Challenge CHAMPION 305 TC Instructions And Parts Manual
  1. Manuals
  2. Brands
  3. Challenge Manuals
  4. Paper Cutters
  5. CHAMPION 305 TC
  6. Instructions and parts manual

Challenge CHAMPION 305 TC Instructions And Parts Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

The Challenge Machinery Company provides owner's manuals 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 noncurrent,
unsupported or no longer produced by The Challenge Machinery Company, and are provided solely as
an accommodation to our customers. By providing these manuals, The Challenge 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, which are 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 responsibility to evaluate the suitability and fitness of the
products in their current use and application. The Challenge Machinery Company makes no
representation, warranty or recommendation regarding any modifications which may be
required 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 Challenge
Machinery Company. The availability of these manuals is solely for the purpose of providing reference
information for the products.
This manual may not be complete in all aspects of product maintenance and repair. All products
should be used only by qualified 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 and properly trained
technicians should perform maintenance, repair and replacement procedures. Attempting these
procedures without proper training may cause machine damage or operator injury!
Products may be unsupported by The Challenge Machinery Company due to age or the unavailability of
parts from their original manufacturer. No parts or product support will be available to repair or maintain
unsupported products. Older products may not be UL listed (if the product does not have a UL label it is
not a listed product), and may not comply with applicable installation or other regulations or
requirements if relocated to a new facility. Many municipalities require a product to be UL listed before
an electrician will connect power to them. Often the cost of updating an older product to comply with
current safety regulations is greater than the value of the product.
CHAMPION 305 TC
Instruction and Parts Manual
Serial Numbers 1301701 & Up
Sold and Serviced by
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441-6081 USA
F.254-J
ChallengeMachinery.com
May 2014

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the CHAMPION 305 TC and is the answer not in the manual?

Questions and answers

Maria
February 4, 2025

please give the dimensions for the knife

0

Subscribe to Our Youtube Channel

Related Manuals for Challenge CHAMPION 305 TC

Summary of Contents for Challenge CHAMPION 305 TC

  • Page 1 Products may be unsupported by The Challenge Machinery Company due to age or the unavailability of parts from their original manufacturer. No parts or product support will be available to repair or maintain unsupported products.

  • Page 2: Introduction

    Fill out the warranty card accompanying your machine and return it DIRECTLY TO 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 Service Department, 6125 Norton Center Drive •...

  • Page 3: Table Of Contents

    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 ........................
  • Page 4 1.0 Introduction 12.12 Clamp Cylinder Adjustment (Clamp Height) ................48 12.13 Clamp Parallel Rod ........................ 48 12.14 Lead Screw Adjustment Nuts....................49 12.15 Knife Bar Gibs ........................50 13.0 Repair and Replacement......................51 13.1 Fuses............................51 13.2 Knife Cylinder Replacement..................... 51 14.0 Troubleshooting ..........................

  • Page 5: 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 6: 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 15.0 Schematics and Parts List.
  • Page 7 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. •...

  • Page 8: Packing List

    3.0 Packing List 3.0 Packing List Part No. Description Qty. Basic Machine Extension Side Tables: 47166 18 x 24 Steel Side Table 47164-1 Side Table Back Plate H-6913-606 Side Table Bolts H-6424-6 Side Table Hex Nuts H-6939-616 Leveling Screws H-6913-6008 Side Table Mounting Bolts (shipped installed) H-7321-6...

  • Page 9: Specifications

    5 HP, 3 Phase, 50 Hz AC; 380/415V, 10 Amps (Service size: 20 Amps) 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 10: Footprint

    5.0 Footprint 5.0 Footprint...

  • Page 11: 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 12: Cleaning

    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 through your Authorized Challenge Dealer. The protective film on the console may be removed. Never clean console with petroleum based solvents – damage will result.

  • Page 13: Hydraulic Power Unit Removal

    If installation requires that the machine pass through a doorway that is less than 49” but greater than or equal to 42” wide, the machine should have been ordered from Challenge “knocked down” with the table removed. If the machine must fit through a doorway that is less than 42” and greater than or equal to 24-1/2”, the hydraulic power unit must be removed on-site.

  • Page 14: Power Hook-Up

    Test line 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. CAUTION: SHOCK HAZARD! Always disconnect power at main power panel before working on the cutter.
  • Page 15 6.0 Installation & Setup Figure 4 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.

  • Page 16: Operation

    THOROUGHLY READ AND UNDERSTAND ALL OF THE INSTRUCTIONS FOUND IN THE OPERATOR AND INSTRUCTION MANUALS INCLUDED WITH YOUR CUTTER. CALL YOUR AUTHORIZED CHALLENGE DEALER IF YOU STILL HAVE ANY QUESTIONS. Complete operating instructions for all TC Model paper cutters can be found in the TC Touch Screen Control Operating Instructions manual that was included with your machine (Figure 6).
  • Page 17 7.0 Operation To install: 1. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout, page 5.) 2. Position the false clamp plate under the clamp, (Figure 7). The locator pegs are positioned to the rear of the cutter and are set into holes in the bottom of the clamp. 1/8”...

  • Page 18: Knife Installation/Changing

    8.0 Knife Installation/Changing 8.0 Knife Installation/Changing Changing knives can be very dangerous unless safety precautions are observed 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. •...

  • Page 19: Knife Removal

    8.0 Knife Installation/Changing 8.1 Knife Removal 1. Clear the cutter table. Place chipboard directly under the knife to prevent nicking if the blade hits the table. On the TC touch screen menu choose “MAINTENANCE” and then “KNIFE CHANGE”. Select “Knife Adjust Mode” then press and hold both cut buttons until the knife and clamp reach the table.

  • Page 20: Knife Installation

    8.0 Knife Installation/Changing 6. DISCONNECT THE POWER AND LOCK IT OUT, (See Power Lockout Procedure on pg. 5). 7. Remove the bolts in the two slotted holes of the knife bar and insert the knife lifter by screwing in the two knife lifter handles. Tighten the handles enough to hold the blade in place.
  • Page 21 8.0 Knife Installation/Changing 2. Check to make sure the paper deflector is locked down (Figure 10, page 19). Also check that the knife adjusting screws have been backed out, (Figure 11, page 19). 3. Place the new knife scabbard on the cutter table. 4.

  • Page 22: Knife Care Tips

    8.0 Knife Installation/Changing the cutting stick, or one end may cut deeper than the other, causing uneven wear on the stick. 15. Tighten all the bolts and release the paper deflector. 16. Restore power to the machine and turn it ON. Follow the prompts on the screen to raise the knife and clamp, and then to preset the backgauge.

  • Page 23: Cutting Stick

    4 times again. 8.3.3 Bevel Angle Challenge recommends that bevel angles for the Champion 305 knives be in the range of 21° to 23°. In general, a 21° bevel angle will provide better cut quality when cutting soft paper (such as newsprint), recycled paper, or bound books.
  • Page 24 8.0 Knife Installation/Changing NOTES...

  • Page 25: Maintenance Section

    Challenge. The Challenge Machinery Company assumes no liability for any modification or alteration to any Challenge products, and any such modification or alteration to any Challenge product is not authorized by The Challenge Machinery Company. Any...

  • Page 26: Cleaning

    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 microscopic abrasive particles that will cause wear between the table and the bottom of the backgauge.

  • Page 27: Console

    9.0 Cleaning cleaner if the excess silicone is not removed. If the excess is not removed, the silicone spray has a substance that holds the 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.

  • Page 28: Lubrication

    10.0 Lubrication 10.0 Lubrication A clean, lubricated machine will cut more accurately, run longer, with less downtime, and fewer repairs. Schedule lubrication maintenance both early in the day and early in the week. This allows the lubricants to work into the machine. Lubrication at the end of the day or week allows the lubricants to run off without any benefit to the machine.
  • Page 29 10.0 Lubrication Knife bar pull-down pin (oil): Figure 16 Left and right clamp guides (grease): Figure 17 Lower knife and clamp cylinder pins (oil): Figure 18...
  • Page 30 10.0 Lubrication Wipe down the knife bar to remove dust and debris (Figure 19). Knife Bar Figure 19 Check knife bar link, bell crank, and hydraulic cylinder pin keepers to make sure they are in place and secure (Figure 20). Knife Bar Link Pin Keepers...

  • Page 31: Hydraulic System

    The hydraulic fluid should be changed YEARLY or EVERY 1,000 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 32: Hydraulic Valve Adjustments

    11.0 Hydraulic System Reservoir Tank Cover Sight Gauge Hydraulic Tank Figure 21 3. Using a hand drill and transfer pump commonly found at hardware and home improvement stores, transfer the used oil to empty containers. 4. Remove the magnet stuck to the bottom of the tank. Clean off any debris that may be attached to it.
  • Page 33 11.0 Hydraulic System For initial setup, adjust in the following order: 1. Main System Relief Valve (Figure 22) – 1,800 psi 2. Knife Down Sequence Valve (Figure 23) – 1,600 psi 3. Clamp Up Sequence Valve (Figure 22) – 400-600 psi 4.
  • Page 34 11.0 Hydraulic System b. Turn the power on and make a cut to hold the knife down on the cutting stick. Read the pressure on the main system pressure gauge (front gauge) while the knife is down. If the gauge does not read 1,800 psi, an adjustment is needed. In order to have more time to read the gauge, it may be helpful to send the knife down using the “Knife Change”...
  • Page 35 11.0 Hydraulic System b. Press the cut buttons, and while reading the pressure on the main gauge (front gauge), release them. The gauge should read between 400-600 psi as the clamp is going up. There should be no clamp movement until the knife is stopped in the up position.
  • Page 36 11.0 Hydraulic System b. To set the maximum pressure, first make sure the correct slide bar is “active” by touching the appropriate slider button. Now press both cut buttons, and after the clamp has contacted the table and while the knife bar is coming down, read the pressure on the right hand pressure gauge.

  • Page 37: Adjustments

    12.0 Adjustments 12.0 Adjustments Several 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 working on the machine, disconnect the power and lock it out (see SAFETY PRECAUTIONS, page 5) unless the directions specifically require the machine to be powered.

  • Page 38: Backgauge Gib Adjustment

    12.0 Adjustments Outer Mounting Screws Inner Mounting Screws Figure 26 3. Loosen the inner mounting screws (Figure 26) to rotate the beams until they are aligned over their width. When the indicator lights indicate proper alignment as shown in Figure 25, tighten all screws.

  • Page 39: Squaring The Backgauge

    12.0 Adjustments Set Screws & Jam Nuts Rail Figure 28 To adjust: 1. Run the backgauge back to 28” (711mm) 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.

  • Page 40: Backgauge Position Accuracy Adjustment

    12.0 Adjustments To adjust squareness: 1. As machine wears, make sure the backgauge gibs are set properly first (see previous section). Then follow steps 2 through 5. NOTE: Gib adjustment is not necessary on initial machine setup because they have been adjusted at the factory.

  • Page 41: Knife Latch Adjustment

    12.0 Adjustments 3. Take several sheets from the center of each lift and compare them to each other. The encoder 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 between the 10”...

  • Page 42: Line Light Adjustment (Incandescent Type)

    12.0 Adjustments 6. Tighten the mounting screws. 7. Tilt the control console back up and secure it with the two screws. Restore power to the machine and perform a cut cycle. Recheck the gap to make sure it is still within the correct range.

  • Page 43: Line Light Adjustment (Led Type)

    12.0 Adjustments To adjust line light: 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. 4.

  • Page 44: Proximity Switches

    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. Challenge Champion cutters incorporate proximity switches to detect stages of operation. These types of limit switches have no moving parts and are more reliable than the old style of contact switches.
  • Page 45 12.0 Adjustments With the power off, set the collar between the proximity switches and then turn on power. Press cut buttons once to turn on the hydraulic motor. The knife will move to the absolute top of its stroke. Move the collar to the top proximity switch until LED turns on, then move it an additional 1/4”...

  • Page 46: Clamp Return Speed Adjustment

    12.0 Adjustments Clamp Up Proximity Switch Actuator Figure 37 This switch senses when the clamp is in the up position and prevents backgauge movement if the clamp is not up. It also diverts the air from the table when the clamp is down to prevent the stock from moving during a cut.

  • Page 47: Pre-Clamp Speed Adjustment

    12.0 Adjustments Adjustment Jam Nut Knob Figure 39 2. Loosen jam nut. 3. Increase the pressure by turning the valve clockwise until the clamp is able to travel down to the table completely when pressing the foot pedal switch. 4. Check to make sure the force under the clamp does not exceed 66 lbs (30 kg). A scale, such as a bathroom scale, should be used to measure this.

  • Page 48: Clamp Cylinder Adjustment (Clamp Height)

    12.0 Adjustments 12.12 Clamp Cylinder Adjustment (Clamp Height) If the clamp piston bottoms in the cylinder before the clamp makes contact with the table, or if the clamp does not make full travel on the up stroke, the clamp cylinder may need adjustment. To adjust: 1.

  • Page 49: Lead Screw Adjustment Nuts

    12.0 Adjustments Connecting Flats Left Jam Nut Right Jam Nut (LH Thread) (RH Thread) Figure 42 – Cutaway Front View 3. Using the flats on the right hand end of the connecting rod, (Figure 42), turn the connecting rod to align the clamp with the table. Place a long strip of paper under each end of the clamp.

  • Page 50: Knife Bar Gibs

    12.0 Adjustments 12.15 Knife Bar Gibs The knife bar gibs are two steel-backed UHMW plates located near the left and right ends of the knife bar that press on the knife bar’s front surface as it travels up and down. If adjusted too tight the knife may not come down smoothly and/or scoring may occur which could damage the knife bar and gibs.

  • Page 51: Repair And Replacement

    13.0 Repair and Replacement 13.0 Repair and Replacement 13.1 Fuses FIRE HAZARD. Replace only with same type and rating fuse. All Champion models have a set of fuses. The fuses are located inside the main power box, (Figure 45). Check the label on the inside of the lower right door for correct ratings for these fuses. Labels can be reproduced using the drawings at the back of this manual if the labels on the cover ever become damaged or illegible.
  • Page 52 13.0 Repair and Replacement E-Ring (Both Ends) Clevis Pin with 1/4-20 Threaded Hole Clevis Jam Nut Proximity Switch Actuator Proximity Switch Bracket Knife Cylinder Hose Connections Pin Keeper Sequence Valve Lower Pin Assembly Figure 46 6. Remove the clevis pin out of the knife bar and clevis by first removing the front E-style retaining ring on the pin (Figure 46).
  • Page 53 13.0 Repair and Replacement Clamp Knife Frame Table 4-1/8” Figure 47 12. Lock the jam nut securely in place. 13. Reconnect the hydraulic hoses. CRUSH HAZARD! Knife and clamp will return to the up position when the key is turned on and the cut buttons are pressed for the first time. Keep hands and tools away.

  • Page 54: Troubleshooting

    14.0 Troubleshooting 14.0 Troubleshooting Never work on this machine with the power on unless the instructions say the machine power must be on. Lock the power off at the wall disconnect switch. See Power Lockout Procedure, page 5. WON’T START 1.
  • Page 55 14.0 Troubleshooting CONCAVE CUTTING- ENDS WIDE, CENTER NARROW 1. Excessive moisture at edges of paper 2. More ink on edges of lift CONCAVE CUTTING- VARIATION OF TOP AND BOTTOM 1. Soft stock not firmly clamped 2. Knife is dull or ground incorrectly 3.
  • Page 56 14.0 Troubleshooting 3. Backgauge gibs loose 4. Dull knife 5. Clamp not parallel to table 6. Accuracy not set correctly BACKGAUGE MOVEMENT ERRATIC 1. Backgauge gibs loose or binding on table way (rail under table) 2. Backgauge nut binding on leadscrew, screw bent or dirty DRAWING OF STOCK 1.
  • Page 57 14.0 Troubleshooting NOTES...

  • Page 58: Schematics & Parts Lists

    15.0 Schematics & Parts Lists 15.0 Schematics & Parts Lists 15.1 Main Assembly – Frame/Tank 47900 Sheet 1...
  • Page 59 15.0 Schematics & Parts Lists 47900 Sheet 1 – Parts List PART NO. DESCRIPTION 47513 MAGNET - HYDRAULIC RESERVOIR 47542 HPU WELDMENT 47543 GASKET - HYDRAULIC RESERVOIR 47901 WELDMENT - 305 FRAME H-238-4 STRAINER H-338 DIFFUSER H-503 ELBOW - PIPE, 90° 3/4 NPT H-6405-12112 NIPPLE - 3/4 X 14"...

  • Page 60: Main Assembly - Hydraulics

    15.0 Schematics & Parts Lists 15.2 Main Assembly – Hydraulics 47900 Sheet 2...
  • Page 61 15.0 Schematics & Parts Lists 47900 Sheet 2 – Parts List PART NO. DESCRIPTION 4411 CLEVIS - CONN. ROD L.H. 8835-1 PIN KEEPER 40016-5 MOUNT - VIBRATION 47092 GUARD - FAN 47110-1 PIN - BELL CRANK 47171-1 BRACKET - CLAMP PROX 47172-1 ACTUATOR - CLAMP PROX 47519...

  • Page 62: Main Assembly - Clamp

    15.0 Schematics & Parts Lists 15.3 Main Assembly – Clamp 47900 Sheet 3...
  • Page 63 15.0 Schematics & Parts Lists 47900 Sheet 3 – Parts List PART NO. DESCRIPTION 4406-D-1 BELLCRANK ASM - R.H. CLAMP 4441-1 DEFLECTOR - PAPER, BLOCK 4461 ROD - CLAMP CONNECTOR 4465 CLEVIS - CONN. ROD R.H. 4466 CLEVIS - CONN. ROD L.H. 4504-2 BAR - CLAMP PULL DOWN 4506...

  • Page 64: Main Assembly - Final Wiring

    15.0 Schematics & Parts Lists 15.4 Main Assembly – Final Wiring 47900 Sheet 4...
  • Page 65 15.0 Schematics & Parts Lists 47900 Sheet 4 – Parts List PART NO. DESCRIPTION E-2805-1 STARTER - 1 PHASE E-2805 STARTER - 3 PHASE E-2376-1 AUXILIARY CONTACT - GOLD CONTACTS E-2441-12 RELAY - OVERLOAD, 1 PHASE E-2441-11 RELAY - OVERLOAD, 3 PHASE EE-2855-1 RIBBON CABLE ASM.

  • Page 66: Main Assembly - Electrical Components, Lower Front

    15.0 Schematics & Parts Lists 15.5 Main Assembly – Electrical Components, Lower Front 47900 Sheet 5...
  • Page 67 15.0 Schematics & Parts Lists 47900 Sheet 5 – Parts List PART NO. DESCRIPTION 40016-8 MOUNT - VIBRATION 47033-3 FRONT ENCLOSURE 47645-1 CLAMP COMPRESSOR ASSEMBLY 47646 FOOT SWITCH BRACKET 47647 FOOT SWITCH BRACKET 47943 SHIELD - TABLE 49249 BACKGAUGE CONTROL ASSEMBLY 49255-1 STAND OFF- SHEETMETAL E-1172-10...

  • Page 68: Main Assembly - Electrical Components, Upper

    15.0 Schematics & Parts Lists 15.6 Main Assembly – Electrical Components, Upper 47900 Sheet 6...
  • Page 69 15.0 Schematics & Parts Lists 47900 Sheet 6 – Parts List PART NO. DESCRIPTION 16047 HINGE- MPS CONSOLE 47195 BRACKET - ARCH JUNCTION 47502 BRACKET - CONSOLE 47568-1 ASSEMBLY - KNIFE LATCH 47958 PROX SENSOR BRACKET 47959 LINE LIGHT BRACKET E-2626-6 TERMINAL STRIP (6P) EE-2149-9...

  • Page 70: Main Assembly - Air Table

    15.0 Schematics & Parts Lists 15.7 Main Assembly – Air Table 47900 Sheet 7...
  • Page 71 15.0 Schematics & Parts Lists 47900 Sheet 7 – Parts List PART NO. DESCRIPTION 47578 BLOWER ASSEMBLY 47652 AIR CHANNEL COVER 47654-1 305 TABLE, AIR E-2189-2_X_14INCHES TUBING - CORRUGATED, FLEXIBLE - 14" E-2189-2_X_23INCHES TUBING - CORRUGATED, FLEXIBLE - 23" E-2191-2 3/4 CONDUIT FITTING H-6650-6 3/8 NPT PLUG - PLASTIC...

  • Page 72: Main Assembly - Table Mounting

    15.0 Schematics & Parts Lists 15.8 Main Assembly – Table Mounting 47900 Sheet 8...
  • Page 73 15.0 Schematics & Parts Lists 47900 Sheet 8 – Parts List PART NO. DESCRIPTION 4171 CUT STICK - 305 4542 STOP - STICK, RH 47115-1 TABLE GUIDE - LH FRONT 47116-1 TABLE GUIDE - RH FRONT 47630 CUT STICK STOP 47654-1 305 TABLE, AIR 47662...

  • Page 74: Main Assembly - Tc Backgauge

    15.0 Schematics & Parts Lists 15.9 Main Assembly – TC Backgauge 47900 Sheet 9 & 10 PART NO. DESCRIPTION 4510 GIB - BACKGAUGE NUT 7922 SPRING - COMPRESSION 8230 ENCODER PINION 8641-2 ACTUATOR - PRESET 13927-1 PULLEY - DRIVE, BACKGAUGE 20206-6123 MACHINE KEY - .125 X .125 X .750 30305-6123...
  • Page 75 15.0 Schematics & Parts Lists 47900 Sheet 9 & 10– Parts List Continued PART NO. DESCRIPTION 47175 BRACKET- ENCODER 47177 SHIELD - ENCODER 47191 PIN- ENCODER 47192 BRACKET- ENCODER 47193 BRACKET- ENCODER MOUNT 47264 X 2INCHES UHMW TAPE - 3/8" W X 2" LONG 47264 X 5PT5INCHES UHMW TAPE - 3/8"...

  • Page 76: Main Assembly - Knife

    15.0 Schematics & Parts Lists 15.10 Main Assembly – Knife 47900 Sheet 11...
  • Page 77 15.0 Schematics & Parts Lists 47900 Sheet 11 – Parts List PART NO. DESCRIPTION 4449 KNIFE ADJUSTING SCREW 4501-2 KNIFE BAR 4503-3 LINK ASM - KNIFE BAR 4505 KNIFE BAR GIB 4507-2 PIN - KNIFE BAR LINK 4518 PIN - KNIFE LINK 8815 WASHER - 3/8 HEAVY 8835-2...

  • Page 78: Main Assembly - Covers And Labels

    15.0 Schematics & Parts Lists 15.11 Main Assembly – Covers and Labels 47900 Sheet 12...
  • Page 79 15.0 Schematics & Parts Lists 47900 Sheet 12 – Parts List PART NO. DESCRIPTION 11145-1 RIVET - 3/16 41130 PLATE - SERIAL NUMBER 47001 COVER - REAR ARCH 47002-1 SHIELD - BACKGAUGE 47003 BRACKET - BACKGAUGE SHIELD 47019-1 GUIDE - RH REAR 47020-1 GUIDE - LH REAR 47050...

  • Page 80: Main Assembly - Table Extensions

    15.0 Schematics & Parts Lists 15.12 Main Assembly – Table Extensions 47900 Sheet 13...
  • Page 81 15.0 Schematics & Parts Lists 47900 Sheet 13 Parts List PART NO. DESCRIPTION 8815 WASHER - 3/8 HEAVY 16026 LH TABLE EXTENSION - 24X36 16027 RH TABLE EXTENSION - 24X36 16028 LH TABLE EXTENSION - 24X36, AIR 16029 RH TABLE EXTENSION - 24X36, AIR 47164-1 PLATE- EXTENSION TABLE 47164-2...

  • Page 82: Power Panel Assembly

    15.0 Schematics & Parts Lists 15.13 Power Panel Assembly EE-3461 Sheet 1, Rev. D...
  • Page 83 15.0 Schematics & Parts Lists EE-3461 Sheet 1, Rev D – Parts List PART NO. DESCRIPTION OF ACCESSORIES 47512 PANEL - POWER E-1089-41 TRANSFORMER - 208-230V "T1" EE-3210 CABLE ASM. CLAMP COMPRESSOR JUMPER E-1429-17 WIRE DUCT & COVER - 9" LONG E-1429-18 WIRE DUCT &...
  • Page 84 15.0 Schematics & Parts Lists EE-3461 Sheet 1, Rev D – Parts List, Continued PART NO. DESCRIPTION OF ACCESSORIES EE-2821-6 CABLE ASM. - UNLOAD VALVE SOLENOID "U" EE-2821-9 CABLE ASM. - CUT SOLENOID "B" (MSCE2) 47645-1 CONDUIT ASSEMBLY - BLOWER/AIR SOL. EE-3030-1 CABLE ASSEMBLY - ENCODER EE-3464...
  • Page 85 15.0 Schematics & Parts Lists Power Panel Assembly EE-3461 Sheet 2, Rev. D...

  • Page 86: Basic Machine Schematic

    15.0 Schematics & Parts Lists 15.14 Basic Machine Schematic E-3462, Rev. C...

  • Page 87: Interconnection Diagram

    15.0 Schematics & Parts Lists 15.15 Interconnection Diagram E-3463, Rev. A...

  • Page 88: Hydraulic Manifold Kit

    15.0 Schematics & Parts Lists 15.16 Hydraulic Manifold Kit H-504-1, Rev. B PART NO. DESCRIPTION OF ACCESSORIES H-465-2 MANIFOLD ASSEMBLY H-242-37 HYDRAULIC HOSE ASSEMBLY (30" LONG) H-242-43 HYDRAULIC HOSE ASSEMBLY (19" LONG) H-242-48 HYDRAULIC HOSE ASSEMBLY (17" LONG) H-437-1 VALVE ASM. - KNIFE DOWN SEQUENCE S-1694-5 TYRAP- IDENTIFICATION...

  • Page 89: Knife Down Sequence Valve Assembly

    15.0 Schematics & Parts Lists 15.16.1 Knife Down Sequence Valve Assembly H-437-1, Rev. C PART NO. DESCRIPTION OF ACCESSORIES 56162-1 TUBE ASM. 56167 ALUMINUM BODY - COUNTER BAL. VALVE KIT H-203-40 COUNTER BALANCE VALVE H-230-10 ELBOW- ORING TO TUBE H-272-1 ELBOW- 45 DEG O-RING TO TUBE H-434 CONNECTOR - ORING TO ORING...

  • Page 90: Hydraulic Manifold Assembly

    15.0 Schematics & Parts Lists 15.16.2 Hydraulic Manifold Assembly H-465-2, Rev. B PART NO. DESCRIPTION OF ACCESSORIES H-468-3 MANIFOLD - HYDRAULIC 8P-629-3 GAGE H-253-2 ADAPTER - PIPE TO TUBE H-425-1 TUBE ASSEMBLY - "G2" PORT H-230 ELBOW - 'O' RING TO TUBE H-6918-413 1/4-20 X 1-5/8"...
  • Page 91 15.0 Schematics & Parts Lists 15.16.2.1 Hydraulic Manifold H-468-3, Rev. B PART NO. DESCRIPTION OF ACCESSORIES H-427-4 PLUG - SAE H-427 PLUG - SAE H-203-41 PRESSURE REDUCING VALVE- ELECTRICAL (TC) NAMEPLATE E-1069-17 COIL (24 VAC) H-427-5 SAE PLUG (220 IN-LB TORQUE) H-427-2 SAE PLUG SAE PLUG (180 IN-LB TORQUE) H-427...

  • Page 92: Hydraulic Schematic

    15.0 Schematics & Parts Lists 15.17 Hydraulic Schematic H-468-3, Rev. B...

  • Page 93: Tc Control Console Assembly

    15.0 Schematics & Parts Lists 15.18 TC Control Console Assembly EE-3456, Rev. C PART NO. DESCRIPTION OF ACCESSORIES EE-3471 PANEL ASM. - FRONT CONTROL, TC 16013-1 BEZEL - CONTROL CONSOLE 47701-1 TC PANEL INSERT - CHAMPION 305 H-6423-#6 NUT - #6-32 HEX (KEP) E-1584-( ) LABEL - ASM.

  • Page 94: Electric Eye Assembly

    15.0 Schematics & Parts Lists 15.19 Electric Eye Assembly EE-3339 Sheet 1, Rev. F PART NO. DESCRIPTION 47944 HOUSING - ELEC EYE, LH 47945 HOUSING - ELEC EYE, RH 47946 ELECTRIC EYE COVER 47943 SHIELD - TABLE E-3370 16" LIGHT CURTAIN SET E-1163-B WIRE - #20GA.
  • Page 95 15.0 Schematics & Parts Lists EE-3339 Sheet 2, Rev. F...

  • Page 96: Cut Button Assembly - Standard

    15.0 Schematics & Parts Lists 15.20 Cut Button Assembly – Standard EE-3382, Rev. C PART NO. DESCRIPTION OF ACCESSORIES 47665 CONTROL BOX ASSEMBLY E-3437-4 PUSHBUTTON SWITCH - MUSHROOM, 3 N.O. E-2078-3 CABLE - #18GA. 8 COND. 49" LONG E-2078 CABLE - #18GA. 6 COND. 38" LONG E-3082 SWITCH - MAIN DISCONNECT (BODY) E-3083...

  • Page 97: Cut Button Assembly - Ergotouch

    15.0 Schematics & Parts Lists 15.21 Cut Button Assembly – ErgoTouch EE-3382-1 Sheet 1, Rev. A PART NO. DESCRIPTION OF ACCESSORIES 47665 CONTROL BOX ASSEMBLY E-3347 SWITCH - ERGO TOUCH EE-3350-2 CONTROLLER - ASM. - TOUCH SWITCH EE-3348-2 CABLE ASM. - TOUCH SWITCH, LH EE-3349-2 CABLE ASM.
  • Page 98 15.0 Schematics & Parts Lists EE-3382-1 Sheet 2, Rev. A...

  • Page 99: Knife Latch Assembly

    15.0 Schematics & Parts Lists 15.22 Knife Latch Assembly 47568-1, Rev. A PART NO. DESCRIPTION OF ACCESSORIES 47505-1 PLATE- KNIFE LATCH MOUNT E-974-3 SOLENOID 47567 LINK- CHAIN H-5254-510 SCREW- 5/16 X 1-1/4 SOC. SHOULDER 47553-1 LINK ASSEMBLY- KNIFE LATCH 41117-1 SPRING- EXTENSION H-6451-0500 RETAINING RING- GRIPPING EXTERNAL...

  • Page 100: Line Light Assembly

    15.0 Schematics & Parts Lists 15.23 Line Light Assembly 47538, Rev. D (Incandescent Type) NOTE: For LED style line light, see Section 15.6 Main Assembly – Electrical Components, Upper, page 68 for the LED line light assembly part number.

  • Page 101: Compressor Assembly

    15.0 Schematics & Parts Lists 15.24 Compressor Assembly 47645-1 Rev. E PART NO. DESCRIPTION OF ACCESSORIES 47644 COMPRESSOR E-1710-3 SPLIT TUBING 12" EE-3210 CABLE ASSEMBLY- COMPRESSOR POWER P-521 VALVE- 2-WAY, N.O. H-261-3 TEE- 1/4 MALE RUN, BRASS H-269-2 ELBOW - 90%%176 STREET, BRASS H-6406-407 NIPPLE- 1/4"...

  • Page 102: Air Table Blower Assembly

    15.0 Schematics & Parts Lists 15.25 Air Table Blower Assembly 47578, Rev. C...

  • Page 103: Encoder Cable Assembly

    15.0 Schematics & Parts Lists 15.26 Encoder Cable Assembly EE-3030-1, Rev C. PART NO. DESCRIPTION OF ACCESSORIES E-2970-10 CABLE #22 GA, 4 COND SHIELDED 90" E-1777-6 HOUSING - SINGLE ROW PLUG, 8 PIN E-787-15 PIN - MALE, 22-38 GA. 47178 CAP - ENCODER E-1453 SHRINK TUBING - 1"...

  • Page 104: Power Panel Connection Procedure Label

    15.0 Schematics & Parts Lists 15.27 Power Panel Connection Procedure Label S-1781-211, Rev. A...

  • Page 105: Warning Label

    15.0 Schematics & Parts Lists 15.28 Warning Label S-1781-16, Rev. D...

  • Page 106: Paper Deflector Kit (Option)

    15.0 Schematics & Parts Lists 15.29 Paper Deflector Kit (Option) AA-13936-1, Rev. A Kit includes the following parts: PART NO. DESCRIPTION A-4511-2 DEFLECTOR ASSEMBLY H-6918-616 3/8-16 X 2 SOCKET HEAD CAP SCREW H-6918-606 3/8-16 X 3/4 SOCKET HEAD CAP SCREW A-4497 LOCK STUD ASSEMBLY H-7324-12...

  • Page 107: Deflector & Shaft Assembly (Part Of Paper Deflector Kit)

    15.0 Schematics & Parts Lists 15.29.1 Deflector & Shaft Assembly (Part of Paper Deflector Kit) A-4511-2 PART NO. DESCRIPTION A-4524-2 DEFLECTOR AND SHAFT ASSEMBLY 4522-3 GUIDE - PAPER DEFLECTOR 4545 SPACER S-1193-25 1/4 'E' RING 47535 SPRING- DEFLECTOR, PAPER 4520 PIN - UPPER...
  • Page 108 15.0 Schematics & Parts Lists NOTES...

  • Page 109: Safety System Tests

    16.0 Safety System Tests 16.0 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 110 F.254-J May 2014...

Table of Contents

Save PDF