Challenge Champion 305 XD Guide

F.254-I-T
October 2019
CHAMPION 305 X, XG, XT
Technical Service and Parts Manual
Serial Numbers 07X1360 & 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................................................................................................................................................5
2.1 Precautions...................................................................................................................................5
2.2 Power Lockout Procedure ............................................................................................................5
2.3 Warning Label Definitions.............................................................................................................6
3.0 Maintenance Guide...........................................................................................................................8
3.1 Maintenance Adjustments ............................................................................................................9
3.1.1 Centering the Backgauge Control Knob................................................................................9
3.1.2 Squaring the Backgauge.......................................................................................................9
3.1.3 Proximity Switches ............................................................................................................. 10
3.1.4 Hydraulic Valve Adjustments.............................................................................................. 13
3.1.5 Clamp Cylinder................................................................................................................... 17
3.1.6 Clamp Parallel Rod ............................................................................................................ 18
3.1.7 Backgauge Gibs................................................................................................................. 19
3.1.8 Lead Screw Adjustment Nuts............................................................................................. 20
3.1.9 Backgauge Drive Belt Adjustment...................................................................................... 21
3.1.10 Knife Bar Gibs .................................................................................................................. 21
3.2 Repair and Replacement........................................................................................................... 23
3.2.1 Fuses.................................................................................................................................. 23
3.2.2 Knife Bar Cylinder .............................................................................................................. 23
3.2.3 Pilot Check Valve ............................................................................................................... 25
3.2.4 Clamp Return Speed Adjustment....................................................................................... 26
3.2.5 Table Maintenance............................................................................................................. 26
4.0 Troubleshooting ............................................................................................................................. 28
5.0 Schematics & Parts Lists ............................................................................................................... 32
5.1 Main Assembly –Front View..................................................................................................... 32
5.2 Main Assembly –Side View ...................................................................................................... 36
5.3 Main Assembly–Top View ........................................................................................................ 38
5.4 Main Assembly –Rear View...................................................................................................... 40
5.5 Main Assembly –X Model Tables ............................................................................................. 44
5.6 Main Assembly –XG/XT Model Table....................................................................................... 46
5.7 Main Assembly - Air Table Assembly........................................................................................ 48
5.8 Main Assembly - Power Panel Wiring–XG/XT - 1 Phase......................................................... 50
5.9 Main Asm. –Front View (Rough) .............................................................................................. 52
5.10 Main Assembly- Electric Eyes................................................................................................. 56
5.11 Main Assembly- Electric Eyes................................................................................................. 58
5.12 Main Assembly –Electric Eyes (X, XG, XT)............................................................................ 60
5.13 Main Assembly - Wiring –‘X’ Model – 1ph............................................................................... 61
5.14 Basic Machine Schematic –XG/XT Models........................................................................... 62
5.15 Basic Machine Schematic –X Models .................................................................................... 64
5.16 Power Panel Assembly –305X ............................................................................................... 66
5.17 Power Panel Asm. –305X (Blower Opt. Wiring)..................................................................... 70
5.18 Power Panel Assembly –305X –XG/XT Models.................................................................... 72
5.19 Interconnection Diagram –305X –XG/XT Models ................................................................ 78
5.20 Interconnection Diagram –305X............................................................................................. 80
5.21 Control Console Assembly - 305XG Model............................................................................. 82
5.22 Control Console Assembly - 305X........................................................................................... 84
5.23 Control Console Assembly - XT Model - Color LCD ............................................................... 86
5.24 Cut Button Assembly (Obsolete) ............................................................................................. 88
5.25 Cut Button Assembly –(Current)............................................................................................. 90
5.26 Kit –Ergonomic Touch Switch (Cut Button Option) ................................................................ 92
5.27 Line Light Assembly................................................................................................................. 94
5.28 Air Table Blower Assembly –Single Phase ............................................................................ 95

1.0 Introduction
4
5.29 Compressor Assembly.............................................................................................................96
5.30 Backgauge Control Assembly S/N 13X1661 & Below.............................................................98
5.31 Backgauge Control Assembly S/N 13X1662 & Above.............................................................99
5.32 X/XG/XT Troubleshooting ......................................................................................................100
5.33 Description of Error Messages...............................................................................................101
5.34 Sensor Data Abbreviations ....................................................................................................102
5.35 Encoder Cable Assembly –305X - X Models........................................................................104
5.36 Encoder Cable Assembly –305X –XG/XT Models...............................................................105
5.37 Knife Latch Assembly.............................................................................................................106
5.38 Bell-Crank Assembly –Clamp ...............................................................................................107
5.39 Hydraulic Manifold Assembly.................................................................................................108
5.40 Hydraulic Power Unit Assembly.............................................................................................109
5.41 Hydraulic Manifold..................................................................................................................111
5.42 Manifold Assembly.................................................................................................................113
5.43 Fuse Charts............................................................................................................................114
5.44 XG/XT Models Label –Power Panel Connection Procedure ................................................115
5.45 305 X Model Label –Power Panel Conn. Procedure. ...........................................................116
5.46 Warning Label........................................................................................................................117
5.47 Paper Deflector (Kit Option)...................................................................................................118
5.48 Paper Deflector Assembly......................................................................................................119
5.49 Extension Tables - 24” x 36” - (Kit Option).............................................................................120
5.50 Extension Air Tables - 24” x 36” (Kit Option) .........................................................................122
5.51 Back Gauge Tape Kit.............................................................................................................124
5.52 Electric Eye Kit Instructions –(Obsolete)...............................................................................126
5.53 Electric Eye Kit Instructions –(Current).................................................................................132
5.54 Jogging Aid Construction Guide.............................................................................................134
5.55 Converting 305X Series from Three Phase to Single Phase.................................................135
5.56 Knife Lifter Assembly..............................................................................................................136
6.0 Safety System Tests.....................................................................................................................137

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 17.0, 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 Maintenance Guide
8
3.0 Maintenance Guide
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: Parts with the express understanding that they are to replace parts
found missing or no longer serviceable on equipment designed and/or manufactured at
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 product is not authorized by The Challenge Machinery Company. Any
modification or alteration of any Challenge product will void any remaining warranty.

3.0 Maintenance Guide
9
3.1 Maintenance Adjustments
3.1.1 Centering the Backgauge Control Knob
The Backgauge Control Knob is coupled with a potentiometer. If the Control Knob is misadjusted, the
backgauge may wander forward or backward.
To adjust the Control Knob, turn the power off and then on and immediately enter Sensor Data Mode.
Hold the rubber coupling in the Control Knob Assembly while turning the knob. Adjust the knob until
.512 is displayed on the screen. Turn the power of and then on once again.
Figure 2
3.1.2 Squaring the Backgauge
To test the backgauge for squareness, place a small lift of paper against the left side of the
backgauge (but not against the side guide) and make a cut.
Figure 3
Now, leave the backgauge in the same position, flip the lift over and against the right side of the
backgauge (but not against the side guide). Make another cut to see if any of the stock will trim off.
Run two checks, one starting on the left and moving to the right, the other, moving from the right to
the left. Trim in either sequence indicates the backgauge is out of square.
1. As machine wears, make sure the backgauge gibs are set properly first (see Backgauge
Gibs), then follow steps 2 through 5.
NOTE: Gib adjustment is not necessary on initial machine setup because they have been
adjusted at the factory.
PAPER

3.0 Maintenance Guide
10
2. Loosen backgauge locking screw (smaller head). Loosen the jam nuts on the backgauge
squaring screws.
Figure 4
3. Back off the squaring screw on the side that the trim occurred and tighten the other.
4. With the squaring screws tight, make another test. Continue to adjust and test until no trim
occurs when testing in either sequence.
5. Tighten the jam nuts and lock screw.
3.1.3 Proximity Switches
These tests 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 cutter is
not accidentally operated while adjustments are being made.
Challenge Champion cutters incorporate proximity switches to detect stages of operation. These
types of limit switches have no moving parts and are more reliable than the old style of contact
switches.
NOTE: Adjust the switches in the following order:
1. Knife Up/Down Limit Switches
2. Hydraulic Up Limit Switch
3. Clamp Up Limit Switch
4. False Clamp Sheath Limit Switch
Locking
Screw
Squaring Screws

3.0 Maintenance Guide
11
CRUSH HAZARD! When the limit switch is actuated, the clamp will return
to the up position. Keep hands and tools clear.
1. Knife Up/Down Proximity Switches
Figure 5
The Knife Up and Knife Down Proximity switches are mounted to a bracket that is attached to the
Knife Cylinder (Figure 5). With the power off, set the collar between the proximity switches and then
turn on power. Press cut buttons once to turn on the hydraulic motor. The knife will move to the
absolute top of its stroke. Move the collar to the top proximity switch until LED turns on, then move it
an additional 1/4” higher and tighten its setscrew. An indicator light on the switch body comes on
when the switch is actuated (proximity switches must be within 1/8” (3.2mm) to actuate). Check the
Knife Down Proximity switch by going into the Maintenance screen to Knife Adjust and lock the knife
in the down position. Check the distance between the proximity switch and the actuator.
2. Hydraulic Up Proximity Switch
This switch is mounted on the left, rear leg of the base casting (Figure 6 on page 12). An indicator
light on the switch body comes on when the switch is actuated (proximity switches must be within 1/8”
(3.2mm) to actuate). The switch senses the extension of the clamp cylinder at the top of its stroke.
This stops hydraulic power to the clamp and knife. If the switch is not properly set, the knife and
clamp cylinders will be under constant load (indicated by excessive heat and noise).
To adjust:
a. Loosen the bottom lock nut and turn the top lock nut down to raise the switch.
b. Turn on the machine and press the cut buttons once to start the hydraulic motor.
c. The knife and clamp will move to the extreme up position and a load will remain on the
hydraulics.
d. When the cylinder has stopped moving, pass a metal object in front of the switch to
actuate it and take the load off the hydraulics. Keeping pressure on the switch to hold it
against its mounting bracket, turn the lock nut up to lower the switch until the indicator
light in the switch comes on. Tighten the lower jam nut.
e. Press the cut buttons to cycle the clamp and check clamp position.

3.0 Maintenance Guide
12
Figure 6
3. Clamp Up Proximity Switch
This switch is mounted inside the rear of the arch casting, Figure 7. It is tripped by the clamp when
the clamp is in the up position. This switch prevents backgauge movement if the clamp is not up. On
machines equipped with the air table option, it also diverts the air from the table when the clamp is
down to prevent the stock from moving during a cut. This switch is tripped by a actuator on the top of
the clamp and must be adjusted to within 1/8” (3.2mm) of the face of the switch.
Figure 7
4. False Clamp Sheath Limit Switch
This switch is mounted on the false clamp sheath on the right side of the machine, Figure 7. It is
tripped when the false clamp plate is in the sheath. This switch prevents the backgauge from getting
any closer then 2” to the clamp if the false clamp plate is not in the sheath. If the switch is actuated
(the false clamp plate is in the sheath) then the minimum cut size is 3/4”. To check the switch –slide
the false clamp plate into the sheath and check that the light on the switch is on. If the switch needs
to be adjusted, move the switch to within 1/8” (3.2mm) from the face of the switch to the metal false
clamp plate.
Hyd. Up
Proximity Switch

3.0 Maintenance Guide
13
Figure 8
3.1.4 Hydraulic Valve Adjustments
Several of the following tests 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 cutter is not accidentally operated while adjustments are being made. Disconnect the power and
lock it out, see Safety Precautions, page 8, whenever working on the machine unless the directions
specifically require the machine to be powered.
For initial setup, adjust the valves in the following order:
1. Main System Relief Valve- 1800 psi
2. Knife down sequence valve- 1600 psi
3. Clamp up relief valve- 400-600 psi
4. Pressure reducer valve (X only)- 1400max/400min psi
5. Electronic Clamp Pressure- 1400max/400min psi
NOTE: Pressure settings fluctuate with oil temperature. Set pressures when the oil is hot.

3.0 Maintenance Guide
14
Figure 9
1. Main System Relief Valve (Figure 9)
This valve maintains the overall hydraulic pressure for the entire system. Factory setting: 1800 psi.
Check Procedure:
a. Open the left access door on front of the cutter.
b. Turn the power on and make a cut to hold the knife down on the cutting stick. Read the
pressure off the main system pressure gauge (front gauge) while the knife is down. If the
gauge does not read 1800 psi, an adjustment is needed. You may need to send knife
down in maintenance mode to read the gauge more easily.
To Adjust:
Loosen the lock nut on the relief valve. Use an Allen wrench to turn the adjusting screw.
Turn clockwise to increase pressure, counter-clockwise, to decrease pressure.
a. Make a cut and hold the buttons in. Or go to knife down adjustment in maintenance
mode to cycle the hydraulics. Adjust the valve screw until you have the correct pressure.
b. Tighten the lock nut while holding the hex wrench in place.
c. Proceed to readjust the other valves.
2. Knife Down Sequence Valve (Figure 9)
This valve controls the clamp and knife sequence. It keeps the knife up until after the clamp has
made contact. It is the upper right valve on the front of the manifold. Factory Setting: 1600 psi.
NOTE: Main System Pressure must be set at 1800 psi before making this adjustment.
Check Procedure:
a. Open the left access door on front of the cutter.
b. Press the cut buttons while reading the pressure on the main system pressure gauge
(front gauge). The gauge should read approximately 1600 psi as the knife is moving
down (when bottomed, the gauge will jump to 1800 psi showing the Main System
Relief Pressure previously set).
c. If correct, proceed to check the Pressure Reducer.
Main
System
Gauge
Electronic
Clamp Valve
Main System
Relief Valve
Knife Down
Sequence
Clamp Up
Sequence

3.0 Maintenance Guide
15
To adjust:
a. Loosen the lock nut.
b. Make a cut and hold the buttons in. While reading the main system gauge, adjust the
valve until you have the correct pressure. Clockwise to increase, counter-clockwise to
decrease.
c. Tighten the lock nut while holding the hex wrench in place.
d. Proceed to readjust the other valves.
3. Clamp Up Sequence Valve (Figure 9 on page 14)
This valve maintains clamp pressure so the clamp remains down until the knife has stopped in
the up position. Factory setting: 400-600 psi.
Check Procedure:
a. Open the left access door of the cutter.
b. Press the cut buttons, and while reading the pressure on the main gauge (front
gauge), release them. The gauge should read between 400-600 psi as the clamp is
going up. There should be no clamp movement until the knife is stopped in the up
position.
c. If correct, proceed to check the Pressure Reducer.
To Adjust:
a. Remove the protective cap and loosen the lock nut on the clamp up sequence valve.
b. Make a cut, then release the buttons. Read the main gauge as the clamp is
returning. Adjust the valve for a reading of 400-600 psi.
c. Tighten the lock nut while holding the hex wrench in place and replace the protective
cap.
d. Proceed to readjust other valves.
4. Manual Pressure Reducer Valve- (X only)
This valve, Figure 10 on page 16, limits the amount of pressure to the clamp system. Factory setting:
1000 psi (1400max/400min).
To Check:
With the hydraulic access door open, activate the cut buttons and read the pressure off
the clamp gauge (rear gauge). It should read 750 psi for average cutting purposes.
To Adjust:
1. Loosen the lock knob. There are two knobs, one behind the other. The outer is the adjusting
knob. The inner is the lock knob.
2. Push the cut buttons and check the reading on the clamp gauge (rear gauge) when the clamp
is on the table and the knife is coming down.

3.0 Maintenance Guide
16
3. Turn the Pressure adjusting knob clockwise for MORE pressure, counter-clockwise for LESS.
DO NOT set the clamp pressure below 400 psi. Severe lacerations or
dismemberment could result! The knife and clamp system will lose sequence settings below 400 psi
and the knife could come down before the clamp.
4. Make another cut and check the pressure gauge. Adjust the pressure to your cutting
application (See Operator Tips or Knives sections).
5. Tighten the locking knob.
Figure 10
1. Electronic Clamp Control Valve- (XG)
The electronic clamping control allows the convenience of changing the clamp pressure at the control
console. The pressure is controlled by use of the up and down arrow keys, 0 being the lowest, 15 the
highest; and is indicated in the upper right hand corner of the display. See below:
Adjustment of the Electronic Valve:
a. To adjust the pressure range, enter the Maintenance Mode and choose Diagnostic.
b. To adjust the pressure, select Clamp Adjust. See the next screen on page 86:
c. Setting the Maximum Pressure: Perform a cut cycle, after the clamp has contacted
the table and while the knife bar is coming down, read the pressure on the right hand
pressure gauge. It should be set at 1400 p.s.i. If not, correct by using the up and
Clamp
Gauge
Pressure Adjust
Knob
Lock
Knob
5.000in
DIAGNOSTIC
Error Code
Sensor Data
Clear Memory
Clamp Adjust
Select & press enter
A) Maint C) Send
B) Job D) Exit

3.0 Maintenance Guide
17
down arrow keys. When finished, choose D), to exit and go to the minimum pressure
set up seen shown below:
d. Setting the Minimum Pressure: Perform a cut cycle, after the clamp has contacted
the table and while the knife bar is coming down, read the pressure on the right hand
pressure gauge. It should be set at 400 p.s.i. If not, correct by using the up and
down arrow keys. When finished, choose C), to return to the Send mode, or D) Exit to
return to Diagnostics.
3.1.5 Clamp Cylinder
If the clamp piston bottoms in the cylinder before the clamp makes contact with the table, or if the
clamp does not make full travel on the up stroke, the clamp cylinder may need adjustment. The
clamp cylinder is located inside the left base casting leg behind the left front door (Figure 11, on page
18).
5.000
Set Maximum
>
Press /\ to Increase
Press \/ to Decrease
A) Main C) Send
B) Job D) Exit
5.000
Set Minimum
>
Press /\ to Increase
Press \/ to Decrease
A) Main C) Send
B) Job D) Exit
Clamp
Cylinder

3.0 Maintenance Guide
18
Figure 11
To adjust:
1. Turn on machine. Start the hydraulic motor by pressing both cut buttons simultaneously.
Turn off the machine.
2. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout procedure, page 5).
3. Loosen the jam nut.
4. Use the flats on the clamp cylinder shaft to turn the shaft into or out of the clevis as required,
(Figure 8). (In decreases, out increases height.) The clamp should be set to 4” above the
table.
Figure 8
5. Retighten the jam nut securely.
3.1.6 Clamp Parallel Rod
If the clamp is not parallel with the table:
1. DISCONNECT THE POWER AND LOCK IT OUT! (See Power Lockout procedure, page 5.)
2. Loosen the jam nuts on each end of the clamp connecting rod, (Figure 9 & Figure 14). (Note:
the left jam nut has left hand threads.)
Figure 9 & Figure 10 –LH & RH End of Rod
Jam
Nut
Jam
Nut
Clevis
Jam Nut
Wrench Flat

3.0 Maintenance Guide
19
3. Using the flats on the end exposed below the base casting, (Figure 9 & 14), turn the
connecting rod and align the clamp with the table. Place a long strip of paper under each end
of the clamp. Push the cut buttons and when the clamp contacts the table, attempt to pull the
strips out. The clamp should be adjusted so neither strip pulls out.
4. Retighten the jam nuts securely.
3.1.7 Backgauge Gibs
If you are having trouble keeping the back-gauge square, check for backgauge side play. Position
the backgauge approximately 2” (50-55mm) from the rear of the table and turn off power.
Remove the rear table cover. From the back, hold each end of the backgauge and try pulling one
end while pushing the other to rock it side to side. If there is noticeable side-to-side play in the
backgauge, the gibs will need adjusting. Check for play at various positions on the table, (Figure 11).
Note: there will be some front to rear movement between the backgauge nut and screw.
Figure 11
The backgauge has two gibs that ride on an iron rail underneath the table, (Figure 12). These are
adjusted with setscrews, which are held in position with jam nuts.
Figure 12
To adjust:
1. Run the backgauge back to 23” (600mm) and disconnect the power.
2. Always adjust the side gib first. Loosen all jam nuts and adjusting screws then tighten the
front and rear screws.
3. Pull each end of the backgauge and try to rock it side to side as before to check for play.
4. Continue to adjust these two screws until there is no play and the hand-wheel still turns easily
(X only).
Set Screws
& Jam Nuts
Rail

3.0 Maintenance Guide
20
5. Lock the screws in place with the jam nuts.
6. Snug up the middle two screws and lock in place with the jam nuts.
7. Snug up the bottom gib adjusting screws finger tight and lock in place with the jam nuts.
8. Run the backgauge back and forth to make sure it does not bind. Readjust if necessary.
9. Replace the rear table cover.
10. Check the backgauge squareness.
3.1.8 Lead Screw Adjustment Nuts
If play is noted in the forward pillow block and thrust bearings, take up the play in the adjustment nuts
by: 1. Loosening the lead screw jam nuts, Figure 13 (“X”) & Figure 14 (“XT”/”XG”) on page 20.
2. Snug up the inner nut to eliminate any play.
3. Tighten the nuts against each other.
4. Check the socket head bolts in the pillow block to make sure they are also tight.
Figure 13 –“X” Model Jam Nut Location
Figure 14 –”XG” Model Jam Nut Location