Challenge Model 20 Power Clamp 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
1433 Fulton Avenue
Grand Haven, MI 49417-1594 USA
ChallengeMachinery.com
F. 058-B
SEPT. 2000
Power Clamp S/N 3252 & Up
Hand Clamp S/N 3292 & Up
MODEL 20
PAPER CUTTING
MACHINE
POWER CLAMP &
HAND CLAMP Models
Sold and Serviced by
INSTRUCTION AND
PARTS MANUAL
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.058-B/MODEL 20/SEPT. 2000
2
INTRODUCTION
WELCOME to 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 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.
SAFETY ALERT! This symbol means CAUTION 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 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 that 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 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 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 Avenue, Grand Haven, MI 49417.
Copyright © 2000 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!

3
F.058-B/MODEL 20/SEPT. 2000
SPECIFICATIONS
Cutting Dimensions
Cutting Width 20” (50.8 cm)
Minimum Cut* ½” (13 mm)
Clamp Opening 3¼” (8.3 cm)
Table Space
Front: 16” (41 cm)
Back: 20” (51 cm)
Machine Dimensions
Table Height 35” (89 cm)
Overall Height 47-1/2” (121 cm)
Overall Length 48-1/4” (123 cm)
Overall Width 35-1/2” (90 cm)
Net Weight (Approximate) 550 lbs (250 kg)
Shipping Weight (Approximate) 650 lbs (295 kg)
Electrical
Standard - 120 Volts (±10%)/12 Amps, 1 Phase, 60 Hz, AC. Service size 15 Amps
Optional - 220 Volts (±10%)/12 Amps, 1 Phase, 60 Hz, AC. Service size 15 Amps
Optional - 220 Volts (±10%)/12 Amps, 1 Phase, 50 Hz, AC. Service size 15 Amps
*With false clamp plate attached, minimum cut is 1-7/8” (48 mm).
**With table removed, can be fit through a 32” (81.3 cm) door opening.
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!

F.058-B/MODEL 20/SEPT. 2000
4
PACKING LIST
Part No. Description Qty.
A-10034 Knife ................................................................................... 1
4166 Cutting Stick (in addition to one installed in machine) ........... 3
F.058-B Instruction and Parts Manual ............................................... 1
A-12608-2 Jogging Aid ......................................................................... 1
20-2150 Tool Kit ............................................................................... 1
H-6918-608 Knife Bolts, 3/8 - 16 x 1” ................................................ 4
8815 Knife Washers, Special ................................................. 4
5064 Cutting Stick Puller ....................................................... 1
S-1245-5 Knife Lifters ................................................................... 2
W-130 3/16” Allen Wrench ........................................................ 1
W-137 5/32” Allen Wrench ........................................................ 1
W-164 5/16” Hex ‘T’ Wrench ..................................................... 1
W-170 9/16 x 1/2” Wrench ....................................................... 1
E-1075-12SB 12 amp slo-blo fuse ....................................................... 1
OPTIONAL ITEMS
Part No. Description Qty.
AA-10061 False Clamp Plate
5-7-M361 Backgauge Book Guides
4166 Cutting Sticks
AA-10095-1 Inch/Metric Conversion Kit
20-2150-1 Optional Tool Kit
8815 Knife Washers, Special ................................................. 6
H-6918-608 Knife Bolts, 3/8-16 x 1” .................................................. 6
W-131 5/16” Allen Wrench ........................................................ 1
W-134 7/32” Allen Wrench ........................................................ 1
W-154 3/32” Allen Wrench ........................................................ 1
W-170 1/2” x 9/16” Wrench ...................................................... 1
5064 Cutting Stick Puller ....................................................... 1
E-1075-12SB 12 Amp slo-blo fuse (120 V) ........................................... 5
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

5
F.058-B/MODEL 20/SEPT. 2000
INTRODUCTION ........................................................................................................ 2
SPECIFICATIONS ..................................................................................................... 3
PACKING LIST ......................................................................................................... 4
OPTIONAL ITEMS .................................................................................................... 4
CAUTION: POWER LOCK-OUT PROCEDURE ......................................................... 7
SAFETY PRECAUTIONS .......................................................................................... 7
¡OJO! ........................................................................................................................ 8
WARNING LABEL DEFINITIONS ............................................................................... 9
OPERATING CONTROLS ........................................................................................ 10
INSTALLATION & SETUP ........................................................................................ 12
Uncrating ................................................................................................... 12
Cleaning ..................................................................................................... 12
Manuvering the Cutter ................................................................................. 12
Removing the Table: ................................................................................... 13
Reattaching the Table ................................................................................. 14
Handwheel Installation - Hand Clamp Model ................................................ 14
Hydraulic Check ......................................................................................... 14
Power Hook-Up .......................................................................................... 14
Knife Installation/Changing .......................................................................... 14
Knife Removal ............................................................................................ 14
Knife Installation ......................................................................................... 16
Jogging Aid ................................................................................................ 17
False Clamp Plate (Optional) ...................................................................... 17
OPERATING TIPS ................................................................................................... 18
KNIFE TIPS ............................................................................................................ 18
NOTICE .................................................................................................................. 21
TROUBLESHOOTING ............................................................................................. 22
MAINTENANCE ...................................................................................................... 23
ADJUSTMENTS ...................................................................................................... 25
Backgauge Gib Adjustments ....................................................................... 25
Squaring the Backgauge ............................................................................. 26
Leadcscrew Collar ...................................................................................... 26
Encoder Disc ............................................................................................. 27
Presetting/Backgauge Position Readout ..................................................... 27
Clamp Up/Knife Up Limit Switch Adjustment ............................................... 28
Hydraulic Valve Adjustments - Manual Clamp .............................................. 28
Hydraulic Valve Adjustments - Power Clamp ................................................ 29
MAIN ASSEMBLY - FRONT VIEW ......................................................................... 32
MAIN ASSEMBLY - FRONT VIEW ......................................................................... 33
MAIN ASSEMBLY - SIDE VIEW .............................................................................. 34
MAIN ASSEMBLY - SIDE VIEW .............................................................................. 35
MAIN ASSEMBLY - TABLE VIEW ALUMINUM TABLE ............................................ 36
MAIN ASSEMBLY - TABLE VIEW ........................................................................... 37
MAIN ASSEMBLY - TABLE VIEW (STEEL TABLE) ................................................. 38
MAIN ASSEMBLY - TABLE VIEW ........................................................................... 39
POWER PANEL ASSEMBLY - 120VOLT ................................................................. 40
POWER PANEL ASSEMBLY - 120VOLT ................................................................. 41
POWER PANEL ASSEMBLY - 230VOLT ................................................................. 42
POWER PANEL ASSEMBLY - 230VOLT ................................................................. 43
120 VOLT MACHINE SCHEMATIC ........................................................................... 44
230 VAC MACHINE SCHEMATIC ............................................................................ 45
HYDRAULIC SEQUENCE OF OPERATION ............................................................. 46
HAND CLAMP HYDRAULICS .................................................................................. 47
TABLE OF CONTENTS
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.058-B/MODEL 20/SEPT. 2000
6
HYDRAULIC MANIFOLD HH-245 ............................................................................. 48
HYDRAULIC MANIFOLD HH-476 ............................................................................. 49
HYDRAULIC MANIFOLD HH-476-1 .......................................................................... 50
HYDRAULIC UNIT ASSEMBLY ................................................................................ 51
KNIFE BAR LATCH ASSEMBLY ............................................................................. 54
20” HAND CLAMP ASSEMBLY ............................................................................... 55
ENGLISH/METRIC CONVERSION OPTION ............................................................. 56
ENGLISH/METRIC CONVERSION OPTION ............................................................. 57
LINE LIGHT KIT INSTALLATION INSTRUCTIONS ..................................................... 58
LINE LIGHT KIT INSTALLATION INSTRUCTIONS ..................................................... 59
LINE LIGHT ASSEMBLY ......................................................................................... 60
MODEL 20 FLOOR PLAN ....................................................................................... 61
TABLE OF CONTENTS CONT.
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

7
F.058-B/MODEL 20/SEPT. 2000
•This machine is designed and safeguarded for ONE PERSON operation. NEVER operate the cutter 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 cutter. If questions still remain, call your
Authorized Challenge Dealer - fingers and hands are too valuable to risk experimentation.
•Only trained and authorized persons should operate the cutter.
•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
main disconnect switch to the off position and disconnect the power plug, see Disconnect Procedure below.
•Be sure the cutter is properly grounded.
•Be sure there is sufficient power to operate the cutter properly.
•Observe all caution plates mounted on this cutter.
•Keep foreign objects off table and away from cutter blade.
•BE EXTREMELY CAREFUL when handling and changing the cutter knife. Severe lacerations or dismemberment
could result from careless handling procedures. Dispose of worn out knives properly.
•Keep the floor around the cutter free of trim, debris, oil and grease.
•When replacing hydraulic parts, loosen the connections slowly to release pressure. Never loosen connections
with the machine running.
•If the cutter 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. Use Jogging Aid to load
paper, and use the backgauge to push paper out before unloading. DO NOT REACH UNDER THE KNIFE AND CLAMP
AREA!
SAFETY PRECAUTIONS
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 instructions
may result in personal injury.
For maximum safety and to prevent unauthorized
use, turn the power switch to the off position and
disconnect the power /power cord whenever ad-
justing, lubricating, or making repairs to the ma-
chine.
CAUTION: POWER LOCK-OUT PROCEDURE
(fig. 1)
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.058-B/MODEL 20/SEPT. 2000
8
• Esta maquina, junto con sus mecanismos de seguridad, esta disenada para ser manejada por
UNA SOLA PERSONA a la vez. Jamas debe ser manejada por mas de una persona al mismo
tiempo.
• La seguridad es la responsabilidad del operario que usa esta maquina.
• LEA DETENIDAMENTE el manual de instrucciones y las PRECAUCIONES DE SEGURIDAD antes de poner a funcionar
la cortadora. Pidale a su supervisor una copia.
• El manejo de la guillotina debe estar exclusivamente a cargo de personal entrenado y autorizado para ello.
• NO MODIFIQUE LOS MECANISMOS DE SEGURIDAD, estan ahi para su proteccion no deben ni modificarse ni
quitarse.
• DESCONECTE LA CORRIENTE ELECTRICA antes de proceder a hacerle servicio de limpieza, engrasar, o de hacer
adjustes que no requieren corriente. Trabe el interruptor en la posicion OFF (apagado); vea “Procedimiento para
cortar la corriente electrica” al pie de esta pagina.
• Eche llave a la guillotina y quite la llave cuando la maquina no esta en operacion; vea “Corriente electrica”.
• Asegurese de que la guillotina este debidamente a tierra. Vea “Conexion de la fuerza electrica”.
• Verifique el voltaje y asegurese de que este sea suficiente para el debido funcionamiento de la guillotina.
• Preste atencion a todas las placas con advertencias instaladas en esta guillotina.
• No permita que objetos estranos esten en la mesa o cerca de la cuchilla cortadora.
• TENGA SUMO CUIDADO al tocar y cambiar la cuchilla. Heridas severas y hasta desmembramiento pueden
resultar del manejo sin cuidado o negligente.
• El suelo alrededor de la guillotina debe mantenerse despejado y libre de recortes, desperdicios, aceite y grasa.
• Al haber la necesidad de reemplazar partes hidraulicas, afloje todas las conexiones poco a poco para dejar
escapar la presion. Jamas debe aflojarse conexiones mientras la maquina este
andando.
• Si la guillotina empezara a sonar o trabajar diferentemente a lo acostumbrado, desconectela y consulte la
seccion “Troubleshooting” (Reparador) de este manual. Si no es posible corregir el problema, llame a su servicio
autorizado para que le examinen la maquina.
• PELIGRO DE MACHUQUE - Mantenga manos y dedos fuera de la agarradera mientras sujeta el papel. Use el
calibrador trasero y su rueda de mano para empujar el papel cortado. NO PONGA SUS MANOS BAJOLA CUCHILLA
O AREA DE LA AGARRADERA.
• NO OPERE SIN LAS GUARDAS PROTECTORAS!
¡ OJO ! PRECAUCION - Como proceder para desconectar
la corriente electrica.
Para maxima seguridad durante ajustes y reparaciones de su maquina, verifique bien que el interruptor principal de
control de corriente al cual la maquina esta conectada, este desconectado. El interruptor deba ser puesto en la posicion
“OFF” (desconectado) y se debe poner un candado en la anilla. La llave del candado debe ser guardada por la persona
que estara efectuando los trabajos de servicio o de reparacion en la guillotina.
Desconecte la corriente electrica antes de proceder a hacer cualquier ajuste o reparacion o de efectuar el engrase en
cualquier maquina.
This Este simbolo de alerta de seguridad significa ¡ OJO ! - INSTRUCCIONES DE
SEGURIDADPERSONAL. Lea las instrucciones porque se refieren a su seguridad personal.
Fall de obedecer las instrucciones que siguen podria resultar en lesiones corporales.
¡OJO!
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

9
F.058-B/MODEL 20/SEPT. 2000
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 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.
WARNING LABEL DEFINITIONS
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!