Challenge Model 20 Power Clamp Instructions And Parts Manual

Challenge Model 20 Power Clamp Instructions And Parts Manual

Paper cutting machine
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These manuals are for reference only. These manuals include products which are non-
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Challenge Machinery Company makes no representation or warranty as to the products,
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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
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no representation, warranty or recommendation regarding any modifications which may be
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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
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in
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maintenance and repair. All
products should be used only by qualified and properly trained personnel, following proper
safety procedures. All products should be regularly inspected and maintained, and their condition,
application and use should be periodically evaluated by qualified personnel. Only qualified and
properly trained technicians should
perform maintenance, repair and replacement
procedures. Attempting these procedures without proper training may cause machine
damage or operator injury!
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unavailability of parts from their original manufacturer. No parts or product support will be
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Summary of Contents for Challenge Model 20 Power Clamp

  • Page 1 The Challenge Machinery Company assumes no liability for any modification or alteration to any Challenge product, and any such modification or alteration to any Challenge product is not authorized by The Challenge Machinery Company.
  • Page 2 Hand Clamp S/N 3292 & Up NSTRUCTION AND ARTS ANUAL MODEL 20 PAPER CUTTING MACHINE POWER CLAMP & HAND CLAMP Models Sold and Serviced by The Challenge Machinery Company 1433 Fulton Avenue Grand Haven, MI 49417-1594 USA ChallengeMachinery.com F. 058-B SEPT. 2000...
  • Page 3: Introduction

    THE CHALLENGE REPUTATION is important to you as a user for the continuous, ready availability of parts and service. THIS MANUAL is designed to help you get the most from your Challenge equipment. Keep this manual in a safe, convenient place for quick reference by operators and service personnel.
  • Page 4: Specifications

    *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.
  • Page 5: Packing List

    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”...
  • Page 6: Table Of Contents

    TABLE OF CONTENTS 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 ....................
  • Page 7 TABLE OF CONTENTS CONT. 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 .............
  • Page 8: Caution: Power Lock-Out Procedure

    • 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.
  • Page 9: Ojo

    ¡OJO! 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. • Esta maquina, junto con sus mecanismos de seguridad, esta disenada para ser manejada por UNA SOLA PERSONA a la vez.
  • Page 10: Warning Label Definitions

    WARNING LABEL DEFINITIONS SINGLE OPERATOR Do not operate with more than one person. SHOCK HAZARD Disconnect power before removing cover. Replace cover before operation. SHOCK HAZARD Disconnect power before removing cover. Replace cover before operation. HAZARDOUS AREA Disconnect power before cleaning, servicing, or making adjustments not requiring power.
  • Page 11: Operating Controls

    OPERATING CONTROLS Backgauge position readout Main Fuse Backgaguge Cut Button Key Switch Cut Button Knife Clamp Backgaguge Handwheel Lock Handwheel Power Clamp Model Shown Power - Keyswitch cut buttons and the machine will shut off. Turn the key to OFF. This is used to adjust the cutting depth of the The machine is activated by knife.
  • Page 12 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.
  • Page 13: Installation & Setup

    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.
  • Page 14: Removing The Table

    (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.) Electrical Panel Mounting Bolts fig. 5 Remove the presetter assembly found under the left rear side of the table.
  • Page 15: Reattaching The Table

    Remove the two rear screws that mount the table to the A cross reference chart is provided in the Maintanence base. (fig. 4) Only remove the two front screws when section. Remove the front panel cover and locate the you have someone supporting the rear of the table. dipstick on top of the hydraulic reservoir.
  • Page 16 3. Raise the clamp and knife by turning the key to the Cut Stick Removal Tool run position. (See CAUTION below.) 5/16” T-Wrench 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.
  • Page 17: Knife Installation

    7. Grasp the knife lifters firmly and, at the same time, tighten the lifters. turn them counterclockwise until the knife is just released from the knife bar. Lower the left end first, 7. Insert the knife bolts with washers and snug to hold then lower the right end as you shift the knife sideways the knife, but don’t tighten them yet.
  • Page 18: Jogging Aid

    sharpen your own knives! See the knife tips section to 2. Turn the key off and remove it. Disconnect the power determine the knife bevel that best meets your cord. requirements. 3. Slide the false clamp plate under the knife and clamp, Jogging Aid (fig.
  • Page 19: Operating Tips

    OPERATING TIPS KNIFE TIPS Carefully lay out each sheet before you start cutting. CAUTION: ! KNIFE SAFETY ! Find the best cut pattern to give you the most pieces Knives are DANGEROUS!!! They are out of the sheet. If the sheet will be folded, be sure heavy and very sharp, even after use.
  • Page 20 • Always use the heavy duty knife bolt washers Cutting Stick provided by Challenge. Failure to do so could result in scratching or marring of the clamp face. A worn cutting stick can affect the cut quality of the bottom sheets. When this happens, the cut stick can •...
  • Page 21 NOTES F.058-B/MODEL 20/SEPT. 2000...
  • Page 22: Notice

    Challenge. The Challenge Machinery Company assumes no liability for any modification or alteration to any Challenge products, and any such modification or alteration to any Challenge products is not authorized by The Challenge Machinery Company. Any modification or alteration of any Challenge product will void any remaining warranty.
  • Page 23: Troubleshooting

    TROUBLESHOOTING CONCAVE CUTTING - ENDS WIDE, CENTER NARROW Excessive moisture at edges of paper. WON’T START Fuse Blown. CONCAVE CUTTING - VARIATION FROM TOP TO Power cord disconnected. BOTTOM Start switch defective or not turned to RUN . Soft paper not firmly clamped. Defective cut button.
  • Page 24: Maintenance

    MAINTENANCE Grease CAUTION: DISCONNECT POWER before making any adjustments or lubricating. See page 7, SAFETY PRECAUTIONS, for Power Lockout Procedure. Place this machine on your plant maintenance schedule. A clean, lubricated machine will run longer, smoother, cut more accurately, with less downtime and fewer costly repairs.
  • Page 25 (fig. 23) Cylinder Bracket Pins, Lower MONTHLY Limit Switch Adjustment — See pg. 28. Backgauge Squaring — See pg. 26. (fig. 21) Knife Bar Links - (Both Ends) Leadscrew Collar Check for slack in handwheel, see page 26. YEARLY Hydraulic Fluid — The hydraulic fluid should be checked weekly and changed AT LEAST ONCE-A- YEAR or after every 1,000 hours of operation.
  • Page 26: Adjustments

    Empty the hydraulic tank and refill with 1 gallon of ADJUSTMENTS International Standards Organization Viscosity Grade 100 (ISO VG 100) rust, oxidation and foam inhibiting hydraulic fluid. CAUTION: Several of the following tests require the machine to be CAUTION: Use one of the operational for checking and recommended oils or an ISO VG 100 adjusting.
  • Page 27: Squaring The Backgauge

    NOTE: The screws should be tightened to hold the backgauge square against the guide rail. Excessive tightening will cause the backgauge to bind and cause Backgauge premature wear of all components. Screws Squaring the Backgauge To test if the backgauge is square, place a small lift of paper against the left end of the backgauge, lock the backgauge in position, and make a cut.
  • Page 28: Encoder Disc

    Encoder Disc If the backgauge position display continues to be inaccurate even though it has been preset and rezeroed, Preset Wand it may be due to the encoder disc slipping on the leadscrew. To check: Preset Sensor 1. Turn the key to the off position and remove it. Disconnect the power cord.
  • Page 29: Clamp Up/Knife Up Limit Switch Adjustment

    Limit switch roller Preset wand Limit switch actuator adjustment screw 3/32”Allen wrench (fig. 35) (fig. 34) Actuator Clamp Up/Knife Up Limit Switch Adjustment The up limit switch operates identically on both the hand clamp and the power clamp models. It is actuated off the knife on the hand clamp model and off of the clamp on the power clamp model.
  • Page 30: Hydraulic Valve Adjustments - Power Clamp

    To adjust: Hydraulic Valve Adjustments - Power Clamp 1. Turn the key to the OFF position and remove power Due to constant improvements the Model 20” hydraulics to the machine. Remove the front panel cover below the you may have one of the following manifolds: table.
  • Page 31 Knife Down Sequence surface of the paper excessively. Excessive pressure causes pile distortion and inaccurate cuts. (Increasing 1. With the clamp pressure reducer valve still turned in, clamp pressure will not eliminate draw caused by a dull Make a cut and read the pressure gauge has the knife knife).
  • Page 32 NOTES F.058-B/MODEL 20/SEPT. 2000...
  • Page 33: Main Assembly - Front View

    F.058-B/MODEL 20/SEPT. 2000...
  • Page 34: Main Assembly - Front View

    Gib Screws Nylon Guide Screws F.058-B/MODEL 20/SEPT. 2000...
  • Page 35: Main Assembly - Side View

    F.058-B/MODEL 20/SEPT. 2000...
  • Page 36: Main Assembly - Side View

    F.058-B/MODEL 20/SEPT. 2000...
  • Page 37: Main Assembly - Table View Aluminum Table

    F.058-B/MODEL 20/SEPT. 2000...
  • Page 38: Main Assembly - Table View

    MAIN ASSEMBLY - TABLE VIEW 10000-5 SHT. 3 OF 3 Rev. J S/N 4339 - 4363 S/N 4524 and Above F.058-B/MODEL 20/SEPT. 2000...
  • Page 39 F.058-B/MODEL 20/SEPT. 2000...
  • Page 40: Main Assembly - Table View

    F.058-B/MODEL 20/SEPT. 2000...
  • Page 41: Power Panel Assembly - 120Volt

    POWER PANEL ASSEMBLY - 120VOLT EE-1738-4 F.058-B/MODEL 20/SEPT. 2000...
  • Page 42: Power Panel Assembly - 120Volt

    POWER PANEL ASSEMBLY - 120VOLT EE-1738-4 * NOTE: When replacing this switch on machines below s/n PC 4080, please use p/n E-1045-9 only. F.058-B/MODEL 20/SEPT. 2000...
  • Page 43: Power Panel Assembly - 230Volt

    POWER PANEL ASSEMBLY - 230VOLT EE-1738-5 F.058-B/MODEL 20/SEPT. 2000...
  • Page 44: Power Panel Assembly - 230Volt

    POWER PANEL ASSEMBLY - 230VOLT EE-1738-5 *NOTE: On machines below s/n PC-4935, item #18 fuse is an 7amp slo-blo, p/n E-1075-7SB. ** NOTE: When replacing this switch on machines below s/n PC 4080, please use p/n E-1045-9 only. F.058-B/MODEL 20/SEPT. 2000...
  • Page 45: 120 Volt Machine Schematic

    120 VOLT MACHINE SCHEMATIC E-1756-2 F.058-B/MODEL 20/SEPT. 2000...
  • Page 46: 230 Vac Machine Schematic

    230 VAC MACHINE SCHEMATIC E-2367 F.058-B/MODEL 20/SEPT. 2000...
  • Page 47: Hydraulic Sequence Of Operation

    HYDRAULIC SEQUENCE OF OPERATION HYDRAULIC SEQUENCE OF OPERATION HYDRAULIC SCHEMATIC REFERENCES DRAWING NUMBER: H-317-() A. Cut module is energized providing power to the With the key in the ON position, depress both cut hydraulic motor. buttons; the electronics sense that both the clamp and knife are up and the knife latch is pulled in, the CUT solenoid will be energized.
  • Page 48: Hand Clamp Hydraulics

    HAND CLAMP HYDRAULICS H-316 CONNECT TO LOWER CONNECT TO UPPER PORT OF HYD. CYLINDER PORT OF HYD. CYLINDER F.058-B/MODEL 20/SEPT. 2000...
  • Page 49: Hydraulic Manifold Hh-245

    HYDRAULIC MANIFOLD HH-245 GOLD ANODIZED (S/N 3252 - 4657) F.058-B/MODEL 20/SEPT. 2000...
  • Page 50: Hydraulic Manifold Hh-476

    HYDRAULIC MANIFOLD HH-476 BLACK/CLEAR ANODIZED (S/N 4658-4749) F.058-B/MODEL 20/SEPT. 2000...
  • Page 51: Hydraulic Manifold Hh-476-1

    HYDRAULIC MANIFOLD HH-476-1 BLUE ANODIZED (S/N 4750 AND UP) F.058-B/MODEL 20/SEPT. 2000...
  • Page 52: Hydraulic Unit Assembly

    HYDRAULIC UNIT ASSEMBLY H-317-( ) Common parts list; for complete list see pgs. 52, 53. NOTE: Some machines are equipped with S-1810-10 o-rings and some are equipped with S-1810-15 7/8” O.D. o-rings. For replacement, measure your existing o-rings. F.058-B/MODEL 20/SEPT. 2000...
  • Page 53 H-317 (120 VOLT, 60HZ) H-317-1 (230 VOLT, 50 HZ) H-317-2 (120 VOLT, 60HZ) F.058-B/MODEL 20/SEPT. 2000...
  • Page 54 H-317- 3 (230 VOLT, 50 HZ) H-317- 4 (120 VOLT, 60 HZ) H-317- 5 (230 VOLT, 50/60 HZ) F.058-B/MODEL 20/SEPT. 2000...
  • Page 55: Knife Bar Latch Assembly

    KNIFE BAR LATCH ASSEMBLY EE-1754-3 F.058-B/MODEL 20/SEPT. 2000...
  • Page 56: 20" Hand Clamp Assembly

    20” HAND CLAMP ASSEMBLY F.058-B/MODEL 20/SEPT. 2000...
  • Page 57 F.058-B/MODEL 20/SEPT. 2000...
  • Page 58: English/Metric Conversion Option

    ENGLISH/METRIC CONVERSION OPTION AA-10095-1 INSTALLATION 4. Drill a 1/4” hole in the nameplate as shown in the CAUTION: SHOCK HAZARD! Disconnect drilling detail opposite page. Install the Eng/Metric switch the power before performing any in the hole and connect to the display board. modifications.
  • Page 59: Line Light Kit Installation Instructions

    F.058-B/MODEL 20/SEPT. 2000...
  • Page 60: Line Light Kit Installation Instructions

    F.058-B/MODEL 20/SEPT. 2000...
  • Page 61: Line Light Assembly

    LINE LIGHT ASSEMBLY EE-2779 F.058-B/MODEL 20/SEPT. 2000...
  • Page 62: Model 20 Floor Plan

    MODEL 20 FLOOR PLAN 10000-5FP F.058-B/MODEL 20/SEPT. 2000...
  • Page 63 © 2000 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A. F.058-B/MODEL 20/SEPT. 2000...

This manual is also suitable for:

Model 20 hand clamp

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