Challenge CHAMPION 305 TC Technical reference manual

F.254-J
May 2014
CHAMPION 305 TC
Instruction and Parts Manual
Serial Numbers 1301701 & 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© 1997-2014 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............................................................................................................................................... 5
2.1 Precautions.................................................................................................................................. 5
2.2 Power Lockout Procedure ........................................................................................................... 5
2.3 Warning Label Definitions............................................................................................................ 6
3.0 Packing List...................................................................................................................................... 8
4.0 Specifications................................................................................................................................... 9
5.0 Footprint......................................................................................................................................... 10
6.0 Installation & Setup........................................................................................................................ 11
6.1 Inspecting Shipment.................................................................................................................. 11
6.2 Uncrating ................................................................................................................................... 11
6.3 Lifting/Moving Instructions......................................................................................................... 11
6.4 Cleaning..................................................................................................................................... 12
6.5 Assembly ................................................................................................................................... 12
6.6 Hydraulic Power Unit Removal.................................................................................................. 13
6.7 Hydraulic Check......................................................................................................................... 13
6.8 Power Hook-Up ......................................................................................................................... 14
7.0 Operation ....................................................................................................................................... 16
7.1 False Clamp Plate ..................................................................................................................... 16
8.0 Knife Installation/Changing............................................................................................................ 18
8.1 Knife Removal ........................................................................................................................... 19
8.2 Knife Installation ........................................................................................................................ 20
8.3 Knife Care Tips.......................................................................................................................... 22
8.3.1 Knife Blade Life.................................................................................................................. 22
8.3.2 Cutting Stick ....................................................................................................................... 23
8.3.3 Bevel Angle ........................................................................................................................ 23
8.3.4 Helpful Suggestions ........................................................................................................... 23
8.3.5 Knife Care .......................................................................................................................... 23
Maintenance Section ......................................................................................................................... 25
9.0 Cleaning......................................................................................................................................... 26
9.1 Table.......................................................................................................................................... 26
9.2 Console...................................................................................................................................... 27
9.3 Machine Frame.......................................................................................................................... 27
10.0 Lubrication.................................................................................................................................... 28
11.0 Hydraulic System......................................................................................................................... 31
11.1 Recommended Hydraulic Oil................................................................................................... 31
11.2 Changing the Oil...................................................................................................................... 31
11.3 Hydraulic Valve Adjustments................................................................................................... 32
12.0 Adjustments ................................................................................................................................. 37
12.1 Electric Eye Alignment............................................................................................................. 37
12.2 Backgauge Gib Adjustment..................................................................................................... 38
12.3 Squaring the Backgauge ......................................................................................................... 39
12.4 Backgauge Position Accuracy Adjustment.............................................................................. 40
12.5 Knife Latch Adjustment............................................................................................................ 41
12.6 Line Light Adjustment (Incandescent Type)............................................................................ 42
12.7 Line Light Adjustment (LED Type)...........................................................................................43
12.8 Proximity Switches................................................................................................................... 44
12.9 Clamp Return Speed Adjustment............................................................................................ 46
12.10 Pre-Clamp Pressure Adjustment........................................................................................... 46
12.11 Pre-Clamp Speed Adjustment............................................................................................... 47

1.0 Introduction
4
12.12 Clamp Cylinder Adjustment (Clamp Height) ..........................................................................48
12.13 Clamp Parallel Rod ................................................................................................................48
12.14 Lead Screw Adjustment Nuts.................................................................................................49
12.15 Knife Bar Gibs........................................................................................................................50
13.0 Repair and Replacement..............................................................................................................51
13.1 Fuses........................................................................................................................................51
13.2 Knife Cylinder Replacement.....................................................................................................51
14.0 Troubleshooting............................................................................................................................54
15.0 Schematics & Parts Lists..............................................................................................................58
15.1 Main Assembly – Frame/Tank .................................................................................................58
15.2 Main Assembly – Hydraulics....................................................................................................60
15.3 Main Assembly – Clamp ..........................................................................................................62
15.4 Main Assembly – Final Wiring..................................................................................................64
15.5 Main Assembly – Electrical Components, Lower Front ...........................................................66
15.6 Main Assembly – Electrical Components, Upper.....................................................................68
15.7 Main Assembly – Air Table ......................................................................................................70
15.8 Main Assembly – Table Mounting............................................................................................72
15.9 Main Assembly – TC Backgauge.............................................................................................74
15.10 Main Assembly – Knife...........................................................................................................76
15.11 Main Assembly – Covers and Labels.....................................................................................78
15.12 Main Assembly – Table Extensions.......................................................................................80
15.13 Power Panel Assembly ..........................................................................................................82
15.14 Basic Machine Schematic......................................................................................................86
15.15 Interconnection Diagram........................................................................................................87
15.16 Hydraulic Manifold Kit ............................................................................................................88
15.16.1 Knife Down Sequence Valve Assembly..........................................................................89
15.16.2 Hydraulic Manifold Assembly..........................................................................................90
15.17 Hydraulic Schematic ..............................................................................................................92
15.18 TC Control Console Assembly...............................................................................................93
15.19 Electric Eye Assembly............................................................................................................94
15.20 Cut Button Assembly – Standard...........................................................................................96
15.21 Cut Button Assembly – ErgoTouch........................................................................................97
15.22 Knife Latch Assembly.............................................................................................................99
15.23 Line Light Assembly.............................................................................................................100
15.24 Compressor Assembly.........................................................................................................101
15.25 Air Table Blower Assembly..................................................................................................102
15.26 Encoder Cable Assembly.....................................................................................................103
15.27 Power Panel Connection Procedure Label..........................................................................104
15.28 Warning Label......................................................................................................................105
15.29 Paper Deflector Kit (Option).................................................................................................106
15.29.1 Deflector & Shaft Assembly (Part of Paper Deflector Kit).............................................107
16.0 Safety System Tests...................................................................................................................109

2.0 Safety
5
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
6
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. The item
number and location of each label can be found in Section 15.0 Schematics and Parts List.
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
7
!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
8
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 – HSS 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:
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
Fuses:
E-889-35 1 Amp S.B. 1
E-2330-5 3.15 Amp S.B. 1
E-2308 3.2 Amp S.B. 1
E-889-5 4 Amp S.B. 1
E-2330-7 5 Amp S.B. 1
E-2330-8 6.3 Amp S.B. 1
E-889-9 8 Amp S.B. 1

4.0 Specifications
9
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, 25 Amps (Service size: 40 Amps)
Optional Phase Converter Kit: K-3482 (1 Phase, 208/230V, Service size: 50 Amps)
Optional: 5 HP, 3 Phase, 60 Hz AC; 460V, 11.5 Amps (Service size: 20 Amps)
Optional: 5 HP, 3 Phase, 50 Hz AC; 380/415V, 10 Amps (Service size: 20 Amps)
Electric Eyes –
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
10
5.0 Footprint

6.0 Installation & Setup
11
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 8. 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/Moving 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 from the front. DO NOT
attempt to lift the machine from the sides or rear.

6.0 Installation & Setup
12
6.4 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.
6.5 Assembly
Unless otherwise specified, the only items that have been disassembled for shipping are the knife,
extension tables, and reach-around shields on the electric eyes. Knife installation instructions are
found in Section 8.0 Knife Installation/Changing. Extension table and reach-around shield attachment
instructions are as follows:
NOTE: Extension tables are heavy. Use two people to attach them to the machine.
1. Assemble the back plates to the extension tables. The extension table bolts and hex nuts are
packed in the tool kit box. Install the back plates such that the half-circle notch at the top of
the plates go toward the center of the cutter. These notches provide clearance for adjusting
the lower knife gib bolt.
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 their operational position.
1. On the bottom of the electric eye housing, loosen (but do not remove) the screw furthest
back (closet to the machine frame) on each side.
2. On the bottom of the electric eye housing, loosen and remove the front two screws. Now
rotate each shield back and to the side – away from of the cut area. Line up the front holes
and re-install the front two 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
13
6.6 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 remove 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.
6.7 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). The hydraulic tank has a sight
gauge in the rear for checking the oil level. The reservoir should be kept full at all times.
Figure 3
NOTE: DO NOT OVERFILL. Overfilling may cause leakage when the machine is hot.
Sight
Gauge
Hydraulic
Tank
Filler
Cap

6.0 Installation & Setup
14
6.8 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. Challenge recommends a dedicated line with a lockable
disconnect 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 5).
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 Phase Hz Circuit Size Wire Size Metric Wire
208/230V 25A 3 PH 60 Hz 40A #8 AWG 4mm sq.
460V 11.5A 3 PH 60 Hz 20A #12 AWG 10mm sq.
380/415V 10A 3 PH 50 Hz 20A #12 AWG 10mm sq.
The power source is connected to the cutter through the bottom of the power panel (right hand side).
Hook-up procedure:
1. DISCONNECT AND LOCK OUT THE POWER at the main panel to prevent accidental power
up. (See Power Lockout, page 5).
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
15
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
1
2
31 2
3

7.0 Operation
16
7.0 Operation
IMPORTANT: DO NOT ATTEMPT TO OPERATE YOUR CUTTER UNTIL YOU HAVE
THOROUGHLY READ AND UNDERSTAND ALL OF THE INSTRUCTIONS FOUND IN THE
OPERATOR AND INSTRUCTION MANUALS INCLUDED WITH YOUR CUTTER. CALL YOUR
AUTHORIZED CHALLENGE DEALER IF YOU STILL HAVE ANY QUESTIONS.
Complete operating instructions for all TC Model paper cutters can be found in the TC Touch Screen
Control Operating Instructions manual that was included with your machine (Figure 6). If you do not
have a copy, or to download the latest version, visit: www.challengemachinery.com/support.
Figure 6
7.1 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.

7.0 Operation
17
To install:
1. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout, page 5.)
2. Position the false clamp plate under the clamp, (Figure 7). The locator pegs are positioned to
the rear of the cutter and are set into holes in the bottom of the clamp.
Figure 7
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.
NOTE: The backgauge will not move to a position less than 2" (51 mm) when the false clamp plate is
installed in the clamp.
When the false clamp plate is not in use, store it on top of the cutter, with the locator pegs inserted
into the 3 holes in the top cover. There is a sensor inside one of these holes that detects when the
false clamp plate is on top of the machine, thereby informing the machine that the false clamp plate is
not installed in the clamp. This allows the backgauge to be positioned less than 2” (51 mm), which it
will not do when the false clamp plate is installed in the clamp.
Locator
pegs
Set
Screws
1/8” Allen
Wrench

8.0 Knife Installation/Changing
18
8.0 Knife Installation/Changing
Changing knives can be very dangerous unless safety precautions are
observed and extreme care is taken when handling knives.
•Make sure knife lifters are properly installed, see instructions following.
•Keep handling of unprotected knives to an absolute minimum.
•Clear off cutter table before removing knife.
•Have scabbard on cutter table and insert knife immediately.
•Warn people of any unprotected knife.
•Knife changing is a ONE PERSON OPERATION. Having more than one person trying to
change knives invites accidents.
Figure 8 – Knife Changing Equipment
The knife changing equipment shown in Figure 8 is included in the cutter tool kit. The following
instructions show how to remove and install a new or re-sharpened knife. Read these instructions AT
LEAST ONCE before attempting to actually change or install any blades.
Figure 9
P/N: 47575

8.0 Knife Installation/Changing
19
8.1 Knife Removal
1. Clear the cutter table. Place chipboard directly under the knife to prevent nicking if the blade
hits the table. On the TC touch screen menu choose “MAINTENANCE” and then “KNIFE
CHANGE”. Select “Knife Adjust Mode” then press and hold both cut buttons until the knife
and clamp reach the table. Now release the buttons (the knife and clamp should stay down).
2. DISCONNECT THE POWER AND LOCK IT OUT, (See Power Lockout Procedure on pg. 5).
3. If equipped with the paper deflector option, lock it down by screwing the lock knob all the way
in (Figure 10).
Figure 10 – Paper Deflector Locking Knob
4. Back off the knife adjusting screws on the top of the knife bar, (Figure 11), as far as they will
go (counter-clockwise). A new knife will cut deeper than a knife that has been ground several
times. If the adjusters are not backed off, damage can result to the new knife and/or the
cutting stick.
Figure 11 – Knife Adjusting Screws
5. Restore power to the machine and turn it ON. Follow the prompts on the screen to raise the
knife and clamp.
Lock Knob
(Paper Deflector
Option Only)
Adjusting
Screws
Knife

8.0 Knife Installation/Changing
20
6. DISCONNECT THE POWER AND LOCK IT OUT, (See Power Lockout Procedure on pg. 5).
7. Remove the bolts in the two slotted holes of the knife bar and insert the knife lifter by
screwing in the two knife lifter handles. Tighten the handles enough to hold the blade in
place. Remove the remaining four bolts (Figure 12). The leftmost bolt must be removed
while the knife bar is “UP”.
Figure 12
8. Clear the table and put the empty knife scabbard on the table.
DANGER: Used knives are heavy and still very sharp. Be careful to
keep the edge away from your body and keep other people out of the area while handling the
blade. Severe lacerations and dismemberment could result from careless handling procedures.
9. Grasp the knife lifter handles firmly while turning counterclockwise to release the knife from
the knife bar. Slowly lower the knife down and to the right. Bring the left side out first.
10. Place the knife with attached lifter on top of the scabbard. Remove the lifter and slide the
knife into alignment with the scabbard screw holes. DO NOT FORGET TO INSTALL THE
SCABBARD SCREWS!
11. Send the dull knife to the grinder.
8.2 Knife Installation
1. Use the cutting stick puller, (Figure 13), to remove the cutting stick. Turn the cutting stick to a
new surface.
Figure 13