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CHALLENGE

CMT 130

BOOK TRIMMER

THE CHALLENGE MACHINERY COMPANY

CMT 130

Book Trimmer

Installation and

Operator's Manual

The Challenge Machinery Company

6125 Norton Center Drive

Norton Shores, MI 49441 USA

ChallengeMachinery.com

SERIAL No.: _____________

F.013 / NOV 2009

11/09

CMT 130 Book Trimmer ii

NOTICE

Service documentation is supplied to Chal-

lenge external customers for informational

purposes only. Service documentation is

intended for use by certified, product-

trained personnel only. Challenge does not

warrant or represent that such documenta-

tion is complete, nor does Challenge repre-

sent or warrant that it will notify or provide

to such customer any future changes to this

documentation. Customer performed ser-

vice of equipment may affect the warranty

offered by Challenge with respect to such

equipment. If the customer services this

equipment, modules, components or parts

thereof, the customer releases Challenge

from any and all liability for the customer

actions, and the customer agrees to in-

demnify, defend and hold Challenge harm-

less from any third party claims which arise

directly or indirectly from such service.

Prepared by:

The Challenge Machinery Company

6125 Norton Center Drive

Norton Shores, MI 49441 USA

Phone: 231.799.8484 Fax: 231.798.1275

ChallengeMachinery.com

Challenge® is a registered trademark of

The Challenge Machinery Company.

11/09

CMT 130 Book Trimmer iii Contents

Contents

Description Page

1 Introduction 1-1

1.1 Warranty Information ................................1-2

1.2 Warning Label Definitions.........................1-3

1.3 Note Definitions.........................................1-3

1.4 Safety........................................................1-3

1.5 Power Lockout Procedure.........................1-4

1.6 Packing List...............................................1-5

1.7 Specifications............................................1-8

1.8 General Locations.................................. 1-10

1.9 Exit Conveyor......................................... 1-11

2 Installation Guide 2-1

2.1 Shipping Claims........................................2-2

2.2 Unpacking.................................................2-2

2.3 Moving.......................................................2-2

2.4 In-Feed/Exit Options.................................2-3

2.5 Power Hookup...........................................2-7

2.6 Air Hookup ................................................2-9

2.7 Cleaning....................................................2-9

3 Operator's Guide 3-1

3.1 Programming.............................................3-2

3.2 User Interface Map ...................................3-5

3.3 Power Up ..................................................3-6

3.4 Improper Wiring.........................................3-6

3.5 Run Mode..................................................3-6

3.6 Job Mode ..................................................3-7

3.7 Status Messages ................................... 3-10

3.8 Example Job .......................................... 3-13

3.9 Serial Communication............................ 3-15

4 Routine Tasks 4-1

4.1 Under Book Air Blast.................................4-2

4.2 Waste Bin..................................................4-2

4.3 Cut Stick....................................................4-2

4.4 Knife..........................................................4-3

4.5 Check Pressure Switch.............................4-6

4.6 Safety Systems Check..............................4-7

5 Book Quality 5-1

5.1 Burr Marks.................................................5-2

5.2 Jagged Bottom Cover...............................5-2

5.3 Burr Marks/Jagged Cover.........................5-2

5.4 Rectangular Crease Lines........................ 5-3

5.5 Linear Crease Lines................................. 5-3

5.6 Draw......................................................... 5-3

5.7 All Sheets Not Cut.................................... 5-4

5.8 Book Not Square...................................... 5-4

11/09

CMT 130 Book Trimmer iv

Notes:

11/09

CMT 130 Book Trimmer 1-1 Introduction

Section Contents

TITLE PAGE

1.1 Warranty Information ................................1-2

1.2 Warning Label Definitions.........................1-3

1.3 Note Definitions.........................................1-3

1.4 Safety........................................................1-3

1.5 Power Lockout Procedure.........................1-4

1.6 Packing List...............................................1-5

1.6.1 Base Machine/Options....................... 1-5

1.6.2 Standard Accessories ........................ 1-6

1.6.3 Optional Items .................................... 1-7

1.6.4 Consumables...................................... 1-7

1.7 Specifications............................................1-8

1.7.1 Book Size Chart ................................. 1-9

1.8 General Locations.................................. 1-10

1.9 Exit Conveyor......................................... 1-11

1.9.1 Advanced In-Feed Conveyor............ 1-12

1.9.2 Elevator ............................................ 1-13

1.9.3 Site Specifications............................ 1-14

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

11/09

CMT 130 Book Trimmer 1-2 Warranty Information

1.1 Warranty Information

READ THIS MANUAL BEFORE OPERATING!

Follow all precautions and instructions. For

parts and service contact the Authorized Chal-

lenge Dealer from whom the machine was pur-

chased. Always give the SERIAL NUMBER

and MODEL of your machine to ensure the cor-

rect parts are sent.

* WARRANTY INFORMATION *

PLEASE REVIEW THE ENCLOSED

WARRANTY INFORMATION SHEET

It is very important that you read and under-

stand the conditions outlined in the Warranty

Information Sheet attached to the outside of the

shipping container of your machine. The War-

ranty Information Sheet must be filled out com-

pletely and returned to THE CHALLENGE

MACHINERY COMPANY in order for the war-

ranty to be issued for this machine.

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.

A________

B________

C________

D________

E________

F________

If you bought a used machine, it is important to

have the following information on record at

Challenge. Copy this page, fill in the informa-

tion and send it care of The Challenge Service

Department, 6125 Norton Center Drive •Norton

Shores •MI 49441.

* INSTALLATION INFORMATION *

Model: CMT 130

Serial No.:

Company Name:

Address:

City:

State/Province:

ZIP Code

Phone No.:

Date Installed:

Dealer Name:

Dealer City:

Accuracy Adjustment Values

B= inches

D= inches

11/09

CMT 130 Book Trimmer 1-3 Warning Label Definitions

1.2 Warning Label Definitions

Warning labels are posted throughout the ma-

chine to indicate areas where physical injury

may occur.

Read the instruction manual.

The instruction manual should be

read and understood before operat-

ing this machine.

Do not operate with more than

one person!

One person only should operate

this machine at a time.

Cut / Crush Hazard!

Do not operate with covers re-

moved.

Do not disable safety devices.

Crush Hazard!

Do not operate with covers re-

moved.

Do not disable safety devices.

Crush / Entanglement Hazard!

Do not operate with covers or

guards removed.

Electrical Shock Hazard!

Disconnect power before removing

cover.

Electrical Shock Hazard!

Disconnect power before removing

cover.

1.3 Note Definitions

The formats of three specific types of notes

found throughout this manual indicate the level

of danger or importance associated with the

task presented. The format of warning notes,

caution notes, and regular notes imply a certain

level of danger. The following examples give a

description. Associate the text format with its

level of danger or importance.

Warning Definition:

WARNING

A warning indicates an operating or maintenance pro-

cedure, practice, or condition that, if not strictly ob-

served, could result in injury or loss of life.

Caution Definition:

CAUTION

A Caution indicates an operating or maintenance procedure,

practice, or condition that, if not strictly observed could re-

sult in damage to, or destruction of, equipment.

Note Definition:

Note: A regular note indicates an operating or maintenance

procedure, practice, or condition that is necessary to ac-

complish a task efficiently.

1.4 Safety

Before installing or operating any equipment, it

is important to take precautions. Read and

thoroughly understand the safety precautions

outlined below.

•This machine is designed for one-

person operation. Never operate the

machine with more than one person.

•Safe use of this machine is the respon-

sibility of the operator. Use good judg-

ment and common sense when working

with and around the machine and its

accessories.

•Read and understand all instructions

thoroughly before using the machine. If

questions remain, contact your Author-

ized Challenge Dealer. Failure to un-

derstand the operating instructions may

result in personal injury.

•Only trained and authorized individuals

should operate this machine.

•Only trained and authorized service

technicians should service this ma-

chine.

•Do not alter safety guards or devices.

They are there for your protection. Se-

vere laceration or dismemberment may

result if safety devices are altered.

•Disconnect power and lock out before

performing any maintenance. See Sec-

tion 1.5 , Power Lockout Procedure.

•Observe all caution and instruction la-

bels on this machine.

•Be extremely careful when handling

and changing knives. Severe lacera-

tions or dismemberment could result

from careless handling procedures.

•Perform the given on page 4-7 before

each shift begins.

11/09

CMT 130 Book Trimmer 1-4 Power Lockout Procedure

•Keep all conveyors and elevator acces-

sories clear of foreign objects. Do not

place foreign objects within the ma-

chine. Cutting anything other than

qualifying perfect bound books could

result in serious damage to the machine

and create safety hazards. A qualifying

perfect bound book will fall into the size

range described in the specifications on

page 1-8.

•Make sure all applicable accessories

are securely bolted to the main ma-

chine. Tip hazards may result from un-

secured accessories.

•If the machine operates abnormally,

consult a Challenge authorized service

agent.

1.5 Power Lockout Procedure

For maximum safety while making ADJUST-

MENTS or REPAIRS to your machine, lock out

the main power disconnect switch. The switch

should be moved to the OFF position and a

padlock securely fastened through the loop.

The person adjusting or servicing the machine

should hold the key.

Figure 1-1. Main Power Disconnect

11/09

CMT 130 Book Trimmer 1-5 Packing List

1.6 Packing List

Compare the contents of the crate against the

following lists and the packing slip to be sure all

items are included with your shipment.

1.6.1 Base Machine/Options

This parts list includes the base machine and

any accessories that may have been ordered

with it.

Part Number Description Qty.

CMC-130 CMT 130 Base Machine 1

Accessory Options

Stand-Alone Options

58500 Book Pile Feeder (shown above) 1

58000 Vertical Stacker (shown above) 1

59200 CMT 130 Manual In-feed (small, not shown) 1

56413 Hand-Feed Conveyor (large, not shown) 1

56420 Exit Conveyor (not shown) 1

In-line Option (not shown)

56600 Tilt In-feed Conveyor 1

56421 Cooling Elevator 1

(also include exit options from above)

Other Options

59099 Multiple Book Option

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