Challenge CMT 330 Setup guide

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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
ChallengeMachinery.com
SERIAL No.: _____________
F.033B / JUL 2011

07/11
CMT 330 Three Knife Trimmer ii Contents
NOTICE
Service documentation is supplied to Chal-
lenge external customers for informational
purposes only. Service documentation is
intended for use by certified, product-
trained personnel only. 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. Customer performed ser-
vice of equipment may affect the warranty
offered by Challenge with respect to such
equipment. If the customer services this
equipment, modules, components or parts
thereof, the customer releases Challenge
from any and all liability for the customer
actions, and the customer agrees to in-
demnify, defend and hold Challenge harm-
less from any third party claims which arise
directly or indirectly from such service.
Prepared by:
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441 USA
Phone: [phone] Fax: [phone]
ChallengeMachinery.com
©2002-2011 by The Challenge Machinery
Company. All rights reserved.
Challenge® is a registered trademark of
The Challenge Machinery Company.

07/11
CMT 330 Three Knife Trimmer iii Contents
Contents
Description Page
1 Introduction 1-1
1.1 Warranty Information ................................1-2
1.2 Warning Label Definitions.........................1-3
1.3 Note Definitions.........................................1-3
1.4 Safety........................................................1-3
1.5 Power Lockout Procedure.........................1-4
1.6 Packing List...............................................1-5
1.7 Specifications............................................1-8
1.8 General Locations.................................. 1-10
2 Installation Guide 2-1
2.1 Shipping Claims........................................2-2
2.2 Unpacking.................................................2-2
2.3 Moving.......................................................2-2
2.4 Option Setup.............................................2-2
2.5 Power Hookup...........................................2-8
2.6 Air Hookup ............................................. 2-10
2.7 Cleaning................................................. 2-10
3 Operator's Guide 3-1
3.1 Programming.............................................3-2
3.2 User Interface Map ...................................3-5
3.3 Power up...................................................3-6
3.4 Improper Wiring.........................................3-6
3.5 Run Mode..................................................3-6
3.6 Job Mode ..................................................3-7
3.7 Status Messages ................................... 3-10
3.8 Example Job .......................................... 3-13
3.9 Serial Communication............................ 3-15
4 Routine Tasks 4-1
4.1 Under Book Air Blast.................................4-2
4.2 Waste Bins................................................4-2
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
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
5.5 Linear Crease Lines................................. 5-3
5.6 Draw......................................................... 5-3
5.7 All Sheets Not Cut.................................... 5-4
5.8 Book Not Square...................................... 5-4

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CMT 330 Three Knife Trimmer iv Contents
Notes:

07/11
CMT 330 Three Knife Trimmer 1-1 Introduction
Section Contents
TITLE PAGE
1.1 Warranty Information ................................1-2
1.2 Warning Label Definitions.........................1-3
1.3 Note Definitions.........................................1-3
1.4 Safety........................................................1-3
1.5 Power Lockout Procedure.........................1-4
1.6 Packing List...............................................1-5
1.6.1 Basic Machine/Options....................... 1-5
1.6.2 Standard Accessories ........................ 1-6
1.6.3 Optional Items .................................... 1-7
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
1.8.1 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
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.
1 Introduction

07/11
CMT 330 Three Knife Trimmer 1-2 Warranty Information
1.1 Warranty Information
READ THIS MANUAL BEFORE OPERATING!
Follow all precautions and instructions. For
parts and service contact the Authorized Chal-
lenge Dealer from whom the machine was pur-
chased. Always give the SERIAL NUMBER
and MODEL of your machine to ensure the cor-
rect parts are sent.
* WARRANTY INFORMATION *
PLEASE REVIEW THE ENCLOSED
WARRANTY INFORMATION SHEET
It is very important that you read and under-
stand the conditions outlined in the Warranty
Information Sheet attached to the outside of the
shipping container of your machine. The War-
ranty Information Sheet must be filled out com-
pletely and returned to THE CHALLENGE
MACHINERY COMPANY in order for the war-
ranty to be issued for this machine.
NOTICE: Failure to use dry, non-lubricated
compressed air that meets or exceeds the re-
quirements given in Section 2.6 may cause
damage to the machine and will result in THE
WARRANTY BEING VOIDED.
RECORD YOUR MACHINE SERIAL NUMBER
in the space provided on the front cover of this
manual. Fill in the warranty card accompanying
this manual and return it DIRECTLY TO CHAL-
LENGE.
The letters in the following diagram correspond
to the accuracy adjustment values listed in the
Installation Information table on the affixed la-
bel.
A________
B________
C________
If you bought a used machine, it is important to
have the following information on record at
Challenge. Copy this page, fill in the informa-
tion and send it care of The Challenge Service
Department, 6125 Norton Center Drive •Norton
Shores •MI 49441.
* INSTALLATION INFORMATION *
Model: CMT 330B
Serial No.:
Company Name:
Address:
City:
State/Province:
ZIP Code
Phone No.:
Date Installed:
Dealer Name:
Dealer City:

07/11
CMT 330 Three Knife Trimmer 1-3 Warning Label Definitions
1.2 Warning Label Definitions
Warning labels are posted throughout the ma-
chine to indicate areas where physical injury
may occur.
Read the instruction manual.
The instruction manual should be
read and understood before operat-
ing this machine.
Do not operate with more than
one person!
One person only should operate
this machine at a time.
Cut / Crush Hazard!
Do not operate with covers re-
moved.
Do not disable safety devices.
Crush Hazard!
Do not operate with covers re-
moved.
Do not disable safety devices.
Crush / Entanglement Hazard!
Do not operate with covers or
guards removed.
Electrical Shock Hazard!
Disconnect power before removing
cover.
Electrical Shock Hazard!
Disconnect power before removing
cover.
1.3 Note Definitions
The formats of three specific types of notes
found throughout this manual indicate the level
of danger or importance associated with the
task presented. The format of warning notes,
caution notes, and regular notes imply a certain
level of danger. The following examples give a
description. Associate the text format with its
level of danger or importance.
Warning Definition:
WARNING
A warning indicates an operating or maintenance pro-
cedure, practice, or condition that, if not strictly ob-
served, could result in injury or loss of life.
Caution Definition:
CAUTION
A Caution indicates an operating or maintenance procedure,
practice, or condition that, if not strictly observed could re-
sult in damage to, or destruction of, equipment.
Note Definition:
Note: A regular note indicates an operating or maintenance
procedure, practice, or condition that is necessary to ac-
complish a task efficiently.
1.4 Safety
Before installing or operating any equipment, it
is important to take precautions. Read and
thoroughly understand the safety precautions
outlined below.
•This machine is designed for one-
person operation. Never operate the
machine with more than one person.
•Safe use of this machine is the respon-
sibility of the operator. Use good judg-
ment and common sense when working
with and around the machine and its
accessories.
•Read and understand all instructions
thoroughly before using the machine. If
questions remain, contact your Author-
ized Challenge Dealer. Failure to un-
derstand the operating instructions may
result in personal injury.
•Only trained and authorized individuals
should operate this machine.
•Only trained and authorized service
technicians should service this ma-
chine.
•Do not alter safety guards or devices.
They are there for your protection. Se-
vere laceration or dismemberment may
result if safety devices are altered.
•Disconnect power and lock out before
performing any maintenance. See Sec-
tion 1.5 , Power Lockout Procedure.
•Observe all caution and instruction la-
bels on this machine.
•Be extremely careful when handling
and changing knives. Severe lacera-
tions or dismemberment could result
from careless handling procedures.
•Perform the Safety Systems Check
given on page 4-9 before each shift be-
gins.

07/11
CMT 330 Three Knife Trimmer 1-4 Power Lockout Procedure
•Keep all conveyors and elevator acces-
sories clear of foreign objects. Do not
manually place foreign objects within
the machine. Cutting anything other
than qualifying perfect bound books
could result in serious damage to the
machine and create safety hazards. A
qualifying perfect bound book will fall
into the size range described in the
specifications on page 1-8.
•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 abnormally,
consult a Challenge authorized service
agent.
1.5 Power Lockout Procedure
For maximum safety while making ADJUST-
MENTS or REPAIRS to your machine, lock out
the main power disconnect switch. The switch
should be moved to the OFF position and a
padlock securely fastened through the loop.
The person adjusting or servicing the machine
should hold the key.
Figure 1-1. Main Power Disconnect

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CMT 330 Three Knife Trimmer 1-5 Packing List
1.6 Packing List
Compare the contents of the crate against the
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 that may have been ordered
with the machine.
Part Number Description Qty.
CMC-330B CMT 330 Basic Machine 1
Accessory Options
In-Line Option In-Line with Tilt In-Feed Conveyor
56600 Tilt In-Feed Conveyor 1
56421 Cooling Elevator 1
Stand-Alone Option Stand Alone
56413 Hand Feed Conveyor 1
Exit Option Fixed (shown above)
56420 Exit Conveyor 1

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CMT 330 Three Knife Trimmer 1-6 Packing List
1.6.2 Standard Accessories
The following list contains pre-installed, stan-
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 HSS Knife Set (scabbard not shown) 2
5 56303 Cut Stick 1
6 56305 Cut Plate 2
7 H-6910-605 Knife Bolt- 3/8-16 x 5/8 BHCS 18
8 W-180 7/32" T-Handle Hex Wrench 1

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CMT 330 Three Knife Trimmer 1-7 Packing List
Part Description Qty. Frequency
E-967-1 Lamp 6 10,000 hrs
47264-2101 UHMW Tape (Elevator) 4 1 yr.
56523-1000 UHMW Tape (Joggers) 2 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 1 6 mo.
56181-1 Right Clamp Pad 1 6 mo.
56178 Center Pad 1 6 mo.
56246 HSS Knives (set of 3) 1 5000 books
56303 Cut Stick 1 rot. 1000, change 8000 books
56305 Cut Plate 2 rot. 1000, change 4000 books
The following consumables are found in Oil Change Kit, K-56040.
Part Description Qty. Frequency
56041 Filter Element (air) 1 1 yr.
H-227-1 Filter Element (oil) 1 1 yr.
S-1991-3 Grade 46 Hydraulic Fluid 1 1 yr.
1.6.3 Optional Items
The following items are optional.
56246-1 Tungsten Carbide Knives (3)
56246-2 DMD 5X Knives (3)
41058 Waste Wagon
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.

07/11
CMT 330 Three Knife Trimmer 1-8 Specifications
1.7 Specifications
WARNING
The CMT 330 was designed specifically for use with the
Challenge in-feed and exit accessories listed in this
table. If any other accessories are used, it is the pur-
chaser's responsibility to comply with ANSI B65.4
Safety Standard for Three-knife Trimmers. Failure to
comply with this standard could result in personal in-
jury or death.
CAUTION
The CMT 330 was specifically designed to trim perfect
bound books only. It should not be used for trimming other
materials. Trimming other materials with the CMT 330 may
result in safety hazards or damage to the machine.
For trimmable book sizes, see section 1.7.1 .
See manuals F.501 and F.502, for specifica-
tions for the Book Pile Feeder and the Vertical
Stacker.
Multiple Book Mode: Note that up to 3 books
may be stacked in multiple book mode. The
total thickness is not to exceed 1-1/4 in. (32
mm). Larger pile thicknesses may be cut, but
the trim may be less accurate and more out-of-
square. Always test before running books out-
side the published specifications.
NOTE: Challenge reserves the right to make changes to
any product or specification without notice and without in-
curring responsibility to existing units.
Description US Units Metric Units
Perfect bound books only
Max. start book 13 (spine) x 9.5 in. 330 (spine) x 241 mm
Min. start book (bottom cover) 7 (spine) x 6.75 in. 177.8 (spine) x 171.4 mm
Min. start book (w/feeder) 7 (spine) x 6.75 in. (single book mode)
7 x 7 in. (multi-book mode) 177.8 (spine) x 171.4 mm 177.8 x 177.8 mm
Min. finish book 5.82 (spine) x 4 in. 147.8 (spine) x 101.6 mm
Max. face trim (fore-edge) 5.5 in. 140mm
Book thickness range 0.048-2.000 in. 1.22-50.8 mm
Min. Trim 0.125 in. 3.2 mm
CMT 330 Basic Machine
Width 34.5 in. 876 mm
Depth 84 in. 2134 mm
Height 61 in 1549 mm
Net Weight 2540 lb. 1140 kg
Shipping Weight 2850 lb. 1300 kg
Floor Loading 60 PSI 4.2 kg/cm2
Waste Bin Capacity 3 @ 14.75 gal. per bin 3 @ 55.8 L per bin
Oil Capacity 5 gal. 19 L
Air Consumption 5 CFM @ 80 PSI 142 LPM @ 5.5 Bar
Knife Re-grind 1/4 in. 6.4 mm
60 Hz Requirements 208/230 V, 20 A, 3 phase
50 Hz Requirements 380/415 V, 10 kW, 3 phase, 12 A
Memory 99 jobs
Time to change book size 15 sec.
Throughput up to 400 books/hr.
56420 Exit Conveyor (85 lb/39 kg net) (210 lb/95 kg ship) (6.76 PSI/.48 kg/cm2load)
Depth 12.14 in. 308.4 mm
Width 47 in. 1194 mm
Height 39.5 in. 1003 mm
56421 Cooling Elevator (335 lb/152 kg net) (470 lb/214 kg ship) (11.86 PSI/.83 kg/cm2load)
Depth 21.5 in. 546 mm
Width 37.03 in. 941 mm
Height 45.5 in. 1156 mm
56600 Tilt In-feed Conveyor (150 lb/68 kg net) (230 lb/105 kg ship) (5.62 PSI/.40 kg/cm2load)
Depth 28.62 in. 727 mm
Width 39.38 in. 1000 mm
Height 26 in. 660 mm
Mates w/ binder @ exit
heights 17.5-25.5 in. 445-648 mm

07/11
CMT 330 Three Knife Trimmer 1-9 Specifications
1.7.1 Book Size Chart
The physical parts of a book are defined as fol-
lows and will be referenced as such throughout
this manual. Book dimensions are referenced
as (spine length) X (top or bottom edge length).
Spine: The edge of a book where the pages
are bound together.
Top edge: Also know as the head, the top
edge is the edge of the book that is facing away
from the reader.
Bottom edge: Also known as the foot, the bot-
tom edge is the edge of the book that is facing
toward the reader.
Face: The face or fore-edge is the edge of the
book from which it is opened.
Book block: A book block is the printed and
collated form of a book 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 been trimmed to finish size.
Trimmed book: A trimmed book has been
bound and trimmed to a finish size.
Figure 1-2 can be used to determine if a specific
book layout can be trimmed using the CMT 330.
From Error! Reference source not found.,
see that (x) is the bottom trim and (h) is the
height of the book. The book size must fall
within the shaded region of the chart but never
exactly on the sloped line.
The CMT 330 software will not allow a book to
be cut outside this range. The operator should
be aware of these size constraints before books
are printed. The CMT 330 will not allow only
one top or bottom edge to be trimmed.
Figure 1-2. Trimmable Book Sizes
Figure 1-3 CMT 330B Throughput Chart

07/11
CMT 330 Three Knife Trimmer 1-10 General Locations
1.8 General Locations
Become familiar with general machine loca-
tions. 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.
Note: The word "rear" refers to the general direction closer
to the back end of the machine. "Back" refers only to the
backside of the machine.
1.8.1 Front Views
The front views shown in Figure 1-4 and Figure
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

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CMT 330 Three Knife Trimmer 1-11 General Locations
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
CMT 330 Three Knife Trimmer 1-12 General Locations
1.8.3 Exit Conveyor
Part Number: 56420
Important locations are shown in Figure 1-7.
Figure 1-7. Exit Conveyor Locations

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CMT 330 Three Knife Trimmer 1-13 General Locations
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

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CMT 330 Three Knife Trimmer 1-14 General Locations
1.8.5 Elevator
Part Number: 56421
Important locations are shown in Figure 1-9.
Figure 1-9. Elevator Locations

07/11
CMT 330 Three Knife Trimmer 1-15 General Locations
1.8.6 Site Specifications
The installation site must have adequate space
and utilities to support the trimmer with its setup
options. It requires a supply of compressed air
and electricity. Refer to section 1.7
Specifications on page 1-8 to verify that the site
can accommodate these requirements. Use the
following figures to determine floor space re-
quirements for the option to be installed.
1.8.6.1 In-Line Option
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.
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 using a rolling cart.
Figure 1-10. In-Line Option 2