Challenge CHAMPION 305 X Technical Service And Parts Manual
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Challenge CHAMPION 305 X Technical Service And Parts Manual

Serial numbers 07x1360 & up
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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 X, XG, XT
Technical Service and Parts Manual
Serial Numbers 07X1360 & Up
Sold and Serviced by
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441-6081 USA
F.254-I-T
ChallengeMachinery.com
October 2019

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Summary of Contents for Challenge CHAMPION 305 X

  • 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 Maintenance Guide ...........................8 3.1 Maintenance Adjustments ......................9 3.1.1 Centering the Backgauge Control Knob ................9 3.1.2 Squaring the Backgauge .......................9 3.1.3 Proximity Switches ......................
  • Page 4 1.0 Introduction 5.29 Compressor Assembly ......................96 5.30 Backgauge Control Assembly S/N 13X1661 & Below ............. 98 5.31 Backgauge Control Assembly S/N 13X1662 & Above ............. 99 5.32 X/XG/XT Troubleshooting ...................... 100 5.33 Description of Error Messages ....................101 5.34 Sensor Data Abbreviations ....................102 5.35 Encoder Cable Assembly –...

  • 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 17.0, 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: Maintenance Guide

    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 9: Maintenance Adjustments

    3.0 Maintenance Guide 3.1 Maintenance Adjustments 3.1.1 Centering the Backgauge Control Knob The Backgauge Control Knob is coupled with a potentiometer. If the Control Knob is misadjusted, the backgauge may wander forward or backward. To adjust the Control Knob, turn the power off and then on and immediately enter Sensor Data Mode. Hold the rubber coupling in the Control Knob Assembly while turning the knob.

  • Page 10: 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 11 3.0 Maintenance Guide CRUSH HAZARD! When the limit switch is actuated, the clamp will return to the up position. Keep hands and tools clear. 1. Knife Up/Down Proximity Switches Figure 5 The Knife Up and Knife Down Proximity switches are mounted to a bracket that is attached to the Knife Cylinder (Figure 5).
  • Page 12 3.0 Maintenance Guide Hyd. Up Proximity Switch Figure 6 3. Clamp Up Proximity Switch This switch is mounted inside the rear of the arch casting, Figure 7. It is tripped by the clamp when the clamp is in the up position. This switch prevents backgauge movement if the clamp is not up. On machines equipped with the air table option, it also diverts the air from the table when the clamp is down to prevent the stock from moving during a cut.

  • Page 13: Hydraulic Valve Adjustments

    3.0 Maintenance Guide Figure 8 3.1.4 Hydraulic Valve 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. Disconnect the power and lock it out, see Safety Precautions, page 8, whenever working on the machine unless the directions specifically require the machine to be powered.
  • Page 14 3.0 Maintenance Guide Main System Gauge Knife Down Electronic Sequence Clamp Valve Clamp Up Sequence Main System Relief Valve Figure 9 1. Main System Relief Valve (Figure 9) This valve maintains the overall hydraulic pressure for the entire system. Factory setting: 1800 psi. Check Procedure: a.
  • Page 15 3.0 Maintenance Guide To adjust: a. Loosen the lock nut. b. Make a cut and hold the buttons in. While reading the main system gauge, adjust the valve until you have the correct pressure. Clockwise to increase, counter-clockwise to decrease. c.
  • Page 16 3.0 Maintenance Guide 3. Turn the Pressure adjusting knob clockwise for MORE pressure, counter-clockwise for LESS. DO NOT set the clamp pressure below 400 psi. Severe lacerations or dismemberment could result! The knife and clamp system will lose sequence settings below 400 psi and the knife could come down before the clamp.

  • Page 17: Clamp Cylinder

    3.0 Maintenance Guide down arrow keys. When finished, choose D), to exit and go to the minimum pressure set up seen shown below: 5.000 Set Maximum > Press /\ to Increase Press \/ to Decrease A) Main C) Send B) Job D) Exit d.

  • Page 18: Clamp Parallel Rod

    3.0 Maintenance Guide Figure 11 To adjust: 1. Turn on machine. Start the hydraulic motor by pressing both cut buttons simultaneously. Turn off the machine. 2. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout procedure, page 5). 3. Loosen the jam nut. 4.

  • Page 19: Backgauge Gibs

    3.0 Maintenance Guide 3. Using the flats on the end exposed below the base casting, (Figure 9 & 14), turn the connecting rod and align the clamp with the table. Place a long strip of paper under each end of the clamp. Push the cut buttons and when the clamp contacts the table, attempt to pull the strips out.

  • Page 20: Lead Screw Adjustment Nuts

    3.0 Maintenance Guide 5. Lock the screws in place with the jam nuts. 6. Snug up the middle two screws and lock in place with the jam nuts. 7. Snug up the bottom gib adjusting screws finger tight and lock in place with the jam nuts. 8.

  • Page 21: Backgauge Drive Belt Adjustment

    3.0 Maintenance Guide 3.1.9 Backgauge Drive Belt Adjustment If the backgauge motor runs but the backgauge does not move or slips, the belt may need adjustment, Figure 15. Figure 15 To adjust the belt: 1. Turn off the machine, DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout procedure, page 5.) 2.
  • Page 22 3.0 Maintenance Guide There are three, socket set screws with jam nuts on each side of the arch that adjust the gibs, (Figure 20). These should be adjusted only with the knife bar directly behind the screws being tightened. Figure 20 To adjust: 1.

  • Page 23: Repair And Replacement

    3.0 Maintenance Guide 3.2 Repair and Replacement 3.2.1 Fuses FIRE HAZARD. Replace only with same type and rating fuse. Figure 16 The Champions each have a set of fuses. The fuses are located inside the main power box, (Figure 16). Check the label inside the cover for correct ratings for these fuses. Labels are reproduced with the drawings at the back of this manual in case those on the cover may be damaged or illegible.
  • Page 24 3.0 Maintenance Guide Clevis Figure 22 6. Remove the clevis pin. E-style retaining rings on each side of the pin can be removed through the access panel in the side of the arch casting. The pin has a 1/4-20 tapped hole in it to aid removal and a clearance hole in the front of the arch provides access to knock the pin out of the knife bar, (pg.

  • Page 25: Pilot Check Valve

    3.0 Maintenance Guide 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. Clamp Knife Arch Table 4-1/8” Figure 18 14.

  • Page 26: Clamp Return Speed Adjustment

    A silicone spray (Challenge P/N 16079) will show the same type of wear as the 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.
  • Page 27 A silicone spray (Challenge P/N 16079) will show the same type of wear as the 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.

  • Page 28: Troubleshooting

    4.0 Troubleshooting 4.0 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 29 4.0 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 30 4.0 Troubleshooting 4. Dull knife 5. Clamp not parallel to table 6. Accuracy not set correctly BACKGAUGE SPEED ERRATIC 1. Oil on pulley belt 2. Belt/pulley loose BACKGAUGE MOVEMENT ERRATIC 1. Backgauge gibs loose or binding on table way (rail under table) 2.
  • Page 31 4.0 Troubleshooting NOTES...

  • Page 32: Schematics & Parts Lists

    5.0 Schematics & Parts Lists 5.0 Schematics & Parts Lists 5.1 Main Assembly – Front View 47500 Sht. 1 of 16, Rev. Z...
  • Page 33 5.0 Schematics & Parts Lists Main Assembly – Front View 47500 Sht. 1 of 16, Rev. Z PART NO. DESCRIPTION OF ACCESSORIES S-1781-116 LABEL- WARNING (XD/XG/XT ONLY) 4506 STUD - CLAMP 47097 DOOR ASM. - R.H. FRONT 47033-3 ENCLOSURE - FRONT 47163 GASKET H-465-1...
  • Page 34 5.0 Schematics & Parts Lists Main Assembly – Front View 47500 Sht. 1 of 16, Rev. Z PART NO. DESCRIPTION OF ACCESSORIES S-1781-52 LABEL - POWER CONN. PROC. - SPACER S-1781-161 LABEL - POWER CONN. PROC. - "X" 47252 FIBER BOARD - KNIFE SLIDE 47645-1 CLAMP COMPRESSOR ASSEMBLY S-1781-34...
  • Page 35 5.0 Schematics & Parts Lists Main Assembly – Front View 47500 Sht. 1 of 16, Rev. Z PART NO. DESCRIPTION OF ACCESSORIES H-6910-504 SCREW- 5/16-18 X 1/2 BUT HD E-2196-24 HOLE PLUG - 3/8 SHORTY 47617 FALSE CLAMP PLATE SHEATH ASM. H-7324-10 WASHER-5/16 INTERNAL TOOTH H-7321-5...

  • Page 36: Main Assembly - Side View

    5.0 Schematics & Parts Lists 5.2 Main Assembly – Side View 47500 Sht. 2 of 16, Rev. L...
  • Page 37 5.0 Schematics & Parts Lists Main Assembly – Side View 47500 Sht. 2 of 16, Rev. L...

  • Page 38: Main Assembly- Top View

    5.0 Schematics & Parts Lists 5.3 Main Assembly– Top View 47500 Sht. 3 of 16...
  • Page 39 5.0 Schematics & Parts Lists Main Assembly- Top View 47500 Sht. 3 of 16...

  • Page 40: Main Assembly - Rear View

    5.0 Schematics & Parts Lists 5.4 Main Assembly – Rear View 47500 Sht. 4 of 16, Rev. N...
  • Page 41 5.0 Schematics & Parts Lists Main Assembly – Rear View – Parts List 47500 Sht. 4 of 16, Rev. N PART NO. DESCRIPTION OF ACCESSORIES 47519 BRACKET - KNIFE PROX. S-1781-15 LABEL - "HAZARDOUS MOVING PARTS" EE-2848 CABLE ASM.- LCD BACK LITE 7032-M TRIM- PLASTIC (9 FT.
  • Page 42 5.0 Schematics & Parts Lists Main Assembly – Rear View – Parts List 47500 Sht. 4 of 16, Rev. N PART NO. DESCRIPTION OF ACCESSORIES 4441-1 PAPER GUIDE E-2186-7 CLAMP- WIRE HARNESS (PROGRAMMABLE ONLY) S-1694-2 TIE- CABLE (#10) S-1781-61 LABEL - KNDN S-1781-62 LABEL - KNUP H-6417-6...
  • Page 43 5.0 Schematics & Parts Lists Notes...

  • Page 44: Main Assembly - X Model Tables

    5.0 Schematics & Parts Lists 5.5 Main Assembly – X Model Tables 47500 Sht. 5 of 16 Rev. D...
  • Page 45 5.0 Schematics & Parts Lists Main Assembly – X Model Tables 47500 Sht. 5 of 16 Rev. D...

  • Page 46: Main Assembly - Xg/Xt Model Table

    5.0 Schematics & Parts Lists 5.6 Main Assembly – XG/XT Model Table 47500 Sht 6 of 16 Rev. H...
  • Page 47 5.0 Schematics & Parts Lists Main Assembly – XG/XT Model Table 47500 Sht 6 of 16 Rev. H...

  • Page 48: Main Assembly - Air Table Assembly

    5.0 Schematics & Parts Lists 5.7 Main Assembly - Air Table Assembly 47500 Sht. 7 of 16 Rev. E...
  • Page 49 5.0 Schematics & Parts Lists Notes...

  • Page 50: Main Assembly - Power Panel Wiring- Xg/Xt - 1 Phase

    5.0 Schematics & Parts Lists Main Assembly - Power Panel Wiring– XG/XT - 1 Phase 47500 Sht. 8 of 16 Rev. D...
  • Page 51 5.0 Schematics & Parts Lists Main Assembly - Power Panel Wiring– XG/XT - 1 Phase 47500 Sht. 8 of 16 Rev. D...

  • Page 52: Main Asm. - Front View (Rough)

    5.0 Schematics & Parts Lists 5.9 Main Asm. – Front View (Rough) 47500 Sht. 11 of 16 Rev. G...
  • Page 53 5.0 Schematics & Parts Lists Main Assembly – Front View (Rough) 47500 Sht. 11 of 16 Rev. G PART NO. DESCRIPTION OF ACCESSORIES 47630 CUT STICK STOP 47529 CLEVIS- CLAMP CYLINDER 47172-1 ACTUATOR- CLAMP PROXIMITY H-431-2 CYLINDER ASM.- CLAMP 47520 BASE 47111 PIN- CLAMP CYLINDER...
  • Page 54 5.0 Schematics & Parts Lists Main Assembly – Front View (Rough) 47500 Sht. 11 of 16 Rev. G PART NO. DESCRIPTION OF ACCESSORIES H-6417-8 NUT- 1/2-13 HEX H-6918-814 SCREW- 1/2-13 X 1-3/4 SOC. H-6918-606 SCREW- 3/8-16 X 3/4 SHC H-6951-824 SCREW- 1/2-13 X 1-1/2 FLT.
  • Page 55 5.0 Schematics & Parts Lists Notes...

  • Page 56: Main Assembly- Electric Eyes

    5.0 Schematics & Parts Lists 5.10 Main Assembly- Electric Eyes 47500 Sht. 13 of 16 Rev. A (For s/n’s 11X1564 and Below)
  • Page 57 5.0 Schematics & Parts Lists Main Assembly- Electric Eyes 47500 Sht. 13 of 16 Rev. A (for s/n’s 11X1564 and Below...

  • Page 58: Main Assembly- Electric Eyes

    5.0 Schematics & Parts Lists 5.11 Main Assembly- Electric Eyes 47500 Sht. 13 of 16 Rev. B (for s/n’s 11X1565 and Up)
  • Page 59 5.0 Schematics & Parts Lists Main Assembly- Electric Eyes 47500 Sht. 13 of 16 Rev. B (for s/n’s 11X1565 and Up) PART NO. DESCRIPTION OF ACCESSORIES EE-3339 CONTROLLER ASSEMBLY - EURO. ELEC. EYES E-3336 CONTROLLER - RELAY 47592 ELECTRIC EYE COVER REF.

  • Page 60: Main Assembly - Electric Eyes (X, Xg, Xt)

    5.0 Schematics & Parts Lists 5.12 Main Assembly – Electric Eyes (X, XG, XT) 47500 Sht. 14 of 16 Rev. A (For s/n’s 11X1564 and Below)

  • Page 61: Main Assembly - Wiring -'X' Model - 1Ph

    5.0 Schematics & Parts Lists 5.13 Main Assembly - Wiring –‘X’ Model – 1ph 47500 Sht. 16 of 16, Rev. A...

  • Page 62: Basic Machine Schematic - Xg/Xt Models

    5.0 Schematics & Parts Lists 5.14 Basic Machine Schematic – XG/XT Models E-2814-1, Rev. C (For s/n’s 11X1564 and Below)
  • Page 63 5.0 Schematics & Parts Lists Basic Machine Schematic – XG/XT Models E-2814-2, Rev. A (For s/n’s 11X1565 and Up)

  • Page 64: Basic Machine Schematic - X Models

    5.0 Schematics & Parts Lists 5.15 Basic Machine Schematic – X Models E-3171-1 Rev. C (For s/n’s 11X1564 and Below)
  • Page 65 5.0 Schematics & Parts Lists Basic Machine Schematic – X Models E-3171-2, Rev. A (For s/n’s 11X1565 and Up)

  • Page 66: Power Panel Assembly - 305X

    5.0 Schematics & Parts Lists 5.16 Power Panel Assembly – 305X EE-3170-1 Sht. 1, Rev. D...
  • Page 67 5.0 Schematics & Parts Lists Power Panel Assembly – 305X EE-3170-1 Sht. 1, Rev. D PART NO. DESCRIPTION OF ACCESSORIES 47512 PANEL - POWER E-1089-41 TRANSFORMER - 208-230V "T1" E-1143 BRIDGE RECTIFIER - PANEL MOUNT E-1429-17 WIRE DUCT & COVER - 9" LONG E-1429-18 WIRE DUCT &...
  • Page 68 5.0 Schematics & Parts Lists Power Panel Assembly – 305X EE-3170-1 Sht. 1, Rev. D PART NO. DESCRIPTION OF ACCESSORIES EE-2820-2 PROX. ASSEMBLY - KNIFE DOWN "K" EE-2820-5 PROX. ASSEMBLY - KNIFE UP "U" EE-3210 CABLE ASM. - CLAMP COMPRESSOR JUMPER EE-2821-8 CABLE ASM.
  • Page 69 5.0 Schematics & Parts Lists Power Panel Assembly – 305X EE-3170-1 Sht. 2, Rev. A...

  • Page 70: Power Panel Asm. - 305X (Blower Opt. Wiring)

    5.0 Schematics & Parts Lists 5.17 Power Panel Asm. – 305X (Blower Opt. Wiring) EE-3170-1 Sht. 3, Rev. A...
  • Page 71 5.0 Schematics & Parts Lists Notes...

  • Page 72: Power Panel Assembly - 305X - Xg/Xt Models

    5.0 Schematics & Parts Lists 5.18 Power Panel Assembly – 305X – XG/XT Models EE-2882-1 Sht 1, Rev. E...
  • Page 73 5.0 Schematics & Parts Lists Power Panel Assembly – 305X – XG/XT Models EE-2882-1 Sht. 1, Rev. E 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 74 5.0 Schematics & Parts Lists Power Panel Assembly – 305X – XG/XT Models EE-2882-1 Sht. 1, Rev. E PART NO. DESCRIPTION OF ACCESSORIES EE-2820-2 PROX. ASSEMBLY - KNIFE DOWN "K" EE-2820-5 PROX. ASSEMBLY - KNIFE UP "U" E-2232-2 RELAY - AIR BLOWER (AR)/ CLAMP COMPRESS. EE-2821-8 CABLE ASM.
  • Page 75 5.0 Schematics & Parts Lists Power Panel Assembly – 305X – XG/XT Models EE-2882-1 Sht. 1, Rev. E PART NO. DESCRIPTION OF ACCESSORIES E-2730-3 FILTER - EMI/EFI, PANEL MOUNT EE-2836-1 CONDUIT ASM. - HYDRAULIC MOTOR, 3 PHASE H-7321-#8 WASHER -#8 FLAT S-1694 TY-WRAP - CABLE (NOT SHOWN)
  • Page 76 5.0 Schematics & Parts Lists Power Panel Assembly – 305X – XG/XT Models EE-2882-1 Sht 2, Rev. A...
  • Page 77 5.0 Schematics & Parts Lists Notes...

  • Page 78: Interconnection Diagram - 305X - Xg/Xt Models

    5.0 Schematics & Parts Lists 5.19 Interconnection Diagram – 305X – XG/XT Models E-2840-1, Rev. E (For s/n’s 11X1564 and Below)
  • Page 79 5.0 Schematics & Parts Lists Interconnection Diagram – 305X – XG/XT Models E-2840-3, Rev. A (For s/n’s 11X1565 and Up)

  • Page 80: Interconnection Diagram - 305X

    5.0 Schematics & Parts Lists 5.20 Interconnection Diagram – 305X E-2841-1 Rev. D (For s/n’s 11X1564 and Below)
  • Page 81 5.0 Schematics & Parts Lists Interconnection Diagram – 305X E-2841-3 Rev. A (For s/n’s 11X1565 and Up)

  • Page 82: Control Console Assembly - 305Xg Model

    5.0 Schematics & Parts Lists 5.21 Control Console Assembly - 305XG Model EE-2823, Rev. C (For Non-Back lit displays)
  • Page 83 5.0 Schematics & Parts Lists Control Console Assembly - 305XG Model EE-2823-1, Rev. A (For Back lit displays)

  • Page 84: Control Console Assembly - 305X

    5.0 Schematics & Parts Lists 5.22 Control Console Assembly - 305X EE-2850, Rev. C (Non-Back Lit Display)
  • Page 85 5.0 Schematics & Parts Lists Control Console Assembly - 305X EE-2850-1, Rev. A (Back Lit Display)

  • Page 86: Control Console Assembly - Xt Model - Color Lcd

    5.0 Schematics & Parts Lists 5.23 Control Console Assembly - XT Model - Color LCD EE-2998-3 rev B (For Serial Numbers 09X1505 and below)
  • Page 87 5.0 Schematics & Parts Lists Control Console Assembly - XT Model - Color LCD EE-2998-4 rev A (For Serial Numbers 09X1506 and Up)

  • Page 88: Cut Button Assembly (Obsolete)

    5.0 Schematics & Parts Lists 5.24 Cut Button Assembly (Obsolete) EE-2832-1, Rev. B (Note: these cut switches are no longer available – they have been replaced with K-3374)
  • Page 89 5.0 Schematics & Parts Lists Kit - Cut Button Replacement K-3374, Rev. B...

  • Page 90: Cut Button Assembly - (Current)

    5.0 Schematics & Parts Lists 5.25 Cut Button Assembly – (Current) EE-3382, Rev. B...
  • Page 91 5.0 Schematics & Parts Lists Cut Button Assembly – Parts List EE-3382, Rev. B PART NO. DESCRIPTION OF ACCESSORIES 47665 CONTROL BOX ASSEMBLY - 305X E-3127-4 PUSHBUTTON SWITCH - MUSHROOM, 3 N.O. E-2078-3 CABLE - #18GA. 8 COND. 49" LONG E-2078 CABLE - #18GA.

  • Page 92: Kit - Ergonomic Touch Switch (Cut Button Option)

    5.0 Schematics & Parts Lists Kit – Ergonomic Touch Switch (Cut Button Option) 5.26 K-3404, Rev. A...
  • Page 93 5.0 Schematics & Parts Lists Kit – Ergonomic Touch Switch (Cut Button Option) K-3404, Rev. A (For S/N’s 11X1565 and up)

  • Page 94: Line Light Assembly

    5.0 Schematics & Parts Lists 5.27 Line Light Assembly 47538, Rev. D...

  • Page 95: Air Table Blower Assembly - Single Phase

    5.0 Schematics & Parts Lists 5.28 Air Table Blower Assembly – Single Phase 47578, Rev. C...

  • Page 96: Compressor Assembly

    5.0 Schematics & Parts Lists 5.29 Compressor Assembly 47645-1 Rev. C...
  • Page 97 5.0 Schematics & Parts Lists Notes...

  • Page 98: Backgauge Control Assembly S/N 13X1661 & Below

    5.0 Schematics & Parts Lists 5.30 Backgauge Control Assembly S/N 13X1661 & Below 49249 Rev. F PART NO. DESCRIPTION 47053 COUPLING 49248 PILLOW BLOCK BRACKET 63210-1 FRONT PILLOW BLOCK 63213 TORSION SPRING 63214 ACTUATOR 63218 KNOB 63221 CONTROL KNOB SHAFT EE-3213 POTENTIOMETER H-6424-6...

  • Page 99: Backgauge Control Assembly S/N 13X1662 & Above

    5.0 Schematics & Parts Lists 5.31 Backgauge Control Assembly S/N 13X1662 & Above 49249 Rev. G PART NO. DESCRIPTION 49248-1 BRACKET - BACKGAUGE CONTROL 49261 ENCODER BRACKET - FLEXIBLE 56676-1 COUPLING 63210-1 FRONT PILLOW BLOCK 63213 TORSION SPRING 63214 ACTUATOR 63218 KNOB 63221...

  • Page 100: X/Xg/Xt Troubleshooting

    5.0 Schematics & Parts Lists 5.32 X/XG/XT Troubleshooting EE-2807-2 (Order programmed IC chip separately.) The following is a description of the various diagnostic LED’s in the power panel. These lights are indicators used to show input and output status.

  • Page 101: Description Of Error Messages

    5.0 Schematics & Parts Lists 5.33 Description of Error Messages Message Description Test Backgauge doesn’t move Backgauge Failure Mechanical bind; encoder failure; main pc board; blown fuse Backgauge at Limit Backgauge is all the way forward or backward Checksum Error Bad program chip Replace EEPROM Clamp Up Failure...

  • Page 102: Sensor Data Abbreviations

    5.0 Schematics & Parts Lists Number Outside of Limit Selected cut position beyond Operator error; false clamp limit machine limits Positioning Error Backgauge failed to move to Mechanical bind; encoder failure; programmed position within +/- .005 main pc board; leadscrew thrust washers loose;...
  • Page 103 5.0 Schematics & Parts Lists Notes...

  • Page 104: Encoder Cable Assembly - 305X - X Models

    5.0 Schematics & Parts Lists 5.35 Encoder Cable Assembly – 305X - X Models EE-2838-3...

  • Page 105: Encoder Cable Assembly - 305X - Xg/Xt Models

    5.0 Schematics & Parts Lists 5.36 Encoder Cable Assembly – 305X – XG/XT Models EE-3030-1 Rev. B...

  • Page 106: Knife Latch Assembly

    5.0 Schematics & Parts Lists 5.37 Knife Latch Assembly 47568-1, Rev. A...

  • Page 107: Bell-Crank Assembly - Clamp

    5.0 Schematics & Parts Lists 5.38 Bell-Crank Assembly – Clamp 47005, Rev. D...

  • Page 108: Hydraulic Manifold Assembly

    5.0 Schematics & Parts Lists 5.39 Hydraulic Manifold Assembly H-465-1, Rev. E...

  • Page 109: Hydraulic Power Unit Assembly

    5.0 Schematics & Parts Lists 5.40 Hydraulic Power Unit Assembly 47541, Rev. L...
  • Page 110 5.0 Schematics & Parts Lists Hydraulic Power Unit Assembly 47541, Rev. L PART NO. DESCRIPTION OF ACCESSORIES H-238-4 STRAINER 40016-5 VIBRATION ABSORBER H-6405-12112 NIPPLE- 3/4 NPT X 14" H-503 ELBOW- 3/4 NPT (FEM.) X 3/4 NPT (FEM.)X90 H-226-1 HEAD- FILTER H-237-17 ELBOW- 3/4 NPT X 3/4-16 SAE 37%%D X 90 H-227-1...

  • Page 111: Hydraulic Manifold

    5.0 Schematics & Parts Lists 5.41 Hydraulic Manifold H-468-1, Rev. B...
  • Page 112 5.0 Schematics & Parts Lists Hydraulic Manifold (Schematic) H-468-1, Rev. A...

  • Page 113: Manifold Assembly

    5.0 Schematics & Parts Lists 5.42 Manifold Assembly H-504, Rev. A...

  • Page 114: Fuse Charts

    5.0 Schematics & Parts Lists 5.43 Fuse Charts...

  • Page 115: Xg/Xt Models Label - Power Panel Connection Procedure

    5.0 Schematics & Parts Lists 5.44 XG/XT Models Label – Power Panel Connection Procedure S-1781-52, Rev. J...

  • Page 116: Model Label - Power Panel Conn. Procedure

    5.0 Schematics & Parts Lists 5.45 305 X Model Label – Power Panel Conn. Procedure. S-1781-161, Rev. B...

  • Page 117: Warning Label

    5.0 Schematics & Parts Lists 5.46 Warning Label S-1781-116, Rev. A...

  • Page 118: Paper Deflector (Kit Option)

    5.0 Schematics & Parts Lists 5.47 Paper Deflector (Kit Option) AA-13936-1...

  • Page 119: Paper Deflector Assembly

    5.0 Schematics & Parts Lists 5.48 Paper Deflector Assembly A-4511-2...

  • Page 120: Extension Tables - 24" X 36" - (Kit Option)

    5.0 Schematics & Parts Lists 5.49 Extension Tables - 24” x 36” - (Kit Option) K-2720, Rev. E...
  • Page 121 5.0 Schematics & Parts Lists Extension Tables - 24” x 36” (Kit Option) K-2720, Rev. E...

  • Page 122: Extension Air Tables - 24" X 36" (Kit Option)

    5.0 Schematics & Parts Lists 5.50 Extension Air Tables - 24” x 36” (Kit Option) K-47631...
  • Page 123 5.0 Schematics & Parts Lists Extension Air Tables - 24” x 36” (Kit Option) K-47631...

  • Page 124: Back Gauge Tape Kit

    5.0 Schematics & Parts Lists 5.51 Back Gauge Tape Kit K-49007...
  • Page 125 5.0 Schematics & Parts Lists Notes...

  • Page 126: Electric Eye Kit Instructions - (Obsolete)

    5.0 Schematics & Parts Lists 5.52 Electric Eye Kit Instructions – (Obsolete) K-3006, Sht. 1 of 4, Rev. D (For s/n’s 11X1564 and Below)
  • Page 127 5.0 Schematics & Parts Lists Electric Eye Kit Instructions K-3006, Sht. 1 of 3, Rev. D (For s/n’s 11X1564 and Below)
  • Page 128 5.0 Schematics & Parts Lists Electric Eye Kit Instructions K-3006, Sht. 2 of 3, Rev. D (For s/n’s 11X1564 and Below)
  • Page 129 5.0 Schematics & Parts Lists Electric Eye Kit Instructions K-3006, Sht. 2 of 3, Rev. D (For s/n’s 11X1564 and Below)
  • Page 130 5.0 Schematics & Parts Lists Electric Eye Kit Instructions K-3006, Sht. 3 of 3, Rev. D (For s/n’s 11X1564 and Below)
  • Page 131 5.0 Schematics & Parts Lists Notes...

  • Page 132: Electric Eye Kit Instructions - (Current)

    5.0 Schematics & Parts Lists 5.53 Electric Eye Kit Instructions – (Current) EE-3339, Sht. 1 of 2, Rev. A (For s/n’s 11X1565 and Up)
  • Page 133 5.0 Schematics & Parts Lists Electric Eye Kit Instructions K-3339 Sht. 2 of 2, Rev. A (For s/n’s 11X1565 and Up)

  • Page 134: Jogging Aid Construction Guide

    5.0 Schematics & Parts Lists 5.54 Jogging Aid Construction Guide A-12608-( ), Rev. E...

  • Page 135: Converting 305X Series From Three Phase To Single Phase

    5.0 Schematics & Parts Lists 5.55 Converting 305X Series from Three Phase to Single Phase. PROCEDURE: 1. Disconnect power to the machine at the wall. 2. Remove the auxiliary contacts from the top of the starter. To remove aux. contacts, locate the release lever at the bottom of the contact and lift up;...

  • Page 136: Knife Lifter Assembly

    5.0 Schematics & Parts Lists 5.56 Knife Lifter Assembly 47575...

  • Page 137: Safety System Tests

    6.0 Safety System Tests 6.0 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 138 F.254-I-T October 2019...

This manual is also suitable for:

Champion 305 xgChampion 305 xt

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