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1. 5 10 20 30 60 minutes Serice Hydrualic Accuracy Cushion Adjust Yess Increase increase No decrease fdecrease Shipping Position Figure 3 2 CMT 330 User Interface Map English French German Spanish Portuguese job number Jab Run Options Side Cut On OFF Stack Number Jogger CMT 330 Three Knife Trimmer 01 03 3 5 User Interface Map 3 3 Power up When the CMT 330 is switched on the power up screen will appear Book Transport Gripper must move to Preset Please press the START button Revision Figure 3 3 Start up Screen Press and hold the green start button until the hydraulic motor starts The following message will be displayed PLEASE WAIT The book transport gripper is moving to the home location Figure 3 4 Start Prompt The gripper will not move for approximately 3 seconds The gripper will then move to ap proximately 1 inch in front of home position back past home then to home 3 4 Improper Wiring If the knives do not move to the up position after power up then the three phase power is hooked up incorrectly The following message is displayed Waiting for knives to lift If this message is displayed for more than 10se
2. 3 16 3 10 Serial Data 3 18 4 Routine Tasks 4 1 4 1 Waste Bins sese 4 2 4 2 Cut Stick Cut 4 2 43 4 4 4 4 Check Pressure Switch 4 8 4 5 Safety Systems 4 9 5 Book Quality 5 1 5 1 Burr 5 2 5 2 Jagged Bottom 5 2 5 3 Burr Marks Jagged Cover 5 2 01 03 CMT 330 Three Knife Trimmer ii Contents Notes 01 03 CMT 330 Three Knife Trimmer iv Section Contents TITLE PAGE 1 1 Warranty Information 1 2 1 2 Warning Label Definitions 1 3 1 3 Note 1 3 WA Safely a c inc tat tos 1 3 1 5 Power Lockout Procedure 1 4 1 6 Packing List E EN 1 5 1 6 1 Basic Machine Options 1 5 1 6 2 Standard Accessories 1 6 1 6 3 1 7 1 7 1 8 1 7 1 Book Size Chart 1 9 1 8 General Locations 1 10 1 8 1 Front
3. 5 4 1 1 Warranty Information 1 2 1 2 Warning Label Definitions 1 3 1 3 Note 1 3 1 4 Satfely 1 3 1 5 Power Lockout 1 4 1 6 Packing 1 5 1 7 1 8 1 8 General Locations 1 10 1 9 Site 1 17 2 Installation Guide 2 1 2 1 Shipping Claims 2 2 2 2 UNPACKING 2 2 2S MOVING 2 2 2 4 Option Setup sss 2 2 2 5 Power 2 8 2 6 Air Hookup 2 9 2 f Cleaning 2 9 Operator s Guide 3 1 3 1 Programming sse 3 2 3 2 User Interface Map 3 5 3 9 FONET UD terere 3 6 3 4 Improper 3 6 3 5 Run 3 6 3 6 Job 3 7 3 7 Maintenance Mode 3 9 3 8 Status Messages 3 13 3 9 Example Job
4. Sends knives side guide to programmed position C 1 ASCII HEX 43 3d 31 0d 0a 21 3 10 3 Command 2 Stop Command Stops input conveyors C 2 3 10 4 Command 3 Reset Book count Resets book count back to 0 C 3 3 10 5 Other commands The following commands are not yet available but are provided for informational purposes 3 10 5 1 Job change The CMT 330 has 99 program locations This command allows a new pre programmed book size to be selected J 1 ASCII HEX 3d 31 0d 0a 21 3 10 5 2 Book Count The book count is sent from the CMT 330 at the end of each book Example BK 20 ASCII HEX 42 4b 3d 32 30 0d 0a The CMT 330 sends back the book count after each book Immediately after receiving the book count a stop command should be sent When the input conveyors are stopped the new book size can be sent or a new job can be se lected A send command must be sent to set the knives and registration assembly Once the machine is in position the input conveyors will restart CMT 330 Three Knife Trimmer 01 03 3 18 Serial Data 3 10 6 Example 1 This example stops input selects JOB 2 and sends knives to job2 location C 2 J 2 1 3 10 7 Example 2 This example stops input selects a 9 X 7 book with a 25 trim and 0 2 thick then sends knives to location C 2 n Ww H W M TO CMT 330 Thre
5. 1 10 1 8 2 Back 1 11 1 8 3 Exit 1 12 1 8 4 In feed Conveyor 1 13 1 8 5 Tilt In feed Conveyor 1 14 1 8 5 Tilt In feed Conveyor 1 14 1 8 6 1 15 1 8 7 Hand feed Conveyor 1 16 1 9 Site 1 17 1 9 1 In line Option 1 1 17 1 9 2 In line Option 2 1 18 1 9 3 Stand alone Option 1 19 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 CMT 330 Three Knife Trimmer 01 03 1 1 Introduction 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 Sh
6. A CAUTION All three knives are a set They must be sharpened as a set Damage or poor performance may result if knives are not from the same set Ay Changing knives can be very dangerous unless safety precautions are observed and extreme care is taken when handling knives Keep handling of unprotected knives to an absolute minimum Have the scabbard nearby and insert knife immediately Warn people of any unprotected knife Av Knife changing is a ONE PERSON OPERATION More than one person changing a knife creates safety haz ards y Even used knives are extremely sharp Use extreme care when handling new re ground knives and used knives The following procedure should be used to change knives 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 Place three empty scabbards on the rolling cart The knives may be re moved or installed in any order 3 The knives are located behind the plas tic doors shown in Figure 4 8 and Figure 4 9 RIGHT SIDE KNIFE LOCATION FACE KNIFE LOCATION Figure 4 8 Knife Locations CMT 330 Three Knife Trimmer 01 03 4 4 Knives LEFT SIDE KNIFE LOCATION Figure 4 9 Left Side Knife Location 4 Open the door and remove the waste chute to access the knife 5 Using the T handle hex wrench remove the two knife bolts that a
7. 1 2 3 4 x INCHES Figure 3 26 Book Chart Program the Job Switch on the trimmer Allow a few seconds for the gripper to find home position The screen will look similar to Figure 3 27 S Cut ON J Extend Stack A Maint B Job Figure 3 27 Example Start Screen Press soft key B to enter the Job screen The display will look similar to Figure 3 28 A 1 Factory Test Job Select Job amp Enter A Lock C Erase D Exit Figure 3 28 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 29 CMT 330 Three Knife Trimmer 01 03 3 16 Example Job Factory Test Job Select Job amp Enter Figure 3 29 Job Number Name the job Use the right arrow key to move the cursor at least one space to the right Use the up down arrow keys to cycle through the alphabet After arriving at the desired letter symbol or number press the right arrow key to move to the next character field Continue until the name is complete The screen looks similar to Figure 3 30 gt 1 Factory Test Job 2 gt Example Job_ Select Job amp Enter A Lock D Exit Figure 3 30 Job Name After the job has been named press the enter key to enter the book dimensions into the job The screen looks similar to Figure 3 31 S Cut ON Example Job J Extend 2 Stack A Maint B Job Figure 3 31 Job Run Screen A
8. 3 Close the door 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 CMT 330 Three Knife Trimmer 01 03 4 9 Safety Systems Check 4 5 1 Safety Check off Sheet Machine Model CMT 330 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 01 03 CMT 330 Three Knife Trimmer 4 10 Safety Systems Check Section Contents TITLE PAGE 5 1 Burr 5 i 5 2 5 2 Jagged Bottom 5 2 5 3 Burr Marks Jagged Cover 5 2 5 4 Rectangular Crease Lines 5 3 5 5 Linear Crease 5 3 5 6 IDIQW beetles 5 3 5 7 All Sheets Not 5 4 5 8 Book Not 5 4 Introduction Operators may occasionally need to trouble shoot book quality issues These quality 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 stick
9. Select amp Press Enter D Exit Figure 3 13 Maintenance Screen 3 7 1 Knife Adjust Knife Adjust mode provides a way to easily set the knife cutting depth after changing knives Selecting Knife Adjust from the maintenance menu bring up the screen shown in Figure 3 14 While the hydraulic pump is running and the conveyors are stopped the knife depth is set by placing a sheet of paper under each knife and pressing the button at the rear of the machine This will cause the knives to cycle Repeat pressing the button and adjusting the depth until the paper is cut clean through See section 4 3 2 Knife Adjustment on page 4 7 Knife Adjust Press the button at the rear of the machine for one second to cycle the knives A Maint B Job D Exit Figure 3 14 Knife Adjust Screen 3 7 2 Parameters In the parameters screen shown in Figure 3 15 on page 3 10 use the up down arrow keys to select a parameter and press the enter key The following sections describe the function of each parameter CMT 330 Three Knife Trimmer 01 03 3 9 Maintenance Mode Parameters Timeout Input Conveyor Knife Cnt 0000 Machine Cnt 0000 Select amp Press Enter A Maint B Job D Exit Figure 3 15 Parameters Screen 3 7 2 1 Timeout This parameter sets the amount of idle time be fore the screen saver activates and the hydrau lic motor turns off The choices are 5 10 20 30 and 60 minutes In the time
10. CMT 330 Three Knife Trimmer 01 03 4 7 Knives 8 Open the sliding door at the right rear hand side of the machine 9 Place a book under the knife with the binding facing the front of the machine 10 Securely close the sliding door 11 Press and hold the green button on the right hand side of the double doors at the back of the machine until the book is cut If the bottom cover and binding are not fully cut turn the side knives ad justment knob 1 4 revolution counter clockwise and repeat steps 8 through 11 All doors must be closed for the machine to cut If the book is fully cut the knife adjustment procedure is com plete 12 Reinstall all waste chutes 13 Securely close all doors and resume normal operation at the console 4 3 3 Knife Sharpening Rules The CMT 330 s knives must be sharpened as a matching set A total of 1 4 6 4mm of mate rial may be removed due to grinding Beyond this the machine will not fully cut through a book 2 50 2 75 in 63 5 69 9 mm Figure 4 15 Knife Height Range The knives must not be sharpened to less than 2 50 in 63 5 mm of knife height as shown in Figure 4 15 4 4 Check Pressure Switch The main air pressure switch should be checked for proper operation each month The main air pressure switch is used to verify that main air is connected and switched on If this switch fails damage to the machine could re sult Switch on power open lower back door
11. 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 231 799 8484 Fax 231 798 1275 ChallengeMachinery com 2002 2011 by The Challenge Machinery Company All rights reserved Challenge is a registered trademark of The Challenge Machinery Company 01 03 CMT 330 Three Knife Trimmer ii Contents 5 4 Rectangular Crease Lines 5 3 5 5 Linear Crease 5 3 5 3 Sec enpuon 5 7 All Sheets Not Cut 5 4 1 Introduction 1 1 5 8 Book Not
12. Switch off main air valve Close the door Seco og ae Go to the console and read the LCD display The message No air pres sure should be displayed Open lower back door Switch on main air valve Close the door Go to the console and read the LCD display The message No air pres sure should not be displayed CMT 330 Three Knife Trimmer 01 03 4 8 Check Pressure Switch 4 5 Safety Systems Check Test Frequency Daily A CAUTION Only one person should perform this test at a time Use the following procedures to test the safety devices throughout the machine If the machine fails any safety system test DO NOT USE the machine Have the machine serviced by an authorized service technician Console Stop Button 1 Switch on the main power 2 Press the green start button at the con sole to start the hydraulic motor 3 Press the clear button and wait for the machine to reset itself 4 Press the red stop button at the con sole The hydraulic motor should shut off Knife Change Operator Stop Button 1 Press the green start button at the con sole to start the hydraulic motor 2 Press the red stop button at the back of the machine The hydraulic motor should shut off Front Sliding Door Interlock 1 Press the green start button at the con sole to start the hydraulic motor 2 Open the front sliding door The hy draulic motor should shut off 3 Close the door
13. Right rear Sliding Door Interlock 1 Press the green start button at the con sole to start the hydraulic motor 2 Open the right rear sliding door The hydraulic motor should shut off 3 Close the door Left rear Sliding Door Interlock 1 Press the green start button at the con sole to start the hydraulic motor 2 Open the left rear sliding door The hy draulic motor should shut off 3 Close the door Back Double Door Interlocks 1 Press the green start button at the con sole to start the hydraulic motor 2 Open the left hand door in the set of double doors at the back of the ma chine The hydraulic motor should shut off Close the door Press the green start button at the con sole to start the hydraulic motor 5 Open the right hand door in the set of double doors at the back of the ma chine The hydraulic motor should shut off Right rear Door Interlock 1 Press the green start button at the con sole to start the hydraulic motor 2 Openthe right rear door The hydraulic motor should shut off 3 Close the door Left rear Door Interlock 1 Press the green start button at the con sole to start the hydraulic motor 2 Open the left rear door The hydraulic motor should shut off 3 Close the door Lower Back Door Interlock 1 Press the green start button at the con sole to start the hydraulic motor 2 Openthe lower back door The hydrau lic motor should shut off
14. Securely close the set of double doors Press and hold the green button on the right hand side of the double doors The hydraulic motor turns on and in about 1 second the machine cuts the book 10 Open the set of double doors and check the book If the bottom cover of the book is not fully cut Turn the face knife adjustment knob 1 4 revolution counter clockwise Repeat steps 7 through 10 until the bottom cover is cut fully All doors must be closed for the machine to cut 11 Now complete the Side Knife Adjust ment procedure Side Knife Adjustment 1 The computer should still be in Knife Adjust mode 2 If the knives were just replaced the side knives adjustment knob should be turned to the full down position If it is not do so by turning the knob clockwise until it stops 3 Turn the side knives adjustment knob about three full revolutions counter clockwise Securely close the doors 5 Open the sliding door at the left hand rear of the machine Place a scrap book underneath the knife with the binding facing the front of the machine Securely close the sliding door Press and hold the green button until the machine cuts the book If the bot tom cover and binding of the book are not fully cut turn the side knives ad justment knob 1 4 revolution counter clockwise and repeat steps 5 through 7 All doors must be closed for the ma chine to cut Continue with the next step if the book is fully cut
15. manually An audio beep is heard each time a sensor is actuated 3 7 3 3 Clear Memory The Clear Memory function resets the memory All jobs are deleted 3 7 3 4 Jogger Pressure The jogger is controlled by an electrically vari able air pressure valve The pressure should be set so it will not crush a 0 1 2 5 mm thick book Adjustment Procedure 1 Enter the jogger pressure setup mode from the Service Screen 2 Place a minimum thickness book at the jogger station 3 Press the up down arrow key until ap propriate pressure is obtained 4 Leaving the menu jogs once Re enter the menu to set the pressure again Jogger Pressure gt Press to increase Press v to decrease A Maint B Job D Exit Figure 3 20 Jogger Pressure Adjust Screen 3 7 3 5 Hydraulic Cushion The Hydraulic Cushion screen allows adjust ment of the slow down speed at the bottom of the knife stroke It primary function is to soften the impact when the hydraulics changes direc tion It can reduce noise and wear and tear on the machine To increase the speed impact is harder press the up arrow To decrease the speed impact is softer press the down arrow Hydraulic Cushion gt Press to increase Press v to decrease D Exit Figure 3 21 Hydraulic Cushion Screen 3 7 3 6 Accuracy Adjust This screen shown in Figure 3 22 allows all ac curacy dimensions to be adjusted simultane ously Adjustment Procedu
16. the backside of the in feed conveyor Lock into place by threading the con nector collar onto the socket 4 Connect the yellow cable from the Cool ing Elevator to the in feed conveyor 5 If the Tilt In feed Conveyor is being used connect the air hose with the red cap to the port on the conveyor Also Cooling Elevator 1 Unwrap the cable labeled Cooling Ele vator 2 Route the cable behind the hydraulic power unit and under the left hand side of the machine base 3 Connect the cable to the socket on the backside of the elevator Lock into place by threading the connector collar onto the socket 4 Unwrap the two coiled hoses with quick disconnect fittings that have yellow and black caps Route them with the cable from step 3 5 Push the hose connector with the black cap into the fitting on the elevator with black label above it 6 Push the hose connector with the yel low cap into the fitting on the elevator with yellow label above it Exit Conveyor 1 Unwrap the cable labeled Exit Con veyor 2 Route the cable under the power panel enclosure and out the right hand side of the trimmer base 3 Connect the cable to the socket on the backside of exit conveyor Lock into place by threading the connector collar onto the socket 2 4 2 In line Option 2 The setup for option 2 is virtually identical to that of option 1 This section will highlight the differences Refer to section 2 4 1 on page 1 17
17. 14 General Locations 1 8 6 Elevator Part Number 56421 Important locations are shown in Figure 1 10 TOP e MOUNTING HOLES ie RIGHT SIDE SIDE LEFT SIDE INPUT SIDE POWER COM amp AIR CONNECTORS ON BACKSIDE VER FRONT s ART COVE SIDE gH D Ws CHAIN COVER Figure 1 10 Elevator Locations 01 03 CMT 330 Three Knife Trimmer 1 15 General Locations 1 8 7 Hand feed Conveyor Part Number 56416 Important locations are shown in Figure 1 11 GATE ADJUSTMENT KNOB BOOK GATE BOOK COVER WEIGHT NOT ATTACHED ADJUSTABLE BOOK GUIDE MOUNTING BRACKET POWER COM C Figure 1 11 Hand feed Conveyor Locations CMT 330 Three Knife Trimmer 01 03 1 16 General Locations 1 9 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 9 1 In line Option 1 This in line option is used when automated transport of books from a binder to the trimmer is required and book size changes are infre quent It includes the CMT 330 basic machine two conveyors and an elevator See Figure 1 12 f
18. 18 19 Make sure main power is still turned off O at the front of the machine and is locked out at the main power discon nect switch as described in section 1 5 Power Lockout Procedure on page 1 4 Make sure all the waste chutes are still removed from the machine Turn both knife depth adjustment handles clockwise until they stop They are accessed through the rear left sliding door and back double doors Figure 4 12 Knife Adjustment Knobs 20 21 22 23 24 25 26 27 28 Place a scabbard containing a re placement knife on the cart Move the cart as close as possible to where the knife is to be installed The knives may be installed in any order After the cart is located make sure the scabbard containing the replacement knife has its protected edge facing the installer Have the knife lifter nearby Carefully remove the two screws that fasten the knife to its scabbard Place the knife lifter on the knife and align the left handle with the second hole from the left end of the knife Align the right handle with the second hole from the right end of the knife Turn the lifter handles clockwise until the ends of the handles touch the scab bard under the knife Turn the handles counterclockwise 1 2 turn so the ends of the handles will not interfere with the clamp inside the ma chine Hold the knife lifter with knife at a safe distance from the body Other people should not b
19. Operator s Guide CMT 330 Three Knife Trimmer 01 03 3 1 Operator s Guide 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 The specific func tion of each key on the console is given in this section START BUTTON SAFETY WARNINGS GREEN LCD SCREEN AND INSTRUCTIONS CMT 990 PATEE menm D gt 200586 oI 1 2 5 Lle acco eens HOO 20 MET NTC pore owowa CJ SA SOO Cae 00060 J P STOP BUTTON IN mm SCALE RED KEYPAD Figure 3 1 CMT 330 Console 01 03 CMT 330 Three Knife Trimmer 3 2 Programming Safety Warnings Multi language safety instructions with symbols are listed in this area of the console Each op erator should read and understand the instruc tions listed If the operator does not understand these instructions he should ask his supervisor for clarification IN mm Scale The IN mm scale can be used for measuring the size of
20. Procedure sories clear of foreign objects Do not manually place foreign objects within For maximum safety while making ADJUST the machine Cutting anything other MENTS or REPAIRS to your machine lock out than qualifying perfect bound books the main power disconnect switch The switch could result in serious damage to the should be moved to the OFF position and a machine and create safety hazards A padlock securely fastened through the loop qualifying perfect bound book will fall The person adjusting or servicing the machine into the size range described in the should hold the key specifications on page 1 8 e Make sure all applicable accessories are securely bolted to the main ma chine Tip hazards may result from un secured accessories e fthe machine operates abnormally consult a Challenge authorized service agent 1 d Figure 1 1 Main Power Disconnect 01 03 CMT 330 Three Knife Trimmer 1 4 Power Lockout Procedure 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 330 CMT 330 Basic Machine 1 Accessory Options In line Option 1 In line Shown above 56401 In feed C
21. all aspects of product maintenance and repair All products should be used only by qualified and properly trained personnel following proper safety procedures All products should be regularly inspected and maintained and their condition application and use should be periodically evaluated by qualified personnel Only qualified and properly trained technicians should perform maintenance repair and replacement procedures Attempting these procedures without proper training may cause machine damage or operator injury Products may be unsupported by The Challenge Machinery Company due to age or the unavailability of parts from their original manufacturer No parts or product support will be available to repair or maintain unsupported products Older products may not be UL listed if the product does not have a UL label it is not a listed product and may not comply with applicable installation or other regulations or requirements if relocated to a new facility Many municipalities require a product to be UL listed before an electrician will connect power to them Often the cost of updating an older product to comply with current safety regulations is greater than the value of the product 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 033 JAN 2003 NOTICE
22. knife slow down proximity sensor may cause this error Stop button pressed Either a stop button is pressed or one is faulty Upper door is Open One of the upper doors is open CMT 330 Three Knife Trimmer 01 03 3 15 Status Messages 3 9 Example Job This example will step through a typical in line job An in line job uses the in feed conveyor to accept books from a perfect binder The in feed conveyor transfers books into the elevator The elevator feeds books into the trimmer The trimmer then drops books onto the exit con veyor This example will trim a 1 thick 9 x 12 book to 8 5 x 11 The right side trim will be 1 4 as shown below 11 000 0 250 1 000 8 500 12 000 Figure 3 25 Example Book Dimensions Preparation Before books are printed the document layout should be checked against the Book Size Chart on page 1 9 Draw a vertical line up from x 0 25 as shown in Figure 3 26 Draw a horizontal line right from h 8 5 The lines intersect within the shaded region therefore the layout is acceptable n 2 DO IS SSNS 5252525 00905 Y Q S S25 OD ef etel 0S E ES I a SA O Di BSA zs 20090000696 000600600 4 90900690901 eee ate lt 95959550109 t 0909090909090 0606060600000 t 9090905091905 160509050 090905 0000909094900 t 90509090905 x COO ve 00000 000048 24220909099290 0540050500000 5 875
23. main power disconnect and resume operation Refer to section 1 6 2 Standard Accessories to obtain the part number for replacement cut sticks 4 2 2 Changing the Cut Plates The cut plates can be rotated once before dis posal One is located underneath each side knife They are accessed by opening the sliding doors on each side of the machine A flat screwdriver is helpful but not necessary when removing cut plates 1 Send the book height cutting dimension to 6 inches so the side knives move to the center of the machine 2 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 3 Open a sliding door on either the left or right side of the machine 4 Remove the black plastic waste chute from the table by lifting and tilting to ward the outside of the machine 5 Lift and wiggle the edge of the cut plate until it slides off the four pins in the ta ble Alternatively slide the end of a screwdriver between the slot in the ta ble and the cut plate Rock the screw driver Alternate between each of the two slots until the cut plate is free Figure 4 7 shows the location of the slots CMT 330 Three Knife Trimmer 01 03 4 3 Cut Stick Cut Plates Figure 4 7 Slots Under Cut Plates 6 Inspect the cut plate for wear It may be used two times once on each sur face before disposal If only one side
24. mm Net Weight 2540 Ib 1140 kg Shipping Weight 2850 Ib 1300 kg Floor Loading 60 PSI 414 kPa Waste Bin Capacity 3 14 75 gal per bin 3 55 8 L per bin Oil Capacity 5 gal 19L Air Consumption 5 CFM 80 PSI 142 LPM 5 5 Bar Knife Re grind 1 4 in 6 4mm 60 Hz Requirements 208 230 V 25 A 3 phase 50 Hz Requirements 380 415 V 10 kW 3 phase 12A Memory 99 jobs Time to change book size 15 sec Throughput up to 400 books hr 56401 Basic In feed Conveyor CMT 330 Three Knife Trimmer Depth 12 14 in 308 4 mm Width 35 4 in 876 mm Height 17 5 445 mm 56420 Exit Conveyor Depth 12 14 in 308 4 mm Width 47 in 1194 mm Height 39 5 in 1003 mm 56421 Cooling Elevator Depth 21 5 in 546 mm Width 37 03 in 941 mm Height 45 5 in 1156 mm 56600 Tilt In feed Conveyor 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 01 03 1 8 Specifications 1 7 1 Book Size Chart Figure 1 3 can be used to determine if a specific book layout can be trimmed using the CMT 330 From Figure 1 2 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
25. of the plate is used turn the plate over and reinstall it with the smooth side up Replace the cut plate with a new one if both sides are used 7 Reinstall the waste chute Securely close the double doors at the back of the machine 9 Repeat steps 3 through 8 with the re maining cut plate 10 Unlock the main power disconnect and resume operation Refer to section 1 6 2 Standard Accessories to obtain the part number for replacement cut plates Hint Depending on what locations on the cut plates are most worn they may be able to be rotated 180 before they are turned over By using this method of rotation each cut plate may be used four times Hint Save your old cut plates to use when trimming out of the ordinary sizes 4 3 Knives The knives should be changed when cut quality becomes unacceptable By default the com puter will issue a Sharpen Knife alarm after 2500 cuts This is a good general purpose value but the most appropriate number will vary depending on the type of paper stock being cut Refer to the Operator s Guide for instructions on changing the value for the Sharpen Knife alarm CAUTION The knives must be adjusted after every knife change Improper knife adjustment may cause damage to the ma chine 4 3 1 Knife Change A stable rolling cart approximately 36 tall the knife lifter the T handle hex wrench an empty scabbard and a set of sharp knives are re quired to perform a knife change
26. out screen use the up down arrow keys to select the timeout period and press the enter key Timeout minutes minutes minutes minutes minutes Select amp Press Enter A Maint B Job D Exit Figure 3 16 Timeout Screen 3 7 2 2 Input This parameter sets the in feed optional equip ment In the Input screen use the up down ar row keys to select the input option and press the enter key Elevator Conveyor Select amp Press Enter A Maint B Job D Exit Figure 3 17 Input Screen 3 7 2 3 Knife Count The Knife Count parameter allows the operator to reset the Knife Alarm and the Lube Alarm The Knife Alarm displays a message to remind the operator to change knives The Lube Alarm displays a message to remind the operator to have the machine lubricated Three functions are within the Knife Count pa rameter Clear Count Knife Alarm and Clear Lube To change the parameter select it using the up down arrow keys and press the enter key The following sections explain each func tion Select amp Press Enter A Maint B Job D Exit Figure 3 18 Knife Count Screen Clear Count Select Clear Count to reset the knife counter after the knives are changed Knife Alarm Select Knife Alarm to change the knife stroke alarm value When this value is reached the display will alert the operator to change the knives and reset the knife counter Knife alarm values are factory set at 500
27. the display Division Key The forward slash key is used to divide num bers in the display Send Key SEND The send key is used to instruct the computer to change the machine setup to match newly en tered book dimensions Clear Key The clear key is used to clear an entry value or clear an status message CMT 330 Three Knife Trimmer 01 03 3 3 Programming Enter Key NTER The enter key selects items in menu screens and processes data that has been entered in the other modes IN mm Key IN MM The units key is used to toggle between decimal inch fractional inches and mm units of length Soft Keys gt The soft keys or letter keys are used to select screen menu options listed at the bottom of the display screen The keys include the letters A B C and D Up Arrow Key E The up arrow key is used to move the screen cursor up It is also used to scroll forwards through the alphabet while naming a job Down Arrow Key The down arrow key is used to move the screen cursor down It is also used to scroll backwards through the alphabet while naming a job Right Arrow Key The right arrow key is used to move the screen cursor right It is also used to move the cursor to the right while naming a job Left Arrow Key The left 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
28. the start book while programming a job The scale can also be used to verify the size of a trimmed book Start Button The green start button is used to switch on the hydraulic pump and begin to trim books A re mote start button is located at the back of the machine Stop Button The red stop button is used to switch off the hydraulic pump and stop trimming books A remote stop button is located at the back of the machine LCD Screen The LCD screen is used to program and view jobs It also lists any errors or messages A message is displayed on the screen 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 Number Keys Number keys are used to write number values on the display Decimal Point This decimal key is used to write a decimal point on the display Priority Add Key The priority add key is used to input fractional numbers when combined with a whole number An underscore is displayed on the screen after the key is pressed 1 1 2 is an example of a number entered using the priority add key This is equivalent to 1 500 Addition Key The plus key is used to add numbers in the dis play Subtraction Key The minus is used to subtract numbers in the display Multiplication Key Lx The multiply key is used to multiply numbers in
29. 0 cuts however this value can be changed to meet specific ap plication needs Clear Lube Select Clear Lube to reset the Lube Alarm after lubricating the machine The alarm will activate after ten times the knife alarm value Contact an authorized service agent to lubricate the ma chine 3 7 2 4 Machine Count Machine Count displays the total number of cuts made by the machine CMT 330 Three Knife Trimmer 01 03 3 10 Maintenance Mode 3 7 3 Service The service screen is helpful to when trouble shooting a machine malfunction or fine tuning its operation Use the up down arrow keys to select the appropriate parameter and press the enter key The following sections describe each service parameter SERVICE Last 5 Messages Sensor Data Clear Memory Jogger Pressure Hydraulic Cushion Accuracy Adjust Shipping Position Select amp Press Enter D Exit Figure 3 19 Service Screen 3 7 3 1 Last 5 Messages The Last 5 Messages function displays the last five status messages that were displayed It stores machine faults and is accessed by a ser vice technician when a problem cannot be re produced 3 7 3 2 Sensor Data The Sensor Data function provides a list of the computer inputs proximity switches etc This function allows a service technician to check the status of a switch as seen by the CMT controller board Operation of the machine is prohibited in this mode so each input must be actuated
30. D Exit Figure 3 12 Stack Number Option Screen This option is used to increase the capacity of the exit conveyor when cutting thin books Be careful not to set the Stack Number too high If the books stack too high before incrementing the exit conveyor later books will jam inside the machine 3 6 8 Running a Job The job must first be opened from the Job screen by using one of two methods 1 Move the cursor to the desired job with the arrow keys and press enter 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 right corner Press the green start button on the console to start the hydraulics and conveyors Press the send key to set the side knives and the registration assembly to the proper position Once the motors start books can be fed into the machine 3 6 9 Closing a Job To close an open job press the soft key B Job to return to Job mode or press the soft key D Exit to exit to the Run screen 3 7 Maintenance Mode Maintenance mode is a screen where many machine functions can be set or modified The four principle functions are Knife Adjust Pa rameters Diagnostics and Language To se lect a particular function use the up down arrow keys to toggle to the desired function and press the enter key The following sections explain each function Maint Menu Knife Adjust Parameters Service Language
31. Lines Description Indentations or crease lines may appear ina rectangular pattern in the near the edges of the book v CREASE LINES Figure 5 5 Linear Crease Lines Possible Causes e clamps have too much clamp pres sure for the stock being cut Solutions e Reduce the clamp pressure by turning the control dial counterclockwise Re duce the pressure until crease lines disappear on test books e Worn cut plates may create these lines on the bottom cover Turn or change 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 5 6 Draw Description The cut face appears to have a slope because all of the sheets are cut at different lengths Figure 5 6 Draw Possible Causes e Clamp pressure may be too low e The knife may be dull Solutions e Check clamp pressure Clamp pres sure should be 80 90 PSI Turn control dial clockwise to increase clamp pres sure Make sure shop air is 80 90 PSI e If the problem is on the face of the book replace all three knives Rotate or replace the cut stick e If the problem is on the top or bottom faces of the book replace the knives Rotate or replace the cut plates CMT 330 Three Knife Trimmer 01 03 5 3 Rectangular Crease Lines 5 7 All Sheets Not Cut Description Bottom sheets are not being cut 5 8 Book Not Square Description The b
32. SSURE CONTROL KNOB LEFT FRONT DOOR LEFT REAR DOOR Figure 1 5 Left Front View CMT 330 Three Knife Trimmer 01 03 1 10 General Locations 1 8 2 Back View Important locations at the back of the machine are shown in Figure 1 6 KNIFE CHANGE OPERATOR STOP BUTTON KNIFE CHANGE OPERATOR START BUTTON BACK DOUBLE DOOR LOWER BACK DOOR MAIN AIR CONNECTOR Figure 1 6 Back View 01 03 CMT 330 Three Knife Trimmer 1 11 General Locations 1 8 3 Exit Conveyor Part Number 56420 POWER COM CONNETOR TRAY FULL SENSOR Important locations are shown in Figure 1 7 ON BACKSIDE SCREWS MOUNTING BRACKETS SPACING CONTROL DIAL Figure 1 7 Exit Conveyor Locations 01 03 CMT 330 Three Knife Trimmer 1 12 General Locations 1 8 4 In feed Conveyor Part Number 56401 Important locations are shown in Figure 1 8 BOOK DEFLECTOR BOOK DETECTION SENSOR BOOK SLIDE ADJUSTABLE BOOK GUIDE SERIAL PLATE FUSE HOLDER POWER COM CONNECTORS Figure 1 8 In feed Conveyor Locations CMT 330 Three Knife Trimmer 01 03 1 13 General Locations 1 8 5 Tilt In feed Conveyor Part No 56600 Important locations are shown in Figure 1 9 BOOK DOOR ADJUSTABLE CONVEYOR an a ee IP RECEIVES BOOKS FROM BINDER Jj ADJUSTABLE LEGS FUSES SERIAL PLATE POWER COM AIR CONNECTORS Figure 1 9 Tilt In feed Conveyor 01 03 CMT 330 Three Knife Trimmer 1
33. The Challenge Machinery Company provides owner s manuals on its products solely as a courtesy to its customers See the information below before using this manual These manuals are for reference only These manuals include products which are non current unsupported or no longer produced by The Challenge Machinery Company and are provided solely as an accomodation to our customers By providing these manuals The Challenge Machinery Company makes no representation or warranty as to the products their current condition or their suitability or fitness for use in any particular application which are the sole and independent responsibility 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 suitability and fitness of the products in their current use and application The Challenge Machinery Company makes no representation warranty or recommendation regarding any modifications which may be required on non current or unsupported products 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 The availability of these manuals is solely for the purpose of providing reference information for the products This manual may not be complete
34. The face knife is adjusted independ ently from the side knives The side knives are adjusted simultaneously To properly adjust the side knives the side knives must be properly installed They should have been installed to the top of the slots of the knife bar If one side knife cuts through and the other does not the knives were not properly installed Use the following procedure to adjust the depth at which the knives cut Scrap or extra books are recommended for use when adjusting the knives No tools are needed 7 Knife adjustment is a ONE PERSON OPERATION More than one person adjusting the knives creates safety hazards Face Knife Adjustment 1 Select A at the console to enter mainte nance mode and choose Knife Adjust 2 Open the set of double doors at the back of the machine 3 Remove the waste chute by lifting it and pulling it toward the outside of the ma chine 4 Find the face knife adjustment knob in the upper right hand corner of the open ing as shown in Figure 4 14 Figure 4 14 Knife Adjustment Knobs 5 If the knives were just replaced the face knife adjustment knob should be turned to the full down position If it is not do so by turning the knob clockwise until it stops Turn the face knife adjustment knob back out about three full revolutions counterclockwise Place the face side of a scrap book un derneath the knife with the binding fac ing the inside of the machine
35. art Description Qty Frequency 56041 FILTER ELEMENT AIR 1 1 yr H 227 1 FILTER ELEMENT OIL 1 1 yr 5 1991 3 GRADE 46 HYD FLUID 1 1 yr 01 03 CMT 330 Three Knife Trimmer 1 7 Packing List 1 7 Specifications pw 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 A CAUTION The CMT 330 was specifically designed to trim perfect bound books only t 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 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 Start book max 9 5 x 12 5 in 241 x 317 5 mm Start book min bottom cover 6 75 x7 171 4 x 177 8 mm Finish book min 4 125 x 5 875 in 104 8 x 149 2 mm Face trim max 5 5 in 140mm Book thickness range 0 048 2 000 in 1 22 50 8 mm Minimum 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
36. ator Figure 2 8 line up with the two slots on the left side of the trimmer s sheet metal enclo sure Adjust the trimmer s leveling pads such that the top of the table is 36 914mm off the floor Raise the two pads at the center of the machine TOP SHELF FLUSH WITH TABLE Figure 2 8 Elevator Mounting Open the trimmer s front door and use a level on the table inside the machine Level the front end of the machine by adjusting the leveling pads Keep the final table height at 36 Open the rear doors and repeat step 4 on the rear end of the machine Check the front end of the machine with the level to make sure the front is still level Adjust as necessary After leveling the machine lower the two pads at the center of the machine Lock all 6 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 CMT 330 Three Knife Trimmer 01 03 2 4 Option Setup Figure 2 9 Tighten Jam Nuts 11 Align the two long slots in the trimmer s enclosure with the two mounting holes in the top cover of the elevator 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 Air Hookup on page 2 9 At this point the setup should look like Figure 2 10 Figure 2 10 Cur
37. b 3 7 3 6 3 Lock Unlock a Job 3 7 3 6 4 Erasing a 3 7 3 6 5 Editing a New Job 3 7 3 6 6 Editing an Existing Job 3 7 3 6 7 Job Options 3 8 3 6 8 Running Job 3 9 3 6 9 Closing a 3 9 3 7 Maintenance Mode 3 9 3 7 1 Knife Adjust esses 3 9 3 7 2 3 9 eco ec 3 11 3 8 Status Messages 3 13 3 9 Example Job 3 16 3 10 Serial Data 3 18 3 10 1 New Book Size Command 3 18 3 10 2 Command 1 Send Command 3 18 3 10 3 Command 2 Stop Command 3 18 3 10 4 Command 3 Reset Book count 3 18 3 10 5 Other commands 3 18 3 10 6 Example 1 3 19 3 10 7 Example 2 3 19 Introduction The operator s guide provides instructions es sential to operating the CMT 330 with each ac cessory option These instructions include pro gramming instructions and book size change over tasks 3
38. bad feeding Stray pieces of scrap may also cause this error Lower door is Open One of the three waste bin doors is open Lubricate Machine The number of machine cycles has exceeded that which is recommended for lubrication It is time to lubricate the machine Memory failed One of the four EEPROM chips on the CMT controller board is faulty Motor starter error ON when it should be off Motor starter was on when it should have been off Output 11 off with output 24 on Motor starter error OFF when it should be off Motor starter was off when it should have been on Output 11 on with output 24 off NO Air Pressure This error message displays when the air pressure falls below 20 PSI 1 4 Bar Number outside limit The value entered is not valid OUTPUT CONVEYOR FULL The output conveyor proximity sensor is covered Positioning error This message displays after three failed attempts are made to position either the side knives or the registration assembly It may be caused by a faulty drive motor faulty en coder or a loose connection between the motor and the lead screw Result is negative This warning displays when a calculated result is a negative value Send canceled This message is displayed when a key is pressed while the side knives or registration assembly is moving Servo Disabled This message is given when the hydraulic motor is off and the gripper is iss
39. c verify the Hydraulic motor rotation See user manual POWER HOOKUP section Figure 3 5 Power Hook Up Warning See section 2 5 1 Power Hookup Procedure or page 2 8 to correct the wiring 3 5 Run Mode After the gripper reaches the home location the Run screen will appear if there are no jobs stored in memory Otherwise the machine will initialize at the last job that was run The con veyors will then start The CMT 330 will sense incoming books and trim until the last book of that size is done S Cut ON J Extend Stack A Maint B Job Figure 3 6 Run Screen CMT 330 Three Knife Trimmer 01 03 3 6 Power up 3 6 Job Mode The CMT 330 can be programmed for up to 99 different jobs A job is a particular book size including trim dimensions and options Enter the Job screen by pressing the soft key B In the Job screen all previously programmed job numbers will be displayed with their name and lock status Locked jobs are indicated by a pad lock symbol after their name A plus sign at the bottom of the job list indicates there are more programmed jobs that are not displayed Press ing the down arrow key will step through all jobs one at a time Pressing the left arrow key and the down arrow key simultaneously will move the cursor down the list nine at a time Name18 Name33 Select Job amp Enter C Erase D Exit Figure 3 7 Job Screen 3 6 1 Creating a Job To create a job enter an
40. ck may need rotation or replacement The knives may also re quire replacement e 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 5 3 Burr Marks Jagged Cover Description A jagged bottom cover may also accompany burr marks A burred knife may not fully cut into the cut stick or cut plate As a result it will leave a jaggedly cut bottom cover BURR MARKS WITH JAGGED COVER Figure 5 3 Burr Marks Jagged Cover Possible Causes e knife is burred and the cut stick cut plates are worn Solutions e problem is on the face of the book replace the knives Rotate or re place the cut stick e If the problem is on the top or bottom faces of the book replace the knives Rotate or replace the cut plates CMT 330 Three Knife Trimmer 01 03 5 2 Burr Marks 5 4 Rectangular Crease Lines Description Indentations or crease lines may appear ina rectangular pattern in the center of the book CREASE LINES Figure 5 4 Crease Lines on Cover Possible Causes e The gripper has too much clamp pres sure for the stock being cut Solutions e Reduce the gripper clamp pressure by turning the control dial counterclock wise Reduce the pressure until crease lines disappear on test books The gripper adjustment gauge only reads gripper pressure while the gripper is holding the book 5 5 Linear Crease
41. ctly connected to the terminal block on the power panel Ay Shock Hazard Always disconnect power at main dis connect switch before working on the trimmer Lock it out to prevent accidental power up See Power Lockout Procedure on page 1 4 1 Locate the power panel door at the front right hand side of the machine Figure 2 20 General Locations Remove the four screws that mount the door to the machine and set the door aside The terminal block is located at the lower left hand corner of the power panel The ground screw is located be neath the terminal block as shown in Figure 2 21 Remove the four screws that mount the lower front door to the machine and set the door aside Route the power cable under the right hand side of the machine and behind the power panel enclosure Locate the cable hole in the back of the power panel enclosure Mount a strain relief in this hole Access this hole through the front door of the machine Route the cable through the strain relief and through the access hole in the power panel Fasten the ground lead to the ground terminal lug labeled GND in Figure 2 21 10 11 TERMINAL BLOCK POWER SOURCE Figure 2 21 Power Panel Fasten the three power leads to the three terminals L1 L2 and L3 Figure 2 21 on the main power terminal block Replace all panel doors Make sure the shop air hose in connected to the ma chine and shop air is switch
42. d down slightly either the dump valve or the proportional valve may not have energized F Knife up FAILURE timed out before reaching up limit This message displays when the face knife does not reach the up limit in time The prox imity sensor is either misadjusted or faulty 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 CMT 330 Three Knife Trimmer 01 03 3 13 Status Messages Status Messages Continued Message Description Input jam Book was lost between binder amp elevator A book was detected on the in feed conveyor but did not reach the elevator Input JAM Conveyor and Lift sensors are active Both the proximity sensors on the elevator and on the input conveyor were on for more than three seconds Input door open A door on either the Tilt In feed conveyor or the Elevator is open or the interlock circuit is open Jogger error OUT when it should be IN Jogger cylinder was out when it should have been in Output 18 is off but input 12 shows jogger extended Jogger error IN when it should be OUT Jogger cylinder was in when it should have been out Output 18 is on but input 12 shows jogger retracted Lost book in machine The book proximity sensor deactivated during a cycle The book may not have been gripped properly due to
43. dam age must be reported to the claims department of the carrier within 15 days Contact your dealer if you need any assistance Check the contents of the crate against both the packing list on page 1 5 and the freight bill Make sure there are no missing items 2 2 Unpacking Remove the packing materials and four lag bolts One lag bolt is located in the frame be hind each of the lower side doors as shown in Figure 2 1 Figure 2 1 Lag Bolt Locations Remove Lag Bolts 1 Remove four screws from each of the two front side doors using a 1 8 hex wrench 2 Using a 9 16 open ended wrench re move the lag bolts from the two front lo cations shown in Figure 2 1 3 Pull open the two lower rear doors and remove the waste bins 4 Remove the two lag bolts from the two rear locations shown in Figure 2 1 5 Reinstall the waste bins and close the rear doors 6 Reinstall the two 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 and placed inside the machine Be careful not to pinch or entangle these in the forks while lifting Figure 2 2 Fork Location for Lifting 2 3 Moving Once the machine is near its final location it can be rolled into place 7 Do not roll on a graded surface Roll only on a flat sur face Personal injury could result It may b
44. e Knife Trimmer 01 03 3 19 Serial Data NOTES 01 03 CMT 330 Three Knife Trimmer 3 20 Serial Data Section Contents TITLE PAGE 4 1 Waste Bins 4 2 4 2 Cut Stick Cut 4 2 4 2 1 Changing the Cut Stick 4 3 4 2 2 Changing the Cut Plates 4 3 43 KnIVes 4 4 4 3 1 Knife 4 4 4 3 2 Knife Adjustment 4 7 4 3 3 Knife Sharpening Rules 4 8 4 4 Check Pressure Switch 4 8 4 5 Safety Systems 4 9 4 5 1 Safety Check off Sheet 4 10 Introduction Certain tasks will be performed on a regular basis but not necessarily on a set schedule The safety systems check however should be done before each shift The waste bins must be emptied when full The knives should be re placed when cut quality becomes unacceptable Performing as many of these tasks before a shift begins prevents down time while a job is in progress and ensures safe operation of the ma chine 4 Routine Tasks CMT 330 Three Knife Trimmer 01 03 4 1 Routine Tasks 4 1 Waste Bins The three waste bins may actually require emp tying in the middle of a shift but it is a good idea to do it before a shift begins When the waste bins ar
45. e displays when the operator tries to send either the knives or the reg istration assembly to a position that is out of range Elevator book jam Check book in elevator sen Sor Book did not clear the sensor in time F knife latch error OFF when it should be ON The face knife latch proximity did not activate This can be caused by a misadjusted or faulty sensor or the the air cylinder did not pull in F knife latch error ON when it should be OFF The face knife latch proximity sensor did not de activate This can be caused by a misad justed or faulty proximity sensor or the air cylinder did not extend This message displays when the face knife fails to leave the down proximity sensor It may be caused by either the cut valve not de energizing or a faulty down limit proximity sensor F Knife at down limit failed to move F Knife at up limit Failed to move This message displays when the face knife fails to leave the up proximity sensor There are four possible reasons for this failure The dump valve did not energize the hydraulic cushion valve did not energize the knife down valve did not energize or the side knife up proximity is faulty F Knife down FAILURE timed out before reaching down limit This message displays when the face knife leaves the up limit but does not reach the down limit in time If the knife went down the proximity sensor is either faulty or misad justed If the knives only move
46. e near capacity during a job run the CMT 330 continues cutting The status indica tor light on top of the machine blinks slowly and the screen displays a message stating that the waste bins are full Use the following procedure to change waste bins If running stop the machine s cutting mode by pressing the red stop button on the console shown in START BUTTON GREEN LCD SCREEN 1 0 DEGERE Ag EXE GIC EI DO STOP BUTTON RED KEYPAD 1 Figure 4 1 To preserve the status of each book in the job press the stop button after the gripper transport re leases a trimmed book but before it clamps the next untrimmed book If the untrimmed book is clamped by the grip per transport and not trimmed it will be ejected onto the Exit Conveyor when the machine is restarted The book can be manually placed onto the In feed conveyor to be trimmed later 390 START BUTTON GREEN LCD SCREEN 1 gt OE 0 pees OBIE EI Hooe RED BUTTON KEYPAD Figure 4 1 Stop Button Location 2 Wheel a cart to any of the three waste bin locations One is located at both the rear right hand and left hand sides of the machine The remaining waste bin is located at the back of the ma chine Figure 4 2 and Figure 4 3 show the waste bin locations LEFT REAR DOOR LOWER BACK DOOR Figure 4 2 Waste Bin Locations RIGHT REAR DOOR Figure 4 3 Waste Bin Location 3 Open a door Tilt and lift the waste bin from
47. e nearby Carry the lifter to the installation location Place the knife behind the knife bar while aligning the lifter handles to the open bolt slots in the knife bar as shown in Figure 4 13 29 KNIFE LIFTER HANDLE Figure 4 13 Knife Installation Lift the knife into the knife bar such that the lifter handles are at the extreme top of the slot A CAUTION The knife lifter handles must be at the extreme top of the slot If they are not it will be difficult to adjust the cutting depth of the knives Damage to the cut plates may result 30 31 32 33 34 Turn the lifter handles clockwise and securely fasten the lifter and knife to the knife bar Make certain the knife does not move down as the handles are tightened Place 4 knife bolts into the 4 available holes in the knife and use the T handle wrench to secure them as shown in Figure 4 13 Turn the lifter handles counterclockwise and remove the lifter from the machine Place 2 knife bolts into the holes from which the knife lifter handles were re moved Use the T handle wrench to secure them Viewed through the in spection holes the blade should be in serted against the stops Repeat steps 18 through 33 to install the remaining two knives CMT 330 Three Knife Trimmer 01 03 4 6 Knives Once the knives have been installed they must be adjusted 4 3 2 Knife Adjustment The knives require adjustment after every knife change
48. e necessary to raise the six leveling pads in order to roll the machine A pad is lo cated under each corner of the machine Each of the remaining two pads is located under the middle of each side of the machine Using ei ther a 3 4 open ended wrench or an adjustable wrench turn the leveling pad counterclockwise to raise it Figure 2 3 Leveling Pads Push the CMT 330 into position Do not lower the leveling pads at this time Its final position may require slight adjustment depending upon the setup 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 In line option 1 56401 Basic In feed Conveyor 56421 Cooling Elevator 56420 Exit Conveyor In line option 2 56600 Tilt In feed Conveyor 56421 Cooling Elevator 56420 Exit Conveyor Stand alone option 56413 Hand feed Conveyor 56420 Exit Conveyor CMT 330 Three Knife Trimmer 01 03 2 2 Shipping Claims 2 4 1 In line Option 1 Dimensions given in this in line setup are typical when used in conjunction with a CP Bourg per fect binder Other binders may require different settings or additional custom equipment to de liver untrimmed books to the in feed conveyor The following brief sequence of operations de scribes the movement of books through this in line system A book falls from the exit chute of the binder onto the i
49. ed book Adjust binder such that glue will not be applied past the end of the binding If normal wear has forced the cutting or transport mechanisms out of square re fer the problem to an authorized service agent TRIMMING Figure 5 8 Twisted Binding BOOK APPEARS OUT OF SQUARE AFTER STRAIGHTENING THE BINDING 1 40 Figure 5 9 Straightened Binding CMT 330 Three Knife Trimmer 01 03 5 4 All Sheets Not Cut Notes in fractional in 0 016 1 64 0 031 1 32 0 047 3 64 0 063 1 16 0 078 5 64 0 094 3 32 0 109 7 64 0 125 1 8 0 141 9 64 0 156 5 32 0 172 11 64 0 188 3 16 0 203 13 64 0 219 7 32 0 234 15 64 0 250 1 4 0 266 17 64 0 281 9 32 0 297 19 64 0 313 5 16 0 328 21 64 Inch Metric Conversion Chart in 0 344 0 359 Fractional in 11 32 23 64 3 8 25 64 13 32 27 64 7 16 29 64 15 32 31 64 1 2 33 64 17 32 35 64 9 16 37 64 19 32 39 64 5 8 41 64 21 32 fractional in mm 43 64 17 07 11 16 17 46 45 64 17 86 23 32 18 26 47 64 18 65 3 4 19 05 49 64 19 45 25 32 19 84 51 64 20 24 13 16 20 64 53 64 21 03 27 32 21 43 55 64 21 83 7 8 22 23 57 64 22 62 29 32 23 02 59 64 23 42 15 16 23 81 61 64 24 21 31 32 24 61 63 64 25 00 64 64 25 40 2002 2011 by The Challenge Machinery Company All rights reserved Printed in the USA F 033 CMT 330 JAN 2003
50. ed on Open the lower rear door and switch the main air disconnect valve to the on 1 position and close the door Unlock and switch on I the main power disconnect Switch on the machine s power 12 Press the green start button key on the console shown in Figure 2 22 The hydraulic motor should turn on The machine was shipped with all three knives in the down position If power is hooked up correctly the knives will automatically raise to the up position If power is incorrectly connected the knives will remain in the down position Continue at step 13 if the knives do not CMT 330 Three Knife Trimmer 01 03 2 8 Power Hookup move to the up position If the knives move skip to step 17 START BUTTON 0 92909229 OO HOOO Be ig p E BI mm STOP BUTTON Figure 2 22 CMT 330 Console 13 Switch off O the machine s main power switch 14 Switch off O the main power discon nect switch and lock it out 15 Remove the power panel door at the right hand side of the machine 16 Exchange any two of the main power leads at the terminals L1 L2 or L3 17 Repeat steps 9 12 2 6 Air Hookup The CMT 330 requires un lubricated com pressed air at a minimum of 5 cubic feet per minute at 80 90 PSI The main air connector shown in Figure 2 23 is a female 3 8 NPT port A facilities maintenance technician should con nect shop air using a male 3 8 NPT fitting using either T
51. eet 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 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 at the right 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 e Norton Shores MI 49441 INSTALLATION INFORMATION Model CMT 330 Serial No Company Name Address City State Province ZIP Code Phone No Date Installed Dealer Name Dealer City Accuracy Adjustment Values inches inches inches CMT 330 Three Knife Trimmer 01 03 1 2 Warranty Information 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 person One person only
52. eflon thread tape or a liquid pipe seal ing compound t AT AIR CONNECTOR LOWER BACK DOOR Figure 2 23 Main Air Connector Using a flexible hose to connect the machine to shop air is preferred in case the location of the machine needs adjustment later A line dropped from the ceiling is also preferred Hav ing the line off the floor enables the operator to wheel a cart to the lower left rear door for waste bin removal 2 7 Cleaning It may be necessary to clean the machines after installation They may be cleaned with a solu tion of dish soap and water Do not use petro leum or acid based solvents to clean the ma chine Damage may result CMT 330 Three Knife Trimmer 01 03 2 9 Air Hookup NOTES 01 03 CMT 330 Three Knife Trimmer 2 10 Cleaning Section Contents TITLE PAGE 3 1 Programming sse 3 2 3 1 1 Console Descriptions 3 2 3 1 2 Key Descriptions 3 3 3 1 3 Using the 3 4 3 2 User Interface Map 3 5 3 3 Power 3 6 3 4 Improper 3 6 8 5 RUN es 3 6 3 6 Job 3 7 3 6 1 Creating 3 7 3 6 2 Editing a Jo
53. eft hand side of the machine base 3 Connect the cable to the socket on the backside of Hand feed Conveyor Lock into place by threading the connector collar onto the socket Exit Conveyor To setup the exit conveyor follow the instruc tions in section 2 4 3 4 Hookup Accessory Ca bles Exit Conveyor on page 2 6 CMT 330 Three Knife Trimmer 01 03 2 7 Option Setup 2 5 Power Hookup This section describes how to hookup main power to the CMT 330 An adequate power supply must be provided to the machine See section 1 7 Specifications on page 1 8 for power requirements It should be on its own circuit with a lockable disconnect switch Too many machines on the same circuit will reduce power to each machine Insufficient voltage may cause overheating loss of cutting clamping force and in extreme cases failure to operate Test the line voltage when the shop is at actual working levels The following table lists recommended wire sizes for different voltage options If a wire is run over 75 feet 23 meters the next size wire should be used POWER PANEL DOOR Recommended Wire Sizes for Main Power Hookup Circuit Size Wire Size Metric Wire V A AWG mm 380 415 15 12 2 5 230 30 10 4 208 30 10 4 2 5 1 Power Hookup Procedure The following procedure describes how to hookup main power to the CMT 330 After power is hooked up running the machine will verify if wires are corre
54. elect either yes or no then press enter Note that locked jobs cannot be erased 3 6 5 Editing a New Job To edit a new job type in a number that is not already assigned to a job and press enter en tering a job number greater that 99 will create 99 The cursor will move to the line corre sponding to the number you entered prompting your for a job name If a job name is not de sired pressing enter again bring up the job edit Screen S Cut ON J Extend Stack A Maint B Job C Options D Exit Figure 3 8 Job Run Screen Use the arrow keys to move the cursor to the dimension to be edited Type the dimension value then press enter All dimensions must be supplied or the job will not run If the book size is outside the machine specifications the message BOOK SIZE CANNOT BE TRIMMED is displayed Refer to section 1 7 1 for sizes that can be cut 3 6 6 Editing an Existing Job If the job is not locked it may be edited from either the Run screen or the Job Run screen Using the arrow keys move the cursor to the dimension to be changed Enter a new value CMT 330 Three Knife Trimmer 01 03 3 7 Job Mode If the job is locked it must be unlocked before editing See section Lock Unlock a Job 3 6 7 Job Options Each job has three options that are listed in the upper left corner of the display These are Side Cut ON OFF Jogger Extend Retract and Stack number 1 3 To edit these opt
55. following information briefly describes effi cient ways to use the functions of the keypad Entering Fractions Fractions are entered using the priority add key The underscore symbol is displayed when the key is pressed This instructs the computer to add the fractional portion of the entry before performing the remaining math 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 Entering Math 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 and division operations are always performed before addition and subtraction Example You wish to enter a dimension which is 8 inches minus 2 times 1 and 5 32 inches plus 1 2 inch This sentence can be entered as 8 2X1 5 3241 2 The result is 6 188 CMT 330 Three Knife Trimmer 01 03 3 4 Programming 3 2 User Interface Map The following chart illustrates the organization of user interface screens encountered in the CMT 330 software Sg a Knife Adjust Parameters Home Gripper Please Wait i Run Screen Machine Time count out Input knife count Conveyors Elevator sum clear Clear count Lube
56. for the remainder of instructions Use the following procedure in place of section 2 4 1 1 In feed Conveyor 2 4 2 1 Tilt In feed Conveyor 1 The ledge on the right end cover should be set to about 13 5 348 mm from the floor Adjust the leveling pads as nec essary Figure 2 14 Height Adjustment 2 The Tilt In feed Conveyor is set in front of the binder such that adjustable por tion of the conveyor is centered on the exit chute of the binder 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 Figure 2 15 Adjustment Range 4 Move the entire conveyor close to the binder to minimize the distance be tween the adjustable conveyor and the binder s exit chute 2 4 3 Stand alone Option This option uses the hand feed conveyor and exit conveyor options to make the CMT 330 a stand alone trimmer The gate opening in the hand feed conveyor is set slightly larger than the thickness of books to be cut Books are stacked onto the conveyor The conveyor feeds them into the trimmer where they are cut Finally the books are de livered to exit conveyor where they are shingled out as necessary Follow these steps to setup the stand alone option CMT 330 Three Knife Trimmer 01 03 2 6 Option Setup 2 4 3 1 Trimmer 1 Make sure there is adequate floor space for this setup Figure 2 16 illus trates how m
57. fter all values have been entered press the send key The side knives will move into posi tion followed by the registration assembly The job can now run Before running books through the binder press and hold the green start button on the console Release the button when the hydraulics and conveyors start Begin running books CMT 330 Three Knife Trimmer 01 03 3 17 Example Job 3 10 Serial Data Under Development The CMT 330 is capable of serial communica tion with another computer Communication Parameters Serial data is transferred under the following parameters Baud rate 9600 Data bits 8 Parity None Stop bits 1 Echo on Each received character is echoed back If the CMT controller does not understand the data ERROR is returned An OK message is sent back to the host after each successful com mand transmission If a command is sent while a book is in process that command will not be executed until the book is complete 3 10 1 New Book Size Command The New Book Size command is sent when the CMT 330 is in Serial Mode All five dimensions must be sent Knife Width Registration Acceleration Face Knife Not Used Figure 3 32 Transferred Data Example Dim1 9 Dim2 25 Dim3 2 Dim4 7 Dim5 10 ASCII HEX 31 3d 39 0d 0a 32 3d 2e 32 35 0d 0a 33 3d 2e 32 0d 0a 34 3d 37 0d 0a 35 3d 31 30 0d 0a 21 3 10 2 1 5
58. gure 4 2 The cut stick puller has a finger hold and hook as shown in Figure 4 4 Figure 4 4 Cut 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 double doors at the back of the machine 3 Remove the black plastic waste chute from the table by lifting and tilting to ward the outside of the machine 4 Hook the Cut Stick Puller over one of the ends of the cut stick with a finger in the loop of the puller Keep the Cut Stick Puller in line with the cut stick 5 Pull the Cut Stick Puller at a slight angle over the cut stick until the end of the cut stick comes out of the table Figure 4 5 Pull at slight angle Remove the remaining cut stick from the table by hand Inspect the cut stick for wear It may be used 8 times twice on each surface before disposal To use a surface twice reinstall the cut stick by turning it such that end that came out of the right end of the slot goes into the left end of the slot If a surface has been used twice rotate the stick to an unused sur face before reinstalling If all 4 sur faces have been used twice replace the stick with a new one SCORE MARKS ROTATE Clu TURN Figure 4 6 Cut Stick Rotation Reinstall the waste chute Securely close the set of double doors at the back of the machine 10 Unlock the
59. ing cart Figure 1 14 Stand Alone Option POWER HOOK UP AIR HOOK UP CMT 330 Three Knife Trimmer 01 03 1 19 Site Specifications NOTES 01 03 CMT 330 Three Knife Trimmer 1 20 Site Specifications Section Contents TITLE PAGE 2 1 Shipping Claims 2 2 2 2 Unpacking i eatin Mei ion ae 2 2 2 3 MOVING ede Eee ins 2 2 2 4 Option Setup 2 2 2 4 1 In line Option 1 2 3 2 4 2 In line Option 2 2 6 2 4 3 Stand alone Option 2 6 2 5 Power 2 8 2 5 1 Power Hookup Procedure 2 8 2 6 Air 2 9 2 7 2 9 Introduction The installation guide provides information and instructions essential to the proper setup of each of the CMT 330 and its accessory options These applications include one option for in line operation and one option for stand alone opera tion 2 Installation Guide CMT 330 Three Knife Trimmer 01 03 2 1 Installation Guide 2 1 Shipping Claims The CMT 330 has been packed to prevent damage during shipment Claims for damage or loss are the responsibility of the recipient Inspect all shipments as soon as they are re ceived If there is any noticeable damage note it on the freight bill Visual and or hidden
60. ions press the C key from the Job Run screen shown in Figure 3 8 Side Cut Jogger Stack Num Select amp Press Enter A Lock 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 3 6 7 1 Side Cut When Side Cut is set to On both the sides top and bottom and the face of the book are cut When the Side Cut option is set to Off only the face is cut The side cut menu screen is shown below Side Cut Select amp Press Enter A Maint B Job D Exit Figure 3 10 Side Cut Option Screen 3 6 7 2 Jogger This parameter sets the jogger to remain ex tended as a book leaves the jogging station or retract immediately In the jogger screen use the up down arrow keys to toggle the required jogger action and press enter Jogger Extend Retract Select amp Press Enter A Maint B Job D Exit Figure 3 11 Jogger Option Screen When cutting very thin books with overhanging covers the jogger option should be set to Ex tend Otherwise it should be set to Retract CMT 330 Three Knife Trimmer 01 03 3 8 Job Mode 3 6 7 3 Stack Number This parameter sets the number of books to be stacked on top of each other at the exit con veyor before it is incremented It can range be tween 1 and 200 Enter number of books to be stacked before incrementing the output conveyor Select amp Press Enter A Maint B Job
61. is important to take precautions Read and thoroughly understand the safety precautions outlined below e This machine is designed for one person operation Never operate the machine with more than one person e 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 e 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 e Only trained and authorized individuals should operate this machine e Only trained and authorized service technicians should service this ma chine e not alter safety guards or devices They are there for your protection Se vere laceration or dismemberment may result if safety devices are altered e Disconnect power and lock out before performing any maintenance See Sec tion 1 5 Power Lockout Procedure e Observe all caution and instruction la bels on this machine e extremely careful when handling and changing knives Severe lacera tions or dismemberment could result from careless handling procedures e Perform the Safety Systems Check given on page 4 9 before each shift be gins CMT 330 Three Knife Trimmer 01 03 1 3 Warning Label Definitions e Keep all conveyors and elevator acces 1 5 Power Lockout
62. n feed conveyor The in feed conveyor deposits the book onto the low est shelf of the elevator The elevator accumu lates books until it reaches capacity Before an additional book enters the elevator the elevator pushes the top book into the trimmer The trimmer will hold one book inside while another is being trimmed The trimmer cuts the book and sends it to the exit conveyor The operator adjusts a dial on the exit conveyor to obtain the desired amount of spacing or overlap between books If a book covers the sensor at the end of the exit conveyor the machine stops The at tendance light on top of the machine blinks slowly Books must be removed from the exit conveyor in order to continue operation Proper setup of each machine is essential be cause books move through four separate ma chines The machines are first set roughly into place relative to the binder 2 4 1 1 In feed Conveyor 1 The ledge on the right end cover should be set to about 13 5 348 mm from the floor Adjust the leveling pads as nec essary 2 Place the in feed conveyor approxi mately flush with the front most face of the binder as shown in Figure 2 4 The covered end of the conveyor faces to the right The right end of the plastic cover should be about 3 1 2 89 mm from the right end of the binder Place the book slide 56480 under the binder s book slide and set the bracket end of the conveyor s book slide against top edge of the deflec
63. onveyor 1 56421 Cooling Elevator 1 In line Option 2 In line with Tilt In feed Conveyor 56600 Tilt In feed Conveyor 1 56421 Cooling Elevator 1 Stand alone Option Stand Alone 56416 Hand feed Conveyor 1 Exit Option Fixed shown above 56420 Exit Conveyor 1 01 03 CMT 330 Three Knife Trimmer 1 5 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 Knife scabbard not shown 6 5 56303 Cut Stick 1 6 56304 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 01 03 CMT 330 Three Knife Trimmer 1 6 Packing List 1 6 3 Consumables The CMT 330 uses the following consumable items Part E 967 1 56527 4700 56523 1000 SU 30 103 SU 30 104 56228 56181 56181 1 56178 56246 56303 56304 Description Qty LAMP 6 UHMW TAPE TABLE 2 UHMW TAPE JOG 2 GREASE EXT PRESS BULK GREASE RYKOTAC EP BULK FACE PAD 1 LEFT CLAMP PAD 1 RIGHT CLAMP PAD 1 CENTER PAD 1 KNIVES SET OF 3 1 CUT STICK 1 CUT PLATE 2 Frequency 10 000 hrs 1 yr 1 yr 1 wk each knife change 6 mo 6 mo 6 mo 6 mo 5000 books rot 1000 change 8000 books rot 1000 change 4000 books The following consumables are found in Oil Change Kit K 56040 P
64. ook appears as though it was not cut square Possible Causes SHEETS NOT CUT CUT THROUGH BINDING NOT Figure 5 7 Not Cutting Through Possible Causes The knife is not adjusted to cut deep enough The cut stick or cut plates may be worn out Solutions If not cutting deep enough on the face of the book adjust the face knife ac cording to instructions in section 4 3 2 Knife Adjustment on page 4 7 If not cutting deep enough on the top or bottom faces of the book adjust the side knives according to section 4 3 2 Knife Adjustment on page 4 7 Replace the cut stick or cut plates The book was allowed to cool with a twisted binding as shown in Figure 5 8 When the book is straightened 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 signifi cant time to harden Cover overhangs the book The over hang reduces the reliability of the squaring process within the trimmer Glue was applied past the binding leav ing a knob like protrusion The protru sion interfered with the trimmer s squar ing process Normal wear has forced the cutting or transport mechanisms out of square Solutions Carefully handle books with soft bind ings Keep twist out of the binding when storing Allow bindings to harden before stacking Cut cover to fall within the size of the untrimm
65. opriate language then press the enter key All messages will be dis played in the selected language LANGUAGE English Espanol Deutsch Francais Portugues Select amp Press Enter A Maint B Job D Exit Figure 3 24 Language Screen CMT 330 Three Knife Trimmer 01 03 3 12 Maintenance Mode 3 8 Status Messages Message Description WASTE BIN FULL The face knife waste bin sensor is covered WASTE BIN FULL The right side waste bin sensor is covered WASTE BIN FULL The left side waste bin sensor is covered Book jam between CMT 330 and elevator Book was covering upper elevator sensor when the book was trying to lift Book elevator FAILED to lift to the proper level The shelf level proximity sensor did not activate properly or in time This con be caused by either a misadjusted or a faulty proximity sensor Center clamp error Down when it should be up The proximity sensor on the center clamp did not turn on This fault can be caused by either the air cylinder not returning or a faulty proximity sensor Center clamp it should be error Up when down The proximity sensor on the center clamp did not turn off This fault can be caused by either the air cylinder not coming down or a faulty proximity sensor Clamp knife down The side knife was down while the side knives or registration assembly was moving DATA IS OUT OF RANGE This error messag
66. or 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 12 In line Option 1 fj POWER HOOK UP AIR HOOK UP CMT 330 Three Knife Trimmer 01 03 1 17 Site Specifications 1 9 2 In line Option 2 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 13 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 HA f POWER HOOK UP Y AIR HOOK UP 2 13 m 39 38 1m 7 88 1 LEFT FRONT RIGHT 53 5 34 5 47 1 4 0 88 m 1 19 m 133 3 38 Figure 1 13 In line Option 2 CMT 330 Three Knife Trimmer 01 03 1 18 Site Specifications 1 9 3 Stand alone Option The stand alone option is used when books are fed to the trimmer by hand It includes the CMT 330 basic machine and two conveyors See Figure 1 14 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 with a roll
67. port is not working properly Servo Port Failed RS 232 port controlling the servo drive failed Servo Relay Error ON when it should be off Output 11 is off and input 23 is on Servo Relay Error OFF when it should be on Output 11 is on and input 23 is off S Knife at up limit Failed to move This message is displayed when the side knives do not leave the up proximity sensor There are at least four reasons for this failure the dump valve did not energize the pro portional valve did not energize the knife down valve did not energize or the side knife up proximity sensor is faulty S Knife down FAILURE timed out before reaching down limit This message is displayed when the side knives leave the up limit but do not reach the down limit in time If the knives did come down the proximity sensor may be faulty or misadjusted If the knives only moved down slightly either the unload valve or the pro portional valve may not have energized Start Button Held in at power up Either the start button or remote cut button is being held in Either button may be faulty S Knife up FAILURE timed out before reaching up limit This message displayed when the side knives do not reach the up limit in time Either a faulty or misadjusted up proximity sensor may cause this error S Slow down Failure The slow down proximity did not respond before the down proximity sensor Either a faulty or misadjust side
68. 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 UNTRIMMED BOOK TRIMMED BOOK FACE BOTTOM EDGE Figure 1 2 Book Terminology NEE _ _ AX KAAS 62 0060600 0 o SS Q ea INCHES h 12 75 2x e RSS 5 eA o 2 p h 1 2 3 4 x INCHES Figure 1 3 Trimmable Book Sizes CMT 330 Three Knife Trimmer 01 03 1 9 Specifications 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 CONSOLE STATUS LIGHT RIGHT REAR SLIDING DOOR FRONT SLIDING DOOR BACK FRONT LOWER FRONT DOOR POWER PANEL DOOR RIGHT REAR DOOR Figure 1 4 Right Front View CLAMP PRESSURE GAUGE LEFT REAR SLIDING DOOR GRIPPER PRESSURE GAUGE GRIPPER PRESSURE CONTROL KNOB CLAMP PRE
69. re 1 Empty the right side waste bin 2 Select the Accuracy Adjust option from the Service menu press the send key The side knives and side guide will ad just to an uncompensated 9 X 6 with a 5 trim CMT 330 Three Knife Trimmer 01 03 3 11 Maintenance Mode 3 Cuta book that is at least 10 00 X 7 00 and 0 25 thick 4 Collect the right side trimming from the waste bin 5 Measure the trim and the book size as accurately as possible preferably with calipers accurate to 001 6 Enter these dimensions into the accu racy adjust screen 7 Exitthe Maintenance Mode and Send the side knives and side guide to a new location 8 Cuta book 9 Measure the book and side trim to ver ify they are accurate If the book does not measure as expected repeat steps 1 through 9 l Press Send 2 Cut Book 3 Enter Dimensions A Maint B Job Figure 3 22 Accuracy Adjust Screen 3 7 3 7 Shipping Position This function allows both the side and the face knives to be slowly lowered to a position ap proximately 1 2 off the table This is done to prevent damage to the hydraulic system caused by dynamic forces during shipment Select Shipping Position from the Service Screen and press the green start button To position knives for shipping press the START button D Exit Figure 3 23 Shipping Position Screen 3 7 3 8 Language In the Language screen use the up down arrow keys to select the appr
70. re in open slots in the knife bar They are the second and fifth bolts from either end of the knife Set the bolts aside and save for knife installation T HANDLE WRENCH KNIFE BOLT Figure 4 10 Knife Bolt Locations 6 Place the knife lifter on top of the knife bar and align each lifter handle with the holes from which the two knife bolts were removed in the previous step Turn the handles clockwise until the lifter is securely fastened to the knife bar as in Figure 4 11 KNIFE LIFTER HANDLE Figure 4 11 Knife Removal 7 Usethe T handle wrench to remove the remaining 4 knife bolts Save the bolts with the two previously removed sus Make certain to have a scabbard on the cart prepared to receive a knife The screws should be removed from the scabbard The protecting edge of the scabbard should be facing 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 be ing removed 8 Slowly turn the knife lifter handles coun terclockwise only until the knife is re leased from the machine DO NOT turn the handles any more than what is re quired to free the knife 9 When the knife is free move it down and clear of the knife bar 10 Hold the knife lifter with knife at a safe distance from the body Other people should not be nearby Carry the lifter to the cart con
71. rent Progress 2 4 1 4 Exit Conveyor Before proceeding go to Section 2 5 Power Hookup on page 2 8 Main power must be con nected to the machine before proceeding 1 Remove 4 sets of screws and wash ers from the power panel door of the Trimmer Save them for later use 2 Make sure the exit conveyor s leveling pads are set to 33 7 8 as shown in Figure 2 11 Adjust as necessary Figure 2 11 Exit Conveyor Leveling Pads 3 Move the exit conveyor to the right hand side of the trimmer such that the slots in the conveyor mounting brackets line up with the holes in the power panel door as shown in Figure 2 12 4 Fasten the conveyor to the trimmer us ing the hardware from step 1 MOUNTING BRACKET POWER PANEL DOOR Figure 2 12 Exit Conveyor Placement The completed setup should look like Figure 2 13 The accessory cables and hoses can now be connected to the trimmer Figure 2 13 Completed Setup 2 4 1 5 Hookup Accessory Cables Power cables must now be connected to each conveyor Two air hoses and one power cable must also be connected to the elevator Access the cables and hoses stored inside the machine through the front door CMT 330 Three Knife Trimmer 01 03 2 5 Option Setup In feed Conveyor 1 Unwrap the two cables labeled In feed Conveyor 2 Route the cable behind the hydraulic power unit and under the left hand side of the machine base 3 Connect the cables to the sockets on
72. s cut plates may require replace ment because they are consumable items 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 5 Book Quality CMT 330 Three Knife Trimmer 01 03 5 1 Book Quality 5 1 Burr Marks Description Burr marks are found on books cut with a knife whose cutting edge has been burred Figure 5 1 illustrates the appearance of burr marks BURR MARKS Figure 5 1 Burr Marks Possible Causes 1 Burrs on knives can occur from im proper knife handling 2 Burrs may also occur from cutting hard irregular materials Solutions e If the any knife is burred replace all three knives and maintain as a set CAUTION All three knives must be sharpened as a set Damage to the cut plates may result from using knives sharpened sepa rately 5 2 Jagged Bottom Cover Description Books can appear as though the bottom few sheets and cover were torn apart rather than sharply cut Tearing of the bottom sheets and cover occur when deep score marks develop in the cut stick or cut plates The cover is pushed into the score mark folded over and torn APPEARS TORN Figure 5 2 Jagged Cover Possible Causes 1 The knife may be dull 2 The cut stick cut plates may be worn Solutions e problem is on the face of the book the cut sti
73. should operate this machine at a time Cut Crush Hazard Do not operate with covers 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 Ay 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 A 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
74. taining the prepared scab bard 11 Place the knife lifter with knife into the scabbard such that the edge of the knife is in the scabbard slot 12 Carefully turn the knife lifter handles counterclockwise and disconnect the lifter from the knife while the knife edge remains in the scabbard slot 13 Align the two knife bolt holes with the holes in the scabbard such that no por tion of the knife edge remains exposed 14 Place a scabbard screw into each hole and turn them clockwise to tighten 15 Use a wrench to secure the knife to its scabbard 16 Set the knife aside 17 Repeat steps 4 through 16 with the re mainder of the knives With all knives removed the replacement knives may be installed A CAUTION All three knives are a set They must be sharpened as a set Damage or poor performance may result if knives are not from the same set pw Changing knives can be very dangerous unless safety precautions are observed and extreme care is taken when handling knives Keep handling of unprotected knives to an absolute minimum Have the scabbard nearby and insert knife immediately Warn people of any unprotected knife CMT 330 Three Knife Trimmer 01 03 4 5 Knives Knife changing is a ONE PERSON OPERATION More than one person changing a knife creates safety haz ards Even used knives extremely sharp Use extreme care when handling new re ground knives and used knives
75. the base of the machine 4 Place the waste bins on the cart and repeat for the remaining bins 5 After emptying and placing the bins back into the trimmer close the doors securely The machine will not operate if a door is ajar Hint Static can accumulate on the plastic waste bins This can occasionally cause trimmings to cling to the handles of the bin The Bin Full sensor is at this location so trimmings blocking the sensor will cause the Waste Bin Full status even if the bin is not full To prevent this from happening lightly spray the inside of each bin with an anti static spray This need only be done on occasion Using additional waste bins may reduce down time To order additional waste bins use Chal lenge part number 56143 4 2 Cut Stick Cut Plates The cut stick and cut plates should either be changed or rotated with every knife change They may also require changing at other times if CMT 330 Three Knife Trimmer 01 03 4 2 Waste Bins deep grooves or jagged edges can be seen along the score marks Cut stick plate wear effects cut quality 4 2 1 Changing the Cut Stick The cut stick can be rotated 8 times before dis posal It is located under the face knife ac cessed through set of double doors at the back of the machine The cut stick puller provided with the machine is used to remove the cut stick The cut stick and other tools are located on the inside of the left rear door that is shown in Fi
76. tor 56415 as shown in Figure 2 5 BOOK SLIDE DEFLECTOR Figure 2 5 Book Slide Placement CMT 330 Three Knife Trimmer 01 03 2 3 Option Setup 2 4 1 2 Elevator 1 The top shelf should be 36 914 mm from the floor as shown in Figure 2 8 Adjust the leveling pads as necessary Align the elevator with the in feed con veyor by sliding the opening of the clear plastic cover over the in feed con veyor s plastic cover PLASTIC COVER PLASTIC COVER Figure 2 6 Elevator Placement 2 4 1 3 Trimmer 1 Install the scanner bracket onto the left front door of the trimmer Make sure the top of the bracket is flush with the trimmer s in feed conveyor belt Remove the lower front door of the trimmer and locate the loose photoelec tric sensor Remove the nuts from the sensor and push the sensor through the split cap bushing in the left side of the trimmer s base Attach the sensor as shown in Figure 2 7 Bar code scanner and additional photo sensor are no longer available BAR CODE SCANNER BOOK OUT OF ELEVATOR SENSOR LOCATION FLUSH WITH TOP OF IN FEED CONVEYOR BELT PHOTO SENSOR Figure 2 7 Scanner Bracket Installation 3 Remove the two sets of screws and washers from the holes in the right side of the top cover of the elevator Figure 2 8 Save them for later use Move the trimmer next to the elevator such that the two holes in the right side of the top cover of the elev
77. uch space this setup will require 2 Move the trimmer to the appropriate lo cation 3 Complete steps 5 10 and 13 in sec tion2 4 1 3 on page 2 4 4 Complete section 2 5 Power Hookup on page 2 8 Figure 2 16 Stand Alone Space Claim 2 4 3 2 Exit Conveyor Complete section 2 4 1 4 Exit Conveyor on page 2 5 2 4 3 3 Hand Feed Conveyor 1 Remove 4 sets of screws and wash ers fastened to the center of the door on the left hand side of the trimmer as shown in Figure 2 18 Save them for later use 2 Make sure the hand feed conveyor s leveling pads are set at 1 1 2 as shown in Figure 2 17 1 1 2 Figure 2 17 Hand feed Leveling Pads 3 Move the hand feed conveyor to the left hand side of the trimmer such that the slots in the conveyor mounting brackets line up with the holes in the Trimmer s left hand door as shown in Figure 2 18 and Figure 2 19 MOUNTING LEFT FRONT DOOR Figure 2 18 Hand Feed Mounting wy A HAND FEED CONVEYOR EXIT CONVEYOR Figure 2 19 Stand Alone Application 4 Fasten the conveyor to the trimmer us ing the hardware from step 1 2 4 3 4 Hookup Accessory Cables Power cables must now be connected to each conveyor Remove the lower front door from the trimmer to access the cables and hoses stored inside the machine Hand Feed Conveyor 1 Unwrap the cable labeled In feed Con veyor 2 Route the cable behind the hydraulic power unit and under the l
78. ued a move command It is typically caused by pressing the stop button in the middle of a book cy cle Sharpen Knife The number of machine cycles has exceeded that which is recommended for a knife change It is time to change knives Shorted Key error A key on the keypad has been actuated for more than 90 seconds Side knife latch failed to disengage The side knife latch proximity sensor did not activate This can be caused by a faulty or misadjusted proximity sensor The air cylinder may have failed to pull in S knife latch error OFF when it should be ON The side knife latch proximity did not activate This can be caused by a faulty or misad justed proximity sensor The air cylinder may have failed to pull in CMT 330 Three Knife Trimmer 01 03 3 14 Status Messages Status Messages Continued Message Description S knife latch error ON when it should be OFF The side knife latch proximity sensor did not de activate This can be caused be a faulty sensor The air cylinder may have failed to extend S Knife at down limit Failed to move This error message displays when the side knives do not leave the down proximity switch Either the cut valve did not de energize or the down limit proximity sensor may be faulty Serial Communication Port Failed The external control port is not working properly Serial error no response from the servomotor The servo control
79. unused job number between 1 and 99 inclusive The job number is created with a blank name 3 6 2 Editing a Job Name The job name is edited in the job mode screen To edit the name use the up down arrow keys to move the cursor to the appropriate job num ber Then press the right arrow key to move the cursor to the desired character position and edit the character by pressing the up or down arrow keys to toggle between characters of the alpha bet Numbers can be entered directly by using the number keys Pressing the clear key clears the current character When finished you may edit the current job by pressing the enter key go to a different job or exit job mode 3 6 3 Lock Unlock a Job Locking a job prevents it from being edited In the Job screen the soft key A will display Lock or Unlock depending on the status of the job If a job is locked the padlock symbol will be displayed at the right of the job name To change the lock status of a job move the cursor to the appropriate job using the up down arrow keys and press the soft key A Lock Unlock The locking function may also be accessed through the Job Options menu section 3 6 7 in the Job Run screen as shown in Figure 3 8 3 6 4 Erasing a Job Erasing a job will permanently remove it from memory Use the arrow keys to select a job to be erased Press the soft key C Erase Clear channel 4 is displayed followed by Yes and No Use the up down arrow key to s

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