CHALLENGE SPARTAN 185 SERVICE MANUAL Provided By http://www.MyBinding.com http://www.MyBindingBlog.
Serial Numbers 051001 & Up TECHNICAL SERVICE AND PARTS MANUAL SPARTAN 185 SA/A/AEP AUTOMATIC PAPER CUTTER Sold and Serviced by The Challenge Machinery Company 6125 Norton Center Drive Norton Shores, MI. 49441 www.challengemachinery.com F.185-T Jul.
1.0 Introduction NOTES Challenge® is a registered trademark of The Challenge Machinery Company• 6125 Norton Center Drive • Norton Shores, MI 49441-6081 Copyright© 2006 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.
1.0 Introduction 1.0 Introduction THIS MANUAL is designed to help you get the most from your Challenge equipment. Keep this manual in a safe, convenient place for quick reference by operators and service personnel. SAFETY ALERT! This symbol means CAUTION: Personal safety instructions! Pay special attention to the instructions in bold type. Personal injury may result if the precautions are not read and followed.
1.0 Introduction TABLE OF CONTENTS 1.0 Introduction ....................................................................................................................................... 3 2.0 Safety................................................................................................................................................ 6 2.1 Precautions .................................................................................................................................. 6 2.
1.0 Introduction 4.20 Main Asm. – Covers and Labels (Models: A, 120/230V, 50/60 Hz) .........................................66 4.21 Main Asm. – Covers & Labels (Models: AEP, 120/230V, 50/60 Hz) ........................................68 4.22 Main Asm. – Accessories (All Models) .....................................................................................70 4.23 Motor and Gearbox Assembly (All Models) ..............................................................................72 4.
2.0 Safety 2.0 Safety 2.1 Precautions • • • • • • • • • • • • • • • • This machine is designed for one-person operation. Never operate the machine with more than one person. Safe use of this machine is the responsibility of the operator. Use good judgment and common sense when working with and around this machine. Read and understand all instructions thoroughly before using the machine. If questions remain, contact the dealer from which you purchased this machine.
2.0 Safety 2.3 Warning Label Definitions The following warning labels are found at various locations on your machine. Read and understand the meaning of each symbol. If a label is lost from the machine, it should be replaced. HAZARDOUS AREA Disconnect power before cleaning, servicing, or making adjustments not requiring power. Do not alter safety guards or devices; they are for your protection. Replace all guards. Do not operate with any guards removed.
2.0 Safety !OJO! This Este simbolo de alerta de seguridad significa ¡ OJO ! INSTRUCCIONES DE SEGURIDADPERSONAL. Lea las instrucciones porque se refieren a su seguridad personal. Fall de obedecer las instrucciones que siguen podria resultar en lesiones corporales. • • • • • • • • • • • • • • • • • • • • Esta maquina, junto con sus mecanismos de seguridad, esta disenada para ser manejada por UNA SOLA PERSONA a la vez. Jamas debe ser manejada por mas de una persona al mismo tiempo.
3.0 Maintenance Guide 3.0 Maintenance Guide NOTICE The instructions on the following pages are for the use of trained service personnel only! Attempting to perform repair and replacement procedures without proper training may cause machine damage or operator injury! PARTS CUSTOMERS: The Challenge Machinery Company provides parts with the express understanding that they are to replace parts found missing or no longer serviceable on equipment designed and/or manufactured by Challenge.
3.0 Maintenance Guide 3.1 Routine Maintenance (All Models) DISCONNECT POWER before making any adjustments or lubricating. See page 6, SAFETY PRECAUTIONS, for Power Lockout Procedure. A clean, lubricated machine will run longer, smoother, cut more accurately, with less downtime and fewer costly repairs. Schedule lubrication both early in the day and early in the week. This allows the lubricants to work into the machine.
3.0 Maintenance Guide 3.2.3 Machine Exterior • The machine’s exterior should be cleaned with a non-abrasive water based detergent applied to a damp cloth. • Always be careful when cleaning around safety warning labels. Use limited amounts of cleaners in those areas. 3.3 Lubrication (All Models) 3.3.1 Clamp Send the clamp down, then turn off the power. Disconnect the power cord, remove and disconnect the display panel, and remove the top cover. Wipe off any old or excess grease.
3.0 Maintenance Guide Grease Guide Shaft Grease Lead Screw Figure 3 3.4 Accessing the Electrical Panel (All Models) SHOCK HAZARD, CAN CAUSE SEVERE INJURY OR DEATH. DISCONNECT POWER before accessing the electrical panel. See page 6, SAFETY PRECAUTIONS, for Power Lockout Procedure. To access the electrical panel for electrical troubleshooting, electrical adjustments, or for access to the inside of the machine, open the panel as shown in Figure 4 below. First disconnect power cord.
3.0 Maintenance Guide 3.5 Adjustments Some of the following tests require the machine to be operational for checking and adjusting. Be very careful that tools and other people are clear of moving parts and that the cutter is not accidentally operated while adjustments are being made. Whenever possible, disconnect the power and lock it out (see SAFETY PRECAUTIONS, page 6) unless the directions specifically require the machine to be powered. 3.5.
3.0 Maintenance Guide Backgauge Adjusting Screws and Jam Nuts Backgauge Adjusting Screws and Jam Nuts Figure 6 4. Back off the adjusting screw on the side that the trim occurred, then tighten the other screw. 5. Tighten jam nuts and make another test. Continue to adjust and test until no trim occurs when testing either sequence. 6. Replace the rear Plexiglas table cover. Note: Once the backgauge is square, check the backgauge accuracy (see Section 3.5.2 below) to make sure it is accurate. 3.5.
3.0 Maintenance Guide Accurate Questionable Figure 7 4. The backgauge accuracy can be corrected by adjusting the preset screw attached to the bottom of the backgauge nut assembly (Figure 8). Preset Screw Figure 8 Turn off power and disconnect the power cord. Remove the rear bottom cover. Place a 3/16” Allen wrench in the preset screw and hold in position while loosening the jam nut. Now adjust the screw as follows: • • If rear pile is short (less than 5”), turn screw out (counterclockwise).
3.0 Maintenance Guide 3.5.3 Backgauge Accuracy Adjustment (Models: AEP) Refer to the Spartan 185 AEP Operator’s Manual. 3.5.4 Knife Bar Gib Adjustments (All Models) 1. Send the knife to the “down” position by making a cut and when the knife reaches the table, continue to hold the left cut button while releasing the right cut button and switching off the power. Then disconnect power cord. 2. Remove and disconnect the display panel, then remove the top cover. 3.
3.0 Maintenance Guide Viewing Hole Viewing Hole Knife Adjusting Screw Figure 10 If knife is cutting deeper on one side than the other, use the following procedure to adjust: 1. Flip the cut stick to a new position and raise the knife depth by several turns of the knife adjusting screw (Figure 10). 2. Slightly loosen the left-most knife screw only (but keep somewhat snug). 3. Place a few sheets of paper over the entire cut stick, and make a cut.
3.0 Maintenance Guide 8. Tighten the (5) accessible knife screws, replace top cover and display panel, restore power to machine, raise knife up by turning on power switch, and tighten (1) remaining knife screw. 3.5.6 Backgauge Gib Adjustments (All Models) If the backgauge does not stay square or moves up and down or back and forth when jogging paper against it, the backgauge gib screws may be loose or worn. To Adjust: 1. Turn off the power and disconnect the power cord. 2. Remove rear bottom cover. 3.
3.0 Maintenance Guide Front Collar Rear Collar Figure 13 5. Turn front hand wheel back and forth to make sure it turns freely with no excess play. 6. Replace electrical panel cover. 3.5.8 Line Light Adjustment (All Models) The line light can be adjusted if necessary as follows: 1. Remove and disconnect the display panel, then remove the top cover. 2. Loosen the three line light mounting screws (Figure 14). Line Light Mounting Screws Figure 14 3.
3.0 Maintenance Guide 3.5.9 Front Guard Switch Adjustment (All Models) The front guard interlock switches must be adjusted correctly in order for machine to function properly and safely. To adjust: 1. Turn off the power and disconnect the power cord. 2. Remove and disconnect the display panel, then remove the top cover. 3. Loosen (2) screws that mount the front guard switches (Figure 15) and slide the switches forward or backward until the actuator lines up with the flat on the hinge rod (Figure 15).
3.0 Maintenance Guide Make necessary adjustments by turning the Sequence Adjustment Screw (Figure 16) located on the electrical panel (See Section 3.4 Accessing the Electrical Panel, page 12). CCW CW Sequence Adjustment Screw Figure 16 3.5.11 Clamp-Up Limit Switch Adjustment (Models: A and AEP) The clamp-up limit switch determines where the clamp stops in the “up” position. If the clamp stops too high or too low, adjust as follows: 1. Turn off the power and disconnect the power cord.
3.0 Maintenance Guide 4. Loosen bracket mounting screws (Figure 18), and slide bracket up or down, depending on the type of adjustment needed. Lowering the bracket will lower the “up” position of the clamp, raising the bracket will raise the “up” position of the clamp. Then tighten screws, and also check to make sure the screws mounting the switch to the bracket are tight. Note: Applying temporary thread lock to bracket mounting screws will help prevent screws from coming loose during operation.
3.0 Maintenance Guide Mounting Screws Figure 19 5. Replace bottom cover. Turn on power and make a cut. Check position of knife – USE CAUTION, THE KNIFE EDGE IS VERY SHARP. The edge of a new knife should be above the bottom of the clamp when the knife and clamp are in the “up” positions. If the knife edge is below the clamp, repeat the adjustment procedure, moving the bracket slightly in the direction that allows the knife to come up further.
3.0 Maintenance Guide 4. Check to make sure the switch bracket slides freely on the mounting bracket. 5. Check condition of spring. 6. Replace bottom cover. 3.5.14 Re-engaging the Knife Pull-Down Gear (All Models) If the knife pull-down gear becomes disengaged, the following procedure must be followed in order to properly re-engage it: 1. Turn off the power and disconnect the power cord. 2. Remove rear bottom cover. It may be helpful to lower electrical panel and slide forward (see Section 3.
3.0 Maintenance Guide Figure 22 5. Release the brake lever to its normal position. 6. Check to make sure the up and down limit switches are positioned correctly to prevent gears from becoming disengaged again (See Section 3.5.12 page 22 and Section 3.5.13 page 23). 7. Replace bottom covers.
3.0 Maintenance Guide 3.6 Troubleshooting Problem 1. The machine will not power up – no display, no line light, and machine will not cycle. Possible Cause a) Power cord is disconnected. b) Main power switch/circuit breaker is off. c) Blown fuse on main circuit board. d) Disconnected wires inside machine. e) No power at electrical outlet. 2. Display and line light are on, but machine will not cycle. a) Front guard is open. b) Front guard has not been opened and closed since previous cut cycle.
3.0 Maintenance Guide Problem 7. Knife cuts deeper on one side than the other. Possible Cause a) Knife is not seated all the way up in knife bar. b) Knife level is not set properly 8. The machine strains through a cut. a) Dull knife. b) Inadequate power source. 9. Concave cutting – ends wide, center narrow. 10. Concave cutting – variation from top to bottom. a) Excessive moisture at edges of paper. a) Knife dull or incorrectly ground. 11. Motor runs at start up and does not stop running. 12.
4.0 Parts Lists 4.0 Parts Lists 4.1 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 PART NO. 47053 56552 60115 63047 63100 63201 63202 63203 63208 63215 63216 63219 11288-5 47214-2 A-10081-4 E-2467 E-1152-104 EE-2534-3 H-21S-250-0750 H-6417-6 H-6424-4 H-6424-6 H-6890-606 H-6909-508 H-6910-406 H-6918-404 H-6918-410 H-6918-604 H-6918-606 H-6938-406 H-6940-412 H-7321-4 H-7321-6 H-7327-8 H-7327-12 S-1681-3 S-1781-135 S-2021-2 DESCRIPTION COUPLING BALL BEARING- 3/8 X .
4.0 Parts Lists 4.2 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 PART NO. 47053 56552 60115 63047 63100 63201 63202 63203 63208 63215 63216 63219 11288-5 47214-2 A-10081-4 E-2467 E-1152-104 EE-2534-3 H-21S-250-0750 H-6417-6 H-6424-4 H-6424-6 H-6890-606 H-6909-508 H-6910-406 H-6918-404 H-6918-410 H-6918-604 H-6918-606 H-6938-406 H-6940-412 H-7321-4 H-7321-6 H-7327-8 H-7327-12 S-1681-3 S-1781-141 S-2021-2 DESCRIPTION COUPLING BALL BEARING- 3/8 X .
4.0 Parts Lists 4.3 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 PART NO.
4.0 Parts Lists 4.4 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 PART NO.
4.0 Parts Lists 4.5 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 PART NO. 63084 63085 47214-1 E-3073 E-1736-2 E-3073-3 E-3074-3 EE-3154 EE-3163 H-6424-4 H-6424-6 H-6910-404 H-6910-408 H-6940-632 H-7324-8 H-7327-8 S-1350-16 S-1694-1 DESCRIPTION SLIDER BRACKET - RH SLIDER BRACKET - LH SHOULDER WASHER PUSHBUTTON SWITCH QUENCHARC PUSHBUTTON SWITCH CIRCUIT BREAKER AND ON/OFF SWITCH, 20A ELEC.
4.0 Parts Lists 4.6 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 PART NO.
4.0 Parts Lists 4.7 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 PART NO. 63084 63085 47214-1 E-3073 E-1736-2 E-3073-3 E-3074-4 EE-2778 EE-3154-1 H-6424-4 H-6424-6 H-6910-404 H-6910-408 H-6940-632 H-7324-8 H-7327-8 S-1350-16 S-1694-1 DESCRIPTION SLIDER BRACKET - RH SLIDER BRACKET - LH SHOULDER WASHER PUSHBUTTON SWITCH QUENCHARC PUSHBUTTON SWITCH CIRCUIT BREAKER AND ON/OFF SWITCH, 12A POWER CORD - 120V ELEC.
4.0 Parts Lists 4.8 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 PART NO.
4.0 Parts Lists 4.9 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 PART NO. 63084 63085 47214-1 E-3073 E-1736-2 E-3073-3 E-3074-4 EE-2778-1 EE-3154-1 H-6424-4 H-6424-6 H-6910-404 H-6910-408 H-6940-632 H-7324-8 H-7327-8 S-1350-16 S-1694-1 DESCRIPTION SLIDER BRACKET - RH SLIDER BRACKET - LH SHOULDER WASHER PUSHBUTTON SWITCH QUENCHARC PUSHBUTTON SWITCH CIRCUIT BREAKER AND ON/OFF SWITCH, 12A POWER CORD - 230V EURO ELEC.
4.0 Parts Lists 4.10 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 PART NO.
4.0 Parts Lists 4.11 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 PART NO.
4.0 Parts Lists 4.12 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 PART NO.
4.0 Parts Lists 4.13 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 PART NO.
4.0 Parts Lists 4.14 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 PART NO.
4.0 Parts Lists 4.15 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 PART NO.
4.0 Parts Lists 4.16 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 PART NO.
4.0 Parts Lists 4.17 Main Asm. – Top Side Elec.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 PART NO.
4.0 Parts Lists 4.18 Main Asm. – Top Side Elec.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PART NO.
4.0 Parts Lists 4.19 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PART NO. 41130 63034 63048 63050 63209 63217 EE-3164 H-6910-404 H-6910-404SS H-6910-63203SS H-6918-604 H-6924-004 S-1781-50 S-1781-125 S-1781-131 S-1781-149 DESCRIPTION PLATE - SERIAL NUMBER TOP COVER - 185SA BOTTOM COVER STAND ENCODER COVER REAR TABLE COVER DISPLAY ASM - DIGITAL SCREW - 1/4-20 X 1/2 BUTTON HEAD CAP SCREW - 1/4-20 X 1/2 BUT. HEAD CAP STAINLESS SCREW - #6-32 X 3/8 BUT.
4.0 Parts Lists 4.20 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PART NO. 41130 63048 63050 63077 63209 63217 EE-3158 H-6910-404 H-6910-404SS H-6910-63203SS H-6918-604 H-6924-004 S-1781-50 S-1781-125 S-1781-149 DESCRIPTION PLATE - SERIAL NUMBER BOTTOM COVER STAND TOP COVER - 185A/185AEP ENCODER COVER REAR TABLE COVER DISPLAY ASM - DIGITAL SCREW - 1/4-20 X 1/2 BUTTON HEAD CAP SCREW - 1/4-20 X 1/2 BUT. HEAD CAP STAINLESS SCREW - #6-32 X 3/8 BUT.
4.0 Parts Lists 4.21 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 PART NO. 41130 63048 63050 63077 63217 63209-1 E-1152-92 EE-3157 EE-3158 H-6910-404 H-6910-404SS H-6910-63203SS H-6918-604 H-6924-004 S-1781-50 S-1781-125 S-1781-149 DESCRIPTION PLATE - SERIAL NUMBER BOTTOM COVER STAND TOP COVER - 185A/185AEP REAR TABLE COVER ENCODER COVER, 185AEP STANDOFF DISPLAY ASM - PROGRAMMABLE DISPLAY ASM - DIGITAL SCREW - 1/4-20 X 1/2 BUTTON HEAD CAP SCREW - 1/4-20 X 1/2 BUT. HEAD CAP STAINLESS SCREW - #6-32 X 3/8 BUT.
4.0 Parts Lists 4.22 Main Asm.
4.0 Parts Lists NO. 1 2 3 4 5 PART NO.
4.0 Parts Lists 4.23 Motor and Gearbox Assembly (All Models) 63002 Rev.
4.0 Parts Lists NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 PART NO.
4.0 Parts Lists 4.24 Magnet Assembly (All Models) 60052 NO. 1 2 3 74 PART NO.
4.0 Parts Lists 4.25 Floor Stand Assembly (All Models) 63050, Rev. A NO. 1 2 3 4 PART NO.
4.0 Parts Lists 4.
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4.0 Parts Lists 4.
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4.0 Parts Lists 4.
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4.0 Parts Lists 4.
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4.0 Parts Lists 4.
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4.0 Parts Lists 4.
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4.0 Parts Lists 4.32 Elec. Interconnection Diagram (Models: SA, 120/230V, 50/60 Hz) E-3150-2, Rev.
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4.0 Parts Lists 4.33 Elec. Interconnection Diagram (Models: A, 120/230V, 50/60 Hz) E-3150-4, Rev.
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4.0 Parts Lists 4.34 Elec. Interconnection Diagram (Models: AEP, 120/230V, 50/60 Hz) E-3150-3, Rev.
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4.0 Parts Lists 4.35 Electrical Power Panel Assembly (Models: SA, 120V, 60 Hz) EE-3154, Rev.
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4.0 Parts Lists 4.36 Electrical Power Panel Assembly (Models: SA, 230V, 50/60 Hz) EE-3154-1, Rev.
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4.0 Parts Lists 4.37 Electrical Power Panel Assembly (Models: A/AEP, 120V, 60 Hz) EE-3133, Rev.
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4.0 Parts Lists 4.38 Electrical Power Panel Assembly (Models: A/AEP, 230V, 50/60 Hz) EE-3133-1, Rev.
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4.0 Parts Lists 4.39 Relay Board Assembly (Models: SA/A/AEP, 120V, 60 Hz) EE-3132, Rev.
4.0 Parts Lists 4.40 Relay Board Assembly (Models: SA/A/AEP, 230V, 50/60 Hz) EE-3165, Rev.
4.0 Parts Lists 4.41 Display Assembly – (Models: SA, 120/230V, 50/60 Hz) EE-3164, Rev.
4.0 Parts Lists 4.42 Display Assembly – (Models: A, 120/230V, 50/60 Hz) EE-3158, Rev.
4.0 Parts Lists 4.43 Display Assembly – (Models: AEP, 120/230V, 50/60 Hz) EE-3157, Rev.
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