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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.
Operator's Manual
CHAMP 150
Serial Numbers:
The Challenge Machinery Company
150CH-A-190000 and up
6125 Norton Center Drive
Norton Shores, MI 49441-6081 USA
Sold and Serviced by
ChallengeMachinery.com
F.150CH-O-A
June 2023
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Table of Contents
Related Manuals for Challenge CHAMP 150
Summary of Contents for Challenge CHAMP 150
- 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.
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Page 2: Introduction
MACHINERY COMPANY in order for the warranty to be issued for this machine. Challenge® is a registered trademark of The Challenge Machinery Co. 6125 Norton Center Drive Norton Shores, MI 49441 Copyright© 2023 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A. -
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 Packing List ............................7 4.0 Specifications ............................8 5.0 Installation & Setup ...........................9 5.1 Inspecting Shipment ........................9 5.2 Uncrating ............................9 5.3 Hydraulic System Check...................... -
Page 4: 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 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. F.150CH-O-A Page 5 June 2023... - Page 6 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. ...
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Page 7: Packing List
3.0 Packing List 3.0 Packing List Part No. Description Qty. – CHAMP 150 Paper Cutter 73012-1 Knife, HSS (installed) Knife Bolts, 3/8-16 x 1” Soc. Hd. (installed) H-6918-608 8815 Knife Washers (installed) A-73050 Knife Lifter Assembly – Knife Scabbard (blade holder) -
Page 8: Specifications
120 Volts AC, 60 HZ, 1 Phase, 12 Amps Recommended service size: 20 Amps Receptacle type: NEMA 5-20R Challenge reserves the right to make changes to any product or specification without notice and without incurring responsibility to existing units. F.150CH-O-A... -
Page 9: Installation & Setup
Remove the plywood “ramp” and set it aside for now. Also remove any accessories and set them aside. Remove the lower front cover from the CHAMP 150. Then remove the four lag screws that hold the CHAMP 150 to the skid, as indicated in Figure 2. - Page 10 Carefully lean the CHAMP 150 forward slightly while having a second person pull out the two boards located at the top of the board stack from the rear side of the CHAMP 150, as shown in Figure 4. Figure 4 Now lean the CHAMP 150 rearward slightly and repeat the procedure for the top two boards at the front side of the machine.
- Page 11 Make sure the casters are not locked and very carefully roll the machine down the ramp (Figure 6). BE SURE TO USE 2 PEOPLE TO DO THIS SAFELY! Figure 6 The CHAMP 150 may now be rolled into its final position. Replace the lower front cover. F.150CH-O-A Page 11...
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Page 12: Hydraulic System Check
5.0 Installation & Setup 5.3 Hydraulic System Check The cutting/clamping mechanism of the CHAMP 150 is powered by a hydraulic system consisting of an electric motor coupled directly to a hydraulic pump. The hydraulic reservoir holds approximately 0.7 gallons (2.6 liters) of with ISO VG 46 hydraulic fluid. It is filled at the factory but the level should be checked before operation. -
Page 13: Power Hook-Up
The CHAMP 150 is rated for use on a 120 Volts AC, 1 Phase, 60 HZ, 20 Amp circuit. It requires the use of a NEMA 5-20R receptacle (Figure 8). -
Page 14: Operation
6.0 Operation IMPORTANT: DO NOT ATTEMPT TO OPERATE THE CHAMP 150 UNTIL YOU HAVE THOROUGHLY READ AND UNDERSTAND ALL OF THE FOLLOWING INSTRUCTIONS. CALL YOUR AUTHORIZED CHALLENGE DEALER IF YOU STILL HAVE ANY QUESTIONS. 6.1 Console Controls The console controls consist of a main power switch, inch/mm selector, and knife adjust switch, and cut/clamp buttons. -
Page 15: Operation Lockout Feature
6.4 Backgauge Control The backgauge position on the CHAMP 150 is controlled by the handwheel located at the front of the machine. The knob to the right of the handwheel and under the table can be used to lock the handwheel in place to prevent it from moving. -
Page 16: Making A Cut
“up” position. In order for the CHAMP 150 to detect proper function of the front shield, the front shield must be opened and closed before each cut cycle. The CHAMP 150 will not make two consecutive cut cycles unless the front shield has been opened and closed at least once between cycles. -
Page 17: Operating Tips
6.0 Operation 6.9 Operating Tips For best results, it is very important to have a sharp blade in the cutter. A dull blade will cause poor quality cuts, may pull or draw the paper and cause uneven cutting, or may not cut through an entire pile. -
Page 18: Knife Installation/Changing
7.0 Knife Installation/Changing 7.0 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 lifter is properly installed, see instructions following. Keep handling of unprotected knives to an absolute minimum. ... -
Page 19: Knife Installation
7.0 Knife Installation/Changing Figure 14 4. Insert the threaded ends of the knife lifter assembly’s handles into the two slotted holes, and screw the handles into the knife itself until the handles are tight. Then remove the remaining two knife bolts (Figure 15). - Page 20 7.0 Knife Installation/Changing 2. Switch the power OFF, then disconnect power and lock it out (Section 2.2 Power Lockout Procedure). 3. Turn out (unscrew) the knife adjusting screws on top of the knife bar several turns (Figure 16). NOTE: Failure to back off the screws could cause damage to the new knife and/or the cutting stick.
- Page 21 7.0 Knife Installation/Changing Figure 17 14. Switch the power OFF, then disconnect power and lock it out (Section 2.2 Power Lockout Procedure). 15. Using the 3/16 hex drive L-wrench, screw the knife adjusters down a small amount at a time on each side, until the knife cuts through the bottom sheets of paper in all three areas –...
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Page 22: Knife Care Tips
4 times again. 7.3.3 Bevel Angle Challenge recommends that bevel angles for the CHAMP 150 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 23: Helpful Suggestions
Always keep knife bolts securely tightened. Always use the heavy-duty knife bolt washers provided by Challenge. Failure to do so could result in scratching or marring of the clamp face. Store knives in a dry environment to prevent corrosion. - Page 24 7.0 Knife Installation/Changing NOTES F.150CH-O-A Page 24 June 2023...
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Page 25: Troubleshooting
8.0 Troubleshooting 8.0 Troubleshooting All service and repairs to this machine should be performed by trained service personnel. Attempting to perform repair and replacement procedures without proper training may cause machine damage or operator injury! 8.1 Troubleshooting Problem Possible Cause Solution 1. -
Page 26: Safety Systems Test
9.0 Safety Systems Test Machine manufacturer CHALLENGE Model CHAMP 150 Serial Number __________________ Frequency of test: THESE TESTS SHOULD BE PERFORMED AT THE BEGINNING OF EACH WORK DAY. Switch power on and make sure the knife and clamp are in the up position (if they are not, follow the instructions in this manual to send them up). - Page 27 9.0 Safety Systems Test Please enter date and initials for both tests. Date ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ Test 1 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ Test 2 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ Date ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ Test 1 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______...
- Page 28 F.150CH-O-A June 2023...