Related Manuals for Challenge CHAMPION 370 XT
Summary of Contents for Challenge CHAMPION 370 XT
- Page 1 CHALLENGE CHAMPION 370 PAPER CUTTER Instruction Manual Provided By http://www.MyBinding.com http://www.MyBindingBlog.com...
- Page 2 Serial Numbers 07276 & Up PERATOR’S ANUAL CHAMPION 370 PAPER CUTTER Models XG & XT Sold and Serviced by The Challenge Machinery Company 6125 Norton Center Drive Norton Shores, MI 49441-6081 USA ChallengeMachinery.com F.370-B-O October 2007...
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Page 3: Introduction
CHALLENGE. 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 Machinery Company • Attn.: Service Department •... - Page 4 1.0 Introduction TABLE OF CONTENTS 1.0 Introduction ............................2 2.0 Safety ..............................5 2.1 Precautions ...........................5 2.2 Power Lockout Procedure ......................5 2.3 Warning Label Definitions......................6 3.0 Packing List............................8 4.0 Specifications ............................9 5.0 Footprint ............................10 6.0 Installation & Setup .........................11 6.1 Inspecting Shipment ........................11 6.2 Uncrating ............................11 6.3 Re-Crating and Shipping ......................13 6.4 Lifting Instructions........................13...
- Page 5 1.0 Introduction 8.13 Job Mode..........................31 8.13.1 Lock/Unlocking a Job......................31 8.13.2 Copying a Job ........................32 8.13.3 Erasing a Job ........................32 8.13.4 Creating a New Job ......................32 8.13.5 Editing an Existing Job...................... 35 8.13.6 Running a Programmed Job..................... 36 8.13.7 Exiting a Job ........................
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Page 6: Safety
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. -
Page 7: Warning Label Definitions
2.0 Safety 2.3 Warning Label Definitions The following warning labels are found at various locations on your machine. Read and understand the meaning of each symbol. If a label is lost from the machine, it should be replaced. The item number and location of each label can be found in Section Error! Reference source not found.. - Page 8 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. •...
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Page 9: Packing List
3.0 Packing List 3.0 Packing List Part No. Description Qty. Basic Machine Extension Side Tables: 16026 36” Steel Side Table (LH) 16027 36” Steel Side Table (RH) 49147 Side Table Back Plate (LH) 49080 Side Table Back Plate (RH) A-8495 Side Table Support (LH) A-8496 Side Table Support (RH) -
Page 10: Specifications
Repeat positioning accuracy is 0.003” or 0.05mm. Electric Eyes: Response time < 68 ms Object detection capability – 12 mm Challenge reserves the right to make changes to any product or specification without notice and without incurring responsibility to existing units. -
Page 11: Footprint
5.0 Footprint 5.0 Footprint... -
Page 12: Installation & Setup
6.0 Installation & Setup 6.0 Installation & Setup 6.1 Inspecting Shipment This machine has been carefully packed to prevent damage during shipment. However, claims for damage or loss are the responsibility of the recipient. Inspect all shipments as soon as they are received. - Page 13 6.0 Installation & Setup Figure 2 Paper Left Arch Deflector End Cover Cable Shipping Block Figure 3...
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Page 14: Re-Crating And Shipping
Always lift and transport from the front of the machine. The carton has lifting instructions, so it must be placed properly on the skid. Challenge is not responsible for an improperly packed machine. The skid and packing materials are available for purchase from Challenge. -
Page 15: Assembly: Standard
6.0 Installation & Setup 6.6 Assembly: Standard Unless otherwise specified, the only items that have been disassembled for shipping are the extension side tables. To assemble the table extensions, follow the procedure below. NOTE: Assembled side tables are awkward and heavy. Use two people to attach the side tables. 1. - Page 16 6.0 Installation & Setup 4. Remove the rear arch cover assembly. 5. Insert the table from the rear of the machine, through the arch. The table is located using two special taper pins through holes on the rear table mounting pads. 6.
- Page 17 6.0 Installation & Setup Figure 6 12. Install the forward and rearward lead screw covers using eight 1/4-20 x ½” button head cap screws, eight ¼” flat washers, and eight ¼” internal tooth lock washers. Figure 7 13. Reconnect the backgauge motor cable. From the table, the cable runs through the strain relief bushing into the motor housing, (Figure 8).
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Page 18: Hydraulic Check
6.0 Installation & Setup Figure 8 14. Connect the tube from the blower to the plastic connector attached to the air channel cover on the bottom of the table if required. Reconnect the wires to the air blower and solenoid according to the wiring diagram for the machine model you have. -
Page 19: Power Hook-Up
Test your voltage when the shop is at actual working levels. Challenge recommends a dedicated line with a lockable disconnect to provide adequate power for this machine. -
Page 20: Three Phase Hook-Up
6.0 Installation & Setup 6.10 Three Phase Hook-Up The power source is connected to the cutter through the bottom of the power panel (right hand side). A main power control switch and power cord providing the machine with power is the responsibility of the customer and should be set in accordance with the local electrical code. - Page 21 6.0 Installation & Setup Figure 12 NOTE: DO NOT ATTEMPT TO OPERATE THE CUTTER UNTIL THE REMAINDER OF THIS MANUAL HAS BEEN THOROUGHLY READ AND UNDERSTOOD. CALL YOUR DEALER IF YOU HAVE ANY QUESTIONS.
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Page 22: Champion 370 Diagram
7.0 Champion 370 Diagram 7.0 Champion 370 Diagram... -
Page 23: Operation
IMPORTANT: DO NOT ATTEMPT TO OPERATE THE CUTTER UNTIL YOU HAVE THOROUGHLY READ AND UNDERSTAND ALL OF THE FOLLOWING INSTRUCTIONS. CALL YOUR AUTHORIZED CHALLENGE DEALER IF YOU STILL HAVE ANY QUESTIONS. 8.1 Power - Main Power Switch Power is brought to the machine when the main power switch is turned to the “ON” position (Figure 13). -
Page 24: Making A Cut
8.0 Operation 8.3 Making a Cut Place the paper against the backgauge and side guide. Press and release both cut buttons once to start the hydraulic motor. Then press and hold both cut buttons to start the cut cycle. While holding the cut buttons, the knife and clamp will complete the cut cycle. -
Page 25: Clamp Pressure Adjustment
The lube alarm will also display 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 Knife Count section on page 30. -
Page 26: Definition Of Keys
8.0 Operation 8.8 Definition of Keys Figure 15 8.8.1 Backgauge Glide Control The backgauge glide control is used to manually position the backgauge. The speed of the backgauge will depend upon where the actuator is pressed. Press farther from center for a faster speed, and closer to center for a slower speed. -
Page 27: Push-Out Key
8.0 Operation The SEND key is used to send the backgauge to any valid position. If an attempt is made to send the backgauge to an illegal position, an error message will be displayed at the bottom of the screen stating “Number outside limit”. -
Page 28: Arrow Keys
8.0 Operation 8.8.10 Arrow Keys The four arrow keys can be used in almost all screens. The arrow keys are primarily used for moving the cursor around on the screen, or to toggle between highlighted selections. In some screens, the left arrow key acts as a backspace key. -
Page 29: Entering Math
8.0 Operation The send mode is the first screen displayed after the backgauge is preset. From this screen the backgauge can be positioned with the backgauge pinpoint control or by entering a value and pressing the SEND key. A mathematical expression can also be entered as a send value. Simply type the expression and press SEND. -
Page 30: Maintenance Mode
8.0 Operation 8.12 Maintenance Mode 5.070 Clamp MAINT MENU Pressure | | | 14 | | | LANGUAGE PARAMETERS DIAGNOSTICS KNIFE ADJUST ------------------------------- Select and press enter C) Up G) Send D) Down F) Job H) Exit The maintenance mode is an area where many machine functions can be set or modified. The four principle functions are: Language, Parameters, Diagnostic, and Knife Adjust. -
Page 31: Diagnostic
The lube alarm will also display the name 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 Clear Lube. -
Page 32: Job Mode
8.0 Operation 8.12.3.2 Sensor Data The Sensor Data function provides a list of computer inputs and outputs (proximity switches, etc.) along with their status (0 for open, 1 for closed). This function allows a service technician to check the status of a switch without removing any covers. Cuts and backgauge movements are allowed in this screen so that the technician may observe the status of the inputs and outputs during machine operation. -
Page 33: Copying A Job
8.0 Operation 8.13.2 Copying a Job First, select a job to copy by moving the cursor up or down to the desired job number and press the soft-key “F” (Copy). “Select Copy to #” will be displayed at the bottom of the screen. Enter a job number for the new job or move the cursor to an existing job and press ENTER. - Page 34 8.0 Operation make it impossible to cut at that position. Pressing both cut buttons on a position marked at a Loading Zone will prompt the backgauge to move to the next position in the job. Using a loading position eliminates the need to reach into the knife/clamp area of the cutter when loading a job. 8.13.4.3 Entering Rotation Mark After entering a send value, pressing the right arrow key, instead of ENTER, will move the cursor to the right and prompt the operator to enter a rotation indicator mark.
- Page 35 8.0 Operation decrease the clamp pressure, or use the numeric keypad to enter a number from 0 to 15 (see Adjusting the Clamp Pressure section, page 24 for information about the clamp pressure setting). This will complete the entry for the current line and move the cursor to the send value of the next line. NOTE: All new entry lines will have the same clamp pressure as the one above it, until it is changed.
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Page 36: Editing An Existing Job
8.0 Operation 5.070 CUTS ------------------------------- RE-ENTER C) Up D) Down H) Exit Use the up and down arrow keys to scroll through the possible layouts. The left display will show each choice visually. Select the desired layout by pressing ENTER. At this point the send values will be automatically calculated and entered, and the job will be complete and ready for use. -
Page 37: Running A Programmed Job
8.0 Operation 5.070 8.5 X 11 L #7 Clamp 1> 8.500 Pressure 2>11.000 | | | 14 | | | Job # Lock Name Status ------------------------------- A) Division E) Insert G) Erase D) Cut & Rec F) Job H) Exit To insert a send value, press the soft-key “E”... -
Page 38: Label Cutting
8.0 Operation 8.13.8 Label Cutting A label-cutting feature is also provided on the Champion XG. After providing the label quantity, size, and gutter, the machine will automatically create a programmed job. Begin by entering the job mode, select a job number and name (optional) then depress ENTER. Depress the soft-key “C” (Label) under the left hand display. -
Page 39: An Example Job – Xg Model
8.0 Operation the send values will be automatically calculated and entered. The job will be complete and ready for use. To make changes, edit the job as described in the “Editing a Job” section below. 8.14 An Example Job – XG Model The following is an example of how to program a job that will be used to make two cuts: one at 8.5”... -
Page 40: Operating Tips
9.0 Operating Tips 9.0 Operating Tips Use a jogging aid to align stock. This will reduce the chance of an accident by not having to reach under the knife or clamp. Likewise, use the backgauge to push out stock before removal. Never attempt to remove paper trim clinging to the blade or clamp until they have stopped moving! Carefully lay out each sheet before you start cutting. -
Page 41: Routine Maintenance/Adjustments
10.0 Routine Maintenance/Adjustments 10.0 Routine Maintenance/Adjustments 10.1 Knife Care CAUTION: ! KNIFE SAFETY ! Knives are DANGEROUS!!! They are heavy and very sharp, even after use. Keep the edge away from your body and keep the area clear of others when handling knives. Never touch the cutting edge! To prevent personal injury and damage to the knife, always keep knives in their holders with screws tightened. -
Page 42: Knife Change
10.0 Routine Maintenance/Adjustments Figure 17 – Knife Changing Equipment 10.1.1 Knife Change The knife changing equipment shown in Figure 17 is included in the cutter tool kit. The following instructions show how to remove and install a new or re-sharpened knife. Read through these instructions AT LEAST ONCE before attempting to actually change or install any blades. - Page 43 10.0 Routine Maintenance/Adjustments Figure 18 9. Clear the table and put the empty knife scabbard on the table. 10. Grasp the knife lifter assembly firmly while turning counterclockwise to release the knife from the knife bar. Slowly lower the knife down and to the right. Bring the left side out first and put the blade in the scabbard immediately.
- Page 44 10.0 Routine Maintenance/Adjustments Knife Adjusting Screw Knife Knife Blade Lock Hold Knife Down Paper Lever Follower Deflector Figure 19 3. Raise the knife bar. 4. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout procedure, page 5.) 5. Use the cutting stick puller to remove the cutting stick. Turn the cutting stick to a new surface.
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Page 45: Cut Quality
10.0 Routine Maintenance/Adjustments 11. Insert the rest of the knife bolts and washers, snug tighten them, but don’t tighten completely. Be sure all bolts have washers. The correct washers are important for proper bolt clearances! 12. Replace the knife lifters with bolts and snug tighten. 13. -
Page 46: Bevel Angle
10.0 Routine Maintenance/Adjustments The machine seems to strain while cutting. This strain can be heard in the hydraulic motor. The knife makes a “rougher” sound as it passes through stock. Nicks are visible on the cutting edge of the knife. 10.1.3 Bevel Angle The most appropriate bevel angle depends upon four factors. -
Page 47: Knife Tips
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. -
Page 48: Lubrication
10.0 Routine Maintenance/Adjustments 2. Position the false clamp plate under the clamp. The locator pegs should be positioned to the rear of the cutter and are set into holes in the bottom of the clamp. 3. With a 1/8" Allen wrench, back off the setscrews in front of the clamp and raise the plate up to the bottom of the clamp. - Page 49 10.0 Routine Maintenance/Adjustments Oil Hole in Knife Bar Grease Lead-screw Oil clamp cylinder pin on both sides of cylinder...
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Page 50: Hydraulic System
Instead of stopping 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 to the hydraulic system. -
Page 51: Recommended Oils
10.0 Routine Maintenance/Adjustments NOTE: Failure to change the oil when needed can damage the seals in the clamp and knife cylinders as well as the manifold. Refill the tank with 15 gallons of an ISO (International Standards Organization) Viscosity Grade 46, rust, oxidation, and foam inhibiting hydraulic oil. -
Page 52: Line Light Adjustment
10.0 Routine Maintenance/Adjustments 3. Place the suction line of the transfer pump into the breather cap hole. Place the pressure line of the transfer pump into an empty five-gallon pail. 4. Turn on the transfer pump and fill the pail. Repeat until tank is empty. 5. -
Page 53: Line Light Bulb Replacement
10.0 Routine Maintenance/Adjustments 3. Using a 3/16” hex wrench, turn one of the adjusting screws until you see a 1/16-1/8” beam. 4. Similarly, turn the adjustment screw of the other bulb until one, continuous beam is seen across the cut stick. 10.5.1 Line Light Bulb Replacement: 1. -
Page 54: Table Conditioning
5. Apply a paste wax (Challenge P/N 16078) to the table to seal the pores of the metal. 6. Note: Do not use a wax that contains a cleaning compound on the table. The cleaner contains microscopic abrasive particles that will cause wear between the table and the bottom of the backgauge. -
Page 55: Program Log
11.0 Program Log 11.0 Program Log It is always good practice to keep written records of important repeat jobs. In case a channel or the entire memory is accidentally lost. Important jobs will not have to be reprogrammed from scratch. Photocopy this page as needed to build a program log. -
Page 56: Channel Log
12.0 Channel Log 12.0 Channel Log It is recommended that you keep an abbreviated Channel Log and detailed Program Logs (copy this form) for important or repeat jobs. In the event memory capacity is reached, a glance at the Channel Log will tell you which channels may be cleared to make more room. -
Page 57: Safety System Tests
13.0 Safety System Tests 13.0 Safety System Tests Machine manufacturer CHALLENGE Model _____________ Serial Number __________________ Frequency of test: THESE TESTS SHOULD BE PERFORMED AT THE BEGINNING OF EACH WORK DAY. Turn on the cutter and start the hydraulic motor (see operator’s manual for instructions). Enable the electric eye safety system. - Page 58 NOTES:...
- Page 59 Copyright © 1998-2007 by The Challenge Machinery Company. Printed in the USA. F.370-B-O October 2007...