Challenge MS-5 Technical Service And Parts Manual
Challenge MS-5 Technical Service And Parts Manual

Challenge MS-5 Technical Service And Parts Manual

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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.
MODEL MS-5
Technical Service and Parts Manual
Serial Numbers:
965600 through 159999,
MS5-A-150000 and up
Sold and Serviced by
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441-6081 USA
F.300-BT
ChallengeMachinery.com
August 2015

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Summary of Contents for Challenge MS-5

  • 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

    Also be sure to 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 ..............................4 2.1 Precautions ...........................4 2.2 Power Lockout Procedure ......................4 2.3 Warning Label Definitions ......................5 3.0 Maintenance Guide ...........................6 3.1 Routine Maintenance ........................7 4.0 Troubleshooting ..........................10 5.0 Main Assemblies ..........................12 5.1 Main Assembly –...
  • Page 4: Safety

    If the machine sounds or operates abnormally, turn it off and consult the Trouble Shooting section of this manual. If the problem cannot be corrected, have it checked by a qualified service person or your Authorized Challenge Dealer.  CRUSH HAZARD, keep feet off the pedal when handling paper under the pressure feet. DO NOT REST FOOT ON PEDAL at any time! ...
  • Page 5: 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 5.0, Main Assemblies.
  • Page 6: 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 modification or alteration of any Challenge product...
  • Page 7: Routine Maintenance

    3.0 Maintenance Guide 3.1 Routine Maintenance General Production losses can be reduced if good maintenance practices are followed. The following suggestions may be helpful: 1. Recognize the fact that the user of hydraulic equipment has more control over maintenance than the manufacturer.
  • Page 8 the oil when running. Use only a recommended premium grade anti-wear hydraulic oil series ISO VG 100. Oils other then the recommended type will cause seals, cups and ‘o’-rings to deteriorate. Oil Fill Level Line Fig. 2 Yearly 1. Check all adjustments 2.
  • Page 9 3.0 Maintenance Guide Lock Nut Fig. 3 PINCH POINT: Replace guard after adjusting Hydraulic Through normal use, hydraulic systems gum up and seals wear. Signs of wear are hydraulic leaks and erratic operations of the vertical speed. Check with your Authorized Dealer for a current repair and/or replacement policy.
  • Page 10: 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 2.2 Power Lockout Procedure page, 4. Whenever repairing hydraulic components, loosen connections slowly to bleed off any trapped pressure.
  • Page 11 4.0 Troubleshooting NOTES...
  • Page 12: Main Assemblies

    5.0 Main Assemblies 5.1 Main Assembly – Front View 45000 Sheet 1 Rev. N...
  • Page 13 5.0 Main Assemblies Main Assembly – Front View – Parts List 45000 Sheet 1 Rev. N PART NO. DESCRIPTION OF ACCESSORIES 16543 LEVELER H-6424-6 3/8-16 HEX JAM NUT 45051 BASE ASSEMBLY 45049 BRACKET - LOWER BASE COVER H-6910-102404 #10-24 X 1/2 BUTTON HD SOC. CAP SCREW H-377 HYDRAULIC CYLINDER H-6424-8...
  • Page 14 Main Assembly – Front View – Parts List (cont) 45000 Sheet 1 Rev. N PART NO. DESCRIPTION OF ACCESSORIES H-6913-1012 5/8-11 X 1-1/2 HEX HD. CAP SCREW H-7327-20 5/8 MEDIUM LOCKWASHER 45137 GUIDE ASSEMBLY - TABLE ROD 45116-2 BRACKET - TABLE MOUNTING H-6910-1010 5/8-11 X 1-1/4 BUTTON HD.
  • Page 15 5.0 Main Assemblies Notes:...
  • Page 16: Main Assembly - Side Elevation

    5.2 Main Assembly – Side Elevation 45000 Sheet 2 Rev. X...
  • Page 17 5.0 Main Assemblies Main Assembly – Side Elevation – Parts List 45000 Rev. X PART NO. DESCRIPTION OF ACCESSORIES E-875-4 FOOTSWITCH (REPAIRS ONLY) REF. H-7324-#10 #10 INT. TOOTH LOCKWASHER H-6423-#10 #10-24 HEX NUT H-6918-102406 #10-24 X 3/4 SOC. HD CAP SCREW 45048 COVER - LOWER BASE H-6910-102404...
  • Page 18 Main Assembly – Side Elevation – Parts List (cont) 45000 Rev. X PART NO. DESCRIPTION OF ACCESSORIES H-5248-4 1/4-28 FLEX LOCK NUT 45012 VERTICAL TABLE GUIDE ASSEMBLY H-6918-612 3/8-16 X 1-1/2 SOC. HD CAP SCREW 56143 WASTE BIN E-3082 SWITCH - MAIN DISCONNECT E-3083 SWITCH FACE - MAIN DISCONNECT 41130...
  • Page 19 5.0 Main Assemblies Main Assembly – Side Elevation – Parts List (cont) 45000 Rev. X PART NO. DESCRIPTION OF ACCESSORIES EE-2751-1 CONDUIT ASM - CONTROL CONSOLE - 3PH EE-2751 CONDUIT ASM - CONTROL CONSOLE - 1PH S-1694-5 TYRAP - IDENTIFICATION S-1781-46 LABEL - BELT INSTALLATION H-6910-102406...
  • Page 20: Main Assembly - Top View

    5.3 Main Assembly – Top View 45000 Sheet 3 Rev. G...
  • Page 21 5.0 Main Assemblies Main Assembly – Top View – Parts List 45000 Rev. G PART NO. DESCRIPTION OF ACCESSORIES 4636-3 SCALE - B/G POSITION S-1781-12 CAUTION LABEL 45035 IDLER ASSEMBLY - STATIONARY 45152 DRILL HEAD ASSEMBLY AS REQ'D 1 FOR STD HEADS 45161 IDLER ASSEMBLY - MOVEABLE...
  • Page 22: Main Assembly - Spindle Guard (S/N's 135928 And Up)

    5.4 Main Assembly – Spindle Guard (S/N’s 135928 and up) 45000 Sheet 4 Rev. G...
  • Page 23 5.0 Main Assemblies Main Assembly – Spindle Guard – Parts List 45000 Rev. G PART NO. DESCRIPTION OF ACCESSORIES 45169-1 GUARD - R.H. SIDE 45170 GUARD - L.H. SIDE 45171 GUARD - CENTER 45180 ACTUATOR - INTERLOCK SWITCH 45174 SUPPORT - SPINDLE GUARD 45175-1 BRACKET - GUARD INTERLOCK KEY 45177...
  • Page 24 5.5 Table Adjustment Assembly 45136-1 Rev. C...
  • Page 25 5.0 Main Assemblies NOTES...
  • Page 26: Basic Machine Schematic

    5.6 Basic Machine Schematic E-2384-1 Rev. B...
  • Page 27 5.0 Main Assemblies Electrical Sequence of Operation NOTE: Please see section on Hydraulic Sequence of Operation for more details Electrical Sequence of Operation Electrical Schematic References (Drawing E-2384-1) While the main disconnect switch “MD” is A. Close the main disconnect switch (MD). closed.
  • Page 28: Power Panel Assembly - 208/230V (1Ph)

    5.7 Power Panel Assembly – 208/230V (1ph) EE-2385-3 Rev. E...
  • Page 29 5.0 Main Assemblies Power Panel Assembly – 208/230V (1ph) Parts List EE-2385-3 Rev. E PART NO. DESCRIPTION OF ACCESSORIES 45119-1 PANEL - ELECTRICAL E-1089-40 TRANSFORMER - 208/230/460 75VA E-2441-14 RELAY - OVERLOAD, 4.5A to 6.5A (H2) S-1781-42 LABEL - MAIN GROUND E-2445-1 BRACKET - OVERLOAD RELAY E-2805...
  • Page 30 Power Panel Assembly – 208/230V (1ph) Parts List (cont.) EE-2385-3 Rev. E PART NO. DESCRIPTION OF ACCESSORIES E-1356-107 LABEL - TERMINAL BLOCK E-1356-108 LABEL - TERMINAL BLOCK EE-3122 WIRES - CUT LIST (208/230V 1PH) E-2441-15 RELAY - OVERLOAD, 6.0A to 8.5A (H1) H-6910-403 SCREW - 1/4-20 x 3/8 BUT HD SOC CAP H-7324-8...
  • Page 31 5.0 Main Assemblies NOTES...
  • Page 32: Power Panel Assembly - 208/230/460V (3Ph)

    5.8 Power Panel Assembly – 208/230/460V (3ph) EE-2386-3 Rev. F...
  • Page 33 5.0 Main Assemblies Power Panel Assembly – 208/230/460V (3ph) Parts List EE-2386-3 Rev. F PART NO. DESCRIPTION OF ACCESSORIES 45119-1 PANEL - ELECTRICAL E-1089-40 TRANSFORMER - 208/230/460 75VA E-2441-14 RELAY - OVERLOAD (H1 & H2), 4.5A to 6.5A E-2445-1 BRACKET - OVERLOAD RELAY E-2805 STARTER - 24V COIL (A16-30-10-81) (RL1) E-2403-8...
  • Page 34 Power Panel Assembly – 208/230/460V (3ph) Parts List (cont) EE-2386-3 Rev. F PART NO. DESCRIPTION OF ACCESSORIES H-7324-8 WASHER - 1/4" INT. TOOTHLOCK H-6910- 83204 SCREW - #8-32 X 1/2" BUT HD SOC CAP H-7321-#8 WASHER - #8 USS FLAT H-7330-#8 LOCKWASHER - #8 SHAKEPROOF H-6910-...
  • Page 35 5.0 Main Assemblies NOTES...
  • Page 36: Power Panel Assembly - 380/415V (3Ph)

    5.9 Power Panel Assembly – 380/415V (3ph) EE-2369-3 REV. “D”...
  • Page 37 5.0 Main Assemblies Power Panel l Assembly – 380/415V (3ph) Parts List EE-2369-3 REV. “D” PART NO. DESCRIPTION OF ACCESSORIES 45119-1 PANEL - ELECTRICAL E-1089-39 TRANSFORMER - 230/380/415 50VA E-2441-17 RELAY - OVERLOAD (PUMP), 1.3A to 1.8A (H2) E-2441-16 RELAY - OVERLOAD (SPINDLE), 2.2A to 3.1A (H1) E-2445-1 BRACKET - OVERLOAD RELAY E-2805...
  • Page 38: Label - Component Placement/Heater Settings

    5.10 Label – Component Placement/Heater settings S-1781-47 Rev. B...
  • Page 39 5.0 Main Assemblies Hydraulic Sequence of Operation NOTE: Please see section on Electrical Sequence of Operation for more details Hydraulic Sequence of Operation Hydraulic Schematic References (drawings H-378-2 and H-407-2) Once the pump relay “RL1” is energized, the A. Pump relay is energized providing power to the hydraulic motor.
  • Page 40: Hydraulic Power Unit - Single And Three Phase

    5.11 Hydraulic Power Unit – Single and Three Phase H-378-2 Rev. A (50/60Hz 1ph) H-407-2 Rev. A (50/60Hz 3ph)
  • Page 41: Drill Head Assembly

    5.0 Main Assemblies 5.12 Drill Head Assembly 45152-1 Rev. A...
  • Page 42: Narrow Drill Head Assembly

    5.13 Narrow Drill Head Assembly 45200 Rev. A.
  • Page 43 5.0 Main Assemblies Notes...
  • Page 44: Two Hand Control Option

    5.14 Two Hand Control Option A-4851-48 Rev. A...
  • Page 45 5.0 Main Assemblies Two Hand Control Option – Parts list A-4851-48 Rev. A...
  • Page 46: Drill Guard Kit

    5.15 Drill Guard Kit K-45180 Rev B (S/N’s: 965600 to 135927)
  • Page 47: Belt Guard Switch Replacement Kit

    5.0 Main Assemblies 5.16 Belt Guard Switch Replacement Kit K-45181 Rev. A (For S/N’s: 965600 to 975272 Only)
  • Page 48 F.300-BT August 2015...

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