F.254-I (1)

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The Challenge Machinery Company provides owner'smanuals 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 non-current, unsupported or no longer produced by The Challenge Machinery Company, and are

provided solely as an accomodation to our customers. By providing these manuals, TheChallenge 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, whichare 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 responsibili ty to evaluate the suitability and fitness of the products in their current use and application. The Challenge Machinery Company makesno representation, warranty or recommendation regarding any modifications which may berequired 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 ChallengeMachinery Company. The availability of these manuals is solely for the purpose of providingreference information for the products.

This manual may not be complete in all aspects of product maintenance and repair. Al l products should be used only by qualif ied 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 andproperly trained technicians should perform maintenance, repair and replacementprocedures. Attempting these procedures without proper training may cause machinedamage or operator injury!

Products may be unsupported by The Challenge Machinery Company due to age or th

unavailability of parts from their original manufacturer. No parts or product support will b

available to repair or maintain unsupported products. Older products may not be UL listed (the product does not have a UL label it is not a listed product), and may not comply withapplicable installation or other regulations or requirements if relocated to a new facilityMany municipalities require a product to be UL listed before an electrician will connect powe

to them. Often the cost of updating an older product to comply with current safety regulations greater than the value of the product.

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F.254-IMarch, 2007

CHAMPION 305 PAPER CUTTING

MACHINE

Models X, XD, XG, XT

Sold and Serviced by

The Challenge Machinery Company6125 Norton Center Drive

Norton Shores, MI 49441-6081 USA

ChallengeMachinery.com

Serial Numbers 06X1278 & U

INSTRUCTION AND

P ARTS M ANUAL

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1.0 Introduction

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1.0 IntroductionThis manual is designed to help you get the most from your Challenge equipment. Keep this manualin a safe, convenient place for quick reference by operators and service personnel.

SAFETY ALERT! This symbol means CAUTION: Personal safety in-structions! Pay special attention to the instructions in bold type. Personal injury may result if theprecautions are not read and followed.

READ THIS MANUAL BEFORE OPERATING! Follow the precautions and instructions given. If af-ter reading the manual questions still remain, contact your Authorized Challenge Dealer.

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

RECORD YOUR MACHINE SERIAL NUMBER in the space provided on the front cover of this man-ual. Fill out the warranty card accompanying your machine and return it DIRECTLY TO CHAL-LENGE.

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 NUMBERATTN COMPANY

ADDRESS

CITY STATE/PROVINCE ZIPPHONE DATE INSTALLEDDEALER 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 CHALLENGEMACHINERY COMPANY in order for the warranty to be issued for this machine.

Challenge® is a registered trademark of

The Challenge Machinery Company • 6125 Norton Center Drive • Norton Shores MI 49417Copyright© 1997-2007 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A

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1.0 Introducti

TABLE OF CONTENTS

1.0 Introduction .......................................................................................................................................2 2.0 Safety ................................................................................................................................................8

2.1 Precautions...................................................................................................................................8 2.2 Power Lockout Procedure ............................................................................................................8 2.3 Warning Label Definitions.............................................................................................................9

3.0 Packing List.....................................................................................................................................11 4.0 Specifications ..................................................................................................................................12 5.0 Installation & Setup .........................................................................................................................13

5.1 Inspecting Shipment ...................................................................................................................13 5.2 Uncrating ....................................................................................................................................13 5.3 Lifting Instructions.......................................................................................................................13 5.4 Moving Instructions.....................................................................................................................14 5.5 Cleaning......................................................................................................................................14 5.6 Assembly: Standard....................................................................................................................14 5.7 Assembly: Table Out ..................................................................................................................14 5.8 Hydraulic Power Unit Removal...................................................................................................18 5.9 Hydraulic Check..........................................................................................................................19 5.10 Power Hook-Up ........................................................................................................................19

5.10.1 Three Phase Hook-Up.......................................................................................................20 5.10.2 Single Phase Hook-Up......................................................................................................21

6.0 Champion 305 X/XD/XG Cutter Diag..............................................................................................22 7.0 Operation X Model ..........................................................................................................................23

7.1 Power – Main Switch ..................................................................................................................23 7.2 Table Light ..................................................................................................................................23 7.3 Presetting the Backgauge ..........................................................................................................24 7.4 Backlash Indicator ......................................................................................................................24 7.5 Backgauge Lock .........................................................................................................................24 7.6 IN/MM Toggle Switch..................................................................................................................24 7.7 Making a Cut...............................................................................................................................24 7.8 Turning Off the Hydraulic Motor .................................................................................................25 7.9 Jogging Aid .................................................................................................................................25 7.10 Manual Clamping (Using the Foot Pedal).................................................................................25 7.11 Air Table ON/OFF.....................................................................................................................25 7.12 Adjusting the Clamp Pressure ..................................................................................................25 7.13 Re-zeroing the Backgauge .......................................................................................................26 7.14 Knife Down Mode .....................................................................................................................27 7.15 Electric Eyes .............................................................................................................................27 7.16 False Clamp Plate ....................................................................................................................27

8.0 Diagnostics......................................................................................................................................28 8.1 Error Code Reference Chart.......................................................................................................28

9.0 Operation – XD Model ....................................................................................................................29 9.1 Power - Main Power Switch........................................................................................................29 9.2 Table Light ..................................................................................................................................29 9.3 Start Up.......................................................................................................................................29 9.4 Making a Cut...............................................................................................................................30 9.5 Jogging Aid .................................................................................................................................30 9.6 Adjusting the Clamp Pressure ....................................................................................................31 9.7 Manual Clamping........................................................................................................................31 9.8 Knife Change Alarm and Lubrication Alarm ...............................................................................31 9.9 Champion XD – Display Panel ...................................................................................................32 9.10 Definition of Keys......................................................................................................................32

9.10.1 Backgauge Glide Control ..................................................................................................32

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9.10.2 IN/MM Key ........................................................................................................................ 32 9.10.3 Air Table ON/OFF Key......................................................................................................32 9.10.4 Send Key ..........................................................................................................................33 9.10.5 Push-Out Key....................................................................................................................33 9.10.6 Clear Key ..........................................................................................................................33 9.10.7 Enter Key ..........................................................................................................................33 9.10.8 Priority Add (X/Y) Key.......................................................................................................33 9.10.9 Soft-Keys ..........................................................................................................................34 9.10.10 Arrow Keys......................................................................................................................34 9.10.11 Contrast Control..............................................................................................................34

9.11 Manual Backgauge Control......................................................................................................34 9.11.1 Backgauge Glide Control..................................................................................................34 9.11.2 Backlash Indicator.............................................................................................................34

9.12 Send Mode ............................................................................................................................... 34 9.12.1 Entering Math....................................................................................................................35 9.12.2 Entering Fractions.............................................................................................................35

9.13 Maintenance Mode...................................................................................................................35 9.13.1 Language ..........................................................................................................................35 9.13.2 Parameters .......................................................................................................................36 9.13.3 Knife Adjust.......................................................................................................................37 9.13.4 Diagnostic ......................................................................................................................... 37

9.14 Job Mode - (Programmable Model Only).................................................................................38 9.14.1 Lock/Unlocking a Job........................................................................................................38 9.14.2 Copying a Job ................................................................................................................... 38 9.14.3 Erasing a Job .................................................................................................................... 38 9.14.4 Creating a New Job ..........................................................................................................39 9.14.5 Editing an Existing Job......................................................................................................40 9.14.6 Running a Programmed Job.............................................................................................40 9.14.7 Exiting a Job .....................................................................................................................41

9.15 An Example Job ....................................................................................................................... 41 9.16 Electric Eyes.............................................................................................................................43 9.17 False Clamp Plate .................................................................................................................... 43 9.18 Operating Tips..........................................................................................................................43

10.0 Operation – XG Model..................................................................................................................44 10.1 Using the Machine....................................................................................................................44 10.1.1 Power - Main Power Switch..............................................................................................44 10.1.2 Table Light ........................................................................................................................ 44 10.1.3 Start Up.............................................................................................................................44 10.1.4 Making a Cut.....................................................................................................................45 10.1.5 Jogging Aid ....................................................................................................................... 45 10.1.6 Adjusting the Clamp Pressure .......................................................................................... 46 10.1.7 Manual Clamping .............................................................................................................. 46 10.1.8 Knife Change Alarm and Lubrication Alarm .....................................................................46

10.2 Electric Eyes.............................................................................................................................46 10.3 False Clamp Plate .................................................................................................................... 46 10.4 Champion XG – Display Panel.................................................................................................47 10.5 Definition of Keys ..................................................................................................................... 47 10.5.1 Backgauge Glide Control..................................................................................................47

10.5.2 IN/MM Key ........................................................................................................................ 47 10.5.3 Air Table ON/OFF Key......................................................................................................47 10.5.4 Send Key ..........................................................................................................................48 10.5.5 Push-Out Key....................................................................................................................48 10.5.6 Clear Key ..........................................................................................................................48 10.5.7 Enter Key ..........................................................................................................................48 10.5.8 Priority Add (X/Y) Key.......................................................................................................48 10.5.9 Soft-Keys ..........................................................................................................................49

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10.5.10 Arrow Keys ......................................................................................................................49 10.5.11 Contrast Control ..............................................................................................................49

10.6 Manual Backgauge Control ......................................................................................................49 10.6.1 Backgauge Glide Control ..................................................................................................49 10.6.2 Backlash Indicator .............................................................................................................49

10.7 Send Mode ...............................................................................................................................49 10.7.1 Entering Math ....................................................................................................................50 10.7.2 Entering Fractions .............................................................................................................50

10.8 Repeat Mode ............................................................................................................................50 10.9 Maintenance Mode ...................................................................................................................51

10.9.1 Language ..........................................................................................................................51 10.9.2 Parameters........................................................................................................................51 10.9.3 Diagnostic..........................................................................................................................52

10.10 Job Mode ................................................................................................................................53 10.10.1 Lock/Unlocking a Job ......................................................................................................54 10.10.2 Copying a Job .................................................................................................................54 10.10.3 Erasing a Job ..................................................................................................................54 10.10.4 Creating a New Job.........................................................................................................54 10.10.5 Editing an Existing Job....................................................................................................58 10.10.6 Running a Programmed Job ...........................................................................................59 10.10.7 Exiting a Job....................................................................................................................59

10.11 An Example Job – XG Model .................................................................................................60 11.0 Operating Tips...............................................................................................................................61 12.0 Knife Installation/Changing ...........................................................................................................63

12.1 Knife Removal ..........................................................................................................................64 12.2 Knife Installation .......................................................................................................................65 12.3 Using the Shielded Knife Lifter .................................................................................................67 12.4 False Clamp Plate ....................................................................................................................67 12.5 Knife Care Basics .....................................................................................................................68

12.5.1 Cut Quality.........................................................................................................................68 12.6 Bevel Angle...............................................................................................................................69 12.7 Helpful Suggestions..................................................................................................................69 12.8 Knife Care.................................................................................................................................70

13.0 Lubrication.....................................................................................................................................71 13.1 Hydraulic System......................................................................................................................74 13.2 Recommended Oils ..................................................................................................................74 13.3 Changing the Oil .......................................................................................................................75 13.4 Alternate Draining Procedure ...................................................................................................76

14.0 Operator Adjustments/Cleaning....................................................................................................77 14.1 Line Lights ................................................................................................................................77 14.2 Manual Pressure Reducer – (305X Only).................................................................................78 14.3 Operator Cleaning ....................................................................................................................79

14.3.1 Hydraulics..........................................................................................................................79 14.3.2 Table..................................................................................................................................79 14.3.3 Console .............................................................................................................................79 14.3.4 Machine Base....................................................................................................................79

15.0 Maintenance Guide.......................................................................................................................80

15.1 Maintenance Adjustments ........................................................................................................81 15.1.1 Squaring the Backgauge...................................................................................................81 15.1.2 Proximity Switches ............................................................................................................82 15.1.3 Hydraulic Valve Adjustments.............................................................................................84 15.1.4 Clamp Speed Control Damper ..........................................................................................89 15.1.5 Clamp Cylinder..................................................................................................................90 15.1.6 Clamp Parallel Rod ...........................................................................................................91 15.1.7 Backgauge Gibs ................................................................................................................91

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15.1.8 Lead Screw Adjustment Nuts ...........................................................................................92 15.1.9 Backgauge Drive Belt Adjustment .................................................................................... 93 15.1.10 Knife Bar Gibs.................................................................................................................94

15.2 Repair and Replacement .........................................................................................................95 15.2.1 Fuses ................................................................................................................................ 95 15.2.2 Knife Bar Cylinder ............................................................................................................. 96 15.2.3 Pilot Check Valve..............................................................................................................98 15.2.4 Foot Pedal Cable Assembly .............................................................................................98 15.2.5 Table Maintenance ......................................................................................................... 100

16.0 Troubleshooting..........................................................................................................................102 17.0 Schematics & Parts Lists............................................................................................................106

17.1 Main Assembly – Front View – 47500 Sht. 1 of 16, Rev. M...................................................106 17.2 Main Assembly – Side View – 47500 Sht. 2 of 16, Rev. H .................................................... 108

Main Assembly – Side View – 47500 Sht. 2 of 16, Rev. H........................................................109 17.3 Main Assembly– Top View – 47500 Sht. 3 of 16 ................................................................... 110 17.4 Main Assembly – Rear View – 47500 Sht. 4 of 16, Rev. K....................................................112 17.5 Main Assembly – X Model Tables – 47500 Sht. 5 of 16 Rev. D............................................ 114 17.6 Main Assembly – XD & XG Model Table - 47500 Sht 6 of 16 Rev. H ...................................116 17.7 Air Table Assembly – 47500 Sht. 7 of 16 Rev. D...................................................................118 17.8 Power Panel Wiring– Prog. 1 Phase 47500 Sht. 8 of 16 Rev. D ........................................... 120 17.9 Power Panel Wiring- Euro Prog. 47500 Sht. 9 of 16 Rev. D .................................................121 17.10 Power Panel Wiring 305 X 47500 Sht. 10 of 16, Rev. C .....................................................123 17.11 Main Asm. – Front View (Rough) – 47500 Sht. 11 of 16 Rev. C ......................................... 125 17.12 Optional Voltages – 305 XD & XG – 47500 Sht. 12 of 16, Rev. A.......................................127 17.13 Main Assembly- Electric Eyes 47500 Sht. 13 of 16 ............................................................. 129 17.14 Main Asm.- Light Curtain Instructions (X, XD, XG, XT) 47500 Sht. 14 of 16.......................131 17.15 Main Assembly- Wiring –Manual Backgage – 1PH rev. A...................................................132 17.16 Machine Basic Schematic – XD & XG Models E-2814, Rev. J............................................133 17.17 Basic Machine Schematic – X Model – E-3171 Rev. A .......................................................134 17.18 Power Panel Assembly – 305 X – EE-3170 Sht. 1, Rev. A ................................................. 135 17.19 Power Panel Assembly – 305 X – EE-3170 Sht. 2, Rev. A ................................................. 137 17.20 Power Panel Assembly – 305 XD & XG – EE-2882 Sht 1, Rev. U......................................138 17.21 Interconnection Diagram – XD & XG Models – E-2840, Rev. E.......................................... 141 17.22 Interconnection Diagram – X Model – E-2841-1 rev. A .......................................................142 17.23 305 X and XG Models Console- EE-2823, Rev. C ..............................................................143 17.24 305 XD Control Console – EE-2850, Rev. B .......................................................................144 17.25 Control Console- XT Color LCD EE-2998-2 ........................................................................145 17.26 Control Console- XT Color LCD EE-2998-3 rev A............................................................... 146 17.27 Cut Button Assembly – EE-2832, Rev. B.............................................................................147 17.28 Line Light Assembly – 47538, Rev. C..................................................................................148 17.29 Air Table Blower Assembly – Single Phase – 47578, Rev. C..............................................149 17.30 X/XD/XG Troubleshooting....................................................................................................150 17.31 Description of Error Messages.............................................................................................151 17.32 Sensor Data Abbreviations .................................................................................................. 152 17.33 305 X Encoder Assembly, EE-2838.....................................................................................153 17.34 305 XD, XG, XT Encoder Cable Assembly, EE-2822-1 Rev. B...........................................154 17.35 Knife Latch Assembly – 47568, Rev. C................................................................................155 17.36 Bell-Crank Assembly – Clamp – 47005, Rev. B ..................................................................156 17.37 Hydraulic Manifold Assembly– H-465-1, Rev. C..................................................................157 17.38 Hydraulic Power Unit Assembly– 47541, Rev. E................................................................. 158 17.39 Hydraulic Manifold– H-468-1, Rev. A...................................................................................160 17.40 Manifold Assembly– H-504, Rev. A ..................................................................................... 162 17.41 Fuse Charts..........................................................................................................................163 17.42 XD & XG Models Label – Power Panel Connection Procedure – S-1781-52, Rev. F......... 164 17.43 305 X Model Label – Power Panel Conn. Procedure.– S-1781-161, Rev. A.......................165

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17.44 Warning Label – S-1781-116, Rev. A...................................................................................166 17.45 Paper Deflector (Kit Option) – AA-13936-1 ..........................................................................167 17.46 Paper Deflector Assembly A-4511-2 ....................................................................................167 17.47 24” x 36” Ext. Table on 305 (Kit Option) – K-2720, Rev. E ..................................................168 17.48 24” x 36” Ext. Table on 305 (Kit Option) – K-2720, Rev. E ..................................................169 17.49 24” x 36” Ext. Table on 305 Air (Kit Option) – K-2731, Rev. D.............................................170 17.50 24” x 36” Ext. Table on 305 Air (Kit Option) – K-2731, Rev. D.............................................171 17.51 24” x 36” Ext. Table on 305 Air (Kit Option) – K-47631........................................................172 17.52 24” x 36” Ext. Table on 305 Air (Kit Option) – K-47631........................................................173 17.53 Back Gauge Teflon Tape Kit - 49007 ...................................................................................174 17.54 Electric Eye Kit Instructions- K-3006, Sht. 1 of 3, Rev. A.....................................................175 17.55 Electric Eye Kit Instructions- K-3006, Sht. 1 of 3, Rev. A.....................................................176 17.56 Electric Eye Kit Instructions- K-3006, Sht. 2 of 3, Rev. A.....................................................177 17.57 Electric Eye Kit Instructions- K-3006, Sht. 3 of 3, Rev. A.....................................................179 17.58 Jogging Aid Construction Guide – A-12608-( ), Rev. E........................................................180 17.59 Converting 305X Series from Three Phase to Single Phase. ..............................................181 17.60 Knife Lifter Assembly – 47575..............................................................................................182

18.0 Program Log ...............................................................................................................................183 19.0 Channel Log................................................................................................................................184 20.0 Safety System Tests ...................................................................................................................185

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2.0 Safety

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2.0 Safety

2.1 Precautions

•

This machine is designed for one-person operation. Never operate the machine with more thanone person.

• Safe use of this machine is the responsibility of the operator. Use good judgment and commonsense 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. Failure to understand the operatinginstructions 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 mayresult.

• Disconnect power before cleaning or performing maintenance. See Section 2.2 Power LockoutProcedure.

• 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 ordismemberment 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 loosenconnections with the machine running.

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

• CRUSH HAZARD, keep hand and fingers from under the clamp while clamping. Use Jogging Aidto 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 themain power control switch to which the machine is connected. The switch should be moved to theOFF position and a padlock placed in the loop. The person servicing the machine should hold thekey.

Figure 1

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2.0 Safe

2.3 Warning Label Definitions

The following warning labels are found at various locations on your machine. Read and understandthe meaning of each symbol. If a label is lost from the machine, it should be replaced. The itemnumber and location of each label can be found in Section 17.0, Schematics and Parts List.

HAZARDOUS AREA

Disconnect power before cleaning, servicing, or making adjustments not requiringpower. Do not alter safety guards or devices; they are for your protection. Replaceall 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.

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2.0 Safety

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!OJO!

This Este simbolo de alerta de seguridad significa ¡ OJO ! - IN-STRUCCIONES DE SEGURIDADPERSONAL. Lea las instrucciones porque se refieren a su

seguridad personal. Fall de obedecer las instrucciones que siguen podria resultar en lesionescorporales.

• 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 maquina.

• 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 autorizadopara ello.

• NO MODIFIQUE LOS MECANISMOS DE SEGURIDAD, estan ahi para su proteccion no debenni 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 posicionOFF (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 “Corrienteelectrica”.

• 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 laguillotina.

• 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 desmem-bramiento 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 yconsulte la seccion “Troubleshooting” (Reparador) de este manual. Si no es posible corregir elproblema, llame a su servicio autorizado para que le examinen la maquina.

• PELIGRO DE MACHUQUE - Mantenga manos y dedos fuera de la agarradera mientras sujeta elpapel. Use el calibrador trasero y su rueda de mano para empujar el papel cortado. NO PONGASUS MANOS BAJOLA CUCHILLA O AREA DE LA AGARRADERA.

• NO OPERE SIN LAS GUARDAS PROTECTORAS!

¡ OJO ! PRECAUCION - Como proceder para desconectarla corriente electrica.

Para maxima seguridad durante ajustes y reparaciones de su maquina, verifique bien que el interruptor principalde control de corriente al cual la maquina esta conectada, este desconectado. El interruptor deba ser puesto enla posicion “OFF” (desconectado) y se debe poner un candado en la anilla. La llave del candado debe ser guar-dada 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 en-grase en cualquier maquina.

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3.0 Packing L

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3.0 Packing List

Part No. Description Qty.

Basic Machine 1Extension Side Tables:

47166 18 x 24 Steel Side Table 247164-1 Side Table Back Plate 2H-6913-606 Side Table Bolts 8H-6424-6 Side Table Hex Nuts 8H-6939-616 Leveling Screws 4H-6913-6008 Side Table Mounting Bolts (shipped installed) 4H-7321-6 Side Table Mounting Washers (shipped installed) 447006-2 False Clamp Plate (shipped installed) 1

47507 Knife 2H-6918-608 Knife Bolts 68815 Knife Washers, Special 64171 Cutting Sticks (one installed) 4A-12608-4 Jogging Aid 1Tool Kit: 5064 Cutting Stick Puller 1W-164 Hex “T” Wrench 1W-158 5/16 Open End Wrench 1W-141 1/8” 1W-137 5/32” 1

Fuses: E-2308 3.2 A (X, XD, XG Series) 1E-2330-11 0.2 A S.B. (X Series) 1E-889-7 6.25 A (X Series) 1E-2330-7 5 A S.B. (X, XD, XG Series) 1E-889-35 1 A S.B. (X, XD, XG Series) 1E-889-5 4 A S.B. (X, XD, XG Series) 1E-889-9 8 A S.B. (X, XD, XG Series) 1E-2330-8 6.3 A S.B. (XD, XG Series) 1E-2330-3 2 A S.B. (XD, XG Series) 1

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4.0 Specifications

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4.0 Specifications

Description Inch Units Metric Units

Cutting Width 30 ½” 77.5 cm

Clamp Opening 4” 10.2 cmClamping Force 400-5000 lbs. 1.8 – 22 kNMinimum Cut – Standard ¾” 1.9 cm

- Special ½” 1.3 cm- w/ False Clamp Plate 2” 5.1 cm

Table SpaceFront: (std.)Back:

25”30 ½”

63.5 cm77.5 cm

DimensionsTable Height 36 ½“ 92.7 cmOverall Height 58 ½” 148.6 cm

Overall Length 69 ½” 176.5 cmOverall Width 48 ½” 123 cm

w/ Side Tables 78 ½” 200 cmw/o Side Tables 48 ½” 123 cm

Approx. Net Weight 2550 lbs 1157 kgApprox. Shipping Weight 2750 lbs 1247 kgWill pass through door:

Assembled 49” 125 cmTable/treadle out 42” 112 cmTable/treadle/pwr unit out 19” 48.5 cm

Electrical Standard: 5 HP, 3 Phase, 60 Hz AC; 208/230V, @ 25A or 460V @ 11.5AOptional: 5 HP, Single Phase, 60 Hz AC; 208V, @ 44A or 230V @ 44A

3 Phase, 50 Hz AC; 220V or 380VSingle Phase, 50 Hz AC; 220V

SpacerXD & XG series spacer has 9801 cuts on 99 channels.XT series spacer has 47000 cut positions within the machine. (Unlimited with floppy discPort.)

Minimum space between cut positions is 0.005” or 1mm. Repeat positioning accuracy is0.003” or 0.05mm.

Electric Eyes –

Response time = 68 msObject detection capability = 12 mm

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

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5.0 Installation & Set

1

5.0 Installation & Setup

5.1 Inspecting Shipment

This machine has been carefully packed to prevent damage during shipment. However, claims fordamage or loss are the responsibility of the recipient. Inspect all shipments as soon as they are re-ceived. If there is any noticeable damage, note it on the freight bill. Visual and/or hidden damagemust be reported to the claims department of the carrier within 15 days. Contact your dealer if youneed any assistance. Check the contents of the box against the packing list on page 11. Make surethere are no missing items.

5.2 Uncrating

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

5.3 Lifting Instructions

Unpacking, handling, and positioning should be done by professional handlers. If handling or un-packing is a problem, your dealer or a local trucking facility should be able to supply or recommend aqualified rigger. This 2550-lb/1157-kg machine should be moved with experienced people and theproper equipment. Do not risk personal injury or damage by attempting to move machinery with in-adequate equipment or manpower.

Champion cutters may include an optional block for lifting the machine. Remove the protective coverfrom the rear of the arch. Install the block with the hole up. Use a hook and chain or lifting strapsrated at 3000-lb/1360-kg or higher. Carefully lift the machine off its skid, and remove the skid. Placethe machine on the floor.

Lifting straps may also be used to lift the machine by placing the straps around the front and rear ofthe table. When straps are used in this way, wood blocks must be placed beside the lead screw toprevent 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 closethe machine body as possible. Gently lift the cutter, remove the skid and carefully place the cutter onthe floor.

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Once the machine is off its skid, it can be moved with a forklift or pallet jack. The foot pedal assemblymust first be removed.

5.4 Moving Instructions

Once the machine is off its skid, it may still be necessary to move it into position. To use a pallet jack

or fork truck, the foot pedal assembly must first be removed. Disconnect the cable from the footpedal by removing the nut underneath the foot pedal arm. Detach the foot pedal pivot plate from themachine base by removing its (2) mounting screws at the rear of the machine. Slide the foot pedalout towards the front of the machine. Insert the pallet jack or forklift from the front of the machine, liftand move carefully. Once in position, install foot pedal assembly.

5.5 Cleaning

Wipe down the table and bare metal surfaces with a non-flammable solvent such as CRC or blanketwash. The table surface is cast iron, and it will rust if left unprotected. Coat the table with a non-abrasive wax. A Cutter Care Kit, p/n 16077, with cleaner and wax, is available thru your AuthorizedChallenge Dealer. See section 15.2.5 on page 100 for instructions. The protective film on the con-sole may be removed. Never clean console with petroleum based solvents. Damage will result. See

also, Operator Cleaning, pg. 79.

5.6 Assembly: Standard

Unless otherwise specified, the only items that have been disassembled for shipping are the knifeand extension side tables. Knife installation will be covered later. Side table attachment follows.

NOTE: Assembled side tables are awkward and heavy. Use two people to attach the side tables.

1. Assemble the side table backs to the table surfaces. The extension table bolts and hex nutsare packed inside the tool kit box. Tables are installed with the clearance hole for the knifegibs towards the middle of the cutter.

2. Have one person hold the table in position while the other aligns the holes and starts thread-ing the mounting bolts with washers. (Mounting bolts are shipped installed in the side of ta-ble- remove them to install tables.)

3. Use a 9/16” socket and extension to snug tighten the mounting bolts, then tap the extensiontable up or down with your hand or a rubber mallet until it is flush with the main table. Run astraight edge or sheet of paper over the seam to check the fit. Make sure your stock will notcatch on the seam.

4. Locate the leveling setscrews. They will be found in the tool kit. Insert them into thethreaded holes next to the mounting bolts and use them to level the tables. You may have toloosen the mounting bolts a little to allow enough play to level the table. When the extensiontables are leveled and the surface joints even, tighten the mounting bolts securely.

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

5.7 Assembly: Table Out

If your cutter has been shipped “knocked down”, it is even more important to have a rigger or qualifiedpersonnel with the right equipment to position and assemble your cutter.

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Your cutter will arrive in two crates. One contains the arch/base assembly. The second, a “DutchBox”, contains the parts and accessories with the table upside down on the bottom. Reassemble asfollows:

1. Remove the crate from the arch/base assembly.

2. Remove the accessories from the Dutch box.

3. Lift the table out of the Dutch box and turn it right side up. NOTE: Be careful not damage orbend the lead screw or backgauge drive motor assembly. Use wood blocks beside the screwif straps are used (see Figure 2 on page 13).

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 twotaper pins in the cut stick slot.

6. After locating the table, install the eight (8) table bolts. Seat the taper pins and tighten thebolts.

7. Attach the front and rear side guides. Install the table end cover. Install the rear table Plexi-glas cover to the table end cover and side guides.

8. Install the Paper Deflector Option if ordered. Install it from the inside of the left arch post.

Depress the deflector with your thumb while installing the assembly to clear the knife bar, (Figure3). Attach with one 3/8-16 x 3/4" and two 3/8-16 x 2" socket head cap screws.

Figure 3

The two 2" socket screws must be installed from inside the arch, (Figure 4 on page 16). Remove

the side guard plate for access. All three bolts should have shake proof lock washers.

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16

Figure 4

9. Reconnect the cut button cable assembly. Route the cable through hole in the center of theelectrical enclosure. Wire to power panel according to instructions found on Main Assemblysheets 8, 9, or 10 (depending upon your model). Use pliers to snap strain relief bushing ontocable outside power panel. Snap bushing into top of enclosure.

10. Reconnect the main power disconnect switch. Route cable through the hole in the top rightportion of the power panel enclosure. Make sure the elbow is outside the enclosure (Figure5) and the wires pass through its nut. The nut should be on the inside of the enclosure. Wireto power panel according to instructions found on Main Assembly sheets 8, 9, or 10 (depend-ing upon your model). Insert the conduit elbow in the top of the enclosure and screw on itsnut. Tighten the nut. Place a flat screwdriver against one of the nut’s prongs and tap thescrewdriver with a hammer.

Figure 5

11. Route the encoder cable underneath the table to the encoder. Start by threading the cablefrom the back of the arch to the table brace. Secure it to the brace with an electrical ty-wrapand connect it to the table bottom with the plastic cable clamp, (Figure 7 on page 17). Attachthe retractor spring to the table bottom with the button head cap screw as shown. Make surethe plastic encoder cover is on the cable and then attach the wire connector to the bottom of

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the encoder as shown in (Figure 6). Press the plastic cover over the encoder and the wireconnection.

Figure 6

Figure 7

12. Reconnect the backgauge motor cable (“X” Model has no backgauge motor). From the table,the cable runs through the strain relief bushing into the motor housing, (Figure 8). Attach thewires according to the wiring schematic in the back of this manual for the machine model thatyou have.

Figure 8

13. Reattach the clamp foot pedal assembly. Locate the pedal mounting plate (Figure 9 on page18). The pedal is located with a clevis pin and is secured with a hairpin cotter. Place oneend of the return spring on the machine bolt fastened to the side of the pedal arm. From in-side the left front enclosure, lift the other end of the spring up through the access hole andplace the end into the locator hole next to it, (Figure 10 on page 18). Use the cut stick pullerfrom the tool kit to make this connection. Now connect the pedal to the clamp pull down ca-ble. Insert the cable end through the pedal bracket. Adjust the nut until the cable is in slighttension.

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Figure 9

Figure 10

14. If your cutter has the air table option, connect the tube from the blower to the “T” connectorattached to the hoses on the bottom of the table.

5.8 Hydraulic Power Unit Removal

If the installation required that the machine must pass through a doorway that is less than 49” butgreater than or equal to 42” wide, the machine should have been ordered from Challenge “knockeddown” with the table and foot pedal removed. If the machine must fit through a doorway that is lessthan 42” and greater than or equal to 19”, the hydraulic power unit must be removed on-site. To re-move 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. Locate the hose that connects the manifold to the oil filter. Disconnect it from the filter. Lo-cate the hose that the manifold to the hydraulic pump. Disconnect it from the manifold. At-tach the hose that was connected to the manifold to the oil filter. Attach the hose that wasconnected to the filter to the manifold. This will minimize oil leakage. After the unit is in-

stalled, reconnect the hoses to their original location.

3. Remove the (4) bolts that attach the hydraulic assembly to the cutter base. They are locatedat the bottom of the opening in the base.

4. USE EXTREME CAUTION WHILE REMOVING THE POWER UNIT. It is very heavy andshould be removed using a fork truck. CAUTION, the machine will be top heavy and may tipeasily with the power unit removed.

LocatorHole

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

6. Reinstall the power unit, conduits, hoses, and foot pedal after the machine is in position.

5.9 Hydraulic Check

The hydraulic reservoirs on the Champion cutters are filled with 13-1/2 gallons of Rykon No. 46 hy-draulic oil at the factory. The fluid level should be checked before operation, and at least once perweek during normal operation. The reservoir is located behind the cutter, beneath the table (Figure11). The hydraulic tank has a sight gauge in the rear for checking the oil level. The reservoir shouldbe kept full at all times.

Figure 11

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

5.10 Power Hook-Up

For satisfactory operation, be sure that your cutter is wired for the correct phase and voltage and hasadequate 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 in-formation to the front cover of this manual.

Watch Setup Voltage- Inadequate power to the cutter can be a major source of problems. Toomany machines on the same circuit will reduce the power to each machine. Inadequate voltage will

frequently cause overheating, loss of power, and in extreme cases, failure to operate. Test your volt-age when the shop is at actual working levels. Challenge recommends a dedicated line with a lock-able disconnect to provide adequate power for this machine.

CAUTION: SHOCK HAZARD! Always disconnect power at mainpower panel before working on the cutter. Lock it out to prevent accidental power up. (SeePower Lockout Procedure page 8).

SightGauge

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

Electrical Specifications for Champion Cutters

Volts Amps Circuit Size Wire Size Metric Wire3 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.

5.10.1 Three Phase Hook-Up

The power source is connected to the cutter through the bottom of the power panel (right hand side).

1. DISCONNECT AND LOCK OUT THE POWER at the main panel to prevent accidental power

up. (See Power Lockout, page 8).

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

3. Fasten the ground lead to the ground terminal lug (Figure 12).

Figure 12

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 turn-ing the same direction as the arrow on the motor casing.

If it isn’t, disconnect the power and simply exchange any two leads of the power cord as in Figure 13on page 21.

The motor will now turn the correct direction. Double check to make sure.

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Figure 13

5.10.2 Single Phase Hook-Up

The power source is connected to the cutter through the bottom of the power panel (right hand side).

1. DISCONNECT THE POWER AND LOCK IT OUT at the main power panel to prevent acci-dental power up. (See Power Lockout, page 8).

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

3. Fasten the ground lead to the ground terminal lug, (Figure 12 on page 20).

4. Fasten the two power leads to the L1 and L2 terminals of the main terminal block.

5. Close the electrical panel doors and latch them. Unlock the main panel and turn on thepower. Turn on the main power disconnect switch and simultaneously press both cut buttonsto start the hydraulic motor.

1

2

3 1 2

3

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6.0 Champion 305 X/XD/XG Cutter Diag.

22

6.0 Champion 305 X/XD/XG Cutter Diag.

Figure 14

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7.0 Operation X Mod

2

7.0 Operation X Model

Figure 15

IMPORTANT: DO NOT ATTEMPT TO OPERATE THE CUTTER UNTIL YOU HAVE THOROUGHLYREAD AND UNDERSTAND ALL OF THE FOLLOWING INSTRUCTIONS. CALL YOUR AUTHOR-IZED CHALLENGE DEALER IF YOU STILL HAVE ANY QUESTIONS.

7.1 Power – Main Switch

Power is brought to the machine when the main power switch is turned to the “ON” position (Figure16). The display and line lights are turned on at this time.

Figure 16

The display and line lights will shut off after 2 minutes without any activity. To restore power to the

display and line lights, press a cut button.

NOTE: Do not turn handwheel when power is off.

7.2 Table Light

The table light is turned on and off by a switch located under the arch (Figure 14, page 22). The ta-ble light will also turn on and off with the main power, provided the table light switch is in the “on” po-sition.

OFF ON

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7.3 Presetting the Backgauge

The backgauge must be preset every time the power is turned on. Using the handwheel, turn thebackgauge until it passes forward through the 5” position. The display readout will then show the cor-rect backgauge position.

7.4 Backlash Indicator

A small red dot will appear in the upper corner of the display if the backgauge was last moved back-wards. To insure accurate cuts, always approach the desired backgauge position from behind (mov-ing the backgauge forward).

7.5 Backgauge Lock

Tightening the backgauge lock prevents the backgauge from moving while positioning paper againstit. The Champion X model has a thumb screw lock beneath the hand wheel, (Figure 17).

Figure 17

7.6 IN/MM Toggle Switch

This switch will toggle the display readout between inches and millimeters. It will be found on theconsole as shown in Figure 15, on page 23.

7.7 Making a Cut

Place the paper against the backgauge and left side guide. Press and release both cut buttons onceto start the hydraulic motor. Then press and hold both cut buttons to start the cut cycle. While hold-ing the cut buttons, the knife and clamp will complete the cut cycle. If the buttons are released at anytime during the cycle, the knife and clamp will immediately return to the up position.

Note: Both cut buttons must be released before a new cut can be made. The cut buttons must bepressed within 0.5 seconds of each other both to start the hydraulic motor and to make a cut.

DO NOT ATTEMPT TO REMOVE TRIM UNTIL THE KNIFE AND CLAMPHAVE STOPPED IN THE UP POSITION! Due to static buildup, fine trim may have a tendency tostick to the clamp or knife surfaces. Fingertips might be drawn into the knife by the clamp if this isattempted. Wait until the knife and clamp have BOTH STOPPED MOVING before removing stocktrim.

Thumb Screw

Lock

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7.0 Operation X Mod

2

7.8 Turning Off the Hydraulic Motor

The hydraulic motor will turn off after 2 minutes without any activity. The hydraulic motor can also beshut off manually by pressing and holding the left cut button.

7.9 Jogging Aid

All Champion cutters include a jogging aid as standard equipment. The jogging aid allows the opera-tor to load and align stock without placing hands or arms under the clamp and knife area.

Load and align the paper against the side guide, (Figure 18), then square it to the backgauge for cut-ting.

Figure 18

Additional jogging aids can be purchased by contacting your authorized Challenge dealer.

Always remove the jogging aid from the table before making a cut.

7.10 Manual Clamping (Using the Foot Pedal)All Champion cutters are equipped with a manual clamping feature which allows the operator tomanually clamp paper before beginning the cut cycle. To use this feature, press down on the footpedal until the clamp comes down on the paper. While holding the foot pedal down, press the cutbuttons. Release it once the cut has been completed.

7.11 Air Table ON/OFF

If your machine is equipped with an air table, it can be turned on and off by pressing and holding theright cut button.

7.12 Adjusting the Clamp Pressure

DO NOT set the clamp pressure below 300 psi. Pressures below thiswill not allow the auto-cycle to operate properly, and the knife will come down before theclamp. Severe lacerations and stock spoilage could result.

A pressure reducer valve and gauge located inside the left door housing on the front of the cutter be-low the table. By adjusting the pressure reducer valve, clamping pressure can be set (see HydraulicAdjustments section) to a maximum of 1400 psi for heavy stock or large reams to a minimum of 300

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psi for pressure sensitive jobs like carbon or NCR sets. For pressure sensitive stock using the falseclamp plate is also recommended.

7.13 Re-zeroing the Backgauge

If the backgauge position readout does not match the actual measurement between the knife and the

backgauge, the cutter must be re-zeroed. This inaccuracy can occur due to rough handling duringshipment.

The accuracy can be checked by comparing cut sheets of paper. This process is described below.

NOTE: The backgauge gibs should be adjusted and the backgauge squared before attempting to re-zero, see Adjustments.

1. Place a 1/4 to 1/2 inch (5 to 13mm) lift of 8-1/2 X 11 (A4) paper against the center of thebackgauge.

2. Trim cut lengthwise and rotate 1800. Using the backgauge position readout, bring the paperup to the 10" (254mm) position and make a cut. Move the backgauge up to 5" (127mm) and

make another cut.

3. Take several sheets from the center of each lift and compare them to each other. The en-coder system on your cutter will space accurately between your 10” (254mm) and 5"(127mm) cuts, whether the overall accuracy is correct or not. The stack of paper betweenthe 10” (254mm) and 5" (127mm) cuts will be a true 5", but the paper left against the back-gauge will not if the backgauge position readout is off.

4. If the backgauge position readout is off, you will have to adjust the pre-setter wand attachedto the bottom of the backgauge, (Figure 19).

Figure 19

5. The leading edge of the pre-setter wand activates the pre-setter sensor as the backgauge ismoving forward through it. If your test showed the backgauge measurement to be short, adjust the wand forward. If tests show the measurement to be long, adjust the wand backward.

6. Run the backgauge back, then bring it forward through the 5" (127mm) pre-setter again andmake another test. Continue to adjust and preset until your test sheets match.

Presetter PresetterWand

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7.0 Operation X Mod

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7.14 Knife Down Mode

The knife down mode is used to send the knife and clamp to the down position without returning up.This provides a way for the service technician to change the knife. To send the knife down, flip thetoggle switch (shown in Figure 14, on page 22), and press and hold the cut buttons until the knife andclamp come down and the hydraulic motor shuts off.

To send the knife and clamp back up, flip the toggle switch to normal run, shut the main power dis-connect switch off and then back on, press both cut buttons.

7.15 Electric Eyes

The electric eyes prevent reaching into the cutting area while a cut is being made. If the beams arebroken while a cut is being made, the knife and clamp will return to the up position.

7.16 False Clamp Plate

The false clamp plate should be stored in its sheath when not in use. The sheath contains a sensorthat signals the computer that the false clamp plate has been removed. The computer automaticallyallows the minimum cut when the sensor detects the false clamp plate.

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8.0 Diagnostics

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8.0 Diagnostics

8.1 Error Code Reference Chart

The Champion X model power panel computer monitors machine operations. The warning or errorcode numbers will be shown on the digital backgauge position display when an improper operation isdetected. An explanation of the codes is given below. When an incorrect operation occurs, the ma-chine will stop all functions. The code and cutter can only be reset by turning the main power switchoff and back on again.

Warning Codes Error CodesCommunication (01-19) Power Panel (45-69)

00 Reserved 45 Unused

01 – 14 Unused 46 Knife latch out of position at power on15 Power Panel Reset (Normal Condition) 47 Knife latch movement – outside of hydraulic

routine

16 – 19 Unused 48 Knife latch position error during cut cycleConsole (20-29) 49 Unused

20 – 29 Unused 50 UnusedBackgauge (30-39) 51 Outputs on, outside of hydraulic routine

30 – 38 Unused 52 Starter dropped out while energizedPower Panel (40-44) 53 Contactor de-energized but failed to drop out in

time 40 Cut button and/or footswitch stuck in –

power up54 Contactor de-energized but was stuck in

41 Cut relay stuck on at power up 55 Unused

42 Cut relay failed to disengage after a cut 56 Unused43 Cut relay on – outside of hydraulic routine 57 Hydraulic motor contactor failed to pull in

44 Guard muted during cut cycle 58 Unused59 Safety system shut down (if equipped with this

option)60 Unused

61 Outputs on, without cut button depression (MConly)

62 – 66 Unused

67 Knife drift

68 Clamp drift

Hydraulics (70-79)

70 Unused

71 Clamp cylinder failed to come up normally

72 Unused

73 Clamp cylinder failed to come up normally

74 Knife failed to leave the up limit

75 Knife failed to come up

76 Knife change (normal)

77 Sequence error

78 – 79 Unused

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9.0 Operation – XD Mod

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9.0 Operation – XD Model

IMPORTANT: DO NOT ATTEMPT TO OPERATE THE CUTTER UNTIL YOU HAVE THOROUGHLYREAD AND UNDERSTAND ALL OF THE FOLLOWING INSTRUCTIONS. CALL YOUR AUTHOR-

IZED CHALLENGE DEALER IF YOU STILL HAVE ANY QUESTIONS.

9.1 Power - Main Power Switch


Figure 20

The screen saver will activate and the line lights will shut off after 5 minutes without any activity. Thisshut-off time can be changed in the Parameters screen of the Maintenance Mode (see the “OperatingControls/Maintenance Mode/Parameters/Time Out” section, page 36). To restore power to the dis-play and line lights, press any button on the keyboard.

9.2 Table Light

The table light is turned on and off by a switch located under the arch (Figure 14, on page 22). Thetable light will also turn on and off with the main power, provided the table light switch is in the “on”position.

9.3 Start Up

Once power has been turned on, the display will show the following:

OFF ON

55.000 in

Backgauge must move to be preset.Please clear the table.Revision x.x

Press clear to startA) MaintSSXSSSS

SerialNumber

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When the CLEAR key is pressed, the backgauge will move to coordinate the true position into thecomputer (if the knife and clamp are not in the “up” position, the display will prompt the operator toraise them by pressing the cut buttons prior to presetting the backgauge). When finished, the ma-chine will be in “Send Mode” and the display will appear similar to the display shown below.

The backgauge may now be sent to a desired position by simply typing the dimension and pressingSEND (see the Send Mode section on page 49, for more details).

9.4 Making a Cut

Place the paper against the backgauge and left side guide. Press and release both cut buttons onceto start the hydraulic motor. Then press and hold both cut buttons to start the cut cycle. While hold-ing the cut buttons, the knife and clamp will complete the cut cycle. If the buttons are released at anytime during the cycle, the knife and clamp will immediately return to the up position.

Note: Both cut buttons must be released before a new cut can be made. They must be pressedwithin 0.5 seconds of each other in order to make a cut.


The hydraulic motor can be shut off at any time by pressing soft-key “C” (Mtr Off) or by pressing andholding the left cut button. The hydraulic motor will also shut off when the screen saver is activated.This shut-off time can be changed in the Parameters screen of the Maintenance Mode (see the “Op-erating Controls/Maintenance Mode/Parameters/Time Out” section).

9.5 Jogging AidAll Champion cutters include a jogging aid as standard equipment. The jogging aid allows the opera-tor to load and align stock without placing hands or arms under the clamp and knife area.

Load and align the paper against the side guide, (Figure 21 on page 31), then square it to the back-gauge for cutting.

5.000 in

>_

A) Maint

14CP

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Figure 21

Always remove the jogging aid from the table before making a cut.Additional jogging aids can be purchased by contacting your authorized Challenge dealer.

9.6 Adjusting the Clamp Pressure

The clamp pressure is shown in the upper right corner of the display. Clamp pressure ranges from 0to 15, where 15 is the maximum. To change the clamp pressure, use the up and down arrow keys.NOTE: When using settings 0 or 1, the knife and clamp may begin moving at the same time during acycle.

9.7 Manual Clamping

All Champion cutters are equipped with a manual pre-clamping feature, which allows the operator to

manually clamp paper before beginning the cut cycle. To use this feature, depress the foot pedal un-til the clamp comes down on the paper. While holding the pedal down, press the cut buttons. Re-lease the pedal once the cut has been completed.

9.8 Knife Change Alarm and Lubrication Alarm

The Champion 305 XD has two built in alarms that will be displayed after a certain number of cuts.The knife alarm displays a message to remind the operator to change the knife. The lube alarm dis-plays a message to remind the operator to have the machine lubricated. The lube alarm will also dis-play the name and phone number of the Challenge dealer from which the machine was purchased.To reset either alarm, or to change the knife alarm value, see the “Operating Controls/MaintenanceMode/Parameters/ Knife Count” section on page 36 . The lube alarm value is factory set at 2,500cuts and cannot be changed.

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9.9 Champion XD – Display Panel

9.10 Definition of Keys

9.10.1 Backgauge Glide Control

The backgauge glide control is used to manually position the backgauge. The speed of the back-gauge 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.

9.10.2 IN/MM Key

This key toggles the display to show the position and programmed send values in inches (e.g. 5.250),inch fractions to the nearest 1/64” (e.g. 5_ 1 /

4), or millimeters (e.g. 133.3).

9.10.3 Air Table ON/OFF Key

This key turns the air table on and off.

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9.10.4 Send Key

The SEND key is used to send the backgauge to any valid position. If an attempt is made to send thebackgauge to an illegal position, an error message will be displayed at the bottom of the screen stat-ing “Number outside limit”. In the Job mode, the SEND key will also advance the backgauge to thenext sequential cut position before performing the cut.

9.10.5 Push-Out Key

The push-out key will move the backgauge forward 5 inches (or to the most forward position) andthen return it to its previous position. This allows paper to be removed from the cutter without puttinghands under the knife and clamp.

Never place hands in the clamp and knife area. Use the push-out keyor the backgauge glide control to move the paper to an area where it can be reached.

9.10.6 Clear Key

The CLEAR key is used to clear error messages and the current entry line.

9.10.7 Enter Key

The ENTER key selects items in the maintenance mode and processes data that has been entered inthe other modes.

9.10.8 Priority Add (X/Y) Key

The priority add key is used for entering fractions when they are combined with whole numbers. Thesymbol displayed when this key is pressed is the underline symbol “_”. An example of a number en-tered using the priority add key is 1_1/2.

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9.10.9 Soft-Keys

There are a total of four soft-keys labeled “A” through “D”. The functions of these keys change de-pending on the operating mode. The function of each key can be found on the bottom of the displayscreens.

9.10.10 Arrow Keys

The four arrow keys can be used in almost all screens. The arrow keys are primarily used for movingthe cursor around on the screen, or to toggle between highlighted selections. In some screens, theleft arrow key acts as a backspace key.

9.10.11 Contrast Control

The contrast of each display screen can be adjusted by using the contrast control buttons located

directly above each display screen.

9.11 Manual Backgauge Control


The backgauge can be moved manually by use of the backgauge glide control. Press “down” for for-ward travel and “up” for reverse travel. The further away from center that the actuator is pushed, thefaster the backgauge will travel. Press the center to display true position.

9.11.2 Backlash Indicator

To insure accurate cuts, the backgauge must be brought to the cut position from the rear of the table.In the display, to the right of the backgauge position, there is a small arrow to indicate reverse travel.This arrow should be off when making a cut. Moving back past your cut position, then forward to it,compensates for any play in the backgauge nut and leadscrew.

9.12 Send Mode

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>_

A) MaintB) Job

ReverseIndicator

Arrow

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3

The send mode is the first screen displayed after the backgauge is preset. From this screen thebackgauge can be positioned with the backgauge glide control or by entering a value and pressingthe SEND key. A mathematical expression can also be entered as a send value. Simply type theexpression and press SEND. You can also enter an equation, which begins with the current back-gauge position. For example, if you want to send the backgauge 2” forward from its current position, just press [-] [2] and SEND.

The send mode screen can also be used for doing math calculations that are larger than the back-gauge’s reverse limit. In this case, you must press ENTER to have the result displayed on thescreen.

9.12.1 Entering Math

In the simple send mode, the Champion XD is capable of calculating an entire math string such as,10- 5x6+2_3/4. However, the result is limited to 29999.000 and the result cannot be a negativevalue. In job mode, and during a send, the result of the calculation must be less than the backgaugelimit of 30.500 inches.

9.12.2 Entering FractionsFractions are entered with the priority add key X/Y. The symbol displayed when this key is pressed isthe underline symbol “_”. This instructs the computer to add the fractional portion of the entry beforeperforming the remaining math. This key is useful when entering a formula as follows: 3x2_3/4 =8_1/4. If a simple plus had been used instead, the result would be as follows: 3x2+3/4 = 6_3/4.

9.13 Maintenance Mode

The maintenance mode is an area where many machine functions can be set or modified. The fourprinciple functions are: Language, Parameters, Diagnostic, and Knife Adjust. To select a particularfunction, use the up and down arrow keys to toggle to the desired function and press ENTER. Seethe following descriptions for an explanation of each function.

9.13.1 Language

In the language screen, use the up and down arrow keys to toggle to the desired language, and pressENTER. All messages will be displayed in the selected language.

5.000 in

MAINT MENULANGUAGEPARAMETERSDIAGNOSTICKNIFE ADJUST

C) SendB) Job D) Exit

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36

9.13.2 Parameters

In the parameter screen, use the up and down arrow keys to toggle to the desired parameter, andpress ENTER. See the descriptions that follow for an explanation of each parameter.

9.13.2.1 False Clamp

The false clamp plate is an optional attachment, which reduces the creasing of paper caused by theclamp. The disadvantage of using the false clamp plate is that it limits the smallest cut dimension.The computer must know when the false clamp plate is installed on the machine to preventthe backgauge from crashing into it. In the false clamp screen, use the up and down arrow keys totoggle between ON or OFF to indicate the presence of the false clamp plate, and press ENTER.

9.13.2.2 Time-out

This parameter sets the amount of idle time for which the screen saver activates and the line lightsand hydraulic motor turn off. The choices are 2, 5, 10, 20, and 30 minutes. In the time-out screen,use the up and down arrow keys to toggle to the desired time-out, and press ENTER.

9.13.2.3 Push-out

Normally, whenever the backgauge is sent to a larger dimension, a five-inch (127mm) push-out isperformed to aid the operator in accessing the paper. In some situations, it may be necessary to turnthis feature off. It is recommended that this feature be left on whenever possible. In the push-outscreen, use the up and down arrow keys to toggle to the on or off status as desired, and press EN-TER.

9.13.2.4 Accuracy Adjust

This parameter provides a means for adjusting the accuracy of the backgauge. To change the accu-racy, send the backgauge to 2 inches (50.8mm) and cut some paper. Measure the paper, and type inwhat you actually measure. The computer will calculate the amount of error and will compensate.The amount of error could also be added to or subtracted from the value already displayed.

9.13.2.5 Knife count

The knife count parameter allows the operator to reset the knife alarm and the lube alarm. The knifealarm displays a message to remind the operator to change the knife. The lube alarm displays amessage to remind the operator to have the machine lubricated. The lube alarm will also display thename and phone number of the Challenge dealer from which the machine was purchased.

There are three functions within the knife count parameter: Clear Count, Knife Alarm, and ClearLube. Select the desired function and press ENTER. See the following descriptions for an explana-tion of each function.

Select Clear count to reset the knife counter when a knife change has been performed.

Select Knife Alarm to enter or change the knife stroke alarm value. When this value is reached, thedisplay will alert you to change the knife and reset the knife counter. Knife alarm values for theChampion XD are factory set at 2,500 cuts. However, you may want to change this value based onyour specific machine applications. See the Knives section for help in choosing a knife alarm valuefor your machine.

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Select Clear lube to reset the lube alarm after performing the lubrication requirements as shown inthe maintenance section of this manual (page 80). NOTE: The alarm will activate after 2,500 cuts.This value is set at the factory and cannot be changed.

9.13.2.6 Machine count

The number displayed is the total number of cuts made by the machine and cannot be reset.

9.13.3 Knife Adjust

The knife adjust function provides a way for the service technician to change the knife. In the KnifeAdjust screen, use the up and down arrow keys to toggle to the up or down status as desired, andpress ENTER. Press and hold the cut buttons to send the knife to the desired position.

9.13.4 Diagnostic

The diagnostic area can be very helpful in locating a problem in the event of a machine malfunction.Use the up and down arrow keys to toggle to the desired selection, and press ENTER. See the fol-lowing descriptions for an explanation of each.

9.13.4.1 Error Code

The Error Code function simply recalls the last five error messages that were displayed. This can bevery useful in cases when the malfunction cannot be reproduced in the presence of the service tech-nician.

9.13.4.2 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 checkthe status of a switch without removing any covers. Cuts and backgauge movements are allowed inthis screen so that the technician may observe the status of the inputs and outputs during machineoperation.

9.13.4.3 Clear Memory

The Clear Memory function resets the memory to a known state. All cut positions will be erasedduring this operation.

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DIAGNOSTICError CodeSensor DataClear MemoryClamp Adjust

A) Maint C) SendB) Job D) Exit

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9.13.4.4 Clamp Adjust

This function is used to set the maximum and minimum clamp pressures. First adjust the maximumpressure with the up and down arrow keys. Press “D” (Exit) then adjust the minimum pressure. Thenpress “C” to return to the Send Mode or “D” to return to Diagnostics. For more information see Main-tenance Adjustments/Hydraulics section on page 84 .

9.14 Job Mode - (Programmable Model Only)

The 305XD can be programmed for up to 99 different jobs or channels. A job is used for making asequence of cuts using the send (or cut) values of the job as the backgauge positions for each cut.Each job can hold up to 99 send values. If 2 channels are linked, up to 198 send values can be ac-cessed from one job. When the job mode is entered, all previously programmed jobs will be dis-played along with their name and lock status. Locked jobs will be indicated by an asterisk “*”. A plus“+” sign at the bottom of the screen indicates there are more jobs programmed than what are dis-played. An example of a job mode screen display is shown above.

9.14.1 Lock/Unlocking a Job

In the Job Mode screen, the soft-key “A” will display “Lock” or “Unlock” depending on the currentstatus of the job. If a job is locked, an asterisk “*” will be displayed to the right of the job name. Tochange the lock status of a job, simply move the cursor to the desired job using the up and down ar-row keys, and press the soft-key “A” (Lock/Unlock).

9.14.2 Copying a Job

First, select a job to copy by moving the cursor up or down to the desired job number and press thesoft-key “B” (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 islocked, the copy will not be allowed. NOTE: if the new job is not locked, but contains data, the olddata WILL BE LOST.

9.14.3 Erasing a Job

Select a job to erase by moving the cursor to the desired job. Press the soft-key “C” (Erase). “Clearchannel #”. To erase a send value, press the soft-key “C” (Erase). This will remove the cut valuecurrently being pointed to will be displayed, followed by YES or NO. Use the up and down arrow keys

>

1> JOB 12> TESTJOB5>6> BOBS JOB *7> 8.5 X 11 *9>

10>+

A) Lock C) EraseB) Copy D) Exit

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to toggle to YES or NO. YES will erase the job, NO will leave the job unchanged. NOTE: locked jobs can be erased!

9.14.4 Creating a New Job

To create a new job, type in a number that is not already assigned to a job and press ENTER (enter-

ing a job number greater than 99 will create job #99). The cursor will move to the line correspondingto the number you typed in, prompting you for a job name. If no job name is desired, simply pressENTER again to begin entering send values (see below). To name the job, press the right arrow keyto move the cursor to the first character position. Enter a character of the alphabet by using the upand down arrow keys to toggle to the desired character. The numeric keys can be used to enternumbers directly into the job name. When the desired character is in place, use the right arrow key tomove to the next character position. The job name can be up to 10 characters long. A letter can beremoved from the job name by moving the cursor to the undesired character and pressing the CLEARkey. When finished, press ENTER to save the name and to begin entering send values. The screenshould now look similar to the one shown next:

9.14.4.1 Entering Send Values

Now enter send values by using any of the following methods: 1) Type in the desired value and pressENTER, 2) Press ENTER at a blank line - this will enter the current position of the backgauge as asend value, or 3) Use the “Cut and Record” feature as described below.

9.14.4.2 Cut and Record

To use this feature when creating a new job, simply send the backgauge to a desired position usingthe backgauge glide control or by using SEND, then make a cut. The current backgauge position willautomatically be displayed in the next available cut location and the operator will be prompted topress ENTER to record the current value. If ENTER is not pressed, the value will not be recordedinto the job as a send value. This can be very convenient for setting up a program when the actualcut positions are not known.

9.14.4.3 Channel Linking

If more than 99 cut values are needed, 2 channels can be linked together into one job providing up to198 cut values. This is done automatically when a job is at 99 cuts and an attempt is made to addanother value. At this point, a screen is displayed asking: do you want to link to the next channel?Use the up or down arrow key to select yes or no. If no is selected, the last cut will be discarded andthe new value will be inserted. If yes is selected, the last cut will be pushed into the first value of thenext channel, although it will be displayed as value 100 of the current channel. If the next channel is

5.000in # 1

1> _

A) Insert C) EraseB) Job D) Exit

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40

locked, linking will not be allowed. NOTE: If the next channel is not locked, but contains data, the olddata WILL BE LOST. After 2 jobs have been linked, the linked job will be displayed as “^^^^^^^^” andwill be locked.

To unlink a job, use the up or down arrow key to point to the linked job name and press soft-key “C”(Erase).

9.14.4.4 When Finished

When finished entering send values you may exit the current job by pressing soft-key “B” (Job) to goback to the job mode screen or soft-key “D” (Exit) to exit to send mode. Or you may use the current job for cutting by pressing the down arrow at the last line and following the instructions in the “Run-ning a Programmed Job” section.

9.14.5 Editing an Existing Job

9.14.5.1 Editing the Job Name

The job name can be edited (or added if an existing job does not have a name) in the job modescreen. To edit the name, move the cursor down to the desired job number by pressing the downarrow key. Then press the right arrow key to move the cursor to the desired character position andedit the character by pressing the up or down arrow keys to toggle between characters of the alpha-bet. Numbers can be entered directly by using the number keys. Pressing CLEAR clears the currentcharacter. When finished, you may either go to the current job by pressing ENTER, or go to a differ-ent job, or exit job mode.

9.14.5.2 Editing Send Values

To edit send values of an existing job, start by opening the desired job from the job mode screen. A job is opened by one of two methods: pointing at the desired job with the cursor and pressing EN-TER, or by entering the job number with the keypad and pressing ENTEROnce a job has been opened, the current job number will be displayed in the upper right corner.Note: If the job is locked, it cannot be edited.

Send values can now be edited by moving the cursor up or down to the desired send value and thentyping over the existing value.

To insert a send value, press the soft-key “A” (Insert). This moves all send values down and providesa blank line after the current send value. If more than 99 send values are needed, the job can belinked (see Channel Linking under Creating a New Job, page 39).

To erase a send value, press the soft-key “C” (Erase).This will remove the cut value currently being pointed to by the cursor. To backspace over the cur-rent send value without removing the line, press the left arrow key.

When finished editing the job, you may exit the current job by pressing soft-key “B” (Job) to go back

to the job mode screen or soft-key “D” (Exit) to exit to send mode. Or you may use the job for cuttingsince it is already open.

9.14.6 Running a Programmed Job

To use an existing job for cutting, you must first open it by using one of two methods: move the cur-sor to the desired job with the arrow keys and press ENTER, or enter the job number with the keypadand press ENTER. Once a job has been opened, the current job number will be displayed in the up-per right corner. Now press SEND to move the backgauge to the first programmed position (or send

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value). Push both cut buttons and make a cut. Once the cut is made, the backgauge will automati-cally push out the paper (if “push-out” is enabled) and move to the next programmed position. Afterthe last cut in the job is made, the backgauge will move to the first cut position of the current job.Pressing SEND at any time during the job will send the backgauge to its next programmed positionwithout making a cut. A plus “+” sign will be displayed at the bottom of the screen if more cuts remainin the current job.

9.14.7 Exiting a Job

To exit an open job, press the soft-key “B” (Job) to return to the job mode screen, or press the soft-key “D” (Exit) to exit to the send mode screen.

9.15 An Example Job

The following is an example of how to program a job which 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 “B”(Job) to go to job mode.

2. Type in a new job number and press ENTER. Note: It must be a number that does not corre-spond to an existing job. All existing jobs will be displayed on the screen (you may have toscroll through them to see them all). If you wish to replace an existing job with the new job,first erase the existing job by moving the cursor to it and press the soft-key “C” (Erase). Nowtype in the new number and press ENTER. In this example, job #’s 1, 2, 5, and 6 already ex-ist. We will use job # 7 for our new job. Press “7” and ENTER.

3. The cursor will move down to the new job number. At this point, press the right arrow keyonce to move the cursor to the first character position. Now name the job “8.5 X 11”. To dothis, press “8” on the number keypad. Then press the decimal “.” key and so on. To enterthe spaces and the letter “X”, use the up and down arrow keys to toggle through the alphabetand press the right arrow key to move to the next character position. When the last character

has been typed in, the display should look similar to the one shown below:

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7

1> 8.5002> 11.0003> _


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Now press ENTER to begin programming the job. The display should now look similar to this:

4. To enter the first send value of 8.5”, simply type in 8.5 and press ENTER. The cursor willmove to the second line. Now type 11 and press enter.

At this point, you could exit and save the job by pressing the soft-key “D” (Exit) to exit to sendmode, or the soft-key “B” (Job) to exit back to the job mode screen. However, lets use this job tocut paper.

5. Press the down arrow key once. This will remove the blank line 3 and move the cursor to thefirst send value (8.5”). Now press SEND. This will move the backgauge to the 8.5” position.Place the paper to be cut against the backgauge, close the front guard, and press the cut but-ton. Once the cut cycle is complete, the backgauge will push out the paper and move to thenext send value (11”). Now position the paper again, close the guard, and make another cut.After the cut is made, the backgauge will push out the stock and return to the first cut posi-

tion, ready to repeat the current job.

6. Now lets lock the current job so it cannot be edited. First, exit back to job mode by pressingsoft-key “B” (Job). Now move the cursor down to the new job using the down arrow key.Now press the soft-key “A” (Lock) to lock the job. An asterisk will appear indicating the jobhas been locked.

7. To exit back to send mode, press the soft-key “D” (Exit).

>

1> JOB 12> TESTJOB

5> BOBS JOB *6>7> 8.5 X 11_

+A) Lock C) EraseB) Copy D) Exit

5.000in # 7

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9.16 Electric Eyes




9.18 Operating Tips

Carefully lay out each sheet before you start cutting. Find the best cut pattern to give you the mostpieces out of the sheet. If the sheet will be folded, be sure grain of the paper is running in the samedirection as the fold or you will get a rough edge on the fold.

If an accurate cut is necessary for close register work, you MUST have a sharp blade in the cutter. Adull blade will pull or draw the paper and cause uneven cutting. Increased clamp pressure will noteliminate draw caused by a dull knife.

The correct clamping pressure varies from paper to paper. The general rule is that you should haveenough pressure to hold the paper securely but not so much that it marks the surface of the paperexcessively. Excessive pressure causes pile distortion and inaccurate cuts.

Mark the gripper edge and the guide edge of printed paper and make sure the first cuts are with theseguide edges against the backgauge.

Measure printed paper to check for shrinkage or expansion of the paper from humidity. You mayhave to disregard the printed cut lines and make your own.

When cutting narrow strips (1” or less), place lifts of equal height on opposite sides of the table to

prevent wear of the clamp guides.

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10.0 Operation – XG Model

44

10.0 Operation – XG ModelIMPORTANT: DO NOT ATTEMPT TO OPERATE THE CUTTER UNTIL YOU HAVE THOROUGHLYREAD AND UNDERSTAND ALL OF THE FOLLOWING INSTRUCTIONS. CALL YOUR AUTHOR-IZED CHALLENGE DEALER IF YOU STILL HAVE ANY QUESTIONS.

10.1 Using the Machine

10.1.1 Power - Main Power Switch

Figure 22


The screen saver will activate and the line lights will shut off after 5 minutes without any activity. Thisshut-off time can be changed in the Parameters screen of the Maintenance Mode (see the “OperatingControls/Maintenance Mode/Parameters/Time Out” section). To restore power to the display and linelights, press any button on the keyboard.

10.1.2 Table Light

The table light is turned on and off by a switch located under the arch (Figure 14, on page 22). Thetable light will also turn on and off with the main power, provided the table light switch is in the “on”position.

10.1.3 Start Up

Once power has been turned on, the display will show the following:

OFF ON

ClampPressure

| | | 14 | | |

-------------------------------C) UpD Down

55.000 in

>_ Backgauge must move to be

preset. Please clear the table.Revision 1.0

Press clear to startE) MaintF Job H Re eat

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10.0 Operation – XG Mod

4

When the CLEAR key is pressed, the backgauge will move to coordinate the true position into thecomputer (if the knife and clamp are not in the “up” position, the display will prompt the operator toraise them by pressing the cut buttons prior to presetting the backgauge). When finished, the ma-chine will be in “Send Mode” and the display will appear similar to the display shown below.

The backgauge may now be sent to a desired position by simply typing the dimension and pressingSEND (see the “Send Mode” section, page 49, for more details).

10.1.4 Making a Cut

Place the paper against the backgauge and side guide. Press and release both cut buttons once tostart the hydraulic motor. Then press and hold both cut buttons to start the cut cycle. While holdingthe cut buttons, the knife and clamp will complete the cut cycle. If the buttons are released at anytime during the cycle, the knife and clamp will immediately return to the up position.

NOTE: Both cut buttons must be released before a new cut can be made. Also, the cut buttons mustbe pressed within 0.5 seconds of each other in order to make a cut.


The hydraulic motor can be shut off at any time by pressing soft-key “B” (Mtr Off). The hydraulic mo-tor will also shut off when the screen saver is activated. This shut-off time can be changed in the Pa-rameters screen of the Maintenance Mode (see the “Operating Controls/MaintenanceMode/Parameters/Time Out” section, page 51).

10.1.5 Jogging Aid

All Champion cutters include a jogging aid as standard equipment. The jogging aid allows the opera-tor to load and align stock without placing hands or arms under the clamp and knife area.

Load and align the paper against the side guide, (Figure 23 on page 46), then square it to the back-gauge for cutting.

ClampPressure| | | 14 | | |

-------------------------------C) UpD) Down

5.070 in>_

E) MaintF) Job H) Repeat

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Figure 23

Always remove the jogging aid from the table before making a cut.

Additional jogging aids can be purchased by contacting your authorized Challenge dealer.

10.1.6 Adjusting the Clamp Pressure

The clamp pressure can be adjusted by pressing soft-key “C” (Up) to increase the pressure, and soft-key “D” (Down) to decrease the pressure. The pressure scale ranges from 0 to 15, 15 being themaximum.

10.1.7 Manual Clamping

All Champion cutters are equipped with a manual clamping feature, which allows the operator tomanually clamp paper before beginning the cut cycle. To use this feature, press down on the footpedal until the clamp comes down on the paper. While holding the pedal down, press the cut buttons.Release the pedal once the cut has been completed.

10.1.8 Knife Change Alarm and Lubrication Alarm

The Champion 305 XG has two built in alarms that will be displayed after a certain number of cuts.The knife alarm displays a message to remind the operator to change the knife. The lube alarm dis-plays a message to remind the operator to have the machine lubricated. The lube alarm will also dis-play the name and phone number of the Challenge dealer from which the machine was purchased.To reset either alarm, or to change the knife alarm value, see the “Operating Controls/MaintenanceMode/Parameters/ Knife Count” section on page 52 . The lube alarm value is factory set at 2,500cuts and cannot be changed.

10.2 Electric Eyes




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10.4 Champion XG – Display Panel

10.5 Definition of Keys


The backgauge glide control is used to manually position the backgauge. The speed of the back-

gauge 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 movethe backgauge backward, press upward.

10.5.2 IN/MM Key

This key toggles the display to show the position and programmed send values in inches (e.g. 5.250),inch fractions to the nearest 1/64” (e.g. 5_ 1 /

4), or millimeters (e.g. 133.3).

10.5.3 Air Table ON/OFF Key

This key turns the air table on and off.

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10.5.4 Send Key

The SEND key is used to send the backgauge to any valid position. If an attempt is made to send thebackgauge to an illegal position, an error message will be displayed at the bottom of the screen stat-ing “Number outside limit”. In the Job mode, the SEND key will also advance the backgauge to thenext sequential cut position before performing the cut.

10.5.5 Push-Out Key

The push-out key will move the backgauge forward 5 inches (or to the most forward position) andthen return it to its previous position. This allows paper to be removed from the cutter without puttinghands under the knife and clamp.

Never place hands in the clamp and knife area. Use the push-out key orthe backgauge glide control to move the paper to an area where it can be reached.

10.5.6 Clear Key

The CLEAR key is used to clear error messages and the current entry line.

10.5.7 Enter Key

The ENTER key selects items in the maintenance mode and processes data that has been entered inthe other modes.

10.5.8 Priority Add (X/Y) Key

The priority add key is used for entering fractions when they are combined with whole numbers. Thesymbol displayed when this key is pressed is the underline symbol “_”. An example of a number en-tered using the priority add key is 1_1/2.

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10.5.9 Soft-Keys

There are a total of eight soft-keys labeled “A” through “H”. The functions of these keys change de-pending on the operating mode. The function of each key can be found on the bottom of the displayscreens.

10.5.10 Arrow Keys

The four arrow keys can be used in almost all screens. The arrow keys are primarily used for movingthe cursor around on the screen, or to toggle between highlighted selections. In some screens, theleft arrow key acts as a backspace key.

10.5.11 Contrast Control

The contrast of each display screen can be adjusted by using the contrast control buttons located

directly above each display screen.

10.6 Manual Backgauge Control


The backgauge can be moved manually by use of the backgauge glide control. Press towards theoperator for foward travel and away from the operator for reverse travel. The further away from centerthat the actuator is pushed, the faster the backgauge will travel.

10.6.2 Backlash Indicator

To insure accurate cuts, the backgauge must be brought to the cut position from the rear of the table.In the display, to the right of the backgauge positon, there is a small arrow to indicate reverse travel.This arrow should be off when making a cut. Moving back past your cut position, then forward to it,compensates for any play in the backgauge nut and leadscrew.

10.7 Send Mode


-------------------------------C) UpD) Down

5.070 in^

>_


ReverseIndicator

Arrow

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The send mode is the first screen displayed after the backgauge is preset. From this screen thebackgauge can be positioned with the backgauge pinpoint control or by entering a value and pressingthe SEND key. A mathematical expression can also be entered as a send value. Simply type theexpression and press SEND. You can also enter an equation which begins with the current back-gauge position. For example, if you want to send the backgauge 2” forward from its current position, just press [-] [2] and SEND.

The send mode screen can also be used for doing math calculations that are larger than the back-gauge’s reverse limit. In this case, you must press ENTER to have the result displayed on thescreen.

10.7.1 Entering Math

In the simple send mode, the Champion XG is capable of calculating an entire math string such as,10-5+5x6+2_3/4. However, the result is limited to 29999.000 and the result cannot be a negativevalue. In the job mode, and during a send, the result of the calculation must be less than the back-gauge limit of 30.500 inches.

10.7.2 Entering Fractions

Fractions are entered with the priority add key X/Y. The symbol displayed when this key is pressed isthe underline symbol “_”. This instructs the computer to add the fractional portion of the entry beforeperforming the remaining math. This key is useful when entering a formula as follows: 3x2_3/4 =8_1/4. If a simple plus had been used instead, the result would be as follows: 3x2+3/4 = 6_3/4.

10.8 Repeat Mode

This mode allows the operator to make a series of cuts during which the backgauge moves a speci-fied distance between each cut. To enter repeat mode, press soft-key “H” (Repeat). The display willthen look like the one below:

Type in the desired initial backgauge position and press ENTER. The backgauge will then move tothat position. Then type in the step value and press ENTER. Position the paper and make a cut.The backgauge will then move forward by the step amount, and a new cut can be made. When fin-ished, press soft-key “H” (Exit) to exit back to send mode.


-------------------------------

C) Up

5.070 in

ORIGIN >_ STEP

Initial Position

H) Exit

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5

10.9 Maintenance Mode

The maintenance mode is an area where many machine functions can be set or modified. The fourprinciple 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. Seethe following descriptions for an explanation of each function.

10.9.1 Language

In the language screen, use the up and down arrow keys to toggle to the desired language, and pressENTER. All messages will be displayed in the selected language.

10.9.2 Parameters

In the parameter screen, use the up and down arrow keys to toggle to the desired parameter, andpress ENTER. See the descriptions that follow for an explanation of each parameter.

10.9.2.1 False Clamp

The false clamp plate is an optional attachment, which reduces the creasing of paper caused by theclamp. The disadvantage of using the false clamp plate is that it limits the smallest cut dimension.The computer must know when the false clamp plate is installed on the machine to preventthe backgauge from crashing into it. In the false clamp screen, use the up and down arrow keys totoggle between ON or OFF to indicate the presence of the false clamp plate, and press ENTER.

10.9.2.2 Time-out

This parameter sets the amount of idle time for which the screen saver activates and the line lightsand hydraulic motor turn off. The choices are 2, 5, 10, 20, and 30 minutes. In the time-out screen,use the up and down arrow keys to toggle to the desired time-out, and press ENTER.

10.9.2.3 Push-out

Normally, whenever the backgauge is sent to a larger dimension, a five-inch (127mm) push-out isperformed to aid the operator in accessing the paper. In some situations, it may be necessary to turnthis feature off. It is recommended that this feature be left on whenever possible. In the push-outscreen, use the up and down arrow keys to toggle to the on or off status as desired, and press EN-TER.

Clamp

Pressure| | | 14 | | |

-------------------------------C) UpD) Down

5.070 in

MAINT MENU

LAN-GUAGE

PARAMETERSDIAGNOSTICSKNIFE ADJUST

Select and press enterG) Send

F) Job H) Exit

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52

10.9.2.4 Accuracy Adjust

This parameter provides a means for adjusting the accuracy of the backgauge. To change the accu-racy, send the backgauge to 2 inches (50.8mm) and cut some paper. Measure the paper, and type inwhat you actually measure. The computer will calculate the amount of error and will compensate. Avalue may also be added to or subtracted from the current value.

10.9.2.5 Knife Count

The knife count parameter allows the operator to reset the knife alarm and the lube alarm. The knifealarm displays a message to remind the operator to change the knife. The lube alarm displays amessage to remind the operator to have the machine lubricated. The lube alarm will also display thename and phone number of the Challenge dealer from which the machine was purchased.

There are three functions within the knife count parameter: Clear Count, Knife Alarm, and ClearLube. Select the desired function and press ENTER. See the following descriptions for an explana-tion of each function.

Select Clear count to reset the knife counter when a knife change has been performed.

Select Knife Alarm to enter or change the knife stroke alarm value. When this value is reached, thedisplay will alert you to change the knife and reset the knife counter. Knife alarm values for theChampion XG are factory set at 2,500 cuts. However, you may want to change this value based onyour specific machine applications. See the Knife section for help in choosing a knife alarm value foryour machine.

Select Clear lube to reset the lube alarm after performing the lubrication requirements as shown inthe Lubrication section of this manual. NOTE: The alarm will activate after 2,500 cuts. This value isset at the factory and cannot be changed.

10.9.2.6 Machine count

The number displayed is the total number of cuts made by the machine.

10.9.3 Diagnostic

The diagnostic area can be very helpful in locating a problem in the event of a machine malfunction.Use the up and down arrow keys to toggle to the desired selection, and press ENTER. See the fol-lowing descriptions for an explanation of each.


-------------------------------C) UpD) Down

5.070 in

DIAGNOSTICError CodeSensor DataClear MemoryAdjust Clamp

Select and press enterA) Maint G) SendF) Job H) Exit

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5

10.9.3.1 Error Code

The Error Code function simply recalls the last five error messages that were displayed. This can bevery useful in cases when the malfunction cannot be reproduced in the presence of the service tech-nician.

10.9.3.2 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 checkthe status of a switch without removing any covers. Cuts and backgauge movements are allowed inthis screen so that the technician may observe the status of the inputs and outputs during machineoperation.

10.9.3.3 Clear Memory

The Clear Memory function resets the memory to a known state. All cut positions will be erasedduring this operation.

10.9.3.4 Knife Adjust

The knife adjust function provides a way for the service technician to change the knife. In the KnifeAdjust screen, use the up and down arrow keys to toggle to the up or down status as desired, andpress ENTER. Press and hold the cut buttons to send the knife to the desired position.

10.10 Job Mode

The Champion XG can be programmed for up to 99 different jobs. A job is a sequence of pro-

grammed cut positions. The backgauge moves to each position after a cut cycle is made. Each jobcan hold up to 99 send values. Job mode is entered by pressing soft-key “F”. When the job mode isentered, all previously programmed jobs will be displayed along with their name and lock status.Locked jobs display the word “Lock” after their name. A plus “+” sign at the bottom of the screen indi-cates there are more jobs programmed than what are displayed. Pressing the left arrow key and thedown arrow key simultaneously will page down to the next set of jobs. Page 59 contains an exampleof how to program a job.

Clamp

Pressure| | | 14 | | |

-------------------------------C) UpD) Down

>

1>JOB 1

2>TESTJOB5>6>BOBS JOB Lock7>8.5 X 11 Lock9>

10>+

E) Lock G) EraseF) Copy H) Exit

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54

10.10.1 Lock/Unlocking a Job

In the Job Mode screen, the soft-key “E” will display “Lock” or “Unlock” depending on the currentstatus of the job. If a job is locked, the word “Lock” will be displayed to the right of the job name.Locking a job prevents it from being edited. To change the lock status of a job, simply move the cur-sor to the desired job using the up and down arrow keys, and press the soft-key “E” (Lock/Unlock).

10.10.2 Copying a Job

First, select a job to copy by moving the cursor up or down to the desired job number and press thesoft-key “F” (Copy). “Select Copy to #” will be displayed at the bottom of the screen. Enter a jobnumber for the new job or move the cursor to an existing job and press ENTER. If the new job islocked, the copy will not be allowed. NOTE: if the new job is not locked, but contains data, the olddata WILL BE LOST.

10.10.3 Erasing a Job

Select a job to erase by moving the cursor to the desired job. Press the soft-key “G” (Erase). “Clearchannel #” will be displayed, followed by YES or NO. Use the up and down arrow keys to toggle to

YES or NO. YES will erase the job, NO will leave the job unchanged. NOTE: locked jobs cannot beerased.

10.10.4 Creating a New Job

To create a new job, type in a number that is not already assigned to a job and press ENTER (enter-ing a job number greater than 99 will create job #99). The cursor will move to the line correspondingto the number you typed in, prompting you for a job name. If no job name is desired, simply pressENTER again to begin entering send values (see below). To name the job, press the right arrow keyto move the cursor to the first character position. Enter a character of the alphabet by using the upand down arrow keys to toggle to the desired character. The numeric keys can be used to enternumbers directly into the job name. When the desired character is in place, use the right arrow key tomove to the next character position. The job name can be up to 10 characters long. A letter can be

removed from the job name by moving the cursor to the undesired character and pressing the CLEARkey. When finished, press ENTER to save the name and to begin entering send values. The screenshould now look similar to the one below:

10.10.4.1 Entering Send Value

Send values can now be entered by using any of the following methods: 1) Type in the desired valueand press ENTER, 2) Press ENTER at a blank line - this will enter the current position of the back-


-------------------------------A) Division

D) Cut & Rec.

5.070 in JOB1

#11>_

E) Insert G) EraseF) Job H) Exit

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5

gauge as a send value, 3) Use the “Cut and Record” feature (described later) or 4) Use the “SheetDivision” feature.

10.10.4.2 Creating a Stock Loading Position

After typing 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 or Load Zone (LZ). Selecting LZ willmake it impossible to cut at that position. Pressing both cut buttons on a position marked at a Load-ing Zone will prompt the backguage to move to the next position in the job. Using a loading positioneliminates the need to reach into the knife/clamp area of the cutter when loading a job.

10.10.4.3 Entering Rotation Mark

After typing in a send value, pressing the right arrow key instead of ENTER will move the cursor tothe right and prompt the operator to enter a rotation indicator mark. The display will look similar to theone shown below:

Use soft-keys “C” and “D” to choose a turn indicator. Pressing ENTER will place an indicator mark tothe right of the send value, as shown below:

When the desired indicator mark is in place, press the right arrow key. The cursor will move to theright and prompt the operator to enter a clamp pressure (see the following section).

NOTE: All new entry lines will have the same turn indicator mark as the one above it, until it ischanged.

Turn IndicatorOffccw >cw <180 Turn >>Load Zone LZSelect & Press Enter

C) UpD) Down

5.070 in JOB1

#11> 5.070 _

H) Exit


-------------------------------C) UpD) Down

5.070 in JOB1

#11> 5.070 >>

H) Exit

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56

10.10.4.4 Entering the Clamp Pressure

A separate clamp pressure can be entered for each cut in a job. To enter the desired clamp pres-sure, first enter the desired send value (described above), then press the right arrow key and enterthe rotation mark if necessary (described above), then press the right arrow key again to move thecursor to where the clamp pressure can be entered. Use soft-keys “C” and “D” to increase or de-

crease the clamp pressure, or use the numeric keypad to enter a number from 0 to 15 (see Adjustingthe Clamp Pressure section, page 46 for information about the clamp pressure setting). This willcomplete 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.

10.10.4.5 Cut and Record

To use this feature when creating a new job, simply send the backgauge to a desired position usingthe backgauge glide control or by using SEND, then make a cut. The current backgauge position willautomatically be displayed in the next available cut location and the operator will be prompted topress ENTER to record the current value. If ENTER is not pressed, the value will not be recordedinto the job as a send value. This can be very convenient for setting up a program when the actualcut positions are not known.

10.10.4.6 Sheet Division Feature

The Champion XG has a sheet division feature that automatically creates a complete set of send val-ues using the parent and finished sheet sizes specified by the user. Since this feature creates anentire set of send values, it is best to use it only when creating a new job. However, this feature canalso be used when editing or using an existing job. It will simply insert the new set of send valuesafter the current send value.

Begin by pressing soft-key “A” (Division). The display will be similar to the following:

The program guides the operator through the steps of entering the necessary dimensions. Then theprogram asks if the columns are to be cut separate (as opposed to stacking the columns and cuttingthem all at once). Press “1” for Yes and “0” for No. The display will now look similar to the oneshown on the next page (it may vary based on the input).

-------------------------------C) UpD) Down

5.070 in #1

DIM A>_ DIM BDIM CDIM D

Enter Dimension A.


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5

Use the up and down arrow keys to scroll through the possible layouts. The left display will showeach choice visually. Select the desired option and press ENTER. The send values will be automati-cally 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.

10.10.4.7 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) un-der the left hand display. The display will be similar to the following:

The program guides the operator through the steps of entering the necessary information. A & B are

label quantities, C & D are the actual label size and E & F are gutter dimensions. Then the programasks if the columns are to be cut separate (as opposed to stacking the columns and cutting them allat once). Press “1” for Yes and “0” for No. The display will now look similar to the one shown on thenext page (it will vary based on the input).

-------------------------------C) UpD) Down

5.070

QTY QTYOPT OUT CUTS

1 8 92 8 9

3 8 94 6 75 8 96 6 7

RE-ENTER

H) Exit

A

5.070 in #1

*Label Cutting*

QTY A>_ QTY BDIM CDIM DDIM EDIM F

Enter Quantity A.E) MaintF) Job H) Repeat

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58

Use the up and down arrow keys to scroll through the possible options (if more than one). The leftdisplay will show each choice visually. Select the desired option, then press ENTER. At this point

the send values will be automatically calculated and entered. The job will be complete and ready foruse. To make changes, edit the job as described in the “Editing a Job” section below.

10.10.4.8 When Finished

When finished entering send values you may exit the current job by pressing soft-key “B” (Job) to goback to the job mode screen or soft-key “D” (Exit) to exit to send mode. Or you may use the current job for cutting by pressing the down arrow at the last line and following the instructions in the “Run-ning a Job” section (page 59).

10.10.5 Editing an Existing Job

10.10.5.1 Editing the Job Name

The job name can be edited (or added if an existing job does not have a name) in the job modescreen. To edit the name, move the cursor down to the desired job number by pressing the downarrow key. Then press the right arrow key to move the cursor to the desired character position andedit the character by pressing the up or down arrow keys to toggle between characters of the alpha-bet. Numbers can be entered directly by using the number keys. Pressing CLEAR clears the currentcharacter. When finished, you may either go to the current job by pressing ENTER, or go to a differ-ent job, or exit job mode.

10.10.5.2 Editing Send Values

To edit send values of an existing job, start by opening the desired job from the job mode screen. A job is opened by one of two methods: pointing at the desired job with the cursor and pressing EN-TER, or by entering the job number with the keypad and pressing ENTER. Once a job has beenopened, the current job number will be displayed in the upper right corner. NOTE: If the job islocked, it cannot be edited.

Send values can now be edited by moving the cursor up or down to the desired send value and thentyping over the existing value. To page up and page down, press the left and down arrow keys simul-taneously.

5.070

QTY QTYOPT OUT CUTS

1 8 9

RE-ENTER (0)Select and Press Enter

H) Exit

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5

To insert a send value, press the soft-key “E” (Insert). This moves all send values down and providesa 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. Then press soft-key “D” (Cut & Rec). “C & R” will appearin the upper right corner of the left display. Each cut will add the current backgauge position as asend value. When finished, press soft-key “D” (Cut & Rec) again to exit cut & record mode. If thereis a blank line where the cursor is, press the down arrow and it will disappear.

To erase a send value, press the soft-key “G” (Erase). This will remove the cut value currently beingpointed to by the cursor. To backspace over the current send value without removing the line, pressthe left arrow key.

When finished editing the job, you may exit the current job by pressing soft-key “F” (Job) to go back tothe job mode screen or soft-key “H” (Exit) to exit to send mode. Or you may use the job for cuttingsince it is already open.

10.10.6 Running a Programmed Job

To use an existing job for cutting, you must first open it by using one of two methods: move the cur-sor to the desired job with the arrow keys and press ENTER, or enter the job number with the keypadand press ENTER. Once a job has been opened, the current job name and number will be displayedin the upper right corner. Now press SEND to move the backgauge to the first programmed position(or send value). Make a cut by pressing both cut buttons. Once the cut is made, the backgauge willautomatically push out the paper (only if the next position is larger than the current one, and if “push-out” is enabled) and move to the next programmed position. If the job was created using the “SheetDivision” feature, the left screen will display a diagram of where to place the paper for each cut. Afterthe last cut in the job is made, the backgauge will move to the first cut position of the current job.Pressing SEND at any time during the job will send the backgauge to its next programmed positionwithout making a cut. A plus “+” sign will be displayed at the bottom of the screen if more cuts remain

in the current job.

10.10.7 Exiting a Job

To exit an open job, press the soft-key “F” (Job) to return to the job mode screen, or press the soft-key “H” (Exit) to exit to the send mode screen.


-------------------------------A) Division

D) Cut & Rec

5.070 in 8.5 X 11

L # 71> 8.5002>11.000

E) Insert G) EraseF) Job H) Exit

JobName

LockStatus

Job #

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60

10.11 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. Note: It must be a number that does notcorrespond to an existing job. All existing jobs will be displayed on the screen (you may haveto scroll through them to see them all). If you wish to replace an existing job with the new job,first erase the existing job by moving the cursor to it and press the soft-key “G” (Erase). Nowtype in the new number and press ENTER. In this example, job #’s 1, 2, 5, and 6 already ex-ist. We will use job # 7 for our new job. Press “7” and ENTER.

3. The cursor will move down to the new job number. At this point, press the right arrow keyonce to move the cursor to the first character position. Now name the job “8.5 X 11”. To dothis, press “8” on the number keypad. Then press the decimal “.” key and so on. To enterthe spaces and the letter “X”, use the up and down arrow keys to toggle through the alphabet

and press the right arrow key to move to the next character position.

Now press ENTER to begin programming the job.

4. To enter the first send value of 8.5”, simply type in 8.5 and press ENTER. The cursor willmove to the second line. Now type 11 and press enter. At this point, you could exit and savethe job by pressing the soft-key “H” (Exit) to exit to send mode, or the soft-key “F” (Job) to exitback to the job mode screen. However, lets use this job to cut paper.

5. Press the down arrow key once. This will remove the blank line 3 and move the cursor to thefirst send value (8.5”). Now press SEND. The backgauge will move to the 8.5” position.Place the paper to be cut against the backgauge and press the cut buttons. Once the cut cy-cle is complete, the backgauge will push out the paper and move to the next send value(11”). Now position the paper again and make another cut. After the cut is made, the back-gauge will push out the stock and return to the first cut position, ready to repeat the current job.

6. Now lets lock the current job so it cannot be edited. First, exit back to job mode by pressingsoft-key “F” (Job). Now move the cursor down to the new job using the down arrow key.Now press the soft-key “E” (Lock) to lock the job. A lock symbol will appear indicating the jobhas been locked.

7. To exit back to send mode, press the soft-key “H” (Exit).

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11.0 Operating Ti

6

11.0 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 outstock before removal.

Never attempt to remove paper trim clinging to the blade or clamp until they havestopped moving!

Carefully lay out each sheet before you start cutting. Find the best-cut pattern to giveyou the most pieces out of the sheet. If the sheet will be folded, be sure the grain ofthe paper is running in the same direction as the fold or you will get a rough edge onthe fold.

If an accurate cut is necessary for close register work, you MUST have a sharp bladein the cutter. A dull blade will pull or draw the stock and cause uneven cutting. SeeKnives section, below.

Clamp pressure should not be increased to eliminate draw without first checking forknife sharpness. Draw from a dull knife can only be eliminated by installing a sharpknife. See Knives section, below.

Appropriate clamp pressure will vary from one stock to another. As a rule, you

should have enough pressure to securely hold the stock but not so much that thestock is unacceptably deformed. Excessive clamp pressure causes pile distortionand inaccurate cutting.

To make stock slide as easily as possible on the cutter table, wash the table withnon-offset powder or with a silicone/rust preventative.

Mark the gripper edge and the guide edge of printed stock and make sure the firstcuts are with these guide edges against the backgauge.

Measure printed stock to check for shrinkage or expansion of the paper from humid-ity. You may have to disregard the printed cut lines and make your own.

If you notice the knife and clamp returning before the cut is complete, then the elec-tric eyes are probably being triggered accidentally. A tie or loose clothing may causethis to occur.

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11.0 Operating Tips

62

NOTES

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12.0 Knife Installation/Changin

6

12.0 Knife Installation/Changing

Changing knives can be very dangerous unless safety precautions areobserved 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 tochange knives invites accidents.

Figure 24 – Knife Changing Equipment

The knife changing equipment shown in Figure 24 is included in the cutter tool kit. The following in-structions show how to remove and install a new or re-sharpened knife. Read these instructions ATLEAST ONCE before attempting to actually change or install any blades.

If your machine is serial no.99X524 or above you will have a shielded knife lifter instead of the looseknife lifters shown above. The shielded knife lifter is shown in Figure 25. Before proceeding, readthe special instructions for its use on page 67, Figure 31.

Figure 25

Cut Stick Re-moval Tool

1/8” HexWrench

HexT-Wrench

KnifeLifter

KnifeLifter

5/32” HexWrench

Wrench

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64

12.1 Knife Removal

1. Clear the cutter table. Place chipboard directly under the knife to prevent nicking if the bladehits the table.

X models) Toggle the knife change switch located on the right hand side of thepower panel enclosure. Initiate a cut and hold the cut buttons until power turns off

with the knife in the down position. Turn off the main power switch.

XD, XG models) On the screen menu choose “MAINT.” and then “Knife Change”.The menu will lead you through the rest of this step, then lock out the main powersource as shown on page 8.

2. If equipped with the paper deflector option, lock it down by screwing the lock knob all the wayin Figure 26.

Figure 26

3. Back off the knife adjusting screws on the top of the knife bar, (Figure 27), as far as they willgo (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 cut-ting stick.

Figure 27

4. Raise the knife.X models) Toggle the knife change switch to normal operation. Turn on the mainpower switch. Activate the hydraulics by depressing both cut buttons simultaneously.Knife returns to “UP” position.

XD, XG models) Press Exit. Push both cut buttons, and the knife will return up.

Paper Deflec-tor Lock Knob

(Optional)

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6

5. DISCONNECT THE POWER AND LOCK IT OUT , (See Power Lockout Procedure on pg. 8.)

6. Remove the bolts in the two slotted holes of the knife bar and replace them with the knife lift-ers. Tighten the lifters enough to hold the blade in place. Remove the remaining four bolts(Figure 28). The leftmost bolt must be removed while the knife bar is “UP”.

Figure 28

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

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

8. Grasp the knife lifters firmly while turning counterclockwise to release the knife from the knifebar. Slowly lower the knife down and to the right. Bring the left side out first and put theblade in the scabbard and secure immediately.

9. Send the dull knife to the grinder.

12.2 Knife Installation

1. Use the cutting stick puller, (Figure 29), to remove the cutting stick. Turn the cutting stick to anew surface.

Figure 29

2. Check to make sure the paper deflector is locked down, see Knife Removal, step 2 above.Also check that the knife adjusters have been backed out, (Figure 27 on page 64).

Remove Knife Bolts &Install Lifters

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66

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

4. Remove the knife retainer screws and insert the knife lifters into the knife bolt holes (use thelowest holes) corresponding to the slotted holes in the knife bar. Turn threaded portion ofknife lifters into holes in the knife until they contact the scabbard, then back off 1-1/2 turns.

5. Grasp the knife lifters, lift the blade, and insert the blade into the knife bar slot. Slowly guidethe 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 lifters to hold the knife.

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

6. 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 clear-ances!

7. Replace the knife lifters with bolts and snug tighten.

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

9. Turn the power ON, lock the knife down (repeat step 1), and then lock out power (see page8).

10. Turn the knife adjusters down, a little at a time (Figure 30), until the blade cuts through thepaper evenly, the length of the stick. Be sure the blade is parallel to the cutting stick, or oneend may cut deeper than the other, causing uneven wear on the stick.

Figure 30

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

12. Turn power on and send the knife to the “UP” position as previously instructed.

13. Make a test cut through a full lift of stock. Make minor adjustments by loosening the boltsand repeating steps 9 through 11.

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

Wrench

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6

12.3 Using the Shielded Knife Lifter

There are some differences to be noted for those using the shielded knife lifters as shown in Figure25 on page 63. When installing the lifter into the knife, use the following procedure.

1. After the scabbard has been placed on the front table and the scabbard screws have been

removed, place your fingers along the top edge of the scabbard and your thumbs in the holesin the knife.

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

3. Place the lifter on top of the knife and thread the handles into the knife until they touch thescabbard. Then back the handles off 1/2 turn.

4. Install the knife as described above while using the holes and notches in the shield to seethat you are properly aligned. The two center bolts are accessed through holes in the shield.Install the end two bolts, remove the lifter, and install the rest of the bolts. An installed lifter isshown in Figure 31 below.

Figure 31

When placing a knife back in its scabbard place the knife and attached lifter on top of the scabbard.Remove the lifter and slide the knife into alignment with the scabbard screw holes. DO NOT FOR-GET TO INSTALL THE SCABBARD SCREWS!


To prevent marking on pressure sensitive jobs, a false clamp plate has been included (installed) withyour machine. This plate attaches to the bottom of the clamp. It is secured from the front of the cut-ter with three setscrews that hold connector rods that pass up into the clamp.

NOTE: On XD and XG model cutters, the forward limit value must be changed any time the falseclamp plate is installed or removed. See Operating Instruction section for your model.

ALWAYS disconnect the power and LOCK IT OUT before installing or re-moving the false clamp plate. NEVER attempt to install or remove the false clamp plate while themachine is running. Remove all tools and stand clear when reconnecting power.

1. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout, page 8.)

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2. Position the false clamp plate under the clamp, (Figure 32). The locator pegs are positionedto the rear of the cutter and are set into holes in the bottom of the clamp.

Figure 32

3. With a 1/8" Allen wrench, back off the setscrews in front of the clamp and raise the plate up tothe bottom of the clamp. It may be necessary to bring the clamp down slightly with the footpedal in order to access the far left setscrew. Raise the false clamp plate evenly or it willhave 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 turnon the power.

NOTE: The cutter cannot be operated closer than 2" (50.8 mm) with the false clamp plate installed.

NOTE: DO NOT ATTEMPT TO OPERATE THE CUTTER UNITL THE REST OF THIS MANUALHAS BEEN THOROUGHLY READ AND UNDERSTOOD. CALL YOUR DEALER IF YOU STILLHAVE ANY QUESTIONS.

12.5 Knife Care Basics

! KNIFE SAFETY ! Knives are DANGEROUS!!! They are heavy and verysharp, even after use. Keep the edge away from your body and keep the area clear of others whenhandling 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 othersmay not be. Never attempt to hone, polish, or service the knife in any way. Failure to follow safetyprocedures may result in severe lacerations or dismemberment.

12.5.1 Cut Quality

Assuming the proper bevel angle has been chosen for the material being cut, cut quality dependsupon blade sharpness and surface finish. Three cut characteristics can indicate a blade needssharpening:

1. Burnishing appears on cut face of lift.2. The cut does not appear straight when viewed from the top.3. The profile of the cut (side view) does not appear to be perpendicular to the table.

Other signs that a knife needs sharpening are:

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.

Locator pegs

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Nicks are visible on the cutting edge of the knife.

12.6 Bevel Angle

The most appropriate bevel angle depends upon four factors.

1. The length of time desired between sharpening2. Physical properties of the stock being cut (hardness, impurities, density)3. Power output of machine4. Amount of clamp pressure applied

1. Length of Time Between SharpeningUnder identical cutting conditions, knives with larger bevel angles will require sharpening lessoften than knives with smaller bevel angles. There is more material supporting the cuttingedge of larger bevel angles.

2. Physical Properties of Stock In general a smaller bevel achieves a better quality cut. Hard, dense, and impure papers,however, will dull a small angle bevel quickly. Impurities may put nicks on the cutting edge.

As a result, cut quality is lost quickly, and knives require sharpening often. Therefore, a lar-ger angle bevel should be chosen for such materials. Soft materials can be cut with smallangle bevels without adversely affecting sharpening frequency.

3. Power Output of Machine As the bevel angle increases, more power is required to push the knife through stock. If abevel angle is too large for a machine, the machine may take excessive wear-and-tear andmay stall part way through the cut cycle. Although the knife will require sharpening less of-ten, the machine may incur costly damage.

4. Amount of Clamp Pressure Applied As clamping pressure increases, the pile density increases. As discussed in number 2,above, more dense materials are harder to cut. This presents a dilemma. Higher clampingpressures are used to reduce draw when cutting with large angle bevels. While higher bevelangles increase the lifetime of the knife, high pressure clamping increases the material’sdensity and detracts from knife life. As a result, a compromise must be made between knifelife and cut quality.

12.7 Helpful Suggestions

If your shop is large enough to purchase more than one set of knives, the following sugges-tions may be helpful. A set consists of 3 knives, one in the machine, one back up, and one atthe grinder.

If you cut a variety of stocks (easy and hard to cut), purchase two sets of knives. One setshould be beveled at around 210 and the other around 230.

Use the smaller angle bevel to cut softer stocks at lower clamping pressures. Begin by cut-ting the most pure, easy to cut stocks. As the knife dulls, begin cutting the less pure of thesofter stocks.

Use the larger bevel to cut harder more dense stocks at higher clamping pressures. Begin bycutting the softer and most pure of the hard stocks. Then move to cutting the harder and lesspure of the hard stocks.

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The following suggestions apply to those who can support only one set of knives. The bevel angle onthe knives shipped with your machine was chosen for its versatility. It is not the ideal angle for everymaterial, but these suggestions may improve the cut quality for those materials being cut with an in-appropriate bevel:

First, cut the softest, most pure stocks at lower clamping pressures.

Move to the harder, more pure stocks at higher pressures. You may also need to reduce pileheights.

Softer, impure stocks are next, followed by the hard impure stocks.

Following these guidelines will decrease the frequency of knife sharpening while maintaining a qualitycut as long as possible.

Suggestions for all:

If the machine seems to strain and cut quality is still good, reduce the pile height. You mayalso carefully apply glycerin to the bevel when cutting hard, coated stocks. Tie a cloth to theend 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 yourmachine and reduce maintenance.

If the machine seems to strain and cut quality becomes unacceptable, the knife should bechanged.

Typical bevel angles vary from 260 to 190. The most appropriate general purpose bevel angle(230) was chosen for your machine. If your most common applications warrant a different an-gle, careful thought should be given before making the investment.

12.8 Knife Care

To prevent corrosion you received your knife coated with light oil. It should be REMOVEDWITH CARE.

While removing or installing a knife, be careful not to allow the edge to bump against the ma-chine. 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.

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13.0 Lubricati

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13.0 LubricationA clean, lubricated machine will cut more accurately, run longer, with less downtime, and fewer re-pairs.

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

Clean off old, dirty excess grease. Clean accumulated dust off valves, hoses, and connections. Builtup dust increases operating temperatures and causes premature wear of all hydraulic components.

Oil and Grease Points WEEKLY.

Run the knife down and Lock Out the Power, see Power Lockout Procedure, page 8. All movingparts require lubrication. Remove all panel covers and look for all oil locations (marked with redpaint). 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 andsome are grease points. Wipe off old and excess grease. Use a National Lubricating Grease Insti-tute No. 1 consistency, extreme pressure grease.

Replace all guards. Never operate cutter with any guards removed.

GREASE OIL

Figure 33

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Figure 34

Figure 35

Figure 36

IMPORTANT!!!! Upper and Lower Knife Bar Link Pin lubrication (grease fittings, behind upper archcover and below table, and oil holes) are the most critical lubrication points on the entire machine.Grease and oil WEEKLY to prevent build-up of hardened grease, or more often, if cutter is to be op-erated continuously for extended periods.

While lubricating, check pin locks to make sure they are in place and secure.

Both Cylin-der Pins

Both Knife Bar Link Pins

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Figure 37

Figure 38

Figure 39

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13.1 Hydraulic System

The Champion Series Cutters have both hydraulic cutting and hydraulic clamping operation. The cut-ter is powered by an electric motor coupled directly to a hydraulic pump. The pump has a fixed flowrate output of 7.5 GPM at 1800 psi (max. system relief setting) at 1800 RPM.

The clamp action is powered by a hydraulic cylinder. When the cut buttons are depressed, this cylin-der pulls on the clamp bell crank and brings the clamp down (or brings the clamp up to full hydraulicpressure if the manual foot clamp is down). The cutting action is also powered by a hydraulic cylinderconnected directly to the knife bar. The knife sequence valve generates 1600 PSI of back pressurethroughout the system to maintain full clamp pressure during the cut. One big advantage of the hy-draulic system is the immediate return of the knife when the cut buttons are released. Instead ofstopping in place, the knife immediately returns to the upper position.

The hydraulic fluid should be changed YEARLY or EVERY 1000 HOURS of operation.

The oil filter (Challenge part H-227-1) should be changed yearly or whenever any repairs are made tothe hydraulic system.

NOTE: Failure to change the oil when needed can damage the seals in the clamp and knife cylin-ders.

Refill the tank with 13.5 gallons of an ISO (International Standards Organization) Viscosity Grade 46,rust, oxidation, and foam inhibiting hydraulic oil. NOTE: NEVER use Automatic Transmission Oilor Brake Fluid as a substitute for the correct hydraulic fluid. Dangerous operation conditionscould result.

A table of various manufacturers and their equivalents is listed in the Recommended Oils section onpage 74.

Check the level of the Hydraulic Reservoir WEEKLY or whenever the machine sounds like it is labor-ing (this could be due to low oil level). The tank has a sight gauge on the back so you can check theoil level.

13.2 Recommended Oils

Use only one of the recommended oils or an ISO VG 46 Hydraulic Fluid equivalent. Oils other thanthe recommended type will cause seals, cups, and O-rings to deteriorate. See CAUTION be-low.

Oil Name Distributor Rykon No. 46 AMOCOEnergol HLP 46 BPAW Oil 46 ChevronPacemaker XD 46 CitgoSuper Hydraulic 46 ConocoUnivis N46 ExxonSecurity AW 46 GulfKenoil R&O AW 46 KendallDTE 15M MobilTellus 46 ShellRando HDZ 46 Texaco

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NEVER USE Automatic transmission oil or brake fluid as a substitute! Oilsother than the recommended type will cause seals, cups, and O-rings to deteriorate. Unsafe opera-tions conditions will result.

Figure 40

13.3 Changing the Oil

Only change oil when it is cold. Burns could result from changing oil whileit is hot.

Before beginning, you will need (3) empty five gallon buckets, three oil pans or more, a funnel and anassistant. If oil is hot, wait until it cools.

1. Make sure main power to the machine is off.

2. Remove the hydraulic tank cover.

3. Place a pan under the drain port on the hydraulic tank and remove the drain plug.

4. After the first pan is filled, replace it with an empty.

5. Use the funnel to pour the full drain pan into an empty five-gallon pail.

6. Repeat steps 3-5 until reservoir is empty.

7. Remove the magnet stuck to the bottom of the tank. Clean off any debris that may be at-tached to it.

8. With a clean rag, wipe out any visible debris remaining in the tank.

9. Place the magnet at the location from which it was removed.

SightGauge

Drain Plug is underthe rear of the tankweldment.

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10. Inspect the drain plug. If it is an ‘O’-ring plug, make sure the ‘O’-ring is not broken or severelycrushed. Replace the ‘O’-ring as necessary. Screw the drain plug back into the tank. Donot over-tighten an ‘O’-ring plug, leakage will result. Finger tighten plug until ‘O’-ring contactsthe tank. Using a tool, tighten the plug 1-2 additional turns. When filling the tank check thedrain plug for leaks. If it does leak, back off on the plug until the leak stops. If the plug is notan ‘O’-ring plug, it should be securely tightened.

11. Replace the oil filter. Place a thin film of new hydraulic oil on the seal of the new filter to in-sure a proper seal. Firmly hand-tighten the filter onto the filter head.

12. Fill the tank with recommended fluid until the level is just above the sight gauge shown inFigure 40 on page 75. As you fill, check the drain plug for leakage.

13. Re-install the tank cover with gasket.

14. Before turning on the machine, make sure all hydraulic hose fittings are tight. Make sure thedrain plug has no leaks and the oil filter has been firmly hand tightened to the filter head.

15. Turn on main power to the machine. Turn on the hydraulic motor by pressing both cut buttonsonce. Inspect the hydraulic system for leaks. If leaks are found, turn off main power to the

machine and tighten any leaking fittings. If the drain plug leaks, follow instructions given instep 10.

16. Repeat step 15 as necessary.

13.4 Alternate Draining Procedure

Only change oil when it is cold. Burns could result from changing oil whilehot.

Before beginning, you will need (3) empty five gallon buckets, an oil pan, and a transfer pump. If oil ishot, wait until it cools.

1. Make sure main power to the machine is off.

2. Remove the hydraulic tank cover.

3. Place the suction line of the transfer pump into the filler cap hole. Place the pressure line ofthe transfer pump into an empty five-gallon pail.

4. Turn on the transfer pump and fill the pail. Repeat until tank is empty.

5. Go to CHANGING OIL section and continue oil change with steps 7-9 and 11-16.

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14.0 Operator Adjustments/Cleani

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14.0 Operator Adjustments/Cleaning

14.1 Line Lights

The line light comes on whenever main power is turned to the ON position. The light from each of twobulbs reaches the table after passing between the knife and clamp, (Figure 41).

Figure 41

Each light is focused with a socket head cap screw recessed into the arch, directly behind the con-sole, (Figure 42).

Figure 42

Adjust line:

1. Let the console down by removing the two screws at the top.

2. Place a wide sheet(s) of paper on the cut stick to view the line.

3. Using a 3/16” hex wrench, turn one of the cap screws until you see a 1/16-1/8” beam.

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4. Similarly, turn the adjustment screw of the other bulb until one, continuous beam is seenacross the cut stick.

Bulb replacement:

1. Make sure the power is OFF and remove key. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout procedure, page 8)

2. Lower the console.

3. Remove the old bulb by lightly pushing bulb into the socket and turning it counter-clockwise.CAUTION!- If the bulb is still hot, allow a few minutes to cool before changing.

4. Insert the new bulb into the socket and twist clockwise until the bulb locks into place.

5. Reattach the console.

6. Reconnect the power and turn ON.

7. If necessary, adjust the line as above.

8. Unless the cutter will be operated immediately, turn the power off.

14.2 Manual Pressure Reducer – (305X Only)

Figure 43

This valve limits the amount of pressure to the clamp system. Factory setting: 1000 psi (1400max/300 min).

To Check:

With the hydraulic access door open, activate the cut buttons and read the pressure off the

clamp gauge (rear gauge). It should read 750 psi for average cutting purposes. For XD andXG models see Operating Instructions.

To Adjust:

1. Loosen the lock knob. There are two knobs, one behind the other, (Figure 43). The outer isthe adjusting knob and the inner is the lock knob.

2. Push the cut buttons and check the reading on the clamp gauge when the clamp is on the ta-ble and the knife is moving down.

ClampGauge

Clamp PressureReducer

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3. Turn the pressure-adjusting knob clockwise for MORE pressure, counterclockwise for LESS.

4. Make another cut and check the pressure gauge. Adjust the pressure to your cuttings needs(see OPERATING TIPS).

5. Tighten the locking knob.

DO NOT set the clamp pressure below 300 psi. Severe lacerations ordismemberment could result! The Knife and Clamp System loses sequence at settings below 300PSI and the knife could come down before the clamp.

14.3 Operator Cleaning

14.3.1 Hydraulics

1. The hydraulic fan and tank should be wiped off weekly to maintain maximum cooling of thetank/hydraulic oil.

2. The hydraulic manifold and fittings should be wiped off weekly.

14.3.2 Table

1. If you have an air table, the dust should be wiped from the air blower inlet screen on a weeklybasis. This will insure unrestrained flow into the blower.

2. The front table should be cleaned periodically to remove rust and wax buildup. This shouldbe done using cleaners provided in the optional cutter care kit. (p/n 16077) Do not clean ex-tension tables with these cleaners. Damage to their finish will result.

3. The extension tables should be cleaned either with a dry or damp cloth or a mild water based

detergent.

4. The rear, table cover may be cleaned with glass cleaner or a mild, water based detergent ap-plied to a damp cloth. Some petroleum-based solvents may damage the Plexiglas cover.

14.3.3 Console

The console should be cleaned with a mild water based detergent applied to a damp cloth orpaper towel. Petroleum based solvents will damage the console.

14.3.4 Machine Base

1. The machine base 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 amounts ofcleaners in those areas.

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80


NOTICEThe instructions on the followingpages are for the use of trained

service personnel only!

Attempting to perform repair andreplacement procedures withoutproper training may cause ma-

chine damage or operator injury! PARTS CUSTOMERS: Parts with the express understanding that they are to replace partsfound missing or no longer serviceable on equipment designed and/or manufactured atChallenge. The Challenge Machinery Company assumes no liability for any modification oralteration to any Challenge products, and any such modification or alteration to any Chal-lenge product is not authorized by The Challenge Machinery Company. Any modification oralteration of any Challenge product will void any remaining warranty.

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15.1 Maintenance Adjustments

15.1.1 Squaring the Backgauge

To test the backgauge for squareness, place a small lift of paper against the left side of the back-gauge (but not against the side guide) and make a cut.

Figure 44

Now, leave the backgauge in the same position, flip the lift over and against the right side of thebackgauge (but not against the side guide). Make another cut to see if any of the stock will trim off.

Run two checks, one starting on the left and moving to the right, the other, moving from the right tothe left. Trim in either sequence indicates the backgauge is out of square.

1. As machine wears, make sure the backgauge gibs are set properly first (see BackgaugeGibs), then follow steps 2 through 5.

NOTE: Gib adjustment is not necessary on initial machine setup because they have been adjusted at the factory.

2. Loosen backgauge locking screw (smaller head). Loosen the jam nuts on the backgaugesquaring screws.

Figure 45

3. Back off the squaring screw on the side that the trim occurred and tighten the other.

4. With the squaring screws tight, make another test. Continue to adjust and test until no trimoccurs when testing in either sequence.

5. Tighten the jam nuts and lock screw.

PAPER

LockingScrew

Squaring Screws

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15.1.2 Proximity Switches

These tests require the machine to be operational for checking and adjust-ing. Be very careful that tools and other people are clear of moving parts and that the cutter is notaccidentally operated while adjustments are being made.

Challenge Champion cutters incorporate proximity switches to detect stages of operation. Thesetypes of limit switches have no moving parts and are more reliable than the old style of contactswitches.

NOTE: Adjust the switches in the following order:

1. Knife Up/Down Limit Switch2. Hydraulic Up Limit Switch3. Clamp Up Limit Switch

CRUSH HAZARD! When the limit switch is actuated, the clamp will return

to the up position. Keep hands and tools clear.

1. Knife Up/Down Proximity Switch

Figure 46

More current machines have one knife up proximity bracket and one collar (Figure 46). With thepower off, set the collar between the proximity switches and then turn on power. Press cut buttonsonce to turn on the hydraulic motor. The knife will move to the absolute top of its stroke. Move thecollar to the top proximity switch until LED turns on, then move it an additional 1/4” higher and tightenits setscrew. An indicator light on the switch body comes on when the switch is actuated (proximity

switches must be within 1/8” (3.2mm) to actuate).

Alternate Setup: The knife up and knife down limit switches are mounted to the same bracket as-sembly. The bracket assembly is mounted to the knife cylinder. Turn off power to the cutter. Thebracket assembly should be adjusted such that the center-to-center distance between the proximityswitches is about 6-1/4” (Figure 47 on page 83). It is mounted to the knife cylinder. The collar foundon the knife cylinder rod should be loosened with a hex wrench. Let the collar rest on the top of thecylinder. Cycle power to the machine and depress the cut buttons once. This will bring the knife cyl-inder to the top of its stroke. Move the collar up the knife cylinder rod until the LED indicator on theswitch turns on. Then move it an additional 1/4” up the rod. An indicator light on the switch body

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comes on when the switch is actuated (proximity switches must be within 1/8” (3.2mm) to actuate).Tighten the collar’s setscrew.

Figure 47

2. Hydraulic Up Proximity Switch

This switch is mounted on the left, rear leg of the base casting (Figure 48 on page 84). An indicatorlight on the switch body comes on when the switch is actuated (proximity switches must be within 1/8”(3.2mm) to actuate). The switch senses the extension of the clamp cylinder at the top of its stroke.This stops hydraulic power to the clamp and knife. If the switch is not properly set, the knife andclamp cylinders will be under constant load (indicated by excessive heat and noise).

To adjust:

a. Loosen the bottom lock nut and turn the top lock nut down to raise the switch.

b. Turn on the machine and press the cut buttons once to start the hydraulic motor.

c. The knife and clamp will move to the extreme up position and a load will remain on thehydraulics.

d. When the cylinder has stopped moving, pass a metal object in front of the switch to actu-ate it and take the load off the hydraulics. Keeping pressure on the switch to hold itagainst its mounting bracket, turn the lock nut up to lower the switch until the indicatorlight in the switch comes on. Tighten the lower jam nut.

e. Press the cut buttons to cycle the clamp and check clamp position.

ADJ. SCREWS

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Figure 48

3. Clamp Up Proximity Switch

This switch is mounted inside the rear of the arch casting, Figure 49. It is tripped by the clamp whenthe clamp is in the up position. This switch prevents backgauge movement if the clamp is not up. Onmachines equipped with the air table option, it also diverts the air from the table when the clamp is

down to prevent the stock from moving during a cut. This switch is tripped by a spring loaded actua-tor on the top of the clamp and requires no adjustment.

Figure 49

15.1.3 Hydraulic Valve Adjustments

Several of the following tests require the machine to be operational forchecking and adjusting. Be very careful that tools and other people are clear of moving parts and thatthe cutter is not accidentally operated while adjustments are being made. Disconnect the power andlock it out, see Safety Precautions, page 8, whenever working on the machine unless the directionsspecifically require the machine to be powered.

For initial setup, adjust the valves in the following order:

1. Main System Relief Valve- 1800 psi2. Knife down sequence valve- 1600 psi3. Clamp up relief valve- 400-600 psi4. Pressure reducer valve (X only)- 1400max/300min psi

Hyd. Up Prox-imity Switch

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5. Electronic Clamp Pressure- 1400max/300min psi

NOTE: Pressure settings fluctuate with oil temperature. Set pressures when the oil is hot.

Figure 50

1. Main System Relief Valve (Figure 50)

This valve maintains the overall hydraulic pressure for the entire system. Factory setting: 1800 psi.

Check Procedure:a. Open the left access door on front of the cutter.b. Turn the power on and make a cut to hold the knife down on the cutting stick. Read the

pressure off the main system pressure gauge (front gauge) while the knife is down. If thegauge does not read 1800 psi, an adjustment is needed. You may need to send knifedown in maintenance mode to read the gauge more easily.

To Adjust: Loosen the lock nut on the relief valve. Use an Allen wrench to turn the adjusting screw.

Turn clockwise to increase pressure, counter-clockwise, to decrease pressure.

PINCH POINT — It will require two people to perform the following adjustment. One holds the cut buttons in and the other adjusts the valve screw. Be extremely careful tokeep hands and tools away from moving parts. The only thing that has to be handled is the adjustingwrench! A possible pinch point exists between the clamp parallel rod and the top of the valve sole-noids. Do not place hands or tools in this area if the machine is to be cycled.

a. Make a cut and hold the buttons in. Or go to knife down adjustment in maintenancemode to cycle the hydraulics. While reading the main system gauge, adjust the valvescrew until you have the correct pressure.

b. Tighten the lock nut while holding the hex wrench in place.

c. Proceed to readjust the other valves.

2. Knife Down Sequence Valve (Figure 50)

This valve controls the clamp and knife sequence. It keeps the knife up until after the clamp hasmade contact. It is the upper right valve on the front of the manifold. Factory Setting: 1600 psi.

Main

SystemGauge

ElectronicClamp Valve

Main SystemRelief Valve

Knife DownSequence

Clamp UpSequence

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NOTE: Main System Pressure must be set at 1800 psi before making this adjustment.

Check Procedure:a. Open the left access door on front of the cutter.

b. Press the cut buttons while reading the pressure on the main system pressure gauge(front gauge). The gauge should read approximately 1600 psi as the knife is movingdown (when bottomed, the gauge will jump to 1800 psi showing the Main System Re-lief Pressure previously set).

c. If correct, proceed to check the Pressure Reducer.

To adjust:a. Loosen the lock nut.

b. Make a cut and hold the buttons in. While reading the main system gauge, adjust thevalve until you have the correct pressure. Clockwise to increase, counter-clockwise todecrease.

NOTE: The knife should not move until the clamp contacts the stock. If it does, you must in-crease the pressure.

c. Tighten the lock nut while holding the hex wrench in place.

d. Proceed to readjust the other valves.

3. Clamp Up Sequence Valve (Figure 50 on page 85)

This valve maintains clamp pressure so the clamp remains down until the knife has stopped inthe up position. Factory setting: 400-600 psi.

Check Procedure:

a. Open the left access door of the cutter.

b. Press the cut buttons, and while reading the pressure on the main gauge (frontgauge), release them. The gauge should read between 400-600 psi as the clamp isgoing up. There should be no clamp movement until the knife is stopped in the upposition.

c. If correct, proceed to check the Pressure Reducer.

To Adjust:a. Remove the protective cap and loosen the lock nut on the clamp up sequence valve.

b. Make a cut, then release the buttons. Read the main gauge as the clamp is return-

ing. Adjust the valve for a reading of 400-600 psi.

c. Tighten the lock nut while holding the hex wrench in place and replace the protectivecap.

d. Proceed to readjust other valves.

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4. Manual Pressure Reducer Valve- (X only)

This valve, Figure 51 on page 87, limits the amount of pressure to the clamp system. Factory setting:1000 psi (1400max/300min).

To Check: With the hydraulic access door open, activate the cut buttons and read the pressure off

the clamp gauge (rear gauge). It should read 750 psi for average cutting purposes.

To Adjust:1. Loosen the lock knob. There are two knobs, one behind the other. The outer is the adjusting

knob. The inner is the lock knob.

2. Push the cut buttons and check the reading on the clamp gauge (rear gauge) when the clampis on the table and the knife is coming down.

3. Turn the Pressure adjusting knob clockwise for MORE pressure, counter-clockwise for LESS.

DO NOT set the clamp pressure below 300 psi. Severe lacerations ordismemberment could result! The knife and clamp system will lose sequence settings below 300 psiand the knife could come down before the clamp.

4. Make another cut and check the pressure gauge. Adjust the pressure to your cutting applica-tion (See Operator Tips or Knives sections, page 61).

5. Tighten the locking knob.

Figure 51

1. Electronic Clamp Control Valve- (XD/XG)

The electronic clamping control allows the convenience of changing the clamp pressure at the controlconsole. The pressure is controlled by use of the up and down arrow keys, 0 being the lowest - 15the highest; and is indicated in the upper right hand corner of the display. See below:

Adjustment of the Electronic Valve:a. To adjust the pressure range, enter the Maintenance Mode and choose Diagnostic.

b. To adjust the pressure, select Clamp Adjust. See the next screen on page 86:

Clamp Gau e

Pressure AdjustKnob

Lock

Knob

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88

c. Setting the Maximum Pressure: Perform a cut cycle, after the clamp has contactedthe table and while the knife bar is coming down, read the pressure on the right handpressure gauge. It should be set at 1400 p.s.i. If not, correct by using the up anddown arrow keys. When finished, choose D), to exit and go to the minimum pressureset up seen shown below:

d. Setting the Minimum Pressure: Perform a cut cycle, after the clamp has contactedthe table and while the knife bar is coming down, read the pressure on the right handpressure gauge. It should be set at 300 p.s.i. If not, correct by using the up anddown arrow keys. When finished, choose C), to return to the Send mode, or D) Exit toreturn to Diagnostics.

5.000 in

DIAGNOSTICError CodeSensor Data

Clear MemoryClamp Adjust

Select & press enterA) Maint C) SendB) Job D) Exit

5.000Set Maximum>

Press /\ to Increase

Press \/ to Decrease

A) Main C) SendB) Job D) Exit

5.000Set Minimum>

Press /\ to Increase

Press \/ to Decrease

A) Main C) SendB) Job D) Exit

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15.1.4 Clamp Speed Control Damper

Earlier machines have an adjustable speed control damper that applies a force resisting the motion ofthe clamp. (Dampeners on later machines and replacement dampeners are not adjustable). Itshould be adjusted such that the clamp will fall at a safe speed if the clamp return spring were tobreak. It also reduces impact as the clamp returns to the UP position.

To adjust:1. Make sure the main power is off. DISCONNECT THE POWER AND LOCK IT OUT! (See

Power Lockout procedure, page 8)

Crush Hazard- Do not place hands or tools under knife and clamp.

2. Remove rear arch cover.

3. Loosen the setscrew on the damper valve adjustment knob.

4. Turn the knob in increments of one (1) unit, then slowly depress the foot pedal.

5. Continue until the clamp travels at a safe speed when the foot treadle is depressed quickly.

6. Tighten adjustment knob set screw.

7. Replace rear arch cover.

Figure 52

Adjustment

Knob

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90

15.1.5 Clamp Cylinder

If the clamp piston bottoms in the cylinder before the clamp makes contact with the table, or if theclamp does not make full travel on the up stroke, the clamp cylinder may need adjustment. Theclamp cylinder is located inside the left base casting leg behind the left front door (Figure 53, on page90).

Figure 53

To adjust:1. Turn on machine. Start the hydraulic motor by pressing both cut buttons simultaneously.

Turn off the machine.

2. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout procedure, page 8).

3. Loosen the jam nut.

4. Use the flats on the clamp cylinder shaft to turn the shaft into or out of the clevis as required,(Figure 54). (In decreases, out increases height.)

Figure 54

5. Retighten the jam nut securely.

ClampCylinder

Clevis

Jam Nut

Wrench Flat

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15.1.6 Clamp Parallel Rod

If the clamp is not parallel with the table:1. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout procedure, page 8.)

2. Loosen the jam nuts on each end of the clamp connecting rod, (Figure 55 & Figure 56).

(Note: the left jam nut has left hand threads.)

Figure 55 & Figure 56 – LH & RH End of Rod

3. Using the flats on the end exposed below the base casting, (Figure 55 & 56), turn the con-necting rod and align the clamp with the table. If a single sheet is placed under each end ofthe clamp and manually clamped, a level clamp will not allow either sheet to be pulled out.

4. Retighten the jam nuts securely.

15.1.7 Backgauge Gibs

If you are having trouble keeping the back-gauge square, check for backgauge side play. Positionthe backgauge approximately 2” (50-55mm) from the rear of the table and turn off power.

Remove the rear table cover. From the back, hold each end of the backgauge and try pulling oneend while pushing the other to rock it side to side. If there is noticeable side-to-side play in the back-gauge, the gibs will need adjusting. Check for play at various positions on the table, (Figure 57).Note: there will be some front to rear movement between the backgauge nut and screw.

Figure 57

JamNut

JamNut

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92

The backgauge has two gibs that ride on a iron rail underneath the table, (Figure 58). These are adjusted with setscrews, which are held in position with jam nuts.

Figure 58

To adjust:1. Run the backgauge back to 23” (600mm) and disconnect the power.

2. Always adjust the side gib first. Loosen all jam nuts and adjusting screws then tighten the

front and rear screws.

3. Pull each end of the backgauge and try to rock it side to side as before to check for play.

4. Continue to adjust these two screws until there is no play and the hand-wheel still turns easily(X only).

5. Lock the screws in place with the jam nuts.

6. Snug up the middle two screws and lock in place with the jam nuts.

7. Snug up the bottom gib adjusting screws finger tight and lock in place with the jam nuts.

8. Run the backgauge back and forth to make sure it does not bind. Readjust if necessary.

9. Replace the rear table cover.

10. Check the backgauge squareness.

15.1.8 Lead Screw Adjustment Nuts

If play is noted in the forward pillow block and thrust bearings, take up the play in the adjustment nutsby:

1. Loosening the lead screw jam nuts, Figure 59 (“x”) & Figure 60 (“XD”/”XG”) on page 93.

2. Snug up the inner nut to eliminate any play.

3. Tighten the nuts against each other.

4. Check the socket head bolts in the pillow block to make sure they are also tight.

Set Screws& Jam Nuts

Rail

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9

Figure 59 – “X” Model Jam Nut Location

Figure 60 – “XD”/”XG” Model Jam Nut Location

15.1.9 Backgauge Drive Belt Adjustment

If the backgauge motor runs but the backgauge does not move or slips, the belt may need adjust-ment, Figure 61.

Figure 61

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94

To adjust the belt:1. Turn off the machine, DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lock-

out procedure, page 8.)

2. Remove the drive belt cover guard at the rear of the table.

3. Loosen the four socket head screws holding the motor to the mounting plate.

4. Slide the motor down to put more tension on the belt, or lift it up to reduce tension for remov-ing belt.

5. If belt cannot be tightened, replace with a new belt.

6. Adjust the tension of the belt so that there is a 1/2”-3/4” (10mm) flex remaining and tightenthe mounting plate socket screws.

7. Replace the belt guard cover.

8. Reconnect the power to the machine.

15.1.10 Knife Bar Gibs

The knife bar gibs are two metal plates on either side of the arch that guide and hold the knife as itcuts. If adjusted too tight the knife may not come down, or scoring could damage the gibs and knifebar. If too loose, you could get uneven or inaccurate cuts.

WARNING: Knives are heavy and very sharp (even after use). Severelacerations could result. Follow all safety precautions and knife changing instructions fromthe Knives section of this manual.

There are three, socket set screws with jam nuts on each side of the arch that adjust the gibs, (Figure62). These should be adjusted only with the knife bar directly behind the screws being tightened.

Figure 62

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9

To adjust:1. Start the machine and make a cut. When the knife is half way down, have someone press

the stop button. The knife bar should be stopped half way across the gibs.

2. Loosen all (6) jam nuts on the gib adjusting screws and back the screws out 1/2 turn.

3. Adjust center (2) screws until snug - not tight to eliminate the air gap between the knife barand gib. Tighten those (2) jam nuts.

4. Place the machine into knife down adjustment mode. See Operating instructions for yourmachine’s model.

5. Adjust the bottom two screws the same way the middle screws were adjusted. Tighten the jam nuts.

6. Start the machine. The knife should return to the up position. Shut the machine off.

7. Adjust the upper (2) gib adjusting screws and tighten the jam nuts.

8. Turn the power back on and cycle the knife several times. Recheck the gibs (repeat steps 2-6

as necessary).

9. Don’t over-tighten the gibs; this will scrape off the lubricants and score the knife bar.

10. If your knife bar and gibs do get scored, simply remove only the burrs by scraping and thensanding smooth. Grease the gibs and the knife bar then reset the gibs. Deep scores neednot be removed - they will retain lubricants.

15.2 Repair and Replacement

15.2.1 Fuses

FIRE HAZARD. Replace only with same type and rating fuse.

Figure 63

The Champions each have a set of fuses. The fuses are located inside the main power box, (Figure63). Check the label inside the cover for correct ratings for these fuses. Labels are reproduced withthe drawings at the back of this manual in case those on the cover may be damaged or illegible. (Seepages 164, 165, & 166.)

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96

15.2.2 Knife Bar Cylinder

Replacing the Knife Bar Cylinder:1. Remove the knife from the cutter (see Knife, Installation and Set Up).

2. Place a 3” (60mm) lift of paper under the clamp only to hold it up and out of the way of the

knife bar. Then place a 3’ (1 meter) long 2x4 board flat side down under the right end of theknife bar. This will be used for leverage on the knife bar when removing and reinstalling theknife bar pin.

3. Lock the clamp and knife down by following instructions in the Operator Controls section foryour particular model of machine.

4. Turn off the main power disconnect switch. DISCONNECT POWER AND LOCK IT OUT! See page 8.

Loosen connections slowly to bleed off any trapped pressure!

5. Place a pan underneath the cylinder and gradually loosen and remove the hydraulic connec-tions. Loosen the connections slowly to bleed off any trapped pressure.

Figure 64

6. Remove the clevis pin. E-style retaining rings on each side of the pin can be removedthrough the access panel in the side of the arch casting. The pin has a 1/4-20 tapped hole init to aid removal and a clearance hole in the front of the arch provides access to knock the pinout of the knife bar, (pg. 95, fig. 65). Use the board to block up the knife bar and to releasepressure from the pin to make it easier to remove.

7. Now, remove the pin retainer and the Tru-arc retaining ring from the lower mounting pin hold-ing the cylinder to the base.

8. Remove the old cylinder. With the shaft of the old cylinder bottomed out, note the dimensionbetween the top of the cylinder body and the bottom of the cylinder clevis. Also note the ap-proximate position of the proximity switch actuator. Transfer the proximity switch actuator,the clevis lock nut, and the clevis onto the new cylinder and insert it into position on the cut-ter.

9. Reinstall the base pin, Tru-arc retainers, and the pin retainer.

10. Install the upper pin to connect the cylinder to the knife bar and replace the retaining rings.

Clevis

Jam

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9

11. The cylinder shaft can be threaded into the clevis to adjust the position of the knife bar.When properly adjusted, the distance from the top of the knife bar recess to the table with theknife in the down position should measure 4-1/8” (103mm), (Figure 66).

Figure 65

12. Lock the jam nut securely in place.

13. Reconnect the hydraulic hoses.

CRUSH HAZARD! Knife and clamp will return to the up position whenthe key is turned on and the cut buttons are pressed for the first time. Keep hands and toolsaway.

Figure 66

14. Reconnect the power to the cutter and turn main power on.

15. Adjust the Knife up proximity switch actuator. Press the cut buttons once to turn on the hy-draulic motor and raise the knife and clamp. Allow machine to run for a few minutes to workthe air out of the system.

16. See Knife Installation and Set up for reinstalling the knife.

Clamp

KnifeBar

Arch

Table

4-1/8”

¼-20 Tapped Hole E-Ring

Clevis

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98

15.2.3 Pilot Check Valve

The Pilot Check Valve on the knife cylinder (Figure 67) helps to hold the knife in the up position. If itbecomes stuck or plugged, the clamp will come down but the knife will remain in the up position.

Figure 67

To check:

1. Follow the knife changing procedures to remove the knife blade and then block the knife barin the up position.

2. Turn the main-power disconnect switch to the off position, DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout Procedure, page 8.)

3. Place a pan underneath the valve and slowly loosen the pilot valve connections to bleed offany pressure.

4. Remove the check valve and hoses from the knife cylinder. Replace the hose fitting attachedto the cylinder with the two 900 fittings on the check valve. (The smaller fitting goes on thetop port.) Reconnect the hoses.

5. Reconnect the power and run the machine.

6. If the knife cycles without the valve in line, replace with a new check valve.

LACERATION HAZARD. This is a test procedure only. Do not operatecutters without a functional check valve installed. Possible knife drift could occur exposing the bladeedge below the clamp.

15.2.4 Foot Pedal Cable Assembly

Use the following procedure to replace the foot pedal cable assembly.

Remove old cable:1. Turn the main power disconnect to the off position, DISCONNECT THE POWER AND LOCK

IT OUT! (See Power Lockout Procedure, page 8.)

2. To remove the old cable, remove the lock nut from the cap screw on the left hand bell-crank.Pull the eyelet off the screw.

Pilot CheckValve

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9

Figure 68

3. Loosen the jam nut on the turnbuckle at the mid-section of the cable assembly. Unthread thecable stud from the turnbuckle.

4. Remove the bottom half of the cable by pulling the ball end found on the underside of the footpedal arm.

Installing the new cable:Install the new cable assembly in the reverse order in which the old cable was removed. The cableshould then be properly tensioned. Thread the stud into the turnbuckle so that all slack in the cable istaken up. Continue to tighten the stud until there is a slight pull on the bell-crank. Lock the stud inplace by tightening the jam nut.

Figure 69

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100

15.2.5 Table Maintenance

The table of a paper cutter requires periodic maintenance to remove surface oxidation. Polishing isalso required to provide a smooth surface for paper to move freely. The frequency of this mainte-nance 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, use the following instructions.

1. Remove the rust-protective coating from the table with a solvent.2. Remove all solvent residues 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 mi-croscopic 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 excesssilicone is not removed. If the excess is not removed, the silicone spray has a substance that holdsthe 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 wearand 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. Thenremove it with paper toweling. Or, pour a small quantity of SAE 10-weight motor oil onto the ta-ble. Using a Scotch-Brite Pad or a 400 grit sand paper, polish the table following the “grain” ofthe 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.

Note: Do not use a wax that contains a cleaning compound on the table. The cleaner contains mi-croscopic 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 excesssilicone is not removed. If the excess is not removed, the silicone spray has a substance that holdsthe 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.

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NOTES

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16.0 Troubleshooting

102


Never work on this machine with the power on unless the instruc-tions say the machine power must be on. Lock the power off at the wall disconnect switch.

See Power Lockout Procedure, page 8.

WON’T START 1. Fuse blown 4. Cut button defective2. Starter is defective 5. Check error codes3. Loose plug or wire

CUT BUTTONS PUSHED- MACHINE SHUTS OFF 1. Knife and clamp are out of sequence. Turn off power and turn back on.2. Check clamp and knife up limit switches.3. When cutting a full pile, the clamp up limit switch does not break contact, either adjust limit switch

or cut down on pile height.4. Defective circuit board

CUT BUTTONS ACTIVATED- WON’T CUT 1. A cut button is defective.2. Motor wired wrong, going in opposite direction of the arrow sticker on the motor3. Pilot check on the knife cylinder is defective4. Sequence valve pressure is set too high5. Either down solenoid in valves inoperative6. Knife up limit switch is not properly adjusted7. Defective circuit board

ERRATIC OPERATION- POWER LOSS 1. Low hydraulic oil level2. Debris in relief valve

3. Defective pump4. Oil bypassing clamp cylinder seals

CLAMP WON’T OPERATE 1. Bind in linkage or gibs2. Clamp pressure reducer valve set too low3. High pressure solenoid defective4. Relief valve defective5. Clamp return spring defective

CLAMP WON’T HOLD PRESSURE 1. Clamp cylinder seals worn2. Pressure valve setting too low3. Clamp not parallel to table

CLAMP WON’T BOTTOM 1. Clamp cylinder out of adjustment2. Clamp return spring broken or out of adjustment

CLAMP NOT PARALLEL TO TABLE1. The clamp connecting rod is out of adjustment.

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16.0 Troubleshooti

10

CONCAVE CUTTING- ENDS WIDE, CENTER NARROW 1. Excessive moisture at edges of paper2. More ink on edges of lift

CONCAVE CUTTING- VARIATION OF TOP AND BOTTOM 1. Soft stock not firmly clamped2. Knife is dull or ground incorrectly3. Knife bar gibs loose4. Air in stock when clamped, pulls away from backgauge5. Clamp not parallel to table

INCONSISTENT STOPPING OF KINFE IN UP POSITION 1. Bind in knife linkage or gibs2. Up sequence valve not properly adjusted3. Knife links worn

HESITATION OF KNIFE 1. Dull knife2. Seals worn in knife or clamp cylinder3. Defective pilot check on knife cylinder

4. Knife links worn

KNIFE WON’T RETURN 1. Defective high pressure valve2. Directional valve(s) stuck in3. Up sequence pressure too low

CLAMP WON’T RETURN1. Up sequence pressure too high2. Bind in clamp linkage or gibs3. Clamp not parallel to table4. Clamp return spring defective

KNIFE DRIFTS DOWN 1. Knife bar gibs out of adjustment2. Defective pilot check on knife cylinder3. Defective seals in knife cylinder4. Knife latch out of adjustment

KNIFE STOPS IN STOCK 1. Knife dull2. Relief valve defective3. Pressure control valve clogged or defective4. Knife cylinder seals worn5. Clamp cylinder seals worn6. Motor stalling due to low voltage or too small wire to machine

NOISY AND SLUGGISH HYDRAULIC SYSTEM 1. Cylinder seals worn on clamp or knife2. Low on hydraulic fluid3. Worn spline coupling in motor/pump

INACCURATE CUTTING 1. Backgauge not square2. Knife bar has play- tighten gibs3. Backgauge gibs loose

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104

4. Dull knife (See Knives section page 63)5. Clamp not parallel to table6. Accuracy not set correctly

BACKGAUGE SPEED ERRATIC 1. Oil on pulley belt2. Belt/pulley loose

BACKGAUGE MOVEMENT ERRATIC 1. Backgauge gibs loose or binding on table way (rail under table)2. Backgauge nut binding on leadscrew, screw bent or dirty3. Problem with electrical drive component4. Defective circuit board

DRAWING OF STOCK 1. Dull knife2. Low clamp pressure3. Hydraulic fluid low4. Air in lift- reduce pile height5. Clamp not parallel to table

SLOW KNIFE 1. Defective seals in clamp cylinder2. Defective pilot check valve on knife cylinder3. Pump not achieving full pressure4. Main system or clamp pressure reducer is by-passing fluid

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16.0 Troubleshooti

10

NOTES

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1 0 6

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1 0 7

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17.0 Schematics & Parts Lists

108

17.2 Main Assembly – Side View – 47500 Sht. 2 of 16, Rev. H

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17.0 Schematics & Parts Lis

10

Main Assembly – Side View – 47500 Sht. 2 of 16, Rev. H

S U -

3 0 - 1 0 3 M O L Y - G R A P H

L U B E

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110

17.3 Main Assembly– Top View – 47500 Sht. 3 of 16

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11

Main Assembly- Top View – 47500 Sht. 3 of 16

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112

17.4 Main Assembly – Rear View – 47500 Sht. 4 of 16, Rev. K

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11

Main Assembly – Rear View – 47500 Sht. 4 of 16, Rev. K

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11

Main Assembly – X Model Tables – 47500 Sht. 5 of 16 Rev. D

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116

17.6 Main Assembly – XD & XG Model Table - 47500 Sht 6 of 16 Rev. H

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11

Air Table Assembly – 47500 Sht. 7 of 16 Rev. D

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12

17.9 Power Panel Wiring- Euro Prog. 47500 Sht. 9 of 16 Rev. D

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122

Power Panel Wiring - Euro Programmable 47500 Sht. 9 of 16 Rev. D

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12

17.10 Power Panel Wiring 305 X 47500 Sht. 10 of 16, Rev. C

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124

Power Panel Wiring- 305 X 47500 Sht. 10 of 16 Rev. C

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12

17.11 Main Asm. – Front View (Rough) – 47500 Sht. 11 of 16 Rev. C

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12

17.12 Optional Voltages – 305 XD & XG – 47500 Sht. 12 of 16, Rev. A

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128

Optional Voltages – 305 XD & XG – 47500 Sht. 12 of 16, Rev. A

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12

17.13 Main Assembly- Electric Eyes 47500 Sht. 13 of 16

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130

Main Assembly- Electric Eyes 47500 Sht. 13 of 16

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13

17.14 Main Asm.- Light Curtain Instructions (X, XD, XG, XT) 47500 Sht.14 of 16

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132

17.15 Main Assembly- Wiring –Manual Backgage – 1PH rev. A

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1 3 3

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134

17.17 Basic Machine Schematic – X Model – E-3171 Rev. A

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13

17.18 Power Panel Assembly – 305 X – EE-3170 Sht. 1, Rev. A

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136

Power Panel Assembly – 305 X – EE-3170 Sht. 1, Rev. A

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13

17.19 Power Panel Assembly – 305 X – EE-3170 Sht. 2, Rev. A

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138

17.20 Power Panel Assembly – 305 XD & XG – EE-2882 Sht 1, Rev. U

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140

Power Panel Assembly – 305 XD & XG – EE-2882 Sht 2, Rev. D

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142

17.22 Interconnection Diagram – X Model – E-2841-1 rev. A

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144

17.24 305 XD Control Console – EE-2850, Rev. B

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14

17.25 Control Console- XT Color LCD EE-2998-2

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146

17.26 Control Console- XT Color LCD EE-2998-3 rev A

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14

17.27 Cut Button Assembly – EE-2832, Rev. B

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15

17.31 Description of Error Messages

Message Description Test

Backgauge Failure Backgauge doesn’t move Mechanical bind; encoder failuremain pc board; blown fuse

Backgauge at Limit Backgauge is all the way forward orbackward

Checksum Error Bad program chip Replace EEPROM

Clamp Up Failure Clamp failed to return to up positionwithin 7 seconds

Clamp up sequence valve; sole-noid (cut) valve

Clamp Down Failure Clamp failed to come down Solenoid valves; low pressure;low voltage

Clamp or Knife Down Clamp or knife stayed downs No main pressure; stuck solenovalve

Cut Relay Error 1 Cut relay energized when it shouldbe off

Cut relay is stuck

Cut Relay Error 0 Cut relay de-energized when itshould be energized

Output may be bad

DATA IS OUT OF RANGE The number is outside the limits ofthe machine

Informational error

Hydraulic Latch Failure 1 Latch relay was OFF when it shouldhave been ON

Defective relay

Hydraulic Latch Failure 0 Latch relay was ON when it shouldhave been OFF

Defective relay

Key is Invalid in Graphics Mode Tried to delete or insert a cut in anauto-programmed job

Information error

Knife Latch Failure 1 Latch prox. ON when it should havebeen OFF

Loose solenoid wire; mechanicabind; knife up prox. Switch out oadjustment; defective prox.Switch

Knife Latch Failure 0 Latch prox. OFF when it should

have been ONKnife Down Failure Knife failed to come down within 4

secondsLow main pressure; low voltageknife down sequence valve

Knife Up Failure Knife failed to return within 1.17seconds

Mechanical bind; solenoid (cut)valve

Knife at Both Limits Knife up and down prox. Switchesare on at the same time

Prox. Switches; broken knife bacomponents

Lubricate Machine Lubricate machine alarm Have machine lubricated

Memory Failed A memory error occurred duringtest

Memory Locked Tried to change a locked channel

Motor Starter Error 1 Motor starter engaged when itshould not have been

Starter stuck

Motor Starter Error 0 Motor starter disengaged when itshould not have been

Output may be bad

Next Channel Locked Tried to link two channels togetherand the linked channel is locked

No Finish > Parent While entering sheet division data,the sheet dimensions were greaterthan the starting sheet

Number Outside of Limit Selected cut position beyond ma-chine limits

Operator error; false clamp limit

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152

Positioning Error Backgauge failed to move to pro-grammed position within +/- .005

Mechanical bind; encoder failure;main pc board; leadscrew thrustwashers loose; gives loose

Result is Negative When a math operation yields anegative number

Send Cancelled Console key was pressed while

backgauge was moving

Operator error; key board failure

Sequence Error Timing error in either up or downcycle

Low main pressure; any se-quence valve

Sharpen Knife Sharpen knife alarm Have knife sharpened

Shorted Key Error Console key shorted Operator error; defective key-board

** IF ERROR CODES CANNOT BE RESET BY DEPRESSING THE CLEAR KEY, THE POWERWILL HAVE TO BE TURNED OFF AND ON**

17.32 Sensor Data Abbreviations

RGHTCUT 0 Right Cut Button Under RHS of table front

LEFTCUT 0 Left Cut Button Under LHS of table frontCUTRLY (input) 1 Cut Relay On power panelHYDLAT 1 Hydraulic Latch Relay Main pc board

KNFDWN 1 Knife Down Proximity Switch On bracket attached to knife cylinderPRESET 1 Preset Sensor Rear of cutter, under left side of table

CUTSOL (output) 0 Cut Relay Relay below motor contactorAIRSOL 0 Air Solenoid Solenoid valve on top of air motor

KNLATSOL (output) 0 Knife Latch Solenoid Behind display console, on latch as-sembly

CLAMPUP 1 Clamp up Proximity Switch Rear of cutter, right side of archHYDUP 1 Hyd. Clamp Up Proximity Rear of cutter, at top of clamp cylinder

KNFUP 1 Knife Up Proximity Switch On bracket attached to knife cylinderMTRSTRT (input) 0 Motor Start Relay On top of motor contactor block

KNFLAT (input) 0 Knife Latch Prox. Behind display console, on latch as-sembly

HYDMOT (output) 0 Hydraulic Motor Relay Contactor, top right of main pcbAIRMTR 0 Air Table Motor Behind oil tank

LTLINE (output) 1 Line Light Output Line light relay on main pcbUNLOAD 0 Unload Valve Solenoid valve on front of Manifold

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154

17.34 305 XD, XG, XT Encoder Cable Assembly, EE-2822-1 Rev. B

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15

17.35 Knife Latch Assembly – 47568, Rev. C

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15

17.37 Hydraulic Manifold Assembly– H-465-1, Rev. C

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160

17.39 Hydraulic Manifold– H-468-1, Rev. A

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162

17.40 Manifold Assembly– H-504, Rev. A

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16

17.41 Fuse Charts

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164

17.42 XD & XG Models Label – Power Panel Connection Procedure – S-1781-52, Rev. F

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166

17.44 Warning Label – S-1781-116, Rev. A

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16

17.45 Paper Deflector (Kit Option) – AA-13936-1

17.46 Paper Deflector Assembly A-4511-2

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168

17.47 24” x 36” Ext. Table on 305 (Kit Option) – K-2720, Rev. E

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170

17.49 24” x 36” Ext. Table on 305 Air (Kit Option) – K-2731, Rev. D

(For S/N up to 03X1063)

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17

17.50 24” x 36” Ext. Table on 305 Air (Kit Option) – K-2731, Rev. D

(For S/N up to 03X1063)

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172

17.51 24” x 36” Ext. Table on 305 Air (Kit Option) – K-47631

(For S/N 03X1064 and up)

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17.54 Electric Eye Kit Instructions- K-3006, Sht. 1 of 3, Rev. A

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176


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19.0 Channel Log

184

19.0 Channel LogIt is recommended that you keep an abbreviated Channel Log and detailed Program Logs (copy thisform) for important or repeat jobs. In the event memory capacity is reached, a glance at the ChannelLog will tell you which channels may be cleared to make more room.

CHAN. JOB/CUSTOMER SAVE CHAN. JOB/CUSTOMER SAVE

01 3602 3703 38

04 3905 40

06 4107 42

08 4309 44

10 4511 46

12 4713 4814 49

15 5016 51

17 5218 5319 54

20 5521 56

22 5723 58

24 5925 6026 61

27 6228 63

29 6430 65

31 6632 6733 68

34 6935 70

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20.0 Safety System Tes

18

20.0 Safety System Tests

Machine manufacturer CHALLENGE Model _____________

Serial Number __________________

Frequency of test: THESE TESTS SHOULD BE PERFORMED AT THE BEGINNING OF EACHWORK DAY.

Turn on the cutter and start the hydraulic motor (see operator’s manual for instructions). Enable theelectric eye safety system.

Test #1: Using a 12 mm wide test piece, check the object detection capability of the electric eye sys-tem. Do this by waving the test piece throughout the electric eye beam area. The steady green andsteady orange lights on the emitter side (RH) should change to steady red and flashing orange.

Test #2: Press both cut buttons to begin a cut cycle. During the downward motion of the knife orclamp, lean into the path of the electric eye beams. The downward motion of the knife and clampshould stop immediately, and the knife and clamp should return to the up position.

If the machine fails either test, DO NOT use machine. Repair or adjust is necessary.

Please enter date and initials for both tests (make copies of this form if necessary).

Date ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Test 1 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Test 2 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Date ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Test 1 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Test 2 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Date ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Test 1 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Test 2 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Initials of

Repairs Repairer Date _________________________________________ ________ _____________ _________________________________________ ________ _____________ _________________________________________ ________ _____________ _________________________________________ ________ _____________ _________________________________________ ________ _____________ _________________________________________ ________ _____________ _________________________________________ ________ _____________

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20.0 Safety System Tests

Documents

F.254-I (1)