Challenge CMT Accessory 2016 Book Pile Feeder 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

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

Qty.

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)

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)

Maximum Book Thickness

2” (51 mm)

Pile Feeder Dimensions

Overall Width

20-3/4” (53 cm)

Overall Height

53-3/4” (137 cm)

55-3/4” (142 cm)

Overall Depth

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 Accessory 2016 Book Pile Feeder Manual

Challenge CMT Accessory 2016 Book Pile Feeder Manual

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