Challenge SPARTAN 120 Instructions And Parts Manual
Challenge SPARTAN 120 Instructions And Parts Manual

Challenge SPARTAN 120 Instructions And Parts Manual

Bench top cutter
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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 non-
current, unsupported or no longer produced by The Challenge Machinery Company, and are
provided solely as an accomodation 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.

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Summary of Contents for Challenge SPARTAN 120

  • Page 1 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.
  • Page 2 Serial Numbers 99100 & Up NSTRUCTION AND ARTS ANUAL SPARTAN 120 SPARTAN 120 SPARTAN 120 SPARTAN 120 BENCH TOP CUTTER Sold and Serviced by The Challenge Machinery Company 6125 Norton Center Drive Norton Shores, MI 49441-6081 USA ChallengeMachinery.com...
  • Page 3: Introduction

    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 4: 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 3.0 Packing List............................7 4.0 Specifications ........................... 8 5.0 Installation Guide ..........................9 5.1 Inspecting Shipment ........................9 5.2 Unpacking .............................9 5.3 Moving ............................9 5.4 Setup.............................9 5.5 Cleaning............................9...
  • Page 5 1.0 Introduction 8.1.11 Main Assembly- Finish and Parts List................30 8.1.12 Main Assembly- Controls ....................31 8.1.13 50025 Bell-Crank Assembly....................32 8.1.14 50025 Bell-Crank Assembly Parts List ................33 8.2 Electrical ............................. 35 8.2.1 E-2896 Basic Machine Schematic ..................35 8.2.2 EE-2895 Rev.
  • Page 6: Safety

    • Read and understand all instructions thoroughly before using the machine. If questions remain, contact your Authorized Challenge Dealer. Failure to understand the operating instructions may result in personal injury. • Only trained and authorized people should operate this machine.
  • Page 7 2.0 Safety Warning Label Definitions The following warning label is found on the front cover of the machine. Read and understand the meaning of this symbol. If this label is lost from the machine, it should be replaced. The item number and location of this label can be found in section 8.1.11 Main Assembly- Finish and Parts List.
  • Page 8: Packing List

    3.0 Packing List 3.0 Packing List Part No. Description Qty. CMC-120 Basic Machine 50042 Jogging Aid 50056 Cut Stick 50051 Knife Lifter K-50043 Tool Kit Tool Kit Includes: 41121 Felt Washer 5064 Cut Stick Hook W-107 7/32 Hex “T” Wrench W-137 5/32 Hex Wrench W-141 1/8 Hex Wrench 36134 Pocket Pull Handle...
  • Page 9: Specifications

    4.0 Specifications 4.0 Specifications Description US Units Metric Units Cutting Width 12 in. 30.5 cm Clamp Opening 1.5 in. 3.8 cm Table Behind Knife 17.25 in. 43.8 cm Table In Front of Knife 8.5 in. 21.6 cm Minimum Cut 1.25 in. 3.2 cm Cutting Force 1767 lbs.
  • Page 10: Installation Guide

    Do not place the machine on a cart. A cart will raise the center of gravity and create a tipping hazard. If a stand is required, purchase a Challenge stand, P/N 35470. Make sure to install the (4) screws from the tool kit into the top of the stand to prevent the machine from being pushed off the stand.
  • Page 11: User's Guide

    6.3 Load Paper Lift the front hood and jog the stock against the backgauge. Challenge recommends centering the stock on the backgauge to ensure square cutting. The side-guides may not be precisely square to the backgauge and knife although the backgauge and knife are parallel.
  • Page 12: Cut Stick Rotation And Replacement

    6.0 User’s Guide 6.6 Cut Stick Rotation and Replacement Through time the cut stick will become worn, affecting the quality of cut on the lower sheets of a pile. Rotating or replacing the cut stick will provide a fresh surface for cutting. Disconnect main power.
  • Page 13: Appendix A - 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 14: Mechanical System

    7.0 Appendix A - Maintenance Guide 7.1 Mechanical System The machine should be lubricated every 6 months, and the knife should be changed when cut quality becomes unacceptable. 7.1.1 Lubrication Grease Disconnect main power. See Section 2.2 Power Lockout Procedure. 1.
  • Page 15: Changing The Knife

    7.0 Appendix A - Maintenance Guide 8. Apply light machine oil to all six bell-crank pins under the table as shown in Figure 4- Front Gib Lubrication and Figure 5- Bell-Crank Lubrication. 9. Brush high-pressure grease along the backgauge guide shaft and lead-screw as in Figure 5- Bell-Crank Lubrication Figure 5- Bell-Crank Lubrication Figure 4- Front Gib Lubrication...
  • Page 16: Knife Disposal

    The used knife must be mounted to the scabbard. It should be properly discarded. Check with the appropriate authorities (local code or waste-management company) for proper disposal. You may also check with your regrind shop or Authorized Challenge Dealer for disposal options. 7.1.4 Hood Switch Adjustment...
  • Page 17: Hood Plunger Adjustment

    7.0 Appendix A - Maintenance Guide 1. Remove the right arch side panel. 2. Lift hood and place 5/8” (15.9 mm) thick material on the front edge of the table. 3. Loosen hood switch mounting screws. 4. Adjust the hood switch plunger to touch the steel actuator flap. 5.
  • Page 18: Replacing Hydraulic Fluid

    5. Using a long funnel, add fluid until the recommended level is reached. Only use 100- weight hydraulic fluid. This can be ordered from Challenge in five-gallon containers, part number S-1991-3. See Section 7.2.3 for a compatibility list. DO NOT OVERFILL! 6.
  • Page 19: Hydraulic Fluid Compatibility List

    7.0 Appendix A - Maintenance Guide 7.2.3 Hydraulic Fluid Compatibility List Any of the following hydraulic fluids may be used. Product Name Distributor Rykon No. 100 AMOCO Energol HLP 100 AW 100 Chevron Pacemaker XD 100 Citgo Super Hydraulic 100 Conoco Univis N100 Exxon...
  • Page 20 7.0 Appendix A - Maintenance Guide...
  • Page 21: Appendix B - Parts List

    8.0 Appendix B - Parts List 8.0 Appendix B - Parts List 8.1 Mechanical 8.1.1 Main Assembly- Arch Cover/Hood...
  • Page 22: Main Assembly- Arch Cover/Hood Parts List

    8.0 Appendix B - Parts List 8.1.2 Main Assembly- Arch Cover/Hood Parts List...
  • Page 23: Main Assembly- Frame, Front View

    8.0 Appendix B - Parts List 8.1.3 Main Assembly- Frame, Front View...
  • Page 24: Main Assembly- Frame, Front View Parts List

    8.0 Appendix B - Parts List 8.1.4 Main Assembly- Frame, Front View Parts List...
  • Page 25: Main Assembly- Frame, Rear View

    8.0 Appendix B - Parts List 8.1.5 Main Assembly- Frame, Rear View...
  • Page 26: Main Assembly- Frame, Rear View Parts List

    8.0 Appendix B - Parts List 8.1.6 Main Assembly- Frame, Rear View Parts List...
  • Page 27: Main Assembly- Base

    8.0 Appendix B - Parts List 8.1.7 Main Assembly- Base...
  • Page 28: Main Assembly- Base Parts List

    8.0 Appendix B - Parts List 8.1.8 Main Assembly- Base Parts List...
  • Page 29: Main Assembly- Lead-Screw And Table

    8.0 Appendix B - Parts List 8.1.9 Main Assembly- Lead-screw and Table...
  • Page 30: Main Assembly- Lead-Screw And Table Parts List

    8.0 Appendix B - Parts List 8.1.10 Main Assembly- Lead-screw and Table Parts List...
  • Page 31: Main Assembly- Finish And Parts List

    8.0 Appendix B - Parts List 8.1.11 Main Assembly- Finish and Parts List...
  • Page 32: Main Assembly- Controls

    8.0 Appendix B - Parts List 8.1.12 Main Assembly- Controls...
  • Page 33: 50025 Bell-Crank Assembly

    8.0 Appendix B - Parts List 8.1.13 50025 Bell-Crank Assembly...
  • Page 34: 50025 Bell-Crank Assembly Parts List

    8.0 Appendix B - Parts List 8.1.14 50025 Bell-Crank Assembly Parts List...
  • Page 35 8.0 Appendix B - Parts List...
  • Page 36: Electrical

    8.0 Appendix B - Parts List 8.2 Electrical 8.2.1 E-2896 Basic Machine Schematic...
  • Page 37: Ee-2895 Rev. B Panel Assembly- Electrical Controls

    8.0 Appendix B - Parts List 8.2.2 EE-2895 Rev. B Panel Assembly- Electrical Controls...
  • Page 38: Ee 2895 Panel Assembly- Electrical Controls Parts List

    8.0 Appendix B - Parts List 8.2.3 EE 2895 Panel Assembly- Electrical Controls Parts List...
  • Page 39: S-1781-85 Fuse Replacement Label

    8.0 Appendix B - Parts List 8.2.4 S-1781-85 Fuse Replacement Label...
  • Page 40: Hydraulic

    8.0 Appendix B - Parts List 8.3 Hydraulic 8.3.1 H-549 Hydraulic Schematic...
  • Page 41: H-549 And H-549-1 Hydraulic Power Unit

    8.0 Appendix B - Parts List 8.3.2 H-549 and H-549-1 Hydraulic Power Unit The parts listed on this drawing replace parts for both the 60 Hz and 50 Hz models.
  • Page 42: Appendix C- Troubleshooting

    9.0 Appendix C- Troubleshooting 9.0 Appendix C- Troubleshooting Problem Possible Cause Solution 1. The machine will not cycle a) Power cord is disconnected. a) Plug in cord b) Blown fuse b) Check fuse F2 c) Disconnected wires c) Check for wires disconnected from switches, the power panel, or the hydraulic power unit...
  • Page 43: Appendix D- Safety System Tests

    10.0 Appendix D- Safety System Tests 10.0 Appendix D- Safety System Tests Machine Model ___________________ Serial Number _________ Frequency of test: THIS TEST SHOULD BE PERFORMED AT THE BEGINNING OF EACH WORK- DAY AND AFTER EACH KNIFE CHANGE. Test Procedure: CAUTION: ONLY ONE PERSON should perform this test AT A TIME.
  • Page 44 NOTES:...
  • Page 45 Copyright© 2000-2006 by The Challenge Machinery Company F.120...

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99100

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