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

Challenge CMT 330 Installation And Operator's Manual

Three-knife trimmer
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Summary of Contents for Challenge CMT 330

  • Page 1 The Challenge Machinery Company assumes no liability for any modification or alteration to any Challenge product, and any such modification or alteration to any Challenge product is not authorized by The Challenge Machinery Company.
  • Page 2 THE CHALLENGE MACHINERY COMPANY CMT 330 Three-Knife Trimmer Installation and Operator's Manual The Challenge Machinery Company 6125 Norton Center Drive Norton Shores, MI 49441 USA SERIAL No.: _____________ ChallengeMachinery.com F.033B / JUL 2011...
  • Page 3 Challenge does not warrant or represent that such documenta- tion is complete, nor does Challenge repre- sent or warrant that it will notify or provide to such customer any future changes to this documentation.
  • Page 4: Table Of Contents

    4.3 Cut Stick / Cut Plates ........4-3 4.4 Knives ............4-4 4.5 Check Pressure Switch......4-9 4.6 Safety Systems Check......4-9 5 Book Quality 5.1 Burr Marks..........5-2 5.2 Jagged Bottom Cover .......5-2 5.3 Burr Marks/Jagged Cover ......5-2 5.4 Rectangular Crease Lines ......5-3 07/11 Contents CMT 330 Three Knife Trimmer...
  • Page 5 Notes: 07/11 Contents CMT 330 Three Knife Trimmer...
  • Page 6 1.7.1 Book Size Chart ......... 1-9 1.8 General Locations........1-10 1.8.1 Front Views........1-10 1.8.2 Back View......... 1-11 1.8.3 Exit Conveyor ........1-12 1.8.4 Tilt In-feed Conveyor ......1-13 1.8.5 Elevator ..........1-14 1.8.6 Site Specifications ......1-15 07/11 Introduction CMT 330 Three Knife Trimmer...
  • Page 7: Warranty Information

    Challenge. Copy this page, fill in the informa- Follow all precautions and instructions. For this manual and return it DIRECTLY TO CHAL- tion and send it care of The Challenge Service Department, 6125 Norton Center Drive • Norton parts and service contact the Authorized Chal- LENGE.
  • Page 8: Warning Label Definitions

    Author- Cut / Crush Hazard! A warning indicates an operating or maintenance pro- ized Challenge Dealer. Failure to un- cedure, practice, or condition that, if not strictly ob- Do not operate with covers re- served, could result in injury or loss of life.
  • 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 07/11 Power Lockout Procedure CMT 330 Three Knife Trimmer...
  • Page 10: Packing List

    Accessory Options In-Line Option In-Line with Tilt In-Feed Conveyor 56600 Tilt In-Feed Conveyor 56421 Cooling Elevator Stand-Alone Option Stand Alone 56413 Hand Feed Conveyor Exit Option Fixed (shown above) 56420 Exit Conveyor 07/11 Packing List CMT 330 Three Knife Trimmer...
  • Page 11: Standard Accessories

    1.6.2 Standard Accessories The following list contains pre-installed, stan- dard accessories for the CMT 330. Item Part Number Description Qty. 5064 Cut Stick Puller 56028 Knife Lifter 56143 Waste Bin 56246 HSS Knife Set (scabbard not shown) 56303 Cut Stick...
  • 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 330 uses the following consumable items. Part Description Qty. Frequency E-967-1 Lamp 10,000 hrs 47264-2101 UHMW Tape (Elevator) 1 yr.
  • Page 13: Specifications

    177.8 (spine) x 171.4 mm Min. start book (w/feeder) 7 x 7 in. (multi-book mode) 177.8 x 177.8 mm The CMT 330 was designed specifically for use with the Min. finish book 5.82 (spine) x 4 in. 147.8 (spine) x 101.6 mm Challenge in-feed and exit accessories listed in this table.
  • Page 14: Book Size Chart

    The book size must fall within the shaded region of the chart but never Figure 1-2. Trimmable Book Sizes exactly on the sloped line. The CMT 330 software will not allow a book to be cut outside this range. The operator should 07/11 Specifications...
  • Page 15: General Locations

    1-5 locate the front, back, right, and left sides of the machine. Remember these references while reading instructions in this manual. Refer back to these figures as necessary. Figure 1-4. Right Front View Figure 1-5. Left Front View 07/11 General Locations CMT 330 Three Knife Trimmer 1-10...
  • Page 16: Back View

    1.8.2 Back View Important locations at the back of the machine are shown in Figure 1-6. Figure 1-6. Back View 07/11 General Locations CMT 330 Three Knife Trimmer 1-11...
  • Page 17: Exit Conveyor

    1.8.3 Exit Conveyor Part Number: 56420 Important locations are shown in Figure 1-7. Figure 1-7. Exit Conveyor Locations 07/11 General Locations CMT 330 Three Knife Trimmer 1-12...
  • Page 18: Tilt In-Feed Conveyor

    1.8.4 Tilt In-feed Conveyor Part No.: 56600 Important locations are shown in Figure 1-8. Figure 1-8. Tilt In-feed Conveyor 07/11 General Locations CMT 330 Three Knife Trimmer 1-13...
  • Page 19: Elevator

    1.8.5 Elevator Part Number: 56421 Important locations are shown in Figure 1-9. Figure 1-9. Elevator Locations 07/11 General Locations CMT 330 Three Knife Trimmer 1-14...
  • Page 20: Site Specifications

    This In-Line option is used when automated transport of books from a binder to the trimmer is required and book size changes are frequent. It includes the CMT 330 basic machine, two conveyors, and an elevator. See Figure 1-10 for space requirements.
  • Page 21 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 1-11. Stand Alone Option 07/11 General Locations CMT 330 Three Knife 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 330 and its accessory options. 2.3 Moving............2-2 These applications include one option for In- 2.4 Option Setup ..........2-2 Line operation and one option for Stand-Alone 2.4.1 In-Line Option ........
  • Page 23: Shipping Claims

    2.4 Option 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 accesso- ries required for each application.
  • Page 24: In-Line Option

    3. The adjustable portion should be set to the height of the bottom of the binder's exit chute. After adjusting the legs, lock into place with jam nuts. 07/11 Option Setup CMT 330 Three Knife Trimmer...
  • Page 25 Figure 2-8. Attach the op- side of the machine's base as in Figure tional bar code scanner and sensor if 2-10. The nuts are accessed from in- applicable. side the machine. 07/11 Option Setup CMT 330 Three Knife Trimmer...
  • Page 26 12. Using the hardware removed in step 1, reach through the trimmer's front door and fasten the trimmer to the elevator. 13. Connect shop air to the port at the rear of the trimmer. Refer to 2.6 07/11 Option Setup CMT 330 Three Knife Trimmer...
  • Page 27 Two air hoses and one power cable ing the hardware from step 1. must also be connected to the elevator. Access the cables and hoses stored inside the machine through the front door. 07/11 Option Setup CMT 330 Three Knife Trimmer...
  • Page 28: Stand-Alone Option

    Elevator to the in-feed conveyor. This option uses the hand-feed conveyor and 5. If the Tilt In-feed Conveyor is being exit conveyor options to make the CMT 330 a used, connect the air hose with the red Figure 2-15. Stand Alone Space Claim Stand-Alone trimmer.
  • Page 29: Power Hookup

    The following procedure describes how to 2. Route the cable behind the hydraulic hookup main power to the CMT 330. After power unit and under the left-hand side power is hooked up, running the machine will of the machine base.
  • Page 30 Continue at step 13 if the knives do not move to the up position. If the knives move, skip to step 17. Figure 2-20. Power Panel Figure 2-21. CMT 330 Console 07/11 Power Hookup CMT 330 Three Knife Trimmer...
  • Page 31: Air Hookup

    The main air connector shown in Figure 2-22 is 2.6 Air Hookup a female 3/8 NPT port. A facilities maintenance The CMT 330 requires 80-90 PSI regulated, technician should connect shop air using a male dry, non-lubricated compressed air at a mini- 3/8 NPT fitting using either Teflon thread tape or mum of 5 cubic feet per minute (at 80-90 PSI).
  • Page 32 NOTES: 07/11 Cleaning CMT 330 Three Knife Trimmer 2-11...
  • Page 33: Operator's Guide

    TITLE PAGE The operator's guide provides instructions es- 3.1 Programming..........3-2 sential to operating the CMT 330 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 34: Programming

    3.1 Programming The programming section gives detailed de- scriptions of how to efficiently program and store jobs within the CMT 330 computer. 3.1.1 Console Descriptions The console is found on the front, right-hand side of the machine. General areas of the con- sole are shown in Figure 3-1.
  • Page 35: Key Descriptions

    The plus key is used to add numbers in the dis- through maintenance screens. play. The clear key is used to clear an entry value or clear an status message. 07/11 Programming CMT 330 Three Knife Trimmer...
  • Page 36: Using The Keypad

    Enter Key Down Arrow Key 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 you intend to use this feature. Multiplication...
  • Page 37: 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 07/11 User Interface Map CMT 330 Three Knife Trimmer...
  • Page 38: Power Up

    3.3 Power up 3.5 Run Mode seconds. The gripper will then move to ap- When the CMT 330 is switched on, the power After the gripper reaches the home location, the proximately 1 inch in front of home position, up screen will appear.
  • Page 39: Job Mode

    #99). The cursor will move to the line corre- The job name is edited in the job mode screen. The CMT 330 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 40: 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. 07/11 Job Mode CMT 330 Three Knife Trimmer...
  • Page 41: Running A Job

    2. Enter the job number with the keypad and press enter. Once a job has been opened, the current job name and number will be displayed in the upper 07/11 Job Mode CMT 330 Three Knife Trimmer...
  • Page 42: Status Messages

    F-Slow down Failure 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. 07/11 Status Messages CMT 330 Three Knife Trimmer 3-10...
  • Page 43 The side knife latch proximity did not activate. This can be caused by a faulty or misad- should be ON justed proximity sensor. The air cylinder may have failed to pull in. 07/11 Status Messages CMT 330 Three Knife Trimmer 3-11...
  • Page 44 Stop button pressed Either a stop button is pressed or one is faulty. Upper door is Open One of the upper doors is open. 07/11 Status Messages CMT 330 Three Knife Trimmer 3-12...
  • Page 45: 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. 07/11 Example Job CMT 330 Three Knife Trimmer 3-13...
  • Page 46 1 Factory Test Job start button on the console. Release the button 2>Example Job_ when the hydraulics and conveyors start. Begin running books. Select Job & Enter A)Lock C)Erase D)Exit Figure 3-18. Job Name 07/11 Example Job CMT 330 Three Knife Trimmer 3-14...
  • Page 47: Serial Communication

    “trimmer “ Example- Sub code 1 data length 4.2.2 Sub Code (11) Software level 1010FF0204172101032202006423022AF8 (Optional) Message type sub code 2 “3.3” 24022328250201F4260230D445(CR)(LF) Sub code 2 data length 07/11 Serial Communication CMT 330 Three Knife Trimmer 3-15...
  • Page 48 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) 07/11 Serial Communication CMT 330 Three Knife Trimmer 3-16...
  • Page 49: Routine Tasks

    4.4.2 Knife Adjustment ........ 4-7 progress and ensures safe operation of the ma- 4.4.3 Knife Sharpening Rules...... 4-8 chine. 4.5 Check Pressure Switch......4-9 4.6 Safety Systems Check......4-9 4.6.1 Safety Check-off Sheet ....4-11 07/11 Routine Tasks CMT 330 Three Knife Trimmer...
  • Page 50: Under Book Air Blast

    When the waste bins are near capacity during a job run, the Figure 4-3. Waste Bin Locations CMT 330 continues cutting. The status indica- tor light on top of the machine blinks slowly, and 07/11...
  • Page 51: Cut Stick / Cut Plates

    The cut stick and cut plates should either be stick comes out of the table. at the back of the machine. changed or rotated with every knife change. They may also require changing at other times if 07/11 Cut Stick / Cut Plates CMT 330 Three Knife Trimmer...
  • Page 52: Knives

    WARNING 4.4 Knives Even used knives are extremely sharp! Use extreme care when handling new/re-ground knives and used knives. The knives should be changed when cut quality becomes unacceptable. By default, the com- 07/11 Knives CMT 330 Three Knife Trimmer...
  • Page 53 9. When the knife is free, move it down and clear of the knife bar. Figure 4-11. Knife Bolt Locations 10. Hold the knife lifter with knife at a safe distance from the body. Other people 07/11 Knives CMT 330 Three Knife Trimmer...
  • Page 54 Keep handling of unprotected knives to an absolute minimum. Have the scabbard nearby and insert knife immediately. Warn people of any unprotected knife. Figure 4-13. Knife Adjustment Knobs 07/11 Knives CMT 330 Three Knife Trimmer...
  • Page 55: Knife Adjustment

    The hydraulic motor turns on, and in serted against the stops. about 1 second, the machine cuts the book. 34. Repeat steps 18 through 33 to install the remaining two knives. 07/11 Knives CMT 330 Three Knife Trimmer...
  • Page 56: Knife Sharpening Rules

    If the bottom cover of the hand side of the machine. book is not fully cut. Turn the face knife The CMT 330's knives must be sharpened as a 9. Place a book under the knife with the adjustment knob 1/4 revolution counter- matching set.
  • Page 57: Check Pressure Switch

    2. Open the front sliding door. The hy- 2. Open the right rear door. The hydraulic draulic motor should shut off. motor should shut off. 3. Close the door. 3. Close the door. 07/11 Check Pressure Switch CMT 330 Three Knife Trimmer...
  • 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 photocopies of the check-off sheet as neces- sary. 07/11 Safety Systems Check CMT 330 Three Knife Trimmer 4-10...
  • Page 59: Safety Check-Off Sheet

    Use this sheet to sign tester's initials and test dates for performing the Safety Systems Check Serial Number: _________________________ on page 4-9 of the Installation and Operator's Manual. TESTER DATE TESTER DATE TESTER DATE 07/11 Safety Systems Check CMT 330 Three Knife Trimmer 4-11...
  • Page 60: Book Quality

    5.8 Book Not Square........5-4 Other quality issues such as accuracy and square should be referred to an authorized technician because they involve service repairs or adjustments, which are outside the scope of an operator's training. 07/11 Book Quality CMT 330 Three Knife Trimmer...
  • Page 61: Burr Marks

    Rotate or replace the cut plates. rately. • If the problem is on the top or bottom faces of the book, the cut plates may need rotation or replacement. The knives may also require replacement. 07/11 Burr Marks CMT 330 Three Knife Trimmer...
  • Page 62: Rectangular Crease Lines

    Note: Reducing the clamp pressure too much will cause Rotate or replace the cut plates. other quality problems such as draw. Only reduce clamp pressure by necessary amounts. 07/11 Rectangular Crease Lines CMT 330 Three Knife Trimmer...
  • Page 63: All Sheets Not Cut

    If normal wear has forced the cutting or Knife Adjustment on page 4-7. • transport mechanisms out of square, re- Replace the cut stick or cut plates. fer the problem to an authorized service agent. 07/11 All Sheets Not Cut CMT 330 Three Knife Trimmer...
  • Page 64 8.33 0.984 63/64 25.00 0.656 21/32 16.67 1.000 64/64 25.40 07/11 © 2002-2011 by The Challenge Machinery Company. All rights reserved. Printed in the USA F.033 / CMT 330B / JUL 2011 Book Not Square CMT 330 Three Knife Trimmer...

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