Challenge JO 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
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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.

F.393-F
JUNE 2003
MODEL JO
PAPER DRILLING
MACHINE
Sold and Serviced by
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441-6081 USA
ChallengeMachinery.com
Serial Numbers 74046 & Up
INSTRUCTION AND
PARTS MANUAL

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 precautions and instructions given and you
should have years of trouble-free operation. 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
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 the correct
parts are sent as soon as 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
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 49441-6081.
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 49441-6081
Copyright© 1999-2003 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..........................................................................................................................................4
2.1 Precautions.............................................................................................................................4
2.2 Power Lockout Procedure .......................................................................................................4
2.3 Warning Label Definitions........................................................................................................5
3.0 Packing List.................................................................................................................................6
4.0 Specifications..............................................................................................................................7
5.0 Installation Guide.........................................................................................................................8
5.1 Inspecting Shipment................................................................................................................8
5.2 Uncrating the Paper Drill .........................................................................................................8
5.3 Assembly Instructions..............................................................................................................8
5.4 Power Hook Up.....................................................................................................................10
6.0 Operating Instructions................................................................................................................11
6.1 Starting the Machine .............................................................................................................11
6.2 Operating the Drill .................................................................................................................11
6.3 Setting the Side Guide Stops.................................................................................................11
6.4 Using the Side Guide ............................................................................................................11
7.0 Routine Adjustments/Maintenance.............................................................................................12
7.1 Adjusting the Vertical Stroke..................................................................................................12
7.2 Removing the Cutting Block ..................................................................................................12
7.3 Removing Drills From the Chuck ...........................................................................................12
7.4 Service Checklist...................................................................................................................12
7.4.1 Daily ..............................................................................................................................12
7.4.2 Weekly...........................................................................................................................12
8.0 Troubleshooting.........................................................................................................................13
9.0 Drilling Tips ...............................................................................................................................14
10.0 Parts List.................................................................................................................................16
10.1 Main Assembly – 46000, Rev. D..........................................................................................16
10.2 Backgauge Assembly – 10456, Rev. J.................................................................................18
10.3 Slitting and Slotting Attachments .........................................................................................19
10.3.1 V-Slotting.....................................................................................................................19
10.3.2 Slitting..........................................................................................................................21
10.4 Light Duty Cornering Machine – A-6401 ..............................................................................22
11.0 Accessories for Challenge Paper Drilling Machine ...................................................................25
11.1 Genuine Challenge Hollow Drills..........................................................................................25
11.2 Challenge Drill-Ease Lubricant Stick....................................................................................26
11.3 Challenge Drilling Blocks.....................................................................................................26
11.4 Challenge Fiber Blocks........................................................................................................26
11.5 Challenge Power Sharpener................................................................................................26
11.6 Hollow Drill Sharpener.........................................................................................................27
11.7 Fixed Gages and Extra Stops..............................................................................................28
11.7.1 Challenge Standard Fixed Gages.................................................................................28
11.7.2 Extra Stops ..................................................................................................................28

2.0 Safety
4
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 on this machine.
•High Speed Drill - Keep rags, loose clothing and long hair away form rotating drill. Personal
injury could result from items being caught on drill.
•Keep foreign objects off table and away from drill.
•Be extremely careful when handling and changing the drills. 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.
•CRUSH HAZARD, keep feet off the pedal when handling paper under the clamp. DO NOT
REST FOOT ON PEDAL at any time!
•DO NOT REACH UNDER THE DRILL AND CLAMP AREA!
•DO NOT OPERATE WITH ANY GUARDS REMOVED! Replace all guards after adjusting,
lubricating or servicing the machine.
•Severe Lacerations - Contact with high-speed drill could cause severe injury. Always turn
machine off and wait for drill to stop before removing drill bits. Keep hands away from drill(s)
when operating.
2.2 Power Lockout Procedure
For maximum safety while making adjustments or repairs to your machine, be sure to disconnect
power to the machine. Disconnect the power plug from its socket.
Figure 1- Main Power Disconnect

2.0 Safety
5
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 10.0 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.

3.0 Packing List
6
3.0 Packing List
Part No. Description
Qty.
Basic Machine 1
14056 Backgauge Assembly 1
46022 Table Assembly 1
46018 Tool Kit 1
CD-4 Hollow Drill, ¼” 1
H-6913-512 5/16-18 x 1/12” Hex Bolt 4
H-6938-506 5/16-18 x 3/8” Socket Setscrew 2
H-7321-5 5/16 Flat Washers 4
K-85 Cover, Drill Drift Hole 1
MFG-007 Drill Set-up Guide 1
3949 Shim, Drill Block 2
4681 Drill Block 2
4688 Lubrication Stick 1
4687 Drill Drift 1
6448 Shim Plate 1
W-154 3/32” Allen Wrench 1
W-137 5/32” Allen Wrench 1
W-170 ½-9/16” Hex Wrench 1

4.0 Specifications
7
4.0 Specifications
Description Inch Units Metric Units
Drill Head Operation, Hand Lever
Drill Diameters 13 sizes from 1/8” to ½” 3-13mm
Lift Capacity 2” for drills ¼” or larger 51mm
Minimum Distance Btw. Holes 3/8” center to center 10mm
With Fixed Gages ¼” center to center 6mm
Maximum Distance Drill to Side
Guide 12” 30cm
Maximum Margin Hole Center to
Sheet Edge 2-3/4” 7cm
Cornering Attachments ½” capacity light duty
Slitting/Slotting ½” capacity light duty
Side Guide Trip Manual
Dimensions
Net Weight 50 lbs. 31kg
Table Space 18” x 27” 46 x 69cm
Height Overall 27” 68.6cm
Electrical
115 Volts, 5.4 Amps, 60Hz, 1 phase, AC.
Challenge reserves the right to make changes to any product or specification without notice and
without incurring responsibility to existing units.

5.0 Installation Guide
8
5.0 Installation Guide
Refer to the parts lists and drawings in the back of this manual for part identification and orientation,
as necessary.
All guards and instruction plates are installed for your safety and information and must remain on the
machine as shipped from the factory.
5.1 Inspecting Shipment
This machine has been carefully packed to prevent damage during shipment. However, claims for
damage or loss are the responsibility of the recipient. Inspect all shipments as soon as they are
received. If there is any noticeable damage, note it on the freight bill. Visual and/or hidden damage
must be reported to the claims department of the carrier within 15 days. Contact your dealer if you
need any assistance. Check the contents of the box against the packing list on page 6. Make sure
there are no missing items.
5.2 Uncrating the Paper Drill
Unless otherwise specified, this machine is shipped in a cardboard carton with the table, back-gauge
and handle removed. These items are packed separately in the box. The machine should be
unpacked by carefully removing the carton so as not to damage any of the machine parts.
Clean all parts with a commercial cleaning solvent (such as CRC) before installing or using the
machine.
5.3 Assembly Instructions
You will need the following tools to assemble your JO Drill:
5/32" Allen wrench (supplied)
1/2" hex wrench (supplied)
Check contents against the Packing List (page 6).
Figure 2
Contents consists of:
1 - Table Asm., 1 – Handle, 1 – Back-gauge Asm., 1 - Tool kit, 1 - Drill Head Asm.

5.0 Installation Guide
9
Please refer to the manual if any of these parts are damaged or missing.
1. Unpack the drill carefully. Locate parts listed above.
2. Lay drill head so the backside is on a flat surface (Figure 3). Place the sheet metal table
shim between the tabletop and the bottom of the drill base. Locate the four mounting bolts
and washers in the tool kit. Place the washers under the bolt heads and insert bolts through
the table into the drill base, finger tighten only.
Figure 3
3. Lift the drill so it is now standing upright, resting on the table support. Insert the two 5/16-
18x3/8 socket set screws found in the tool kit into the ends of the cross shaft. Place the two
ends of the handle into the holes in the cross shaft. With the bottom edges of the handle flush
with the bottom of the shaft, tighten the setscrews.
4. Next, install the backgauge. While holding the thumbscrew of the backgauge to the right side,
slide the backgauge onto the table. Lift the pressure foot up and slide the backgauge
underneath. Position the backgauge at the 1" marks on the table scales. Tighten the
thumbscrew.
5. Position a side guide stop at the 3" mark on the backgauge. Align the side guide to this
position. Place the drift hole cover on the spindle; insert the hollow drill into the spindle and
the drill block into the table (Figure 4).
Figure 4
Position
stop at 3”
Align side
guide to stop Insert drill and
drill block
Install
backgauge from
front with
thumbscrew on
backside

5.0 Installation Guide
10
6. Locate the drill alignment guide shipped in the manual. Place it against the backgauge and
side guide as shown in Figure 5. Bring the hollow drill down with the handle and notice the
alignment of the drill in reference to the hole in the guide. By moving the drill base, align the
drill with the hole in the guide (Figure 5). (NOTE: leave the backgauge and side guide
locked in position - adjust the mounting position of the drill-to-table assemblies to align drill to
the alignment guide.)
Figure 5
7. When the drill has been sufficiently aligned, finish tightening the mounting bolts under the
table. Start with the bolts at the rear of the machine. (They can be accessed without moving
the drill- see Figure 6.)
Figure 6
8. After tightening the two rear bolts, tilt the drill on its back and tighten the two remaining bolts.
Return the drill to the upright position.
5.4 Power Hook Up
The JO Paper Drill is factory wired to 115 Volt specifications. It is important that the power source
complies with the electrical specifications of the machine. We recommend that this machine be
plugged into a 15 Amp circuit.
Always disconnect the power cord when cleaning, servicing or lubricating
your drill.

6.0 Operating Instructions
11
6.0 Operating Instructions
6.1 Starting the Machine
The power for this machine is supplied by a single motor, which directly drives the spindle. It is
started and stopped by a toggle type switch located on the bottom of the motor. The "on" and "off"
position is so indicated. Be sure that the motor is operating before trying to drill paper.
Do not reach under pressure foot or drill area. Allow machine to stop
before changing drills.
6.2 Operating the Drill
First, be sure that the motor is on. Pulling the lever toward you brings the drill down through the lift of
stock. After the drill reaches the bottom of its stroke, return the lever slowly to its top position.
By releasing the downward pressure on the lever, the operator can stop the drill in its down-stroke
allowing it to return to the normal up position, preventing costly errors.
6.3 Setting the Side Guide Stops
First set the rear gage to the desired back margin. Be sure both sides are set to the same dimension
and tighten the thumbscrew. Next, loosen the setscrews that hold the stops in place and slide the
stops to the desired distance between holes (a scale in the backgauge is provided for this purpose).
The first stop is always set for the distance from the edge of the sheet to the center of the first hole.
The side guide comes equipped with three stops. Additional stops can be purchased at a very
nominal price.
6.4 Using the Side Guide
Bring the side guide to the right past the first stop, then back to the left until the latch is in contact with
the first stop. After drilling the first hole, trip the latch and move the guide into contact with the second
stop and at the same time move the pile of stock against the guide with the right hand. Continue this
same procedure for all stops being used.

7.0 Routine Adjustments/Maintenance
12
7.0 Routine Adjustments/Maintenance
7.1 Adjusting the Vertical Stroke
The depth of vertical stroke is controlled with a stop screw knob on top of the drill. Turning the knob
clockwise lowers the drill spindle while turning it counter-clockwise raises the drill spindle. This
adjustment should be set so that the drill bit just cuts through the bottom sheet of a lift. Do not set
this adjustment too low or the drill will “burn” into the cutting block at the bottom of its stroke.
NOTE: Whenever changing drill bits or using slitting, slotting, or cornering attachments, be sure to
back off the spindle stop screw to prevent ruining stock and damaging drill bits and cutting blocks.
7.2 Removing the Cutting Block
Disconnect the power cord and simply reach under the table and push the block up, grasping it when
it clears the table.
7.3 Removing Drills From the Chuck
Always handle drills with care to avoid severe lacerations; even dull drills
are sharp enough to cause lacerations.
Disconnect the power cord. Rotate the drill drift cover (spring clip) on the end of the chuck to uncover
the drift hole. The cover prevents drill chips from flying out of the drift hole while drilling small
diameter holes. Insert the drill drift, flat side down, into the hole and lift upward. The upward
movement forces the drill down and releases it from the chuck.
NOTE: After heavy drilling, the drills may become so firmly seated in the chuck that it is necessary to
tap on the drift to get the drill to release. To prevent this, always use a sharp drill and lubricate often.
7.4 Service Checklist
Always disconnect the power cord when cleaning, servicing or lubricating.
7.4.1 Daily
Sharpen the hollow drill often and reset the spindle adjusting screw if needed.
Lubricate the hollow drill frequently with the Drill-Ease provided.
For better hollow drill life, remove the drill when not in use, remove any drill chips from inside the drill
shaft and soak in light oil.
7.4.2 Weekly
Disconnect the power and clean guide bar shaft. Lubricate with standard 30-weight oil.
Clean side guide shaft and lubricate with light oil.
Lubricate all spindle lever linkage pins with light oil.

8.0 Troubleshooting
13
8.0 Troubleshooting
(Refer to Parts lists for part location, number, and description.)
Problem Area to Check Solution
1. Lack of power Check voltage at machine – may be
low Remove other machinery on line or provide a separate branch
circuit
2. Drill head won’t return Check for bind in lever assembly
Check lift spring – may be broken or
stuck
Check if pull down shaft is stuck in
frame
Free bind, clean and oil
Pry up head, clean and oil shaft
(Replace spring if necessary)
Pry up head, clean and oil shaft
(Replace spring if necessary)
3. Drill head will not come
down Check for broken lift – spring may be jammed Replace spring

9.0 Drilling Tips
14
9.0 Drilling Tips
Important! To prevent the drill from overheating, always avoid drilling too slowly. The drill should be
brought down as rapidly as possible allowing the drills to easily cut through the paper.
Slotted Holes - Instead of punching slotted holes for five and seven-hole universal binding work,
save time and cost by drilling a 1/2 inch diameter hole in place of the slot. The slot is only intended to
allow the post or ring to be used in either location, and the large hole permits this.
Plastic Bindings - Drilling holes for plastic bindings, instead of punching them, is practical and saves
a great deal of time, particularly on long run jobs.
Keep Drills Sharp - A dull drill is the major cause of drill breakage and production tie-ups. Usually
after three hours of drilling, depending on the type of paper being processed, the drill should be
sharpened. A dull drill results in poor quality work.
Keep Drills Clean - A dirty and rusty drill will not permit the free upward passage of the drill chips.
Pressure built up by a clogged drill will split or break the drill. To keep it free from dirt or rust, clean
the drill of all chips after each use and apply light oil to the inside and outside. Drills should be
cleaned out immediately after each use. This is particularly true if a coated or varnished stock has
been drilled. On these jobs the coating on the chips frequently fuse the chips into one solid mass
when the drill cools, causing breakage the next time the drill is used.
Lubricate Drills - Lubrication assists in the passage of the chips and helps avoid overheating of the
drills. Use readily available stick lubricants for this purpose. Hold the end of the stick against the side
of the rotating drill. Be sure to touch the cutting edge with the lubricant also. Wipe off excess oil
before drilling. CARE MUST ALWAYS BE TAKEN WHEN HANDLING DRILLS.
Keep Spindle Clean - Clean out the drill spindle frequently. This will prevent any buildup in the
spindle of the drill.
Set the Drills Correctly - Do not cut too deeply into the cutting block. The drill should just touch the
block and cleanly cut through the bottom sheet. During drilling, do not set the drill deeper into the
block but change the position of the block frequently. Drilling deeper into the block dulls the drills
quickly. Use a piece of chipboard underneath your stock. This will make handling the stock easier
and will ensure that the last sheet is cut cleanly through.
Check for Drill Wobble - If the spindle is badly worn or bent through mis-adjustment, have it
replaced immediately. A wobbly or loosely held drill will break.
Check Your Drill Sharpener - The cutting edge of the sharpening bit should be inspected frequently
to make certain that it is sharp and free of nicks. Never let a drill drop onto the sharpening bit. It will
chip the sharpening edge. Use gentle pressure when sharpening - let the sharpening bit do the work.
Check the sharpness of the drill after sharpening. The cutting edge should be razor sharp.
Just a little time and effort taken with each use of your paper-drilling machine should result in trouble
free operation over many years.
Parts Customers: The Challenge Machinery Company provides parts with the express
understanding that they are to replace parts found missing or no longer serviceable on equipment
designed and/or manufactured by Challenge. The Challenge Machinery Company assumes no
liability for any modification or alteration to any Challenge products, and The Challenge Machinery
Company does not authorize any such modification or alteration to any Challenge products. Any
modification or alteration of any Challenge product will void any remaining warranty.

9.0 Drilling Tips
15
NOTES

10.0 Parts List
16
10.0 Parts List
10.1 Main Assembly – 46000, Rev. D

10.0 Parts List
17
Main Assembly – 46000, Rev. D

10.0 Parts List
18
10.2 Backgauge Assembly – 14056, Rev. L

10.0 Parts List
19
10.3 Slitting and Slotting Attachments
DISCONNECT POWER before cleaning, servicing, or lubricating your drill.
10.3.1 V-Slotting
To cut V-slot holes, first drill the round holes. Turn off the power and remove the drill.
Figure 7
Remove the pressure foot by lifting up the foot and removing the two snap rings.
Rear Gauge Filler
6409
Screw
¼-20 x 1”
Screw
¼-20 x ½”
Bracket
4684
V-Slotting
Assembly
Knife Holder
4704
Knives (pair)
A4708
Knife Thrust Block
4703
Flat Head Screw
10-24 x 3/8”
Knife Holder Plate
4704
3/16” Allen
Wrench
W-130