Challenge Titan 230 Operator's Manual
The Challenge Machinery Company
6125 Norton Center Drive
Norton Shores, MI 49441-6081 USA
ChallengeMachinery.com
The Challenge Machinery Company provides owner's manuals on its
products solely as a courtesy to its customers. See the information below
before using this manual.
These manuals are for reference only. These manuals include products which are noncurrent,
unsupported or no longer produced by The Challenge Machinery Company, and are provided solely as
an accommodation to our customers. By providing these manuals, The Challenge Machinery Company
makes no representation or warranty as to the products, their current condition, or their suitability or
fitness for use in any particular application, which are the sole and independent responsibility of the
product owner and user.
Older products may not comply with current safety procedures, guidelines or regulations, and it
is the product owner's and user's responsibility to evaluate the suitability and fitness of the
products in their current use and application. The Challenge Machinery Company makes no
representation, warranty or recommendation regarding any modifications which may be
required on non-current or unsupported products. The Challenge Machinery Company assumes
no liability for any modification or alteration to any Challenge product, and any such
modification or alteration to any Challenge product is not authorized by The Challenge
Machinery Company. The availability of these manuals is solely for the purpose of providing reference
information for the products.
This manual may not be complete in all aspects of product maintenance and repair. All products
should be used only by qualified and properly trained personnel, following proper safety
procedures. All products should be regularly inspected and maintained, and their condition, application
and use should be periodically evaluated by qualified personnel. Only qualified and properly trained
technicians should perform maintenance, repair and replacement procedures. Attempting these
procedures without proper training may cause machine damage or operator injury!
Products may be unsupported by The Challenge Machinery Company due to age or the unavailability of
parts from their original manufacturer. No parts or product support will be available to repair or maintain
unsupported products. Older products may not be UL listed (if the product does not have a UL label it is
not a listed product), and may not comply with applicable installation or other regulations or
requirements if relocated to a new facility. Many municipalities require a product to be UL listed before
an electrician will connect power to them. Often the cost of updating an older product to comply with
current safety regulations is greater than the value of the product.
TITAN 230
Operator’s Manual
Serial Numbers 070001 & Up
Sold and Serviced by
F.230-O
March 2015
1.0 Introduction
CHALLENGE MODEL
SERIAL NUMBER
ATTN
COMPANY
ADDRESS
CITY
STATE/PROVINCE
ZIP
PHONE
DATE INSTALLED
DEALER NAME & CITY
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.
* 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© 2007 by The Challenge Machinery Company. All rights reserved. Printed in the U.S.A
2
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 Side Tables ................................................................................................. 10
5.4.2 Removing the Table ........................................................................................................... 11
5.4.3 Removing the Electric Eyes ............................................................................................... 13
5.4.4 Removing the Foot Treadle ................................................................................................ 13
5.4.5 Attaching the Table ............................................................................................................ 13
5.4.6 Attaching the Electric Eyes................................................................................................. 14
5.4.7 Attaching the Side Tables .................................................................................................. 14
5.5 Hydraulic System Check............................................................................................................ 14
5.6 False Clamp Plate (Optional) .................................................................................................... 15
5.7 Power Hook-Up ......................................................................................................................... 16
6.0 Operation ....................................................................................................................................... 18
6.1 Power – Main Switch ................................................................................................................. 18
6.2 Start Up ...................................................................................................................................... 18
6.3 Making a Cut .............................................................................................................................. 19
6.4 Jogging Aid ................................................................................................................................ 19
6.5 Knife Change Alarm and Lubrication Alarm .............................................................................. 20
6.6 Manual Clamping (Using the Foot Treadle)............................................................................... 20
6.7 Adjusting the Clamping Pressure .............................................................................................. 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 .......................................................................................................................... 22
6.9.3 Send Key ............................................................................................................................ 22
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 080074 and Below) .................................................... 22
6.9.11 Contrast Control (Serial Numbers 080075 and Above) ................................................... 23
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 ................................................................................................................... 24
6.11.2 Entering Fractions ............................................................................................................ 24
6.12 Maintenance Mode .................................................................................................................. 24
6.12.1 Knife Adjust ...................................................................................................................... 24
6.12.2 Parameters ....................................................................................................................... 24
6.12.3 Diagnostic ......................................................................................................................... 26
3
1.0 Introduction
6.12.4 Language .......................................................................................................................... 26
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 .......................................................................................................... 27
6.13.5 Editing an Existing Job...................................................................................................... 29
6.13.6 Running a Programmed Job ............................................................................................. 29
6.14 An Example Job ....................................................................................................................... 30
6.15 Operating Tips .......................................................................................................................... 31
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................................................................................................................................ 39
9.0 Titan 230 Floor Plan ....................................................................................................................... 42
10.0 Safety Systems Test ..................................................................................................................... 43
4
2.0 Safety
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
5
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.
6
3.0 Packing List
Part No.
Description
Qty.
42007
Knife
2
42008
Cutting Stick (in addition to one installed in machine)
3
42014
Knife Lifter Assembly
1
F.230-O
Operator Manual
1
A-12608-2
Jogging Aid
1
20-2150-7
Tool Kit
1
5064
Cutting Stick Puller
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
Part No.
Description
Qty.
41058
Waste Wagon
42007-1
High Speed Steel Knife
42008
Cutting Stick
42013
False Clamp Plate
5-7-M361
Backgauge Book Guides
50082
Magnetic Clamp Pads – Pkg of 2 – 3”x15” ea.
S-1991-4
Rykon 100 Hydraulic Oil – 5 gallon container
42000 sh’t 5
Air Table
K-42050
Large Side Tables (18” x 20”)
3.0 Packing List
Optional Items
7
4.0 Specifications
Description
Inch Units
Metric Units
Cutting Width
23”
58.4 cm
Minimum Cut*
½”
13 mm
Clamp Opening
3 ¼”
8.3 cm
Table Space
Front:
Back:
24¼”
24”
61.6 cm
61 cm
Dimensions**
Table Height
36”
91.4 cm
Overall Height
53”
135 cm
Overall Length***
66”
168 cm
Overall Width
50”
127 cm
Approx. Net Weight
1,000 lbs
454 kg
Approx. Shipping Weight
1,250 lbs
567 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 42.
***With table, elec eyes, and foot treadle removed, can be fit through a 29” (74 cm) door opening.
Challenge reserves the right to make changes to any product or specification without notice and
without incurring responsibility to existing units.
4.0 Specifications
8
5.0 Installation & Setup
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 230 weighs approximately 1,000 lbs (454 kg). 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 230 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.
9
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 230 cutter will not fit through an opening less than 50-1/4” (128 cm) without the table being
removed. With the table removed, the Titan 230 will fit through a 35” (89 cm) opening. With the
table, electric eyes, and foot treadle removed, it will fit through a 29” (74 cm) opening.
5.4.1 Removing the Side Tables
Make sure power is disconnected from the machine. Remove the hardware that mounts the side
tables and remove the side tables (Figure 4). Now remove the two extension table support brackets.
10
View from underneath table
Figure 4
5.0 Installation & Setup
Encoder Plug
Rear Support
Leg
5.4.2 Removing the Table
1. 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 and press the CLEAR button. This will preset the backgauge
and send the knife and clamp up.
2. Turn off the machine and unplug the power cord.
3. Make sure the side tables and side table mounting brackets have been removed (see
previous section).
4. Remove the cut buttons from the bottom of the table.
5. Remove all rear covers that are 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.
6. Unplug the cable to the encoder at the back of the machine (Figure 5).
7. Remove the motor junction box cover and disconnect the wires to the motor (Figure 6).
Remove the leadscrew cover and the nylon wire-ties that are attached to the bottom of the
table. The motor wires and encoder wires should now be free from the table.
8. If this machine is equipped with an Air Table – unplug the three air hoses from the bottom of
the table
11
Figure 5
5.0 Installation & Setup
Motor Junction
Box Cover
Left Side
Guide
Presetter Board
Assembly
Figure 6
9. From the rear of the machine, remove the presetter board assembly from the table (Figure 7).
12
Figure 7
10. Open the top cover and remove the left and right side guides and the cut stick stops as
shown in Figure 8 & Figure 9.
Figure 8
5.0 Installation & Setup
Cut Stick
Stop
Cut Stick
Right Side
Guide
Figure 9
11. Remove the two taper pins from the bottom side of the table by tightening the jam nut on the
taper pin. Then remove the four screws that mount the table to the base. CAUTION: the
table assembly is very heavy and requires at least four people to remove. Pull the table
out towards the back of the machine.
5.4.3 Removing the Electric Eyes
Make sure power is disconnected from the machine. Open top cover. Remove the four hex-head
screws for each electric eye assembly from the inside of the machine. By sliding some of the slack in
the cable through the side of the machine, the eye assemblies can be set on the machine. If it is
necessary to completely remove the eyes from the machine, the wires must be disconnected from the
power panel.
5.4.4 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.
5.4.5 Attaching the Table
Set the table in position, and start its front two mounting screws. Then start the rear four mounting
screws. Replace the two taper pins (must be snug to seat the table), and then tighten all six screws.
Attach the right and left side guides (Figure 8 & Figure 9), the presetter board assembly (Figure 7),
the motor and encoder wires (Figure 5 & Figure 6), and all other items that were removed (See
Section 5.4.2 page 11).
Once the table is installed, the backgauge squareness and accuracy must be readjusted. See the
Titan 230 Technical Service and Parts manual for information on how to do this.
13
5.0 Installation & Setup
5.4.6 Attaching the Electric Eyes
Make sure power is disconnected from the machine. If necessary, connect the wires to the power
panel. Attach electric eye assemblies with provided hardware, making sure that the bottom of the
electric eye housings are parallel to the table. Once power is hooked up, the electric eyes should be
checked for alignment. See the Titan 230 Technical Service and Parts manual for information on how
to do this.
5.4.7 Attaching the Side Tables
Using (4) 3/8-16 cap screws and washers, attach the table supports to the under side of the main
table (Figure 10), making sure to route each cut button cable through the slots in the brackets. Lay
the side tables on top of the support brackets and insert the mounting hardware. Slide the table
extension tight to the table and tighten the hardware.
View from underneath table
Figure 10
5.5 Hydraulic System Check
The cutting/clamping mechanism of the Titan 230 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 11 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 Titan230 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.
14
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