CHALLENGE SPARTAN 150M PARTS MANUAL Service Manual Provided By http://www.MyBinding.com http://www.MyBindingBlog.
Serial Numbers 041001 & Up TECHNICAL SERVICE AND PARTS MANUAL SPARTAN 150 M DIGITAL/LEVER PAPER CUTTER Sold and Serviced by The Challenge Machinery Company 6125 Norton Center Drive Norton Shores, MI. 49441 www.challengemachinery.com F.150M-T Nov.
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 Move the knife and clamp down. Disconnect the power cord and remove clamp handle, cutting lever handle, and top cover. Wipe off any old or excess grease.
3.0 Maintenance Guide Apply Oil Figure 4 3.3.2 Backgauge Leadscrew With the top cover ON, place machine on a flat level surface on it’s left side. Use any brand-name type of grease or light oil to lubricate backgauge leadscrew (Figure 5). 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 3.4.1 Squaring the Backgauge To test if the backgauge is square, place a small lift of paper against the left side of the backgauge (but not against the side guide) and make a cut. Leave the backgauge in the same position, flip the lift over and push it against the right side of the backgauge (but not against the side guide). Make another cut to see if any of the paper will trim off (Figure 6).
3.0 Maintenance Guide 4. With the squaring screws tight, make another test. Continue to adjust and test until no trim occurs when testing either sequence. 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.
3.0 Maintenance Guide 1/2 turn = .021” (7/32”) 2/3 turn = .028” (9/32”) 1 turn = .042” (13/32”) Preset Screw Figure 9 5. Lay the machine flat, and connect power. Note: If power was not off, reset power, otherwise the 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 the knife is in up position and disconnect the power cord. 2. Lower the clamp to the table.
3.0 Maintenance Guide Top Knife Bar Gib Screw Top Knife Bar Gib Screw Bottom Knife Bar Gib Screw Bottom Knife Bar Gib Screw Figure 10 4. Tighten gib screws such that the knife will not fall when the lever is released from any position. Tighten the top screws with the knife in the UP position. Tighten the bottom screws with the knife in the DOWN position. The motion of the lever should remain smooth. Hold screws in position with hex wrench and tighten jam nuts. 5.
3.0 Maintenance Guide adjustment screw counter-clockwise. To set the knife to cut shallower, turn the screw clockwise (Figure 12). Adjustment Screw Figure 12 3. Note which side is not cutting completely through the paper. Lower the clamp to the table with partially cut paper underneath. 4. Lower the clamp to the table. Remove the clamp handle, cutting lever handle, and top cover. 5. Slightly loosen the knife screws, keeping them somewhat snug. 6.
3.0 Maintenance Guide 3.4.5 Backgauge Gib Adjustments 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. Disconnect the power cord. 2. Place machine on a flat level surface on it’s left side. 3. Loosen the two gib screw jam nuts (Figure 14, page 16). Backgauge Gib Screw Backgauge Gib Screw Figure 14 4. Tighten the two nylon set screws until they are just snug.
3.0 Maintenance Guide Leadscrew Collars Figure 15 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. Lay the machine flat. 3.4.7 Line-Light Adjustment The line-light can be adjusted if necessary as follows: 1. Lower the clamp to the table. Remove the clamp handle, cutting lever handle, and top cover. 2.
3.0 Maintenance Guide 3. Place a white sheet of paper over the cut stick connect the power to activate the line-light. Note: 9V 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 disconnect power. Reinstall the clamp handle, cutting lever handle, and top cover. 3.4.
3.0 Maintenance Guide 3.5 Hood and Knife Latch Adjustments The hood and knife latch work together as the primary safety feature of this machine. They should be checked for proper operation every time the machine is serviced. 1. Lower the clamp to the table. Remove the clamp handle, cutting lever handle, and top cover. 2. Raise the hood. The hood should remain in the UP position when released. If it does not, tighten the screws that mount the hood to the machine base (Figure 18).
3.0 Maintenance Guide 3.5.1 Knife Latch Replacement 1. Use kit number K-61074 as shown on page 41. Lower the clamp to the table. Remove the clamp handle, cutting lever handle, and top cover. 2. Remove the knife latch, knife latch spring, and hood. The hood must be removed at the machine frame, not at the hood mounting brackets. Remove Remove Figure 20 3. Remove the old knife bar keeper. 4. Install the new keeper using semi-permanent thread locking compound on the screws. 5. Reinstall hood.
3.0 Maintenance Guide 3.6 Troubleshooting Problem 1. The machine will not power up – no display, no linelight. Possible Cause a) Power cord is disconnected. b) Disconnected wires inside machine. c) No power at electrical outlet. 2. Power is on, but backgauge display is blank. a) Disconnected wires inside machine. b) Faulty display circuit board. c) Backgauge in Preset Position on power-up. Solution a) Plug in cord. b) Check for wires that are disconnected from circuit boards, power cord, etc.
4.0 Parts Lists 4.0 Parts Lists 4.1 Main Assembly – Backgauge Bracket 61000 Sht.
4.0 Parts Lists Main Assembly – Backgauge Bracket 61000 Sht. 1 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part No.
4.0 Parts Lists 4.2 Main Assembly – Clamp 61000 Sht.
4.0 Parts Lists Main Assembly – Clamp 61000 Sht. 2 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part No.
4.0 Parts Lists 4.3 Main Assembly – Knife Drive 61000 Sht.
4.0 Parts Lists Main Assembly – Knife Drive 61000 Sht. 3 Item 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 Part No.
4.0 Parts Lists 4.4 Main Assembly – Backgauge 61000 Sht.
4.0 Parts Lists Main Assembly – Backgauge 61000 Sht. 4 Item 1 2 3 4 5 6 7 8 9 10 11 Part No. 60203 61057 61059 H-6423-4 H-6910-404SS H-6918-606 H-6918-608 H-6938-416 H-7321-4 H-7321-6 H-7327-12 Description BACKGAUGE ASSEMBLY SIDE GUIDE REAR COVER NUT - 1/4-20 HEX KEP SCREW - 1/4-20 X 1/2 BUT. HEAD CAP STAINLESS SCREW - 3/8-16 X 3/4 SOCKET HEAD CAP SCREW - 3/8-16 X 1 SOCKET HEAD CAP SCREW - 1/4-20 X 1 CUP SOC SET WASHER - 1/4 SAE PLAIN WASHER - 3/8 SAE PLAIN WASHER - 3/8 MEDIUM LOCK Qty.
4.0 Parts Lists 4.5 Main Assembly – Top Cover 61000 Sht. 5 Item 1 2 3 4 5 6 7 30 Part No. 61049 H-6910-404SS S-1076-2 S-1781-119 S-1781-126 S-1781-131 S-1781-136 Description ARCH COVER SCREW - 1/4-20 X 1/2 BUT. HEAD CAP STAINLESS CHALLENGE LABEL LABEL- FRONT PANEL LABEL- DIGITAL DISPLAY LABEL - TOP COVER LABEL- DO NOT ALTER SAFETY DEVICES Qty.
4.0 Parts Lists 4.6 Main Assembly – Hood 61000 Sht. 6 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part No. 61052 61054 61055 61056 61060 61074 61075 E-1152-99 H-21S-125-0500 H-6442-#10 H-6910-102408 H-6910-102406SS H-6918-102406 H-6918-102410 Description HOOD BUSHING HINGE BLOCK HINGE BRACKET TILT SHIELD STIFFENER MAGNET BLOCK ASSEMBLY TORSION SPRING STANDOFF ROLL PIN - 1/8 X 1/2 NUT - #10-24 NYLOC SCREW - #10-24 X 1 BUTTON HEAD CAP SCREW - #10-24 X 3/4 BUT.
4.0 Parts Lists 4.7 Main Assembly – Electrical 61000 Sht.
4.0 Parts Lists Main Assembly – Electrical 61000 Sht. 7 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part No.
4.0 Parts Lists 4.8 Main Assembly – Encoder Mount 61000 Sht.
4.0 Parts Lists Main Assembly – Encoder Mount 61000 Sht. 8 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part No.
4.0 Parts Lists 4.9 Main Assembly – Preset 61000 Sht. 9 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 36 Part No.
4.0 Parts Lists 4.
4.0 Parts Lists 4.11 Interconnection Diagram E-3130, Rev.
4.0 Parts Lists 4.12 Label- Electrical S-1781-134, Rev. A 4.13 Label – Caution S-1781-119, Rev.
4.0 Parts Lists 4.14 Optional Floor Stand Assembly 61070, Rev. A Item 1 2 3 40 Part No. 61067 40016-6 H-6910-408 Description STAND MOUNT - VIBRATION SCREW - 1/4-20 X 1 BUTTON HEAD CAP Qty.
4.0 Parts Lists 4.15 Knife Latch Replacement Kit K-61074, Rev. “A”. See instructions in Section 3.5.1 Knife Latch Replacement on page 20. Item 1 2 3 4 Part No. 61039 61042 61071 61072 Description KNIFE BAR KEEPER KNIFE LATCH TORSION SPRING KNIFE LATCH CAP Qty.
