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 accomodation to our customers.
Serial Numbers 07276 & Up OPERATOR’S MANUAL CHAMPION 370 PAPER CUTTER Models XG & XT Sold and Serviced by The Challenge Machinery Company 6125 Norton Center Drive Norton Shores, MI 49441-6081 USA ChallengeMachinery.com F.
1.0 Introduction 1.0 Introduction THIS MANUAL is designed to help you get the most from your Challenge equipment. Keep this manual in a safe, convenient place for quick reference by operators and service personnel. SAFETY ALERT! This symbol means CAUTION: Personal safety instructions! Pay special attention to the instructions in bold type. Personal injury may result if the precautions are not read and followed.
1.0 Introduction TABLE OF CONTENTS 1.0 Introduction .......................................................................................................................................2 2.0 Safety ................................................................................................................................................5 2.1 Precautions ...................................................................................................................................5 2.
1.0 Introduction 8.13 Job Mode.................................................................................................................................. 31 8.13.1 Lock/Unlocking a Job........................................................................................................ 31 8.13.2 Copying a Job ................................................................................................................... 32 8.13.3 Erasing a Job ...................................................
2.0 Safety 2.0 Safety 2.1 Precautions • • • • • • • • • • • • • • • • • This machine is designed for one-person operation. Never operate the machine 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 questions remain, contact the dealer from which you purchased this machine.
2.0 Safety 2.3 Warning Label Definitions The following warning labels are found at various locations 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 location of each label can be found in the Technical Manual. 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.
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.
3.0 Packing List 3.0 Packing List Part No. Extension Side Tables: 16026 16027 49147 49080 A-8495 A-8496 H-6913-606 H-6424-6 H-6913-606 H-7321-6 49012 49055 H-6918-608 8815 4173 A-12608-6 Tool Kit (P/N: K-49000): 49226 5064 W-178 W-164 W-158 W-141 W-137 Fuses: E-2308 E-2330-7 E-889-35 E-889-5 E-889-9 E-2330-8 E-2330-3 8 Description Basic Machine Qty.
4.0 Specifications 4.0 Specifications Description Cutting Width Clamp Opening Clamping Force Minimum Cut – Standard - w/ False Clamp Plate Table Space Front: (std.) Back: Dimensions Table Height Overall Height Overall Length Overall Width w/ Side Tables w/o Side Tables Approx. Net Weight Approx. Shipping Weight Will pass through door: Assembled Table/treadle out Electrical Inch Units 37” 5-1/4” 2000-6900 lbs. ¾” 2-5/8” Metric Units 94.0 cm 13.3 cm 8896 – 30693 N 1.9 cm 6.7 cm 25” 40” 63.5 cm 101.
5.0 Footprint 5.
6.0 Installation & Setup 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.
6.
6.0 Installation & Setup 6.3 Re-Crating and Shipping Save the packing materials and braces. All packing blocks and hardware should be saved or reproduced in order to ship the machine again. If the machine is not repacked as it came from the factory, damage will result when trucked. • Remove the knife before shipping. • Brace the back-end of the table to the skid using a 2x4. • Use a skid larger than the outer tip-to-tip dimensions of the machine. • Block the counter-weight according to Figure 2.
6.0 Installation & Setup 6.6 Assembly: Standard Unless otherwise specified, the only items that have been disassembled for shipping are the extension side tables. To assemble the table extensions, follow the procedure below. NOTE: Assembled side tables are awkward and heavy. Use two people to attach the side tables. 1. Install the side table supports. Each support is attached to the frame with two (2) bolts and washers. (Mounting bolts are shipped installed in the frame - remove them to install supports.
6.0 Installation & Setup 4. Remove the rear arch cover assembly. 5. Insert the table from the rear of the machine, through the arch. The table is located using two special taper pins through holes on the rear table mounting pads. 6. After locating the table, install the eight (8) table bolts. Seat the taper pins and tighten the bolts. 7. Attach the front and rear side guides. Install the table end cover. Install the rear table polycarbonate cover to the table end cover and side guides. 8.
6.0 Installation & Setup Figure 6 12. Install the forward and rearward lead screw covers using eight 1/4-20 x ½” button head cap screws, eight ¼” flat washers, and eight ¼” internal tooth lock washers. Figure 7 13. Reconnect the backgauge motor cable. From the table, the cable runs through the strain relief bushing into the motor housing, (Figure 8). Attach the wires according to the wiring schematic in the back of this Cable manual for the machine model you have.
6.0 Installation & Setup Figure 8 14. Connect the tube from the blower to the plastic connector attached to the air channel cover on the bottom of the table if required. Reconnect the wires to the air blower and solenoid according to the wiring diagram for the machine model you have. 15. Open each electric eye end-cover. Mount the electric eyes to the machine as shown in Figure 9. The end-covers are oriented toward the outside of the machine.
6.0 Installation & Setup can be removed for changing the oil and checking the oil level. The reservoir should be kept full at all times. Fill the reservoir so that the oil level is 3/4” below the top of the inside of the hydraulic tank. NOTE: DO NOT OVERFILL. Overfilling may cause leakage when the machine is hot. Breather Cap Hydraulic Reservoir Figure 10 6.9 Power Hook-Up SHOCK HAZARD! Always disconnect power at main power panel before working on the cutter. Lock it out to prevent accidental power up.
6.0 Installation & Setup 6.10 Three Phase Hook-Up The power source is connected to the cutter through the bottom of the power panel (right hand side). A main power control switch and power cord providing the machine with power is the responsibility of the customer and should be set in accordance with the local electrical code. 1. DISCONNECT AND LOCK OUT THE POWER (See Power Lockout procedure, page 5) 2. Thread the power cord through a conduit connector into the power panel. 3.
6.0 Installation & Setup 1 3 2 1 2 3 Figure 12 NOTE: DO NOT ATTEMPT TO OPERATE THE CUTTER UNTIL THE REMAINDER OF THIS MANUAL HAS BEEN THOROUGHLY READ AND UNDERSTOOD. CALL YOUR DEALER IF YOU HAVE ANY QUESTIONS.
7.0 Champion 370 Diagram 7.
8.0 Operation 8.0 Operation IMPORTANT: DO NOT ATTEMPT TO OPERATE THE CUTTER UNTIL YOU HAVE THOROUGHLY READ AND UNDERSTAND ALL OF THE FOLLOWING INSTRUCTIONS. CALL YOUR AUTHORIZED CHALLENGE DEALER IF YOU STILL HAVE ANY QUESTIONS. 8.1 Power - Main Power Switch Power is brought to the machine when the main power switch is turned to the “ON” position (Figure 13). The display, table light and line lights are turned on at this time.
8.0 Operation 8.3 Making a Cut Place the paper against the backgauge and side guide. Press and release both cut buttons once to start the hydraulic motor. Then press and hold both cut buttons to start the cut cycle. While holding the cut buttons, the knife and clamp will complete the cut cycle. If either button is released at any time during the cycle, the knife and clamp will immediately return to the up position. 5.
8.0 Operation Figure 14 Additional jogging aids can be purchased at your authorized Challenge dealer. (P/N A-12608-6) Always remove the jogging aid from the table before making a cut. 8.5 Clamp Pressure Adjustment The clamp pressure can be adjusted by pressing soft-key “C” (Up) to increase the pressure, and softkey “D” (Down) to decrease the pressure. The pressure scale ranges from 0 to 15, 15 being the maximum. 8.
8.0 Operation 8.8 Definition of Keys Figure 15 8.8.1 Backgauge Glide Control The backgauge glide control is used to manually position the backgauge. The speed of the backgauge will depend upon where the actuator is pressed. Press farther from center for a faster speed, and closer to center for a slower speed. To move the backgauge forward, press downward. To move the backgauge backward, press upward. Pressing the center displays true position. 8.8.
8.0 Operation The SEND key is used to send the backgauge to any valid position. If an attempt is made to send the backgauge to an illegal position, an error message will be displayed at the bottom of the screen stating “Number outside limit”. In the Job mode, the SEND key will also advance the backgauge to the next sequential cut position before performing the cut. 8.8.
8.0 Operation 8.8.10 Arrow Keys The four arrow keys can be used in almost all screens. The arrow keys are primarily used for moving the cursor around on the screen, or to toggle between highlighted selections. In some screens, the left arrow key acts as a backspace key. 8.8.11 Contrast Control The contrast of each display screen can be adjusted by using the contrast control buttons located directly above each display screen. 8.9 Manual Backgauge Control 8.9.
8.0 Operation The send mode is the first screen displayed after the backgauge is preset. From this screen the backgauge can be positioned with the backgauge pinpoint control or by entering a value and pressing the SEND key. A mathematical expression can also be entered as a send value. Simply type the expression and press SEND. You can also enter an equation that begins with the current backgauge position.
8.0 Operation 8.12 Maintenance Mode 5.070 in Clamp Pressure | | | 14 | | | ------------------------------C) Up D) Down MAINT MENU LANGUAGE PARAMETERS DIAGNOSTICS KNIFE ADJUST Select and press enter F) Job G) Send H) Exit The maintenance mode is an area where many machine functions can be set or modified. The four principle functions are: Language, Parameters, Diagnostic, and Knife Adjust. To select a particular function, use the up and down arrow keys to toggle to the desired function and press ENTER.
8.0 Operation 8.12.2.4 Knife Count The knife count parameter allows the operator to reset the knife alarm and the lube alarm. The knife alarm displays a message to remind the operator to change the knife. The lube alarm displays a message to remind the operator to have the machine lubricated. The lube alarm will also display the name and phone number of the Challenge dealer from which the machine was purchased.
8.0 Operation 8.12.3.2 Sensor Data The Sensor Data function provides a list of computer inputs and outputs (proximity switches, etc.) along with their status (0 for open, 1 for closed). This function allows a service technician to check the status of a switch without removing any covers. Cuts and backgauge movements are allowed in this screen so that the technician may observe the status of the inputs and outputs during machine operation. 8.12.3.
8.0 Operation 8.13.2 Copying a Job First, select a job to copy by moving the cursor up or down to the desired job number and press the soft-key “F” (Copy). “Select Copy to #” will be displayed at the bottom of the screen. Enter a job number for the new job or move the cursor to an existing job and press ENTER. If the new job is locked, the copy will not be allowed. NOTE: if the new job is not locked, but contains data, the old data WILL BE LOST. 8.13.
8.0 Operation make it impossible to cut at that position. Pressing both cut buttons on a position marked at a Loading Zone will prompt the backgauge to move to the next position in the job. Using a loading position eliminates the need to reach into the knife/clamp area of the cutter when loading a job. 8.13.4.3 Entering Rotation Mark After entering a send value, pressing the right arrow key, instead of ENTER, will move the cursor to the right and prompt the operator to enter a rotation indicator mark.
8.0 Operation decrease the clamp pressure, or use the numeric keypad to enter a number from 0 to 15 (see Adjusting the Clamp Pressure section, page 24 for information about the clamp pressure setting). This will complete the entry for the current line and move the cursor to the send value of the next line. NOTE: All new entry lines will have the same clamp pressure as the one above it, until it is changed. 8.13.4.
8.0 Operation 5.070 ------------------------------C) Up D) Down QTY OPT OUT 1 8 2 8 3 8 4 6 5 8 6 6 RE-ENTER QTY CUTS 9 9 9 7 9 7 H) Exit Use the up and down arrow keys to scroll through the possible layouts. The left display will show each choice visually. Select the desired layout by pressing ENTER. At this point the send values will be automatically calculated and entered, and the job will be complete and ready for use.
8.0 Operation 5.070 in Clamp Pressure | | | 14 | | | 1> 8.500 2>11.000 Job # Job Name ------------------------------A) Division D) Cut & Rec 8.5 X 11 L #7 E) Insert F) Job Lock Status G) Erase H) Exit To insert a send value, press the soft-key “E” (Insert). This action moves all send values down and provides a blank line after the current send value. Send values can also be entered using the “Cut and Record” feature. Move the cursor to the line where the send values are to be inserted.
8.0 Operation 8.13.8 Label Cutting A label-cutting feature is also provided on the Champion XG. After providing the label quantity, size, and gutter, the machine will automatically create a programmed job. Begin by entering the job mode, select a job number and name (optional) then depress ENTER. Depress the soft-key “C” (Label) under the left hand display. The display will be similar to the following: 5.070 in #1 *Label Cutting* A QTY QTY DIM DIM DIM DIM A>_ B C D E F Enter Quantity A.
8.0 Operation the send values will be automatically calculated and entered. The job will be complete and ready for use. To make changes, edit the job as described in the “Editing a Job” section below. 8.14 An Example Job – XG Model The following is an example of how to program a job that will be used to make two cuts: one at 8.5” and one at 11”. 1. Turn on the machine and press CLEAR to preset the backgauge. Press the soft-key “F” (Job) to go to job mode. 2. Type in an unused job number and press ENTER.
9.0 Operating Tips 9.0 Operating Tips Use a jogging aid to align stock. This will reduce the chance of an accident by not having to reach under the knife or clamp. Likewise, use the backgauge to push out stock before removal. Never attempt to remove paper trim clinging to the blade or clamp until they have stopped moving! Carefully lay out each sheet before you start cutting. Find the best-cut pattern to give you the most pieces out of the sheet.
10.0 Routine Maintenance/Adjustments 10.0 Routine Maintenance/Adjustments 10.1 Knife Care CAUTION: ! 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.
10.0 Routine Maintenance/Adjustments Figure 17 – Knife Changing Equipment 10.1.1 Knife Change The knife changing equipment shown in Figure 17 is included in the cutter tool kit. The following instructions show how to remove and install a new or re-sharpened knife. Read through these instructions AT LEAST ONCE before attempting to actually change or install any blades. 10.1.1.1 Knife Removal 1. Clear the cutter table. Place chipboard directly under the knife to prevent nicking if the blade hits the table.
10.0 Routine Maintenance/Adjustments Figure 18 9. Clear the table and put the empty knife scabbard on the table. 10. Grasp the knife lifter assembly 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 and put the blade in the scabbard immediately. 11. Send the dull knife to the grinder. 10.1.1.2 Knife Installation 1. Lower the knife bar. See section 8.12.3.
10.0 Routine Maintenance/Adjustments Knife Blade Knife Adjusting Screw Knife Bar Lock Paper Deflector Hold Down Lever Knife Bar Follower Figure 19 3. Raise the knife bar. 4. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout procedure, page 5.) 5. Use the cutting stick puller to remove the cutting stick. Turn the cutting stick to a new surface. 6. Clear the cutter table and extension tables. Place chipboard directly under the knife to prevent nicking if the blade hits the table. 7.
10.0 Routine Maintenance/Adjustments 11. 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! 12. Replace the knife lifters with bolts and snug tighten. 13. Place a few sheets of paper across the table to cover the cutting stick. NOTE: Before the knife bar is run down make sure the following is checked: a. The (3) knife adjusting screws have been backed off completely.
10.0 Routine Maintenance/Adjustments The machine seems to strain while cutting. This strain can be heard in the hydraulic motor. The knife makes a “rougher” sound as it passes through stock. Nicks are visible on the cutting edge of the knife. 10.1.3 Bevel Angle The most appropriate bevel angle depends upon four factors. 1. 2. 3. 4.
10.0 Routine Maintenance/Adjustments The following suggestions apply to those who can support only one set of knives. The bevel angle on the knives shipped with your machine was chosen for its versatility. It is not the ideal angle for every material, but these suggestions may improve the cut quality for those materials being cut with an inappropriate bevel: First, cut the softest, most pure stocks at lower clamping pressures. Move to the harder, more pure stocks at higher pressures.
10.0 Routine Maintenance/Adjustments 2. Position the false clamp plate under the clamp. The locator pegs should be positioned to the rear of the cutter and are set into holes in the bottom of the clamp. 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 slightly with the foot pedal in order to access the far left setscrew.
10.
10.0 Routine Maintenance/Adjustments While lubricating, check pin locks to make sure they are in place and secure (Figure 20) there are a total of six. The bell crank pins do not require lubrication. Pin Locks Figure 20 10.4 Hydraulic System The Champion Series Cutters have both hydraulic cutting and hydraulic clamping operation. The cutter is powered by an electric motor coupled directly to a hydraulic pump. The pump has a fixed flow rate output of 10.5 GPM at 1800 PSI (max.
10.0 Routine Maintenance/Adjustments NOTE: Failure to change the oil when needed can damage the seals in the clamp and knife cylinders as well as the manifold. Refill the tank with 15 gallons of an ISO (International Standards Organization) Viscosity Grade 46, rust, oxidation, and foam inhibiting hydraulic oil. NOTE: NEVER use Automatic Transmission Oil or Brake Fluid as a substitute for the correct hydraulic fluid. Dangerous operation conditions could result.
10.0 Routine Maintenance/Adjustments 3. Place the suction line of the transfer pump into the breather cap hole. Place the pressure line of the transfer pump into an empty five-gallon pail. 4. Turn on the transfer pump and fill the pail. Repeat until tank is empty. 5. Replace the oil filter. Place a thin film of new hydraulic oil on the seal of the new filter to insure a proper seal. Firmly hand-tighten the filter onto the filter head. 6.
10.0 Routine Maintenance/Adjustments 3. Using a 3/16” hex wrench, turn one of the adjusting screws until you see a 1/16-1/8” beam. 4. Similarly, turn the adjustment screw of the other bulb until one, continuous beam is seen across the cut stick. 10.5.1 Line Light Bulb Replacement: 1. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lock-out procedure, page 5) 2. Tilt the console down. 3. Remove the old bulb by lightly pushing bulb into the socket and turning it counterclockwise.
10.0 Routine Maintenance/Adjustments 2. Always be careful when cleaning around safety warning labels. Use limited amounts of cleaners in those areas. 10.6.1 Table Conditioning 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.
11.0 Program Log 11.0 Program Log It is always good practice to keep written records of important repeat jobs. In case a channel or the entire memory is accidentally lost. Important jobs will not have to be reprogrammed from scratch. Photocopy this page as needed to build a program log.
12.0 Channel Log 12.0 Channel Log It is recommended that you keep an abbreviated Channel Log and detailed Program Logs (copy this form) for important or repeat jobs. In the event memory capacity is reached, a glance at the Channel Log will tell you which channels may be cleared to make more room. CHAN. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 JOB/CUSTOMER SAVE CHAN.
13.0 Safety System Tests 13.0 Safety System Tests Machine manufacturer CHALLENGE Model _____________ Serial Number __________________ Frequency of test: THESE TESTS SHOULD BE PERFORMED AT THE BEGINNING OF EACH WORK DAY. Turn on the cutter and start the hydraulic motor (see operator’s manual for instructions). Enable the electric eye safety system. Test #1: Using a 12 mm wide test piece, check the object detection capability of the electric eye system.
NOTES:
Copyright © 1998-2009 by The Challenge Machinery Company. Printed in the USA. F.
