Challenge MS-5 Technical reference manual

The Challenge Machinery Company
1433FultonAvenue
GrandHaven,MI49417-1594USA
ChallengeMachinery.com
F.300-B
JULY 2000
Serial Numbers 965600 & Up
MODEL MS-5
PAPER DRILLING
MACHINE
Sold and Serviced by
INSTRUCTION AND
PARTS MANUAL

F.300-B/MS-5 DRILL/JULY 2000
2
INTRODUCTION
WELCOME tothe family of Challenge®users. Challenge has been developingand manufacturing Graphics Arts
Equipmentfor over 100 years and is today one of the world’s leading producers and distributors of Paper Cutters,
Paper Drills and Bindery Equipment.
SAFETYALERT! This symbol meansCAUTION OR WARNING: Personal safety instructions! Pay
special attention to the instructions in bold type. Personal injury may result if the precautions are not
readandfollowed. SeeSAFETYPRECAUTIONS,page4.
•This machine is designed forONEPERSONOPERATIONONLY!
•Always DISCONNECT THE POWER before working on this machine.
•DO NOT OPERATEWITHANY GUARDS REMOVED! Replaceallguardsbeforeoperating.
•CRUSH HAZARD - Keep hands, hair, cleaning rags, & loose clothing away from drills.
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-
lengeDealer.
FOR PARTS AND SERVICEcontacttheAuthorizedChallenge Dealer from whomyou 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 MODELofyourmachine to insure that the correct parts are sent as soon as possible.
Take a few minutes right now to RECORD YOUR MACHINE 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, 1433 Fulton Avenue, Grand
Haven,MI 49417-1594.
CHALLENGE MODEL SERIAL NUMBER
ATTN COMPANY
ADDRESS
CITY STATE ZIP
PHONE DATE INSTALLED
DEALER’S NAME AND CITY
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.
WARRANTY INFORMATION
Challenge® is a registered trademark of The Challenge Machinery Company. 1433 Fulton Street, Grand Haven, MI 49417.
Copyright © 1996 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A.

3
F.300-B/MS-5 DRILL/JULY 2000
INTRODUCTION........................................................................................... 2
CAUTION: POWERLOCK-OUT PROCEDURE ............................................ 4
SAFETYPRECAUTIONS ............................................................................. 4
PACKINGLIST ............................................................................................ 5
SPECIFICATIONS ........................................................................................ 5
WARNINGLABEL DEFINITIONS.................................................................. 6
INSTALLATION ............................................................................................ 7
Unpacking ............................................................................................. 7
Power Hookup ....................................................................................... 7
SETUPINSTRUCTIONS ............................................................................... 7
Starting the Machine .............................................................................. 7
Safety Interlock System ......................................................................... 8
HydraulicCheck .................................................................................... 8
PositioningDrillHeads........................................................................... 8
DriveBelt Adjustment............................................................................. 9
Drill Installation ...................................................................................... 9
DrillRemoval ......................................................................................... 9
StrokeAdjustment (TableHeightAdjustment).......................................... 9
AdjustingtheStroke Speed .................................................................... 9
SettingUpthe Backgage ..................................................................... 10
Using the Side Guide(s) ....................................................................... 10
Drill Blocks.......................................................................................... 10
Emptying the Drill Chips ...................................................................... 10
OPERATION .............................................................................................. 10
DRILLINGTIPS ...........................................................................................11
ACCESSORIESFORCHALLENGE PAPERDRILLINGMACHINES ............ 12
TECHNICAL SECTION FOR TRAINED PERSONNEL ONLY
TROUBLESHOOTING ................................................................................ 16
ROUTINEMAINTENANCE ......................................................................... 17
SERVICECHECKLIST ............................................................................... 17
NOTES...................................................................................................... 19
MAINASSEMBLY-FRONTVIEW ............................................................. 20
MAIN ASSEMBLY -SIDE VIEW ................................................................. 22
MAIN ASSEMBLY -SIDE VIEW ................................................................. 24
MAINASSEMBLY- TOPVIEW ................................................................... 26
MAINASSEMBLY- TOPVIEW ................................................................... 27
MAINASSEMBLY- DRILLGUARD(50HZ ONLY) ...................................... 28
MAINASSEMBLY- DRILLGUARD(50HZ ONLY) ...................................... 29
BELTINSTALLATION ................................................................................. 30
HYDRAULICPOWERUNITASSEMBLY .................................................... 32
HYDRAULICSEQUENCEOFOPERATION ................................................ 33
BASICMACHINESCHEMATIC .................................................................. 34
ELECTRICALSEQUENCE OFOPERATION............................................... 35
POWERPANEL ASSEMBLY ..................................................................... 36
POWERPANEL ASSEMBLY ..................................................................... 38
POWERPANEL ASSEMBLY ..................................................................... 40
DRILLHEADASSEMBLY .......................................................................... 42
POWER PANEL LABEL ............................................................................ 43
TWOHAND CONTROLOPTION ................................................................ 44
DRILLGUARD KIT ..................................................................................... 46
BELTGUARDSWITCH REPLACEMENT KIT.............................................. 47
DRILLGUARD SWITCHREPLACEMENTKIT............................................. 48
SAFETYSYSTEM TESTS ......................................................................... 49
TABLE OF CONTENTS

F.300-B/MS-5 DRILL/JULY 2000
4
SAFETY PRECAUTIONS
•This machine is designed and safeguarded for ONE PERSON operation. NEVER operate the machine
with more than one person.
•Safety of this machine is the responsibility of the user and operator. Use good judgement and com-
mon sense when working with and around this machine.
•READ and understand all instructions thoroughly before using the machine. If questions still remain,
call your Authorized Challenge Dealer - Failure to understand operating instructions may result in
personal injury.
•Only trained and authorized persons should operate the machine.
•DO NOT ALTER SAFETY GUARDS OR DEVICES, they are for your protection and should not be al-
tered or removed. Severe lacerations could result.
•DISCONNECT POWER before cleaning, lubricating, servicing, or making adjustments not requiring
power. Lock the disconnect switch in the OFF position, see Power Lockout Procedure below.
•HIGH SPEED DRILL - Keep rags, loose clothing and long hair away form rotating drill. Personal injury
could result from items being caught on drill.
•Have your electrician make sure the machine is properly grounded, see Power Hookup,page 7.
•Have your electrician check for sufficient power to operate the machine properly, see page 7.
•OBSERVE ALL CAUTION PLATES AND LABELS on this machine.
•KEEP FOREIGN OBJECTS off table and away from drill.
•BE EXTREMELY CAREFUL when handling and changing the drills. Severe lacerations or dismember-
ment could result from careless handling procedure.
•KEEP THE FLOOR around the machine free of trim, debris, oil and grease.
•When replacing hydraulic parts, loosen the connections slowly to release pressure. Never loosen
connections with the machine running.
•If the machine sounds or operates abnormally, turn it off and consult the Trouble Shooting section of
this manual. If the problem cannot be corrected, have it checked by a qualified service person or your
Authorized Challenge Dealer.
•CRUSH HAZARD, keep feet off the pedal when handling paper under the clamp. DO NOT REST FOOT
ON PEDAL at any time!
•DO NOT REACH UNDER THE DRILL AND CLAMP AREA!
•DO NOT OPERATE WITH ANY GUARDS REMOVED! Replace all guards after adjusting, lubricating or
servicing the machine.
•SEVERE LACERATIONS - Contact with high speed drill could cause severe injury. Always turn ma-
chine off and wait for drill to stop before removing drill bits. Keep hands away from drill(s) when
operating.
CAUTION: POWER LOCK-OUT PROCEDURE
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 thrown to the
OFFpositionand a padlockplaced in theloop. The
key should be held by the person servicing the
machine.
(fig. 1)
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.

5
F.300-B/MS-5 DRILL/JULY 2000
SPECIFICATIONS
Drilling
Number of Drill Heads 2 to 5
Drill Bit Sizes Available 1/8” to 1/2” (3 mm to 13 mm)
Center To Center Maximum 15” (38 cm)
Minimum Center Distance Between Heads 17/8” (8.7 cm)
Maximum Drilling Capacity (Pile Height) 21/2” (63 mm)
Strokes per Minute (Adjustable) Up to 18
Backgage Adjustment 0 to 5” (0 to 13 cm)
VerticalAdjustment of Individual Heads 1/4” (6mm)
Dimensions
Table 173/4” x 34” (45 cm x 86.4 cm)
TableHeight 37” (94 cm)
Overall Height 56” (142 cm)
Floor Space Needed 36” x 36” (92 cm x 92 cm)
Net Weight (Approximate) 830 lbs (373.5 kg)
ShippingWeight (Approximate) 1000 lbs (453.6 kg)
Electrical
208/230 Volts (±10%)/18 Amps, 1 Phase, 60 Hz, AC. Service size 30 Amps.
Pump: 1/2H.P. Spindle: 11/2H.P.
Optional Motor: 208/230 Volts (±10%)/10 Amps, 3 Phase, AC. Service size 20 Amps.
460 Volts (±10%)/5 Amps, 3 Phase, AC. Service size 15 Amps.
Sound Emission
A-weighted sound pressure level measured in an enclosed room at 6 feet (183 cm)
abovefloor:
Machinerunning: Less than 70 dB
Machinedrillingpaper: 71 dB
Challenge reserves the right to make changes to any product or specification without notice and without
incurring responsibility to existing units.
PACKING LIST
Part No. Description Qty.
Basic Machine ....................................................................1
W-105-1 Allen Wrench,1/4” ‘T’ Handle ...............................................1
A-6588 Wrench,‘T’ Handle Drill Drift ...............................................1
4688 Lubrication Stick, Drill Ease .................................................1
A-4950 Drill Sharpener, Hand..........................................................1
6564 Drill Block ...........................................................................3
45067 Backgage Filler Block Asm. (magnetic) ...............................2
45163 Spring - Drill Block ..............................................................1
8278-1 Knob...................................................................................2
Drill Head(s)-as orderedIncludes as Standard (per head)
CD-4-21/21/4” (64mm) Hollow Drill .......................................................1
K-85 Drift Hole Cover ..................................................................1

F.300-B/MS-5 DRILL/JULY 2000
6
SINGLEOPERATOR
SHOCK HAZARD
SHOCK HAZARD
HAZARDOUS AREA
Do not operate with more than one person.
Disconnect power before removing cover. Replace
coverbeforeoperation.
Disconnect power before removing cover. Replace
coverbeforeoperation.
Disconnect power before cleaning, servicing, or mak-
ingadjustmentsnot requiringpower. Donotaltersafety
guards or devices, they are for your protection. Re-
place all guards, do not operate with any guards re-
moved.
WARNING LABEL DEFINITIONS

7
F.300-B/MS-5 DRILL/JULY 2000
INSTALLATION
Unpacking
Unless otherwise specified, this machine is packaged
completely assembled. The drill head(s) specified on
the order are shipped already installed. The machine
should be unpacked carefully by removing the pack-
aging materials without damaging any of the machine
parts.
Immediately after uncrating, check off parts received
against the packing list. Also, examine for any physi-
cal signs of damage incurred during shipment. The
machine is inspected before and after crating at our
plant. The responsibility for filing a claim against the
carrierfor damages incurredduring shipment rests with
the receiver of the goods (FOB our factory).
The machine is held in place on its shipping skid with
plastic strapping material. The machine weighs ap-
proximately 850 lbs. (380 kg.), so be sure you have
sufficientequipment and manpowerto handle the ma-
chinesafely. Contact yourAuthorizedChallenge Dealer
to arrange for installation.
Remove the protective coating of light oil from the
machined surfaces with a cleaning solvent, such as
typewash. Cleanallothersurfaceswithasolventsuch
as C.R.C.
Power Hookup
The machine is factory wired to the customer’s speci-
fication. It is the customer’s responsibility to wire the
motorforthecurrent and voltage specifiedonthename
plate. It is important that the line voltage specified be
maintained. Failureto do so willresult in improper op-
eration of the machine (see trouble shooting section
forspecific problems). It may benecessary to provide
a dedicated line for the machine.
Thestandardmotor forthismachineisa208/230 single
phase. This machine should be on a 30 amp circuit
and wired with #10 gauge wire. Optional three phase
motorsareavailablealso;230/208 three phase, 20 amp
circuit,#12GA. wire; and 460 voltthree phase, 15 amp
circuit, with #14 GA. wire.
Remove the lower front cover. Remove the knockout
plugon the right side ofthe machine. Route the power
cord through the knockout hole and secure using a
conduit connector. Connect wire leads to terminals as
shown in fig 2 (single phase use L1 and L2 only). Con-
nect the ground lead to the power panel as shown.
Replace the front cover.
Onthree phase machines, check to see that the motor
turns in the proper direction. Briefly turn the machine
on and off then look at the belt. If it turns in the oppo-
site direction of the arrow on top of the motor, discon-
nect power to the machine and switch the connection
of any one wire with another. Check the rotation of the
motor again to be sure it turns in the proper direction.
SETUP INSTRUCTIONS
Starting the Machine
The power for this machine is supplied by two motors;
one is for the hydraulic power pack and the other is for
the spindle. The hydraulic motor drives the pump di-
rectly while the spindle motor drives the drill heads.
Thetwomotorsare started andstoppedsimultaneously
by “on” and “off” push-buttons located on the control
panel (the main disconnect switch must be in the “on”
position, see fig. 3). The on button has a collar guard
toreduce the possibility ofaccidental contact. Be sure
both motors are operating before trying to drill paper.
WARNING: DISCONNECT POWER be-
forecleaning,lubricating, servicing, or
making adjustments not requiring
power. Lock the disconnect switch in the OFF
position (see Power Lockout Procedure,pg. 4).
NOTE: All guards and instruction plates are in-
stalled for your safety and information and must
remain on the machine as shipped from the fac-
tory.
Ground
Power Panel
Fuse
(fig. 2)

F.300-B/MS-5 DRILL/JULY 2000
8
Safety Interlock System
The MS-5 paper drill is equipped with a safety inter-
lock system which prevents the machine from being
started with the front cover open or the optional drill
guard removed. If the cover is opened or the guard
removed when the drill is in operation, the motors will
shut off and must be restarted when the cover and
guard are back in place. This is a safety feature pro-
vided to prevent accidental contact with moving parts
and must not be tampered with.
Hydraulic Check
Checkthehydraulicoil supply for the proper level. This
checkismadebyremovingtherearpanelandunscrew-
ing the dip stick located on the hydraulic tank (fig. 4).
The oil level should be no higher than ½” (13 mm) up
from the bottom of the dip stick to allow room for ex-
pansion of the oil when running. Recommended oils
and a cross-reference chart are found in the mainte-
nance section of this manual.
Positioning Drill Heads
Drill heads ordered with your machine have been in-
stalled at the factory. One ¼” drill is supplied as stan-
dardequipmentwitheachheadunless otherwise speci-
fied. The MS-5 handles two to five drilling heads
mounted on a dovetail. Each head is independently
adjustable allowing a minimum center-to-center dis-
tanceof17/8"(47.6 cm) to a maximum center-to-center
distance of 15" (381 mm). NOTE: Any number of
heads (up to five) or combination of drill hole sizes
can be drilled at one time. However, when using
½” (13 mm) drills, it is recommended that no more
than three heads be used at the same time.
Always position heads so that the lift of paper being
drillediscentered onthetable. Drillheadsare mounted
on a dovetail and positioned by a scale mounted on
the front of the dovetail (fig. 5).
To move heads: raise the front cover and release the
drive belt tension by lifting the belt lever. Loosen the
socket head screws holding the head to the dovetail
and position the heads according to the scale (fig. 5).
The dovetail scale is calibrated from the center of the
table and is setup to give readings to the center of the
holes. The scale is read from the outside edge of the
drillheads. (Heads mounted to the right of center read
thescale from the right side,heads to the left ofcenter
are read to the left of the head.) Once the heads are in
the desired position, tighten the socket head screws in
the dovetail.
(fig. 4)
(fig. 5)
Dipstick
Cap
(fig. 3)
Scale
(reads from out-
side edge of head)
Dovetail
Clamps

9
F.300-B/MS-5 DRILL/JULY 2000
Drive Belt Adjustment
Whenever changing head configurations or reposition-
ing heads, reset the drill head belt tension. This is
done by backing off the knurled adjusting nut (fig. 6)
with the belt lever in the up position. Lower the lever
and turn the knurled nut out until it is tight. Raise the
lever and turn the knurled nut out an additional 1½ to 2
turns. Lower the lever and close the front cover.
Drill Installation
Insert the tapered head of the hollow drills into the
spindles. Press the drills firmly into place so they do
not fall out when the motor is first started. To prevent
drillchipsfromflyingoutbesurethatthe drift hole cov-
ers(blackbands)areinplacebeforeoperation (fig. 7).
Make sure the cutting stick blocks are in position be-
fore trying to drill paper.
Drill Removal
After use, drills may become seated making it difficult
to remove them. Use the T-handled drill drift tool to
free stuck drills. Uncover the drill drift hole by sliding
the cover down. Insert the drill drift with the flat edge
downandlift up to force thedrillout of the head (fig.7).
Stroke Adjustment (Table Height Adjustment)
Wheneverinstallingneworresharpeneddrills,thetable
strokeand drill height must be adjusted. Turnin (clock-
wise) the table height adjustment to lower the table
(fig. 3). Next, lift the front cover and back off the drill
head adjustment on each head. Place a single sheet
of paper under the drills and raise the table with the
foot treadle. Gradually raise the table height by turn-
ing the table height knob out (counter clockwise) and
pressing the foot treadle to check the table height.
Continue to do this until the first drill cuts through the
paper. Once the table height has been set, adjust the
drillheadsindividuallyuntil all the drillsnowcutthrough
the paper. When cutting full lifts, any further stroke
adjustment can now be made with the table height ad-
justment knob.
Note: The MS-5 uses 2” and 21/2” long drills. Be sure
toadjustthetable stroke and/or drill height accordingly
when changing from one drill length to another.
Adjusting the Stroke Speed
Thehydraulic unit is equipped withan adjustable valve
for regulating the table stroke speed (up and down
travel). Maximumspeedis18strokesperminutewhich
is the speed used on the average run of work. Soft
stocks such as mimeographs, NCR, etc., are apt to
wrinkle at high speeds, and the speed should be regu-
lated to a point where the best results are obtained.
This is found mostly by “trial and error.”
Thisadjustmentismadeby turning the adjustable valve
(located on the left side of the control panel) counter-
clockwise to reduce speed and clockwise to increase
speed.
Never turn the speed control knob more than 2½ turns
counterclockwise (slow speed) as the drill will not bot-
tom and engage the return cycle. Less than one turn
counterclockwise should suffice for all drilling opera-
tions. Slow speeds may also cause the drills to “burn”
through the paper. If burning occurs, either increase
(fig. 6)
CAUTION: Always handle drills with
care to avoid severe lacerations. Even
dull drills are sharp enough to cause
lacerations.
(fig. 7)
Drive Belt
Adjusting
Lever
Knurled Nut
Drive Belt
Drift Hole
Cover

F.300-B/MS-5 DRILL/JULY 2000
10
For EMERGENCY STOP release foot from
treadle and turn main disconnect switch to “off”
position.
CAUTION: NEVER REST YOUR FOOT
ON THE TREADLE WITHOUT INTEND-
ING TO BRING UP THE TABLE.
CAUTION: NEVER PUT HANDS OR
FINGERS NEAR DRILL HEADS WHEN
OPERATION THE MACHINE. SEVERE
LACERATIONS COULD RESULT.
theverticalspeed, sharpenthedrillsorcheckfor proper
belt tension.
Slower vertical speeds are recommended when drill-
ing with the maximum number of heads.
Setting Up the Backgage
Scalesareprovidedinthe table for setting up the back-
gage. The scales read in inches/mm and will give you
the dimension from the back of the sheet to the
centerline of the holes. Two magnetic filler blocks are
provided if it is necessary to drill within 1" of the edge
of the sheet, fig. 8. The blocks are ½” (13 mm) thick
and when used, ½” (13 mm) must besubtracted from
the scale reading to give the set up dimension. Ex-
ample: To drill3/4"(19 mm) from the edge of thesheet,
install the filler blocks and set the backgage to 1¼” (32
mm) on the scale.
Using the Side Guide(s)
The adjustment for the location of the holes to the top
or bottom edge of the sheet is provided by a sturdy
side guide. The backgage has a series of threaded
holes to which the side guide is attached with two
threaded knobs. In addition, the side guide is slotted
to fine adjust the position of the paper. When setting
up drill head positions and side guides, always try to
keep the paper centered on the table as much as pos-
sible.
Two side guides are provided as standard equipment
so stock may be drilled to the left or right or for setting
upmultipledrillingsequences for more than five holes.
Drill Blocks
Place the drill blocks in the slot in the table. They are
held tightly in place by pinching the drill block spring
and placing it in the slot in the table at the end of the
drill blocks (fig 9).
(fig. 8)
Thedrill blocks are removedby simply lifting themfrom
their groove in the table. They should set flush with
the table and may be shimmed if necessary. For best
use and longest life, turn them end for end, top and
bottom.
Emptying the Drill Chips
A large capacity chip bag attached to the rear of the
machine, can be easily taken off and emptied by slip-
ping it off the two hooks provided.
OPERATION
Pressing the foot treadle activates the hydraulic unit
bringing the table and stock up to the drills and return-
ing back again automatically. The pedal must be re-
leased and depressed again before the next drill cycle
assuring full control and allowing no repeat stroke.
Releasing the pedal at any time stops the table move-
ment and returns it to its normal down position, thus
preventing costly errors.
The vertical movement of the table is actuated by the
hydraulic unit. Depressing the foot treadle sets the
hydraulic unit into action. Keeping your foot on the
(fig. 9)
Filler Blocks Side Guide Table
Scale
Spring
Drill Block

11
F.300-B/MS-5 DRILL/JULY 2000
treadle allows the drills to drill through the entire lift of
stockandreachthebottom of their stroke. At thispoint,
the solenoid is de-energized and the valve released,
relieving the pressure off of the cylinder and allowing
the table to return to the down position.
DRILLING TIPS
Important! To prevent the drill from overheating, always avoid drilling too slowly. The table should be brought
up as rapidly as possible allowing the drills to easily cut through the paper. Also, adjust the vertical table guide to
return the table to the down position as rapidly as possible to avoid spinning the drills in the stock.
Slotted Holes - Instead of punching slotted holes for five and seven hole universal binding work, save time and
costby drilling a 1/2 inchdiameter hole in place ofthe slot. The slot is onlyintended to allow the postor ring to be
used in either location, and the large hole permits this.
Plastic Bindings - Drilling holes for plastic bindings, instead of punching them, is practical and saves a great
deal of time, particularly on long run jobs.
Keep Drills Sharp - A dull drill is the major cause of drill breakage and production tie-ups. Usually after three
hours of drilling, depending on the type of paper being processed, the drill should be sharpened. A dull drill
results in poor quality work.
Keep Drills Clean - A dirty and rusty drill will not permit the free upward passage of the drill chips. Pressure built
upbya clogged drill will split orbreakthe drill. To keep it free fromdirtor rust, clean the drillofall chips after each
use and apply a light oil to the inside and outside. Drills should be cleaned out immediately after each use. This
is particularly true if a coated or varnished stock has been drilled. On these jobs the coating on the chips
frequentlyfuse the chipsinto one solid mass when the drill cools, causing breakagethe next time the drill is used.
Lubricate Drills - Lubrication assists in the passage of the chips and helps avoid overheating of the drills. Use
readilyavailable stick lubricantsfor this purpose. Hold the end of the stick against the side of the rotating drill. Be
sureto touch the cutting edge with the lubricant also. Wipe off excess oil before drilling. CARE MUST ALWAYS
BE TAKEN WHEN HANDLING DRILLS.
Keep Spindle Clean - Clean out the drill spindle frequently. This will prevent any buildup in the spindle of the
drill.
Set the Drills Correctly - Do not cut too deeply into the cutting block. The drill should just touch the block and
cleanly cut through the bottom sheet. During drilling, do not set the drill deeper into the block but change the
position of the block frequently. Drilling deeper into the block dulls the drills quickly. Use a piece of chipboard
underneath your stock. This will make handling the stock easier and will ensure that the last sheet is cut cleanly
through.
Check for Drill Wobble - If spindles are badly worn or bent through misadjustment, have them replaced imme-
diately. A wobbly or loosely held drill will break.
Check Your Drill Sharpener - The cutting edge of the sharpening bit should be inspected frequently to make
certain that it is sharp and free of nicks. Never let a drill drop onto the sharpening bit. It will chip the sharpening
edge. Usegentle pressure whensharpening - let the sharpening bit do the work. Check the sharpness of thedrill
after sharpening. The cutting edge should be razor sharp.
Just a little time and effort taken with each use of your paper drilling machine should result in trouble free opera-
tion over many years.

F.300-B/MS-5 DRILL/JULY 2000
12
1/8”3/16”1/4”9/32”11/32”13/32”1/2”
5/32”7/32”17/64”5/16”3/8”7/16”
ACCESSORIES FOR CHALLENGE PAPER DRILLING MACHINES
Genuine Challenge Hollow Drills
In 13 Standard Sizes For Every Drilling Need
All drills carried in stock by local Challenge dealers (17/32” & 9/16” available by special order).
Challenge Drill-Ease Lubricant
Stick
Cat. No. 4688
This lubricating stick provides a dry stainless lubricant
which has many uses throughout the printing plant. It
is specially recommended for use on hollow drills for
easier drilling, particularly when drilling clay coated
stock. It eliminates binding and excessive heating of
the drill. Will not discolor the stock.
CARE MUST ALWAYS BE TAKEN WHEN USING
STICK AND HANDLING DRILLS.
Challenge Drilling Blocks
Cat. No. A-6626-24
These Challenge 11/4 x 6” End-Wood Drilling Blocks
are for round hole drilling operations. Sold in pack-
ages of 24.
HOLLOW DRILLS
Diameter x Drill Capacity Cat. No.
1/8” x 5/8” (3.2 x 16 mm) ................... CD-2-3
5/32” x 11/8” (4 x 29 mm) ................... CD-52
3/16” x 15/8“ (4.8 x 41 mm) ................ CD-3
7/32” x 2” (5.6 x 51 mm) ................... CD-72
1/4” x 2” (6.3 x 51 mm)..................... CD-4
1/4” x 21/2” (6.3 x 63.5 mm)............... CD-4-21/2
17/64” x 2” (6.7 x 51 mm) .................. CD-174
9/32” x 2” (7.1 x 51 mm) ................... CD-92
5/16” x 2” (7.9 x 51 mm) ................... CD-5
5/16” x 21/2” (7.9 x 63.5 mm) ............. CD-5-21/2
11/32” x 2” (8.7 x 51 mm) .................. CD-112
3/8” x 2” (9.5 x 51 mm)..................... CD-6
3/8” x 21/2” (9.5 x 63.5 mm)............... CD-6-21/2
13/32” x 2” (10.3 x 51 mm) ................ CD-132
7/16” x 2” (11.1 x 51 mm).................. CD-7
1/2” x 2” (12.7 x 51 mm)................... CD-8
1/2” x 21/2” (12.7 x 63.5 mm)............. CD-8-21/2
Special order drills
17/32” x 2” (13.5 x 51 mm) ................ CD-172
9/16” x 2” (14.3 x 51 mm).................. CD-9
TEFLON COATED HOLLOW DRILLS
Diameter x Drill Capacity Cat. No.
1/8” x 5/8” (3.2 x 16 mm) ................... TCD-2-3
5/32” x 11/8” (4 x 29 mm) ................... TCD-52
3/16” x 15/8“ (4.8 x 41 mm) ................ TCD-3
7/32” x 2” (5.6 x 51 mm) ................... TCD-72
1/4” x 2” (6.3 x 51 mm)..................... TCD-4
1/4” x 21/2” (6.3 x 63.5 mm)............... TCD-4-21/2
17/64” x 2” (6.7 x 51 mm) .................. TCD-174
9/32” x 2” (7.1 x 51 mm) ................... TCD-92
5/16” x 2” (7.9 x 51 mm) ................... TCD-5
5/16” x 21/2” (7.9 x 63.5 mm) ............. TCD-5-21/2
11/32” x 2” (8.7 x 51 mm) .................. TCD-112
3/8” x 2” (9.5 x 51 mm)..................... TCD-6
3/8” x 21/2” (9.5 x 63.5 mm)............... TCD-6-21/2
13/32” x 2” (10.3 x 51 mm) ................ TCD-132
7/16” x 2” (11.1 x 51 mm).................. TCD-7
1/2” x 2” (12.7 x 51 mm)................... TCD-8
1/2” x 21/2” (12.7 x 63.5 mm)............. TCD-8-21/2

13
F.300-B/MS-5 DRILL/JULY 2000
ACCESSORIES FOR CHALLENGE PAPER DRILLING MACHINES
Challenge Power Sharpener
(115 Volt / 60 HZ only)
Cat. No. A-6450
A power drill sharpener. Plugs into any standard 115
volt,60 cycle, AC outlet. HandlesChallenge and other
tapershank drills. Adaptors also available forhandling
practically all other makes.
Item Cat. No.
Replacement Cutting Bit 6469
Resharpening Service - Your Old Bit 6469-R
HOLLOW DRILL SHARPENER For fast, easy drill sharpening
CAUTION: Drills are sharp even after use. Be careful to keep edge
away from your body. To prevent personal injury and/or damage to
the drill, ALWAYS keep drills in protected area.
Here’s a unit that really makes drill sharpening easy.
All you do is place the hollow drill in the tapered end of
thedrill holder, insert the unit on the cylinder, then turn
two or three times...and you have a perfectly sharp-
ened drill.
This Challenge Hollow Drill Sharpener can pay for it-
self many times over through longer drill life, easier,
faster drilling, and less sharpening time. All sizes of
drills from1/8 to 1/2inch in diameter can be sharpened.
The drill sharpener automatically puts just the right
amount of bevel on the hollow drill for the best drilling
results. It’sself centering, too, so that the centerof the
sharpening bit exactly meets the center of the hollow
drill. Thedrill sharpener also hasa replaceable sharp-
ening bit.
Item Cat. No.
Challenge Hollow Drill Sharpener A-4950
Extra Cutting Bit 4952
Instructions:
NOTE: Always handle carefully
1. Be sure to wipe off all grease before using the
sharpener.
2. Remove any paper chips from the hollow drill.
3. Place the hollow drill in the drill holder section.
Insert the sharpening section, being very careful
to bring the drill and cutting tool together without
bumping.
4. Turnthecutting unitclockwise,maintainingan even
pressure until the hollow drill is sharpened (usu-
ally two or three turns). The cutting tool seldom
requiresregrinding,butwhenit does, the bit should
be sent to the factory as regrinding must be done
on a diamond wheel.
NOTE: The cutting tool is made of a glass hard
material and may be chipped by careless han-
dling.

F.300-B/MS-5 DRILL/JULY 2000
14
ACCESSORIES FOR CHALLENGE PAPER DRILLING MACHINES
Optional Narrow Drill Head Assembly, p/n: 45200
Fordrilling holeswith a center to centerdistance aslow as1-3/8”/3.5 cm

15
F.300-B/MS-5 DRILL/JULY 2000
NOTICE
The instructions on the
following pages are for the
use of trained service
personnel only!
Attempting to perform
repair and replacement
procedures without proper
training may cause machine
damage or operator injury!
PARTS CUSTOMERS: The Challenge Machinery Company provides parts with the express under-
standing that they are to replace parts found missing or no longer serviceable on equipment designed
and/or manufactured by Challenge. The Challenge Machinery Company assumes no liability for any
modification or alteration to any Challenge products, and any such modification or alteration to any
Challenge products is not authorized by The Challenge Machinery Company. Any modification or
alteration of any Challenge product will void any remaining warranty.

F.300-B/MS-5 DRILL/JULY 2000
16
WARNING: DISCONNECT THE POWER AND LOCK IT OUT whenever working on the machine
unless the instructions specifically require the machine to be powered (see Power Lockout
Procedure, page 4). Several of the following tests may require the machine to be operational
for checking and adjusting. Be very careful that tools and other people are clear of moving parts, and
that the drill is not accidentally operated while adjustments are being made.
CAUTION: Whenever repairing hydraulic components, loosen connections slowly to bleed
off any trapped pressure.
Problem Area to Check Solution
1. No power Power to machine Connect Power
Main Disconnect Switch Turn to ON position
Interlocking Guards Replace guards
Fuse blown Replace fuse - see fig. 2 page 7
2. Lack of power Relief valve in pump may be bad Cleanorreplace relief valve or pump.
or have dirt in it.
Check oil level - may be low. Addoil.
Check voltage at machine - may Remove other machinery on line or
be low. provide a dedicated line.
3. Spindle motor stalls Dull drills. Sharpen drills.
Check for low voltage. (See above).
Check drive pulley and belt for (SeeSETUP INSTRUCTIONSinmain
tightness. sectionforadjustment).
Check for paper plugging drills Clean out hollow drills - We recom-
mend cleaning and soaking drills in
oil overnight.
4. Table stroke won’t adjust StrokeAdjustmentChain off Remove back panel and replace
sprockets. chain (fig. 10).
TROUBLESHOOTING
(fig. 10)
Table Lift Rod

17
F.300-B/MS-5 DRILL/JULY 2000
ROUTINE MAINTENANCE
General
Productionlossescanbe reduced ifgoodmaintenance
practicesare followed. The following suggestions may
behelpful:
1. Recognizethefact that theuserofhydraulicequip-
ment has more control over maintenance than the
manufacturer.
2. Operators should be familiar with use, care, and
limitations of the equipment. ALL OPERATORS
SHOULD READ THIS MANUAL COMPLETELY.
3. Use properly trained maintenance personnel.
4. Establish a program of systematic preventative
care for your equipment or put this machine on an
existingpreventativemaintenance program.
5. Analyze and isolate trouble before having any part
oftheequipment dismantled.
6. Be aware of how your machine should sound and
perform. If the machine is not operating properly
or if it doesn’t “sound right”, stop running your job
immediately and try to identify the problem.
7. Call the dealer for any problems that cannot be
handled by your own personnel.
Vertical Table Guide
The vertical table guide is located on the right side of
the machine beneath the table and may need periodic
adjustment to keep the table steady yet allow it and
stock to fall away from the drills as rapidly as possible.
The table down stroke is controlled by a return spring.
Remove the guide block cover guard. Tighten the two
guide block lock nuts (fig. 11) and power the table up
by pressing the foot treadle. Gradually back the lock-
nuts off evenly until the table releases freely. Retest
the upstroke and table return, and check the table for
side play. Replace the guard.
SERVICE CHECKLIST
Daily
1. Keep drills sharp!
2. Lubricate the hollow drill frequently with the lubri-
cating stick provided.
3. For better hollow drill life, remove the drills when
notin use and soak in light oil. Wipeoff excess oil
before drilling.
4. Wipe off excess grease from the drill heads and
idlers.
Weekly (or every 40 hours of operation)
1. Check belt wear/tension.
2. Oil the table lift rod between the table and stand
with light oil (fig. 10).
CAUTION: PINCH POINT. This adjust-
ment requires a guard to be removed
for adjustment and testing purposes
only. Be very careful while adjusting. Replace
all guards before operating. Do not operate
machine with any guards removed.
(fig. 11)
Lock Nut
CAUTION: PINCH POINT.
Replace guard after adjusting.

F.300-B/MS-5 DRILL/JULY 2000
18
Monthly
1. Oilthetableheightadjustingknobshaftwithalight
machine oil. Wipe off excess oil.
2. Checkthe hydraulic oilsupply for theproper level.
This check is made by removing the rear panel
andremovingthe dip stick/plug (pg. 8,fig. 3). The
oil should be visible on the dip stick but no higher
than 1/2“ up from the bottom when cool. This al-
lows for expansion of the oil when hot. Use only
one of the recommended oils or an ISO VG 100
HydraulicFluidequivalent. Oilsotherthantherec-
ommendedtypewillcauseseals,cups and O-rings
to deteriorate. See Chart & CAUTION.
Yearly
1. Check all adjustments.
2. Tighten all screws.
3. Changehydraulic oil in reservoir. Oil may have to
bechanged more often if contaminationof any kind
gets in the oil.
Hydraulic
Through normal use, hydraulic systems gum up and
seals wear. Signs of wear are hydraulic leaks and er-
ratic operation of the vertical speed. Check with your
Authorized Challenge Dealer for a current repair and/
or replacement policy.
Drill Heads
Through normal use, bearings will wear and need re-
placing. Signs of wear are excessive noise, heat, or
loose spindles.
RecommendedOils
Oil Name Distributor
Rykon No. 100 AMOCO
Duro AW Oil 465 Arco
AW Machine Oil 100 Chevron
Pacemaker XD No. 100 Citgo
CAUTION: NEVER USE Automatic
Transmission oil or brake fluid as a
substitute! Oils other than the recom-
mended type will cause seals, cups and O-rings
to deteriorate. Unsafe operating conditions will
result.
Super Hydraulic 100 Conoco
Nuto H-100 Exxon
Harmony 100 AW Gulf
HO 2A Hydraulic Oil Lubriplate
DTE No. 18 Mobil
Pennzoil AW 100 Pennzoil
Magnus A Oil 215 Phillips
Tellus 100 Shell
Energol HLP 100 Sohio
Industron 100 Std. Oil Indiana/Boron
Sunvis 851 WR Sunoco
Rando HD 100 Texaco
Unax AW 100 Union Oil Co.

19
F.300-B/MS-5 DRILL/JULY 2000
NOTES

F.300-B/MS-5 DRILL/JULY 2000
20
MAIN ASSEMBLY - FRONT VIEW
45000 SHEET 1 REV L