Challenge EH-3C User 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.
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current, unsupported or no longer produced by The Challenge Machinery Company, and are
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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
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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
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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.

The Challenge Machinery Company
6125NortonCenterDrive
Norton Shores, MI 49441-6081 USA
ChallengeMachinery.com
F. 352-KT
August 2003
Serial Numbers 995774 & Up
MODEL EH-3C
PAPER DRILLING
MACHINE
Sold and Serviced by
TECHNICAL SERVICE
AND PARTS MANUAL

F.352-KT/EH-3C DRILL/AUG 03
ii
INTRODUCTION
WELCOME to the family of Challenge® users. Challenge has been developing and manufacturing Graphics Arts
Equipmentfor over100 yearsand istoday oneof theworld’s leadingproducers anddistributors ofPaper Cutters,
Paper Drills and Bindery Equipment.
SAFETYALERT! This symbol meansCAUTION OR WARNING: Personal safety instructions! Pay
special attention to the instructions in bold type. Personal injury may result if the precautions are not
read and followed. See SAFETY PRECAUTIONS,pagev.
•This machine is designed forONEPERSONOPERATIONONLY!
•Always DISCONNECT THE POWER before working on this machine.
•DONOT OPERATE WITH ANYGUARDSREMOVED! Replace all guards before operating.
•CRUSH HAZARD - Keep hands, hair, cleaning rags, & loose clothing away from drills.
FOR PARTS AND SERVICEcontact the Authorized Challenge Dealer from whom you purchased your machine.
Alwaysgive the SERIAL NUMBERandMODELofyour machinetoinsure thatthe correctpartsare sentassoon
aspossible.
Challenge® is a registered trademark of The Challenge Machinery Company. 6125 Norton Center Drive, Norton Shores, MI 49441-6081.
Copyright © 2003 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A.

iii
F.352-KT/EH-3C DRILL/AUG 03
TABLE OF CONTENTS
INTRODUCTION........................................................................................... ii
SAFETY PRECAUTIONS ..............................................................................v
CAUTION: POWER LOCK-OUTPROCEDURE .............................................v
WARNINGLABELDEFINITIONS..................................................................vi
1.0 MAINTENANCE .................................................................................. 1-1
1.1TROUBLESHOOTING ................................................................... 1-2
1.2ROUTINEMAINTENANCE ............................................................ 1-3
1.2.1 Daily ................................................................................... 1-3
1.2.2Weekly................................................................................ 1-3
1.2.3 Monthly ............................................................................... 1-3
1.2.4Yearly.................................................................................. 1-3
1.3ADJUSTMENTS ............................................................................ 1-3
1.3.1Table PositionAdjustment .................................................... 1-3
1.3.2 Belt Tightness Adjustment ................................................... 1-4
1.4 DRILL HEAD REPLACEMENT ...................................................... 1-5
1.4.1 Side Head Bearing Replacement .......................................... 1-5
1.4.2 Center Head Bearing Replacement ....................................... 1-6
1.5HYDRAULIC ................................................................................. 1-6
1.5.1RecommendedOils ............................................................. 1-6
2.0PARTSLISTS ..................................................................................... 2-1
MAIN ASSEMBLY - FRONT VIEW ...................................................... 2-2
MAIN ASSEMBLY - UPPER RIGHT VIEW........................................... 2-4
MAINASSEMBLY -LOWER RIGHTVIEW .......................................... 2-6
MAIN ASSEMBLY - TOP VIEW .......................................................... 2-7
MAINASSEMBLY -WIRING ............................................................... 2-8
ELECTRICALPOWER PANELASSEMBLY ...................................... 2-10
HYDRAULIC/BASEASSEMBLY ....................................................... 2-12
HYDRAULICPOWER UNITASSEMBLY ........................................... 2-14
HYDRAULICPOWERUNIT .............................................................. 2-15
TABLE ASSEMBLY .......................................................................... 2-16
BACKGAUGE ASSEMBLY ............................................................... 2-18
OPTIONALAUTO-TRIPBACKGAUGEASSEMBLY ........................... 2-20
SPINDLE HEAD ASSEMBLY, RIGHT HAND ...................................... 2-22
SPINDLE HEAD ASSEMBLY, LEFT HAND ........................................ 2-23
OPTIONALDRILL SHIELDKIT .......................................................... 2-24

F.352-KT/EH-3C DRILL/AUG 03
iv
NOTES

v
F.352-KT/EH-3C DRILL/AUG 03
SAFETY PRECAUTIONS
•This machine is designed and safeguarded for ONE PERSON operation. NEVER operate the machine
with more than one person.
•Safety of this machine is the responsibility of the user and operator. Use good judgement and com-
mon sense when working with and around this machine.
•READ and understand all instructions thoroughly before using the machine. If questions still remain,
call your Authorized Challenge Dealer - Failure to understand operating instructions may result in
personal injury.
•Only trained and authorized persons should operate the machine.
•DO NOT ALTER SAFETY GUARDS OR DEVICES, they are for your protection and should not be altered
or removed. Severe lacerations could result.
•DISCONNECT POWER before cleaning, lubricating, servicing, or making adjustments not requiring
power. See Power Lockout Procedure below.
•HIGH SPEED DRILL - Keep rags, loose clothing and long hair away form rotating drill. Personal injury
could result from items being caught on drill.
•ALWAYS WEAR SAFETY GLASSES when operating the drill machine.
•Have your electrician make sure the machine is properly grounded.
•Have your electrician check for sufficient power to operate the machine properly.
•OBSERVEALL CAUTION PLATES AND LABELSonthismachine.
•KEEP FOREIGN OBJECTS off table and away from drill.
•BE EXTREMELY CAREFUL when handling and changing the drills. Severe lacerations or dismember-
ment could result from careless handling procedure.
•KEEP THE FLOOR around the machine free of trim, debris, oil and grease.
•When replacing hydraulic parts, loosen the connections slowly to release pressure. Never loosen
connections with the machine running.
•If the machine sounds or operates abnormally, turn it off and consult the Trouble Shooting section of
this manual. If the problem cannot be corrected, have it checked by a qualified service person or
your Authorized Challenge Dealer.
•CRUSH HAZARD, keep feet off the pedal when handling paper under the clamp. DO NOT REST FOOT
ON PEDAL at any time!
•DO NOT REACH UNDER THE DRILL AND CLAMP AREA!
•DO NOT OPERATE WITH ANY GUARDS REMOVED! Replace all guards after adjusting, lubricating or
servicing the machine.
•SEVERE LACERATIONS - Contact with high speed drill could cause severe injury. Always turn ma-
chine off and wait for drill to stop before removing drill bits. Keep hands away from drill(s) when
operating.
CAUTION: POWER LOCK-OUT PROCEDURE
Formaximum safety when makingadjustmentsor
repairs to your machine, be sure to lock out the
main power control switch to which the machine
is connected. The switch should be thrown to the
OFF position and a padlock placed in the loop.
The key should be held by the person servicing
the machine.
(fig. i)
This safety symbol means CAUTION/WARNING - PERSONAL SAFETY INSTRUCTION. Read the
instructions because it has to do with safety. Failure to comply with the following instructions
may result in personal injury.

F.352-KT/EH-3C DRILL/AUG 03
vi
CUT/CRUSH HAZARD
SINGLEOPERATOR
SHOCK HAZARD
SHOCK HAZARD
HAZARDOUS AREA
Keep hands from under drills.
Donot operatewith morethan oneperson.
Disconnectpowerbeforeremovingcover. Replacecover
beforeoperation.
Disconnectpowerbeforeremovingcover. Replacecover
beforeoperation.
Disconnectpowerbeforecleaning,servicing,ormaking
adjustments not requiring power. Do not alter safety
guards or devices, they are for your protection. Re-
place all guards, do not operate with any guards re-
moved.
WARNING LABEL DEFINITIONS

1-1
F.352-KT/EH-3C DRILL/AUG 03
1.0 MAINTENANCE
NOTICE
The instructions on the
following pages are for the
use of trained service
personnel only!
Attempting to perform
repair and replacement
procedures without proper
training may cause machine
damage or operator injury!
PARTS CUSTOMERS: The Challenge Machinery Company provides parts with the express under-
standing that they are to replace parts found missing or no longer serviceable on equipment de-
signed and/or manufactured by Challenge. The Challenge Machinery Company assumes no liability
for any modification or alteration to any Challenge products, and any such modification or alteration
to any Challenge products is not authorized by The Challenge Machinery Company. Any modification
or alteration of any Challenge product will void any remaining warranty.
1.0 MAINTENANCE

F.352-KT/EH-3C DRILL/AUG 03
1-2
1.0 MAINTENANCE
WARNING: DISCONNECT THE POWER AND LOCK IT OUT whenever working on the machine
unless the instructions specifically require the machine to be powered (see Power Lockout
Procedure, page v). Some of the following tests may require the machine to be operational
for checking and adjusting. Be very careful that tools and other people are clear of moving parts, and
that the drill is not accidentally operated while adjustments are being made.
CAUTION: Whenever repairing hydraulic components, loosen connections slowly to bleed
off any trapped pressure.
Problem Area to Check Solution
1.Nopower Power to machine Connect Power
Fuse blown Replacefuse
2. Lack of power Reliefvalve inpumpmay bebad Clean or replace relief valve or pump.
or have dirt in it.
Check oil level - may be low. Add oil.
Check voltage at machine - may Remove other machinery on line or
below. provide a dedicated line.
3. Drill head won’t return Check lift springs - may be broken Pry up head, clean & oil shafts.
or stuck (replace if necessary).
Pull down shafts froze in frame. Pry up head, clean & oil shafts.
4. Drill head won’t come Check for broken lift spring - may Replace spring.
down be jammed.
Speedcontrol valveout ofadjustment Try to readjust, may have to replace.
ordefective.
5. Spindle motor stalls Dull drills. Sharpen drills.
Checkfor lowvoltage. (Seeabove).
Drive belt may be loose. Adjust belt tension. (See Adjustment
section of this manual).
Check for paper plugging drills Clean out hollow drills - We recom-
mend cleaning and soaking drills in
oilovernight.
1.1 TROUBLESHOOTING

1-3
F.352-KT/EH-3C DRILL/AUG 03
1.0 MAINTENANCE
1.2 ROUTINE MAINTENANCE
Productionlosses canbereduced ifgoodmaintenance
practicesare followed. Thefollowingsuggestions may
be helpful:
1. Recognize the fact that the user of hydraulic equip-
ment has more control over maintenance than the
manufacturer.
2. Operators should be familiar with use, care, and
limitations of the equipment. ALL OPERATORS
SHOULD READ THIS MANUAL COMPLETELY.
3. Use properly trained maintenance personnel.
4. Establish a program of systematic preventative
care for your equipment or put this machine on an
existing preventative maintenance program.
5. Analyze and isolate trouble before having any part
of the equipment dismantled.
6. Be aware of how your machine should sound and
perform. Ifthe machineisnot operatingproperly or
if it doesn’t “sound right”, stop running your job im-
mediately and try to identify the problem.
7. Call the dealer for any problems that cannot be
handledby your ownpersonnel.
1.2.1 Daily
1. Sharpenthe hollowdrills oftenand reset thespindle
adjusting knobs if needed.
2. Lubricate the hollow drill frequently with the lubri-
cating stick provided.
3. For better hollow drill life, remove the drills when
notin use, cleanout,and soakinlight oil. Wipe off
excess oil before drilling.
1.2.2Weekly
(or every 40 hours of operation)
1. Checkthe drivebelttightness andwear. The drive
belt must be kept tight or it will stall the motor and
plug or break the drills. See Section 1.3.2 for in-
structions on how to tighten the belt.
2. Clean and oil the guide bar shafts around frame.
3. Cleanand oiltherear supportbrackets.
1.2.3 Monthly
1.Check the hydraulic oil supply for the proper level.
Thischeck ismadeby removingthe rearpaneland
visually inspecting the level of the oil in the clear
reservoir. The oil should be filled to the fill line on
the tank. If your machine is equipped with a dip
stick on the breather cap, remove the cap and
checkthe dipstick. There shouldbe approximately
1/8” (3 mm) of oil on the stick.
Use only one of the recommended oils or an ISO
VG 100 Hydraulic Fluid equivalent. Oils other than
the recommended type will cause seals, cups and
O-ringsto deteriorate. SeeSection1.5.
1.2.4 Yearly
1. Check all adjustments.
2. Tighten all screws.
3. Change hydraulic oil in reservoir. Oil may have to
bechangedmoreoften if contaminationofanykind
gets in the oil. (Capacity: 11/2 Quarts/1.4liters)
4. Grease lift springs.
1.3 ADJUSTMENTS
1.3.1 Table Position Adjustment
Setthe backgaugeto the1”position. Drill afew sheets
of paper and measure the distance between the cen-
ter of each hole to the edge of the paper. If it is not 1”
(2.5 cm), loosen the (4) screws that mount the table to
the base and carefully move the table to compensate
for the error. Tighten the screws and drill some more
paper. Repeat this procedure until the holes measure
1” (2.5 cm).
CAUTION: Always disconnect the
power when cleaning, servicing, or
lubricating your drill, see Lock Out Pro-
cedures, pagev.

F.352-KT/EH-3C DRILL/AUG 03
1-4
1.0 MAINTENANCE
1.3.2 Belt Tightness Adjustment
Loosen the two set screws(fig. 1-1). Turn the Adjust-
ment Screw (fig. 1-1) to move the motor in and out as
needed. The belt must be tight enough that it does not
slip. Tighten both set screws when finished.
(fig. 1-1)

1-5
F.352-KT/EH-3C DRILL/AUG 03
1.0 MAINTENANCE
1.4.1 Side Head Bearing Replacement
1. Remove end plate “A” and shield “F” from shaft.
2. Slide head off shafts.
3. Remove chip chute “B” from head.
4. Remove pulley “H” from spindle.
5. Tap spindle “G” out from head.
6. Tap out bearings (must use rod from opposite end
of each bearing).
7. Tap the upper bearing (S-706) in place using a
piece of wood between the hammer and the bear-
ing (an old drill block works fine).
8. Placethe lowerbearing (S-706)on the spindleand
tapin the spindleandbearing simultaneously. Use
the wood block from the previous step to protect
the spindle.
9. Replace the chip chute and pulley.
1.4 DRILL HEAD REPLACEMENT
Through normal use, bearings will wear and need re-
placing. Signs of wear are excessive noise, heat, or
loose spindles.
Replacement Procedure:
1. Remove cover.
2. Remove belt.
3. Remove chip pan assembly.
CAUTION: Always disconnect the
power when cleaning, servicing, or
lubricating your drill, see Lock Out Pro-
cedures, pagev.
(fig. 1-2)

F.352-KT/EH-3C DRILL/AUG 03
1-6
1.0 MAINTENANCE
CAUTION: NEVER USE Automatic
Transmissionoil or brake fluidasasub-
stitute! Oils other than the recom-
mended type will cause seals, cups and O-rings
to deteriorate. Unsafe operating conditions will
result.
1.4.2 Center Head Bearing Replacement
1. Raisehead asfar aspossible byturning knob“C”.
2. Removepulley“H”.
3. Removechip chute“D”.
4. Remove cutting block from table.
5. Backoffbolts“E”approximately1/2”andslidehead
up on rods so there is enough clearance between
table and bottom of head to allow spindle to be re-
moved(place block betweentableand headtohold
in up position).
6. Tap out spindle (down).
7. Tap out bearings (must use rod from opposite end
ofeachbearing).
8. Taptheupperbearing(S-706)inplaceusingapiece
of wood between the hammer and the bearing (an
old drill block works fine).
9. Placethe lowerbearing (S-706)on the spindleand
tap in the spindle and bearing simultaneously. Use
the wood block from the previous step to protect
the spindle.
10. Replace the chip chute and pulley.
11. Adjust head for drill depth.
1.5 HYDRAULIC
Through normal use, hydraulic systems gum up and
seals wear. Signs of wear are hydraulic leaks and er-
ratic operation of the vertical speed. Check with your
Authorized Challenge Dealer for a current repair and/or
replacementpolicy. Replaceoil yearly. (Capacity:11/2
Quarts/1.4liters)
1.5.1RecommendedOils
Oil Name Distributor
Rykon No. 100 .............................................AMOCO
DuroAW Oil465................................................Arco
AW Machine Oil 100.....................................Chevron
Pacemaker XD No. 100 .....................................Citgo
Super Hydraulic 100...................................... Conoco
NutoH-100 .....................................................Exxon
Harmony100AW ...............................................Gulf
HO 2A Hydraulic Oil...................................Lubriplate
DTE No. 18.......................................................Mobil
Pennzoil AW 100 .........................................Pennzoil
MagnusA Oil215 ..........................................Phillips
Tellus100 ......................................................... Shell
EnergolHLP100 .............................................Sohio
Industron 100...........................Std. Oil Indiana/Boron
Sunvis851WR............................................. Sunoco
Rando HD 100 ...............................................Texaco
Unax AW 100 .......................................Union Oil Co.

2-1
F.352-KT/EH-3C DRILL/AUG 03
2.0 PARTS LISTS
2.0 PARTS LISTS
MAIN ASSEMBLY - FRONT VIEW ............................................................ 2-2
MAIN ASSEMBLY - UPPER RIGHT VIEW ................................................. 2-4
MAINASSEMBLY -LOWER RIGHTVIEW ................................................ 2-6
MAIN ASSEMBLY - TOP VIEW ................................................................. 2-7
MAINASSEMBLY -WIRING ..................................................................... 2-8
ELECTRICALPOWER PANELASSEMBLY ............................................ 2-10
HYDRAULIC/BASEASSEMBLY ............................................................. 2-12
HYDRAULICPOWER UNITASSEMBLY ................................................. 2-14
HYDRAULICPOWERUNIT..................................................................... 2-15
TABLE ASSEMBLY ................................................................................ 2-16
BACKGAUGE ASSEMBLY ..................................................................... 2-18
OPTIONALAUTO-TRIPBACKGAUGEASSEMBLY ................................. 2-20
SPINDLE HEAD ASSEMBLY, RIGHT HAND ............................................ 2-22
SPINDLE HEAD ASSEMBLY, LEFT HAND .............................................. 2-23
OPTIONALDRILL SHIELDKIT ................................................................ 2-24

F.352-KT/EH-3C DRILL/AUG 03
2-2
2.0 PARTS LISTS
MAIN ASSEMBLY - FRONT VIEW
A-5846-9 SHEET 1 OF 5 (REV. G)

2-3
F.352-KT/EH-3C DRILL/AUG 03
2.0 PARTS LISTS
MAIN ASSEMBLY - FRONT VIEW
A-5846-9 SHEET 1 OF 5 (REV. G)

F.352-KT/EH-3C DRILL/AUG 03
2-4
2.0 PARTS LISTS
MAIN ASSEMBLY - UPPER RIGHT VIEW
A-5846-9 SHEET 2 OF 5 (REV. J)

2-5
F.352-KT/EH-3C DRILL/AUG 03
2.0 PARTS LISTS
MAIN ASSEMBLY - UPPER RIGHT VIEW
A-5846-9 SHEET 2 OF 5 (REV. J)

F.352-KT/EH-3C DRILL/AUG 03
2-6
2.0 PARTS LISTS
MAIN ASSEMBLY - LOWER RIGHT VIEW
A-5846-9 SHEET 3 OF 5 (REV. A)

2-7
F.352-KT/EH-3C DRILL/AUG 03
2.0 PARTS LISTS
MAIN ASSEMBLY - TOP VIEW
A-5846-9 SHEET 4 OF 5 (REV. D)