Challenge 305 Technical reference manual

F.194-J
May 2019
CHAMPION 305
Manual Backgauge
Instruction and Parts Manual
Serial Numbers:
1301708 through 1599999,
305M-J-150000 and up
Sold and Serviced by
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441-6081 USA
ChallengeMachinery.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 noncurrent,
unsupported or no longer produced by The Challenge Machinery Company, and are provided solely as
an accommodation to our customers. By providing these manuals, The Challenge Machinery Company
makes no representation or warranty as to the products, their current condition, or their suitability or fitness
for use in any particular application, which are the sole and independent responsibility of the product
owner and user.
Older products may not comply with current safety procedures, guidelines or regulations, and it
is the product owner's and user's responsibility to evaluate the suitability and fitness of the
products in their current use and application. The Challenge Machinery Company makes no
representation, warranty or recommendation regarding any modifications which may be required
on non-current or unsupported products. The Challenge Machinery Company assumes no liability
for any modification or alteration to any Challenge product, and any such modification or
alteration to any Challenge product is not authorized by The Challenge Machinery Company. The
availability of these manuals is solely for the purpose of providing reference information for the products.
This manual may not be complete in all aspects of product maintenance and repair. All products should
be used only by qualified and properly trained personnel, following proper safety procedures. All
products should be regularly inspected and maintained, and their condition, application and use should
be periodically evaluated by qualified personnel. Only qualified and properly trained technicians should
perform maintenance, repair and replacement procedures. Attempting 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.

1.0 Introduction
2
1.0 Introduction
This manual is designed to help you get the most from your Challenge equipment. Keep this manual
in a safe, convenient place for quick reference by operators and service personnel.
SAFETY ALERT! This symbol means CAUTION: Personal safety
instructions! Pay special attention to the instructions in bold type. Personal injury may result if the
precautions are not read and followed.
READ THIS MANUAL BEFORE OPERATING! Follow the precautions and instructions given. 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
the 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.
RECORD YOUR MACHINE SERIAL NUMBER in the space provided on the front cover of this
manual. 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 Norton Shores MI 49441.
CHALLENGE MODEL
SERIAL NUMBER
ATTN
COMPANY
ADDRESS
CITY
STATE/PROVINCE
ZIP
PHONE
DATE INSTALLED
DEALER NAME & CITY
* WARRANTY INFORMATION *
It is very important that you read and understand the conditions outlined in the Warranty Information
Sheet attached to the outside of the shipping container of your machine.
The Warranty Information Sheet must be filled out completely and returned to THE CHALLENGE
MACHINERY COMPANY in order for the warranty to be issued for this machine.
Challenge® is a registered trademark of
The Challenge Machinery Company 6125 Norton Center Drive Norton Shores MI 49417
Copyright© 1997-2019 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A

1.0 Introduction
3
TABLE OF CONTENTS
1.0 Introduction .......................................................................................................................................2
2.0 Safety................................................................................................................................................6
2.1 Precautions...................................................................................................................................6
2.2 Power Lockout Procedure ............................................................................................................6
2.3 Warning Label Definitions.............................................................................................................7
3.0 Packing List.......................................................................................................................................9
4.0 Specifications................................................................................................................................. 10
5.0 Footprint......................................................................................................................................... 11
6.0 Installation & Setup........................................................................................................................ 12
6.1 Inspecting Shipment.................................................................................................................. 12
6.2 Uncrating ................................................................................................................................... 12
6.3 Lifting Instructions...................................................................................................................... 12
6.4 Moving Instructions.................................................................................................................... 13
6.5 Cleaning..................................................................................................................................... 13
6.6 Assembly................................................................................................................................... 13
6.7 Hydraulic Power Unit Removal.................................................................................................. 14
6.8 Hydraulic Check......................................................................................................................... 14
6.9 Power Hook-Up ......................................................................................................................... 15
7.0 Operation ....................................................................................................................................... 17
7.1 Power –Main Switch ................................................................................................................. 17
7.2 Table Light................................................................................................................................. 17
7.3 Presetting the Backgauge ......................................................................................................... 18
7.4 Backlash Indicator ..................................................................................................................... 18
7.5 Backgauge Lock ........................................................................................................................ 18
7.6 IN/MM Toggle Key..................................................................................................................... 18
7.7 Making a Cut.............................................................................................................................. 18
7.8 Turning Off the Hydraulic Motor ................................................................................................ 19
7.9 Jogging Aid................................................................................................................................ 19
7.10 Pre-Clamping........................................................................................................................... 19
7.11 Air Table ON/OFF.................................................................................................................... 19
7.12 Adjusting the Clamp Pressure................................................................................................. 19
7.13 Knife Down Mode .................................................................................................................... 20
7.14 Electric Eyes............................................................................................................................ 20
7.15 False Clamp Plate ................................................................................................................... 20
7.16 Operating Tips......................................................................................................................... 21
8.0 Knife Installation/Changing ............................................................................................................ 22
8.1 Knife Removal ........................................................................................................................... 23
8.2 Knife Installation ........................................................................................................................ 24
8.3 Knife Care Tips.......................................................................................................................... 26
8.3.1 Knife Blade Life .................................................................................................................. 26
8.3.2 Cutting Stick ....................................................................................................................... 27
8.3.3 Bevel Angle ........................................................................................................................ 27
8.3.4 Helpful Suggestions ........................................................................................................... 27
8.3.5 Knife Care........................................................................................................................... 27
Maintenance Section............................................................................................................................ 29
9.0 Cleaning......................................................................................................................................... 30
9.1 Table.......................................................................................................................................... 30
9.2 Console...................................................................................................................................... 31
9.3 Machine Frame.......................................................................................................................... 31
10.0 Lubrication.................................................................................................................................... 32
11.0 Hydraulic System......................................................................................................................... 35

1.0 Introduction
4
11.1 Recommended Hydraulic Oil ...................................................................................................35
11.2 Changing the Oil.......................................................................................................................35
11.3 Hydraulic Valve Adjustments ...................................................................................................36
12.0 Adjustments..................................................................................................................................41
12.1 Electric Eye Alignment .............................................................................................................41
12.2 Backgauge Gib Adjustment......................................................................................................42
12.3 Squaring the Backgauge..........................................................................................................43
12.4 Backgauge Position Accuracy Adjustment ..............................................................................44
12.5 Knife Latch Adjustment ............................................................................................................45
12.6 Line Light Adjustment (Incandescent Type).............................................................................46
12.7 Line Light Adjustment (LED Type)...........................................................................................47
12.8 Proximity Switches...................................................................................................................48
12.9 Clamp Return Speed Adjustment.............................................................................................50
12.10 Pre-Clamp Pressure Adjustment............................................................................................51
12.11 Pre-Clamp Speed Adjustment................................................................................................51
12.12 Clamp Cylinder Adjustment (Clamp Height) ..........................................................................52
12.13 Clamp Parallel Rod ................................................................................................................53
12.14 Lead Screw Adjustment Nuts.................................................................................................53
12.15 Knife Bar Gibs ........................................................................................................................54
13.0 Repair and Replacement..............................................................................................................56
13.1 Fuses (skip this section if the machine has Circuit Breakers)..................................................56
13.2 Knife Cylinder Replacement.....................................................................................................56
14.0 Troubleshooting............................................................................................................................59
14.1 Menu Tree................................................................................................................................62
14.2 Diagnostic LED’s ......................................................................................................................63
14.3 Description of Error Messages.................................................................................................64
14.4 Sensor Data Abbreviations ......................................................................................................65
15.0 Schematics & Parts Lists..............................................................................................................66
15.1 Main Assembly –Frame/Tank .................................................................................................66
15.2 Main Assembly –Hydraulics....................................................................................................68
15.3 Main Assembly –Clamp ..........................................................................................................70
15.4 Main Assembly–Electrical Components, Lower Front ............................................................72
15.5 Main Assembly –Electrical Components, Upper.....................................................................74
15.6 Main Assembly –Electrical Components, Upper.....................................................................76
15.7 Main Assembly –Air Table Option...........................................................................................78
15.8 Main Assembly –Table Mounting............................................................................................80
15.9 Main Assembly –Backgauge Assembly..................................................................................82
15.10 Main Assembly –Knife...........................................................................................................84
15.11 Main Assembly –Covers and Labels.....................................................................................86
15.12 Main Assembly –Table Extensions.......................................................................................88
15.13 Power Panel Assembly (w/ Fuses) ........................................................................................90
15.14 Power Panel Assembly (w/Circuit Breakers) .........................................................................95
15.15 Basic Machine Schematic w/Fuses......................................................................................100
15.16 Basic Machine Schematic –Ergo Touch Models w/Fuses..................................................101
15.17 Basic Machine Schematic –Standard Cut w/Circuit Breakers ............................................103
15.18 Basic Machine Schematic –Ergo Touch w/Circuit Breakers...............................................104
15.19 Interconnection Diagram......................................................................................................105
15.20 Hydraulic Manifold Kit...........................................................................................................106
15.20.1 Knife Down Sequence Valve Assembly........................................................................107
15.20.2 Hydraulic Manifold Assembly........................................................................................108
15.20.2.1 Hydraulic Manifold.................................................................................................109
15.21 Hydraulic Schematic.............................................................................................................110
15.22 Control Console Assembly...................................................................................................111
15.23 Cut Button Assembly............................................................................................................113
15.24 Cut Button Kit –Ergo Style Touch Switches........................................................................115

1.0 Introduction
5
15.25 Line Light Assembly............................................................................................................. 117
15.26 Compressor Assembly......................................................................................................... 118
15.27 Encoder Cable Assembly .................................................................................................... 119
15.28 Knife Latch Assembly.......................................................................................................... 120
15.29 Power Panel Connection Procedure Label (Fuses) ............................................................ 121
15.30 Power Connection Procedure Label –Circuit Breakers...................................................... 122
15.31 Air Table Blower Assembly (For Air Table Option).............................................................. 123
15.32 Paper Deflector Kit (Option) ................................................................................................ 124
15.32.1 Deflector & Shaft Assembly (Part of Paper Deflector Kit)............................................ 125

2.0 Safety
6
2.0 Safety
2.1 Precautions
This machine is designed for one-person operation. Never operate the machine with more than
one person.
Safe use of this machine is the responsibility of the operator. Use good judgment and common
sense when working with and around this machine.
Read and understand all instructions thoroughly before using the machine. If questions remain,
contact 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.
Disconnect power before cleaning or performing maintenance. See Section 2.2 Power Lockout
Procedure.
Observe all caution labels and plates on this machine.
Be sure the cutter is properly grounded.
Be sure there is sufficient power to operate the cutter properly.
Keep foreign objects off the table and away from cutter blade.
BE EXTREMELY CAREFUL when handling and changing the cutter knife. Severe lacerations or
dismemberment could result from careless handling procedures.
Keep the floor around the cutter free of trim, debris, oil and grease.
When replacing hydraulic parts, loosen the connections slowly to release pressure. Never loosen
connections with the machine running.
If the cutter sounds unusual or operates abnormally, turn it off and consult the troubleshooting
section of this manual. If the problem cannot be corrected, have it checked by a qualified service
person.
CRUSH HAZARD, keep hands and fingers from under the clamp while clamping. Use Jogging
Aid to load paper, and use the backgauge to push paper out before unloading. DO NOT REACH
UNDER THE KNIFE AND CLAMP AREA!
2.2 Power Lockout Procedure
For maximum safety when making adjustments or repairs to your machine, be sure to lock out the
main power control switch to which the machine is connected. The switch should be moved to the
OFF position and a padlock placed in the loop. The person servicing the machine should hold the
key.
Figure 1

2.0 Safety
7
2.3 Warning Label Definitions
The following warning labels are found at various locations on your machine. Read and understand
the meaning of each symbol. If a label is lost from the machine, it should be replaced. .
HAZARDOUS AREA
Disconnect power before cleaning, servicing, or making adjustments not requiring
power. Do not alter safety guards or devices; they are for your protection. Replace
all guards. Do not operate with any guards removed.
SHOCK HAZARD
Disconnect power before removing cover. Replace cover before operation.
SHOCK HAZARD
Disconnect power before removing cover. Replace cover before operation.
SINGLE OPERATOR
Do not operate with more than one person.

2.0 Safety
8
!OJO!
This Este simbolo de alerta de seguridad significa ¡ OJO ! -
INSTRUCCIONES DE SEGURIDADPERSONAL. Lea las instrucciones porque se refieren a su
seguridad personal. Fall de obedecer las instrucciones que siguen podria resultar en lesiones
corporales.
Esta maquina, junto con sus mecanismos de seguridad, esta disenada para ser manejada por
UNA SOLA PERSONA a la vez. Jamas debe ser manejada por mas de una persona al mismo
tiempo.
La seguridad es la responsabilidad del operario que usa esta maquina.
LEA DETENIDAMENTE el manual de instrucciones y las PRECAUCIONES DE SEGURIDAD
antes de poner a funcionar la cortadora. Pidale a su supervisor una copia.
El manejo de la guillotina debe estar exclusivamente a cargo de personal entrenado y autorizado
para ello.
NO MODIFIQUE LOS MECANISMOS DE SEGURIDAD, estan ahi para su proteccion no deben
ni modificarse ni quitarse.
DESCONECTE LA CORRIENTE ELECTRICA antes de proceder a hacerle servicio de limpieza,
engrasar, o de hacer adjustes que no requieren corriente. Trabe el interruptor en la posicion
OFF (apagado); vea “Procedimiento para cortar la corriente electrica” al pie de esta pagina.
Eche llave a la guillotina y quite la llave cuando la maquina no esta en operacion; vea “Corriente
electrica”.
Asegurese de que la guillotina este debidamente a tierra. Vea “Conexion de la fuerza electrica”.
Verifique el voltaje y asegurese de que este sea suficiente para el debido funcionamiento de la
guillotina.
Preste atencion a todas las placas con advertencias instaladas en esta guillotina.
No permita que objetos estranos esten en la mesa o cerca de la cuchilla cortadora.
TENGA SUMO CUIDADO al tocar y cambiar la cuchilla. Heridas severas y hasta
desmembramiento pueden resultar del manejo sin cuidado o negligente.
El suelo alrededor de la guillotina debe mantenerse despejado y libre de recortes, desperdicios,
aceite y grasa.
Al haber la necesidad de reemplazar partes hidraulicas, afloje todas las conexiones poco a poco
para dejar escapar la presion. Jamas debe aflojarse conexiones mientras la maquina este
andando.
Si la guillotina empezara a sonar o trabajar diferentemente a lo acostumbrado, desconectela y
consulte la seccion “Troubleshooting” (Reparador) de este manual. Si no es posible corregir el
problema, llame a su servicio autorizado para que le examinen la maquina.
PELIGRO DE MACHUQUE - Mantenga manos y dedos fuera de la agarradera mientras sujeta el
papel. Use el calibrador trasero y su rueda de mano para empujar el papel cortado. NO PONGA
SUS MANOS BAJOLA CUCHILLA O AREA DE LA AGARRADERA.
NO OPERE SIN LAS GUARDAS PROTECTORAS!
¡ OJO ! PRECAUCION - Como proceder para desconectar
la corriente electrica.
Para maxima seguridad durante ajustes y reparaciones de su maquina, verifique bien que el interruptor principal
de control de corriente al cual la maquina esta conectada, este desconectado. El interruptor deba ser puesto en
la posicion “OFF” (desconectado) y se debe poner un candado en la anilla. La llave del candado debe ser
guardada por la persona que estara efectuando los trabajos de servicio o de reparacion en la guillotina.
Desconecte la corriente electrica antes de proceder a hacer cualquier ajuste o reparacion o de efectuar el
engrase en cualquier maquina.

3.0 Packing List
9
3.0 Packing List
Part No.
Description
Qty.
Basic Machine
1
Extension Side Tables:
47166
18 x 24 Steel Side Table
2
47164-1
Side Table Back Plate
2
H-6913-606
Side Table Bolts
8
H-6424-6
Side Table Hex Nuts
8
H-6939-616
Leveling Screws
4
H-6913-6008
Side Table Mounting Bolts (shipped installed)
4
H-7321-6
Side Table Mounting Washers (shipped installed)
4
47006-2
False Clamp Plate (shipped installed)
1
47508
Knife
2
H-6918-608
Knife Bolts
6
8815
Knife Washers, Special
6
4171
Cutting Sticks (one installed)
4
47575
Knife Lifter Assembly
1
A-12608-4
Jogging Aid
1
Tool Kit:
K-47548-1
5064
Cutting Stick Puller
1
W-164
Hex “T” Wrench
1
W-158
5/16 Open End Wrench
1
W-141
1/8”
1
W-137
5/32”
1

4.0 Specifications
10
4.0 Specifications
Description
Inch Units
Metric Units
Cutting Width
30 ½”
77.5 cm
Clamp Opening
4”
10.2 cm
Clamping Force
400-5000 lbs.
1.8 –22 kN
Minimum Cut –Standard
¾”
1.9 cm
- Special
½”
1.3 cm
- w/ False Clamp Plate
2”
5.1 cm
Table Space
Front: (std.)
Back:
25”
30 ½”
63.5 cm
77.5 cm
Dimensions
Table Height
36 ½“
92.7 cm
Overall Height
58 ½”
148.6 cm
Overall Length
69 ½”
176.5 cm
Overall Width
48 ½”
123 cm
w/ Side Tables
78 ½”
200 cm
w/o Side Tables
48 ½”
123 cm
Approx. Net Weight
2550 lbs
1157 kg
Approx. Shipping Weight
2750 lbs
1247 kg
Will pass through door:
Assembled
49”
125 cm
Table/treadle out
42”
112 cm
Table/treadle/pwr unit out
24-1/2”
63 cm
Electrical
Standard: 5 HP, 3 Phase, 60 Hz AC; 208/230V, @ 25A or 460V @ 11.5A
Optional: 3 Phase, 50 Hz AC; 220V or 380V , 1 Phase –phase converter kit K-3482
Electric Eyes –E-3370
Response time = 68 ms
Object detection capability = 12 mm
Challenge reserves the right to make changes to any product or specification without notice and
without incurring responsibility to existing units.