User Manual
Contents
1. o 7422 1 ASSEMBLY STOP ROD 6918 612 SCREW 3 8 16 1 1 2 SOC HD CAP 6414 4 SCREW 1 4 20 X 1 BUTT HD 12 H 324 8 WASHER 1 4 SHAKEPROOF LOCK 13 5254 606 BOLT 3 8x3 4 SHOULDER 14 H 5247 5 NUT 5 16 18 FLEX 15 7411 CLAMP BAR 1 8 0 1 2 1459 1 BUSHING 3 4 16 5 1882 FIXTURE PIPE CLAMP 17 519 1 NUT 3 4 CONDUIT LOCK 4 pros ME __ 1 S 1884 EYEBOLT 1 4 2 5 16 LONG 21 22 H 6431 4 NUT 1 4 20 ACORN PLATED 23 S 1885 EYEBOLT 03 8 3 5 16 LONG 25 7321 6 WASHER 3 8 PLATED 26 7524 12 WASHER 3 8 SHAKEPROOF LOCK 28 H 6918 405 SCREW 1 4 20 X 5 8 SOC HD CAP 29 5 1885 HANDLE W SCREW 30 7401 DOOR 31 7321 68 WASHER 1 2 PLATED 55 H 5254 812 SCREW 1 2 SHOULDER 1 1 2 LONG 34 7437 LABEL PADDY WAGON 35 5 1886 PLASTIC END CAP 4 36 H 6961 1006 WOODSCREW 10 X 3 4 FLAT HD 37 H 6442 6 NUT 3 8 16 NYLOC HEX 39 7427 SPACER 40 6414 6 NUT 3 8 16 WHIZ LOCK 41 W 175 CASTER WRENCH NOT SHOWN 42 7432 CLUTCH DISC 43 A 74353 SPRING 44 A 7434 SWIVEL 1046 45 A 7455 SLIDING HEAD WHITAKER 800 243 9226 46 A 7436 SCREW amp HANDLE 47 5 1781 17 LABEL CAUTION2. Install the four casters into the bottom of the stand and tighten with the caster wrench supplied Figure 3 Figure 3 Set the stand assembly upright position the table assembly on the stand and while one person holds the table assembly Figure 4 Figure 4 WHITAKER 800 243 9226 W 5 0 Assembly Instructions The other person should insert the pivot screw with a large washer between the stand and the table frames Figure 5 d L 1 907 K Figure 5 Place a second large washer on the bolt then secure one of the smaller washers with one of the hex nuts Repeat on the opposite side Figure 6 Figure 6 CAUTION PINCH POINT While assembling machine care should be taken when mounting the table assembly onto the stand Tilt the top section back and rest it on one of the filler boxes Figure 7 Figure 7 WHITAKER 800 243 9226 W 5 0 Assembly Instructions Attach the Stop Rod to the bottom of the table with the shoulder bolt and flex lock nut Use the two remaining 3 8 polished washers between the U and the brace if necessary to fill the gap Figure 8 Shoulder Bolt Lock Nut l n Polished Washers Figure 8 Thread a hex nut onto the Stop Rod all the way to the top of the threads Figure 9 Figure 9 Guide the bottom of the Stop Rod through the hole in the cross brace as you tilt the top of the padder to the upright position Figure
3. Plated Hex Jam Nut 3 8 x 1 1 2 Soc Hd Stop Screw 10 x 34 Flat Head Wood Screw WIWHITAKER 800 243 9226 4 0 Specifications 4 0 Specifications Description Inch Units Metric Units Maximum Pile Width 23 1 2 60cm Maximum Pile Height Fits easily through any standard 32 81cm door Dimensions Z gt 30 x 30 ___ 66 j 76 Challenge reserves the right to make changes to any product or specification without notice and without incurring responsibility to existing units W WHITAKER 800 243 9226 5 0 Assembly Instructions 5 0 Assembly Instructions You will need the following tools to assemble your Paddy Wagon e Phillips Screwdriver e 1 4 Hex Wrench and e 9 16 Open End Wrench Immediately after unpacking check off parts received against the packing list Also examine for any physical signs of damage incurred during shipment The machine is inspected before and after packaging at our plant The responsibility for filing a claim against the carrier for damages incurred during shipment rests with the receiver of the goods FOB our factory Figure 2 Two people should be used to take the base and top out of the box Figure 2 They re fairly heavy and awkward to handle for one person If you don t have two people carefully cut the side out of the box and slide the pieces onto the floor WHITAKER 800 243 9226 W 5 0 Assembly Instructions
4. the stand tubes Note that two of the caps have a portion cut off These are to be installed on the top of stand tubes to clear the pivot bolts Figure 14 Figure 14 Attach the handles to both doors and the padder is ready for work Figure 15 Figure 15 WHITAKER 800 243 9226 12 W 6 0 Operating Instructions 6 0 Operating Instructions CAUTION Always lower top section slowly Do not allow top to free fall into position Lift the stop rod to tilt the machine forward load the paper against the doors and the side pipe tap any loose sheets flush to the doors Figure 16 You can load the paper to within 5 inches of the top brace and the padder will still be steady It s designed to hold a full load but you must leave room at the top for the clamping bar and clamps Figure 16 Place the clamping bar on top of the stack against the doors If you re padding 2 stacks they should be of equal height so you get even clamping If you re just padding one side hold the clamping bar in place until you can bring the clamp down to hold it Tighten the stack side first and even it out with a turn on the other side when it needs it Figure 17 Figure 17 To bring the Quick Release Clamp down to the Clamping Bar just squeeze the lock and it will slide easily Figure 18 on page 14 The clamp won t come back up without unlocking 13 WHITAKER 800 243 9226 W 6 0 Operating Instructions Figu
5. 10 Figure 10 WHITAKER 800 243 9226 10 W 5 0 Assembly Instructions Tilt the top back slightly and slide the spacer onto the Stop Rod Then thread the plated weldnut onto the Tilt Rod Adjust the hex nut above the spacer until it and the Tilt Rod will just slide freely into the hole in the cross brace Next tighten the weld nut against the tube Be sure the weldnut is positioned side to side in the same direction as the center brace If necessary loosen the nut slightly reposition the weld nut and tighten the nut Figure 10 on page 10shows the weld nut in the vertical lock position Install the 3 8 16 nyloc nut against the weldnut Figure 11 shows the Stopper in the Tilt position Figure 11 To release the locking mechanism lift up on the handle and tilt the top of padder back Figure 12 Install a hex nut on each of the two leveling screws and insert through the frame under the table Figure 13 W WHITAKER 800 243 9226 5 0 Assembly Instructions CAUTION Always lower top section slowly Do not allow top section to free fall into position These are used as stops when the padder is in the vertical position These should be adjusted to prevent uneven alignment of the padder Tilt the padder to the vertical position and tighten the screws until they make contact and adjust them so they have equal pressure on each side Then tighten the jam nuts Insert the plastic End Caps onto the ends of
6. 2011 WIWHITAKER 800 243 9226 1 0 Introduction 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 CAUTION 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 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 Be sure to fill out the warranty card accompanying your machine 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 e Norton Shores e MI 49441 6081 ee IP DEALER NAME WARRANTY INFORMATION It is very import
7. 3 9226 W 2 0 Safety 2 0 Safety 2 1 Precautions W 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 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 your protection Severe personal injury may result Observe all caution labels on this machine CRUSH HAZARD Keep hands from under paper clamp KEEP THE FLOOR around the machine free of trim debris oil and grease the machine operates unusually have it checked by a qualified service person or your Authorized Challenge Dealer DO NOT STAND OR SIT ON THE MACHINE WHITAKER 000 243 9220 3 0 Packing List 3 0 Packing List Pa Description Qty Table Assembly Stand Assembly End Caps Top rt No End Caps Bottom Clamp Bar Caster Caster Wrench Handle Stop Rod Assembly Plastic Handle Stop Rod Plated Spacer Plated Weldnut 3 8 x 3 4 Shoulder Bolt 5 16 18 Flex Lock Nut 3 8 Polished Washer 5 Plated Washer 2 x 1 1 2 Shoulder Bolt 3 8
8. ant 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 e 6125 Norton Center Drive e Norton Shores MI 49441 6081 Copyright 1999 2011 by The Challenge Machinery Company All rights reserved Printed in the U S A 2 800 243 9226 1 0 Introduction TABLE OF CONTENTS TOTO GUC oru u uuu san uu E E N 2 4 UON 4 TOFA KDO EIST IO IOS sss sss sss 5 PECCA S 6 OPS Se AON MAS UIC Oi u E A 7 OCDE r INS rir 13 UTO q E 16 8 0 Drawings 17 8 1 Main Assembly A 7400 Rev Q cccccccccccccccsseeceeeeeeeseceeecaeseceeeeeaessceeseeeueeeeeseeaeeeeeesaaaeeeeeesenes 17 9 2 Mam Ass embiy A 7400 REV Q 18 WHITAKER 800 24
9. ity ask the pressman to watch the counter on the press and slip a strip of paper in to mark the pads You can then insert the chipboard as you jog and load the job that s not possible use a counter gauge Count out one pad measure it with the gauge and count the rest Brushing With regular paper and regular compound two thin coats will work better than one thick one When you re applying the compound try to put the second coat on until the first coat is dry or the brush will stick to the compound of the first coat and ruin it To speed up the process a hot air hair dryer can be used to decrease the drying time Since you have to wait 10 or 15 minutes for the compound to dry take advantage of the wheels on the PADDY WAGON and roll it into the corner while you work on something else The Compound Regular padding compound tends to lose moisture the more it s used so by the time you get half way through the bottle it s pretty thick To thin it out again just add a little water and stir it up Don t add too much or the compound will be too thin and curl the edge of the paper NCR When padding NCR or self bonding papers that must absorb the compound don t use too much pressure on the clamps The heavy pressure will squeeze the edge of the paper too tight and harden it so the compound can t sink in One coat usually works fine with this type of compound Make sure the paper is good and dry before you release the pressure
10. on the bar or the sets may not separate like they should Separating the Pads To cut the pads apart use an ink knife paint scrapper or kitchen knife If the knife s edge is too sharp or square it will cut into the paper rather than separate the pads A rounded blade seems to work the best Try to time the drying times you could use an egg timer with a bell if you re inclined to forget things when you re busy It ll make cutting the pads apart easier and neater If you separate them too soon the pads will tend to break apart If you wait too long the compound will harden and cut very roughly making the pads look sloppy Wait about 15 minutes drying time on the second coat or when it s dry to the touch Cleaning The edge of the clamping bar and the table edge were designed to be easy to clean Just use your padding knife to scrape the dried compound off the metal edges If you want it really clean finish up with a wet rag or sponge W WHITAKER 800 243 9226 8 0 Drawings amp Schematics 8 0 Drawings amp Schematics 8 1 Main Assembly A 7400 Rev Q AO Q FULL SCALE VIEW A vy WHITAKER ITAKER 800 243 9226 K 8 0 Drawings amp Schematics 18 8 2 Main Assembly A 7400 Rev Q NO PART NO DESCRIPTION OF ACCESSORIES 1 H 6416 616 2 3 8 WELDNUT PLATED S 1881 1 CASTER SWIVEL 5 DIA 6 4 729 8 1 G N
11. re 18 To release a tightened clamp loosen the wing screw to release some pressure then push up on the lock It will release and slide up easily Tighten the wing screws of the clamps until they are snug Figure 19 a p P Figure 19 CAUTION Do not allow the Paddy Wagon to drop into position Hold as shown in Figure 20 and ease into the upright position Tilt the padder to the vertical position as shown Figure 20 Figure 20 WHITAKER 800 243 9226 14 W 6 0 Operating Instructions CAUTION Do not stand on the machine to tilt the top section back into vertical position Open the doors by lifting the handles and swinging them out Figure 21 Figure 21 Paint the padding compound on the paper and spread it out thinly and evenly Let it dry about 10 minutes or until it s dry to the touch Figure 22 Figure 22 Paint on the second coat and wait about 10 or 15 minutes or until its dry to the touch Release the clamps the pads can be cut apart with an ink or table knife 15 WHITAKER 800 243 9226 W 7 0 Padding Tips 7 0 Padding Tips Loading The Paddy Wagon is on wheels to save you time while handling paper You can load it directly from the cutter after a trim or you can take it out of the press jog it and load it directly into the padder there Then roll it into the bindery department to be padded Counting When you re making a batch of pads of the same quant
12. ual 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 W WHITAKER 800 243 9226 INSTRUCTION AND PARTS MANUAL PADDY WAGON PADDING PRESS Sold and Serviced by The Challenge Machinery Company 6125 Norton Center Drive Norton Shores MI 49441 6081 USA ChallengeMachinery com May
13. www WhitakerBrothers 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 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 man
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