Challenge 305 - User 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.

Summary

Guarantee Information

Installation and Operating Instructions

Installation Procedures

Steps for cutter setup, including crating removal, lever attachment, and motor wiring.

Oil Seal Plug Replacement

Instructions for removing the oil seal plug and replacing it with a breather cap.

Knife Installation

Detailed steps for installing the knife into the knife bar.

Backgage Tape Installation

Guide for attaching the backgage tape and wheel to the table.

Backgage Squaring Procedure

How to square the backgage to align correctly with the cutter knife.

Cutter Operation

Basic steps for operating the knife bar and clamp controls.

Knife-Bar Gib Adjustment

Procedure for adjusting the knife-bar gibs for proper fit and movement.

Knife Sharpening and Adjustment

Guidance on knife sharpening frequency, technique, and adjustment for cut depth.

Clamp Holding Spring Replacement

Steps for replacing the clamp holding spring assembly.

Troubleshooting Common Issues

Pump Performance Issues

Addresses issues related to oil delivery, power, noise, and sluggishness of the pump.

Clamp and Cutting Problems

Solutions for clamp pressure loss, inaccurate cuts, knife drift, and cutting variations.

Knife and Cylinder Adjustments

Troubleshooting and adjustment procedures for the knife auto-lift valve and bar cylinder.

Clamp System Adjustments

Procedures for checking and adjusting clamp pressure and cylinder travel.

Hydraulic Unit Information

Adjusting Knife and Clamp Controls

Knife Controls Operation

Adjusts knife lever engagement and disengagement for proper operation.

Clamp Controls Operation

Adjusts clamp lever movement for precise control and safe neutralization.

Challenge Two-Handed Safety Device

Cutter Accessories

False Clamp Plate Attachment

Plate to prevent clamp marking on soft stock.

Split Back Gage Description

A three-section gage for book trimming and multi-pile cuts.

Challenge 305 Specifications

General

Battery Voltage	18 V
Chuck Size	13 mm
Max Torque	50 Nm
Type	Drill
Power Source	Battery