Challenge SPARTAN 185 Service Manual Download Page 6 | Manualshive

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1.0 Introduction

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4.20 Main Asm. – Covers and Labels (Models: A, 120/230V, 50/60 Hz) .........................................66
4.21 Main Asm. – Covers & Labels (Models: AEP, 120/230V, 50/60 Hz) ........................................68
4.22 Main Asm. – Accessories (All Models) .....................................................................................70
4.23 Motor and Gearbox Assembly (All Models) ..............................................................................72
4.24 Magnet Assembly (All Models) .................................................................................................74
4.25 Floor Stand Assembly (All Models) ..........................................................................................75
4.26 Electrical Schematic (Models: SA, 120V, 60 Hz)......................................................................76
4.27 Electrical Schematic (Models: SA, 230V, 50/60 Hz) ................................................................78
4.28 Electrical Schematic (Models: A, 120V, 60 Hz) ........................................................................80
4.29 Electrical Schematic (Models: A, 230V, 50/60 Hz) ...................................................................82
Electrical Schematic (Models: AEP, 120V, 60 Hz) ...........................................................................84
4.30 Electrical Schematic (Models: AEP, 230V, 50/60 Hz) ..............................................................86
4.31 Elec. Interconnection Diagram (Models: SA, 120/230V, 50/60 Hz) .........................................88
4.32 Elec. Interconnection Diagram (Models: A, 120/230V, 50/60 Hz) ............................................90
4.33 Elec. Interconnection Diagram (Models: AEP, 120/230V, 50/60 Hz) .......................................92
4.34 Electrical Power Panel Assembly (Models: SA, 120V, 60 Hz) .................................................94
4.35 Electrical Power Panel Assembly (Models: SA, 230V, 50/60 Hz) ............................................96
4.36 Electrical Power Panel Assembly (Models: A/AEP, 120V, 60 Hz) ...........................................98
4.37 Electrical Power Panel Assembly (Models: A/AEP, 230V, 50/60 Hz) ....................................100
4.38 Relay Board Assembly (Models: SA/A/AEP, 120V, 60 Hz)....................................................102
4.39 Relay Board Assembly (Models: SA/A/AEP, 230V, 50/60 Hz)...............................................103
4.40 Display Assembly – (Models: SA, 120/230V, 50/60 Hz) ........................................................104
4.41 Display Assembly – (Models: A, 120/230V, 50/60 Hz)...........................................................105
4.42 Display Assembly – (Models: AEP, 120/230V, 50/60 Hz) ......................................................106

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Summary of Contents for SPARTAN 185

Page 1: ...Provided By http www MyBinding com http www MyBindingBlog com CHALLENGE SPARTAN 185 SERVICE MANUAL...

Page 2: ...185 SA A AEP AUTOMATIC PAPER CUTTER Sold and Serviced by The Challenge Machinery Company 6125 Norton Center Drive Norton Shores MI 49441 www challengemachinery com Serial Numbers 051001 Up TECHNICAL...

Page 3: ...OTES Challenge is a registered trademark of The Challenge Machinery Company 6125 Norton Center Drive Norton Shores MI 49441 6081 Copyright 2006 by The Challenge Machinery Company All rights reserved P...

Page 4: ...safety instructions Pay special attention to the instructions in bold type Personal injury may result if the precautions are not read and followed FOR PARTS AND SERVICE contact the Authorized Challen...

Page 5: ...21 3 5 12 Knife Up Limit Switch Adjustment All Models 22 3 5 13 Knife Down Limit Switch Adjustment All Models 23 3 5 14 Re engaging the Knife Pull Down Gear All Models 24 3 6 Troubleshooting 26 4 0 P...

Page 6: ...Schematic Models AEP 230V 50 60 Hz 86 4 31 Elec Interconnection Diagram Models SA 120 230V 50 60 Hz 88 4 32 Elec Interconnection Diagram Models A 120 230V 50 60 Hz 90 4 33 Elec Interconnection Diagram...

Page 7: ...rly grounded Be sure there is sufficient power to operate the cutter properly Observe all caution plates mounted on this cutter Keep foreign objects off table and away from cutter blade BE EXTREMELY C...

Page 8: ...EA 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 gu...

Page 9: ...das en esta guillotina No permita que objetos estranos esten en la mesa o cerca de la cuchilla cortadora TENGA SUMO CUIDADO al tocar y cambiar la cuchilla Heridas severas y hasta desmembramiento puede...

Page 10: ...ery Company provides parts with the express understanding that they are to replace parts found missing or no longer serviceable on equipment designed and or manufactured by Challenge The Challenge Mac...

Page 11: ...ware Remove top cover and bottom cover to check all nuts and bolts for tightness Loose hardware is the cause of most component wear and in the electrical area could cause short circuits and or shock L...

Page 12: ...e off any old or excess grease Use any brand name type of grease and apply to the areas shown in Figure 2 It may be helpful to use a small brush to apply grease Figure 2 3 3 2 Backgauge Lead Screw and...

Page 13: ...e electrical panel for electrical troubleshooting electrical adjustments or for access to the inside of the machine open the panel as shown in Figure 4 below First disconnect power cord Then remove th...

Page 14: ...a small lift of paper against the left side of the backgauge but not against the side guide and make a cut Now leave the backgauge in the same position flip the lift over and push it against the righ...

Page 15: ...can be checked by the following procedure NOTE The backgauge should be squared before attempting to adjust the accuracy See Section 3 5 1 page 13 1 Place a 1 4 to 1 2 lift of 8 1 2 x 11 paper against...

Page 16: ...sening the jam nut Now adjust the screw as follows If rear pile is short less than 5 turn screw out counterclockwise If rear pile is long more than 5 turn screw in clockwise 1 4 turn 012 backgauge adj...

Page 17: ...just snug then add a 1 8 turn Hold screws in position with tool then tighten jam nuts 5 Replace top cover and display panel plug in power cord and turn power on Knife and clamp will return to up posi...

Page 18: ...eet of paper on either side 4 Once the knife begins to cut through the bottom sheet on one side leave the knife down by holding in the left cut button while releasing the right cut button and turning...

Page 19: ...center screw is a spring loaded plunger and should not be adjusted 5 Run the backgauge back and forth the length of the table and check for any binding Readjust if necessary Replace the bottom cover 3...

Page 20: ...panel then remove the top cover 2 Loosen the three line light mounting screws Figure 14 Figure 14 3 Place a white sheet of paper or papers over the entire cut stick and turn the power on to activate t...

Page 21: ...the back page of the Operator s Manual to make sure machine works properly 3 5 10 Knife Clamp Sequence Adjustment Models A and AEP During a normal cut cycle the clamp moves down until it reaches paper...

Page 22: ...nect the power cord Attempting to adjust this limit switch or to move the clamp away from the limit switch with out disconnecting power could cause the clamp motor to inadvertently start up and cause...

Page 23: ...the clamp repeat the adjustment procedure moving the bracket slightly down to allow the clamp to stop below the edge of the knife Or it may be necessary to adjust the knife up limit switch see Section...

Page 24: ...NOTE The knife should not be able to come up so far that the gears become disengaged or damage to the machine could result 3 5 13 Knife Down Limit Switch Adjustment All Models The down limit switch is...

Page 25: ...lectrical panel and slide forward see Section 3 4 Accessing the Electrical Panel page 12 3 Disengage the motor brake by holding the brake lever either up or down Figure 21 Figure 21 4 With the brake d...

Page 26: ...e the brake lever to its normal position 6 Check to make sure the up and down limit switches are positioned correctly to prevent gears from becoming disengaged again See Section 3 5 12 page 22 and Sec...

Page 27: ...nd 3 5 13 Knife Down Limit Switch Adjustment page 23 e Reset breaker switch located on outside of electrical panel f See 3 5 10 Knife Clamp Sequence Adjustment page 20 g Check for wires that are disco...

Page 28: ...10 Concave cutting variation from top to bottom a Knife dull or incorrectly ground a Change the knife with a new or sharpened one See Operator s Manual for knife changing information and instructions...

Page 29: ...4 0 Parts Lists 28 4 0 Parts Lists 4 1 Main Asm Backgauge Drive Models SA 120 230V 50 60 Hz 63000 Sheet 1...

Page 30: ...3 4 2 20 H 6417 6 NUT 3 8 16 HEX 2 21 H 6424 4 NUT 1 4 20 HEX JAM 5 22 H 6424 6 NUT 3 8 16 HEX JAM 3 23 H 6890 606 SCREW 3 8 16 X 3 4 NYLON SOC SET 2 24 H 6909 508 SCREW 5 16 18 X 1 FLAT HEAD CAP 1 2...

Page 31: ...4 0 Parts Lists 30 4 2 Main Asm Backgauge Drive Models A 120 230V 50 60 Hz 63000 Sheet 1...

Page 32: ...3 4 2 20 H 6417 6 NUT 3 8 16 HEX 2 21 H 6424 4 NUT 1 4 20 HEX JAM 5 22 H 6424 6 NUT 3 8 16 HEX JAM 3 23 H 6890 606 SCREW 3 8 16 X 3 4 NYLON SOC SET 2 24 H 6909 508 SCREW 5 16 18 X 1 FLAT HEAD CAP 1 25...

Page 33: ...4 0 Parts Lists 32 4 3 Main Asm Backgauge Drive Models AEP 120 230V 50 60 Hz 63000 Sheet 1...

Page 34: ...X 2 32 H 6417 N10 NUT 10 24 HEX 2 33 H 6423 N4 NUT 4 40 HEX KEP 2 34 H 6424 4 NUT 1 4 20 HEX JAM 5 35 H 6424 6 NUT 3 8 16 HEX JAM 3 36 H 6890 606 SCREW 3 8 16 X 3 4 NYLON SOC SET 2 37 H 6909 508 SCREW...

Page 35: ...4 0 Parts Lists 34 4 4 Main Asm Knife Drive All Models 63000 Sheet 2...

Page 36: ...H 1 13 E 3112 2 MICROSWITCH 1 14 H 6910 404 SCREW 1 4 20 X 1 2 BUTTON HEAD CAP 4 15 H 6910 405 SCREW 1 4 20 X 5 8 BUTTON HEAD CAP 1 16 H 6910 404SS SCREW 1 4 20 X 1 2 BUT HEAD CAP STAINLESS 2 17 H 691...

Page 37: ...4 0 Parts Lists 36 4 5 Main Asm Bottom Side Electrical Models SA 120V 60 Hz 63000 Sheet 3...

Page 38: ...KER AND ON OFF SWITCH 20A 1 8 EE 3154 ELEC PANEL 185 SA 120V 60HZ 1 9 EE 3163 POWER CORD 120V 1 10 H 6424 4 NUT 1 4 20 HEX JAM 2 11 H 6424 6 NUT 3 8 16 HEX JAM 1 12 H 6910 404 SCREW 1 4 20 X 1 2 BUTTO...

Page 39: ...4 0 Parts Lists 38 4 6 Main Asm Bottom Side Electrical Models A AEP 120V 60 Hz 63000 Sheet 3...

Page 40: ...074 3 CIRCUIT BREAKER AND ON OFF SWITCH 20A 1 12 EE 3133 ELEC PANEL 185 A AEP 120V 60HZ 1 13 EE 3163 POWER CORD 120V 1 14 H 6424 4 NUT 1 4 20 HEX JAM 2 15 H 6424 6 NUT 3 8 16 HEX JAM 1 16 H 6910 404 S...

Page 41: ...4 0 Parts Lists 40 4 7 Main Asm Bottom Side Electrical Models SA 230V 60 Hz 63000 Sheet 3...

Page 42: ...R AND ON OFF SWITCH 12A 1 8 EE 2778 POWER CORD 120V 1 9 EE 3154 1 ELEC PANEL 185 SA 230V 50 60 1 10 H 6424 4 NUT 1 4 20 HEX JAM 2 11 H 6424 6 NUT 3 8 16 HEX JAM 1 12 H 6910 404 SCREW 1 4 20 X 1 2 BUTT...

Page 43: ...4 0 Parts Lists 42 4 8 Main Asm Bottom Side Electrical Models A AEP 230V 60 Hz 63000 Sheet 3...

Page 44: ...74 4 CIRCUIT BREAKER AND ON OFF SWITCH 12A 1 12 EE 2778 POWER CORD 120V 1 13 EE 3133 1 ELEC PANEL 185 A AEP 230V 50 60 1 14 H 6424 4 NUT 1 4 20 HEX JAM 2 15 H 6424 6 NUT 3 8 16 HEX JAM 1 16 H 6910 404...

Page 45: ...4 0 Parts Lists 44 4 9 Main Asm Bottom Side Electrical Models SA 230V 50 Hz 63000 Sheet 3...

Page 46: ...ND ON OFF SWITCH 12A 1 8 EE 2778 1 POWER CORD 230V EURO 1 9 EE 3154 1 ELEC PANEL 185 SA 230V 50 60 1 10 H 6424 4 NUT 1 4 20 HEX JAM 2 11 H 6424 6 NUT 3 8 16 HEX JAM 1 12 H 6910 404 SCREW 1 4 20 X 1 2...

Page 47: ...4 0 Parts Lists 46 4 10 Main Asm Bottom Side Electrical Models A AEP 230V 50 Hz 63000 Sheet 3...

Page 48: ...CIRCUIT BREAKER AND ON OFF SWITCH 12A 1 12 EE 2778 1 POWER CORD 230V EURO 1 13 EE 3133 1 ELEC PANEL 185 A AEP 230V 50 60 1 14 H 6424 4 NUT 1 4 20 HEX JAM 2 15 H 6424 6 NUT 3 8 16 HEX JAM 1 16 H 6910...

Page 49: ...4 0 Parts Lists 48 4 11 Main Asm Clamp Models SA 120 230V 50 60 Hz 63000 Sheet 4...

Page 50: ...D GD 2 19 H 5254 606 SCREW 3 8 X 3 4 SHSS 2 20 H 5254 608 SCREW 3 8 X 1 SHSS 2 21 H 6123 30304 MACHINE KEY 188 X 188 X 500 2 22 H 6123 30312 MACHINE KEY 188 X 188 X 1 500 1 23 H 6417 4 NUT 1 4 20 HEX...

Page 51: ...4 0 Parts Lists 50 4 12 Main Asm Clamp Models A AEP 120V 60 Hz 63000 Sheet 4...

Page 52: ...D 2 19 H 5254 606 SCREW 3 8 X 3 4 SHSS 2 20 H 5254 608 SCREW 3 8 X 1 SHSS 2 21 H 6123 30304 MACHINE KEY 188 X 188 X 500 2 22 H 6123 30312 MACHINE KEY 188 X 188 X 1 500 1 23 H 6417 4 NUT 1 4 20 HEX 2 2...

Page 53: ...4 0 Parts Lists 52 4 13 Main Asm Clamp Models A AEP 230V 50 60 Hz 63000 Sheet 4...

Page 54: ...GD 2 19 H 5254 606 SCREW 3 8 X 3 4 SHSS 2 20 H 5254 608 SCREW 3 8 X 1 SHSS 2 21 H 6123 30304 MACHINE KEY 188 X 188 X 500 2 22 H 6123 30312 MACHINE KEY 188 X 188 X 1 500 1 23 H 6417 4 NUT 1 4 20 HEX 2...

Page 55: ...4 0 Parts Lists 54 4 14 Main Asm Knife All Models 63000 Sheet 5...

Page 56: ...06 DOWEL PIN 1 4 X 3 4 HD GD 2 13 H 5246 814 DOWEL PIN 1 2 X 1 3 4 HD GD 2 14 H 6417 4 NUT 1 4 20 HEX 2 15 H 6417 5 NUT 5 16 18 HEX 16 16 H 6909 403 SCREW 1 4 20 X 3 8 FLAT HEAD CAP 5 17 H 6909 416 SC...

Page 57: ...4 0 Parts Lists 56 4 15 Main Asm Front Shield All Models 63000 Sheet 6...

Page 58: ...UT 4 40 HEX KEP 2 12 H 6910 404 SCREW 1 4 20 X 1 2 BUTTON HEAD CAP 4 13 H 6910 410 SCREW 1 4 20 X 1 1 4 BUTTON HEAD CAP 1 14 H 6910 102404 SCREW 10 24 X 1 2 BUTTON HEAD CAP 1 15 H 6910 405SS SCREW 1 4...

Page 59: ...4 0 Parts Lists 58 4 16 Main Asm Backgauge All Models 63000 Sheet 7...

Page 60: ...CKGAUGE MACHINED 1 4 H 5246 406 DOWEL PIN 1 4 X 3 4 HD GD 1 5 H 6417 4 NUT 1 4 20 HEX 2 6 H 6910 406 SCREW 1 4 20 X 3 4 BUTTON HEAD CAP 6 7 H 6918 610 SCREW 3 8 16 X 1 1 4 SOCKET HEAD CAP 1 8 H 6938 4...

Page 61: ...4 0 Parts Lists 60 4 17 Main Asm Top Side Elec Models SA 120 230V 50 60 Hz 63000 Sheet 8...

Page 62: ...2 EE 3162 BOARD 1 3 H 6918 83203 SCREW 8 32 X 3 8 SOCKET HEAD CAP 3 4 H 6918 102403 SCREW 10 24 X 3 8 SOCKET HEAD CAP 3 5 H 7321 N8 WASHER 8 SAE PLAIN 3 6 H 7324 N6 WASHER 6 INT TOOTH 2 7 H 7327 N8 WA...

Page 63: ...4 0 Parts Lists 62 4 18 Main Asm Top Side Elec Models A AEP 120 230V 50 60 Hz 63000 Sheet 8...

Page 64: ...N HEAD CAP 2 6 H 6918 63208 SCREW 6 32 X 1 SOCKET HEAD CAP 2 7 H 6918 83203 SCREW 8 32 X 3 8 SOCKET HEAD CAP 3 8 H 6918 102403 SCREW 10 24 X 3 8 SOCKET HEAD CAP 3 9 H 7321 4 WASHER 1 4 SAE PLAIN 2 10...

Page 65: ...4 0 Parts Lists 64 4 19 Main Asm Covers and Labels Models SA 120 230V 50 60 Hz 63000 Sheet 9...

Page 66: ...Y ASM DIGITAL 1 8 H 6910 404 SCREW 1 4 20 X 1 2 BUTTON HEAD CAP 5 9 H 6910 404SS SCREW 1 4 20 X 1 2 BUT HEAD CAP STAINLESS 9 10 H 6910 63203SS SCREW 6 32 X 3 8 BUT HEAD CAP STAINLESS 4 11 H 6918 604 S...

Page 67: ...4 0 Parts Lists 66 4 20 Main Asm Covers and Labels Models A 120 230V 50 60 Hz 63000 Sheet 9...

Page 68: ...1 7 EE 3158 DISPLAY ASM DIGITAL 1 8 H 6910 404 SCREW 1 4 20 X 1 2 BUTTON HEAD CAP 5 9 H 6910 404SS SCREW 1 4 20 X 1 2 BUT HEAD CAP STAINLESS 9 10 H 6910 63203SS SCREW 6 32 X 3 8 BUT HEAD CAP STAINLES...

Page 69: ...4 0 Parts Lists 68 4 21 Main Asm Covers Labels Models AEP 120 230V 50 60 Hz 63000 Sheet 9...

Page 70: ...EE 3157 DISPLAY ASM PROGRAMMABLE 1 9 EE 3158 DISPLAY ASM DIGITAL 1 10 H 6910 404 SCREW 1 4 20 X 1 2 BUTTON HEAD CAP 5 11 H 6910 404SS SCREW 1 4 20 X 1 2 BUT HEAD CAP STAINLESS 9 12 H 6910 63203SS SCR...

Page 71: ...4 0 Parts Lists 70 4 22 Main Asm Accessories All Models 63000 Sheet 10...

Page 72: ...rts Lists 71 NO PART NO DESCRIPTION QTY 1 5064 CUT STICK PULLER 1 2 63073 KNIFE LIFTER ASM 1 3 A 12608 2 JOGGING AID 1 4 H 6913 1048 SCREW 5 8 11 X 6 HEX HEAD CAP 4 5 W 191 WRENCH 3 16 T HANDLE HEX AL...

Page 73: ...4 0 Parts Lists 72 4 23 Motor and Gearbox Assembly All Models 63002 Rev A...

Page 74: ...172 47 BEARING SLEEVE 2 11 A 10172 52 BEARING SLEEVE 2 12 A 10172 54 BEARING SLEEVE 2 13 E 1600 104 MOTOR 1 14 E 3128 1 BRAKE 1 15 H 6123 30306 MACHINE KEY 188 X 188 X 750 1 16 H 6417 6 NUT 3 8 16 HEX...

Page 75: ...4 0 Parts Lists 74 4 24 Magnet Assembly All Models 60052 NO PART NO DESCRIPTION QTY 1 60046 BLOCK HOOD HANDLE 1 2 60053 MAGNET RARE EARTH 1 3 H 21S 187 0500 ROLL PIN 3 16 X 1 2 1...

Page 76: ...25 Floor Stand Assembly All Models 63050 Rev A NO PART NO DESCRIPTION QTY 1 41014 SWIVEL CASTER WITH BRAKE 4 2 63051 STAND WELDMENT 1 3 H 6431 5 NUT 5 16 18 ACORN CAP 16 4 H 6913 505 SCREW 5 16 18 X...

Page 77: ...4 0 Parts Lists 76 4 26 Electrical Schematic Models SA 120V 60 Hz E 3148 1...

Page 78: ...4 0 Parts Lists 77...

Page 79: ...4 0 Parts Lists 78 4 27 Electrical Schematic Models SA 230V 50 60 Hz E 3148 2...

Page 80: ...4 0 Parts Lists 79...

Page 81: ...4 0 Parts Lists 80 4 28 Electrical Schematic Models A 120V 60 Hz E 3147 1...

Page 82: ...4 0 Parts Lists 81...

Page 83: ...4 0 Parts Lists 82 4 29 Electrical Schematic Models A 230V 50 60 Hz E 3147 2...

Page 84: ...4 0 Parts Lists 83...

Page 85: ...4 0 Parts Lists 84 4 30 Electrical Schematic Models AEP 120V 60 Hz E 3156 1...

Page 86: ...4 0 Parts Lists 85...

Page 87: ...4 0 Parts Lists 86 4 31 Electrical Schematic Models AEP 230V 50 60 Hz E 3156 2...

Page 88: ...4 0 Parts Lists 87...

Page 89: ...4 0 Parts Lists 88 4 32 Elec Interconnection Diagram Models SA 120 230V 50 60 Hz E 3150 2 Rev A...

Page 90: ...4 0 Parts Lists 89...

Page 91: ...4 0 Parts Lists 90 4 33 Elec Interconnection Diagram Models A 120 230V 50 60 Hz E 3150 4 Rev A...

Page 92: ...4 0 Parts Lists 91...

Page 93: ...4 0 Parts Lists 92 4 34 Elec Interconnection Diagram Models AEP 120 230V 50 60 Hz E 3150 3 Rev A...

Page 94: ...4 0 Parts Lists 93...

Page 95: ...4 0 Parts Lists 94 4 35 Electrical Power Panel Assembly Models SA 120V 60 Hz EE 3154 Rev D...

Page 96: ...4 0 Parts Lists 95...

Page 97: ...4 0 Parts Lists 96 4 36 Electrical Power Panel Assembly Models SA 230V 50 60 Hz EE 3154 1 Rev A...

Page 98: ...4 0 Parts Lists 97...

Page 99: ...4 0 Parts Lists 98 4 37 Electrical Power Panel Assembly Models A AEP 120V 60 Hz EE 3133 Rev E...

Page 100: ...4 0 Parts Lists 99...

Page 101: ...4 0 Parts Lists 100 4 38 Electrical Power Panel Assembly Models A AEP 230V 50 60 Hz EE 3133 1 Rev B...

Page 102: ...4 0 Parts Lists 101...

Page 103: ...4 0 Parts Lists 102 4 39 Relay Board Assembly Models SA A AEP 120V 60 Hz EE 3132 Rev C...

Page 104: ...4 0 Parts Lists 103 4 40 Relay Board Assembly Models SA A AEP 230V 50 60 Hz EE 3165 Rev A...

Page 105: ...4 0 Parts Lists 104 4 41 Display Assembly Models SA 120 230V 50 60 Hz EE 3164 Rev A...

Page 106: ...4 0 Parts Lists 105 4 42 Display Assembly Models A 120 230V 50 60 Hz EE 3158 Rev A...

Page 107: ...4 0 Parts Lists 106 4 43 Display Assembly Models AEP 120 230V 50 60 Hz EE 3157 Rev A...

Page 108: ...4 0 Parts Lists 107 NOTES...

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