Challenge CMT-130, CMT-130TC 2016 Instruction and Parts Manual

Type
Instruction and Parts Manual
F.501TCA
March 2018
Book Pile Feeder
Instruction and Parts Manual
Serial Numbers:
BPFD-A-160000 and up
Sold and Serviced by
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441-6081 USA
ChallengeMachinery.com
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 noncurrent,
unsupported or no longer produced by The Challenge Machinery Company, and are provided solely as
an accommodation 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 in 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.
1.0 Introduction
2
1.0 Introduction
THIS MANUAL is designed to help you get the most from your Challenge equipment. Keep this
manual in a safe, convenient place for quick reference by operators and service personnel.
SAFETY ALERT! This symbol means CAUTION: Personal safety
instructions! Pay special attention to the instructions in bold type. Personal injury may result if the
precautions are not read and followed.
READ THIS MANUAL BEFORE OPERATING! Follow precautions and instructions given and you
should have years of trouble-free operation. If after reading the manual questions still remain, contact
your Authorized Challenge Dealer.
Take a few minutes right now to RECORD YOUR MACHINE SERIAL NUMBER in the space
provided on this page. Also be sure to fill out the warranty card accompanying your machine and
return it DIRECTLY TO CHALLENGE.
If you bought a used machine, it is important to have the following information on record at Challenge.
Copy this page, fill in the information, and send it care of The Challenge Service Department 6125
Norton Center Drive Norton Shores, MI 49417-1594.
CHALLENGE MODEL
SERIAL NUMBER
ATTN
COMPANY
ADDRESS
CITY
STATE/PROVINCE
ZIP
PHONE
DATE INSTALLED
DEALER NAME & CITY
* WARRANTY INFORMATION *
PLEASE REVIEW THE ENCLOSED WARRANTY INFORMATION SHEET
It is very important that you read and understand the conditions outlined in the Warranty Information
Sheet attached to the outside of the shipping container of your machine.
The Warranty Information Sheet must be filled out completely and returned to THE CHALLENGE
MACHINERY COMPANY in order for the warranty to be issued for this machine.
Challenge® is a registered trademark of The Challenge Machinery Company
6125 Norton Center Drive Norton Shores MI 49441-6081
Copyrigh2018 by The Challenge Machinery Company. All rights reserved. Printed in the USA.
1.0 Introduction
3
TABLE OF CONTENTS
1.0 Introduction .......................................................................................................................................2
2.0 Safety ................................................................................................................................................4
2.1 Caution Labels ..............................................................................................................................4
2.2 Precautions ...................................................................................................................................4
3.0 Packing List .......................................................................................................................................5
4.0 Specifications ....................................................................................................................................6
5.0 Installation and Setup .......................................................................................................................7
5.1 Stand-Alone Installation with a New CMT-130 or CMT-330 Trimmer ..........................................7
5.2 In-line Installation with a New CMT-130 or CMT-330 Trimmer ................................................. 10
6.0 Operation ....................................................................................................................................... 13
6.1 Operating the Feeder ................................................................................................................. 13
6.2 Load Capacity Adjustment ......................................................................................................... 14
6.3 Adjusting the Tilt Angle of the Pusher Back Plate ..................................................................... 14
6.4 Using the Transition Conveyor Extension for Small Books in Multi-Book Mode ....................... 15
6.5 Single Book Feeding Through the Access Door (if equipped) .................................................. 15
6.6 Operating Tips ........................................................................................................................... 15
7.0 Troubleshooting ............................................................................................................................. 17
8.0 Part Lists and Wiring Diagrams ..................................................................................................... 18
8.1 Main Assembly 130 Model, 58500TCA (1/9) Side Frames ................................................. 18
8.2 Main Assembly 130 Model, 58500TCA (2/9) Tilt Conveyor ................................................ 20
8.3 Main Assembly 130 Model, 58500TCA (3/9) Tilt Mechanism ............................................. 22
8.4 Main Assembly 130 Model, 58500TCA (4/9) Transition Conveyor ..................................... 24
8.5 Main Assembly 130 Model, 58500TCA (5/9) Pusher .......................................................... 26
8.6 Main Assembly 130 Model, 58500TCA (6/9) Feed Table ................................................... 28
8.7 Main Assembly 130 Model, 58500TCA (7/9) Table Guides ................................................ 30
8.8 Main Assembly 130 Model, 58500TCA (8/9) Covers .......................................................... 32
8.9 Main Assembly 130 Model, 58500TCA (9/9) Side Input Config’s ....................................... 34
8.10 Main Assembly 330 Model, 58600TCA (1/9) Side Frames ............................................... 36
8.11 Main Assembly 330 Model, 58600TCA (2/9) Tilt Conveyor .............................................. 38
8.12 Main Assembly 330 Model, 58600TCA (3/9) Tilt Mechanism ........................................... 40
8.13 Main Assembly 330 Model, 58600TCA (4/9) Transition Conveyor ................................... 42
8.14 Main Assembly 330 Model, 58600TCA (5/9) Pusher ........................................................ 44
8.15 Main Assembly 330 Model, 58600TCA (6/9) Feed Table ................................................. 46
8.16 Main Assembly 330 Model, 58600TCA (7/9) Table Guides .............................................. 48
8.17 Main Assembly 330 Model, 58600TCA (8/9) Covers ........................................................ 50
8.18 Main Assembly 330 Model, 58600TCA (9/9) Side Input Config’s ..................................... 52
8.19 Power Panel Assembly EE-3515 ............................................................................................. 54
8.20 Basic Machine Schematic E-3514 ........................................................................................... 56
8.21 Pneumatic Diagram 58500TCA-P ........................................................................................... 57
2.0 Safety
4
2.0 Safety
2.1 Caution Labels
Electrical Shock Hazard!
This symbol indicates an electrical shock hazard exists behind the panel on which it
is found. Power should be disconnected before removing the panel.
Crush Hazard!
This symbol indicates a crush hazard exists at a nearby access area to the inside of
the machine. Power should be disconnected before reaching inside the machine.
2.2 Precautions
The following list of safety precautions should be observed:
The machine should only be serviced by an authorized Challenge service technician.
Do not place hands inside the machine while power is on.
Always disconnect power to the machine before servicing. Disconnect plugs from feeder.
3.0 Packing List
5
3.0 Packing List
Part No.
Description
58500TCA
58600TCA
Book Pile Feeder 130 Model
Book Pile Feeder 330 Model
1
58582
Transition Conveyor Extension for small books
1
56080
CMT Mounting Bracket
1
58598
CMT Mounting Bracket
1
F.501TCA
Instruction and Parts Manual
1
4.0 Specifications
6
4.0 Specifications
Description
130 Model
330 Model
Book Dimensions
Pile Height Maximum
35-1/2” (90 cm)
35-1/2” (90 cm)
Minimum Book Size, Single Book Mode
(Spine Length x Book Width)
7” x 5”
(178 x 127 mm)
7” x 5“
(178 x 127 mm)
Minimum Book Size, Multi-Book Mode
(Spine Length x Book Width)
7” x 6-3/4
(178 x 171 mm)
7” x 8
(178 x 203 mm)
Maximum Book Size
(Spine Length x Book Width)
13” x 9-1/2
(330 x 241 mm)
13” x 13”
(330 x 330 mm)
Minimum Book Thickness
1/8” (3 mm)
1/8” (3 mm)
Maximum Book Thickness
2” (51 mm)
2” (51 mm)
Pile Feeder Dimensions
Overall Width
20-3/4” (53 cm)
20-3/4” (53 cm)
Overall Height
53-3/4” (137 cm)
55-3/4” (142 cm)
Overall Depth
56-1/2” (144 cm)
56-1/2” (144 cm)
Approx. Net Weight
370 lbs (168 kg)
390 lbs (177 kg)
Approx. Shipping Weight
420 lbs (191 kg)
440 lbs (200 kg)
Electrical
Electrical hookup to CMT trimmer
Compressed Air
Compressed air hookup to CMT trimmer
Challenge reserves the right to make changes to any product or specification without notice and
without incurring responsibility to existing units.
5.0 Installation and Setup
7
5.0 Installation and Setup
5.1 Stand-Alone Installation with a New CMT-130 or CMT-330 Trimmer
Figure 5-1. Stand-Alone installation of Pile Feeder shown with a CMT-130TC
Instructions
1. Remove the Pile Feeder from its carton and crate.
2. Raise the four leveling pads and roll the machine to the desired location.
3. Lower the leveling pads and raise the Pile Feeder until the height of the feeder’s out-feed belt is
approximately 36” (91.5 cm) above the floor and level.
4. Move the CMT trimmer into position against the Pile Feeder, aligning the mounting brackets on
the Pile Feeder to the corresponding holes in the side of the trimmer.
5. Set the trimmer height according to the installation instructions in the CMT trimmer instruction
manual.
6. Attach the Pile Feeder to the CMT trimmer using supplied mounting hardware.
Cable and Air Tubing Connections
1. Remove the lower front panel of the trimmer and locate the yellow power cable coiled up inside
the trimmer that is labelled with the number that corresponds to the label on the Pile Feeder near
the input connectors. The power cables are the larger diameter cables with 7-pin connectors on
the end.
2. Route the power cable under the hydraulic unit and out of the left side of the trimmer.
3. Connect the power cable as shown in Figure 5-2.
5.0 Installation and Setup
8
Figure 5-2. Power Cable Connection
4. Now locate the yellow communication cable or cables coiled up inside the trimmer that are
labelled with the number that corresponds to the label on the Pile Feeder near the input
connectors. They are small diameter cables with a 3-pin connector on the end.
5. Connect the communication cables as shown in Figure 5-3.
Figure 5-3. Communication Cable Connections
5.0 Installation and Setup
9
6. Now locate the coiled-up line of blue air tubing with a red and white connector on the end that is
labelled with the number that corresponds to the label on the Pile Feeder near the input
connectors.
7. Connect the air tubing as shown in Figure 5-4.
Figure 5-4. Air Tubing Connection
8. Continue the trimmer setup according to the installation instructions in the CMT trimmer
instruction manual.
5.0 Installation and Setup
10
5.2 In-line Installation with a New CMT-130 or CMT-330 Trimmer
Figure 5-5. In-line installation of Pile Feeder shown with a CMT-130TC
Instructions
1. Place the Tilt-Conveyor and Elevator into position and setup according to the installation
instructions in the CMT trimmer instruction manual.
2. Remove the Pile Feeder from its carton and crate.
3. Raise the four leveling pads and roll the Pile Feeder to the proper location next to the Elevator,
aligning the mounting brackets on the Elevator to the corresponding holes in the side of the Pile
Feeder.
4. Lower the leveling pads and raise the Pile Feeder until the height of the feeder’s out-feed belt is
slightly below the top shelves of the Elevator, approximately 36” (91.5 cm) above the floor and
level.
5. Attach the Elevator to the Pile Feeder using the supplied hardware.
6. Move the CMT trimmer into position against the Pile Feeder, aligning the mounting brackets on
the Pile Feeder to the corresponding holes in the side of the trimmer.
7. Set the trimmer height according to the installation instructions in the CMT trimmer instruction
manual.
8. Attach the Pile Feeder to the CMT trimmer using supplied mounting hardware.
Cable and Air Tubing Connections
1. Remove the lower front panel of the trimmer and locate the yellow power cable coiled up inside
the trimmer that is labelled with the number that corresponds to the label on the Elevator near the
input connectors. The power cables are the larger diameter cables with 7-pin connectors on the
end.
2. Route the power cable under the hydraulic unit and out of the left side of the trimmer.
3. Connect the power cables as shown in Figure 5-6.
5.0 Installation and Setup
11
Figure 5-6. Power Cable Connections
4. Now locate the yellow communication cable or cables coiled up inside the trimmer that are
labelled with the number that corresponds to the label on the Pile Feeder and Elevator near the
input connectors. They are small diameter cables with a 3-pin connector on the end.
5. Connect the communication cables as shown in Figure 5-7.
Figure 5-7. Comm. Cable Connections
6. Now locate the coiled-up line of blue air tubing with a red and white connector on the end that is
labelled with the numbers that correspond to the labels on the Pile Feeder, Elevator, and Tilt
Conveyor near the input connectors. Also locate any separate air tubing sections that may have
been supplied with the infeed/outfeed options.
7. Connect the air tubing as shown in Figure 5-8.
5.0 Installation and Setup
12
Figure 5-8. Air Tubing Connections
8. Continue the trimmer setup according to the installation instructions in the CMT trimmer
instruction manual.
6.0 Operation
13
6.0 Operation
6.1 Operating the Feeder
Figure 6-1 CMT TC Trimmer Screen
LOAD
On the CMT trimmer screen, press the Load button to send the Pile Feeder’s pusher back plate down
to the Loading Capacity Stop (see “Pile Size Adjustment” below), thus allowing books to be loaded.
The Load button on the screen turns green to show that it is loading.
FEED
Once books have been loaded on the Pile Feeder’s feed table, press the Feed button to begin
operation. Books will be pushed to the top of the feed table and stop. Once the trimmer is initialized
and ready, the feeder will deliver books to the trimmer. The Feed button on the screen turns green to
show that it is feeding. After all of the books have been fed, the pusher back plate will automatically
return to the Loading Capacity Stop.
STAND-BY MODE
Pressing the Feed button while it is green will put the feeder in stand-by mode. The Feed button will
turn yellow and the feeder will stop feeding books into the trimmer. To resume feeding, press the
Feed button again.
6.0 Operation
14
6.2 Load Capacity Adjustment
The distance that the pusher returns down the table can be adjusted by sliding the Adjustable
Loading Capacity Stop (Figure 6-2) up or down. Slide the block on the guide rod to stop the pusher
at the desired location.
Figure 6-2 - Adjustable Loading Capacity Stop
6.3 Adjusting the Tilt Angle of the Pusher Back Plate
Sometimes it is necessary to adjust the tilt angle of the pusher back plate when large stacks of books
become skewed due to the spines being the thickest part of the book. Adjust the tilt angle by turning
the hand wheel until the leading books are perpendicular to the feed table, as shown in Figure 6-3.
Figure 6-3 - Tilt Angle Adjustment of Pusher Back Plate
6.0 Operation
15
6.4 Using the Transition Conveyor Extension for Small Books in Multi-
Book Mode
When using the Pile Feeder in Multi-Book mode AND the starting book width is less than what is
shown in the chart below, it may be necessary to use the Transition Conveyor Extension.
Transition Conveyor Extension use chart
CMT-130 Model (Multi-Book Mode): Book Width Less than 6-3/4” (171 mm)
CMT-330 Model (Multi-Book Mode): Book Width Less than 9” (229 mm)
To install, open the access door and place the extension against the bar that is located at the end of
the transition conveyor (Figure 6-4). It should be placed such that the top surface of the extension is
parallel to the conveyor belt, and the tapered side of the extension is facing down.
Figure 6-4 - Transition Conveyor Extension
6.5 Single Book Feeding Through the Access Door (if equipped)
To feed a single book through the access door, first put the Pile Feeder in Stand-By mode by
pressing the Feed button on the TC screen until the button turns yellow. This will stop the Pile
Feeder from feeding books from the feed table and also lower the tilt conveyor to a level position.
Now open the access door, place the book on the conveyor, and close the door. Make sure that the
book dimensions are programmed properly in the trimmer and press the green start button to start the
trimmer. The trimmer will then call for the book to be sent, and the book will be fed into the trimmer.
6.6 Operating Tips
To ensure consistent operation, follow these guidelines:
Do not feed tape-bound books or stitched booklets.
6.0 Operation
16
Do not feed books with excessive nail-head (glue build-up) or rounded spines as shown in
Figure 6-5.
Figure 6-5 - Excessive Nail-Head and Rounded Spine
A small book block inside a large cover can result in a very distorted pile if many books are
loaded at one time. This can lead to more than one book feeding at a time. Either reduce
the number of books loaded onto the feed table, or make the cover and book block match
more closely before binding.
For best feeding results, adjust the tilt angle of the pusher back plate such that the leading
books are perpendicular to the feed table (see Section 6.3 Adjusting the Tilt Angle of the
Pusher Back Plate).
Use the Adjustable Loading Capacity Stop to customize the amount of books that can be
loaded onto the feed table (see Section 6.2 Load Capacity Adjustment). This can be a
timesaver in many cases.
To prevent corrosion of the pusher guide rod, occasionally place oil on a rag or paper towel
and rub it along the length of the guide rod.
To maintain the grip properties of the pusher conveyor belts, clean them with a moist cloth.
The grip properties of the belts help prevent slumping of large, slippery book piles.
7.0 Troubleshooting
17
7.0 Troubleshooting
The following table lists potential causes to operational problems:
Problem
Solutions
The machine does not operate.
Make sure that all cables are properly connected to the Pile
Feeder.
Check that the CMT Trimmer motor is running. If not, press
the trimmer’s green start button and wait for the trimmer to
initialize.
Make sure the Feed button on the trimmer’s touch screen is
green. If not, press the Feed button until it becomes green.
Make sure the access door is closed (if equipped).
Larger size books get caught on
tilt conveyor (last conveyor).
The transition conveyor extension is installed. Open the door
and remove the extension.
More than one book is fed at a
time (or more than two when
operating in multi-book mode).
Check to make sure the book drop sensor is on target with
the reflective tape. Readjust the sensor if necessary.
Books get lost in the Pile Feeder
by travelling over the top of the tilt
conveyor back-stop.
Check that the compressed air tube is properly connected to
the Pile Feeder.
Check the air tubing inside the Pile Feeder, making sure that
none of the air tubing is disconnected, pinched, or severed.
Check the flow control valves for the tilt conveyor. Make sure
the tilt conveyor is arriving at the up position in time.
More than the intended number of
books drop from the feed table
Adjust the tilt angle of the pusher back plate such that the
leading books are perpendicular to the feed table.
If the book pile is highly distorted or slumping, load fewer
books onto the feed table.
8.0 Part Lists and Wiring Diagrams
18
8.0 Part Lists and Wiring Diagrams
8.1 Main Assembly 130 Model, 58500TCA (1/9) Side Frames
8.0 Part Lists and Wiring Diagrams
19
ITEM PART NO. DESCRIPTION QTY
1 47171-1 BRACKET - CLAMP PROX 1
2 51036 FOOT 4
3 56025-1 REGULATOR W/ GAUGE AND BRACKET 1
4 56456 THREADED ROD - 1/2-13 X 5 4
5 56805 CASTER 4
6 58004-1 LOWER CROSS BRACKET 2
7 58006 CROSS BRACKET - ELEC PANEL 1
8 58501 SIDE FRAME- RH 1
9 58502-1 SIDE FRAME- LH 1
10 58503 HINGE MOUNTING BRACKET 1
11 58504 BEARING BLOCK SUPPORT 1
12 58539 TIE BAR 3
13 58542 TIE BAR- POWER PANEL 1
14 58546 TIE BAR 1
15 A-11074-2 FOOT - RUBBER 4
16 E-3505 'CAN' CABLE JUMPER 1
17 EE-3460-3 PLUG ASM. - MALE, 'CAN' REF
18 EE-3460-4 PLUG ASM. - FEMALE, 'CAN' REF
19 EE-3515 ELECTRICAL PANEL ASSEMBLY 1
20 EE-3533-4 PROX. ASM.- TILT CONVEYOR DOWN "T" REF
21 EE-3550 PLUG ASM. - MALE, INCOMING POWER REF
22 H-6417-6 NUT - 3/8-16 HEX 2
23 H-6423-4 NUT - 1/4-20 HEX KEP 6
24 H-6423-#10 NUT - #10-24 HEX KEP 2
25 H-6424-8 NUT - 1/2-13 HEX JAM 4
26 H-6910-102404 SCREW - #10-24 X 1/2 BUT HD 2
27 H-6910-405 SCREW - 1/4-20 X 5/8 BUT HD 2
28 H-6910-406 SCREW - 1/4-20 X 3/4 BUT HD 4
29 H-6910-506 SCREW - 5/16-18 X 3/4 BUT HD 22
30 H-6910-606 SCREW - 3/8-16 X 3/4 BUT HD 8
31 H-6918-102404 SCREW - #10-24 X 1/2 SOC HD 2
32 H-6918-406 SCREW - 1/4-20 X 3/4 SOC HD 16
33 H-6918-612 SCREW - 3/8-16 X 1-1/2 SOC HD 2
34 H-7321-4 WASHER - 1/4 SAE PLAIN 2
35 H-7321-#10 WASHER - #10 SAE PLAIN 4
36 H-7327-10 WASHER - 5/16 MEDIUM LOCK 22
37 H-7327-12 WASHER - 3/8 MEDIUM LOCK 10
38 H-7327-8 WASHER - 1/4 MEDIUM LOCK 16
39 H-7327-#10 WASHER - #10 MEDIUM LOCK 2
40 P-503-402 ELBOW-1/4 TUBE X 1/4 NPT 2
41 P-515 PUSH-IN CONNECTOR (1/4 FEM PASS-THRU) 1
42 S-1781-15 LABEL - MOVING PARTS HAZARD 1
8.0 Part Lists and Wiring Diagrams
20
8.2 Main Assembly 130 Model, 58500TCA (2/9) Tilt Conveyor
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Challenge CMT-130, CMT-130TC 2016 Instruction and Parts Manual

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