Challenge CHAMPION 305 Instructions And Parts Manual page 4

1.0 Introduction
11.1 Recommended Hydraulic Oil ................................................................................................... 35
11.2 Changing the Oil ....................................................................................................................... 35
11.3 Hydraulic Valve Adjustments ................................................................................................... 36
12.0 Adjustments .................................................................................................................................. 41
12.1 Electric Eye Alignment ............................................................................................................. 41
12.2 Backgauge Gib Adjustment ...................................................................................................... 42
12.3 Squaring the Backgauge .......................................................................................................... 43
12.4 Backgauge Position Accuracy Adjustment .............................................................................. 44
12.5 Knife Latch Adjustment ............................................................................................................ 45
12.6 Line Light Adjustment (Incandescent Type) ............................................................................. 46
12.7 Line Light Adjustment (LED Type) ........................................................................................... 47
12.8 Proximity Switches ................................................................................................................... 48
12.9 Clamp Return Speed Adjustment ............................................................................................. 50
12.10 Pre-Clamp Pressure Adjustment ............................................................................................ 51
12.11 Pre-Clamp Speed Adjustment ................................................................................................ 51
12.12 Clamp Cylinder Adjustment (Clamp Height) .......................................................................... 52
12.13 Clamp Parallel Rod ................................................................................................................ 53
12.14 Lead Screw Adjustment Nuts ................................................................................................. 53
12.15 Knife Bar Gibs ........................................................................................................................ 54
13.0 Repair and Replacement .............................................................................................................. 56
13.1 Fuses (skip this section if the machine has Circuit Breakers).................................................. 56
13.2 Knife Cylinder Replacement ..................................................................................................... 56
14.0 Troubleshooting ............................................................................................................................ 59
14.1 Menu Tree ................................................................................................................................ 62
14.2 Diagnostic LED's ...................................................................................................................... 63
14.3 Description of Error Messages ................................................................................................. 64
14.4 Sensor Data Abbreviations ...................................................................................................... 65
15.0 Schematics & Parts Lists .............................................................................................................. 66
15.1 Main Assembly - Frame/Tank ................................................................................................. 66
15.2 Main Assembly - Hydraulics .................................................................................................... 68
15.3 Main Assembly - Clamp .......................................................................................................... 70
15.4 Main Assembly- Electrical Components, Lower Front ............................................................ 72
15.5 Main Assembly - Electrical Components, Upper ..................................................................... 74
15.6 Main Assembly - Electrical Components, Upper ..................................................................... 76
15.7 Main Assembly - Air Table Option ........................................................................................... 78
15.8 Main Assembly - Table Mounting ............................................................................................ 80
15.9 Main Assembly - Backgauge Assembly .................................................................................. 82
15.10 Main Assembly - Knife ........................................................................................................... 84
15.11 Main Assembly - Covers and Labels ..................................................................................... 86
15.12 Main Assembly - Table Extensions ....................................................................................... 88
15.13 Power Panel Assembly (w/ Fuses) ........................................................................................ 90
15.14 Power Panel Assembly (w/Circuit Breakers) ......................................................................... 95
15.15 Basic Machine Schematic w/Fuses...................................................................................... 100
15.16 Basic Machine Schematic - Ergo Touch Models w/Fuses .................................................. 101
15.17 Basic Machine Schematic - Standard Cut w/Circuit Breakers ............................................ 103
15.18 Basic Machine Schematic - Ergo Touch w/Circuit Breakers ............................................... 104
15.19 Interconnection Diagram ...................................................................................................... 105
15.20 Hydraulic Manifold Kit........................................................................................................... 106
15.20.1 Knife Down Sequence Valve Assembly........................................................................ 107
15.20.2 Hydraulic Manifold Assembly ........................................................................................ 108
15.20.2.1 Hydraulic Manifold ................................................................................................. 109
15.21 Hydraulic Schematic............................................................................................................. 110
15.22 Control Console Assembly ................................................................................................... 111
15.23 Cut Button Assembly ............................................................................................................ 113
15.24 Cut Button Kit - Ergo Style Touch Switches ........................................................................ 115
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