Challenge CHAMPION 305 TC Instructions And Parts Manual

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 inj ury!

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

6125 Norton Center Drive

Norton Shores, MI 49441-6081 USA

ChallengeMachinery.com

F.254-J

May 2014

CHAMPION 305 TC

Instruction and Parts Manual

Serial Numbers 1301701 & Up

Sold and Serviced by

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 safe ty 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 the precautions and instructions given. If after reading the manual questions still remain, contact your Authorized Challenge Dealer.

FOR PARTS AND SERVICE, contact the Authorized Challenge Dealer from whom you purchased the machine. Use the illustrations and parts lists at the back of this manual to identify the correct parts needed. Always give the SERIAL NUMBER and MODEL of your machine to insure the correct parts are sent as soon as possible.

RECORD YOUR MACHINE SERIAL NUMBER in the space provided on the front cover of this manual. 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 49441.

CHALLENGE MODEL SERIAL NUMBER ATTN COMPANY

ADDRESS CITY STATE/PROVINCE ZIP PHONE DATE INSTALLED DEALER NAME & CITY

* WARRANTY INFORMATION *

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.

The Challenge Machinery Company • 6125 Norton Center Drive • Norton Shores MI 49417

Challenge® is a registered trademark of

1.0 Introduction

TABLE OF CONTENTS

1.0 Introduction ...................................................................................................................................... 2

2.0 Safety............................................................................................................................................... 5

2.1 Precautions.................................................................................................................................. 5

2.2 Power Lockout Procedure ........................................................................................................... 5

2.3 Warning Label Definitions............................................................................................................ 6

3.0 Packing List...................................................................................................................................... 8

4.0 Specifications................................................................................................................................... 9

5.0 Footprint......................................................................................................................................... 10

6.0 Installation & Setup........................................................................................................................ 11

6.1 Inspecting Shipment.................................................................................................................. 11

6.2 Uncrating ................................................................................................................................... 11

6.3 Lifting/Moving Instructions......................................................................................................... 11

6.4 Cleaning..................................................................................................................................... 12

6.5 Assembly ................................................................................................................................... 12

6.6 Hydraulic Power Unit Removal.................................................................................................. 13

6.7 Hydraulic Check......................................................................................................................... 13

6.8 Power Hook-Up ......................................................................................................................... 14

7.0 Operation ....................................................................................................................................... 16

7.1 False Clamp Plate ..................................................................................................................... 16

8.0 Knife Installation/Changing............................................................................................................ 18

8.1 Knife Removal ........................................................................................................................... 19

8.2 Knife Installation ........................................................................................................................ 20

8.3 Knife Care Tips.......................................................................................................................... 22

8.3.1 Knife Blade Life.................................................................................................................. 22

8.3.2 Cutting Stick ....................................................................................................................... 23

8.3.3 Bevel Angle ........................................................................................................................ 23

8.3.4 Helpful Suggestions ........................................................................................................... 23

8.3.5 Knife Care .......................................................................................................................... 23

Maintenance Section ......................................................................................................................... 25

9.0 Cleaning......................................................................................................................................... 26

9.1 Table.......................................................................................................................................... 26

9.2 Console...................................................................................................................................... 27

9.3 Machine Frame.......................................................................................................................... 27

10.0 Lubrication.................................................................................................................................... 28

11.0 Hydraulic System......................................................................................................................... 31

11.1 Recommended Hydraulic Oil................................................................................................... 31

11.2 Changing the Oil...................................................................................................................... 31

11.3 Hydraulic Valve Adjustments................................................................................................... 32

12.0 Adjustments ................................................................................................................................. 37

12.1 Electric Eye Alignment............................................................................................................. 37

12.2 Backgauge Gib Adjustment..................................................................................................... 38

12.3 Squaring the Backgauge ......................................................................................................... 39

12.4 Backgauge Position Accuracy Adjustment.............................................................................. 40

12.5 Knife Latch Adjustment............................................................................................................ 41

12.6 Line Light Adjustment (Incandescent Type)............................................................................ 42

12.7 Line Light Adjustment (LED Type)...........................................................................................43

12.8 Proximity Switches................................................................................................................... 44

12.9 Clamp Return Speed Adjustment............................................................................................ 46

12.10 Pre-Clamp Pressure Adjustment........................................................................................... 46

12.11 Pre-Clamp Speed Adjustment............................................................................................... 47

1.0 Introduction

12.12 Clamp Cylinder Adjustment (Clamp Height)..........................................................................48

12.13 Clamp Parallel Rod................................................................................................................48

12.14 Lead Screw Adjustment Nuts.................................................................................................49

12.15 Knife Bar Gibs........................................................................................................................50

13.0 Repair and Replacement..............................................................................................................51

13.1 Fuses........................................................................................................................................51

13.2 Knife Cylinder Replacement.....................................................................................................51

14.0 Troubleshooting............................................................................................................................54

15.0 Schematics & Parts Lists..............................................................................................................58

15.1 Main Assembly – Frame/Tank .................................................................................................58

15.2 Main Assembly – Hydraulics....................................................................................................60

15.3 Main Assembly – Clamp ..........................................................................................................62

15.4 Main Assembly – Final Wiring..................................................................................................64

15.5 Main Assembly – Electrical Components, Lower Front ...........................................................66

15.6 Main Assembly – Electrical Components, Upper.....................................................................68

15.7 Main Assembly – Air Table ......................................................................................................70

15.8 Main Assembly – Table Mounting............................................................................................72

15.9 Main Assembly – TC Backgauge.............................................................................................74

15.10 Main Assembly – Knife...........................................................................................................76

15.11 Main Assembly – Covers and Labels.....................................................................................78

15.12 Main Assembly – Table Extensions.......................................................................................80

15.13 Power Panel Assembly..........................................................................................................82

15.14 Basic Machine Schematic......................................................................................................86

15.15 Interconnection Diagram........................................................................................................87

15.16 Hydraulic Manifold Kit ............................................................................................................88

15.16.1 Knife Down Sequence Valve Assembly..........................................................................89

15.16.2 Hydraulic Manifold Assembly..........................................................................................90

15.17 Hydraulic Schematic ..............................................................................................................92

15.18 TC Control Console Assembly...............................................................................................93

15.19 Electric Eye Assembly............................................................................................................94

15.20 Cut Button Assembly – Standard...........................................................................................96

15.21 Cut Button Assembly – ErgoTouch........................................................................................97

15.22 Knife Latch Assembly.............................................................................................................99

15.23 Line Light Assembly.............................................................................................................100

15.24 Compressor Assembly.........................................................................................................101

15.25 Air Table Blower Assembly..................................................................................................102

15.26 Encoder Cable Assembly.....................................................................................................103

15.27 Power Panel Connection Procedure Label..........................................................................104

15.28 Warning Label......................................................................................................................105

15.29 Paper Deflector Kit (Option).................................................................................................106

15.29.1 Deflector & Shaft Assembly (Part of Paper Deflector Kit).............................................107

16.0 Safety System Tests...................................................................................................................109

2.0 Safety

2.1 Precautions

• This machine is designed for one-person operation. Never operate the machi ne with more than one person.

• Safe use of this machine is the responsibility of the operator. Use good judgment and common sense when working with and around this machine.

• Read and understand all instructions thoroughly before using the machine. If questio ns remain, contact the dealer from which you purchased this machine. Failure to understand the operating instructions may result in personal injury.

• Only trained and authorized people should operate this machine.

• Do not alter safety guards or devices. They are for your protection. Severe personal injury may

result.

• Disconnect power before cleaning or performing maintenance. See Section 2.2 Power Locko ut Procedure.

• Observe all caution labels and plates on this machine.

• Be sure the cutter is properly grounded.

• Be sure there is sufficient power to operate the cutter properly.

• Keep foreign objects off the table and away from cutter blade.

• BE EXTREMELY CAREFUL when handling and changing the cutter knife. Severe lacerations or

dismemberment could result from careless handling procedures.

• Keep the floor around the cutter free of trim, debris, oil and grease.

• When replacing hydraulic parts, loosen the connections slowly to release pressure. Never loosen

connections with the machine running.

• If the cutter sounds unusual or operates abnormally, turn it off and consult the troubleshooting section of this manual. If the problem cannot be corrected, have it checked by a qualified service person.

• CRUSH HAZARD, keep hands and fingers from under the clamp while clamping. Use Jogging Aid to load paper, and use the backgauge to push paper out before unloading. DO NOT REACH

UNDER THE KNIFE AND CLAMP AREA!

2.2 Power Lockout Procedure

For maximum safety when making adjustments or repairs to your machine, be sure to lock out the main power control switch to which the machine is connected. The switch should be moved to the OFF position and a padlock placed in the loop. The person servicing the machine should h old the key.

Figure 1

2.0 Safety

2.3 Warning Label Definitions

The following warning labels are found at various locations on your machi ne. Read and understand the meaning of each symbol. If a label is lost from the machine, it should be replaced. The item number and location of each label can be found in Section 15.0 Schematics and Parts List.

HAZARDOUS AREA

Disconnect power before cleaning, servicing, or making adjustments not requiring power. Do not alter safety guards or devices; they are for your protection. Replace all guards. Do not operate with any guards removed.

SHOCK HAZARD Disconnect power before removing cover. Replace cover before operation.

SHOCK HAZARD

Disconnect power before removing cover. Replace cover before operation.

SINGLE OPERATOR

Do not operate with more than one person.

2.0 Safety

!OJO!

This Este simbolo de alerta de seguridad significa ¡ OJO ! INSTRUCCIONES DE SEGURIDADPERSONAL. Lea las instrucciones porque se refieren a su seguridad personal. Fall de obedecer las instrucciones que siguen podria resultar en lesiones corporales.

• Esta maquina, junto con sus mecanismos de seguridad, esta disenada para ser manejada por

• UNA SOLA PERSONA a la vez. Jamas debe ser manejada por mas de una persona al mismo

• tiempo.

• La seguridad es la responsabilidad del operario que usa esta maqu ina.

• LEA DETENIDAMENTE el manual de instrucciones y las PRECAUCIONES DE SEGURIDAD

antes de poner a funcionar la cortadora. Pidale a su supervisor una copia.

• El manejo de la guillotina debe estar exclusivamente a cargo de personal entrenado y autorizado

para ello.

• NO MODIFIQUE LOS MECANISMOS DE SEGURIDAD, estan ahi para su proteccion no deben

ni modificarse ni quitarse.

• DESCONECTE LA CORRIENTE ELECTRICA antes de proceder a hacerle servicio de limpieza,

engrasar, o de hacer adjustes que no requieren corriente. Trabe el interruptor en la posicion OFF (apagado); vea “Procedimiento para cortar la corriente electrica” al pie de esta pagina.

• Eche llave a la guillotina y quite la llave cuando la maquina no esta en operacion; vea “Corriente

electrica”.

• Asegurese de que la guillotina este debidamente a tierra. Vea “Conexion de la fuerza electrica”.

• Verifique el voltaje y asegurese de que este sea suficiente para el debido funcionamiento de la

guillotina.

• Preste atencion a todas las placas con advertencias instaladas en esta guillotina.

• No permita que objetos estranos esten en la mesa o cerca de la cuchilla cortadora.

• TENGA SUMO CUIDADO al tocar y cambiar la cuchilla. Heridas severas y hasta

desmembramiento pueden resultar del manejo sin cuidado o negligente.

• El suelo alrededor de la guillotina debe mantenerse despejado y libre de recortes, desperdicios,

aceite y grasa.

• Al haber la necesidad de reemplazar partes hidraulicas, afloje todas las conexiones poco a poco

para dejar escapar la presion. Jamas debe aflojarse conexiones mientras la maquina este

• andando.

• Si la guillotina empezara a sonar o trabajar diferentemente a lo acostumbrado, desconectela y

consulte la seccion “Troubleshooting” (Reparador) de este man ual. Si no es posible corregir el problema, llame a su servicio autorizado para que le examinen la maquina.

• PELIGRO DE MACHUQUE - Mantenga manos y dedos fuera de la agarradera mientras sujeta el

papel. Use el calibrador trasero y su rueda de mano para empujar el papel cortado. NO PONGA

SUS MANOS BAJOLA CUCHILLA O AREA DE LA AGARR ADERA.

• NO OPERE SIN LAS GUARDAS PROTECTORAS!

¡ OJO ! PRECAUCION - Como proceder para desconectar la corriente electrica.

Para maxima seguridad durante ajustes y reparaciones de su maqu ina, verifique bien qu e el interruptor princi pal de control de corriente al cual la maquina esta con ectada, este d esconectado. El interru ptor deba ser puesto e n la posicion “OFF” (desconectado) y se debe poner un candado en la anilla. La llave del candado debe ser guardada por la persona que estara efectuando los trabajos de servicio o de reparacion en la guillotina.

Desconecte la corriente electrica antes de proceder a hacer cualquier ajust e o reparacion o de efectuar el engrase en cualquier maquina.

3.0 Packing List

Part No. Description Qty.

Basic Machine 1

Extension Side Tables:

47166 18 x 24 Steel Side Table 2 47164-1 Side Table Back Plate 2 H-6913-606 Side Table Bolts 8 H-6424-6 Side Table Hex Nuts 8 H-6939-616 Leveling Screws 4 H-6913-6008 Side Table Mounting Bolts (shipped installed) 4 H-7321-6 Side Table Mounting Washers (shipped installed) 4 47006-2 False Clamp Plate (shipped installed) 1 47508 Knife – HSS 2 H-6918-608 Knife Bolts 6 8815 Knife Washers, Special 6 4171 Cutting Sticks (one installed) 4 47575 Knife Lifter Assembly 1 A-12608-4 Jogging Aid 1

Tool Kit:

5064 Cutting Stick Puller 1 W-164 Hex “T” Wrench 1 W-158 5/16 Open End Wrench 1 W-141 1/8” 1 W-137 5/32” 1

Fuses:

E-889-35 1 Amp S.B. 1 E-2330-5 3.15 Amp S.B. 1 E-2308 3.2 Amp S.B. 1 E-889-5 4 Amp S.B. 1 E-2330-7 5 Amp S.B. 1 E-2330-8 6.3 Amp S.B. 1 E-889-9 8 Amp S.B. 1

4.0 Specifications

Description Inch Units Metric Units

Cutting Width 30 ½” 77.5 cm Clamp Opening 4” 10.2 cm Clamping Force 400-5000 lbs. 1.8 – 22 kN Minimum Cut – Standard ¾” 1.9 cm

- Special ½” 1.3 cm

- w/ False Clamp Plate 2” 5.1 cm Table Space Front: (std.) Back:

Dimensions

Table Height 36 ½“ 92.7 cm Overall Height 58 ½” 148.6 cm Overall Length 69 ½” 176.5 cm Overall Width 48 ½” 123 cm w/ Side Tables 78 ½” 200 cm w/o Side Tables 48 ½” 123 cm Approx. Net Weight 2550 lbs 1157 kg Approx. Shipping Weight 2750 lbs 1247 kg Will pass through door: Assembled 49” 125 cm Table/treadle out 42” 112 cm Table/treadle/pwr unit out 24-1/2” 63 cm

Electrical

Standard: 5 HP, 3 Phase, 60 Hz AC; 208/230V, 25 Amps (Service size: 40 Amps) Optional Phase Converter Kit: K-3482 (1 Phase, 208/230V, Service size: 50 Amps)

Optional: 5 HP, 3 Phase, 60 Hz AC; 460V, 11.5 Amps (Service size: 20 Amps) Optional: 5 HP, 3 Phase, 50 Hz AC; 380/415V, 10 Amps (Service size: 20 Amps)

Electric Eyes – Response time = 68 ms Object detection capability = 12 mm

Challenge reserves the right to make changes to any product or specification without notice and without incurring responsibility to existing units.

25”

30 ½”

63.5 cm

77.5 cm

5.0 Footprint

6.0 Installation & Setup

6.1 Inspecting Shipment

This machine has been carefully packed to prevent damage during shipment. However, claims for damage or loss are the responsibility of the recipient. Inspect all shipments as soon as they are received. If there is any noticeable damage, note it on the freight bill. Visual and/or hidden damage 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 box against the packing list on page 8. Make sure there are no missing items.

6.2 Uncrating

This machine is lagged to a wood skid and covered with a triple-walled corrugated container. Loosen the flaps of the carton where they are attached to the skid. When loose, the carton can be lifted straight up. Remove the side tables and accessory box, which are also attached to the skid. Place the cutter/skid about where the machine will be positioned and remove the lag screws from the skid.

6.3 Lifting/Moving Instructions

Unpacking, handling, and positioning should be done by professional riggers. If handling or unpacking is a problem, your dealer or a local trucking facility should be able to supply or recommend a qualified rigger. This 2550-lb/1157-kg machine should be moved with experienced peo ple and the proper equipment. Do not risk personal injury or damage by attempting to move machinery with inadequate equipment or manpower.

Lifting straps may also be used to lift the machine by placing the straps around the front and rear of the table. When straps are used in this way, wood blocks must be placed beside the lead screw to prevent damage, (Figure 2). A bent lead screw will cause the backgauge to bind.

Figure 2

The backgauge should be positioned all the way to the front of the table and straps placed as close the machine body as possible. Gently lift the cutter, remove the skid and carefully place the cutter on the floor.

Once the machine is off its skid, it can be moved with a forklift or pallet jack from the front. DO NOT attempt to lift the machine from the sides or rear.

6.0 Installation & Setup

6.4 Cleaning

Wipe down the table and bare metal surfaces with a non-flammable solvent such as CRC or blanket wash. The table surface is cast iron, and it will rust if left unprotected. Coat the table with a nonabrasive wax. A Cutter Care Kit, p/n 16077, with cleaner and wax, is available through your Authorized Challenge Dealer. The protective film on the console may be removed. Never clean console with petroleum based solvents – damage will result.

6.5 Assembly

Unless otherwise specified, the only items that have been disassembled for shipping are the knife, extension tables, and reach-around shields on the electric eyes. Knife installation instructions are found in Section 8.0 Knife Installation/Changing. Extension table and reach-around shield attachment instructions are as follows:

NOTE: Extension tables are heavy. Use two people to attach them to the machine.

1. Assemble the back plates to the extension tables. The extension table bolts and hex nuts are packed in the tool kit box. Install the back plates such that the half-circle notch at the top of the plates go toward the center of the cutter. These notches provide clearance for adjusting the lower knife gib bolt.

2. One person should hold the extension table in position while the other aligns the holes and starts threading the mounting bolts with washers. The mounting bolts are shipped installed in the side of table- remove them to install tables.

3. Use a 9/16” socket and extension to snug tighten the mounting bolts, then tap the extension table up or down with your hand or a rubber mallet until it is flush with the main table. Run a straight edge or sheet of paper over the seam to check the fit. Make sure your stock will not catch on the seam.

4. Insert the leveling setscrews into the threaded holes next to the mounting bolts. You may have to loosen the mounting bolts slightly to allow enough play to level the table. After the extension tables are leveled and the surface joints even, tighten the mounting bolts securely.

5. The extension tables are powder-coated and need only be wiped down with a dry cloth. DO NOT apply solvents or abrasive cleaners to extension table surfaces. They may cause discoloration or scratches.

NOTE: The reach-around shields for the electric eyes are in their shipping positions – follow the instructions below to secure them in their operational position.

1. On the bottom of the electric eye housing, loosen (but do not remove) the screw furthest back (closet to the machine frame) on each side.

2. On the bottom of the electric eye housing, loosen and remove the front two screws. Now rotate each shield back and to the side – away from of the cut area. Line up the front holes and re-install the front two screws. Tighten all screws (See the instruction sheet included in the shipping material for more details).

ATTENTION POTENTIAL CRUSH/LACERATION HAZZARD – THE SHIELDS ARE THERE FOR YOUR SAFETY.

: FAILURE TO INSTALL THE REACH-AROUND SHIELDS COULD CAUSE A

6.0 Installation & Setup

6.6 Hydraulic Power Unit Removal

If installation requires that the machine pass through a doorway that is less than 49” but greater than or equal to 42” wide, the machine should have been ordered from Challenge “knocked down” with the table removed. If the machine must fit through a doorway that is less than 42” and greater than or equal to 24-1/2”, the hydraulic power unit must be removed on-site. To remove the hydraulic power unit, follow the instructions below.

1. Disconnect the electrical conduits to the hydraulic motor, air blower, and hydraulic cooling fan, junction box.

2. Remove the filler cap and use a transfer pump to remove the hydraulic fluid into buckets.

3. Locate the hose that connects the manifold to the oil filter. Disconnect it from the filter. Disconnect the hydraulic pump hose from the manifold. Attach the hose that was connected to the manifold to the oil filter. Attach the hose that was connected to the filter to the manifold. This will minimize oil leakage. After the unit is installed, reconnect the hoses to their original location.

4. Remove the (4) bolts that attach the hydraulic assembly to the cutter base. They are located at the bottom shelf the base.

5. USE EXTREME CAUTION WHILE REMOVING THE POWER UNIT. It is very heavy and should be removed using a fork truck. CAUTION, the machine will be top heavy and may tip easily with the power unit removed. Move the reservoir through the doorway on its side.

6. DO NOT ATTEMPT TO LIFT THE CUTTER BY PLACING STRAPS OR THE FORKS OF A TRUCK UNDER THE CLAMP. This can damage the machine.

7. Reinstall the power unit, conduits, hoses, after the machine is in position. Refill the hydraulic reservoir.

6.7 Hydraulic Check

The hydraulic reservoir is filled with 13-1/2 gallons of ISO VG 46 hydraulic oil at the factory. The fluid level should be checked during installation, and at least once per week during normal operation. The reservoir is located behind the cutter, beneath the table (Figure 3). The hydraulic tank has a sight gauge in the rear for checking the oil level. The reservoir should be kept full at all times.

Filler

Cap

Sight Gauge

Hydraulic Tank

Figure 3

NOTE: DO NOT OVERFILL. Overfilling may cause leakage when the machine is hot.

6.0 Installation & Setup

6.8 Power Hook-Up

For satisfactory operation, be sure that your cutter is wired for the correct phase and voltage and has adequate power. The correct electrical specifications for your machine are shown on the serial plate. Check the machine serial plate before connecting the power. For future reference, transfer this information to the front cover of this manual.

Watch Setup Voltage- Inadequate power to the cutter can be a major source of problems. Too many machines on the same circuit will reduce the power to each machine. Inadequate voltage will cause overheating, loss of power, and in extreme cases, failure to operate. Test line voltage when the shop is at actual working levels. Challenge recommends a dedicated line with a lockable disconnect to provide adequate power for this machine.

CAUTION: SHOCK HAZARD! Always disconnect power at main

power panel before working on the cutter. Lock it out to prevent accidental power up. (See Power Lockout Procedure page 5).

Important: You must have an adequate size circuit and heavy enough wiring for this machine. The circuit size should be a minimum of 20% greater than the amperage rating on the machine nameplate. If a wire is run over 75 feet (23 meters), the next size wire should be used. Check local electrical codes.

Electrical Specifications for Champion Cutters

Volts Amps Phase Hz Circuit Size Wire Size Metric Wire

208/230V 25A 3 PH 60 Hz 40A #8 AWG 4mm sq.

460V 11.5A 3 PH 60 Hz 20A #12 AWG 10mm sq.

380/415V 10A 3 PH 50 Hz 20A #12 AWG 10mm sq.

The power source is connected to the cutter through the bottom of the power panel (right hand side). Hook-up procedure:

1. DISCONNECT AND LOCK OUT THE POWER at the main panel to prevent accidental powe r up. (See Power Lockout, page 5).

2. Thread the power cord through a conduit connector into the power panel.

3. Fasten the ground lead to the ground terminal lug (Figure 4).

6.0 Installation & Setup

Figure 4

4. Fasten the three power leads to the three terminals of the main power terminal block- L1, L2, & L3.

5. Close the electrical panel doors and latch them. Unlock the main panel and turn on the power. Turn on the main power disconnect switch located on the front face of the table.

6. Press both cut buttons simultaneously to activate the motor and check to make sure it is turning the same direction as the arrow on the motor casing. If it is not turning the proper direction, disconnect the power and exchange any two leads of the power cord as in Figure 5.

31 2

Figure 5

7.0 Operation

IMPORTANT: DO NOT ATTEMPT TO OPERATE YOUR CUTTER UNTIL YOU HAVE THOROUGHLY READ AND UNDERSTAND ALL OF THE INSTRUCTIONS FOUND IN THE OPERATOR AND INSTRUCTION MANUALS INCLUDED WITH YOUR CUTTER. CALL YOUR AUTHORIZED CHALLENGE DEALER IF YOU STILL HAVE ANY QUESTIONS.

Complete operating instructions for all TC Model paper cutters can be found in the TC Touch Screen Control Operating Instructions manual that was included with your machine (Fig ure 6). If you do not have a copy, or to download the latest version, visit: www.challengemachinery.com/support

Figure 6

7.1 False Clamp Plate

To prevent marking on pressure sensitive jobs, a false clamp plate has been included (installed) with your machine. This plate attaches to the bottom of the clamp. It is secured from the front of the cutter with three set screws.

ALWAYS disconnect the power and LOCK IT OUT before installing or removing the false clamp plate. NEVER attempt to install or remove the false clamp plate while the machine is running. Remove all tools and stand clear when recon necting power.

7.0 Operation

To install:

1. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout, page 5.)

2. Position the false clamp plate under the clamp, (Figure 7). The locator pegs are positioned to the rear of the cutter and are set into holes in the bottom of the clamp.

1/8” Allen

Wrench

Set

Screws

Locator

pegs

Figure 7

3. With a 1/8" Allen wrench, back off the setscrews in front of the clamp and raise the plate up to the bottom of the clamp. It may be necessary to bring the clamp down onto a stack of paper with the foot pedal in order to access the far left setscrew. Raise the false clamp plate evenly or it will have a tendency to bind. When the plate has been raised into position and is flush with the bottom of the clamp, tighten the setscrews to hold the plate in position.

4. Make sure that all tools have been taken off the cutter table, reconnect the power, and turn on the machine.

NOTE: The backgauge will not move to a position less than 2" (51 mm) when the false clamp plate is installed in the clamp.

When the false clamp plate is not in use, store it on top of the cutter, with the locator pegs inserted into the 3 holes in the top cover. There is a sensor inside one of these holes that detects when the false clamp plate is on top of the machine, thereby informing the machine that the false clamp plate is not installed in the clamp. This allows the backgauge to be positioned less than 2” (51 mm), which it will not do when the false clamp plate is installed in the clamp.

8.0 Knife Installation/Changing

Changing knives can be very dangerous unless safety precautions are

observed and extreme care is taken when handling knives.

• Make sure knife lifters are properly installed, see instructions following.

• Keep handling of unprotected knives to an absolute minimum.

• Clear off cutter table before removing knife.

• Have scabbard on cutter table and insert knife immediately.

• Warn people of any unprotected knife.

• Knife changing is a ONE PERSON OPERATION. Having more than one person trying to

change knives invites accidents.

P/N: 47575

Figure 8 – Knife Changing Equipment

The knife changing equipment shown in Figure 8 is included in the cutter tool kit. The following instructions show how to remove and install a new or re-sharpened knife. Read these instructions AT LEAST ONCE before attempting to actually change or install any blades.

Figure 9

8.0 Knife Installation/Changing

8.1 Knife Removal

1. Clear the cutter table. Place chipboard directly under the knife to prevent nicking if the blade hits the table. On the TC touch screen menu choose “MAINTENANCE” and then “KNIFE CHANGE”. Select “Knife Adjust Mode” then press and hold both cut buttons until the knife and clamp reach the table. Now release the buttons (the knife and clamp should stay down ).

2. DISCONNECT THE POWER AND LOCK IT OUT, (See Power Lockout Procedure on pg. 5).

3. If equipped with the paper deflector option, lock it down by screwing the lock knob all the way in (Figure 10).

Lock Knob

(Paper Deflector

Option Only)

Figure 10 – Paper Deflector Locking Knob

4. Back off the knife adjusting screws on the top of the knife bar, (Figure 11), as far as they will go (counter-clockwise). A new knife will cut deeper than a knife that has been ground several times. If the adjusters are not backed off, damage can result to the new knife and/or the cutting stick.

Adjusting Screws

Knife

5. Restore power to the machine and turn it ON. Follow the prompts on the screen to raise the knife and clamp.

Figure 11 – Knife Adjusting Screws

8.0 Knife Installation/Changing

6. DISCONNECT THE POWER AND LOCK IT OUT, (See Power Lockout Procedure on pg. 5).

7. Remove the bolts in the two slotted holes of the knife bar and insert the knife lifter by screwing in the two knife lifter handles. Tighten the handles enough to hold the blade in place. Remove the remaining four bolts (Figure 12). The leftmost bolt must be removed while the knife bar is “UP”.

Figure 12

8. Clear the table and put the empty knife scabbard on the table.

DANGER: Used knives are heavy and still very sharp. Be careful to keep the edge away from your body and keep other people out of the area while handling the blade. Severe lacerations and dismemberment could result from careless handling procedures.

9. Grasp the knife lifter handles firmly while turning counterclockwise to release the knife from

the knife bar. Slowly lower the knife down and to the right. Bring the left side out first.

10. Place the knife with attached lifter on top of the scabbard. Remove the lifter and slide the

knife into alignment with the scabbard screw holes. DO NOT FORGET TO INSTALL THE SCABBARD SCREWS!

11. Send the dull knife to the grinder.

8.2 Knife Installation

1. Use the cutting stick puller, (Figure 13), to remove the cutting stick. Turn the cutting stick to a

new surface.

Figure 13

8.0 Knife Installation/Changing

2. Check to make sure the paper deflector is locked down (Figure 10, page 19). Also check that the knife adjusting screws have been backed out, (Figure 11, page 19).

3. Place the new knife scabbard on the cutter table.

4. Remove the knife retainer screws.

5. Place your fingers along the top edge of the scabbard and your thumbs in the holes in the knife.

6. Pull the knife up in its scabbard until the bevel is exposed.

7. Place the lifter on top of the knife and insert the knife lifter handles into the corresponding knife bolt holes (use the lowest holes) and thread the handles into the knife until they touch the scabbard. Then back the handles off 1/2 turn.

8. Grasp the knife lifter handles, lift the blade, and insert the blade into the knife bar slot. Slowly guide the blade into the cutter right end first, then bring the left end in parallel to the knife bar. Raise the knife into the knife bar slot as high as it will go. Tighten the handles firmly to hold the knife. An installed lifter is shown in Figure 14 below.

Figure 14

NOTE: If the blade will not go in, either the handles are screwed into the blade too far or the blade is not centered over the table, and the end of the blade is hitting the end stop in the knife bar.

9. Insert the rest of the knife bolts and washers, snug tighten them, but don’t tighten completely. Be sure all bolts have washers. The correct washers are important for proper bolt clearances!

10. Remove the knife lifter and insert the remaining two bolts and washers and snug tighten.

11. Place paper across the table to cover the cutting stick.

12. Restore power to the machine and turn it ON. Follow the prompts on the screen to preset the backgauge. Then choose “MAINTENANCE” and then “KNIFE CHANGE”. Select “Knife Adjust Mode” then press and hold both cut buttons until the knife and clamp reach the table. Now release the buttons (the knife and clamp should stay down).

13. DISCONNECT THE POWER AND LOCK IT OUT, (See Power Lockout Procedure on pg. 5).

14. Turn the knife adjusters down (Figure 11, page 19) a little at a time, until the blade cuts through the paper evenly over the entire length of the stick. Be sure the blade is parallel to

8.0 Knife Installation/Changing

the cutting stick, or one end may cut deeper than the other, causing uneven wear on the stick.

15. Tighten all the bolts and release the paper deflector.

16. Restore power to the machine and turn it ON. Follow the prompts on the screen to raise the knife and clamp, and then to preset the backgauge.

17. Make a test cut through a full lift of stock. Make minor adjustments by loosening the bolts and repeating steps 9 through 11.

NOTE: If the knife ends cut but the middle does not, you could have dips or uneven spots in either the knife or the cutting stick. These can be eliminated to some extent by laying 1/2" (13mm) strips of paper beneath the cutting stick to shim it up.

8.3 Knife Care Tips

! KNIFE SAFETY ! Knives are DANGEROUS!!! They are heavy and very sharp, even after use. Keep the edge away from your body and keep the area clear of others when handling knives. Never touch the cutting edge! To prevent personal injury and damage to the knife, always keep knives in their holders with screws tightened. You are aware of the dangers, but others may not be. Never attempt to hone, polish, or service the knife in any way. Failure to follow safety procedures may result in severe lacerations or dismemberment.

8.3.1 Knife Blade Life

Knife blade life, or the time between sharpenings, can be affected by many factors. One important factor is the type of paper being cut. Abrasive paper, such as recycled paper, soft paper such as newsprint paper, and bound books can all significantly shorten knife blade life. Also, if the knife depth is set too deep, the knife will cut too deep into the cutting stick and can dull the knife blade.

A knife can last between 2,000 and 5,000 cuts before it needs to be sharpened. Cutting soft paper (such as newsprint paper) or paper with high post-consumer recycled content ca n cause the knife to need sharpening after only 2,000 to 3,000 cuts. Cutting pure paper, such as bond pape r with no recycled content, or hard paper can allow the knife to be used for as many as 5,000 cuts before it needs to be sharpened. In all cases, the operator should continually check the quality of the cut to determine when the knife blade needs to be sharpened. Some characteristics that indicate a blade needs sharpening are:

• The knife hesitates or stalls while making a cut.

• The sheets are not all cut to the same length (usually the top few sheets are longer than the

rest of the sheets - this is sometimes called “draw”).

• Cut marks appear on the cut face of the paper.

• The profile of the cut (side view) is not perpendicular to the table.

• The cut does not appear straight when viewed from the top.

• The knife makes a “rougher” sound as it passes through paper.

• Nicks are visible on the cutting edge of the knife.

8.0 Knife Installation/Changing

8.3.2 Cutting Stick

A worn cutting stick can affect the cut quality of the bottom sheets. When this happens, the cut stick can be rotated. Usually, the stick should be rotated one or two times between knife sharpenings.

There are 8 possible cut stick positions. The stick can be rotated 4 times, and then turned en d to end, and rotated 4 times again.

8.3.3 Bevel Angle

Challenge recommends that bevel angles for the Champion 305 knives be in the range of 21° to 23°. In general, a 21° bevel angle will provide better cut quality when cutting soft paper (such as newsprint), recycled paper, or bound books. However, 21° angle knives can become dull sooner than 23° knives, which results in shorter knife blade life. A knife with a 23° bevel angle, on the other hand, will not dull as easily, and can provide satisfactory results when cutting most types of paper. Knives shipped with the Champion 305 from the factory have a bevel angle of 23°.

8.3.4 Helpful Suggestions

 If your establishment is large enough to purchase more than one set of knives, have one set

beveled at 21° and the other at 23°. Note: A set consists of 3 knives: one in the machine, one as a back up, and one at the grinder.

 If the machine seems to strain but the cut quality is still good, reduce the pile height. You

may also carefully apply glycerin to the bevel when cutting hard, coated paper. Tie a cloth to the end of a stick; dip the stick in glycerin, and apply. Never apply by hand! In lieu of glycerin you may lightly rub white bar soap along the bevel. Lubrication will prolong the life of your machine and reduce maintenance.

8.3.5 Knife Care

• To prevent corrosion, knives are coated with light oil. It should be REMOVED WITH CARE.

• While removing or installing a knife, be careful not to allow the edge to bump against the

machine. Nicks will result.

• If a knife bolt is damaged, replace it.

• Always keep knife bolts securely tightened.

• Always use the heavy-duty knife bolt washers provided by Challenge. Failure to do so could

result in scratching or marring of the clamp face.

• Store knives in a dry environment to prevent corrosion.

• Never attempt to service a knife in any way.

8.0 Knife Installation/Changing

NOTES

8.0 Knife Installation/Changing

Maintenance Section

NOTICE

The instructions on the following

pages are for the use of trained

service personnel only!

Attempting to perform repair and

replacement procedures without

proper training may cause

machine damage or operator

injury!

PARTS CUSTOMERS: Parts with the express understanding that they are to replace parts found missing or no longer serviceable on equipment designed and/or manufactured at Challenge. The Challenge Machinery Company assumes no liability for any modification or alteration to any Challenge products, and any such modification or alteration to any Challenge product is not authorized by The Challenge Machinery Company. Any modification or alteration of any Challenge product will void any remaining warranty.

9.0 Cleaning

9.1 Table

The table of a paper cutter requires periodic maintenance to remove surface oxidation. Polishing is also required to provide a smooth surface for paper to move freely. The frequency of this maintenance will be determined by a number of factors. Among these are the humidity, environmental dust, handprints, liquid spills, and type of paper stock. We recommend the use of the Challenge Cutter Care Kit P/N 16077 for of your table care needs.

To prepare a new machine’s table, follow the procedure below:

1. Remove the rust-protective coating from the table with a solvent.

2. Remove all solvent residue from the table with a dry cloth. Continue until the cloth shows no sign of residue.

3. Apply a light coating of an SAE 10-weight non-detergent motor oil or equivalent to the table and allow it to penetrate for at least one hour.

4. Remove all excess oil from the table with paper toweling (not cloth) until the paper towel you are using shows no sign of oil.

5. Apply a paste wax (Challenge P/N 16078) to the table to seal the pores of the metal.

Note: Do not use a wax that contains a cleaning compound on the table. The cleaner contains microscopic abrasive particles that will cause wear between the table and the bottom of the backgauge. A silicone spray (Challenge P/N 16079) will show the same type of wear as the cleaner if the excess silicone is not removed. If the excess is not removed, the silicone spray has a substance that holds the silicone to the surface it is sprayed on that causes a black, gummy build-up under the backgauge. If a silicone spray is used, paper toweling must be used to remove the excess to prevent this wear and build-up.

To clean surface oxidation from a table, follow the procedure below:

1. Spray “Rust-B-Gone” (Challenge P/N 16080) on the table and allow it to dissolve the rust. Then remove it with paper toweling. Or, pour a small quantity of SAE 10-weight motor oil onto the table. Using a Scotch-Brite Pad or a 400 grit sand paper, polish the table following the “grain” of the metal until all oxidation is removed to your satisfaction.

2. Remove all of the oil from the table until the cloth you are using shows no sign of residue.

3. Apply a light coating of an SAE 10-weight non-detergent motor oil or equivalent to the table and allow it to penetrate for at least one hour.

4. Remove all excess oil from the table with paper toweling (not cloth) until the paper towel you are using shows no sign of oil.

5. Apply a paste wax (Challenge P/N 16078) to the table to seal the pores of the metal.

9.0 Cleaning

cleaner if the excess silicone is not removed. If the excess is not removed, the silicone spray has a substance that holds the silicone to the surface it is sprayed on that causes a black, gummy build-up under the backgauge. If a silicone spray is used, paper toweling must be used to remove the excess to prevent this wear and build-up.

9.2 Console

 The console should be cleaned with a mild water based detergent applied to a damp cloth or

paper towel. Petroleum based solvents will damage the console.

9.3 Machine Frame

1. The machine frame should be cleaned with a mild, water based detergent applied to a damp cloth.

2. Always be careful when cleaning around safety warning labels. Use limited am ounts of cleaners in those areas.

10.0 Lubrication

A clean, lubricated machine will cut more accurately, run longer, with less downtime, and fewer repairs.

Schedule lubrication maintenance both early in the day and early in the week. This allows the lubricants to work into the machine. Lubrication at the end of the day or week allows the lubricants to run off without any benefit to the machine.

Clean off dirty, excess grease. Clean accumulated dust off valves, hoses, and connections. Dust build-up increases operating temperatures and causes premature wear of all hydraulic component s.

Oil and grease WEEKLY as described below. When necessary, send the knife down by choosing “MAINTENANCE” and then “KNIFE CHANGE” on

the TC touch screen. Select “Knife Adjust Mode” then press and hold both cut buttons until the knife and clamp reach the table. Now release the buttons (the knife and clamp should stay down).

DISCONNECT THE POWER AND LOCK IT OUT, (See Power Lockout Procedure on pg. 5). Most moving parts require lubrication. Remove all panel covers and look for all oil locations (marked

with red paint). Make sure oil holes are not plugged and lubricate with a 30 weight oil. See the photos below for critical locations (not all locations are illustrated here). Notice that some are oil locations and some are grease points. Wipe off old and excess grease. Use a National Lubricating Grease Institute No. 1 consistency, extreme pressure grease.

Replace all guards before operating. Never operate cutter with any

guards removed.

GREASE OIL

Backgauge leadscrew (oil):

Figure 15

10.0 Lubrication

Knife bar pull-down pin (oil):

Figure 16

Left and right clamp guides (grease):

Lower knife and clamp cylinder pins (oil):

Figure 17

Figure 18

10.0 Lubrication

Wipe down the knife bar to remove dust and debris (Figure 19).

Knife Bar

Figure 19

Check knife bar link, bell crank, and hydraulic cylinder pin keepers to make sure they are in pla ce an d secure (Figure 20).

Knife Bar

Link Pin

Keepers

(x2)

Bell Crank

Pin Keepers

(x2)

Hyd. Cyl.

Pin Keepers

(x2)

Figure 20

+ 80 hidden pages

Challenge CHAMPION 305 TC Instructions And Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual