Challenge Champion 305 X, Champion 305 XT, Champion 305 XG Operator's Manual
The Challenge Machinery Company provides owner's manuals on its
products s olely as a court esy to i ts cust omers. Se e the inf ormati on belo w
before using this manual.
These manuals are for reference only. These manuals include products which are noncurrent,
unsupported or no longer pr oduced by The Chal l enge M achi nery Com pany , and are pr ov ided sol el y as
an accommodat i on to our c ustom ers. By prov i ding these m anuals, T he Ch al lenge M achi nery Com pany
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 i ndependent responsibility of the
product owner and user.
Older produ cts may not co mply with curren t safety pro cedures, guidel ines or regu lat ions, and i t
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 o r u nsuppo rted prod ucts. T he Ch allenge Mach inery Co mpan y 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 Comp any. The av ailabilit y of t hese manuals is sol el y for t he purpose of provi ding ref erence
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. Al l product s should be regular l y i nspected and m aintai ned, and their condition, appli cation
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 pr oper training may cause machine dam age or operat or injury!
Products may be unsup por ted by The Chall enge M ac hinery Company due to age or the unavailability of
parts from their ori ginal m anufactur er. No parts or produc t support will be available to repair or maintain
unsupported prod uc ts. Older products may not be UL listed (if the product does not have a UL l abel it i s
not a listed product), and may not comply with applicable installation or other regulations or
requirement s if rel ocated to a new f acilit y. Many munici palities requi re a product t o be UL l isted bef ore
an electrician will connect power to them. Often the cost of updating an older pro duct to com ply with
current saf ety r egulations is greater than the v alue of t he product .
The Challeng e Machin ery Comp any
6125 Norton Center Drive
Norton Shores, MI 49441-6081 USA
ChallengeMachinery.com
F.254-I-O
February 2014
CHAMPION 305 X, XG, XT
Operator’s Manual
Serial Numbers 07X1360 & Up
Sold and Serviced by
1.0 Introduction
1.0 Introductio n
This manual is designed t o help you get the most from your Challenge equipment. Keep this manual
in a safe, convenient place for quick reference by operators and serv ice personnel.
SAFETY ALERT! This symbol means CAUTION: Personal safet y
instructions! Pay special attention to the instructions in bol d ty pe. Personal injury may result if the
precautions are not r ead and followed.
READ THIS MANUAL BEFORE OPERATING! Follow the precautions and instructions given. If
after reading the manual questions still rem ain, contact your Authorized Challenge Dealer.
FOR PARTS AND SERVICE, contact t he Author ized Challenge Dealer from whom you purc hased
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 t he 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 c ar d ac c om panyi ng 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 Chall enge.
Copy this page, fill in the information and send it care of The Challenge Serv ice Department, 6125
Norton Center Driv e • Norton Shor es • 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 y ou r ead and under st and the conditions outli ned in the Warr anty Information
Sheet att ached to the outside of the shipping cont ainer of your machine.
The Warr anty Inf or m ation 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 Dr ive • Norton Shores MI 49417
Copyright© 1997-2014 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A
2
Challen ge® is a registered trad em ark of
1.0 Introduction
TABLE OF CONTENTS
1.0 Introduc tion................................................................................................................................. 2
2.0 Safety.........................................................................................................................................6
2.1 Precautions.............................................................................................................................6
2.2 Power Lockout Proc edur e .......................................................................................................6
2.3 Warning Label Definitions........................................................................................................7
3.0 Packing List.................................................................................................................................9
4.0 Specifications............................................................................................................................10
5.0 Footprint....................................................................................................................................11
6.0 Installation & Setup...................................................................................................................12
6.1 Inspecting Shipment..............................................................................................................12
6.2 Uncrating.............................................................................................................................. 12
6.3 Lifting Instructions.................................................................................................................12
6.4 Moving Instructions............................................................................................................... 13
6.5 Cleaning ............................................................................................................................... 13
6.6 Assembly.............................................................................................................................. 13
6.7 Hydraulic Power Unit Removal.............................................................................................. 14
6.8 Hydraulic Check....................................................................................................................15
6.9 Power Hook-Up.....................................................................................................................15
6.9.1 Three Phase Hook-Up ................................................................................................... 16
6.9.2 Single Phase Hook-Up................................................................................................... 17
7.0 Champion 305 Diagram ............................................................................................................. 18
8.0 Operation X Model .................................................................................................................... 19
8.1 Power – Main Switch.............................................................................................................19
8.2 Table Light ............................................................................................................................ 20
8.3 Presetting the Backgauge ..................................................................................................... 20
8.4 Backlash Indicator.................................................................................................................20
8.5 Backgauge Lock ................................................................................................................... 20
8.6 IN/MM Toggle Soft Key......................................................................................................... 20
8.7 Making a Cut.........................................................................................................................20
8.8 Turning Off the Hydraulic Motor.............................................................................................21
8.9 Jogging Aid........................................................................................................................... 21
8.10 Pre-Clamping...................................................................................................................... 21
8.11 Air Table ON/OFF............................................................................................................... 21
8.12 Adjusting the Clamp Pressure............................................................................................. 22
8.13 Re-calibr ating the Backgauge.............................................................................................. 22
8.14 Knife Down Mode................................................................................................................ 22
8.15 Electric Eyes.......................................................................................................................23
8.16 False Clamp Plate...............................................................................................................23
9.0 Operation – XG Model............................................................................................................... 24
9.1 Using the Machine................................................................................................................ 24
9.1.1 Power - Main Power Switch............................................................................................24
9.1.2 Table Light..................................................................................................................... 24
9.1.3 Start Up......................................................................................................................... 24
9.1.4 Making a Cut..................................................................................................................25
9.1.5 Jogging Aid.................................................................................................................... 25
9.1.6 Adjusting the Clamp Pressure........................................................................................ 26
9.1.7 Pre-Clamping.................................................................................................................26
9.1.8 Knife Change Alarm and Lubrication Alarm .................................................................... 26
9.2 Electric Eyes.........................................................................................................................26
9.3 False Clamp Plate.................................................................................................................26
9.4 Champion XG – Display Panel .............................................................................................. 27
9.5 Definition of Keys.................................................................................................................. 27
3
1.0 Introduction
9.5.1 Backgauge Glide Control................................................................................................27
9.5.2 IN/MM Key......................................................................................................................27
9.5.3 Air Ta b le ON / OFF Key....................................................................................................27
9.5.4 Send Key........................................................................................................................27
9.5.5 Push-Out Key.................................................................................................................28
9.5.6 Clear Key........................................................................................................................28
9.5.7 Enter Key........................................................................................................................28
9.5.8 Priority Add (X/Y) Key.....................................................................................................28
9.5.9 Soft Keys........................................................................................................................28
9.5.10 Arrow Keys...................................................................................................................28
9.5.11 Contrast Control (Only on Serial numbers 10x1535 and below).....................................29
9.5.12 Contrast Control (For Serial numbers 10x1536 and up).................................................29
9.6 Manual Backgauge Cont r ol....................................................................................................29
9.6.1 Backgauge Glide Control................................................................................................29
9.6.2 Backgauge Cont rol Knob................................................................................................29
9.6.3 Backlash Indicator..........................................................................................................29
9.7 Send Mode............................................................................................................................30
9.7.1 Entering Math.................................................................................................................30
9.7.2 Entering Fractions...........................................................................................................30
9.8 Repeat Mode.........................................................................................................................31
9.9 Maintenance Mode ................................................................................................................31
9.9.1 Language .......................................................................................................................31
9.9.2 Parameters.....................................................................................................................32
9.9.3 Diagnostic.......................................................................................................................33
9.10 Job Mode.............................................................................................................................34
9.10.1 Lock/Unlocking a Job....................................................................................................34
9.10.2 Copying a Job...............................................................................................................34
9.10.3 Erasing a Job................................................................................................................34
9.10.4 Creating a New Job......................................................................................................35
9.10.5 Editing an Existing Job..................................................................................................39
9.10.6 Running a Programmed Job .........................................................................................40
9.10.7 Exiting a Job.................................................................................................................40
9.11 An Example Job – XG Model ...............................................................................................40
10.0 Operating Tips.........................................................................................................................42
11.0 Knife Installation/Changing.......................................................................................................43
11.1 Knife Removal.....................................................................................................................44
11.2 Knife Installation..................................................................................................................45
11.3 Using the Shielded Knife Lifter.............................................................................................46
11.4 False Clamp Plate................................................................................................................47
11.5 Knife Care Basics................................................................................................................48
11.5.1 Cut Quality....................................................................................................................48
11.6 Bevel Angle.........................................................................................................................49
11.7 Helpful Suggest ions.............................................................................................................49
11.8 Knife Care............................................................................................................................50
12.0 Lubrication...............................................................................................................................51
12.1 Hydraulic System.................................................................................................................53
12.2 Recommended Oils .............................................................................................................54
12.3 Changing the Oil..................................................................................................................54
13.0 Operator Adj ustm ents/Cleaning................................................................................................56
13.1 Line Lights...........................................................................................................................56
13.2 Manual Pr essure Reducer – (305X Only).............................................................................57
13.3 Operator Cleaning................................................................................................................58
13.3.1 Hydraulics.....................................................................................................................58
13.3.2 Table Conditioning........................................................................................................58
13.3.3 Console........................................................................................................................59
4
1.0 Introduction
13.3.4 Machine Base.............................................................................................................. 59
14.0 Program Log........................................................................................................................... 60
15.0 Channel Log ............................................................................................................................ 61
16.0 Safety System Tests............................................................................................................... 62
5
2.0 Safety
2.0 Safety
2.1 Precautions
• This machine i s designed f or one- per son operation. Never operate the machine with more than
one person.
• Safe use of this machi ne is the r esponsibility of the operator . Use good judgment and common
sense when working with and around this machine.
• Read and understand all instructions thoroughl y before using the machine. If questions remain,
contact the deal er from whic h y ou purchased this machine. Failure to under stand the operating
instructions may result in personal injury.
• Only trained and aut hor iz ed people should operate this machine.
• Do not alter saf ety guar ds or devic es. They are for your protection. Severe personal injury may
result.
• Disconnect power bef or e cl eaning or performing mai ntenance. See S ection 2.2 Power Lockout
Procedure.
• Observe all cauti on labels and plates on this machine.
• Be sure the cutter i s properly grounded.
• Be sure there is sufficient power to operate the cutter properly.
• Keep foreign objec ts off the table and away from cutter blade.
• BE EXTREMELY CAREFUL when handling and changing the cutter knif e. Severe lacerations or
dismemberm ent could result from careless handling pr oc edur es.
• Keep the floor around the cutter free of trim, debris, oil and grease.
• When replacing hy dr aulic 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 thi s manual. If the problem cannot be corrected, have it chec k ed by a qualified service
person.
• CRUSH HAZARD, keep hands and fingers from under the clamp while clam ping. Use Jogging
Aid to load paper, and use the back gauge to push paper out before unloading. DO NOT REACH
UNDER THE KNIFE AND CLAMP AREA!
2.2 Power Lockout Procedure
For maximum safety when m aki ng 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 hold the
key.
6
Figure 1
2.0 Safety
2.3 Warning Label Definitions
The following warni ng labels are found at various loc ations on your machine. Read and understand
the meaning of each symbol. If a label is lost from the machine, it should be replaced. The item
number and locati on of each label can be found in Section 17.0, Schem atics and Parts List.
HAZARDOUS AREA
Disconnect power bef or e cl eaning, servicing, or m aki ng adjustm ents not requiring
power. Do not alter saf ety guar ds or devices; they are for your prot ection. Replace
all guards. Do not operate with any guards removed.
SHOCK HAZARD
Disconnect power bef or e r em ov ing cover. Replace cover before operation.
SHOCK HAZARD
Disconnect power bef or e r em ov ing cover. Replace cover before operation.
SINGLE OPERATOR
Do not operate with m or e than one person.
7
2.0 Safety
!OJO!
This Este simbolo de alerta de seguridad significa ¡ OJO ! INSTRUCCIONES DE SEGURIDADPERSONAL. Lea las i nstrucciones po rque 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 mi smo
• tiempo.
• La seguridad es la responsabilidad del operario que usa esta maquina.
• LEA DETENIDAMENTE el manual de instrucciones y las PRECAUCIONES DE SEGURIDAD
antes de poner a funcionar la c or tadora. Pidale a su supervisor una copia.
• El manejo de la guill otina debe estar exclusivamente a cargo de per sonal entrenado y autoriz ado
para ello.
• NO MODIFIQUE LOS MECANISMOS DE SEGURI DAD, estan ahi para su proteccion no deben
ni modificar se ni quitarse.
• DESCONECTE LA CORRIENTE ELECTRICA antes de proceder a hacerle servicio de limpieza,
engrasar, o de hacer adjustes que no requieren corrient e. Trabe el interruptor en la posicion
OFF (apagado); vea “Procedimiento para cortar la corriente elect ri c a” al pi e de esta pagi na.
• 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 debidament e a tierra. V ea “Conexion de la fuerza electrica”.
• Verifique el v oltaje y asegurese de que este sea suficient e par a el debido funcionamiento de la
guillotina.
• Preste atenci on a todas las pl ac as con advertencias instaladas en esta guillotina.
• No permita que objetos estranos esten en la mesa o cerca de la cuchilla cort ador a.
• TENGA SUMO CUIDADO al tocar y cambiar la cuchilla. Heridas severas y hasta
desmembrami ento pueden resultar del manejo sin cui dado o negligente.
• El suelo alrededor de la guillotina debe mantenerse despejado y libre de recortes, desperdi c ios,
aceite y grasa.
• Al haber la necesidad de r eem plazar partes hidraulic as, afloje todas las conexiones poco a poco
para dejar escapar l a pr esi on. Jamas debe aflojarse conexiones mientras la maquina este
• andando.
• Si la guillotina empezara a sonar o trabajar difer entemente a lo acostumbrado, desconectela y
consulte la seccion “Troubleshooting” ( Reparador) de este manual. Si no es posible corregir el
problema, llam e a su servi ci o autorizado para que le examinen la maquina.
• PELIGRO DE MACHUQUE - Mantenga manos y dedos f uer a de la agar r ader a mi entras sujeta el
papel. Use el calibr ador trasero y su rueda de mano para empujar el papel cortado. NO PONGA
SUS MANOS BAJOLA CUCHILLA O AREA DE LA AGARRADERA.
• NO OPERE SIN LAS GUARDAS PROTECTORAS!
¡ OJO ! PRECAUCION - Como proceder para desco nect ar
la corriente electrica.
Para maxima seguridad durante ajustes y reparaciones de su maquina, verifique bien que el interruptor principal
de control de corriente al cual la maquina esta conectada, este desconectado. El interruptor deba ser puesto en
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 ajuste o reparacion o de efectuar el
engrase en cualquier maquina.
8
3.0 Packing List
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 i nstalled) 4
47006-2 False Clamp Plate (shipped installed) 1
47507 Knife 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-2308 3.2 A (X, XG Series) 1
E-2330-7 5 A S.B. (X, XG Series) 1
E-889-35 1 A S.B. (X, XG Series) 1
E-889-5 4 A S.B. (X, XG Series) 1
E-889-9 8 A S.B. (X, XG Series) 1
E-2330-8 6.3 A S.B. (XG Series) 1
E-2330-3 2 A S.B. (XG Series) 1
9
4.0 Specification s
4.0 Specificati ons
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, @ 25A or 460V @ 11.5A
Optional: 5 HP, Single Phase, 60 Hz AC; 208V, @ 44A or 230V @ 44A
3 Phase, 50 Hz AC; 220V or 380V
Single Phase, 50 Hz AC; 220V
Spacer
XD & XG series spacer has 9801 cuts on 99 channels.
XT series spacer has 47000 cut positions within the machine. (Unlimited with USB
Port.)
Minimum space between cut positions is 0.005” or 1mm. Repeat positioning accuracy is
0.003” or 0.05mm.
Electri c Eyes –
Response time = 68 ms
Object detection capability = 12 mm
Challenge reserves the right to make changes to any product or specif ication without notic e and
without inc ur ri ng r esponsibility to existing units.
25”
30 ½”
63.5 cm
77.5 cm
10
5.0 Footprint
5.0 Footprint
11
6.0 Installati on & Setup
6.0 Installation & Setup
6.1 Inspecting Shipm ent
This machine has been carefully packed to prevent damage during shipment. However, claim s f or
damage or loss are the responsibility of the recipient. Inspect all shipment s as soon as they are
received. If there is any noticeable damage, note it on the fr eight bill. Visual and/or hidden damage
must be report ed 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 9. Make sure
there are no missing items.
6.2 Uncrating
This machine i s lagged to a wood skid and covered with a triple-walled cor r ugated container. Loosen
the flaps of the carton where they ar e attached to the skid. When loose, the carton c an be lift ed
straight up. Remove t he 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 ski d.
6.3 Lifting Instructio ns
Unpacking, handling, and positioni ng shoul d be done by prof essional riggers. If handling or
unpacking is a problem, your dealer or a local trucking facility should be able to supply or recomm end
a qualified rigger. This 2550-lb/1157-kg m achi ne should be moved with experienced people and t he
proper equipment. Do not risk personal injury or damage by att em pting to move machinery with
inadequate equipm ent or manpower.
Champion cutt ers may include an opt i onal bloc k for lifting t he machi ne. Remove the prot ective cov er
from the rear of the arch. Install t he block with the h ole up. Use a hook and chain or lifti ng straps
rated at 3000-l b/1360- kg or higher. Carefull y lift the machi ne off its skid, and remov e the skid. Place
the machine on the fl oor .
Lifting str aps may also be u sed to lif t the m achine by placi ng the straps arou nd the f ront and rear of
the table. When straps are used i n this way, wood blocks must be pl aced beside the lead screw to
prevent dam age, (Figure 2). A bent lead screw will cause the backgauge to bind.
Figure 2
The backgauge shoul d be po siti oned all the way to th e fr ont of the t able and straps placed a s clo se
the machine body as possible. Gently lift the cutter, r em ov e the skid and caref ully place the cutter on
the floor.
Once the machine is off its skid, it can be moved with a forklift or pallet jack.
12
6. 0 In st all ation & Setup
6.4 Moving Instructi ons
Use a forklift or pallet jack to move the machine from the front. Do not attempt to lif t f r om the si des or
rear.
6.5 Cleaning
Wipe down the table and bare m etal surfaces with a non-flammable solvent such as CRC or blanket
wash. The table surf ac e is cast iron, and it will rust if left unprotected. Coat t he table with a nonabrasive wax. A Cutt er Care Kit, p/n 16077, with cleaner and wax, is av ailable through your
Authorized Challenge Dealer. The protective film on the console may be removed. Never clean
console with petroleum based solvents. Damage will result . Also see, Operator Cleani ng, pg. 58.
6.6 Assembly
Unless otherwise speci fied, the only items t hat have been disassem bled for shipping are the knif e,
Reach-Around shiel ds on the electric eyes and extension tables. Knife installati on wil l be c ov er ed
later. Extension table attachment follows.
NOTE: Extension tables are heavy. Use two people to attach them to the machi ne.
1. Assemble the back stops to the extension t ables. The extension table bolt s and hex nut s are
packed in the tool kit box. Tables are installed with the clearanc e hole for the knife gibs
towards the center of the cutter.
2. One person should hold the extension t able 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 tight en the mounting bolts, then tap the ext ensi on
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 t he threaded holes next to the mounting bolts. You may
have to loosen the mounting bolts slightly to allow enough pl ay to level the table. After the
extension tables are leveled and the surface joint s even, tighten the mounti ng 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
discolorat ion or scratches.
NOTE: The Reach-Around S hields for the electric eyes are in thei r shipping positions – follow the
instructions below to secure them in the operational position.
1. On t he bottom of the electric eye housing – loosen the screw closet to the machine. Do not
remove the screw
2. On t he bottom of the electric eye housing – loosen and rem ove the other two screws – rotate
the shield back out of t he c ut area. Line up the holes and re-install the screws – tighten all
screws (See the i nstr uc tion sheet included in the shipping material for more details).
ATTENTION
POTENTIAL CRUSH/LA CE RATIO N HAZZARD – THE SHIELDS AR E THERE FOR YOUR SAFETY.
: FAILURE TO INSTALL THE REACH-AROUND SHIELDS COULD CAUSE A
13
6.0 Installati on & Setup
6.7 Hydraulic Power Unit Removal
If install ati on requi res that t he machi ne pass throu gh a door way that i s les s than 49” but great er t han
or equal to 42” wide, the machine should have been ordered from Challenge “k noc k ed down” with the
table rem oved. If the m achine must fi t through a doorway that is less t han 42” and greater than or
equal to 24-1/2” , the hydr aulic power unit m ust be remov ed on-site. T o remov e the hydrauli c power
unit, follow the instructions below.
1. Disconnect the electrical c onduits to the hydraulic motor, air blower, and hy dr aulic cooling
fan, junction box.
2. Locate the hose that connects the manifold to the oil filter. Disconnect it from the filter.
Disconnect the hy dr aulic pump hose from the manifold. Att ac h the hose that was connected
to the manifold to t he oil filter. Attach the hose that was connected to the filter to the
manifold. This will mi nimi z e oil leak age. After the unit is install ed, rec onnec t the hoses to
their original location.
3. Rem ov e the filler cap and use a transfer pump to remove the hydr aulic fluid into buckets.
4. Rem ov e the ( 4) bolts that attach the hydraulic assembly t o the cutter base. They are located
at the bottom shelf t he base.
5. USE EXTRE M E CAUTION WHILE REMOVING THE POWER UNIT. It is very heavy and
should be removed usi ng a fork truck. CAUTION, the machine will be top heavy and m ay tip
easily with the power unit removed. Move the reservoir thr ough 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 i s in position. Refill the hydraulic
reservoir.
14
6. 0 In st all ation & Setup
6.8 Hydraulic Check
The hydrauli c r eservoir is fill ed with 13-1/ 2 gal lons of ISO VG 46 hydr auli c oil at the f actory . The fl uid
level should be check ed during i nstallati on, and at least onc e per week during norm al operati on. The
reservoir is located behind the cutt er, beneath the tabl e (Figure 3). The hydr aulic tank has a sight
gauge in the rear for c hec ki ng the oil level. The reservoir should be kept full at all times.
Sight
Gauge
Figure 3
NOTE: DO NOT OVERFILL. Overfilling m ay cause leak age when the machine is hot.
6.9 Power Hook -U p
For satisfact ory oper ation, be sure that your cutt er is wired for the correct phase and v ol tage and has
adequate power. The c orrect elect rical specifi cations for your machine are shown on the seri al 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 machi ne. Inadequat e volt age will
cause ov erheating, loss of power, and in ex treme cases, f ailure to operat e. Test li ne voltage when
the shop is at actual working levels. Challenge recommends a dedicated line with a lockable
disconnect to pr ov ide adequate power for this machine.
CAUTION: SHOCK HAZARD! Always disconnect power at main
power panel befo re working on the cutter. Lock it out to prevent accidental power up. (S ee
Power Loc kout Procedure pa ge 6).
Important: You must have an adequ ate size c ir cuit and heavy enough wiri ng f or t his mac hine. T he
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 siz e wire should be used. Check local
electric al c odes.
15
6.0 Installati on & Setup
Electrical Specifications for Champion Cutters
Volts Amps Circuit Size Wire Size Metric Wire
3 Phase: 460 V 11.5 20 A #12 AWG 4mm sq.
230 25 35 #8 10mm sq.
208 25 35 #8 10mm sq.
1 Phase: 230 37 44 #6 16mm sq.
208 38.7 44 #6 16mm sq.
6.9.1 Three Phase Hook-Up
The power source is connect ed to the cutter through the bott om of t he power panel (right hand side).
1. DISCO NNE CT AND LOCK OUT THE POWER at the main panel to prevent accident al power
up. (See Power Lockout, page 6).
2. Thread the power cord through a conduit connec tor into the power panel.
3. Fasten the ground lead to the ground terminal lug (Figure 4).
4. Fasten the three power leads to the thr ee termi nals of the main power terminal block - L1, L2,
& L3.
5. Close the electrical panel doors and l atch 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.
16
Figure 4
6. 0 In st all ation & Setup
6. Press both cut buttons simultaneously to activate the motor and check to make sure it is
turning the same dir ec tion 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.
1
2
31 2
3
Figure 5
6.9.2 Single Phase Hook-Up
The power source is connect ed to the cutter through the bott om of t he power panel (right hand side).
1. DISCO NNE CT THE POWER AND LOCK IT OUT at the main power panel to prevent
accidental power up. ( S ee P ower Lockout, page 6).
2. Thread the power cord through a conduit connec tor into the power panel.
3. Fasten the ground lead to the ground terminal lug, (Figure 4 on page 16).
4. Fasten the two power leads to the L1 and L2 terminal s of the m ain termi nal block.
5. Close the electrical panel doors and l atch them. Unlock the main panel and turn on the
power. Turn on the main power disconnect switch and simult aneousl y pr ess both cut buttons
to start the hydraulic motor.
17
7.0 Champion 305 Diagram
7.0 Champion 30 5 Diag r am
18
Figure 6
8.0 Operation X Model
8.0 Operation X Model
Figure 7
IMPORTANT: DO NOT ATTEMPT TO OPERATE THE CUTTER UNTIL YOU HAVE THOROUGHLY
READ AND UNDERSTAND ALL OF THE FOLLOWING INSTRUCTIO NS. CALL YOUR
AUTHORIZED CHALLENGE DEALER IF YOU STILL HAVE ANY QUESTIONS.
8.1 Power – Main Switch
Power is applied t o the mac hine when the main power switch is turned to t he “ON” position (Figure 8).
The display and line lights are turned on at this time.
OFF ON
Figure 8
The display and line lights will shut off after 2 minutes without any activity. To restore power to the
display and line li ghts, press either cut button.
19
8.0 Operation X Model
8.2 Table Light
The table light is turned on and off using a switch located under the ar c h (Figure 6, page 18). The
table light will also turn on and off with the main power, provided t he table light switch is in the “on”
position.
8.3 Presetting the Backgauge
The backgauge must be preset every time the power is turned on. Using the hand wheel, turn the
backgauge until it passes forward through the 5” position. The display readout will then show the
correct back gauge posi tion.
8.4 Backlash Indica to r
A small carat will be displ ay ed nex t to the backgauge position if the back gauge was last moved
backward. To insure accurat e c uts, always approach the desired backgauge position from behi nd
(moving the backgauge forward).
8.5 Backgauge Lock
Tightening the backgauge lock prevents the bac k gauge from mov ing while positioning paper against
it. The Champion X model has a thumb screw l oc k beneath t he hand wheel, (Figure 9).
Thumb Screw
Lock
Figure 9
8.6 IN/MM Toggle Soft Key
This switch will toggle the display readout bet ween inc hes, fractions, and millimet er s. It can be f ound
on the console as shown in Fi gur e 7, on page 19.
8.7 Making a Cut
Place the paper agai nst the backgauge and left side guide. Press and release both c ut buttons once
to start the hydraulic motor. Then press and hold both cut buttons to start the cut cycle. While
holding the cut butt ons, the knife and clamp will complete t he c ut cycle. If the buttons are released at
any time during the c ycle, the knife and clamp will immediately return to the up position.
Note: Both cut butt ons must be released before a new cut can be made. The cut buttons must be
pressed withi n 1/2 second of each other both to start the hydraulic m otor and to make a cut.
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