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!

F.058-B/MODEL 20/SEPT. 2000
10
OPERATING CONTROLS
Power - Keyswitch
The machine is activated by
turning the key to the RUN or
ADJ position. Removing the key
prevents unauthorized use of the
cutter.
OFF Position
Disconnects power to the hydraulic unit. Key removal
prevents unauthorized use by rendering the cut buttons
inactive. The backgauge display will remain on.
RUN Position
For normal cutting operation. Activates cut buttons so
motor/pump engages to make a cut when cut buttons
are pressed.
ADJ Position
The Adjust position is used to stop the knife and clamp
in the down position. With the key is in the ADJ position,
depress and hold the cut buttons, the machine will make
a cut cycle. When the knife is on the table, release the
ADJ
OFF
RUN
cut buttons and the machine will shut off. Turn the key
to OFF. This is used to adjust the cutting depth of the
knife. CAUTION! When the key is turned to the RUN
position, the knife and clamp will automatically return
to the up position.
Cut Buttons
With the key in the RUN position, the cut buttons must
be depressed simultaneously (within 1/2 second of each
other) to bring the knife down. Releasing either or both
of the buttons at any time during a cut returns the knife
CAUTION: When running the knife to
the up position after using ADJ,
DAMAGE TO THE LATCH MAY RESULT IF THE KEY
IS TURNED TO RUN AND BACK TO OFF BEFORE
THE KNIFE IS ALL THE WAY UP! Turn the key
from ADJ to RUN and wait for the knife to return
to the up position. A damaged knife latch could
allow the knife to drift down exposing the blade
edge below the clamp. Severe lacerations could
result.
Backgauge
position
readout
Cut Button
Main Fuse
Clamp
Backgaguge
Handwheel Handwheel Lock
Key Switch
Cut Button
Power Clamp Model Shown
Knife
Backgaguge
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

11
F.058-B/MODEL 20/SEPT. 2000
and clamp to the up position. this feature helps eliminate
or minimize stock spoilage due to mispositioning.
Paper Clamp
The clamp holds stock securely for cutting. On power
clamp models, the clamp pressure is adjustable for
cutting pressure sensitive stock.
An optional false clamp plate can be installed to prevent
marking stock.
Backgauge
The handwheel operated leadscrew moves the
backgauge to position stock for cutting. The backgauge
position is shown by a lighted L.E.D. display. The
backgauge should always be brought forward to the cut
position to eliminate any slack in the leadscrew/
backgauge components. An indicator light in the upper
right hand of the display warns of backwards motion of
the backgauge. The light should always be off when
cutting. See illustration below.
Backgauge Handwheel Lock
The thumb screw under the handwheel locks the
backgauge in position. Use to prevent the backgauge
from moving when jogging and doing repeat cuts. Turn
c.c.w. until snug to lock, turn c.w. to unlock.
5.00
Backgauge Position
Reverse lnidicator Light
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.058-B/MODEL 20/SEPT. 2000
12
fig. 1
INSTALLATION & SETUP
Uncrating
Your cutter has been carefully packaged to prevent
damage during shipping. Inspect all shipments as soon
as they are received. Note any damage on the freight
bill and notify the claims department of the carrier within
15 days. All claims for damage are the responsibility of
the receiver, so remember to inspect promptly. Check
the contents of the crate against the packing list at the
front of this manual.
The Model 20 weighs approximately 550 lbs (250kg).
DO NOT risk personal injury or damage by attempting
to move machinery with makeshift equipment or
inadequate manpower. This machine is shipped on a
wooden skid and enclosed in a protective, corrugated
top. The machine is secured to the skid with a 2x4
brace at the rear of the skid and with lag bolts on the
inside of the stand. The tool kit is packed inside of the
machine; the knife and cut sticks are fastened to the
rear of the skid.
Remove the carton by removing the nails or staples
holding it to the skid and lift it straight up over the cutter.
If you don’t have the ceiling clearance to do this, carefully
slit the carton down the side and then unwrap it from
around the cutter. Remove the lag screws from the
brace across the rear of the skid. Remove the lower
front cover of the cutter and remove the two lag screws
inside of the stand. With the front cover still off, the
cutter can now be lifted off the skid with a fork truck
Cleaning
After unpacking, wipe down all machine panels and clean
the table surface.
Manuvering the Cutter
The Model 20 cutter will fit through a standard 36 1/2”
(93 cm) doorway. The machine will have to be angled
through the doorway to fit. To manuver the machine thru
a 32” (81cm) door you have two options:Tilting machine
on it’s side, or removing the table.
1. To maneuver the cutter through a 32” doorway, remove
the rear table support. (fig. 1)
2. Place the cutter on a appropriate size dolly and tilt
the cutter towards the right. (fig.2) NOTE: to prevent
hydraulic fluid leakage, the cutter must only be tilted to
the right (when facing the cutter from the operators
position.)
3. Pivot the cutter through the doorway. (fig. 3) NOTE:
Care should be taken so none of the components under
the table are damaged.
4. Right the cutter and replace the table brace.
5. Remove the front cover and inspect the hydraulic area
for any leakage. Clean immediately if necessary and
replace the front cover.
CAUTION: This procedure should not be
attempted by one person. Personal injury
or damage to the machine could result. The
cutter weighs approximately 550lbs/kg. Use the
appropriate personnel.
fig. 2
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

13
F.058-B/MODEL 20/SEPT. 2000
Removing the Table:
Make sure the knife and clamp are in the “up” position.
Turn off the machine and unplug the power cord. Remove
the knife blade if installed.
Remove the rear table support leg, the lower back panel,
and the lower front cover of the machine. Remove the
electrical box cover from under the front of the table.
(fig. 4)
Locate the four bolts that mount the electrical panel to
the table and remove them; let the panel hang down.
Rear Table
Support
Rear
Cover
Front
Cover
fig. 4
Electrical
Box
Cover
Front
Guides
Rear
Guides
Presetter
Asm.
Table Mounting
Bolts
fig 3
(fig. 5) The encoder board can now be removed from
under the front of the table. (Be careful not to bend the
encoder disc, fig. 6.)
Remove the presetter assembly found under the left rear
side of the table. (fig. 4, Let the encoder and presetter
hang down out of the way.) Remove the front and rear
side guides. (fig. 4) Run the backgauge to the rear of
the table, and remove the front pillow block mounting
screws. While holding the pillow block, turn the hand
wheel counter-clockwise until the lead screw is free of
the backgauge nut, then remove it. (fig. 6)
Next, remove the cut stick from the table using the cut
stick removal tool, remove the two cut stick stops and
tap out the two taper pins (that are in the cutting stick
slot) from the bottom of the base. (fig. 7, Note: taper
pins are only found in machines s/n PC 4922 and above.)
Electrical Panel
Mounting Bolts
fig. 5
Cutting Stick
Stops
Taper Pins
fig. 7
fig. 6
Encoder Disc
Encoder Board
Front Pillow
Block
NOTICE: UNSUPPORTED PRODUCT!
NO TECHNICAL SUPPORT AVAILABLE!
NO REPAIR PARTS AVAILABLE!

F.058-B/MODEL 20/SEPT. 2000
14
Dipstick
Remove the two rear screws that mount the table to the
base. (fig. 4) Only remove the two front screws when
you have someone supporting the rear of the table.
NOTE: the table assembly is very heavy and requires
at least two people to remove. Pull the table out from
the back of the machine. Locate the four round spacers
that were between the table and the base - you will
need them later for mounting the table.
Reattaching the Table
Set the table in position. Lift up the table from the front
and set the front two spacers in place. Then start the
front two socket head screws. Then lift the table from
the rear and set the rear two spacers in place. Start the
two rear socket head screws. Replace the two taper
pins, seat with a punch and hammer, then tighten all
four screws. Attach the right and left side guides, the
presetter board assembly (fig. 4 pg. 11), the encoder
(fig’s. 6 pg. 11), and all guards and panels. Once the
table is installed, the backgauge accuracy and
squarness will have to be readjusted. To do this, see
the “Operator Controls/Maintenance Mode/Parameters/
Accuracy in this manual.
Handwheel Installation - Hand Clamp Model
To prevent damage to the handwheel asembly during
transit, your cutter has been shipped with the handwheel
removed. To install, simply remove the taper pin from
the clamp screw (ill. 1). Install the handwheel to align
the tapered holes and reinstall the taper pin.
NOTE: The holes in the clamp screw and handwheel
are tapered, so be sure they are aligned properly and
the pin is inserted from the correct side.
Hydraulic Check
The hydraulic reservoir holds 1 gallon (3.8 liters) of
hydraulic fluid. It is filled with Rykon 100 hydraulic fluid
at the factory, but should be checked before operation
and once a week under normal operating conditions.
HANDWHEEL
TAPER PIN
ARCH
ill. 1
A cross reference chart is provided in the Maintanence
section. Remove the front panel cover and locate the
dipstick on top of the hydraulic reservoir. (fig. 8). The
fluid level should be within 1/8” ( 3.17mm) of the end of
the dipstick (check with the dipstick cap screwed in).
Top off if necessary, but avoid overfilling, as this could
result in leakage when hot. Replace the front panel.
Power Hook-Up
It is the customer’s responsibility to provide a properly
grounded, 115volt, 15amp, 3 prong recepticle that meets
power requirements and all local electrical codes. On
the optional 220 volt 50/60Hz machines, it is up to the
customer to supply the correct 220volt, 15amp, 3 prong
plug and recepticle. Hire a qualified electrician to install
one if your location is not so equipped.
Connect the power cord to a grounded, 3-prong
recepticle only!
Knife Installation/Changing
The knife changing equipment shown in fig. 9, is included
in the cutter tool kit. The following instructions show
how to remove and install a new or resharpened knife.
Read through these instructions AT LEAST ONCE before
attempting to actually change or install any blades.
Knife Removal
1. Make sure the knife and clamp are in the “up” position.
Turn the key switch to the ADJ position and depress
both cut buttons to bring the clamp and knife down.
When the key is in the ADJ position the clamp knife will
stay down until the key is returned to the run position.
Dipstick
(fig. 8)
CAUTION: NEVER CUT THE GROUND
LUG OFF of a 3-prong plug to fit a 2-
prong socket! You run the risk of
electrical shock which could cause
personal injury or death.
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15
F.058-B/MODEL 20/SEPT. 2000
2. Back off the knife adjusting screws on top of the knife
bar several turns (fig. 10). A new knife will cut deeper
than one that has been ground several times. Failure to
back off the screws could damage the knife and/or the
cutting stick.
CAUTION: Changing knives can be
very dangerous unless safety
precautions are observed and
extreme care is taken when
handling knives.
•Make sure knife lifters are properly
installed, see instructions following.
•Keep handling of unprotected knives to an
absolute minimum.
•Clear off cutter table before removing
knife.
•Have scabbard on cutter table and insert
knife immediately.
•Warn people of any unprotected knife.
•Knife changing is a ONE PERSON
OPERATION. Having more than one
person trying to change knives invites
accidents.
Knife Adjusting Screws
(fig. 10)
3. Raise the clamp and knife by turning the key to the
run position. (See CAUTION below.)
4. Remove the key and disconnect the machine power
cord to prevent accidental power-up while servicing the
cutter.
5. Remove the knife bolts from the two slotted knife bar
holes and replace with the Knife Lifters. (fig. 11) Tighten
the lifters to hold the knife in place and remove the
remaining knife bolts.
6. Clear the table surfaces and place the empty knife
scabbard on the table. Remove the scabbard’s knife
retaining screws.
CAUTION: When returning the knife to
the up position after using ADJ,
DAMAGE TO THE KNIFE LATCH MAY
RESULT if the key is turned to RUN
and back to OFF before the knife is all the up.
Turn the key from ADJ to RUN and WAIT for the
knife to return to the up position. Do not turn
the key to OFF until the knife has come to rest
in the up position. A damaged knife latch
could allow the knife to drift down, exposing
the blade edge below the clamp. Sever
lacerations could result.
CAUTION: ALWAYS pull the plug
itself, NEVER pull on the cord to
disconnect the power. Cord fatigue
and electrical shock could result!
(fig. 11)
CAUTION: Knives are heavy and
always very sharp! Be sure to keep
the edge away from your body and
keep other people out of the area
while handling the blade. Severe lacerations
or dismemberment could result from careless
handling procedures.
(fig. 9)
5/16”
T-Wrench
Knife Lifters
Cut Stick
Removal Tool
3/16”
Hex Allen
Wrench
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F.058-B/MODEL 20/SEPT. 2000
16
fig. 12
7. Grasp the knife lifters firmly and, at the same time,
turn them counterclockwise until the knife is just
released from the knife bar. Lower the left end first,
then lower the right end as you shift the knife sideways
to the left. Bring the right end of the knife around the
knife bar guide frame. Maneuver the right end into the
space between the guide frame and the shroud as the
left end is brought clear of the left guide frame. Move
the knife to the right, then bring the knife out of the
cutter, left end first. Put the blade in the scabbard
immediately and secure with the knife retainer screws.
(fig.12)
Knife Installation
1. Make sure the knife bar and clamp are in the up
position. If they are not, turn on the power to raise them.
2. Turn off the machine, remove the key, and unplug
the power cord.
3. Pull out the cutting stick using the cut stick removal
tool and turn it to a new surface. If the cutting stick is
not level or flush with the table, 1/2” strips of paper can
be placed in the table slot under the cutting stick to
shim it.
4. Remove the left hand screw that retains the knife to
the scabbard, and replace it with a knife lifter. Screw
the lifter all the way in and then back it out 3/4 turn.
5. Remove the other scabbard retainer screw and repeat
the above procedure.
6. Double check to make sure the knife adjusting screws
have been backed out all the way (step #2, Knife
Removal). Lift the blade and insert it into the knife bar
slot. Guide the blade, right edge first, into the space
between the shroud and the knife bar guide frames. Tip
to clear the table side guides, then move the left end of
the blade into the knife bar slot dropping the left end as
the right end is brought around the right knife bar
guideframe and up into the knife bar slot. Raise the
knife into the knife bar slot as high as it will go and
tighten the lifters.
7. Insert the knife bolts with washers and snug to hold
the knife, but don’t tighten them yet.
NOTE: If the blade will not go in, either the lifters are
screwed into the blade too far, or the end of the blade is
hitting the cylinder bracket at the right end of the knife
slot. In this case, drop the left end when inserting the
knife.
8. Remove the knife lifters one at a time and replace
with bolts and washers.
9. Place a few sheets of paper over the cut stick,
covering the stick end-to-end.
10. Plug in the power cord and replace the key.
11. Turn the key to the to the ADJ position and press
the cut buttons to bring the knife all the way down. TURN
THE KEY OFF AND REMOVE IT!
13. Turn the knife adjusters down evenly, a little at a
time, until the knife cuts through the bottom sheet of
paper the entire length of the cutting stick (fig. 13).
Turning the screws down evenly prevents uneven wear
on the knife and cutting stick.
14. Replace the key and raise the knife by turning the
key to the RUN position.
15. Tighten all knife bolts securely.
16. Make a test cut through a full lift of paper and make
minor adjust as needed by repeating steps 11 though
15. NOTE: If the ends cut but the middle doesn’t, you
could have dips or uneven spots in the knife and or cut
sticks. These can be eliminated by placing 1/2” strips
of paper in the table slot beneath the cutting stick to
shim it.
17. Send the dull knife to a grinder. Do not attempt to
fig. 13
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17
F.058-B/MODEL 20/SEPT. 2000
CAUTION: Always remove the
jogging aid from the table before
making a cut.
(fig.14 )
(fig. 15)
(fig. 16)
Locator Pins
2. Turn the key off and remove it. Disconnect the power
cord.
3. Slide the false clamp plate under the knife and clamp,
(fig. 16). Slide the plate up into position with the locator
pins toward the front of the machine. The locator pins
insert into holes in the bottom front of the clamp.
4. Hold the plate in position and secure with the wing
nuts provided.
NOTE: The minimum cut with the false clamp plate
attached is 1-3/4”
sharpen your own knives! See the knife tips section to
determine the knife bevel that best meets your
requirements.
Jogging Aid
A jogging aid is included as standard equipment with
the Model 20. This tool allows the operator to load and
align paper without the need to place hands or arms
under the knife or clamp.
To use, load the paper against the side and backgauge
using the jogging aid (fig’s. 14 & 15). Remove the jogging
aid from the table and make the cut.
False Clamp Plate (Optional)
To prevent marking on pressure sensitive jobs, a false
clamp plate is available as an optional item for your
machine. This plate attaches to the bottom of the clamp.
It is secured with wing nuts on studs that pass through
the top of the clamp.
To install:
1. Make sure the knife and clamp are in the up position.
If they are not, turn the keyswitch to the RUN position,the
knife and clamp will return up automatically.
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F.058-B/MODEL 20/SEPT. 2000
18
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. You are aware
of the dangers, but others may not be. Never at-
tempt to hone, polish, or service the knife in any
way. Failure to follow safety procedures may re-
sult in severe lacerations or dismemberment.
OPERATING TIPS
Carefully lay out each sheet before you start cutting.
Find the best cut pattern to give you the most pieces
out of the sheet. If the sheet will be folded, be sure
grain of the paper is running in the same direction as
the fold or you will get a rough edge on the fold.
If an accurate cut is necessary for close register work,
you MUST have a sharp blade in the cutter. A dull blade
will pull or draw the paper and cause uneven cutting.
Increased clamp pressure will not eliminate draw caused
by a dull knife.
The correct clamping pressure varies from paper to paper.
The general rule is that you should have enough pressure
to hold the paper securely but not so much that it marks
the surface of the paper excessively. Excessive pressure
causes pile distortion and inaccurate cuts.
Mark the gripper edge and the guide edge of printed
paper and make sure the first cuts are with these guide
edges against the backgauge.
Measure printed paper to check for shrinkage or
expansion of the paper from humidity. You may have to
disregard the printed cut lines and make your own.
When cutting narrow strips (1” or less), place lifts of
equal height on opposite sides of the table to prevent
wear of the clamp guides.
KNIFE TIPS
Knife Blade Life
Knife blade life, or the time between sharpenings, can
be affected by many factors. One important factor is
the type of paper being cut. Abrasive paper, such as
recycled paper, soft paper such as newsprint paper, and
bound books can all significantly shorten knife blade
life. Also, if the knife depth is set too deep, the knife will
cut too deep into the cutting stick and can dull the knife
blade.
A knife can last anywhere between 2,000 and 5,000
cuts before it needs to be sharpened. Cutting soft paper
(such as newsprint paper) or paper with high post-
consumer recycled content can cause the knife to need
sharpening after only 2,000 to 3,000 cuts. Cutting pure
paper, such as bond paper with no recycled content, or
hard paper can allow the knife to be used for as many
as 5,000 cuts before it needs to be sharpened. In all
cases, the operator should continually check the quality
of the cut to determine when the knife blade needs to
be sharpened. Some characteristics that indicate a
blade needs sharpening are:
•The knife hesitates or stalls while making a cut.
•The sheets are not all cut to the same length (usually
the top few sheets are longer than the rest of the
sheets - this is sometimes called “draw”).
•Cut marks appear on the cut face of the paper.
•The profile of the cut (side view) is not perpendicular
to the table.
•The cut does not appear straight when viewed from
the top.
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19
F.058-B/MODEL 20/SEPT. 2000
•The knife makes a “rougher” sound as it passes
through paper.
•Nicks are visible on the cutting edge of the knife.
Cutting Stick
A worn cutting stick can affect the cut quality of the
bottom sheets. When this happens, the cut stick can
be rotated. Usually, the stick should be rotated one or
two times between knife sharpenings.
There are 8 possible cut stick positions. The stick can
be rotated 4 times, then turned end to end, and rotated
4 times again.
Bevel Angle
Challenge recommends that bevel angles for the Model
20 knives 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. However, 21° angle knives can become dull
sooner than 23° knives, which results in shorter knife
blade life. A knife with a 23° bevel angle, on the other
hand, will not dull as easily, and can provide satisfactory
results when cutting most types of paper. The knife
shipped with the Model 20 from the factory have a bevel
angle of 23°.
Helpful Suggestions
•If your shop is large enough to purchase more than
one set of knives, have one set beveled at 21° and
the other at 23°. Note: A set consists of 3 knives:
one in the machine, one as a back up, and one at
the grinder.
•If the machine seems to strain but the cut quality is
still good, reduce the pile height. You may also
carefully apply glycerin to the bevel when cutting
hard, coated paper. Tie a cloth to the end of a
stick; dip the stick in glycerin, and apply. Never
apply by hand! In lieu of glycerin you may lightly
rub white bar soap along the bevel. Lubrication will
prolong the life of your machine and reduce
maintenance.
Knife Care
•To prevent corrosion, knives are coated with light
oil. It should be REMOVED WITH CARE.
•While removing or installing a knife, be careful not
to allow the edge to bump against the machine.
Nicks will result.
•If a knife bolt is damaged, replace it.
•Always keep knife bolts securely tightened.
•Always use the heavy duty knife bolt washers
provided by Challenge. Failure to do so could result
in scratching or marring of the clamp face.
•Store knives in a dry environment to prevent
corrosion.
•Never attempt to service a knife in any way. Dispose
of worn out knives properly.
NOTICE: UNSUPPORTED PRODUCT!
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