-2 4.2 Waste Bin..........4-2 4.3 Cut Stick............4-2 4.4 Knife ............4-3 4.5 Check Pressure Switch......4-6 4.6 Safety Systems Check......4-7 5 Book Quality 5.1 Burr Marks..........5-2 5.2 Jagged Bottom Cover .......5-2 5.3 Burr Marks/Jagged Cover ......5-2 11/09 Contents CMT 130 Book Trimmer...
  • Page 5 Notes: 11/09 CMT 130 Book Trimmer...

  • Page 6: Introduction

    1.6.4 Consumables........1-7 1.7 Specifications ..........1-8 1.7.1 Book Size Chart ......... 1-9 1.8 General Locations........1-10 1.9 Exit Conveyor......... 1-11 1.9.1 Advanced In-Feed Conveyor.... 1-12 1.9.2 Elevator ..........1-13 1.9.3 Site Specifications ......1-14 11/09 Introduction CMT 130 Book Trimmer...

  • Page 7: Warranty Information

    Dealer Name: ________ pletely and returned to THE CHALLENGE MACHINERY COMPANY in order for the war- Dealer City: ranty to be issued for this machine. ________ Accuracy Adjustment Values ________ ________ ________ inches inches 11/09 Warranty Information CMT 130 Book Trimmer...

  • Page 8: Warning Label Definitions

    Severe lacera- tions or dismemberment could result Electrical Shock Hazard! from careless handling procedures. Disconnect power before removing • Perform the given on page 4-7 before cover. each shift begins. 11/09 Warning Label Definitions CMT 130 Book Trimmer...

  • Page 9: 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 11/09 Power Lockout Procedure CMT 130 Book Trimmer...

  • Page 10: Packing List

    CMT 130 Base Machine Accessory Options Stand-Alone Options 58500 Book Pile Feeder (shown above) 58000 Vertical Stacker (shown above) 59200 CMT 130 Manual In-feed (small, not shown 56413 Hand-Feed Conveyor (large, not shown 56420 Exit Conveyor (not shown) In-line Option...

  • Page 11: Standard Accessories

    1.6.2 Standard Accessories The following list contains pre-installed, stan- dard accessories for the CMT 130. Item Part Number Description Qty. 5064 Cut Stick Puller 41058 Waste Bin 59050 Cut Stick 59051-2 DMD 5X Knife 59070 Knife Lifter Assembly H-6910-606 Knife Screw- 3/8-16 X ¾ BHC W-180 7/32"...

  • Page 12: Optional Items

    K-56030 Spare Parts Kit K-56040 Oil Change Kit K-56031 Oil Change Tool Kit S-1991-3 Hydraulic Fluid (5 Gal.) 1.6.4 Consumables The CMT 130 uses the following consumable items. Part Description Qty. Frequency E-967-1 Lamp 10,000 hrs as needed 56523-1000 UHMW Tape 1 yr.

  • Page 13: Specifications

    177.8 x 177.8mm WARNING 147.8 (spine) x 101.6 mm Min. finish book 5.82 (spine) x 4 in. The CMT 130 was designed specifically for use with the Max. trim (Top) 6 in. 152 mm Challenge in-feed and exit accessories. If any other Max.

  • Page 14: Book Size Chart

    1.7.1 Book Size Chart are printed. The CMT 130 will not allow the top The physical parts of a book are defined as fol- or bottom to be trimmed by itself. lows and will be referenced as such throughout this manual.

  • Page 15: General Locations

    This manual frequently refers to these locations. In order to understand the instruc- tions presented, it is necessary to have a work- ing knowledge of machine locations. Figure 1-3 Left Rear View Figure 1-4 Right Front View 11/09 General Locations CMT 130 Book Trimmer 1-10...

  • Page 16: Exit Conveyor

    1.9 Exit Conveyor Part Number: 56420 Important locations are shown in Figure 1-5. Figure 1-5. Exit Conveyor Locations 11/09 Exit Conveyor CMT 130 Book Trimmer 1-11...

  • Page 17: Advanced In-Feed Conveyor

    1.9.1 Advanced In-Feed Conveyor Part No.: 56600 Important locations are shown in Figure 1-6. Figure 1-6. Advanced In-Feed Conveyor 11/09 Exit Conveyor CMT 130 Book Trimmer 1-12...

  • Page 18: Elevator

    1.9.2 Elevator Part Number: 56421 Important locations are shown in Figure 1-7. Figure 1-7. Elevator Locations 11/09 Exit Conveyor CMT 130 Book Trimmer 1-13...

  • Page 19: Site Specifications

    It includes the CMT 130 base machine, the Ad- vanced Infeed Conveyor, the Elevator, and the Vertical Stacker. See Figure 1-8 for space re- quirements.
  • Page 20 Note the locations of 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 with a rolling cart. Figure 1-9. Stand-Alone Option 11/09 Exit Conveyor CMT 130 Book Trimmer 1-15...
  • Page 21 Notes: 11/09 Exit Conveyor CMT 130 Book Trimmer 1-16...

  • Page 22: Installation Guide

    The installation guide provides information and 2.1 Shipping Claims ........2-2 instructions essential to the proper setup of 2.2 Unpacking ..........2-2 each of the CMT 130 and its accessory options. 2.3 Moving............2-2 2.4 In-Feed/Exit Options .........2-3 2.4.1 In-Line Options ........2-3 2.4.2 Stand-Alone Options ......

  • Page 23: Shipping Claims

    2.1 Shipping Claims screws from the two front locations WARNING The CMT 130 has been packed to prevent dam- shown in Figure 2-1. Do not roll on a graded surface. Roll only on a flat sur- age during shipment. Claims for damage or face.

  • Page 24: In-Feed/Exit Options

    2.4.1.2 Elevator 2.4 In-Feed/Exit Options 1. The top shelf should be 36" (914 mm) The CMT 130 can be used either in-line with a from the floor as shown in Figure 2-8. perfect binder or as a stand-alone trimmer. Adjust the leveling pads as necessary.
  • Page 25 8. Lock all (4) leveling pads in place by tightening the jam nuts against the in- side of the machine's base as in Figure 2-9. The nuts are accessed from inside the machine. Figure 2-10. Current Progress 11/09 In-Feed/Exit Options CMT 130 Book Trimmer...
  • Page 26 Cables and air hoses must now be connected to pads are set to 33-7/8" as shown in the accessories. Figure 2-12. Adjust as necessary. Access the cables and hoses stored inside the machine through the front door. 11/09 In-Feed/Exit Options CMT 130 Book Trimmer...

  • Page 27: Stand-Alone Options

    This option uses the hand-feed conveyor and 2.4.2.2 Exit Conveyor 5. If the Tilt In-feed Conveyor is being exit conveyor options to make the CMT 130 a used, connect the air hose with the red Complete sections 2.4.1.4 Exit Ramp (Standard stand-alone trimmer.

  • Page 28: Power Hookup

    1. Remove (3) sets of screws and wash- This section describes how to hookup main ers fastened to the center of the door power to the CMT 130. An adequate power on the left-hand side of the trimmer as supply must be provided to the machine. See shown in Figure 2-18.
  • Page 29 Figure 2-20. General Locations Figure 2-21. Power Panel 2. Remove the four screws that mount the Figure 2-22. CMT 130 Console 7. Fasten the three power leads to the cover to the machine and set the door three terminals L1, L2, and L3 (Figure aside.

  • Page 30: Air Hookup

    2.6 Air Hookup 2.7 Cleaning The CMT 130 requires non-lubricated, com- It may be necessary to clean the machines after pressed air at a minimum of 5 cubic feet per installation. They may be cleaned with a solu- minute at 80-90 PSI. The main air connector tion of dish soap and water.
  • Page 31 NOTES: 11/09 Cleaning CMT 130 Book Trimmer 2-10...

  • Page 32: Operator's Guide

    TITLE PAGE The operator's guide provides instructions es- 3.1 Programming..........3-2 sential to operating the CMT 130 with each ac- 3.1.1 Console Descriptions ......3-2 cessory option. These instructions include pro- 3.1.2 Key Descriptions ........ 3-3 gramming instructions and book size change- 3.1.3 Using the Keypad .......

  • Page 33: Programming

    NOTE: Advanced operators may benefit from scriptions of how to efficiently program and accessing the Service menu. To access the store jobs within the CMT 130 computer. Service menu, select Service from the menu and enter 2.001 when prompted. 3.1.1 Console Descriptions The console is found on the front, right-hand side of the machine.

  • Page 34: Key Descriptions

    Clear Key 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. 11/09 Programming CMT 130 Book Trimmer...

  • Page 35: Using The Keypad

    Enter Key Down Arrow Key Rather than using a separate calculator, the CMT 130's computer can calculate lengths as you enter values. However, you should be fa- miliar with the order of numerical operations if you intend to use this feature. Multiplication...

  • Page 36: User Interface Map

    3.2 User Interface Map The following chart illustrates the organization of user interface screens encountered in the CMT 130 software. Figure 3-2. CMT 130 User Interface Map 11/09 User Interface Map CMT 130 Book Trimmer...

  • Page 37: Power Up

    3.3 Power Up 3.5 Run Mode seconds. The gripper will then move to ap- When the CMT 130 is switched on, the power After the gripper reaches the home location, the proximately 1 inch (2.54 cm) in front of home up screen will appear.

  • Page 38: Job Mode

    #99). The cursor will move to the line corre- The job name is edited in the job mode screen. The CMT 130 can be programmed for up to 99 sponding to the number you entered, prompting To edit the name, use the up/down arrow keys different jobs.

  • Page 39: Job Options

    Ex- A)Lock tend. Otherwise, it should be set to Retract. D)Exit Figure 3-9. Job Options Screen Use the up/down arrow keys to select the option and press enter to set the option. 11/09 Job Mode CMT 130 Book Trimmer...

  • Page 40: Running A Job

    2. Enter the job number with the keypad racy adjustment, jogger pressure, and hydraulic and press enter. cushioning. Once a job has been opened, the current job name and number will be displayed in the upper 11/09 Job Mode CMT 130 Book Trimmer...

  • Page 41: Status Messages

    Slow down Failure The slow down proximity sensor did not respond before the down proximity sensor. The knife slow down proximity sensor is either misadjusted or faulty. 11/09 Status Messages CMT 130 Book Trimmer 3-10...
  • Page 42 Side knife latch failed to The side knife latch proximity sensor did not activate. This can be caused by a faulty or disengage misadjusted proximity sensor. The air cylinder may have failed to pull in. 11/09 Status Messages CMT 130 Book Trimmer 3-11...
  • Page 43 Either the start button or remote cut button is being held in. Either button may be faulty. power up Stop button pressed Either a stop button is pressed or one is faulty. Upper door is Open One of the upper doors is open. 11/09 Status Messages CMT 130 Book Trimmer 3-12...

  • Page 44: Example Job

    D)Exit Figure 3-16. Job Screen Create a new job number by typing a number from 2 to 99, then press the enter key. The screen will then look like Figure 3-17. 11/09 Example Job CMT 130 Book Trimmer 3-13...
  • Page 45 The screen looks similar start button on the console. Release the button to Figure 3-18. when the hydraulics and conveyors start. Begin running books. 11/09 Example Job CMT 130 Book Trimmer 3-14...

  • Page 46: Serial Communication

    251C) Sequence number-------------------------- 4.5.5 Sub Code (25) Book Thickness 4.1.1 Sub Code (10) request Ma- 00-FF chine information and reset (0.100- Message type------------------------------- message sequence number. 2.000)(0064-07D0) see following information Example 1010FF02000110EC(CR)(LF) 11/09 Serial Communication CMT 130 Book Trimmer 3-15...
  • Page 47 Book Height (7.000- 12.500)(1B58-30D4) Example- 1010FF0204172101032202006423022AF8 24022328250201F4260230D445(CR)(LF) 4.5.7 Sub Code (30) Current Job Data Request will respond with code (64) data Example-1010FF02040130C8(CR)(LF) 4.6 Host command- (03) 4.6.1 Sub Code (13) Initiate/Eject Book Example-1010FF01030113EF(CR)(LF) 11/09 Serial Communication CMT 130 Book Trimmer 3-16...

  • Page 48: Routine Tasks

    4.4.3 Knife Sharpening Rules...... 4-6 progress and ensures safe operation of the ma- 4.5 Check Pressure Switch......4-6 chine. 4.6 Safety Systems Check......4-7 4.6.1 Safety Check-Off Sheet...... 4-8 11/09 Routine Tasks CMT 130 Book Trimmer...

  • Page 49: Under Book Air Blast

    4. Pull the Cut Stick Puller at a slight angle lenge part number, 41058. over the cut stick until the end of the cut Use the following procedure to change the stick comes out of the table. waste bin. 11/09 Under Book Air Blast CMT 130 Book Trimmer...

  • Page 50: Knife

    Set the bolts aside and save for 7. Securely close the door and replace the knife installation. waste bin. WARNING 8. Unlock the main power disconnect and resume operation. 11/09 Knife CMT 130 Book Trimmer...
  • Page 51 9. When the knife is free, move it down and clear of the knife bar. 11/09 Knife CMT 130 Book Trimmer...

  • Page 52: Knife Depth Adjustment

    Make certain the knife does cut. Turn the face knife adjustment not move down as the handles are knob 1/4 revolution counterclockwise. 3. Open the rear door. tightened. Repeat steps 7 through 10 until the bot- 11/09 Knife CMT 130 Book Trimmer...

  • Page 53: Check Pressure Switch

    The message, "No air pres- sure," should not be displayed. The knife must not be sharpened to less than 2.50 in. (63.5 mm) of knife height as shown in Figure 4-10. 11/09 Check Pressure Switch CMT 130 Book Trimmer...

  • Page 54: Safety Systems Check

    Front Door Interlock: 1. Press the green start button at the con- sole to start the hydraulic motor. 2. Open the front door. The hydraulic mo- tor should shut off. 3. Close the door. 11/09 Safety Systems Check CMT 130 Book Trimmer...

  • Page 55: Safety Check-Off Sheet

    Use this sheet to sign tester's initials and test Serial Number: _________________________ dates for performing the on page 4-7 of the In- stallation and Operator's Manual. TESTER DATE TESTER DATE TESTER DATE 11/09 Safety Systems Check CMT 130 Book Trimmer...

  • Page 56: Book Quality

    40k-60k cuts Other quality issues such as accuracy and square should be referred to an authorized technician because they involve service repairs or adjustments that are outside the scope of an operator's training. 11/09 Book Quality CMT 130 Book Trimmer...

  • Page 57: Burr Marks

    2. The cut stick may be worn. Solutions Solutions • • Solutions Replace the knife. Replace the knife and rotate or replace the cut stick. • Rotate or replace the cut stick. The knife may also require replacement. 11/09 Burr Marks CMT 130 Book Trimmer...

  • Page 58: Rectangular Crease Lines

    Turn or change holding the book. the cut plates. Note: Reducing the clamp pressure too much will cause other quality problems such as draw. Only reduce clamp pressure by necessary amounts. 11/09 Rectangular Crease Lines CMT 130 Book Trimmer...

  • Page 59: All Sheets Not Cut

    Knife Depth Adjustment on page 4-5. • transport mechanisms out of square, re- Replace the cut stick or cut plates. fer the problem to an authorized service agent (see FX.013, Section 4). 11/09 All Sheets Not Cut CMT 130 Book Trimmer...
  • Page 60 Inch / Metric Conversion Chart Fractional in. fractional in. fractional in. 0.344 11/32 8.73 0.016 1/64 0.40 0.672 43/64 17.07 0.359 23/64 9.13 0.031 1/32 0.79 0.688 11/16 17.46 0.375 9.53 0.047 3/64 1.19 0.703 45/64 17.86 0.391 25/64 9.92 0.063 1/16 1.59...
  • Page 61 © 2009-2010 by The Challenge Machinery Company. All rights reserved. Printed in the USA F.013 / CMT 130 / NOV 2009...

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