User Manual
Contents
1. nnne 74 SLITTER SHAFT ASSEMBLY COMPONENTS 76 SLITTER SHAFT ASSEMBLY COMPONENTS 77 ROLLER REPLACEMENT REPAIR 78 SPECIFICATIONS Stock Handlin Maximum Sheet Size 14 x 20 35 6 cm x 50 8 cm Minimum Sheet Size 4 x 6 10 2 cm x 15 2 Paper Weight 9 bond to 654 cover 34 g m to 176 g m Number of Plates 2 Fold Plate Depth plate 1 2 to 17 5 1 cm to 43 2 cm plate 2 2 to 9 5 1 cm to 22 9 cm Fold Roller Diameter 1 1 2 3 8 cm Roller Adjustments Roller Calipers Fold Rollers 820 Rubber 870 Combination rubber steel Maximum Speed 30 000 Sheets Hour 8 1 2 x 11 A1 Dimensions Overall Height 25 63 5 cm Overall Length 61 5 156 2 cm Overall Width 25 63 5 cm Net Weight approximate 275 lbs 124 kg Shipping Weight approximate 300 lbs 135 k Electrical Standard Motor 120 Volt 01096 60 Hz 1 Phase 15 Amps Service size 20 Amps Optional Motor 240 Volt 010 50 Hz 1 Phase 10 Amps Service Size 15 Amps Sound Emission A Weighted sound pressure level at operator level 6 ft 1 83m folding 20lb 759 8 1 2 x 11 216X279mm Machine Folding 91 dB A Weighted sound power level at operator level 6 ft 1 83m folding 2010 75g n 8 1 2 x 11 216X279mm Machine Folding 101 dB Challenge reserves the right to make changes to any product2. 5 3109193939 144905 310 143234 018 016 VOL 3504 018 0176 VELE 3504 4 2 35013 Agog 35013 JIALS OHQ3 VACL OLE H3AOO MOVE 54140553997 40 NOlLdlMd S3 sale ele ATANASSV ALV Id MOVE 028 068 61 800 243 9226 WHITAKER ub gt 8ONM 27 2 ONOT ONENL NiHHS LL 901 ANNOYS SOLIO3NNOO ol HOLMS 4015 18 15 WEN 318 70 0992 33 6 NOT MIN ON VO 08 688 3 8 028 ISMVA3N 13141000 69752 2 Mib3AOUN3l0d gu Jae EE SE OSI MIND SNI ATINA 06 1 NNOO lt 2 21 3 20 53 0553202 40 NOlLdlHOS3d ON LAVd ON HOLIMS 4015 OL 0815 33 A18N3SSV T3NVd 1 028 F 669 D 820 870 Jan 98 800 243 9226 5 WHITAKER W HOIIMS 4015 AONADYAWA Ol MIN vb H 6y8 3 LI 950 MONO SNI ATINA D 9 1 NNO2 EC 9 pO OL JOOMd3wvHsS 9f v 7 ee aff LIN Sh BEER CN le MOSN3SOlOHd ATenassy 499233 A YHMOUNHOd WSV Java GHT 3 emere INS HEINNO9 TEN S3boS5309v 40 2530 Sto 69
3. Vacuum Feed Sheet Separator Feeding Bleeder Valve Vacuum Adjustment NET T T wil Roller Caliper Quick Set Up JM iere SPECIAL APPLICA e RIGHT ANGLE CROSSFOLD SYSTEM MAO m Conveyor Set OPTIONAL CROSSFOLD CONVERSION KIT 35537 Wi zu d r rcr Vacuum Pump Compressor General Inspection nennen nnne _ MODEL 820 MAIN ASSEMBLY Right Hand Side MODEL 820 MAIN ASSEMBLY Front View MODEL 870 MAIN ASSEMBLY Left Hand Side MODEL 870 MAIN ASSEMBLY Right Hand Side MODEL 870 MAIN ASSEMBLY Front View FOLDPLATE ASSEMBLY 1 FOLDPLATE 5 RI
4. 1 aso li 158 105 79909 2208 7 0 NO _ 2 e 5 v 8 CN CA CA ON CA Un Un PIVOT DEFLECTOR PIN 3 16 X 1 2 SEL LOC FOLDPLATE SUPPORT 7324 48 WASHER 8 INTER LOCK 6910 83203 SCREW 48 32 x 3 8 BUT HD SOC CAP 10644 2 COLLAR 1 2 1 0 STEEL 18 35187 ADJUSTMENT KNOB 19 11288 10 WASHER SPACER 35065 CHANNEL 35066 FOLD PLATE ANGLE SPACER GUIDE BLOCK PAPER STOP ADJUSTMENT KNOB NUT 410 24 HEX SCREW 410 24 X 3 8 BUTTON HD SCALE FOLDPLATE ECCENTRIC FOLD PLATE WASHER INT TOOTHLOCK LABEL FOLDPLATE MICRO ADJUSTMENT ON 1 NIJ O 35072 957 5 6423 10 6910 102403 5075 5081 7324810 11116 N CA 28 9 CA WHITAKER 6800 243 9226 43 FEEDER ASSEMBLY 35100 2 L mn e 9 45 C T 4 d 49 5 AN e f amp ae mE 54 urat In 50 Gel 56 DE WHITAKER F 669 D 820 870 Jan 98 WAKER 800 243 9226 FEEDER ASSEMBLY F 2 REV 35100 WSV 318vl 39334 Ea 135 205 B G X 20 8 5 012 8 8 lt 60 v9 IshvaaN ava 31 1 60 e9 LNB v
5. no 77703747 87 00711 2 276 MUFFLER PNEUMATIC 3 4 STR Far 1 REDUCER 3 4 MALE 3 4 FEMALE NIPPLE 3 8 CLOSE SCREW 5 16 18 x 2 4 HEX HD CAP LOCKWASHER 5 16 MEDIUM WASHER 5 16 STANDARD 45165 1 BASE PUMP 35164 RUBBER SCREW 3 8 16 x 1 HEX HD 3 LOCKWASHER 3 8 MEDIUM WASHER 3 B STANDARD CABLE with plug 6405 1612 NIPPLE 1 CLOSE ADAPTER 2 4 17 MALE STR else 19 5 190 6 BUSHING HEYCO al E 1237 1 Zu 267 NIPPLE 1 CLOSE 5 EZ E E CN NIA ho N WHITAKER 800 243 9226 STANDARD ACCESSORIES 11214 WHITAKER 00 23 25 A W STANDARD ACCESSORIES AA 11214 NO PART DESCRIPTION OF ACCESSORIES STRIPPER ASSEMBLY PERFORATOR 2 SPRING ASSEMBLY STACKER 5 BLADE HOLDER 4 BLOCK PERFORATOR 5 BLOCK SCORING SCORING BLADE THIN 7 PERFORATOR BLADE 41N TIRE SCORING RUBBER 40 24 x 3 8 RD HD MACHINE SCREW 10 5 16 18 NC x 1 4 BRASS TIP SET SCREW 11 WRENCH ALLEN 5 32 12 WRENCH ALLEN 1 8 13 WRENCH 5 32 SCREWDRIVER HANDLE 14 SCREW 8 32 x 3 16 SOC SET NOT SHOWN NOTE EEEEP Eg e If desired item 14 replaces knob item 20 pg 44 WHITAKER
6. 8 0 0 2 4 3 9 2 2 6 Printed in the U S A F 669 D 820 870 Jan 98
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8. 021 Tav 121 1821 5 TAAHMONYH 0907 29752 B DOS ld 1414 X OZ 1 MOSS vOv Or69 H 8 205 INOI B S X 02 1 5135 80v Sv69 H mon oenecle 8 1 09 1019 2 3140 305 40 530 0 LAAHS 09795 M9IA 14014 A THIN3SSV NIVIN 028 13000 39 800 243 9226 WHITAKER ub gt FOLDPLATE ASSEMBLY 1 35061 REV 3 4 G9 16 9 OO 299 1 o WHITAKER 800 243 9226 reen FOLDPLATE ASSEMBLY 1 35061 REV DESCRIPTION ACCESSORIES lee stp EN COLLAR 1 2 1 0 STEEL WASHER 10 INT TOOTHLOCK WHITAKER 800 243 9226 W FOLDPLATE ASSEMBLY 2 35080 REV lo 9 DEE FF B HH AM 3 FG HJ KL X MN mum 8 SINCE 1945 W FOLDPLATE ASSEMBLY 2 35080 REV PART DESCRIPTION ACCESSORIES 35063 35184 1 5062 5068 6940 102412 5070 5069 1 5064 5073 4 6423 8 NOSE PLATE SPACER NOSE PLATE TOP HINGE SCREW 10 24 X 3 4 FLT PT SOC SET DEFLECTOR SCALE FOLDPLATE STOP SHAFT NUT 48 32 HEX FINISHED SCREW 8 32 x 1 2 BUTTON HD SOC CAP N CN nos
9. 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 35300 1 3 1850 MODEL 820 MAIN ASSEMBLY Left Hand Side lt 14 03 7 vv R 9 0 0 2 4 3 9 2 2 6 F 669 D 820 870 Jan 98 NMOHS LON AMOSS300V vz ww NMOHS LON ZuM NMOHS LON 439334 1 60 AINO NOISN3DG 97 NMOHS LON WSV NMOHS LON WSV dNnd 0ZZ dd NMOHS LON LMVHO NMOHS LON 1 L6OLL V 339334 AFTINd 9292 05 GH 14 02 HL MIOS 90 6069 U3TIOM LbOvVuH LL GE ATEW3SSV T33HM 535915 BEIGE NIENASSV 3095 1 82156 95 HJNOISN3L 3119 11182 7205 8 9 20 01 MIHIS GOV ZOL 8L69 H X ze 8 MAHOS 02 8 0169 H MANOISNAL 1738 ELIS amp N3NOISN3L CIN 8 9 029 1 lt 0 0169 2 53110553959 40 ON 440 QNS lt 92 MOIOW A18W3SSV 318VO e mmm vue 31882 9688 3112 dH 7205 9 5 02 MRIJS
10. tif you have purchased the Crossfold System as addition to your folder you may have to add the pigtail cable connector to the electrical panel of your existing folder The instructions for making this connection are located in the back of this manual beginning on page 72 Conveyor Set Up Take a folded sample of stock coming off the transfer table and insert it into the marble guide Position the marble guide of the crosscarrier conveyor carefully so that the folded sheets land under the bevelled edge of the holder You will probably need to position the guide plate to help guide the paper under the marble guide fig 38 Push a sample sheet through by hand until it butts the fold rollers Adjust the angle of the guide so the stock enters the rollers squarely When running the angled position of the rollers will pull the paper under the marbles and against the guide to align the stock for delivery into the fold rollers Your crosscarrier comes with three types of marbles glass steel and plastic fig 38 to provide different amount of holder pressure Typically heavier marbles are used closer to the rollers to provide more guiding action Fold plate set up is identical to the folder see pg 14 NOTE Crosscarrier systems are factory set up to fold 90 to the left as it exits the folder If it is necessary to fold 90 to the right a simple kit is available from the factory to switch the direction of the cr
11. 6800 243 9226 67 31 6 Tift 0104 55040 ONVH V OL 55082 1431 V WONJ OL Z GGEf lt SION 30 or 3HL NO 31 201 ES oe 8 9 Si 1 h S o 6 B O9 14 Pa MAT ri 11 iY fou rr 1 14 ee an Q v 00666 A18W3SSV SSOHO E dg Li xd i ji EM ES A dl an a d Kane Denk By gell ZA St E ee YS _ 2 i E E at EI D T i P gt VAA F 669 D 820 870 Jan 98 800 243 9226 BROTHERS WHITAKER W C 02 _ _____ IAN 02 9 1 vZ9 H S9 3 4251356 DOS t l X 2 010 707001 8 lt 69 dvo 205 NOLING 2 1 20 88 20268 0169 59 INI ONINVI3H 601 6999 19 907001 0169 dvo 7205 INA 2 010 3 7205 1 14 8 6 2 010 607201 6069 1821 dvo 205 2 1 27 91 0068 0169 Z M3HOS 205 Z X 72 01 vOvZOL
12. 90 8169 61 108 X 54 01 5 201 0168 81 206 dll sSvua 9 X OZ v L MIIS 135 0 9969 SL MiOVds N3HSVM 561 9901 vi Y30434 Je 714 9 X 81 91 6 MIHIS 22113 AlHW3SSV 341 0333 onie Ol ieee v x 8 9 5 MIIS 908 0169 H JMOddns H3OvdS zizee 9 AdBHW3SSV 3015 perse 5 8 8 OZ v l WANS S0 6068 H 635055300 40 ON 15 ON LAAHS 00595 PUEH 91 ATEINASSV 068 13 29 800 243 9226 WHITAKER BEERS gt NOILOSNNOD ANNOYS JOISNI 3HL WO dJl8WN3SSV 4 1 JHL GNNOYV NOS LNIVd 4 31Q0N W3HDS 2812 3 HOYW 204 9692 44 W3HOS 915789 1820 43 HOYW AOGL 303 6690 33 1s ANIHOVW OL ilV d 49 09 10 IVNS3INI AINO HOVW ov XZ 31925 LONG WO ONT Oo 310N A 10 1 09 992 33 WO S3MIM 4015 AON4dOS4dW3 ATL tls INA 1 13 4 SNIMIM 9NISIM mm s E i E 2 95 Va LASNI 93331439 38 OL Z4 WALI 310N SCH WEU 55 ch 38 JO c LAAHS 00595 opis 146 4 AT8W3SSV
13. 3 6 LA 3016 5314055 00 30 ON LAAHS 09795 PUEH 91 455 NIVIN 0 8 TAOON 35 800 243 9226 WHITAKER ub gt 5 3HL Wout dig8Wassv Q JHL FHL 3AONIH SLO 3NIHOVW 2ISVH 8044 43 HOVN 504 9542 33 jNIHOvW ovg 592 33 AOZL 04 5940 33 WER E as 46 O 9o AINO HOVN WIS 6c UTING ps vvf WO ONNOYS FIOSNOS 1O31NOO 9 33 53 4616 AON3ON3WG TA ING CD Wiad 3996 WISN OO 2 333 Ba 7 3015 40 38 OL D 31925 7 P d 13581 d JO 1431 JHL OL Ov Will 1INAON V A38 JO Z 19365 06766 epis pueH 14013 ATANASSY NIVIN 0 8 F 669 D 820 870 Jan 98 800 243 9226 WHITAKER BEERS W Eg XOONI Wey HvJ 000 0842 3318 EN EE wpovis xin ec ett Lee OH Ire 1 x ze aif 202601 0869 2 205 COH ng 2 x zeef wee 9 s4 Ie ae ONOJ 8 5 09 5 0 09 6069 2 8 6
14. 800 243 9226 WHITAKER BROTHERS __ Adjusting Knob Vacuum Pesition 1 Heavy Stock Adjusting mm Knob Vacuum Position 2 Medium to Light Stack Vacuum Advanced ill 2 Feeding Paper 1 Loada lift of paper onto the feed table The lift should be no higher than the side guides 2 b1mm Position the backstop up against the lift fig 20 2 Turn on the air vacuum pump The air should float the bottom of the lift approximately 1 16 to 1 8 16 to 32mm Air blast can be controlled by adjusting the valve located at the end of each side guide fig 21 amp fig 22 pg 14 Air Blast Openings ar a T Air Blast Control Knobs an WCS gt CUu k m d e 3 21 13 Air Blast Openings fig 22 3 Turn the speed control to 1 2 or full speed Place your thumb on the back of the lift to keep paper from feeding Press the green rocker switch the sucker wheel will start to turn Reduce the pressure of your thumb to feed only 3 to 4 sheets Press your thumb down to stop the feeding again Press the red rocker switch to stop the sucker wheel from turning If the paper did not feed adjust the position of the vacuum advance fig 20 pg 13 bleeder valve fig 23 or sheet sepa rator fig 19 pg 12 4 Check the accuracy of the 3 or 4 sheets fed It may be necessary to adjust the fold stop fig 24 or the
15. ANO 062 30 0 8 48 AINO 021 VSO 1 ELLIS 021 dvo 206 X 52 0 0 201 8169 96 ota Das uva se I eem ie fo 12 ams wee 62 595 ONIN 000 09 01 v e X 0Z 4 L 907 6069 72 NITION NNW 11 0029 92 52 wao ONNWIaN SNY 23 ZZ X 06 0 052 612 vz x 1 91 6 Naxos 909 6069 H 6 GH 206 9 6 02 9 5 90 8 69 8 cod 190 9 2 ersooz 2 1 Masos vl al X 81 6 80 956 CL S E u3HsvM g S Zl X 4 1 MINOS 0 6 NONE 2 1 2 01 Mayos 0 00 0 69 N3A00 TaNvd 40313 10313 _______ ADEL A EWGssv _______ 592 33 5 AINO oma ____ eza MOTTA ONM zaje 3SVE ON LOVINOD 2 2 NO AOEZ NO JSM wus 000 1 092
16. A3Thd za 2 205 8 x 2 01 Mayas 0 201 4169 6 0000 Wmm 9 EROL sl avo a z vesi s 9 5 055422 40 530 53 085422 1 INO A 022 e 65 600 243 9226 ch JO c L33HS 00595 opis pueH A18IN3SSV NIVIN 028 WHITAKER BROTHERS SINCE 1945 gt MODEL 820 MAIN ASSEMBLY Front View 35300 SHEET 3 OF 3 F 669 D 820 870 Jan 98 wr HITAKER 800 243 9226 4 028 W nn Tan 99 EN oie N3HSVM NOUN Z 88Zll am mau We 14084408 ONINVIGE 3 06 lt 611 6 960 s asma 7005 2 X Oz v i Mos 90v 8169 H 92 LVHS T33HM ONVH WSV Se T33HM ONVH 11252 9 206 L X M3HOS 135 0720 8769 ASVAHD NOIVIINEN 9NILLIJ 2 1 oN 05 04 5 16 ws owe oe os Du Tee ue o ED lt 621 5 92 Ga H3HSVM 12 880211 ONIN ONINIV 001 lt 01 6 sanossicov ON
17. 4 ele HS WSV 4306 ele NMOQQ10H MIYOS BINON 02552 Wem I 19958 OL NMOQTIOH 1138 958 6 N3NOISN31 1738 lNHS 8 N3NOIBNAl 1138 MOOIE SE 4 1504405 YaISNVYL 911 s 53140553009 30 40530 A18N3SSV 35 71 800 243 9226 WHITAKER BEERS gt CROSSFOLD ELECTRICAL HOOK UP 2670 1 US ES ES ALO diNVd scs AINO LNlMd SNOILOMYLSNI 1 0282 3 9 711914 ATBNISSV 9014 HZ Jvlold 307103 v vd ATaWassv 319 9 33 1 1914 070355050 AIBNISSV 2492 33 070385050 ATanassv UZ 1 S3lHOSS309V 40 530 ON MOD 7 8 JV GON 7 35 3S0HM SJNIHOVA NO 035 38 LON Nvo SIHL JLON Os 29850612 Doc v9c 1 101 7091905 Hoe voc 30MLNOO F 669 D 820 870 Jan 98 800 243 9226 5 WHITAKER gt W CROSSFOLD ELECTRICAL HOOK UP INSTRUCTIONS WARNING Shock Hazard Disconnect and lockout the power to both machines before proceeding with the following instructions Crossfold Folder Power
18. Disconnect the power remove the fold plates and clean rollers with blanket wash not type wash or a commer cial product designed for the type of rollers your machine is equipped with Turn the rollers with the handwheel never attempt to clean rollers with the machine running see Warning above Check rollers periodically for wear During normal use fold rollers will gradually wear Worn rollers will be evident by increased setup times increased spoilage inaccurate folding and inability to control the sheet If one or more of these conditions are noted contact your authorized Challenge folder dealer to inquire about inspection and or possible roller replacement Vacuum Pump Compressor Filters Because the printing process produces large amounts of paper dust as well as offset powder regular inspection and cleaning of pump filters is an important part of folder maintenance Filters should be removed fig 43 and blown out at least weekly more if you are running large long run jobs Filters should be washed periodically with a cleaning solvent and dried thoroughly before replacement If filters become difficult to clean or deteriorate they should be replaced immediately Replace any filters which become contaminated with oil or grease Pump Vanes To prevent dirt and dust buildup from causing the pump vanes to stick or break the pump should be flushed periodically Use a nonflammable safety solvent Remove the hoses disconne
19. NMOHS LON NMOHS LON NMOHS LON a NMOHS LON Nid HMI 30334 312 NMOHS LON AOFZ NSV 3 Z dd WSV MOSN3SO10Hd ING L X 9 MANOS amp 0 9 0169 H 1 MOSN3S de MYA 4 ONNOS Wen 205 1v v X 02 o 5 mon NWN WSV 130948 ste NSV T33HM M3NOISN31 205 8 9 Z Ol 201 8169 lt 3 055322 30 IVd EX ES ES EX ES EE ES ES ES ES ES ES m N3NOISN31 1138 Nid M3NOISN3 ZZ 108 B G X OZ v MIYOS 907 0169 440 QNVIS Lover SL 18 355 318vO 0560 33 ZZ JANE NNMIS 37875 RE 7205 6 X 00 1 GH 108 2 1 X 2 01 M3NOS 0 201 0169 41 i 205 dil SSVHA 2 1 X OZ v AMIS 0 969 91 M3oVdS M3HSVM SL 30334 ANd 3115 M X 8 91 lt MIYOS a geen 0333 2 00152 6 108 6 81 91 6 MIS 908 0169 H 9 l1MOddns 30334 VIVES 21262 GH 4 B S X 0 4 1
20. X 65 01 8 204 lt 01 0069 29 3 2 16 dn zezas 19 dvo GH 205 22 40 MANOS EE 135 205 dll SSVHH X 81 91 2221 4001 91 9 MJHSVM OL LZEL H SS 81 91 8 InN 6 6099 95 135 208 1 26 0 5 702 01 6 69 Mme LVHS 911 14 135 205 91 9 X 81 91 9 OS dvo GH 905 7 6 26 88 5 27 Jeu 8f 000 BAZEL THM LGB ELLGE 2160 1999 iv ONINIVL3M ei ONIN 06 0 6 9 6 MOOTHIOOL YILNI 88 8 YZeL H 9 dvo ING 2 1 20 80 vOZ 8 0169 H 92 1 204 9 SAINOSSADOV 40 40559 gt C EE En EX EET ES ES ES EH EE EE 221 En 2 Ea EX EX EE AD Wou Ze 135 205 14 08 88 ie Wun 980 6 016 Zz dvo X 04 1 lt 0 0169 92 MOlVNVd3S 13386 138 1 Yadvd dun 35 uve 11 9019
21. fig 6 Place the sound cover on top of the 1 foldplate the sound cover is optional on 820 model 4 Install the feed table Insert the table between the F 669 D 820 870 Jan 98 Locating Pins Feeder Notch fig 7 side frames Install the feed table so the notches in the side brackets fig 7 mate with the mounting pins in side the folder side frames NOTE Mounting pins should be located in the upper set of threaded holes Lower holes are used to mount a crossfold carrier assembly Left Side Locator Hole fig 8 5 Install the stacker table assembly fig 8 on the back of the folder Insert the spring loaded end right side viewed from rear of the folder of the drive shaft into the locator hole in the side frame compress the spring against the side frame and swing the opposite end into position in the other side frame fig 9 6 To pile folded materials insert ears of stacker tray into end of stacker table as shown fig 9 Ben BROTHERS 800 243 9226 10 7 Attach the stacker wheel assembly to the tie bar next to the jam detector as shown fig 10 fig 11 8 Using two people position the compressor on the bottom shelf of the stand fig 11 I fig 12 9 Install the strainer screen shipped with the acces sory kit to the intake opening of the blower unit fig 12 13 10 Con
22. the taper plates will have to be removed and remounted onto the opposite side of the frame Replace the factory installed LH marble holder assembly with the RH part supplied in the kit Marble Holder Mounting Guide Block Mounting Arm E ring Wi Pi 19 42 9 8 Gd ak d 3 Bm TG E pr her TE dev rer La mt vi siint 5 SCH CC WHITAKER vy BROTHERS gt SINCE 1945 800 243 9226 13 Remove the marble holder mounting shaft 14 Remove the squaring assembly hardware squar ing knob wing nut and spring fig 42 15 Remove the original LH marble holder by loosen ing the setscrew and removing the mounting screw fig 42 Reassemble with the new RH marble holder 16 Remove the marble shaft guide block ill 8 ref 22 rotate it 180 and reassemble to the marble holder mounting arm ref 23 17 Replace the squaring assembly hardware removed in step number 14 amp 15 above 18 Slide the marble holder mounting shaft through the guide block and reassemble to the shaft mounting blocks on the edges of the crosscarrier frame 19 Adjust the plastic support screws ill 8 ref 41 on the ends of the marble holder so the holder is level and does not touch any of the rollers Lock into posi tion with the plastic lock nuts ref 42 20 Position the new drive belt covers ill 8 ref 50 8 51 from the kit over the ends of the crosscarrier roll
23. E E STACKER ASSEMBLY E LONG STACKER 5 STACKER WHEEL ASSEMBLY nene CALIPER ASSEMBLY MEDALIST STAND ASSEMBLY RIGHT ANGLE STAND ASSEMBLY AN WHITAKER ana Aas anma F669 D820 870Jan 98 800 243 9226 TABLE OF CONTENTS CONT D JAM DETECTOR ASSEMBLY 52 ELECTRICAL SEQUENCE OF 53 820 BASIC MACHINE SCHEMATIC 120 54 820 BASIC MACHINE SCHEMATIC 230 55 870 BASIC MACHINE SCHEMATIC 120 56 870 BASIC MACHINE SCHEMATIC 230 57 820 870 BACK COVER PLATE ASSEMBLY 120 VOLT 58 820 870 BACK COVER PLATE ASSEMBLY 230 VOLT 60 820 CONTROL PANEL ASSEMBLY 62 870 CONTROL PANEL ASSEMBLY 63 120 220 VOLT PUMP ASSEMBLY 64 STANDARD ACCESSORIES EE 66 CROSS CARRIAGE ASSEMBLY 68 TRANSFER ASSEMBLY TU T E 70 CROSSFOLD ELECTRICAL HOOK UP 72 CROSSFOLD ELECTRICAL HOOK UP INSTRUCTIONS 73 IMPOSITION MANUAL
24. Panel Connections Steps 1 4 1 Remove the power panel of the crossfold machine There is enough wire to lay the panel down flat in front of the machine 2 From the kit locate the pigtail labeled A item 2 in the drawing on the opposite page Insert the wire end of the pigtail through the hole in the top of the power panel housing 3 Connect the wires to the terminal strip as shown in the CROSSFOLD FOLDER POWER PANEL detail in the draw ing on the opposite page 4 Double check the wiring connections against the drawing and when it is correct replace the power panel Parallel Folder Power Panel Connections Steps 5 9 5 Remove the power panel of the parallel machine There is enough wire to lay the panel down flat in front of the machine 6 From the kit locate the pigtail labeled b item 3 in the drawing on the opposite page Insert the wire end of the pigtail through the hole in the top of the power panel housing 7 Locate the Jam Detector Cable and trace wire 36 to the terminal strip Remove wire 36 from the termi nal strip and using the wire nut supplied in the kit con nect this wire 36 from the Jam Detector to wire 36 of the pigtail 8 Connect wire 368 of the pigtail to the terminal strip at the position from which wire 36 of the Jam Detec tor was just removed 9 Double check the wiring connections for the PARAL LEL FOLDER POWER PANEL against the drawing on the opposite page an
25. X 02 9 1 MINDS 60 6069 04 sle NEIJNVINHOd 318V0 Ovez m 99 HOLMS 5384103 099233 H3 MOdsNvHL WSv 2092 33 99 ______ 9 _ ___ 1 64196 dll ssvue L 02 4 1 MIHOS 135 0 ________ 19 oun oun mg mg 000000 25266 09 Nw eones 208 x zc ef 0208 0169 8 IRQ Ton Bons 04402 1505 95 NSV 1083 9 0104 0806 WSV NR 305 05946 510 2 3 25 NI dVNS SNiHsn8 01 2212 3 19 ADtZ Hie 230 Ad De ANO AOLZ 001 INI OLF 91112115 11 11 AINO AOZL INI 01 262 7 0 WE cOVZOL 0L69 H Move 9992 33 SANG X Off MIYOS 900 069 27 S3blOSS300V 40 AOL 4309 13891 SL 1BZL S 09 A 077 005 NMO 22 3 ee A 02 08 2 MOH 9 EN Ova 13871 Ss A 021 MOOHS 2313 21 1821 5
26. ers fig 39 Secure with the single button head screw ref 38 21 Reinstall the crosscarrier assembly into the paral lel unit Follow the Right Angle Crossfold Installation Instructions on page 20 to position the reoriented cross fold system behind the Medalist folder and make all electrical connections as instructed 55 s oe d via 718755 14 13 51 2 ill 8 drawing appears for instructional reference only see page 68 69 for enlarged drawing amp parts list LOCATE ON THE NSIDE F 669 D 820 870 Jan 98 W MAINTENANCE Cleaning Take a few minutes at the end of each day to wipe off accumulations of paper dust Cover your machine when not in use These practices will keep your machine clean and in tip top operating condition Rollers Keep fold rollers clean Most folding problems are the result of material accumulations on the fold rollers Although designed to minimize accumulations over a period of time ink and dust buildup will prevent the rollers from gripping the stock evenly Rollers must be cleaned on a regular basis to maintain optimum folding performance WARNING Always disconnect the power cord before cleaning Rollers have a strong grip Keep tools clothing hair and cleaning rags away from rollers Severe injuries and machine damage could result from items being caught in rollers Do not operate folder with guards or fold plates removed
27. label is included with the manual and may be conveniently placed on the deliv ery tray Used along with scales on the fold plates the guide will help you quickly establish a rough set up for some of the most common folding jobs Quick Setup Scales read at these points Plate Stop 24 Coarse adjustments made loosening lock screws on the plate stops fig 24 then moving the stop The plate stop lines up with the scale marks along its front edge not where the paper contacts the stop Fine adjustments are made with the micro adjust knobs on the ends of the fold plates fig 25 pg 15 vy WHITAKER BROTHERS 8 1945 800 243 9226 F 669 D 820 870 Jan 98 vy Micro adjus NN fig 25 A 26 For easy access to the second bottom fold plate while making coarse adjustments NOT WHILE RUNNING the feed table may be lifted out of the way and held there by inserting the holding pin in the side frame fig 26 Roller Caliper Set up 870 only WARNING DO NOT MAKE ROLLER ADJUSTMENTS WITH THE FOLDER RUNNING Serious personal injury or machine damage could result from tools fingers hair or clothing being caught by rollers Always disconnect the power cord when setting rollers Never operate folder with any guards or fold plates removed Adjustable calipers are used on the Medalist 870 to obtain clean crisp folds
28. or specification without notice and without incurring responsibility to existing units WHITAKER 800 243 9226 W SAFETY PRECAUTIONS 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 instruc tions may result in personal injury This machine is designed and safeguarded for ONE PERSON operation NEVER operate the ma chine with more than one person Safety of this machine is the responsibility of the user and operator Use good judgement and common 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 Onlytrained 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 DISCONNECT POWER before cleaning lubricating servicing or making adjustments not requir ing power See Power Lockout Procedure below HIGH SPEED ROLLERS Keep rags loose clothing and long hair away from rollers Personal injury could result from items being caught on rollers Have your electrician make sure the machine is properly grounded Have your electrician check for sufficient power to operate the machin
29. pG92 33 vos TINA Wu UU UU UU PU UU ULE SCH TEST A18N3SSV T3NVd 1IOGLNOD 048 63 800 243 9226 WHITAKER BEERS W 120 220 VOLT PUMP ASSEMBLY PP 270 PP 274 S 9 2 o 5 2 2 KD 03 lt D Wunn 800 243 9220 120 VOLT 60 HERTZ PUMP ASSEMBLY PP 270 1 P 272 Pu vacuum Li umer EC 1 273 ADAPTER 3 4 HOSE 3 4 STR FEMALE H 235 2 REDUCER 3 4 NPT MALE 3 4 NPT FEMALE 6405 612 NIPPLE 3 8 CLOSE 6913 506 SCREW 5 16 18 x 3 4 HEX HD CAP 7327 10 LOCKWASHER 5 16 MEDIUM 7521 5 WASHER 5 16 STANDARD 35165 41 BASE PUMP 35164 FOOT RUBBER 641 5 608 SCREW 5 8 16 x 1 HEX HD CAP 7327 12 LOCKWASHER 3 8 MEDIUM 7321 6 WASHER 2 8 STANDARD 2343 CABLE with plug 6405 1612 NIPPLE 1 CLOSE 210 8 ADAPTER 3 4 HOSE 1 MALE STR 289 5 17 5 1350 16 BUSHING HEYCO 1223 1 BLOWER REGENERATIVE 664 WIRE 16 107 LONG 1257 1 WIRE NUT YELLOW 282 24 278 VALVE BALL 267 TEE 3 8 NPT L REBAR SHON 102 STRAINER 220 VOLT 50 HERTZ PUMP ASSEMBLY PP 274 7 A WIN
30. set up to center the paper on the sucker wheel Initially set each side guide 1 4 6mm wide Do not tighten the lock knobs A 800 243 9226 WHITAKER BROTHERS Raise the sheet separator so it is away from the sucker wheel fig 19 Place a sheet of the paper to be folded on the feed table Slide the sheet forward into the rollers The sheet must contact the rollers evenly and not touch the side guides Turn the hand wheel so about 1 2 3mm is pulled into the rollers 4 Position the operator side guide so it is just touching the sheet but not pushing it The side guide must be even to the sheet from end to end Tighten the front lock knobs then the rear knobs fig 17 amp 18 5 Repeat step 4 on the nonoperator side guide 6 The paper will now feed square into the rollers Now that the side guides are square the feed table squar ing screw fig 17 can be adjusted for fine tuning the overall squareness Vacuum Feed Sheet Separator The sheet separator will have to be adjusted for the weight of stock you are folding Ideal adjustment will feed only one sheet without marking the paper or feed ing doubles Use the following procedure to get started Fine tune these adjustments according to the condi tion of the paper and the environmental conditions of your particular work area Adjustment procedure 1 Raise the separator ccw to avoid marking the sucker wheel NOTE DO NOT MAKE SE
31. shown in fig 32 4 Install the cross carriage support legs to the cross carriage frame fig 33 The legs are mounted with two 10 24 x button head cap screws 5 Insert the crosscarrier assembly between the side frames making sure the support legs rest on the cross carrier stand Make sure the mounting pins for the crosscarrier conveyor assembly are in the lower set of holes in the roller side frames fig 34 Install the left hand screw first then the right hand side vy 800 243 9226 WHITAKER BROTHERS SINCE 1945 UAE mine Ti reme ramen um Din 32 5 2 fig 33 Use LOWER hole for Crosscarrier Mounting Pin fig 34 A little downward pressure on the crosscarrier assem bly will help to align the holes to aid installing the mount ing screw the friction drive is located under the right side requiring the pressure to align the mounting holes F 669 D 820 870 Jan 98 NOTE If you have purchased a crosscarrier as an after market addition to convert a second folder to a right angle you will need to perform three additional procedures A C as follows nd MEL ms eg Colle 1 4 y BAL fig 35 A Reposition the O ring friction drive collar from the center feed table position to align with the drive collar of th
32. squareness of the fold stop fig 25 pg 15 or the squareness of the side guides Try only one agjust ment at a time then repeat step 3 5 If the folds look good the job may now be run The speed of the folder will affect the accuracy of the folds Folds set up at slow speed will be different at high speed and will need to be fine tuned Note All of the controls mentioned above contribute to smooth and accurate folding There are many combi nations possible depending on the condition of the pa per and environment Bleeder Valve Vacuum Adjustment Wa fig 23 There is a bleeder valve on the vacuum pump fig 23 which allows for vacuum adjustment from com pletely off to completely on General settings for the bleeder valve are half open for 20 stock and closed for 80 and heavier stock If your machine is feeding doubles this can be opened slightly to relieve some of the vacuum and stop the double feeding Fold Plates Plate set up will depend on the type of stock and type of fold you require The fold plate design on the Med alist allows changing from open or closed deflector up and or down folds without removing or turning the plates 41 Caliper DELIVERY ill 3 A good understanding of the roller plate configuration will help you decide which plate to open or close for up or down folds Illustration 3 shows the paper path for a common Z fold A self adhesive folding guide
33. 1 69196 vogue 2 1 8 2 Maas 09 929 51 HOLMS MOSS3NJNOD Nev Flava 0992 33 oz zl 91 1841 5 Gw al 80 9v28 H vi MFNYOASNVYL NSV 09 33 69 072 0800 N3MOd 8 1891 8 CL E ume GINO 78 00 voos arn wouwe mevi po ANVHLN NIA Ou L 6ZI8C o ANG 952 ds JU3NSVN 591 98 AINO A OET annos 896140 AWO A Wor 98 KINO A oez annos polar G8 KINO A 052 01 5 8 X 4 1 MIos zl dem 28 251 OH 2 1 72 01 MGNOS 70 201 0169 M3ADO 13 4 12313 LAMIVHE 0979 120313 36735 008 LSTNQO3N 138 1 ADZL IONINO9 ATISNASSV 13 08 2 33 LONG A 021 961 2 3 AINO A0 Z 138 ES AINO ADEZ O N Lovinoo 2 2 SIND LSIML WoONHSQN 0 1 2 2 3 5 0885122 30 BNd OZL 52 2 1118 SSvMB v L X Oz v L MANDS el 707 7969 WIND A 021 wa
34. 28 4 JAHOJSNVHL F 669 D 820 870 Jan 98 800 243 9226 WHITAKER BEERS W m HOLIMS dayna NSV 318vO 0942 33 27 A QI 6 0891 3 NMOHS LON 69 5 3 layovde 879 v 22222 r MZ WHO Z9 015533 w NMOHS LON NMOG Z HZ 3 OF NMOHS LON Man Avis EUA 62 ON 5 HOLO3NNOO 8 02 11 ES S INNON dls 5 9090 3 9c X3H ZE Bf LAN MOOTHLOOL INI 80 13HSVM dvo 205 GH 108 v 1 1 X 26 88 01068 0169 205 8 4 X 20 87 MINOS 0268 0169 205 ING Z X 22 98 MANOS 0058 0 69 16 tars ane MOOTHLOOL INI vf 5 sf vecL H QM X 2 25 Zl0vv 269 H 015530 LE MS dOlS lNVIS S3HdWOO ATaWassv 0994 3392 NVP ATBNISSV HOLMS 092 33 314055320 30 NOILJHOS IO ON ON Wsv 06 z 33 vz Mil3WollNAlod WSV 31895 33 M3NHOdsNVHL WSV 092 33 EN SNOT 91 3349 MIN SL 9 6 8 3 IZ Kad 1 9 MLW vo af JM 9 6 8 3
35. 3 1 s3Nossz00v 40 V A38 JO Z L33HS 06766 epis pueH 14013 ATGINASSV NIVIN 028 37 800 243 9226 WHITAKER ub gt MODEL 870 MAIN ASSEMBLY Front View 35450 SHEET 3 OF 3 96 gt WHITAKER 800 243 9226 0 9 3400 TAN 2979 59 NOUN 51 88211 Zv We ONRIV38 104405 00 OF ONIN 3 06 lt 611 5 dvo 205 OZ 1 M3HoS LAVHS TH3HMQNVH ASV 1404405 64098 ONS E 13 74206 v X 2 01 MINIS 70 001 8 69 35 349 NOUWOMENT 9 941 5 2 1 9N 06 lt 01 5 LE LHS 2 01266 144 1 CLOGS 64 B3HMONVH 60246 84 S LSNYHL 7006 1 5 22 LSNYHL L S6cl 92 SNINIV LFH 001 5 201 5 S3lMOSS320V JO NOlLdlMOS30 ON 4 ES 0Z v INN 279 GL OOS 1 OE H L M3H08 8169 81 NSV 1509905 500 ot 91 5 x 22 2 lt 05 1019 61 H3MOVIS 1 2056 vi now tis 052 r
36. 49441 6081 USA ChallengeMachinery com WHIJAKER 800 243 9226 INTRODUCTION WELCOME to the family of Challenge users Challenge has been developing and manufacturing Graphics Arts Equipment for over 100 years and is today one of the world s leading producers and distributors of Paper Cutters Paper Drills and Bindery Equipment special attention to the instructions in bold type Personal injury may result if the precautions are not SAFETY ALERT This symbol means CAUTION OR WARNING Personal safety instructions Pay read and followed See SAFETY PRECAUTIONS page 6 e This machine is designed for ONE PERSON OPERATION ONLY Always DISCONNECT THE POWER before working on this machine NOT OPERATE WITH ANY GUARDS REMOVED Replace all guards before operating e CRUSH HAZARD Keep hands hair cleaning rags amp loose clothing away from rollers 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 Chal lenge 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 that the correct parts are sent as soon as possible Take a few minutes right now to RECORD YOUR MACH
37. 8L69 H 138 HI HOI 26666116 138 HH WSV H3NO0 19996 OG o svt 6 NMOHS ION 50109140 OZGGE 9 MANOS 205 diL 5548 OZ 1 vOv V969 H MANOS 1 X 2 01 807001 0169 25 206 9 1 1 X OZ v 1 017 8169 v NOTAN INN 02 9 Ve9 H 2Uusvid 2 1 02 9 1 80 1889 H 1 MASIS NOLLNG 2 1 2 017 707001 0169 0 otso 25 NOlInH 8 6 X 2 017 201 0169 MINDS 205 IVd 2 1 X 92 010 201 6069 63 065322 40 0530 ON 194 ON 8 2 3825135 205 8 x 2 01 90 20 8869 INN Xil Zg8 Lves H 3 OH 205 80088 8168 16 9NOl 9 620 9899 og IBO AANS 5055 gz ANNO MOO 92 Lite NITION INNON N3Q70H 12660 ez isnrav ONS LZ M3HOS 205 1 X vc OLf 80 201 8169 OZ Hl H3010H pen 919 BL 3iguvW ONIHSAG 02 0211 3 vl 1 Ziege 0 NONIAN Y 55 NATI
38. I JOS GH LNG 2 1 X ve Ol MIYOS 707201 0169 H HOIVSVIIS ls HY AT8W3SSV 395 113 2 1 26 89 MEE JOS GH 118 2 E X ZE Ol MANOS 02 01 0269 3015 m Om ANIL 1 28 21 NIENISSV 9015 of 4334 3IOS Toy X DLC 0620 281 512 114 X 26 88 SS3NHVH 3MIM den 9 9812 3 20 2 TOV Lis Onee IRE 2 78 AlBN3SSV 318VL 5314055305 40 4 2539 45 800 243 9226 WHITAKER ub gt STACKER ASSEMBLY 35128 1 Pr see swr rw Ga a s mss wenza lm EN EE 1 e sss En CE E EN ESE s M024 1 2 BUTT HO sos m Ja Ee e sma Immo 8 SINCE 1945 LONG STACKER ASSEMBLY OPTIONAL 35290 1 Fesser su moe 37a 10 Le Ls seer gt Roc ram SHELF STACKER SUPPORT SHOWN WHITAKER 800 243 9226 47 STACKER WHEEL ASSEMBLY 35198 REV E PART NO DESCRIPTION OF ACCESSORIES eos ne x 174 1 seer ee 9 0 0 2 4 3 9 2 2 6 F 669 D 820 870 Jan 98 W BROTHERS CALIPER ASSEMBLY 35041 7 SHAFT ADJUSTME
39. INE 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 DIRECT 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 SERIAL NUMBER ATTN COMPANY ADDRESS CITY STATE ZIP PHONE DATE INSTALLED DEALER S NAME AND CITY WARRANTY INFORMATION PLEASE REVIEW THE ENCLOSED WARRANTY SHEET It is very important that you read and understand the conditions outlined in the Warranty Information Sheet included with the manual information package The Warranty Information Sheet must be filled out completely returned and be ON FILE at 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 1996 by The Challenge Machinery Company All rights reserved Printed in U S A F 669 D 820 870 Jan 98 WAKER 800 243 9226 W Your fig 1 Medalist Air Feed Table Model Folder 870 shown with stand PACKING LIST folder has been carefully packaged to prevent damage in shipment Inspect all shipments as soon as they are received Not
40. Jan 98 800 243 9226 5 WHITAKER W 1 162 33 LO HaINNO09 1996 33 405435 13395 Bey 9 LVO HI LINS 4015 40193130 Wer S me lt lt 1 2 3 og e WHO 29 6 9 HOLIMS HOLIMS HOLIMS d 1MVIS 4015 On vay YOSSAYdNOO ce LHM 22 2 ce d 1 E OVER OD EOL i 3614 014 015 CN ue T v8 q E ERE 22 mae d 1591 3 2 05 2 3 N 2031409 HALI e 03345 ME M 1 c OC GC LC vo Se Id D m co 019 015 Y4AMOd Voie WHO MG ul 0334 8492 4 W Hyld wal NOMJ ANNOYS 1571 INN gf INN 97 5 Wall NOMJ Wall SONNONS IN43G 03395 ams 22 SS M3AHOJSNV3L 0 4J3I3NOUN310d LH Fava 3725 MAIN Q 90 3 BEN 92 Gs z AJH 52 MS dols luvs MS WP p H 4 o roe INE ME 10 1 1 la o o 6692 33 L1OA OEL ATHW3SSV ALV1d H3AOO 0 8 0
41. NIVIN 028 133OlN F 669 D 820 870 Jan 98 800 243 9226 WHITAKER BEERS W gt 31 N 28 NSV Toa 089 96 Ha 305 ANO IG BAN AINO Die 031931084 T38v1 EE 3lvid 330 89011 4 VALS Nd 1 61 1914 HEN OZ v MAIS 90b 6069 H 67 Ma AIBNASSV 130448 92 Gaya 5 avaa 1618 98 2 ee ee AINO AOSZ 2901 INI SEE oy sg BALS LNG t i X 76 01 200 lt 01 0269 08 X207 INI Seen 018 9261 1 ON 3 z 208 Ina 1 1 x ze sf 0068 0169 s4 EAT Ina 8 2 X vZ Olf MAYS FOVZOL OLG8 H X 9 1 0620 088 512 eam Ro 1028 une EEN nn 8 6 Op vf 0 099 6268 GL OEZ WSV ui MOVB 8992 35 m OOS b s X Oz v 1 maas SOv 8I69 H 6 oa ono EA C ee om B S 02 9 1 wous 907 6069 3Nu OH x Of Ms vOO vzes H _ E ual3WolNilod ev mavo 14 138
42. NT WASHER NYLON A 10172 24 BUSHING ES SEI EN ES ES En WHITAKER 000 243 9226 SINCE 1945 MEDALIST STAND ASSEMBLY 35470 REV sve oon 1 F 669 D 820 870 Jan 98 W WHITAKER 800 243 9226 RIGHT ANGLE STAND ASSEMBLY 35473 REV Pe 17 om a WHITAKER 800 243 9226 51 JAM DETECTOR ASSEMBLY 2607 REV 55 BLACK 56 RED NOTES STRIP CABLE JACKET BACK 1 ON SWITCH END AND 6 ON THE OTHER D STRIP WIRE INSULATION BACK 1 4 ALL WIRES BOTH ENDS BLACK 3 WIRE TAG ALL WIRES AS SHOWN ONE END ONLY WIRING DETA a WIRES SOLDERED AS SHOWN m SEE WIRE DETAIL Lr som OR MOER 12 EREECHEN 105204 MOX 1 4 SOC sev D sjees ewm 105202 2 x 17 GAP 575 X 3 8 2 x 12 wee gt wem smo 0 1 leese x 1 4 soer id eme m 2 COND 0 8 SINCE 1945 W ELECTRICAL SEQUENCE OF OPERATION ELECTRICAL SEQUENCE OF OPERATION A Close the POWER switch B Press the compressor ON switch C Press the START button D Adjust the SPEED CONTROL ELECTRICAL SCHEMATIC REFERENCES Drawings E 2657 amp E 2658 While the POWER switch is closed power is brought to the transformer provided t
43. OA 082 A18IN3SSV 3LV 1d H3AOO 048 028 F 669 D 820 870 Jan 98 800 243 9226 WHITAKER BEERS W HOLIMS MOO M3LlNI Weu 318v2 09 2 33 2 ES E Hl4V3 Q319310Md Ad T38V1 1 EOI 91 1 5 NMOHS LON YINYOASNVYL LIMOVHE OYV HONING AHO Z9 0151 538 LON 2 NMOHS LON Nid AV TM 1342098 G3LVINSN 104 Z LNhOW 13NVd 15 29 88 INN MOOTHLOOL INI 8 H3HSVM 205 OH INA v 1 L X ze 8f MANOS dyo 205 INA 9 9 X 2 lt 8 MIHOS 205 LNB 0 1 X z gf 5 LAN MOOTHLOOL INI vf YAHSVM GH QM 9 6 X MANOS M3MOd 3SMOH 401564 MS dOlS l1NVl1S S3NHdWOO AJ8N3SSV 218 2 NVP 55 HILIMS 541405539907 40 9 2530 L1OA 022 8 9696 33 WSV MAYI YALFWOILNSLOd WSV 218 NINXOIASNVYL NSV HIVOS 91 N33H9 MIN SLE G MIN N33HO 9 MLW 93 vo 9 Q4044N SV MLW vo gif 1 91 00 ATINA et 1 01 61 06 GD SNI HOIO3NNOO 1 91 SNI ANNA HOLO3NNOO 7l 9L SNI AMAA HOLO3NNO2 ONIN GALVINSNI 8 NHOlO3NNOO
44. ON INNON 1495 9 IHOddNS 5040 931 626661 INNON poes INNOW N3010H 929 63140656300 40 2634 ON IVd ON 1191 521 22 1282 1 61 04 00666 SSOHO 69 800 243 9226 WHITAKER ub gt HS SV Will ONILSIXS 30 143 55 HAJSNVHL d19NV IHOIM ONISN NAHM SJLON 11 25 v L 40 OGGGE A18W3SSV HAASNVHL VHS NO LNNON De DU 1 5 Mills JWvui 40 NO 3lV2O1 Le 31455 NN F 669 D 820 870 Jan 98 800 243 9226 WHITAKER BROTHERS W Bevi eass E 008 GH 2 1 X of 0169 57 DE NE gt lMOdSNv4l 1138 1 3406136 dll v 1 S1 91 8 708 969 92 EE mmo 3 6136 205 1 72 01 OPZOL 9 69 H ze 3405136 205 1 x 7 02 8 8869 sz MANOS GIHS 205 2 1 X 91 4 Cl M3MOS OH 2 1 X 2 01 0 201 0169 GZ 6315055320 0 0930 ON IVd ON OGGGE dvd 205 dH 2180 pZ OL 07001 6069 1
45. OZ Q3033N SY MIN vo at OEE _ 01 21 06 SNI ATINA v L HO103NNOO 28 0121 3 81 22 481 1 Q O ATINA v L NOLO3NNOO 91 91 06 TO SNI ATINA ONY Bf MOlO3NNOO 0000 po oao 37019303 134008 zeeZ 3 310143033 8 018 015 vst 3503 16 688 3 018 015 VG 3503 9 688 3 121 AQ08 3583 i 0 6 3 VAZL O3S M3JWHOJSNVML 00 00 0281 31 M3N00 MOVE lt 3 055302 30 ON LNVd ON HE 11 1 151 gt 6692 33 L1OA 021 A18N3SSV ALV Id MOVE 028 028 59 800 243 9226 WHITAKER ub gt YIN 35 ld 4 011800 HOON Wis 26 48 3419714 u3HSVM Bi INN 9f H3HEVM 817 LZ wai af Wau NON ONNOHD Wal ANNOYS ef Mai cT wal NONA ONDON5 1541 Q3TWISNI 22 s ec s GE BE LE GE EZ M5 dQLs lvis e eem 20097 H 5 uum UY ers V Eaei jo sen Ar VO S lt 0692 33 L1
46. OlLdlMOS3Q ON 1YYd 600SE VV Jed oM SLNANOdWOO A TANASSV LAVHS 4311115 77 800 243 9226 WHITAKER BEERS W ROLLER REPLACEMENT REPAIR KITS 870 COMBO ROLLER REBUILD KIT K 35294 Qty P n Combo rollers 4 35055 Roller gears 4 35052 Gear keys 4 H 6121 604 Idle roller bushings 6 A 10257 5 Main roller bushings 2 35029 Sucker wheel belt 2 35113 Ring drive belt 5 35179 1 Out feed tires 4 A 10249 Tech notes 1 MFG 016 870 RUBBER ROLLER REBUILD KIT K 35293 Rubber rollers 4 35051 Roller gears 4 35052 Gear keys 4 H 6121 604 Idle roller bushings 6 A 10257 5 Main roller bushings 2 35029 Sucker wheel belt 2 35113 Ring drive belt 5 35179 1 Outfeed tires 4 A 10249 Tech notes 1 MFG 016 820 ROLLER REBUILD KIT K 35298 Rubber rollers 4 35051 Roller gears 4 35052 Gear keys 4 H 6121 604 Idle roller bushings 6 35283 Main roller bushings 2 35029 Roller spring 6 1922 Sucker wheel belt 2 35113 Ring drive belt 5 35179 1 Outfeed tires 4 A 10249 Tech notes 1 MFG 016 WHITAKER BROTHERS 800 243 9226 W NOTE ROLLER PLATE GAUGES ARE HIGHLY RECOMMENDED WHENINSTALLING A ROLLER RE BUILD KIT ROLLER PLATE GAUGE KIT K 35292 Plate gauge 2 A 10471 opacer bar 3 Roller 1 35289 Tech notes 1 MFG 016 CHALLENGE WILL NOT ACCEPT RETURN OF SUGGESTED PARTS NOT USED IN A REBUILD F 669 D 820 870 Jan 98 WHITAKER 800 243 9226 5 W
47. PARATOR ADJUSTMENTS WHILE THE FOLDER IS RUNNING Separator Guide Plate fig 19 2 the handwheel until the separator tip is posi tioned over a solid portion of the sucker wheel i e be tween the rows of holes F 669 D 820 870 Jan 98 W 3 Place a one inch wide 25mm double thickness piece of stock to be folded under the tip of the separa tor plate fig 19 Lower the separator cw until there is a slight drag on the paper as it is pulled from under the separator Adjusting Knob Sheet Separator Vacuum Backstop Vacuum _ Advance fig 20 4 The vacuum advance knob is located on the side of the feed table fig 20 Adjusting the knob will position where the vacuum contacts the lift of paper ill 2a amp 2b Raising the knob will move the vacuum away from the lift and toward the rollers light papers Lowering the knob will move the vacuum contact toward the lift and away from the rollers heavy papers Horizontal Separator Adjustment 1 Raise the separator ccw to avoid marking the sucker wheel 2 Loosen knob ill 2 Setscrew in Accessory Kit item 14 pg 67 may replace knob if desired 3 As a starting reference turn the handwheel until a set of sucker wheel holes is at the 12 o clock position 4 Adjust separator assembly so that the plate is 1 16 forward of the 12 o clock position measure from the feed side of the plate 5 Tighten knob ill 2
48. 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 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 Serial Numbers 961533 8 Up INSTRUCTION AND PARTSMANUAL M EDALIST 820 870 TABLE MODEL Sold and Serviced by The Challenge Machinery Company 6125 Norton Center Drive Norton Shores MI
49. WHO 29 HS HOLIMS HOLIMS 14915 4015 GE TV 4 1041 09 03395 V Zd WHO MS 13 145 4015 AON3S9diNd HOLIMS IN vds dalla NYS HOLIMS 401931399 Wvr S Somos Se 7 Ge JOSS3HdWOO 261 HE 9 5 CT __ 1 Send 1018 0185 VC Ea VQ iZ Ze SE 2 T pZ po YOLOW 019 015 Al md MED 0820 3 L1OA OEZ JILVWN3HOS ANIHOVW 21578 028 Ge LG OND Z Lil dg 55 800 243 9226 WHITAKER BEERS W ce WHO 29 LH Hem EE HOLIMS 1 15 15 6E HOLIMS dOls 1 1622 33 135344 133 5 NSV 41873 2992 33 256 Gei SNVHLL CIVNOLLdO HOLIMS 015 40193139 A9N3933IN3 T EUM TN 0 o0 O e HO LIMS 7 ne 2 E ons MOSS3MdAOO LHM zz 26 6 Q D 4 3514 018 015 N39 vz p 77 22 970 741 1991 3 1044402 03395 TT DE LT Sg LZ LZ L1 Cd YOLOW 015 Y4IMOd E WHO 43385 G92 3 1 021 216 0 8 OoOoOoznutitLiuuot SE s F 669 D 820 870
50. ation and even scores and perfs scoring blade The degree of score desired may be obtained by moving the collars either closer or farther away from the blade Score Blade Score Collars Scoring ill 5 F 669 D 820 870 Jan 98 Perforating Perforating may be used to deliver a perforated sheet flat or as a guide for additional right angle folds NOTE A stripper is required for each perforator blade Stripper Adjusting Screw Perforator Blade Perforator Collar Perforating ill 6a The perforating blade and any additional blades purchased in addition to the one supplied is mounted on the upper shaft of the slitter assembly The perfo rating blade is run against the inside edge of the groove in the perforating collar mounted on the lower shaft ill 6a The curved slotted stripper finger is mounted on the square tie bar above the slitter assembly with one finger on either side of the perf blade The stripper finger prevents the paper from wrapping around the perf wheel It may be ad justed by loosening the button head screw in the mounting bracket and moving the fingers up or down ill 6a The fingers should be adjusted as close to the blade as possible without rubbing on it Contact with the holder will cause pre mature wear of the stripper fingers Slitting With the addition of a pair of slitting blades folded sheets may be cut apart after folding or before delivery to a right angle cross carrie
51. ct the fil ters and pour several teaspoons of solvent through the intake into a rag held over the opposite side fig 43 Pump Lubrication Your Challenge folder uses an oil less pump and motor Do Not Attempt to lubricate the pump or motor WHITAKER 800 243 9226 25 MAINTENANCE CONTD General Inspection All moving parts are subject to wear Periodic inspection will avoid machine failure in the middle of critical job runs Inspection should cover the following list of items Hoses Inspect for cracks and leaks Replace as necessary Drive Belts All belts stretch and wear Check and replace as necessary Keep replacement parts on hand Register Tapes and Stacker Belts Check for signs of wear alignment and proper tension Schedule replace ment before they fail on a critical job Rubber Wheels Pullout tires scoring wheels and stacker wheels should be inspected also Make sure they are in good condition to insure consistent delivery of folded pieces consistent stacking and accurate folds Keep extra score wheels on hand and make sure stacker wheels rotate freely DC Motor Brushes Motor brushes should be inspected approximately every three months If worn to 1 4 7mm or less replace the brushes Lubrication To ensure long life lubricate your machine weekly or after every 8 hours of use The best time to lubricate your machine is early in the week before start up This allows the lubricants to work in
52. d when they are correct replace the power panel WHITAKER BROTHERS 800 243 9226 Operation Crossfold System To run the two machines together as a Right Angle Crossfold System turn off the power to both machines Position the two machines together and connect the Crossfold Jumper Assembly item 1 in the drawing on the opposite page to the pigtails installed in the power panels Turn on the Right Angle Crossfold Unit FIRST When connected as a Crossfold System the Right Angle Crossfold unit is the master and must have the power turned on first Make any operational setup and ad justments as described in the operating section of this manual Operation Independent Folding Units To run two machines independently of each other disconnect the power and remove the Crossfold Jumper Assembly Install the Terminator Jumper Plug item 4 opposite page to the pigtail of the Parallel Folder Now the Parallel Unit and the Crossfold Unit may be operated independent of each other Cross fold Unit does not require a terminator WARNING Always disconnect the power to both folding units before making jumper or terminator connections 73 IMPOSITION MANUAL of the most common impositions are illustrated in the next pages These appear for reference only and do not imply suitability or practicality To assist you in planning any folding job first fold a Dummy by hand Use the most logical layout to avo
53. de so it is level with the fold rollers End to end it does not have to be level adjusting screws need only to be set low enough to provide enough contact between the friction drive collars fig 35 to drive the crosscarriage rollers 7 Reposition the delivery table and stacker wheel as sembly from the folder to the back of the right angle parallel unit fig 37 8 Position the transfer table onto the back of the folder It mounts in the same manner as the delivery table Insert the spring loaded end right side when viewed from the rear of the folder of the drive shaft into the locator hole in the side frame compress the spring against the frame and swing the opposite end into po sition in the other side fig 37 NOTE Make sure the drive gears mesh as shown in fig 36 9 Position the crosscarrier right angle unit against the back of your folder as in figure 32 pg 20 and proceed to make your conveyor and fold plate adjustments 10 Connect the electrical cable pigtails protruding above the electrical panels This allows the folders to communicate and shut down simultaneously in case of a paper jam in one or the other unit 11 Connect the power cord into the back of the power panel Plug the cord into a 20 amp grounded recep tacle 21 12 Turn on the Right Angle Crossfold Unit F RST When connected as a Crossfold System the Right Angle Crossfold unit is the master and must have the power turned on first
54. e any signs of damage on the freight bill and notify the claims department of the carrier within 15 days All claims for damage or loss are the responsibility of the receiver INSPECT PROMPTLY Check the contents of your container s against the following list NOTE The vacuum pump unit is shipped a separate container In the folder carton you should find the following sub assemblies 1 2 ONO O1 CO 10 11 12 Feed Table Assembly First Fold Plate Second Fold Plate otacker Tray Assembly otacker Wheel Assembly Accessory Package see parts list of Standard Accessories pg 66 Vacuum Tubes 3 Sound Guard Feeder Back Stop Compressor Unit Strainer Pump Unit P 102 The folder stand will arrive in a separate carton WHITAKER BROTHERS SINCE 1945 800 243 9226 5 INTRODUCTION clic WE SPECIFICATIONS SAFETY PRECAUTIONS CAUTION POWER LOCKOUT PROCEDURE WARNING LABEL DEFINITIONS N TAUA TION 1 T Power Hookup POW ET GOONS M Control 9 52551241
55. e cross carrier fig 35 Loosen the set screws in the collar and move the collar to the right until it aligns with the collar on the crosscarrier O rings should alternate contacts Retighten the set screws Transfer Table fig 36 B Install a transfer table drive gear onto the lower slitter shaft of the machine that is to be used as the main folder Remove the lower slitter shaft and re move all the drive wheels and any perf score or slit ting blades wheels Install the drive gear teeth first onto the shaft position and secure 1 4 from the end of the shaft see fig 36 Replace the drive wheels and any accessory wheels blades or collars Replace the scoring shaft into the folder Gear may be repositioned on the shaft if necessary once the transfer table has been installed Make sure all the set screws are tight ened securely BROTHERS 800 243 9226 C Install the electronic pigtail assembly so the ma chines can electronically communicate with each other Instructions for making this hookup can be found on pages 72 amp 73 in the Parts and Assembly Drawings section of this manual 6 Once the crosscarrier legs have been attached and the crosscarrier installed into the parallel unit level the crosscarrier by adjusting the leveling screws attached to the bottom of the support legs fig 33 pg 20 NOTE The carrier must be level side to si
56. e properly OBSERVE ALL CAUTION PLATES AND LABELS on this machine Keep foreign objects off table and away from rollers BEEXTREMELY CAREFUL when handling and changing the slitter perforating or scoring blades Severe lacerations or dismemberment could result from careless handling procedure Keepthe floor around the machine free of trim debris oil and grease e 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 DO NOT CLEAN ROLLERS WITH THE MACHINE RUNNING Disconnect the power and use the handwheel to turn the rollers DO NOT OPERATE WITH ANY GUARDS REMOVED Replace all guards after adjusting lubricating or servicing the machine CAUTION POWER LOCKOUT PROCEDURE For maximum safety and to prevent unauthorized use turn the power switch to the off position and disconnect the power cord whenever adjusting lubricating or making repairs to the machine fig 2 AF WHITAKER onn aaa 05592 F 69 D 82 870Jan 98 WHITAKER 800 243 9226 W WHITAKER BROTHERS WARNING LABEL DEFINITIONS SINGLE OPERATOR SHOCK HAZARD SHOCK HAZARD HAZARDOUS AREA 800 243 9226 Do not operate with more than one person Disconnect power before removing cover Replace cover before operation Disconnect power before removin
57. folded two or more up and slit apart EIGHT PAGE STEP FOLD Use Plates Parallel 1 2 be folded two or more up and slit apart F 669 D 820 870 Jan 98 THE FOLLOWING LAYOUTS REQUIRE THE USE OF THE CROSSFOLD SYSTEM DESIGNATED BY Right Angle IN THE ILLUSTRATIONS BELOW EIGHT PAGE 2 R A OBLONG Use Plates Parallel 1 Right Angle 1 TWELVE PAGE BOOK SADDLE STITCH Use Plates Parallel 1 2 Right Angle 1 TWELVE PAGE LETTER FOLD HEADS OUT Use Plates Parallel 1 Right Angle d W WHITAKER 800 243 9226 EIGHT PAGE RIGHT ANGLE Use Plates Parallel 1 Right Angle 1 TWELVE PAGE LETTER FOLD ACCORDIAN Use Plates Parallel 1 Right Angle 1 2 SIXTEEN PAGE FOLD Use Plates Parallel 1 Right Angle 1 2 s QG 2 d AJUO 921919191 10J 1 191 08 600SE VV Jed seiguiessy OM SLNANOdNOD ATEINASSV LAVHS 4311115 F 669 D 820 870 Jan 98 800 243 9226 WHITAKER BEERS W TION X 91 2 512250 X 8 91 114205 SSVMBO MANOS 135 00 9069 De AlgW3ssv ANH inoTind 88 900 W 9 8 6 ONIN 9NINIVL3M 8 01 8 4 X L 91 S 113005 135 POG 969 H ES A1BW3SSV 831115 Nid 20 53150853997 40 N
58. g cover Replace cover before operation Disconnect power before cleaning servicing or mak ing 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 INSTALLATION Note For Right Angle amp Crosscarrier assembly see page 20 Open the stand carton first and assemble ac cording to the instructions enclosed Using two people center the folder on the stand as shown fig 3 with the stand opening towards the front Do Not Lift on Drive Shaft round bar fig 3 Remove the parts of the folder checking them against the packing list on page 3 of this manual Remove and save the roller spacers on 820 only Steps for assembling the Medalist folder fig 4 1 Install the 2 lower foldplate Lower the cover and insert the 2 foldplate making sure the pins latch into WHITAKER BROTHERS SINCE 1945 800 243 9226 W the rail guides fig 4 and tighten the eccentric plate locks fig 6 Note both plates have two sets of locat ing holes in the plate rails The first set is used when the plate deflector is down the other when the plate is open see fig 5 1 Fold Plate Locating Pins Notched Plate Rail 5 2 Install the 1 upper foldplate fig 5 fig 6 3 Make sure the foldplate pins are located in the guide rails then lower the plate locks
59. he 8A fuse is conductive The transformer provides power to the start stop circuit and to the sheet counter Opening the main disconnect switch at any time cuts power to the transformer When the compressor ON switch is closed power is brought to the compressor When the START switch is closed the folder motor relay coil K will energize provided the jam detector switch the rear guard switch the emergency stop switch opt and the stop switch are closed Power is then supplied to the folder motor provided the 3 15A fuse is conductive The relay coil K remains energized until any of the above listed switches are opened The speed of the folder motor can be adjusted by turning the SPEED CONTROL knob WHITAKER 800 243 9226 53 CIVNOILdO HOLIMS TRUE E 3015 40193139 NYT WHO _ ag HOLIMS HOLIMS HOLIMS INI INVIS 9015 HVA CE CE 9 Cc 9 3514 018 015 T LE d G 26 1991 3 01145 V 77 vz 1 12 3514 Ld HOON 018 015 VG WHO MG 141445 1840 9 NYO 18 2 CG Nao L1OA 051 JILVW3HOS 216 028 E E OND M N N OND 1 OO Sp 0707210 0 pul E F 669 D 820 870 Jan 98 800 243 9226 BROTHERS WHITAKER W LVO e LVM Z OE
60. he Medallist 870 feature quick set up calipers Calipers adjust the space or tension be tween rollers to provide the proper grip on the paper for clean crisp folds Each time the paper is folded the thickness increases To compensate for this the cali pers on both sides of the machine have strips of paper inserted The correct number of paper strips to be placed into the calipers corresponds to the tail end of Fold Type 1 Caliper 2 Caliper Letter 1 1 2 1 1 1 2 Double 1 2 Parallel Stacker The stacker consists of a table belts wheels stacker springs and a delivery tray The stacker accumulates Stacker Springs fig 28 Stacker Wheels folded stock for easy removal and stocking The springs and stacker wheels keep the delivered sheets from opening up interleaving and creating paper jams Set up 1 Setthe stacker wheels back from the slitter shaft the width of the folded sheet plus an additional 1 4 2 wheels should be placed towards the center of the folded piece to stop it in position as it is ejected from the slitter assembly 3 Center stacker belts under stacker wheels 3 Caliper the sheet which will be the minimum thickness of the stock passing between the rollers Use 3 4 wide cut strips of the same material being folded Torn or folded strips will give improper settings Make sure that the calipers on both sides of the machine are set up with exactly the same
61. hold downs or deflectors from the crossfold assembly 2 Remove all the marbles from the marble holder 3 Loosen and remove the mounting screws holding the crosscarrier assembly to the parallel unit and take it off the machine 4 Remove the marble holder assembly by loosening the setscrews in the marble holder shaft mounting blocks fig 39 5 Remove the belt cover guards held with one screw in the middle of the frame WHITAKER 000 243 9226 BROTHERS W Marble Holder fig 39 fig 40 7 Remove the marble holder shaft mounting blocks 2 from their original position and reinstall them to the position fig 40 8 Remove the entire roller assembly by loosening the mounting screws 4 on each side that hold the roller mounting rails to the frame fig 41 23 9 Remove the four 4 screws fig 41 pg 23 mount ing the roller drive blocks and reposition from the A mounting holes to the B holes ill 8 INSET A 10 Grasp the roller assembly mounting rails and while turning the rollers slightly shift the assembly so that the rollers are positioned at the opposite angle as shown in illustration 7 11 Reassemble the cross carrier assembly to the frame by mounting in the appropriate holes 12 Taper plates should be flipped end to end and re mounted to the crosscarrier frame NOTE The mount ing blocks ill 8 ref 10 supporting the wide end of
62. id unnecessary folding problems such as air pockets and adverse grain effects If the stock or imposition is un usual try running a sample on the folder BEFORE PRINTING In order to use this imposition guide correctly itis necessary to refer to the plates in each section as follows Parallel Plates 1 2 Crosscarrier 1 2 up fold down fold up fold down fold FOUR PAGE Use Plates Parallel 1 May be folded two or more up and slit apart GATEFOLD Open Use Plates Parallel 1 2 be folded two or more up and slit apart WHITAKER BROTHERS SINCE 1945 800 243 9226 When planning a form check your folded Dummy for proper page numbers and correct guide edges As illustrated the sheets are visualized lying on the feed table The end toward the rollers is marked HEAD Illustrations of the folded product are shown as delivered to the delivery table The numbers on the illustrations indicate the page number of the final folded product Page numbers within circles indicate the page numbers on the side which woukd face down on the feed table Letters are used instead of numbers for pieces without distinct pages When folded letter surfaces will be face to face NOTE No responsibility either direct or assumed is indicated for errors in these examples Double Check Your Folded Dummy SIX PAGE ACCORDIAN Use Plates Parallel 1 May be
63. ith the hand wheel 3 Remove the spacers before running the next job F 669 D 820 870 Jan 98 vy Power Hookup The standard Medalist Folder requires a 120 volt 20 amp circuit with a three prong grounded receptacle It is the customer s responsibility to provide a power line that meets all local electrical codes Optional 50 Hz 240 volt machine draws 10 amps Provide proper circuit to handle load WARNING DISCONNECT PROCEDURE NEVER PULL THE CORD to disconnect the plug Cord fatigue could lead to shorts resulting in fire or personal injury from shock Always grasp plug body to disconnect power cord fig 2 pg 6 WARNING SHOCK HAZARD NEVER CUT THE GROUND LUG 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 Power Controls Power Cord Tum Een ER L Compressor 2 Switch 15 The power panel fig 15 is located on back of the folder below the first fold plate and stacker table The compressor unit power cord plugs into the socket on the left side of the power panel Make sure the power switch is in the OFF O or Open position The external power cord plugs into the power panel socket next to the switch WHITAKER BROTHERS 800 243 9226 C
64. lade Blade Holder Colla fig 30 Your Medalist includes perforator and scoring blades two scoring collars a rubber score wheel a blade holder and a grooved perf collar as standard equip ment fig 30 Installation of accessory blades and collars is simpli fied by the removable slitter assembly fig 31 Loosen the set screw in the sliding collar fig 31 Simply slide the slitter shaft to the right bring the opposite end out of the folder frame and remove the shaft assem Scoring Position your scoring blade as desired Scores should be made so that the blade runs on the side of the sheet that will be on the inside of the finished fold Scores may be made on the Medalist in two ways 1 The blade may be run on top of the rubber scoring wheel supplied The rubber wheel is simply positioned on the slitter shaft opposite the score blade 2 For a more controlled fold as might be needed with various stock thick nesses use the scoring collars on the shaft opposite the score blade ill 5 Position the collars on either side of the WHITAKER vy BROTHERS 8 SINCE 1945 800 243 9226 31 bly Install the accessory items as required rein stall NOTE Before tightening blade holder screws mount the holder with the blade loosely attached onto the slit ter shaft Now tighten the holder screws This en sures the blade is concentric with the slitter shaft mak ing for easier install
65. nect the compressor hoses to feed table assembly The sucker wheel hose threads through the ty rap and table support underneath the feed table then onto the end of the sucker wheel shaft tube as shown in fig 13 Blower Fittings fig 14 11 Attach the air hoses from the ends of the pile guides to the double hose fittings of the blower The single hose from the sucker wheel fitting attaches to the vacuum fitting fig 14 NOTE Make sure all shipping plugs are removed from the pump openings before attaching the hoses WHITAKER 000 243 9226 W Cleaning A clean machine will reflect in the quality of the work it produces As you unpack your folder wipe off any excess protective oil dirt or dust which may have ac cumulated during shipping Keep your machine clean and wipe off any accumulations of paper dust at the end of each day Cover your machine anytime it is not in use See the maintenance section for addi tional cleaning instructions NOTICE 820 ONLY Whenever the machine is not being used reinsert the roller spacers shipped in the machine to prevent spots from forming This is a operator controled maintenance function Roller flat spots are NOT COVERED under war ranty CAUTION DISCONNECT THE POWER BEFORE INSTALLING THE ROLLER SPACERS 1 Close the deflectors on both fold plates 2 Place one roller spacers at each side of the feed table and feed between the rollers w
66. number of paper strips The chart below gives the set ups for calipers and plates for sev eral common folds 1 Plate open open open open 2 Plate open open closed open 4 Position the stacker springs on the slitter shaft tie bar They should be positioned towards the outside of the sheet to hold the edges of the folded piece down fig 28 The springs may be bent for best operation 5 Depending on the stock and the type of fold best stacking performance may be had by using just the springs or the stacker wheels only Fine tune these adjustments as you run your job 6 Loosen lower knob to adjust stacker wheels from side to side Jam Detector As standard equipment all Medalist folders come equipped with a delivery area jam detector fig 29 This device senses jams at the feed table and immedi ately stops the folder until the jam is removed and the machine is restarted The jam detector is mounted on the center of the tie bar and looks similar to a third stacker spring it may be bent for best operation Er rh Jam Detector 4 29 F 669 D 820 870 Jan 98 WHITAKER 600 243 9220 W 5 5 WHITAKER 800 243 9226 W SPECIAL APPLICATIONS CAUTION Use extreme care when handling and changing the scoring or perforating blades Severe lacerations could result from careless handling procedures SLITTER ACCESSORIES JO gef LE B
67. on a variety of stock The proper amount of paper strips of the same material being folded in each caliper will give the best grip for a good fold As the paper is folded the thicknesses of the paper passing between the rollers increases The number of paper strips placed in the calipers should be equal to the minimum thickness of the paper pass ing between the rollers tail end of the sheet WHITAKER BROTHERS 800 243 9226 fig 27 To provide the proper clearance between rollers 3 4 wide paper strips are inserted into the calipers fig 27 Simply press the caliper lever and insert the cor rect number of strips into the open gap Put the same number of strips into both sides of the folder Do not use folded or torn strips of paper they may give false Dep Thickness 1 Caliper 1 Up Plate pi ill 4 readings Illustration 4 diagrams the position of roll ers fold plates feed table calipers and the correct number of paper strips to be placed into the calipers for a common Z fold The chart on page 16 shows the caliper and plate set up for several common folds NOTICE Whenever the machine is not being used put chipboard into the roller calipers in place of paper to prevent rollers from getting flat spots This is an operator controlled maintenance function Roller flat spots are NOT under warranty 15 Roller Caliper Quick Set Up Guide Roller calipers on t
68. ontrol Panel m A 711 1 41 Sheet Counter Reset Spec Control Roller Star Compressor Motor fig 16 The individual on off switches for the compressor and the roller motor are located on top of the roll guard cover fig 16 870 model shown They are marked with the international ON I and OFF symbols The rotary knob is the roller Speed Control The Sheet Counter window and the Counter Reset button optional on 820 models are located on the far left of this control panel as viewed from the feed table 11 Squaring In order for your machine to fold stock squarely it must be fed into the rollers square Your Medalist has been adjusted at the factory and should only require peri odic checks The Medalist has a unique feed table ad justment feature to quickly and easily adjust it if needed WARNING DISCONNECT THE POWER See power lockout procedure on page 6 Feed Table Squaring Screw fig 17 1 Adjust the feed table squaring screw and align the center line of the scale with the center mark on the feeder table fig 17 Front yr 4 Side Guides fig 18 2 Loosely position the feed table side guides to the scales on the feed table fig 178 18 Read the front scale at the inside edge of the side guide clamp block The rear scale will line up with the inside edge of the side guide The scales are
69. osscarrier Contact your authorized Challenge Dealer for details Instructions and parts included in the kit are as noted on the following pages W F 669 D 820 870 Jan 98 WHITAKER 800 243 9226 i OPTIONAL CROSSFOLD CONVERSION KIT 35537 A CAUTION Turn off the power to all units and disconnect the power cords before disassembling or making any electronic con nections Y M Standard LH ao AN Delivery i p de m RH We 50 ill 7 Crossfold Conversion Kit 35537 Ref Part No Description Qty A 35514 Marble Holder Assembly RH 1 Assembly includes items d f below B 35533 Cover RH Roller Belt 1 35534 Cover LH Roller 1 E 1172 20 Bushing Marble Holders 20 e H 6881 408 1 4 20x1 2 Hex Screw Plastic 2 f 6412 4 1 4 20 Hex Nut Plastic 2 In order to have your right angle crossfold machine carry to the right as it exits the folder the crosscarrier is used with simple repositioning of components No additional drilling or tapping of holes is required A few parts contained in the conversion kit will have to be exchanged Reference numbers in the instructions refer to parts in drawing at bottom of page 24 INSTRUCTIONS TO REPOSITION THE ROLLER ASSEMBLY FOR RH DELIVERY TO THE RIGHT ANGLE PARALLEL UNIT 1 Remove any
70. r Slitting blades are Slitting Blades Scoring ill 6b attached in the same manner as perforating blades Note that blades are mounted to blade holders with special flathead countersunk screws Mount the blade holder unit onto the upper shaft in the position the slit is to be made Position the second blade holder onto the lower slitter shaft as shown in illustration 6b above so that the flat edges of the blades fit together snug too much space will give ragged cuts Slitting blades may also be installed to run against a collar as shown in the perforating instructions WHITAKER 800 243 9226 W RIGHT ANGLE CROSSFOLD SYSTEM Challenge offers a Right Angle Crossfold System which 15 used in conjunction with the Medalist The System consists of a second parallel unit a cross fold carrier table shorter stand and a transfer assem bly which displaces the delivery table of the folder the delivery table is placed on the back of the crossfolder Disconnect power to units before positioning the crossfold sys tem and making the electronic connections Installation 1 Remove the stacker wheel assembly and delivery table from your folder See note on page 70 2 Reposition the folder on its stand Move the folder to the back edge of the stand as shown in the photo above fig 32 3 Place the folder for the crosscarrier onto its stand should also be positioned towards the back edge of its stand as
71. to the parts as the machine is operated rather than simply running off Oil and grease locations are listed below For oil locations use a Non Detergent 30 weight oil or approved equivalent Be careful not to over oil Oil left on rollers will cause them to swell which will interfere with folder performance For grease locations use Amoco Amalith 2 Challenge Part 6614 or approved equivalent Wipe off any excess Locations Model 820 Model 870 Drive Shaft Bearings page 30 ref no 60 page 36 ref no 59 Roller Bearings Not Applicable page 36 ref no 64 ES Stacker Drive Shaft Bearings page 32 ref no 40 amp 17 page 38 ref no 40 amp 17 ES Caliper Assembly Bearings Not Applicable page 36 ref no 64 Grease Locations ES All Roller Gears page 32 ref no 1 page 38 ref no 1 ES Slitter Drive Gears page 30 ref no 32 amp 68 page 36 ref no 30 amp 65 Slitter amp Handwheel Needle Bearings page 28 ref no 37 page 34 ref no 36 page 30 ref no 28 page 36 ref no 26 page 32 ref no 32 page 38 ref no 32 NOTE The vacuum pump unit is of an oil less type Do not attempt to lubricate the pump or motors Service Authorized Challenge Dealers are located throughout the United States Canada and the world They have factory trained service personnel on staff to handle all your service needs Call 1 616 842 8300 for the dealer nearest you WHITAKER 800 243 9226 m A NOTICE A
72. www WhitakerBrothers com The Challenge Machinery Company provides owner s manuals on its products solely as a courtesy to its customers oee the information below before using this manual manuals 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
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