Challenge MEDALIST 820 Technical reference manual

F.669-D
August 2015
MEDALIST 820/870
Instruction and Parts Manual
Serial Numbers:
961533 through 159999,
870-A-150000 and up
Sold and Serviced by
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441-6081 USA
ChallengeMachinery.com
The Challenge Machinery Company provides owner's manuals on its
products solely as a courtesy to its customers. See the information below
before using this manual.
These manuals are for reference only. These manuals include products which are noncurrent,
unsupported or no longer produced by The Challenge Machinery Company, and are provided solely as
an accommodation to our customers. By providing these manuals, The Challenge Machinery Company
makes no representation or warranty as to the products, their current condition, or their suitabilityor 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.

F.669-D/820-870/Jan 98
2
INTRODUCTION
WELCOME to the family of Challenge® users. Challenge has been developing and 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
read and followed. See SAFETY PRECAUTIONS, page 6.
•This machine is designed forONEPERSONOPERATIONONLY!
•Always DISCONNECT THE POWER before working on this machine.
•DONOT OPERATE WITH ANYGUARDS REMOVED! Replace all guards before operating.
•CRUSH HAZARD - Keephands, hair,cleaning rags,& looseclothing awayfrom rollers.
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 SERVICEcontact the Authorized Challenge Dealer from whom you 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 MODELofyourmachineto insurethatthecorrectparts aresentassoonas 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, 6125 Norton Center Drive,
NortonShores,MI 49441-6081.
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
includedwiththemanualinformationpackage.
The Warranty Information Sheet must be filled out completely, returned, and beON-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, 6125 Norton Center
Drive, Norton Shores, MI 49441-6081.
Copyright © 1996 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A.

3
F.669-D/820-870/Jan 98
Medalist Air Feed Table Model Folder
(870 shown with stand)
PACKING LIST
Your folder has been carefully packaged to prevent damage in shipment. Inspect all
shipmentsassoonastheyarereceived. Noteanysigns of damage onthefreightbilland
notify the claims department of the carrierwithin 15 days. All claims for damage or loss
are the responsibility of the receiver,INSPECT PROMPTLY! Checkthecontentsofyour
container(s)* against the following list. NOTE: The vacuum-pump unit is shipped in a
separatecontainer.*
Inthe folder cartonyou shouldfind the followingsub assemblies:
1). Base Machine
2). Feed Table Assembly
3). First Fold Plate
4). Second Fold Plate
5). Stacker Tray Assembly
6). Stacker Wheel Assembly
7). Accessory Package (see parts list of Standard Accessories, pg 66)
8). Vacuum Tubes (3)
9). Sound Guard
10). Feeder Back Stop
11).* CompressorUnit
12).* Strainer,Pump Unit P-102
Thefolderstandwillarriveinaseparatecarton.
(fig. 1)

F.669-D/820-870/Jan 98
4
TABLE OF CONTENTS
INTRODUCTION........................................................................................... 2
PACKING LIST ............................................................................................ 3
SPECIFICATIONS ........................................................................................ 5
SAFETY PRECAUTIONS ............................................................................. 6
CAUTION: POWERLOCKOUTPROCEDURE ............................................. 6
WARNINGLABELDEFINITIONS.................................................................. 7
INSTALLATION ............................................................................................ 8
Cleaning.............................................................................................. 10
Power Hookup ......................................................................................11
Power Controls .....................................................................................11
Control Panel........................................................................................11
Squaring.............................................................................................. 12
OPERATION.............................................................................................. 12
Vacuum Feed Sheet Separator ............................................................ 12
Feeding Paper ..................................................................................... 13
Bleeder Valve (Vacuum Adjustment) ..................................................... 14
FoldPlates.......................................................................................... 14
........................................................................................................... 15
Roller Caliper Set up (870 only) ............................................................ 15
Stacker ............................................................................................... 16
Roller Caliper Quick Set Up Guide........................................................ 16
JamDetector....................................................................................... 16
SPECIALAPPLICATIONS .......................................................................... 18
Scoring ............................................................................................... 18
Perforating........................................................................................... 19
Slitting ................................................................................................ 19
RIGHT ANGLE CROSSFOLD SYSTEM...................................................... 20
Installation........................................................................................... 20
ConveyorSetUp.................................................................................. 22
OPTIONAL CROSSFOLDCONVERSION KIT35537 ................................... 23
MAINTENANCE ......................................................................................... 25
Cleaning.............................................................................................. 25
Rollers ................................................................................................ 25
Vacuum Pump–Compressor................................................................. 25
GeneralInspection............................................................................... 26
Lubrication .......................................................................................... 26
Service ................................................................................................ 26
NOTICE ..................................................................................................... 27
MODEL 820 MAIN ASSEMBLY - Left Hand Side ........................................ 28
MODEL 820 MAIN ASSEMBLY - Right Hand Side ...................................... 30
MODEL 820 MAIN ASSEMBLY - Front View .............................................. 32
MODEL 870 MAIN ASSEMBLY - Left Hand Side ........................................ 34
MODEL 870 MAIN ASSEMBLY - Right Hand Side ...................................... 36
MODEL 870 MAIN ASSEMBLY - Front View .............................................. 38
FOLDPLATEASSEMBLY#1...................................................................... 40
FOLDPLATEASSEMBLY#2...................................................................... 42
FEEDER ASSEMBLY ................................................................................ 44
STACKER ASSEMBLY .............................................................................. 46
LONG STACKER ASSEMBLY .................................................................... 47
STACKER WHEEL ASSEMBLY ................................................................. 48
CALIPERASSEMBLY ............................................................................... 49
MEDALIST STAND ASSEMBLY ................................................................. 50
RIGHT ANGLE STAND ASSEMBLY ........................................................... 51

5
F.669-D/820-870/Jan 98
SPECIFICATIONS
Stock Handling
Maximum Sheet Size 14” x 20” (35.6 cm x 50.8 cm)
Minimum Sheet Size 4” x 6” (10.2 cm x 15.2 cm)
Paper Weight 9# bond to 65# cover
34 g/m2to 176 g/m2
Number of Plates 2
Fold Plate Depth (plate #1) 2” to 17” (5.1 cm to 43.2 cm)
(plate #2) 2” to 9” (5.1 cm to 22.9 cm)
Fold Roller Diameter 1-1/2” (3.8 cm)
Roller Adjustments RollerCalipers
Fold Rollers -820 Rubber
-870 Combination (rubber & steel)
Maximum Speed 30,000 Sheets/Hour (8-1/2” x 11”)(A1)
Dimensions
Overall Height 25” (63.5 cm)
Overall Length 61.5” (156.2 cm)
Overall Width 25” (63.5 cm)
Net Weight (approximate) 275 lbs. (124 kg)
Shipping Weight (approximate) 300 lbs. (135 kg)
Electrical
Standard Motor 120 Volt (± .010%), 60 Hz, 1 Phase, 15 Amps, Service size 20 Amps.
Optional Motor 240 Volt (± .010%), 50 Hz, 1 Phase, 10 Amps, Service Size 15 Amps
Sound Emission
A- Weightedsound pressure level at operator level 6ft. (1.83m);folding 20lb(75g/m2), 8-1/2”x11” (216X279mm)
Machine Folding: 91 dB
A - Weighted sound power level at operator level 6 ft. (1.83m); folding 20lb (75g/m2), 8-1/2” x 11” (216X279mm)
Machine Folding: 101 dB
Challenge reserves the right to make changes to any product or specification without notice and without incurring responsibility to existing units.
JAMDETECTORASSEMBLY .................................................................... 52
ELECTRICAL SEQUENCE OF OPERATION............................................... 53
820 BASIC MACHINE SCHEMATIC - (120 VOLT) ........................................ 54
820 BASIC MACHINE SCHEMATIC - (230 VOLT) ........................................ 55
870 BASIC MACHINE SCHEMATIC - (120 VOLT) ........................................ 56
870 BASIC MACHINE SCHEMATIC - (230 VOLT) ........................................ 57
820/870BACK COVER PLATEASSEMBLY - (120VOLT)........................... 58
820/870BACK COVER PLATEASSEMBLY - (230VOLT)........................... 60
820 CONTROL PANEL ASSEMBLY ........................................................... 62
870 CONTROL PANEL ASSEMBLY ........................................................... 63
120/220VOLT PUMPASSEMBLY ............................................................. 64
STANDARDACCESSORIES...................................................................... 66
CROSS CARRIAGE ASSEMBLY ............................................................... 68
TRANSFER ASSEMBLY ............................................................................ 70
CROSSFOLD ELECTRICAL HOOK-UP ...................................................... 72
CROSSFOLDELECTRICAL HOOK-UPINSTRUCTIONS ............................. 73
IMPOSITION MANUAL ............................................................................... 74
SLITTERSHAFT ASSEMBLYCOMPONENTS ........................................... 76
SLITTERSHAFT ASSEMBLYCOMPONENTS ........................................... 77
ROLLERREPLACEMENTREPAIR KITS ................................................... 78
TABLE OF CONTENTS
(CONT’D)

F.669-D/820-870/Jan 98
6
SAFETY PRECAUTIONS
•This machine is designed and safeguarded for ONE PERSON operation. NEVER operate the ma-
chine with more than one person.
•Safety of this machine is the responsibility of the user and operator. Use good judgement and
common 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
altered or removed.
•DISCONNECT POWER before cleaning, lubricating, servicing, or making adjustments not requir-
ing power. See Power Lockout Procedure below.
•HIGH SPEED ROLLERS - Keep rags, loose clothing and long hair away from rollers. Personal
injury could result from items being caught on rollers.
•Have your electrician make sure the machine is properly grounded.
•Have your electrician check for sufficient power to operate the machine properly.
•OBSERVE ALL CAUTION PLATES AND LABELS on this machine.
•Keep foreign objects off table and away from rollers.
•BE EXTREMELY CAREFUL when handling and changing the slitter, perforating or scoring blades.
Severe lacerations or dismemberment could result from careless handling procedure.
•Keep the floor around the machine free of trim, debris, oil and grease.
•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.
•DO NOT CLEAN ROLLERS WITH THE MACHINE RUNNING! Disconnect the power and use the
handwheel to turn the rollers.
•DO NOT OPERATE WITH ANY GUARDS REMOVED! Replace all guards after adjusting, lubricating
or servicing the machine.
CAUTION: POWER LOCKOUT PROCEDURE
Formaximum safety and toprevent unauthorized
use, turn the power switch to the off position and
disconnect the power cord whenever adjusting,
lubricating, or making repairs to the machine.
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.
(fig. 2)

7
F.669-D/820-870/Jan 98
SINGLE OPERATOR
SHOCK HAZARD
SHOCK HAZARD
HAZARDOUS AREA
Do not operate with more than one person.
Disconnect power before removing cover. Replace
cover before operation.
Disconnect power before removing cover. Replace
cover before operation.
Disconnect power before cleaning, servicing, or mak-
ingadjustments not requiring power. Do not alter safety
guards or devices, they are for your protection. Re-
place all guards, do not operate with any guards re-
moved.
WARNING LABEL DEFINITIONS

F.669-D/820-870/Jan 98
8
Note: For Right Angle & Crosscarrier assembly see
page20. Openthe standcarton firstand assembleac-
cordingto the instructionsenclosed. Using twopeople,
center the folder on the stand as shown, fig. 3, with the
stand opening towards the front.
INSTALLATION
(fig. 3)
Remove the parts of the folder checking them against
the packing list on page 3 of this manual. (Remove and
savetherollerspacerson820only.)
Steps for assembling the Medalist folder:
the rail guides, (fig. 4), and tighten the eccentric plate
locks,(fig. 6). Notebothplates havetwo setsoflocat-
ing holes in the plate rails. The first set is used when
the plate deflector is down, the other when the plate is
open, see fig. 5.
(fig. 5)
2. Install the #1 (upper) foldplate, fig. 5.
(fig. 6)
3.Make sure thefoldplate pinsare located inthe guide
rails, then lower the plate locks, (fig. 6).
Place the sound cover on top of the #1 foldplate. (the
sound cover is optional on 820 model).
4. Install the feed table. Insert the table between the
(fig. 4)
1. Install the #2 (lower) foldplate. Lower the cover and
insert the #2 foldplate making sure the pins latch into
Do Not Lift
on Drive
Shaft
(round bar)
Notched
Plate Rail
#1 Fold Plate/
Locating Pins

9
F.669-D/820-870/Jan 98
(fig. 7)
sideframes. Install thefeed tableso the notchesin the
side brackets, (fig. 7), mate with the mounting pins in-
side the folder side frames.
NOTE: Mounting pins should be located in the upper
set ofthreaded holes. (Lower holes are used to mount
a crossfold carrier assembly.)
(fig. 8)
5. Install the stacker table assembly, (fig. 8), on the
back of the folder. Insert the spring-loaded end (right
side – viewed from rear of the folder) of the drive shaft
into the locator hole in the side frame, compress the
spring against the side frame and swing the opposite
end into position in the other side frame.
(fig. 9)
6. To pile folded materials, insert ears of stacker tray
into end of stacker table, as shown, fig. 9.
(fig. 10)
7. Attach the stacker wheel assembly to the tie bar
next to the jam detector, as shown, fig. 10.
(fig. 11)
8. Using two people, position the compressor on the
bottom shelf of the stand, (fig. 11).
(fig.12)
9. Install the strainer screen (shipped with the acces-
sory kit) to the intake opening of the blower unit, (fig.
12).
Left Side
Locator
Hole
Locating Pins/
Feeder Notch

F.669-D/820-870/Jan 98
10
(fig. 13)
10. Connect the compressor hoses to the feed table
assembly. The sucker wheel hose threads through the
ty-rap and table support, underneath the feed table,
then onto the end of the sucker wheel shaft tube, as
shown in fig. 13.
Blower
Fittings
Vacuum
Fitting
(fig.14)
11.Attach theairhoses fromthe endsofthe pileguides
to the double hose fittings of the blower. The single
hose from the sucker wheel fitting attaches to the
vacuum fitting, (fig. 14).
NOTE: Make sure all shipping plugs are removed
from the pump openings before attaching the
hoses!
Cleaning
A clean machine will reflect in the quality of the work it
produces. As you unpack your folder, wipe off any
excess protective oil, dirt, or dust which may have ac-
cumulated during shipping.
Keep your machine clean, and wipe off any
accumulationsofpaperdustattheendofeach
day. Cover your machine anytime it is not in
use. See the maintenance section for addi-
tionalcleaninginstructions.
NOTICE
820ONLY: Whenever the machineisnot being
used,reinserttherollerspacersshippedinthe
machinetopreventflatspotsfromforming.This
is a operator controled maintenance function.
Roller flat spots areNOTCOVEREDunderwar-
ranty.
CAUTION:DISCONNECTTHEPOWERBEFORE
INSTALLINGTHEROLLERSPACERS.
1. Close the deflectors on both fold plates.
2. Place one roller spacers at each side of the
feed table and feed between the rollers with
the hand wheel.
3. Removethespacersbeforerunningthenext
job.