Challenge DOCUTRIM Technical reference manual

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 non-
current, unsupported or no longer produced by The Challenge Machinery Company, and are
provided solely as an accomodation 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 t hese 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.

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 non-
current, unsupported or no longer produced by The Challenge Machinery Company, and are
provided solely as an accomodation 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 t hese 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.
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

Instruction and
Parts Manual
This safety alert symbol means CAUTION OR WARNING-PERSONAL SAFETY INSTRUC-
TION. Personal injury may result if safety precautions are not carefully read before attempt-
ing to operate or repair this machine. See SAFETY PRECAUTIONS, page vii.
•This machine is designed for ONE PERSON OPERATION ONLY!
•Always DISCONNECT THE POWER before working on this machine.
•DO NOT OPERATE WITH ANY GUARDS REMOVED! Replace all guards before operating.
•NEVER BYPASS SAFETY DEVICES OR INTERLOCKS!
•PINCH POINT - Keep hands from under transport clamp.
SAFETY ALERT
SERIAL NO-
MODEL-
DD
DD
DOCUOCU
OCUOCU
OCUTT
TT
TRIMRIM
RIMRIM
RIMTMTM
TMTM
TM
DOCUMENTDOCUMENT
DOCUMENTDOCUMENT
DOCUMENT
TRIMMERTRIMMER
TRIMMERTRIMMER
TRIMMER
Patent No. 5,694,823
This manual covers serial numbers 9712329E & up.
ALWAYS GIVE THE SERIAL NUMBER OF YOUR MACHINE WHEN WRITING.
Sold and serviced by
THE CHALLENGE MACHINERY COMPANY
1433 Fulton Avenue/Grand Haven, Michigan 49417-1594 U.S.A.
ChallengeMachinery.com F.400-E
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.400-E/NOV 97
ii
INTRODUCTION
WELCOMEto the family of Challenge® users. Challenge has been developing and manufacturing Graphics Arts
Equipment for over 100 years and is today one of the world’s leading producers and distributors of Paper Cutters,
Paper Drills and Bindery Equipment.
THE CHALLENGE REPUTATIONis important to you as a user for the continuous, ready availability of parts and
service.
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 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.
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-
lenge Dealer.
FOR PARTS AND SERVICE contact 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 MODEL of your machine to insure that the correct parts are sent as soon as pos-
sible.
Take a few minutes right now to RECORD YOUR MACHINE SERIAL NUMBER in the space provided on the
front cover of this manual. Also be sure to fill out the warranty card accompanying this manual and return it
DIRECT TO CHALLENGE.
If you bought a used machine, it is important to have the following information on record at Challenge. Copy this
page, fill in the information and send it care of: The Challenge Service Department, 1433 Fulton Avenue, Grand
Haven, MI 49417-1594.
CHALLENGE MODEL SERIAL NUMBER
ATTN COMPANY
ADDRESS
CITY STATE ZIP
PHONE DATE INSTALLED
DEALER’S NAME AND CITY
PLEASE REVIEW THE ENCLOSED WARRANTY SHEET!
It is very important that you read and understand the conditions outlined in the Warranty Information Sheet. It is
in an envelope attached to the outside of the shipping container.
The Warranty Information Sheet must be filled out completely, returned, and be ON-FILE at THE CHALLENGE
MACHINERY COMPANY in order for the warranty to be issued for this machine.
WARRANTY INFORMATION
Challenge® is a registered trademark of The Challenge Machinery Company. 1433 Fulton Street, Grand Haven, MI 49417.
Copyright © 1997 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A.
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

iii
F.400-E/NOV 97
PACKING LIST
STANDARD ITEMS
Qty. Part Description Part No.
2 Knife 41001
4 Knife Bolts, 3/8-16 x 1” H-6918-608
4 Knife Washers, Special 8815
3 Cutting Stick (in addition to one installed) 4168
1 False Clamp Plate (installed) 41032
1 Tool Kit 20-2150-6
1 - Cutting Stick Puller 5064
2 - Knife Lifters S-1245-5
4 - Knife Screws H-6918-608
4 - Knife Washers 8815
1 - 3/16" Hex Wrench W-130
1 - 1/8" Allen Wrench W -141
1 - 3/32" Allen Wrench W -154
1 - 5/32" Allen Wrench W -137
1 - 5/16" Hex ‘ L ’ Wrench 41087
2 - Door Key S-1839-5
2 - Start/Stop Key S-1839-4
1 Waste Cart 41058
OPTIONAL EQUIPMENT
1 Two-up Book Block Split K-41132-1
1 False Clamp Plate Pad Replacement Kit K-41118
1 Maintenance Kit - Basic K-41090
1 Maintenance Kit - Extended K-41091-2
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.400-E/NOV 97
iv
SPECIFICATIONS
CAPACITY/SIZES:
Pile Size (height) 1.75” 44 mm
Book Trim Sizes
spine to face – min. 5.25” 134mm
spine to face – max. 9.20” 233mm
top to bottom – min. 8.00” 204mm
top to bottom – max. 12.60” 320mm
Two-up Book Block Splits Option
length – min. 11.00” 280mm
length – max. 12.60” 320mm
width – min. 5.25” 134mm
width – max. 9.20” 233mm
CYCLE TIME:
Book Cycle Time (approx.) 20 seconds
SPECIFICATIONS:
Height 521/4" 132.6cm
Width 40" 101.6cm
Depth 37" 94.0cm
(will pass through standard 32"/81.3cm door)
Weight 837 lb. 377 kg.
Shipping Weight (approx.) 950 lb. 431 kg.
Maximum Operating Altitude 4000 ft. 1.2 km.
Noise Emissions Under 70 DB(A)
ELECTRICAL:
230 volt (±10%), 15 amp, 50/60 Hz., 1 phase, AC
Maximum overcurrent protective device: 15 amps
FEATURES:
LCD Display, Memory for Thirty (30) User Programmable
Book Sizes
Challenge reserves the right to make changes to any product or specification without notice and without incurring
responsibility to existing units.
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

v
F.400-E/NOV 97
TABLE OF CONTENTS
INTRODUCTION............................................................................................ ii
PACKING LIST .............................................................................................. iii
STANDARD ITEMS ....................................................................................... iii
SPECIFICATIONS ......................................................................................... iv
SAFETY PRECAUTIONS............................................................................. vii
POWER DISCONNECT PROCEDURE ....................................................... vii
WARNING LABEL DEFINITIONS ............................................................... viii
1.0 INSTALLATION .................................................................................... 1-1
1.1 Uncrating........................................................................................ 1-1
1.1.1 Installation Using Fork Truck ................................................ 1-1
1.1.2 Installation Using "Ramp" ..................................................... 1-2
1.2 Chip Chute & Cover Installation ..................................................... 1-3
1.3 Hydraulic Check ............................................................................. 1-4
1.4 Assembly ....................................................................................... 1-4
1.5 Cleaning ......................................................................................... 1-4
1.6 Power Hookup................................................................................ 1-4
2.0 OPERATION ........................................................................................ 2-1
2.1 ON/OFF - Keyswitch ...................................................................... 2-1
2.2 Footswitch ...................................................................................... 2-1
2.3 Keyboard ........................................................................................ 2-1
2.3.1 Function Keys ....................................................................... 2-1
2.4 Display ........................................................................................... 2-2
2.5 Programming Jobs ......................................................................... 2-2
2.5.1 Job Select Mode ................................................................... 2-2
2.5.2 Job Edit Mode ....................................................................... 2-2
2.5.3 Job Run Mode ...................................................................... 2-3
2.6 Setup Mode .................................................................................... 2-3
2.6.1 Operator Setup Mode ........................................................... 2-3
2.6.2 Maintenance Setup Mode ..................................................... 2-4
2.7 Diagnostic Error Codes .................................................................. 2-5
3.0 KNIFE INSTALLATION/CHANGING ..................................................... 3-1
3.1 Knife removal ................................................................................. 3-1
3.2 Knife installation ............................................................................. 3-2
3.3 Knife Care Tips .............................................................................. 3-3
3.3.1 Knife Blade Life ..................................................................... 3-3
3.3.2 Cutting Stick.......................................................................... 3-4
3.3.3 Bevel Angle........................................................................... 3-4
3.3.4 Helpful Suggestions .............................................................. 3-4
3.3.5 Knife Care ............................................................................. 3-4
4.0 MAINTENANCE ................................................................................... 4-1
4.1 Troubleshooting .............................................................................. 4-2
4.2 Routine Maintenance ..................................................................... 4-3
4.2.1 Weekly .................................................................................. 4-3
4.2.2 Monthly ................................................................................. 4-4
4.2.3Yearly .................................................................................... 4-4
4.3 Hydraulic System ........................................................................... 4-4
4.3.1 Recommended Hydraulic Oils .............................................. 4-5
4.4 Adjustments ................................................................................... 4-6
4.4.1 Clamp Up/Knife Up Proximity Switches ................................ 4-6
4.4.2 Knife Down Proximity Switch ................................................ 4-6
4.4.3 Knife Latch Adjustment Procedure........................................ 4-6
4.4.4 Knife Latch Proximity Switch ................................................. 4-7
4.4.5 Positive Trolley Limit and Linear Preset Proximity Switches.. 4-7
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.400-E/NOV 97
vi
TABLE OF CONTENTS
(continued)
4.4.6 Rotational Proximity Switch ................................................... 4-8
4.4.7 Hydraulic Valve Adjustments................................................. 4-8
4.4.8 Pneumatic Adjustments ........................................................ 4-9
5.0 PARTS LIST AND SEQUENCE OF OPERATIONS .............................. 5-1
MAIN ASSEMBLY - FRONT VIEW ...................................................... 5-2
MAIN ASSEMBLY - SIDE VIEW .......................................................... 5-4
MAIN ASSEMBLY - TABLE VIEW ........................................................ 5-6
MAIN ASSEMBLY - PLUMBING SCHEMATIC ..................................... 5-8
PNEUMATIC SEQUENCE OF OPERATION ....................................... 5-9
MAIN ASSEMBLY - TABLE VIEW ...................................................... 5-10
MANIFOLD ASSEMBLY..................................................................... 5-12
HYDRAULIC SEQUENCE OF OPERATION ...................................... 5-13
HYDRAULIC POWER UNIT KIT ........................................................ 5-14
ELECTRICAL SEQUENCE OF OPERATION .................................... 5-15
BASIC MACHINE SCHEMATIC ......................................................... 5-17
POWER PANEL ASSEMBLY ............................................................. 5-18
PCB ASSEMBLY - POWER PANEL CONTROL ................................ 5-20
LED INDICATOR INFORMATION ...................................................... 5-21
CONTROL CONSOLE ASSEMBLY ................................................... 5-22
POWER PANEL LABEL ..................................................................... 5-23
KNIFE LATCH ASSEMBLY ................................................................ 5-24
FOOTSWITCH ASSEMBLY ............................................................... 5-25
TILT TABLE KIT ................................................................................. 5-26
TRANSPORT BELT REPLACEMENT/ADJUSTMENT ...................... 5-27
DOCUTRIM REPAIR KITS ................................................................. 5-28
SAFETY SYSTEM TESTS ................................................................. 5-29
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

vii
F.400-E/NOV 97
SAFETY PRECAUTIONS
• This machine is designed and safeguarded for ONE PERSON operation. NEVER operate the trim-
mer with more than one person.
• Safety is the responsibility of the user of this machine. Use good judgement and common sense when
working with and around this machine.
• READ and understand all instructions thoroughly before using the trimmer. If questions still remain,
call your Authorized Challenge Dealer - fingers and hands are too valuable to risk experimentation.
• Only authorized and properly instructed persons should operate the trimmer.
• DO NOT ALTER SAFETY MECHANISMS, they are for your protection and should not be altered or
removed. Severe lacerations or dismemberment could result.
• DISCONNECT POWER before cleaning, lubricating, servicing or making adjustments not requiring
power. Turn the key to the off position and disconnect the power plug, see Disconnect Procedure
below.
• Lock the trimmer and remove the key when not in use, see "Main Power–Keyswitch", page 2-1.
• Be sure the trimmer is properly grounded, Power Hookup, page 1-4.
• Be sure there is sufficient power to operate the trimmer properly.
• Observe all caution plates mounted on this trimmer.
• Keep foreign objects off table and away from trimmer blade.
• BE EXTREMELY CAREFUL when handling and changing the trimmer knife. Severe lacerations or
dismemberment could result from careless handling procedures, see page 3-1.
• Keep the floor around the trimmer free of trim, debris, oil and grease.
• When servicing or replacing hydraulic and pneumatic parts, loosen the connections slowly to release
pressure. Never loosen connections with the machine running.
• If the trimmer sounds or operates unusually, 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 hand and fingers from under the clamp when clamping paper.
NEVER ATTEMPT TO REACH INTO THE CUTTING AREA!
POWER DISCONNECT PROCEDURE
The socket-outlet shall be installed near the equipment and shall be easily accessible. For maximum safety when
making adjustments or repairs to your machine, be sure to disconnect the power cord. In addition, the machine
switch should be turned to the OFF position and the keys should be held by the person servicing the machine.
Power Disconnect
Switch
(Fig. i)
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.
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.400-E/NOV 97
viii
CRUSH HAZARD
PINCH HAZARD
CUT/CRUSH HAZARD
SHOCK HAZARD
SHOCK HAZARD
HAZARDOUS AREA
Keep hands from under paper clamp.
Use two hands when lowering cover. The cover be-
comesheavierwhen itnearstheclosed position. Lower
the cover slowly!
Severelacerationscould result. Keephandsawayfrom
the blade and the clamp.
Disconnect power before removing cover. Replace
coverbeforeoperation.
Disconnect power before removing cover. Replace
coverbeforeoperation.
Disconnect power before cleaning, servicing, or mak-
ingadjustmentsnot requiringpower. Donotalter safety
guards or devices, they are for your protection. Re-
place all guards, do not operate with any guards re-
moved.
WARNING LABEL DEFINITIONS
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!