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Challenge CMT-130 Installation And Operator's Manual
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Challenge CMT-130 Installation And Operator's Manual

Challenge CMT-130 Installation And Operator's Manual

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CMT-130
Book Trimmer
Installation and
Operator's Manual
Serial Numbers:
12110562 through 15999999, and
130T-B-150000 through 130T-B-169999
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441 USA
ChallengeMachinery.com
CMT-130 Book Trimmer
THE CHALLENGE MACHINERY COMPANY
SERIAL No.: ____________________
F.013B / FEB 2017

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Summary of Contents for Challenge CMT-130

  • Page 1 THE CHALLENGE MACHINERY COMPANY CMT-130 Book Trimmer Installation and Operator's Manual Serial Numbers: 12110562 through 15999999, and 130T-B-150000 through 130T-B-169999 The Challenge Machinery Company 6125 Norton Center Drive Norton Shores, MI 49441 USA SERIAL No.: ____________________ ChallengeMachinery.com F.013B / FEB 2017...
  • 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

    3.5 Status Messages ........3-10 3.6 Example Job ........... 3-14 4. Routine Tasks Section Contents ..........4-1 Introduction ............. 4-1 4.1 Book Underside Air Lift ......4-2 4.2 Waste Bin ..........4-2 4.3 Cut Stick ........... 4-2 FEB 2017 CMT-130 Book Trimmer Introduction...
  • Page 4 Notes: FEB 2017 CMT-130 Book Trimmer Introduction...

  • Page 5: Introduction

    1.8.2 Site Specifications ......1-12 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. FEB 2017 CMT-130 Book 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 FEB 2017 CMT-130 Book Trimmer 1. Introduction...

  • Page 9: Packing List

    1.6 Packing List CMT-130 Shown with Pile Feeder and Vertical Stacker Part Number Description Qty. CMC-130B CMT-130 Basic Machine Infeed Options – In-Line 56600B & 56421B Tilt In-Feed Conveyor and Cooling Elevator Infeed Options – Stand Alone 58500A Book Pile Feeder...

  • Page 10: Base Machine/Options

    1.6.1 Base Machine/Options This parts list includes the base machine and any accessories that may have been ordered with it. FEB 2017 CMT-130 Book Trimmer 1. Introduction...

  • Page 11: Standard Accessories

    Qty. 5064 Cut Stick Puller 41058 Waste Bin 59050 Cut Stick 59051-2 Super High Speed Steel Knife 59070 Knife Lifter Assembly H-6910-606 Knife Screw- 3/8-16 X ¾ BHC W-180 7/32" T-Handle Hex Wrench FEB 2017 CMT-130 Book Trimmer 1. Introduction...

  • Page 12: Optional Items

    The following consumables are found in Oil Change Kit, K-56040. Part Description Qty. Frequency 56041 Filter Element (Air) 1 yr. H-227-1 Filter Element (Oil) 1 yr. S-1991-3 Grade 46 Hydraulic Fluid 5 gal. 1 yr. FEB 2017 CMT-130 Book Trimmer 1. Introduction...

  • Page 13: Specifications

    Height x Width x Depth 5 x 10 x 12 in. 13 x 25 x 30 cm Note: See Section 1.8.2 for floor space requirements of the CMT-130 with various option configurations. FEB 2017 CMT-130 Book Trimmer 1. Introduction...

  • Page 14: Book Size Chart

    The CMT 130 software will not allow a book to be cut outside this range. The operator should Figure 1-2. Book Size Charts FEB 2017 CMT-130 Book Trimmer 1-10 1. Introduction...

  • Page 15: General Locations

    Remember these references while reading instructions in this manual. Refer back to these figures as necessary. Figure 1-4 Left Rear View Figure 1-3 Right Front View FEB 2017 CMT-130 Book Trimmer 1-11 1. Introduction...

  • Page 16: Site Specifications

    1.8.2.1 Hand Feeder and Stacker Configura- tion Figure 1-5 Hand Feeder and Stacker Configuration FEB 2017 CMT-130 Book Trimmer 1-12 1. Introduction...
  • Page 17 1.8.2.2 Pile Feeder and Stacker Configura- tion Figure 1-6 Pile Feeder and Stacker Configuration FEB 2017 CMT-130 Book Trimmer 1-13 1. Introduction...
  • Page 18 1.8.2.3 In-line Tilt Conveyor with Elevator and Stacker Configuration Figure 1-7 In-line Tilt Conveyor with Elevator and Stacker Configuration FEB 2017 CMT-130 Book Trimmer 1-14 1. Introduction...
  • Page 19 1.8.2.4 Hand Feeder and Exit Conveyor Con- figuration Figure 1-8 Hand Feeder and Exit Conveyor Configuration FEB 2017 CMT-130 Book Trimmer 1-15 1. Introduction...
  • Page 20 1.8.2.5 Pile Feeder and Exit Conveyor Con- figuration Figure 1-9 Pile Feeder and Exit Conveyor Configuration FEB 2017 CMT-130 Book Trimmer 1-16 1. Introduction...
  • Page 21 1.8.2.6 In-line Tilt Conveyor with Elevator and Exit Conveyor Configuration Figure 1-10 In-line Tilt Conveyor with Elevator and Exit Conveyor Configuration FEB 2017 CMT-130 Book Trimmer 1-17 1. Introduction...
  • Page 22 1.8.2.7 Hand Feeder and Exit Ramp Configu- ration Figure 1-11 Hand Feeder and Exit Ramp Configuration FEB 2017 CMT-130 Book Trimmer 1-18 1. Introduction...
  • Page 23 1.8.2.8 Pile Feeder and Exit Ramp Configu- ration Figure 1-12 Pile Feeder and Exit Ramp Configuration FEB 2017 CMT-130 Book Trimmer 1-19 1. Introduction...
  • Page 24 1.8.2.9 In-line Tilt Conveyor with Elevator and Exit Ramp Configuration Figure 1-13 In-line Tilt Conveyor with Elevator and Exit Ramp Configuration FEB 2017 CMT-130 Book Trimmer 1-20 1. Introduction...
  • Page 25 Notes: FEB 2017 CMT-130 Book Trimmer 1-21 1. Introduction...

  • Page 26: Installation Guide

    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 each of the CMT 130 and its accessory options. FEB 2017 CMT-130 Book Trimmer 2. Installation Guide...

  • Page 27: Shipping Claims

    2.4 In-feed Setup The CMT-130 can be used either In-Line with a perfect binder or as a Stand-Alone Book Trim- mer. The following table lists the in-feed options Figure 2-2. Fork Locations for Lifting for each application.

  • Page 28: 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 FEB 2017 CMT-130 Book Trimmer 2. Installation Guide...
  • Page 29 4. Connect the air hose with the black cap into the fitting on the elevator with black 5. Move the trimmer in position against the label above it. elevator, aligning the mounting brackets on the elevator to the corresponding FEB 2017 CMT-130 Book Trimmer 2. Installation Guide...

  • Page 30: Pile Feeder Option Setup

    2. Remove (4) sets of screws and washers in Figure 2-14. 5. Fasten the conveyor to the trimmer us- fastened to the side of the trimmer just ing the hardware from step 1. FEB 2017 CMT-130 Book Trimmer 2. Installation Guide...

  • Page 31: 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-130 out-feed options (3) are tion, follow these steps to complete the trim- Figure 2-18. Exit Conveyor as follows:...

  • Page 32: Power Hookup

    380/415 2.7.1 Power Hookup Procedure The following procedure describes how to hookup main power to the CMT-130. 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 33: Air Hookup

    11. Unlock and switch on ( ) the main power disconnect. 2.8.1 Compressed Air Requirements The CMT-130 requires 80-90 PSI regulated, dry, 12. Switch on ( ) the machine's power. non-lubricated compressed air at a minimum of 13. Press the green start button key on the 5 cubic feet per minute (at 80-90 PSI).

  • Page 34: Cleaning

    Damage may result. 3/8 NPT fitting using either Teflon thread tape or a liquid, pipe sealing compound. FEB 2017 CMT-130 Book Trimmer 2. Installation Guide...
  • Page 35 Notes: FEB 2017 CMT-130 Book Trimmer 2-10 2. Installation Guide...

  • Page 36: Operator's Guide

    3.6 Example Job ........... 3-14 Introduction The operator's guide provides instructions es- sential to operating the CMT 130 with each ac- cessory option. These instructions include pro- gramming instructions and book size changeo- ver tasks. FEB 2017 CMT-130 Book Trimmer 3. Operator's Guide...

  • Page 37: Programming

    General areas of the con- sole are shown in Figure 3-1. The specific func- tion of each key on the console is given in this section. Figure 3-1. CMT 130 Console FEB 2017 CMT-130 Book Trimmer 3. Operator's Guide...

  • Page 38: 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. FEB 2017 CMT-130 Book Trimmer 3. Operator's Guide...

  • Page 39: Using The Keypad

    This eliminates the need for parentheses. Example: 3X2_3/4=8.250. If you use a plus instead of the priority add, the result would be 3X2+3/4=6.750. FEB 2017 CMT-130 Book Trimmer 3. Operator's Guide...

  • Page 40: 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 FEB 2017 CMT-130 Book Trimmer 3. Operator's Guide...

  • Page 41: Power Up

    3.4 Jobs B ) J o b 3.3.1 Initialization The CMT-130 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 42: Creating A Job

    Numbers FEB 2017 CMT-130 Book Trimmer 3. Operator's Guide...

  • Page 43: 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 FEB 2017 CMT-130 Book Trimmer 3. Operator's Guide...

  • Page 44: Running A Job

    Or if you are ready to start feeding and trimming books, simply press FEB 2017 CMT-130 Book Trimmer 3. Operator's Guide...

  • Page 45: Status Messages

    3.5 Status Messages FEB 2017 CMT-130 Book Trimmer 3-10 3. Operator's Guide...
  • Page 46 The knife latch proximity sensor did not activate. This can be caused by a faulty or misadjusted d i s e n g a g e proximity sensor. The air cylinder may have failed to pull in. FEB 2017 CMT-130 Book Trimmer 3-11 3. Operator's Guide...
  • Page 47 Either a stop button is pressed or one is faulty. U p p e r d o o r O p e n One or more of the doors are open. FEB 2017 CMT-130 Book Trimmer 3-12 3. Operator's Guide...
  • Page 48 FEB 2017 CMT-130 Book Trimmer 3-13 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. FEB 2017 CMT-130 Book Trimmer 3-14 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 FEB 2017 CMT-130 Book Trimmer 3-15 3. Operator's Guide...
  • Page 51 FEB 2017 CMT-130 Book Trimmer 3-16 3. Operator's Guide...

  • Page 52: 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. FEB 2017 CMT-130 Book Trimmer 4. Routine Tasks...

  • Page 53: Book Underside Air Lift

    1.5 Power Lockout Procedure 3. To increase the amount of lift, such as on page 1-4. for thicker books, adjust the valve coun- Figure 4-2. Stop Button Location ter-clockwise. FEB 2017 CMT-130 Book Trimmer 4. Routine Tasks...

  • Page 54: Knife

    8. Unlock the main power disconnect and ing a knife creates safety hazards. resume operation. New cut sticks may be purchased from your Challenge dealer using part number 59050. WARNING Even used knives are extremely sharp! Use 4.4 Knife extreme care when handling new/re-ground knives and used knives.
  • Page 55 The ad- tion of the knife-edge remains exposed. justment handle is located at the rear Figure 4-7. Knife Lifter left corner of the machine. FEB 2017 CMT-130 Book Trimmer 4. Routine Tasks...

  • Page 56: Knife Depth Adjustment

    4. Find the knife adjustment knob at the holes in the knife and use the T-handle left rear of the machine as shown in Fig- wrench to secure them as shown in Fig- ure 4-9. ure 4-8. FEB 2017 CMT-130 Book Trimmer 4. Routine Tasks...

  • Page 57: Check Pressure Switch

    5. Go to the console and read the LCD dis- tom cover is cut fully. All doors must be 3. Close the door. play. The message, "No air pressure," closed for the machine to cut. should not be displayed. FEB 2017 CMT-130 Book Trimmer 4. Routine Tasks...
  • Page 58 Use the table on the following page to record the initials of the person performing the tests and the date the tests are performed. Make photo- copies of the check-off sheet as necessary. FEB 2017 CMT-130 Book Trimmer 4. Routine Tasks...

  • Page 59: Safety Check-Off Sheet

    Use this sheet to sign tester's initials and test dates for performing the on page 4-6 of the In- stallation and Operator's Manual. TESTER DATE TESTER DATE TESTER DATE Machine Model: CMT 130 FEB 2017 CMT-130 Book Trimmer 4. Routine Tasks...

  • Page 60: 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 that are outside the scope of an op- erator's training. FEB 2017 CMT-130 Book Trimmer 5. Book Quality...

  • Page 61: Burr Marks

    2. The cut stick may be worn. Solutions  Solutions Replace the knife.  Replace the knife and rotate or replace  Rotate or replace the cut stick. The the cut stick. knife may also require replacement. FEB 2017 CMT-130 Book Trimmer 5. Book Quality...

  • Page 62: Rectangular Crease Lines

    Rotate or replace book. the cut stick. Note: Reducing the clamp pressure too much will cause other quality problems such as draw. Only reduce clamp pressure by necessary amounts. FEB 2017 CMT-130 Book Trimmer 5. Book Quality...

  • Page 63: All Sheets Not Cut

      Replace the cut stick or cut plates. If normal wear has forced the cutting or transport mechanisms out of square, re- fer the problem to an authorized service agent. FEB 2017 CMT-130 Book Trimmer 5. Book Quality...
  • Page 64 NOTES FEB 2017 CMT-130 Book Trimmer 5. Book Quality...
  • Page 65 0.641 41/64 16.27 0.984 63/64 25.00 0.656 21/32 16.67 1.000 64/64 25.40 FEB 2017 © 2002-2017 by The Challenge Machinery Company. All rights reserved. Printed in the USA F.013B / CMT-130B / FEB 2017 CMT-130 Book Trimmer 5. Book Quality...