the challenge machinery company provides owner's manuals ...6125 norton center drive norton...

The Challenge Machinery Company provides owner's manuals on its products solely as a courtesy to its customers. See the information below before using this manual. These manuals are for reference only. These manuals include products which are non-current, unsupported or no longer produced by The Challenge Machinery Company, and are provided solely as an accomodation to our customers. By providing these manuals, The Challenge Machinery Company makes no representation or warranty as to the products, their current condition, or their suitability or fitness for use in any particular application, which are the sole and independent responsibility of the product owner and user. Older products may not comply with current safety procedures, guidelines or regulations, and it is the product owner's and user's responsibility to evaluate the suitability and fitness of the products in their current use and application. The Challenge Machinery Company makes no representation, warranty or recommendation regarding any modifications which may be required on non-current or unsupported products. The Challenge Machinery Company assumes no liability for any modification or alteration to any Challenge product, and any such modification or alteration to any Challenge product is not authorized by The Challenge Machinery Company. The availability of these manuals is solely for the purpose of providing reference information for the products. This manual may not be complete in all aspects of product maintenance and repair. All products should be used only by qualified and properly trained personnel, following proper safety procedures. All products should be regularly inspected and maintained, and their condition, application and use should be periodically evaluated by qualified personnel. Only qualified and properly trained technicians should perform maintenance, repair and replacement procedures. Attempting these procedures without proper training may cause machine damage or operator injury! Products may be unsupported by The Challenge Machinery Company due to age or the unavailability of parts from their original manufacturer. No parts or product support will be available to repair or maintain unsupported products. Older products may not be UL listed (if the product does not have a UL label it is not a listed product), and may not comply with applicable installation or other regulations or requirements if relocated to a new facility. Many municipalities require a product to be UL listed before an electrician will connect power to them. Often the cost of updating an older product to comply with current safety regulations is greater than the value of the product.

The Challenge Machinery Company6125 Norton Center Drive

Norton Shores, MI 49441-6081 USA

ChallengeMachinery.com

F. 200-ASept. 1999

Serial Numbers 971103 & Up

TITAN 200PAPER CUTTING

MACHINEPower Backgauge &

Programmable Models

Sold and Serviced by

INSTRUCTION ANDPARTS MANUAL

NOTICE: UNSUPPORTED PRODUCT!

NO TECHNICAL SUPPORT AVAILABLE!

NO REPAIR PARTS AVAILABLE!

F.200-A/TITAN 200/SEPT 99ii

INTRODUCTION

WELCOME to the family of Challenge® users. Challenge has been developing and manufacturing Graphics ArtsEquipment for over 100 years and is today one of the world’s leading producers and distributors of Paper Cutters,Paper Drills and Bindery Equipment.

SAFETY ALERT! This symbol means CAUTION OR WARNING: Personal safety instructions! Payspecial attention to the instructions in bold type. Personal injury may result if the precautions are notread and followed. See SAFETY PRECAUTIONS, pg. viii.

• This machine is designed for ONE PERSON OPERATION ONLY!• Always DISCONNECT THE POWER before working on this machine.• DO NOT OPERATE WITH ANY GUARDS REMOVED! Replace all guards before operating.• CUT/CRUSH HAZARD - Keep hands from under paper clamp and knife.

READ THIS MANUAL BEFORE OPERATING! Follow precautions and instructions given and you should haveyears of trouble-free operation. If after reading the manual questions still remain, contact your Authorized ChallengeDealer.

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 givethe 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 thefront cover of this manual. Also be sure to fill out the warranty card accompanying this manual and return itDIRECT TO CHALLENGE.

If you bought a used machine, it is important to have the following information on record at Challenge. Copy thispage, 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 ZIP

PHONE DATE INSTALLED

DEALER’S NAME AND CITY

PLEASE REVIEW THE ENCLOSED WARRANTY SHEET!

It is very important that you read and understand the conditions outlined in the Warranty Information Sheet. It isin 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 CHALLENGEMACHINERY COMPANY in order for the warranty to be issued for this machine.

WARRANTY INFORMATION

Challenge® is a registered trademark of The Challenge Machinery Company. 6125 Norton Center Drive, Norton Shores, MI 49441.Copyright © 1998 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A.




iiiF.200-A/TITAN 200/SEPT 99

PACKING LISTPart No. Description Qty.A-10034 Knife ...................................................................................24166 Cutting Stick (in addition to one installed in machine) ..........3F.200-A Instruction and Parts Manual...............................................1A-12608-2 Jogging Aid.........................................................................120-2150-2 Tool Kit ...............................................................................1

H-6918-608 Knife Bolts, 3/8 - 16 x 1” ................................................48815 Knife Washers, Special .................................................45064 Cutting Stick Puller .......................................................1S-1245-5 Knife Lifters ..................................................................2W-130 3/16” Allen Wrench .......................................................1W-137 5/32” Allen Wrench .......................................................1W-164 5/16” Hex ‘T’ Wrench ....................................................1W-170 9/16 x 1/2” Wrench .......................................................1SU-10-113 Grease Brush ...............................................................1

OPTIONAL ITEMSPart No. Description Qty.AA-10061 False Clamp Plate5-7-M361 Backgauge Book Guides4166 Cutting Sticks (in addition to one installed in machine)

SERIAL NO -UPGRADE CODE -




F.200-A/TITAN 200/SEPT 99iv

SPECIFICATIONSCutting DimensionsCutting Width 20” (508 mm)Minimum Cut* ½” (13 mm)Clamp Opening 3¼” (83 mm)Table Space

Front: 16” (406 mm)Back: 20” (508 mm)

Machine Dimensions**Table Height 36” (91 cm)Overall Height 53” (135 cm)Overall Length*** 49” (124 cm)Overall Width 36” (91 cm)Net Weight (Approximate) 755 lbs (342 kg)Shipping Weight (Approximate) 950 lbs (431 kg)Electrical208/230 Volts 12 Amps, 1 Phase, 50/60 Hz, AC. Service size 15 AmpsRecommended Recepticle: 208-230 Volt, NEMA 6-15R, NEMA 6-20RSound EmissionA-weighted sound pressure level measured in an enclosed room at operator level (6 feet/183 cm):

Machine cutting a full lift of paper: 77 dB

*With false clamp plate attached, minimum cut is 1-7/8” (48 mm).**For complete floor plan layout, see page 5-24.***With table, front guard, and foot treadle removed, can be fit through a 28” (71 cm) door opening.

Challenge reserves the right to make changes to any product or specification without notice and withoutincurring responsibility to existing units.




vF.200-A/TITAN 200/SEPT 99

TABLE OF CONTENTS

INTRODUCTION...................................................................................................... iiPACKING LIST ....................................................................................................... iiiOPTIONAL ITEMS .................................................................................................. iiiSPECIFICATIONS .................................................................................................. ivCAUTION: POWER LOCK-OUT PROCEDURE.................................................... viiiSAFETY PRECAUTIONS...................................................................................... viii¡OJO! ...................................................................................................................... ixWARNING LABEL DEFINITIONS .............................................................................x1.0 INSTALLATION & SETUP .............................................................................. 1-1

1.1 UNCRATING ............................................................................................ 1-11.2 CLEANING .............................................................................................. 1-11.3 FITTING THROUGH NARROW DOOR .................................................... 1-1

1.3.1 Removing the Table ........................................................................ 1-11.3.2 Removing the Foot Treadle ............................................................. 1-31.3.3 Removing the Front Guard (If Equipped) ......................................... 1-31.3.4 Reattaching the Table ..................................................................... 1-3

1.4 INSTALLING EXTENSION TABLES......................................................... 1-31.5 HYDRAULIC SYSTEM CHECK ................................................................ 1-31.6 FALSE CLAMP PLATE (OPTIONAL) ....................................................... 1-41.7 POWER HOOK-UP .................................................................................. 1-41.8 LINE LIGHT ............................................................................................. 1-5

1.8.1 Adjustment ...................................................................................... 1-51.8.2 Bulb Replacement ........................................................................... 1-5

2.0 OPERATION .................................................................................................. 2-12.1 POWER - MAIN SWITCH......................................................................... 2-12.2 START UP ............................................................................................... 2-12.3 MAKING A CUT (Using OPTIONAL Two-Hand Cut Buttons) ..................... 2-12.4 MAKING A CUT (Using Front Guard) ....................................................... 2-12.5 JOGGING AID ......................................................................................... 2-22.6 KNIFE CHANGE ALARM AND LUBRICATION ALARM ............................ 2-22.7 MANUAL CLAMPING (Using the Foot Treadle) ........................................ 2-22.8 DISPLAY PANEL ..................................................................................... 2-22.9 DEFINITION OF KEYS............................................................................. 2-3

2.9.1 Variable Speed Pinpoint Backgauge Contol ..................................... 2-32.9.2 IN/MM Key ...................................................................................... 2-32.9.3 SEND Key ...................................................................................... 2-32.9.4 Push-Out Key ................................................................................. 2-32.9.5 Clear Key ........................................................................................ 2-32.9.6 Enter Key ........................................................................................ 2-32.9.7 Priority Add (X/Y) Key ..................................................................... 2-42.9.8 Soft-Keys ........................................................................................ 2-42.9.9 Arrow Keys ..................................................................................... 2-42.9.10 Contrast Control ............................................................................ 2-4

2.10 MANUAL BACKGAUGE CONTROL ....................................................... 2-42.10.1 Backgauge Glide Control ............................................................... 2-42.10.2 Backlash Indicator ......................................................................... 2-4

2.11 SEND MODE ......................................................................................... 2-42.11.1 Entering Math................................................................................ 2-42.11.2 Entering Fractions ......................................................................... 2-42.11.3 Upgrading Power Backgauge Models to Programmable Models ..... 2-5

2.12 MAINTENANCE MODE.......................................................................... 2-52.12.1 Knife Adjust ................................................................................... 2-52.12.2 Parameters ................................................................................... 2-5

2.12.2.1 False Clamp ......................................................................... 2-5




F.200-A/TITAN 200/SEPT 99vi

2.12.2.2 Time-out ...............................................................................2-52.12.2.3 Push-out ...............................................................................2-52.12.2.4 Accuracy Adjust ....................................................................2-52.12.2.5 Knife Count ...........................................................................2-52.12.2.6 Machine count ......................................................................2-6

2.12.3 Diagnostic ......................................................................................2-62.12.3.1 Error Code ............................................................................2-62.12.3.2 Sensor Data ..........................................................................2-62.12.3.3 Clear Memory .......................................................................2-62.12.3.4 Electric Clamp .......................................................................2-62.12.3.5 Clamp Adjust ........................................................................2-6

2.12.4 Language .......................................................................................2-62.13 JOB MODE (Programmable Models Only) ...............................................2-6

2.13.1 Lock/Unlocking a Job .....................................................................2-72.13.2 Copying a Job ................................................................................2-72.13.3 Erasing a Job .................................................................................2-72.13.4 Creating a New Job ........................................................................2-7

2.13.4.1 Entering Send Values ...........................................................2-72.13.4.2 Cut and Record .....................................................................2-72.13.4.3 Channel Linking ....................................................................2-7

2.13.5 Editing an Existing Job ...................................................................2-82.13.5.1 Editing the Job Name ............................................................2-82.13.5.2 Editing Send Values ..............................................................2-82.13.5.3 Inserting Send Values ...........................................................2-82.13.5.4 Erasing Send Values .............................................................2-8

2.13.6 Running a Programmed Job ...........................................................2-82.13.7 Exiting a Job ..................................................................................2-8

2.14 AN EXAMPLE JOB .................................................................................2-82.15 OPERATING TIPS ................................................................................2-102.16 NOTE TO DEALER ...............................................................................2-10

2.16.1 Entering the Dealer Name and Phone Number .............................2-103.0 KNIFE INSTALLATION/CHANGING ................................................................3-1

3.1 KNIFE REMOVAL .....................................................................................3-13.2 KNIFE INSTALLATION .............................................................................3-23.3 KNIFE CARE TIPS ....................................................................................3-3

3.3.1 Knife Blade Life ................................................................................3-33.3.2 Cutting Stick ....................................................................................3-33.3.3 Bevel Angle .....................................................................................3-33.3.4 Helpful Suggestions .........................................................................3-33.3.5 Knife Care ........................................................................................3-4

4.0 MAINTENANCE ..............................................................................................4-14.1 TROUBLESHOOTING ..............................................................................4-24.2 ERROR MESSAGES AND DESCRIPTIONS .............................................4-34.3 SENSOR DATA ABBREVIATIONS ...........................................................4-44.4 ROUTINE MAINTENANCE .......................................................................4-4

4.4.1 Weekly .............................................................................................4-44.4.2 Monthly ............................................................................................4-54.4.3 Yearly ..............................................................................................4-5

4.5 CHECKING/CHANGING THE HYDRAULIC FLUID ...................................4-54.5.1 Recommended Hydraulic Oils ..........................................................4-5

4.6 OIL AND GREASE ....................................................................................4-54.7 ADJUSTMENTS .......................................................................................4-7

4.7.1 Backgauge Gib Adjustments ............................................................4-74.7.2 Squaring the Backgauge ..................................................................4-74.7.3 Proximity Switches ...........................................................................4-8

TABLE OF CONTENTS (cont.)




viiF.200-A/TITAN 200/SEPT 99

4.7.4 Hydraulic Valve Adjustments ............................................................4-94.7.4.1 Pressure Settings: ...................................................................4-94.7.4.2 Adjustment Procedure: ............................................................4-94.7.4.3 Optional Electronic Clamp Pressure Control Adjustment .......4-10

4.8 CLEANING .............................................................................................4-105.0 PARTS LIST AND SEQUENCE OF OPERATIONS .........................................5-1

MAIN ASSEMBLY - FRONT VIEW ..................................................................5-2MAIN ASSEMBLY - RIGHT SIDE VIEW ..........................................................5-4MAIN ASSEMBLY - TABLE ASM. VIEW .........................................................5-6HYDRAULIC POWER UNIT (S/N 971156 & BELOW) .....................................5-8HYDRAULIC POWER UNIT (S/N 971157 & ABOVE) ......................................5-9HYDRAULIC MANIFOLD ASSEMBLY AND SCHEMATIC .............................5-10HYDRAULIC SEQUENCE OF OPERATION .................................................5-11POWER PANEL ASSEMBLY ........................................................................5-12BASIC MACHINE SCHEMATIC ....................................................................5-14ELECTRICAL SEQUENCE OF OPERATION ................................................5-15CONTROL CONSOLE ASSEMBLY ..............................................................5-16CONTROL PC ASSEMBLY ..........................................................................5-17KNIFE LATCH ASSEMBLY (S/N 981341 & BELOW) ....................................5-18KNIFE LATCH ASSEMBLY (S/N 981342 & ABOVE) .....................................5-19LINE LIGHT ASSEMBLY ..............................................................................5-20CUT BUTTON ASSEMBLY ...........................................................................5-21POWER PANEL LABEL ................................................................................5-22TITAN 200 FLOOR PLAN .............................................................................5-24SAFETY SYSTEM TESTS ............................................................................5-25

TABLE OF CONTENTS (cont.)




F.200-A/TITAN 200/SEPT 99viii

• This machine is designed and safeguarded for ONE PERSON operation. NEVER operate the cutter with morethan one person.

• Safety is the responsibility of the user of this machine. Use good judgement and common sense when workingwith and around this machine.

• READ and understand all instructions thoroughly before using the cutter. If questions still remain, call yourAuthorized 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. Turnthe main disconnect switch to the off position and disconnect the power plug, see Disconnect Procedurebelow.

• 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. Severelacerations or dismemberment could result from careless handling procedures.

• Keep the floor around the cutter free of trim, debris, oil and grease.

• When replacing hydraulic parts, loosen the connections slowly to release pressure. Neverloosen connections with the machine running.

• If the cutter sounds or operates unusually, turn it off and consult the troubleshooting section of this manual. Ifthe 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 loadpaper, and use the backgauge to push paper out before unloading. DO NOT REACH UNDER THE KNIFE ANDCLAMP AREA!

SAFETY PRECAUTIONSThis safety symbol means CAUTION/WARNING - PERSONAL SAFETY INSTRUCTION. Readthe instructions because it has to do with safety. Failure to comply with the following instruc-tions may result in personal injury.

For maximum safety and to prevent unauthorizeduse, turn the power switch to the off position anddisconnect the power cord whenever adjusting, lu-bricating, or making repairs to the machine.

CAUTION: POWER LOCK-OUT PROCEDURE

(fig. i)




ixF.200-A/TITAN 200/SEPT 99

• Esta maquina, junto con sus mecanismos de seguridad, esta disenada para ser manejada porUNA SOLA PERSONA a la vez. Jamas debe ser manejada por mas de una persona al mismotiempo.

• 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 afuncionar 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 niquitarse.

• DESCONECTE LA CORRIENTE ELECTRICA antes de proceder a hacerle servicio de limpieza, engrasar, o dehacer adjustes que no requieren corriente. Trabe el interruptor en la posicion OFF (apagado); vea “Procedimientopara 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 puedenresultar 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 dejarescapar la presion. Jamas debe aflojarse conexiones mientras la maquina esteandando.

• Si la guillotina empezara a sonar o trabajar diferentemente a lo acostumbrado, desconectela y consulte laseccion “Troubleshooting” (Reparador) de este manual. Si no es posible corregir el problema, llame a suservicio autorizado para que le examinen la maquina.

• PELIGRO DE MACHUQUE - Mantenga manos y dedos fuera de la agarradera mientras sujeta el papel. Use elcalibrador trasero y su rueda de mano para empujar el papel cortado. NO PONGA SUS MANOS BAJOLACUCHILLA O AREA DE LA AGARRADERA.

• NO OPERE SIN LAS GUARDAS PROTECTORAS!

¡ OJO ! PRECAUCION - Como proceder para desconectarla corriente electrica.

Para maxima seguridad durante ajustes y reparaciones de su maquina, verifique bien que el interruptor principal de controlde 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 queestara 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 encualquier maquina.

This Este simbolo de alerta de seguridad significa ¡ OJO ! - INSTRUCCIONES DESEGURIDADPERSONAL. Lea las instrucciones porque se refieren a su seguridad personal.Fall de obedecer las instrucciones que siguen podria resultar en lesiones corporales.

¡OJO!




F.200-A/TITAN 200/SEPT 99x

SINGLE OPERATOR

SHOCK HAZARD

SHOCK HAZARD

HAZARDOUS AREA

Do not operate with more than one person.

Disconnect power before removing cover. Replacecover before operation.

Disconnect power before removing cover. Replacecover before operation.

Disconnect power before cleaning, servicing, or makingadjustments not requiring power. Do not alter safetyguards or devices, they are for your protection. Replaceall guards, do not operate with any guards removed.

WARNING LABEL DEFINITIONS




1-1F.200-A/TITAN 200/SEPT 99

1.0 INSTALLATION & SETUP

1.0 INSTALLATION &SETUP

1.1 UNCRATING

Your cutter has been carefully packaged to preventdamage during shipping. Inspect all shipments as soonas they are received. Note any damage on the freightbill and notify the claims department of the carrier within15 days. All claims for damage are the responsibility ofthe receiver, so remember to inspect promptly. Checkthe contents of the crate against the packing list at thefront of this manual.

The Titan 200 weighs approximately 755 lbs (342kg).DO NOT risk personal injury or damage by attemptingto move machinery with makeshift equipment orinadequate manpower. This machine is shipped on awooden skid and enclosed in a protective, corrugatedtop. The skid is designed to allow the machine to berolled off without any special lifting equipment. Themachine is held in place by two, 2x4 braces lag boltedto the skid. All accessories are shipped inside of themachine.

Remove the carton by removing the nails or staplesholding 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 unwrapit from around the cutter.

Remove all lag screws from the skid. Remove the lowerfront cover of the Titan 200 and remove the two lagscrews in the base. Remove the accessories.

Using the rear bumper board, pry one side of the

machine up, and slide out the top layer of the supportriser (fig. 1-1). Do the same on the other side.

Use the flat board provided as a ramp and position asshown in fig 1-2. Hold the ramp in place with the nailsprovided. Make sure the casters are not locked andvery carefully roll the machine down the ramp.

The cutter may now be rolled into position.

1.2 CLEANING

After unpacking, wipe down all machine panels andclean the table surface.

1.3 FITTING THROUGH NARROW DOOR

The Titan 200 cutter will not fit through an opening lessthan 36” (91 cm) without the table being removed.With the table removed, the Titan 200 will fit through a35” (89 cm) opening. With the table, front guard, andfoot treadle removed, it will fit through a 28” (71 cm)opening.

1.3.1 Removing the Table

Make sure the knife and clamp are in the “up” position.If they are not, read the Power Hookup section (section1.7) to connect power to the machine. Turn on thepower using the red and yellow main power switch,close the front guard, and press the CLEAR button.This will preset the backgauge and send the knife andclamp up.

Turn off the machine and unplug the power cord.

(fig. 1-1)

(fig. 1-2)




F.200-A/TITAN 200/SEPT 991-2


Remove the plexiglass cover and the three sheetmetal covers on the rear of the table. Remove thebackgauge motor cover, the rear table support leg, thelower back panel, and the lower front cover of themachine.

Unplug the cable to the motor encoder at the back ofthe machine (fig. 1-3).

Remove the motor junction box cover and disconnectthe wires to the motor (fig. 1-4). Remove theleadscrew cover and the nylon tyraps that are attachedto the bottom of the table. The motor wires andencoder wires should now be free from the table.

From the rear of the machine, remove the presetterboard assembly from the table (fig. 1-5).

Open the front guard, open the top cover and removethe left and right side guides and the cut stick stops asshown in figures 1-6 and 1-7.

Next, remove the cut stick from the table using the cut

stick removal tool and tap out the two taper pins fromthe bottom side of the table. Then remove the fourscrews that mount the table to the base. NOTE: thetable assembly is very heavy and requires two peopleto remove. Pull the table out from the back of themachine. Locate the four round spacers that werebetween the table and the base - you will need them

Motor JunctionBox Cover

(fig. 1-4)

Presetter BoardAssembly

(fig. 1-5)

Cut Stick Stop

(fig. 1-7)

Right SideGuide

Cut Stick

Encoder Plug

Rear Support Leg

(fig. 1-3)

Left SideGuide

(fig. 1-6)




1-3F.200-A/TITAN 200/SEPT 99


later for mounting the table.

1.3.2 Removing the Foot Treadle

Make sure the power is off and the power cord isdisconnected. Remove the lower front cover. Use anopen-end wrench to remove the two cables attached tothe base, which hold up the foot treadle. Carefully,remove the springs. Now remove the pins at the rearpivot points of the foot treadle. Remove the treadle.

1.3.3 Removing the Front Guard (If Equipped)

Make sure the power is off and disconnect the powercord. Open the front guard. Remove the cylinderbracket screws (fig. 1-8).

Then open the top hood and remove one set of hingescrews (fig. 1-9). Slide the front guard out of the otherhinge.

1.3.4 Reattaching the Table

Set the table in position. Lift the table from the frontand set the two front spacers in place. Insert the fronttwo socket head screws, but do not tighten. Lift thetable from the rear and set the two rear spacers in

place. Start the rear two socket head screws. Reinsertthe two taper pins, and tap into position so they arebelow bottom of the slot. Tighten all four screws.Attach the right and left side guides (fig. 1-6 & 1-7), thepresetter board assembly (fig. 1-5), the motor andencoder wires (fig’s. 1-3 & 1-4), and all guards andpanels. Once the table is installed, the backgaugesquareness and accuracy will have to be reset. Seesections 2.12.2.4 Accuracy Adjust and 4.7.2 Squaringthe Backgauge.

1.4 INSTALLING EXTENSION TABLES

Using the wood screws provided, attach a back plateto each extension table. Using (4) 3/8-16 capscrews,attach the table support to the under side of the maintable as shown in fig. 1-10. If the machine is equippedwith 2-hand cut buttons, route each cut button wirethrough the slots in the bracket and relocate the cutbuttons to the extension tables (as shown). Place theprovided flat washers on the table support above eachslot receiving a screw to mount the extension table onthe support. Lay the table extension on top of thespacers and insert the screws. Slide the tableextension tight to the table. Shim the extension tablesas neccessary to make the tables flush using theprovided shims.

1.5 HYDRAULIC SYSTEM CHECK

The cutting/clamping mechanism of the Titan 200 ispowered by a hydraulic system consisting of anelectric motor coupled directly to a hydraulic pump.

The hydraulic reservoir holds 4 quarts (1 gallon) ofhydraulic fluid. It is filled with Rykon 100 hydraulic fluidat the factory but should be checked before operation.Remove the lower rear panel cover and unscrew the capon top of the tank (fig. 1-11). Fluid level should be at 1/8” from the end of the dip stick (check with dip stickcap screwed in). Add fluid if necessary but avoid

HingeScrews

(fig. 1-9)

(fig. 1-10)BracketScrews

(fig. 1-8)




F.200-A/TITAN 200/SEPT 991-4


overfilling as this could cause leakage when hot.Replace the rear panel when finished. For moreinformation about checking and changing the hydraulicfluid, including a cross reference chart of approvedfluids, see section 4.5 of this manual.

The hydraulic fluid should be checked weekly andchanged AT LEAST ONCE-A-YEAR or after every 1,000hours of operation.

1.6 FALSE CLAMP PLATE (OPTIONAL)

To prevent marking on pressure sensitive jobs, a falseclamp plate is available as an optional item for yourmachine. This plate attaches to the bottom of theclamp. It is secured with wing nuts on studs that passthrough the top of the clamp.

To install:

1. Make sure the knife and clamp are in the upposition. If they are not, turn on the power usingthe red and yellow main power switch, close thefront guard, and press the CLEAR button. This willpreset the backgauge and send the knife andclamp up.

2. Turn the power off and disconnect the power cord.

3. Open the front guard and slide the false clamp plateunder the knife and clamp (fig. 1-12), and slide theplate up into position with the locator pins towardthe front of the machine. The locator pins insertinto holes in the bottom front of the clamp.

4. Hold the plate in position and secure with the wingnuts provided.

5. Change the false clamp setting of the machine toON to prevent the backgauge from crashinginto the false clamp plate. This is done in theMaintenance Mode/Parameters/False Clampscreen. For more details on how to do this, seesection 2.12.2.1.

NOTE: The minimum cut with the false clamp plateattached is 1-3/4”

1.7 POWER HOOK-UP

It is the customer’s responsibility to provide a properlygrounded receptacle that meets the power requirementsspecified on the name plate of this machine, as well asall local electrical codes. Have a qualified electricianinstall one if your location is not so equipped.

Check incoming voltage and position the voltageselection jumper in the proper location as shown below:

(fig. 1-12)

Locator Pins

CAUTION: NEVER CUT THE GROUNDLUG OFF of a 3-prong plug to fit a 2-prong socket! You run the risk of

electrical shock which could cause personalinjury or death.

Dipstick

(fig. 1-11)




1-5F.200-A/TITAN 200/SEPT 99


NOTE: The terminal block jumper must be set tothe correct location according to the supplyvoltage of the machine. Failure to set the terminalblock jumper will cause damage to the machine!

Connect the power cord into a grounded, 3-prongreceptacle only! (Recommended receptacle: 208-230Volt, NEMA 6-15R, or NEMA 6-20R.)

1.8 LINE LIGHT

The Titan 200 is equipped with two lights which providea line of light on the paper in the approximate location ofwhere the paper will be cut. The lights come on whenpower to the machine is turned on. The light from eachbulb reaches the table after passing between the knifeand clamp. Each light is focused with a socket headcapscrew (fig. 1-13).

1.8.1 Adjustment

1. Place a wide sheet of paper on the cut stick to viewthe line light.

2. Using a 3/16” hex allen wrench, turn one of the capscrews until you see a 1/16-1/8” beam. Note: it isbest to start by turning the screw clockwise. If thescrew turns all the way in before a line appears,begin turning the screw counterclockwise.

3. Similarly, turn the adjustment screw of the otherbulb, until one continuous beam is seen across thecut stick.

1.8.2 Bulb Replacement

1. Make sure power is off and unplug the machine(see power lockout procedure, pg. viii).

(fig. 1-13)

Line LightAdjustment

Screw

2. Open the front guard.

3. Remove the old bulb by lightly pushing the bulb intothe socket and turning it counterclockwise.CAUTION! If the bulb is still hot, allow a fewminutes for it to cool.

4. Insert the new bulb into the socket and twist itclockwise until the bulb locks into place.

5. Reconnect power and turn the main power switchon. Readjust the line if necessary.




F.200-A/TITAN 200/SEPT 991-6


NOTES




2-1F.200-A/TITAN 200/SEPT 99

2.0 OPERATION

2.0 OPERATION

IMPORTANT: DO NOT ATTEMPT TO OPERATE THECUTTER UNTIL YOU HAVE THOROUGHLY READAND UNDERSTAND ALL OF THE FOLLOWINGINSTRUCTIONS. CALL YOUR AUTHORIZEDCHALLENGE DEALER IF YOU STILL HAVE ANYQUESTIONS.

2.1 POWER - MAIN SWITCH

Power is brought to the machine when the main powerswitch is turned to the “ON” position (fig. 2-1). Thedisplay and line lights are turned on at this time. Thehydraulic motor will not be activated until a cut cycle isinitiated, and it will shut off after the completion of thecut cycle.

The display and line lights will shut off after 5 minuteswithout any activity. This shut-off time can be changedin the Parameters screen of the Maintenance Mode(see section 2.12.2.2). To restore power to the displayand line lights, press any button on the keyboard or liftup the front guard (if equipped).

2.2 START UP

Once power has been turned on, the Titan 200 will showthe following display:

When the CLEAR key is pressed the clamp and knifewill move up if they are not already in the up position(provided the front guard is closed). Then thebackgauge will move to coordinate the true positioninto the computer. When finished, the machine will bein “Send Mode” and the display will appear similar tothe display shown below.

The backgauge may now be sent to a desired positionby simply typing the dimension and pressing SEND(see section 2.11 Send Mode for more details).

2.3 MAKING A CUT (Using OPTIONALTwo-Hand Cut Buttons)

Place the paper against the backgauge and left sideguide. Note: if the cut will leave strips of paper lessthan 1/2” wide, place the paper against the right sideguide. This will prevent the strips from getting caughtin the small opening near the left side guide.

To make a cut simply press both cut buttons (locatedbeneath the front face of the table) within 1/2 secondof each other. Hold the buttons in until the knifereaches the table. Releasing the cut buttons at anytime during the cut cycle will immediately send theknife and clamp to the up position.

2.4 MAKING A CUT (Using Front Guard)

Open the front guard and place the paper against thebackgauge and left side guide. Note: if the cut willleave strips of paper less than 1/2” wide, place thepaper against the right side guide. This will preventthe strips from getting caught in the small opening nearthe left side guide.

To make the cut, close the front guard and press thecut button. If the guard is raised at any time during thecut cycle, the knife and clamp will immediately returnto the up position.

55.000 in

Backgauge must move to be preset.Please clear the table and closeguard.Warning! Clamp and Knife maymove.Revision 1.0

Press clear to startA) MaintB) Job

5.000 in

>_

A) MaintB) Job

ONOFF

(fig. 2-1)




F.200-A/TITAN 200/SEPT 992-2

2.0 OPERATION

CAUTION: Always remove thejogging aid from the table beforemaking a cut.

(fig. 2-2)

(fig. 2-3)

Note: The guard must be opened and closed eachtime a new cut is made.

2.5 JOGGING AID

A jogging aid is included as standard equipment withthe Titan 200. This tool allows the operator to load andalign paper without the need to place hands or armsunder the knife or clamp.

To use, load the paper against the side and backgaugeusing the jogging aid (fig’s. 2-2 & 2-3). Remove thejogging aid from the table, close the guard, and makethe cut.

2.6 KNIFE CHANGE ALARM ANDLUBRICATION ALARM

Titan 200 has two built in alarms that will be displayedafter a certain number of cuts. The knife alarm displaysa message to remind the operator to change the knife.The lube alarm displays a message to remind the

operator to have the machine lubricated. The lubealarm will also display the name and phone number ofthe Challenge dealer from which the machine waspurchased. For instructions on how to reset eitheralarm, or to change the knife alarm value, see section2.12.2.5 Knife Count. The lube alarm value is factoryset at 2,500 cuts and cannot be changed.

2.7 MANUAL CLAMPING (Using the FootTreadle)

The Titan 200 is equipped with a manual clampingfeature which allows the operator to manually clamppaper before beginning the cut cycle. To use thisfeature, press down on center of the foot treadle untilthe clamp comes down on the paper. While holdingthe foot treadle down, close the guard and press thecut button. Release the foot treadle once the cut hasbeen completed.




2-3F.200-A/TITAN 200/SEPT 99

2.0 OPERATION

2.9 DEFINITION OF KEYS

2.9.1 Variable Speed Pinpoint Backgauge Contol

The backgauge control is used to manually position thebackgauge. The speed of the backgauge will dependupon where the actuator is pressed. Press farther fromcenter for a faster speed. Press toward the operator forforward direction and away from the operator for reversedirection.

2.9.2 IN/MM Key

This key toggles the display to show the position andprogrammed send values in inches (e.g. 5.250), inchfractions to the nearest 1/64” (e.g. 5_1/4), or millimeters(e.g. 133.3).

2.9.3 SEND Key

The SEND key is used to send the backgauge to anyvalid position. If an attempt is made to send thebackgauge to an illegal position, an error message willbe displayed at the bottom of the screen stating“Number outside limit”. In the Job mode, the SEND keywill also advance the backgauge to the next sequentialcut position before performing the cut.

2.9.4 Push-Out Key

The push-out key will move the backgauge forward 5inches (or to the most forward position) and then returnit to its previous position. This allows paper to beremoved from the cutter without putting hands underthe knife and clamp.

2.9.5 Clear Key

The CLEAR key is used to clear error messages andthe current entry line.

2.9.6 Enter Key

The ENTER key selects items in the maintenancemode and processes data that has been entered in theother modes.

CAUTION! Never place hands in theclamp and knife area. Use the push-out key or the backgauge glide

control to move the paper to an area where itcan be reached.

Cut Button

SEND Key IN/MM Key

Soft Keys

Push-Out Key

Arrow Keys

CLEAR KeyENTER KeyPriority Add (X/Y) Key

Display

2.8 DISPLAY PANEL

(fig. 2-4)

Variable SpeedPinpoint Backgauge

Control




F.200-A/TITAN 200/SEPT 992-4

2.0 OPERATION

2.9.7 Priority Add (X/Y) Key

The priority add key is used for entering fractions whenthey are combined with whole numbers. The symboldisplayed when this key is pressed is the underlinesymbol “_”. An example of a number entered using thepriority add key is 1_1/2.

2.9.8 Soft-Keys

The soft-keys are labeled as A, B, C, and D. Thedefinition for these keys change depending on theoperating mode. The function of the key can be foundon the bottom of the display screen.

2.9.9 Arrow Keys

The four arrow keys can be used in almost all screens.The arrow keys are primarily used for moving the cursoraround on the screen, or to toggle between highlightedselections. In some screens, the left arrow key acts asa backspace key.

2.9.10 Contrast Control

The contrast of the display can be adjusted by usingthe contrast control knob, which is located directlybehind the display panel, sticking out of the displaypanel cover. To access, open the front guard, reach inwith your left hand until you feel the knob, and adjustthe contrast as necessary.

2.10 MANUAL BACKGAUGE CONTROL

2.10.1 Backgauge Glide Control

The backgauge can be moved manually by use of thebackgauge glide control. Press towards the operator forfoward travel and away from the operator for reversetravel. The further away from center that the actuator ispushed, the faster the backgauge will travel.

2.10.2 Backlash Indicator

To insure accurate cuts, the backgauge must bebrought to the cut position from the rear of the table. Inthe display, to the right of the backgauge positon, thereis a small arrow to indicate reverse travel (fig. 2-5).This arrow should be off when making a cut. Movingback past your cut position, then forward to it,compensates for any play in the backgauge nut andleadscrew.

2.11 SEND MODE

The send mode is the first screen displayed after thebackgauge is preset. From this screen the backgaugecan be positioned with the backgauge pinpoint controlor by entering a value and pressing the SEND key. Amathematical expression can also be entered as asend value. Simply type the expression and pressSEND. You can also enter an equation which beginswith the current backgauge position. For example, ifyou want to send the backgauge 2” forward from itscurrent position, just press [-] [2] and SEND.

The send mode screen can also be used for doingmath calculations that are larger than the backgauge’sreverse limit. In this case, you must press ENTER tohave the result displayed on the screen.

2.11.1 Entering Math

In the simple send mode, the Titan 200 is capable ofcalculating an entire math string such as, 10-5+5x6+2_3/4. However, the result is limited to29999.000 and the result cannot be a negative value.In the job mode, and during a send, the result of thecalculation must be less than the backgauge limit of20.000 inches.

2.11.2 Entering Fractions

Fractions are entered with the priority add key X/Y.The symbol displayed when this key is pressed is theunderline symbol “_”. This instructs the computer toadd the fractional portion of the entry beforeperforming the remaining math. This key is usefulwhen entering a formula as follows: 3x2_3/4 = 8_1/4.If a simple plus had been used instead, the resultwould be as follows: 3x2+3/4 = 6_3/4.

5.000 in /\

>_

A) MaintB) Job

reverseindicator

arrow

(fig. 2-5)




2-5F.200-A/TITAN 200/SEPT 99

2.0 OPERATION

2.11.3 Upgrading Power Backgauge Models toProgrammable Models

In Send Mode, power backgauge models will display“B) Upgrade” instead of “B) Job”. Call your authorizedChallenge dealer if you wish to purchase the upgradecode that will upgrade your machine to aprogrammable model.

If you have purchased the code and wish to upgradeyour machine, press the soft-key B to go to the upgradescreen. Type in the upgrade code and press ENTER. Ifthe code is correct, the machine will be upgraded to aprogrammable model and the display will return to theStart Up screen. Soft-key B should now read “Job”instead of “Upgrade”.

NOTE: Upgrade codes can only be obtained from TheChallenge Machinery Co. through authorized Challengedealers. Each machine has a unique upgrade codethat will not work on other machines. Please have themachine serial number (as displayed in the lower leftcorner of the display, or on the machine nameplate)ready when calling, as it is necessary to obtain thecode.

2.12 MAINTENANCE MODE

The maintenance mode is an area where manymachine functions can be set or modified. The fourprinciple functions are: Language, Parameters,Diagnostic, and Knife Adjust. To select a particularfunction, use the up and down arrow keys to toggle tothe desired function and press ENTER. See thefollowing descriptions for an explanation of eachfunction.

2.12.1 Knife Adjust

The knife adjust function provides a way for the servicetechnician to change the knife. In the Knife Adjustscreen, use the up and down arrow keys to toggle tothe up or down status as desired, and press ENTER.

Close the front guard and press ENTER to send theknife to the desired position. Note: To exit the knifedown screen and return to the knife adjust screen,press the cut button.

2.12.2 Parameters

In the parameter screen, use the up and down arrowkeys to toggle to the desired parameter, and pressENTER. See the descriptions that follow for anexplanation of each parameter.

2.12.2.1 False Clamp

The false clamp plate is an optional attachment whichreduces the creasing of paper caused by the clamp.The disadvantage of using the false clamp plate is thatit limits the smallest cut dimension. The computermust know when the false clamp plate is installedon the machine to prevent the backgauge fromcrashing into it. In the false clamp screen, use the upand down arrow keys to toggle between ON or OFF toindicate the presence of the false clamp plate, andpress ENTER.

2.12.2.2 Time-out

The time-out parameter allows the operator to set theamount of idle time before the display and line lightsturn off. The choices are 2, 5, 10, 20, and 30 minutes.In the time-out screen, use the up and down arrowkeys to toggle to the desired time-out, and pressENTER.

2.12.2.3 Push-out

Normally, whenever the backgauge is sent to a largerdimension, a five inch (127mm) push-out is performedto aid the operator in accessing the paper. In somesituations, it may be necessary to turn this feature off.It is recommended that this feature be left on wheneverpossible. In the push-out screen, use the up and downarrow keys to toggle to the on or off status as desired,and press ENTER.

2.12.2.4 Accuracy Adjust

This parameter provides a means for adjusting theaccuracy of the backgauge. To change the accuracy,send the backgauge to 2 inches (50.8mm) and cutsome paper. Measure the paper, and type in what youactually measure. The computer will calculate theamount of error and will compensate.

2.12.2.5 Knife Count

The knife count parameter allows the operator to reset

5.000 in

MAINT MENUKNIFE ADJUSTPARAMETERSDIAGNOSTICLANGUAGE

C) SendB) Job D) Exit




F.200-A/TITAN 200/SEPT 992-6

2.0 OPERATION

5.000 in

DIAGNOSTICError CodeSensor DataClear MemoryElectric ClampClamp Adjust

A) Maint C) SendB) Job D) Exit

the knife alarm and the lube alarm. The knife alarmdisplays a message to remind the operator to changethe knife. The lube alarm displays a message to remindthe operator to have the machine lubricated. The lubealarm will also display the name and phone number ofthe Challenge dealer from which the machine waspurchased.

There are three functions within the knife countparameter: Clear Count, Knife Alarm, and Clear Lube.Select the desired function and press ENTER. See thefollowing descriptions for an explanation of eachfunction.

Select Clear count to reset the knife counter when aknife change has been performed.

Select Knife Alarm to enter or change the knife strokealarm value. When this value is reached, the displaywill alert you to change the knife and reset the knifecounter. Knife alarm values for the Titan 200 are factoryset at 2,500 cuts. However, you may want to changethis value based on your specific machine applications.See the “Knife Tips” section 3.3 for help in choosing aknife alarm value for your machine.

Select Clear lube to reset the lube alarm afterperforming the lubrication requirements as shown in themaintenance section 4.6. Note: The alarm willactivate after 2,500 cuts. This value is set at thefactory and cannot be changed.

2.12.2.6 Machine count

The number displayed is the total number of cuts madeby the machine.

2.12.3 Diagnostic

The diagnostic area can be very helpful in locating aproblem in the event of a machine malfunction. Use theup and down arrow keys to toggle to the desiredselection, and press ENTER. See the following

descriptions for an explanation of each.

2.12.3.1 Error Code

The Error Code function simply recalls the last five errormessages that were displayed. This can be very usefulin cases when the malfunction can not be reproducedin the presence of the service technician.

2.12.3.2 Sensor Data

The Sensor Data function provides a list of computerinputs and outputs (proximity switches, etc.) along withtheir status (0 for open, 1 for closed). This functionallows a service technician to check the status of aswitch without removing any covers. Cuts andbackgauge movements are allowed in this screen sothat the technician may observe the status of the inputsand outputs during machine operation.

2.12.3.3 Clear Memory

The Clear Memory function resets the memory to aknown state. All cut positions will be erased duringthis operation.

2.12.3.4 Electric Clamp

This function turns the optional electric clamp pressurecontrol on or off.

2.12.3.5 Clamp Adjust

This function allows for the adjustment of the electricclamp function. (See section 4.7.4 HydraulicAdjustments)

2.12.4 Language

In the language screen, use the up and down arrowkeys to toggle to the desired language, and pressENTER. All messages will be displayed in the selectedlanguage.

2.13 JOB MODE (Programmable ModelsOnly)

The Titan 200 can be programmed for up to 99different jobs or channels. A job is used for making asequence of cuts using the send (or cut) values of thejob as the backgauge positions for each cut. Each jobcan hold up to 35 send values. If 2 channels are linked,up to 70 send values can be accessed from one job.When the job mode is entered, all previouslyprogrammed jobs will be displayed along with theirname and lock status. Locked jobs will be indicated




2-7F.200-A/TITAN 200/SEPT 99

2.0 OPERATION

by an asterisk “*”. A plus “+” sign at the bottom of thescreen indicates there are more jobs programmedthan what are displayed. An example of a job modescreen display is shown below.

2.13.1 Lock/Unlocking a Job

In the Job Mode screen, the soft-key “A” will display“Lock” or “Unlock” depending on the current status ofthe job. If a job is locked, an asterisk “*” will bedisplayed to the right of the job name. To change thelock status of a job, simply move the cursor to thedesired job using the up and down arrow keys, andpress the soft-key “A” (Lock/Unlock).

2.13.2 Copying a Job

First, select a job to copy by moving the cursor up ordown to the desired job number and press the soft-key“B” (Copy). “Select Copy to #” will be displayed at thebottom of the screen. Enter a job number for the newjob or move the cursor to an existing job and pressENTER. If the new job is locked, the copy will not beallowed. NOTE: if the new job is not locked, butcontains data, the old data WILL BE LOST.

2.13.3 Erasing a Job

Select a job to erase by moving the cursor to thedesired job. Press The soft-key “C” (Erase). “Clearchannel #” will be displayed, followed by YES or NO.Use the up and down arrow keys to toggle to YES orNO. YES will erase the job, NO will leave the jobunchanged. NOTE: locked jobs can be erased!

2.13.4 Creating a New Job

To create a new job, type in a number that is not alreadyassigned to a job and press ENTER (entering a jobnumber greater than 99 will create job #99). The cursorwill move to the line corresponding to the number youtyped in, prompting you for a job name. If no job name

is desired, simply press ENTER again to begin enteringsend values (see below). To name the job, press theright arrow key to move the cursor to the first characterposition. Enter a character of the alphabet by using theup and down arrow keys to toggle to the desiredcharacter. The numeric keys can be used to enternumbers directly into the job name. When the desiredcharacter is in place, use the right arrow key to move tothe next character position. The job name can be up to10 characters long. A letter can be removed from thejob name by moving the cursor to the undesiredcharacter and pressing the CLEAR key. When finished,press ENTER to save the name and to begin enteringsend values. The screen should now look similar to theone shown next:

2.13.4.1 Entering Send Values

Now enter send values by using any of the followingmethods: 1) Type in the desired value and pressENTER, 2) Press ENTER at a blank line - this will enterthe current position of the backgauge as a send value,or 3) Use the “Cut and Record” feature as describedbelow.

When finished entering send values you may exit thecurrent job by pressing soft-key “B” (Job) to go back tothe job mode screen or soft-key “D” (Exit) to exit tosend mode. Or you may use the current job for cuttingby pressing the down arrow at the last line and followingthe instructions in the “Running a Job” section (pg. 23).

2.13.4.2 Cut and Record

To use this feature, send the backgauge to a desiredposition using the backgauge glide control or by usingSEND, then make a cut. The current backgaugeposition will automatically be entered into the job as asend value. This can be very convenient for setting up aprogram when the actual cut positions are not known.

2.13.4.3 Channel Linking

5.000in # 1

1> _

A) Insert C) EraseB) Job D) Exit

>

1> JOB 12> TESTJOB5>6> BOBS JOB *7> 8.5 X 11 *9>

10>+

A) Lock C) EraseB) Copy D) Exit




F.200-A/TITAN 200/SEPT 992-8

2.0 OPERATION

If more than 35 cut values are needed, 2 channels canbe linked together into one job providing up to 70 cutvalues. This is done automatically when a job is at 35cuts and an attempt is made to add another value. Atthis point, a screen is displayed asking: do you want tolink to the next channel? Use the up or down arrow keyto select yes or no. If no is selected, the last cut will bediscarded and the new value will be inserted. If yes isselected, the last cut will be pushed into the first valueof the next channel, although it will be displayed asvalue 36 of the current channel. If the next channel islocked, linking will not be allowed. NOTE: If the nextchannel is not locked, but contains data, the old dataWILL BE LOST. After 2 jobs have been linked, the linkedjob will be displayed as “^^^^^^^^” and will be locked.

To unlink a job, use the up or down arrow key to point tothe linked job name and press soft-key “C” (Erase).

When finished entering send values you may exit thecurrent job by pressing soft-key “B” (Job) to go back tothe job mode screen or soft-key “D” (Exit) to exit tosend mode. Or you may use the current job for cuttingby pressing the down arrow at the last line andfollowing the instructions in the Running a Job section2.13.6.

2.13.5 Editing an Existing Job

2.13.5.1 Editing the Job Name

The job name can be edited (or added if an existingjob does not have a name) in the job mode screen. Toedit the name, move the cursor down to the desiredjob number by pressing the down arrow key. Thenpress the right arrow key to move the cursor to thedesired character position and edit the character bypressing the up or down arrow keys to toggle betweencharacters of the alphabet. Numbers can be entereddirectly by using the number keys. Pressing CLEARclears the current character. When finished, you mayeither go to the current job by pressing ENTER, or goto a different job, or exit job mode.

2.13.5.2 Editing Send Values

To edit send values of an existing job, start by openingthe desired job from the job mode screen. A job isopened by one of two methods: pointing at the desiredjob with the cursor and pressing ENTER, or by enteringthe job number with the keypad and pressing ENTER.Once a job has been opened, the current job numberwill be displayed in the upper right corner. Note: If thejob is locked, it cannot be edited.

Send values can now be edited by moving the cursor upor down to the desired send value and then typing over

the existing value.

When finished editing the job, you may exit the currentjob by pressing soft-key “B” (Job) to go back to the jobmode screen or soft-key “D” (Exit) to exit to send mode.Or you may use the job for cutting since it is alreadyopen.

2.13.5.3 Inserting Send Values

To insert a send value, press the soft-key “A” (Insert).This moves all send values down and provides a blankline after the current send value. If more than 35 sendvalues are needed, the job can be linked (see ChannelLinking under Creating a New Job, section 2.13.4.3).

2.13.5.4 Erasing Send Values

To erase a send value, press the soft-key “C” (Erase).This will remove the cut value currently being pointed toby the cursor. To backspace over the current sendvalue without removing the line, press the left arrow key.

2.13.6 Running a Programmed Job

To use an existing job for cutting, you must first open itby using one of two methods: move the cursor to thedesired job with the arrow keys and press ENTER, orenter the job number with the keypad and pressENTER. Once a job has been opened, the current jobnumber will be displayed in the upper right corner. Nowpress SEND to move the backgauge to the firstprogrammed position (or send value). Close the frontguard and make a cut. Once the cut is made, thebackgauge will automatically push out the paper (if“push-out” is enabled) and move to the nextprogrammed position. After the last cut in the job ismade, the backgauge will move to the first cut positionof the current job. Pressing SEND at any time duringthe job will send the backgauge to its next programmedposition without making a cut. A plus “+” sign will bedisplayed at the bottom of the screen if more cutsremain in the current job.

2.13.7 Exiting a Job

To exit an open job, press the soft-key “B” (Job) to returnto the job mode screen, or press the soft-key “D” (Exit)to exit to the send mode screen.

2.14 AN EXAMPLE JOB

The following is an example of how to program a jobwhich will be used to make two cuts: one at 8.5” andone at 11”.




2-9F.200-A/TITAN 200/SEPT 99

2.0 OPERATION

1. Turn on the machine and press CLEAR to presetthe backgauge. Press the soft-key “B” (Job) to goto job mode.

2. Type in a new job number and press ENTER.Note: It must be a number that does notcorrespond to an existing job. All existing jobs willbe displayed on the screen (you may have to scrollthrough them to see them all). If you wish toreplace an existing job with the new job, first erasethe existing job by moving the cursor to it andpress the soft-key “C” (Erase). Now type in thenew number and press ENTER. In this example,job #’s 1, 2, 5, and 6 already exist. We will use job# 7 for our new job. Press “7” and ENTER.

3. The cursor will move down to the new job number.At this point, press the right arrow key once tomove the cursor to the first character position.Now name the job “8.5 X 11”. To do this, press “8”on the number key pad. Then press the decimal“.” key and so on. To enter the spaces and theletter “X”, use the up and down arrow keys totoggle through the alphabet and press the rightarrow key to move to the next character position.When the last character has been typed in, thedisplay should look similar to the one shownbelow:

Now press ENTER to begin programming the job.The display should now look similar to the oneshown next:

4. To enter the first send value of 8.5”, simply type in8.5 and press ENTER. The cursor will move tothe second line. Now type 11 and press enter.

At this point, you could exit and save the job bypressing the soft-key “D” (Exit) to exit to sendmode, or the soft-key “B” (Job) to exit back to thejob mode screen. However, lets use this job to cutpaper.

5. Press the down arrow key once. This will removethe blank line 3 and move the cursor to the firstsend value (8.5”). Now press SEND. This willmove the backgauge to the 8.5” position. Placethe paper to be cut against the backgauge, closethe front guard, and press the cut button. Oncethe cut cycle is complete, the backgauge will pushout the paper and move to the next send value(11”). Now position the paper again, close theguard, and make another cut. After the cut ismade, the backgauge will push out the stock andreturn to the first cut position, ready to repeat thecurrent job.

6. Now lets lock the current job so it cannot be edited.First, exit back to job mode by pressing soft-key“B” (Job). Now move the cursor down to the newjob using the down arrow key. Now press the soft-key “A” (Lock) to lock the job. An asterisk will

5.000in # 7

1> _

A) Insert C) EraseB) Job D) Exit

5.000in # 7

1> 8.5002> 11.0003> _

A) Insert C) EraseB) Job D) Exit>

1> JOB 12> TESTJOB5> BOBS JOB *6>7> 8.5 X 11_

+A) Lock C) EraseB) Copy D) Exit




F.200-A/TITAN 200/SEPT 992-10

2.0 OPERATION

appear indicating the job has been locked.

7. To exit back to send mode, press the soft-key “D”(Exit).

2.15 OPERATING TIPS

Carefully lay out each sheet before you start cutting.Find the best cut pattern to give you the most piecesout of the sheet. If the sheet will be folded, be suregrain of the paper is running in the same direction asthe 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 dullblade will pull or draw the paper and cause unevencutting. Increased clamp pressure will not eliminatedraw caused by a dull knife.

The correct clamping pressure varies from paper topaper. The general rule is that you should have enoughpressure to hold the paper securely but not so muchthat it marks the surface of the paper excessively.Excessive pressure causes pile distortion andinaccurate cuts.

Mark the gripper edge and the guide edge of printedpaper and make sure the first cuts are with these guideedges against the backgauge.

Measure printed paper to check for shrinkage orexpansion of the paper from humidity. You may have todisregard the printed cut lines and make your own.

When cutting buisness cards or narrow strips of paper,place lifts of equal height on opposite sides of the tableto prevent wear of the clamp guides.

2.16 NOTE TO DEALER

2.16.1 Entering the Dealer Name and PhoneNumber

To enter or change the dealer name and phone numberthat will be displayed when the lubrication alarm isdisplayed and when the upgrade screen is displayed,you must first enter the “Dealer Mode” screen. To dothis, turn off the power, then simultaneously hold theleft and right arrow keys while turning on the power.Continue to hold the arrow keys for a few seconds afterthe machine turns on. Now enter the desired dealerinformation by using the up and down arrow keys totoggle through the characters (similar to naming a job).Use the right arrow key to move to the next characterand to move to the 2nd line. When finished, turn off thepower.




3-1F.200-A/TITAN 200/SEPT 99

3.0 KNIFE INSTALLATION/CHANGING


The knife changing equipment shown in fig. 3-1 isincluded in the cutter tool kit. The following instructionsshow how to remove and install a new or resharpenedknife. Read through these instructions AT LEASTONCE before attempting to actually change or installany blades.

3.1 KNIFE REMOVAL

1. Make sure the knife and clamp are in the “up”position. Turn the main power switch to the “OFF”position and disconnect the machine power cordto prevent accidental power-up while servicing thecutter.

2. Back off the knife adjusting screws on top of theknife bar several turns (fig. 3-2). A new knife willcut deeper than one that has been ground severaltimes. Failure to back off the screws could damagethe knife and/or the cutting stick.

3. Remove the knife bolts from the two slotted knifebar holes and replace with the knife lifters (fig. 3-3). Tighten the lifters to hold the knife in place,then remove the remaining knife bolts.

4. Clear the table surfaces and place the empty knifescabbard on the table. Remove the scabbard’s kniferetaining screws.

5. Grasp the knife lifters firmly and, at the same time,turn them counterclockwise to release the knife fromthe knife bar (fig. 3-4). Lower the left end first,then lower the right end as you shift the knifesideways to the left. Bring the right end of the knifearound the knife bar guide frame. Maneuver theright end into the space between the guide frameand the shroud as the left end is brought clear ofthe left guide frame. Move the knife to the rightthen bring the knife out of the cutter, left end first.Put the blade in the scabbard immediately andsecure the knife retainer screws.

Knife Adjusting Screws

(fig. 3-2)

(fig. 3-3)

(fig. 3-1)

5/16”T-Wrench

Knife Lifters

Cut StickRemoval Tool

3/16”Hex AllenWrench

CAUTION: Changing knives can bevery dangerous unless safetyprecautions are observed and

extreme care is taken when handling knives.

• Make sure knife lifters are properlyinstalled, see instructions following.

• Keep handling of unprotected knives to anabsolute minimum.

• Clear off cutter table before removingknife.

• Have scabbard on cutter table and insertknife immediately.

• Warn people of any unprotected knife.• Knife changing is a ONE PERSON

OPERATION. Having more than oneperson trying to change knives invitesaccidents.




F.200-A/TITAN 200/SEPT 993-2


3.2 KNIFE INSTALLATION

1. Make sure the knife and clamp are in the up position.If they are not, turn on the power using the red andyellow main power switch, close the front guard,and press the CLEAR button. This will preset thebackgauge and send the knife and clamp up.

2. Turn off the machine and unplug the power cord.

3. Pull out the cutting stick using the cut stick removaltool and turn it to a new surface. If the cutting stickis not level or flush with the table, 1/2” strips ofpaper can be placed in the table slot under thecutting stick to shim it.

4. Remove the left retainer screw from the new bladeand screw the knife lifters into the new blade. Screwthe lifters all the way in and then back them out 3/4 turn).

5. Remove the other scabbard retainer screw.

6. Double check to make sure the knife adjustingscrews have been backed out all the way (step #2,Knife removal). Lift the blade and insert it into theknife bar slot. Guide the blade, right edge first, intothe space between the shroud and the knife barguide frames. Tip to clear the table side guides,then move the left end of the blade into the knife barslot dropping the left end as the right end is brought

around the right knife bar guide frame and up intothe knife bar slot. Raise the knife into the knife barslot as high as it will go and tighten the lifters.

NOTE: If the blade will not go in, either the lifters arescrewed into the blade too far, or the end of the blade ishitting the cylinder bracket at the right end of the knifeslot. In this case, drop the left end when inserting theknife.

7. Insert the knife bolts with washers and snug to holdthe knife, but don’t tighten them yet.

8. Remove the knife lifters one at a time and replacewith 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 turn the power on.

11. Go to the MAINTENANCE screen and chooseKNIFE ADJUST. Choose KNIFE DOWN, close theguard, and press the cut button to send the knife tothe down position (for more details on how to dothis, see section 2.12.1).

12. Turn the power off and disconnect the machine powercord.

13. Turn the knife adjusters down evenly, a little at atime, until the knife cuts through the bottom sheetof paper the entire length of the cutting stick (fig. 3-5). Turning the screws down evenly prevents unevenwear on the knife and cutting stick.

14. Plug in the power cord and turn the power on.

15. Close the front guard and press CLEAR. This willraise the knife and clamp to the up position.

(fig. 3-5)

(fig. 3-4)

CAUTION: Knives are heavy andalways very sharp! Be sure to keepthe edge away from your body and

keep other people out of the area whilehandling the blade. Severe lacerations ordismemberment could result from carelesshandling procedures.




3-3F.200-A/TITAN 200/SEPT 99


16. Turn the power off and disconnect the machine powercord.

17. Tighten all knife bolts securely.

18. Plug in the power cord and turn the power on. Makea test cut through a full lift of paper and make minoradjustments if necessary by repeating steps 9through 17. NOTE: If the knife ends cut but themiddle doesn’t, you could have dips or uneven spotsin the knife and/or cutting stick. These can beeliminated by placing 1/2” strips of paper in the tableslot beneath the cutting stick to shim it.

19. Send the dull knife to a knife grinder. Do not attemptto sharpen your own knives! See the Knife Tipssection 3.3 to determine the knife bevel angle.

3.3 KNIFE CARE TIPS

3.3.1 Knife Blade Life

Knife blade life, or the time between sharpenings, canbe affected by many factors. One important factor isthe type of paper being cut. Abrasive paper, such asrecycled paper, soft paper such as newsprint paper, andbound books can all significantly shorten knife bladelife. Also, if the knife depth is set too deep, the knife willcut too deep into the cutting stick and can dull the knifeblade.

A knife can last anywhere between 2,000 and 5,000cuts 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 needsharpening after only 2,000 to 3,000 cuts. Cutting purepaper, such as bond paper with no recycled content, orhard paper can allow the knife to be used for as manyas 5,000 cuts before it needs to be sharpened. In allcases, the operator should continually check the qualityof the cut to determine when the knife blade needs to

be sharpened. Some characteristics that indicate ablade needs sharpening are:

• The knife hesitates or stalls while making a cut.

• The sheets are not all cut to the same length (usuallythe top few sheets are longer than the rest of thesheets - this is sometimes called “draw”).

• Cut marks appear on the cut face of the paper.

• The profile of the cut (side view) is not perpendicularto the table.

• The cut does not appear straight when viewed fromthe top.

• The knife makes a “rougher” sound as it passesthrough paper.

• Nicks are visible on the cutting edge of the knife.

3.3.2 Cutting Stick

A worn cutting stick can affect the cut quality of thebottom sheets. When this happens, the cut stick canbe rotated. Usually, the stick should be rotated one ortwo times between knife sharpenings.

There are 8 possible cut stick positions. The stick canbe rotated 4 times, then turned end to end, and rotated4 times again.

3.3.3 Bevel Angle

Challenge recommends that bevel angles for the Titan200 knives be in the range of 21° to 23°. In general, a21° bevel angle will provide a better cut quality whencutting soft paper (such as newsprint), recycled paper,or bound books. However, 21° angle knives can becomedull sooner than 23° knives, which results in shorterknife blade life. A knife with a 23° bevel angle, on theother hand, will not dull as easily, and can providesatisfactory results when cutting most types of paper.Knives shipped with the Titan 200 from the factory havea bevel angle of 23°.

3.3.4 Helpful Suggestions

• If your shop is large enough to purchase more thanone set of knives, have one set beveled at 21° andthe other at 23°. Note: A set consists of 3 knives:one in the machine, one as a back up, and one atthe grinder.

• If the machine seems to strain but the cut quality isstill good, reduce the pile height. You may also

CAUTION: ! KNIFE SAFETY ! Knivesare DANGEROUS!!! They are heavyand very sharp, even after use. Keep

the edge away from your body and keep thearea clear of others when handling knives.Never touch the cutting edge! To preventpersonal injury and damage to the knife,always keep knives in their holders with screwstightened. You are aware of the dangers, butothers may not be. Never attempt to hone,polish, or service the knife in any way. Failureto follow safety procedures may result in severelacerations or dismemberment.




F.200-A/TITAN 200/SEPT 993-4


carefully apply glycerin to the bevel when cuttinghard, coated paper. Tie a cloth to the end of astick; dip the stick in glycerin, and apply. Neverapply by hand! In lieu of glycerin you may lightlyrub white bar soap along the bevel. Lubrication willprolong the life of your machine and reducemaintenance.

3.3.5 Knife Care

• To prevent corrosion, knives are coated with lightoil. It should be REMOVED WITH CARE.

• While removing or installing a knife, be careful notto 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 washersprovided by Challenge. Failure to do so could resultin scratching or marring of the clamp face.

• Store knives in a dry environment to preventcorrosion.

• Never attempt to service a knife in any way.




4-1F.200-A/TITAN 200/SEPT 99

4.0 MAINTENANCE

NOTICE

The instructions on thefollowing pages are for the

use of trained servicepersonnel only!

Attempting to performrepair and replacement

procedures without propertraining may cause machinedamage or operator injury!

PARTS CUSTOMERS: The Challenge Machinery Company provides parts with the express under-standing that they are to replace parts found missing or no longer serviceable on equipment designedand/or manufactured by Challenge. The Challenge Machinery Company assumes no liability for anymodification or alteration to any Challenge products, and any such modification or alteration to anyChallenge products is not authorized by The Challenge Machinery Company. Any modification oralteration of any Challenge product will void any remaining warranty.

4.0 MAINTENANCE




F.200-A/TITAN 200/SEPT 994-2

4.0 MAINTENANCE

4.1 TROUBLESHOOTING

WON’T STARTFuse Blown.Power cord disconnected.Main power switch not turned on.

BACKGAUGE DISPLAY INACCURATEPreset circuit board malfunction.Encoder malfunction.Main circuit board malfunction.Thrust washers are loose.

BACKGAUGE DISPLAY INACCURATE - BYCONSTANT AMOUNTBackgauge needs accuracy adjustment.Presetter malfunction.

CUT BUTTON PUSHED - WON’T CUTCheck error codes.Guard open.Guard hasn’t been opened since last cut.Hydraulic fluid low.Main relief valve setting off.Sequence pressure set wrong.Button defective.Motor relay defective.Knife latch solenoid defective.Knife down coil defective.Cylinder or hose(s) leaking.Cylinder disconnected from cylinder bracket.Knife bar dirty or dry, lubricate knife guideways.Dirt in hydraulic system.

CLAMP STARTS UP BEFORE KNIFE IS UPClamp Up Sequence Valve setting incorrect.

CONCAVE CUTTING - ENDS WIDE, CENTERNARROWExcessive moisture at edges of paper.

CONCAVE CUTTING - VARIATION FROM TOP TOBOTTOMSoft paper not firmly clamped.Knife dull or incorrectly grounded.

ERRATIC OPERATION-POWER LOSSHydraulic fluid low.Dirt in hydraulic system.Cylinder or hoses leaking.Voltage supply is low.

KNIFE DRIFTS DOWNKnife latch not engaging or damaged.

KNIFE HESITATES OR STALLSDull knife.Main relief valve setting off.Paper clamped too tight - lower clamp pressure reducersetting.Cylinder seals worn - leaking pressure.Hydraulic fluid low.Voltage supply is low.

KNIFE STARTS DOWN BEFORE CLAMP REACHESTABLEKnife down sequence valve setting incorrect.

KNIFE WON’T RETURN UPSolenoid defective.Limit switch out of adjustment.Cylinder disconnected from bracket.

PUMP-MOTOR WON’T SHUT OFFKnife/Clamp Up Limit switch not activated - readjust.Motor relay contacts welded.




4-3F.200-A/TITAN 200/SEPT 99

4.0 MAINTENANCE

4.2 ERROR MESSAGES AND DESCRIPTIONS

Message Description Test

Knife Latch Failure Latch failed to disengage knife bar Loose solenoid wire; mechanicalwithin .6 seconds. bind; knife up prox. switch out of

adjustment; defective prox. switch

Clamp Up Failure Clamp failed to retrun to up position Clamp up sequence valve; solenoidwithin 7 seconds (cut) valve

Knife Down Failure Knife failed to come down within 4 Low main pressure; low voltage;seconds knife down sequence valve

Knife Up Failure Knife failed to return within 1.17 mechanical bind; solenoid (cut)seconds valve

Clamp or Knife Down Clamp or knife stayed down No main pressure; stuck solenoidvalve

Sequence Error Timing error in either up or down Low main pressure; any sequencecycle valve

Knife at Both Limits Knife up and down prox. switches Prox. switches; broken knife barare on at the same time components

Send Cancelled Console key was pressed while Operator error; key board failurebackgauge was moving.

Number Outside of Limit Selected cut position beyond Operator error; false clamp limit

Positioning Error Backgauge failed to move to pro- Mechanical bind; encoder failure;grammed position within +/- .005 main pcboard; leadscrew thrust

washers loose

Hydraulic Latch Failure Hydraulic latch holding relay failed Defective relay; safety hood switch-to pull in. es defective or need adjusting.

Backgauge Failure Backgauge doesn’t move Mechanical bind; encoder failure;main pcboard; blown fuse

Shorted Key Error Console key held in for over 90 Operator error; defective keyboardseconds

NOTE: ERRORS CAN ONLY BE RESET BY TURNING THE POWER OFF AND ON




F.200-A/TITAN 200/SEPT 994-4

4.0 MAINTENANCE

4.3 SENSOR DATA ABBREVIATIONS

4.4 ROUTINE MAINTENANCE

Place this machine on your plant maintenanceschedule. A clean, lubricated machine will run longer,smoother, cut more accurately, with less downtime andfewer costly repairs. Schedule lubrication both earlyin the day and early in the week. This allows thelubricants to work into the machine. Lubrication at theend of the day or week allows the lubricants to run offwithout any benefit to the machine. The followingguidelines will help you set up a regular maintenanceschedule:

Abbreviations Standby Description Location

RHSAFE 0 Right Safety Switch Inside right of front coverLHSAFE 0 Left Safety Switch Inside left of front coverKNFLAT 1 Knife Latch Proximity Switch Left side of cutter openingHYDLAT 1 Hydraulic Latch Relay Main pcb boardKNFDWN 1 Knife Down Proximity Switch Inside of cutter opening, right sidePRESET 1 Preset Sensor Rear of cutter, under left side of tableCUTSOL 0 Cut Valve Solenoid Valve on left side of ManifoldUNLOAD 0 Unload Valve Solenoid Valve * (not in use yet)KNLATSOL 0 Knife Latch Solenoid Inside of cutter opening, left sideCLAMPUP 1 Clamp up Proximity Switch Inside rear of cutter opening, left sideHYDUP 1 Hyd. Clamp Up Proximity At bottom of clamp cylinderKNFUP 1 Knife Up Proximity Switch Inside of cutter opening, left sideCUTBTN 0 Cut Button On display consoleN.C. 0 No ConnectionHYDMOT 0 Hydraulic Motor Relay Top right side of main pcbN.C. 0 No ConnectionLTLINE 1 Line Light Output Inside rear cutter opening, left sideCBTNLIT 0 Cut Button Light In display console

CAUTION: DISCONNECT POWERbefore making any adjustments orlubricating. See page 4, SAFETY

PRECAUTIONS, for Power Lockout Procedure.

4.4.1 Weekly

Clean — Clean off old, dirty excess grease. Removethe front panel cover and clean accumulated dust offvalves, hoses and connections. Built-up dust increasesoperating temperatures which causes premature wearto all hydraulic components.

Hardware — Remove front panel cover, rear panelcover, and top hood to check all nuts and bolts fortightness. Loose hardware is the cause of mostcomponent wear and in the electrical area could causeshort circuits and/or shock.

Hydraulic Fluid — Low fluid level causes excessiveheat and wear on the system. Check the fluid level asdescribed in section 4.5 below.




4-5F.200-A/TITAN 200/SEPT 99

4.0 MAINTENANCE

Oil and Grease — See section 4.6

4.4.2 Monthly

Proximity Switch Adjustment — See section 4.7.3.

Backgauge Squaring — See section 4.7.2.

4.4.3 Yearly

Change Hydraulic Fluid — See section 4.5.

4.5 CHECKING/CHANGING THEHYDRAULIC FLUID

The hydraulic fluid level should be checked weekly.To check, remove the lower rear cover and unscrewthe cap on top of the tank (fig. 4-1). Fluid level shouldbe at 1/8” from the end of the dip stick (check with dipstick cap screwed in). Add fluid if neccessary but avoidoverfilling as this could cause leakage when hot.Replace the rear panel when finished.

The hydraulic fluid should be changed AT LEASTONCE-A-YEAR or after every 1,000 hours of operation.NOTE: Failure to change oil when needed can damageseals in the cylinders, pump, and valves.

Empty the hydraulic tank and refill with 1 gallon ofInternational Standards Organization Viscosity Grade100 (ISO VG 100) rust, oxidation, and foam inhibitinghydraulic fluid (Challenge part no. S-1991).

NOTE: NEVER use automatic transmission fluid orbrake fluid as a substitute for the correct hydraulic fluid.A table of various manufacturers and their equivalentsis listed below.

4.5.1 Recommended Hydraulic Oils

Oil Name DistributorRykon No. 100 AMOCODuro AW Oil 465 ArcoAW Machine Oil 100 ChevronPacemaker XD No. 100 CitgoSuper Hydraulic 100 ConocoNuto H-100 ExxonHarmony 100 AW GulfHO 2A Hydraulic Oil LubriplateDTE No. 18 MobilPennzoil AW 100 PennzoilMagnus A Oil 215 PhillipsTellus 100 ShellEnergol HLP 100 SohioIndustron 100 Std. Oil

Indiana/BoronSunvis 851 WR Sun Oil Co.Rando HD 100 TexacoUnax AW 100 Union Oil Co.

4.6 OIL AND GREASE

Turn the power off and disconnect the power cord. Openthe front guard (if equipped) and open the top hood foraccess. Parts requiring oiling are marked with redpaint. See figures 4-2 to 4-9 for oil and greaselocations. Figures 4-2 to 4-4 require the knife and clampbe in the up position. Figures 4-5 to 4-9 require theknife and clamp be down. Wipe off any old or excessgrease. Use any brand-name type of grease or lightoil to lubricate. It may be necessary to use the suppliedgrease brush to access some locations. Note: theleadscrew may be lubricated with grease or oil. Oilhas a tendency to run off and must be lubricated morefrequently; grease tends to collect paper dust and mustbe cleaned off periodically.

Dipstick

(fig. 4-1)

CAUTION: Use one of therecommended oils or an ISO VG 100Hydraulic Fluid equivalent only. Oils

other than the recommended type will causeseals and O-rings to deteriorate. Unsafeoperating conditions will result.




F.200-A/TITAN 200/SEPT 994-6

4.0 MAINTENANCE

Knife Bar Link - Right Side, LowerKnife Bar

Knife Cylinder Bracket, Upper (fig. 4-6)

Clamp Guide (fig. 4-7) Clamp Guide (fig. 4-8)

Knife Bar Link - Left Hand Side, Upper (fig. 4-2)

Grease Oil

Knife Bar (fig. 4-4)

Knife Bar Link - Right Hand Side, Upper (fig. 4-3)

Knife Bar Link - Left Hand Side, Lower(fig. 4-5)




4-7F.200-A/TITAN 200/SEPT 99

4.0 MAINTENANCE

4.7 ADJUSTMENTS

4.7.1 Backgauge Gib Adjustments

If the backgauge does not stay squared or jumps upand down when jogging paper against it, the backgaugegib screws are probably loose or worn.

To Adjust:

1. Send the backgauge near the rear of the table.

2. Turn off the power and disconnect the power cord.

3. Remove the leadscrew cover under the table.

4. Loosen the two side gib screws and the bottomnylon guide screws (fig. 4-10).

5. Tighten the bottom, nylon guide screws until theyjust touch the guide. Do not overtighten or theycould cause the backgauge to bind.

6. Similarly, turn the side gib screws in until they justtouch the guide. Lock in position with the jam nuts.

7. Run the backgauge back and forth the length ofthe table using the backgauge glide control. Checkfor any binding. Readjust if necessary.

NOTE: The screws should be tightened to hold thebackgauge square against the guide rail. Excessivetightening will cause the backgauge to bind and causepremature wear of all components.

4.7.2 Squaring the Backgauge

To test if the backgauge is square, place a small lift ofpaper against the left side of the backgauge (but notagainst the side guide) and make a cut. Now, leavethe backgauge in the same position, flip the lift overand push it against the right side of the backgauge(but not against the side guide). Make another cut tosee if any of the paper will trim off. Run two checks,one starting on the left and moving to the right. Theother, moving from the right to the left. If paper istrimmed in either sequence, the backgauge is out ofsquare.

1. Make sure the backgauge gibs are set properly(see section 4.7.1).

NOTE: Gib adjustments are not necessary on initialmachine setup as gibs have been adjusted at thefactory.

2. Remove the rear plexiglass table cover.

3. Loosen the two backgauge screws (fig. 4-12).

4. Place a 90° square or triangle against thebackgauge and left side guide. Square the

Gib Screws

Nylon GuideScrews

(fig. 4-10)Leadscrew and Backgauge Guide (fig. 4-9)

(fig. 4-11)

PAPER PAPER

CAUTION: Several of the followingtests require the machine to be opera-tional for checking and adjusting. Be

very careful that tools and other people are clearof moving parts and that the cutter is not acci-dentally operated while adjustments are beingmade. Whenever working on the machine, dis-connect the power and lock it out (see SAFETYPRECAUTIONS, page viii) unless the directionsspecifically require the machine to be powered.




F.200-A/TITAN 200/SEPT 994-8

4.0 MAINTENANCE

backgauge, hold it in place, and tighten the twoscrews.

Note: Once the backgauge is square, restore powerto the machine and check the backgauge accuracy (seesection 2.12.2.4) to make sure it is accurate.

4.7.3 Proximity Switches

Proximity switches are used to inform the computer ofthe up and down positions of the knife and clamp. Theydo not determine the stopping positions of the knifeand clamp, and therefore rarely need to be adjusted.However, if a proximity switch is not sensing the knifeor clamp position correctly, it may need adjustment.

To check if the four proximity switches are sensingcorrectly, go to Maintenance Mode and selectDiagnostic. Then select Sensor Data, and a list ofabbreviations for several inputs and outputs will belisted, along with their status (0 for open, 1 for closed).The four proximity switches should have the followingstatus during the various knife and clamp positions:

Knife Up Knife Up Knife Up Clamp Down Clamp Down Knife DownClamp Up (Manually) (Hydraulically) Clamp Down

Knfdwn 1 1 1 0Clampup 1 0 0 0Knfup 1 1 1 0Hydup 1 1 0 0

If any of the four proximity switches has a status of 0when it should be 1, adjust the switch as describedbelow.

Knife Down Proximity Switch (Knfdwn)

Make sure the clamp and knife are in the up position.Turn the power switch off and disconnect the powercord. Open the front guard and the top hood.

(fig. 4-13)

MountingScrews

(fig. 4-12)

backgaugescrews

Adjust the knife down proximity switch (fig. 4-13) byloosening the two mounting screws and sliding theswitch closer to the knife bar. The gap between theproximity switch and the knife bar should be 1/32” to 1/16” (0.5 to 1.5 mm). No vertical adjustment is necessary.

Clamp Up Proximity Switch (Clampup)

Make sure the clamp and knife are in the up position.Turn the power switch off and disconnect the power cord.Open the front guard, the top hood, and the upper rearcover.

Adjust the clamp up proximity switch (fig. 4-14) byloosening the two actuator mounting screws and slidingthe actuator up or down. The gap between the actuatorand the proximity switch should be 1/32” to 1/16” (0.5to 1.5 mm).

Knife Up Proximity Switch (Knfup)

Make sure the clamp and knife are in the up position.

(fig. 4-14)

Actuator




4-9F.200-A/TITAN 200/SEPT 99

4.0 MAINTENANCE

(fig. 4-15)

MountingScrews

Gauge

2

1

3

4

(fig. 4-17)

(fig. 4-16)

MountingPlate

HoseClampScrews

ActuatorPlate

Turn the power switch off and disconnect the powercord. Open the front guard and the top hood.

Adjust the knife up proximity switch (fig. 4-15) byloosening the two mounting screws and sliding theactuator up or down. The switch should be adjustedsuch that it senses the knife bar at the very top of itsstroke only. The gap between the switch and the knifebar should be 1/32” to 1/16” (0.5 to 1.5 mm).

Hydraulic Clamp Up Proximity Switch (Hydup)

Make sure the clamp and knife are in the up position.Turn the power switch off and disconnect the powercord. Remove the lower front panel.

Adjust the hydraulic clamp up proximity switch (fig. 4-16) by loosening the two hose clamp screws and slidingthe switch plate up or down. The gap between theswitch and the actuator plate should be 1/32” to 1/16”(0.5 to 1.5 mm).

4.7.4 Hydraulic Valve Adjustments

Note: When adjusting valves, first loosen the jam nutaround the stem, then use a hex allen wrench to turnthe stem clockwise to increase pressure, orcounterclockwise to decrease pressure.

4.7.4.1 Pressure Settings:

1. Main System Relief Pressure — 1,400 psi.2. Knife Down Sequence Pressure — 900 psi.3. Clamp/Knife up Sequence Pressure — 600 psi.4. Clamp Pressure Reducer — 400-800 psi.

4.7.4.2 Adjustment Procedure:

1. Remove the lower front cover panel.

2. Loosen the locknut and turn the clamp pressurereducer valve (item 4, fig. 4-17) all the way in(clockwise). (Note: If your machine is equippedwith the optional electronic clamp control valve, youwill have to enter the Maintenence Mode and choseKnife Adjust, Knife Down. This will close theelectronic valve allowing you to read the Main Sys.and Knife Down pressures.)

3. MAIN SYSTEM RELIEF PRESSURE: Make a cutand read the pressure on the gauge when the knifeis bottomed on the table. Adjust the main systemrelief valve (item 1, fig. 4-17) if necessary to obtaina 1,400 psi reading.

4. KNIFE SEQUENCE PRESSURE: Begin a cut cycleand read the pressure from the gauge as the knifeis traveling down (after the clamp reaches the table).The pressure should read 900 psi. If necessary,




F.200-A/TITAN 200/SEPT 994-10

4.0 MAINTENANCE

adjust the knife sequence valve (item 2, fig. 4-17) toobtain the proper reading.

5. CLAMP/KNIFE UP SEQUENCE PRESSURE:Activate a cut cycle and read the pressure after theknife has returned up and while the clamp is movingup. The pressure should read approximately 600psi. If necessary, adjust the clamp up sequencevalve (item 3, fig. 4-17) to obtain this pressure. If,during a cut cycle, the clamp will not stay downuntil after the knife returns completely to the upposition, re-adjust the clamp up sequence valve untilthis happens.

6. CLAMP PRESSURE: Adjust the clamp pressurereducer (item 4, fig. 4-17) to the desired setting. Itis factory preset at 800 psi. Read the gauge withthe clamp down and as the knife begins to movedown.

Note: When cutting pressure sensitive paper, you maywant to reduce the clamping pressure (400 psiminimum) to prevent marking the paper.

4.7.4.3 Optional Electronic Clamp Pressure ControlAdjustment

The electronic clamping control option allows theconvenience of changing the clamp pressure at thecontrol console. The pressure is controlled by use ofthe up and down arrow keys, 0 being the lowest - 15the highest; and is indicated in the upper right handcorner of the display.

Note: To turn the electronic clamp control option on oroff, enter the Maintenance Mode and choose Diagnostic.Then choose Electric Clamp and select “ON” or “OFF”.

To adjust the actual clamp pressure maximum andminimum, first make sure the Electric Clamp option isset to “ON” (see above paragraph). Enter theMaintenance Mode and choose Diagnostic. Then

choose Clamp Adjust, and the following screen shouldbe displayed:

Now perform a cut cycle. After the clamp has contactedthe table and while the knife bar is coming down, readthe pressure on the right hand pressure gauge. It shouldread 800 psi. If it does not, correct by using the up anddown arrow keys. When finished, press soft-key “D” toexit and go to the minimum pressure set up screenshown below:

Perform a cut cycle. After the clamp has contacted thetable and while the knife bar is coming down, read thepressure on the right hand pressure gauge. It shouldread 400 p.s.i. If it does not, correct by using the upand down arrow keys. When finished, press soft-key“C” to return to Send Mode, or soft-key “D” to return toDiagnostics.

4.8 CLEANING

Before cleaning inside machine, turn off and lockoutpower, pg. viii.

Hydraulics

1. The vent fan should be wiped off weekly to maintainmaximum cooling of the hydraulic system.

5.000 Set Minimum >

Press /\ to Increase

Press \/ to Decrease

A) Main C) Send B) Job D) Exit

5.000 Set Maximum >

Press /\ to Increase

Press \/ to Decrease

A) Main C) Send B) Job D) Exit

CAUTION: DO NOT set the clamppressure below 400 psi. Severelacerations or dismemberment could

result! The knife and clamp system losessequence at settings below 400 psi and theknife could come down before the clamp.




4-11F.200-A/TITAN 200/SEPT 99

4.0 MAINTENANCE

2. The hydraulic manifold, fittings, and hoses shouldbe wiped off weekly to maintain maximum cooling.Remove then replace panels as necessary.

Table

1. The front table should be wiped down periodically.Use a non-abrasive cleaner along with a protective wax.

2. The rear table cover and front guard may be cleanedwith glass cleaner or a mild water based detergent.Some petroleum based solvents may damage theplexiglass.

Console

1. The console should be cleaned with a mild waterbased detergent applied to a damp cloth or paper towel.Petroleum based solvents will damage the console.

Machine Exterior

1. The machine’s exterior should be cleaned with anon-abrasive water based detergent applied to a dampcloth.

2. Always be careful when cleaning around safetywarning labels. Use limited amounts of cleaners in thoseareas.




F.200-A/TITAN 200/SEPT 994-12

4.0 MAINTENANCE

NOTES




5-1F.200-A/TITAN 200/SEPT 99

5.0 PARTS LIST & SEQUENCE OF OPERATIONS

5.0 PARTS LIST AND SEQUENCE OF OPERATIONS

MAIN ASSEMBLY - FRONT VIEW ......................................................................... 5-2MAIN ASSEMBLY - RIGHT SIDE VIEW .................................................................. 5-4MAIN ASSEMBLY - TABLE ASM. VIEW ................................................................. 5-6HYDRAULIC POWER UNIT (S/N 971156 & BELOW) .............................................. 5-8HYDRAULIC POWER UNIT (S/N 971157 & ABOVE) ............................................... 5-9HYDRAULIC MANIFOLD ASSEMBLY AND SCHEMATIC....................................... 5-10HYDRAULIC SEQUENCE OF OPERATION .......................................................... 5-11POWER PANEL ASSEMBLY ............................................................................... 5-12BASIC MACHINE SCHEMATIC ............................................................................ 5-14ELECTRICAL SEQUENCE OF OPERATION......................................................... 5-15CONTROL CONSOLE ASSEMBLY ....................................................................... 5-16CONTROL PC ASSEMBLY .................................................................................. 5-17KNIFE LATCH ASSEMBLY (S/N 981341 & BELOW) ............................................. 5-18KNIFE LATCH ASSEMBLY (S/N 981342 & ABOVE).............................................. 5-19LINE LIGHT ASSEMBLY ...................................................................................... 5-20CUT BUTTON ASSEMBLY ................................................................................... 5-21POWER PANEL LABEL ...................................................................................... 5-22TITAN 200 FLOOR PLAN ..................................................................................... 5-24SAFETY SYSTEM TESTS ................................................................................... 5-25




F.200-A/TITAN 200/SEPT 995-2


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MAIN ASSEMBLY - RIGHT SIDE VIEW43000 SHEET 2 OF 3 REV. M




5-5F.200-A/TITAN 200/SEPT 99


MAIN ASSEMBLY - RIGHT SIDE VIEW43000 SHEET 2 OF 3 REV. M




F.200-A/TITAN 200/SEPT 995-6


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5-11F.200-A/TITAN 200/SEPT 99


HYDRAULIC SEQUENCE OF OPERATIONNOTE: PLEASE SEE THE SECTION ON ELECTRICAL SEQUENCE OF OPERATION FOR MORE DETAILS

HYDRAULIC SEQUENCE OF OPERATION HYDRAULIC SCHEMATIC REFERENCESDRAWING NUMBER: HH-476-1

A. Pump relay is energized providing power to thehydraulic motor.

B. Energize the CUT Solenoid.(Knife and Clamp are sent down).

C. De-energize the CUT Solenoid.(Knife and Clamp are sent up).

The hydraulic motor is first run with the CUT solenoid(Item #5) de-energized so that both the clamp and knifewill be in the extreme up position. When the electronicssense that both the clamp and knife are up and theknife latch is pulled in, the CUT solenoid (Item #5) willbe energized.

When the CUT solenoid (Item #5) is energized, oil willflow freely to the knife down (KD) cylinder port and throughthe pressure reducing valve (Item #4) to the clamp downcylinder port (CD). Since oil is restricted by the knifesequence valve (Item #3) and blocked by a check valve(Item #2), the knife will stay up, and the clamp will startdown. When the clamp stops downward motion, thesystem pressure will rise. Pressure in the clamp downline will level off to the setting of the pressure reducingvalve (Item #4). The system pressure will continue torise until the knife sequence pressure valve (Item #3)opens allowing the knife to come down. The knife willcontinue down until the cylinder reaches the extreme ofits travel. System pressure will increase until the mainsystem relief valve trips (Item #11). At this time, theelectronics will sense that the knife is down, and de-energize the CUT solenoid.

With the CUT solenoid de-energized, oil flow is directedto the knife up cylinder port (KU) and the clamp upcylinder port (CU). Since the clamp down port (CD) isblocked by a check valve (Item #2) and the clamp upsequence valve (Item #1), the clamp will stay down whilethe knife goes up. When the knife reaches the upextreme, system pressure builds until the clamp upsequence valve (Item #1) opens and allows the clampto go up. System pressure will increase until the mainsystem relief valve trips (Item #11). At this time, theelectronics will sense that the knife and clamp are up,and de-energize the pump relay (M).




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5-15F.200-A/TITAN 200/SEPT 99


ELECTRICAL SEQUENCE OF OPERATIONNOTE: PLEASE SEE THE SECTION ON HYDRAULIC SEQUENCE OF OPERATION FOR MORE DETAILS

ELECTRICAL SEQUENCE OF OPERATION ELECTRICAL SCHEMATIC REFERENCESSCHEMATIC DRAWING NUMBER: E-2771-1(MSL = MACHINE SCHEMATIC LOCATION)

A. Turn Main Disconnect switch to “on” position(MSL=1O).

B. Press CLEAR key on the keyboard to direct thebackgauge forward through the presetter.

C. Backgauge control via keyboard.

D. Make a cut by closing the guard and pressing thecut button.

If fuses F3 and F4 are conductive, power is brought tothe main control board (EE-2807 MSL=27R,4AH). Theline lights (MSL=10K, 12K) will illuminate. Power isalso brought to the circuit board. Fuse F1 and F2(MSL=15R, 16Q) are located on the main control boardin the power panel. If fuse F2 is conductive, power willbe supplied to the logic on the board. If the logic isfunctioning, the operator’s console display will illuminate.If fuse F1 is conductive, power will be supplied forbackgauge movement.

To coordinate the console display with the actualbackgauge position, the backgauge must be broughtforward through the presetter. When the backgaugeposition reaches approximately five inches, thepresetter, (MSL=25L) located beneath the table, isactuated. The display will then count up and downfrom this point as signals are received from theincremental encoder (MSL=27L). For generalbackgauge information see C below.

The backgauge control (MSL=20AQ) on the keyboardis used to manually control the backgauge position.The speed of the backgauge motor will depend uponwhere the actuator is pressed. The backgauge controlacts as a potentiometer which controls the voltage thatis sent to the backgauge motor. If the backgauge motorfails to move, the following should be checked: TheCLAMP UP prox (IN 2, MSL=19Y), the HYD UP prox(IN 3, MSL=21Y), and the KNIFE UP prox (IN 4,MSL=22Y) should all be on.

When the front guard is closed, contacts for the left (A,MSL=17X) and right (B, MSL=18X) safety interlocksclose. The CUT BUTTON light (MSL=17K) will light up,indicating that the machine is ready to cut. When theCUT button is pressed, the hydraulic motor relay (PUMPRELAY, MSL=18K) will energize, and power will bebrought to the hydraulic motor. The KNIFE LATCHsolenoid (MSL=16K) will energize and the knife latchwill pull in. CUT solenoid A (MSL=20K) will energize,and the machine will make a cut. When the knifereaches the down position, the KNIFE DOWN prox (IN9, MSL=26Y) will open, which, after a slight time delay,causes the logic to de-energize the CUT solenoid,bringing the knife and clamp to the up position. Whenthe clamp reaches the up position, the HYD UP prox(IN 3, MSL=21Y) will close, which causes the logic tode-energize the hydraulic motor relay, and the hydraulicmotor will stop.




F.200-A/TITAN 200/SEPT 995-16


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F.200-A/TITAN 200/SEPT 995-18


KNIFE LATCH ASSEMBLY (S/N 981341 & BELOW)41120-1 REV. A




5-19F.200-A/TITAN 200/SEPT 99


KNIFE LATCH ASSEMBLY (S/N 981342 & ABOVE)41120-3 REV. A




F.200-A/TITAN 200/SEPT 995-20


LINE LIGHT ASSEMBLYEE-2779 REV. B




5-21F.200-A/TITAN 200/SEPT 99


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5-23F.200-A/TITAN 200/SEPT 99


Fuse Value and Function

Location Fuse Value/Type Circuit Transformer/Voltage Dimension

F1 2A - T Backgauge motor 230 VAC 5mm x 20mmF2 3.15A - T Pcb output T1. Secondary 5mm x 20mmF3 5A - T Line lights 12 VDC 5mm x 20mmF4 10A - T Main - Hot 230 VAC 13/32” x 1 1/2”F5 .5A - T 5V - logic, preset, T2 Primary 1/4” x 1 1/4”

encoder/15v - prox.F6 1.25A-T 12v, 24v Pcb outputs T1 Primary 1/4’ x 1 1/4”F7 10A - T Main - Neutral 230VAC 13/32” x 1 1/2”FL 5A - T Backgauge motor 230 VAC 5mm x 20mm

T= Time Delay Fuse

NOTE: Titan 200 cutters s/n 991733 and below donot have FL fuse.




F.200-A/TITAN 200/SEPT 995-24


TITAN 200 FLOOR PLAN43000-FP




5-25F.200-A/TITAN 200/SEPT 99


SAFETY SYSTEM TESTS

Machine manufacturer CHALLENGE Model TITAN 200

Serial Number __________________

Frequency of test: THESE TESTS SHOULD BE PERFORMED AT THE BEGINNING OF EACH WORK DAY.

Turn the power on and press CLEAR to preset the backgauge. Make sure the knife and clamp are in the upposition (if they are not, follow the instructions in this manual to send them up).

Test #1: With the front guard open, press the cut button. Nothing should happen. If the knife and/or clampcomes down with the front guard open, do not use the machine. Repair or adjustment is needed.

Test #2: Close the front guard and press the cut button. While the clamp or knife is coming down, open the frontguard. The knife and clamp should immediately return to the up position. If they do not, do not use the machine.Repair or adjustment is needed.

Please enter date and initials for both tests.

Date ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Test 1 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Test 2 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Date ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Test 1 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Test 2 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Date ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Test 1 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Test 2 ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______

Initials ofRepairs Repairer Date_________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ _____________




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