CHALLENGE SPARTAN 150SA PAPER CUTTER Service Manual Provided By http://www.MyBinding.com http://www.MyBindingBlog.
Serial Numbers 041001 & Up TECHNICAL SERVICE AND PARTS MANUAL SPARTAN 150 SA SEMI-AUTOMATIC PAPER CUTTER Sold and Serviced by The Challenge Machinery Company 6125 Norton Center Drive Norton Shores, MI. 49441 www.challengemachinery.com F.150-T Dec.
1.0 Introduction 1.0 Introduction THIS MANUAL is designed to help you get the most from your Challenge equipment. Keep this manual in a safe, convenient place for quick reference by operators and service personnel. SAFETY ALERT! This symbol means CAUTION: Personal safety instructions! Pay special attention to the instructions in bold type. Personal injury may result if the precautions are not read and followed.
1.0 Introduction TABLE OF CONTENTS 1.0 Introduction....................................................................................................................................... 2 2.0 Safety ............................................................................................................................................... 4 2.1 Precautions .................................................................................................................................. 4 2.
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 DISCONNECT POWER before making any adjustments or lubricating. See page 4, 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 3.3.1 Clamp Send the knife down by activating a cut cycle and when the knife reaches the bottom, release only the right cut button and turn off the power before releasing the left cut button.
3.0 Maintenance Guide 3.3.2 Backgauge Leadscrew With the top cover ON, place machine on a flat level surface on it’s left side and remove bottom cover. Use any brand-name type of grease or light oil to lubricate backgauge leadscrew (Figure 4). It may be helpful to use a small brush to apply grease. Note: the leadscrew may be lubricated with grease or oil. Oil has a tendency to run off and must be lubricated more frequently; grease tends to collect paper dust and must be cleaned off periodically.
3.0 Maintenance Guide Figure 5 To square the backgauge: 1. Make sure the backgauge gibs are set properly (see section 3.4.5 ). 2. Remove the rear Plexiglas table cover. 3. Loosen the jam nuts on the backgauge adjusting screws. (Figure 6). Backgauge Adjusting Screws Backgauge Adjusting Screws Figure 6 4. Back off the adjusting screw on the side that the trim occurred, then tighten the other screw. 5. With the squaring screws tight, make another test.
3.0 Maintenance Guide Note: Once the backgauge is square, check the backgauge accuracy (see section 3.4.2 ) to make sure it is accurate. 3.4.2 Backgauge Accuracy Adjustment If the backgauge position readout does not match the actual measurement between the knife and the backgauge, the accuracy can be adjusted. The accuracy can be checked by the following procedure: NOTE: The backgauge should be squared before attempting to adjust the accuracy. (See Section 3.4.1 Squaring the Backgauge, page 10.) 1.
3.0 Maintenance Guide Preset Screw Figure 8 5. Replace bottom cover, lay machine flat, and turn on power. Note: If power was not off, reset power now or else reading will be false. Bring the backgauge to the front to reset the display and make another test. Repeat adjustment procedure if necessary. 3.4.3 Knife Bar Gib Adjustments 1. Make sure knife is in up position and turn off power and disconnect power cord. 2. Remove clamp hand wheel and top cover. 3.
3.0 Maintenance Guide 5. Replace top cover, plug in power cord, turn power on, and start a cut cycle. 6. When knife is all the way down, release right cut button only and switch off power. 7. Now with the knife in the down position, disconnect power cord, remove top cover, and repeat gib screw adjustment for the BOTTOM GIB SCREW on each side. 8. Replace top cover and clamp handle. 3.4.
3.0 Maintenance Guide 6. Slightly loosen the remaining (5) knife screws, keeping them somewhat snug. 7. Adjust the knife leveling screw (Figure 11) that corresponds with the side of the knife which does not cut all the way through. Tug on the paper while adjusting and stop when the bottom sheet is cut all the way through. Knife Leveling Screws Figure 11 8.
3.0 Maintenance Guide Backgauge Gib Screw Backgauge Gib Screw Figure 12 4. Tighten the two nylon set screws until they just touch the guide. Do not over-tighten or they could cause the backgauge to bind. Lock in position with jam nuts. The center screw is a spring loaded plunger and should not need adjustment. 5. Run the backgauge back and forth the length of the table and check for any binding. Readjust if necessary. Replace the bottom cover and lay machine flat. 3.4.
3.0 Maintenance Guide Leadscrew Collars Figure 13 4. Make sure there is a slight gap between the front hand crank and the machine, slide collars up tight against the nylon washers and tighten the collar screws. 5. Check to make sure the hand crank turns freely with no play. 6. Replace bottom cover and lay machine flat. 3.4.7 Line Light Adjustment The line light can be adjusted if necessary as follows: 1. Remove the top clamp hand wheel and top cover. 2.
3.0 Maintenance Guide Line Light Mounting Screws Figure 14 3. Place a white sheet of paper over the cut stick and turn the power on to activate the line light. Note: 24V is being supplied to line light board while power is on. 4. Slide the line light assembly forward or backward to get a single, crisp line. 5. Tighten the screws and turn power off. Replace the cover and hand wheel. 3.4.
3.0 Maintenance Guide Hinge Rod Mounting Screws Figure 15 4. Tighten screws, replace cover and clamp handle. 5. Test to make sure machine works properly, using the test found at the end of this manual. 3.4.9 Knife Up Limit Switch Adjustment If the knife up limit switch becomes loose or needs adjustment, adjust as follows: 1. Turn off the power and disconnect the power cord. 2. With the top cover ON, place machine on a flat level surface on it’s left side and remove bottom cover. 3.
3.0 Maintenance Guide Mounting Screws Figure 16 5. Replace bottom cover, lay machine flat, and turn on power. 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 described above, and move the bracket slightly in the slots to allow the knife to come up further.
3.0 Maintenance Guide Bracket Mounting Screws Limit Switch Switch Bracket Figure 17 4. Check to make sure the switch bracket slides freely on the mounting bracket. 5. Check condition of spring. 6. Replace bottom cover and lay machine flat. 3.4.11 Backgauge Encoder/Belt Adjustment The backgauge encoder system reads the position of the backgauge, and sends the information to the display. The encoder uses a belt and pulley system to read the actual position of the backgauge.
3.0 Maintenance Guide Belt Encoder Pulley Bracket Mounting Screws Figure 18 4. Inspect the belt and make sure it is tight. If it is not, loosen the (2) screws at the rear of the machine, pull belt tight, then tighten the screws. 5. Make sure the pulley is properly lined up with the belt (Figure 18). If not, the position of the pulley can be adjusted by loosening the pulley set screw, then slide the pulley into place, then tighten the set screw. 6.
3.0 Maintenance Guide Disengage Brake Figure 19 4. Now move the gears in the directions shown in Figure 19. Some machines are equipped with gears that have a small stub on them which can be used to turn the gear using a pliers or wrench if necessary. If the larger gear cannot be moved by hand, carefully tap on it with a rubber hammer, or carefully pry it with a long bar. Be very careful not to damage the gear teeth. Rotate the gears so that at least one whole tooth is engaged (Figure 20).
3.0 Maintenance Guide 6. Check to make sure the up and down limit switches are positioned properly to prevent gears from becoming disengaged again (See Section 3.4.9 page 19 and Section 3.4.10 page 20). 7. Replace bottom cover and lay machine flat. 3.5 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.
3.0 Maintenance Guide Problem 6. Backgauge display is inaccurate. Possible Cause a) Backgauge accuracy needs adjustment. b) Encoder malfunction. c) Faulty display circuit board. 7. Knife cuts deeper on one side than the other. 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) Paper clamped too tight. c) Inadequate power source. Solution a) See Section 3.4.2 Backgauge Accuracy Adjustment, page 12.
4.0 Parts Lists 4.0 Parts Lists 4.1 Main Assembly – Backgauge Bracket 60000 Sht. 1, Rev.
4.0 Parts Lists Main Assembly – Backgauge Bracket 60000 Sht. 1, Rev.
4.0 Parts Lists 4.2 Main Assembly – Leadscrew 60000 Sht. 2, Rev.
4.0 Parts Lists Main Assembly – Leadscrew 60000 Sht. 2, Rev.
4.0 Parts Lists 4.3 Main Assembly – Knife Drive 60000 Sht. 3, Rev.
4.0 Parts Lists Main Assembly – Knife Drive 60000 Sht. 3, Rev.
4.0 Parts Lists 4.4 Main Assembly – Bottom Side Electrical 60000 Sht. 4, Rev.
4.0 Parts Lists Main Assembly – Bottom Side Electrical 60000 Sht. 4, Rev.
4.0 Parts Lists 4.5 Main Assembly – Clamp 60000 Sht. 5, Rev.
4.0 Parts Lists Main Assembly – Clamp 60000 Sht. 5, Rev.
4.0 Parts Lists 4.6 Main Assembly – Knife 60000 Sht. 6, Rev.
4.0 Parts Lists Main Assembly – Knife 60000 Sht. 6, Rev.
4.0 Parts Lists 4.7 Main Assembly – Front Shield 60000 Sht. 7, Rev.
4.0 Parts Lists Main Assembly – Front Shield 60000 Sht. 7, Rev.
4.0 Parts Lists 4.8 Main Assembly – Backgauge 60000 Sht. 8, Rev.
4.0 Parts Lists Main Assembly – Backgauge 60000 Sht. 8, Rev.
4.0 Parts Lists 4.9 Main Assembly – Top Side Electrical 60000 Sht. 9, Rev.
4.0 Parts Lists Main Assembly – Top Side Electrical 60000 Sht. 9, Rev.
4.0 Parts Lists 4.10 Main Assembly – Covers and Labels 60000 Sht. 10, Rev.
4.0 Parts Lists Main Assembly – Covers and Labels 60000 Sht. 10, Rev.
4.0 Parts Lists 4.11 Main Assembly – Accessories 60000 Sht. 11, Rev.
4.0 Parts Lists Main Assembly – Accessories 60000 Sht. 11, Rev.
4.0 Parts Lists 4.12 Motor and Gearbox Assembly – Sheet 1 60005 Sht. 1, Rev.
4.0 Parts Lists 4.13 Motor and Gearbox Assembly – Sheet 2 60005 Sht. 2, Rev.
4.0 Parts Lists 4.14 Motor and Gearbox Assembly – Sheet 3 60005 Sht. 3, Rev.
4.0 Parts Lists 4.
4.0 Parts Lists 4.
4.0 Parts Lists 4.17 Electrical Power Panel Assembly EE-3061, Rev.
4.0 Parts Lists 4.18 Wire Harness Assembly EE-3116, Rev.
4.0 Parts Lists Wire Harness Assembly EE-3116, Rev.
E-3062 4.19 Electrical Schematic 4.
4.20 Electrical Interconnection Diagram E-3125 Rev. B 4.
4.0 Parts Lists 4.21 Label – Fuse Replacement S-1781-129, Rev.
4.0 Parts Lists 4.22 Optional Floor Stand Assembly 60065, Rev.
