Challenge Titan 200 Operation Manual

The

Challenge Machinery Company provides owner's

manuals on its products solely as a courtesy to its customers. See the informati on belo w b efore usi ng this ma nu al.

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This

products should be used only by qualified and properly trained personnel, following proper safety procedures. All products should be regularly inspected and maintained, and their condition,

application and use should be periodically evaluated by qualified personnel. Only qualified and properly trained technicians should perform maintenance, procedures. Attempting these procedures without proper training damage or

Products unavailability available the pro duct does n ot have a U L label it is not a list ed produc t), and m ay not com ply with applicable installation or other regulations or requirements if Many

to them. Often the cost of updating an older product to comply with current safety regulations is greater than the value of the product.

manual

municipalities require a product

may not be

operator

may be

of parts from their

to repair or

injury!

unsupported by The Challenge Machinery Company

maintain unsupported

complete

original manufacturer.

in all aspects of

products.

to be UL

listed

product

No parts or

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before

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products

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Serial Numbers 032425 & Up

PERATION

ANUAL

The Challenge Machinery Company

6125 NortonCenter Drive

Norton Shores, MI 49441-6081 USA

ChallengeMachinery.com

F.200-CO

TITAN 200

PAPER CUTTING

MACHINE

Sold and Serviced by

August 2003

1.0 Introduction

THIS MANUAL is designed to help you get the most from your Challenge equipment. Keep this manual in a safe, convenient place for quick reference by operators and service personnel.

SAFETY ALERT! This symbol means CAUTION: Personal safety instructions! Pay special attention to the instructions in bold type. Personal injury may result if the precautions are not read and followed.

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

Take a few minutes right now to RECORD YOUR MACHINE SERIAL NUMBER in the space provided on the front cover of this manual. Also be sure to fill out the warranty card accompanying your machine and return it DIRECTLY TO CHALLENGE.

If you bought a used machine, it is important to have the following information on record at Challenge. Copy this page, fill in the information and send it care of The Challenge Service Department • 6125 Norton Center Drive • Norton Shores, MI 49417-1594.

CHALLENGE MODEL SERIAL NUMBER ATTN COMPANY

ADDRESS CITY STATE/PROVINCE ZIP PHONE DATE INSTALLED DEALER NAME & CITY

* WARRANTY INFORMATION *

It is very important that you read and understand the conditions outlined in the Warranty Information Sheet attached to the outside of the shipping container of your machine.

The Warranty Information Sheet must be filled out completely and returned to THE CHALLENGE MACHINERY COMPANY in order for the warranty to be issued for this machine.

Challenge® is a registered trademark of The Challenge Machinery Company• 6125 Norton Center Drive • Norton Shores, MI 49441-6081 Copyright© 2003 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A

1.0 Introduction

TABLE OF CONTENTS

1.0 Introduction .......................................................................................................................................2

2.0 Safety................................................................................................................................................5

2.1 Precautions...................................................................................................................................5

2.2 Power Lockout Procedure ............................................................................................................5

2.3 Warning Label Definitions.............................................................................................................6

3.0 Packing List.......................................................................................................................................7

4.0 Specifications....................................................................................................................................8

5.0 Installation & Setup ...........................................................................................................................9

5.1 Inspecting Shipment .....................................................................................................................9

5.2 Uncrating ......................................................................................................................................9

5.3 Cleaning......................................................................................................................................10

5.4 Fitting Through Narrow Door......................................................................................................10

5.4.1 Removing the Table ............................................................................................................10

5.4.2 Removing the Foot Treadle.................................................................................................13

5.4.3 Removing the Front Guard (If Equipped)............................................................................13

5.4.4 Reattaching the Table.........................................................................................................13

5.5 Installing Optional Extension Tables (Front Guard Machines Only) ..........................................14

5.6 Hydraulic System Check.............................................................................................................14

5.7 False Clamp Plate (Optional) .....................................................................................................15

5.8 Power Hook-Up ..........................................................................................................................16

5.9 Line Light ....................................................................................................................................16

5.9.1 Adjustment...........................................................................................................................17

5.9.2 Bulb Replacement...............................................................................................................17

6.0 Operation ........................................................................................................................................18

6.1 Power – Main Switch ..................................................................................................................18

6.2 Start Up.......................................................................................................................................18

6.3 Making a Cut (Machines With Electric Eyes)..............................................................................19

6.4 Making a Cut (Machines With Front Guard)...............................................................................19

6.5 Jogging Aid.................................................................................................................................19

6.6 Knife Change Alarm and Lubrication Alarm ...............................................................................20

6.7 Manual Clamping (Using the Foot Treadle)................................................................................20

6.8 Display Panel..............................................................................................................................21

6.9 Definition of Keys........................................................................................................................21

6.9.1 Variable Speed Pinpoint Backgauge Control......................................................................21

6.9.2 IN/MM Key...........................................................................................................................21

6.9.3 Send Key.............................................................................................................................21

6.9.4 Push-Out Key/Hold-To-Run Backgauge Key......................................................................22

6.9.5 Clear Key.............................................................................................................................22

6.9.6 Enter Key.............................................................................................................................22

6.9.7 Priority Add (X/Y) Key .........................................................................................................22

6.9.8 Soft-Keys.............................................................................................................................22

6.9.9 Arrow Keys..........................................................................................................................22

6.9.10 Contrast Control (Serial Numbers 083330 and Below).....................................................22

6.9.11 Contrast Control (Serial Numbers 083331 and Above) ....................................................22

6.10 Manual Backgauge Control ......................................................................................................23

6.10.1 Backgauge Glide Control ..................................................................................................23

6.10.2 Backlash Indicator.............................................................................................................23

6.11 Send Mode ...............................................................................................................................23

6.11.1 Entering Math....................................................................................................................23

6.11.2 Entering Fractions .............................................................................................................24

6.12 Maintenance Mode ...................................................................................................................24

6.12.1 Knife Adjust .......................................................................................................................24

6.12.2 Parameters........................................................................................................................24

1.0 Introduction

6.12.3 Diagnostic .........................................................................................................................26

6.12.4 Language..........................................................................................................................27

6.13 Job Mode..................................................................................................................................27

6.13.1 Lock/Unlocking a Job........................................................................................................27

6.13.2 Copying a Job...................................................................................................................27

6.13.3 Erasing a Job....................................................................................................................27

6.13.4 Creating a New Job ..........................................................................................................28

6.13.5 Editing an Existing Job......................................................................................................29

6.13.6 Running a Programmed Job.............................................................................................30

6.13.7 Exiting a Job .....................................................................................................................30

6.14 An Example Job .......................................................................................................................30

6.15 Operating Tips..........................................................................................................................32

6.16 Note to Dealer ..........................................................................................................................32

6.16.1 Entering the Dealer Name and Phone Number................................................................32

7.0 Knife Installation/Changing.............................................................................................................33

7.1 Knife Removal............................................................................................................................33

7.2 Knife Installation.........................................................................................................................35

7.3 Knife Care Tips...........................................................................................................................36

7.3.1 Knife Blade Life...................................................................................................................36

7.3.2 Cutting Stick........................................................................................................................37

7.3.3 Bevel Angle.........................................................................................................................37

7.3.4 Helpful Suggestions............................................................................................................37

7.3.5 Knife Care...........................................................................................................................37

8.0 Oil and Grease................................................................................................................................40

9.0 Titan 200 Floor Plan .......................................................................................................................43

10.0 Safety Systems Test.....................................................................................................................44

2.0 Safety

2.1 Precautions

• This machine is designed for one-person operation. Never operate the machine with more than one person.

• Safe use of this machine is the responsibility of the operator. Use good judgment and common sense when working with and around this machine.

• Read and understand all instructions thoroughly before using the machine. If questions remain, contact the dealer from which you purchased this machine. Failure to understand the operating instructions may result in personal injury.

• Only trained and authorized people should operate this machine.

• DO NOT ALTER SAFETY GUARDS OR DEVICES. They are for your protection. Severe

personal injury may result.

• Disconnect power before cleaning or performing maintenance. See Section 2.2 Power Lockout Procedure.

• Observe all caution labels on this machine.

• Be sure the cutter is properly grounded.

• Be sure there is sufficient power to operate the cutter properly.

• Observe all caution plates mounted on this cutter.

• Keep foreign objects off table and away from cutter blade.

• BE EXTREMELY CAREFUL when handling and changing the cutter knife. Severe lacerations or

dismemberment could result from careless handling procedures.

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

• When replacing hydraulic parts, loosen the connections slowly to release pressure. Never loosen

connections with the machine running.

• If the cutter sounds or operates unusually, turn it off and consult the troubleshooting section of this manual. If the problem cannot be corrected, have it checked by a qualified service person.

• CRUSH HAZARD, keep hand and fingers from under the clamp when clamping paper. Use Jogging Aid to load paper, and use the backgauge to push paper out before unloading. DO NOT

REACH UNDER THE KNIFE AND CLAMP AREA!

2.2 Power Lockout Procedure

For maximum safety while making adjustments or repairs to your machine, be sure to disconnect power to the machine. Disconnect the power plug from its socket

Figure 1 - Main Power Disconnect

2.0 Safety

2.3 Warning Label Definitions

The following warning labels are found at various locations on your machine. Read and understand the meaning of each symbol. If a label is lost from the machine, it should be replaced.

HAZARDOUS AREA Disconnect power before cleaning, servicing, or making adjustments not requiring

power. Do not alter safety guards or devices; they are for your protection. Replace all guards. Do not operate with any guards removed.

SHOCK HAZARD

Disconnect power before removing cover. Replace cover before operation.

SHOCK HAZARD Disconnect power before removing cover. Replace cover before operation.

SINGLE OPERATOR Do not operate with more than one person.

3.0 Packing List

Part No. Description Qty.

A-10034 Knife 2 4166 Cutting Stick F.200-CO Operator Manual 1 A-12608-2 Jogging Aid 1 20-2150-2 Tool Kit 1 H-6918-608 Knife Bolts, 3/8 – 16 x 1” 4 8815 Knife Washers, Special 4 5064 Cutting Stick Puller 1 43108 Knife Lifter Assembly 1 W-130 3/16” Allen Wrench 1 W-137 5/32” Allen Wrench 1 W-164 5/16” Hex ‘T’ Wrench 1 W-170 9/16 x ½” Wrench 1 SU-10-113 Grease Brush 1

Optional Items

Part No. Description Qty.

AA-10061 False Clamp Plate 5-7-M361 Backgauge Book Guides 4166 Cutting Stick A-10034-1 High Speed Steel Knife

(in addition to one installed in machine)

4.0 Specifications

Description Inch Units Metric Units

Cutting Width 20” 51 cm Minimum Cut* ½” 13 mm Clamp Opening 3 ¼” 8 cm Table Space Front: Back: Dimensions Table Height 36” 91 cm Overall Height 53” 135 cm Overall Length*** 49” 124 cm Overall Width 36” 91 cm Approx. Net Weight 800 lbs 361 kg Approx. Shipping Weight 920 lbs 418 kg Electrical 208/230 Volts, 12 Amps, 1 Phase, 60 Hz, AC. Service size 15 Amps Recommended Recepticle: 208-230 Volt, NEMA 6-15R, NEMA 6-20R

UL/cUL Listed

Sound Emission

A-weighted sound pressure level measured in an enclosed room at operator level (6 feet/183 cm): Machine cutting a full lift of paper: 77 dB

*With false clamp plate attached, minimum cut is 1-7/8” (48 mm). **For complete floor plan layout, see page 43. ***With table, front guard or elec eyes, and foot treadle removed, can be fit through a 28” (71 cm) door opening.

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

15¼”

20”

39 cm 51 cm

5.0 Installation & Setup

5.1 Inspecting Shipment

This machine has been carefully packed to prevent damage during shipment. However, claims for damage or loss are the responsibility of the recipient. Inspect all shipments as soon as they are received. If there is any noticeable damage, note it on the freight bill. Visual and/or hidden damage must be reported to the claims department of the carrier within 15 days. Contact your dealer if you need any assistance. Check the contents of the box against the packing list on page 7. Make sure there are no missing items.

5.2 Uncrating

The Titan 200 weighs approximately 755 lbs (342kg). DO NOT risk personal injury or damage by attempting to move machinery with makeshift equipment or inadequate manpower. This machine is shipped on a wooden skid and enclosed in a protective, corrugated top. The skid is designed to allow the machine to be rolled off without any special lifting equipment. The machine is held in place by two, 2x4 braces lag bolted to the skid. All accessories are shipped inside of the machine.

Remove the carton by removing the nails or staples holding it to the skid and lift it straight up over the cutter. If you don’t have the ceiling clearance to do this, carefully slit the carton down the side and then unwrap it from around the cutter.

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

Using the rear bumper board, pry one side of the machine up, and slide out the top layer of the support riser (Figure 2). Do the same on the other side.

Use the flat board provided as a ramp and position as shown in (Figure 3 on page 10). Hold the ramp in place with the nails provided. Make sure the casters are not locked and very carefully roll the machine down the ramp. The cutter may now be rolled into position.

Figure 2

5.0 Installation & Setup

Figure 3

5.3 Cleaning

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

5.4 Fitting Through Narrow Door

The Titan 200 cutter will not fit through an opening less than 36” (91 cm) without the table being removed. With the table removed, the Titan 200 will fit through a 35” (89 cm) opening. With the table, front guard, and foot treadle removed, it will fit through a 28” (71 cm) opening.

5.4.1 Removing the Table

Make sure the knife and clamp are in the “up” position. If they are not, read the Power Hookup section (page 16) to connect power to the machine. Turn on the power using the red and yellow main power switch, close the front guard, and press the CLEAR button. This will preset the backgauge and send the knife and clamp up.

Turn off the machine and unplug the power cord. If equipped with electric eyes, remove the electric eye mounting brackets, the small side tables, and

the side table mounting bracket from bottom of table. Remove the cut buttons from the bottom of the table. Remove the Plexiglas cover and the three sheet metal covers on the rear of the table. Remove the

backgauge motor cover, the rear table support leg, the lower back panel, and the lower front cover of the machine.

Unplug the cable to the encoder at the back of the machine (Figure 4 on page 11).

5.0 Installation & Setup

Rear Support

Leg

Motor Junction

Encoder Plug

Figure 4

Remove the motor junction box cover and disconnect the wires to the motor (Figure 5). Remove the leadscrew cover and the nylon tyraps that are attached to the bottom of the table. The motor wires and encoder wires should now be free from the table.

Box Cover

Figure 5

From the rear of the machine, remove the presetter board assembly from the table (Figure 6 on page

12).

Open the front guard (if equipped); open the top cover and remove the left and right side guides and the cut stick stops as shown in (Figure 7 & Figure 8 on page 12).

Next, remove the cut stick from the table using the cut stick removal tool. Locate the two taper pins in the cut stick slot. These must be tapped out from under the base through the table slot and removed. Then remove the four screws that mount the table to the base. NOTE: The table assembly is very heavy and requires two people to remove. Pull the table out from the back of the machine. Locate the four round spacers that were between the table and the base - you will need them later for mounting the table.

5.0 Installation & Setup

Assembly

Cut Stick

Right S

ide

Guide

Presetter Board

Figure 6

Left Side

Guide

Figure 7

Cut Stick

Figure 8

Stop

5.0 Installation & Setup

Screws

5.4.2 Removing the Foot Treadle

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

5.4.3 Removing the Front Guard (If Equipped)

Make sure the power is off and disconnect the power cord. Open the front guard. Remove the cylinder bracket screws (Figure 9).

Bracket

Figure 9

Then open the top hood and remove one set of hinge screws (Figure 10). Slide the front guard out of the other hinge.

Hinge Screws

Figure 10

5.4.4 Reattaching the Table

Set the table in position. Lift the table from the front and set the two front spacers in place. Insert the front two socket head screws, but do not tighten. Lift the table from the rear and set the two rear spacers in place. Start the rear two socket head screws. Reinsert the two taper pins, and tap into position so they are below bottom of the slot. Tighten all four screws. Attach the right and left side guides (Figure 7 & Figure 8 on page 12), the presetter board assembly (Figure 6 on page 12), the motor and encoder wires (Figure 4 & Figure 5 on page 11), and all other items that were removed. Once the table is installed, the backgauge squareness and accuracy will have to be reset. See the Titan 200 Technical Service and Parts manual for information on how to do this.

5.0 Installation & Setup

5.5 Installing Optional Extension Tables (Front Guard Machines Only)

Using the wood screws provided, attach a back plate to each extension table. Using (4) 3/8-16 capscrews, attach the table support to the under side of the main table as shown in (Figure 11). Route each cut button wire through the slots in the bracket and relocate the cut buttons to the extension tables (as shown). Place the provided flat washers on the table support above each slot receiving a screw to mount the extension table on the support. Lay the table extension on top of the spacers and insert the screws. Slide the table extension tight to the table. Shim the extension tables as necessary to make the tables flush using the provided shims.

Figure 11

5.6 Hydraulic System Check

The cutting/clamping mechanism of the Titan 200 is powered by a hydraulic system consisting of an electric motor coupled directly to a hydraulic pump.

The hydraulic reservoir holds 4 quarts (1 gallon) of hydraulic fluid. It is filled with Rykon 100 hydraulic fluid at the factory but should be checked before operation. Remove the lower rear panel cover and unscrew the cap on top of the tank (Figure 12 on page 15). Fluid level should be at 1/8” from the end of the dip stick (check with dip stick cap screwed in). Add fluid if necessary but avoid overfilling as this could cause leakage when hot. Replace the rear panel when finished. For more information about checking and changing the hydraulic fluid, including a cross-reference chart of approved fluids, see the Titan200 Technical Service and Parts manual.

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

+ 32 hidden pages

Challenge Titan 200 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual