Technical Manual

Challenge

Titan 200

Paper Cutter

The Challenge Machinery Company

Grand Haven. MI 49417-1594 USA

TM. 200-A

March 2000

INTRODt'CTION The information contained in this document is intended solely for Challenge trained service technitiaes.There may be situations that are not covered by this manual.Ihe information contained iu this manual is to guide a technician to possible repair solutions. 'l'his manual is to be used in conjunetian w ith the TITAV 20l instruetion anud parts smanual PN F-2nl (-A).

Table Of Contents

TABLE OF CONTENTS. GENIRALINFORVATION.

Ielic'Tric'Ai.Speific'Ations

Machinediminsions

Jitavmainboarid Rlisions

Clampidampenerassemblymohnirlvision

MANE:AI. MISPRINT.

Single(Utrltionriyision

Hy Ir All Icp Lmp Revision

MANIFOLDSLAI.REVISHON.

Backgalgefl.Se Revision

Front Gl Arid In Teri Ock Switch Revision

GENERAI.IYTRAILK INI ARMATION.. IYDRAULIC FLUICIIANE. PRESSURE Ci AGE....

Uoperaturseitingclamppressure

PRI LIM IN ARY VAI VE SEIJIN.

Valve Information

SOITWAREREISHONS.

Frrorcosdescriptions. .10

Errr Messagesihaidnirlquireaflok'Chart

Error Messages That Rlqure Aflow'Ciari

Sensordataabbreviationsandmfanings

Testing Down Valve Coil Magnitisv

Jstingany Hyidrallicai.Ve Spool Operatjion

SEQETNCEOF AILISTING HYDRALLICPRLSSLRLS..

Testingand Adi[Istingprox Siasor

Maataliyactiatingthehyirauiicmotor 14

Testeng And Repair Of Backgaige Rrake Resistor 14

Tes I Eng Encoder

Testingencoderbackgaglaccuracy

Testing Esc Oder Cable

Testinginplt<Onmaincirct:Jt Hoard 15

Installationandaduistmentsforoftheknifelatchassembly:. .16

Test Back Gla Lar Maturi

Irontglardinterlokswithadjlstmeni

TISTING AND MANLALLYACTIVATINGKEYBOARID.

Ee-X07 Main Board

B.ASIC MACHINE SC'HEMATTC'..

Basic hydraulic schemaric. (HAMPIONn:I TITAN CON SOL PROGRAM MAP Hyadtaulie Motor didn't sant... Posiionng crrur... lampKmfe dow:

lamp sluk l n... Slow backyauge mn rmen: to end uftle Hycriulic up tailurc. Knife dow n fa:ure. Knife at buh limits...

Baickyauge fulure.

Keite lateli Failure '. K-ife latch failure Il..

Single Operator

Do not operate with morc than uonc person.

Shock Hazard

Disconnecl power before retuoving cover. Replace coser before operation

Shock Hazard

Disconnccl power beture removing covcr. Rcplace covcr hctore operalion

Hazard Area

Disconuect power before cleaning, ser:icing or making adjustmcnts not rcquiring pow er. Do nol alter satety guards ot dleviccs, thcy arc for your prolcction. Replace all guards. do not opcrate with any guards renoved.

When inage Matters.

General Information

El.Ectricai.Speihications

6-1 SR o h-tR receptacle. The proper n ay test snllaye is from hefirre powet up througli a complete cycle. The voltage smus1 be lestec al 1he

Jow tollage Tccord function. A lou cualt me'sr will no rcspond fas1 enouga lo g3e

vollage r the cutter uill blow he rmair fscs.When the toitage drops. the D+ac solenoids mcSdc(compute)wi'Ihac proble-s. Ihe low lumit es Iu0 vac using 1he above tes1. The high lnt is 24s as. The so trg fn: ihe power panel can he marched to the measured incoming oltagc.Reposition 1he pmper lacaled in the ccnsrof ihe termiealstr:p.Ibo nal remo sans wires.

cul, J buck-buvst trans for rner p'n K-2834, is requinedl. Note: Tne buck boust cun also te rew inesl to h.atk oluge 2sunae down. ('all C hallenge for ieu iring. Always check the seria. nunbr tag o delermine the prper solleye range.

Maciunl Imensions

ThNel weight is 755 1 B q242kg1[he heigh: is S"1115ni. lerg1h is 494124cm], and wdtl: is 36" (9!em). Remm al efthe tasle. front guard and tTealle vill allou the mtchine (o go ihaugh a l 1 4"

Machine Revisions

Jitavaiainboaki)Reyisions

The main cireut hoard, LI-2762, was changed to EF-2762-1. 4"nen asing an EE-2762-1. the F-10 anc H-II musl nul b "reled.

H ! yumpei rust he conneted and H-: I jumper must not be connecied. Both blck piastie jirpers art louuled ear the 1 3 1use. The k.h.-2s1 can not he used for replacement a E-27b? and hh-2762-1. Jle FE-2sO7-1 is a direet replaremeat for the EE-2x07. The E- :0 unper must he connee'ed and :he I1-

Clamp Damp Lner Asnenblymoinjreisun

The upper mouning stud for :he clamp-dapened eylinder h> hee: chngedl 1 a thee-ere -rumrig. The 1rs1 pruduerion liltar with Ihe charge 1s <n 9sli19. 4July-Us1. 1he parT numbers afe E-9is-416 1 4x2x1"sel screw1. E-11S2-6x (1 4x20x:"hex spacer1, El-691x-412 t1 42fx1 " cap screwJ. II 1he s1ud

Fume. Tghte 1he peker onle ihe setscre. Slide he cap scrcw itu the 1op hole of the campened then :he reser oit of the purap.

Manlal Msprini

Itans s n ?110 and up mun board yetlow IN7 pu. Fer adruule lteh uil never light. The Sersur

I sep.arate rc:ay hoard.

Sjnglecuitblttonreyision

The gteen light butlon was chenged tu a lerier cuy m-iyhing s1yle. Thsheavy dly huntton vus used begnning vitt scnai number 98 1 i42. E:arly machines recuire conseTsun kit K-2s74

Hydral.Lic Pi.Mp Revision

The lirst machine sith the revsed molor pump is <n 971157 iDee 971. Replacenen1 punp motor number :s 1-2z0-s. Replacement noto pump units have a difrelen: mnuntung boh paltem. It is atccepteble use on'y twq moun:ing bolts.Parts ere zol nter chang cas le fiom eurer 1n late enits.The manilold and

Manifol.D Seai. Revision

Elyd-uulit: manifolds stanped xinh a "-A" in the top cumet use a x' O- ring The two O- lings are

Backgalgefiserevision

A kit is anaitsble tu keep the "FI' fuse frorn blowing. The ki1 :umber is K-290s. A 5A (SB] fuse s bentg added. The firs: Tian 200 wrth ths new fise is s 091734. Augs1 99. 11 is lorated on the revised

Froniguariintereocksaitchrevision

The interlock swtch mouned on eiher side of :he front ppening wds chaged by 1he marularturer. The lirst machines affested v cre buil; late April 20n0. The replecement su itea is pan mumber E-245T-6, also

Whe Image Matters.

General Hydraulic Information

oniy. An tecin and lll prnp can be used to teue :he oil rom reservoir through the tiller hele. The hyalraulie punp does have il streiner and mognel. I is recommenced as pin of 1he regulur oi. change thet te rexrvoir be eed 1 s ipe rhe ineri n'the 1unk clean, Tle O- rng seal my be seuscd it nt s no: dam.ged ip n is S-1x10.371.

Pressl.Rf Gage

Ihe gage supplied vith the Y:tar: is Flld w:l clear glcerin. If the gauge liquid lums yellsu, hydraulie Itud has leaked int the gange and it nust be tepliced. Ifthe rubber lnp seal leaks, replace the geuge (p n

Operators]Tiingllampprensl.Re

The clarpicg pressne rnge is 4fki te xif psi. Tening 1he clamp rressere rerucer caticge ca increases pressure and ceu decreases pressure (hne arn of ihe alustmnl s*ru rlual appr osim a ely 75 psi 1lon1 idjusi below sj0 psi. the because clamp and knife aill be ot of sequence.

Preliminary Valve Setiing

The or ldustabie catridge salves in 1he Eydraule sy sem can be presct manuall, to n apprximate setiny Tlhese atl just mc nts should be done only as a last reson. Tnc alves are nol interchangeab.ce. 上.uch valve is 1o be lumed in el tle say (ewy then turned cu tccwj a pecilie anount of tums. Mfaic. pressure canridge 4 :ums. Kmle dow secuence 3 1ums. Clamp up sequenee I um. .amp pessure ieduce1 Iadjusahle by 1he cperaor1 -4 lur:s (M0 psi1. Llse the hydraulie pre>st-re setng section in tle manual for rinal aJjustine.t.

L:s1ed ·s general infonnation for [esting ard ceckiny

Manlifactures Spring Inner Spol

Valve (Hallengl

Number

Main System

Clamipress

Edlm

KN.D.SEQ.

Mellm1

Light

• * C'anridge comes wnth coil E-Ih9-19

Software Revisions

Titan 200 uith re guu usirg FF-2762 cireit b0rl and EE-1766-41 softwte.

Orginal saffuure. Incrcased snife lkrsh tmmg. 1ale C'amp Plate nni wJs t 750: cnanged it to I 85. This rer ision conarns atli of :he lar guages. In fraction mode comeered posirconing problen. InerecIsed lining betcen ser and hrak: lurny cn an nft Th:s is perfuned at the hegunmng Erables the Prese: mterrupt luwg 1he zeru cross. Alkowed maintenance rude srceas dunireg pesx1 scren. I'henged semd rouine for better positoniny iccuracy. Added no.se pruylectian to pres eml erunvous backgauge conirol touch pad mos emeat. This eTor <auses the mnhire lt ~hw artual h-rkgauge pus:ton inslead of the 'sent to" + aluc. A low accuraey sdjust to be se1 in mm. Fixed a hackgaye reep prh'e- thal would occu f the foct pedal was prcssed during d slldNote: Tais is the hghest pssble rrvisiun soltw、lre thc fo: IE-2762 circu hoard.

Added a delay in the hin'sguge 1outine to prevent luses frm bxing Elus n te the huk- gauge chcuit when usng he slide pot in the center or bottom cdge.

A) Atded ( hallenge logo to slecp screen.

C lmmediately positiun to &lier pfesel. Changed reverse limit frun 2n,050 to 20.030 to prevent bumpiny in th: bacs. A1 Elevtionie clamp pre ssures range adjustable in the DlAGiNOSTl. menu.

B) RE POSITIONING is added es as option 1n tae parameters menu. This aliows the machune to reposilitsn au luma ti rally Fon a en: pnsition i :he baek sauge moves back (1 V hen uering data in a joh, :I a math futn key is pressed, th apralin assume the prcvious data. not the hackgauge pusilen.

Allox FLECTRIC' ('L.AMP oplion to he on

If the hac'sgduge is mon ng a1 a high seeo. 1he briuke is applied near the fron1 and back 1o prevent bumping. Al Added auto menury nritializaticen fer new boards. B1 Added memocy test to inializaton routine.

Ci ('orrel Iramslation crrnrs

Aj Imprnved posilipurng e by shorlening tie sas dewn distances aeal making ihc slpw dow n disluce self-aljusting betueen 2" anh .7s" B1 Added r:pul status to 1he cnd of stv eral enor messages. Kmife Lutch Failure 1 = Latch. disengoged when it slould b enguged Knife 1 atch Fiure 1 = Latch engaged wher. il shula he dsengaged Hyo Ialch Eilue I= Larch Relay Is nff WFen in shn;ld be on. Hyd Letch Failure Il I.ateh Relay is ur whel r; slould e utf. A1 Adyus1 for new 1 x hr bacs grage motor B}Ser ice messagr reuds "L:bricae Machine

C'j I.uhricnte eanm frequency lwce knite aarr rount

[Dj Allempl 1o reduee ]1 tluw ing runpuer respunls cuicker lo the basgauge moverent lmpravee electrumc clamp pressure ruutine to red:cing chsnging "C'P" slumer.

The tevision dectiptions for 2 0 and on is the <almte EE-1 7h6|

Original soltwate'. It'the backgauge is mos Ing at a htgh speed, tne brake is applied nea the fron and back tu prc'cnl bunping.

H A:dlea meory tes1 1o ieitializanjm rtine

At lImproed posiltenmg ume by shortening the slos cown cislanees and making the slos down distunce self-adjusr'ng between .E' and .75". B Arleed inu status tq the etd of several error messages. Kufe Lal:h Failue 1 - I.alch dlsensyged when i1 should be engJged Knte Lalzh Failure fLuch cngaged when in should be disergaged Hy'd I.alch filure I = Lalch Re'ay Is of? Wheni it should be on. Iy'd I.aneh failure t] - Latch Re'ay Is on when it shauid he ol1.

When Iinage Matters.

Error Codes Descriptions

Pri'Eurf

En Plan A Tio In

Errir

Press U lear key

Reul: sNgnie Afata operaten resut was negati e

Pre<s t'lear key

IDatt out of Kange

Back geuge n nonor and a consale key Fres (leasr key then Send

key10 complele

Press ('leur key

Aumber Lpuside limitl Send position beyunl fors iuld er exerse

Mote back gauge in

Reck gge posinim at et'er end of rable Back gauge a: L.imit

sppuste direction Press Clear key

I'ried to chunge a lucked channel Memory l.orked

1 inkel chl locked Nex1 Chanel Loked

locked chunnel a unother.

tlear message

Operator sets knte count for sha pemy Sharpuer Knife

Ller Parumelers.

Enter clear coun1. Press exI 4 1mes

C'harge snie count Fnter Kmfe Count Hnter Knfe Alarm.

Lubricure 3lachine

Eu terM a inen arce Lnter Puramelers. Frter knife coun: Frler clear lube. Prescsit 4 1ies Replace chip

LDefecve H1ROM chip.

Replice man hoard.

Memory failured

Boarc mounted reay failed ro tum cff 1lyd lanch error ∩ Sensur date. "hyllanl' didn'1 change fom O te I Orcurs when pump motor rums nff

Proldurf

See low chat pige 27

'lamp smk dowrl

See 1luw char paye 2x

movemert to end uf table llaled.

See fou chur peye 24

Iydraulie motor ddn: Mutur led:'t stnt :t tte beginning et'g cut

Sex Positoning ler.

Press (1.IEAR o sop alann A cnntirious beeping

Jestprdure

Ixplanation

Errr

See llow chan page 29

('lanp fuled teo relusn up aier 4 sce.

See flos' clhat page 30

Knile don filure

Scc Scquence Irror ot Knife at both lirmlls Knife up falure

See How char page 31

Knife came dluun brrore clarnp: urC lanp ca up beroe knife. ('lamp up prox made shile knife up prnx unmad.

See Hla cparl page 32

Knif un hoth lnins

See flou chart pagu 25

Back gatuge msscd puogremned position

Positinnirg cmr

hy Ons". Back gauge accuracey ofl by .110" he wand yues thougll peel ellor, (lump Knite doun "en in a program or send mote :Nn: manual heckgiugs model

See How chal1 page i

('lanip diJ ro1 come drwn al the slarl uf : cycle Clanp dovn failure

Sze tlow charl page 31

Eackgauge iailure Backgeuge did not move afier presetng

See fluw carn page 5

Any key lexeept backgauge slidejheldl on Shurtec key erTor fer longer tan seroncs

hack yage Psrwel wlles ale backu ards. Backguge diection Typicaly this happens orly o, at ruble art Revcrsed insal'ation.

See 1losv chart puye 37

Prmx sersor on s hen should be o1?. Krife lalch falure 1 The pin should be in the dlisergiged pasilon i.. pulled out ror ander knife bar.

See flow char. page 3x

Prox sensor oll uhen should be Dn. Ihe pin shauld he in the nggsd puslon i puslhel urder snfe bar.

See tlou charl puge 39

ot or will not la rl Senspr Jala. "lhydla didn1 chazge fron I 10 1)

SEAS OR DATA ABB RIVI AT IONS AND MEANINGS The knife and clap ane at luor of stroke wthrhe hydrr:lic onot off and linc hght on

Location

Inpiis/Oltpuis Idi.F. Description

Inside righu font cos er

RHSAFF (in) R.I[. satety swch orcut bul1on

[nside let Front cuvet [.efi sde a culler opening

Man boar:1

Luu er rhi corner of kzife bat Knl dow ~ proximily sensoT [.nder 'eft side o tuhle

PRESFTin! Preset scnsor

Socnnid n left side e hyd. nanald

1. efl sde ut culter opening Knite latch soeroid KNI.A ISOL 1ou

Top =ghi comer of clamp irear vew) (.lamp up proximly Hulom of clamp eylinder

HD:P iin1 ( lanp cyhnder up prosimity

lop lef: coner v knifk bar Knite np pu imiy Sngle cut butloT Rushi of main board hyeiraule motor reluy

I ire table I.gh1 Fv ligiet bulas arove knite bar LTLINE (uut)

Titan2O0Test&Adjustmentprocedures

I. Rene ihe " nu holding the co:I to the +shve.

7. Slhde t'e eul away fr the hase of the val e*

+. Rleke l eut. s. 11hee is eltage ar the coil is guod. macetsm sill mo e it hack the " to he bse of1he vale.

Ihe cml, ruable and rein beard :s gcnd tesed.

IESINi ANY IYDRAUI.IC VALVE SPOOL OPERATION

1 Kemsy the ane trom 1he rmiait. There isn't trapped hylra:lc pressμre. sne fi:id ill flow out Always use a I box end wrench or deep sell sockel onis on the lex orn ile ta've Neve use an lcjustahie wrench cr plers o -emove ot i"stall a sah c.

2. UIse a smal rod to push n on ihe end of 1he sal e 1har vas in :hc manirold. The spuol insid the <al< mus1 move smoothl, e: both direetions. Fach alvc lype has a dhtheren1 spnny lerson and some do not hive spings al all. tIn aljulahle vales, tse spring tensian <an be less<nec to help in 1esting spool nos ement. Icosen tle jarn mut then tern tle allee: scfes CfW' Iu reduee spig pressue. See ereral Hdulic nfammaton, ie 'alve infumatiun ror >pnny lension. . ('heck for camaged blick *O" rngs ot wnite spl: Tellon spucet>,

4. ( heck the manufold csvity For kose parliches 5 Rerstall salve I1 cues not require escessise force to reighten the vale. Du zol ughten evet 4uI FT I.B af'torque.

6. Typica.ly. a val e thal cmo1 sir-st its pnessure tange is lefectise.

['um rdjuster clockwise 1o inerease press.are. cocmer clock wise to reduce rressure. Retererre

1. 2(4) pur> manual hydruuhe schemaic page For curindge loculion ITun 1lhe clamp eduzer vase litem 4i. Incated en frnnt face ot blue mnanifold block. C'' ali the way.

2. Read main srster pressute shen clany arnd kmle are at the luslto af st ike Auljusl valve tiem 11j on frt ut blark pump tc I4fmpsi.

3. Read knte doaz sequence pressurc uhen clamp is at the 1uble anl 1he knite is mo ing down. Adljust front sJle fnten?i located o riglht fiace nf manitoid blocs to pullps1. 4 Rend tlap up sequece hen the kfe is a top of stroke ad 1he clanp is ruing up. Adjus1 rear ale (fem 11 aatel riglt fare f manitold hloxcx 1n 6ffipsi.

5. Adjust ciarp redueer al e. item 4. o a range ur a00 te D0psi w her. clarrp ml kcafe at: il 1he ballum

Testing An A Diu Sting Prox Sessor

• . eeess the"SESOR DATA " rnenu n he console. Ise zern and ones te 1he rght of the abbr es i at ions ill ndhcde changcd stalus ds ihe prox s actisared.

2. Place a lhi: metal serip in front ot'sensor. The taryet arcit has tour red squatcs in a block pullem. V hen the strp is plaee:d in front ut thue sttsor :he red LED shull t.rn on ard 1he sensu dlala indicutor should change.

1. 1I he distamce from the iectangult prox sensor io a movirg purl is ypieal'y 0l" 1o fK. The distsnee frem the round prox sensor o e muo ing per is typcally 0l" 1o .12>"

Mani Aiiy Activatingthf Hydraulicmhotur

Pressing 1he manuil pn u: :he meiar relay vill activare the muroThis xill raise the clamp ard knife 10 e ill ur pasiran The relay i lecated nn tie right siue cemer of 1he electrcal pane. Eo rot pash he re'ay for lonyer 1han I seronds. the ma: fuses rmay blou '

2. §. A y?1l0s aed up the elay is 3' x 3 and hlck in color. Press the luop whe lasle piece down.

TESTING AND REPAIR OF BACK GA IF BRAKE RESISTOR Resislar Is a hitc. 2" long by 3. 8" square fmay he [wq sie by sidej. lecaled on lhe tigh cnd of m:un band FF -x17-1. [he reistor is nex o the BRK. St'R. and [DJR red LLD's

2. easute resislanee fium one led te Lhe vtl:er. A feading o" 5 chms puans the ressiur is gcnd. A rcading ot':mfininy means the resisinr is open and must be rep'acec.
3. A pur nf Il chm, tsatl resistors can be purchsel tnom Radio Shack. +271-132.
4. ('u the cefeelse Tesistor leads at the erd of the Iesistor. Jhis u ill leas e a leld frm the hoerd 1o soder

$. Apl silevtl selat to 1he hnllm sfthe new resisr

6. Lay tne nea Jesistors side b, side (uith silicue seulunt in bel ceni rlen w rap oue lend around hc
7. Place new resislor on the boerd then eu: the lcads te averlap the leats cn lhe board by 3'x". XSolder resister leads 1o bourc Ieads.

Jestingfvcode:R

Measure saltages on the screu heads of the El-2x07-1 header. II the voltages iare cunect. the FF-28i17 js defertive. The lest yit es 3 genera. condnion of the ecoder as it inpossible 1o count all eacouet pulses If the voltages are not cumect, see "1hS IINti CARt.E". 1f eabie is gund. the encoder is defecrie. Tum mutur pulley +ery. very slus ly vhen 1estmg A and B pulsc. Cable connector Ileader

togglkes 5 & 0 vde toggles5& 0 vle

I-Stingfacuerbackgageaccuracy

This 1est is preloml s hen th -kruacy alarm is aetiated or 1here ss 3 queston ol buckyge poin 1

1. Remove lhe backgeuge pulley cover. [um off the REJOS]IIOINCi oplton u the patameter men. Move the backgage 1o reer of the tahle. Menually tarm :he leadscrew pulley back 1il 1he backgoge s1ons W'iine douu 1lie dimensim shown on the dispiay. Move :he backgage only vith the manual slide romtrol lu at leasl h liferent positions. never cong

Repeu1 step 3.The [wo numbers shoud match wihin I- oT-1.02. If the numbers natch the accuray prnblem ts in the loudung ofhe paper. backcage squuring or 'racy adulrreu. If:he numbers dn nol match tne cncoder. encuder cable or main beard may c

Wheliimage Matters.

Is Ting And Leveling The Clamp

2. Place a 2 1" < 22* sinps of paper lengthsise form under te clamp (rght ard ler:1 tus 1he frmt edge 1

3. ( lose yuarc. Ii eupped, ind mke a ru.

4. W'hen the e' amp is at the lable uncl slhe knile i sau Ifnging dou n, pull on the piper s1rips. . Iftle clamp is panilel. buh ips sil he le'il. Ifnce of the stips is luose he clamp w: have lo be

6. The adjustmernt is made by 1uming the muts on the top nd hottor of the peli camp pll doa n rods. Aupust te sice that sloes not held the sinp. Mlake only I 8-um dj=siments. Loosen the upper rat. Tghen :le los er nut to lowv'r lthe hgh sicle. . Repeal sleps : :hruugh 7 urtl buth 1ips are helad.

1. Ihe retraced position of ihe knile lah pin is adusted herore installation. The cmd ot :he pin should be ∩=sh w ith the facc of :lc bock thal t slles hrough qthe plastie screw head docs nol millerl. (heck the pusition ot the pin by puslhing in the solennid plumger icam the les e1 lo bullum cl i1s travel. bj. Push in the sulenoid plunyer 1o bouom nf is uravel. cl. O- the 41t20-1 versian slide the so.cnoid with plunyer pushed in so the knife latch pin end is Flash w1h 1he bluck. n 1he 4l 12n3 versror. shde the solenonl with plunget pushed n s the luslie Srrew' nn end of :he atch pin :s flush wth. the biock. dj. Retighter the sulenoid mourg scrws.

2. The laxch assemhly rmusnung plate shoule be visuall parallel to the knite bar. . Jhe 1op of the k:fe latch pin shol be I.4' (i.mml 1o '2" fi.mm below 1he knife bar.This clearanee is sct snly when the knife is in ihe full up pusilio 1see maually section "Activating :he hy draulic cunun"'1. The latch pl:te moumting screus wall have te be locscned slghils. The height adjust:ng

lighlen the jum cul. Tighten the monting plate sctews. ISJALLATllN T1P. llhe top cover of the cutter shoud he talled foruard and te lefi fon1 table side guide shrould be renovee for casier arcess. lable side guce mocnlng strews ca: he remaved throuyh the [so sicke lef anvss hole cnvers using :he snite bol1 wrene'.

sensor hs a red fuur-poir.t targul for actis alion.

TEST BAC KGl ACiE ARk1ATURE(Prccedure measuring backgauge trolor for opens and shoris]

2. I Inpiug the 1flconnector on :he main huard and enus c mola covex. Measure :he resistanee betuecn w Ire 45 anc. . KRotete r.ulor puiley :n small :ncrements fone complete lum while readiey the rcsistancc at caca inctemunta: slop. The nominal resislance should be I2 oams. Vslues above 1? inlicate open and vaes below indcate a short in tlhe armalure.
3. Llnplug te Hlconncclor cn the nan buard.leasufe tne resisiunce betseen wire 45 and dh to the unpainted part ofthe nukn cise A ieadng of infnty lopenl us correct. A teadng less than inlinity inlicates a shor.

Frontguardinteri.Olk Switch A Iai List Ment

1. Remore the inlerlock sw i1ch bracke1 assembly Iom the lup cre1.
2. Bend the stiap. near the mount'ng screws. so il is parallel to the fare ut the inerlock swiich und hus f." clearanee lo the lip of the plnger.

asse-nbly sn the sttap is Ilat agatinst the cot er le:t rot depe's'rg 1he p:lmyer.

Disassembiy Of Soenoidhcoi1 C'Able Connector

I . Remote scres completely frorn the center uf squle conector then ennve cunrector frem co:1.

2. l.nscteu cable stran reliel nu1.
3. Tum conneclor =psle down. Place a small screwdriver in 1he r.arow slo: m cne of the coners of the Ted centet plere then pry it out Thc cable wall seed ho be pusled in. ↓. Voltuge ra :lhe he -mensure berwc- Ihe uires

Testingthe Tispi.Ay Contrasi

The L(D displa uscs I9 Vols DC for 1he contrast adjustnen:. The voitage is produced on 1he man clreut hoard. Iili-2k7. The conirast soltage on :he main buard can be mteasured fram header H2 pin 7. t0 :hc nor-lne ml furu:le) uf the diotle locled nexl n the IIa heasler. [se 1he leti crauing bclow for Id! ciode locaton,

H8 Header

T'he lesel of conlrast is adjused by a pan len to meter locaed on the back of the conscslc. Ihe volage 1s rmeasred on the keybourd interface buard lucaled ttsdet the comsole cover. I se the abuve nighe drawing lor reference tise the lefi end of tae resistor Ishou wmh a "C"1 as the common. Iae tolage at leg 3 on

19vale. Nommnal operational voltuge is ep proxima tc ly 12vdc. t'onclusions: No volage be1ween dhode and H7-2. defective EE-2x07. No olluge betwee: "C" and 2. defectiv FF-2764. All voltages good. defectine ICD cispiay, defective EL-275x-1.

Testingandmani'Ailyactivatingkiydoard

1. Remove 1he meta. conet behin the corsol ?. 1senrnect hlue t:ppaed sibhor cable fron imerface bcard.

4. l's a jusxrci wife shortng the cxposcd pns to munually act:vate a key function. Use the dugrint and key list he.ow.

5. If 1he corsole shnu s aclit ity hy maneal'y jumping the pins, 1he kevboard is defectve, 43002.

Backgaugc Slide Key Intertace board

Khy Pin Kf:Y

Whenllnage Matters.

CHAMPION and TITAN CONSOLE PRO GRAN MAP

Send Screen

Refeat Jcb

(xg or:y)

Lock

Mantence Erase Copy

Or:Ginste Job Auyser

Language Nifeadjust

LA3EL μxg crly.

Lanual

Upoown Frogramng

Cermen Spersh

Cut&Rec

PARAVETERS [xg only)

Achine Cnt False Clamp

Pushout

Accuracy Du

Onff

Diagnostkcs

Repostion

Adlgt Clmp Errorccces Senggs:Dar

Set Mx Yum

Knifecnt Timeout

Set Mnimun!

Knife Alarm

MINUTES ELECT A UCC LAP ony

Clearlube

Clearoount Set1

SERVICE QUALITY ISSUES / INSTALL FORM

CSS TECH NAME

DATE 4/26,27,30/07

CUSTOMER NAME

Kinkos

PHONE NUMBER

937-429-2585

CONTACT NAME

Rob S.

REP #

TIME IN

TIME OUT

GBC LOCAL TECH AT SITE? X ONE

YES X

1400/1300/1200 LOCAL TECH NAME – Brian Thompson, Doug Wood

ADDRESS

2646 Colonel Glenn Hwy

MODEL NO. SERIAL NO. Challenge Titan- 52753

INSTALL DATE

CITY Fairborn

STATE

Oh.

ZIP 45324

TRACKER #

CYCLE COUNT

ACTIVITY / CUSTOMER COMPLAINT- Wont Cut

CONDITION / MODE OF FAILURE – When cut buttons pressed, pump will run but clamp will not come down/ Clamp Down Failure.

PROBLEM

CORRECTIVE ACTION

LIST EACH PROBLEM AND CORRECTIVE ACTION SEPARATELY - USE ANOTHER SHEET OF PAPER IF NECESSARY. LIST THE PARTS REPLACED TO CORRECT THE PROBLEM IN THE CORRECTIVE ACTION COLUMN NEXT TO THE CORRECTIVE ACTION. Problem Repair

One hood switch was bad (right side)

R&R switch

One cut button also bad (left side)

Comments –

Suggestions to Tech. – Add both switches to their inventory. This is the 3 rd titan I’ve been involved with that has had issues with these switches.

Clamp stuck down

Free damp by pryirg up on the side cf 1he clarmp that thats not holding paper. Plare ycur iccl on the manual camp oar bo 2reven: the ciamp ffar. bcuncing up.

Suggesticns to prevent this frm happening again. For fpl guirg iterms refer to the adjustrrenl yrocedure sactior.

Check for brcken Greasa damp

Lower damp Paralel damp

clamp return guides. narowl stock in

pressure 100 to

sprung. cen'er of damp.

200 psi.

Slow backgauge movement to end of table

Dd bacx gauge mcve to the ear anter pressngy CLEAR?

The warxl must traval thwough

'she Yes

a5 posshle wthou louching. preset se"scr brgken The wand and sensor ms1 or kxxe?

Are wiEs #12. ; connection.

Dr 1he rman board 7

Does he

Repltce presel

fioxm (vdc: 1o 5vcc belween wirg 12 an#1B wnen bccing the pesst sensor with chip mad ?

Replace rain

Knife down failure

he s8rsor dala

EE-2807-1 1he knfe dw

Crc he knie bar

I and knke cyfinder.

Sequence error

Sor: oth:r retunn Ic Ihe ko pf strokg

bor slar onbeo

belo* S0psi?

C'eck fer undo bnd.

Clamp down failure

Se HydraL ic Molor

Ddnt Salow

2 Me and CiTSL chargelo a 1 board, ieiLhe sensr data meny ?

Replaoa man

betveen wies #2 and #5 al thr man bosd? EE-2607-1

here 24yac Check cut bul to nf in le nock switches. wie between wies R44 and #35 conneclhons and see hoxd adjustment al te gy leminal procedue secfon stio?

24vac bctwcen wires 44 an t35 at e don

repbce cabe.EE-27G9

Does he coil have magnetism See Rapare col.

Afler einstaling the vatve. Doestre

Repace vale,

cantaminalioe in the fuid.

Replace luid and clean prpcedues

bank, stainer, magret.

When Image Matte

Backgauge failure

Doas the fusc F1 or FL blow aler luse holcer.

badkgage surge hen

back gage bnd when Locate ane rermove mechancal b*a. the rgar puley is turned

When the Replece EE-2807

the BRkled lum ofl?

Dees the mctor Replace mobor. Sae manual for Ye5

par number

short. See Adjustmen

Is here any dc

Reclace EE-2807 votege berween wre

Check lor cpen motor amalure, brpkan mre. stuckmotor brus SeP

Shorted key error

console have a single beep c power

Coes the

the dear is

oxnsole sound a single Nomal

pressed ooes the backgauge

beepafter he blue keytoan catle ls operalion.

move to the Fxd ar

unplugged and pugged in

Replece Replans the key Discomec kayboard EE-2807-1. cable jusl after the

dsar kay is pEsSed.

Does Ihe backgauge move as

Replace the koy

MyBindil 35

"Encoder wires 9 and 10 are reversed" or "Backgauge direction reversed"

occurafer a lable ou inslallaicr

comecled to H21 and cablewireandredmqlorwire wire #19connacledH2-2on nnedted to bowncable main board? ire?

Wire corecthy

Wire corredty. :Checkther Chrck dthor

Knife latch failure 1

Didn't Slert ow

Does the pn dsengage from he

the krfebar isa1 top of strake, is there .03".

Adjust bxracket. 1mm, cbarance rom pn b knife

bar? See adjustment

I he sensor dala Repace main board.

manu does he KNFLAT change Ye5 EE-280-17 a D during a stoke?

led output6 urning Repace EE-2807-1

a cu s hcrc 24vac atsdlenoid

Dxes he Replace fthe man YES tum aff?

there 24 vac al mainl board wres 35,

goxd replace proximity sensor, E-2204-1

Knife latch failure 0

knielatcth pin under the klfe Dar wben she knile bar is at the lop

Replace TE'11 the sersor data Rer:lace spring. xard.FE-2807- enu is 1he KNFL 41117 proken?

Rupace man Is the Yes

Doard EE-280-1 yelkaw inpu LED 6 Chock for bids engerized?

Redace main

If wire 好9 connechions knifte latch proximiy are goxi, replare the rec LEDit ? proximity sensor,

lartc:h levur wlhin connadlions are good, .03, 1mrn c the proxmily replacB proximity sensor, E-2204-1

Sce knife latdh acjustment

Hydraulic latch error 1

See Hydraulic

the pump tum Motor Didn't start on? flow chart

Does wire #39 have a good No Repair connection at main boardheader and the gray terminal

Does wire #35 have a good connection at main board H7-4 header and at the gray temmiral ship?

jumper H-10 on the main board have a good

Replace main circuit board,

Serial Numbers 971103 & Up

Instruction And

Parts Manual

Titan 200

Challenge

Paper Cutting

Machine

Power Backgauge & Programmable Models

Sofd and Serviced by

The Challenge Machinery Campany

Grand Haven.MI49417-1594USA

Fax: 616-842-6511

F. 200-A

Introduction

WELCOME 1o 1rc fam ly of ChallengeC users. Challenge has Leer1 deve oping and manufac:uring Graphics Ars Equipment for over 1o0 years and is today one of the wcrld's leadirg producers and d stributors of Paper Cutters.

PaperDills ancBirceryEquiprrent

speclal zttention to Ihe ir'struc:uris irl vuold type. Personal njury imay result f the precautions are not readand foliowed.SeeSAFETYPRECAUT1ONS.pg.vii.

+This machine Is deSicned forONE PERSON OPERATION ONEY!

DONOTOPERATEWITHANYGUARDSREMOVED!RepaCe all guards be lore ODe rating

CUTICRUSH HAZARD - Keep hands from under peper clamp and kn fc.

Dealer or:e Calle nge Service Department.For the dealer reares: you or Icr service cuestians call16j-842-

FOR PARTS AND SERVICE contact the Authorized Challernge Dealer frorn whoir you purchased yocr mach:ne. Use the illustrations ard parls lists at tne back ot 1his manual lo idenufy the corrcct parls nceded. Always give

Take a few muules nghil nOw to RECORD YOUR MACHINE SERIAL NUMBER in thc spacc provicded on Ire

DIRECTTO CHALLENGE. If you sought a used inacline, it is imponlant :o have :he followirg information on record al Challenge. Copy this page.fllin the information and send it care o': The Challege Service Depatment. 1433 Fultcn Avenue. Grand Haven, Ml 49417-1594. Fax (616) 842-6511. Ph0re (616) 842-8300.

Serial Number

Challenge Model

Company

Aiin

Address

State Zip

Date Installed

Phone

Dealer'Snameandcity

Warranty Information

Please Review The Enclosed Warranty Sheet!

Il is very important thatyou read and understand the condions oulinedin the Warranty Infcrmation Shecr. t is rrar) erivelope affached fo the outsrde of the shippurng container

MACHiNERY COMPANY in order fortine warrarty tobe issuedfor fhis rmachine.

Challenge& Is a regis:ered raderark of Te Clegleruje Machinery Crmpany1433 Fullcr Aveme Grain Haven Ml 49417 Cop,righ: 15 by Tre Challengc Machuriery Coxupany. All rghls reserved Pr ~led in tmg U SA

F.200-Atitan200Sept99

Serial No-

Upgrade Code-

Packing List

Part No. A-10C34 Knife.... Cuttig S: c< in addiion to one irstalled in machine) Instruction and Parts Manual A-2608-2 Jogging Ad.. Tocl Kit..... Knife Bclts3:8-16x 1" Knife Wrashers.Special. 5C64 Cutting Stick Puller Knifel irers 316"AllenWrercn -..

Grease Brush

Optional Items

Part No. Description AA-10061 False ClarpPlate

Backgauge Book Guides

Cutting Sticks (in addition to one inslalled ir machine)

When Image l

F.200-Atttan20Sept99

Specifications

Cutting Dimensions Curling Width

Tabe Spece

Machine Dimensions* Tab e lleight Overall Heignt Overall Lengih... Overall Vidth

755 .bs (342kg)

Shioping Weigh:[Approximaiei

Sound Emission

A-weigh:ec sound pressure level measu:edin a'enclosed rorril alopelalor level i6 feet!

Machine ci.tingaft.Iiftof paper

h false c ar > plale altarhed. rn r m ? cu: 1s 1-7·8 48 mm'.

Far complee Icor pla~ laou1see pag 5-4

"/vibs lablc fon: gurd aind *oct Iread'e removed car be ir hrougn a 28 /71 cm doc: erening Challenye ieserves he r glr lo reke changes lo 2^y produc1 cr spec fical oe yalha.1 nofce and eithcu1

Table Of Contents

INTRODUCTION. PACKINGLIST..

Optional Items

Specifications

Caution:Powerlock-Ou1Procedure

SAFETY PRECAUTIONS..

OJO!.... ix

Warning Label Def In It I Cns

1.0INSTALLATION&SEUP 1.1 UNCRATING 1.2 CLEAVING 1.3FITTINGTHROUGHNARROWDOOR 1.3.1 Removing the Tale 1 3.2Removing the Foot 1reade 1 3 3 Rerovirng the F·uml Guard (lf Equippeci 1.3.4 Reatachirg 1he Table... 1.4INSTALLINGEXTENSION TABLES 1.5HYDRAULICSYSTEMCHECK 1-3 1.6FALSE CLAMP PLATE(OPTIONAL) 1.7POWERHOOK-UP 1.6 LINELIGHT 1.8.1 Adjustment. 18.2BubReplacement 1-5 2.0 OPERATION 2.1POWER-MAINSWITCH.. 2.2STARTUP 2.3 MAKING A CUT ;Using OPTIOKAL Two-Hand Cut Bultonsj 2.4 NAKING A CUT ;Using Front Guard} 2.5 JOGGING AID 2.6KNIFE CHANGE ALARM AND LUBRICATION ALARM 2.7 MANUAL CLAN PING iUsing the Foo:Treadlej 2.8 DISPLAY PANEL 2.9DEFINITION OFKEYS 2.9.1 Variable Speed inpoirt Backgauge Contol

2.9. P.sh-Out Key . 2.9.5 Clear Key ... . 2-3

2.9.7Priorily Add(XY]Key 2.9.8 Sof-Keys 2-4 2.9.9 Arrow Keys 2.9.10 Coniras: Con1rol. 2.10 MANUAL BACKGAUGE CONTROL 2.15.1 Backgauge Glide Control... 2.10.2Backlash lrcicalor .... 2.11 SEND MODE 2 11.1 Fntering Maln 2 12 Entering Fractions... 2.11.3 Upgrading Pcwer Backgauge Mudels tu Pro yr anim able Models... 2-5 2.12 MAINTENANCE MODE 2-5 2 12.1 Kvife Adst.

2.12.2.1 False Clamp. 2-5

F.200-Atitan 200'Sept 99

TABLE OF CONTENTS (cOnt.)

2.12.2.2 T me-0ut .. 2.12.2.3 Push-out . 2.12.2.4 Accuracy Adjust 2.12.2.5 Knife Ccunt... 2 12.2.6 Machine counl.

212.3.2 Sensor Data..

2 12 3.4 Elertric Clarnp 2.12 3.5 C aTp AcjLst

2 13 JOB MODE (Proyrarmable Mcdels Only) 2.13.1 Lcck/Unlocking a Job 2.13 2 Cocyng a Job 2.13.3 Erasm a Job 2.13.4 Creaing a New Job 2.13 4.1 Enteing SendValues

2.13.4.3 Charnel Linking 2 13 5 Fciting an Existing lah 2.13.5.1 Editing 1he Jcb Naine 2.13.5.2 Ediring Send Va ues.. 2.13 5.3Inse:ling Send Values 2.13.5.4 Erasing Send Values 2.13.6 RJrning a Programmed Job 2.13. Exting a Jeb 2.14 AN EXAMPLE JOB 2.15OPERATINGTIPS 2.16 NOTE TODEALER 2.16.1Enenng:heDealer Name and Phone Numoer 3CKNIFEINSTALLATION/CHANGING 3.1 KNIFE REMOVAL.. 3.2 KNIFE INSTALLATION 3.3KNIFECARETIPS 3.3.1 Krife Blace Life 3.3.2 Cuttir.g Stick. 3.3.3 Bevel Angle 3.3.4 Helpful Suggestiors 3.3.5Knfe Carg 4.0 MAINTENANCE 4.1TROUBLESHOOTING 42ERRORMFSSAGESANDDESCRIPTIONS 43SENSORDATAABBREVIATIONS 4.4ROUTINEMAINTENANCE

4.4.2 hionthly.

4.5CHECKING:CHANGING THE HYDRAULIC FLUID 4.5.1 Recommendeo Hydraulic Qils 4.6OILAND GREASE 4./ADJUSTMENTS. 4.7.1 Backgauge Gib Adjustments 4.7.2 Squaring the Bac<gauge . . 4.7.3 Proximty Switches..

F200.ATITAN200SEPT99 Tatters.

TABLE OF CONTENTS (cont.)

A.!A Hydrauic Valve Adus:merts 4-9 47 4.1Pressure Settings.... 4.7.4.2 Adjus:ment Procedu'e'..

4.8CLEANING.... 5.0PARTSLISTANDSEQUEVCEQFOPFRATIONS

Mainassembly-Frontview

Mainassembly-Richtsideview

Mainassembly-Tableas?Vifw

Hydraulicpowerunit(Sn971156&Below}

HYDRAULICPQWERUNIT[S/NS71157&ABOVE). HYO RAUL IC MANIFOLD ASSEMBLY AND SCHEMATIC.

Hydraulic Sequence Of Operation

POWER PANEL ASSEMBLY... BASIC MACHINE SCHEMATIC.. ELECTRICAL SEQUENCE OF OPERA II ON.

Controlconsoleassembiy

CONTROL PC ASSEMBLY.

Knifelatchassembly(S/N98'341&Below)

Knifelatchassembly(S/N981342&Above)

LINE LIGHT ASSEMBLY.

Cut Button Assembly

Powerpanel Label

Titan200Floorplan

Safety System Tests

When Image Mattepi

F.200-Atttan200Sept99

Safety Precautions

the instructions because it has to do with safety.Failure to comply with the fallowing instruc- tions may result in personal injury. This machine is designed and safeguarded for ONE PERSON operatior. NEvER operate the cutter with more Ihan one person.

with and around this machine.

READ and understand all in st ruc lions thoroughly belore using the cutler. lf queslions slil remain. call your Authorized Challenge Dealer -fingers and hands are loo valuable Io risk experimentation.

DO NOT ALTER SAFETY MECHANISMS, they are for your proleclion and should nol be allered or removed. Severe lacerations or dismemberment could result. DISCONNECT POwER before cleaning. lubricating, servicing or making adjustmenls nol requiring power. Turn the main disconnect switch to the off position and disconnect thc power plug: see Disconnect Procedure

Be sure the culter is properly grounded. Be sure there is sufficient power to operate the culter properly.

Observe all caution plates mounted on I his cutler.

Keeptoreign objects atff table and away fromcutter blade.

BE EXTREMELY CAREFUL when handling and changing theculterknile.Severe lacerations or dismembermment couldresultfram careless handling procedures.

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

When replacing hydraulic parts, loosen the connectlons slowly to release pressure. Never loosen connections with the machine running.

If lhecuttersounds or operates unusualy.1um it offand consult the troubleshooting section of this manual.H theprobiem cannot becorrected,haveil checked by aqualified service person. CRUSH HAZARD, keep hand and fingers from underthe clamp when clamping paper. Use Jogging Aid ta load paper, and use the backgauge to push paper out before unloading. DO NOT REACH UNDER THE KNIFE AND

Clampareai

Caution: Power Lock-Out Procedure

For maximum safety and ta prevent unauthorized use,tum the power switch to the offposition and

bricating,or making ropairs to the machine.

F.200-Atitan20Disept99

vii atters.

Thls Este simbolo de alerta de seguridad signilica i OJO!-INSTRuCClONES DE SEGURIDADPERSONAL.Lealasinstruccionesporque Serefierenasu sc guri dad personal. Fall de obedecer las in str ucc i ones que siguen podria resultar en lesiones corporales.

LEA DE TEN IDA MEN TE el manual de instruccionesy las PRE CA UCI ONES DE SEGURIDAD antes de poncr funcionar la cortadora. Pidale a su supervisor una copia.

hacer adjustes que no requieren corrienle. Trabe el in mter rup lor en La posicion OFF (apagadoj: vea "Procedirmiento para cortar la corriente eleclrica"al pie de estapagina.

Asegurese de que la guilliotina este debidamente a tierra. Vea "Conexion de la fuerza electrica'.

Preste atencion a lodas las placas con advert en cias instaladas en esta guillolina. No permita que objelos estranos esten en la mesa ccrca de la cuchilla corladora.

resuHar del manejo sin cuidado o negligente. El suela alrededor de la guillotina debe mantenerse despejado y libre de recorles, des per dic ios, aceile y grasa. Al haber la necesldad de reemplazar partes hidraulicas, afloje todas las conexiones poco a poco para dejar escapar la presion. Jamas debe aflojarse conexiones mientras la maquina este

Gervicio au lori za do para quo leexaminen lamaquina.

calibrador trasero y su rueda de mano para enmpujar el papel cortadq. NO PONGA SUS MANOS BAJOLA CU CHILL AO ARE ADELA AGAR RADER A.

Noo Peres In Las Guard As Protector As!

: OJO ! PRECAUCION -( Como proceder para desconectar

la corriente electrica.

de corrisile al cual la rraquir'a sta curerlada. este desc omne cta do. El nter rup tor deba ser Fueso en la posicicn "OfF" estara efecluando los trabajos de servicio o de repa'zcion er la guillotina.

When Image Mie

Warning Label Definitions

SINGLE OPERATOR Do rol cperate with more than one person.

Disconnect power before remcving cover. Replace

Shockhazard

SHOCK HAZARD Disconnect rower before remcvng cover. Replace cover before operation.

Disconnec: power before cleaning. servicing. or mak ng

Hazardous Area

adjustments nct requiring power. Do not alter safety guards crdevicos. thcy are for your protectian. Replacc all guards, du rut uperale with any gu.ards rermnqved.

1.0INSTALLATHON&SETUP

machine up, 2nd slide ou1 the top layer of the support

1.0 INSTALLATION & riser fflig 1-1j. Do the same cr the other side.

Setup

1.1 UNCRATING

damage durirkg sh pping. Inspect all shipments as soon as thcy are rece vcc. Note ay darage on the freght bill ard nctify the clams ueuaitrent cf the carrer wthin 5 days All claims for damage are the responsiblty of the receiver so remerber to inspec: prorT ptly Check the contents of Ihe crete agaiis: the pack·ng list at thc front of this marual.

The Tita 200 weigrs approximately 755 bs (347kg) DO NOT risk pcrsonal njury or damage by attempling tomove machinery with makeshift equipment cr inadeauate manpower. This machine s shipsed on a wooden skid and encloseo in a protective, corugated to5. The skid is vesigned to allow the machinc 1o ve rolled aff without any svecial lifing equipmen. Tne machine is held in place by wo. 2x4 braces lag bolted Use the flat board provided as a rarmp and position as to Ihe skid All arcessores are shipped nsde of 1he shown in fig 1-2. Hlold the ramp n place with the nails

providcd. Make sure Ihe caste's are not locked anc very carefully rollthe machine down the ramip.

Remove the carton by removing the nails or staples holding itto the skid ang lift it straiyht up cver the cutter Ihe culter rnay ow be ra led irto posilion. 11you don't have lhe celing clcarance to so this. ca'efully slit the carlon dcwn the side and then urwrap 1.2 CLEANING it from arourd the cutter.

Atter unpacking. wice down all machine panels and

Remcve allag screw's froT: the skid. Remove the lower clean the table surface front cover of :ne Titan 200 and remove the twc lag screws in the base.Rcrrove tho accessonies. 1.3FITTINGTHROUGHNARROWDOOR Using the rear bumper board, pry one side of the The Ttan 200 cutler wil not it thrcLgh ar opening less

W ththe table removed.theTitar 200will fit throjgh a 35'(89 cmj opening with the table.front guard, and foot treadle removed, it willfit through a 28 (71 cn)

1.3.1Removing theTable

Make sure the knife and clamp are in the 'up' pos:tion. Ithey are not, read:hePoweHooklp section secl i gr 1.7} to connecl power to the machime. Tu:m on the power using the red and yellow main power switch, close 1hc frant guard. and press:ne CLEAR Dullon. Tvs will ores ct thc back gauge and send the knife anc clamp up.

Tum cff the mach.ne and unplug the power cord.

F.2D0-ATITAN200SEPT99 When Image Mqttr

1.0INSTALLATION&SETUP

Remove tre plexiglass cover and 1he three sheet meta'covers oterear of thcable.Rc.movc thc backgauge nso:or cover, the rear lable support leg,the lcwer back parel. and the lower frort cover of :re

Unplug the cable lo the malcr ercoder al the pack cf the rT:achine (fig. 1-3).

Pre sr lter Board

Rear Support Leg

Remove the mctorjunction box cover and discornect :he wires to the motor (fig.1-4).Rerrove the [fig. 1-6) leads cr cwc over and1ncnylon tyra psI ral are attachcd :hebotam oftneable.The noor wires and ercoder wiresshouldncwbefreefcm thetable Cut Stick Stop

Cut Stick

Right Side

From therearof:lhe machine.removethepresetler

board assembly from the table (fig. 1-5). stick removal tool and tap olt the two tapcr pins from

the bottom side cfthe:ab·e.Thenremove the four

Open the frart guard. open the top cover and remove screws that mou nl thelabiecthebase.NOTE:the

lable assembly is very hcavy and rcquirus two pcople

the ef! and nghl side guides and te cut stick stops as shown in figures 1-6 anc 1-7. toremove.P.ill 1hetable out from the back of the

machine.Locare the four rounc spacers that were berween the rab e and the base - you vill need them

Nexl, remove the cut siick from 1he rable using :he cut ng

F.200-Atttan200Sept99

1.0INSTALLATION&SETUP

place.Star thereartw'socket headsrrew's.Reinset

later for T ounling t:e lable.

below bottomof thc slot.Tightcn all'or Screws.

1.3.2Removing theFoot Treadle

A:tacthe nght ard left side guides (fig. 1-6& 1-7) :he presetter board assembly ifig.1-5j.the molor and

Make sure the cower 5off and thc sowcr card Is

encoder wires (fig's. 1-3 & 1-4). and all cuards and

disc on rec led. Remove thelcweront cover Use an

panels. Once the lable s installed. tne backgauge

open-ene wench to emove he wo cables altav'ed l

squareness ard accuracy wl have to be resel. See

the ase. which holc up te foo: treadle. Carefully.

sectons 2.12.2 4 Accuracy Adjust and 4 7 7 Sql.aring

remcve the sonngs. Ncw remove the pns a the ear pivo1pcints ofthe foot:eadleRemcve thereacle. the Back gauge

1.4 INSTALLING EXTENSION TABLES

1.3.3 Removing the Front Guard (lf Equipped)

Make sure the power s off and disccnnecl tnc pcvcr cord. Open he front guard.Remove 1he cylinder bracket screws {fg 1-81.

Capscrew

Tae.Sjfort

Using the wcod screivs provided. attach a back plate to each ex tens on tableUsing(4)38-16capscrews. atach 1he table support :c the under side of 1he man table as shown in fig. 1-10. I the machine is equpped with2-hand cut buttons.routeeach cutbutto7wrire

The7oper the tosFood and remove one set of hinge through Ihe slots in thebracket ardrelocare the cut screvws (fig. 1-9i. S ide the fron guarc out of 1he oter butlons to the extension tables (as shown). Place thc

provided flat washers on the table support above each slot receiving a screw lomouni the extension table on the suppcrt.Lay the table extension or lop ol the spacers and insert the screws.Slide the table

Hinge extension1ignttothetableShimtheextensinrlables

Screws as neccessary to maxe the tables Push jsirg the provided shims.

1.5 HYDRAULIC SYSTEM CHECK

The cutingrclarmping mochanism of the Titan 200 is powered by a hydraulic system consisling of an electric rotor coupled directly to a hyoraulic pump.

The hydrallic reservcir holds 4 cuarts [ gallon] of hydraulic fluid. It is filled with Rykon 100 hydraulic flud

1.3.4 Reattaching the Table althe 'actory bul shculd be checked before cperatior.

Reincve the kower reer senel cover aix urscrew lhe cap

Set lhe table :n position. Lifl the table from the front on top of the tank (fig. 1-1. Fluid level should be a: 1! and set1he two front sp2cersin place. Insert 1he front 8" from 1he eno of the dp stick icheck with dip sick lwo socse: head screws. bu1 do rot tighten. Lin the cap screwed injAdd fluid if necessary but avoid table from therear and set ihe tworear spacers n

F.200-Atitan200Sept 99 1-3

1.0INSTALLATION&SETUP

Turn the poveroff ard disconnect 1ne power cord

Oper: he front gua'd and slide the fatse clamp prate Jnder tne krife and clempifig 1-'2). ardsllde 1he clate Jp into pcsition with ine ocator pins toward 1he frot of the nachire. The locator pins msert no Foles in :he bo:lom fron: of the clamp.

Hold 1le plate in posilicn anc secue wih the wiry nuts provided

Charge the false clanp selting of the macnine to

OV to prevent the backgauge from crashing

overlling as this cculc cause leakage when hct. into the false clamp plate.This is doe in the

Maintenance Mode:ParametersiFalse Clamp

Repiace the rear panel wher finstied.For more

scrce.For more dctals on now to dc 1his. scc

flud incl.ding a crcss reference cra1 cf aperoved flu ds. see seclion 4.5 cf tris rmar'ual.

NOTE: The minimur cut wik the false clamp clate

The hydraulic fluid srould be checked weekly and attachedis1-3:4 cherlged AT LEAST ONCE-A-YEAR Jr after every 1,000 Fours cf operaticn. 1.7POWERHOOK-UP

1.6 FALSE CLAMP PLATE (OPTIONAL) CAUTION:NEVERCUTTHEGROUND

LUG OfF of a 3-prong plug to fit a 2- prong socketl You run the risk of

lo prevent marking on prcssurc sonsitvc jcbs, a fals0

electrical shock which could cause personal

clarp slate is ava lable as an optiona item for your

injury or death.

rachire.Tris olale attaches tohe bottom of the clamp.1is securecwith wing nutsonstuds thatpass l'rough the lop of the clamp. It:s 1he custcmer's resporsbilily to p'ovide aproperly

grcunded receplacle :hat meets the power re cui rem ents

Toinstall: speciliec on the name plare o* this machine.as wel. as

Make sure tne knife anc clamp are in the up install one I your lccaticr Is nct so equipped. position. I* they are not. tum on the power us ng

Check ircoming voltage and pusilior 1he voltage

the red and ye:low main power switch. close lhe front guard. and prcss the CLEAR button. Tnis w Il selection jumper in :he proper location as sh:own belkw: preset the backgauge and send the knile anc clarr:p up.

Locator Pins

(fig. 1-12)

↑.0INSTALLATIDN& SETUP

Open the f'on: cuard.

NOTE: The terminal block jumper must be set to 2. the correct location according to lhe supply voltage of the machine. Failure to set the terminal Remove 1ie uld bull by hghly pushing the bul irtc block jumper will cause damage to the machine! :he socket and tiring1 counterclockwise.

CAUTlONiIf 1he bulo Is stillhol. allow a tew ni^ules for :t to coul.

Connecl the power cord into e grounced. 3-prung receptaclc on:y! (Rccommendedrecep:acle:208-230

Insert the new bulc in:o the socke: and twist it clockwise urlil the vull: locks into place

1.8 LINE LIGHT

Reconnect power and tjm 1ne mzn power switch cn. Reacjjst the I ne if necessary.

Tlhe Tilan 200 is ecupped with twc lights which provice a line of light on the paper in the approximate lccalion of where Ihe caper wil be cut Tao ighis ccme cn when power o :ne mach:ne is tumcd an The lignt from each bulhreaches the tabie afterpassirg between the knife anc clamp. Each light is focused with a socke: hcad capscrew [fig i-13].

Line Light

(fig. 1-13)

the line lighr.

Using a 3/16"ncx allc wrench. turn one ofthe ca screws until yoJ see a 1/16-1/8' beam Note: it is best lu star by tunming the screw clockwise. If the scrcw tu'ns all the way in before a line appea's. begin tur ring the screwcounterclockwrise

Similarly. turn the adjustment screw of the olher bulb. until one conlinuous bear is seen acrcss the cu: slick.

Make su'e power is off and unplug Ihe machine (see power lockoul prored ure, pg. viil. Binding F.200-ATITAN200/SEPT99 WhenImageM5

2.0 OPERATHN

Wren :he CLEAR key is pressed ihe carrp and kn-fe

2.0 OPERATION

will move uo if they are nol aleady in :ie up yos:ticn iprcvided the frant guard is closcd). Tncn the

IMPORTANT:DONOTATTEMPTTOOPERATETHE backgaLge will move to coordinate the trle position CUTTER UNTIL YOU HAVE THOROUGHLY READ into the corpuler. When finished. the rrachine will be AND UNDERSTAND ALL OF THE FOLLOWING in *Send Mcde' and the display will appcar simila' to INSTRUCTIONS.CALL YOUR AUTHORIZED the d splay sr:owyi :e yw.

Challenge Dealerif You Stillhave Any

QUESTIONS. 5.000m

2.1 POWER - MAIN SWITCH

Power is brcught to the machire wnen1ne main cowe' switch is tumed tc the'ON'posr on (fg.2-1). The display a'd ine lights &re turmed on at th s tirmeThe hydratlic mctor wil no: be activates urtil a cul cycle is miliated. and it will shut off aler the comslction othc

The backgauge miay now be sent to a desired posilicn by simply typirg the cimension and prcssing SFND [see sectics: 2.11 Send Mode for more cetails)

2.3 MAKING A CUT (Using OPTIONAL

Two-Hand Cut Buttons)

Place the papcr aqainst the backgauge and left side guloe. Note: if the cut wil lcave strips of paper less

The display and line ighs will shut off zfter 5 mnutes than 1!2' wice piace Ihe paper against the right side without ary acvity. This shu:-of lume car be changed guide. This w ll prevent :he strios fron cerling caughl in the Parametcrs scrcen cf :he Maintenance Mcde In tnc small opcning near theeft side guice. (see seclior 2.12.2.2). To 'estcre power to the display ard lune liyhs. μess ary buttcr or. Ie keyboard or lin Tc make a cut sirmply press both cut buttons (localec up the 'ronl guard (if cquipped}. beneath the fron: face of the tablej within 1i2seconc

ofeach oiherHold the buttons in until the knife

2.2STARTUP reaches the table.Releasing tie cu1 buttons at any

tume during the cu: cycle will i rr mediate ly send the

Qnce power has seen 1Jrnedor.the Titan 2cc will snow knife anaclarrp1o Ihc upposition. :he fallowing dispiay

2.4 MAKING A CUT (Using Front Guard)

Cpen the front guard and plate the paper against tne

Bacgauge must mcve tobspreset. backgauge ard lef: side guide.Ncte:if tre cul will Plcasc clcar the table and close leave strips of papcr lcss than 1/2' wide. place :he guard paper against the ight side guide. This will preveni Warr.ng! Clamp and Knife ray the slnps fror get:ing caughl ir 1ne small oper ing near

the left side guide.

Revision 1.0

To make 1he cut. close the fronl guard and press lhe

Press clear to slart cut buttan.If theguard isralsedal any time duning the A}Mainl cut cycle, the knife 2nd camp will immediately return

10 the up posiian.

When Image Matt

F.200-Atitan 200Isept 99

2.0OPER&TION

operator to have Ire rrachie lubricated. Tne luoe

Note: Te gLard irust be ovenec and closed each

alarm will also display the name anc shone nlmoer o :re Challenge dealer from which the mechine was pLrchased. For in str rc lions on hcw to reset sirner

2.5JOGGING AID

alarr: or to change the kife alarm value、see seclion 2 12.2 5 Knife Count. Thc lubc a a'T val.ie is fcclory

A pogging aic is ircludcd as standard equpment with

sel al 2,500 cuts ard canrot be changed.

the Tan 2c0. This too! allows the operator toloac an algn paper without the need to place hands or arrnus

2.7 MANUAL CLAMPING (Using the Foot

Lrde're <nife or clamp.

To use, loac the pape' against the side and backgauge Lsing the .ogging aid tfig s. 2-2 & 2-3) Remcve 1he Tne Tian 200 is equpped wlh a imalual clarping joggueg ancd fror 1he lable close Ihe g.ard. and make rea:re which allows the operalor to marually clamp the cLt. pape'eforeeginning the cui cycleToJsethis

the clamp cones downl or the paser. Wh le lolding

jogging aid from the table before the foot :readle down. close the guarc and press the

cul bullyn. Release rhe fon1 treadile once the cu1 has

making acut.

2.6KNIFE CHANGE ALARM AND

Lubrication Alarm

Titan 2c0 has two buit in alarms that will be displayed after a cenain number af cuts. The kn fe alarm displays Tiessageoremrd1iecperatorochange theknite. The Itbe alarn displays a niessage to rem:nd the TBinding

2.0 OPERATION

2.8 DISPLAY PANEL

INiMM Key

Variable Speed Pinpoint Backgauge

CuLBurtton Soft Keys

CLEAR Key

Priority Add (XY}Key (fig. 2-4) ENTERKey

2.9 DEFINITION OF KEYS

2.9.1 Variable Specd Pinpaint Backgauge Contol 2.9.4 Push-Out Key Tne backgauge control is used to manually position the Ihe pus7-ou: key wll move tne backgajge fonvard 5 backgauge. The speed cf the backgauge will cepend ircnes (or lo the most forwarc sosition) and 1ren rel.rn unnn where the actuator is pressed.Press farther from It to its previous pcsition. Th s allcws paper to be center for a faster speedPress luvard the operator for removed from the cu:ler withoul putting hands Lnder fonvard drectionand away from the operator for reveise :he knife and camp.

CAUTION!Neverplacehandsin the

2.9.2 IN/MM Key clamp and knife area.Use the push-

outkey or the backgauge glide

This key toggles the display to snow the posirion and control to move the paper to an area where it p'ogrammcd sed valuos in nches (e.g. 5.250), inch can be reached. fractios to the nearest 1/64 je g 5 'f], or milimeters

2.9.5 Clear Key

2.9.3 SEND Key

The CLEAR key is used to clear error messages ard

TheSENDkeysJscd tosend thebac<gaJgeto 2ny the current entry line. valid position. I an attempt is rade 1o send the backgauge ro an illegal position, an erro* message will 2.9.6 Enter Key be cisplayed at the botlom of the screen stating

• Number outside limir'. In the Job mode, the SEND xey The ENIER key selects ilemsin the mainlenancc will also advance the bac<gauge to (ne next sequenitial mcde and processes data that has been entered in the cu: positio: before performing the clt. olner rodes.

F.2D0-ATITAN 200rSEPT 99 When Image Ma2-35

2.0 OPERATON

2.9.7 Priority Add (X/Y) Key 2.11SEND MODE

Tre priority add key s used for enlerng fraclions when trey are compirec with whcle umbers.The symbol cisplayed vhen :ris key is presscd ·s thc urderine symbol"_'. Ar example of a rumber entered usingthe pricr ty adc key is 11:2. reverse

Mole

2.9.8 Soft-Keys

The soft-keys are labeled a5 A. B, C. and U. Ihe cefinilion tor Irese keys cnange depending on the opera:ing mode. The funcion of the key can be "oud A) Maint on theboltom cf hedisplay screen. 2.9.9ArrowKeys (fig. 2-5) T!e [our arrow keys can be Jsed in almost all screens. Te arrowkeys are pri marly used for Tioving:hecursor Tre senc mode is ihe first screen displayed afler the arourd on the screen. or to toggle belwccn highl ghted backgauge is preset. Frorn1ns svleer the backgauge seleclions. In some screens.the left arrcw key ao's a5 can be pos tioncd with the sackgaugc pinpoint control a backspace key. or bye rte ring a value and pressing IheSEND keyA

mathematical expression can also be entered asa

2.9.10 Contrast Control send valuc. Simply lype 1nc cxprcssion and press

SEND You can alsc enter ar equatio which begins

The contrast of 1he display can be 2djusted by usirg wir he current packgauge position. For example, if the cortrasl control kincb. whuch is locaied cirectly you want to scnd the backgauge 2 forwarc from its behind tre disolay Darel. slicking cut of the display CLrrent posi: on, just press [-] [2] and SEND. panel cover To ascess. cpen the fronl guard. reach in wilh your lehandtntil you feel tle krob. ard adjust The send mode screer ca7 also be used for doing the contrast as nccessary. math calc ul at i crs that are larger than the backgajge's

reverse limit. In this case, yct must press ENTER to

2.10MANUALBACKGAUGECONTROL have he resJlt displayed cn the screen.

2.11.1 Entering Math

2.10.1 Backgauge Glide Control

The backgauge can be moved manually by tse of the Ir the simple se:nd mode.1he Titan 200 is capaple u backgal ge glicc control. Press towards the operator for calcularing an cntirc math string such es.10-

5+5x5+2_3i4.Howevertheresultis limitedto

foward travel and away from :ne operator for reverse

29999.300 ar: theesull canrot be a negalive vale.

travel.The furtheraway from centerthat the clu al uris

In the job mode. and dunng 2 send. tne res.l1 of the

pushed, the faster the backgauge willtravel.

calc Jlalion must be less than the backgauge lirrit of 20.000 inches.

2.10.2 Backlash indicator

2.11.2Entering Fractions

To insure accurate cu's. the backgauge must be brought to the cut pus:tun frcin1le rear gf :he talle. In the display.tc the nght of the backgzuge positon,there Fractions are enleredwith:hepriority add keyXiY.

The symhol displayed when lhis key is pressed is the

is a smallarrow ta indicate eve'se travel (fig 7-5) Th:s arrow shculd be off when making a cul. Moving urderline Symbol _".This instructs 1he computer tc

add tre fractional oortion ofthe entry before

bask past your cut sositon, then forward to it.

performing the rerairing math. This key is useful when entering a formula as followrs: 3x2_314 =B_114. If a simple plus had been used instead, the resull would beasfollows:3x2+314=6_3r4.

F.200-ATITAN 200rSEPTggatters.

2.0 OPERATION

C.cse 1he fror guard and press ENTER to serd the

2.11.3 Upgrading Power Backgauge Models to

knife to the desired posir-on. Note: To ex t the knife

Programmable Models

down screen and retum to the knife adjust screen, press the cut bjttor.

In Scnd Modc power backgauge models wili display "Bj Upgrade" insleadof "B) Job". Call your au:^orized Challenge cealer il you w shi lo purchase the upgrade 2.12.2Parameters code tha!willupgrade your machine lo a pro gr arma hero cel. In the parameter screen, use tre up and down arrow

keys 1o loggle tc 1re desired pararmeter and press ENTER.Seehe descriptions [hat[cllowfcr an

Iyou have purchased theccde ancwrish toupgade

your machir'e. press the soft-key B to go tc the upgrade explanation of each parameter. Soreen Type in the upgrade code alr pess ENTER. If the cooe is correct. the machine will be upgraded 1o a 2 12.2.1False Clamp proyrarr alble model a'd the display will returm 1o the Start Uo screen. Soft-key B soulc now read "Jos' The false clamp prate is ar optional attachment vhich.

reduces 1he creasing of paper caused by 1he clamp.

instead of "Upgrace".

The cisadvantage o Lsing the false clarmp plale is that

NOTE: Urgrade codes carn ur·ly be ootained from The ·t limits the smalles:cutdimens:o.The computer

must know when the false clamp plate is inslalled

Challenge Machinery Co.hrcughautrorized Challenge

onthe machineto prevent the backgauge from

OealersFar mach:ne has a uniqje cpgrade code

crashing into it. In 1ne false clarp screen.use the up

thatwillnotworkcrotherrmactines.Pleasehave the

and down anrovw keys to toggle betwee7 ON or OFF 10

machine serial nrber {as displayed in the lower left correr of the display, cr on 1he mach ne nameplate! Iindicate thepresence of the false clamp Dlatc.and

press ENTER.

ready when caling. as il is necessary to obtain the

2.12.2.2 Time-out

2.12MAINTENANCE MODE

Theime-outparameter alows:heoperatar toset the

amount of idle tirme before the disalay and lincIghits

5.000 n turn off The chvices aie 2, 5, 10.20.and 30 minutes

In the time·ott screen. use the up and cown arrow keys tc toggle lo the desired rirme-out. and press

Maintmenl

ENTER.

Knifeadjust

Paramfters

2.12.2.3 Push-out

Diagvostic

Language

Normally.wherever:ne backgauge Is sen: to a larger dimension. a five inch j127mrr} push-cut is performed

situations. it may be rccessary to lurr this feature cff.

D} Exit

pussible. In the push-uul screer, use the up and down arrow keys lo toggle to the onor cff status as desired.

The maintenance mode is an area where rnarly

and press ENTFR.

machine lunclions can be set or modified. The four principle functions are.Language,Parameters.

2.12.2.4 Accuracy Ad ust

Diagnos1 c, and Knife Adjust. To select a palicular function use the uo ane down aTovr keys to toggle to

This pararneler pruvides a means for adusting the

the desired functon and press ENTER. See the follcwing descrip:ions for an explanation of each

serd the backgauge tc 2 inches (50 8mm) and cul some paper. Measure the paper, and type in what yoL actually measure.The computer will ca.culare the

2.12.1Knife Adjust

a'nount of error andwll compensate.

The knife adjust function provces a way for :he service

2.12.2.5Knife Count

technican to change thc knifc.In the Knife Adjust sr'eer. use 1ne up and down arow keys to loggle :o the up or dcwn status as desirec. and press ENTER.

F.200-ATITAN 200rSEPT 99 25

2.0OPERATION

descriptions fcr an explanalion cf each

theknileala'Tand i he ube alarm The knife alarm dispiays a message to remind the opera:or to change the knife. The lute alann dispiays a message to 'errurd 2.12.3ErrorCode the operalor lo have the machine lubricated. The lute alarm willalso dis3lay the name and phone number of TheError Cc def nc tion simo ly recaIshe lastfive emor 1heChallengecealer fromwrichthemacnirewas purcased in cases when:heralfunctcncatnol se reproduced

In the presence of the service ech nic ian.

There a'e three funclicns wilhin theknife coun1 parameter: Clear Counl. Knife Alarm, and C-ear Lube. 2.12.3.2$enscrData Sclcci the desircd fuunction anc press ENTER. Scc the

The Sensor Data funclion rovides a list ofcomputer

fallowing descriptio rs for an explanalian cfeach

inputs arnc outpLts (crcx rnity switches, etc.) along with their status O for cpen,1 for closcd)This function

Select Clear count toresel1heknifecounte'whena allows & service tecnnician tc check the status of a

sw ich withoJl removing any covers. Cuts and

knife chaige has been performec.

backgauge movements are a lowed in Ihis screen so

Select Knife Alarm to enteror change theknife stroke that the lech nic ian may observe Ire s:atus af the inputs alarnl va ue. Wwhen this value is reached. tne display andoutpls dur:ny rachine operatior. wil aler. you lo change the kn:fe and reset the <nitfe counte'. Knife alam values for the Titan 200 are factory 27.3.3ClearMerory set al 2.SC0 culs. Hovrever. you may want to change

The ClearMerory function resets the memory to 2

this valuc based cryour spec ic machine applicanons. See the "Knife ps"sec:icn 3.3 for help in choosing a known state. All cut positions will be erased during knile alarir value Iur your imacine. this operation.

2.'2.3 4 Elec1ic Clamp

Select Clear lube tofeselthelubealarmafle perfom-ng the lubncalion requirements as shoiwn inthe maintenance section 4.6. No:e:The alarm wll Tn is function turns the optional eiectric clamp pressure

control on f.

aclivale afrer 2.5oc cuts.This value is set at the factory and cannot be changed.

2.12.3.5 Clamp Adjus:

2.12 2.6 Machne ccun

Tnis furction allcws fo. the adustment of Ihe elec:ric

The rumber disclayed is the lolal numberof culs made clamp fLnction. (See section 4.7.4 Hydralic by the machne

2.12.4 Language

2.12.3 Diagnostic

In the anguage screen, usc the up a^d down arrow

5.000in keys to roggle tc the desired language. and press

ENTER. All messages wil be dis:layed irn the selecled

Ciagnostic

2.13 JOB MODE (Programmable Models

Clear Memory Only)

Electric Clamp

Clamp Adjust Tne Titan 200 can be programmcd for up to 93

diferent jobs or channels. A job is used for making a

AjMait sequence cf cuts usng the send jor cut) values cf the

Dj Exit job as hebackgaugepcsilionsfcreachcul.Each job

canrold upt35sendvales.Hf 2channes arelinked up to70sendvalues canbe accessed from orejob

The ciagnostic area can be very helpful in iocaling a When the job modeis entered.all previously prob:emin lheevent of amachine malfunction.Use the up anc down arrow keys to toggle to the desired name arnd lock stalus. Locked jobs will be indicated selecticn, ard press ENTER. See the following

F.200-Atitan200/Septs9

2.0 OPERATION

by an astoisk ". A plus *+"sign at the bottcm of tre I5 desired. sirply ess ENTER aga n to begir en:ering

send valjes [see below). To ame :te job, press :he

screen ind cates thereare rrcre jobs prograrmcd

gh1 arrow key to mnve 1he cursor to t'e firs1 chiaracter

thar what zre displayec.Ari exarple of ajob mcce

position. Enter a chzracter of1le alphabet by using :e

screen display is shcwn pc ow.

up and dcwn arrow keys to toggle lc the desired character.The rurmeric kcys can sc used to enter nufT bers direcly into the job nare. Whe the desired cnaracter is in place, usc the right arrow key to move to the nexl characler position. The job nzme can be up to

2>TESTJOB 10 charac:ers lcrg. A leller can le reroved from :ne 5> jos namc by moving tre cursor to the undesired >BOBSJOB chara cle rard pressing the CLEAR key. Wren firished.

p'ess ENTER tc save the name and to beyini erering send values.The screen shcLld now kook similato the one snow nexl:

A} Lock CjErase

2.13.1 Lock/Unlocking aJob

In the Job Mode screer, the soft-kcy *A' wiI display "Lock" o"Unlock' depencing o the curren: statts of the cb If a jos is locked. an asterisx wil be displayec to 1ne right of thc job name. To change he ockstatus oa job.simply move the cursor to the dosired job using the up and down a'row keys. and Ci Erase A; Insert press the sofl-key 'A" (Lock/Unlock]. D) Ext B; Job 2.13.2 Copylng a Job

Now enter send values by using any of the following

down 1o the cesired job number and press the scft-key

methods:1j Type in the desired value and press

ENTER.2}PressEN{ERatablank line-thiswillenter

botlom of :ne screen.Er:ler a job number fcr the rew

the current pcsilion of the sackgauge as a senct value.

job or move the cursor 1o an existing job and press

or3j Use thc'Cut and Record"featureasdescribed

ENTER I the rew job is locked. the copy will not be allowed. NOTE. if :he new job Is not ocked, brit belcw. cCntains data. lhe od data VWILL BE LOST.

When finished er.tering send values you may exit the curren1 job by Fressing soft-key B (Job) lo go back tc

2.13.3 Erasing a Job

tne job mode screenn ur soi-key D" (Exit} to exit tc scnc mode Or you may use the current jcb for cutting

Selecl ajo to erase by moving the cJrsor lothe

by pressing the down arrow a1 the ast line and foilowing

desired job.Press The sofl-keyC"{Erase!"Clear channel #r will be displayeo. followed by YES or NO. the instruct i cns in the "Running a Job"section (pg 23) Use te up and dcwn arrow keys to loggle 1o YES or

2.13..2 Cu: and Record

NO. YES will erase tine job. NO wil: leave 1he job unchanged. NOTE: locked jobs can be erased!

lo use his leaturc. send the backgauge to a desired position using tre backgalge glide conirol or by using

2.13.4 Creating a New Job

SEND. then make a cut. The curreni backgalge pcsition will automatically be entereo into thc job as a

To create a new pob. typc in a number that :s not alreacy

serd valce. This can be very conven ent for setting up a

assigned to a job and pre5s ENTER ferlering a job

program wren the actual cut positions are riot known.

numbergreaterthan99will crcatejob#99j.Thecursor will mcve 1o the line corresponding to the numher you

2.13.4.3 Channel Lir.king

typed in, prarpling you for a job name. if nojob narmle

F.200-Atitan 200Sept 99 2-7

2.0 OPERATION

the existing va ue.

If more than 35 cut va ves are needed. 2 chanrels can be linkec together nto o1e ob prcvding up to 70 cut

When fir is fed editing :e jcb ycu may exit the cur'ent

values. 1 nis is dore auto metic aly wnen a job s a: 35 cuts anc an attempt is made to add anothe'value. At

mode screen or soft-<ey D IE xit; o exit to send mode.

tris po n. a screen is d splayed askng: do you wart to ink to the nexl channe/ Use the up or dowri arro key Oyuu rnay use the ub lor culting since r is already select yes or no. lIf no is selected.the lasl cut wi I be coen. discarded and the new value will be inserted. lf yes is

2.13.5.3 Insering Send Values

sulected. the sl cu: will Le pushed into 1he f rst va-ue

value 36 ot ire current charnel. If the next channelis To inserl a senc va·ue. press the scf-key "A' ilnsert)

This moves ail send values dcwn and prcv des ab ank

ockec. linking will ru1 be allowed. NOTE: II [he nexl

ire afler the current send value. If more than 35 se.d

chanelisotlockec.but contains data.theolccat WILL BE LOST Afler 2obs have been linked. the linked values are neec:ed the jtcan be .inked (see Charnel

Lirking under Crea:ing a New Job, section 2.13.4.3).

2.13 5.4 Erasing Send Values

To un in< a joo, use the up cr down arrow key :o pont to he linked job raine and press sufl-key 'C" (Erase].

To erase send valuc.press the soft-key "C"{Erase}.

Wwhen finshec rnlering send vali.es yau may exi: the. This willremove Ihe cut val:je currently heing pxointed ta

uy tle cursor.Tu backspace cver the currer se value without removing the -ine.press the left arrow key.

send mcce. Or you ray use the curent jos for culing byoressing the down arrow a:thelas:line and 2.13.6 Running a Programmed Job oliowing the instrctions in the Running a Job sect on 2.13.6. Tose an exis:ing jchfarcuttng.you mustfirstopert

by using one of two meihods: move tne curso? 'o the desired jcb with the anorr keys and press ENTER, or

2.13.5 Editing an Existing Job

enter the job number wit :he <eypad and press ENTEROnce a job has beencpened,tne cument job

2.13.5.1 Edll ng theJob Name

number wll be displayed n the upper rght corer. Now

The job name can be edited (cr added if an existing Jress SEND to move the backgauge to the First

rogramrmed position (or send value). Clcse the front

joh doesnothaveanamejinthejob:modescreen.To

guard anc makea cst.Once the cul is made.the

eci1 the ame, mcve 1e cursor dowr: to the desired jobnunber by pressing the cown a'row key.Th:en backgauge will automatically pusn cut the paper if

"push-ou:Is enabed)and movelo the next

press the right anow key to move lhe cursor to the

programmed position. Aftter the last cut in the job is

desiredcharacte'sosition anc edi1he characterby

rmade, the backgauge wllmuve tc :he first culposilio

pressing the up o' down arrow keys lo togyle between

of the ctrrert jos. Pressing SEND at any time du:ng

characters of Inealphabct.Numbcrscanbeenered directly by Js.ng the number keys. Pressing CLEAR :hejo wilsend the back gauge lo its ne xl programmed clears the currenl cliaracer.When firshec.you may josition wilhcul making a cut. A plus *+" sign will be esther gc to the current jo by pressing ENTER, or go displayedatthebottorm.ohescreenif morecuts a d fferen:lohorexitohmode emain in :ne cuTen! job

2.13.5.2 Editing Send Valucs 2.13.7ExilingaJob

To eri send values of ar existig jol. slart tby open.ng To exit an openjoh, press the soft-key "B" (Joh) tc relur" the desired job from lhe job mode screen.A job is opened by one of hvo methods: pointing at the desired exit to the sene rnore screen1. jobwith thecursorandpressingENTER,orbyentering the job number with the keypad and pressing ENTER. 2.14ANEXAMPLEJOB Once a job has been opened. lhe current job number will be displayed in the upper right samer. Note: Ifthe The following is an example of how to program a job jobis ocked.tcannot be edited which will be used 1o maketro cuts: one at 8.5 anc

cne at 11".

or down tc the desired send value and then typing over

F.200-A/Titan200/Sept99

2.0OPERATION

Tu'n on the machine anc press Cl FAR to preset :ne bac<gauge Press the soft-key "B' iJob) to go job mode

Type in a new job number and press ENTER. Noel1 Tust be a nunbetha1 dces not corressonc 1o anexisting job. All existing jcbs wll se displayed on tre screer (you may have to scroll thrDugh :nem o see then all)If yat. wish to replace anexisting job with the new job,first erase the exising job sy rmov ng the cJrsor to I and C: Erase Allrser. press the sof-key "C" (Erase). Now lype in the Bi oh new number and press ENTER ln this example. jot #s 1 2.5. and already exist. We wil usc job

4. To enler the first send value ot 8.5". simply type in

7 foour new Jcb. Press 7"and ENTER.

8.5 anc press ENTERThe cursor will move o :hc secord line. Naw type '1 and press enter

.The curscr wllmove down to the ew job number. A1 thns pout. cress the right atow key once to move ine curscr to the first character pos tiun. 5.000m #7 Now name 1he jcb "8.5 x 11 . To dc this. prcss "8" U'1 the muniber key pad. Then press the decimal ". key and so on. Tc enter the spaces and the 1>8.500 lelter "X.use the up and down arrcw keys 1o 2> 11.000 toggle througr the alphase: and press the right arrow kcy to move to 1ne next character posilion. Wrhen the last characler has beer lyped in. the display should loox sinmlar to the one shown

A) lrser CjErase

B) ob DiExt

At lhis point you could exil and save tre job by

2>TESTJOB

pressing ihe soft-key "O" {Exilj to exil to send

5>BOBSJOB

miode.or the soft-key "B [Job] to exil back tc thc job node screen. However lets use this job 1o cut

Press the down arrow key once. This willremove the blank line 3 and miove the cursor to the first

C) Erase

AI ack

scno value (S.5"). Now press SEND. Th s will

B, Copy D) Exit move thebackgauge1o the8 5positiorPlace

thepaperto se cut againsthebackgauge.clse the frort guard. and press the cu1 bullon Qnce

Vow press ENTER to begin programming the job

the cul cycle s complete, the backgauge wil push

The display shoud now look s milar to the one

out the paper and move to the nexl send valve [1"]. Now position the paper again.close 1re guard. and make another cul. Afler tre cu: s made.the backgauge will push out the stock and return to she first cut posit:on. ready to repeal the current job.

Now lets kock the curent job so it cannot be edited. First,exit back tojob mode by pressing soft-key B"iJobj.Nowmove the cusor down to the neiw jo cs ng the down arrow key. Now aress the soft- key "A" (Lock) to lock the jcb. An aster sk will

F.200-Atttan200Sept99 29

2.0 OPERATION

appearnficatirg the joh has beencke!

7. To exil back ta send moce.press 1re soft-key 'D

2.15 OPERATING TIPS

Carelully lay out each sheer before ycu start cuting. F:nd the best cut patten lo give you the most pleces oul of :ne sheet If the sheet will be folded. be surg grain o the paper is running in ihe same direction as the fo.d cr you will ge: a rough edge on 1re fo!d.

Ian ascu'ale cut isnecessary for close register wcrk, youMUST havea snarpolade in Ihe cuiter.A dull blade will pull ar draw thie paver anc causeureven cutting. Increased c amp pressure will nct elirrinale draw caused by a dull knife.

Tne correct clamp ng pressure vares rom paper to paper. The genera ruie is thal you shculd Fave enough

that it marks ihe surface of the paper excessively. Excessive oressure causes pile dis:ortion and inacurate culs.

Marx the gipper edge and the guide edge of printed paper and make sure the irst cuts are wnth thcse guide

Measure printed paper to check for shrirkage or expansion of he paper from humidity. Ycu may have lc disregard the printed cut fines and make your own.

When cutting bu:sness cards o' rarrow sinps of paper. place liflis of equal height on opposile sides of :ne table toprevent wear of the clamp guides.

2.16NOTETODEALER

2.16.1 Enterlng the Dealer Name and Phone

To enteror change the dealer rame and phone number that wll be displayed when the ubricaticn alarm is

you must firsl enler the 'Dealer Mcce" screen. To dc this.tum off thepower. then simultaneously hold the left and right arrow keys while turning on the power.

the machire tums on.Now enler the desired dealer in for i mali on by csing theup and down arow keys tc toggle through the characters (simiiar Icnaminga job) Use the right arrow key to mcve tc the next character and to move to the 2nd line. when finished, turn off the pover. MuBinding

F.200-Atitan200Sept99

3.0KNIFE INSTALLATION I CHANGING

2. Bac< off the knife adjusting screws on too of the

3.0 KNIFE INSTALLATION/

knife bar several lurns [fig 3-2]. A new knife will

CHANGING cul deeper thar one thathes been grounc scveral

tmes. Falure lo back off 1ne screws couid damage the kn fe andor:he cuting stick.

CAUTlON: Changing knives can be very dangerous unless safety precautions areobserved and Knife Adjusting Screws extreme care istaken when handling knives.

Make sure knife 1lters are properly installed, see instructions following. Keep handling of unprotected knives to an absolute minimum. Clear offcutler lablebeforeremoving

Have scabbard on cuttertable and insert knife immediately.

3. Remcve the knifle bolls from the hwo slottec knfe

Wam people of any unprotected knife.

bar hales and reslace with 1he knife lifers (fig. 3-

Knife changing is a ONE PERSON

3].T gilen 1he lrters to holc the knife I pace.

OPERATION. Having more than one

trenremove theemainingknifebolts

person trying to change knives invites

Hex Allen

Knile Lifters

Clearthe tab e suraces anc place the empty knife scabbard on the:able.Remove the scabbard'sknife

The knife changing equpment shown in fig. 3-: is relainirg screws. included in the cutter lool kil. The following instr.clions shov: how 1o re-mcve and install z new cr resharpened Grasp the kn:fe lifters firmly and. at the same time. knite.Read through Ihese Instructions AT LEAST Iurn therm counterclocksyse to release the knile from ONCE before atlemoting tc actually change or install the knife ber (fig. 3-4). Lower the left end first, any blades. then lower the rigit end as you shift the knife

sldeways to the lefl. Bring the rghl end of the knire

3.1 KNIFE REMOVAL arounsd tre knife bar guide frame. Maneuver the

rigntend into the space belween :ne guide frame

Make sure the knife and charr:p are irn the "up" and the shroud as the ler end is brought clear of posininn. Tum lbe main power switch to lhe *OFF" the left guice frame, Move the knile to lhe riglht cosition and disconmect the machune power cord then brirg the knife Dut o the cuttcr. left end firsl. 10prevent accidental power-up while servicirg the Put the blade in the ssabbard mmediately and cutter secure the knife retaine: screws.

F.200-Atitan200'Sept99

3.0 KNIFE INSTALL A TONI CHANGING

around tne right knire ba guide frare anc up nto theknfe barslct.Rasetheknifeirto theknifeba slp1 as hig as il wl go 2nd hghren 1he lilte's.

NOTE: If :re blade will not go in. ether the liners are screwed into the blade too far. or the end of the blade is hitting the cylinder brackel at the rigrt erd of the xrnifle slo1. In this case、 drop tre left end when nserling 1he kn fe.

7. Insert he xnife sats wilr washers and snug to hold heknie.but don't tighter therr yet.
8. Rermove the kn felifters one ata time and replace
9. Place a few sheets o papcr over the cut slick.

3.2KNIFEINSTALLATION

cover'ng the stick end-tc-enc

CAUTION: Knives are heavy and

10. PlJg in the power cord and turn the power on.

always very sharp! Be sure to keep the edge away from your body and

11Gc to the MAINTENANCE screen and choose

keep other pcople out of the area while

KNIFE ADJUST. ChooSeKNIFE DOWN,cloSc :he

handling the blade. Severe lacerations or

gLard. and press te cul bjlton to senc :he knife to

dismemberment could result from careless

the dow sosilion (fcr morg delails on how ta do

handling procedures.

this. see sec! on 2.12.1).

12. Tum the power off anc disc on net the machine pc wer

Make sure he kn fe and clamp are in the up positior. If they are not. turn on the pcwer using the red ard yelow main power swtch.close tne tront guard,

13. Turn the knfe acjuslers dcwn evenly.a little at a

and press the CLEAR button This will sreset the

time.untl theknife curs through thebotlom sheet

backgauge ard send ne <nife ac clarp up.

of paper the entire length of the cutling slick tfig. 3- 5}.Tumngthe screws downevenlyoreverts uneven

Tu'n off the:machine anc unplug tre poiwer cord

wear onthe knife and cuting slick.

Pullout the cuttirg slick using he cJt stick remcval tool and turn it to a nevr surface. If tne culling stick isnot level orush with the1able,/2"strios of paper car be p aced :n the table slot urder the cuilung slick tc shim it.

.Remove1eleft'etaierscrewfrom thenewblace and screw theknife liters into the new blade.Screw the lifters allthe way in and then back them ou: 3

Rem cve the other scabbard rel air er screw.

Dcuole checs to make sure tre krifle adjusting screwshavebee7backedouiall theway(step#2.

Knife reroval!L.ft the blade and insenit into the

14. Plug in lhe power cord and tur the power or.

knife bar slot. Guide the blade. ight edge first, into the space bctwecn thc srroud and thc knfc bar

15. Close the"ort guardand press CLEAR. Tis wil

guide frames. Tip to clear Ine :able side guides,

raise the ki fe and clamp to the up pos i lion.

F.200-A/Titan200Sept99

3.0KNIFE INSTALLATION I CHANGING

16. Turn the pcweof and cisccanec the machne power be sharpened Some characteristicstra:indicatea

blade neecssharsening are

17. Tigritenall knife bo ts secu'ely The knife hesitates or stalls while making a cul.

12. Plug in the powercord and tum the poweron Make Tre sheers are nct all cul to the same lengh (uslally

the lop lew sheels are urger ihan 1he rest of the

a tes1 c.t:rrougha fulllift of paper and rmake minc

snee's - 1his 1s sometimes called "draw"1.

adjustments1 nccessary by reooa:ing sleps 9 :arough 17. NOTE: If the knre enos cut but 1he

Cut ma'<s appear on t'e ctt face of ire paper.

middle cpesn':. you could have dips ur ureve'1 spos in Ire knife andicr culing slick.Thesc cen bc

Tne prcfile of 1re c.risice view) is not perpendicular

eliminated by clac ng 1:2 strios of xaper nihe table slo1 beneath the cLtting stick tc shim i1. lo the leble.

The cut does nol appear straighl when viewed fram

19. Send the dull knife to a knife grirder. Do nct attempt

the :op.

o sharpen yojr own krives! See the Knife T ps section3.3odetermine the knife be ve ang e

The knife makes a'rcugher' sound as it passes through paper.

3.3KNIFECARETIPS

Nicxs are vis ble on the cutting edge ofthe knile

are DANGEROUS!!! They are heavy 3.3.2Cutting Stick and very sharp, even after use. Keep the edge away from your body and keep the A worr cut:ing stick can afect ihe cu: qualily of the area clear of others when handling knives. bottom sheets.When this happens.the cut srick can Never touch the cutting edge! To prevent be rotatecUsually. 1he s:sck should e rotated one or personal injury and damage to the knife. two limes between knifle sharpenings. tightened.You are awareof thedangers,but There are & oossiole cut s: ck positions The stick can others may nol be.Never attempt to hone. be rotated 4 tirmes. thenlurned end to end, androtaled polish.or scrvice the knife in any way. Failure 4 tirmes again. to follow safety procedures may result in severe laceratiansordismemberment. 3.3.3 Bevel Angle

Challenge recommerds that cevel angles forthe Titar

200<n ves be in :he range of 21 to 23". In gerera. a 21* evel angle will provide a beller cul qjalily whcnl

Knife blade life.or the lime between sharperings can

cul tings of paper isuchasrewsprint)recycledpaper,

be affected by many factors. One important factor15

or bourc books. Howeve:, 21 angle <nives can become dull scone than 23knives.whichresults in shorler

rccycled paer,soft papersuch as newsprint paper. and

kn fe blade life. A knie wit & 23 bevel angle, on the

bound bocks can all s gniicantly shor:en knire clade

other Fand. wil not cul as easily. ard can provde

life. Also.if 1he knife depth is sel too deep, 1he knie will

sal s'aclory results whe7 cul: ng rost types of paper

cLttoo decp into lhc cutling stick and ca~dull the knife

Krnves sh ppeci wilh he Titan 200 from 1he factory have a bevelangle of 23.

A knife can last aryiwhere between 2.00c and 5.000

3.3.4 Helpful Suggestions

cuts before it needs to se sharpened. Cutting soft pape

lf your shop islarge encughto purchase more than

consumer recycled content car cause the knife to need

one set of knives. have one set beveied al 2*^ and

sh:arpening after only 2 0co lo 3.000 cuts. Cutting pure

thc olher at 23'. Note:A set consists of 3 knives:

paper, such as bond pape"wilh no recycled content.cr

onein the macrine.one as a bacs up. and one at

hard paper can allow the knife to vc used for as many as 5,000 cuts before it needs to be sharpened. In all cases. the operator should continually check the ct ality

If :he rachine seems to stain bul the cut quality is

of the cut to determine when the knife blade needsc

stl gcod. reduce he pile height, Yo, may also

F.200-A/Ttan20Qsept99 33

3.0 KNIFE INSTALL AT ON CHANGING

hard.coaled paper. Tie a colh to tre end of a stick: dep lhe slick in glycer. and app y. Never aoply by hanc! In lieu cf glycerin you may lighily rub whie ber soap alorg he bevel. Lubncalon wr l prolory tle life ul your machine ard redtce

3.3.5Knife Care

To orevent corrosicn knives are coated witr light oil.Itshould be REMOvED WITH CARE.

While eincv-ng or istallrg a knife, be careful not to allow the edqe to bums agars: the inachine. Nicks wil reslt.

I a knife bol: is daraged, replace t.

Always keep knife hnlts securely tighlened

Always use re heavy duty kuife bolt washers provided by Challenge Fa lure to do so could esult in scralcning or maming of tre clarip face.

Sio'e knives ·n 2 dry envronment to prevent

Never attermpt lo service a knfe in any way

F.200.Atttan200Sept99

4.0MAINTENANCE

4.0 MAINTENANCE

Notice

The instructions on the following pages are for the use of trained service personnel only!

Attempting to perform repair and replacement procedures without proper training may cause machine damage or operator injury!

PARTS CUSTOMERs: The Challenge Machinery Campany provides parls with the express under-

modification or alteration to any Challenge products, and any such modi fic a lion or alteration to any Challenge products is not authiorized by The Challenge Machinery Company.Any modi fic atl on or alteration of any Challenge product will void any remaining warranty.

F.200-A/Titan 20Sept99

4.0 MAINTENANCE

4.1 TROUBLESHOOTING

Won'T Start

Concavecutting-Variationfromtopto

Fuse Blowr.

Bottom

Power corg disc cnn ec ted

Sof! paper nct finrnly clared.

Manpowe'switch notlurnedcn.

Knife dull or ncorrectly graunded.

Back Gauge Display Inaccurate

Erraticoperation.Powerloss

Preset circu t poard malfunction.

Hydraulic luid low.

Enooder malfunction

Dirt ir. hydraulic sysleT.

Main circuit soard ra function.

Cylinder or hoses leaxing

Thrust washers areloose

Voltage supply is low.

Backgauge Oisplay Inaccurate-By

Knife Drifts Down

Constant Amount

Krite latch not engaging or camaged

Presetter malfunction.

Knife Hesitate Sqr Stalls

Du-I knifc.

Cutbuttonpushed-Won'Tcut

Main relief va ve setrng off

Checke'ror codes.

Paper clamp ec too tight-hower ciamp pressure reducer

Guard open Guard hasr'1 oeen opened sinceiasl cut

Cylinder seals worn - leaking pressure.

Hydrajlic fluid low.

Hydraulic fluid low.

Mair elef valve seting off

Vollage supply is low.

B.lton defective.

Knife Starts Down Before Clamp Reaches

Motor telay de'ectuve

Table

Knife latch soler:oid defective

Krife down secuence valve seting incorrec1.

Knife down coil defective. Cylinder or hoseisi eakirg.

Knifewon'Treturnup

Cylnder dsconnected rom cy lin cer bracket.

Soleroid defective.

Knife bar cidy or dry. lubricate xnife guideways.

Limi: switch out of adjustment

Dirt in hyd'aul c sys:er

Cylinder disc on nec led from bracket.

Clamp Starts Up Before Knife Is Up

Pump-Motorwon'Tshutoff

Clamp Up Sequence Va've setting incorrecl.

KniferClamp Up L.mit switch not activated -readjusl Molor reiay contacts welded.

Concave Cutting-Ends Wide,Center

Narrow

Excessive m:oisture al ecges df paper.

F.200-Atitan200Sept99

4.0 MAINTEHANCE

4.2ERRORMESSAGESANDOESCRIPTIONS

Loose solenoid wire: mechanical

Letct -ailed lo disengage knfe bar Knfe Latch Failure

bnd: knife up prox. switcl cu. of

within .6 secords.

acjustment; defective p'ox. switch

C'amp up sequence valve: solenoid

Clamp Up Fai ure Clamp failcd 10 retrun 0 up pos tion

cuti valve

withn 7 seconds

Knife fai:ed to ccme down w thin 4 Kn-fe Down Fallure Lo main pressure ow' voltage:

xnife cyyn sequence valve

mechan.cal bind; so encid (cuti

Knife fai ed to rotum within 1.17

Krife UpFaiure

Clamp or krife stayed down No rain presstre: stuck solenold

Clamp rKDow

Sequence Eror Timing errcr ir eitherup ordcwn

Prcx switches: broken kn fe bar

Krife at Both Limits are on at the same time

Operalor error; key board failure

Console key was pressed whie Send Cancel ed backgauge was moving

Operator errcr: false clamp lirT:1

Selected cul posilion beyonc

Num5eOutsideof Lm

Posiloning Enor Bacgajge failed to mcve tu pru- Mechamical bind.encodefailure: g'anmed positon wthin +i-.005 main pcooard:leadscrew lhrust

wash:ers loose

Defeclive relay: safety hooc switch-

Hydraulic latch nolding relay faled Hydreuic Latch Fa lure :o pull ir es defeclive or need acjustirg

Backcauge Fai ure Backgajge doesnt mcve Mechanicalbind:encoderfailurc:

main pcboard; blown fuse

Operator error: defective keybcard

Console key held in for over90

Shorted Key Error

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

F 200-ATITAN 200rSEPT 99 43

4.0 MAINTENANCE

4.3SENSORDATAABBREVIATIONS

Standby Descristian

RHSAFE Hside right of fron1 ccver Right Salery Switchi LHS.AFE Le^ Safety Switch Insideleftoffronlcover KNFLAT KnifeLatchProxurily Swtch Left sideofcutterocening Hydra.l c Latch Reley Main pcs board

Hydlat

inside cfcutter opening right side

KNFDWN Kn feD own Proximity Sw tch Preset Sensor Rear of culer.Lnder left side of table

Preset

Soleno:d Va:ve cnlef. side oManifold

CUTSOL Culvalve

Solenoid Valveinct nuse ye:)

UNLOAD Unoec Valve

KVLATSOL Kr:feLatcFSolenoid inside cf cutter opening.let side

CLANPU> inside rear of c.lter opening, eft side Clamp up Prcx miry Swilch Hyd. Clamp Up Proximity At otom of clanp cylinder

Hvdup

KVFUP Knife Lp Pox im by Switch nside of cetter opening. lefl side CUTBTN On disp ay co:1sole

No Connection

Hydra.. c Maor Relay Fop right side of mair pch

Hydvot

N.C. No Connectlon Line Ligh: Outpu: LTLINE Inside rear culter openng.le^ side CBINLIT Cul BLtton Light In disolay conscle

4.4.1 Weekly

4.4ROUTINEMAINTENANCE

Clean - Clean off oldi. oity excess grease Remove

Caution:Disconnectpower

the frontpenel cover and clean accumulated dust cff

before making any adjustmenls or

vaves.hoses and connections.Bult-up dust increases

lubricating. See page 4, SAFETY

operating lemperatures wrichcauses prernature wear

PRECAUTIONS,forPower Lockout Procedure.

t all hydraulic componen's.

Hardware —Rermove rcnt panel ccver,rear panel

Place tr smachine or yourplan1 Tanterance

ccver, and lop hood 1o check all nuts and bo:ts for

schedule. A clean. lubicated machine will run longer,

lightness.Loose hardware is thecause ofrmost

simoother. cul more accurately, withless dcwntime and fewer ccstly repairs. Schedule ubncaticn bo:1 early component wear and in the e ectrical area could cause

short circuits andror shock.

in the day and early in the week.This allows the lubricanls tu work nlute inachne. Lubricalon a1 the

Hydraulic Fluid —Low flJic level causes excessive

cnd nf thc day or weck allows the lubricants to rLn nff

heat andwearon thesystem.Check theflidlevel as

w thout any benelit tc the mach ne. The fcllowing guidelines willtielp you set us a ieyular imarena'ice

F.200-Atitan200Sept99

4.0 MAINTENANCE

4.5.1 Recommended Hydraulic Oils

Oiland Grease — See section 4.6

4.4.2 Monthly

recommended ollsoran ISQ vG 100

Proximity Switch Adjustment — See secllon 4.7.3. Hydraulic Fluid equivalent only.Oils

other lhan the recommended type wil cause seals and O-rings to deteriorate. Unsafe

Backgauge Squaring —See secticn .7.2.

operating conditions will result.

4.4.3 Yearly

Change HydraulicFluid-See secticn4.5

Rykon No. 100 AMOCO

4.5 CHECKING/CHANGING THE Duro AW Oi 465

AwMacine O 100

Hydraulic Fluid

PacemakerXD No'C0

Super Hydraulic 100

The hydraulic luid level shojld be checked weekly.

Nuto H-100

To check.remove the lower real cc ver and unscrew

Hamcny 100 AW

:he cap on top o: tnc tank (fg. 4-1]. Flu d leveshould

HQ 2A Hydaulic Ol

re al 1!8""rom the end of the dip shick (check wth cip

DTE No. 18 Mobil

stick cap svrewed irj. Acd flurd if neccessery but avoid Fen7cl AW 100 Pennzoil overfilling as this could cause leakage when hor.

Megnus A Oil 215

Rep ace the rear panel when finished. Shell Te lus 100

Energo HLP 100 Schin Indusircr 100

Sun Oil Co. RandHD 100 Union Oil Co.

4.6OILAND GREASE

Turn the power off and disccmect Ihe pover cord. Open 1he fot guard (if equipped] and ope:he tophcod for access.Parts requining oiing are marked with red paint See figures 4-2 tn 4-9 for oll and grease localions. Figures 4-2 to 4-4 require the knife and clarp be in the up position. Figures 4-5 tc -9 require the knife and clamp5e down.Wipeoff anyold oexcess

The hydraulic fluld should bc changcd ATLEAST

grease. Use any brand-name type of grease or lignl

ONCE-A-YEAR or alterevery 1.COo hoL.rs of operaticn.

dll to .bricale. lt may bc necessary to use the suspled

NOTE:Failure tochangeoil wen needed car damage

grease brush to access same lccalions.Note:the

seals in the cylinders. pump. and valves.

leedscrew tiay be lubricaled wilh grease or oi. O1 has 2:endency to run off and must be luoricatec more

Empty the hydraulic tank and ref.l with 1 gallon cf

frequenily: grease tends to collect paper dust and reust

Inter nation a i Standards Cr ga niza lion Viscosity Grade

be cleaned off period·cally.

100 (ISO VG 100) rust, oxidation. and foam inh biting hycraulic fljid (Challenge oart nc. S-1991).

NOTE. NEvER use autcmatic Iransmiss cn fluid or Crakcfluid as a subsltulecr thecorrec:hydraulicfluid A lable ofvarious manufacturers and theirequvalents Is lisled below.

F.200-Atitan 200Sept 99 45

4.0 MAINTENANCE

Knife Bar Link - Lefl Hand Side, Lower

Knife Bar Link -Left Hand Side. Upper [Fig. 4-2)

Knlfe Bar Link-Right Side,Lower

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

Knile Bar Link - Right Hand Side, Upper (fig. 4-3}

Knife Bar (fig. 4-4) ClampGuide (fig.4-7) Clamp Guide (fig.4-9] ing

F.200-Atitanzooisept99

4.0MAINTENANCE

Nylon Guide

Leadscrew and Backgauge Guide (fig. 4.9)

NOTE:Thescrewsshould be tigh:ened tohald the

4.7ADJUSTMENTS backgauge square against the guide rall. Excess.ve

tightening will cause the backgauge to bind and cause premalure wear ul all components.

CAUTiON: Several of the following tests require them a chl neto be opera tional for checking and adjusting. Be 4.7.2SquaringtheBackgauge very careful thal lools and other people are clear ofmoving parts and that the cutterIs not acci- dentally operated while adjustments are being made. whenever working on the machine, dis- connect the power and lock it out [see SAFETY PRECAUTIONS, page vij unless the directions

Paper

Paper

spe cifically require the machine to be powered.

4.7.1 Backgauge GibAdjustments

Ic tesl if the backgauge is square. place a smallit of paper agairst the left side of the backgauge (but not

If the backgasge does rot si2y squared or jumos up

againstthesideguide]and make 2 cul.Now,leave

and down when jogcing paper ayains: t, the backgauge

the backgajge in the same posit on. flip the lift over

gib screws a'e probably loose or wo'n.

and push it against the rigit side of the backgauge

To Adjust: (but not against the side guidej. Make anoher cut to

see if any of ite paper wll :am cff. Run lwo checks.

1. Send the ackyauge near the rear of the table. one starling on the left anc rmwing tc the rght. The

other, movirg from the right to the left lf paper is

Turnoff the powe'ard disco nne cl the power cord trimmed in either sequencc. the backgauge is out cf

Rerove the lead screw cc ver under thetable

1. Nake Sure the backgauge gibs a'e set prcperly

Loosen :ne two side gih screws and the bcllom (see section 4.7.1). nylon gude screws ifig. 4-10).

NOTE: Gib adjustmenrs are rict necessary on initial

Tighten the bottam nylon gude screws until 1ney machine selup as gibs have been adjusted at the just touch the guide. Do nct cvertighten ur 1hey factory. could cause the backgaugeo bind.

2. Rernove Ihe rear plexiglass table cover

Similarly, turn the side gib screws in unil they jLst touch the gude. Lock in pcsil.on w th. he jam nurs. Loosen the twc hackgauge screws (fhig. -2)

Rur the backgauge cack and fortr the lengti cf 4. Place a 90* square or triang'e against he :he table using the sackgauge glide control. Checx backgauge and left side guige. Square the for any binding. Readiust if necessary

When Image Matt

F.200-Atitan 200Sept 99 47

4.0 MAINTENANCE

backgauge. hold it n p.ace, and tighten the two

(fig. 4-12) Adjus1 tre krife downn proximity switch (fig. 4-13) by ocsening re two mounting screws and slicing the

Note: Once the backgauge is square.restore power switch clcser to the kn.fe bar. The gap setveen the to 1ne mach ne and check 1he backgauge 2ccuracy isee sroximity switch anc the knife bar shoulc be 1/32"Ic 1/

16' (0.5 to 1.5 mm). No vcrica adjuslir'ent is recessary.

sectior 2.12.2.4] to make sure it is accurale.

4.7.3 Proximlty Switches Clanp Up Pruxirnily Swirch (Clarnpup!

Proximity switches are used to nform the computer of ake sure the clamp and krife are in the up position.

Turn the power switoh: off and disconnect the pover cord.

the up and dcwr posiions oi the knife and clamp. They

Open the font guard. the lop hcod,and the upper rear

do rol celerm·ne the stopping posilicns of the knife anc clarrp,and lhereforerarely need tobe adjusted caver Huwever. if a proxrniy switch is rot sensung the knife or clampposito.n correctly. it ray nced adj stment.

Tocheck if 1he fou'praximity switchesare sensing correctly. go to Maintenance Mode and select Diagncs:ic. Then select Sensor Data, and a list of aborevialiors for several inputs and outputs wll be lisled. along wth their status [0 fo'open. 1 for closed}. The four proximity sw:tches shoulc have the fclicwng status during the various knife and clamp positions

Knire Jp Knife Up Clamg DcwClmp Doun Hydraulic all ri

[fig. 4-14]

If any of the four proximify switches has a sla:us of 0 Adjust the clamp up croxim ty switch (fig. 4-14) by wrhen i: should be 1. adjust the switch as described lxwsening the two actuator mount.ng screws anc sliding

the actuator up or down. The gap berween the actualor and 1ne proximity swilcn should bc 1:32 to 1/16 i0 5

Knife Dcvn Proximity Switch (Knfdwn)

Make sure the clamp cnd knife are in thc up position. Knife Up Proximity Swilch (Knfup) TJrn the power switch off ard disco^nect 1he power co'd. Open:ne front guard and the top hood Make sure 1he clamp ad kaife are inreup position.

F.200-ATITAN200SEPT99 atters.

4,0MAINTENANCE

4.7.4 Hydraulic Valve Adjustments

Turn the power switch cff ard disconnect the power cord. Open the tronl guard and he top hcoc

Notewhen adjusling valvcs. first lcoscn the jan: nu1 a'ound :ne ster, then use a hex allen wrench to l:irr the stem clockwise toincrease pressure.or counte'clockwise to decrcascpressurc.

4.7.4.'Pressure Settings:

Main System Relief Pressure - 1,400psl Knife Down Sequerce Pressure —So0ps1 C arrpiKnire up Sequence Presstre — 60upsl.

4. C amp Pressure Reducer —403-800 psl

(fig. 4-15)

Adjus: 1he knife cp proximity switch tfig. 4-15j by loosen ng the two mountiny screws ard sliding the actuator up or down. The swlch should be adjusted such tha: il senses the krife bar al the very tos of ils strckc crly. The gap between the switch anc 1he knife

Hydaulic Clamp Up Proximily Switch (Hydup)

Make sure the clamp and krile are in the up position. Tum the powe'switchoff ard disconnect Iifepcwer cordRemove the lawer fronl sanel.

4.7.4.2Adjus1ment Procedure:

Mounting Hose

Plate 1. Remove the lowefrcrt cover sanel. Clamp

2. Loosen the locknut and tum the clamp pressure redjcer vave (item 4, fig. 4-17) a.l Ine way in jclockwise]. [Notc: i yoLr mach ne 1s equippcd with the optional electronic clamp conlrol valve you willhaveoenter the Main ten ek cec de and chose Knie Adjusl. Knifc Down. Ths wll close the electronic valve allowing you to read the Mtar Sys and Knife Dowrl pessures.]
3. MAIN SYSTEMRELIEFPRESSURE:Make&Cut and read the pressure on the gauge when the knife Is bottomed on the table. Adjust the main systerm relief valve (item 1, fig. 4-17j if necessary to obtain

Adjust the hydrau ic clamp p prcx:mity swtch (fig. 4-

a 1.400 psl reading.

'6) by loosening the two hcse clamp screws and slidirg the swtcrplate uo or downThe gapbetween the

4. KNIFE SEQUENCE PRESSURE Beg:na Qu1cycle

switch and the acluator plate shoulcbe 1:32"o 1/16

and read tre pressurc from the gauge as ine knife is Iravel:ng down (after the ciamp reaches the table) The press ure shoule lead 900 psi. If necessary.

F.200-Atitan200Sept99 49

4.0 MAINTENANCE

chocse Clamp Adjus1. and the following sc:reen shuuld

acjust :e knife sequence valve [ilem 2, fig. 4-17} to obtain the sroper reading. be displatyed:

Clamp/Knifeup Sequence Pressure:

Activate a ctt cycle and read the pressu'e after :he Se: Maximum knifte hias retumec up and while the clarrp is moving up. The pressure sho:ld read approximate y 500

Press to Increase

ps If necessary. adjusl :e clams up scqLcncc valve (ien 3.fig. 4.7)toobtain this pressre. lf.

Press to Decrcase

during a cut cycle. the clamp will not stay down un:ilafter:hekniteretuins completely to theuc pcs ticr, re-adjust the clanp up sequence velve unti this happer's.

D) ExE

6. CLAMPPRESSURE:Adjus:lheClampessure reducer (item 4. fig. 4-17) tc t:e des red setting. l1 is factory preset a1 8c0 psi. Read the gauge with Now erform a cut cycle.Af:er the clamp has conlacted

tne lable ad while the kn fe bar is cam ng cown, read

the clarnp down and as the knife begins tc move

the cressJre on the right hand pressure gauge. It shouikd

Nole. When cutting pressure sens tive paper, you may down arrow keys.Wher fnished.ress sofl-key'D"tn

exit and gc to the minirnum pressure set up screen

wanl loreduce the clairpinypressure (4od psi

shown below:

minimum) to prevent marking the paper.

CAUTION: DO NOT set the clamp Press to Increase pressure below 400 psi. Severe laceratiansordismemberrmentcould Presso Decrease result! The knife and clamp system loses sequence at settings below 400 psi and the knife could come down before the clamp.

Cj Send

D) Ex

4.7.4.3 Optioral Electronic Clams Pressure Controi Performacutcycle.After1neclamphas contacled thc

lable and while he knife bar is ccming down, read the pressure on the righit 'land pressure gauge. lt shoulc

The e'ecironic clamping controi optior allows the

and down arror keysWhen finished.press soft-key

cc liveni en ce cf cnanging te clanp oressure 2t the

• C"to return to Send Mode,Or soft-key"Doreturn lo

ccrtrol console. The sressure is controlled by use of !ne up and down arrowkeys.C being the lowest -15 :he hrghest, and s indicatec in the upper right hand comcr o' the display. 4.8 CLEANING Noe:To turn the electro ric clar np control opticnn or Before cleaning inside mashine. lur off and lcckoult off, cnlerthe Maintenance Mode and chcose Diagnostic power. pg. vi. Then choose Eleclric Clamp and select *ON"orOFF".

To ac just the aclu al clamps res sure maximum and Tinimum. First make s:ire the Flectric Clarcp opiion Is '. The vontfan should be wipcdof wcckly to mairtain set to "ON"(see above paragrapbi).Enter tne max:mJTcoolingof thehydra.licsyslem Wainrenance Mode and choose Diagnpslic. Then

F.200-A/Titan200Sept99

4.0 MAINTENANCE

2. The hydrallic manirold. fitings. anc hoses shoul! be wiped off weekly to maintair maximum coaling. Rerove lhen replace penels as necessary

1 The frcrt tasle should be wiped down periodically Use a ncn-abrasve clearer along witap'oteclve wax.

2. The rcar tablc cover and front guard may be cleanec wth giass cleaner or a mild water tased dctc'gert. Somepet-uleun basecsclvents may damagethe plex glass.

1. The conso c should be cleaned with & milc walcr based cetergenl appled to a canp clo:h or paper towel Petro eumbascd solverts will damage the console

Machine Exterior

1. The machine's exierior should be cleaned with a non-abrasive wa:er based delergent asolied c a damp
2. Always be careful when cieaning around safery wa ming labe s. Use limiled amounts of ckeaners in those

F.200-Atitan200Sept99 4-11

5-22 POVWER PANEL LABEL 5.0 PARTS LIST & SEGUENCE OF OPERATIONS S-1781-54REV.C !! notiCe !! WARNNG: KCORRECT >ONE? HCOK-LF

Reflace Cn_Yitfsame

Tase

TYPE NDRA NF JS.

Pc Boars

Con'Roller

F.200-A/TITAN 200/SEPT99 208V/230V 208V/230V F2 MACHINES MACI-INE: OER_CAD F4 3AI 3AT 1CA TITAN200 TTAN.265

5. PARTSUST&SEQUENCEOFOPERATIONS

FuseYaluc and Function

Transformer/valtage Dimension

1|Fuse ValuerType

Backgauge mclor T1. Secondary 5mr x 20mm

3.15A -T

5mmx 20mm

F3 L ne I ghts 5A-T Main - Ho: 230VAC T2 Prmary

.5AT SV - ogic, presot.

T1 Primary

1.25A-T 12v. 24v Pcb rputs 10A-T Man -Neulal Backgaugc motcr

Fl 5A·T

T=Time Delay FLse

NOTE: Titan200 cutters s/n 991733 and below do not have FL fuse.

F.200-Atitan200Sept99 5-23

5.0PARTSLIST&SEQUENCEOFOPERATIONS

Titan 200 Floor Plan

49.0 124 53.0 135

53.0 135 58.0 147 74.0 188

MACHNE DIVEVSIONS:AxBxC

Machne Divensions With Side

TAB.F FXTENTIONS:DxBxE CPERATING AREA:FxG

Cverali Maintfna\Ceiarfa: Fxg

F.200-A/Titan 200Nsept 99

5.0PARTSLIST&SEQUENCEOFOPERATIONS

Safety System Tests

Nachine man.itacturer_CHALLENGE

Serial Nurnber

Turn tne power on ard press CLEAR to prcset thc backgauge. Make sure the knife ar.d clamp are in the up position if they are nct, fol ow the instrurclior:s in th s marval to send them up}. Test #1: witr the *ronl guard ocen. press the cJt stton. Nolhing shou d napcen. If the knife and'ur clarrp comes dowrn wilth the *ront guard open, do not use the machine. Repai or acjustment is neeced. Test #2 Clcse the *rort gjerd and prcss the cJt button. While the clamp cr knife is coming down open the front guard. The kn fe and clamp shculc immediately return to the up position. IfIrey do rct. do not use the machine. Repair or adjus:Tent is needed.

Please enter date ancinitia s'cr bcth esis.

Tes1 1

Test 2

Test 1

Test 7

Test 1

Initials cf

Repairs Repairer

F.200-A/Titan 20Wsept 99 5-25