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.

5.0 Footprint
11
5.0 Footprint

6.0 Installation & Setup
12
6.0 Installation & Setup
6.1 Inspecting Shipment
This machine has been carefully packed to prevent damage during shipment. However, claims for
damage or loss are the responsibility of the recipient. Inspect all shipments as soon as they are
received. If there is any noticeable damage, note it on the freight bill. Visual and/or hidden damage
must be reported to the claims department of the carrier within 15 days. Contact your dealer if you
need any assistance. Check the contents of the box against the packing list on page 9. Make sure
there are no missing items.
6.2 Uncrating
This machine is lagged to a wood skid and covered with a triple-walled corrugated container. Loosen
the flaps of the carton where they are attached to the skid. When loose, the carton can be lifted
straight up. Remove the side tables and accessory box, which are also attached to the skid. Place
the cutter/skid about where the machine will be positioned and remove the lag screws from the skid.
6.3 Lifting Instructions
Unpacking, handling, and positioning should be done by professional riggers. If handling or
unpacking is a problem, your dealer or a local trucking facility should be able to supply or recommend
a qualified rigger. This 2550-lb/1157-kg machine should be moved with experienced people and the
proper equipment. Do not risk personal injury or damage by attempting to move machinery with
inadequate equipment or manpower.
Lifting straps may also be used to lift the machine by placing the straps around the front and rear of the
table. When straps are used in this way, wood blocks must be placed beside the lead screw to prevent
damage, (Figure 2). A bent lead screw will cause the backgauge to bind.
Figure 2
The backgauge should be positioned all the way to the front of the table and straps placed as close the
machine body as possible. Gently lift the cutter, remove the skid and carefully place the cutter on the
floor.
Once the machine is off its skid, it can be moved with a forklift or pallet jack.

6.0 Installation & Setup
13
6.4 Moving Instructions
Use a forklift or pallet jack to move the machine from the front. Do not attempt to lift from the sides or
rear.
6.5 Cleaning
Wipe down the table and bare metal surfaces with a non-flammable solvent such as CRC or blanket
wash. The table surface is cast iron, and it will rust if left unprotected. Coat the table with a non-
abrasive wax. A Cutter Care Kit, p/n 16077, with cleaner and wax, is available through your
Authorized Challenge Dealer. The protective film on the console may be removed. Never clean
console with petroleum based solvents. Damage will result.
6.6 Assembly
Unless otherwise specified, the only items that have been disassembled for shipping are the Reach-
Around shields on the electric eyes and extension tables. Extension table attachment follows.
NOTE: Extension tables are heavy. Use two people to attach them to the machine.
1. Assemble the back stops to the extension tables. The extension table bolts and hex nuts are
packed in the tool kit box. Tables are installed with the clearance hole for the knife gibs
towards the center of the cutter.
2. One person should hold the extension table in position while the other aligns the holes and
starts threading the mounting bolts with washers. The mounting bolts are shipped installed in
the side of table- remove them to install tables.
3. Use a 9/16” socket and extension to snug tighten the mounting bolts, then tap the extension
table up or down with your hand or a rubber mallet until it is flush with the main table. Run a
straight edge or sheet of paper over the seam to check the fit. Make sure your stock will not
catch on the seam.
4. Insert the leveling setscrews into the threaded holes next to the mounting bolts. You may
have to loosen the mounting bolts slightly to allow enough play to level the table. After the
extension tables are leveled and the surface joints even, tighten the mounting bolts securely.
5. The extension tables are powder-coated and need only be wiped down with a dry cloth. DO
NOT apply solvents or abrasive cleaners to extension table surfaces. They may cause
discoloration or scratches.
NOTE: The Reach-Around Shields for the electric eyes are in their shipping positions –follow the
instructions below to secure them in the operational position.
1. On the bottom of the electric eye housing –loosen the screw closet to the machine. Do not
remove the screw
2. On the bottom of the electric eye housing –loosen and remove the other two screws –rotate
the shield back out of the cut area. Line up the holes and re-install the screws –tighten all
screws (See the instruction sheet included in the shipping material for more details).
ATTENTION: FAILURE TO INSTALL THE REACH-AROUND SHIELDS COULD CAUSE A
POTENTIAL CRUSH/LACERATION HAZZARD –THE SHIELDS ARE THERE FOR YOUR SAFETY.

6.0 Installation & Setup
14
6.7 Hydraulic Power Unit Removal
If installation requires that the machine pass through a doorway that is less than 49” but greater than
or equal to 42” wide, the machine should have been ordered from Challenge “knocked down” with the
table removed. If the machine must fit through a doorway that is less than 42” and greater than or
equal to 24-1/2”, the hydraulic power unit must be removed on-site. To remove the hydraulic power
unit, follow the instructions below.
1. Disconnect the electrical conduits to the hydraulic motor, air blower, and hydraulic cooling
fan, junction box.
2. Remove the filler cap and use a transfer pump to move the hydraulic fluid into buckets.
3. Locate the hose that connects the manifold to the oil filter. Disconnect it from the filter.
Disconnect the hydraulic pump hose from the manifold. Attach the hose that was connected
to the manifold to the oil filter. Attach the hose that was connected to the filter to the
manifold. This will minimize oil leakage. After the unit is installed, reconnect the hoses to
their original location.
4. Remove the (4) bolts that attach the hydraulic assembly to the cutter base. They are located
at the bottom shelf the base.
5. USE EXTREME CAUTION WHILE REMOVING THE POWER UNIT. It is very heavy and
should be removed using a fork truck. CAUTION, the machine will be top heavy and may tip
easily with the power unit removed. Move the reservoir through the doorway on its side.
6. DO NOT ATTEMPT TO LIFT THE CUTTER BY PLACING STRAPS OR THE FORKS OF A
TRUCK UNDER THE CLAMP. This can damage the machine.
7. Reinstall the power unit, conduits, hoses, after the machine is in position. Refill the hydraulic
reservoir.
6.8 Hydraulic Check
The hydraulic reservoir is filled with 13-1/2 gallons of ISO VG 46 hydraulic oil at the factory. The fluid
level should be checked during installation, and at least once per week during normal operation. The
reservoir is located behind the cutter, beneath the table (Figure 3). Remove the filler cap to check the
fluid level. The fluid level should be approximately 2” (5cm) from the top of the tank.
NOTE: DO NOT OVERFILL. Overfilling may cause leakage when the machine is hot.
Figure 3
Hydraulic
Tank
Filler
Cap

6.0 Installation & Setup
15
6.9 Power Hook-Up
For satisfactory operation, be sure that your cutter is wired for the correct phase and voltage and has
adequate power. The correct electrical specifications for your machine are shown on the serial plate.
Check the machine serial plate before connecting the power. For future reference, transfer this
information to the front cover of this manual.
Watch Setup Voltage- Inadequate power to the cutter can be a major source of problems. Too many
machines on the same circuit will reduce the power to each machine. Inadequate voltage will cause
overheating, loss of power, and in extreme cases, failure to operate. Test line voltage when the shop
is at actual working levels. A dedicated line with a lockable disconnect is required to provide adequate
power for this machine.
CAUTION: SHOCK HAZARD! Always disconnect power at main
power panel before working on the cutter. Lock it out to prevent accidental power up. (See
Power Lockout Procedure page 6).
Important: You must have an adequate size circuit and heavy enough wiring for this machine. The
circuit size should be a minimum of 20% greater than the amperage rating on the machine nameplate.
If a wire is run over 75 feet (23 meters), the next size wire should be used. Check local electrical codes.
Electrical Specifications for Champion Cutters
Volts Amps Circuit Size Wire Size Metric Wire
3 Phase: 460 V 11.5 20 A #12 AWG 4mm sq.
230 25 35 #8 10mm sq.
208 25 35 #8 10mm sq.
The power source is connected to the cutter through the bottom of the power panel (right hand side).
1. DISCONNECT AND LOCK OUT THE POWER at the main panel to prevent accidental power
up. (See Power Lockout, page 6).
2. Thread the power cord through a conduit connector into the power panel.
3. Fasten the ground lead to the ground terminal lug (Figure 4).

6.0 Installation & Setup
16
Figure 4
4. Fasten the three power leads to the three terminals of the main power terminal block- L1, L2,
& L3.
5. Close the electrical panel doors and latch them. Unlock the main panel and turn on the
power. Turn on the main power disconnect switch located on the front face of the table.
6. Press both cut buttons simultaneously to activate the motor and check to make sure it is
turning the same direction as the arrow on the motor casing. If it is not turning the proper
direction, disconnect the power and exchange any two leads of the power cord as in Figure 5.
Figure 5
CUSTOMER
GROUND SCREW
CUSTOMER HOOK-UP
TERMINAL BLOCKS
CUSTOMER HOOK-UP
TERMINAL BLOCKS
CUSTOMER
GROUND SCREW
POWER SOURCE
T1
T2
AIR RELAY
13
12
11
10
4 6 8
9753
2
1
STARTER
OVER-
BLOCKS
FUSE
FUSE
FUSE
PC BOARD
CONTROLLER
L1
L2
L3
EMI
FILTER
TRANSFORMER
FUSE
CLAMP COMP.
FUSE
MSCE1
LOAD
RELAY
FUSES
RELAY
CUT
RELAY
TERMINAL
{
PCF5
EMI
FILTER
PCF2 H7
PCF4 PCF3
11
PCF1
10
TERMINAL
BLOCKS
2
1 3 5
4
7
68
9
TRANSFORMER
T1
LOAD
LINE
CONTROLLER
PC BOARD
12 13
T2
POWER SOURCE
{L3
L2
L1
CLAMP COMP.
AIR RELAY
RELAY
LOAD
STARTER
RELAY
RELAY
CUT MSCE1
OVER-
CIRCUIT
BREAKERS
GND
GND
1
2
3
1
2
3

7.0 Operation
17
7.0 Operation
Figure 6
IMPORTANT: DO NOT ATTEMPT TO OPERATE THE CUTTER UNTIL YOU HAVE THOROUGHLY
READ AND UNDERSTAND ALL OF THE FOLLOWING INSTRUCTIONS. CALL YOUR
AUTHORIZED CHALLENGE DEALER IF YOU STILL HAVE ANY QUESTIONS.
7.1 Power –Main Switch
Power is applied to the machine when the main power switch is turned to the “ON” position (Figure 7).
The display and line lights are turned on at this time.
Figure 7
The display and line lights will shut off after a few minutes (depending on setting) without any activity.
To restore power to the display and line lights, press either cut button.
7.2 Table Light
For machines with a fluorescent table light - the table light is turned on and off using a switch located
under the arch. The table light will also turn on and off with the main power, provided the table light
switch is in the “on” position. If the machine has an LED table light the light turns on and off with the
hydraulic motor.
OFF
ON

7.0 Operation
18
7.3 Presetting the Backgauge
The backgauge must be preset every time the power is turned on. Using the hand wheel, turn the
backgauge until it passes forward through the 5” position. The display readout will then show the
correct backgauge position.
7.4 Backlash Indicator
A small caret will be displayed next to the backgauge position if the backgauge was last moved
backward. To insure accurate cuts, always approach the desired backgauge position from behind
(moving the backgauge forward).
7.5 Backgauge Lock
Tightening the backgauge lock prevents the backgauge from moving while positioning paper against
it. There is a thumb screw lock beneath the hand wheel, (Figure 8).
Figure 8
7.6 IN/MM Toggle Key
This switch will toggle the display readout between inches, fractions, and millimeters. It can be found
on the console as shown in Figure 6.
7.7 Making a Cut
Place the paper against the backgauge and left side guide. Press and release both cut buttons once
to start the hydraulic motor. Then press and hold both cut buttons to start the cut cycle. While
holding the cut buttons, the knife and clamp will complete the cut cycle. If the buttons are released at
any time during the cycle, the knife and clamp will immediately return to the up position.
Note: Both cut buttons must be released before a new cut can be made. The cut buttons must be
pressed within 1/2 second of each other both to start the hydraulic motor and to make a cut.
DO NOT ATTEMPT TO REMOVE TRIM UNTIL THE KNIFE AND CLAMP
HAVE STOPPED IN THE UP POSITION! Due to static buildup, fine trim may have a tendency to
stick to the clamp or knife surfaces. Fingertips might be drawn into the knife by the clamp if this is
attempted. Wait until the knife and clamp have BOTH STOPPED MOVING before removing stock
trim.
Thumb Screw
Lock

7.0 Operation
19
7.8 Turning Off the Hydraulic Motor
The hydraulic motor will turn off after a few minutes (depending on setting) without any activity. The
hydraulic motor can also be shut off manually by pressing and holding the left cut button.
7.9 Jogging Aid
All Champion cutters include a jogging aid as standard equipment. The jogging aid allows the
operator to load and align stock without placing hands or arms under the clamp and knife area. Load
and align the paper against the side guide, (Figure 9), then square it to the backgauge for cutting.
Figure 9
Additional jogging aids can be purchased by contacting your authorized Challenge dealer.
Always remove the jogging aid from the table before making a cut.
7.10 Pre-Clamping
All Champion cutters are equipped with a low pressure clamping feature which allows the operator to
clamp paper before beginning the cut cycle. To use this feature, press the footswitch until the clamp
comes down on the paper. While holding the foot switch down, press the cut buttons. Release it
once the cut has been completed. Although this is low pressure clamping, avoid placing hands under
the clamp at all times.
7.11 Air Table ON/OFF
If your machine is equipped with an air table, it can be turned on and off by pressing the “D” soft key .
7.12 Adjusting the Clamp Pressure
DO NOT set the clamp pressure below 300 psi. Pressures below this
will not allow the auto-cycle to operate properly, and the knife will come down before the
clamp. Severe lacerations and stock spoilage could result.
A pressure reducer valve and gauge located inside the left door housing on the front of the cutter
below the table. By adjusting the pressure reducer valve, clamping pressure can be set (see
Hydraulic Adjustments section) to a maximum of 1400 psi for heavy stock or large reams to a
minimum of 400 psi for pressure sensitive jobs like carbon or NCR sets. For pressure sensitive stock
using the false clamp plate is also recommended.

7.0 Operation
20
7.13 Knife Down Mode
The knife down mode is used to send the knife and clamp to the down position without returning up.
This provides a way for the service technician to adjust the knife. To send the knife down or up, enter
maintenance mode, “A”. Select either Knife Down or Knife Up, and then press the cut buttons. When
sending the knife down, the cut buttons must be held until the motor stops.
7.14 Electric Eyes
The electric eyes prevent reaching into the cutting area while a cut is being made. If the beams are
broken while a cut is being made, the knife and clamp will return to the up position.
7.15 False Clamp Plate
To prevent marking on pressure sensitive jobs, a false clamp plate has been included (installed) with
your machine. This plate attaches to the bottom of the clamp. It is secured from the front of the
cutter with three set screws.
ALWAYS disconnect the power and LOCK IT OUT before installing or
removing the false clamp plate. NEVER attempt to install or remove the false clamp plate while the
machine is running. Remove all tools and stand clear when reconnecting power.
To install:
1. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout, page 6.)
2. Position the false clamp plate under the clamp, (Figure 10). The locator pegs are positioned
to the rear of the cutter and are set into holes in the bottom of the clamp.
Figure 10
3. With a 1/8" Allen wrench, back off the setscrews in front of the clamp and raise the plate up to
the bottom of the clamp. It may be necessary to bring the clamp down onto a stack of paper
with the foot pedal in order to access the far left setscrew. Raise the false clamp plate evenly
or it will have a tendency to bind. When the plate has been raised into position and is flush
with the bottom of the clamp, tighten the setscrews to hold the plate in position.
4. Make sure that all tools have been taken off the cutter table, reconnect the power, and turn
on the machine.
Locator
pegs
Set
Screws
1/8” Allen
Wrench