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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 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.

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Summary of Contents for Challenge DOCUTRIM

  • Page 1 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.
  • Page 2 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.
  • Page 3 TRIMMER 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...
  • Page 4: Introduction

    THE CHALLENGE REPUTATION is 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.
  • Page 5: Packing List

    PACKING LIST STANDARD ITEMS Qty. Part Description Part No. Knife 41001 Knife Bolts, -16 x 1” H-6918-608 Knife Washers, Special 8815 Cutting Stick (in addition to one installed) 4168 False Clamp Plate (installed) 41032 Tool Kit 20-2150-6 1 - Cutting Stick Puller 5064 2 - Knife Lifters S-1245-5...
  • Page 6 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. F.400-E/NOV 97...
  • Page 7: Table Of Contents

    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"...
  • Page 8 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 F.400-E/NOV 97...
  • Page 9: Safety Precautions

    • 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.
  • Page 10: Warning Label Definitions

    WARNING LABEL DEFINITIONS Keep hands from under paper clamp. CRUSH HAZARD Use two hands when lowering cover. The cover be- PINCH HAZARD comes heavier when it nears the closed position. Lower the cover slowly! Severe lacerations could result. Keep hands away from CUT/CRUSH HAZARD the blade and the clamp.
  • Page 11: Installation

    (fig. 1-2) The DocuTrim weighs approximately 837 lbs./377 kg. DO NOT risk personal injury or damage by attempting to move machinery with makeshift equipment or in- adequate manpower.
  • Page 12: Installation Using "Ramp

    The skid is designed to allow a fork truck access under the machine (fig. 1-3). Make sure forks Lag Bolt Location extend far enough under the DocuTrim to sup- four (4) places port the rear frame. Use fork extensions if nec- essary.
  • Page 13: Chip Chute & Cover Installation

    (fig. 1-11) The trimmer may now be rolled into its final oper- ating position. The DocuTrim will fit through a standard 32" (82cm) door if you open the rear access doors (fig. 1-12) and remove the chip Align Wheels to chute.
  • Page 14: Hydraulic Check

    1-18 and 1-19. If your socket/outlets the pin into the socket and tighten the locking ring. The are a different configuration, have your DocuTrim dealer footswitch may be positioned where it is most conve- install the proper plug required. Power to the machine nient for the operator.
  • Page 15 (fig. 1-18) (fig. 1-19) Power Disconnect Switch (fig. 1-20) F.400-E/NOV 97...
  • Page 16 NOTES F.400-E/NOV 97...
  • Page 17: Operation

    2.3.1 Function Keys (fig. 2-2) JOB Key Once the DocuTrim is positioned and hooked up to a power source, the DocuTrim can be turned on and off This key allows the operator to toggle through job po- using the large red emergency stop button on the con- sitions stored in the memory.
  • Page 18: Display

    Once the timer reaches position. zero, the display will be activated in Job Select Mode and the last job that was in use at the time the DocuTrim was turned off will be displayed. ENTER Key 2.5.1 Job Select Mode...
  • Page 19: Job Run Mode

    TOR and MAINTENANCE. Upon initial installation you tion is made. will need to use them to calibrate your DocuTrim and make sure your book trimming is accurate. Once the sides to be trimmed have been indi- cated, the machine will ask the operator to enter 2.6.1 Operator Setup Mode...
  • Page 20: Maintenance Setup Mode

    Press the Edit key to Lock Memory advance to the next function, The DocuTrim memory may be locked or un- Setup Memory (Metric or Inch) locked by the operator to prevent unintentional or unauthorized changes to stored programs. Press This function allows you to choose between Met- the ENTER key at the "LOCK MEMORY ?"...
  • Page 21: Diagnostic Error Codes

    Setup Mode. 2.7 Diagnostic Error Codes If the machine operating system malfunctions, the DocuTrim will lock up and the display will automatically show one or more error codes. See the Troublshooting Section (section 4.1) for a listing of codes, their mean- ings, and appropriate areas to check to correct the mal- function.
  • Page 22 NOTES F.400-E/NOV 97...
  • Page 23: Knife Installation/Changing

    3.0 KNIFE INSTALLATION/ Knife Change CHANGING Tool Location CAUTION: Changing knives can be very dangerous unless safety precau- tions are observed and extreme care is taken when handling knives. • Knife changing is a ONE PERSON OPERATION. Having more than one person changing knives invites accidents.
  • Page 24: Knife Installation

    Grasp the knife lifters firmly and, at the same time, turn them counterclockwise just enough to release the knife from the knife bar (fig. 3-4). (fig. 3-6) Turn out the knife adjusting screws on the top of the knife bar (fig. 3-7). This will prevent a new blade that may be larger than an older, resharpened one from damaging the cutting stick, the knife, or a machine component.
  • Page 25: Knife Care Tips

    3.3 Knife Care Tips CAUTION: ! KNIFE SAFETY ! Knives are DANGEROUS!!! They are heavy and very sharp, even after use. Keep the edge away from your body and keep the area clear of others when handling knives. Never touch the cutting edge! To prevent personal injury and damage to the knife, always keep knives in their holders with screws tightened.
  • Page 26: Cutting Stick

    3.3.3 Bevel Angle Challenge recommends that bevel angles for the Docutrim be in the range of 21° to 23°. In general, a 21° bevel angle will provide a better cut quality when cutting soft paper (such as newsprint), recycled paper, or bound books.
  • Page 27: Maintenance

    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 products is not authorized by The Challenge Machinery Company. Any modifica- tion or alteration of any Challenge product will void any remaining warranty.
  • Page 28: Troubleshooting

    NOTE: The power panel circuit board has a series of indicator LEDs that report the status of various com- ponents of the DocuTrim operating system. See pages 5-20 & 5-21 for a diagram of the circuit board showing the LED locations and a chart of the proper indicator information.
  • Page 29: Routine Maintenance

    4.2 Routine Maintenance CAUTION: DISCONNECT POWER be- fore making any adjustments or lubri- cating. See page vii, SAFETY PRECAU- Dip Stick TIONS, for Power Lockout Procedure. This machine should be placed on a regular mainte- Pump nance schedule. A clean, lubricated machine will run Motor longer and smoother, and cut more accurately with less Pump...
  • Page 30: Monthly

    4 quarts (3.83 liters) of Rykon No. 100 or equiva- lent (see chart). 4.3 Hydraulic System The DocuTrim’s hydraulic system is powered by an electric motor coupled directly to a hydraulic pump. The motor and pump run only when a cut cycle is activated.
  • Page 31: Recommended Hydraulic Oils

    The hydraulic system will immediately stop the knife and clamp in position should the electric eyes at the front opening be broken. The hydraulic fluid should be checked weekly and changed AT LEAST ONCE-A-YEAR or after every 1000 hours of operation. NOTE: Failure to change oil when needed can lead to damaged seals in the knife and clamp cylinders.
  • Page 32: Adjustments

    4.4 Adjustments Knife & Clamp Actuators CAUTION: 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 trimmer is not acci- Nuts dentally operated while adjustments are being made.
  • Page 33: Knife Latch Proximity Switch

    knife latch located on the right rear of the ma- 4.4.4 Knife Latch Proximity Switch chine. This switch monitors the knife latch position. It is lo- cated on the knife latch assembly and is actuated by the latch link. Knife Down The switch should be adjusted as follows: Prox.
  • Page 34: Rotational Proximity Switch

    coordinates the linear position of the transport to the machine’s electronics. They are both located under the table on the right hand side. They are actuated by a wand attached to the right hand side of the transport carriage underneath the table (fig. 4-12). Transport Carriage The switches should be set as follows: Turn off the power to the machine and open the...
  • Page 35: Pneumatic Adjustments

    The clamp up sequence valve 3, fig. 4-16, is fac- tory set so that the clamp stays down until after the knife has gone all the way up. This is a visual check, no pressure readings are required. If an adjustment is required, turn the valve counter- clockwise (ccw) all the way out, then turn back in until the clamp remains on the table until the knife...
  • Page 36 transport clamp setting. Set this adjustment so that the clamp pressure overcomes the internal return spring Air Manifold just enough so the clamp block makes it to the table Low Press. Main System Adj. Screw surface. Valve & Gauge To Adjust this pressure: Pressure Locate the white, manual shift button under the Sensor...
  • Page 37: Parts List And Sequence Of Operations

    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 PROCEDURE ..5-27 DOCUTRIM REPAIR KITS ............... 5-28 SAFETY SYSTEM TESTS ............... 5-29 F.400-E/NOV 97...
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  • Page 45: Pneumatic Sequence Of Operation

    PNEUMATIC SEQUENCE OF OPERATION NOTE: PLEASE ALSO SEE SECTIONS ON THE ELECTRICAL SEQUENCE OF OPERATION AND HYDRAULIC SEQUENCE OF OPERATION FOR MORE DETAILS. Pneumatic Sequence of Operation Pneumatic Schematic References (Drawing 41400) A. Air relay “A” closes to run compressor. The compressor will run and build pressure, until the compressor pressure switch shuts off at 90 - 100 psi.
  • Page 46 F.400-E/NOV 97 5-10...
  • Page 47 F.400-E/NOV 97 5-11...
  • Page 48 F.400-E/NOV 97 5-12...
  • Page 49: Hydraulic Sequence Of Operation

    HYDRAULIC SEQUENCE OF OPERATION NOTE: PLEASE ALSO SEE SECTIONS ON THE ELECTRICAL SEQUENCE OF OPERATION AND PNEU- MATIC SEQUENCE OF OPERATION FOR MORE DETAILS. Hydraulic Sequence of Operation Hydraulic Schematic References (Drawing H-476 & H-477) A. Pump relay is energized providing power Please refer to the electrical sequence of operation for to the hydraulic motor.
  • Page 50 F.400-E/NOV 97 5-14...
  • Page 51: Electrical Sequence Of Operation

    ELECTRICAL SEQUENCE OF OPERATION NOTE: PLEASE ALSO SEE SECTION ON THE HYDRAULIC SEQUENCE OF OPERATION AND PNEUMATIC SEQUENCE OF OPERATION FOR MORE DETAILS. Electrical Sequence of Operation Schematic References MSL = Machine Schematic Location A. Close Main disconnect switch. Power is brought to the hydraulic motor contactor M (MD, MSL=2G) (MSL=4K), the air compressor contactor A (MSL=3K), the stepper motor contact SM (MSL=4N) and trans-...
  • Page 52 (MSL=23F) will change states. Since the footswitch is pressed (MSL=24B), the FSR relay will pull in and latch itself on (MSL=24G). At this point the DocuTrim will automatically trim a book. To trim, the power panel control board will emit pulses to the stepper motor drives to position the book under the clamp and knife.
  • Page 53 F.400-E/NOV 97 5-17...
  • Page 54 F.400-E/NOV 97 5-18...
  • Page 55 F.400-E/NOV 97 5-19...
  • Page 56: Pcb Assembly - Power Panel Control

    PCB ASSEMBLY - POWER PANEL CONTROL EE-2677-1 F.400-E/NOV 97 5-20...
  • Page 57: Led Indicator Information

    LED INDICATOR INFORMATION for EE-2677-1 Inputs – Machine IN 1 – Linear preset – On when tripped by linerar preset wand. IN 2 – Rotary preset – On when tripped by rotary preset wand. IN 3 – Footswitch – On when footswitch is pressed. IN 4 –...
  • Page 58 F.400-E/NOV 97 5-22...
  • Page 59: Power Panel Label

    POWER PANEL LABEL S-1781-44 F.400-E/NOV 97 5-23...
  • Page 60 F.400-E/NOV 97 5-24...
  • Page 61 F.400-E/NOV 97 5-25...
  • Page 62 F.400-E/NOV 97 5-26...
  • Page 63: Transport Belt Replacement/Adjustment

    TRANSPORT BELT REPLACEMENT/ADJUSTMENT (K41110.M) F.400-E/NOV 97 5-27...
  • Page 64 F.400-E/NOV 97 5-28...
  • Page 65: Safety System Tests

    Frequency of test: THESE TESTS SHOULD BE PERFORMED AT THE BEGINNING OF EACH WORK DAY. Select the stored book size that you intend to trim. Place the DocuTrim in the RUN mode by pressing STORE. Place one hand inside the machine opening, just far enough to block the infrared beams. Press and hold the footswitch.
  • Page 66 NOTES F.400-E/NOV 97 5-30...
  • Page 67 NOTES F.400-E/NOV 97 5-31...
  • Page 68 25/64 .39 57/64 .89 13/32 29/32 27/64 .42 59/64 .92 7/16 15/16 29/64 .46 61/64 .95 15/32 31/32 31/64 .48 63/64 .98 1.00 © 1996, 1997 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A. F.400-D/NOV 97...

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