Challenge CMT 330 Installation And Operator'S Manual Download Page 1

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THE CHALLENGE MACHINERY COMPANY

CMT-330 Three Knife Trimmer

F.033C / APR 2018

The Challenge Machinery Company

6125 Norton Center Drive

Norton Shores, MI 49441 USA

ChallengeMachinery.com

SERIAL No.: ____________________

CMT-330

Three-Knife Trimmer

Installation and
Operator's Manual

Serial Numbers: 12040256 through 15999999,

330T-C-150000 and up

Summary of Contents for CMT 330

Page 1: ...R 2018 The Challenge Machinery Company 6125 Norton Center Drive Norton Shores MI 49441 USA ChallengeMachinery com SERIAL No ____________________ CMT 330 Three Knife Trimmer Installation and Operator s...

Page 2: ...of the product owner and user Older products may not comply with current safety procedures guidelines or regulations and it is the product owner s and user s responsibility to evaluate the suitabilit...

Page 3: ...up 2 6 2 7 Power Hookup 2 7 2 8 Air Hookup 2 8 2 9 Cleaning 2 9 3 Operator s Guide 3 1 Contents 3 1 Introduction 3 1 3 1 Control Console 3 2 3 2 User Interface Map 3 5 3 3 Power up 3 6 3 4 Jobs 3 6 3...

Page 4: ...APR 2018 CMT 330 Three Knife Trimmer iv Introduction Notes...

Page 5: ...ons 1 7 1 6 2 Standard Accessories 1 8 1 6 3 Optional Items 1 9 1 6 4 Consumables 1 9 1 7 Specifications 1 10 1 7 1 Book Size Chart 1 11 1 8 General Locations 1 12 1 8 1 Trimmer Front and Back Views 1...

Page 6: ...330 requires 80 90psi regulated dry non lubricated compressed air that meets or ex ceeds ISO 8573 1 Class 2 4 2 See Section 2 8 on page 2 8 Failure to do so may cause dam age to the machine and will r...

Page 7: ...re practice or condition that if not strictly observed could result in damage to or destruction of equipment Note Definition Note A regular note indicates an operating or maintenance procedure practic...

Page 8: ...bed in the specifications on page 1 10 Make sure all applicable accessories are securely bolted to the main ma chine Tip hazards may result from un secured accessories If the machine operates abnormal...

Page 9: ...APR 2018 CMT 330 Three Knife Trimmer 1 5 1 Introduction 1 6 Packing List...

Page 10: ...56600B 56421B Tilt In Feed Conveyor and Cooling Elevator 1 Infeed Options Stand Alone 58500A Book Pile Feeder 1 59200 Standard Hand Feed Conveyor 1 56413 Long Hand Feed Conveyor 1 Outfeed Options 5800...

Page 11: ...1 Introduction following lists and the packing slip to be sure all items are included with your shipment 1 6 1 Basic Machine Options This parts list includes the basic machine and any accessories tha...

Page 12: ...dard accessories for the CMT 330 Item Part Number Description Qty 1 5064 Cut Stick Puller 1 2 56028 Knife Lifter 1 3 56143 Waste Bin 3 4 56246 Knife Set of 3 scabbard not shown 2 5 56275 Knife Height...

Page 13: ...W Tape Elevator 8 ft 1 yr 56523 UHMW Tape Joggers 2 ft 1 yr SU 30 103 Grease Ext Pressure BULK 1 wk SU 30 104 Grease Rycotac EP BULK each knife change 56228 Face Clamp Pad 1 6 mo 56181 Left Clamp Pad...

Page 14: ...ook thickness range 0 05 to 2 00 in 1 3 to 50 8 mm Min Trim 0 10 in 2 5 mm CMT 330 Basic Machine Width 37 in 94 cm will fit through 35 in 89 cm opening with some side covers removed Depth 85 in 216 cm...

Page 15: ...ook that does not include the cover It contains all front and end matter as well as the text block Untrimmed book An untrimmed book is a book block that has been bound with a cover but has not yet bee...

Page 16: ...edge of machine locations Note The word rear refers to the general di rection closer to the back end of the machine Back refers only to the backside of the ma chine 1 8 1 Trimmer Front and Back Views...

Page 17: ...n 1 7 Specifica tions on page 1 10 to verify that the site can ac commodate these requirements Use the follow ing figures to determine floor space require ments for the configuration to be installed N...

Page 18: ...APR 2018 CMT 330 Three Knife Trimmer 1 14 1 Introduction 1 8 2 2 Pile Feeder and Stacker Configura tion Figure 1 7 Pile Feeder and Stacker Configuration...

Page 19: ...APR 2018 CMT 330 Three Knife Trimmer 1 15 1 Introduction 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...

Page 20: ...APR 2018 CMT 330 Three Knife Trimmer 1 16 1 Introduction 1 8 2 4 Hand Feeder and Exit Conveyor Con figuration Figure 1 9 Hand Feeder and Exit Conveyor Configuration...

Page 21: ...APR 2018 CMT 330 Three Knife Trimmer 1 17 1 Introduction 1 8 2 5 Pile Feeder and Exit Conveyor Con figuration Figure 1 10 Pile Feeder and Exit Conveyor Configuration...

Page 22: ...18 CMT 330 Three Knife Trimmer 1 18 1 Introduction 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 Configu...

Page 23: ...APR 2018 CMT 330 Three Knife Trimmer 1 19 1 Introduction 1 8 2 7 Hand Feeder and Exit Ramp Configu ration Figure 1 12 Hand Feeder and Exit Ramp Configuration...

Page 24: ...APR 2018 CMT 330 Three Knife Trimmer 1 20 1 Introduction 1 8 2 8 Pile Feeder and Exit Ramp Configu ration Figure 1 13 Pile Feeder and Exit Ramp Configuration...

Page 25: ...R 2018 CMT 330 Three Knife Trimmer 1 21 1 Introduction 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 Configurati...

Page 26: ...APR 2018 CMT 330 Three Knife Trimmer 1 22 1 Introduction Notes...

Page 27: ...Option Setup 2 5 2 5 Trimmer Setup 2 6 2 6 Out feed Setup 2 6 2 6 1 Vertical Stacker Option Setup 2 6 2 6 2 Exit Conveyor Option Setup 2 6 2 6 3 Exit Ramp Option Setup 2 7 2 7 Power Hookup 2 7 2 7 1...

Page 28: ...wo front side doors Use a forklift to remove the machine from the skid and place it as close as possible to its in stallation location The machine has accessory power cables and air hoses wrapped up a...

Page 29: ...r slightly below the bot tom of the binder s exit chute After ad justing the legs lock into place with jam nuts Figure 2 6 Adjustment Range 4 Move the entire conveyor close to the binder to minimize t...

Page 30: ...r panel In feed Conveyor 1 Unwrap the cables and air hose labeled In feed Conveyor 2 Route the cables and hose behind the hydraulic power unit and under the left hand side of the machine base 3 Connec...

Page 31: ...power unit and under the left hand side of the machine base 6 Connect the cable to the socket on the backside of Hand feed Conveyor Lock into place by threading the connector collar onto the socket 2...

Page 32: ...t end of the machine with the level to make sure the front is still level Adjust as necessary 4 After leveling the machine lower the two pads at the center of the machine such that the trimmer is firm...

Page 33: ...kup main power to the CMT 330 An adequate power supply must be provided to the machine See section 1 7 Specifications on page 1 10 for power requirements It should be on its own cir cuit with a lockab...

Page 34: ...place all panel doors 10 Make sure compressed air in connected to the machine and is switched on See Section 2 8 Air Hookup on page 2 8 11 Unlock and switch on I the main power disconnect 12 Switch on...

Page 35: ...5 is a female 3 8 NPT port A facilities maintenance technician should connect shop air using a male 3 8 NPT fitting using either Teflon thread tape or a liquid pipe sealing compound Figure 2 25 Main A...

Page 36: ...APR 2018 CMT 330 Three Knife Trimmer 2 10 2 Installation Guide Notes...

Page 37: ...ing a Job 3 7 3 4 2 Entering or Editing a Job Name 3 7 3 4 3 Editing a New Job 3 7 3 4 4 Editing an Existing Job 3 7 3 4 5 Lock Unlock a Job 3 8 3 4 6 Erasing a Job 3 8 3 4 7 Job Options 3 8 3 4 8 Run...

Page 38: ...ith 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 spec...

Page 39: ...n when the status light on top of the machine blinks Keypad The keypad is used to enter values into a pro gram scroll through programs and navigate through maintenance screens 3 1 2 Key Descriptions N...

Page 40: ...arrow key is used to move the screen cursor left It is also used to move the cursor to the left while naming a job 3 1 3 Using the Keypad The following information briefly describes effi cient ways to...

Page 41: ...Three Knife Trimmer 3 5 3 Operator s Guide 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 Use...

Page 42: ...to Figure 3 5 below C u t O N N a m e 1 J E x t e n d 1 S t a c k 0 1 0 5 0 0 i n 0 2 5 0 0 5 0 0 8 5 0 0 1 2 0 0 0 9 0 0 0 A M a i n t C O p t i o n s B J o b Figure 3 5 Example Job Run Screen 3 3 2...

Page 43: ...3 Editing a New Job If you do not already have a new job open do so by selecting one in the Job Selection screen and press enter This will bring up the Job Run screen as shown below C u t O N N a m e...

Page 44: ...e in the Job Run screen This will bring up the Job Options screen as shown in Figure 3 10 O p t i o n s C u t O p t i o n s J o g g e r S t a c k N u m S e l e c t P r e s s E n t e r A L o c k D E x...

Page 45: ...ft key B From the Job Selection screen a job can be opened by using one of two methods 1 Enter the job number with the keypad and press enter OR 2 Move the cursor to the desired job using the up down...

Page 46: ...e This can be caused by a misadjusted or faulty sen sor or the the air cylinder did not pull in F k n i f e l a t c h e r r o r O N w h e n i t s h o u l d b e O F F The face knife latch proximity sen...

Page 47: ...or starter was on when it should have been off M o t o r s t a r t e r e r r o r O F F w h e n i t s h o u l d b e o f f Motor starter was off when it should have been on N O A i r P r e s s u r e Thi...

Page 48: ...nd input 23 is off S K n i f e a t u p l i m i t F a i l e d t o m o v e This message is displayed when the side knives do not leave the up proximity sensor There are at least four reasons for this fa...

Page 49: ...cal line up from x 0 25 as shown in Figure 3 15 Draw a horizontal line right from h 8 5 The lines intersect within the shaded re gion therefore the layout is acceptable Figure 3 15 Book Chart Program...

Page 50: ...al Job Run Screen Enter in the first value then press enter Con tinue to enter values until all dimensions have been entered The screen should now look like the one below C u t O N E x a m p J E x t e...

Page 51: ...Run Screen Now all of the dimensions and set tings should be set The side knives and regis tration can be sent to their new positions without initiating trimmer operation by pressing the send key Or i...

Page 52: ...APR 2018 CMT 330 Three Knife Trimmer 3 16 3 Operator s Guide Notes...

Page 53: ...ressure Switch 4 9 4 6 Safety Systems Check 4 9 4 6 1 Safety Check off Sheet 4 10 Introduction Certain tasks will be performed on a regular ba sis but not necessarily on a set schedule The safety syst...

Page 54: ...When the waste bins are near capacity during a job run the CMT 330 continues cutting The status indicator light on top of the machine blinks slowly and the screen displays a message stating that the...

Page 55: ...Stick Puller 1 Switch off O main power at the front of the machine and lock out the main power disconnect switch as described in section 1 5 Power Lockout Procedure on page 1 4 2 Open the set of doub...

Page 56: ...g out of the ordinary sizes 4 4 Knives 4 4 1 Knife Change The knives should be changed when cut quality becomes unacceptable By default the com puter will issue a Sharpen Knife alarm after 2 500 cuts...

Page 57: ...acing the person changing the knife when he is placing the knife in it Make sure the cart is nearby Do not carry the knife across obstructed or slippery floors Warn people nearby that a knife is being...

Page 58: ...to be installed The knives may be in stalled in any order 20 After the cart is located make sure the scabbard containing the replacement knife has its protected edge facing the installer Have the kni...

Page 59: ...chine 4 Locate the face knife adjustment knob as shown in Figure 4 15 Figure 4 15 Knife Adjustment Knobs 5 If the knives were just replaced the face knife adjustment knob should be turned to the full...

Page 60: ...ot from the same set WARNING Changing knives can be very dangerous un less safety precautions are observed and ex treme care is taken when handling knives Keep handling of unprotected knives to an abs...

Page 61: ...the hydraulic motor 2 Open the front sliding door The hy draulic motor should shut off 3 Close the door Right rear Sliding Door Interlock 1 Press the green start button at the con sole to start the hy...

Page 62: ...ety Check off Sheet Use this sheet to sign tester s initials and test dates for performing the Safety Systems Check on page 4 9 of the Installation and Operator s Manual Machine Model CMT 330 Serial N...

Page 63: ...lity issues are addressed by either changing machine set tings or replacing knives Machine settings may require adjustment to be compatible with the type of paper and cover being used Knives and cut s...

Page 64: ...ut stick or cut plates The cover is pushed into the score mark folded over and torn Figure 5 2 Jagged Cover Possible Causes 1 The knife may be dull 2 The cut stick cut plates may be worn Solutions If...

Page 65: ...s equipped with the op tional clamp pressure regulator reduce the clamp pressure by turning the con trol dial counterclockwise Reduce the pressure until crease lines disappear on test books Note Reduc...

Page 66: ...ightened after trimming it looks similar to the book shown in Figure 5 9 This is the most common cause of out of square espe cially in a Stand Alone trimming applica tion where the binding has had sig...

Page 67: ...APR 2018 CMT 330 Three Knife Trimmer 5 5 5 Book Quality Notes...

Page 68: ...6 11 11 0 453 29 64 11 51 0 469 15 32 11 91 0 484 31 64 12 30 0 500 1 2 12 70 0 516 33 64 13 10 0 531 17 32 13 49 0 547 35 64 13 89 0 563 9 16 14 29 0 578 37 64 14 68 0 594 19 32 15 08 0 609 39 64 15...

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