Challenge CHAMP 150 Operator's Manual

Sold and Serviced by The Challenge Machinery Company 6125 Norton Center Drive Norton Shores, MI 49441-6081 USA ChallengeMachinery.com 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 Ma ...

manual in a safe, convenient place for quick reference by operators and service personnel. SAFETY ALERT! This symbol means CAUTION: Personal safety instructions! Pay special attention to the instructions in bold type. Personal injury may result if the precautions are not read and followed. READ THIS MANUAL BEFORE OPERATING! Follow precautions and instructions given and you should have years of trouble-free operation. If after reading the manual questions still remain, contact your Authorized Challenge Dealer. FOR PARTS A ...

1.0 Introduction .......................................................................................................................................2 2.0 Safety ................................................................................................................................................4 2.1 Precautions ...................................................................................................................................4 2.2 Power Lockout Procedure ............................................................................................................4 2.3 Warning Label Defini ...

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.  Read and understand all instructions thoroughly before using the machine. If questions remain, contact the dealer from which you purchased this machine. Failure to understand the operating instructions may result in personal injury.  Only trained and authorized people should operate this machine.  DO NOT ALTER SAFETY GUARDS OR DEVICES. They are for ...

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. HAZARDOUS AREA Disconnect power before cleaning, servicing, or making adjustments not requiring power. Do not alter safety guards or devices; they are for your protection. Replace all guards. Do not operate with any guards removed. SHOCK HAZARD Disconnect power before removing cover. Replace cover before operation. SHOCK HAZARD Disconnect power before removing cover. Replace cover before operation. SINGLE OPERATOR ...

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.  Esta maquina, junto con sus mecanismos de seguridad, esta disenada para ser manejada por  UNA SOLA PERSONA a la vez. Jamas debe ser manejada por mas de una persona al mismo  tiempo.  La seguridad es la responsabilidad del operario que usa esta maquina.  LEA DETENIDAMENTE el manual de instrucciones y las PRECAUCIONES DE SEGURIDAD antes de poner a funcionar la cortado ...

7 3.0 Packing List Part No. Description Qty. – CHAMP 150 Paper Cutter 1 73012-1 Knife, HSS (installed) 1 H-6918-608 Knife Bolts, 3/8-16 x 1” Soc. Hd. (installed) 4 8815 Knife Washers (installed) 4 A-73050 Knife Lifter Assembly 1 – Knife Scabbard (blade holder) 1 73055 Cutting Stick (1 installed, 1 separate) 2 73056 Jogging Aid 1 F.150CHA-O.A Operation Manual 1 Tool Kit: 5064 Cutting Stick Puller 1 W-130 3/16” Hex Key Wrench 1 W-137 5/32” Hex Key Wrench 1 W-141 1/8” Hex Key Wrench 1 W-164 5/16” T-Handle Hex Key Wrench 1 ...

12” 12” 305 mm 305 mm Dimensions Overall Width 28” 71 cm Overall Depth 34” 86 cm Overall Height 54” 137 cm Table Height 36” 91 cm Approx. Net Weight 600 lb 270 kg Approx. Shipping Weight 750 lb 340 kg Electrical 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 ex ...

9 5.0 Installation & Setup 5.1 Inspecting Shipment This machine has been carefully packed to prevent damage during shipment. However, claims for damage or loss are the responsibility of the recipient. Inspect all shipments as soon as they are received. If there is any noticeable damage, note it on the freight bill. Visual and/or hidden damage must be reported to the claims department of the carrier within 15 days. Contact your dealer if you need any assistance. Check the contents of the box against the packing list on page 7. Make sure there are no missing items. 5.2 Uncrating The CHAMP 150 weighs approximately 600 lb ( ...

10 Remove the 4 lag screws from the top of the board stacks, and also the 3 lag screws located at the front of the skid, as indicated in Figure 3Figure 4. Figure 3 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. ...

11 Next, use the provided plywood board as a ramp by first placing it in position as shown in Figure 5. Then secure the ramp to the skid using the provided nails. There are pre-drilled holes in the plywood board, indicated by red circles. Figure 5 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. ...

12 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. The tank is located at the rear of the machine. Fluid level should be approximately 1” from the top of the tank (Figure 7). Add fluid if necessary but avoid overfilling. The hydraulic fluid should be checked weekly and changed AT LEAST ONCE-A-YEAR or after every 1,0 ...

13 5.4 Power Hook-Up SHOCK HAZARD! NEVER CUT THE GROUND TERMINAL from a three- prong plug to fit a two-prong socket. Possible shock could cause personal injury or death. Hire a qualified electrician to provide a power source that meets electrical requirements and all local electrical codes. It is the customer’s responsibility to provide a properly grounded receptacle that meets the power requirements specified on the nameplate of this machine, as well as all local electrical codes. Have a qualified electrician install one if your location is not so equipped. The CHAMP 150 is rated for use on a 120 Volts AC, 60 HZ, 20 Am ...

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. Figure 9 6.2 Backgauge Control The position of backgauge 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. Each tim ...

guide. This will prevent the strips from getting caught in the small opening near the left side guide. When finished, always remove the jogging aid from the table. Figure 10 Figure 11 6.4 Making a Cut With the power on, and the backgauge preset and in the desired location, open the front shield and place the stack of paper tightly against the backgauge and either side guide using the jogging aid as described above. To make the cut, close the front shield and press the left and right cut buttons (Figure 9) simultaneously. Hold the b ...

described previously. Now close the front shield then press and hold both clamp-only down buttons (Figure 9). A cut can now be completed with the paper already clamped, or the clamp can be released without making a cut. To make a cut, press and hold both cut buttons as described in the previous section. To release the clamp without cutting, press and release the clamp up button shown in Figure 9. 6.6 Operating Tips  For best results, it is a MUST to have a sharp blade in the cutter. A dull blade will pull or draw the paper and ca ...

17 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.  Clear off cutter table before removing knife.  Have scabbard on a stable surface very nearby and insert knife immediately.  Warn people of any unprotected knife.  Knife changing is a ONE PERSON OPERATION. Having more than one person change knives is dangerous. Figure 12 – Knife Changing Equipment The knife ...

18 Figure 13 3. Remove the knife bolts from the two slotted knife bar holes and replace with the knife lifter assembly (Figure 14). Tighten the lifters to hold the knife in place, and then remove the remaining knife bolts. Figure 14 4. Clear the table surfaces and place the empty knife scabbard on the table. Remove the scabbard’s knife retaining screws. 5. Grasp the knife lifter handles firmly and, at the same time, turn them counterclockwise to release the knife from the knife bar (Figure 15). Lower the knife and maneuver it out of the cutter. Put the blade in the scabbard immediately and secure the knife retaine ...

19 7.2 Knife Installation Knives are heavy and always very sharp! Be sure to keep the edge away from your body and keep other people out of the area while handling the blade. Severe lacerations or dismemberment could result from careless handling procedures. 1. Make sure the knife and clamp are in the up position. If they are not, switch on the power using the red and yellow main power switch, close the front shield, and press the cut buttons. This will send the knife and clamp up. 2. Switch off the machine and unplug the power cord. 3. Pull out the cut stick using the cut stick removal tool and turn it to a new ...

20 Figure 16 14. Plug in the power cord and switch the power on. Move the Knife Adjust Switch to the Run mode. 15. Close the front shield and push the clamp up button. This will raise the knife and clamp to the up position. 16. Switch power off and disconnect the power cord. 17. Tighten all knife bolts securely. 18. Plug in the power cord and switch power on. Make a test cut through a full lift of paper and make minor adjustments if necessary by repeating steps 9 through 17. NOTE: If the knife ends cut but the middle doesn’t, you could have dips or uneven spots in the knife and/or cut stick. These can be elimina ...