Challenge SPARTAN 120 Technical reference manual

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 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 t hese 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.

SPARTAN 120
SPARTAN 120SPARTAN 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
Serial Numbers 99100 & Up
INSTRUCTION AND
PARTS MANUAL
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

1.0 Introduction
2
1.0 Introduction
This manual is designed to help you get the most from your Challenge equipment. Keep this 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! If you follow precautions and instructions, you should
have years of trouble-free operation. Contact your Authorized Challenge Dealer.
FOR PARTS AND SERVICE, contact the Authorized Challenge Dealer from whom you purchased
your machine. Use the illustrations and parts lists at the back of this manual to identify the correct
parts needed. Always give the SERIAL NUMBER and MODEL of your machine to insure the correct
parts are sent as soon as possible.
Take a few minutes right now to RECORD YOUR MACHINE SERIAL NUMBER in the space
provided on the front cover of this manual. Also be sure to fill out the warranty card accompanying
this manual and return it 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 •Norton Shores •MI 49441-6081.
CHALLENGE MODEL Spartan 120 SERIAL NUMBER
ATTN COMPANY
ADDRESS
CITY STATE/PROVINCE ZIP
PHONE DATE INSTALLED
DEALER NAME & CITY
* WARRANTY INFORMATION *
PLEASE REVIEW THE ENCLOSED WARRANTY INFORMATION SHEET
It is very important that you read and understand the conditions outlined in the Warranty Information
Sheet attached to the outside of the shipping container of your machine.
The Warranty Information Sheet must be filled out completely and returned to THE CHALLENGE
MACHINERY COMPANY in order for the warranty to be issued for this machine.
Challenge® is a registered trademark of
The Challenge Machinery Company•6125 Norton Center Drive•Norton Shores•MI 49441-6081
Copyright© 2000-2006 by The Challenge Machinery Company. All rights reserved. Printed in the USA.
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

1.0 Introduction
3
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
6.0 User’s Guide .................................................................................................................................. 10
6.1 Preset the Backgauge ................................................................................................................10
6.2 Set the Cutting Dimension..........................................................................................................10
6.3 Load Paper .................................................................................................................................10
6.4 Make the Cut ..............................................................................................................................10
6.5 Emergency Power Shut-Off Switch ............................................................................................10
6.6 Cut Stick Rotation and Replacement..........................................................................................11
7.0 Appendix A - Maintenance Guide.................................................................................................. 12
7.1 Mechanical System.....................................................................................................................13
7.1.1 Lubrication...........................................................................................................................13
7.1.2 Changing the Knife..............................................................................................................14
7.1.3 Knife Disposal......................................................................................................................15
7.1.4 Hood Switch Adjustment.....................................................................................................15
7.1.5 Hood Plunger Adjustment ...................................................................................................16
7.1.6 Backgauge Preset Position Adjustment..............................................................................16
7.2 Hydraulic System........................................................................................................................16
7.2.1 Hydraulic Fluid Check .........................................................................................................16
7.2.2 Replacing Hydraulic Fluid....................................................................................................17
7.2.3 Hydraulic Fluid Compatibility List ........................................................................................18
7.2.4 Oil Absorber Replacement..................................................................................................18
7.3 Electrical System........................................................................................................................18
7.3.1 Fuse Check and Replacement............................................................................................18
8.0 Appendix B - Parts List................................................................................................................... 20
8.1 Mechanical..................................................................................................................................20
8.1.1 Main Assembly- Arch Cover/Hood......................................................................................20
8.1.2 Main Assembly- Arch Cover/Hood Parts List......................................................................21
8.1.3 Main Assembly- Frame, Front View....................................................................................22
8.1.4 Main Assembly- Frame, Front View Parts List....................................................................23
8.1.5 Main Assembly- Frame, Rear View.....................................................................................24
8.1.6 Main Assembly- Frame, Rear View Parts List.....................................................................25
8.1.7 Main Assembly- Base..........................................................................................................26
8.1.8 Main Assembly- Base Parts List..........................................................................................27
8.1.9 Main Assembly- Lead-screw and Table..............................................................................28
8.1.10 Main Assembly- Lead-screw and Table Parts List............................................................29
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

1.0 Introduction
4
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. B Panel Assembly- Electrical Controls....................................................36
8.2.3 EE 2895 Panel Assembly- Electrical Controls Parts List....................................................37
8.2.4 S-1781-85 Fuse Replacement Label..................................................................................38
8.3 Hydraulic ....................................................................................................................................39
8.3.1 H-549 Hydraulic Schematic ................................................................................................39
8.3.2 H-549 and H-549-1 Hydraulic Power Unit ..........................................................................40
9.0 Appendix C- Troubleshooting.........................................................................................................41
10.0 Appendix D- Safety System Tests................................................................................................42
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

2.0 Safety
5
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.
•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.
•Do not alter safety guards or devices. They are there for your protection. Severe laceration or
dismemberment may result.
•Disconnect power before cleaning or performing maintenance. See Section 2.2 , Power Lockout
Procedure.
•Observe all caution labels on this machine.
•Be extremely careful when handling knives. Always use the guarded knife lifter provided in the
toolkit. Severe lacerations or dismemberment may result from careless handling procedures.
•Never place your hands under the knife/clamp.
•When replacing hydraulic parts, loosen the connections slowly to relieve pressure. Never loosen
connections while the machine is running. Allow hydraulic fluid to cool before performing
maintenance on the hydraulic system.
•If the machine operates abnormally, consult Appendix C- Troubleshooting.
2.2 Power Lockout Procedure
For maximum safety while making adjustments or repairs to your machine, be sure to disconnect
power to the machine. Disconnect the power plug from its socket.
Figure 1 – Main Power Disconnect
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

2.0 Safety
6
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.
SHOCK HAZARD
Disconnect power before removing cover. Replace cover before operation.
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

3.0 Packing List
7
3.0 Packing List
Part No. Description Qty.
CMC-120 Basic Machine 1
50042 Jogging Aid 1
50056 Cut Stick 4
50051 Knife Lifter 1
K-50043 Tool Kit 1
Tool Kit Includes:
41121 Felt Washer 4
5064 Cut Stick Hook 1
W-107 7/32 Hex “T” Wrench 1
W-137 5/32 Hex Wrench 1
W-141 1/8 Hex Wrench 1
36134 Pocket Pull Handle 4
E-889-35 1 Amp Slo-Blo Fuse 1
E-889-32 10 Amp Slo-Blo Fuse 1
H-6918-406 1/4-20 X 3/4 socket head cap screw
for use with optional stand P/N 35470 4
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

4.0 Specifications
8
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. 7.86 kN
Clamping Force 785 lbs. 3.5 kN
Overall Height 22.4 in. 56.8 cm
Overall Width 23.5 in. 59.7 cm
Overall Length 34.4 in. 87.4 cm
Net Weight 230 lbs. 104 kg
Shipping Weight 250 lbs. 113 kg
Miscellaneous Specifications
Current 11 Amps
Voltage Requirements 120 VAC / 60Hz
or
220 VAC / 50 Hz
Power Consumption 0.75 HP 0.56 kW
Operating Pressure 1000 PSI 6895 kPa
Oil Capacity 1.5 qt. 1.4 L
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

5.0 Installation Guide
9
5.0 Installation Guide
5.1 Inspecting Shipment
Your Spartan cutter 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 crate against the packing list on page 7. Make sure
there are no missing items.
5.2 Unpacking
Remove the packing materials and braces from the top portion of the skid and discard. Use a safe,
material-handling device, such as a pallet jack, to move the cutter with skid next to the installation
location. Note that the installation location must have a 120 VAC (or 220 VAC) wall outlet nearby.
The machine may be lifted from 4 handle locations around the cutter. These handle locations may be
used with appropriate lifting devices.
5.3 Moving
The machine should only be moved using a stable material-handling device that is low to the ground.
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.
5.4 Setup
Once the machine has been placed in its permanent location, simply plug it into a nearby 120 VAC
wall outlet. A knife has been shipped pre-installed. Remove the packing materials. Insert the four
pocket pull handles into the rectangular cutouts in the sides of the cutter. The machine is ready to
use.
If you purchased the optional stand, P/N 35470, assemble the stand and place the machine on top.
Align (4) holes in the top of the stand with (4) holes in the underside of the cutter. The tool kit
contains (4) 1/4-20 x 3/4" cap screws. Run these through the underside of the holes on the stand.
Make sure they enter the clearance holes on the underside of the machine. These screws will
prevent the cutter from being pushed off the stand.
5.5 Cleaning
It may be necessary to clean the cutter after installation. It may be cleaned with a solution of dish
soap and water. Do not use a dripping wet cloth. The cloth should be squeezed out prior to wiping.
Free running liquid may damage the digital display on the right hand side of the table surface. Do not
use petroleum or acid based solvents to clean the machine. Damage may result.
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!